PG-LL9

Ceramic chips are created with binders and solvents added to a specified ceramic powder. The slurry created is dried, forming a sheet or tape of ceramic material. Metal powder is mixed with solvents and additional ceramic material to create a liquid electrode. The liquid is then printed onto the ceramic layer. Layers of the ceramic sheets are stacked and laminated to form a solid structure.

The solid structure is cut into the desired size. Once cutting is complete, the assembly must be kiln fired. The temperature used in the firing process is critical in determining the capacitor’s characteristics. The process is similar for disc and chip styles. Disc capacitors use long leads to mount through circuit boards. Chips use surface mount technology.

High temperature ceramic capacitors and high temperature mica capacitors are often used in situations that require a higher voltage or a higher power than normal. Because of the ways in which they are built, they can offer low ESR and excellent inrush current and ripple capabilities that other types of capacitors cannot. The only downside is that they tend to be physically larger than other types of capacitors.

The automotive industry is another area where high temperature capacitors are required. The temperature conditions can vary dramatically depending on what area of a car you’re talking about. The brake systems, the engine and the transmission are often the most temperature intensive areas.

Founded in 1977, Exxelia Alcon Electronics began by manufacturing aluminum electrolytic capacitors for the Indian consumer electronics market. Over time, the company strategically shifted its focus to power electronics and now offers an extensive range of high CV screw terminal aluminum electrolytic capacitors, as well as a wide variety of film capacitors tailored for demanding industrial and technical applications.

Key product lines include:

• IGBT snubber capacitors with direct mounting and multiple terminal styles to suit various IGBT modules,

• DC-Link film capacitors for energy conversion circuits,

• Power film capacitors for resonant applications such as induction heating, wireless power transfer (IPT & WPT), and medical imaging equipment (MRI, CT scanners, defibrillators).

With its broad and evolving product portfolio, Exxelia Alcon Electronics supports a wide range of industries, including:

• AC drive manufacturers,

• UPS and inverter systems,

• wireless EV charging,

• high-frequency induction heating,

• renewable energy,

• telecom equipment,

• and specialized healthcare and industrial applications such as X-ray, welding systems, and pulse magnetizing equipment.

To meet growing domestic and international demand, the company recently completed a major expansion program, which included increasing its production capacity and building a state-of-the-art R&D laboratory. This facility supports the company’s drive for innovation and modernization and aligns with the Indian government’s “Make in India” initiative.

A major strength of Exxelia Alcon Electronics is its expertise in custom-designed capacitors, which account for approximately 50% of total sales. These products are developed based on a deep understanding of customer applications, emerging technologies, and industry-specific needs. Each stage of design and manufacturing is optimized for performance, reliability, and cost-effectiveness, helping customers choose the right capacitor at the best value.

Currently, 35% of the company’s production is exported to over 20 countries, including the USA, Germany, Japan, China, Italy, and South Korea. Following the latest expansion, Exxelia Alcon Electronics aims to raise exports to 50%. To support this goal, its aluminum electrolytic capacitors now carry the CE mark, and its DC-Link capacitors are UL approved. The company is also certified ISO 9001, ISO 14001, and ISO 45001, demonstrating a strong commitment to quality, environmental protection, and occupational safety in accordance with international standards.

Customer responsiveness is at the core of the company’s commercial strategy. With a technically knowledgeable sales team, Exxelia Alcon Electronics works closely with customers to understand their application requirements, analyze technical challenges, and deliver optimized, cost-effective solutions. The company’s distribution network includes 21 partners in India and 21 others across key international locations, ensuring fast and reliable delivery worldwide.

This customer-centric approach has earned Exxelia Alcon Electronics multiple awards for product quality, service, delivery performance, and technological excellence. Notable companies such as GE Healthcare, Emerson Network, and Fuji Electric have recognized the company for its high standards and reliability.

Exxelia Alcon manufactures a large range of screw terminal aluminium electrolytic capacitors with voltage rating 50 to 500 VDC. Modern manufacturing methodology and equipment ensures good quality and a wide range of capacitance ratings from 330 to 200,000 MFD. In addition to the conventional screw terminal type, special poka yoke type screw terminals are also available. Capacitor with temperature rating -40 to +85° and -40 to +105° rating are manufactured. These have life characteristics of upto 15,000 hours. Custom designed capacitors with cost effective designs, special voltage and capacitance ratings and with higher life expectancy are also available.

Capacitors have an internal design which facilitates efficient cooling. Also, specially designed capacitors with an improved heat dissipation from the base of the capacitor are also manufactured. These types of capacitors are designated as AEST-AL and can be mounted on aluminium water cooled plates or conventional heat sinks.