Manufacture of Electrical Cables, Wire and Wire Products Handbook ( New Arrival ) ( ) ( ) ( ) ( )
Author P.K. Tripathi ISBN 9788195676996
Code ni342 Format Paperback
Price: Rs 2575   2575 US$ 67   67
Pages: 512 Published 2023
Publisher Niir Project Consultancy Services
Usually Ships within 5


Manufacture of Electrical Cables, Wire and Wire Products Handbook

(Copper Wire, Barbed Wire, Spring, Wire Nail, Wire Mesh, Fiber-Optic Cable, PVC Wire and Cable, Aluminum Wire, Steel Wire Rope, Galvanised Wire, Coaxial Cable, Litang Cable LAN/Ethernet Cable, Power Cord Cable, Submersible Cable, XLPE Cable with Machinery Equipment Details & Factory Layout)

The Electrical Cables, Wire and Wire Products Handbook has been written with a dual purpose in mind: the first is to provide information on the actual assembly of cables, wire, and wire products; the second is to serve as an initial reference handbook for electrical cable, wire, and wire products designers.

A successful business needs a good foundation. This handbook will provide you with the basics on electrical cables, wire and wire products. You'll learn about the different types of cables, how they're made and what goes into making a quality product. Plus, you'll get an overview of the factory layout and machinery involved in the manufacturing process. With this knowledge in hand, you'll be well on your way to starting a successful business. Explore the possibilities! Learn about production of different types of wires

The global wires and cables market size was estimated at growth rate (CAGR) of 4.4%.The global copper wire market reached a CAGR of 5.70%. The global spring market size at a CAGR of 4.5%. Global Wire Mesh Market size valued at a CAGR of 3.5%. The global fiber optic cable market a CAGR of 14.5%.‚Äč The CAGR for the plastic coated steel wires market is 6.28%. The global Aluminum Wire market is forecasted to grow at a rate of 3.3%. The global steel wire rope & plastic rope market size at a CAGR of 8.0%. The global hot-dip galvanized steel wire market is expected to grow at a CAGR of 4.5%. The global coaxial cables market size is expected growth rate (CAGR) of 9%. The global ethernet cable market size a CAGR of 11.3%. The global power cables market size a CAGR of 6.8%. The global market for Electric Submersible Cables growing at a CAGR of 3.5%. The global XLPE Cables market size is estimated a CAGR of 5.0%.

The market demand for wire and wire products is constantly growing. This is due to the increasing need for electrical power and the ever-growing telecommunications industry. The manufacture of electrical cables, wire and wire products is a highly specialized process that requires the use of sophisticated machinery and equipment. Examples of this are extruders, crimpers, cutters, heat treaters and insulation converters. These are all machines used in the production of specific types of wire and cable such as copper wire, aluminum wire or fiber optic cable, Barbed Wire, Wire Nail, PVC Wire, Steel Wire. There are also many other types including galvanized steel wire rope, steel springs and metal mesh screens.

The Manufacture of Electrical Cables, Wire and Wire Products Handbook is a comprehensive guide everything from the conception of your business to the execution of your product. This book provides detailed instructions on how to start a business, including how to write a business plan, and how to manufacture your product.

The book covers the manufacture of electrical cables, wire and wire products. It includes production of copper wire, barbed wire, spring wire nail, wire mesh, fiber-optic cable, PVC wire and cable, aluminum wire, steel wire rope, galvanized wire, coaxial cable, litang cable LAN/ethernet cable, power cord cable, submersible cable, XLPE cable with machinery equipment details & factory layout.





1.    Introduction

        1.1        Introduction

        1.2        Wire

        1.3        Cable

        1.4        Different Uses of Wire and Cable

                     1.4.1       Use of Wire

                     1.4.2       Use of Cable

        1.5        Understanding Electrical Wire

        1.6        Size of the Wires

        1.7        Wire Lettering

        1.8        Types

        1.9        Types of Electrical Cables

        1.10     Color-Coded Cable

        1.11     Cable Length

        1.12     Different Advantages of Using Wire and Cable

                     1.12.1     Advantages of Wire

                     1.12.2     Advantages of Cable

2.    How are Electrical Wires Manufactured?

        2.1        Wire Drawing

        2.2        Annealing

        2.3        Wiring

        2.4        Hot Extrusion

        2.5        Voltage Checks

        2.6        Wiring Phases

        2.7        Additional Defense

3.    Copper Wire

        3.1        Types

                     3.1.1       Solid and Stranded

                     3.1.2       Cable

        3.2        Applications

        3.3        Interactive Graphic of Ions and Electrons

                     3.3.1       Electrical Wiring

                     3.3.2       Communications Wiring

                     3.3.3       Coaxial Cables

                     3.3.4       Structured Wiring

                     3.3.5       Power Distribution

                     3.3.6       Appliance Conductors

        3.4        Automotive Conductors

        3.5        Magnet Wire

        3.6        Uses

                     3.6.1       Telecommunication

                     3.6.2       Electricity Supply

                     3.6.3       Automobile Industry

                     3.6.4       Jewelry

        3.7        Copper’s Properties

        3.8        How Copper Conducts

        3.9        Interactive Graphic of Electrical Conduction

                     3.9.1       Conducting Electricity

        3.10     Properties of Copper Useful for the Copper Wire

        3.11     Properties of Copper Wire

                     3.11.1     Electrical Conductivity

                     3.11.2     Tensile Strength

                     3.11.3     Ductility

        3.12     Strength and Ductility Combination

                     3.12.1     Resilience to Creep

                     3.12.2     Corrosion Resistance

                     3.12.3     Coefficient of Thermal Expansion

                     3.12.4     Thermal Conductivity

                     3.12.5     Solderability

                     3.12.6     Ease of installation

        3.13     Splice Closures for Copper Cables

        3.14     Types of Closures

        3.15     Future Trends

        3.16     Pure Copper & Its Importance

        3.17     Certification

        3.18     Magnetometer Test

        3.19     Conductivity and Resistance

        3.20     Density

4.    Copper Wire Manufacturing Process

        4.1        Drawing Process

        4.2        Annealing Process

        4.3        Bunching / Stranding Process

        4.4        Tinning Process

        4.5        Hot Dip Process

        4.6        Electroplating Process

        4.7        Braiding

        4.8        Process for Tinsel Wire

        4.9        Process of Glass Wire

        4.10     Copper Wire Recycling Process

        4.11     Negative Impacts of Using Low-Temperature Burning Process

        4.12     Benefits of Recycling Copper Wire

5.    Copper Wires and Upcoming Trends

        5.1        Prominent Use of Copper Wires

        5.2        Copper: A Preferred Metal for Electric Wiring Purpose

6.    How to Start a Spring Manufacturing Plant

        6.1        Understand the Type of Device Spring Manufacturing Facility will Provide

        6.2        Locate Suppliers for Spring Manufacturing Facility

        6.3        Promote the Spring Manufacturing Industry

7.    Springs

        7.1        Classification

        7.2        Many Kinds

        7.3        Many Kinds of Springs

        7.4        Different Types of Springs: Compression, Extension, Torsion, & Constant Force Springs

        7.5        Torsion Spring

        7.6        Constant Force Spring

        7.7        High-Carbon Spring Steels in Wire Form

        7.8        High-Carbon Spring Steels in Flat Strip Form

        7.9        Alloy Spring Steels

        7.10     Stainless Spring Steels

        7.11     Copper-Base Spring Alloys

        7.12     Nickel-Base Spring Alloys

        7.13     Nickel-Base Spring Alloys with Constant Moduli of Elasticity

        7.14     Metal Springs

        7.15     Springs Types and Common Spring Materials

                     7.15.1     Compression Springs

                     7.15.2     Springs Hooke‘s Law

                     7.15.3     Helical Compression Springs

                     7.15.4     Helical Tension Springs

                     7.15.5     Helical Torsion Springs

                     7.15.6     Special Springs

        7.16     Spring End Types

        7.17     Chapter Four – Common Spring Materials

        7.18     Carbon Steel Springs

        7.19     Alloy Steel

        7.20     Stainless Steels

        7.21     Non-Ferrous Alloys

8.    Spring Manufacturing Process

        8.1        Spring Design

        8.2        Spring Manufacturing

        8.3        According to Design & Row Material Standard

                     8.3.1       Cold Coiling

                     8.3.2       Hot Winding

                     8.3.3       Heat Treatment

                     8.3.4       Grinding

                     8.3.5       Shot Peening (Shot Blasting)

                     8.3.6       Coating

        8.4        Compression Springs

        8.5        Selection a Compression Spring

9.    Wire Nail Manufacturing Business Idea

        9.1        Legal Process Pertaining to the Production of Iron Wire Nails

        9.2        A Wire Nail or the Equipment Needed to make Nails out of Iron Wire

10.  Wire Nails

        10.1     Cut and Wire Nails Differently

        10.2     Uses

        10.3     Specification

        10.4     Market Potential

        10.5     Types

        10.6     Nail Materials

        10.7     Sized

                     10.7.1     Common Nails

                     10.7.2     Box Nails

                     10.7.3     Duplex Head Nails

                     10.7.4     Annular Ring or Ring Shank Nails

                     10.7.5     Masonry/ Concrete Nails

                     10.7.6     Casing/ Finish Nails

                     10.7.7     Brad Nails

                     10.7.8     Roofing Nails or Clout Nails

        10.8     Applications

        10.9     Classification

11.  Wire Nail Manufacturing Process

        11.1     Manufacturing Process

        11.2     Design

        11.3     Raw Materials

        11.4     Manufacturing Process

        11.5     Nail-Making Machines in Series

        11.6     Machine for Combining and Continuous Wire Drawing

        11.7     Forming

        11.8     Further Forming

        11.9     Finishing

        11.10   Packaging

        11.11   Quality Assurance

        11.12   The Upcoming

        11.13   Technical Data of Wire Nail Making Machine

12.  Wire Mesh

        12.1     A Great Variety of Shapes and Applications

        12.2     Characteristics

                     12.2.1     Welded Wire Mesh

                     12.2.2     Wire Fabrics

                     12.2.3     Wire Nettings

        12.3     Basics of Wire Mesh

        12.4     How Wire Mesh is Made

                     12.4.1     Wire Weaving

                     12.4.2     Welded Wire Mesh

        12.5     Types of Wire Mesh

        12.6     What is Welded Wire Mesh?

                     12.6.1     Galvanized Wire Mesh

                     12.6.2     Vinyl-Coated Wire Mesh

                     12.6.3     Welded Steel Bar Gratings

                     12.6.4     Stainless Steel Wire Mesh

                     12.6.5     Wire Mesh Patterns

                     12.6.6     Crimped Wire Mesh

                     12.6.7     Non-Crimped Wire

                     12.6.8     Double Weave Wire Mesh

                     12.6.9     Flat Top Weave Wire Mesh

                     12.6.10   Twill Weave Wire Mesh

                     12.6.11   Dutch Weave Wire Mesh

                     12.6.12   Off Count Wire Mesh

                     12.6.13   Stranded Weave Wire Mesh

                     12.6.14   Mesh Count

                     12.6.15   Wire Mesh Edges

        12.7     Wire Used to Make Wire Mesh

                     12.7.1     Carbon Steel in Wire Mesh

                     12.7.2     Stainless Steel in Wire Mesh

                     12.7.3     Aluminum Wire in Wire Mesh

                     12.7.4     Copper in Wire Mesh

                     12.7.5     Brass in Wire Mesh

                     12.7.6     Bronze in Wire Mesh

        12.8     Uses for Wire Mesh

        12.9     Benefits

        12.10   Market Potential

        12.11   Basis and Presumptions

13.  Welded Wire Mesh Manufacturing Process

        13.1     Wire Rod

        13.2     Cold Rolling

        13.3     Straightening & Cutting

        13.4     Welding

        13.5     Bending & Cutting

        13.6     Finished Mesh

14.  Motions in Wire Mesh Weaving Process

        14.1     Steps Involved in Weaving

15.  Fiber Optic Manufacturing Process

        15.1     Step 1: Prepare and Purify the Raw Materials for Fibre Optics

        15.2     Step 2: Surface Treatment and Melting of the Fibre Optic Core-Rod

        15.3     Step 3: Primary Coating Process and Wire Drawing

                     15.3.1     Process of Primary Coating

        15.4     Step 4: Sorting and Colouring of Fibre Optic Cable Tension

                     15.4.1     Tension Sorting

                     15.4.2     Fiber Optic Coloring Process

        15.5     Step 5: Fiber Optic Secondary Coating or Plastic Coating

        15.6     Step 6: Fiber Optic Cable Core Manufacturing Process (Cable Forming Process)

                     15.6.1     Cable Forming Technology of Layer Stranded Optical Cable

                     15.6.2     SZ Stranding Process

        15.7     Step7: Extrusion Technology of Optical Cable Integrated Jactketing

                     15.7.1     Optical Cable Water Blocking Technology

                     15.7.2     Process of Longitudinal Jacketing

                     15.7.3     Extrusion of Plastic

                     15.7.4     Protective Technology

                     15.7.5     Integrated Jacketing Production Line

16.  Fiber Optic Patch Cord and Pigtail Production

        16.1     Step.1 Fiber Optic Patch Cord Cable Cutting

        16.2     Step.2: Cleaning and Proper Handling of Fibre Optic Patch Cables

        16.3     Step.3 Stripping and Labeling Fiber Patch Jumper Cable

        16.4     Step.4 Fiber Insertion and Fiber Injection into Fiber Optic Ferrule

        16.5     Step.5 Solidifying Fiber Patch Cord

        16.6     Step.6 Ultrasonic Cleaning & Polishing of Fiber Patch Cable

        16.7     Step.7 Fiber Jumper Microscope Inspection

        16.8     Step. 8 FQC, for a Fibre Patch Cord

        16.9     Step. 9: Fiber Patch Cord Packaging

17.  Fiber-Optic Cable

        17.1     Design

        17.2     Capacity and Market

        17.3     Reliability and Quality

        17.4     Cable Types

        17.5     Jacket Material

        17.6     Fiber Material

        17.7     Color Coding

                     17.7.1     Patch Cords

                     17.7.2     Multi-Fiber Cables

        17.8     Safety

        17.9     Hybrid Cables

        17.10   Types

        17.11   Placement

        17.12   How Fiber Optics Works

        17.13   Types of Fiber Optic Cables

        17.14   Single-Mode Fiber

        17.15   Multimode Fiber

        17.16   Fiber Optics vs. Copper Cables

        17.17   Advantages and Disadvantages of Fiber Optics

        17.18   Fiber Optics Uses

                     17.18.1   Networking and Streaming on Computers

                     17.18.2   Internet Access and Cable TV

                     17.18.3   Habitats Under the Sea

                     17.18.4   Armed Forces and Space

                     17.18.5   Medical

        17.19   What Kinds of Fibre Optic Cables Are There?

        17.20   What is the Purpose of Optical Fibre Cable?

                     17.20.1   Rapid Internet Access

                     17.20.2   Networking

                     17.20.3   Centres for Data

                     17.20.4   Military Application

                     17.20.5   Fiber vs Cable: Structure

                     17.20.6   Fiber vs Cable: Availability

                     17.20.7   Fiber vs Cable: Reliability

                     17.20.8   Fiber vs Cable: Speed

                     17.20.9   Fiber vs Cable: Cost

                     17.20.10 Other Deployments, Fiber Networks, and Fiber to the Home

18.  PVC Wire and Cable

        18.1     Introduction

        18.2     Market Potential

        18.3     Basis and Presumptions

        18.4     Technical Aspects

                     18.4.1     Process of Manufacture

        18.5     Advantages

        18.6     Tests

        18.7     Types

                     18.7.1     Cables and Wires in PVC Specialty

                     18.7.2     PVC that Resists Cold

                     18.7.3     PVC that Resists Heat

                     18.7.4     PVC that Resists Oil

        18.8     Uses

        18.9     Customizable

        18.10   Utilizable

        18.11   Process for Manufacturing PVC Cable and Wire

19.  How to Start PVC Cables Manufacturing Business

        19.1     PVC Cables Manufacturing – Market Potential

        19.2     Registration & License for PVC Cables Manufacturing

        19.3     PVC Cables Manufacturing Machine & Testing Equipment

        19.4     Double Bridge Tensile Testing Device by Kalvin

        19.5     Materials Needed to Make PVC Cables

        19.6     Manufacturing of PVC Cables

20.  Wire PVC Coating Line

        20.1     Wire Payoffs & Wire Decoilers

                     20.1.1     Features of the Novo Precision FWPO

                     20.1.2     Medium & Heavy Wire

        20.2     Wire Rolling Wheel

        20.3     PVC Wire Extruder Machine

        20.4     Barrel Charger Machine

        20.5     Cooling Flume

        20.6     Traction Engine

        20.7     Recoiling Machine

21.  Roll Mesh PVC Coating Line

        21.1     Equipment List

                     21.1.1     Auto Eletrical Pre-Heating & Curing Furnace

                     21.1.2     Fluidized Bed, Vibration Generator

                     21.1.3     Roll Mesh Delivery System

                     21.1.4     Mesh De-Coiler

22.  Fence PVC Coating Line

        22.1     Fence PVC Coating Equipment

        22.2     Process Flow

                     22.2.1     Pre-Heating

                     22.2.2     Auto Powder Immersion

                     22.2.3     Curing

                     22.2.4     Coated Work Piece Cooling

                     22.2.5     Packing Machine

23.  Wire Drawing Process

24.  Aluminum Wire

        24.1     Aluminum Wiring

        24.2     Aluminum Conductors

        24.3     Aluminium Cable

        24.4     Aluminium Wire/Rod

        24.5     Application of the Technique

        24.6     Aluminium Alloy Wire

        24.7     Technique Execution

        24.8     Aluminium Alloy Wire

        24.9     Aluminium Alloy Rod

        24.10   Executing a Technique

        24.11   Materials

        24.12   Modern Building Construction

        24.13   Electrical Device Ratings

        24.14   Oxidation

        24.15   Joining Aluminum and Copper Wires

        24.16   Upgrades and Repairs

        24.17   Aluminum Oxidation

25.  Aluminium Wire Process

        25.1     Description

        25.2     Application

                     25.2.1     Aluminum Billet Pre-Heat Furnace

                     25.2.2     Extrusion Machine

                     25.2.3     Breakdown Rolling Machine

                     25.2.4     Aluminum Wire Annealing Furnace

                     25.2.5     Contour Rolling Machine

                     25.2.6     Contour Drawing Machine

                     25.2.7     Bright Annealing Wire Line

                     25.2.8     Wire Winding Machine

26.  Steel Wire Rope

        26.1     Components of a Steel Wire Rope

        26.2     Rope Constructions and Types

                     26.2.1     Single Strand Ropes

                     26.2.2     Single Layer Stranded Rope

                     26.2.3     Multi-Strand Non-Spin Ropes

        26.3     Types of Strand Construction

                     26.3.1     Unequal Lay Strands

                     26.3.2     Triangular Strands

                     26.3.3     Ribbon and Flattened Strands

                     26.3.4     Fibre Cored Strands

                     26.3.5     Fibre Covered Strands (Marline Clad)

                     26.3.6     Compact Strand

        26.4     Lay Configuration

                     26.4.1     Type of Lay

                     26.4.2     Hand of Lay

        26.5     Tensile Strength of Steel

                     26.5.1     Finish of Steel

        26.6     Preformation

        26.7     Lubrication

        26.8     Wire Rope Composition

                     26.8.1     Steel Wire

                     26.8.2     Cord Core

                     26.8.3     Grease

        26.9     Classification

                     26.9.1     Classified by Material

                     26.9.2     Classified by Surface State

                     26.9.3     Classified According to the Method of Tanning

        26.10   Only One Strand

        26.11   Two Strands

        26.12   Three Strands

                     26.12.1   State Classification

        26.13   Construction

                     26.13.1   Wires

                     26.13.2   Strands

                     26.13.3   Spiral Ropes

                     26.13.4   Stranded Ropes

        26.14   Classification According to Usage

        26.15   Rope Drive

        26.16   Safety

        26.17   Terminations

        26.18   Thimbles

        26.19   Wire Rope Clips

        26.20   Eye Splice or Flemish Eye

        26.21   Swaged Terminations

        26.22   Wedge Sockets

        26.23   Potted Ends or Poured Sockets

27.  Steel Wire Ropes Production Process

        27.1     Wire Rod

        27.2     Surface Treatment

        27.3     First Drawing

        27.4     Patenting

        27.5     Intermediate Drawing

        27.6     Stranding

28.  Galvanised Wire

        28.1     Advantages

        28.2     Uses

                     28.2.1     Binding Materials

                     28.2.2     Protective Fencing

                     28.2.3     Making Handicrafts

                     28.2.4     Agricultural Uses

                     28.2.5     Other Daily Uses

29.  Wire Galvanising Plant

        29.1     Clientele

        29.2     Quality Assurance

        29.3     Methods

                     29.3.1     Hot-Dip Galvanizing

                     29.3.2     Galvannealing

                     29.3.3     Pre-Galvanizing

                     29.3.4     Electro Galvanizing

30.  Coaxial Cable

        30.1     Applications

        30.2     Description

        30.3     How Coaxial Cables Work

        30.4     Construction

        30.5     Signal Propagation

        30.6     Connectors

        30.7     Types of Connectors

        30.8     Types

                     30.8.1     Hard Line

                     30.8.2     Radiating

                     30.8.3     RG-6

                     30.8.4     Triaxial Cable

                     30.8.5     Twin-Axial Cable

                     30.8.6     Semi-Rigid

                     30.8.7     Rigid Line

        30.9     Uses of Coaxial Cables

        30.10   Coaxial Cable Sizes

        30.11   Coaxial Cable Connector Types

        30.12   Advantages

31.  Coaxial Cable Manufacturing Process

        31.1     Cutting

                     31.1.1     Cutting Semi-Rigid Coax with a Saw

        31.2     Cutting Flexible Coax with a Saw System

        31.3     Stripping

        31.4     Bending

32.  Ethernet Cable

        32.1     Types

                     32.1.1     Types of Coaxial Cables

                     32.1.2     Connector Types Used in Coaxial Cable

                     32.1.3     Twisted Pair Cable Varieties

                     32.1.4     Types of Fiber Optics

33.  Litang Cable LAN/Ethernet Cable Manufacturing Process

        33.1     Step 1: Wire Diagram

        33.2     Step 2: Copper Wire is Annealed to Increase Ductility
and Soften the Wire

        33.3     Step 3: Copper Wire Extrusion and Insulation (Extruder, Sheath Machine)

        33.4     Step 4: Wire Insulation Diameter Testing (Calipers and Performance Testers)

        33.5     Step 5: Twisting and Stranding Wire (Twisting Machine)

        33.6     Step 6: Cabling (Cabling Machine)

        33.7     Step 7: Jacketing (Jacketing Machine)

                     33.7.1     Cross Filling (Separator Filling)

                     33.7.2     Metal Sheath Filling

                     33.7.3     Braided Wire Filling

                     33.7.4     Drain Wire Filling

                     33.7.5     Rid Cord Filling

                     33.7.6     Outer Cable Jacketing

                     33.7.7     Cooling and Printing

        33.8     Step 8: Pre-Shipment Testing

        33.9     Step 9: Packing

34.  Power Cord Cable

        34.1     Construction

        34.2     Higher Voltages

        34.3     Flexibility of Cables

        34.4     Features

        34.5     Terminologies

                     34.5.1     Electric Cords

        34.6     Interconnection Cord Set

        34.7     AC Power Cords

        34.8     Custom Power Cords

        34.9     Extension Cords

        34.10   Generator Power Cords

        34.11   NEMA Power Cords

        34.12   NEMA 5-15P Power Cords

        34.13   Electrical Plug

        34.14   Sockets or Electrical Receptacles

        34.15   Plug Adapters

                     34.15.1   Connector

        34.16   Appliance Inlet

                     34.16.1   Flexible Cord

        34.17   Pin

        34.18   Pin Live

        34.19   Unbiased Pin

        34.20   Ground Pin

                     34.20.1   Thermal Sleeves

        34.21   Polarized Relationship

        34.22   Shutters

        34.23   Outlet Covers

        34.24   Retainers

        34.25   Rating for Current and Voltage

        34.26   Wire-Sharing Connector

        34.27   Divider for Power Cords

        34.28   Fuse

35.  Power Cord Cable Manufacturing Process and Equipment

        35.1     Step1: Cutting and Stripping the Cable to the Length and Outer Jacket

        35.2     Step 2: Stripping and Twisting the Cable Inner Wire

        35.3     Step3: Crimping the Plug to Cable for Making the Cable
Head Plug

        35.4     Step 4: Crimping the AC Terminal to Cable for making
the Cable Tail Plug

        35.5     Step5: After Crimped the Tail Plug then Manual Insert the Plastic Cover

        35.6     Step6: Injection and Molding

        35.7     Step 7: Cable Performance Testing

        35.8     Step 8: Packing the Power Cord

36.  Submersible Cable

        36.1     Features

        36.2     Applications

        36.3     Type

        36.4     Construction

        36.5     Standards

        36.6     Color Code

        36.7     Benefits

        36.8     Reasons to get Submersible Cable

        36.9     Manufacturing Process

                     36.9.1     Taping Machine

                     36.9.2     Slitting and Rewinding Machine

        36.10   Electrical Industrial Ovens

                     36.10.1   Industrial Oven Heat Sources

                     36.10.2   Industrial Oven Air Flow

        36.11   High Voltage Tester

                     36.11.1   Horizontal Wire Wrapping Machine

                     36.11.2   Wire Vertical Wrapping

        36.12   Packing Steps

37.  Submersible Winding Wire Plant

        37.1     Taping Machine

        37.2     Slitting and Rewinding Machine

        37.3     Electrical Industrial Ovens

                     37.3.1     Industrial Oven Heat Sources

                     37.3.2     Industrial Oven Air Flow

        37.4     High Voltage Tester

        37.5     Horizontal Wire Wrapping Machine

        37.6     Wire Vertical Wrapping

        37.7     Packing Steps

38.  How to Start Barbed Wire Production Business

        38.1     Barbed Wire Production Market Potential

        38.2     Barbed Wire Production Business Registration

        38.3     Investment & Costs for a Manufacturing Company of Barbed Wire

        38.4     Production of Barbed Wire

        38.5     Process Flow Chart

39.  Barbed Wire

        39.1     Design

                     39.1.1     Materials

                     39.1.2     Strand Structure

                     39.1.3     Barb Structure

                     39.1.4     Twist Type

        39.2     Installation

        39.3     Gates

        39.4     Uses

                     39.4.1     Agriculture

        39.5     Different Varieties of Barbed Wire

        39.6     Benefits of the Zinc Coating

        39.7     Benefits of Barbed Wire

        39.8     Primary Uses for Barbed Wire Fencing

40.  Barbed Wire Manufacturing Process

        40.1     Raw Materials

        40.2     Manufacturing Process

                     40.2.1     Making Steel Ingots

                     40.2.2     Making Billets

                     40.2.3     Making Wire

                     40.2.4     Making Barbed Wire

        40.3     Quality Control

        40.4     The Future

41.  XLPE Cable

        41.1     Introduction

        41.2     Types

                     41.2.1     Cross-Linked Polyethylene (XLPE)

        41.3     Uses & Application

        41.4     Advantages

        41.5     Properties

                     41.5.1     Thermal Properties

                     41.5.2     Electrical Properties

                     41.5.3     Mechanical Properties

                     41.5.4 Chemical Properties

42.  Manufacturing Process of XLPE Cable

        42.1     Conductor

        42.2     Dielectric Insulation

        42.3     Screening

                     42.3.1     Conductor Detector

                     42.3.2     Insulation Detector

        42.4     Laying Up

        42.5     Innersheath

        42.6     Armouring

        42.7     Final Testing

43.  Electrical Cable Coating

        43.1     Types of Cable Coating

                     43.1.1     Insulation

                     43.1.2     Semiconductor

                     43.1.3     Metal Screen

                     43.1.4     Filling In

                     43.1.5     Seat

                     43.1.6     Armour

                     43.1.7     Cover (Outer Sheath)

44.  BIS Specifications

45.  ISO Standards

46.  China Cable Standards

47.  US Standards

48.  Factory Layout and Process Flow Chart & Diagrams

49.  Photographs of Plant and Machinery with Supplier’s Contact Details

            Barbed Wire Production Machine

            Electric Cable Production Machine

            Semi-Automatic Cable Production Machine

            Semi-Automatic Coaxial Cable Stripping Machine

            Steel Wire Rope Making Machine

            Twisted Rope Making Machine

            Wire Rope Crimping Press

            Standard Automatic Crimping Press

            Automatic Aluminium & Copper Wire Drawing Machine

            PVC Cable Making Machine

            PVC Wire and Cable Making Machine

            Crimped Wire Mesh Machine

            Wire Nail Making Machine

            Automatic Wire Nail Making Machine

            Fiber Optic Cable Cutter

            Fiber Cable Blowing Machines

            Automatic Fibre Optic Cable Cutting & Rolling Machine

            Aluminum Cable Billet Pre-heat Furnace for Extrusion

            Extrusion Machine for Aluminum Wire

            Aluminum Cable Aging Annealing Furnace

            Bright Annealing Wire Line

            Pit Type Annealing Furnace

            Multi Wire Line Induction Heater

            Induction Bar End Heating System

            Double Twist Copper Wire Stranding Bunching Machine

            Copper Wire Tinning Machine

            Spring Grinding Machine

            Submersible Wire Tapping Machine






NIIR PROJECT CONSULTANCY SERVICES (NPCS) is a reliable name in the industrial world for offering integrated technical consultancy services. NPCS is manned by engineers, planners, specialists, financial experts, economic analysts and design specialists with extensive experience in the related industries.

Our various services are: Detailed Project Report,  Business Plan for Manufacturing Plant, Start-up Ideas, Business Ideas for Entrepreneurs, Start up Business Opportunities, entrepreneurship projects, Successful Business Plan, Industry Trends, Market Research, Manufacturing Process, Machinery, Raw Materials, project report, Cost and Revenue, Pre-feasibility study for Profitable Manufacturing Business, Project Identification, Project Feasibility and Market Study, Identification of Profitable Industrial Project Opportunities, Business Opportunities, Investment Opportunities for Most Profitable Business in India, Manufacturing Business Ideas, Preparation of Project Profile, Pre-Investment and Pre-Feasibility Study, Market Research Study, Preparation of Techno-Economic Feasibility Report, Identification and Section of Plant, Process, Equipment, General Guidance, Startup Help, Technical and Commercial Counseling for setting up new industrial project and Most Profitable Small Scale Business.

NPCS also publishes varies process technology, technical, reference, self employment and startup books, directory, business and industry database, bankable detailed project report, market research report on various industries, small scale industry and profit making business. Besides being used by manufacturers, industrialists and entrepreneurs, our publications are also used by professionals including project engineers, information services bureau, consultants and project consultancy firms as one of the input in their research.

Our Detailed Project report aims at providing all the critical data required by any entrepreneur vying to venture into Project. While expanding a current business or while venturing into new business, entrepreneurs are often faced with the dilemma of zeroing in on a suitable product/line.


And before diversifying/venturing into any product, wish to study the following aspects of the identified product:

• Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period

We at NPCS, through our reliable expertise in the project consultancy and market research field, Provides exhaustive information about the project, which satisfies all the above mentioned requirements and has high growth potential in the markets. And through our report we aim to help you make sound and informed business decision.


The report contains all the data which will help an entrepreneur find answers to questions like:

• Why I should invest in this project?
• What will drive the growth of the product?
• What are the costs involved?
• What will be the market potential?

The report first focuses on enhancing the basic knowledge of the entrepreneur about the main product, by elucidating details like product definition, its uses and applications, industry segmentation as well as an overall overview of the industry sector in India. The report then helps an entrepreneur identify the target customer group of its product. It further helps in making sound investment decision by listing and then elaborating on factors that will contribute to the growth of product consumption in India and also talks about the foreign trade of the product along with the list of top importing and top exporting countries. Report includes graphical representation and forecasts of key data discussed in the above mentioned segment. It further explicates the growth potential of the product.

The report includes other market data like key players in the Industry segment along with their contact information and recent developments. It includes crucial information like raw material requirements, list of machinery and manufacturing process for the plant. Core project financials like plant capacity, costs involved in setting up of project, working capital requirements, projected revenue and profit are further listed in the report.

Reasons for buying the report:

• This report helps you to identify a profitable project for investing or diversifying into by throwing light to crucial areas like industry size, demand of the product and reasons for investing in the product.

• This report provides vital information on the product like its definition, characteristics and segmentation.

• This report helps you market and place the product correctly by identifying the target customer group of the product.

• This report helps you understand the viability of the project by disclosing details like raw materials required, manufacturing process, project costs and snapshot of other project financials.

• The report provides forecasts of key parameters which helps to anticipate the industry performance and make sound business decision.


Our Approach:

• Our research reports broadly cover Indian markets, present analysis, outlook and forecast.

• The market forecasts are developed on the basis of secondary research and are cross-validated through interactions with the industry players. 

• We use reliable sources of information and databases.  And information from such sources is processed by us and included in the report.


Our Market Survey cum Detailed Techno Economic Feasibility Report Contains following information:



Ø  Introduction

·         Project Introduction

·         Project Objective and Strategy

·         Concise History of the Product

·         Properties

·         BIS (Bureau of Indian Standards) Provision & Specification

·         Uses & Applications


Ø  Market Study and Assessment

·         Current Indian Market Scenario

·         Present Market Demand and Supply

·         Estimated Future Market Demand and Forecast

·         Statistics of Import & Export

·         Names & Addresses of Existing Units (Present Players)

·         Market Opportunity


Ø  Raw Material

·         List of Raw Materials

·         Properties of Raw Materials

·         Prescribed Quality of Raw Materials

·         List of Suppliers and Manufacturers


Ø  Personnel (Manpower) Requirements

·         Requirement of Staff & Labor (Skilled and Unskilled) Managerial, Technical, Office Staff and Marketing Personnel


Ø  Plant and Machinery

·         List of Plant & Machinery

·         Miscellaneous Items

·         Appliances & Equipments

·         Laboratory Equipments & Accessories

·         Electrification

·         Electric Load & Water

·         Maintenance Cost

·         Sources of Plant & Machinery (Suppliers and Manufacturers)


Ø  Manufacturing Process and Formulations

·         Detailed Process of Manufacture with Formulation

·         Packaging Required

·         Process Flow Sheet Diagram


Ø  Infrastructure and Utilities

·         Project Location

·         Requirement of Land Area

·         Rates of the Land

·         Built Up Area

·         Construction Schedule

·         Plant Layout and Requirement of Utilities


Project at a Glance

Along with financial details as under:


  •     Assumptions for Profitability workings

  •    Plant Economics

  •    Production Schedule

  •    Land & Building

            Factory Land & Building

            Site Development Expenses

  •    Plant & Machinery

             Indigenous Machineries

            Other Machineries (Miscellaneous, Laboratory etc.)

  •    Other Fixed Assets

            Furniture & Fixtures

            Pre-operative and Preliminary Expenses

            Technical Knowhow

            Provision of Contingencies

  •   Working Capital Requirement Per Month

             Raw Material

            Packing Material

            Lab & ETP Chemical Cost

           Consumable Store

  •   Overheads Required Per Month And Per Annum

         Utilities & Overheads (Power, Water and Fuel Expenses etc.)

             Royalty and Other Charges

            Selling and Distribution Expenses

  •    Salary and Wages

  •    Turnover Per Annum

  •   Share Capital

            Equity Capital

            Preference Share Capital


  •    Annexure 1:: Cost of Project and Means of Finance

  •    Annexure 2::  Profitability and Net Cash Accruals


                Expenses/Cost of Products/Services/Items

                Gross Profit

                Financial Charges     

                Total Cost of Sales

                Net Profit After Taxes

                Net Cash Accruals

  •   Annexure 3 :: Assessment of Working Capital requirements

                Current Assets

                Gross Working. Capital

                Current Liabilities

                Net Working Capital

                Working Note for Calculation of Work-in-process

  •    Annexure 4 :: Sources and Disposition of Funds

  •    Annexure 5 :: Projected Balance Sheets

                ROI (Average of Fixed Assets)

                RONW (Average of Share Capital)

                ROI (Average of Total Assets)

  •    Annexure 6 :: Profitability ratios


                Earnings Per Share (EPS)


             Debt Equity Ratio

        Annexure 7   :: Break-Even Analysis

                Variable Cost & Expenses

                Semi-Var./Semi-Fixed Exp.

                Profit Volume Ratio (PVR)

                Fixed Expenses / Cost 


  •   Annexure 8 to 11:: Sensitivity Analysis-Price/Volume

            Resultant N.P.B.T

            Resultant D.S.C.R

   Resultant PV Ratio

   Resultant DER

  Resultant ROI

          Resultant BEP

  •    Annexure 12 :: Shareholding Pattern and Stake Status

        Equity Capital

        Preference Share Capital

  •   Annexure 13 :: Quantitative Details-Output/Sales/Stocks

        Determined Capacity P.A of Products/Services

        Achievable Efficiency/Yield % of Products/Services/Items 

        Net Usable Load/Capacity of Products/Services/Items   

       Expected Sales/ Revenue/ Income of Products/ Services/ Items   

  •    Annexure 14 :: Product wise domestic Sales Realisation

  •    Annexure 15 :: Total Raw Material Cost

  •    Annexure 16 :: Raw Material Cost per unit

  •    Annexure 17 :: Total Lab & ETP Chemical Cost

  •    Annexure 18  :: Consumables, Store etc.,

  •    Annexure 19  :: Packing Material Cost

  •    Annexure 20  :: Packing Material Cost Per Unit

  •    Annexure 21 :: Employees Expenses

  •    Annexure 22 :: Fuel Expenses

  •    Annexure 23 :: Power/Electricity Expenses

  •    Annexure 24 :: Royalty & Other Charges

  •    Annexure 25 :: Repairs & Maintenance Exp.

  •    Annexure 26 :: Other Mfg. Expenses

  •    Annexure 27 :: Administration Expenses

  •    Annexure 28 :: Selling Expenses

  •    Annexure 29 :: Depreciation Charges – as per Books (Total)

  •   Annexure 30   :: Depreciation Charges – as per Books (P & M)

  •   Annexure 31   :: Depreciation Charges - As per IT Act WDV (Total)

  •   Annexure 32   :: Depreciation Charges - As per IT Act WDV (P & M)

  •   Annexure 33   :: Interest and Repayment - Term Loans

  •   Annexure 34   :: Tax on Profits

  •   Annexure 35   ::Projected Pay-Back Period And IRR