Manufacturing Workshops — Anhui Tongdu Cable Co., Ltd.

Overview

At Anhui Tongdu Cable Co., Ltd., our manufacturing strength is built on a foundation of over 100 sets of advanced domestic and imported production and testing equipment, operated by a team of nearly 100 skilled professionals. Our facilities are strategically divided into specialized workshops at Xinlou Industrial Park, Zongyang Economic Development Zone, each designed to handle specific stages of cable and wire manufacturing—from raw conductor processing to final high-voltage cable assembly. This segmented yet integrated layout ensures full control over quality, efficiency, and customization at every step.

Workshop No. 3 — Wire Production Workshop

Workshop No. 3 is the dedicated facility for wire manufacturing, where we produce a full range of building wires (hard and flexible), decorative flower wires (including fire-resistant and LSZH variants), and low-smoke zero-halogen (LSZH) wires such as the WDZB-BYJ series. The workshop houses high-speed PVC and XLPO extrusion lines capable of processing both solid and stranded conductors.

The production flow follows a strict sequence: conductor drawing and annealing → insulation extrusion → cooling and diameter control → spark testing → length measurement and packaging. Every line is equipped with online diameter monitors and high-frequency spark testers to instantly detect insulation defects, ensuring every meter of wire meets IEC 60228 and GB/T 5023 standards.

Workshop No. 3 — Cable Production Workshop

Workshop No. 3 also houses our standard cable production area, focusing on low-voltage power cables (up to 1 kV) and control cables. The area is equipped with rigid stranding machines, planetary cabling machines, copper wire braiding machines for shielding (individual pair foil and overall copper braid), and PVC/XLPE sheath extrusion lines.

Here we manufacture PVC-insulated power cables (YJV, VV series) in 1-core to 5-core configurations, XLPE-insulated control cables (KYJV, KVV series) with up to 61 cores, and flame-retardant (ZR), fire-resistant (NH), and low-smoke halogen-free (WDZ) variants. Shielded cables undergo 100% continuity testing on both foil and braid screens before the sheath is applied.

Workshop No. 4 — High-Voltage Cable Production Workshop

Workshop No. 4 is our most advanced facility, dedicated to high-voltage and specialty cable production. The centerpiece is our three-layer co-extrusion cross-linking (XLPE) production line, capable of manufacturing power cables from 3.6/6 kV up to 35 kV using dry curing (MDCV) technology. This ensures uniform insulation thickness and optimal cross-linking density, delivering cables with superior dielectric strength and thermal endurance (90°C continuous, 250°C short-circuit).

In addition to high-voltage power cables, Workshop No. 4 produces:

• Metallic-shielded power cables​ for data centers, intelligent buildings, and aerospace monitoring centers—featuring copper wire braid or copper tape wrap shielding for maximum EMI protection.

• Photovoltaic (solar) cables​ using electron-beam cross-linked polyolefin (XLPO) insulation and sheath, compliant with TÜV 2 PfG 1169, IEC 62930, and EN 50618 standards, rated for 25-year outdoor service.

• Flexible power cables for telecom power supply​ with enhanced bending performance for indoor installation in communication facilities.

All high-voltage cables undergo partial discharge testing, high-voltage withstand testing (AC 3.5kV/5min for finished cables), and insulation shield stripping tests​ before release.

Workshop No. 5 — High-Voltage Cable Production Workshop

Workshop No. 5 serves as the final inspection and specialized finishing area​ for our high-voltage cable products, complementing the manufacturing capabilities of Workshop No. 4. This dedicated space is equipped with precision testing instruments for partial discharge measurement, AC high-voltage withstand verification, and insulation shield integrity checks—ensuring every high-voltage cable leaving our facility fully complies with IEC 60502 and GB/T 12706 standards.

In addition to final electrical testing, Workshop No. 5 handles cable marking, laser printing of meter markings, and custom packaging​ (drum selection, wrapping, and sealing) tailored to international shipping requirements. The workshop also supports third-party witness testing, where customers or independent inspectors (such as Anhui Product Quality Supervision & Inspection Research Institute) can observe and certify test results on-site before shipment.

This additional layer of verification reflects Tongdu Cable's commitment to zero-defect delivery for overseas EPC projects, utilities, and infrastructure developers who require absolute confidence in every high-voltage cable shipment.

Workshop No. — In-House Testing Laboratory & Inspection Equipment

Quality verification is fully integrated into our workshop operations. Our in-house laboratory covers every critical performance parameter:

All data is recorded and archived for full batch traceability. We also coordinate with third-party institutions—including the Anhui Product Quality Supervision & Inspection Research Institute​ and Suzhou Product Quality Inspection Institute—for independent verification. Products have consistently passed both provincial and national random inspections with zero non-conformities.

Workshop No. — Workshop Management & Certifications

Every workshop operates under ISO 9001:2015 (Quality), ISO 14001:2015 (Environment), and ISO 45001:2018 (Occupational Health & Safety)​ certified systems. We follow strict 5S principles—Sort, Set in order, Shine, Standardize, and Sustain—to maintain a clean, organized, and safe production environment. Detailed production records from raw material batch numbers to finished product serial numbers ensure full lifecycle traceability.

Why Our Workshops Give You Confidence

When you source from Anhui Tongdu Cable Co., Ltd., you are buying from a manufacturer that controls every step under one roof. From raw copper or aluminum entering Workshop No. 3 to the final high-voltage cable leaving Workshop No. 5, every operation is monitored, tested, and documented by a team that understands international standards and global customer expectations. This is why EPC contractors, utilities, and distributors worldwide trust Tongdu Cable as their long-term manufacturing partner.

ODM & OEM Services — Anhui Tongdu Cable Co., Ltd.

Why Choose Tongdu Cable as Your ODM/OEM Partner

With over 15 years of manufacturing expertise since 2009, Anhui Tongdu Cable Co., Ltd. has built a fully integrated production base capable of handling both high-volume standard orders​ and highly customized cable solutions. Our combination of 100+ advanced production machines, in-house R&D engineering, and internationally certified quality systems makes us a reliable China-based manufacturing partner for global brands, distributors, EPC contractors, and project developers.

What We Offer

1. Full Customization — True ODM Capability

Our engineering team can design and manufacture cables from the ground up based on your project specifications, target market standards, or performance requirements. Every structural element is customizable:

We also support non-standard and obsolete specifications—many customers come to us with legacy drawings or unique site requirements that no standard catalog can match.

2. Private Label & Packaging — OEM Branding

For distributors and brand owners looking to sell under their own name, we provide complete OEM services:

• Cable Surface Printing:​ Your brand name, logo, product code, voltage rating, and meter marks printed directly on the cable sheath via laser or ink-jet marking.

• Drum / Reel Customization:​ Wooden drums, steel drums, or plastic reels with your company label, origin markings, and handling instructions.

• Packaging Materials:​ Custom shrink wrap, moisture-barrier paper, and desiccant packs for long-distance sea freight.

• Documentation in Your Name:​ Commercial invoices, packing lists, and certificates of origin can be issued with your branding where permitted by regulation.

3. Standard Compliance & Certification Support

We manufacture to the standards your target market requires:

• International:​ IEC 60228, IEC 60502, IEC 60332, IEC 60754, IEC 61034, IEC 60840/62067, IEC 62930, IEC 61189

• European:​ BS 6622, BS 7835, BS 5308, EN 50288, EN 50618, TÜV 2 PfG 1169

• North American:​ ASTM B231, UL 4703 (solar), UL 2556

• Chinese:​ GB/T 12706, GB/T 5023, GB/T 9330, GB/T 1179

We hold CCC, CE, ISO 9001, ISO 14001, ISO 45001, and Energy Management System certifications. For orders requiring additional third-party certification (e.g., TÜV, SABS, SONCAP, SASO), we coordinate sample submission and factory audits with the relevant institutions.

4. Rapid Sampling & Prototyping

Our ODM process includes:

1. Technical Consultation​ — English-speaking engineers review your specs or drawings.

2. Quotation & Lead Time​ — Transparent pricing with tooling/sampling fees clearly separated.

3. Sample Production​ — Typical sampling lead time: 7–15 days for standard constructions; 15–25 days for complex multi-shielded or high-voltage designs.

4. Sample Testing​ — In-house test report provided with each sample; third-party testing available upon request.

5. Mass Production​ — Upon sample approval, bulk production begins with scheduled progress updates.

5. Quality Assurance for ODM/OEM Orders

Every ODM/OEM order goes through the same rigorous quality system as our own-brand products:

• Incoming Material Verification​ — All conductors and compounds are tested before production.

• In-Process Inspection​ — Dimensional checks at every extrusion stage; spark testing on 100% of cable length.

• Final Inspection​ — Full electrical, mechanical, and fire-performance testing per applicable standard.

• Third-Party Witness​ — We regularly host inspectors from Anhui Product Quality Supervision & Inspection Research Institute, Suzhou Product Quality Inspection Institute, and customer-appointed agencies.

• Warranty​ — 24-month quality guarantee​ from delivery date. In the event of a confirmed product defect, we provide replacement or compensation per contract terms.

Typical ODM/OEM Project Scenarios

Our Track Record

Tongdu Cable's ODM/OEM capabilities are proven through real-world supply contracts, including:

• China Hongqiao International Investment Co., Ltd.​ — 2×60 MW combined-cycle power plant project in Tierra del Fuego, Argentina. Cables supplied to project specifications with full documentation for international EPC execution.

• Zhejiang CHINT​ — Long-term supply of control and power cables as a qualified sub-supplier.

• Huainan Dili Mining Machinery Sales Co., Ltd.​ — Bulk supply of WDZ, NH, and armored cables with contract values exceeding RMB 10 million.

• Anhui Huipan Technology Development Co., Ltd.​ — Cable supply for the Funan Huilong Sock Capital Project (industrial park, 3 factory buildings).

These partnerships demonstrate our ability to deliver customized, certified, and quality-assured cable products​ on time and at scale—whether for a single overseas project or an ongoing private-label supply program.

Research & Development — Anhui Tongdu Cable Co., Ltd.

R&D Philosophy

At Anhui Tongdu Cable Co., Ltd., research and development is not an isolated department—it is a mindset embedded across every workshop, laboratory, and engineering discussion. Guided by our core value of "Striving for Excellence, Never-Ending Improvement,"​ our R&D approach focuses on three pillars: material innovation, structural optimization, and standards-driven design.​ We invest continuously in equipment upgrades, testing capability expansion, and technical talent development to ensure our products not only meet today's international requirements but anticipate tomorrow's.

R&D Team & Technical Expertise

Our R&D function is led by a team of experienced cable engineers with deep knowledge across multiple disciplines:

• Conductor Design Specialists​ — Experts in copper and aluminum metallurgy, stranding lay-up optimization, and flexible conductor (Class 5) manufacturing for applications ranging from building wiring to photovoltaic systems.

• Polymer & Compounding Engineers​ — Specializing in XLPE cross-linking kinetics, PVC formulation, electron-beam XLPO for solar cables, and LSZH (low-smoke zero-halogen) compound selection to balance flame retardancy, smoke density, and mechanical performance.

• EMC & Shielding Designers​ — Focused on metallic-shielded power cables and instrumentation cables, optimizing copper braid coverage, aluminum foil overlap, and armor-screen combinations for maximum electromagnetic compatibility in data centers, intelligent buildings, and aerospace monitoring environments.

• International Standards Engineers​ — Dedicated to interpreting and mapping IEC, BS, EN, ASTM, and GB/T requirements to product specifications, ensuring every custom design is fully compliant before production begins.

Core R&D Capabilities

1. Custom Cable Design & Structural Engineering

Every cable is a system of interdependent layers. Our R&D team engineers each element to match the target application:

For non-standard requests—such as a 7-core 70 mm² NH-WDZ-YJY with copper tape shielding and SWA—our team produces detailed cross-sectional drawings, bill of materials, and manufacturing process sheets​ before any production begins.

2. Material Science & Formulation

Our laboratory conducts ongoing evaluation of insulation and sheath compounds to verify:

• Thermal endurance​ — Long-term service temperature rating, emergency overload capacity, and short-circuit tolerance (e.g., XLPE at 90°C continuous / 250°C short-circuit).

• Flame retardancy vs. mechanical balance​ — Optimizing filler and compound ratios to achieve IEC 60332 Category A/B/C compliance without compromising tensile strength or elongation.

• Halogen-free performance​ — Ensuring LSZH formulations meet IEC 60754 (HCl ≤ 0.5%, pH ≥ 4.3, conductivity ≤ 10 μS/mm, fluorine ≤ 0.1%) and IEC 61034 (smoke transmittance ≥ 60%).

• UV & weather resistance​ — Accelerated aging protocols for solar cables (720h at 120°C, post-aging tensile/elongation change ≤ ±30%) and outdoor PE-sheathed cables.

We maintain close relationships with leading material suppliers in China and internationally, enabling rapid adoption of new compounds as market demands evolve.

3. Standards Interpretation & New Product Development

A key strength of our R&D team is the ability to translate international standards into manufacturable products. Examples:

• IEC 62930 / EN 50618 / TÜV 2 PfG 1169​ → Development of H1Z2Z2-K photovoltaic cable (DC 1.5 kV, XLPO, 25-year design life).

• BS 6387 / IEC 60331​ → Fire-resistant cable (NH) series maintaining circuit integrity during fire.

• IEC 60502 / GB/T 12706​ → XLPE power cables up to 35 kV with optional metallic shielding for EMC-sensitive environments.

• BS 5308 / EN 50288​ → Instrumentation and control cables for process automation with paired shielding.

When a customer requests a product certified to a standard we have not previously produced, our R&D team conducts a gap analysis, identifies required tooling or material changes, and develops a validation plan​ including type testing at our in-house lab or through third-party institutions.

4. Prototyping & Type Testing

Every new product design goes through a structured validation cycle:

1. Engineering Drawing & BOM​ — Released for prototype production.

2. Small-Batch Prototype​ — Typically 50–200 meters, produced on active production lines under engineering supervision.

3. In-House Type Testing​ — Full electrical, mechanical, and fire-performance test suite (conductor resistance, AC withstand, insulation thickness, tensile/elongation, aging, hot set, flame propagation, smoke density, halogen analysis).

4. Third-Party Validation​ — For critical products, samples are submitted to Anhui Product Quality Supervision & Inspection Research Institute​ or other authorized bodies for independent verification (e.g., Report No. (2023) Wan Jian DZ Zi Di 05531 for WDZB-YJY 1×240; Report No. (2023) Wan Jian DZ Zi Di 05522G for WDZC-KYJY 24×1.5).

5. Design Release​ — Upon passing all tests, the product is formally released for mass production with documented specifications and test records.

5. Continuous Improvement & Process Optimization

R&D at Tongdu Cable does not stop at product launch. We operate a continuous improvement loop:

• Customer Feedback Integration​ — Field performance reports from EPC contractors, utilities, and distributors are reviewed quarterly. Issues (e.g., installation difficulty, connector compatibility) trigger design revisions.

• Manufacturing Process Upgrades​ — Regular evaluation of extrusion parameters, stranding speeds, and cooling efficiency to improve dimensional consistency and reduce material waste.

• Cost Optimization​ — Alternative material sourcing and structural simplifications that maintain performance while reducing cost—passed on to customers as competitive pricing.

• Energy Efficiency​ — As part of our Energy Management System certification, R&D actively explores process modifications that reduce energy consumption per unit of output.

R&D Infrastructure

Our R&D activities are supported by:

• 100+ sets of production equipment​ — Including three-layer co-extrusion XLPE lines, high-speed extruders, rigid and planetary stranders, braiding machines, and armoring lines that double as R&D pilot equipment.

• In-house laboratory​ — Equipped for conductor resistance measurement, tensile testing, aging ovens, hot-set devices, flame chambers, smoke density chambers, halogen gas analysis, low-temperature impact/tensile testing, and high-voltage testing.

• Third-party partnerships​ — Ongoing collaboration with Anhui Product Quality Supervision & Inspection Research Institute for independent testing and standards consultation.

• Industry association membership​ — As a Council Member (5th term, 2023–2028) of the Anhui Provincial Electric Wire & Cable Industry Association, we stay connected to industry-wide R&D trends, regulatory updates, and peer knowledge exchange.

Recent R&D Achievements

R&D for International Markets

Our R&D team is specifically structured to support overseas customers:

• English-language technical documentation​ — Datasheets, test reports, and specification sheets are prepared in English for direct submission to consulting engineers, EPC firms, and certification bodies.

• Standard cross-referencing​ — We provide side-by-side comparisons of IEC, BS, EN, ASTM, and GB/T requirements so customers can confidently approve our products for use in their local regulatory environment.

• OEM/ODM engineering support​ — From initial concept to finished cable, our engineers work alongside your team to refine specifications, validate prototypes, and ensure compliance with your target market's certification scheme (CE, TÜV, SABS, SONCAP, SASO, etc.).

• Rapid response​ — Technical inquiries and custom design requests are typically acknowledged within 24 hours, with preliminary proposals within 3–5 working days.

Looking Ahead

Tongdu Cable's R&D roadmap focuses on:

• Higher voltage capabilities​ — Extending XLPE power cable range beyond 35 kV to serve utility-scale transmission projects.

• Smart cable integration​ — Exploring embedded temperature and fault-sensing technologies for critical infrastructure.

• Circular economy​ — Developing recyclable cable designs and halogen-free compounds with reduced environmental footprint.

• Digitalization​ — Implementing product lifecycle management (PLM) software to streamline design-to-production workflows and improve traceability.