The manufacturing process of electrical wires and cables is complicated. If the manufacturers don’t provide good quality products, the wires will not be the perfect conductor to produce electricity.

1. How Are Electric Wires And
Cables Manufactured?

2. • The electrical wires are manufactured in several different sizes and using several
conductive materials. The electrical wires are excellent conductors of heat.
• An electric wire is an insulating material that is flexible and transmits electricity.
The conducting material mainly used is copper. Copper is an excellent conductor of
electricity. It is flexible and possesses a high-malleable property.
• Power distribution boxes in Sharjah can be used in aerials, underground cables,
and electrical appliances running beneath our feet in our homes and behind our
walls. They carry the electricity and give us power.

3. There Are Different Types Of Cables
Such As
• HT and LT flame-retardant cables
• Flame-retardant low smoke cables
• Power and control cables
• Insulated cables
• Fire survival cables
• Solar cables

4. Overview Of The Manufacturing
Process Of Electric Wires
• The cable is fed into a machine that draws it out through a series of lubricated
pulleys and dies stretching, lengthening, and thinning it out.
• They are eventually winding it onto a giant bobbin. The cable once 10 mm in
diameter is now 2 mm in diameter. The bobbin is loaded. The ends of the bobbins
are cold-welded to one another, guaranteeing an uninterrupted flow once the
machine starts up.
• Multi-core flexible cables are twisted and sheathed with white PVC granules to
obtain the final product. The white flexible cable is coiled on modern coiling
machines with length measuring yards.
• Each coil is packed with a suitable label and shrink wrapped with a polyethylene
layer for safe and moisture-free binding. The PVC insulation is done in a double-
layer process. The first layer is with Virgin PVC of Insulation and an outer layer
which is very thin and commonly called skin with color PVC.

5. • It is done to avoid the adverse effect of color pigments on the insulation resistance
value of PVC as virgin PVC insulation has excellent insulation resistance.
• At high speed, the stranding machines twist seven wires together, forming an
electrical conductor. This is a low voltage conductor under 1000 volts the carrying
you will find in cables that run electricity to your home.
• Their conductors need to be insulated. So a plastic extrusion machine coats the
conductor with polyethylene or PVC. The extrusion process has heated the
conductor, so it has to be cooled down with water. Several conductors are mixed to
form a cable. This plant performs a voltage immersing the cables in water to make
sure they soak it.
• They are insulated the same way as low voltage cables are insulated. The cable
goes into a reel to be tested before it's shipped out to its destination in the middle
of the table surrounded by copper grounding wires and a host of other
components, which is the heart of the electrical cable.

6. Now Let Us See The Step-By-Step
Process Of Manufacturing Of
Electrical Cable
1. Procurement of the purest raw material
• The manufacturing process starts with the procurement of the purest of raw
materials from reputed suppliers. All incoming materials are subjected to a series
of mechanical and electrical checks.
• The plant is capable of drawing wire from 8 mm to 1.6 mm consistency and
resistance tensile. The strength and size of the wire are ensured at all stages of the
drawing process.
• The drawn wires are then stranded to achieve Co-conductors; as per specifications,
conductors are formed on sophisticated high-speed stranding machines and then
compacted to ensure AC losses. To ensure optimum performance, the extensive
focus is paid to the conductors, resistance, and shape.

7. 2. Insulation
• For Insulation, the unit is equipped by power cable suppliers in UAE with a state-
of-the-art CCV extrusion line. The extrusion route with filtered air inlets and a
positive pressure eyes closed system ensures that the insulation process is entirely
free from impurities and imperfections.
3. Twisting and laying
• Insulation is followed by twisting and laying of multi-core cables.
• Wires and cables manufacturers possess a massive drum twisting and laying up
machine, which ensures that no tangential stress is applied over the Insulation;
this mitigates the possibility of any shifting or migration of the insulating layers,
which could otherwise result in air void formations.
• This prevents any chances of failure during the entire lifetime of the cable and the
manufacturer's flexibility to provide longer cable lengths that exhibit excellent and
compact designs.

8. 4. Inner Sheathing
• The later multi-core cables are provided with an inner sheathing through
computerized extrusion lines using PVC compounds.
• Wires and cables manufacturers provide extruded PVC layers over the laid-up
cores to hold the twisted cores in their circular form.
5. Extrusion Process
• The extrusion process also serves as an additional moisture barrier. If the outer
sheath gets damaged as water cannot travel radically up to the surface of the
Insulation. An armoring process follows this.
6. Armoring Process
• Wires and cables manufacturers offer standardized armoring with aluminum or
aluminum alloy wire strips for core cables and steel wires and strips for multi-core
cables, a uniform and perfect mass of zinc coating on the armor, and a rust-free
armor layer.
• It also offers protection to the armor in case of any external damage; the cables
are then provided for the PVC polymer outer sheathing through the latest
sheathing machines.

9. 7. Testing and Validation
• Electric wire manufacturers also have a modern test lab with the latest validation
and testing equipment. Every cable manufactured at the plant is tested for higher
conductivity, flame resistance, oxygen index, smoke density, durability, tensile
properties, and thermal stability.
• There are more than 30 various test parameters- physical, mechanical, electrical,
thermal, chemical, and fire, that different components of cables have to pass
before being certified, and that indeed puts into perspective for you.
8. Packing
• Then the wires and cables are packed with safe moisture free and good-looking
packing to delivering the material in good condition - its esteemed customers.

10. Conclusion
• Thus, the manufacturing process of electrical wires and cables is complicated. If
the manufacturers don't give good quality products, the wires will not be an
excellent conductor to produce electricity. So they should always take care of
specific steps while making electric wires and cables.