Modular Switch Manufacturing Process: Inside Our Mumbai Works
Key takeaways
- Two tracks: insulating parts (body, rocker, plate) are moulded, metal parts (contacts, terminals, springs) are pressed, and they meet at assembly.
- Our catalogue names the materials: polycarbonate (VIYONA, PC sockets), porcelain base (V117–V120A, V263, V1266) and acrylic (Cristal plate V471–V479).
- A plate is a front frame clipped to a base plate. Ours are UV-protected, non-yellowing, 5-year warranty.
- Testing sits between assembly and packing; our own checks are set out in our quality process.
- Every stage is done in-house at our Mumbai works, ISO 9001:2015 certified, across 2000+ products.
What is the modular switch manufacturing process?
The modular switch manufacturing process is the sequence that turns plastic granules, porcelain and metal strip into a finished switch: moulding the body, rocker and plate, making the contact and terminal parts, assembling the mechanism, testing each piece and packing it by the box, usually in that order with checks between stages.
Below, each stage is described as the industry generally does it. Where a code, material or price appears, it comes from our own catalogue: we make everything in-house at our Mumbai works in Marol, Andheri East, and have since 1995.
How are electrical switches made?
Electrical switches are made by moulding an insulating body and operating rocker, producing the metal contacts and terminals separately, then assembling them into a mechanism that snaps on and off, checking that it works and packing it, while the plate is moulded and finished on its own track.
How a modular switch is made: the usual order of stages
Bars show the ORDER of stages only, not time, cost or effort. This is the general industry sequence; in practice moulding and metal parts run side by side and meet at assembly.
Two tracks run in parallel. The insulating parts track covers the body, the rocker and the plate. The current-carrying parts track covers contacts, terminals and screws. A socket shares most steps and adds pin contacts that grip a plug, and often a shutter over the holes.
A switch is only as good as the slowest stage. A perfect moulding with a weak spring still feels loose, and a good mechanism in a poorly moulded body can crack at the screw.
Plate A plate carries no current, so it can take finishes a switch body cannot.
| Stage | What happens (general practice) | Parts made | What a buyer can check |
|---|---|---|---|
| Moulding | Granules melted and injected into a steel mould | Body, rocker, plate frame | No cracks or loose flash |
| Porcelain parts | Ceramic shaped and fired | Bases of heavy-duty parts | Base named in the product code |
| Metal parts | Strip punched and bent on a press | Contacts, terminals, springs | Rating printed on the module |
| Plate finishing | Finish applied, frame clipped to base | Front frame and base plate | Finish even, clips firm |
| Assembly | Contacts, spring, rocker and terminals fitted | Finished module | Crisp click, no rattle |
| Testing | Operation and safety checked | Every module | ISI mark on marked codes |
| Packing | Counted and boxed by code | Boxes of 5 to 50 | Code on the box matches the order |
What are modular switches made of?
Modular switches are made of an insulating body, usually a moulded plastic such as polycarbonate or, for some heavy-duty parts, a porcelain base, with metal contacts, terminals and screws inside it and a separate plate in front, which in our catalogue ranges from plain white to acrylic.
Polycarbonate Our VIYONA range is described in the catalogue as crafted from polycarbonate, and VIZA sockets come in PC versions such as the VIZA 16A socket V263’s sister code V264.
Porcelain base VIZA V117 to V120A are 10A and 20A switches with a porcelain base, and V263 and V1266 are 16A sockets with one. Acrylic The VIZA Cristal plate (V471 to V479) is acrylic. Urea Some VIYONA combined units are listed in urea, and ABS is used for spike guards and plate-type regulators.
The catalogue does not list the contact metal for each switch, so we do not quote one here. In the industry, current-carrying parts are usually a copper alloy such as brass.
Check If the material matters, ask for the code: it is in the product name.
Body, rocker and plate are moulded from insulating material such as polycarbonate.
Contacts, springs and terminals are made separately and decide the rating.
The two tracks meet: mechanism, rocker and terminals come together as one module.
Checked modules are counted and boxed by code, ready to order by the box.
Moulding the switch body, rocker and plate
Moulding is where most of a modular switch takes its shape. In general industry practice, plastic granules are dried, melted and injected under pressure into a closed steel mould, held while they cool, then pushed out as a finished part.
Body The body holds the mechanism and the terminals. Rocker The rocker is the part your finger presses. Front frame and base plate The plate is two mouldings: our VIZA plates are listed as “front frames clipped with base plate”, and the KEMPS Orchid as front frames cupped with a base GSP plate.
A well-made moulding shows it at the screw bosses and clip edges: no hairline cracks, no whitened stress marks and no flash of loose plastic along the joins.
Flash and cracks Papery plastic at a joint or a cracked screw hole is a warning on any make. Fit A rocker that rattles or sits proud of the body points to a moulding that has drifted out of shape.
Why do some sockets have a porcelain base?
Some sockets and heavy-duty switches have a porcelain base because porcelain is a ceramic that does not soften with heat the way plastics can, which suits higher-current parts such as 16A sockets and 20A switches, while polycarbonate versions of the same parts are lighter and tougher against knocks.
Same job, two base materials: MRP of our 16A sockets
Bar length is MRP divided by ₹179, rounded to the nearest 5%. MRPs from our current catalogue. The difference shown is price only; both materials are sold for the same 16A job.
Porcelain is generally shaped and then fired in a kiln, so the base is a separate part. We offer both. The VIZA V1266 16A porcelain socket is ₹179, and the V1267 16A twin socket in PC is ₹170.
16A Porcelain base PC Either is sold for 16A
The base material does not change the rating. A 16A socket is 16A in porcelain or PC; the plug, the wire and the MCB behind it decide whether a heavy appliance is safe. Our guide to 6A vs 16A sockets covers that.
Switch manufacturing process: contacts, springs and terminals
The metal parts decide how a switch behaves under load. In common practice, contact strips and terminals are punched from metal strip on a press, bent to shape, and fitted with contact points where the circuit makes and breaks. A spring gives the rocker its snap, so the contacts open and close quickly.
That is why ratings are printed on the switch. Our KEMPS catalogue lists 10AX 20AX and 32AX switches; the “X” generally marks a switch rated for the harder loads of fans and tube lights. The KEMPS Peony K101 10AX one-way switch is ₹65; the K106 20AX one-way is ₹107; the K116 32AX DP switch with indicator is ₹360.
For lights and fans, a 6A or 10AX switch is the right choice. The higher ratings are for geysers, air conditioners and other heavy points.
6A / 10AX for lights and fans 20AX for heavy points Loose terminal screw A loose terminal warms any switch. Our note on why a switch gets hot or sparks explains what to check.
How are modular switch plates made?
Modular switch plates are made as two parts, a decorative front frame and a base plate that holds the switch modules, which are produced separately, given their finish and clipped together, and it is the finish, from plain white to metallic, wood texture or acrylic, that separates one plate range from another.
Our plates are UV-protected and do not turn yellow, carry a 5-year warranty, and are compatible with all major modular switch systems. Finishes in the catalogue include Metallic Texture and wood textures, and the VIZA Cristal acrylic plate starts at ₹254 for 1M (V471).
KEMPS Orchid plate width by module size (all 95 mm tall)
Bar length is plate width divided by 260 mm, to the nearest 5%. Dimensions as printed in our catalogue for the Orchid plate; square and larger sizes (8M square, 12M, 18M) are taller and are left out here.
Our guide to modular plate sizes shows how to count modules for a board, and the KEMPS Orchid plate range runs from K301 (1M, ₹102 in white) to K309 (18M, ₹520).
Order the plate by module count, not by the number of switches: a 2M socket or regulator takes two spaces.
Assembly: putting a switch and socket together
Assembly brings the two tracks together. Generally, contacts and spring go into the body, the rocker fits over them, and terminals and screws are set for wiring. A socket adds pin contacts and, on many designs, a shutter over the holes.
Our range shows those options side by side. The VIZA V262 6A 2-pin socket with shutter is ₹78, against ₹63 for the V261 without one. The V266 is a 6A 2 in 1 five pin socket with shutter at ₹75.
Shutter Indicator Bell push Rating printed on module
A 2 in 1 five pin socket is a 6A socket. It is not made to take a 16A plug, and forcing one in overheats the contacts.
Where testing fits in switch manufacturing
Testing sits between assembly and packing, but in a well-run works it is not only at the end. Checks at moulding catch a bad part early; checks after assembly catch a mechanism that does not switch cleanly. Our catalogue states that our products undergo a regimen of testing and inspections, and we follow a “first-time-right” approach.
We describe our own checks, step by step, in how we ensure quality in every product. We do not repeat them here.
ISO 9001:2015 Tested before packing Rating on the module ISI mark on marked codes
Some of our codes are sold with the ISI mark, such as the VIYONA 151 and 152 switches. Check the mark on the product itself, not the box. Our guide to spotting a fake ISI mark shows what to look for.
ISO 9001:2015 certifies how the process is run and recorded. It is not a product rating, so read it next to the rating printed on the switch.
Packing: why pack sizes differ by part
Packing is the last stage before dispatch. Small parts go more to a box than large ones, and pack sizes matter to a contractor because you order in boxes.
Pieces per box in our catalogue, by part
Bar length is pieces per box divided by 50. Pack quantities are the “PKG per box” column of our current catalogue. Larger parts pack fewer to a box.
Order by code: invoices also carry the HSN code: our catalogue lists 85365020 for switches, 85366910 for sockets and 85389000 for plates and boxes.
Count a site in boxes before you order. A flat of 18M plates holds 5; a box of 1M switches holds 20.
Check the code on the box The code confirms the right finish.
Modular switch manufacturing company in Mumbai
Vinayak Electricals is a modular switch manufacturing company in Mumbai that has made switches, sockets and plates since 1995 at its own works in Marol, Andheri East, with every stage done in-house and nothing outsourced, under an ISO 9001:2015 certified process, across a range of more than 2000 products.
Since 1995 Marol, Andheri East 100% in-house ISO 9001:2015 2000+ products
Making everything in one place means a fault found at testing goes back to the stage that caused it. Our works in Mumbai is our only manufacturing site; the products reach the rest of India through our dealers. More on the company is on our modular switch manufacturer in Mumbai page, and on why this matters to buyers in made in India electrical products.
One works, one process: every KEMPS, VIZA and VIYONA product is made at our Mumbai works.
What comes off the line: KEMPS, VIZA and VIYONA
The same process makes three series. The KEMPS modular range carries the Peony, Daisy and Orchid switches with codes from K101, in white and grey. The VIZA modular series covers piano, porcelain-base and slim switches and a wide plate choice, from Royal to Cristal. The VIYONA PC series covers everyday switches, sockets and accessories.
Sample MRPs across the three: VIYONA 151 one-way switch with ISI mark ₹74, KEMPS K101 ₹65, VIZA V117 porcelain-base switch ₹95, KEMPS K225 SP MCB ₹295.
KEMPS VIZA VIYONA The range also includes MCBs: KEMPS K225 and K226 are modular single-pole and double-pole MCBs, and the VIYONA MCB is 10 kA.
Series names are brands, not ratings. Choose the rating first, then the series and the finish you like.
What the manufacturing process means when you buy
Before you buy, check four things the process leaves on the product.
Rating printed on the module, and right for the load. Code matching the box and the catalogue. Shutter on sockets in homes with children. Clean moulding with no cracks at the screw holes.
We do not sell online. You can buy our products from our dealers, by phone, or by visiting us; the contact page has the details.
For help putting a board together, our guide on how to choose a switch board walks through modules, plates and ratings. If you sell electrical products, see how to become a dealer or distributor of our range.
No rating printed A switch with no rating on it is one to leave on the shelf.
FAQs
How are modular switches manufactured?
What material is used to make modular switches?
Is a porcelain base better than polycarbonate?
How are modular switch plates made?
Where does Vinayak Electricals manufacture its products?
How can I buy switches made at your Mumbai works?
Why buyers choose Vinayak Electricals
- Every stage done in-house at our Mumbai works, Marol, Andheri East.
- Making switches since 1995, ISO 9001:2015 certified.
- Materials named in the product code: porcelain base or PC.
- Plates that are UV-protected, do not turn yellow and carry a 5-year warranty.
- KEMPS, VIZA and VIYONA: 2000+ products with catalogue MRPs.
- Sold through dealers and by phone, with our dealer network open to new partners.
See what our Mumbai works makes
Browse KEMPS, VIZA and VIYONA switches, sockets and plates by code, then buy from a dealer or call us.
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