✓ ISO 9001:2015 Certified

Enamelled Aluminium Strip

BMI Cables manufactures enamelled aluminium strip rectangular cross-section EC-grade aluminium conductor with uniform enamel insulation on all four faces. Designed for distribution transformer LV disc windings, power coil applications, and high current-density winding configurations where round wire cannot achieve the required conductor packing density.

 
Enamelled Aluminium Strip
Product Overview

What Is Enamelled Aluminium Strip — And Why Is It Used in Transformer Windings?

Enamelled aluminium strip is an EC-grade aluminium conductor with a rectangular or flat cross-section, uniformly coated with a continuous polymer enamel insulation on all four faces. Unlike round enamelled wire, the rectangular profile of aluminium strip allows individual conductor turns to pack together with minimal air gaps in a winding window — maximising current-carrying capacity for a given winding window cross-section.

Also referred to as rectangular enamelled aluminium conductor, aluminium strip winding conductor, or flat enamelled aluminium wire, enamelled aluminium strip is the preferred winding conductor for distribution transformer LV disc windings, power transformer coils, and dry-type transformer windings where high current density and efficient use of the winding window are critical design parameters.

The key advantage of the rectangular cross-section is conductor space factor — the ratio of conductor cross-sectional area to total winding window area. Rectangular strip conductors achieve a significantly higher space factor than equivalent round wire windings, reducing winding resistance, I²R losses, and transformer temperature rise for a given current rating. Combined with the cost and weight advantages of an aluminium conductor over copper, enamelled aluminium strip is the standard LV winding conductor choice for distribution transformer manufacturers across India.

BMI Cables manufactures enamelled aluminium strip from EC-grade aluminium at our ISO 9001:2015 certified facility in Bhiwadi, Rajasthan — in Class F and Class H thermal grades, with custom width and thickness dimensions specified at the order stage to match your winding design requirements exactly.

 

Rectangular Cross-Section — Maximum Space Factor

The flat profile of enamelled aluminium strip allows conductor turns to nest precisely, eliminating inter-turn air gaps and maximising the conductor space factor in transformer disc and layer windings.

Enamel on All Four Faces

Uniform enamel insulation applied continuously on all four flat and edge faces — providing turn-to-turn insulation across the full contact surface of adjacent strip conductors in tightly wound disc coils.

Aluminium Conductor — Major Cost Saving vs Copper Strip

EC-grade aluminium strip conductor is typically 60–70% lower in material cost than equivalent copper strip — a critical BOM saving for high-volume distribution transformer manufacturing.

Custom Dimensions per Winding Design

Width and thickness of the aluminium strip conductor specified at order stage to match your winding window geometry, current rating, and disc winding configuration exactly.

Wire Grades

Our Enamelled Aluminium Strip Range — Two High-Performance Thermal Grades

 BMI manufactures enamelled aluminium strip in Class H and Class DC thermal grades — each with the specific enamel chemistry for that IS 13730 / IEC 60317 sub-standard. Custom width and thickness dimensions specified at order stage.

 
 
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Key Features

What Makes BMI Enamelled Aluminium Strip the Reliable Choice for Transformer OEMs

The performance parameters that define enamelled aluminium wire quality — built into BMI’s manufacturing process, not claimed after the fact.

 

Uniform Enamel on All Four Faces

Consistent enamel thickness on both flat faces and both edge faces of the strip conductor — providing turn-to-turn dielectric insulation across the full contact surface of adjacent disc winding turns.

EC-Grade Aluminium — Low Resistivity

Electrical-conductor grade aluminium with minimum 99.5% purity minimises conductor resistivity — reducing I²R losses in transformer disc windings and improving transformer efficiency at rated load.

Precise Strip Dimensions to Specification

Width and thickness held within agreed dimensional tolerance throughout production. Dimensional consistency is critical for reliable disc stacking, uniform insulation layer compression, and predictable winding inductance.

Spark Testing on All Four Enamel Faces

Continuous spark testing of all four enamelled faces during production detecting enamel pinholes on flat faces and edges before the strip reaches the spool. Critical for transformer disc windings where enamel failure on any face causes turn insulation breakdown.

Certified Thermal Class Integrity

Class F uses polyesterimide enamel chemistry. Class H uses EIW base plus PAI overcoat. Each thermal class is a distinct product not a relabelled variant. Confirmed by batch test report with every order.

Aluminium Conductor — 60–70% Lower Cost vs Copper Strip

For high-volume transformer manufacturers, replacing copper strip conductor with enamelled aluminium strip in LV windings delivers significant BOM cost reduction — without compromising insulation class performance when correctly designed.