Alnyc Cables Manufacturer in India
The growing need for lighter, safer, and environmentally responsible cable solutions has positioned Alnyc technology as the preferred choice for critical industrial infrastructure. Compared to conventional lead-sheathed cables, Alnyc cables offer 44% weight reduction and an 8% smaller overall diameter, significantly easing transportation, handling, and installation. Their compact multi-barrier construction delivers equivalent chemical protection without the environmental and health concerns associated with lead, making them indispensable for modern industrial projects.
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Applications of Alnyc Cables
- Oil and Gas Facilities: Alnyc cables are widely deployed in offshore platforms, onshore pipelines, and gas processing units where incidental contact with hydrocarbons is a regular operational risk. The combined barrier of aluminum, polyolefin, and polyamide layers ensures the cable sheath remains impermeable to aliphatic and aromatic hydrocarbons, maintaining system reliability in these high-risk zones.
- Refineries and Petrochemical Complexes: In refinery environments, cables are routinely exposed to benzene, trichloroethylene, and various processed fuel derivatives that can rapidly degrade standard cable sheaths. Alnyc cables, tested and certified against such chemicals, including reference oils IRM 902 and IRM 903, maintain their structural and electrical integrity under these demanding conditions.
- Chemical Processing and Manufacturing Plants: Chemical plants frequently handle oxidizing acids, chlorinated solvents, and corrosive bases that pose serious threats to conventional cable installations. The polyolefin barrier layer specifically resists acids and bases, while the polyamide outer sheath adds a further line of defense, making Alnyc cables a dependable wiring solution across aggressive chemical processing environments.
- Instrumentation and Process Control Systems: Alnyc cables are the preferred choice for instrumentation networks in hazardous industrial areas, including DCS, SCADA, and PLC-based control systems. The built-in aluminum tape also functions as an electromagnetic screen, eliminating the need for a separate screen layer and reducing overall cable construction size without compromising signal accuracy.
- Direct Burial Underground Installations: When fitted with optional steel wire armour (SWA), Alnyc cables are fully suitable for direct burial applications in industrial complexes and plant perimeters. The moisture-blocking aluminum layer combined with mechanical armoring provides reliable protection against both soil-borne chemical contamination and physical damage from ground movement.
- Industrial Plants with High Mechanical and Chemical Stress: Heavy manufacturing environments involving engine oils, cutting fluids, and industrial lubricants demand cables that resist both mechanical stress and chemical permeation simultaneously. Alnyc cables handle exposure to reference oils equivalent to ASTM grades 2 and 3, performing reliably in machine rooms, workshops, and process areas where cables may contact these substances regularly.
Alnyc Cable Specifications
| Instrumentation cables | 1 pair – 24 pairs |
| Conductor sizes | 0.5 – 10 sq mm |
| Screening | Individual Overall/Overall Screened |
| Armouring | Steel Wire Armour (SWA) |
Our detailed control cable size chart is available in our comprehensive product catalogue. Whether you need specific control cable size specifications for compact installations or larger configurations, Elegar Kerpen has the right solution.
Why Elegar Kerpen's Alnyc Cables?
Elegar Kerpen stands among the most reliable control cable manufacturers, delivering premium-quality control cables that are built to perform in the most demanding conditions. Here's what sets them apart:
- Precision-Engineered Multi-Layer Sheath Construction: Elegar Kerpen's Alnyc cables feature a carefully engineered (L)2Y4Y multi-layer sheath system. The construction begins with a plastic-coated aluminum tape longitudinally applied, overlapped, and sealed in contact with a drain wire. Over this, an extruded HDPE (High Density Polyethylene) inner sheath is bonded directly to the coated side of the aluminum tape, followed by an outer polyamide (nylon) sheath of at least 300 µm thickness, each layer contributing a specific and measurable barrier function.
- Layer-Specific Chemical Protection: Each sheath layer in Elegar Kerpen's design targets distinct chemical threats. The aluminum layer blocks water, aqueous solutions, and both aliphatic and aromatic hydrocarbons. The polyolefin (HDPE) layer resists hydrocarbons as well as acids and bases. The polyamide outer sheath provides a final barrier against water, aqueous solutions, and hydrocarbons, meaning all three layers together constitute a complete and redundant chemical protection system verified through independent testing.
- Independently Certified to replace Lead Sheath: As a trusted wires and cables manufacturer, Elegar Kerpen subjects its Alnyc cables to rigorous third-party qualification testing. KEMA Nederland B.V., an internationally recognized independent test institute, has certified that the Alnyc sheath is suitable as a direct replacement for commonly used lead sheaths in chemically hazardous areas, industrial environments, refineries, and oil and gas facilities.
- Significant Weight and Size Advantage: The Alnyc sheath measures just 150 µm in metal layer thickness compared to 1,100 µm for a conventional lead sheath, resulting in a cable that is approximately 44% lighter and 8% smaller in overall diameter. For a 10-pair, 1.0 mm² cable, this translates to a weight reduction from 1,700 kg/km to 960 kg/km, directly lowering transportation costs, accessory expenses (glands, jointing boxes), and overall installation effort.
- Built-In Electromagnetic Screening: The aluminum tape layer serves a dual-purpose chemical barrier and electromagnetic screen. This eliminates the need for a separate (ST) screen and an additional inner sheath within the cable construction, resulting in a more compact design with a better length-to-volume ratio and smaller bending radii, further reducing installation complexity.
- Environmentally Responsible and Safe to Handle: Unlike lead-sheathed cables, Alnyc cables present no environmental hazards during installation or disposal. This wire cable company ensures cable waste can be handled without specialized health protection measures for installation teams, simplifying compliance with environmental and workplace safety regulations while delivering cost savings on waste management.
- Standards Compliance and Temperature Performance: The ICON range of Alnyc cables is constructed according to EN 50288-7, available in core (C), pair (P), triple (T), or quad (Q) configurations, with or without individual metal foil (IMF) screening. Insulation options include XLPE (2X) or HDPE (2Y), and cables are rated for an operating temperature range up to 80°C, covering the requirements of most industrial and process industry applications. As one of the dependable wires and cables manufacturers in India, Elegar Kerpen ensures full traceability and documentation for every cable supplied.
Frequently Asked Questions
Find answers to frequently asked questions related to Alnyc Cables.
ALNYC stands for Aluminium tape laminated to polyolefin (AL) with a Nylon Coating sheath (NYC). It comprises three layers: a plastic-coated aluminum tape, an extruded HDPE inner sheath, and an outer polyamide sheath of a minimum 300 µm thickness.
Independent tests covered reference oils IRM 902 and IRM 903 (equivalent to ASTM 2 and 3), benzene (100%), trichloroethylene (100%), and nitric acid at 32% concentration, representing a broad range of industrial chemical hazards.
Yes. KEMA Nederland B.V. has independently certified that the Alnyc sheath is a suitable replacement for lead sheaths in chemically hazardous areas, refineries, industrial plants, and oil and gas facilities without compromising protection levels.
For a 10-pair, 1.0 mm² cable, the Alnyc version weighs approximately 960 kg/km versus 1,700 kg/km for the lead-sheathed equivalent—a reduction of roughly 44%, with overall diameter reduced by 8%.
No. The aluminum tape layer inherently acts as an electromagnetic screen, eliminating the need for a separate screen layer or additional inner sheath, which also reduces the overall cable size and construction complexity.
Yes. With the optional steel wire armour (SWA) layer, Alnyc cables are suitable for direct burial installations, providing additional mechanical protection alongside the existing chemical and moisture barrier of the multi-layer sheath.
The ICON range supports XLPE (2X) or HDPE (2Y) insulation, in core, pair, triple, or quad configurations, with or without individual metal foil screening, all rated up to 80°C operating temperature.
None. Unlike lead-sheathed cables, Alnyc cables involve no hazardous materials, require no special health protection during handling, and can be disposed of without the environmental restrictions that apply to lead-containing cable waste.
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