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The Afterlife of High Voltage Cables: Where Do They Go?

High voltage (HV) cables are the cornerstone of India’s electrical networks; from grids and metros to renewables and industrial installations. But ever spared a thought about what happens when these cables reach their retirement age?

These high voltage cable wires are made of copper and aluminum cores wrapped in thick, protective layers, usually made from material known as cross-linked polyethylene (XLPE) or other speciality insulation.

It is a material prized for its thermal stability, mechanical strength, and insulation performance in high-voltage applications. That is why it is the global standard across the industry, including in our own triple-layer extruded cable products.

Copper and aluminum cores are still recyclable. However, XLPE’s same qualities that make it robust also make it difficult to recycle using conventional means. It is like an indestructible skin which can neither be easily broken down nor recycled using traditional methods. 

Unfortunately, the practical reality is not ideal. As per the industry data, a significant 30–40% of a cable’s mass consists of insulation materials. These polymeric sheathings are either burned or buried, harming the environment.

Are Thermoplastics the Answer to Cable Insulation Recoverability?

India’s cable and wire market is approximately projected to reach over $17 billion, raising demands for collective innovation. Around the world, companies are testing new materials such as thermoplastic alternatives to XLPE.

But why thermoplastic? Because it is easier to recycle and reuse while retaining the electrical performance. Some Asian and European research groups are piloting methods such as mechanical grinding of cable scrap and microwave pyrolysis to recover polymers and metals cleanly.

How as a Responsible Industry Should We Respond?

It is time to innovate around the challenge and create systems that extend these cables’ value beyond first use.

For example, at DICABS, we manufacture HV cables using high-purity XLPE insulation with triple-layer extrusion that ensures long service life, minimal maintenance, and reduced risk of early failure.

This extends the replacement cycle and helps our clients reduce their overall waste generation over time. Looking for HV cables with optimal electrical and mechanical performance, minimal breakdowns, and a longer lifespan? Please visit us here: https://dicabs.com.