Manufacturing and Innovation Highlights
At Polycab, state-of-the-art manufacturing and a deep-rooted culture of innovation form the backbone of our competitive edge. Our advanced production facilities are equipped with cutting-edge technologies, robust automation and stringent quality control systems that ensure precision, consistency and efficiency at scale. Coupled with our continuous focus on process innovation and product development, this enables us to deliver superior value to our customers — through high-quality, reliable and future-ready solutions. These capabilities not only differentiate us from peers but also strengthen our ability to meet evolving market needs with agility and confidence.
Fans
We have developed a wide range of fans to meet diverse consumer needs. From offering premium, antique finishes to vibrant, designer models for children’s rooms and high-performance, super-speed fans — our portfolio is tailored to fulfil changing customer aspirations and expectations. Our ISO-certified manufacturing facilities in Roorkee and Halol, with an annual manufacturing capacity of ~90 million fans, are equipped with state-of-the-art technologies such as automated CNC machines, precision assembly lines and computerised testing systems to ensure the highest standards of quality and efficiency. As pioneers in die-casting rotors and fan body covers, we adhere to Six Sigma processes for zero-defect production. Furthermore, we offer energy-efficient solutions that conform with evolving environmental standards. Our continued focus on innovation, quality and operational excellence positions us for sustained growth in a competitive market.
Machine Shop
Our CNC Machining Centre is specially designed with double-ended, custom tools to precisely develop motor end covers and rotors. The advanced machining systems ensure zero-defect production with high precision and consistency. We use automated online gauging combined with Statistical Process Control (SPC) to continuously monitor and maintain quality. This streamlined approach leads to improved productivity, higher efficiency and increased output, ensuring best results during the production process.
Winding and Testing Process
We utilise CNC-programmed winding machines for precise and efficient coil production. The coils are compact and layered, designed to deliver optimal performance and long-lasting durability. Our microprocessor-based testing systems guarantee the reliability and longevity of motor windings. The integrated conveyorised system streamlines the preheating, varnishing and baking processes for stators, improving overall production efficiency. Adhering to Six Sigma standards, we maintain zero defects and ensure exceptional consistency and quality across every product.
Assembly Process
Our conveyorised assembly lines help to streamline the motor and blade assembly process, ensuring consistently high productivity. Each stage of assembly is equipped with cutting-edge machinery and mechanisms, guaranteeing precision and efficiency. The automated packing system uses advanced machines to provide accurate and high-productivity packaging, ensuring both consistency and speed in the final stages of production.
Pre-Treatment and Paint Systems
Our integrated pre-treatment and paint systems employ state-of-the-art technology for seamless and efficient processes. PLC-controlled time cycles precisely manage transporter movement during the pre-treatment phase, ensuring consistency across each tank. Advanced nano technology solutions are utilised for pre-treatment, using environment-friendly, pollution-free chemicals. The automated paint system incorporates PLC-controlled systems to monitor reciprocator movement, bell applicators and conveyor speeds, ensuring uniform paint application. Additionally, our efficient baking process uses specially designed ovens that maximise heat transfer efficiency, ensuring uniform baking while maintaining a pollution-free environment throughout the production process.
Storage and Layout
Our integrated plant optimises workflow and space, ensuring maximum operational efficiency. Wide gangways and passages are clearly marked, allowing for smooth, unobstructed movement of materials. Palletised stacking and material movement ensure efficient handling of components and finished goods. Ergonomically designed workstations enhance employee comfort and further improve ease of operation. With a focus on minimum manual intervention, automation and a strategic layout, it enhances efficiency and safety across the plant.
Testing and Quality Control
We employ advanced testing equipment and systems that utilise latest technology to ensure quality at every stage of production. Our modern testing facilities provide 100% verification of motors and blades before packing. An internal product audit system is implemented at each manufacturing stage to enhance customer satisfaction and ensure product consistency. The integrated automation system for air delivery measurement in ceiling fans guarantees performance accuracy. A CNC-controlled testing panel ensures that each product meets all required parameters in an acoustic-controlled environment. Comprehensive quality assurance checks are conducted throughout the production process by a team of qualified professionals committed to maintaining the highest standards of excellence.
R&D Projects
We take pride in our R&D capabilities, driving continuous innovation to meet the evolving needs of modern consumers. Our commitment to setting new standards of excellence in quality and process improvement enables us to stay ahead of the curve. By constantly improving our products and processes, we deliver superior solutions that make life safer, easier and more inspiring for our customers.
Polycab Super ROI Fans
We introduced the Polycab Super ROI Series as part of our ongoing commitment to providing energyefficient, high-performance solutions in the FMEG segment. These fans are developed through advanced in-house engineering, utilise BLDC motor technology, which consumes up to 50% less energy while delivering up to 25% more airflow with minimal noise. The series also includes features such as reverse rotation for seasonal adaptability, smart remote control and custom speed settings, meeting the evolving consumer expectations for comfort, efficiency and intelligent design. Available in over 30 aesthetic variants and built with 100% copper winding for long- lasting durability, the series reflects our commitment to innovation that combines performance, sustainability and long-term value.
Industry-Leading Manufacturing
~90 lakh fans
per year produced in state-of-the-art manufacturing units. With a capacity of ~60 lakh fans per year, our Halol plant is the largest fan factory under one roof
Advanced Pre-Treatment Process
7-tank pre-painting treatment
guarantees better rust resistance and longer paint life
Reliable Quality Assurance
Computerised air delivery chambers
and strict internal checks enables each fan to meet the highest standards of performance
Better Air Distribution
Larger air delivery cones
ensure even and wider distribution of air throughout the room
Superior Speed and Air Delivery
400 RPM
speed of Polycab fans, higher than the usual 360-370 RPM and offers air delivery between 225-260 CMM, outperforming the typical 190-220 CMM
Durability and Finish
95% Gloss finish
With robotic paint shops and GP (Galvanised Plain) sheets for rust resistance, higher than the typical 80% gloss found in fans manufactured by other brands
After-Sales Service Nationwide
>450
we provide comprehensive post-sale service
Choice in Fans
Safe Packaging
Automatic packing machine
ensures secure and damage-free delivery
Pre-Treatment with Nano Technology
Nano-technology solutions
used for pre-treatment with environmental & pollution-free chemicals
Advanced Quality Control
Computer-controlled tests
that ensure superior quality and performance, far beyond manual inspection standards
Powerful Motors
220-270 grams of copper
inside the fans windings, creating more powerful motors compared to competitors’ 150-220 grams
Precision Engineering
Automated winding machines and robotic painting
used to eliminate manual error and ensure consistent quality
Higher Standards
500VAC
Polycab fan capacitors (vs. competitors’ 440VAC)
B-class insulation
for higher reliability, compared to E-class in most fans
2mm shanks
used in Polycab fans, compared to 1.6 to 1.8mm in most others ensuring superior performance and durability
Switches
Polycab offers a unique and industry-first proposition in the switches category with our ‘any colour, same price’ policy — something no other competitor provides. This innovative approach gives our dealers and distributors unmatched flexibility to cater to diverse customer preferences without additional cost implications. It empowers them to offer customised choices while maintaining competitive pricing, helping us meet demand across multiple customer segments and deliver superior value for money.
Our commitment to innovation in switches is further reinforced by our robust R&D efforts and focus on intellectual property. In FY 2024–25, our R&D team filed two patents related to switch mechanisms and registered five new designs, making these products exclusive to Polycab in terms of usage, sale and production. To date, we have registered 23 unique designs, with another 29 under application and in the process of registration. While most competitors rely on a single design for flat-switch mechanisms, our engineers have developed two distinct mechanisms to deliver the same sleek operation — underscoring our pursuit of both functionality and aesthetic versatility. This deep product differentiation strengthens our market position and enhances the value we deliver to customers.
Recognition
Our Design team received national and international recognition at the QCFI convention on Quality Concepts
- Gold Trophy and Abhinav Trophy at the State Level (Ankleshwar & Vadodara)
- Par Excellence Trophy at the National Level (Gwalior)
- Par Excellence Trophy at the Offshore Convention (Thailand), qualifying for the international convention in FY 2025-26
Product Development
We have introduced two new product ranges:
Fabelle Range
A complete range for the economy segment, offering modern designs without compromising quality.
IoT Smart Switches
A new premium segment range with Wi-Fi connectivity, designed to meet the demands of the evolving market.
Switchgears
Polycab’s low - voltage switchgear products are manufactured at a state-of-the-art facility, meeting national and international standards. Our fully automated production lines ensure precision across the entire MCB range for various applications. With advanced in-house tool manufacturing and design software, we ensure high accuracy and innovation. The facility also includes a world-class test laboratory for rigorous product validation and certification are conducted in line with global benchmarks.
We continually upgrade our products to meet evolving market demands and regulatory standards, ensuring our offerings remain competitive. All critical sheet metal and plastic components are produced in-house using top-grade raw materials, ensuring exceptional quality and reliability
Product Development
UL Testing for MCBs:
We have successfully completed UL testing for our Miniature Circuit Breakers (MCBs), which enhances our potential for expansion in the international market.
MCCB Launch:
We have successfully launched our Molded Case Circuit Breakers (MCCBs) in international markets.
RCCB ‘A’ Type Certification & BIS Inclusion:
Our Residual Current Circuit Breakers (RCCBs) have received ‘A’ type certification and inclusion in the Bureau of Indian Standards (BIS). The specifications include:
Ratings: 25A, 40A, 63A
Poles: 2P & 4P
Rated Residual Current: 30mA, 100mA, & 300mA
Standard: IS 12640
7.5 kA MCB Certification:
We have completed certification for our 7.5 kA MCBs with the following ratings:
Ratings: 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, & 63A
‘D’ Curve MCB Certification & BIS Inclusion:
Our ‘D’ Curve MCBs have received certification and BIS inclusion with the following ratings:
Ratings: 0.5A, 1A, 2A, 3A, 4A, 5A, 6A, 10A, 16A, 20A, 25A, 32A, 40A, 50A, & 63A
Lighting and Luminaries
In our Lighting and Luminaires business, we advanced our manufacturing and innovation capabilities by shifting focus toward highmargin, design-led categories beyond traditional bulbs and battens.
Our R&D and product teams worked closely to develop energy-efficient, durable and aesthetically appealing solutions under the brand proposition, “Innovative Lighting for Brighter Living”.
Backed by enhanced production processes and faster go-to-market execution, we continue to meet evolving consumer and professional needs while strengthening our position as a differentiated and reliable lighting brand.
Product Development
FY 2024-25 Launches:
- Gliss COB Decorative Ceiling Range (for high-end retail)
- Consumer Outdoor Range
Product Strategy:Focused on design differentiation and energy optimisation
Pipeline:
- Expansion in ceiling lighting
- Development of solar-integrated SKUs
- Industry-specific fittings
- Façade lighting projects
Wires & Cables
Established in 2016 and accredited by the Department of Scientific and Industrial Research (DSIR), India, Polycab’s Polymer R&D Centre plays a pivotal role in driving innovation in polymer materials for Wires & Cables. Focused on creating value through advanced, sustainable and globally compliant compounds, the centre integrates deep research expertise with market-driven insights. A robust quality assurance framework governs every stage — from raw material selection to final output — ensuring high-performance, safe and reliable products tailored to evolving industry needs.
Product Development
- Developed moisture-curable HDPEbased track-resistant compound for MV cables, complying with ICEA S-121-733-2016 and BS EN 50397- 1 standards.
- Introduced polyolefin-based electron beam cross-linked heat resistance, flame retardant, low smoke zero halogen insulation compound suitable for 110°C operation in power cables.
- Developed polyolefin-based heatresistant, flame-retardant, low smoke zero halogen thermoplastic outer sheathing compound for LT cables.
- Supplied cables for Vande Bharat trains as part of our collaboration with Indian Railways.
- Created EV charging cables to support the growing electric vehicle infrastructure in India.
Testing Operations and Assembly Lines
At Polycab, product reliability begins with uncompromising quality checks. Each item undergoes extensive testing in advanced laboratories equipped with the latest PLC-controlled systems. From motor and blade validation in fans to high-voltage and continuity assessments in switches and switchgear, our tests replicate realworld operating conditions to ensure consistent performance. This rigorous approach contributed to a flawless record in BIS market sample tests during the last financial year, reinforcing customer trust and product credibility.
Our manufacturing lines are built for efficiency, featuring conveyorised systems that support single-piece flow and boost output. Through lean manufacturing practices, we streamline inventory, minimise waste and maintain agile operations - further strengthening our commitment to excellence and customer satisfaction.
Technology Adoption at Polycab
We have implemented strategic IT projects to make Polycab future ready. It has enabled us to eliminate manual processes from manufacturing, adopt automation and improved production scheduling and inventory planning operations. These changes have enhanced efficiency, reduced manual working hours and led to better inventory visibility, collectively helping to lower production costs.
IT Modernisation
To modernise our IT infrastructure, we have shifted from conventional data centres to scalable cloud solutions. It has reduced costs, enhanced scalability, improved business continuity and strengthened security and compliance.
This transformation began with a comprehensive evaluation of the current infrastructure, followed by a migration to Azure. It has helped to optimise performance and cost efficiency throughout the process.
As a result, operational expenses were significantly reduced and system performance, scalability and disaster recovery capabilities saw notable improvements. The migration also accelerated innovation and deployment speed, while enhancing security, offering the flexibility needed to meet changing market demands.
72
Servers Migrated to Azure
Supply Planning
We have implemented an advanced supply planning module for demand forecasting, identification of market trends and collation of historical data. This helps to predict demand and optimise production schedules. Material planning has also been automated for tracking lot expiry dates, component dates and inventory reservations. It has reduced excess inventory, helped to manage stocks effectively and optimised costs.
Real-time insights into inventory and production schedules have improved resource planning, refined production timelines and enabled better collaboration with suppliers. This proactive approach has led to timely order deliveries, boosting customer satisfaction and retention. The automated and centralised module offers scalability and flexibility to adapt to market changes.
EPM
We have implemented the Enterprise Performance Management (EPM) system to provide a unified framework for planning, budgeting, forecasting and reporting. It addresses inefficiencies and data errors commonly found in manual processes for resource allocation, forecasting and budget distribution. By automating repetitive tasks, enabling scenario analysis and fostering collaboration among stakeholders, EPM reduces redundant efforts, saves time and cuts costs.
Top-down and bottom-up planning connect finance, operations and various business lines. Furthermore, it also caters to Depreciation Forecasting and Gross Block Forecasting.
CAPEX Projects Module
Robust reporting and analytics is essential for effective tracking of costs, budgets and expenditures. The CAPEX Projects module helps to allocate resources, develop schedules, ensure on-time deliverables and capital expenditures, acting as an integrated cost management solution.
New Capex Module supports detailed Planning and Budgeting of Projects at task level. It also supports Complex Approvals, Encumbrance and Utilisation tracking, Version Controls and Capitalisation process. In the past, managing Capital Projects, Budgets and Plan vs. Actual visibility was conducted offline and manually, resulting in accounting inaccuracies. However, the automated system has streamlined operations, improving both efficiency and accuracy.
40+
Projects successfully operationalised
Data Analytics (BI)
Power BI serves as a powerful tool in data analytics, allowing raw data to be transformed into actionable insights. By consolidating data from various sources into a single Management Information Systems (MIS) platform, it enables real-time analysis, interactive visualisations and comprehensive reporting.
With Power BI, teams have streamlined operations, enhanced data-driven strategies and achieved greater efficiency and transparency in reporting. This year, we successfully built a highly skilled Power BI team that delivered 64 dashboards across multiple departments, showcasing our ability to provide comprehensive and insightful data analytics for the entire organisation.
64
Dashboards delivered across multiple departments
Active Directory (AD) Protect
The AD Protect IT project enhances the security and resilience of Active Directory a key component for managing access to network resources. Due to its central role, AD is often targeted by cyberattacks. This project focuses on regular AD data backups and a recovery strategy to ensure swift restoration in case of an attack. Its goal is to build a secure, resilient AD environment that can withstand threats, protecting critical IT services within the organisation.
48
Critical vulnerabilities identified
Web Application Firewall
The Web Application Firewall (WAF) IT project enhances web application security and provides protection from cyber threats. The goal of the WAF project is to create a robust security layer that protects applications from common exploits, improves availability and safeguards sensitive data. By implementing WAF, we have reduced the risk of cyberattacks and strengthened our security posture in an increasingly digital world. WAF has been deployed on 14 critical business applications within the organisation.
14
Critical business applications secured
Privileged Access Management
The Privileged Access Management (PAM) IT project is essential for securing and managing privileged accounts. Over 440 devices have been successfully added to the PAM system. More than 20 critical admin accounts are now secured against potential threats and 30+ users have been onboarded to the platform, enabling strict access controls and continuous monitoring. These measures strengthen our security framework and protect sensitive assets, ensuring the integrity of our IT environment.
440
Devices successfully added to the PAM system
Next-Generation Secure Web Gateway
The Secure Web Gateway (SWG) implementation has strengthened our internet security by ensuring safe, compliant and threat-free web usage. Deployed for over 2,000 users, it provides comprehensive protection across the organisation. We have set up 33 real-time protection categories to guard against various web-based threats and monitored 1,954 sanctioned and unsanctioned applications to control internet usage. The SWG also oversees 2,786 websites accessed by employees, ensuring secure browsing across the organisation.
2,000+
Users safeguarded
through SWG
Cybersecurity Training
Cybersecurity training plays a crucial role in educating employees about recognising, preventing and responding to security threats. It aims to reduce human error and strengthens the organisation’s security posture. The training programme includes induction sessions for new employees and quarterly updates on various cybersecurity topics to keep employees informed about emerging threats.
This year, we have conducted 3 cybersecurity training sessions. Our recent campaign achieved a 61% adoption rate. Additionally, we share one infographic every fortnight to help employees keep track of cybersecurity measures.
61%
Adoption rate achieved through our recent campaign
Planned IT Initiatives
ISO Standards Implementation
Ensures compliance and quality management across the organisation
Zero Trust Network Access (ZTNA)
Enhances cybersecurity to provide secure and seamless network access
Data Privacy Programme
Safeguards sensitive information and ensures compliance with data protection regulations
Copilot Projects
Leverages AI to improve productivity and decision-making processes
Accounts Payable (AP) Automation
Streamlines financial operations, reduces manual effort and increases efficiency
Hedging Solutions
To manage deal tickets of commodities
Procurement Modernisation
Optimises procurement processes to drive cost savings and enhances efficiency
Experts App
As part of our digital and IT initiatives, the Polycab Experts app has emerged as a flagship platform for transforming engagement with electricians and retailers. Built as a tiered, digital-first loyalty solution, the app combines real-time rewards, gamified participation, multilingual support and training modules to drive deeper relationships and long-term value.
Since its launch, the platform has achieved a 1.5× increase in enrolments within just two quarters, a 57% rise in active users and a 48% growth in transactions. Over 2,00,000 electricians and retailers are now part of the Experts community, reflecting the app’s intuitive design and seamless user experience. Operational efficiency has also significantly improved, with 90% of manual processes automated and 100% KYC compliance ensuring secure, verified interactions. The platform supports features like instant bank transfers for reward redemptions, fast scanning, tierbased benefits and e-learning, which have collectively contributed to increased retention and share of wallet. Built on a scalable, cloud-based architecture and integrated closely with Polycab’s broader digital ecosystem, the app continues to evolve with upcoming capabilities such as AI-driven fraud detection, automated Bill of Quantity generation and personalised learning modules — solidifying its role in empowering and uplifting India’s electrical workforce.
Data Lake — Groundwork for AI
Our Data Lake serves as a core foundation for AI and machine learning, enabling efficient data storage, processing and analysis at scale. One key application is AI/ML-based monitoring within the Experts App, which led to the identification and blocking of 1,364 users geospatial analytics —strengthening loyalty reward system integrity. We also implemented image analytics for outlet validation using multimodal LLMs (vision and text). The platform further enabled beat automation pilot for approximately 10,000 outlets across various geographies and supported the deployment of Agentforce (Salesforce’s Agentic AI product), which digitally transformed our sales team and empowered them to leverage the product’s LLM capabilities, enabling them to interact with their data and enhance customer engagement.
Additional applications include AI-enabled headcount tracking at our Daman facility for safety and efficiency and a paperless transformation at Halol Rolling Mill Unit 2, enabling real-time data monitoring.
Our Experts platform earned multiple industry accolades including 1. International Loyalty Awards in B2B category, 2. Retail Asia awards 2025 award ‘Loyalty Program of the Year’, 3. CII Digital Transformation award ‘Most Innovative and Best Practices in Digital Transformation’ and 4. UBS forums ‘CX Technology Implementation of the Year’. These awards reflect our commitment to driving innovation, enhancing customer engagement, and delivering measurable business impact through technology.
