SEZ page – Coral

Why Coral Special Economic Zone?

Precision Manufacturing & Proven Engineering.

Coral Engineering Works SEZ brings together advanced manufacturing, precision engineering and rigorous quality assurance within a single integrated facility. Every process follows defined engineering standards. Every product undergoes meticulous validation. Every project reflects our commitment to manufacturing reliable, high-performance coils for critical industrial applications.

Our infrastructure supports hydro generators, turbo generators and rotating machines with complete in-house manufacturing capabilities that strengthen quality, improve production efficiency and accelerate project execution.

World-Class Integrated Coil Manufacturing Facility

At Coral Engineering Works SEZ, we operate one of the most advanced and integrated coil manufacturing facilities in the industry, spread across a total built-up area of 1,25,000 sq. ft.

1,05,000 sq. ft. dedicated exclusively for advanced coil manufacturing operations.
20,000 sq. ft. dedicated machine shop for precision tooling, fixture development, and jig manufacturing

Our infrastructure is designed to support complete in-house manufacturing, precision engineering, testing, validation, and custom development for hydro, turbo, and rotating machine coils.

State-of-the-Art Machine Shop & Tooling Division

Our exclusive machine shop is equipped with advanced machinery for manufacturing high-precision tooling, fixtures, molds, and custom engineering components required for coil production.

In-House Machine Shop Capabilities

CNC Vertical Machining Center (VMC)
Precision Lathe Machines
Iron Working Machines
Surface Grinding Machines
3D Printer (Advanced 3D Printing Technology for prototype development and profile validation)

To ensure highly accurate coil profiling and repeatability, we utilize:

Advanced 3D CAD modeling
Large-scale engineering print layouts
In-house 3D Printing Technology for prototype and profile validation

This enables us to manufacture highly accurate coil geometries with superior dimensional consistency and faster development cycles.

Advanced Coil Manufacturing Bays

Our shop floor is designed as a modern, process-oriented manufacturing facility with dedicated bays for every stage of production, ensuring optimized workflow, quality control, and operational efficiency.

Dedicated Manufacturing Bays

Each bay is designed with dedicated handling systems, process controls, and safety standards to ensure seamless production flow and precision manufacturing.

Advanced Coil Forming & Taping Technologies

High-Precision Coil Forming Systems

We utilize imported and custom-engineered coil forming equipment to achieve superior dimensional accuracy and repeatability.

Advanced coil forming machine imported from Vincent Machines
Achieves up to 99% profile accuracy
Ensures precise coil geometry and repeatable manufacturing quality

Automated Taping Systems

Our facility includes

4 Two-Axis Taping Machines
1 Six-Axis CNC-Controlled Taping Machine
1 Fully Robotic Eight-Axis Taping Machine

The eight-axis robotic system is

Fully automated
In-house assembled and integrated
Equipped with advanced FANUC (Japan) robotic technology

These systems provide

Uniform insulation application
High process repeatability
Improved productivity
Reduced human error
Enhanced insulation reliability

Molding, Looping & Thermal Processing Infrastructure

Molding & Looping Capabilities

13 High-Capacity Molding Machines
5 Looping Machines
Maximum loop length capability up to 4.5 meters

Industrial Ovens

2 Heavy-Duty Industrial Ovens

8-meter oven
10-meter oven

VPI Facility Capacity

2.5-meter Diameter Capacity
12.5-meter Length Capacity

This ensures:

Deep resin penetration
Void-free insulation
Superior mechanical strength
Enhanced thermal and dielectric performance

NABL-Approved Advanced Testing Laboratory

Coral Engineering Works SEZ houses a comprehensive NABL-accredited testing facility equipped with advanced diagnostic and validation systems.

Testing Capabilities

Multi-Station Testing Infrastructure

Heavy-Duty Material Handling Infrastructure

To ensure safe and efficient movement of large coils and assemblies, our facility is equipped with:

Overhead Crane Systems

2 Nos. – 20 Ton Overhead Cranes
1 No. – 40 Ton Overhead Crane

Additional Handling Systems

3 Jib Cranes
Air Balancers for precision coil handling

These systems improve:

Operational safety
Handling precision
Reduced material damage
Faster manufacturing movement

Precision Assembly & Jig Development Area

Our facility also includes a dedicated heavy-duty assembly and fabrication area featuring:

Surface Table Infrastructure

Precision surface table size: 3m × 9m

Used for:

Jig fabrication

Core assembly activities

Dimensional verification

Large fixture alignment

Complete End-to-End Manufacturing Excellence

At Coral Engineering Works SEZ, we provide complete in-house solutions from:

This integrated manufacturing approach ensures:

✔ Superior quality control
✔ Faster development cycles
✔ Reduced dependency on external vendors
✔ High dimensional accuracy

✔ Improved reliability & durability
✔ Customized engineering solutions
✔ Compliance with IEC, IEEE, and ISO standards

Industry-Leading Infrastructure with Next-Generation Engineering

Backed by advanced automation, robotic systems, precision engineering, and a highly skilled technical team, Coral Engineering Works SEZ stands as a technologically advanced manufacturing hub capable of delivering world-class coil solutions for critical industrial applications worldwide.

Proven Capability in Large-Scale Power Projects

Coral Engineering Works SEZ has successfully executed coil manufacturing and engineering solutions for large-scale power generation projects, demonstrating our capability to handle highly critical and complex applications.

Successfully executed projects up to 430 MW capacity
Coil manufacturing and testing capability for systems up to 20 kV phase voltage
Expertise in hydro and turbo generator applications
Proven performance in high-voltage, high-capacity rotating machine projects

Our advanced infrastructure, engineering expertise, and stringent quality standards enable us to deliver reliable, high-performance coil solutions for demanding power generation environments.

Additional Points

Decades of expertise in coil manufacturing for critical applications.
State-of-the-art infrastructure with precision engineering capabilities.
Comprehensive in-house testing for reliability and safety assurance.
Custom design and engineering support for unique customer requirements.
Proven track record in executing large-scale coil manufacturing projects.

Specialized Expertise for Every Stage of Coil Manufacturing

We believe in precision engineering through specialization. Our dedicated team of technical experts and advisors ensures excellence at every stage, from coil design to final validation. Each domain is handled by industry-leading specialists, providing in-depth guidance, optimization, and troubleshooting support.

1. Coil Design & Engineering – Tailored for Performance & Efficiency

Expert Coil Designers optimize conductor configurations for enhanced electrical performance, lower losses, and improved heat dissipation.
Advanced winding patterns & slot geometries ensure maximum efficiency in stator and rotor coils.

Technical Advisor: Dedicated experts ensure compliance with international electrical and thermal standards.

2. Robel Design & Analysis – Perfecting Winding Transitions & Joint Integrity

Specialists in Robel Bar Design ensure seamless coil-to-coil connections with minimal resistance.
Advanced shaping & profiling techniques enhance durability and conductivity.
Joint resistance testing & metallurgical evaluation ensure optimal mechanical strength.

Technical Advisor: Robel experts focus on mechanical endurance.

3. Insulation Scheme Development – Ensuring Electrical & Thermal Reliability

Custom insulation systems designed for high-voltage, high-temperature, and moisture resistance.
Expertise in mica-based and epoxy-resin-rich insulation for superior dielectric strength.
Layer-by-layer insulation design ensures long-lasting performance in harsh environments.

Technical Advisor: Specialists evaluate insulation thickness, creepage distance, and corona resistance.

4. Resin Selection & VPI Process Optimization – Enhancing Coil Longevity & Mechanical Strength

Material engineers select the best resins and varnishes for thermal class and chemical resistance.
Vacuum Pressure Impregnation (VPI) specialists ensure deep resin penetration, preventing voids and ensuring mechanical robustness.
Advanced curing cycles & thermal analysis to improve adhesion and endurance.

Technical Advisor: Experts in resin chemistry ensure superior dielectric integrity and mechanical bonding.

5. Final Coil Processing & Dimensional Validation – Precision Fit & Compliance

Dimensional experts ensure coil geometry meets exact motor/generator core specifications.
Quality control specialists verify coil alignment, ensuring zero tolerance deviations.

Technical Advisor: Experts oversee final inspections to ensure perfect fitment & functional integrity.

Our Expertise-Driven Approach

✔ Dedicated experts for every stage of coil manufacturing.

✔ Advanced R&D-backed solutions for superior performance.

✔ Industry-leading advisors for insulation, resin, and winding technology.

✔ Tailored solutions ensuring compliance with IEC, IEEE, and ISO standards.

A Dynamic Team, Backed by Expertise

We take pride in our young, energetic team, with 90% of our workforce comprising next-generation engineers who bring a fresh, analytical, and data-driven approach to coil manufacturing.

While our experienced senior technical advisors provide strategic guidance and industry insights, our young technical specialists drive innovation, efficiency, and precision across.

Expertise in Complete Re-Design & Power Enhancement

our highly skilled engineering team, backed by seasoned technical advisors, possesses the expertise to completely redesign hydro and turbo generator bars, optimizing their performance for higher power output, efficiency, and reliability.

With a data-driven and analytical approach, we specialize in:

Full Re-Engineering of Hydro & Turbo Bars – Tailored for enhanced electrical and mechanical performance.
Power Enhancement Solutions – Optimizing conductor configuration, insulation systems, and thermal management for increased capacity.
Customization for Operational Demands – Designing solutions that align with site-specific requirements, voltage levels, and environmental factors.

we have a dedicated in-house facility for manufacturing single, fully cured VPI Diamond Coils

Precision Redesign Through Advanced 3D Scanning

We utilize advanced 3D scanning technology for precise coil replication and design optimization, allowing us to capture detailed geometries and generate accurate manufacturing blueprints. This enables seamless adaptation, performance enhancement, and exact fitment for replacement or upgraded coils. By combining digital reconstruction with advanced engineering methodologies, we ensure high-precision manufacturing, improved efficiency, and reduced turnaround times for custom coil solutions.

NABL-Approved Testing for Performance & Durability

Our NABL-accredited testing laboratory is equipped to perform comprehensive coil testing, including Voltage Endurance Test (VET), Type Tests and Thermal Cycle Tests (TCT). Our VET capabilities allow us to assess insulation durability under prolonged electrical stress, ensuring superior dielectric strength, partial discharge resistance, and long-term reliability. With advanced diagnostics and precise failure analysis, we guarantee that every coil meets the highest industry standards for performance and durability.

Trusted & Approved Vendor for Leading OEMs

We have successfully undergone stringent supplier audits and are an approved vendor for renowned OEMs. Our commitment to quality, precision, and compliance with industry standards has earned us the trust of major original equipment manufacturers. With a robust quality management system, advanced testing capabilities, and a strong technical foundation, we ensure that every coil meets the highest performance and reliability standards required by OEMs worldwide.

End-to-End Coil Manufacturing with Custom Tooling & Fixtures

We offer complete coil manufacturing solutions, including the design and development of all necessary tooling and fixtures such as bending fixtures and molding fixtures. With our advanced in-house capabilities, we can take a coil drawing from concept to production, ensuring precise engineering, optimized manufacturability, and seamless integration with customer requirements. Equipped with state-of-the-art machinery and process expertise, we deliver high-quality, custom-manufactured coils with superior accuracy, reliability, and performance.

Trust with our

Certificates

We are backed by more than 9+ industry standards, including ISO, WRAS and FDA.

Why Us?

End To End

Coral Coil provides complete design and reverse engineering services for motors and generators. As an IMS-certified company (ISO 9001:2008, ISO 14001, ISO 18001), we handle everything from design to servicing coils and turbo bars for LT/HT motors and generators.

OEM

Each OEM has specific requirements and standards and at Coral, we ensure your needs are fully met. Often, we establish a dedicated production line and team for your recurring orders, ensuring they are well-trained to enhance quality, efficiency and timing.

Repair/Rewind

Coral Coil, born in the industry, grasps coil supply urgency. With short motor downtime, we prioritise emergency coil quotes, production and delivery. Strong supplier ties secure materials, while our shipper ensures swift, certified shipments.

Export

All customers are treated equally when shipping. We ensure safe, timely delivery with trusted logistics. Wooden mock-ups for fitment checks guarantee precise coil fitting, reducing on-site deformation risks.

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