CABLES & CABLE ACCESSORIES
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The latest technologies in electrical cables and accessories T he world of electrical cables and accessories is experiencing a technological revolution, driven by the growing demand for safer, more efficient, and environmentally friendly electrical systems. From cutting-edge materials to smart cable management solutions, the latest innovations are setting new standards in performance and reliability. Here’s a look at some of the most exciting technologies shaping the future of electrical cables and their accessories. High-performance conductors and insulation Traditional copper and aluminium conductors are now being complemented by advanced materials such as superconducting cables, which offer minimal electrical resistance and dramatically reduce power losses. High-temperature superconductors (HTS) are especially promising for high-capacity power transmission in urban areas. On the insulation front, cross-linked polyethene (XLPE) and ethylene-propylene-rubber (EPR) are increasingly used, offering enhanced thermal stability, flexibility, and longevity compared to conventional PVC. Fire-resistant and low-smoke cables Safety regulations and urbanisation have spurred the development of fire-resistant, flame-retardant, and low-smoke, zero-halogen (LSZH) cables. These cables are designed to emit minimal toxic fumes when exposed to fire, making them ideal for use in public infrastructure such as airports, subways, and hospitals. The use of non-halogenated compounds not only increases safety but also supports green building initiatives. Smart cables and IoT integration The integration of the Internet of Things (IoT) into cable technology is revolutionising cable management and maintenance. Smart cables now feature embedded sensors that monitor parameters such as temperature, current flow, and mechanical strain in real time. This data enables predictive maintenance, reducing downtime and preventing failures before they occur. Such technology is vital for critical infrastructure, including data centres and industrial plants.
LESCO’s Cable manufacturing excellence: An exclusive interview with Melusi Sibiya
LESCO Manufacturing has firmly established itself as a benchmark of quality, innovation, and local production within South Africa’s cable sector. In a recent discussion with Melusi Sibiya, Cable Production Leader at LESCO Manufacturing, we explored the operational mechanics, triumphs, and hurdles shaping the company’s manufacturing landscape. While historically celebrated for its premium switch ranges, LESCO has strategically expanded its footprint by investing heavily in advanced production lines for extension cords and garden leads. “Our goal is to provide versatile power solutions that never compromise on the strictest safety standards,” Sibiya notes. Uncompromising quality & rigorous testing At LESCO, quality control isn’t just a final check—it is the foundation of the entire assembly line. The company uses dedicated, full-time quality inspectors who oversee multi-stage testing throughout the production cycle. Total compliance: Every item is evaluated at each stage of manufacturing to ensure alignment with domestic and global safety benchmarks. Continuous upskilling: Regular training regimes ensure the workforce remains highly adept at maintaining quality, health, and safety protocols. Navigating raw material volatility Sourcing raw materials presents distinct challenges, particularly given the volatility in pricing and supply of essential commodities like PVC and brass. LESCO mitigates these vulnerabilities through a dual-pronged approach: Strategic stockpiling: Maintaining optimal inventory reserves to buffer against market dips. Supplier synergies: Cultivating robust relationships with domestic and global vendors. “We prioritise local sourcing wherever feasible,” Sibiya highlights. “This not only injects life back into the South African economy but drastically insulates us from international supply chain disruptions.” From concept to conductor: the engineering journey The transition from a design blueprint to a market-ready cable is a highly calculated process: [Standard Review] → [Material Selection] →
Melusi Sibiya.
[Prototyping] → [Rigorous Internal Testing] → [Mass Production] Every project begins with an exhaustive analysis of local and international regulatory frameworks. Engineers then meticulously select the appropriate cable gauge, housing materials, and plug configurations tailored to the product’s specific application. Only prototypes that pass internal trials without issue progress to the final assembly line. Driving efficiency through targeted automation Innovation remains a primary catalyst for growth at LESCO. The integration of a semi-automated cable preparation machine has revolutionised operational throughput, delivering a remarkable 75% productivity surge to meet client demand. “This capital investment has dramatically elevated both our volume capacity and product consistency,” says Sibiya. Complementing this upgrade is a newly introduced semi- automated packaging system, further demonstrating LESCO’s commitment to lean manufacturing practices. Bespoke client collaboration When it comes to specialised, custom cable designs, LESCO adopts a highly collaborative approach. The engineering team works hand in hand with clients to dissect unique specifications and create initial prototypes for client verification. Because production is localised, LESCO can offer significantly faster turnaround times for bespoke orders than international competitors. Sustainable & eco-conscious manufacturing Environmental stewardship is deeply woven into LESCO’s daily operations. The factory actively minimises waste by: • Recycling production-line plastics. • Repurposing brass components salvaged from any rejected units. “We are deeply committed to keeping ecological responsibility at the heart of our manufacturing philosophy,” Sibiya affirms. The power of local heritage What truly elevates LESCO above the competition is its fierce commitment to local manufacturing. In a market saturated with cheap imports, LESCO’s cables are proudly made in South Africa and engineered to withstand rugged, demanding environments. Sibiya emphasises that this reliability is rooted in human capital: “Our dependability begins with our workforce.” By pairing strategic semi-automation with skilled local craftsmanship, LESCO supports the domestic job market while boosting production efficiency. Through continuous evolution, rigorous quality governance, and an unwavering commitment to its workforce and the environment, LESCO Manufacturing continues to lead the future of South African cable production.
Discover more: www.lescosk.com
SPARKS ELECTRICAL NEWS
JULY 2026
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