Synergy Transformers Pvt. Ltd. engineers and manufactures premium grade, highly reliable distribution transformers designed for continuous grid-connected utility duty and heavy industrial substations. Incorporating advanced step-lap CRGO core cutting and foil-wound LV coils, our transformers deliver low operational losses, exceptional dielectric withstand strength, and robust short-circuit withstand capabilities over a design lifespan exceeding 25 years.
Whether you require pole-mounted distribution units for rural electrification projects, plinth-mounted transformers for urban distribution grids, or specialized oil-immersed and dry-type units for demanding industrial loads, every unit is manufactured under audited ISO quality management systems inside our 103,500+ sq. ft. plant in Rajkot, India.
Engineered to eliminate dielectric breakdown, minimize thermal hot-spots, and lower total cost of ownership (TCO) across power distribution networks.
Low Voltage (LV) windings utilize high-purity electrolytic aluminium or copper foil instead of conventional multi-strand wire conductors. Foil winding eliminates axial short-circuit forces, distributes thermal gradient evenly, and enhances mechanical withstand performance during grid fault events.
Magnetic cores are fabricated using prime-grade Cold Rolled Grain Oriented silicon steel (MOH, ZDKH, and Amorphous grades). Precision step-lap core assembly (5, 7, or 9 step design) minimizes no-load losses, lowers excitation current, and significantly reduces operational acoustic noise.
Fully compliant with BIS 1180 Level 1 and Level 2 efficiency standard requirements as well as IEC 60076 loss specifications. Guaranteed no-load and load loss parameters ensure long-term energy savings and reduced operational expenditure for utility discoms and industrial plants.
Optimized insulation geometry allows windings to withstand severe lightning impulse surges and transient voltage spikes. Vacuum oil filling under high vacuum levels ensures void-free dielectric insulation and prevents internal partial discharge.
Equipped with complete protective accessory suites including Pressure Relief Devices (PRD), Buchholz relays, magnetic oil level gauges, and winding/oil temperature indicators (WTI/OTI) with alarm and trip contacts for continuous equipment protection.
Every transformer undergoes full routine testing inside our Rajkot test bay. Conductor purity (Hindalco/Sterlite), CRGO magnetic loss certificates, and insulating oil dielectric strength test records are fully documented and supplied with each unit dossier.
Tailored for outdoor grid installations, indoor commercial substations, and harsh industrial environmental conditions.
Designed for medium-voltage utility distribution grids, industrial facilities, and commercial infrastructure. Built as hermetically sealed corrugated tank or conservator units with off-circuit tap changers (OCTC) or on-load tap changers (OLTC).
Ideal for rural electrification schemes, remote residential networks, and light commercial loads. Engineered for sturdy pole-mounting with high overload capacity and minimal maintenance requirements.
Flame-retardant, non-polluting cast resin units for hospitals, high-rise buildings, underground metros, and airports where fire safety compliance (F1, E2, C2) and zero oil-spill risks are strictly required.
Specifically manufactured to Indian Standards Institute guidelines (BIS 1180 Level 1 & Level 2 energy efficiency ratings) covering ratings up to 2500 kVA in 11 kV, 22 kV, and 33 kV voltage classes.
Indicative technical envelope for B2B procurement officers and engineering consultants.
| Specification Parameter | Oil-Immersed Distribution Transformer | Cast Resin Dry-Type Distribution Transformer |
|---|---|---|
| Power Rating Range | 16 kVA to 3150 kVA | 100 kVA to 2500 kVA |
| Primary Voltage Class | 11 kV, 22 kV, 33 kV (Custom HV up to 36 kV) | 11 kV, 22 kV, 33 kV class |
| Secondary Voltage | 415V / 433V / 400V (or project specific LV) | 415V / 433V (or project specific LV) |
| Operating Frequency | 50 Hz / 60 Hz | 50 Hz / 60 Hz |
| Winding Material | Electrolytic Copper / Aluminium (Foil LV) | Electrolytic Copper / Aluminium |
| Cooling Method | ONAN (Oil Natural Air Natural) | AN (Air Natural) / AF (Air Forced) |
| Insulation Class | Class A | Class F / Class H |
| Tapping Range | Off-Circuit Tap Switch (±2.5% to ±5%) / OLTC | Off-Circuit Tap Links (±2.5% to ±5%) |
| Vector Group | Dyn11, Dyn5, Ynd11 (or as specified) | Dyn11, Dyn5 (or as specified) |
| Applicable Standards | IS 1180, IS 2026, IEC 60076, BS EN 60076 | IEC 60076-11, IS 11171 |
Every distribution transformer undergoes rigorous routine testing inside our modern Rajkot laboratory prior to dispatch clearance.
Measurement of winding resistance, voltage ratio and phase displacement check, short-circuit impedance & load loss measurement, no-load loss & current test, separate-source AC voltage withstand test, and induced overvoltage withstand test.
Client witness testing and third-party inspection agencies (SGS, BV, TÜV, Intertek) are supported. Type testing options include Lightning Impulse Withstand, Temperature Rise, and Short-Circuit Withstand testing via accredited labs (CPRI / ERDA).
Units are packed in robust seaworthy wooden crates or skid-mounted frames with moisture absorbers, nitrogen filling (where required), complete technical test dossiers, name-plate drawings, and installation O&M manuals.
Synergy manufactures three-phase and single-phase distribution transformers ranging from 16 kVA up to 3150 kVA in 11 kV, 22 kV, and 33 kV primary voltage classes. Secondary voltages are standard 415V/433V or tailored to match recipient country grid specifications.
Foil winding replaces wire turns with continuous copper or aluminium foil sheets. This distributes magnetic axial short-circuit forces uniformly across the coil height, eliminates crossover mechanical stress, optimizes heat dissipation, and minimizes hot-spot temperature rise, doubling the operational reliability during short-circuit grid faults.
Yes. Our distribution transformers are engineered and tested in accordance with BIS 1180 (Level 1 and Level 2 loss limits), IS 2026, and international standard IEC 60076. Cast resin dry-type transformers comply with IEC 60076-11.
Yes. Procurement clients and international inspection agencies (such as SGS, Bureau Veritas, Intertek, or TÜV) are invited to witness factory acceptance testing (FAT) at our Rajkot facility prior to seaworthy packing and dispatch.
Standard distribution transformers are typically manufactured within 3 to 5 weeks following GA drawing approval. Customized transformer packages or bulk utility contract orders require approximately 6 to 8 weeks depending on exact accessories and design complexity.
Submit your technical specifications, single-line diagrams (SLD), or project schedules directly to our pre-sales engineering department for competitive export pricing.
