Facilities
ZDVolt has integrated manufacturing facilities on its 3 campuses total about 35 acres, headquarter Jurong/Nanjing, porcelain insulator shop at Henan, and metal castings shops at Susong. ZDVolt has 9 in-house test labs, 2 dozens of bushings winding machines, over a hundred of current transformer winding machines, 2 LSR injection machines and 2 of 650t and 2 of 1800t HTV injection machinery. Hundreds of CNC metal machinery and 4000T forging machine and 1250T pressing forging machine. ZDVolt produces its own fiberglass production with CWFP (Continuous Windings Fiberglass Pipe ) method. The porcelain is made in its Henan campus by ZDVolt enhanced cold isostatic pressing machinery.
In-house Test Labs
ZDVolt’s four state-of-the-art Bushings Test Laboratories are the cornerstone of ZDVolt’s quality assurance program. The EHV lab is equipped with advanced test equipment capable of handling voltages up to 1100 kV AC and 1600 kV impulse, the laboratory performs comprehensive type tests, routine tests, and special tests in accordance with IEC 60137, IEEE C57.19.00/01, and other international standards. And its background noise level is less than 2pC. P&OTM series bushings has its own dedicated lab.
ZDvolt also has one chemistry/material lab, one 220kV and one 550kV GIS/breaker bushings lab,
The laboratories are staffed by experienced test engineers and operate under ISO/IEC 17025 accreditation, ensuring the highest standards of measurement accuracy and test reliability.
Bushings Winding
Our bushing winding facility houses 22 automated winding machines capable of producing condenser cores up to 22 meter length for both OIP and RIP bushings. The precisely controlled winding process ensures uniform paper thickness, consistent impregnation, and optimal capacitance grading across every condenser core.
Advanced quality monitoring systems track critical parameters in real-time throughout the winding process, including tension, speed, and temperature, ensuring consistent quality from unit to unit.
Bushings CT Winding
The dedicated Bushing CT Winding facility produces high-precision toroidal current transformers using automated winding technology. Each CT core is wound with carefully selected grain-oriented silicon steel and secondary windings of enameled copper wire.
Ratio accuracy, burden performance, and composite error are verified for every unit before integration with bushing assemblies.
Enhanced Cold Isostatic Porcelain Production
ZDVolt’s porcelain production facility employs Enhanced Cold Isostatic Pressing (CIP) technology — a process that produces porcelain bodies with exceptional density, mechanical strength, and dielectric properties. This advanced manufacturing method ensures uniform pressure distribution during forming, eliminating internal voids and density variations.
The facility includes automated glazing lines, high-temperature kilns with precise atmosphere control, and comprehensive quality inspection stations with ultrasonic testing capabilities.
BambuX™ Production
The BambuX™TM production facility manufactures ZDVolt’s proprietary composite insulator technology. BambuX™TM insulators combine the mechanical strength of fiberglass-reinforced polymer (FRP) cores with advanced silicone rubber housing, delivering superior performance in contaminated and coastal environments.
The facility features automated injection molding systems, FRP pultrusion lines, and UV/weathering test chambers for accelerated aging validation.
Hollow Composite Insulator Production
This facility specializes in manufacturing hollow composite insulators used as external housings for transformer bushings. The production process combines precision FRP tube winding with automated silicone rubber injection molding to create lightweight, shatter-proof insulator housings.
CNC Metal Machining
Our CNC Metal Machining center houses multiple 5-axis CNC machining centers, precision lathes, and specialized boring machines for manufacturing bushing flanges, terminals, and hardware components. All metalwork is performed to tight tolerances with full dimensional inspection using coordinate measuring machines (CMMs).
Pressure Forging
The 1640 metric tons pressure forging facility produces high-strength aluminum and copper alloy components used in bushing assemblies. Hot forging and cold forging processes create components with superior grain structure and mechanical properties compared to cast alternatives.