Dynamic Cables Launches Next-Generation HTLS Conductors

With around four decades of expertise, Rajasthan-based Dynamic Cables integrates Industry 4.0 technologies, including real-time monitoring, predictive maintenance, rigorous material selection and lean manufacturing, to drive efficiency and consistency in its operations. In an exclusive interview with Wire & Cable India, Mr. Ravindra Jain, Advisor, Dynamic Cables Limited talks about the latest development and innovation at hand. The company recently launched next-generation HTLS conductors featuring advanced composite cores, delivering higher current-carrying capacities and reduced sag. Catering to the renewable energy and power sector both domestically and internationally, the company has earned UL certification. Further, investments in advanced simulation testing facilities ensure compliance with BIS, UL, IEC, and other international standards.

Wire & Cable India: What types of EHV cables and conductors do you manufacture for power transmission and distribution systems?

Ravindra Jain: Our company stands as a trusted, reliable partner specializing in Extra High Voltage (EHV) cables up to 66 kV, MV covered conductors, aerial bunched cables and conductors such as ACSR, AAAC, and HTLS up to 765 kV. We provide innovative, quality, and cost-effective solutions to meet the evolving demands of modern infrastructure. Our products are designed to address modern power transmission needs, including long-distance transmission, urban infrastructure, and renewable energy integration.

WCI: Walk us through your unique manufacturing setup.

RJ: Our manufacturing facilities are equipped with machinery, including CCV extrusion lines, high-speed stranding machines, and advanced quality control systems. Each facility operates under stringent environmental management protocols and is certified with ISO 9001, ISO 14001, and ISO 45001 standards to ensure optimized processes, cost-effectiveness, world-class quality and sustainability.

The hi-tech manufacturing shop floors, EV material handling equipment, company vehicles turning into EVs, and our green head office building depicts our commitment towards green initiative.

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WCI: How do your products stand out in terms of properties and performance?

RJ: Our cables and conductors are engineered with advanced materials and innovative designs, ensuring superior electrical performance, lower transmission losses, and high thermal stability.

The use of water-blocking compounds, low smoke zero halogen compounds, water-soluble tapes, improved conductor compactness, and corrosion-resistant materials enhances product performance.

WCI: What recent innovations and advancements have developed in your technology to enhance efficiencies in power transmission? How do they improve performance or reduce costs?

RJ: Our proprietary PE insulation formulations are optimized for enhanced dielectric strength and better thermal resistance, allowing for higher operating temperatures and increased load capacities. We are also integrating messaging and OFC systems to provide real-time diagnostics for cables and conductors.

We have recently introduced next-generation HTLS conductors with advanced composite cores for higher current carrying capacities and reduced sag. Apart from that, our Medium Voltage Covered Conductors (MVCC) being produced regularly are safe, reliable and reduce power interruptions and outages. We have taken UL certification through a rigorous process of material selection, manufacturing quality, comprehensive testing as per detailed procedures outlined.

The thermal efficiency of our XLPE cables minimizes energy losses, leading to lower operational costs. Our HTLS conductors enable higher power transmission without requiring new infrastructure, significantly reducing capital expenditure. Our MVCC product drastically helps in reducing costs towards installation, and even maintenance as well.

WCI: What quality control processes are in place to ensure the cables and conductors meet industry standards and reliability benchmarks?

RJ: We employ a multi-tier quality control system, including raw material verification, online dimensional process monitoring, and high-voltage tests, impulse testing, partial discharge analysis, and accelerated aging tests, to ensure compliance with BIS, IEC, IEEE, UL and other global standards.

Our products are rigorously tested covering routine, acceptance and type tests to perform under extreme environmental conditions. We take utmost precaution in designing robust packaging solutions to withstand all handling issues during transportation and storage.

We are committed to compliance with RoHS and sustainability standards, and eco-friendly initiatives such as reduction of carbon footprint across production processes, development of recyclable and low-impact materials. Our products are approved by UL which speaks volumes about our capability of complying to industry quality standards.

WCI: What is the typical lifespan of your EHV cables and conductors?

RJ: Our EHV cables and conductors are designed for a lifespan of 30–40 years, depending on operating conditions and maintenance practices. Continuous improvements in materials and designs ensure their performance exceeds industry benchmarks over their lifecycle.

WCI: What value-added services do you provide to customers in the field?

RJ: We offer customizable designs tailored to specific project needs, including conductor type, insulation material, and armoring. Our services include engineering support, on-site installation supervision and testing guidance, training for operational teams, predictive maintenance programs to address urgent requirements and troubleshooting assistance.

WCI: What are the various markets that you serve?

RJ: The market we serve includes utilities and power grids that strengthen the national and regional power networks. We also cater to renewable energy projects- supporting solar farms, wind energy installations, and hydroelectric plants. We uphold the urban infrastructure market, empowering smart city initiatives with reliable power solutions and lastly, we serve industrial applications markets ranging from oil & gas to heavy manufacturing, enabling uninterrupted power supply.

WCI: What new technologies have you invested in to cater to emerging customer and market demands?

RJ: We are investing in enabling production lines with Industry 4.0 analytical support, real-time monitoring systems, predictive maintenance and lean manufacturing for enhanced consistency and operational efficiency.

We have invested in advanced real-world simulation testing facilities for electrical, thermal, and mechanical properties for compliance certifications covering BIS, UL, IEC and other internationally recognized standards. The entire operations are supported by SAP right from planning to marketing to dispatch and sales thereof.

Also Read: CTC Global’s New ACCC® Conductor Facility at Pune

WCI: What are some of the major challenges you are experiencing in the business?

RJ: The key challenges include fluctuating raw material prices, stringent testing and certification requirements, and the need to implement sustainable practices. Additionally, the transition to renewable energy sources demands a restructure of conventional cable designs to meet stringent requirements of outdoor exposed decentralized power systems.

WCI: Where do you see the market headed in the next 5 years in terms of growth, innovations, technology changes, and new challenges?

RJ: The market is shifting towards high-capacity cables & conductors for renewable energy integration, smart grid-enabled systems, and environmentally sustainable solutions. The demand for specialized cables for solar farms, wind energy installations, electric vehicles, data centers, and semi-conductor manufacturing will grow significantly as cross-border projects increase. A few of these products are already under our focus area for expansion projects.

WCI: How are you preparing your company for the new emerging scenario?

RJ: We are enhancing our R&D efforts to develop products aligned with green energy projects and expanding our global footprint to meet regional demands. We are building strong teams to ensure we stay at the forefront of innovation. Our R&D team is working on eco-friendly insulation materials and enhanced conductor conductivity to meet growing environmental demands.

WCI: What is your positioning in the emerging landscape of the cable and conductor industry?

RJ: We position ourselves as a global leader in providing high-performance and sustainable cable solutions. Our focus on innovation, quality, and customer-centric services ensures that we are a trusted partner for critical infrastructure projects worldwide.