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Manufacturing Standards


Our cables make use of the highest quality materials to ensure strength and efficiency
CONDUCTORS
INSULATION
COLOUR IDENTIFICATION
LAYING IT ALL UP
INNER SHEATH
ARMOURING
OUTER SHEATH
Manufacturing
Standards
Our cables make use of the highest quality materials to ensure strength and efficiency
Conductors

Our conductors are drawn from bright electrolytic grade, annealed high conductivity copper and H2/H4 grade aluminium. Apart from various sizes, our conductors can be configured as solid, stranded, circular or shaped.

All our conductors are manufactured to national and international standards of IS 8130, IEC 60228 and BS 6360.
Conductors
Our conductors are drawn from bright electrolytic grade, annealed high conductivity copper and H2/H4 grade aluminium. Apart from various sizes, our conductors can be configured as solid, stranded, circular or shaped.

All our conductors are manufactured to national and international standards of IS 8130, IEC 60228 and BS 6360.
Insulation

We safeguard all our cables with high quality PVC/XLPE insulation material having high insulation resistance. Our modern high-speed extrusion lines guarantee improved reliability and consistency in a compact package. The XLPE extruded cores are cured according to specific temperature requirements.

Insulation at Varsha Cables is carried out in accordance with national and international standards of IS 5831, IS 7098, BS 6746, BS 5467 and IEC 60502
Insulation
We safeguard all our cables with high quality PVC/XLPE insulation material having high insulation resistance. Our modern high-speed extrusion lines guarantee improved reliability and consistency in a compact package. The XLPE extruded cores are cured according to specific temperature requirements.

Insulation at Varsha Cables is carried out in accordance with national and international standards of IS 5831, IS 7098, BS 6746, BS 5467 and IEC 60502
Colour Identification

Colours are assigned to the different cores within the cable. Colour identification is especially important for control cables. We use the following color scheme

Single Core    Red, Yellow, Blue, Black, Grey, White etc
2-Core Red and Black
3-Core Red, Yellow and Blue
4-Core Red, Yellow, Blue and Black
5-Core Red, Yellow, Blue, Black and Grey


If there are more than five cores, adjacent cores (counting core and directional) in each layer are coloured blue and yellow while the remaining cores in the layer are coloured light grey. Core identification within control cables can also be provided with numbers.
Colour Identification
Colours are assigned to the different cores within the cable. Colour identification is especially important for control cables. We use the following color scheme

Single Core    Red, Yellow, Blue, Black, Grey, White etc
2-Core Red and Black
3-Core Red, Yellow and Blue
4-Core Red, Yellow, Blue and Black
5-Core Red, Yellow, Blue, Black and Grey


If there are more than five cores, adjacent cores (counting core and directional) in each layer are coloured blue and yellow while the remaining cores in the layer are coloured light grey. Core identification within control cables can also be provided with numbers.
Laying it all up

Laying up is the process is used to create the core bundle once the conductors have been insulated.

All cores within the cables are tested thoroughly during production and are laid up as per the specified colour code. We use advanced lay‐up machines ensuring a uniform circularity of cable.
Laying it all up
Laying up is the process is used to create the core bundle once the conductors have been insulated.

All cores within the cables are tested thoroughly during production and are laid up as per the specified colour code. We use advanced lay‐up machines ensuring a uniform circularity of cable.
Inner Sheath

All of our multicore cables have a common covering known as the inner sheath. This is applied over the laid-up cores using an extrusion process.

The sheath ensures the circularity of the cores.
Inner Sheath
Laying up is the process is used to create the core bundle once the conductors have been insulated.

All of our multicore cables have a common covering known as the inner sheath. This is applied over the laid-up cores using an extrusion process

The sheath ensures the circularity of the cores.
Armouring

Armouring is applied on top of the inner sheath of the cables for mechanical protection. Single core cables used in AC systems are armoured with non-magnetic material to minimize losses arising due to magnetic hysteresis.

If the diameter of the inner sheath is upto 13 mm, G.I wires and above 13 mm, G.I strips are used for armouring conforming to IS 3975.
Armouring
Armouring is applied on top of the inner sheath of the cables for mechanical protection. Single core cables used in AC systems are armoured with non-magnetic material to minimize losses arising due to magnetic hysteresis.

If the diameter of the inner sheath is upto 13 mm, G.I wires and above 13 mm, G.I strips are used for armouring conforming to IS 3975.
Outer Sheath

A tough outer sheath of high grade PVC is applied over the armour of the armoured cables and inner sheath of unarmoured cables. A black outer sheath is generally used as it offers the best resistance to outdoor exposure, although any colour can be provided if specified.

The name and size of the cable is inscribed on the outer sheath. Additionally, the voltage grade, the year of manufacturing and the word 'ELECTRIC' are also printed on the outer sheath at regular intervals.
Outer Sheath
A tough outer sheath of high grade PVC is applied over the armour of the cables. A black outer sheath is generally used as it offers the best resistance to outdoor exposure, although any colour can be provided if specified.

The name and size of the cable is inscribed on the outer sheath. Additionally, the voltage grade, the year of manufacturing and the word 'ELECTRIC' are also printed on the outer sheath at regular intervals.
ISO Certificates


Our manufacturing and quality assessment procedures are ISO 9001:2000 certified. Click below to see the various certificates:




ISO 9001-2008
ISO 14001-2004
ISO 18001-2007

BIS 694 Licence
BIS 1554 Lisence
BIS 7098 Lisence

ISO 9001-2015
ISO 14001-2015
ISO 45001-2018

Zed gold certificate