Where Every Transformer Is Built. Our Manufacturing Facility.
A purpose-built transformer manufacturing facility at IDA Phase 3, Pashamylaram — equipped for the complete production cycle from 3D design engineering through to factory-tested despatch.
Where Engineering Excellence Becomes Reliable Power
At KLR Transformers, manufacturing is more than a production process—it is a disciplined integration of engineering, precision, quality, and technology. Located at IDA Phase III, Pashamylaram, Hyderabad, our purpose-built manufacturing facility is designed to support the complete transformer lifecycle, from engineering and design through manufacturing, testing, servicing, and refurbishment.
Advanced Engineering & Design
Every transformer begins with detailed engineering using advanced CAD and 3D modelling tools. Our design team develops optimized solutions with national and international standards.
World-Class Testing Facilities
Every transformer undergoes comprehensive routine testing before dispatch. Our advanced testing laboratory is equipped to perform routine, type, special, and customer-witnessed tests in accordance with applicable standards.
Built for Reliability
Supported by certified management systems, skilled technical personnel, and continuous process improvement, our facility delivers transformers designed to perform reliably in the most demanding operating environments.
Precision Manufacturing
Our facility incorporates dedicated infrastructure for CRGO core assembly, conductor winding, active part assembly, insulation processing, vacuum drying, oil processing, and final transformer assembly.
Core Manufacturing Strengths
- SolidWorks-based 3D Engineering & Design
- Precision Step-Lap CRGO Core Construction
- Automated Foil and Strip Winding Technology
- Advanced Vacuum Drying Systems
- Vacuum Oil Processing & Impregnation
- Automated Testing Infrastructure
- Manufacturing Capacity up to 100 MVA, 220 kV Class
From Design File to Tested Transformer — 4 Stages.
Every transformer KLR manufactures passes through four controlled production stages. Each manufacturing stage is executed under strict process controls, ensuring
consistency, accuracy, and long-term product reliability.
Design & Engineering
Precision 3D modelling in SolidWorks. Every transformer designed from first principles before production begins.
Core & Winding
CRGO step-lap cores. Automated foil and strip winding in climate-controlled bays. Dimensional accuracy at every layer.
Assembly & Vacuum Treatment
Active part assembly, Vapour Phase Drying (VPD), and vacuum oil filling for complete dielectric integrity.
Testing & Certification
Full routine tests in our in-house laboratory. Test certificates issued with every unit as standard.
We build
better products
Design & Engineering.
Every transformer KLR manufactures begins as an engineering project, not a production order. Our design team works in 3D SolidWorks — producing a complete digital model before a single material is ordered or a single component cut. The model captures winding geometry, core dimensions, insulation clearances, thermal distribution, and tank proportions. Design conflicts are identified and resolved before they reach the shop floor — reducing rework, improving accuracy, and ensuring the finished unit matches the specification exactly.
Core & Winding Manufacturing.
The core and winding stages determine the transformer’s electrical performance. Both are executed in dedicated, controlled production areas using purpose-built equipment — with no outsourcing of either process.
- CRGO step-lap core cutting
- Precision lamination stacking
- Low no-load loss core geometry
- Automated foil winding machines
- Climate-controlled winding bays
- Controlled inter-turn insulation
Assembly, Tanking & Vacuum Treatment.
Core and winding assemblies come together in the assembly bay, where every clearance is verified against the design model before the unit undergoes Vapour Phase Drying and vacuum oil impregnation for complete dielectric integrity.
- Active part assembly and dimensional verification
- Vapour Phase Drying (VPD) — complete moisture removal
- Vacuum oil filling — zero air voids in insulation
Testing & Quality Certification.
Every transformer produced at KLR is tested in our in-house laboratory before it leaves the facility. Testing verifies that the finished unit meets every parameter of its specification — from winding resistance and voltage ratio to impulse withstand and insulation integrity. A complete test report is issued with every unit as standard documentation.
- Winding resistance and voltage ratio measurement
- No-load loss and magnetising current
- Load loss and impedance voltage
- Insulation resistance — winding-to-winding and winding-to-earth
- Applied and induced voltage withstand
- Oil breakdown voltage (BDV) on completed unit
Tell Us About Your Transformer Requirement.
Our engineering team responds within 1 business day — with a technical proposal, not just a price.