Manufacturing & Testing

Our manufacturing facility and testing process

ISO 9001:2015 certified manufacturing and in-house testing, backed by 20+ years of engineering experience. From precision core assembly to IEC 60076 compliant testing, every transformer is built and verified in-house.

Transformer manufacturing floor at Magnetic and Controls, Coimbatore
Core Assembly

Precision-engineered core assemblies

We specialize in manufacturing high-quality transformers, with a particular emphasis on precision-engineered core assemblies.

  • Precision cutting: advanced cutting techniques produce laminations with high dimensional accuracy, ensuring tight joints and reducing gaps that can lead to increased losses.
  • Core stacking: laminations are assembled in a step-lap or full mitre configuration to minimize air gaps, enhance magnetic flux continuity, and reduce noise levels.
  • Material selection: premium Cold Rolled Grain Oriented (CRGO) silicon steel is used for its superior magnetic properties and minimal energy losses.
  • Quality testing: rigorous testing, including insulation resistance and core loss measurements, verifies that each core assembly meets design specifications and performance criteria.
Transformer winding facility at Magnetic and Controls
Winding Facilities

State-of-the-art winding facility

Our winding facility is equipped with cutting-edge machinery to ensure precision, reliability, and efficiency in transformer manufacturing.

  • Spenics automatic winding machines: high-speed precision winding with automated tension control for consistent quality.
  • Delta semi-automatic winding machines: combines automation with manual adjustments for customized solutions.
  • Foil winding machines: designed for high-current applications with low impedance.
Transformer manufacturing capability up to 5 MVA, across distribution, isolation, and specialized transformer configurations.
VPI Facility

Vacuum Pressure Impregnation (VPI)

We utilize cutting-edge Vacuum Pressure Impregnation technology to enhance the durability, insulation, and performance of transformer coils.

1

Pre-drying & preparation

Moisture removal for optimal resin absorption.

2

Vacuum cycle

Air and gas elimination within insulation layers.

3

Resin impregnation

Deep penetration into windings under controlled conditions.

4

Pressure application

Uniform resin saturation and bonding.

5

Curing & final processing

Oven curing at precise temperatures for mechanical strength.

Testing facility

Our testing facility ensures that every transformer undergoes rigorous quality checks in compliance with IEC 60076 standards, ensuring reliability, efficiency, and long-term performance.

Engineers monitoring the transformer testing control panel

Routine tests — every transformer

  • Measurement of winding resistance
  • Measurement of voltage ratio and phase displacement check
  • Measurement of short-circuit impedance and load loss
  • Measurement of no-load loss and current
  • Insulation resistance test
  • Induced overvoltage withstand test
  • Separate-source AC withstand voltage test

Special tests — on request

  • Short-circuit withstand test
  • Sound level measurement
  • Magnetic balance test
  • Inrush current test
  • Measurement of harmonics

Type tests — selected transformers

  • Temperature rise test

Equipment & capabilities

Photos of production and testing equipment will be added here.

Production and testing floor at Magnetic and Controls
Manufacturing floor with testing lab and testing area
Winding machine and coil-forming equipment on the production floor
Overview of the manufacturing facility floor with overhead crane and finished units
VPI vacuum pressure impregnation tanks and control panel
Transformer testing panel used for routine and type tests