My Experience in Manufacturing CTC Make AGL Isolating Transformers Since 2020

In a 6.6 A series circuit, the isolating transformer ensures electrical isolation between the primary circuit and the secondary lamp circuit while maintaining continuity across the entire string of fittings. Its reliability directly impacts runway and taxiway safety — a single failed unit (for example, one with an open primary) can affect the whole circuit, not only the fittings near it.

That single fact — one transformer, one point of failure, an entire circuit at stake — is what shaped every manufacturing decision described in this article.

One of the key technical improvements introduced during development was 360-degree machine winding of transformer coils. Instead of manual or semi-automatic winding, we adopted precision-controlled machine winding to achieve:

• Uniform turn distribution
• Better coil compactness
• Fewer voids between turns
• Improved magnetic coupling
• Stable electrical performance

This directly enhanced efficiency, reduced losses, and improved long-term reliability. The objective was not simply to automate manufacturing, but to improve consistency and repeatability in a safety-critical AGL component.

We developed a fully injection-molded transformer body built to the requirements of FAA AC 150/5345-47, issued by the Federal Aviation Administration (this describes design and test to the specification and is not, by itself, FAA equipment certification under AC 150/5345-53). Injection molding reduced the inconsistencies commonly seen in conventional potting methods, and the advantages achieved included:

For underground airfield lighting applications, where equipment can be exposed to moisture and demanding environmental conditions, consistency in construction is particularly important.

Parallel to transformer development, we designed CTC Make ESSNA Connectors — Plug, Receptacle & Inline Connectors — as per FAA AC 150/5345-26. The main focus areas included:

• Robust connector housing
• Corrosion-resistant contacts
• Waterproof sealing system
• Strong strain relief
• Reliable series-circuit continuity

The connectors are compatible with FAA-style L-823 configurations used globally in airfield lighting systems. Their development complemented the isolating transformer programme by addressing another critical part of the AGL series circuit.

To ensure independent validation, we tested all CTC Make AGL Isolating Transformers and ESSNA Connectors at a Government MSME Testing Laboratory in Chennai. Testing covered dielectric withstand, insulation resistance, temperature rise, load testing, and mechanical and sealing checks.

Independent testing was an important part of the development journey — it provided an additional level of technical verification beyond internal manufacturing quality controls.

Building the right ecosystem for CTC manufacturing and testing meant travelling extensively — for selecting high-precision testing instruments, evaluating advanced winding and molding machinery, developing vendors, and validating processes.

We invested in high-tech machinery for manufacturing, ensuring automation, repeatability, and scalable production capacity. Building the manufacturing ecosystem required not only technical decisions but also coordination between machinery suppliers, testing facilities, vendors, and production teams.

From prototype to mass production, we implemented a structured quality-control process:

• Incoming raw material inspection
• In-process quality checks
• Routine and type testing
• Batch traceability

The combination of 360-degree machine winding and injection molding has enabled consistent electrical and mechanical performance across batches. For a critical airport component, manufacturing consistency is essential because reliability must be maintained from one production batch to the next.

Today, our brand has sold more than 15,000 Nos. AGL Isolating Transformers in India and international markets. This growth reflects both technical strength and market trust.

Feedback received from the field so far has been encouraging on moisture-related failures, temperature behaviour and maintenance downtime; it is informal and is not a measured failure-rate study. The journey from product development to wider field adoption has provided valuable feedback about how manufacturing decisions translate into actual airport performance.

This journey strengthened my expertise in FAA specification interpretation, manufacturing process engineering, high-voltage insulation systems, testing instrumentation selection, and cross-functional coordination.

From concept to AAI approval and large-scale market acceptance, I have been actively involved in building a strong and reliable Indian brand for AGL components. The experience has demonstrated that successful aviation manufacturing requires a combination of technical knowledge, process discipline, testing capability, field understanding, and long-term commitment.

The focus going forward remains on:

• Advanced insulation materials
• Improved connector sealing technology
• Enhanced environmental performance
• Global competitiveness under FAA and ICAO standards