Maillefer has introduced automation and AI-powered quality control in their machines to enhance efficiency and precision. Focussing on energy efficiency, they are helping with solutions that offer waste reduction by optimizing raw material usage through automation and precise extrusion. During a conversation with Wire & Cable India, their R&D Director, Mr. Mikko Lahti shared that Maillefer envisions global technology leadership by investing in R&D and digitalization.
Wire & Cable India: What are the key innovations and emerging trends shaping the wire and cable industry?
Mikko Lahti: The wire and cable industry is rapidly evolving with advancements in materials, smart technology integration, and sustainability. Key trends in materials include the rise of high-performance, lightweight, and eco-friendly materials. There is an increasing demand for fiber optic cables to support 5G and high-speed connectivity. Cable manufacturers are moving towards automation and Industry 4.0 technologies, including IoT-enabled smart cable manufacturing, alongside focusing on fire-resistant, low-smoke, halogen-free cables for safety compliance. The industry is witnessing advancements in HVDC transmission and modern IoT technologies such as machine learning in quality control and intelligent processes.
WCI: Please highlight the latest advancements and technological developments that you have introduced in your machines to address these evolving needs.
ML: We have introduced state-of-the-art automation and AI-powered quality control in our machines to enhance efficiency and precision. Some key developments include energy-efficient extrusion technologies, and advanced insulation and sheathing technologies for minimizing the material over usage.
Our automatic crosshead centering combines the latest technology with sustainability. By placing more intelligence in manufacturing components, we get to create winning production concepts. Here, economy meets ecology and the reality of a sustainable future together.
In the ever-evolving world of cable manufacturing, precision and data-driven insights are key to maintaining quality and efficiency. Our forthcoming data storage solution will revolutionize how manufacturers collect, store, and analyze production data. By combining topography scanning with advanced data warehousing, we are paving the way for smarter manufacturing and unparalleled optimization. The topography scanner system can extract detailed quality information from the cable manufacturing process and its detection system can automatically find defects and other anomalies on the cable surface during production. The detection sensitivity of the topography scanner can be adjusted, so that only desired defects are reported to the operators. Linking the detailed quality information to line control data opens up new means for process optimization and predictive maintenance actions.
Integration of digital twins for process simulation and optimization is another key development. The economic benefits of AI-driven systems like Smart Buffering are clear. By improving product quality, reducing waste, increasing uptime, and lowering maintenance costs, these systems provide a compelling return on investment. Early adopters of AI-based automation will gain a significant competitive advantage, as they will be able to produce higher-quality products more efficiently than their competitors.
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WCI: How do you help your customers achieve better efficiency in their production processes?
ML: We focus on energy efficiency by implementing eco-friendly and power-efficient systems to reduce energy consumption. We provide to our clients an enhanced quality experience by using precision control and AI-based monitoring to minimize defects. Our solutions offer waste reduction by optimizing raw material usage through automation and precise extrusion.
WCI: Do you have an R&D team that addresses evolving needs? Please elaborate on your R&D efforts.
ML: Our dedicated R&D team constantly innovates to meet market demands. Key focus areas include developing next-gen insulation processes, enhancing production automation and digitalization, researching new manufacturing technologies for high-voltage and extra-high-voltage cables, and collaboration with universities and research institutes for cutting-edge solutions.
WCI: What is your current product portfolio catering to the wire & cable sector? Are there any expansion plans in the pipeline?
ML: Our portfolio includes manufacturing solutions for power cables- HV, MV and LV power transmission solutions; telecommunication cables- fiber optics and high-speed data cables; industrial & automotive cables- specialized solutions for different industries.
Our expansion plans involve setting up new manufacturing units, diversifying into smart cable solutions, and expanding our presence in emerging markets.
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WCI: Could you provide insights into your market presence and key clientele globally & in India?
ML: We have a strong global footprint, serving clients across North America, Europe, the Middle East, and Asia. In India, we are a key supplier to industries such as power, telecom, construction, and infrastructure. Our clients include major utility companies, telecom giants, and industrial manufacturers.
Our expansion plans involve setting up new manufacturing units, diversifying into smart cable solutions, and expanding our presence in emerging markets.
WCI: How do you integrate sustainability into your manufacturing and application processes?
ML: We integrate sustainability by concentrating on better material choice and adopting energy-efficient manufacturing processes to lower utility costs. We provide solutions that require less material and reduce scrap. We ensure compliance with global environmental regulations and constantly provide sustainable value in all aspects of business.
WCI: What are your company’s long-term growth strategies and future plans?
ML: Our future growth is driven by attaining technology leadership by investing in R&D and digitalization. We are aiming for global expansion to strengthen our presence in high-growth markets. We have certain sustainability goals to achieve by reducing carbon footprint and adopting green manufacturing. We have plans for strategic partnerships and collaborating with our customers, industry leaders and research institutions.
