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 renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

Our Services

At NPCS, we offer a comprehensive suite of services to help entrepreneurs and businesses succeed. Our key services include:

  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
  • Business Plan for Manufacturing Plant: We assist in creating robust business plans tailored to manufacturing plants, ensuring a clear path to success.
  • Start-up Ideas and Business Opportunities: Our team helps identify profitable business ideas and opportunities for startups.
  • Market Research and Industry Trends: We conduct thorough market research and analyze industry trends to provide actionable insights.
  • Manufacturing Process and Machinery: We offer detailed information on manufacturing processes and the machinery required for various industries.
  • Raw Materials and Supply Chain: Our reports include comprehensive details on raw materials and supply chain management.
  • Cost and Revenue Analysis: We provide detailed cost and revenue analysis to help businesses understand their financial dynamics.
  • Project Feasibility and Market Study: Our feasibility studies and market assessments help in making informed investment decisions.
  • Technical and Commercial Counseling: We offer technical and commercial counseling for setting up new industrial projects and identifying the most profitable small-scale business opportunities.


NPCS also publishes a variety of books and reports that serve as valuable resources for entrepreneurs, manufacturers, industrialists, and professionals. Our publications include:

  • Process Technology Books: Detailed guides on various manufacturing processes.
  • Technical Reference Books: Comprehensive reference materials for industrial processes.
  • Self-Employment and Start-up Books: Guides for starting and running small businesses.
  • Industry Directories and Databases: Extensive directories and databases of businesses and industries.
  • Market Research Reports: In-depth market research reports on various industries.
  • Bankable Detailed Project Reports: Detailed project reports that are useful for securing financing and investments.

Our Approach

Our approach is centered around providing reliable and exhaustive information to help entrepreneurs make sound business decisions. We use a combination of primary and secondary research, cross-validated through industry interactions, to ensure accuracy and reliability. Our reports are designed to cover all critical aspects, including:

  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
  • Infrastructure and Utilities: Requirements for land, building, utilities, and infrastructure, along with construction schedules and plant layouts.

Financial Details and Analysis

Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

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

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
  • Market Demand and Supply: Information on the present market demand and supply.
  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
  • Market Opportunity: Identification of market opportunities.

Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
  • Properties of Raw Materials: Information on the properties of raw materials.
  • Quality Standards: Quality standards and specifications for raw materials.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
  • Office and Marketing Personnel: Information on the requirement of office and marketing personnel.

Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

  • Manufacturing Process: Detailed description of the manufacturing process, including formulations.
  • Packaging Requirements: Information on packaging requirements.
  • Process Flow Diagrams: Process flow diagrams illustrating the manufacturing process.

Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
  • Built-Up Area: Details on the built-up area required.
  • Construction Schedule: Information on the construction schedule.
  • Plant Layout: Details on the plant layout and utility requirements.

Project at a Glance

Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.


Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
  • Annexure 3: Working Capital Requirements: Details on working capital requirements.
  • Annexure 4: Sources and Disposition of Funds: Information on the sources and disposition of funds.
  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.


Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.


Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.