Raising the standards of wires and cables for a safe power supply

The Union Budget serves as the cornerstone and roadmap for the “Amrit Kaal” economy for the next 25 years, emphasising research and development for burgeoning industries, eco-friendly solutions, and technological progress in pursuit of a thriving economy. The budget prioritises building the framework for 5G spectrums and optical fibre and facilitating accessible broadband services in rural regions, further propelling the wire and cable sectors.
The emphasis is on clean and sustainable energy for powering electric vehicles, intending to foster industrial progress and promote overall national growth. This represents a noteworthy advancement, as addressing clean energy requirements holds great promise for the country.
The GOI has sanctioned ₹3,03,758 Crore over five years to reduce pan-India AT&C losses to 12-15 percent and eliminate the ACS-ARR gap by 2024-25. This move will aid DISCOMs in enhancing their financial sustainability and operational efficiencies, creating ample opportunities for the cable industry. In the ensuing discussion, we will discuss how companies prioritise quality and safety-critical wire and cable installations to address the related challenges.
Safe and reliable power through high-quality wires and cables
As the demand for power increases and renewable sources are being used more frequently, there will be a growing need for wires and cables with new and advanced features. In India, an emerging economy with significant growth in the construction and infrastructure sectors such as real estate, hotels, hospitals, and educational institutions, the wire and cable industry is also experiencing significant growth.
The budget’s main focus is on holistic development, which is favourable for most manufacturing industries, including the wire and cable industry. The current budget draws from the previous financial year’s budget, which suggests it will benefit the wire and cable industry.
Shashi Amin, CEO of Apar Industries, highlights that as their innovative APAR Anushakti house wire, which is powered by e-beam technology and is melt-resistant, fire-retardant, and offers 50 years of life. As India’s largest manufacturer of electron beam cables, Apar Industries has three e-beam accelerators (1.5 MeV, 2.5 MeV, and 3 MeV) and has recently commissioned a 2.5 MeV e-beam line at their Khatalwada plant in Gujarat. To meet the growing demand for cable products that are easy to install and last, Amin is developing a complete range of cable harnesses for locomotives and railway coaches, earthing kits for rolling stock, PA system cable harnesses, and more.
Arvind Agrawal, Senior Vice President of Havells India, notes that the construction industry is shifting towards using flame retardant low smoke and low smoke zero halogen products, which offer improved fire safety and resistance properties. He emphasises the importance of maintaining high-quality standards and customer trust, focusing on minimising costs and avoiding product failures. To achieve this, Havells India invests in state-of-the-art machinery and uses high-quality raw materials to ensure cost-effectiveness and superior product quality.
Prospects for green or sustainable wires and cables
APAR Industries has made significant progress in environmental performance, energy conservation, and improved safety considerations in product design. Its ESG initiatives include:

• Water conservation.
• Reducing fossil fuel-based grid energy consumption.
• Increasing rainwater harvesting capacities for sustainable water security at various plants.

Amin also states that APAR has entered into a definitive agreement with a leading supplier to jointly develop a 3 MW hybrid power project (wind-solar hybrid) under the captive group model.
With a target of 500 GW of renewable energy by 2030 and new Renewable Purchase Obligations, DISCOMs are required to purchase renewable power, transforming from fossil fuel-based energy to renewable energy. This development will naturally synchronise with the cable market’s growth. Amin explains that the ₹ 19,500 Crore solar PLI scheme and 449 ongoing projects totalling $181.86 billion will skyrocket demand for sustainable and eco-friendly cables.
As the power sector undergoes smart evolutions, wires and cables, play an important role in carrying current. With renewable power gaining momentum, the types of cables being used are transforming, with RoHS-compliant material being used in cable production. According to Agrawal, wires such as HR-FR, FRLS-H, and HFFR are specifically designed to maximise safety while minimising environmental implications. More wires are being manufactured without lead, which harms the environment, and cables are being developed without materials like halogen to prevent the emission of harmful gases or soil contamination. Agrawal also highlights the increasing trend in using flame retardant low smoke and low smoke zero halogen products in the construction industry, which has better fire safety and fire-resistant properties.
Substandard wires and ecosystem
The backbone of any electrical distribution network is cables. However, selecting the appropriate cable for a specific application requires prioritising annual operating costs and ensuring safe and functional performance. Amin expresses concern that substandard cables lead to direct financial loss due to high annual running costs and unsafe conditions. The nation suffers significant losses due to excessive energy consumption caused by using substandard cables. Typically, aluminium and copper make up more than 70 percent of the total cost of a cable.
Amin suggests that small cable manufacturers who do not hedge against fluctuating raw material prices cut corners by drawing down the smaller diameter of wires or using impure or recycled material to reduce the input cost of copper or aluminium. Such practices can seriously affect direct financial loss in terms of excessive power consumption, overheating, and the level of safety in the electrical system network. Furthermore, Agrawal stresses that substandard wires have inferior quality raw materials, an under-gauge conductor, or less insulation thickness, leading to increased chances of an electric fire or shock.
Although Indian wire and cable manufacturers mainly use PVC insulation conforming to Bureau of Indian Standards (BIS) specifications and codes included in the National Building Code of India, the long-term challenge is raising awareness among consumers and electricians. Wires and cables are often given little to no attention after installation and are only revisited when they need replacement or repair.
The key factor in India that needs improvement is using the correct product for the right application. Additionally, the proper termination of all electrical circuits is essential. Understanding all the technical details of an electrical system may be challenging for a layperson, and it is essential to trust an experienced professional for wiring, rewiring, and maintenance work. A typical case study shows that a cable purchased at a 10 percent lower price may become 20 percent more expensive for a lifetime if proper attention is not given to the quality of the cables.
Great emphasis on the quality of wires and cables
APAR is committed to continuously improving its cable facilities in Umbergaon and Khatalwada in Gujarat by implementing Kaizen and Lean Six Sigma programs. They also invest in new technologies and methods to make operations more efficient, reduce waste, and enhance their products and services. APAR’s R&D team is currently developing high-amped cables with high-temperature capabilities, improving anti-rodent properties, and designing specialised cables for specific applications in defence, telecom, renewable energy, and other industrial segments.
On the other hand, Havells prioritises consumer safety and promotes halogen-free flame retardant (HFFR) insulated wires to minimise hazardous emissions and smoke during fire outbreaks. Environmental and safety concerns drive the shift towards alternative FRLS-H, Halogen-Free Flame-Retardant (HFFR) compounds from PVC insulation.
India’s manufacturing industry has enormous potential for global recognition and job creation for the youth, particularly in the electronic item sector, with the government providing duty concessions. However, executing announced measures for the power and electrical sectors is crucial to emphasise sustainability. The measures should benefit the steel and infrastructure sectors and produce solid macroeconomic growth.
Shashi Amin, CEO of APAR Industries 
Sub-standard cables lead to direct financial loss due to high annual running costs and unsafe conditions.
Arvind Agrawal, Senior Vice President, Havells India 
Cables are being developed without materials like halogen to prevent harmful emissions.