Raw material and other inputs the main raw material sources like Quartz, Feldspar, China Clays and Ball Clays are located within 12-15 hours distance by road transport. Similarly the metal parts manufacturers are also situated close by.

Raw materials are tested at the IEC plant under the most stringent testing conditions. The process parameters are controlled at every stage of operation under the procedure laid down in ISO 9001-2000 to get quality products at every stage of operation.

For maintaining high quality of production, the IEC plant has the following:
1. Sedigraph for particle size control
2. Thermal apparatus for dilotometric thermal granulometric analysis and glaze thermal stress tests,
3. Atomic absorption spectro-photometer for checking various elements.

The manufacture is through the wet ball-milling route to ensure proper distribution of the particles of the raw materials. The forming and shaping are done at soft stage to give quality output at a faster time and to avoid micro cracks. The unit is also equipped with a good Cutting & Grinding section and Assembly Jigs for cementing metal parts to the porcelain insulators.

Raw materials such as Alumina powder, Quartz, Feldspar, Ball clay and China clay in the required ratio are homogenized in the Ball Mills. The resulting slurry is passed through a series of vibratory screens and magnetic filters.

The slurry is dewatered to get uniform filter cakes in modern filter presses, which have a core blowing facility, and also provide close control on pumping pressure. Cakes, stored in ageing rooms, are sliced and fed into De-Airing Pug Mills and drawn into blanks.

Shaping is done either by turning or jiggering. Solid-core & Bushing insulators are turned CNC photocopying lathes. Disc insulators are shaped in automatic jiggering machines.

Shaped Insulators are loaded into driers where humidity and temperature are controlled using programmable controllers.

The green insulators are inspected and glazed. We produce Insulators with brown glaze as well as grey glaze keeping in tune withthe international requirements. These insulators are fired in the shuttle kilns where strict control is maintained with regard to uniformity of temperature.

A printout of the firing curve, indicating the uniformity of temperature profile across the kiln cross section, is maintained. The fired insulators are inspected and subjected to a temperature cycle test and mechanical and electrical tests. The insulators are assembled with special cement mixture in special jigs. The assembled insulators are then cured and subjected to routine electrical and mechanical tests.