Plugs & Moulds
Precision-Engineered Solutions for the Global Wind Industry
Indutch Composites Technology Pvt. Ltd. is a trusted partner for leading wind turbine manufacturers, delivering world-class Plugs and Moulds designed for large, complex composite structures. With deep expertise, advanced engineering capabilities, and world-class manufacturing infrastructure, we support OEMs and blade manufacturers with reliable, high-accuracy tooling solutions that enhance production efficiency and blade performance.
We carefully select combination of high-performance materials to ensure that every plug achieves the highest standards of dimensional stability, machinability, and surface finish. Our material systems are chosen based on part size, complexity, thermal requirements, and customer specifications, such as: Tooling Board, Epoxy Tooling Paste, MDF
Up to 86m long Mould supplied so far.
Summary of End-to-End Workflow
Engineering
Plug Manufacturing
Mould Manufacturing
Final Finishing
Mould Manufacturing Process
Once the plug finishes, mould manufacturing begins.
MOULD
MANUFACTURING
PROCESS
Galactica/ Gantry
It is most important tool for Blade Manufacturing w.r.t the positioning and reduce cycle time. Indutch has expertise in Manufacturing Galactica from 40m to 80 m long blade.
Purpose of Galactica:
Wind blade Moulds are extremely large (40–100+ meters) and require highly accurate surfaces to ensure aerodynamic performance.
- Heavy steel and metallic frameworks
- Precision linear rails
- High load supporting columns and supporting legs
- Integrated platforms for tool heads and machining units
The structure is designed to carry the large dead weight of the mould tool, CNC machine head, and operational loads, without deformation.
Offerings:
- One Galactica can be designed for 2 Moulds.
- Tolerance & Spacing Tolerance
- Repeatability was achieved with 3 Wind Blades without any further adjustment.
- Power backup up to 30 Mins
Jigs & Fixtures
Our specially designed Jigs & Fixtures ensure dimensional accuracy, repeatability, and efficiency throughout the entire composite manufacturing process. These systems are engineered to support large, complex geometries while maintaining high structural stability and quality control.
1. Jigs & Fixtures for Wind Blade Manufacturing
Root End Drilling & Machining Jigs
Bond Line Jigs
Shear Web Assembly Fixtures
Vacuum Infusion
Fixtures
Tipping, Handling & Transport Fixtures
2. Jigs & Fixtures for Mould Manufacturing
Plug Alignment
Fixtures
Plug Alignment
Fixtures
Heating, Cooling & Vacuum Integration Fixtures
Closing & Clamping Fixtures
Gelcoat & Surface Finishing Fixtures
Services
To ensure long-term performance, accuracy, and reliability of Wind Blade Moulds, Indutch Composites Technology Pvt. Ltd. offers comprehensive Annual Maintenance Contracts (AMC). Our AMC program is designed to maintain mould health, improve productivity, and extend the operational life of your Moulds with minimal downtime.
- Surface degradation
- Gelcoat cracks
- Vacuum leakage
- AMC package covers all essential services required to keep the mould performing at peak efficiency.
- Gelcoat touch-up and polishing
- Localized repair of cracks, dents, and surface wear
- Restoring Class-A surface quality
We provide complete Installation & Commissioning (I&C) services for Wind Blade Moulds at customer sites worldwide. Our expert team ensures that each mould is installed with precision, aligned to OEM specifications, and ready for production—ensuring smooth ramp-up and defect-free blade manufacturing.
Composites Experts, Hydraulic Experts, EMT Experts total 80 Experts capable of handling installation of 3 Moulds at the same time.
Complete Installation Support:
- Site Preparation & Inspection
- Mould Placement & Structural Integration
- Alignment of Mould Halves
- Design of Tooling & Process Documentations for Wind Blades
We support OEMs through initial blade trial production to ensure the mould consistently delivers the expected output.
We provide complete Prototype Development and Production Support services for wind turbine blade manufacturers, composite tool makers, aerospace programmes, and industrial composite applications. Our end-to-end capability ensures customers receive rapid development, reliable engineering solutions, and consistent production-quality output.
We specialize in transforming concepts into functional, test-ready composite prototypes. Our engineering and manufacturing teams work closely with OEMs to achieve fast, accurate, and cost-efficient prototype development.
Our Prototype Capabilities Include:
- Rapid Tooling & Plug/Mould Manufacturing
- Material Selection & Process Development
- Prototype Part Fabrication
- Web Mould Adjustment as per Final Glue Gap
Wind Rotor Blade Raw Material Kitting
Indutch Composites Technology Pvt. Ltd. is a trusted partner in the design, engineering, and manufacturing of Raw Material (RM) Kitting solutions for the wind rotor blade industry.
With 15+ years of composites expertise, we support global wind OEMs and blade manufacturers with high-quality, cost-effective, and precisely engineered kitting solutions. We have a dedicated Plant for Kitting Business having 1,12,680 sq ft area.
At Indutch, kitting is not just an activity — it is our core competence.
Our Kitting Capabilities
- Core Kitting – Rigid/Flex Balsa & PET/PVC Foam
- Glass Fabric Kitting
- Infusion Supporting Materials
- Root Closers
- Manhole Covers & Bulkheads
All kits are delivered ready-to-use, optimized for faster blade lay-up and reduced shop-floor variability.
Design & Prototyping Excellence
Perfect core fitment is critical for blade quality and performance.
- Engineering from customer drawings & mould data
- Prototype kits developed to match exact mould curvature
- On-site engineering support during prototype trials
- Multiple iterations ensured for best fitment inside blade moulds
Our engineers bring strong hands-on blade manufacturing knowledge, ensuring smooth transition from prototype to series production.
Advanced Manufacturing Infrastructure
All kits are produced with high accuracy and repeatability, using:
- 5-Axis CNC Machining
- 3-Axis CNC Machining
- CNC Multi-Drilling Machines
- Specialized surface finishing equipment
Technical Expertise
- Foam processing up to 200 kg/m³ density
- Advanced profiles:
- ML Core
- Flat-Back Core
- Bonding Edge Core Panels
- LPS Core
Continuous process monitoring ensures stable, sustainable, and scalable production.
Our USP – Quality & Reliability
- Zero-Defect Quality Philosophy
- Strict adherence to specifications
- On-time delivery with agile manufacturing
- Highly competitive and affordable commercial solutions
Quality is the cornerstone of our competitiveness, and the reason customers trust Indutch.
Proven Track Record
- 12,000+ Raw Material kits manufactured and delivered in the last 9 years
- Successful exports of core kits and composite components
- Trusted by leading global wind blade manufacturers
Why Indutch?
INDUTCH
Kitting
Integration
Supply
Focused
Serial Production
Wind Blade Internal Components
We supply a full range of precision-engineered internal components used in modern wind turbine blades. Each component is designed for structural reliability, aerodynamic efficiency, safety, and long-term durability. All items are manufactured as per OEM specifications with high accuracy and fully traceable materials.
Balancing Tray / Balancing Chamber
Reinforcement Ring
TE Serration (Trailing Edge Serration)
TERF Foam Set
Access Panel
LAR (Lightning Attachment Receptor)
Root Bulkhead
Support Plate
Root Bush
Rotor Blade
Access Ladders / Hatches
Hub Cover / Nose Cone
Spinner
Brackets & Mounts
Fasteners & Bolts
Lightning Protection
Vibration Dampers
FRP Cable Trays
Turbine Components
Indutch Composites Technology specializes in the engineering and manufacturing of high-performance composite components for modern wind turbines. Our solutions are designed to ensure durability, aerodynamic efficiency, and long-term reliability in demanding operating environments. Key turbine components supplied by Indutch include:
Nacelle Cover
Spinner Cover
Heli-Hoist Platform / Heli-Hoist Cover
Climb-Free Cage
Contract Manufacturing
We offer complete Wind Blade Contract Manufacturing solutions for global Wind Turbine OEMs. With state-of-the-art composite facilities, advanced engineering capabilities, and process-driven execution, Indutch delivers high-quality rotor blades that meet stringent international standards.
Our contract manufacturing services cover the full lifecycle of blade production, including:
Transport Frame
Sea-Worthy & Road-Worthy Solutions by Indutch Composites Technology
We design and manufacture high-performance Transport Frames engineered to safely secure and transport Wind Turbine Rotor Blades and critical blade components across long distances. Our frames are built to withstand the demanding conditions of both road transport and marine shipment, ensuring complete protection and stability throughout the logistics cycle.
Sea-Worthy Transport Frames
Our sea-worthy transport systems are developed to meet international marine logistics requirements.
Road-Worthy Transport Frames
Indutch road-worthy frames are optimized for highway, city, and site movement: Our frames reduce handling risk and transportation time, ensuring safe and damage-free delivery from plant to wind farm.
Blade & Turbine Service
We provide comprehensive Blade Turbine Services designed to support Wind Turbine OEMs and asset owners throughout the entire lifecycle of rotor blades. With deep expertise in composites, advanced inspection technologies, and precision engineering, Indutch ensures long-term blade performance, reliability, and operational efficiency.
Blade Inspection & Health Assessment
Blade Repair & Refurbishment
Blade Repair & Refurbishment
Blade Repainting & Surface Treatment
Root End & Bonding Line Restoration
Blade Balancing, Weight Adjustment & Profiling
End-of-Life Blade Solutions
Blade Root Bush Refit Solutions
We provide specialized Wind Blade Turbine Services supported by certified manpower, proven industry experience, and the capability to handle complex blade service challenges across diverse site conditions and geographies.
Manpower & Certifications
- 200+ Skilled Technicians dedicated to wind blade inspection, repair, and maintenance activities
- All technicians are GWO Certified, ensuring compliance with global safety and operational standards
- 20 Technicians are IRATA Certified, enabling rope access solutions for high-risk and hard-to-reach blade operations
Experience & Customer Base
Indutch has delivered Wind Blade Turbine Services to leading OEMs and Independent Power Producers (IPPs), both in India and internationally.
OEMs / Technology Providers
- Acciona
- Nordex
- Suzlon
- Envision
- Vestas (India, Taiwan, Morocco)
Independent Power Producers (IPPs)
- Greenko
- Ecoren
- Apraava
- ReNew Power
- CleanMax
- Sembcorp
- Continuum
- Powerica
Our Strength
What is not possible by others is possible by the Indutch Blade Service Team.
Our technical expertise, certified workforce, and field-proven execution enable us to deliver reliable blade service solutions while maintaining the highest standards of safety, quality, and efficiency.
Why Choose Indutch for Blade Turbine Services?
- Team of trained composite specialists and certified blade technicians
- Experience across leading global OEM blade models
- Advanced tools, jigs, fixtures, and repair infrastructure
- Fast turnaround time with high-quality documentation
- Support for onshore and offshore wind turbines
- Commitment to safety, compliance, and long-term blade reliability