Nirmal Wires to increase production capacity of Aluminium rods from 3,000 to 10,000 tons per month

Advanced zinc and zinc- aluminium coatings can enhance durability in renewable energy infrastructure, protecting wind turbines and solar panel structures against corrosion.

With over 50 years in the steel industry, Nirmal Wires has witnessed the rapid growth of the steel sector in India, now the second-largest producer globally. While production levels in India still trail behind China, Indian steel products are increasingly gaining popularity in international markets. India’s growing recognition drives this shift as a reliable supplier that offers high-quality products at competitive prices. The ‘China plus one’ strategy, once focused on, is now evolving into ‘India plus one’, signalling India’s rising prominence as an alternative source. This trend marks a significant opportunity for further expansion and global positioning.. Nirmal Saraf, Managing Director of Nirmal Wires (Group Nirmal), shares insights into the industry through an interaction with EPR.

What are the key areas of the renewable energy sector to which you can contribute?

One key area where we can contribute to the renewable energy sector is through the production of zinc wires, which are used for corrosion protection in windmills and other structures. Wind turbines, a significant part of the renewable energy framework, require long-lasting protection to ensure their durability and efficiency. By coating the steel structures of windmills with zinc wires, we can help extend their life, making them more resilient against environmental wear and tear.

Steel wires are a vital component in numerous engineering applications, and their use in renewable energy is no exception. Steel structures, such as solar panel systems, are foundational in many renewable energy installations. These systems often rely on steel frames to support panels lasting 30 to 40 years. However, the supporting structure’s durability often limits the panels’ lifespan. By providing corrosion protection to these steel frames, we can significantly enhance their longevity, ensuring that renewable energy assets operate efficiently for many years.

Our corrosion protection innovation includes advanced zinc-aluminium coatings, which offer three times the lifespan of standard zinc coatings. We are also exploring zinc-aluminium-magnesium alloys for coating steel, further improving corrosion resistance. These coatings help preserve the integrity of the steel structures, ensuring they remain functional and durable over the long term.

Through these innovations, we aim to significantly contribute to the renewable energy sector by extending the life of the supporting infrastructure. By enhancing the durability of the steel used in wind turbines, solar panel structures, and other renewable energy assets, we can help ensure that these technologies operate sustainably for decades.

How can the industry integrate customer-centric solutions and flexible financial models for sustainable growth?

The steel industry and its broader applications are poised for significant growth, with India at a pivotal point. Currently, steel production in India stands at 130 million tons, a stark contrast to China’s 1,000 million tons, representing nearly seven times growth potential. This gap highlights a massive opportunity for expansion in the steel sector and beyond. The key to capturing this growth lies in increasing production and focusing on value-added products that meet customers’ evolving needs. 

As industries shift towards customer-centric approaches, the focus will move from simply manufacturing products to offering solutions that directly serve customers. The same principle can be applied in the steel industry as software has transitioned from a product to a service model through cloud-based subscriptions. For instance, instead of purchasing a steel fence upfront, customers could pay for it based on usage, much like a subscription model. This approach reduces the financial burden on the customer and allows for continuous service and support, ensuring longevity and lower lifecycle costs.

The future of product development lies in integrating technology with financial engineering. By combining innovative product design with flexible financial solutions, companies can offer customers products that evolve with their needs. This shift from capital investment to a pay-as-you-go model enables more customers to access high-quality products without the upfront costs while ensuring that they realise the value through long-term savings and support. The focus must be on innovation, customer satisfaction, and seamless technology integration to provide sustainable and cost-effective solutions for the future.

How do you plan to scale production capacity, and how does your product improve energy transmission efficiency and reduce costs?

We have recently acquired a strategically located unit in Khurda, positioned about 40 kilometres from Bhubaneswar and 100 kilometres from key aluminium manufacturing hubs like Angul, Sambalpur, and Jharsuguda. These areas house major smelters such as NALCO, BALCO, and HINDALCO, making the location ideal for logistics and supply chain efficiency. Our production capacity is 3,000 tons per month, with plans to expand to 10,000 tons monthly in the near future. This expansion positions us as a significant player in the aluminium rod market.

Our core focus at this unit is on the quality of our aluminium products. Rather than selling aluminium by weight, we aim to market our products based on their current-carrying capacity. Customers are primarily concerned with efficient energy transmission, not just the material itself. Therefore, our selling point is to offer solutions that enable more cost-effective energy transmission, ultimately benefiting both the customer and the broader economy.

We plan to educate our customers on how choosing our products will lead to more affordable energy transmission solutions. By emphasising the current characteristics of our aluminium rods and how they contribute to energy savings, we aim to shift the focus from mere weight to the real value our products bring. This approach will ensure that our customers understand that they are investing in a product that will deliver superior energy transmission capabilities at a better price, contributing to their long-term savings and efficiency.

How can the industry ensure total quality control to enhance consumer electricity experience?

I want to convey to the entire industry that we must upgrade our quality standards. We must not only meet international standards but strive to exceed them. To illustrate this, let us take the example of supplying a conductor. The end consumer of this conductor is the individual who receives electricity in their home. If the conductor’s quality is compromised, the electricity reaching the consumer will be subpar. This ripple effect impacts the overall consumer experience.

It is critical to understand that the end customer, the individual who consumes the electricity, is ultimately the true recipient of our product. By ensuring total quality control, we can enhance the end-user experience. As suppliers, we need to ensure that our products deliver functional reliability and a superior experience for the consumer. Every step in the supply chain plays a role in shaping this outcome. By focusing on the end consumer’s satisfaction, we set ourselves on a path for continued success and innovation. Through this commitment to quality, we advance in the competitive market.