Digital transformation is revolutionising industries, and the automation of systems becomes an essential part of this process, introducing an avenue of possibilities for the cables and connectors used in machinery. Gary Bateman, Managing Director, LAPP India, in an exclusive interview with Manufacturing Today, explains the scope for the growth in cable and connection technology with Industry 4.0. and the sectors of potential growth.
Here are the excerpts.Â
What is the potential you see for the growth of cable and connection technology in the era of Industry 4.0?
Digitisation has transformed industries globally, paving the way for revolutionary ways of working and Industry 4.0. Smart factories enable ergonomic and resource-efficient ways of production with the implementation of the Industrial Internet of Things (IIoT). Faster data transfer is a critical need in the age of digitisation. Industry 4.0 includes customised systems dealing with high data rates and providing higher performance with minimum wastage. It calls for customised industrial components that have higher flexibility and adaptability to the industry demands.
Digital transformation is revolutionising industries, and the automation of systems becomes an essential part of this process, introducing an avenue of possibilities for the cables and connectors used in machinery. We see great scope for the growth in cable and connection technology with Industry 4.0. Manufacturers must rethink and re-define their solutions to implement digital transformations.
With the advent of 5G and miniaturisation, machines are becoming more powerful and compact. The ability to transmit high data loads demands cables that are more flexible and have a higher bending radius and are not hindered by factors such as electromagnetic interference. Space-saving solutions with tight-bending radii suitable for usage in high mechanical stresses or harsh environments with high oil usage will ensure long product life with minimum maintenance.
Irrespective of the sector, the overall productivity of the machines and systems essentially depends on the efficiency of the cables and connectors used. The solutions must combine flexibility, robustness, the transmission of high data rates and convenient installation of network connectors in the field without special tools. Even with the advent of 5G, cables will continue to function as an essential part of the infrastructure as data will continue to flow through conventional channels in combination with fibre-optic cables. It is not possible to develop a wireless infrastructure without cables.
Which are the sectors that you foresee having great potential for cable and connection technology?
Currently, LAPP has a product portfolio that has over 40,000 standard products and customised solutions across a diverse set of segments, including textile, machine tools, food & beverage, infrastructure & building, railways, renewable and automotive.Â
In India, we see great potential for the railways, renewable energy, F&B, automotive and automation sectors. With the record budget allocation by the government of Rs 1.1 lakh crore for the Indian Railways this year, we see scope for massive development in the sector.
The demand for EVs continues to grow in India, driven by several major policy changes and incentives from the central and state governments. India is the fifth largest car producer in the world, where the EV market is estimated to be an Rs 50,000 crore opportunity by 2025, making it another sector with great potential.
Companies and individuals are becoming more environmentally conscious and adopting renewable energy. This sector will see major shifts in the coming years, with India’s ambitious target to achieve 175 GW worth of renewable energy by the end of 2022, which expands to 450 GW by 2030. It is the world’s largest expansion plan in renewable energy. The renewable energy installed capacity has increased 226 per cent in the last five years.
The Food and Beverage industry in India is expected to show an annual growth rate (CAGR 2020-2024) of 14.2 per cent, providing a strong growth opportunity for the cable and connection technology market.
What are some of the necessary features demanded by the F&B sector from wires and cables to ensure safety and hygiene in factories?
The F&B sector is the single largest employer in the country, accounting for 3 per cent of India’s GDP. The sector is undergoing rapid modernisation as an ever-growing industry with changing customer demands.
During processing, food is in direct contact with the manufacturing equipment and their electrical components, making it necessary to incorporate features in wires and cables to ensure safety and food hygiene in factories. Components in the machines and facilities must be subjected to product-specific hygiene regulations to minimise the risk of microbiological, chemical and physical contaminations.
If you take the example of simple cable glands, they often form a potential breeding ground for germs in hygiene-control cabinets. The use of specialised cable glands can help prevent such unfavourable situations. High resistance to chemicals and temperatures is required. These components should be easy to clean and should also have a high IP rating to minimise the ingress of moisture and dirt. Drips or splashes of food in the manufacturing equipment can lead to contamination.
Hygienic component designs will decrease the downtime for cleaning the machine and facility components. It will, in turn, lead to reduced usage of cleaning agents and disinfectants, which will improve the durability of materials and reduce costs.
Even in the manufacturing areas where the machinery is not in direct contact with food, the wire and cable components need to have chemical, thermal and mechanical resistance with adequate protection. Installation of the right type of cables can help avoid the accumulation of dirt pockets in the machinery. The cable components used in such machinery are identified based on customer-specific tests. The usage of unsuitable components could cause the corrosion of screw joints and swelling of cable insulation, affecting the functionality of the machinery.Â
Cables and components used in the F&B industry also need to adhere to standards and certifications by industry bodies and working groups. Examples of these would be EHEDG (European Hygienic Engineering & Design Group), 3-A Sanitary Standards Inc, E COLAB, NSF International (National Sanitation Foundation) and the FDA. LAPP only uses products that are developed based on the certification requirements and that comply with hygiene guidelines and directives by these groups.
What are the latest products that LAPP India has launched across sectors recently in India?
Recently, LAPP has added a range of new products to its existing diverse product portfolio. These products were developed keeping in mind the various challenges faced across sectors. The new ETHERLINE T1 Y Flex 1x2x22/7 AWG single-pair Ethernet cables are a part of the ETHERLINE T1 product family generally utilised in industrial machinery /systems and need only one pair of cores to transmit data.
It is a UL-certified 2-core data cable used for high-speed information exchange that maintains the same high data rates while significantly reducing the setup required. Its characteristic small bending radii and small outer diameter make it exceptionally lightweight, space-saving and easy- to-install, which is indispensable for connection at the field level. The ETHERLINE CABINET CAT.6A.for the control cabinet in PROFINET networks prove especially useful in confined spaces, owing to its small bending radii. Information can be exchanged quickly at up to 10 Gbit/s over 60 m using these.
We also launched the ready-to-use connection assembly ÖLFLEX®PLUG 540 P, having multi-strength cable, compatibility with various connector systems and third-party certification for quick and easy installation. The new range also includes the SKINTOP MS-M 40×1.5 PLUS for the optimum cable assembly with a rectangular connector housing. Finally, the single-core cable ÖLFLEX TRAIN 331 600 V launched for rail vehicles is now available in varied dimensions of (0.5 + 0.75 mm²) as well as in additional colours (BN, GN, YE, WH, GY, OG, VT).
How does LAPP’s technology leadership reflect in your state-of-the-art manufacturing facilities in India?
Our operations started in 1998 with a state-of-the-art manufacturing plant in Jigani, Bengaluru, followed by another in Pilukhedi, Bhopal, in 2012. We were the first multi-national cable manufacturer to set up operations in India. The second manufacturing plant was set up primarily to produce best-in-class electrical wires for the building segment.
Our production capacity was further expanded in 2014 by doubling the production area in Bengaluru and adding a new multi-core line in Bhopal with a total investment of almost €5 million. We are currently the third-largest manufacturing facility of LAPP. The Bengaluru and Bhopal plants contribute 36 per cent and 38 per cent to LAPP India’s revenue, respectively.
The Bengaluru plant can manufacture 550 metric tonnes/month. Ninety per cent of the plant’s power requirements are fulfilled by solar power, leading to a reduction in the carbon footprint of almost 1264 tonnes/year. The employees’ transportation needs are met by electric vehicles. The Bhopal plant supports the retail, solar, infrastructure, building and OEM segments while having the lowest scrap rate and TCGP in the group. In 2012, it only catered to single-core cable manufacturing. Multi-core cable manufacturing began in 2015 and expanded to solar cable manufacturing in 2018. A 1-Megawatt solar power plant on the premises meets the energy requirements of the plant. Our testing labs are NABL-certified, and the stocks in the warehouses are digitally tracked.Â