Sai Extrusiontek to Gear-Up on R&D, Automation, and Capacity Expansion to Meet Global Demands

With an international footprint spanning Europe, the USA, the Middle East, and China, Sai Extrusiontek Inc. exports world-class extrusion technology that competes with European and American OEMs. In an exclusive interview with Wire & Cable India, Mr. Mohan Nambiar, Director of Sai Extrusiontek Inc., reveals that the company aims to expand its R&D investments to bring more automation and AI-driven control systems into its extrusion machinery. The company will also increase its production capacity to meet the growing demand from emerging markets in Asia, Africa, and Latin America, while strengthening its presence in Europe and the US markets. Additionally, the company will build strategic partnerships to advance material innovation and sustainable manufacturing solutions.

Wire & Cable India: With the introduction of new compounds and innovations in the wire and cable sector, the extrusion machinery has also evolved over time. How have you catered to these new equipment needs with your tooling solutions?

Mohan Nambiar: Over the past 25 years, Sai Extrusiontek Inc. has been at the forefront of addressing the evolving demands of the wire and cable industry. With the arrival of advanced compounds such as XLPE, EPR, HFFR, and special insulation materials, extrusion machinery must now deliver precise flow distribution, layer uniformity, and defect-free insulation. We have responded by designing crossheads and tooling engineered with imported metallurgy and exact flow-channel dimensioning, ensuring perfect concentricity and layer thickness control. Our triple-layer crossheads for MV/HV XLPE and EPR cables are a prime example of how we align tooling solutions with modern material requirements—delivering reliability, safety, and world-class performance.

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WCI: How do you customize extrusion machine solutions for effective wire and cable manufacturing?

MN: Customization is at the heart of our business. Each customer has unique product ranges, plant layouts, and productivity targets. We carefully analyze their requirements and offer tailor-made extrusion solutions—whether its compact designs for space optimization, specialized adapters, or quick-change die & tip systems to reduce downtime. By integrating automation, safety features, and user-friendly operation, we ensure our machines are not only efficient but also versatile. This approach allows cable manufacturers to optimize output while maintaining consistency across varying cable sizes and materials.

WCI: Can you tell us about your company, its product portfolio and market footprint?

MN: Sai Extrusiontek Inc., under the leadership of Director Mr. Mohan Nambiar, has established itself as a trusted name in the global wire and cable industry. Our portfolio includes crossheads & tooling that include single, double, and triple-layer crossheads for LV, MV, and HV cable applications. We also produce high-speed extrusion lines, Sioplas lines, FR-XLPE lines, and customized solutions. We also have world-class machine tools, adapters, and dies designed for precision and durability.

Our products are renowned for their safety, automation, high efficiency, and operator-friendly features. With a presence spanning Europe, the USA, the Middle East, China, and India, we continue to export world-class extrusion technology that competes directly with European and American OEMs.

WCI: The R&D department stands as a pillar of support for innovation. Are there new products or innovations in the pipeline and its applications in the wire and cable industry? If yes, how do these developments set you apart from your competitors?

MN: Our R&D is continuously focused on future-ready innovations. Currently, we are working on next-generation crossheads with enhanced flow-channel design for superior concentricity and minimal material wastage. We are also working on energy-efficient extrusion systems that reduce power consumption without compromising productivity, and specialized solutions for new-age compounds used in fire-retardant, high-voltage, and eco-friendly cables. Our automation-driven tooling systems are for faster changeovers and reduced operator dependency.

What sets us apart is not just the innovation itself, but our ability to integrate global OEM-level technology at a cost-effective scale. Customers get European precision and quality with the cost benefits and flexibility of an Indian manufacturer—this is our competitive edge.

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WCI: What are your future growth plans for the next 5–10 years?

MN: Our vision is to be among the top global leaders in extrusion tooling and lines by combining innovation, quality, and customer focus. In the next decade, we aim to expand our R&D investments to bring more automation and AI-driven control systems into extrusion. We will also strengthen our presence in Europe and the US markets with dedicated service networks. We will build strategic partnerships for advanced materials and sustainable manufacturing solutions and increase our production capacity to meet the growing demand from emerging markets in Asia, Africa, and Latin America

We will continue to set benchmarks in affordable world-class technology, helping our customers remain globally competitive At Sai Extrusiontek Inc., our philosophy is simple: ‘world-class innovation, made accessible.’ This guiding principle will continue to drive our growth journey in the years to come.