Started in 1971, Nirmal Wires Private Limited has five manufacturing facilities that synergize to offer an annual production capacity of 180,000 tons. Nirmal Wires offers an extensive range of over 100 diverse wire products including galvanized and black steel wires, aluminum conductors, ribbed wires, welding electrodes, and hot rolled steel products. Their market footprint is truly global, with exports spanning across 40+ countries. Their commitment to innovation is exemplified by the introduction of products like Tricon®, Niznal™, and their upcoming line of Nirmal Cables. In a recent conversation with Wire & Cable India, Mr. Parag Saraf, Director, Nirmal Wires (Group Nirmal), spoke about the company’s history and journey, recent innovations and developments, and product portfolio. He goes on to discuss the new revolutionary product, NiznalTM.
Wire & Cable India: Could you give us a brief overview of the business journey of your company?
Parag Saraf: Our journey began in 1971 with Mr. Ramautar Saraf at the helm. Fueled by the spark to create the best quality steel products in West Bengal he established a small wire drawing unit under the corporate entity Central Store Supplies Private Limited incorporated in 1942 by his late father Mr. Jhabarmal Saraf. After many years of hard labor and facing multifarious challenges, he kept the flame alive, and in 1985 put up a steel wire galvanizing plant under the corporate entity Nirmal Wires Private Limited incorporated in 1981.
He handed over the torch, kindled by him, to his sons Mr. Nirmal Saraf, Mr. Raman Saraf, and Mr. Piyush Saraf. With the infusion of youthful energy, team Nirmal knew no limits. In 1995, we commenced the production of welding electrodes under Shieldarc Equipments followed by a rolling mill making hot rolled products in 1996. In a few years, we had established a flourishing business in the steel products industry mainly steel wires and rolled products. The torch burning brighter than ever before was handed over to the third generation of leaders: Mr. Varun Saraf, Mr. Prateek Saraf, Mr. Vidyut Saraf, and Mr. Parag Saraf. In 2003, the group, further strengthened by younger leaders, launched Tricon®, a revolutionary product that disrupted the steel bar market. A major project commission in 2013, was our state-of-the-art manufacturing facility at Deulti, which consequently pushed production capacity to 1,20,000 TPA by 2021.
Our business has now expanded to international horizons, with export relations in over 40+ countries. Moving from one milestone to another, we have now expanded our product range to over 100 SKUs of different products including galvanized and black steel wires, aluminum conductors, ribbed wires, welding electrodes, and hot-rolled steel products. Some of our newer products include Niznal™, PVC-coated wires and fences as well as cables.
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WCI: Kindly walk us through the company’s manufacturing facilities, infrastructure, and machinery setup along with production capacity.
PS: At Group Nirmal, our manufacturing prowess is fueled by five state-of-the-art facilities that stand as testaments to our commitment to excellence. These facilities have been meticulously designed to ensure optimal efficiency, precision, and quality control at every step of the production process.
The biggest among our manufacturing units is the sprawling Deulti facility. This cutting-edge powerhouse stands as a symbol of innovation and scale. The Deulti facility alone wields a monthly production capacity of 10,000 tons. Moreover, our commitment to precision and quality is reflected in our airtight quality control management systems. These systems are embedded at every stage of the manufacturing process, from raw material sourcing to the final product dispatch. This meticulous approach ensures that each product that bears the Nirmal Wires name adheres to our stringent quality standards, making it synonymous with reliability and excellence.
Collectively, our five manufacturing facilities synergize to offer an annual production capacity of 180,000 tons. This figure signifies our ability to not only meet market demands but also drive innovation and progress within the wire manufacturing industry. Our production capacity is a testament to our relentless pursuit of excellence and our unwavering commitment to delivering top-tier products to our clients and partners.
WCI: Tell us about the range of wire products that Nirmal Wires offers. How do these products cater to different industries and applications?
PS: Nirmal Wires offers an extensive range of over 100 diverse wire products, including galvanized and black steel wires, aluminum conductors, ribbed wires, welding electrodes, and hot rolled steel products. These wires find applications in a multitude of industries. They serve as integral components for producing umbrella ribs, various springs, earthing solutions, staying wires, cables’ armoring, and concrete reinforcement. With applications spanning power transmission, distribution, and generation, as well as security, protection, fencing, agriculture, general engineering, and automotive sectors, our wires are versatile and dependable.
From power industry necessities to everyday essentials, our distribution network caters to a diverse array of consumers. This includes the agricultural sector and individual households, offering products such as chain link fences, barbed wire, and galvanized wire. Our retail segment further addresses the varied needs of industrial consumers, providing welding consumables, wire nettings, and more through conveniently accessible retail counters.
Beyond our product diversity, what truly sets us apart is our commitment to being a holistic solutions provider. Beyond assuring product quality, we are dedicated to comprehensive after-sales service, underpinned by a robust customer feedback collection system that exemplifies our customer-centric approach.
WCI: How does Nirmal Wires prioritize innovation in its manufacturing processes and product development?
PS: Nirmal Wires places innovation at the forefront of its manufacturing processes and product development. As articulated in our mission statement, innovation is a fundamental value that guides our approach. We actively cultivate a culture of creativity and progress, constantly seeking novel ways to enhance our efficiency, quality, and offerings. Our commitment to innovation is exemplified by the introduction of products like Tricon®, Niznal™, and our upcoming line of Nirmal Cables. Through ongoing investment in research, collaboration, and the integration of advanced technologies, we ensure that innovation remains integral to our operations. This proactive stance allows us to anticipate market trends, address evolving needs, and consistently deliver superior solutions to our customers.
We understand that innovation encompasses both product development and process enhancement. As a result, we consistently invest in optimizing our operations to achieve higher levels of efficiency, quality, and sustainability. This approach not only ensures that our products remain cutting-edge but also reinforces our commitment to delivering the best solutions to our customers.
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WCI: Niznal™ is one of your recent developments. What are its key features and advantages over other types of alloy wires?
PS: Niznal™ is a high-performance wire made from a special alloy of zinc and aluminum, which gives it superior corrosion resistance and durability compared to a traditional galvanized wire. It provides up to 6X longer life (as compared to a standard GI Wire) and therefore lower product lifecycle cost. Once installed, Niznal™ requires minimal maintenance and provides long-lasting performance, allowing users to focus on their projects with complete peace of mind. This unique attribute saves time, effort, and resources, making Niznal™ the ideal choice for those seeking reliability and convenience.
The utility and usage of Niznal™ are diverse and impressive. It has found applications in industries such as gabion, fencing, weld mesh manufacturing, construction, and agriculture, among others. From strengthening gabion boxes to supporting crops in agriculture, from securing loads in shipping containers to providing strength in fencing structures, Niznal™ excels in every domain.
WCI: What future trends do you see shaping the wire industry?
PS: The wire industry’s future trends are strongly centered on sustainability and green technology. Our commitment to responsible practices is reflected in our introduction of Niznal™, a zinc aluminum alloy coated wire that exemplifies strength, durability, and reduced environmental impact – aligning with the global call for eco-conscious solutions.
Moreover, the Indian wire industry is set to embrace Industry 4.0 integration, infusing automation, data analytics, and IoT for enhanced manufacturing efficiency. Our advanced facilities echo this trend, embedding technology to elevate our production standards.
Safety and reliability standards are also slated for elevation. With our history of prioritizing quality, we anticipate an industry-wide focus on wires that withstand stringent demands while ensuring safety. Our adherence to the highest quality control measures positions us well in this evolving landscape.
WCI: How is Nirmal Wires preparing to adapt to future trends?
PS: Nirmal Wires is strategically aligning with future trends through proactive measures. Our commitment to sustainability is showcased by innovations like Niznal™, embodying eco-conscious practices. Embracing Industry 4.0, we’re integrating automation and data analytics into our state-of-the-art facilities, elevating efficiency and precision. Our unwavering focus on quality positions us well to meet heightened safety and reliability demands. As a holistic solutions provider, we’re not just adapting; we’re pioneering future-ready solutions.
WCI: Could you share some insight on your current market footprint and strategies to expand your global footprint?
PS: Our market footprint is truly global, with exports spanning across 40+ countries, showcasing our expanding global reach. Simultaneously, we hold a robust presence in the Indian market, cementing our position as one of the largest steel wire manufacturers. To further expand our global footprint, we’re strategically focusing on strengthening our distribution networks, intensifying collaborations with international partners, and leveraging our extensive product portfolio to cater to diverse market demands. These approaches, combined with our commitment to quality and innovation, underpin our pursuit of sustainable growth on both regional and global fronts.
WCI: What are the future plans for your company?
PS: Moving ahead, some new products have been recently developed – ASTM class C and class B zinc-coated wires. Globally, companies with the ability to manufacture these wires can be counted on one’s finger types. Future product offerings include aluminum-clad wires, low relaxation pre-stressed concrete wires, and patented steel wires. Our future plans include attaining raw material security by establishing long-term relationships with our raw material manufacturers and by backward integration. We are constantly working on new product innovations to expand our portfolio. We have also started production of top-quality PVC coated wires, PVC barbed wire, and PVC chain links.
