Download our 2025 Product Catalog for detailed drawings and technical parameters of all switchgear components.
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Distribution Transformer manufacturing is the backbone of the power grid, responsible for stepping down medium voltage (6kV-35kV) to usable low voltage levels. It involves two distinct technologies: Oil-Immersed (liquid-filled) transformers for outdoor utility use and Dry-Type (cast resin) transformers for indoor commercial safety. As a specialized Distribution Transformer Manufacturer, XBRELE operates a dual-production facility capable of producing high-efficiency units that meet IEC 60076 standards. Whether you need a rugged S13 Oil Transformer for a rural grid or a fire-safe SCB Cast Resin Transformer for a high-rise building, XBRELE provides OEM manufacturing with a focus on low losses and long service life.
The manufacturing process for transformers is complex, involving precise electromagnetic design and insulation engineering. At XBRELE, we follow a strict quality protocol for both our dry and oil product lines.
Core Stacking (Step-Lap Technology): The heart of the transformer is the iron core. We use high-permeability Grain-Oriented Electrical Steel (GOES). Our cores are cut and stacked using “Step-Lap” technology, which reduces the magnetic flux gap at joints. This significantly lowers the No-Load Loss and noise levels, a critical factor for modern eco-friendly grids.
Winding (Foil Technology): For the Low Voltage (LV) coils, XBRELE utilizes Automatic Foil Winding instead of traditional wire winding. This technique uses copper or aluminum foil sheets, which eliminates the helix angle and reduces short-circuit axial forces. This ensures the transformer can withstand sudden fault currents without mechanical deformation.
Vacuum Casting (Dry Type): For our SCB series, the coils are placed in a vacuum casting tank. Epoxy resin is poured under vacuum to ensure deep impregnation. This eliminates air bubbles that could cause Partial Discharge (PD), ensuring the insulation lasts for decades.
Vacuum Drying & Oil Filling (Oil Type): For our S13 series, the active part is dried in a kerosene vapor phase drying plant to remove all moisture. The tank is then filled with degassed mineral oil under vacuum, ensuring perfect insulation strength.
A transformer is only as good as its materials. XBRELE sources premium raw materials to ensure high efficiency (low I²R and hysteresis losses).
XBRELE’s factory is equipped with modern machinery designed to ensure consistency across thousands of units.
Automatic Foil Winding Machines: These machines automatically control tension and alignment, wrapping the insulation paper and conductor foil simultaneously. This eliminates human error and creates a coil with high mechanical strength.
Vacuum Casting Plant: Our static mixing and casting chambers allow for the precise control of resin temperature and vacuum levels, essential for producing “PD-Free” Dry Type Transformers.
Corrugated Tank Production Line: For hermetically sealed oil transformers, we manufacture the corrugated fin tanks in-house. These fins expand and contract with oil temperature changes, eliminating the need for a conservator tank and preventing air from contacting the oil.
Testing is critical to verify the efficiency and safety of a transformer. Every XBRELE unit undergoes Routine Tests according to IEC 60076 before shipment.
| Test Name | Product Type | Purpose |
|---|---|---|
| Ratio & Vector Group Test | All | Verifies the voltage transformation ratio and phase relationship (e.g., Dyn11). |
| Winding Resistance | All | Checks for loose connections and verifies the copper/aluminum quality. |
| Load Loss & Impedance Voltage | All | Measures efficiency under load and verifies short-circuit impedance (Uk%). |
| Applied Voltage Test | All | Verifies insulation level between windings and earth (Power Frequency Withstand). |
| Partial Discharge (PD) | Dry Type | Ensures the cast resin insulation is void-free (< 10pC). |
| Oil Leakage Pressure Test | Oil Type | Pressurizes the tank to ensure seals are tight and leak-proof. |
We also perform Type Tests (Temperature Rise, Lightning Impulse) on prototype units to validate the design’s thermal and dielectric capabilities.
Grid requirements vary globally. A standard 11kV/400V transformer for China might not work for a project in the Philippines (13.2kV) or South Africa (11kV/415V). XBRELE specializes in Custom Voltage Manufacturing.
We can customize the Tapping Range (e.g., ±2×2.5% or ±5%) and the Vector Group (Dyn11, Yyn0, or special industrial groups). For Dry Type Transformers, we offer custom IP ratings (IP20, IP23, IP44) for the enclosure, allowing installation in dusty or semi-outdoor environments.
Our engineering team also designs transformers with specific impedance voltages (Uk%) to match existing units for parallel operation, a crucial requirement for plant expansions.
Transformer manufacturing is a mature industry where experience counts. XBRELE has decades of experience optimizing core designs to balance cost and efficiency. We understand the trade-offs between “No-Load Loss” (Iron loss) and “Load Loss” (Copper loss).
Our experience with Amorphous Alloy Technology allows us to produce ultra-high-efficiency units for modern green energy projects (Solar/Wind farms), helping clients meet strict energy efficiency directives (like Tier 2 EU standards).
XBRELE provides a significant cost advantage for global EPCs and utilities. Located in China, we have access to a massive supply chain of electrical steel and copper.
Our “Direct-from-Factory” model eliminates distributor margins. Furthermore, our efficient foil winding process reduces labor time and material waste compared to older wire-winding methods. This allows us to offer high-spec units (e.g., K-Factor rated transformers) at prices that are highly competitive in international tenders.
XBRELE offers a diverse product portfolio under one roof. We manufacture standard Pole-Mounted Transformers for overhead distribution and Pad-Mounted units for underground systems.
We are adaptable to special applications. We produce Rectifier Transformers for industrial electrolysis, Furnace Transformers for steel mills, and Isolation Transformers for sensitive data centers. This versatility allows XBRELE to serve as a comprehensive power solution partner.
Transformers are long-life assets (20-30 years), so sustainability is key. XBRELE focuses on producing “Eco-Design” transformers with reduced losses. Our Amorphous Alloy Series is a prime example, reducing standby energy consumption by up to 75%.
In manufacturing, we utilize closed-loop oil handling systems to prevent spillage and recycle scrap copper and steel. Our dry-type transformers are inherently eco-friendly, as they contain no oil and pose zero soil contamination risk, making them the preferred choice for sustainable building certifications (LEED/BREEAM).
China is the world’s largest producer of power transformers. XBRELE leverages this ecosystem to offer:
When selecting a supplier, consider these critical factors:
XBRELE invites you to inspect our facility or request a virtual tour to see our quality control in action.
Get a direct quote for Dry Type, Oil Immersed, or Amorphous Alloy transformers today.
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