INTRODUCTION

Eastern Cables Ltd. with its office and factory at Patenga, Chittagong was established in 1967 and started its commercial production on 1st March 1971 for manufacturing of cables and conductors. Eastern Cables Limited, a subsidiary Company of Bangladesh Steel & Engineering Corporation (BSEC) is the biggest cables and conductor manufacturer in Bangladesh. The range of its products not only includes PVC insulated and PVC sheated single core and multi core low tension domestic cable but also control, flexible and power cables with copper conductor having continuous permissible voltage grade up to 12 KV. It also enjoys the honour of being the pioneer in this country in the production of armored and screened cables. The different sizes of bare and insulated. All Aluminum Conductor (AAC) and Aluminum Conductor Steel Reinforced (ACSR) are also being manufactured here.

CABLES

A group or bundle of conductors, fibers, or wires, or bound together, sharing a common protective sheath or jacket, and perhaps strength members and shielding. People usually get confused describing the functions of wires and cables and often end up naming one for the other. Although, professionals know and understand the operational functions of wires and cables, they often give a blank expression when it comes to defining one of them. As an attempt to put an end to this unanswered question, we at Polycab have come up with an exclusive blog post to educate people on the difference between wires and cables and its working.

MANUFACTURING PROCESS OF CABLES IN EASTERN CABLES INDUSTRIES

Cables come in various sizes, materials and quality depending on their specifications and usage. The voltage usage determines the insulation needed, the carrying capacity determines the cross sectional size and the environmental conditions the cable will be used in determine the type of outer jacket. While manufacturing processes vary, there are some common features.

Raw materials

1. COPPER WIRE
2 ALUMINIUM WIRE
3. CHLOROPARAFFIN
4. ANTIMONY TRI-OXIDE
5. TITAN DI-OXIDE (RUTLLE GRADE)
6. COPPER STRIP
7. STEEL FLAT WIRE
8. STEEL STRIPS
9. PARAFFIN WAX
10. SOOT PASTE (Carbon black paste for PVC)
11. RED/ YELLOW/ BLUE PIGMENT
12. D O P
13. PVC RESIN
14. CHALK POWDER
15. CYCLOHEXANONE (Commercial Grade)
16. GRAPHITE POWDER
17. CONDUCTING PVC COMPOUND (CABELAC)
18. STABILIZER FOR PVC COMPOUND

19. TERMITE REPELLENT
20. GUMMED COTTON TAPE
21. STEEL CORE WIRE FOR ACSR CONDUCTOR
22. STRANDED GALVANIZED STEEL CORE FOR ACSR
23. STEEL CORE WIRE FOR ACSR ‘DOG’
24. STEEL CORE WIRE FOR ACSR ‘WOLF’
25. STEEL CORE WIRE FOR ACSR ‘RABBIT’
26. STEEL CORE WIRE FOR ACSR ‘GOPHER’
27. STEEL CORE WIRE FOR ACSR ‘RAVEN’
28. STEEL CORE WIRE FOR ACSR ‘SWALLOW’
29. STEEL CORE WIRE FOR ACSR ‘PENGUIN’
30. STEEL CORE WIRE FOR ACSR ‘MERLIN’
31. NYLON SEMICONDUCTING TAPE
32. KREPP PAPER
33. CALCINED CLAY
34. TRIBASE (TRIBASIC LEAD SULPHATE)
35. SOFT PVC TAPE

PROCESS DESCRIPTION

Multiwire drawing
Bulk copper is formed into wire of varying diameters by drawing it through a series of dies. For
flexible/stranded conductor, fine wire drawing is carried out on high-speed fine multiwire
drawing machine from copper rods. Since the drawing process causes the copper to become hard
and brittle, it should be annealed.
Stranding
The fine drawn parallel wires undergo bunching process which combines many fine wires into a
thick bunch of copper which acts as a single conductor. Anywhere from 20-100 (very fine copper
conductor wires) are twisted into cords which will be used in making flexible wire and cable.
Layers of wires (1+6+12+18+24 etc.) are stranded together to make copper conductors. The
maximum nominal cross-section area of a power cable core is 500m􀩍.This process is known as
twisting.
Nozzling
The conductor that is bunched is then nuzzled through a nozzle to check for uneven copper ends.
Insulation
The copper conductors, whether they are single wire or multiple stranded wire, are covered by
PVC for current insulation. Insulation of copper conductor is carried out on high-speed twin head
extrusion system with online spark testing system that ensures no fault in our wires. Three or four
of these PVC insulated copper conductors are assembled into power cables.
Sheathing
Complete cables are formed by sheathing twin-core or multiple-core PVC insulated copper
conductors with PVC. Special purpose power cables must be surrounded with steel wires in order
to increase the cable structure strength.
Routine testing
The insulated copper wire that is obtained is then sent to our fully equipped lab for routine
testing which is done by qualified lab experts and supervisors who involve themselves at every
step of our manufacturing process.
Coiling
Tested wire spools are then sent to coiling machines that make coils of standard sizes in automaticcoiling machines. Quality is prime thing at proflex. High quality is the outcome of quality
assurance program have adopted.

ABOUT PRODUCTS OF EASTERN CABLES

Eastern Cable Limited offers various products to its clients such as PVC insulated and PVC seated single core and multi core low tension domestic cable. It also offers fully controlled, flexible and power cables with copper conductor holding continuous permissible voltage grade up to 12 KV. Eastern Cable Limited also manufactures All Aluminium Conductor shortly known as (AAC) and Aluminium Conductor Steel Reinforced in short, it is also known as (ACSR) with different sizes. Eastern Cable Limited is also known as a leading organization for producing Armored and Screened cables.
From the very beginning, Eastern Cable Limited is trying to produce extra ordinary products not only for Bangladeshi clients, but also for foreign consumers. It is very strict in maintaining its quality product and this organization believes in “quality over quantity” slogan. All Cables and Conductors are constructed here according to the international standard specification. But question may arrive, who has provided the quality stamp on Eastern Cables Limited? The answer is world famous organization “Kabelwerke Reinshagen” of Germany, which is also known as “Delphi Automotive Systems” at present days. Eastern Cables Limited is manufacturing PVCcables corresponding to Bangladesh Standard (BDS), German Metric Standard (VDE), and British Metric Standard. So, it is clear that “Eastern Cables Limited” is one of the pioneer company producing quality cable products in the global world. It has achieved people’s trust and as a result it has gained ISO 9002:1994 Certificate on 26.03.2003 and ISO 9001:2000 Certificate on 22.04.2004. This organization also achieved “National Export Trophy” several times for its great contribution to the national export.

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