E-Beam Technology

Electron Beam
Cross-Linked Cables

1.5 MeV × 2 (60 mA × 2) Hybrid Crossfire Electron Processing System accelerators at our Pune plant cross-link cable insulation using electricity alone, giving cables that hold up to heat, oil and wear.

Let's Connect See How It Works
Isometric blueprint of the Elegar Kerpen electron beam facility, showing the accelerator vessels, control cabinets and the fenced cable handling area

Disclaimer: Illustration of the e-beam facility; not to scale.

1.5 MeV × 2(60 mA × 2)
Electron beam capacity
0.5–300 mm²(1.5–3.5 mm dia.)
Wire size range processed
−50 °C to +130 °C
Operating range, by application
99.6%
Of light speed, electron velocity
About the technology

What is an E-Beam Cable?

E-beam cables are made using electron beam processing. A focused beam of electrons irradiates the polymer in the cable's insulation and sheath and cross-links it, which strengthens its mechanical and thermal properties well beyond those of a conventional cable.

Our e-beam facility at the Pune plant in Maharashtra runs two electron beam accelerators and processes wire from 0.5 sq mm to 300 sq mm (1.5 mm to 3.5 mm diameter). We use it to produce specialised cables for industries where heat, chemicals and mechanical stress are part of daily operation.

Isometric blueprint of the Elegar Kerpen electron beam facility, with the accelerator vessels and the fenced cable handling area
What the beam changes

Inside the Insulation

Insulation starts as long polymer chains that can slide past each other when they get hot. The electron beam joins neighbouring chains into a connected network, and that network is where the gains in heat resistance, strength and chemical resistance come from.

Before: separate polymer chains. As temperature rises they can slide apart, so the insulation softens.
Insulation behaviour Not cross-linked
Under heat
Softens and can deform as temperature rises.Holds its shape and properties, with an operating range of −50 °C to +130 °C depending on application.
Tensile strength
Baseline strength of the compound.15 to 30% higher through cross-linking, with better elongation for flexible use.
Under long-term load
Can creep and lose shape over years of service.Improved creep resistance for long-term reliability.
Oils, solvents and chemicals
More exposed to swelling and chemical attack.Excellent resistance to oils, solvents and chemical exposure, plus abrasion.
Electrical behaviour
Insulation properties shift as temperature changes.Improved insulation and stable electrical performance across the temperature range.
How the line works

From Wire to Cross-Linked Cable

Our line runs on the linear accelerator principle. Electrons are accelerated, spread into a curtain and passed through the product, all in a single controlled step.

  1. 1
    Extrude

    Insulation or sheath compound is extruded onto the conductor and wound, ready for treatment.

  2. 2
    Accelerate

    Electrons travel through a vacuum tube inside the Dynamitron® accelerator, reaching about 99.6% of the speed of light.

  3. 3
    Spread

    The beam is fanned out into an even curtain of accelerated electrons across the product path.

  4. 4
    Cross-link

    Wire runs through the curtain inside the shielded vault, where neighbouring polymer chains bond into a network.

  5. 5
    Test and trace

    Every batch is tested against its specification and documented for full traceability.

A simple on and off process

The beam runs on electricity, with no radioactive source and no chemical additives. That keeps process control reproducible, so quality stays consistent from one production batch to the next.

Testing

Two Hours at 200 °C

Cross-linking holds the polymer chains together, so the material keeps its shape where standard PE collapses.

Standard PE
Standard PE pipe before heat ageing
Standard PE pipe collapsed after heat ageing
BeforeAfter
Aged 2 h at 200 °C

Collapses and loses its round cross-section.

Cross-linked PEGel 65%
Cross-linked PE pipe before heat ageing
Cross-linked PE pipe intact after heat ageing
BeforeAfter
Aged 2 h at 200 °C

Holds its shape and stays serviceable.

Technical data

E-Beam Cable Specification

Every electron beam cross-linked cable we produce is tested against this framework before it leaves the plant.

Specification Framework
Wire Size Range0.5 sq mm to 300 sq mm (1.5 mm to 3.5 mm diameter)
Tensile Strength15 to 30% improvement through cross-linking
ElongationEnhanced elongation properties for flexible applications
Creep ResistanceImproved, for long-term reliability
Where it's used

Applications of E-Beam Cables

Electron beam cables serve industries where a cable failure is costly and the environment is hard on materials.

Transportation

Rail, automotive and aviation cabling that holds up to vibration, mechanical stress and temperature swings.

Transportation
Solar & Wind Power

Built for years of outdoor service on solar arrays and wind turbines, through UV, heat and weather.

Solar & Windpower
Defence

Cables for extreme-condition and mission-critical use, where strength and heat resistance are specified.

Defence
OEM Industry

Custom constructions for equipment makers, engineered for performance and long service life.

OEM / Custom solutions
Product advantages

Advantages of E-Beam Cables

Why electron beam cross-linked cables are the preferred choice in critical applications.

Enhanced Mechanical Strength
Cross-linking improves strength and resistance, reducing the risk of damage during installation and in operation.
Extended Temperature Range
Rated from −50 °C to +130 °C depending on application, so the cable holds up in extreme heat and cold where conventional cables are likely to fail.
Chemical and Abrasion Resistance
Stands up to chemicals, abrasion and other environmental stress for long, reliable service in demanding conditions.
Reduced Downtime
High reliability and durability keep maintenance to a minimum, so operations stay productive for longer.
Consistent Batch Quality
A reproducible beam process, ISO certified manufacturing and AERB approval keep results the same from one production batch to the next.
Environmental Benefits
No chemical cross-linking additives are needed, making production cleaner. All products are RoHS and REACH compliant.
Support FAQ

Frequently Asked Questions

Common questions from engineers and buyers about electron beam cross-linked cables.

Does electron beam processing make a cable radioactive?
No. The beam is produced electrically by the accelerator and uses no radioactive source. It is a simple on and off process, and the finished cable is safe to handle and install.
What wire sizes can your e-beam line process?
Our two 1.5 MeV accelerators process wire from 0.5 sq mm to 300 sq mm.
What temperature range can e-beam cables handle?
Operating temperatures range from −50 °C to +130 °C, depending on the application and construction. Cross-linked insulation keeps its electrical and mechanical properties at these extremes.
How is e-beam cross-linking different from chemical cross-linking?
E-beam cross-linking uses accelerated electrons instead of chemical additives, heat or moisture curing. The result is a cleaner process with reproducible control and consistent quality across batches.
Can I specify e-beam cross-linking for a custom cable?
Yes. We offer customised engineering, and electrical properties can be tailored to specific voltage and frequency requirements. Share your specification and our team will advise on the construction.
How is the quality of each batch verified?
Every e-beam cable batch is rigorously tested under ISO certified processes, with third-party verification of specifications and traceability documentation for every parameter.
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