POLYCAB HV XLPE cables are manufactured at its most modern manufacturing setup in DAMAN. Manufacture of HV XLPE CABLES requires great care and skill at all stages of processing. Work on HV cables has shown to raise the electric stress of XLPE cables it is essential that the extruded insulation is of high cleanliness without any imperfection, free of contamination, voids and manufacturing defects, and that the screen interface is smooth. In addition an integrated extrusion plant employing a Continuous Centenary Vulcanizing (CCV) process line (Dry Curing Line) is required. Polycab easily met these two criteria by carefully selecting imported insulating materials and by installing 2 CCV lines sourced from world renowned manufacturers.
The cable core is triple extruded and crosslinked in the fully enclosed process in which the inner “semi-conducting” screen, the XLPE insulation and the outer semi conducting screen are applied simultaneously  to the pre-heated cable conductor. Specialized in-line inspection techniques using X-rays are employed to monitor the dimensional accuracy of the extruded core. These examinations confirm the correct levels of dimensional accuracy.
The final stage of HV cable manufacture is the high voltage test, which comprises an HV withstand, and a partial discharge detection test. These tests take place in Polycab’s sophisticated HV Test Lab . The tests are of short duration, typically 30 minutes, and are capable of detecting the defects that initiate partial discharges, as small as one “pico-coulomb”. Such defects lead to gradual deterioration of the XLPE and eventually breakdown may occur.

WINDING WIRESKamadhenu manufactures POWER-FLEX® Polyester and Bi-axially Oriented Polypropylene (BOPP) wrapped copper winding wires. These are used in starter coil winding of borewell and open well submersible motors.
POWER-FLEX® winding wires have the electrolytic grade annealed bare copper conductor wrapped in triple layer with Polyester and BOPP films and heat sealed to ensure perfect concentricity around the conductor for high dielectric qualities with very less leakage current and can with stand operation even at 130o C.
High quality levels are in-built into the wires at every stage of manufacture and the finished product meets the BIS standard IS:8783 (Part 4/Section 3) 1995.

COPPER PROFILESKamadhenu manufactures Copper Profiles as per customers requirements and is the preferred supplier to leading submersible motor manufactures.

CONDUCTOR:POWER-FLEX® Single core and Multicore cables are manufactured using Electrolytic Grade 99.97% purity copper with more than 100% conductivity. The high purity & conductivity ensures superior working of the wires throughout their life. The conductor is drawn from bright electrolytic grade copper and annealed copper are bunched tightly together in heavy duty high speed bunchers in circular construction to get perfect concentric shape without any loose strands.

INSULATION:The bunched conductors are insulated with specially formulated PVC compounds with additional FR properties whose values exceed the specifications laid down by the Bureau of Indian standards. The compound is resistant to moisture, oil, alkali and grease and has high insulation and dielectric values. The FR properties with high Oxygen and temperature index help in restricting propagation of fire at high temperatures. The insulation is carried out on state-of-the-art high speed double extrusion lines with self centering cross head. Automatic diameter controllers ensures precision centering and perfect concentric insulation. The skin insulation determines the colour identification while the inner layer is pure insulation free from any impurities. The high quality tooling ensures smooth insulation.
Online spark testers ensure fail proof high voltage test by employing non destructive form of testing at six times the rated voltage ensuring consistent application of voltage throughout the length of the cable.

POLYCAB HV XLPE cables are manufactured at its most modern manufacturing setup in DAMAN. Manufacture of HV XLPE CABLES requires great care and skill at all stages of processing. Work on HV cables has shown to raise the electric stress of XLPE cables it is essential that the extruded insulation is of high cleanliness without any imperfection, free of contamination, voids and manufacturing defects, and that the screen interface is smooth. In addition an integrated extrusion plant employing a Continuous Centenary Vulcanizing (CCV) process line (Dry Curing Line) is required. Polycab easily met these two criteria by carefully selecting imported insulating materials and by installing 2 CCV lines sourced from world renowned manufacturers.
The cable core is triple extruded and crosslinked in the fully enclosed process in which the inner “semi-conducting” screen, the XLPE insulation and the outer semi conducting screen are applied simultaneously  to the pre-heated cable conductor. Specialized in-line inspection techniques using X-rays are employed to monitor the dimensional accuracy of the extruded core. These examinations confirm the correct levels of dimensional accuracy.
The final stage of HV cable manufacture is the high voltage test, which comprises an HV withstand, and a partial discharge detection test. These tests take place in Polycab’s sophisticated HV Test Lab . The tests are of short duration, typically 30 minutes, and are capable of detecting the defects that initiate partial discharges, as small as one “pico-coulomb”. Such defects lead to gradual deterioration of the XLPE and eventually breakdown may occur.

WINDING WIRESKamadhenu manufactures POWER-FLEX® Polyester and Bi-axially Oriented Polypropylene (BOPP) wrapped copper winding wires. These are used in starter coil winding of borewell and open well submersible motors.
POWER-FLEX® winding wires have the electrolytic grade annealed bare copper conductor wrapped in triple layer with Polyester and BOPP films and heat sealed to ensure perfect concentricity around the conductor for high dielectric qualities with very less leakage current and can with stand operation even at 130o C.
High quality levels are in-built into the wires at every stage of manufacture and the finished product meets the BIS standard IS:8783 (Part 4/Section 3) 1995.

COPPER PROFILESKamadhenu manufactures Copper Profiles as per customers requirements and is the preferred supplier to leading submersible motor manufactures.

CONDUCTOR:POWER-FLEX® Single core and Multicore cables are manufactured using Electrolytic Grade 99.97% purity copper with more than 100% conductivity. The high purity & conductivity ensures superior working of the wires throughout their life. The conductor is drawn from bright electrolytic grade copper and annealed copper are bunched tightly together in heavy duty high speed bunchers in circular construction to get perfect concentric shape without any loose strands.

INSULATION:The bunched conductors are insulated with specially formulated PVC compounds with additional FR properties whose values exceed the specifications laid down by the Bureau of Indian standards. The compound is resistant to moisture, oil, alkali and grease and has high insulation and dielectric values. The FR properties with high Oxygen and temperature index help in restricting propagation of fire at high temperatures. The insulation is carried out on state-of-the-art high speed double extrusion lines with self centering cross head. Automatic diameter controllers ensures precision centering and perfect concentric insulation. The skin insulation determines the colour identification while the inner layer is pure insulation free from any impurities. The high quality tooling ensures smooth insulation.
Online spark testers ensure fail proof high voltage test by employing non destructive form of testing at six times the rated voltage ensuring consistent application of voltage throughout the length of the cable.