§1What this business is
Copper or aluminium rod is drawn down in stages (to 3 mm, then 11–16 SWG, then 16–22 SWG), flattened into strip where needed, and covered with two layers of kraft or insulating paper (or cotton braiding) on DPC covering machines. The wire is wound on spools, tested and packed. Transformer makers use it for the high- and low-tension windings of power and distribution transformers. The profile says a unit can also buy ready fine wire and only do the paper covering, which cuts machinery cost.
Capacity: 600 tonnes a year: 268.5 t aluminium and 268.5 t copper paper-covered round wire plus scrap; turnover ₹8.38 crore by the profile's sales table (its cover page prints ₹7.54 crore).
§2Is it right for you?
Who it is for
A metal trader or engineer with large capital and links to transformer makers and repair shops.
Who it is not for
A small first-time founder; the metal stock alone runs into crores.
Advantages
- Every power and distribution transformer needs winding wire
- Demand grows with power capacity and new transformers
- Can start with paper covering only and buy ready wire
- Sold to a known IS standard
Drawbacks
- Huge working capital: copper and aluminium are almost all the cost
- Metal prices swing daily
- Buyers are a small group of transformer makers and repairers
- Insulation faults cause transformer failure, so buyers are strict
Skills you need
- Wire drawing and annealing
- Paper covering and tension control
- Testing to IS 6162 and IS 7404
- Metal buying and credit control
Why difficulty 4/5: Very heavy working capital and metal-price risk.
§3Market
Who buys
- Power and distribution transformer makers
- Transformer repair shops
- Electricity boards' repair workshops
How it sells
- Direct supply on order
- Tenders
Good to know
- The profile links demand to growth in power generation and transformer capacity.
- Purity of copper and aluminium must be 99.9% for electrical use (profile).
§4Raw material & machinery
| Item | Qty | Cost |
|---|---|---|
| Wire drawing machine, 3 dies, with spooling | 1 set | ₹3,60,000 |
| DPC wire covering machine, 4 line | 4 | ₹2,08,000 |
| Paper slitting machine, 30" (4–20 mm) | 1 | ₹1,20,000 |
| Medium wire drawing machine (11–16 SWG, 6 dies) | 1 set | ₹1,10,000 |
| Fine wire drawing machine (16–22 SWG, 5 dies) | 1 set | ₹75,000 |
| Strip flattening machine and strip covering machine | 1 each | ₹1,25,000 |
| Paper roll slitting machine 42", vacuum annealing, 2 t weighbridge | 1 each | ₹1,15,000 |
| Tensile testing machine | 1 | ₹1,60,000 |
| Kelvin bridge, wrapping tester, AVO meter and multimeter, misc. | 1 lot | ₹1,15,000 |
From: DC-MSME project profile — DPC Wire (2003)
- Copper wire rod22.5 t a month at ₹1,35,000/t = ₹30.38 L
- Aluminium rod, EC grade22.5 t a month at ₹95,000/t = ₹21.38 L
- Kraft / insulating paper5 t a month at ₹95,000/t = ₹4.75 L
- Stores and spares₹20,000 a month
From: DC-MSME project profile — DPC Wire (2003)
Suppliers in Building Business Bazaar
Aluminium Corporation · Kolkata →Bharat Aluminium Co. Ltd · Kolkata →Bharat Engg. Works · Kolkata →Bluestar Ltd · Kolkata →Devendra Industries · Delhi →Global Merchantiles Pvt. Ltd · Kolkata →Golden Engineering Industries · Delhi →Hargolal and Sons Ambala Cantt · Harayana →Hind Engineering Works · Howrah →HINDALCO Industrial Ltd · Kolkata →New Bishbakrtima Mechanical Works (P) Ltd · Howrah →Nihar Engineering and Sons · Howrah →
In our raw material database
§5Licences & registration
- Udyam registration
- GST
- BIS certification to IS 7404 / IS 6162 where buyers ask for it
- State Pollution Control Board consent
- Factory licence
§6Schemes & subsidies
- CGTMSECentralActiveNo collateral, up to ₹10 crore
- Stand-Up IndiaCentralClosed₹10 lakh – ₹1 crore loan
At ₹1.95 crore the project is above PMEGP and MUDRA limits; CGTMSE covers collateral-free loans and Stand-Up India can fund part for SC/ST and women founders.
§7Money
How the investment is worked out: DC-MSME profile: land and building ₹9.10 L (5,000 sq ft land ₹2.50 L, 3,200 sq ft shed ₹4.80 L, 900 sq ft office and store ₹1.80 L); machinery ₹11.13 L (3-die wire drawing ₹3.60 L, 4 DPC covering machines ₹2.08 L, paper slitter ₹1.20 L, medium and fine wire drawing ₹1.85 L, strip flattening and covering ₹1.25 L and more) + testing ₹2.75 L + electrification ₹1.11 L + dies and office equipment ₹50,000; total fixed capital ₹24.65 L; working capital for 3 months ₹1.71 crore; total ₹1.95 crore.
Working capital: Working capital for 3 months ₹1.71 crore; monthly spend ₹56.91 L, almost all metal (aluminium rod 22.5 t ₹21.38 L, copper rod 22.5 t ₹30.38 L) and paper (5 t ₹4.75 L).
Prices from 2002–03 — machinery, material and wage costs will be much higher now.
§8Export potential
Confirm the HS code in the DGFT ITC(HS) lookup before you export
Export council / board: EEPC India
- Confirm the 8-digit ITC(HS) line with DGFT or your customs broker before shipping.
- You need an Import Export Code (IEC) from DGFT before the first shipment.
§9Risks — where people fail
- Copper and aluminium price changes
- Large receivables from transformer makers
- Rejection on insulation tests
- Competition from large wire makers
§1030 / 60 / 90-day plan
A general plan that applies to any business. A plan for this business will be added after research.
- Days 1–30: Visit a working dpc (double paper covered) transformer winding wire unit, ask 10 buyers about price and quantity, and get quotations from 3 suppliers.
- Days 31–60: Udyam and the licences you need (Udyam registration, GST), a project report (DPR), and the scheme or loan file.
- Days 61–90: Space and machines, trial production, and first deliveries to 10 customers.
§11Who to connect with
Associations, clusters and training institutes — the directory is being built. Connect
§12Watch
There is no episode on this business yet. Shows are coming soon on the Podcast page.
Want to start DPC (Double Paper Covered) Transformer Winding Wire?
DPR, loan file or registration — ask us on WhatsApp.
¶Sources
Data review: 6 October 2026. Spotted a mistake? Report it. For information only — not legal or financial advice.