Group Nirmal Set to Double its Aluminium Capacity and Expand Product Portfolio at Khurda Plant

Group Nirmal is set to double the production capacity of its recently acquired 60,000 TPA aluminium rod and aluminium conductor facility in Khurda, Orissa by installing a state-of-the-art mill as part of its strategic expansion. Additionally, it plans to expand its conductor portfolio to include ACAR, AACSR, and ACSS types; and increase steel wire production by 7,000 tonnes per month. The company has earmarked INR 100 crore for this comprehensive expansion and a portion of the investment will be directed towards upgrading the company’s Deulti, West Bengal facility. In an exclusive interview with Wire & Cable India, Mr. Nirmal Saraf, Managing Director, Group Nirmal (Nirmal Wires Private Limited), revealed that Group Nirmal is the first Indian steel wire manufacturer to be approved under Japanese international standards—underscoring its commitment to quality, and reliable wire and cable products.

Wire & Cable India: Please tell us about your manufacturing capabilities with respect to aluminum rod and conductors.

Nirmal Saraf: In 2024, we strategically acquired a state-of-the-art manufacturing unit covering 50 acres in Khurda, Orissa. This significantly enhanced our ability to produce high-quality EC-grade aluminum rods and a comprehensive range of conductors.

With an annual production capacity of 60,000 tonnes, the facility has modern machinery and the latest technology. Currently, our product lineup includes aluminum conductors (AAC), All Aluminum Alloy Conductors (AAAC), Aluminum Conductor Steel Reinforced (ACSR), AL-59, and specialized 6xxx series aluminum alloy wire rods, all tailored to meet various industry specifications. Expanding into this facility has been crucial for broadening our product portfolio, allowing us to meet the growing demands of the power transmission sector and related industries.

We are committed to continuous innovation, investing in the latest research and development and production methods. Our rigorous in-house quality assurance processes adhere strictly to international IS standards, ensuring that our products consistently meet the highest benchmarks for reliability, safety, and performance. This relentless focus on quality positions us as a key player in meeting the evolving needs of the industry, enabling us to respond swiftly and effectively to market requirements while reinforcing our reputation for excellence in manufacturing.

WCI: What quality control processes are in place to ensure the conductors meet industry standards and meet reliability and safety benchmarks for various environmental conditions?

NS: Our quality assurance efforts start from sourcing raw materials exclusively from reputable and established suppliers, recognized for their reliability and excellence in quality. This strategic choice significantly minimizes material wastage and the risk of defects.

We ensure using high-grade aluminum to obtain consistent and predictable output properties. To ensure our conductors consistently meet and exceed stringent industry standards, as well as demanding reliability and safety benchmarks, we have implemented a comprehensive framework of quality control processes.

Our quality assurance regimen includes detailed inspections at multiple critical stages of the manufacturing process, starting from the initial assessment of raw materials to the final product evaluation.

Stringent quality checks are performed at each phase, involving thorough examinations of key parameters such as conductivity, tensile strength, and integrity. These rigorous inspections are designed to identify and rectify any deviations from precise specifications, ensuring that our products maintain the highest standards of quality and reliability.

As a result, this approach enhances the overall reliability and performance of our conductors in various operational environments such as high-temperature industrial settings and harsh weather conditions.

Our products conform to all major international standards like IS, JIS, ASTM, EN, DIN, BSEN etc. This reinforces our quality first approach to manufacturing.

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WCI: Which key markets does your company primarily serve, and what measures are you implementing in production to meet growing demand?

NS: Our aluminum rods are a vital foundation for the production of cables and conductors, which are essential components in various industries.

Our conductors play a crucial role in power transmission and distribution, railways, and numerous industrial applications. With the Indian cable and conductor industry expected to grow significantly, reaching an estimated USD 17.08 billion by 2032, we are proactively aligning our efforts to meet this rising demand.

To address the increasing needs of our customers, we are intensifying our R&D initiatives aimed at driving innovation in our product offerings. This includes exploring advanced materials and technologies to enhance performance and durability.

Additionally, we are implementing strategic initiatives to expand our production capacity, enabling us to effectively meet anticipated market demands. Throughout these efforts, we remain committed to delivering high-quality products, ensuring compliance with international standards, and prioritizing customer satisfaction.

WCI: With the government’s emphasis on power transmission, the demand for aluminum conductors is experiencing significant growth. What innovations and future growth do you anticipate in this sector?

NS: The Indian government is placing strong emphasis on bolstering its power transmission infrastructure, with planned investments exceeding INR 9 lakh crore (approximately USD 108 billion) by 2032.

This substantial financial commitment is significantly driving the demand for aluminum conductors within the nation, which are essential components in modern power distribution systems.

The Indian aluminum bare wire conductor market, valued at USD 1,668.2 million in 2023, is projected to surge to USD 2,522.5 million by 2033, reflecting a compound annual growth rate (CAGR) of 4.3%.

This growth trajectory is largely influenced by various factors, including rural electrification initiatives aimed at providing electricity to remote and underserved areas, as well as the increasing integration of renewable energy projects such as solar and wind farms. These developments necessitate expanded and efficient transmission networks to effectively transfer generated power to urban centers and industrial hubs.

Aluminum conductors are particularly favored in this context due to their lower cost and lighter weight compared to copper alternatives, which translates into more cost-effective and efficient deployment of extensive power lines across India’s diverse geographical terrain. As a result, aluminum conductors are becoming the material of choice for utilities in constructing new transmission lines and upgrading existing infrastructure.

Looking ahead, the Indian market is expected to witness the adoption of global innovations that will further enhance the performance and reliability of power transmission. These include the use of advanced aluminum alloys designed to withstand extreme weather conditions and high-temperature; low-sag conductors that optimize existing infrastructure while minimizing energy losses; and smart conductor technologies integrated with digital monitoring systems to aid in grid modernization. Together, these advancements position the aluminum conductor sector as a vital component in India’s energy future, as the country strives to meet its growing energy demands sustainably and efficiently.

WCI: How do you help your customers achieve better efficiency, productivity & quality?

NS: Our comprehensive in-house manufacturing capabilities generate 15,000 tonnes of steel wires and 4,000 tonnes of products monthly. Our goal is to empower our customers with improved efficiency and productivity through a vertically integrated production process.

This integration allows us to control every stage of production, to ensure delivery of uniform, high-quality output. Our commitment to excellence is demonstrated by our stringent quality control measures maintained throughout the manufacturing process.

We take pride in our achievements, including obtaining several international certifications, and we are the first Indian steel wire manufacturer to receive approval under Japanese international standards. This distinction highlights our dedication to maintaining exceptional quality and reliability in our products. We adhere to our unwavering commitment to quality. Our conductors are engineered to perform reliably in diverse and challenging operational environments, contributing to the overall quality and success of our clients’ infrastructure projects. This holistic approach positions us as a leader in the industry and solidifies our role as a trusted partner in driving our customers’ success.

WCI: Where do you see yourself in the next 5 years? Also, what challenges do you foresee in the industry as the industry continues to boom?

NS: In the next 5 years, we envision innovating and re-imagining corrosion resistance solutions for the wire and cable industry. Our strategy focuses on significantly expanding production capabilities, pioneering technological advancements in products and solutions, and strategically penetrating new markets through enhanced distribution.

We are committed to developing sustainable production methods while navigating foreseeable industry challenges. These include the volatility of raw material prices across all materials, intense competition and pricing pressures requiring differentiation through quality and innovation, and the rapid pace of technological disruption demanding continuous R&D.

Our continued adherence to stringent quality standards and regulatory compliance will also be paramount as we solidify our position as a dominant force in the booming Indian wire and cable sector.

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WCI: What new technologies or process advancements have you integrated into your aluminum rod and conductor manufacturing units?

NS: As part of our ongoing commitment to meet the growing demand for high-quality aluminum conductors, we are making significant improvements to our manufacturing capabilities. We plan to make a substantial investment in our newly acquired Khurda plant to double its capacity. This includes installing a brand-new mill at the Khurda facility. We also plan on expanding our range of conductors, such as ACAR, AACSR, and ACSS.

In addition, we will boost our steel wire production capacity by 7,000 tonnes monthly and increase our aluminum capacity by another 5,000 tonnes monthly this year. This INR 100 crore expansion will mainly take place at our Orissa plant, with the remaining investment directed toward our Deulti facility in the Howrah district of West Bengal.
Given our efficient production cycle and short lead times, we are confident that we can complete this expansion within the current calendar year to effectively meet the increasing market demands.