Where Every Transformer Is Built.
Our Manufacturing Facility.
A purpose-built transformer manufacturing facility 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
- Core Assembly
- Automated Foil and Strip Winding Technology
- Advanced Vacuum Drying Machine
- Vacuum Oil Processing Machine
- Fully-Automated Testing Lab
- BUSBAR Bending Tool Machine
- Hydraulic Coil Pressing Machine
- Tanking under Vacuum
- In-house Impulse Lab
From Design File to Tested Transformer
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
Our design facility is equipped with high-end computer systems featuring the latest 3D software.
Incoming Materials Inspection
Our Laboratory facilities are designed to verify the Incoming Materials (Winding Copper, Core, Steel, Bushings, PRV, Temperature Indicators and other Accessories)
Core Assembly & Winding Manufacturing
CRGO cores are precision-stacked in our core bay, while copper windings are produced in climate-controlled bays using automated foil and strip winding machines with dimensional accuracy verified at every layer.
Core Coil Assembly and Connection
The core and winding assemblies are united in our assembly bay, where every clearance is verified against the design model and all HV and LV lead connections are made before the active part proceeds to tanking.
Tanking, Vacuum Treatment and Oil Filtration
Every transformer undergoes Vapour Phase Drying (VPD) after tanking, followed by vacuum oil filling with separately filtered and tested transformer oil — eliminating moisture and air voids from the insulation system without exception.
Testing and Quality
Every transformer is tested in our in-house laboratory across the full routine test programme — winding resistance, voltage ratio, losses, insulation resistance, and dielectric withstand — with a signed test certificate issued before dispatch.
- Fully- Automized Test Lab
- 60 MVA 220 KV Power Transformer Testing
- Impulse Lab
Packing and Dispatch
Completed and tested transformers are packed for transit with nitrogen filling or oil preservation as required, and dispatched with a full documentation pack including the test certificate, dimensional drawing, and operation manual.
Infrastructure
EOT CRANES
BUS BAR BENDING TOOL
HYDRAULIC COIL PRESSING MACHINE
VACUUM OVEN MACHINE
VACUUM FILTER MACHINE
Tell Us About Your Transformer Requirement.
Our engineering team responds within 1 business day with a technical proposal, not just a price.