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Materials for high voltage
Electrical insulation systems for rotating high voltage machines
Why electrical insulation systems are essential
Rotating high‑voltage machines such as hydro and turbo generators, traction motors, and a wide range of industrial drives must operate reliably under extreme thermal, electrical, environmental, and mechanical stresses. Robust electrical insulation systems are therefore essential to ensure machine efficiency, operational safety and long-term reliability throughout the entire service life of the machine.
ELANTAS develops tailor-made insulation systems that support modern high‑performance machine designs enabling increased power density, compact geometries, and extended operating cycles.
Purpose & function
Essential functions of electrical insulation systems
Electrical insulation systems fulfill several essential functions in rotating high-voltage machines. They provide the primary insulation barrier designed for required electrical field strength and controlling partial‑discharges, while maintaining insulation integrity over long duty cycles.
In addition, the electrical insulation system must ensure mechanical stability by withstanding vibration, centrifugal forces, and thermal expansion while supporting coil and end‑winding structures. Protection against moisture, contaminants, and chemical exposure helps preserve insulation performance across the full operating environment.
Electrical insulation materials
Tailored electrical insulation systems for rotating high‑voltage machines
ELANTAS offers a globally aligned range of materials engineered for high‑voltage applications:
- Mica tapes for conductor, main‑wall and end‑winding insulation
- Conductive and semi-conductive tapes, sheets and varnishes for corona protection
- Mica mastics, impregnated tapes and sheets for coil and bar consolidation
- Lashing, protection and auxiliary materials for various applications
- High‑voltage impregnating resins (epoxy, polyester imide, silicone) for VPI and RR processing
The appropriate material selection depends on the winding design of the machine and the manufacturing techniques applied.
For detailed technical or processing recommendations, please get in touch with us!
Portfolio & applications
Full spectrum of rotating high‑voltage machines equipment
ELANTAS electrical insulation systems support a wide range of applications across global power generation, industrial drives and rail transportation markets:
Hydro and turbo generators
Hydro and Turbo generators, which benefit from robust mica insulation and durable resin systems.
Wind power generators
Wind power generators, which have harsh environmental exposure and limited maintenance access demand high reliability and long life.
High‑speed train motors and transformers
High‑speed train motors and transformers, which require lightweight, compact, and highly efficient insulation systems.
Industrial drives and heavy-duty motors
Industrial drives and heavy-duty motors, which rely on high mechanical strength and thermal robustness to support demanding operating conditions.
Gensets
Gensets, which operate under volatile loads, strong vibrations, and temperature extremes.
One system, multiple market segments
All these applications benefit from ELANTAS’ system approach, enabling OEMs to use matching electrical insulation materials. Discover our overview of market segments to learn more!
Transportation
Power generation
Industry
Product brands
Brands tailored to every application
The ELANTAS high‑voltage insulation systems portfolio is offered under a range of established product brands. These include CABLOSAM, ELAN‑VOLT, EPOXYLITE, ISOMICA, MICA MAT, MICA MAX, MIGLASIL, POLY GLAS, SAMICA, SAMICATHERM, and VIPAK. Following the merger of the companies, the long‑standing competence and product portfolio of vonRoll in high‑voltage insulation have been fully integrated into the ELANTAS offering, strengthening the depth and continuity of the portfolio. Together, all these brands provide coordinated solutions for high‑voltage rotating machines, enabling system‑level reliability across diverse designs, manufacturing processes, and operating conditions.
Quality & performance
Consistent quality and long‑term reliability
ELANTAS electrical insulation materials are engineered for stable, predictable performance from manufacturing through decades of machine operation. They offer consistent system behavior, ensuring all insulation components work together reliably. Controlled and reproducible processing characteristics support efficient VPI and resin‑rich manufacturing, while long‑term dielectric endurance helps resist partial‑discharge and corona aging.
The materials maintain thermal and mechanical stability under demanding load cycles and provide strong resilience against moisture, contaminants, and harsh industrial conditions. Extensive testing at both material and system level further contributes to dependable lifetime performance.
Testing & technical expertise
System solutions and engineering support
ELANTAS provides comprehensive technical expertise for electrical insulation systems through dedicated engineering support around the world. Our specialists assist with system selection, processing strategies, and compatibility across tapes, resins, conductors, and auxiliary materials.
In addition, the ELANTAS Institute for High‑Voltage Insulation in Büsserach, Switzerland, offers advanced training, hands‑on diagnostics, as well as testing and validation capabilities, enabling customers to continuously improve their insulation systems.
Global footprint & leadership
High‑voltage excellence worldwide
With a global manufacturing and R&D network, ELANTAS delivers electrical insulation systems to OEMs and service specialists worldwide. The company covers the full value chain - from raw material sourcing to finished insulation materials - and operates sustainable mica mines in Brazil, ensuring secure supply, responsible extraction, and consistent product quality. Through international application laboratories and cross‑regional engineering support, ELANTAS supports customers in power generation, industrial drives and rail transportation markets with proven high‑voltage insulation expertise.
