WIRE & CABLE MANUFACTURING UNIT

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A cable includes multiple wires which are twisted, bonded, or braided together to form an assembly. The cables & wires are encapsulated with insulating materials, generally, polyethylene or PVC, to ensure protection to users & the surrounding environment. PVC cables act as a primary component for transmitting and distributing electric power. They are prominently used in distribution systems, substations, house wiring, distribution systems, street lighting. PVC insulated cables & wires are prominently used for power distribution. PVC cables manufacturing process is quite straightforward. Anybody intending to venture into this business can get started with a smaller investment.

The electric cable & wire market in India has witnessed massive growth in the past few years and have managed to thrive @ 16% CAGR in the period 2015-2019.

The insulated cable & wire market in India is expected to grow @ 10.3% CAGR through 2023, mainly on account of ever-increasing government investment towards infrastructure development projects.

Rapid urbanization across the nation under smart cities mission paired with the escalating number of electronic items per household & development of manufacturing facilities under the initiative, viz ‘Make in India’, which is stimulating demand for power, are projected to scale up market demand in near future. Furthermore, escalating demand for reliable & efficient data communication from rural regions & tier II & III cities and towns would influence the nation’s insulated cable market.

The cables & wires cable market in our country comprises almost 40% of the electrical industry & is thriving @ 15% CAGR as a result of the development of the power & infrastructure sectors. The Indian cable & wires market is highly fragmented, mainly dominated by small and medium enterprises.

The production of high voltage durable & specialty cables is mainly catered by the organized sector. Meanwhile, the unorganized sector deals with the production of low-voltage cables.

The ever-increasing demand for cable and wires can also be credited to the advent of cutting-edge technologies by manufacturers in India & prompt expansion of automated and low-cost manufacturing technologies, which have considerably improve the production of cables and wires.

The worldwide cable market size was projected at 186.09 billion dollars in 2017 and is expected to experience a CAGR of 6.4% over the projected period. Ever-rising reserves in growing renewable energy production, smart grid technology, & government initiatives for advancing the distribution & transmission system are projected to steer this market.

Increasing utilization of smart grid technology has met the growing demand for grid interconnections, resulting in increased investments in underground cables & new submarines. Additionally, the market growth is credited to the increasing high voltage direct current links & offshore wind farms.

The demand for cables & wires largely depends on the expansion and diversification of the industrial regime & infrastructure development in the power generation, telecommunication, & commercial sectors.

Rising global population and swift urbanization have escalated the demand in these regions, thereby underpinning plenty of opportunities to the global cable & wire market.

Wire is used to carry the current from one place to another A wire is a single conductor (material most commonly being copper or aluminium) while cable is two or more insulated wires wrapped in one jacket. Multiple conductors that have no insulation around would be classified as a single conductor.

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Description

INTRODUCTION
TYPES OF ELECTRICAL WIRES
THERE ARE TWO MAIN TYPES OF WIRES: SOLID OR STRANDED.
COPPER WIRE
PROPERTIES
PROPERTIES OF COPPER WIRE:
ELECTRICAL CABLE
PVC COPPER CABLE
PROPERTY
APPLICATION
ADVANTAGES
ADVANTAGES OF PVC CABLES
SOME OF THE MAJOR ADVANTAGES OF PVC CABLES
CONSTRUCTION
CONDUCTOR
1. SOLID/STRANDED
A. SOLID
B. STRANDING
2. CIRCULAR/ SHAPED
A. CIRCULAR
B. SHAPED
INSULATION
THE FOLLOWING COLOUR CODE IS USED FOR IDENTIFICATION:
LAYING UP
INNERSHEATH
A. EXTRUDED INNERSHEATH
B. TAPPED INNERSHEATH
ARMOURING
OUTERSHEATH
USES AND APPLICATION
B.I.S. SPECIFICATION
SEQUENCES IN PVC CABLE MANUFACTURE
PVC CABLES MANUFACTURING: QUALITY CONTROL & STANDARDS
PROCESS FLOW CHART
MANUFACTURING PROCESS
(1) DRAWING
(2) ANNEALING
(3) STRANDING
(4) INSULATION
(5) QUALITY CONTROL
CABLES ARE MANUFACTURED AND UNDERGO THE FOLLOWING TESTS:
(A) TYPE TEST
1. THE FOLLOWING TESTS ARE TYPE TEST OF ELECTRICAL POWER CABLE.
PHYSICAL TESTS FOR INSULATION AND SHEATH
(B) ACCEPTANCE TEST:
(C) ROUTINE TEST:
CONDUCTOR RESISTANCE TEST OF ELECTRICAL POWER CABLES
TEST FOR THICKNESS OF INSULATION OF POWER CABLE
APPARATUS REQUIRED TESTING FOR THICKNESS OF INSULATION OF POWER CABLE
PROCEDURE FOR TESTING OF THICKNESS OF INSULATION OF POWER CABLE
ANNEALING TEST FOR WIRES AND CONDUCTORS
PROCESS OF ANNEALING TEST FOR WIRES AND CONDUCTORS
TENSILE TEST OF CONDUCTORS
APPARATUS REQUIRED FOR TENSILE TEST:
METHOD OF TENSILE TEST OF CONDUCTORS
PROCEDURE
PERSULPHATE TEST OF CONDUCTOR
WHY COPPER WIRES ARE TINNED?
METHODS
METHOD A:
METHOD B:
TEST SPECIMEN FOR TINNING TEST (FOR METHOD B)
WRAPPING TEST FOR CONDUCTORS
(6) COILING AND PACKING
MARKET OVERVIEW OF WIRE AND CABLE INDUSTRY
INCREASING DEMAND FOR RENEWABLE POWER GENERATION IS A VITAL TREND
GROWING DEMAND FROM DATA CENTERS AND IT FACILITIES IS A CURRENT TREND
DEMAND FOR CABLES IN RAILWAYS
5G INFRASTRUCTURE WILL CREATE THE DEMAND FOR CABLES
INDUSTRY CHALLENGES
FUTURE OF WIRE AND CABLE INDUSTRY IN INDIA
BUILDING BLOCKS OF INDUSTRY 4.0
BIG DATA AND ANALYTICS:
AUTOMATED ROBOTS:
HORIZONTAL AND VERTICAL SYSTEM INTEGRATION:
THE INDUSTRIAL INTERNET OF THINGS:
CYBER SECURITY:
ADDITIVE MANUFACTURING:
SIMULATION:
THE CLOUD:
AUGMENTED REALITY:
GLOBAL MARKET SCENARIO OF WIRE AND CABLE
SINGLE CORE CABLES CU/XLPE/PVC
PERMIT AND LICENSES FOR PVC CABLE MANUFACTURING
GET AN INCORPORATION CERTIFICATE
KEY POINTS TO PONDER
FACTORY LICENSE
TRADE LICENSE
NOC FROM SPCB
BIS CERTIFICATION
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIERS OF PVC COPPER WIRE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COOPER WIRE ROD
SUPPLIERS OF PVC COMPOUND CABLE GRADE
SUPPLIERS OF PACKAGING MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF WIRE DRAWING MACHINE
SUPPLIERS OF PVC EXTRUSION PLANT
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF WIRE STRANDING MACHINE
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF DG SETS
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF WEIGHING MACHINE (PLATFORM TYPE)
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

500 Coils/Day
Land & Building

(800 sq.mt.)
Plant & Machinery

US$ 123571
Rate of Return

59%
Break Even Point

43%

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