Innovation & Sustainability in Cable Systems Manufacturing

Benoit Lecuyer, CEO, Prysmian India § ACPL, a seasoned business professional with 30 years of expertise, specializes in strategic planning, budgeting, and business planning, driving organizations towards success. In his conversation with The Industry Outlook, he divulged the innovative passage of cable systems integrating sustainability through eco-materials, efficient design, and collaborative industry efforts, thus driving advancements in energy efficiency.

How is innovation changing the way cable systems are made while considering sustainability in the industry?

R&D has enabled the development of more sustainable, eco-friendly materials, specifically recyclable and biodegradable options for cable insulation, sheathing, and jointing in cable manufacturing. Cable design optimization allows for the precise use of raw materials, reducing scrap and changeover during production. The new generation of cables is more efficient, lighter, and more compact, minimizing power consumption and installation time. For instance, Prysmian can now deploy 525kV HVDC cables, transporting more power in a compact cable. Smart systems facilitate anticipative maintenance for asset protection and enhanced testing, anticipating potential degradations on joints, terminations, and the outer sheath of cables, which could be caused by third parties and preventing fire hazards and factory interruptions.

Prysmian has developed the Prycam system, which can be used online and easily identifies the location requiring attention. This promotes efficiency, sustainability, and longer material life. Cables contribute to decarbonization as they are installed in all renewable energy clusters, including wind, solar, hydro, nuclear, carbon capture, and geothermal projects, thereby participating in the decarbonization process. India is significantly advanced in the large-scale deployment of renewable energies. EPC companies play a crucial role by adopting simpler cable routing and laying methods to minimize their impact on the ecosystem, thus contributing to the reduction of scope 3 emissions.

What are the top sustainable practices that are becoming standard in cable systems manufacturing, driven by innovation? 

I would say the use of recycled materials, recyclability, end-of-life product practices, and ease of disassembly and recycling. This helps to reduce the demand for pure, virgin materials. The circular economy is applied by many stakeholders nowadays. One of the best and fastest-moving practices in design for sustainability is the generalization of halogen and lead-free materials, which eliminate the risk of harmful gases if burnt. In manufacturing processes, optimized heating and cooling systems should be considered, as well as water management, recycling, and reduced use of diesel and LPG for electricity. Moreover, utilizing solar or wind energy for factories reduces greenhouse gas emissions and packaging waste. The use of eco-friendly materials and avoiding painting can yield favorable results, along with optimizing transportation methods.

What challenges do cable systems manufacturers commonly face in integrating innovative technologies while staying committed to sustainability? 

Sustainable processes initially involve higher costs, which can lead some companies to refrain from using them. However, reasonable payback should be obtained, and access to funds eased by banks. End users need to be informed and aware of sustainability practices and their benefits in order to demand them, thus becoming specifiers of sustainability solutions. Adaptation of production machines may require time and costs, technical challenges, and possible production disruptions in the initial stages. Additionally, the supply chain of eco-friendly materials can pose challenges.  Habits must be set aside to address training and skill gaps and to avoid resistance. Standard evolution should follow to secure technology choices, and clients should include sustainability practices in their specifications.

How can the industry drive advancements in cable systems to significantly reduce energy loss during transmission? 

The development and use of high-conductivity materials for cable conductors minimize electrical resistance and reduce energy loss. Superconductors or materials with low resistivity result in low energy loss. Improved insulating materials can enhance the efficiency of signal transmission and reduce the need for higher power levels. Innovative cable designs to minimize skin effect and proximity effect also reduce energy loss, as do cooling systems for high-power applications.

Power management systems adopted in large megacities can adjust power levels based on fluctuating demand. Smart grids and monitoring reduce unnecessary energy loss during periods of low demand. High-quality materials used for connectors and joints minimize energy loss at fragile points, as well as ensuring constant voltage along the cable. Reputed fiber manufacturers shall be able to optimize signal transmission and quality. At Prysmian, we apply these principles; we have designed lighter armor made of synthetic fibers for faster installation and full recyclability.

How are industry collaborations driving both innovation and sustainability efforts within cable systems manufacturing? 

A good example is the partnership with suppliers to reduce Scope 3 emissions and share best practices for energy reduction. Suppliers' qualifications can now include sustainability criteria. Collaboration on a large scale can improve standardization, ensure precise directives, and foster the adoption of sustainable practices not only within the cable industry but also among utilities, heavy industries, electronics, and telecoms. Examples of good practices that suppliers and clients can discuss include the increased use of e-mobility in-house and in selected logistics solutions, greater utilization of electric forklifts, solar energy, and rainwater collection.

The expanded presence of the Common Platforms forum serves as a great enabler, involving universities, research centers, startups, and government bodies. This collaboration can facilitate favorable regulations, the discovery and utilization of new materials, tax incentives, and subsidies. Sustainability concerns all departments and should be monitored with precise Key Performance Indicators (KPIs) at regular intervals. The results, documented and audited by independent third parties such as MSCI, EcoVadis, STBI, and Clean200, lend legitimacy to the outcomes and can convince banks to finance large-scale sustainability projects.