Conductor Shop

- RBD with annealer and drop coilers
- Intermediate and fine wire drawing lines with in-line annealing
- Multi-wire bunchers and stranding lines

Cable Assembly & Armouring Shop

- Rigid stranders and skip stranders (e.g. 37, 61 cores)
- Drum twister lines for large power cables
- Steel wire armouring (SWA) and strip armouring
- Copper/steel taping heads and screening lines

Extrusion & Cross-
linking Area

- 80 mm / 150 mm extruders for insulation and sheathing
- Tandem lines (80+50 etc.) for high productivity
- Sioplas and MVCC cross-linking systems for MV/HT cables
- E-beam accelerator hall, with shielded area and specialised handling

Testing & QA Area

- Routine test bays for LV cables
- HT lab for MV & HT testing up to 33 kV
- Mechanical and physical test laboratory for polymer and conductor tests

Integrated Process Flow – From Rod to Reel

1. Raw Material Receipt & Inspection
- Copper / aluminium rods
- Compounds (PVC, XLPE, Sioplas, special polymers)
- Steel wires, tapes, armour materials

2. Wire Drawing & Annealing
- RBD for converting rods into smaller sizes
- Intermediate and fine drawing with online annealing for conductor grades

3. Stranding / Bunching / Laying
- Multi-wire bunchers for flexible conductors
- Rigid and skip stranders for power cores (e.g. 6+1, 19, 37, 61)
- Drum twisting for large section cables

4. Armouring, Screening & Taping
- Steel wire/strip armouring
- Copper tapes, steel tapes and screening tapes as required
- Multiple taping heads for instrumentation and control cables

5. Extrusion, Cross-linking & Sheathing
- Insulation extrusion (PVC / XLPE / Sioplas)
- Bedding / inner sheath and outer sheath extrusions
- E-beam cross-linking or MVCC/Sioplas curing as per product design

6. Testing & Quality Assurance
- Online testing (spark, diameter, marking)
- Offline electrical, mechanical and fire performance tests

7. Coiling, Drum Winding & Dispatch
- Automatic coiling for small sizes
- Drum winding for higher sizes and long lengths
- Final inspection, documentation and dispatch

Technology Focus – Electron Beam (E-Beam) Cross-linking

E-beam cross-linking is at the heart of RG POWER’s advanced cable offerings.

What is E-Beam Cross-linking?
In E-beam cross-linking, high-energy electrons are used to modify the molecular structure of polymeric materials used in cable insulation and sheathing. This creates a three-dimensional network within the polymer, significantly improving its performance.

Key Advantages
- Higher continuous operating temperature ratings
- Improved current-carrying capacity
- Excellent resistance to heat, ozone, oils, chemicals and abrasion
- Superior ageing characteristics and extended service life
- Potential reduction in insulation thickness, enabling more compact cable design

Applications
- Cables in high-temperature industrial environments
- Renewable energy and solar cables
- Special instrumentation and control cables subjected to harsh conditions
- OEM applications where cable reliability is mission-critical

Technology Focus – MVCC & Sioplas Systems
For medium and high-voltage cables, RG POWER uses MVCC and Sioplas (dry-cure silane) technologies to produce XLPE-insulated power cables.

MVCC (Medium Voltage Continuous Curing)
- Continuous vulcanisation process for MV cables
- Ensures uniform cross-linking of XLPE insulation
- Improved dielectric strength and long-term stability

Sioplas (Dry-Cure Silane Technology)
- Two-component silane system where cross-linking occurs via moisture curing
- Enables reliable XLPE performance with controlled curing conditions
- Widely used in MV cable production due to versatility and process flexibility

Benefits for Customers
- Reliable MV/HT cable performance up to 33 kV
- Stable electrical characteristics under thermal and electrical stress
- Enhanced mechanical strength and environmental resistance

Integrated Process Flow – From Rod to Reel