The product mix in electrical cables and fittings includes a wide range of products and components.
Electrical Fittings:
Electric switches (Piano), Sockets, Bulb holders, Bell Push, Ceiling Rose etc. are quite familiar to people as they are found in every home. These products are relatively produced on mass level and getting 70% of the total electrical fittings production. While the other products which may include Power Plugs, Indicators, Fuse, Buzzer, Fan Dimmer, Tube Choke & Patti, Main Switch, Wire Extensions etc. comprise 30% of the total production. They can be manufactured using different major raw materials e.g., steel, brass, thermosetting or thermo-plastic resins. Bakelite powder also known as phenol formaldehyde resin is chiefly used for the manufacture of these items.
Electrical Cables:
Electrical Power Cables, Control Cables, Instrument Signal Cables, Thermocouple extension Cables, Marine ship board Cables, Fire proof MICC Mineral Insulated Copper Cables, Welding Cables etc with various insulation, such as PVC, XLPE, SWA, LC, Rubber, Fiber, Teflon.
Production Process Flow
The production process of electrical fittings in this industry can be divided into following heads:
- Molding and finishing of the plastic body
- Fixing of metallic inserts
- Assembly and packing
Electrical Fittings Manufacturing Process Flow Chart
The manufacturing process for all the electrical fittings is more or less the same. Mold making is the first step in this manufacturing process. Then, a calculated amount of Bakelite is poured into the mold fixed on a hydraulic press. There are two gas burners in this press, one placed below the mould and other on top. Burners are switched on, once the Bakelite powder is poured into the mould, and the press is locked manually. Time taken to get the desired shape and strength varies from product to produce.
Each step in this process flow has to be calculated and executed carefully as a minor mistake can lead to disfigured or products with less than desired strength. After the specific time is over and the products take its desired shape, the press is lifted and the finished product is taken out. It can be done either manually or mechanically. After the product is taken out of mold, pipes and pins are attached to the main body of the product. Most electrical fitting products are made by assembling different components. So, different parts are also attached at this stage with the help of screws and nuts. Now final finishing of the product takes place to chop off any lose raw material or minor defects. After this it goes for packaging.
