A cable comprises two or more wires which are bonded, twisted, or braided together to form an assembly. The wires and cables are encapsulated with non-conducting plastic materials, usually PVC or polyethylene, to impart protection to users and the surrounding environment. PVC cables are major equipment for transmission & distribution of electrical power. They are suitable for use in substations, distribution systems, Industrial installations, house wiring, street lighting. PVC insulated wires and cables are the ultimate medium for distribution of electricity. PVC cables manufacturing process is simple. The business can be initiated as small and medium scale basis.
PVC CABLES MANUFACTURING – MARKET POTENTIAL
Electric wire and PVC cable market in Nigeria is expected to grow at a CAGR of 16.18% over the period 2015-20120. The demand for domestic electric cable will increase firstly. This is due to ambitious programme for electrification and house building. It also due to renovation job as old cable has to be removed to avoid any short circuit due to ageing with the new advanced cable of high conductivity in given size with perfect insulation against any electric fault. Some of the bulk purchasers of this product are coal fields & collieries, Electricity Boards, Railways, All types of Power Stations, Aviation industry and Housing Boards/Colonisers.
REGISTRATION & LICENSE FOR PVC CABLES MANUFACTURING
In starting PVC cables manufacturing, register your business with CAC. Obtain Trade License from Municipal Authority. Apply for VAT Registration. Protect your brand name with Trademark registration. This is a pollution-free manufacturing operation. However, waste minimization of PVC compound to strictly adhere. Apply for ‘No Objection Certificate’ from your state Pollution Control Board.
PVC CABLES MANUFACTURING MACHINE & TESTING EQUIPMENT
- PVC Extruder and Wire Coating Machine 50 mm complete with cooling through supply stand take up unit control panel with Automatic Temperature
- indicator controller and electrical motors.
- Wire Straightening equipment
- Cable Printing Machine
- Measuring & Coiling Machine
- Extrusion Dies, NOZZLES etc.
- Spark Tester
- Vernier Micrometer
- Travelling Microscope 0.100 mm least count 0.001 magnification 10X
- Chemical Balance 0.200 gm Least measure 0.1 mg
- Kalvin’s Double Bridge
- Tensile testing machine
- Electrically heater thermostatically controlled Air cooled Oven
- Pressure test apparatus (for Hot deformation)
- High Voltage test set AC (0 to 10 KV)
RAW MATERIAL FOR PVC CABLES MANUFACTURING
The required raw materials are E.C. Grade Aluminium Wire, PVC Compound (Cable Grade) and packaging consumables. The raw materials can be procured either from a wholesale market or from the manufacturer of the said items.
PVC CABLES MANUFACTURING PROCESS
Copper conductor (wire) of the required size is fed into the Extruder wherein PVC is coated on the wire to the specified thickness. The extruded wire after passing through the cooling tank is coiled on the take off system. The wire is coiled into the length of 100 meters and tested as per IS specification.
Insulation is strict as per National and International specification. PVC cables are available as a Thermoplastic dielectric. PVC cables use PVC compound that takes care of overload and short circuit currents with both coarse and fine protection systems.
Laying up: Cores are tested on the line during production both for the physical and electric characteristic. For multi-core cables, cores are laid upon a latest laying machine, equipped with sector correction equipment.
Laid up cables are provided with insulation of high-quality PVC polymer which is softer than outer sheath and are compatible with the temperature rating of the cables. Cables are provided with PVC/polymer outer sheath with various characteristics of sheathing compounds.
The final step is testing. Cables are undergone the following tests:
- Conductor resistant test
- Thickness of thermoplastic and elastomeric insulation and sheath
- Tensile strength and elongation at break of thermoplastic and elastomeric insulation and sheath.
- Thermal ageing in the air.
- Shrinkage Test.
- Ozone resistant Test
- Heat shock Test.
- Hot deformation Test.
- Bleeding Test.
- Cold impact Test.
- Water absorption test (electrical)
- Environmental stress cracking test