Nirmal Wires expands into cable production  

Nirmal Wires is at the forefront of innovation in the wire and cable industry, focusing on advanced manufacturing processes, sustainable practices, and digitalisation. With a strong commitment to R&D, the company is expanding its capabilities to meet the growing demands of the renewable energy sector and contribute to the country’s infrastructure development. Nirmal Saraf, Managing Director of Nirmal Wires (Group Nirmal),  delves into the industry to share more insights.  

How does Nirmal Wires plan to leverage digitalisation and automation to enhance operational efficiency and sustainability?

At Nirmal Wires, we drive efficiency through continuous innovation. We leverage advanced manufacturing processes such as high-speed wire drawing and precision extrusion while prioritising sustainability through recycling byproducts and energy-efficient practices. We are also extending our focus towards digitalisation by integrating automation and data analytics into our state-of-the-art facilities to streamline operations, manage inventory, and improve customer service. Committed to innovation and quality, we continuously invest in various R&D initiatives to develop innovative products that cater to the unique demands of various industries. This commitment is further strengthened by our recent acquisition of a new 50,000 MT plant in Khurda, Orissa, enabling us to expand our offerings in the power sector with sustainable solutions like AL-59, ACAR and ACSS conductors. We have also recently ventured into the production of various cable products, including LT PVC, LT AB and LT XLPE Cables, to cater to the expanding needs of the power industry. Our consistent efforts towards integrating green practices throughout our operations, along with a commitment towards innovation and upholding the highest quality standards, reassures our ability to deliver cutting-edge solutions that enhance efficiency and sustainability across industrial and commercial sectors. 

How are advancements in cable technology supporting the integration of renewable energy into India’s grid?

The rapid urbanisation and booming renewable energy sector in India, which witnessed a 15.83 per cent increase in power generation, are driving significant changes in the country’s power infrastructure. The increasing demand for solar and wind power is generating demand for cables that withstand extreme weather, high voltages and the fluctuating nature of these sources. Examples include specialised cables with UV-resistant insulation for solar power and strong winds and extreme temperatures for wind power. The integration of renewable energy into the grid is pushing the demand for high-voltage direct current (HVDC) cables for efficient long-distance transmission, while the rise of distributed generation setups like rooftop solar panels is increasing the need for advanced medium- and low-voltage cables with higher power capacity and improved insulation technology, like XLPE. The development of ‘smart cables’ equipped with sensors for real-time monitoring of temperature, current, and voltage to enable predictive maintenance, improve grid reliability and enhance the overall efficiency of the renewable energy system is also a result of the growing demand for renewable energy in India. These advancements are crucial for ensuring renewable energy’s reliable and efficient integration into the grid and supporting the transition to a sustainable energy future. 

How can the wire and cable industry address evolving demands for smart grid and IoT integration?

Integration of smart grids and IoT technologies are revolutionising the Indian wire and cable industry, which is leading to an increasing demand for advanced materials like high-temperature superconductors and fibre optics for efficient, data-driven power transmission. This shift necessitates the development of specialised cables for diverse applications like connecting renewable energy sources. Furthermore, the industry must prioritise reliability, durability, and sustainability while being vigilant towards cyber security challenges and integrating advanced manufacturing techniques. The integration of IoT will enable real-time monitoring, predictive maintenance and data-driven design optimisation, which will lead to improved efficiency and reduced downtime. With modernisation and increased automation, the demand for high-speed communication and control systems will soar, requiring robust cabling infrastructure. Ultimately, the industry’s success hinges on continuous innovation, collaboration, and a proactive approach towards addressing the evolving needs of a smarter, more interconnected energy landscape. 

How can the Indian wire and cable industry capitalise on Budget opportunities to drive growth and innovation?

With its enhanced focus on renewable energy, particularly solar and wind power, this year’s budget brings renewed emphasis on infrastructure development. This presents significant opportunities for the Indian wire and cable industry, especially those utilising aluminium conductors. Compared to previous budgets, the increased allocation for solar power projects directly translates to a surge in demand for solar cables, often employing lightweight and cost-effective solutions. Furthermore, grid modernisation initiatives to accommodate the growing renewable energy capacity will gradually necessitate using highly efficient transmission lines, where aluminium conductors excel due to their superior conductive capacity and lower weight. The government’s continued support for domestic manufacturing, including PLI schemes and a focus on MSMEs, can incentivise domestic production of aluminium conductors, reducing reliance on imports and fostering innovation within the industry. To leverage these opportunities, it is important to invest in Research & Development to develop innovative and cost-effective conductor technologies, expand manufacturing capacity in quantity and quality to meet the growing demand, focus on reliability and invest in skill development programmes to enhance the workforce. Proactively addressing these areas will help the Indian wire and cable industry to effectively harness the opportunities presented by the budget and contribute significantly to the nation’s economic growth, infrastructure development and energy transition.

How do your expanded aluminium and cable capabilities align with the evolving demands of India’s power sector?

At ELECRAMA 25’, we are excited to share our expanded aluminium capabilities, showcasing a diverse portfolio of cutting-edge power supply innovations. From high-performance aluminium rods (EC Grade & Alloy) and AL-59 rods to specialised conductors like ACAR, ACSS & AACSR, our solutions are engineered to meet the evolving demands of the dynamic power industry. Our upcoming plant at Khurda, Orissa, adds up to 50,000 MT of capacity in our aluminium business, positioning us to effectively address the surging demands of the Indian wire and cable industry. Our brand of cable products, Nirmal Cables, is also active now, and we are producing significant quantities LT PVC, LT AB and LT XLPE Cables. With the rising demand for our cable products, we are looking at possible expansion in our cable manufacturing capacities to better service the industry. Furthermore, our recent acquisition of Cee Dee Metalloys has enabled us to offer a comprehensive range of high-quality zinc products such as pure zinc wires, zinc rods and zinc aluminium wires (85/15 composition). As we look towards the future of the power sector, we remain committed to providing high-quality, reliable solutions that meet and exceed industry standards, contributing to a sustainable and efficient energy landscape.