Manufacturing
Discover our advanced manufacturing process at Doncaster Cables. Learn about our technology, quality control, and commitment to British manufacturing excellence.
Our Manufacturing Excellence
Doncaster Cables is the largest British owned manufacturer of general wiring cables and flexible cords in the UK. We manufacture cables to the highest British, European and International Standards.
Manufacturing Excellence
Everything is made at our single-site factory—giving us full control to innovate and deliver smarter, time-saving cable solutions. Quicker installs. Neater finishes. Less hassle.
Manufacturing Capabilities
Quality Control
We manufacture cables to the highest British, European and International Standards with rigorous quality control processes.
Quality tested
Innovation
Our range of equipment, over 1000 years of direct cable manufacturing experience drives us to innovate.
Years combined experience
British Made
We are the largest British owned manufacturer of general wiring cables and flexible cords in the UK.
Largest range of cables
Manufacturing Features
Wire Drawing
Investment in our wire drawing facility allows us to manufacture copper wires to our own exacting standards.
We go above and beyond British, European and International Standards to ensure both the highest product quality, and an easy product to install. Our copper wires are annealed to extremely high standards to give added flexibility and durability during installation.
Compounding
Our compound facility allows us to manufacture compound to our own specific recipes.
Each cable is assessed for how it is installed and what characteristics are important for the installer. Then specialist grades are compounded for each cable type. Our T&E grades are soft and easy to strip, SWA grades are impact and abrasion resistant, flex grades are flexible and have a nice shiny appearance. We set our own testing criteria which is higher than required in the relevant standard, and focused on what is important for the installer.
Bunching and Stranding
We have multiple bunching and stranding machines that we use to twist together copper wires to form Class 2 or Class 5 conductors.
Controlling this aspect of production gives us the ability to manufacture a wide range of conductors from a limited amount of raw materials. A shorter supply chain means we can react quickly to customer requirements, as well as control the technical characteristics of our copper wires.
Insulation
Significant investment in a large variety of extrusion equipment, combined with the ability to manufacture our own wires and compounds, allows us to produce a wide range of products.
Our insulation lines run at high speed (up to 1000 meters per minute) and the insulated cores are continuously tested at high voltage to ensure electrical integrity throughout the entire length of the cable. Across our machines we process polyvinyl chloride (PVC), cross linked polythenes (XLPE), low smoke non halogen (LSNH), silicone rubber and more.
Core Assembly
A range of machinery to assemble/lay-up cores gives us the opportunity to make the largest range of cables in the UK.
Being in control of this process allows us to set machine parameters that effect flexibility, durability and usability of products. Our equipment and knowledge mean that we can make cables to both established standards, in addition to custom-made specialist requirements, and innovative new products. All whilst again continually testing at high voltage to ensure electrical integrity.
Wire Armouring
We process tons of steel wire in a variety of diameters through our wire armouring machines.
These machines add a layer of mechanical protection in the form of galvanized steel across a range of our products. The coverage of steel wire is higher than most competitors as we add value in the form of extra protection, rather than cheapening the design and reducing the amount of steel wires to a level that offers less protection.
Sheathing
Multiple sheathing extruders allow us to offer a huge range of product types, and to achieve the 'one stop shop' goal for electrical wholesalers.
Special compound grades give our cables features and benefits in terms of aesthetic appearance, stripability, ease of routing, ease of dressing and many more. Our extrusion operators are very experienced and produce the highest quality products.
Testing
Our laboratory contains all of the test equipment needed to test our cables above and beyond the relevant standards.
Every drum of our cable is tested at high voltage to ensure electrical integrity. More in depth testing is conducted on a regular and defined basis which includes (but is not limited to), tensile strength, elongation, cold impact, cold bend, water absorption, long term insulation resistance, thermal ageing tests, fire testing and many, many more!
Final Winding
A variety of winding machines allows us to package our cables in lengths for all requirements.
From small short length retail style coils, to 100m reels, to large 1500mm drums. We can cater for all needs to ensure we even add value at the final winding stage. Our packaging is also 100% recyclable and already contains recycled content, as we are always trying to reduce our impact on the environment.
