Smart cables and safer grids drive the next wave of electrification

With the help of advanced design technologies, wires and cables are now being developed with built-in sensors for continuous real-time monitoring.

The demand for high-performance, specialised cables has surged due to the recent boost in sectors such as smart grids, railway electrification, EV infrastructure, and renewable energy. Simultaneously, the adoption of Industry 4.0 technologies and embedded smart features is reshaping both product innovation and manufacturing practices. The focus on fire safety and solar cables is addressing growing market demand. Gloster Cables is at the forefront of this evolution, leveraging research and development, sustainability and quality assurance to stay competitive. Vinay Rathi shares how the sector is adapting to these dynamic trends and overcoming key challenges to achieve a secure energy future in India.

How is digitalisation reshaping the Indian electric wire and cable industry?

Digitalisation is significantly reshaping the smart electric wire and cable industry in India. With the help of advanced design technologies, wires and cables are now being developed with built-in sensors for continuous real-time monitoring. This increases performance, facilitating predictive maintenance and optimising power distribution. Manufacturing processes are embracing Industry 4.0, integrating automation, AI and IoT to reduce waste, improve quality control and enhance efficiency through real-time data analytics. Smart cables are crucial for developing smart cities, 5G networks and renewable energy infrastructure. This enables intelligent grid management with enhanced safety and seamless communication.

How is Gloster Cables aligning with smart electricity trends through innovation and quality assurance?

At Gloster Cables, we are aligning with emerging smart electricity trends by intensifying our R&D efforts in sustainable and specialised cable solutions. Our focus on fire survival and solar cables addresses growing market needs and evolving environmental standards. We ensure rigorous compliance of our products with national and international standards through in-house testing and quality assurance. This helps in maintaining our reputation for safety and reliability in a rapidly evolving regulatory landscape.

How is the wires and cables industry supporting the growth of railway electrification and EV charging infrastructure?

The Indian wires and cables industry is actively preparing to support the country’s aggressive electrification goals by focusing on specialised products and enhancing manufacturing capabilities. For the near-total electrification of Indian Railways, the industry is providing high-performance catenary and contact wires, high-voltage power cables for substations, and robust signalling and communication cables, which are essential for reliable electric traction.

Simultaneously, the industry is developing specialised cables for EV charging networks under schemes like PM E-Drive, including high-capacity power cables for fast charging stations and durable, safe wiring solutions for public and home chargers. Manufacturers are also investing in advanced materials and production technologies to meet stringent safety standards and handle the increased power demands of both railway electrification and the growing electric vehicle (EV) ecosystem.

What key challenges do Indian cable manufacturers face amid rapid electricity market growth and innovation?

Cable manufacturers face significant challenges due to the ambitious growth of the Indian electricity market. Capacity scaling is a major hurdle that requires substantial investment in expanding manufacturing units and overcoming raw material price volatility (e.g. copper, aluminium). Technologically, the focus shifts to producing higher-voltage, smarter, and more specialised cables (e.g., XLPE, E-beam treated, sensor-embedded) for green energy, EV charging, and smart grids. A critical challenge also lies in ensuring consistent high quality to meet stringent new standards and combating the prevalence of substandard products, especially from unorganised players. Addressing the shortage of a skilled workforce to handle advanced production processes is also a major challenge.

How is your company positioning itself to meet the rising demand and ensure competitiveness?

To capitalise on the burgeoning demand in the power sector, we are implementing a multi-pronged strategy. Firstly, we are significantly expanding our manufacturing capacity to meet the sheer volume requirements driven by infrastructure and renewable energy projects. Secondly, we are investing heavily in R&D to develop specialised, high-performance cables. And lastly, we are strengthening our supply chain resilience to mitigate raw material price volatility and ensure timely delivery. We are also leveraging government initiatives, such as ‘Make in India’ and the PLI scheme, to boost domestic production and competitiveness.

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