Established in 2004, Synergy Transformers Pvt. Ltd. is a premier ISO 9001:2015 certified transformer manufacturer based in Rajkot, Gujarat, India. Operating from a modern 103,500+ sq. ft. built-up manufacturing plant over 131,500+ sq. ft. of industrial land, we engineer custom power, distribution, cast resin dry-type, furnace, and renewable energy inverter duty transformers up to 33 kV class.
Equipped with advanced manufacturing technology and an experienced team of 70+ electrical engineers and technical specialists, our facility holds official Indian Standards Institution approvals for distribution transformers ranging from 16 kVA to 2500 kVA (under BIS – 1180) and up to 5000 kVA under IS 2026 and IEC 60076 standards. Every unit is engineered for long-term dielectric stability, low losses, and high mechanical strength under severe electrical grid conditions.
Guided by technical innovation, environmental stewardship, and uncompromised product reliability for international utilities and EPC contractors.
To consistently innovate and achieve technological advancement in electromagnetic transformer design while maintaining total harmony with environmental sustainability. We aim to be the global supplier of choice for high-efficiency energy distribution equipment.
To expand our global footprint by delivering high-reliability transformers that offer technical excellence, optimum efficiency, and maximum value for money. We promote eco-friendly practices, lower carbon footprints, and transparent commercial integrity.
As a morally responsible manufacturer, we comply strictly with environmental regulations and statutory laws. We maintain internal audit procedures, clear communication, and complete material traceability to build lasting trust with global buyers.
Every transformer undergoes nine controlled manufacturing stages under a single ISO quality control plan to ensure maximum operational uptime.
Our senior design engineers utilize advanced electromagnetic and thermal calculation software to optimize flux density, minimize no-load losses, and withstand electromagnetic forces under transient short-circuit conditions.
We source prime-grade Cold Rolled Grain Oriented (CRGO) silicon steel laminations, high-purity electrolytic copper/aluminium foils, and electrical-grade transformer oil strictly from audited, tier-1 global material suppliers.
Laminations are precision-cut and stacked with step-lap miter joints to significantly reduce magnetizing current and core noise levels while maintaining structural integrity during mechanical handling.
Technicians execute low-voltage foil winding and high-voltage layer/disc winding under tension-controlled conditions. Foil winding eliminates axial short-circuit stress and distributes thermal dissipation evenly.
High-dielectric, thermally upgraded pressboards, insulating papers, and inter-layer spacers are installed to safeguard windings against high thermal spikes, impulse surges, and dielectric breakdown over long operational cycles.
The wound coils and core assembly are aligned, clamped with heavy-duty steel frames, and locked in position with rigid wood-pressboard blocks to ensure high mechanical withstand under heavy fault currents.
The complete Core-Coil Assembly undergoes deep thermal drying in custom vacuum ovens to eliminate all residual moisture from cellulosic insulation, ensuring high insulation resistance values prior to oil immersion.
The CCA is lowered into shot-blasted, leak-tested steel tanks. Inhibited dielectric insulating oil is processed under high vacuum to remove dissolved gases and moisture, filling the tank completely free of air pockets.
Every single unit undergoes routine acceptance testing in our in-house testing laboratory, including voltage ratio, vector group, winding resistance, insulation resistance, separately-sourced withstand, and loss measurements.
Our custom-engineered transformers are operating across critical industrial sectors, utility grids, and infrastructure developments worldwide.
Continuous heavy-duty transformers engineered for high-current loads and severe harmonic stress in brass component manufacturing plant networks.
Furnace transformers designed to handle rapid load fluctuations, thermal expansion cycles, and continuous high secondary currents.
Robust distribution transformers engineered for non-stop multi-shift continuous production plants with dust-protected tank enclosures.
Sealed oil-immersed transformers with specialized surface anti-corrosion paint coatings designed for harsh, chemical-laden site atmospheres.
Energy-efficient distribution transformers providing clean, uninterrupted voltage to sensitive automated process and packaging lines.
Low-noise, fire-safe cast resin dry type transformers ensuring maximum power safety and hygiene in sensitive indoor medical facilities.
Compact substations and dry-type transformers providing safe, space-saving power distribution inside shopping malls, hotels, and high-rises.
Specialized multi-winding inverter duty step-up transformers designed for non-linear harmonic spectrums and daily solar/wind cycling.
Every unit is tested and documented with factory routine test certificates prior to dispatch.
| Test Parameter | Standard / Protocol | Factory Acceptance Verification |
|---|---|---|
| Voltage Ratio & Vector Group | IEC 60076-1 / IS 2026-1 | Verified on all tap positions; phase angle relationship confirmed. |
| Winding Resistance | IEC 60076-1 / IS 2026-1 | Measured for all windings at cold ambient with temperature correction. |
| No-Load Loss & Current | IS 1180 / IEC 60076-1 | Guaranteed loss limits checked at 100% rated frequency and voltage. |
| Load Loss & Impedance | IS 1180 / IEC 60076-1 | Verified at rated current; corrected to standard reference temperature (75°C). |
| Separate-Source AC Withstand | IEC 60076-3 / IS 2026-3 | High-voltage dielectric strength test applied to HV and LV windings. |
| Insulation Resistance (MEGGER) | IEEE / IEC Standards | Insulation integrity measured between HV-LV, HV-Earth, and LV-Earth. |
We welcome third-party inspectors (SGS, TUV, Intertek, Bureau Veritas) or customer quality representatives to witness routine factory acceptance testing at our Rajkot bay.
Export orders ship with full engineering documentation: approved GA drawings, guaranteed technical particulars (GTP), routine test reports, and installation manuals.
Units are packed using wooden crating, moisture-barrier wrapping, and nitrogen filling (where required) to protect external bushings and fittings during international transit.
Review technical specifications, dimensional drawings, loss guarantees, and compliance certifications for our entire power and distribution transformer portfolio.
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