Durga Engineering Works, with 50+ successful 11 kV to 33 kV Sioplas extrusion lines for HT cable applications, is progressing toward the 66 kV CCV line, setting new standards in high-voltage extrusion technology. In an exclusive interview with Wire & Cable India, Mr. Charan Singh Dagar, Managing Director of Protomac Extrusion Private Limited and Durga Engineering Works, revealed that the company is setting up a greenfield manufacturing facility spanning 46,500 sq. meters., which is slated to become fully operational in the upcoming financial year. This major expansion will significantly boost production capacity, streamline workflow efficiencies, and enable the company to achieve its target of delivering any extrusion line within 30 days.
Wire & Cable India: Please highlight the latest advancements and technology developments that you have introduced in your machines to cater to the evolving needs.
Charan Singh Dagar: Over the past year, we have focused heavily on strengthening our technology portfolio to meet the rapidly evolving requirements of the wire and cable industry. One of our major achievements has been our commitment to developing and supplying 11 kV to 33 kV Sioplas extrusion lines for HT cable applications, with 50+ successful Sioplas installations completed so far. These lines are engineered for superior consistency, excellent bonding performance, and long-term reliability in medium- and high-voltage applications.
Beyond Sioplas, we have also successfully delivered 1000+ insulation, sheathing, and rewinding lines, reinforcing our position as a strong and dependable technology partner across the entire cable production range.
After achieving significant success in the 33 kV segment, we are now progressing toward the 66 kV CCV line, with a confirmed order already in hand. Our team is fully dedicated to making this project a benchmark and one of its kind, setting new standards in high-voltage extrusion technology.
In the rubber cable segment, we have further expanded our capabilities by manufacturing extrusion lines suitable for applications up to 35 kV, meeting the increasing demand for high-performance rubber-based HT cables.
For the building wire segment, we have upgraded our line capabilities to deliver production speeds of up to 1000 mpm, enabling customers to significantly enhance throughput and reduce production costs. Additionally, we now support bobbin sizes up to 1250 mm with fully automatic changeover, ensuring continuous, interruption-free operation and improved operational efficiency.
Across all product categories, our focus remains on delivering high-quality machines with the fastest possible manufacturing and delivery timelines, backed by advanced process control, improved stability, and robust engineering standards.
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WCI: How do you help your customers achieve better efficiencies in their production processes?
CSD: We support our customers in achieving higher production efficiency by ensuring that all our machines are engineered with precision, consistency, and long-term reliability in mind. Internally, we rely on the latest manufacturing technologies and advanced software systems, which significantly reduce human error and enhance overall accuracy. Our machines are compatible with Industry 4.0, so that we can use the data of our machines for further analysis and improvements.
Our production ecosystem includes state-of-the-art equipment such as CNC laser cutting, CNC laser welding, CNC screw cutting machine, CNC deep hole machines, CNC turning machines capable of operating materials up to 1.2 meters dia and 5 meters in length, and VMC systems that operate on components up to 3 × 6 × 2.5 meters.
We also maintain a fully in-house powder-coating facility and several automated sub-processes to ensure superior finishing and consistent quality.
These capabilities allow us to manufacture extrusion lines that are high in output, low in maintenance, and cost-effective, enabling customers to reduce downtime, optimize energy consumption, and improve overall production throughput.
For the building wire segment, we have upgraded our line capabilities to deliver production speeds of up to 1000 mpm, enabling customers to significantly enhance throughput and reduce production costs.
WCI: What is your future technology roadmap and upcoming developments for the wire & cable industry?
CSD: Our future technology roadmap is strongly aligned with our vision of scaling up capabilities and delivering next-generation solutions to the wire and cable industry. We are currently developing a new greenfield manufacturing facility spread across 46,500 sq. meters, which is already under construction and scheduled to become fully operational in the upcoming financial year. This expansion will significantly enhance our production capacity, workflow efficiency, and meet our goal of 30 days delivery of any extrusion line.
The new plant will integrate state-of-the-art machinery, advanced automation systems, and upgraded precision technologies aimed at reducing manual intervention and improving manufacturing consistency. A major focus will be on automating most of the manual processes to ensure higher accuracy, faster production cycles, and improved repeatability.
Additionally, our dedicated R&D team is actively working on new product developments and technological upgrades that will further strengthen our offerings and support the evolving needs of the global wire and cable market.
WCI: How do you ensure product quality and reliability across your entire machine portfolio?
CSD: To ensure consistent product quality and long-term reliability, we follow a fully standardized and process-driven manufacturing approach. All our machines are produced using high-precision CNC equipment, automated systems, and advanced quality control procedures, which minimizes variability and enhances accuracy across every stage of production.
Each critical component undergoes multiple quality checks, including dimensional inspection, load testing, electrical verification, and full performance validation before assembly. We work only with certified raw material suppliers and conduct regular supplier audits to maintain strict consistency in material quality.
With strong in-house capabilities—covering machining, fabrication, powder coating, assembly, and testing—we maintain complete control over quality without relying heavily on external processes. Before dispatch, every machine goes through a full-load trial run, ensuring defect-free performance and stable operation at the customer’s site.
This disciplined approach ensures that every machine in our portfolio delivers high output, long service life, and dependable performance, even under demanding production conditions.
Our production ecosystem includes state-of-the-art equipment such as CNC laser cutting, CNC laser welding, CNC screw cutting machine, CNC deep hole machines, CNC turning machines capable of operating materials up to 1.2 meters dia and 5 meters in length, and VMC systems that operate on components up to 3 × 6 × 2.5 meters.
WCI: How do you support customers after the sale in terms of service, spares, training, and technical assistance?
CSD: Our customers and partners have always been at the core of our journey. To ensure seamless support, we provide immediate guidance and assistance within 24 hours of machine supply, followed by the deployment of our dedicated installation and commissioning team to ensure smooth start-up and stable production. We also maintain readily available spares for all our machines, enabling quick replacements and minimizing downtime for our customers.
Our commitment is to build long-term relationships based on trust, transparency, and consistent performance, ensuring customers always receive dependable and future-ready solutions.
Our vision for all upcoming machines is providing failure-free performance supported by IOT-based assistance, enabling real-time monitoring, predictive maintenance, and enhanced operational visibility and setting new benchmarks for quality, reliability, and technological excellence in our industry. Additionally, we aim to achieve the shortest delivery timelines to support our customers’ growing production demands and market commitments.
WCI: What are the key innovations and emerging trends shaping the wire and cable industry?
CSD: The key innovations & emerging trends shaping the wire and cable industry include advanced materials & safety products such as halogen-free, low-smoke, fire-resistant (LSZH) cables, and high-performance polymers and elastomers for durability, heat, and UV resistance.
Electrification & high-voltage transmission is an emerging trend with the growth in HVDC, smart grids, and underground/submarine cables. The industry is driven by renewable energy, power infrastructure, and urban development.
Development of high-speed fiber-optic and data cables for 5G, data centers, and smart cities in the telecom & data infrastructure sector is the focal point, targeting bandwidth, signal integrity, and latency reduction. The innovations also include smart/intelligent cables that are embedded with sensors for real-time monitoring, fault detection, and predictive maintenance, and supports smart grids and automated infrastructure management.
The automated manufacturing & Industry 4.0 is another emerging trend in the industry with robotics, AI, IoT, and digital twins ensuring quality, efficiency, and consistency in wire and cable manufacturing. It optimizes production of high-performance and specialized cables.
Sustainability & green manufacturing is another critical trend in the industry with eco-friendly materials, recyclable polymers, and low-carbon production that has become a necessity and the wire and cable manufacturers need to comply with safety and green-building standards.
All in all, market drivers including urbanization, infrastructure expansion, renewable energy, telecom growth, and EV adoption are creating rising demand for safe, durable, high-performance, and environmentally friendly cables. The industry is moving toward safer, smarter, high-performance, and sustainable cable solutions to meet the growing demands of electrification, digitalization, and green infrastructure.
In the rubber cable segment, we have further expanded our capabilities by manufacturing extrusion lines suitable for applications up to 35 kV, meeting the increasing demand for high-performance rubber-based HT cables.
