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Infrastructure

Infrastructure

At Bhuwal Insulation, we believe in supporting our customers the best that we can. Backing us up is the state-of-the-art infrastructure we have on our sites. The employee strength in our company is 150 skilled and experienced professionals, with an annual turnover of 12 million usd. Our factory is located in Valsad (Gujarat) spread across 35000 square feet with the latest manufacturing technology.

The machinery in our factory consists of both outsourced and domestic automated equipment. Efficient in terms of processing and energy consumption, our factory has a high rate of production. Some machines in our factory include an elastomer extruder, wrapping machine, rubber mixing mills, bunching machine, and extruder. Our equipment undergoes frequent audits and calibration checks to improve delivery lead time. The staff at our factory have the qualifications to handle the equipment. Their prior experience gives them an edge in the production process that takes place here.

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Rubber mixing mills

The mixing of rubber takes place in a Mixing mill. Many in the industry also refer to this equipment as a rolling mill. In this process, a rubber base undergoes processing with several additives. These additives include softeners, fillers, processing aids, and colorants to form the raw material. The mill has two stainless steel rollers that rotate in the opposite direction. The rollers run at differing speeds to create friction. The friction that takes place between the rollers is what mixes the rubber.

Elastomer extruder

An extruder plays a pivotal role in the cable manufacturing process. In this process, feeding the elastomeric chips or pellets into the melting chamber is the initial step. Subsequently, the application of heat to the melt chamber causes the pellets to dissolve uniformly. Upon dissolution, there is a channel that causes a diversion such that this melt will move to a die. The shape of the die nozzle will be the size of the wire or cable desired. Since the property of an elastomer is high stretchability, it is possible to achieve filaments of very thin diameters. On extrusion from the machine, getting the filament cut into smaller pieces is the next step.

Extruder

The next step in the process is coating the metal wires with the elastomer. Similar to an elastomeric extruder, the melt chamber in the machine will melt the filaments. The difference here is that the elastomer acts as an insulating material to coat metal wires. After drawing and annealing the wire, a formula determines the twist length. The use of this formula is to twist wires in multiples of two or more. Because the wire undergoes processing, they become ductile. In the next step, the melted filament will coat the soft wire that passes through the extruder. As it is an ongoing process, the elastomeric wires are hot. To prevent sticking of the wire, it will pass through a cooling system.

Bunching machine

The term bunching refers to an assembly of multiple strands of wire to a bunch. The machine at our factory suits many copper and aluminum-derived wire and works at a relatively high speed. Bunching machines have a steady twist pitch, making them suitable for cables like HDMI, power, and communications.

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