Packaging Solutions by Wire Journal International, Inc.

WIRE JOURNAL APRIL 2010

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I N T E R N A T I O N A L w w w. w i r e n e t . o r g

Packaging Solutions

update OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . 6

CONTENTS

Volume 43 | Number 4 | April 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 28 Update: Wire Expo 2010 . . . . . . . . .36

Fastener Update . . . . . . . . . 30 WAI News . . . . . . . . . . . . . . 32 Chapter Corner . . . . . . . . . . 34

A brief update on WAI’s traveling road show, which will be co-located with two other industry events in Milwaukee at the Midwest Airlines Center. It includes news on AWPA’s seminar and the Electrical Wire Processing Expo as well as comments from some Wire Expo exhibitors who supply reels and spools.

Technical Papers . . . . . . . 66-82 Products/Media . . . . . . . . . . 84

Packaging Technology . . . . . . . . . . .44

Classified . . . . . . . . . . . . . . 91

This feature presents a range of technology from suppliers or reels and spools as well as an on-line presentation of automated packaging equipment and more.

Career Opportunities . . . . . . 91 Advertisers’ Index . . . . . . . . 94

T ECHNICAL

SECTION

European developments in the reaction to fire testing of cables Terence Journeaux . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Plan ahead! June 2010 WJI • wire Düsseldorf wrapup • Ancillary equipment

Estimation of standard PN-EN 10264 – steel wire for rope Jan Krnac, Rafał Włudzik, Jan W. Pilarczyk, and Robert Kruzel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Material savings by utilizing in-line dimensional measurement and control Kevin Weaver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Cover: Suppliers of packaging equipment, a staple of the wire and cable industry, continue to strive to offer better solutions, which increasingly means that a “green” focus will be part of the overall package.

APRIL 2010 | 3

INSIDE THIS ISSUE CONTENTS

U PDATE : W IRE E XPO 2010 . . . . .36

POINTED MEETING

. . . . . . .11, 32

Scheduled in conjunction with Wire Expo 2010.

Co-located with Wire Expo 2010.

Wire Expo 2010, the National Electrical Wire Processing Technology Expo and the American Wire Producers Association, which will stage its first Long Products Supply Chain Symposium, have largely finalized their respective events, to be held the week of May 10 in Milwaukee, Wisconsin, USA. This update presents a few more details, but for the most complete information—and a sign of the times—it’s best to visit the organizations’ respective websites.

An over-the-shoulder look at the screen displays of WAI’s computer guru, Chuck Syzmaszek, who masterminded the new technology that went into the WAI’s March 11 Points Meeting for Interwire 2011. See p. 11 for a photo of the “live” floor plan, and p. 32 for more details.

Visit us at Wire Expo booth #608

4 | WIRE JOURNAL INTERNATIONAL

EDITORIAL WIRE JOURNAL

EDITORIAL

I N T E R N A T I O N A L

Toyota’s problems remind us not to ever take manufacturing quality for granted

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Senior Graphic Designer | Bill Branch

Every few years, something happens in the operations area that causes a review of standard operating procedures. It might be something predictable, such as equipment replacement, a new supplier, or product enhancements. These are controlled, manageable exercises that are typical in the manufacturing business. However, in some cases, quality problems are the trigger and the stakes increase exponentially. Imagine the discussion, debate and dissection taking place within and around Toyota as a result of the quality problems that have occupied the headlines for weeks. Every procedure, quality specification and engineering design is being reviewed and tested. Even the deeply embedded culture of Kaizen is going to get tested. It will be years before the full cost of the Toyota’s quality lapse can be calculated, as the immediate implications are just surfacing. Clearly, billions of dollars are in play with regard to recall costs, lost sales, future discounting, market share, brand image, lawsuits, employee satisfaction and public relations. The damage extends to Toyota’s suppliers, who are facing additional testing costs while production is reduced, and to existing customers, who won’t see the same resale value (like me). It was even suggested that there will be implications for the overall Japanese export market and, of course, any consultant specializing in Kaizen must feel a little uneasy. Quality problems are learning experiences that remind us that manufacturing is our business and that continuous improvement is not about cost cutting. Over the years, systems have been established to improve quality, and significant investments have been made in all stages of production as part of efforts to perfect the process. However, as Toyota has proven, quality is a goal that one can never file away with a “Completed” stamp. Past excellence is not a guarantee of future excellence. While the economic downturn causes delays in capital expenditures, reduced training, and cost cutting in engineering, Toyota’s trouble will serve to swing the pendulum back to the center.

Steve Fetteroll WAI Executive Director

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2010 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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Cornelia Fischer, Sales Manager, SIKORA ITALIA

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CALENDAR

CALENDAR April 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com. April 27-28, 2010: Polymers in Cables 2010 Orlando, Florida, USA. To be held at the Radisson Resort Orlando-Celebration. Contact: Margit Korsak, tel. 610-478-0800, mk@amiplastics-na.com. May 9-11, 2010: AWPA Long Products Supply Chain Symposium and AWPA Annual Meeting Milwaukee, Wisconsin, USA. The American Wire Producers Association (AWPA) is organizing this new symposium, to be held May 10-11 at the Pfister Hotel, as well as holding its Annual Meeting on May 9-10. Contact: Heather Outhuse, AWPA, tel. 703-299-4434, www.awpa.org. May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event will be co-located with The National Electrical Wire Processing Technology Expo and in conjunction with AWPA’s Long Products Supply Chain Symposium. Contact: WAI, tel. 203-4532777, www.wirenet.org. May 12-13, 2010: The National Electrical Wire Processing Technology Expo Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event will be co-located with Wire Expo 2010. Contact: Jay Partington, Expo Productions, Inc., tel. 262-367-5500, www.expoproductionsinc.com. Sept. 21-24, 2010: wire China 2010 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe

Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 18-20, 2010: ITC Mexico Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities. Contact: WAI, tel. 203-453-2777, www.wirenet.org. Oct. 27-Nov. 3, 2010: K 2010 Düsseldorf, Germany. This event for the plastics and rubber industry will be held at the Düsseldorf Fairgrounds, Halls 1-17. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. Organized by the Confederation of Indian Industry (CII), this event will be held at the Bombay Exhibition Centre in Goregaon. Contact: CII, tel. 91-2224931790, www.cii.in/. May 3-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. June 19-23, 2011: JI Cable Versailles, France. This multi-organizer international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1Cable 11, www.jicable.org. ■

W IRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; Internet www.wirenet.org. May 12-13, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. See main listing. Oct. 18-20, 2010: ITC Mexico Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities. May 3-5, 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

8 | WIRE JOURNAL INTERNATIONAL

March 5-8, 2011: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland. WAI’s Poland Chapter members are among those organizing this event, which will present theoretical and practical research results. Topics include: steel wire and wire products; nonferrous wire and wire products; electrical wires and special products; and poster papers. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl; www.konferencja.mim.pcz.czest.pl.

INDUSTRY NEWS

INDUSTRY NEWS CommScope to relocate Newton manufacturing operations

Leoni AG reports Siemens order for range of cables for its MRT units

U.S.-based CommScope, Inc., announced that it plans to relocate cable production from its facility in Newton, North Carolina, later this year, a move that will result in the loss there of approximately 85 hourly and salaried employees. A press release said that CommScope will consolidate the Newton wireless network cable production into a larger existing manufacturing facility in Joliet, Illinois, an action that it noted was expected to begin in September and be completed by year-end. “These actions are difficult yet unavoidable, and we regret the impact on our employees,” said CommScope Executive Vice President and Chief Supply Officer Randy Crenshaw. “We are in the midst of a comprehensive review of our global manufacturing footprint as we work to improve facility utilization, minimize cost and protect the profitability of our business in response to reduced—and more volatile— customer spending patterns.” CommScope’s Newton facility also houses another approximately 45 workers in non-manufacturing roles who are unaffected by the production relocation, said the release, adding that those staffers will remain at Newton, pending a decision about the facility’s long-term future. “As we transition production from Newton to Joliet, we intend to ensure that customers continue receiving the superior service that they have come to expect from CommScope,” Crenshaw said. The action was expected to cost the company between $3 million and $4 million, and once completed, to provide annualized savings of the same amount, the release said.

Germany’s Leoni AG announced that it has begun providing the latest generation of Siemens magnetic resonance tomography (MRT) units with standard and special cables, a follow-up contract that it saw “is worth an eight-digit euro amount.” “Thanks to this order we are consolidating our position as a supplier for the healthcare sector,” Dr. Klaus Probst, CEO and president of Leoni, said in a press release. “We consider medical technology to be an important market of the future, which will need more and more high quality cable systems.” With the latest contract, Leoni has continued its successful collaboration with one of the largest providers in the healthcare sector, it said, noting that the relationship has worked well for both parties. “Leoni qualified thanks to its extensive range of products and services, an international footprint and our good collaboration on past projects,” said Thomas Bank from the magnetic resonance purchasing Leoni is providing the wiring for Siemens’s latest department of Siemens’ Healthcare sector on award generation of MRT units. of the new contract. The release said that Leoni already provided the wiring for the Magnetom Avanto and Espree MRT units from Siemens. “With its latest Magnetom Aera and Skyra generation, Siemens again sets trends by supporting patients and hospitals in a forwarding-looking way with respect to their primary objective of getting the best possible diagnosis while simultaneously increasing productivity.” The MRTs require glass and polymer fiber optic cables and copper conductors in the form of coaxial and symmetrical cables as well as fully assembled and ready-to-install cable systems, the press release said. The cables must provide the correspondingly efficient data and signal transmission for as well as power supply to the devices, it said, adding that Leoni has also developed a number of special hybrid cables that perform several functions with a smaller outer diameter and thus reduce the weight of the units. The new mobile table, which is used with these MR units for faster preparation of patients for scans, is also fitted with Leoni cables, it said.

General Cable acquires French-based ignition wire harness manufacturer U.S.-based General Cable Corp. reports that it has acquired Beru SAS, a manufacturer of ignition wire harnesses, from BorgWarner France SAS, which is a business of U.S.-based BorgWarner, a global automotive industry components and parts supplier. Beru will operate as General Cable Automotive Europe (GCAE), a press release said. It noted that General Cable already has wire harness manufacturing operations in the U.S. and Mexico and that this acquisition “is an important step in the globalization of our ignition wire harness business and supports the strategy to participate in the increasingly homogenous global market for these products.”

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

Approximately 70% of booth space booked at Interwire 2011 Points Meeting The above image reflects activity at the March 11 Points Meeting held at WI’s headquarters. See p. 32. The dark booths represent those that were booked. To see who took what, go to www.wirenet.org and click on the Interwire logo.

Southwire expands its range of cable products for HVAC market U.S.-based Southwire Co. announced that it has expanded its range of products for the HVAC (Heating, Ventilating and Air Conditioning) market with the acquisition of equipment from Ford Wire, a U.S. producer of HVAC products based in Florida. The deal, which does not include the manufacturing plant, will enable Southwire to further diversify, a press release said. “Today marks a new direction for Southwire as we build upon our commitment to provide the best products and service in the HVAC market,” said Stu Thorn, Southwire’s president and CEO. “While Southwire already manufactures a limited line of cables used in the production and installation of HVAC equipment, this acquisition allows us to expand that product offering and better assist those serving the industry.” Southwire OEM Division President Norman Adkins said in the release that the acquisition fits perfectly with the company’s strategy to explore new market

segments, while developing closer ties to its customers. “It’s very important that we forge strong relationships with our customers and remain sensitive to their needs,” he said. “Exceeding our customers’ expectations has been a key to our success. We must continually focus on what they think is important and on what truly delivers value. Our customers expect to grow and we must grow with them by offering a compelling, competitive advantage.” In other new news, the company reported that it has laid off another 18 of the 38 employee at its Watkinsville plant, which last year saw some 80 positions cut because of weak demand.

Central Wire Industries expands with rod mill acquisition, more Canadian-based Central Wire Industries Inc. announced that the company has acquired Charter Steel’s U.S. wire rod finishing mill in Fond du Lac, Wisconsin. The facility, a press release said, consists of an automated pickling line, batch annealing and finishing APRIL 2010 | 11

INDUSTRY NEWS

capabilities, with advanced computerized system that assure exceptional levels of surface finish, dimensional and metallurgical consistency. The acquisition allows Central Wire to expand its product line into a broader array of ferritic and martensitic stainless steel grades up to 1.0 in. diameter, the release said. In addition to serving the company’s traditional customers, focusing on cold heading wire and high-temperature, corrosion-resistance grades, this acquisition will also provide pickling and annealing services to rod producers requiring improved surface quality and consistency of product, it said. In other news, the company reported that it also acquired the bearing steel division of Hitachi Metals and transferred the equipment to its U.S. facility in Lancaster, South Carolina. The facility, in operation since January 2009, produces bearing steel and other alloys in coil form, centerless ground bar and blanks for machining and ball bearing applications servicing the automotive, medical and other business sectors. The Lancaster location can also supply stainless and nickel wire from .030 in.- .750 in. in coil form, reels and payoff packs for the forming, cold heading, weaving/belt and spring wire markets. Central Wire’s growth in recent years, the release said, is “the result of an aggressive pursuit of product quality combined with the acquisition of facilities consistent with the company’s long range plans.”

the additional stake … was taken given the increased strategic focus from El Sewedy’s management on the wind energy sector as one of the fastest growing industries worldwide during the last four years.” El Sewedy believes that it is well positioned to capitalize on part of this growth especially in its main operating domain of Africa and the Middle East where abundant wind resources and a growing need for different sources of energy makes this a market of huge potential, the release said. With its majority stake in MTOI, El Sewedy Cables will be manufacturing the majority of the components of a wind farm (turbines, towers, cables, transformers, transmission lines, etc.). The ability to offer those components besides the contracting and engineering activities, will help El Sewedy consolidate its position in the wind energy sector, the release said, noting that MTOI is developing a 2.5 megawatt turbine for early 2011, and that the two companies have already signed a contract to supply and install 60 MW of wind power technology worth 82 million euro in North Africa and an additional 36 MW worth EUR 38 million in Europe.

Nexans reports Chinese contract

Nexans announced that it has won a US$13 million contract to supply more than 10,000 km of its FLAMEX® cables for China Railway high-speed trains. The contract calls for Nexans to supply the cables, to be used for 79 train-sets, to CNR Corporation Limited, a El Sewedy Cables expands scope Chinese state-owned vehicle producer, a press release said. The cables will be used for China Railway HighEgypt’s El Sewedy Cables Company S.A.E. reports that speed (CRH) trains that will enter service between it has increased its stake from 30% to 90% in Manuel Beijing and Shanghai in 2011, it said, adding that the Torres Ólvega Industrial (MTOI), expanding its scope as cable will be manufactured at Nexans Chinese production a supplier of wind farm technology. facilities in Waigaoqiao and Baoshan, both in Shanghai. A press release said that, in 2008 El Sewedy Cables Delivery is scheduled for completion by next March. made its initial 200 million euro investment in MTOI, “This is one of the biggest spot orders for Nexans which supplies key components used for wind farms. Rolling Stock business,” said the release, which noted That deal allowed for further investment, which has been the following. The cables will be delivered to CNR successfully renegotiated so an additional 60% of the subsidiaries that are responsible for developing and shares could be acquired, it said. “The decision to acquire manufacturing the high-speed trains. The new CRH trains will include 16 cars, have a design speed of 350km/h, and be able to carry up to 1,026 passengers, it said. “Nexans cables were selected by CNR because we demonstrated high levels of quality, technical High quality steel reels services, an ability to meet tight and handling systems deadlines, thanks to our local Visit us at WIRE Expo USA 2010 factories in China,” the release 2010 said. The company noted that it had Booth 320 previously been awarded a contract Wire Machine Systems, Inc. in 2009 from CNR for control, Ph: (260) 483-9269 E-Mail: sales@wire-machine.com power and data cables for the IWE Spulen und Handling GmbH same project. Dieselstraße 3 · D-96465 Neustadt bei Coburg · Phone: ++49(0)95 68-854-0

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INDUSTRY NEWS

Vandor division plans expansion Reel Options, a division of Vandor Corporation based in Richmond, Indiana, USA, announced that it plans an expansion that will create 16 new jobs. A press release from the Board of Directors of the Economic Development Corporation of Wayne County, Indiana, said that it will provide approximately $15,000

to help the Vandor business with its planned investment of $975,000 to purchase new equipment for a new product line that is expected to result in 16 new jobs. It noted that the Reel Options brand was developed by Vandor in 2000 to provide packaging reels injection molded from reprocessed plastic, and that the new machinery will allow the company to produce plywood reels and utility spools. The company noted that it has added an extrusion line to make plastic tubes from 2 in. up to 8 in. diameters. The plastic tubes, which serve as cores for the reels, will coincide with the addition of a spin welding machine to make plastic utility spools, it said. “We already have tooling in place for the utility spool flanges (6.5 in. and up) and the spin welder will be in within weeks. We will offer any of our reels, including plywood flanged reels, with plastic tubes. That’s a plus for companies worried about long term weather exposure on paper tubes.”

EIS Wire & Cable this year celebrates centennial anniversary U.S.-based EIS Wire & Cable (EIS), a privately owned manufacturer of custom, bulk wire and cable products, is celebrating 100 years in business. Based at its 125,000 sq-ft plant in South Hadley, Massachusetts, USA, EIS was founded in 1910 as Holyoke Covered Wire Company. A

press release noted that achieving a century in business is significant, especially with more recent factors, such as globalization, economic instability and geopolitical turbulence. “The perseverance and adaptability of the company have helped it endure changes in ownership, the creation and obsolescence of technologies and

14 | WIRE JOURNAL INTERNATIONAL

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INDUSTRY NEWS

the emergence of intense global competition in the marketplace.â&#x20AC;? â&#x20AC;&#x153;EIS would not have persisted and prospered over the past 100 years were it not for the innovative spirit, professionalism and commitment of its employees which, throughout its history, have been residents of western Massachusetts,â&#x20AC;? said Nick Moceri, EIS President and a partner of the Providence Capital Group, which has

owned the company since 1998. â&#x20AC;&#x153;Interestingly, recent years have seen EIS fuse the distinctly American history and values that have sustained it with cutting edge, internationally recognized management principles such as the LEAN Manufacturing, â&#x20AC;&#x2DC;continuous improvementâ&#x20AC;&#x2122; System,â&#x20AC;? he said. EIS Wire & Cable operates out of a 125,000-sq-ft facility in South Hadley.

Goldman Sachs sells final Prysmian stake Visit us at Wire Expo booth #712

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Goldman Sachs Group Inc. reported that it has sold its remaining 16.8% stake in Prysmian SpA, which came about from its 2005 acquisition of Pirelliâ&#x20AC;&#x2122;s Energy and Telecom Cables and Systems business, for approximately US$1.6 billion. The deal, part of Pirelliâ&#x20AC;&#x2122;s refocusing on its core businesses, included operations that had 2004 sales of US$3.2 billion, with 52 plants around the world and some 12,000 employees.

National Standard to offer RevWires wire

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U.S.-based National Standard, a Heico Wire Company, reports that it has entered a strategic alliance with RevWires LLC of Troy, Ohio, that will enable it to offer the Troy companyâ&#x20AC;&#x2122;s cored welding wire. A press release from National Standard, a large supplier of solid carbon and stainless wire to the North American welding industry, said that RevWires manufactures â&#x20AC;&#x153;measurably superior cored welding wire.â&#x20AC;? RevWire combines proprietary international and U.S. patentpending machinery and processes with a modern facility to produce products that are unique to the worldwide welding industry, it said. â&#x20AC;&#x153;This partnership provides National Standard with an important new product, cored wire, to complement and complete its already extensive product lines,â&#x20AC;? said Heico Wire Group President and CEO Jim

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INDUSTRY NEWS

Hillebrandt. The release described the partnership as “a critical step by National Standard to meet its strategic objective to be a full product line supplier to the welding industry.”

Huawei Marine wins Networks reports winning contract for Libya cable project Huawei Marine Networks Co., Ltd., announced that it has a contract for the Libya LPTIC T-E submarine cable project, to provide end-to-end turnkey submarine system solutions for the venture, which will connect the Libya coastal cities of Tubrok and Emasaed. A press release said that the system will have a total length of about 177 km and be designed to carry a maximum capacity of 3.2Tbit/s. The completed system will integrate the whole country of Libya’s backbone network, providing a more extensive route protection, as well as improve the country’s international communications bandwidth, to meet the continuous increase of Libya’s external communications demand, it said. The project is expected to be delivered in the middle of 2010. “We are very pleased to cooperate with Huawei Marine (as) its technical solutions very well meet our needs,” it said.

LPTIC, a state-owned telecom carrier in Libya, notes that its business includes fixed, mobile, the Internet and so on. Following the mission to provide people with the best telecommunications services, LPTIC has achieved a continuous expansion in Libya’s domestic market in recent years, and now begins to set foot in North Africa, the international market.

News briefs Robert Wilson, sales vice president of York Wire & Cable, Inc., has been appointed by Secretary Locke of the U.S. Dept. of Commerce as the newest member of the Industry Trade Advisory Committee on Small and Minority Business (ITAC ll), which operates with the Commerce Department and the U.S. Trade Representative office. The committee supports government and private industry efforts when negotiating trade agreements with other nations. The 28 members offer technical advice on patterns of actual and potential competition between the U.S. and foreign enterprises in international trade, with issues including market Robert Wilson

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INDUSTRY NEWS

access, customs matters, foreign investment and intellectual property protection. â&#x20AC;Ś Cicoil Corporation has been recognized for its quality and delivery performance by Raytheon Integrated Defense Systems. Cicoil received a 4-Star Supplier Excellence Award at a recent ceremony held at Gillette Stadium in Boston, Massachusetts. Cicoil was recognized for its 100% quality score and 100% on-time delivery performance in 2009. Cicoil highperformance cable assemblies are used in many of Raytheonâ&#x20AC;&#x2122;s advanced missile systems, including AIM-9X Sidewinder, RAM Missile, EKV, and Patriot Missile systems. â&#x20AC;&#x153;We are extremely pleased to be honored by Raytheon with this prestigious award,â&#x20AC;? said Cicoilâ&#x20AC;&#x2122;s CEO Howard Lind (pictured). â&#x20AC;&#x153;Raytheon has over 5,000 suppliers, and to be recognized as one of only 40 suppliers to receive a 4-Star Award is a tremendous achievement.â&#x20AC;? â&#x20AC;Ś Pelican Wire Company, Inc., reports that the company achieved a long-time goal by being ISO 9001:2008 certified. The effort was headed up by

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Pelican staffers, from l-r, Joe Karkoski, CFO; Ted Bill, President; Martha Langston, Director of Quality Control; Theresa Bill, Founder & Corporate Secretary; Bob Ferris, VP of Operations. Pelicanâ&#x20AC;&#x2122;s Director of Quality, Martha Langston, who joined the company two years ago. A press release noted that ISO certification â&#x20AC;&#x153;had been a distant dream for Pelicanâ&#x20AC;&#x2122;s founder, Larry Bill but it wasnâ&#x20AC;&#x2122;t until his son, Ted Bill, took over the company reins that the dream started to coalesce into probability.â&#x20AC;? Pelican Wire was aided in the effort by a grant from the state of Florida that covered about half the consulting costs. â&#x2013;

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ASIAN FOCUS Prymsian has plans for Asia expansion Prysmian, among the worldâ&#x20AC;&#x2122;s largest cable companies, has revealed ambitious plans to grow its market presence in both China and India as part of a global expansion program. Speaking at the FTTH Council conference in Lisbon, Prysmian Telecoms Business Director Hakan Ozmen said that while Prysmian already has facilities in China and major customers there that include China Unicom, China Telecom and China Mobile, he was looking for new partners as part of a bid to increase market share. In India, where Prysmian has a successful partner network, Ozmen said that the company was now considering establishing production within the country to further boost its presence. Those comments follow Prysmianâ&#x20AC;&#x2122;s stated goals of making Asia a major part of its business. In 2008, Prysmian opened a new plant in Tianjin, and at that time the company had five plants and more than 1000 employees. It has also taken an active role in India, including taking a majority stake in the Indian group of Ravin Cables.

Ravin is one of India's most competitive and reputed cable manufacturers, with a range including low- and mediumvoltage cables and a market that also extends to Africa and the Middle East. Apart from its principal manufacturing facility in Pune, near Mumbai, Ravin is also present in the Emirate of Fujairah with the company Power Plus Cable Co. LLC, a joint venture with the Government of Fujairah, and for which it is in charge of operational management. â&#x20AC;&#x153;We are very pleased we have found a well-reputed, well managed and competitive partner in India who is also present in the Middle East, with whom we look to pursue a growth strategy with a primary focus on the development in the areas of high-tech cables for utilities as well as industrial cables,â&#x20AC;? said Prysmian Chief Executive Valerio Battista.

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India’s ISWP plans to build new mill Indian Steel and Wire Products (ISWP) is set to launch an expansion program, backed by Tata Steel, which took over the company in 2003. The company’s goal is to build a new Thermomechanical Mill Treatment (TMT) mill and procure wiredrawing machine (GF1) from Tata Steel’s wire division, based in Mumbai. The original ISWP was formed following World War I, but the business struggled, closing more than once, most recently in 1998, at which point it was then referred to the Board for Industrial and Financial Reconstruction (BIFR). After being closed for six years, ISWP struck a deal with Tata Steel on December 20, 2003. The ISWP manufactures wire rod, cast-iron, and steel-based rolls.

Copper demand weak in China, lacks ‘power’ Copper demand in China, the world’s largest consumer of the metal, is “weak” because of lackluster consumption from the power industry, according to the Tongling Nonferrous Metals Group Co., The Cable Directory reports. “From what we learned from our customers, copper demand is now weak,” Chairman Wei Jianghong said in an

interview in Beijing, the article noted. Slowing demand in China may indicate stockpiles in the country may continue to climb after reaching the highest level in more than seven years in February, it said, noting that Goldman Sachs Group Inc. recently ended its recommendation to bet on higher copper prices because of concern that economic recovery in developed markets isn’t on “solid footing.” “About 60 percent of copper is used in the power industry, and our sales to wire and cable users reflected that demand is rather weak,” the article cited Wei as saying while attending the National People’s Congress.

Cords Cable announces expansion plans India’s Cords Cable Industries announced that it will undergo a US$1.9 million expansion plan to augment its cable capacity, especially for specialty cables. Naveen Sawhney, managing director, Cords Cable Industries, said that machinery orders have been placed and work has begun on the project in the Alwar district in Rajasthan. Much of the cable production will go toward the power industry, refineries, airport modernization, metro railways, he said. The company expects about 20 to 25 percent of its products will be sold in the overseas markets across Eastern Europe, the Middle East, and Africa. ■

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ASIAN FOCUS

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PEOPLE

PEOPLE Mark Mulone has joined Guill Tool & Engineering Inc. as global sales representative manager for the representative organizations that handle the complete line of Guill’s tooling and equipment, especially for wire and cable applications. He has more than 20 years of experience in extrusion and interrelated busiMark Mulone nesses, having served as an applications engineer for Teledyne Farris Engineering, and as a project engineer and a sales engineer for Coperion, for which he later handled all of its Latin American sales efforts. He also served as national sales manager for the Conair Group, and vice president of U.S. sales for SIG Plastics Technologies Inc. He has authored technical papers and holds a B.S. degree in mechanical engineering from Roger Williams University. Based in West Warwick, Rhode Island, USA, Guill Tool & Engineering Co., Inc., supplies extrusion tooling for sectors that include wire and cable.

Lloyd & Bouvier, Inc., has named Doug Sedgwick as the company’s general manager, effective immediately. Along with his general manager responsibilities, he will remain active in sales and marketing for Lloyd & Bouvier. A 15-year veteran of the wire and cable industry, Sedgwick most recently worked for The Gauder Group USA as its sales manager, based in Atlanta, Georgia. He previously held positions in sales and project management at Skaltek and at Canterbury Engineering. He holds a bachelor’s degree in business administration from the Doug Sedgwick University of Wisconsin. He is a member of the Wire Association International and the Association of Machinery and Equipment Appraisers. Based in Clinton, Massachusetts, USA, Lloyd & Bouvier, Inc., provides rebuilt, new and used equipment to the wire and cable industry as well as appraisal services and more.

Visit us at Wire Expo booth #108 24 | WIRE JOURNAL INTERNATIONAL

OBITUARIES PEOPLE

Peter Farago, 87, the founder of New England Printed Tape Co. (NEPTCO), in Pawtucket, Rhode Island, died at his home in Florida on Sunday, Feb. 21, 2010. A holocaust survivor, he endured more than a year of forced labor before escaping, and became an asset to the U.S. military and its agencies. In 1948, he entered the Peter Farago U.S. and enrolled at the Rhode Island School of Design and married his wife, Daphne, in 1951. He earned a B.S. degree in textile engineering in 1952, and in 1954 he established NEPTCO, a supplier to the insulated wire and cable industry. The company expanded in Lenoir and Granite Falls, North Carolina, and Ontario, Canada, growing to more than 200 employees. A 1992 recipient of the WCMA Distinguished Career Award, he retired in 1989. “We are moving forward in our industry without one of the greats,” said NEPTCO President Guy Marini. “Mr. Farago spent most of his time working the inside of the business. He was a teacher and a mentor, and was capable of making tough decisions. He demanded that we recognize our own value and he made sure that we understood the urgency of doing a job well. Perhaps his greatest accomplishments are in the development of his people, who to this day continue to lead a successful business with the passion and discipline that he taught us.” He is survived by his wife Daphne; and sons Alan, of Coral Gables, Fla.; Paul, of Asheville, N.C.; and Robert, of Providence; and nine grandchildren. Wafios reports that Wilhelm Harter, who spent more than two decades (from the beginning of 1960 until 1982), serving as its management spokesman, died Feb. 8 at age 95. Experienced both as an engineer and as an accountant and a holder of the Cross of Merit of the Federal Republic of Germany, Harter represented Wafios at the board level within the VDMA (German Engineering Federation), VOW (German Machine Tool Builders’ Association), SOl (Federation of German Industry), as well as the German Chambers of Industry and Commerce and the Federation of Employers. He was known for devoting his technical and interpersonal skills to the good of the company, and in addition to his high level of expertise and tireless energy, he had the vision to drive the company forward in terms of growth. A statement from the company observed, “Wilhelm Harter rendered great service to our company. In his passing, we have lost a personality with an outstanding entrepreneurial spirit. The principles he lived will continue to be an obligation to our company. We shall remember Wilhelm Harter with gratitude.” APRIL 2010 | 25

PEOPLE

Switzerland’s Maillefer SA reports that Chief Executive Officer Pentti Hätälä has left his executive position and been named chairman of the board of the Maillefer Group. He served in the plastics and wire and cable industries for more than 30 years. He joined Nokia Machinery in Finland over 20 years ago and moved up the company’s ranks, becoming CEO of Maillefer in 2001. In his new role as chairman of the board, he will continue to offer his valuable input in steering the company forward. Replacing Hätälä as CEO is Chief Pentti Hätälä (l) and Peter Roos. Operation Officer Peter Roos, who joined the company about a year ago. He has more than 20 years of experience in the European automotive industry, including several years in key management positions. He has worked closely with Hätälä over the last year. Based in Ecublens, Switzerland, Maillefer SA provides manufacturing systems to the global wire and cable and tube and pipe industries.

26 | WIRE JOURNAL INTERNATIONAL

Stefan Schwarz has been appointed general manager for the sales division at Germany’s Friedrich Kocks GmbH & Co. KG. He has worked for several years for the company. Based in Hilden, Germany, Friedrich Kocks GmbH supplies rolling mills for tube, wire rod and bar worldwide. Evraz Inc. NA reports the retirement of Jim Declusin, who served as CEO for the company and its predecessor, Oregon Steel Mills, for six years. He has 40 years of experience in the steel industry, with prior employers including Kaiser Steel Corp. and California Steel Industries Inc. He is replaced by Mike Rehwinkel, who had been with GeorgiaPacific, where he was president of the Wood Products organization. Based in Portland Oregon, USA, Evraz Inc. NA, a subsidiary of Evraz Group S.A., has a product line that includes wire rod. Lincoln Electric has expanded the duties of Richard J. Seif, who is now senior vice president, global marketing and product development. He previously was senior vice president, global marketing and automaton. He joined the company in 1971 and has held a wide range of positions. He holds a bachelor’s degree in electrical engineering and an MBA in marketing from Michigan State University. Based in Cleveland, Ohio, USA, Lincoln Electric supplies a wide range of welding technology. ■

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FIBER WATCH

FIBER WATCH Plan to lay 1,100 miles of fiber across Maine not universally welcomed … A new business, Maine Fiber Company, plans to lay 1,100 miles of optical fiber in a project called the “Three Ring Binder,” because it calls for three rings of fiber to be strung through Western, Northern and Downeast Maine. Only the project has had its detractors, and there is a possibility that the initiative could be held up, risking its funding. The company, created by a coalition that included Biddeford Internet Corp., has $7 million of private funding but is depending on additional funding from the American Recovery and Reinvestment Act of 2009. The act sets aside money for improving access to broadband Internet service in areas where such service has been hard to come by, reports wire stories. As part of the grant application, responsibility for the network went to Maine Fiber Company, the reports said. They noted that last December, U.S. Secretary of Commerce Gary Locke announced that the Three Ring Binder project would receive a $25.4 million federal grant. Maine Fiber´s private investors will be providing approximately $7 million

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28 | WIRE JOURNAL INTERNATIONAL

more to complete the project. The goal is to lay 1,100 miles of fiber optic cable across Maine, providing broadband service to more than 100 rural communities with 110,000 households, 600 community institutions, and 38 government facilities that are not served today. However, the Bangor Daily News reports lessthan-supportive news because of a

View of the proposed “Three Ring Binder” network.

… while a town’s fiber system that is already in place cannot be fully used The broadband capacity of a 13-year old fiber that loops 17 miles around Longmont, Colorado, would be welcomed by homes and businesses in the city, but an article in the Longmont Times-Call reports that the network the city helped make remains vastly underused. It also shows how

what might appear to be a sure thing (community support) is not necessarily so. The article notes that the city leases unused fiber to a company called Reliance that provides service to major customers, such as the school district, town hall and the local hospital. However, rules prevent the city from partnering with a private company to offer it elsewhere to smaller customers. In 1996, the city council approved the construction of a fiber optic system, which became a 17-mile loop serving Longmont, Loveland, Fort Collins and Estes Park. A 2005 state law, however, prohibits Colorado cities from partnering with private companies to provide telecom services to residents. A provision allowed voters to change that status, but last November such a measure was voted down. The article cited one opponent who wrote, “Approval...would throw open the door to the city getting deeply involved in the telecom business...with or without partners from private enterprise. If the city has a specific plan, it hasn’t bothered to share it with voters.” So, for now, the city uses 12 of the 144-fiber network, another body owns 12 fibers and it leases 26 dark fibers to other users, such as Reliance Globalcom and Longmont Hospital, which leaves 94 unused fibers. ■

APRIL 2010 | 29

FIBER WATCH

protracted battle between FairPoint Communications and Maine Fiber Co. It notes that FairPoint, which has been expanding its broadband footprint since it took over Maine operations from Verizon Communications in early 2008, claims that the Three Ring Binder network duplicates its efforts. Maine Fiber, it said, agrees that there is some overlap with FairPoint’s network, but notes that its service would offer tenfold the capacity of FairPoint’s. A spokesman for FairPoint was quoted in the Bangor Daily News report as saying that the company’s network was designed to accommodate customers with high-capacity needs. It noted that the Three Ring Binder network has yet to be built and Maine Fiber has till December 2012 to get the project up and running, or the federal funding could be lost as well as the investment of the private investors, it said.

FASTENER UPDATE

FASTENER UPDATE Ukraine fastener show set for June Organizers of Kyiv Technical Trade Show 2010, scheduled to be held June 1-3 in Kyiv, Ukraine, at the new exhibition center KyivExpoPlaza, report that KTTS 2010 will include Wires & Fasteners Ukraine 2010, a specialized show for wire and fasteners. Organizers of the conference and exhibition include the National Metallurgical Academy of Ukraine, Interpipe Corporation, the Ukrainian Association UkrTruboProm, the Ministry of the Industrial Policy of Ukraine and TDS-Expo Ltd. In a press release, the organizers noted that the Ukrainian outlook is good, bolstered by plans for construction of the projects for the European Soccer Championship, EURO 2012, which will be hosted by the Ukraine and Poland. Alongside the exhibition an international conference will be held, Anticor Ukraine 2010, “Current problems and modern methods of corrosion protection of wire, tubes, sheet

metal and other metal products.” For more details, contact Olga Krasko, TDS-Expo Ltd., olga@welding.kiev.ua, www.weldexpo.com.ua.

Black & Decker unit acquires Fastener Innovation Technology U.S.-based Emhart Teknologies, a Black & Decker Company, announced that it has acquired Fastener Innovation Technology, Inc. (FIT), a designer and manufacturer of critical, highly specialized aerospace fasteners based in Gardena, California. The price was not disclosed. A press release said that FIT manufactures aerospace threaded fasteners including industry standard, customerspecific and proprietary designs for sophisticated applications. The company has developed proprietary products in addition to special products for OEMs requiring unique fastening solutions, it said. “Combined with our Heli-Coil® initiatives and the 2008 purchase of Spiralock Corporation, bringing FIT under the Emhart brand enables us to integrate the finest aerospace fastener platforms into a single-source organization,” Emhart Teknologies President Michael A. Tyll said in the release. “This acquisition allows us to better serve

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educate our customers on fastener and tool selection. In past, we talked of proper fastener selection and how it impacts quality. Now we can actively introduce and assist our customers with the expertise of Mr. Metric's product knowledge and product line.”

Mountz acquires Mr. Metric

Fastener tech handbook available

U.S.-based Mountz, Inc. reports that it has acquired all the assets of Mr. Metric, Inc., a fastener importer and distributor located in San Jose, California. The value of the deal was not disclosed. A press release said that Mr. Metric will serve as the flagship brand name for all Mountz fastener products. Fastener products will be integrated into the Mountz logistics system and sold under the strong Mr. Metric brand name. Mountz, the release said, plans to roll out a fresh and revived Mr. Metric brand to a combined 6,000 active customers. Mr. Metric has imported screws, nuts, bolts, and hardware for more than 30 years. It noted that it focuses on the industrial marketplace, but its customer base includes car and motorcycle enthusiasts and hobbyists of all types who need to find specialty metric fasteners. National Sales Manager Daniel Andeel said that the deal will help customers of both companies. “Our goal is to use the synergies and experience of a combined sales force to

U.S.-based Industrial Fasteners Institute (IFI) has published “IFI Fastener Technology Handbook,” a 313-page hardback book that presents fastener industry history, easyto-understand explanations of types of fasteners, fastener materials and performance details, installation insights, and more. A press release notes that the book, which is an informational, educational handbook and not a book of standards, is a “must have” for every fastener supplier for training company personnel and customers about the fastener industry and its technology. Individual copies of the book can be purchased from the IFI online store. Suppliers can buy copies in lots of 50 with their logo and name on the cover for a reduced price. Requests can be sent to techinfo@indfast.org. For more details, contact Joe Greenslade, director of engineering technology, at tel. 817-995-4685, jgreenslade@indfast.org, www.indfast.org. ■

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APRIL 2010 | 31

FASTENER UPDATE

the aerospace, military and commercial aircraft industries where FIT enjoys a strong reputation.” It also reported that Randy Aardema will lead FIT as General Manager. He recently joined Emhart from Acument Aerospace and prior to that worked with Textron Fastening Systems.

WAI NEWS

WAI

NEWS

70% of floor space for Interwire 2011 booked at March 11 Points Meeting Approximately 70 percent of the inventoried floor space for Interwire 2011 was booked at the Points Meeting held March 11 at WAI’s headquarters. Over 140 companies participated in the meeting, where 70,400 sq ft of booth space was booked by exhibiting companies, WAI Sales Director Robert Xeller said. “Based on the economic forecast Tom Siedlarz (back, l) and Mark Spencer (front, r) joined WAI staff for the ahead of us, this was a strong reinforceInterwire 2011 Points Meeting. The results of the meeting are shown on p. 11. ment reflecting the industry’s support of Interwire. It was good to see companies some stability at the moment, and I’m looking at the booked not only participate but continue to support Interwire with floor space as a positive picture at this time.” major booth configurations.” Booths are allocated based on the points/seniority system Interwire exhibits will be held May 3-5, 2011, at the that was approved by WAI’s board of directors. Georgia World Congress Center in Atlanta, Georgia, The next major allocation of booths will be done during USA, where WAI will hold its trade show and the the wire Düsseldorf show in April, where the floor plan will Association’s 81st Annual Convention. be available at the WAI stand and booths will be sold on a One twist to the Points Meeting process was that it was first-come, first-served basis, Xeller said. done “live” on-line, so participants could see which booths had been taken where and by whom, and decide what Extrusion seminar by SAMP USA’s available ones would best work. The photo on p. 11 shows what the floor plan looked like at the end of the day. To Perroud draws 2 dozen attendees see the current status, go to www.wirenet.org and click WAI’s continuing series of webinars saw 24 participants on the “Interwire Exhibition” box. take part in the Feb. 9 webinar, “Extruders/Extrusion Two WAI volunteers who helped out WAI staff during the Groups,” presented by SAMP USA Inc. Managing day-long process said they felt it had gone quite well, in Director Dominique Perroud. He fielded a number of large part due to the prior preparation. questions from the audience that remained engaged for “A lot of work was done by a lot of people to make sure the full 75-minute program, which covered the technical that Interwire 2011 provides what the industry needs,” said and process requirements at the extrusion group level. W. Gillies Technologies’ Mark Spencer, who is on the The presentation got good reviews, with attendee comExhibition Planning Committee as well as a member of the ments including, “The webinar was great, in time and WAI’s Board of Directors.” There were big changes, such as material exposed,” “Very interesting and worthwhile,” the return to Atlanta and compressing the exhibition from “Very useful,” and “Excellent.” four days to three days, but there were also smaller changes Observed WAI Director of Education Marc Murray, that matter to exhibitors, he said. For instance, the floor plan was redesigned to offer more opportunities for exhibitors to “When people ask lots of questions and stay involved select smaller booth sizes in more strategic locations, he even after the scheduled end time of the program, we said. “At the Points Meeting, I think that the exhibitors who know they are getting a lot out of it.” took part on-line were able to get a better understanding of The webinar is now part of a series of WAI webinars the size and scope of the selection process. It was easier to that can be accessed on-line at www.wirenet.org. The understand your options and be able to make decisions.” access is free for WAI members. Past WAI webinars “I thought that the Points Meeting process reflected a sign include: “The State of Manufacturing,” “Wiredrawing of some confidence for the industry,” said Plastic Equip, Lubrication”/“Lubricación en el Trefilado de Alambre LLC’s Tom Siedlarz, noting that he sensed that exhibitors (en Español),” “Copper: Managing Price Risk,” are looking forward to the event. “I thought that the live “Green Descaling and Polymer Coating of Stainless on-line format for booth assignments spurred interest and Steel Wire,” and “Descaling and Polymer Coating of activity, as many were ready to move on their selections or Ferrous Wire.” ■ to question booth allotments. It seems as if we are seeing

32 | WIRE JOURNAL INTERNATIONAL

What goes around, comes around. For your earth-conscious utility customers, Eco™ reels are best all around.

Today’s utility companies are actively looking for ways to build a greener image while improving their operating efﬁciencies. Sonoco’s EcoReelSM recycling program lets

recycling centers. We categorize, clean and refurbish them in a process that brings them back to like-new condition—ready for you to rewind.

you provide your customers with the best-all-around choice in recyclable wire and cable reels, saving them money and reducing their reel disposal costs.

Your customers deserve the industry’s best combination of service, quality and longevity that Sonoco Reels provides—and there’s no reel producer with a stronger commitment to sustainability, either. Contact Sonoco to learn about your best-all-around reel choices and the most comprehensive reel recycling program in the industry. Click or call:

The EcoReel program has been making reel management effortless since 1991. Sonoco, a decades-long veteran in recovery, reuse and recycling, picks up used reels from your customer’s location and transports them to one of 13 regional

sonoco.com/reels 800/633-3962

CHAPTER CORNER

CHAPTER CORNER Midwest Chapter to return June 21 to St. Andrews golf course in Illinois The WAI Midwest Chapter will hold its 8th Annual Golf Tournament, on Monday, June 21, at the St. Andrews Golf & Country Club in West Chicago, Illinois. Last year, a total of 52 golfers took part in the scramble format tournament, where the team of Dane Armendariz, Michael Brewer and Dave Dohman of Henkel Corp., along with Michael Malwitz of Metal-Matic, Inc., turned in a tourney best score of 60. “The 2009 Midwest Chapter outing was a huge success,” said Chapter President John Kukalis, Henkel Corp. “There is no other way to put it. Everyone left with a gift and a smile on their face. There was a lot enthusiasm and the upbeat attitudes around the course allowed us to put aside the economic struggles for a day and just enjoy.” The goal is to match that experience. The event includes a reception and dinner as well as the golf match itself and the various skills contests. Sponsorships are available to help fund the event, including opportunities for the $10,000 holein-one; Closest-to-the-Pin; long drive; most accurate drive; and the popular putting contest.

The Midwest Chapter will return to the St. Andrews Golf & Country Club on June 21. The tournament helps benefit the WAI Midwest Chapter Scholarship Fund which, with the Wire Foundation, provides two $1,000 scholarships annually. For more details, contact WAI’s Chip Marsh, tel. 203-453-1748, cmarsh@wirenet.org. ■

n on ottiio M Mo n n ii ttss c c uu oodd r r B IN G • PR O F IL E S PP • TU

Visit us at

WIRE EXPO Booth 110

SE nngg i i HO y y • f f ttii LE deenn E • CAB IId

WIR

We Manufacture Equipment for Printing, Marking, Guiding & Measuring your Product.

OUR SIGNATURE PRODUCT LINE: • Inkjet Marking Equipment • Engraved Print Wheels • Gravure & Offset Printers • Indent & Embossing Wheels • Guide Rollers & Assemblies

www.wgillies.com W. GILLIES TECHNOLOGIES, LLC • 250 Barber Ave. • P.O.Box 60329 • Worcester, MA 01606 • USA Phone: 508-852-2502

34 | WIRE JOURNAL INTERNATIONAL

Fax: 508-852-6453

E-mail: sales@wgillies.com

Choices abound when you’re best all around.

Just one call gets you the best in service, selection, size and performance.

You may have known us as Crellin or Econoreel. Today we are part of Sonoco—one of the world’s largest manufacturers of high-quality, high-performance plastic reels and spools. Sonoco offers you whatever size and capacity reel or spool you can imagine. For more than ﬁve decades, manufacturers around the world have relied on this family of plastic reels and spools. The Reel Tough® line offers you less weight, less maintenance, and long life through the rigors of high-speed winding applications. We continue to grow your choices, adding

patented corrugated (fluted rib) flange technology with lighter-weight, strong, low-cost utility spool options. Whether you need process reels, fine wire or standard spools, reel-in-the-box packaging or lightweight utility spools, Sonoco works to help you control packaging costs. Perhaps even better, every reel and spool is backed by a company that has loyally served and valued its customers for more than 110 years. Contact Sonoco for more details about your best-all-around plastic reel and spool choices. Call, visit or e-mail: 518/392-1700

sonoco.com/reels david.gluth@sonoco.com

Visit us at Wire Expo booth #116 Sonoco Reels and Spools 87 Center Street, Chatham, NY 12037 • 518/392-1700 sonoco.com/reels

MILWAUKEE UPDATE

WIRE EXPO UPDATE Schedules set for co-located organizations in Milwaukee Wire Expo 2010 and the National Electrical Wire Processing Technology Expo and the American Wire Producers Association, which will stage its first Long Products Supply Chain Symposium, have largely finalized the schedules for their respective events, to be held the week of May 10 in Milwaukee, Wisconsin, USA. More than 185 exhibiting companies will be represented at Wire Expo 2010. Below are a few booth descriptions followed by comments from exhibitors who supply reels and spools. This section also includes further information about the other two events. For further details, go to www.expoproductions.com and see their ad on p. 96, and for the supply chain symposium, go to www.awpa.org and see their ad on p. 88. For the latest on Wire Expo 2010, go to www.wirenet.org.

Amaral Automation Associates Tel. 401-405-0755 fax 401-405-0757 www.amaralautomation.com insidesales@amaralautomation.com USA Booth 109 Exhibiting: Amaral Automation is the N.A. distributor for the PWM line of cold pressure welders, dies and spares and is the N.A. distributor for Subec, a manufacturer of roller guides, wire straighteners, sheaves, pulleys and ceramics. Amaral is the Northeast representative for B&H Tool Co., Maag Pump Systems, Rosendahl/Nextrom, Rolf Schlicht GmbH, TSM Control Systems, Tulsa Power, Vulcan; W. Gillies, Yield Management and

Zumbach. It also reps for these controls, drives and motor suppliers: Bardac, Benshaw, Engineered Control Systems (ECS), Industrial Indexing Systems (IIS), New England Temperature Solutions (NETS) and Powertec Motors. Information will be available. Personnel: Rick Amaral, Joe Snee. Kyocera Industrial Ceramics Tel. 828-698-4135 fax 828-692-1663 www.kyocera.com don.costa@kyocera.com USA Booth 622 Exhibiting: The company’s ceramic cones, capstans rings and accessories.

Personnel: Don Costa, John Fairchild, Frank Roginski. PolyOne Corporation Tel. 440-930-1000 fax 440-930-3799 www.polyone.com robert.eiden@polyone.com USA Booth 801 Exhibiting: PolyOne is a total polymer solutions provider for the wire and cable industry. With the ability to meet diverse global regulatory and product specifications, it draws on a wide range of polymers, colorants and services to find optimum solutions for customer needs, whether it’s vinyl, color concentrates, contract compounding,

Scheduled in conjunction with Wire Expo 2010.

36 | WIRE JOURNAL INTERNATIONAL

Co-located with Wire Expo 2010.

(LSFOH) compounds used for both sheathing and primary insulation. Specially designed for thin wall extrusion applications, low-smoke and highly flame retardant, these compounds will not emit corrosive gases when burned. Personnel: Al McInnes, Tammi Dower, Bob Freeman. Rainbow Rubber & Plastics Tel. 610-685-2800 fax 610-685-7574 www.rainbowbelts.com mmackimm@rainbowbelts.com USA Booth 720 Exhibiting: Rainbow Rubber & Plastics has partnered with PowerHandling to offer an innovative range of hand-operated machines that allow a single operator to easily and safely move cable or wire reels up to 50 tons! Operating on either compressed air or rechargeable battery

3 Events 1 Location

packs, these devices are the most compact, most powerful and most reliable in the industry with units running successfully in every major cable/wire manufacturer in North America. Personnel: Mark MacKimm, Scott Whitmore.

Visit us at Wire Expo booth #301

NEW ENTRIES Machines still installed in German cable factory, promptly available! Ref. no. 10-7607 STOLBERGER, tubular strander, model SVR 12/630, 900 min-1, encircling bearings Ref. no. 10-7608 STOLBERGER, tubular strander SVR 12/355, 1100 min-1 , encircling bearings Ref. no. 10-7609 STOLBERGER, tubular strander SVR 12/560, GESADUR underrollers Ref. no. 10-7610 STOLBERGER-NIEHAUS, tubular stranders, encircling bearings, 1100 min-1, 2 sets for 1+6 and 2 sets for 1+12 bobbins, 250 mm ø Ref. no. 15-7614 MALI, planetary strander, model KV 6+12 bobbins 630 mm ø, specially designed for OPGW cable Ref. no. 13-7612 HENRICH, double twist buncher, take-up bobbin 630 mm, with 7 flyer-type pay-off ’s (2 machines available) Ref. no. 61-7619 HENRICH, copper rod drawing machine model 30R13, 13 dies, inlet 8,0 mm, finished ø 1,4 mm, continuous annealer, dual spooler AR 1000 for bobbins 630 mm ø, plus bundle packer / static coiler for bobbins 1250 mm ø Ref. no. 61-7620 HENRICH, aluminium rod drawing machine model 30R13, 13 dies, inlet max. ø 9,5 / 12 mm, finished ø 2,0 – 4,5 mm, spooler max. 1250 mm ø Ref. no. 66-7600 NIEHOFF, 8-wire drawing line, type MMH 101, 21 dies, inlet 1,5 mm ø, finishing size 0,2 – 0,30 mm, continuous annealer R 160, automatic static coiler for 630 mm bobbins Further medium and fine wire drawing machines as well as drawing lines for copper alloys and flat- / trolley wire.

QUEINS & CO. GMBH

Hans-Georg-Weiss-Straße 12 52156 Monschau GERMANY

Tel.: +49 2472 8080 Fax: +49 2472 3014 Email: info@queins.com www.queins.com

APRIL 2010 | 37

MILWAUKEE UPDATE

crosslinked polyethylene, halogenfree or other specialty compounds. Products and services include: vinyl compounds, a full range of UL and CSA listings used in almost every possible jacketing and primary insulation application; color concentrates that set the worldwide standard in color and color metering. A wide color range is available from stock as well as custom formulations. Easy-to-process concentrates are suitable for multiple polymers, and are available in lead-free and non-halogen formulations. PolyOne’s Producer Services business can quickly help satisfy customers’ polymeric needs via its ISO- and QScertified facilities that compound a full range of polymers, using diverse equipment, including pilot plant scaleups and automated process controls. Products include ECCOH™ Low Smoke and Fume, Zero Halogen

MILWAUKEE UPDATE

Roteq Machinery Inc. Tel. 905-660-8800 fax 905-660-8898 www.roteqmachinery.com dave.alexander@roteqmachinery.com Canada Booth 307

Exhibiting: Stranding of copper and aluminum conductors, cabling of insulated conductors and Milliken strand, along with a wide range of strip armoring solutions will be the focus of Roteq’s presentation. New this year is an extension of the single input methodology for the manufacture of compressed and compact copper strand and an update on the SIW aluminum strand schedules to 1000 kcm or 500 sq mm using new and traditional stranding processes. Recent developments in the strip armoring process to increase productivity for offshore and on-shore pump cable applications will also be highlighted. Personnel: Dave Alexander, Andy Blackmore, Mike Marshall.

Wire Expo 2010: Reels & Spools booth comments Ace Metal Inc. Booth 716 Ace Metal, Inc. is the oldest U.S. manufacturer of fine wire metal spools, and the country’s only tire cord spool manufacturer, manufacturing metal spools from 6 in. to a 12.75 in. flange diameter, with varying sizes of both traverse and arbors. We believe that innovation is the key to success. The ability to make even the slightest modifications to your current product(s) gives you the means to offer your customers a better product without having to increase costs. Ace Metal is now manufacturing a new drum design for customers that will enable

38 | WIRE JOURNAL INTERNATIONAL

them to produce a more level wind than in the past to produce a better package for customers at no additional cost. This new drum design will be shown at Wire Expo. Our company has the design team and in-house tooling facility to customize a spool for you and your specific customer’s needs for their equipment. Carris Reels & Spools Booth 612 Carris will have over 100 years worth of ‘reel’ experience in Milwaukee, including manufacturing, logistics, package design and materials alternatives. We hope our visitors bring their challenges and allow the Carris expertise to work for you. We can offer solutions such as substituting nailed wood reels for large steel reels and evaluate recycled reel programs. We will provide an outlook for our dynamic material markets; lumber, softwood plywood, hardwood plywood, resins and steel. Package efficiency is critical to our customers – no one wants to pay anything more than absolutely necessary. In this endeavor we want to review everything from carrying capacity to downstream handling in order to define the need. Then, from a variety of material alternatives, we begin the design recommendation. We know that there is much more to total cost than invoice price. Costs, for example, can be hidden in areas of handling, inventory, processing (from take-up to shipping) and more. The trade show presents an ideal environment for a “40,000 ft” look at reel packaging and to talk about your “wish list.” If you could take a snapshot of your current reel program, what is it you would change? Let’s talk about it. GMP-Slovakia/Howar Equipment Booth 716 Visitors to the GMP/Howar booth will benefit from over 100 years of combined experience that allows us to help provide solutions for all reel-related issues. Our focus has always been to supply and design application appropriate reels that take today’s

machine capabilities into greater consideration. Stop by and Luca Ruggenenti and Chris Hauer can explain the subtle differences between alternative reels and reel manufacturers. Many small assembly and design differences often amount to large long-term improvements and durability when it comes to the reel as well as the machinery it is being used in. We will explain and demonstrate the difference between using an unbalanced, un-machined reel and one with a properly structured flange with balancing and machined components that allow the reel to be used at higher speeds and results in less wear on the machinery while putting out a more consistent final cable. We look forward to your questions and issues and want to discuss how your reels are affecting your machinery, the product, or both, and what kind of improvements we can offer. L-S Industries Booth 103 At this year’s Expo, key L-SI personnel will be on hand to discuss our products and capabilities with you. The various types of reel wraps and drum liners are the focus of our booth but will be displaying some of our other capabilities and products as well. Our flange protectors give a smooth surface for the cable to lay up against on older wooden or metal reels. Our printable placards provide a highly visible location to display your company name and order information on spoke reels. L-SI has the capability to do other packaging for you. We cut, laminate, heat-seal, and sonic-weld a multitude of materials to create a unique package for your business. Metavan/Howar Equipment Booth 716 Pressed steel shipping and process reels will be the main product lines discussed and displayed at the show. With Metavan’s superior ability to supply affordable and short manufacturing times for these steel reels, Francis Vanhaelewijn and Chris Hauer

Mossberg Associates, Inc. Booth 710 Mossberg Associates is excited about sponsoring a booth for the first time at

Wire Expo. As an exclusive representative in the U.S. and Canada for Boxy SpA, John Henschel and Rene Mayer bring over 50 years of design, manufacturing and sales experience in the reel business. Information will be available on reels and ancillary equipment we can offer your company. Beyond the reels and equipment made by Boxy, we also work with other partners to offer a wider range of products and services. This includes,

John Henschel and Rene Mayer

Strip With Precision Stripping faulty cable jackets from costly cable cores demands precision and protection. Huestis Industrial Cable Jacket Strippers remove jackets quickly and easily without damaging the valuable core. A protective stripping tool and rotating blade work together to lift, cut and separate the jacket from bare or braided cable cores. Free-standing, bench-mounted or custom models quickly remove jackets from various cable cores from .030"–4.0" (.76–102 mm) diameters.

For more details or to place an order, call us at 800-972-9222, or email us at sales@huestis.com

www.huestis.com Air Wipes, Pay-offs, Take-ups, Buncher Pay-offs, Accumulators, Spoolers, Cold Pressure Welders, Cable Jacket Strippers, Custom Machinery

68 Buttonwood Street, Bristol, Rhode Island 02809 USA 401-253-5500 800-972-9222 Fax: 401-253-7350

but is not limited to, small pressed spools, large demountable drums, used reels and drums and reel reconditioning and repair. Our file history of reels made over the past 90 years is extensive, so we can usually find what you are looking for. Stop by with your reel specifications, questions or problems and we will help find solutions. Not looking for anything right now? Just stop by and say “hi.” As an independent sales representative, we have information on a variety of products and will talk to anyone seeking industry representation. Pittsfield Plastics Engineering, Inc. Booth 712 U.S.-based Pittsfield Plastics Engineering, Inc., was founded 42 years ago, and our team of plastic spool and reel experts is looking forward to meeting you at the Wire Expo. Customers with unique packaging issues can find help from Pittsfield

Huestis Industrial Cable Jacket Strippers Model CJS 1000

WIRE EXPO

Model BJS 1000*

Milwaukee, WI

May 12–13 Booth 515

*Model BJS 1000 is bench mounted. All other models are free standing. Strippers can be customized to meet your speciﬁc requirements.

ISO9001

REGISTERED

Cable Core Salvage System APRIL 2010 | 39

MILWAUKEE UPDATE

Hauer welcome visits to discuss reel requirements. Metavan’s pressed steel reels focus on a quality product rather than on a large variety of different constructions. The main advantage is the ability to supply a cost effective and short delivery time for the pressed steel reels needed by wire manufacturers. The reels with a “curly” edge are available in a large array of diameters ranging from 12 in.– 48 in. With a new manufacturing facility with state-of-the-art cutting, forming, welding and powder-coating lines, Metavan is able to offer unsurpassed quality and consistency. Its dedication to automation ensures that each reel meets specifications and reduces manufacturing costs, providing the best quality, manufacturing time, and price.

MILWAUKEE UPDATE

because it can design a reel that meets specific needs. We recently expanded our plant in Pittsfield, Massachusetts, by 30 percent. We are not only a domestic spool and reel supplier, we have an in-house mold making and repair shop. Our broad product line of spools and reels includes its new patented Break-Down ™ Reels. These reels can be shipped unassembled, saving on freight, and they are easily assembled without tools in 10 seconds. Customers can easily disassemble and return the components for reuse, thus providing more cost savings. Sonoco Spools and Reels Booth 116 Sonoco Spools and Reels has participated at Wire Expo many times and will do so again in 2010, exhibiting our complete product line of plastics spools and reels as well as some of its well-known quality wood reels. Our staff will be ready to talk about solutions, be they plastic or wood. Experience tells us our wire and cable customers want high performance, cost competitive plastic spools and reels in a timely manner. Sonoco’s Reel Tough® product line offers less

weight, less maintenance, and long life through the rigors of high speed winding applications. The acquisition of EconoReel in December 2009 added some exciting new plastic reels and spools to the product line. The Sonoco EconoReel patented corrugated (fluted rib) flange technology offers lighter weight, strong, stiff, and low cost utility spool options. Sonoco’s goal is to help wire companies lower packaging costs and increase productivity. Whether your need is an in-process reel, fine wire/standard spool, reel in the box packaging or light weight utility spool, Sonoco has the answer. As for wood reels, Sonoco has long been acknowledged as a leader in the field. The company’s nailed wood reels, both returnable and non-returnable, are available in a variety of sizes, from 14-in. to 120-in. reel-head diameters. With five manufacturing plants, 13 recycling centers (see p. 46), 26 service/assembly centers and complete packaging supply chain services, Sonoco wood reels provide real value. Whatever your choice, we can provide the reels you need on a dependable basis.

Reel Options/Vandor Corporation USA Booth 914 The EnviroMold trademark is synonymous with environmentally responsible plastics production. Our popular Dead~Bolt and stapled EnviroMold flanges have been a lowcost alternative for customers. The patented EZ~Brake system reduces or eliminates backlash tangles during despooling for reel-in-a-box customers. Stop by the booth for a demonstration. Product Engineer Gary Cox will be happy to discuss the braking system. Mark Elder, vice president of sales, will be there to discuss some of the exciting new projects that Reel Options will be unveiling in 2010. Driven by customer demand, Reel Options has added CNC plywood cutting capabilities to our expanding product line. We’ll be able to provide plywood flanges for KD shipping and assembled reels ready for winding. The specially designed system is capable of cutting over 7 million flanges per year. That’s nearly 300% more than typical CNC cutting systems. Reel Options also offers EnviroMold plastic cores for all weather applications and utility spools.

Seminars set for Electrical Wire Processing Expo A total of six seminars will be offered over two days at the National Electrical Wire Processing Technology Expo, to run concurrently with Wire Expo on May 12-13 at the Midwest Airlines Center in Milwaukee, Wisconsin, USA. The presentations will be held on the second floor (one level below the exposition floor), where more than 100 exhibitors will be showcasing the latest technology for the electrical wire and cable processing industries. The program will be led off Wednesday, May 12, by Aina Vilumsons, Executive Director, Wisconsin Procurement Institute (WPI), whose 8:30 am to 9:30 am talk is on, “Making the Government Your Next Customer.” She notes that the federal market is being increasingly competitive, but there are significant opportunities for businesses. The second seminar, from 10:30 am to 11:30 am, “Wiring the Next Generation of North American Automobiles,” is presented by the Electrical Wiring Component Application Partnership

40 | WIRE JOURNAL INTERNATIONAL

(EWCAP), a sub group of the United States Counsel for Automotive research (USCAR LLC). Scheduled participants include: Don Price, Ford Motor Co., Connectors & Components Engineering Technical Specialist; Matt Marzeo, Chrysler, Connectors & Components Engineering Product Engineer; Jim Roberts, USCAR, Electrical Wiring Components Application Partnership Technical Specialist; and Tom Simko, GM Powertrain, Wiring & Connectors Engineering Technical Specialist. The third session, from 12:30 pm to 1:30 pm, “Crimp Quality Verification Methods and Trends,” will be presented by Rob Boyd, Crimping Product Manager, Schleuniger, Inc. On Thursday, May 13, the first session, from 8:30 am to 9:30 am, is “Revamping Medical and Robotic Cable Design,” by Donald Dodge, VP Research, Calmont Wire & Cable. The second session, from 10:30 am to 11:30 am, is “Utilizing Ultrasonic Metal Welding in Today’s

As a COMPLEMENT to our new machinery business! Trust NIEHOFF ENDEX with the rebuild of your existing NIEHOFF and ENDEX equipment using OEM-parts and NEW control systems to outperform your competition Our expertise includes: • Evaluation, inspection, recommendation & consulting • Upgrades, overhauls and retrofits with warranty • Control system integration using the latest technology • Start-up’s and re-commissioning • OEM parts at reasonable prices • US-based engineering (process, electrical and mechanical) • We can provide new controls fulfilling customer brand specifications and rearrange existing machinery to meet new process demands • Best quality guaranteed before MASCHINENFABRIK NIEHOFF GmbH & Co. KG Fürther Straße 30, 91126 Schwabach, Germany Telephone +49 9122 977 - 0 Telefax +49 9122 977 - 155 E-mail info@niehoff.de

after

NIEHOFF ENDEX NORTH AMERICA INC. 1 Mallard Court, Swedesboro, NJ 08085, USA Telephone +1 856 803-1800 Telefax +1 856 467-0584 E-mail service@niehoffendex

before

after

Visit us at Wire Expo booth #613 www.niehoff.de

Production Environments,” by Tim Crider, Midwest Operations Manager, Stapla Ultrasonics Corporation. The third session, from 12:30 pm to 1:30 pm, is “Current Status and Growth of Solar Photovoltaic Technology,” by Bill Duncan, Director of Product Management, Komax Solar. The seminars, to be held in room 201 A&B, are sponsored by Wire & Cable Technology International. For more details about the presenters and an outline of what aspects they will specifically cover go to www.electricalwireshow.com. The exhibit hours will be from 9 am to 4 pm on Wednesday, May 12, and from 9 am to 3 pm on Thursday, May 13, at the Midwest Airlines Center. Attendees can visit more than 100 exhibitors and Attendee activity at the 2009 Wire Processing Technology Expo. service companies that collectively offer the technology needed for today’s wiring harness and cable assembly hand to answer your most challenging questions. shops, cord set manufacturers and companies that process Make sure to look for the Show Program at the event for electric wire and cable. Machines will be on site and under the most complete information, including room assignpower, with industry experts and applications personnel on ments. See the show ad on p. 96.

APRIL 2010 | 41

ADVANCE REGISTRATION FORM Midwest Airlines Center | Milwaukee, Wisconsin, USA | Exhibit Dates: May 12-13, 2010 1. COMPLETE AND MAIL OR FAX THIS FORM TODAY

1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Tel.: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org Note: Please print neatly and complete all information to ensure accurate registration. If you choose to mail this form, make sure you keep a photocopy. FIRST NAME

MIDDLE

INTERNAL USE

LAST NAME

TITLE

DT RCD

AMT PD

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PYMT

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2ND ADDRESS LINE IF NEEDED

CITY

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TELEPHONE (include area code)

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E-MAIL [

]

2. BUSINESS INFORMATION (These two questions must be completed for proper processing.) A. Which ONE of the following best describes your company’s type of business? PLEASE CHECK ONLY ONE. WIRE MANUFACTURING 10 ❏ Aluminum & Al. Alloys (Rod/Bar, Bare Wire) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire) 40 ❏ Other Metal (Rod/Bar, Bare Wire) 50 ❏ Electrical (Insulated Wire) 53 ❏ Communication (Insulated Wire) 55 ❏ Fiber Optics

FASTENERS, WIRE FORMING, FABRICATING 61 ❏ Fastener Manufacture 62 ❏ Four-Slide forming 64 ❏ Hot and/or Cold forming and heading 66 ❏ Spring manufacture 68 ❏ Wire cloth mesh screening 69 ❏ Other forming and fabricating Please Specify ______________________________

WIRE END-USER 11 ❏ Appliance 12 ❏ Communications (Voice/Data) 13 ❏ Computer 14 ❏ Construction/Building 15 ❏ Electrical (Equip./Components/Power) 16 ❏ Transportation/Vehicular 17 ❏ Wire Formed Durable Goods

SUPPLIERS TO THE WIRE INDUSTRY 72 ❏ Machinery 74 ❏ Process, Accessories, Materials

OTHER 80 ❏ Service Cntrs, Distrib.& Warehouses 90 ❏ Consultants 92 ❏ Govt., Library, others allied to field

B. Which ONE of the following best describes your primary job function? CHECK ONLY ONE. 10 ❏ General & Administrative Management 20 ❏ Engineering and/or Operations and/ or Production 30 ❏ Technical and/or Research & Development and/or Quality Control 40 ❏ Purchasing 50 ❏ Sales & Marketing 90 ❏ Other Please Specify _______________________________

3. EVENT REGISTRATION (This section must be completed for proper processing.) *advanced (on or before MAY 1, 2010) on-site (after MAY 1, 2010) Please Print Your WAI Member Number ________________________________ *advance

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FUNDAMENTALS OF WIRE MANUFACTURING (INCLUDES EXHIBITS) (GDS)

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The American Wire Producers Association (AWPA) will be in Milwaukee, holding its annual meeting, May 9-10, and the new Long Products Supply Chain Symposium, May 10-11, which will provide a valuable industry-wide picture of economic conditions. This new event has the support of industry organizations from every level of the supply chain, bringing together participants for a unique opportunity to meet with a full range of vendors, suppliers, and colleagues representing viewpoints from the entire supply chain of the Long Products industries. The 11 associations listed here have all agreed to promote this unique event, which is the first-time this level of cooperation has been undertaken. • American Institute for International Steel (AIIS) • American Wire Producers Association (AWPA) • Asociación Nacional De Productores De Acero (ANTAAC) • Chain Link Fence Manufacturers Institute

(CLFMI) • Cold Finished Steel Bar Institute (CFSBI) • Concrete Reinforcing Steel Institute (CRSI) • Industrial Fasteners Institute (IFI)• Spring Manufacturers Institute (SMI) • Steel Manufacturers Association (SMA • Wire Association International (WAI) • Wire Fabricators Association (WFA) The May time frame will be a very important time to be gathering information about the industry recovery, and this meeting will provide the knowledge you will need, all in one place. The participation of organizations supporting the Symposium ensures that you will receive good intelligence from suppliers, colleagues and customers. Don’t miss out on a great opportunity to see everyone together in one place, gain some knowledge about these everchanging industries and save money on event fees and travel. The AWPA would like to thank the Association Sponsors partners from up and down the Supply Chain for helping to make this event a success! For more information about the Program, and to register, visit www.awpa.org. See our ad on p. 88. ■

Visit us at Wire Expo booth #714

APRIL 2010 | 43

MILWAUKEE UPDATE

AWPA Symposium: it’s the whole supply chain!

FEATURE

Packaging Solutions his feature presents a range of technology from packaging solution suppliers,

including comments from one manufacturer about what he looks for, how two

companies have focused on recycling wood reels and six automated equipment suppliers whose story begins here and is presented on-line at www.wirenet.org. Also, on p. 37, further comments from suppliers who are also Wire Expo exhibitors.

A. Appiani/Lesmo Machinery America

Boxy SpA/Mossberg Associates

Italy’s A. Appiani, represented in North America by Lesmo Machinery America, manufactures standard and custom built steel reels according to DIN specifications or to customer requirements. A leading world manufacturer of shipping and process reels since 1962, it offers a comprehensive selection of pressed steel reels and plastic and steel composite reels. The range also includes fabricated steel reels, machined and partially machined steel reels and collapsible reels (mechanical, hydraulic and pneumatic). A leading supplier of production and shipping reels, its core competencies lie in small and large diameter pressed steel reels for wiredrawing, cable bunching and steel cord production. Large diameter reels are also available as machined and manufactured types. Ancillary products include steel pallets for reels, steel baskets, automatic re-flanging for spool reconditioning for b-type spools, take-apart reels, reel tilters, reel grabbers. www.appiani.reels.it, www.lesmoamerica.com.

Like many companies manufacturing or supplying reels today, Italy’s Boxy SpA offers a complete array of metal reels and equipment for all aspects of wire manufacturing. Specifically, its line includes fully machined drawing and multi-wire reels; heavy-duty fabricated and reinforced process reels for drawing, bunching, twisting and stranding; pressed metal (durable and lightweight) process and shipping Reels from Italy’s Boxy SpA. reels; large structural cable drums; and reels for special applications (conical, grooved, forged, hardened, etc.). Its products include take-apart reels for making coils; baskets, reel and coil tilting and lifting units and pallets. This however is where the comparison to competitors ends. The company’s strength is the experience it can bring to the customer. Together, Boxy SpA and its North American representative, Mossberg Associates, Inc., have more than 120 years of design and manufacturing

Steel reels from Italy’s A. Appiani.

44 | WIRE JOURNAL INTERNATIONAL

service toolbox. Time proven forecasting tools are less reliable as visibility is static and limited. Abbreviated order visibility translates to effective execution through collaborative information sharing beyond the transactional

FEATURE

experience. A newly redesigned heavy-duty drawing reel has shown increased strength while lowering costs. This type of experience allows the company to offer the customers and machinery manufacturers the best products they need for the processes they perform. Beyond selling new products, it can also solve problems for customers with older reels and equipment by recommending ways to rework existing reels or offering a redesign to meet the customer’s needs. Experience, there is no substitute! Boxy is ISO 9001 certified and manufactures from two locations in Eastern Europe. Both facilities are equipped with CNC machining centers, laser cutting and rolling machines; robotic welding; balancing machines and large presses. www.boxy.com, www.mossberg-reel.com.

Carris Reels Geography plays a critical role in minimizing freight and enabling rapid and effective response to a dynamic order cycle. Carris Reels is a 100% employee-owned company operating seven manufacturing plants in the U.S. and Mexico and eight warehouse/assembly locations. Also, its J. Hamelin partnership includes two manufacturing plants in Montreal, Quebec, and Bowmanville, Ontario, and a recycling facility in Chambly, Quebec. Today’s response time serves a critical function in the

An assortment of products from Carris Reels. level. As priorities change daily, visibility is afforded with employee owners throughout the manufacturing chain. The range of reel types at Carris is even more critical today as customers seek to minimize inventory dollars and warehouse footprint. From lightweight stamped metal spools to plastics, plywood, nailed wood (new and recy-

What does a manufacturer want? At the end of the day, a supplier has to satisfy its customers. WJI asked Encore Wire Corporation Quality Control Manager Steve Griffin to share his thoughts about packaging equipment. WJI: What aspects do you consider most important in packaging technology? Are there aspects that could be improved? Griffin: A well-packaged product is the sum of a number of successes in small installments. An Encore Wire product needs a great spool that protects and supports it. A dependable box needs to sustain the weight and dimensions of the spool. A dependable glue is needed to hold down the flaps of this really dependable box, you get the idea. Encore needs dependable labels, dependable pallets, dependable pallet wrap, dependable tape, etc. A structural breakdown at any step in packaging negates or delays all the “great” things that preceded it. I can’t say enough about durability. It trumps everything. No packaging item will ever be “all it can be.” We are delighted to see improvements, if indeed they are true improvements. We know, however, that true innovation in one area will eventually put the burden on other components to live up to the new standard. In packaging, that can be exciting if it all happens according to our schedule. In

any case, we proceed cautiously, but with an eye for optimism. WJI: What could suppliers offer that would provide more value to your production process, and would you be willing to pay extra for it? Griffin: It’s exciting to think of the places technology could take packaging. Certainly anything that saves labor, material, Steve Griffin space, or money is worth looking at. In general, it would be interesting to see sturdy, simpler, recyclable or reusable packaging ideas that somehow exhibit the quality of the product itself. I’m sure our willingness to pay extra for more technologically advanced packaging products or services would be weighed against two things: how does it affect Encore’s family of workers in the plants? And ultimately, does it please our customers more?

APRIL 2010 | 45

FEATURE

A ‘green’ touch for wood reels can be good for business It’s hard to write a story on just about any industry today without addressing “green” aspects, and while plastic reels and spools can be designed to be recyclable, large wood reels pose logistical challenges that require a concerted effort. Two U.S. companies that have found such efforts to be worthwhile are Sonoco Reels and Spools and Carris Reels.

Sonoco’s recycling efforts have been recognized by the Dow Jones Sustainability World Index. Last September, Sonoco, a large diversified global packaging business and major producer of wooden, composite and metal reels for the wire and cable industry, announced that it was one of just seven U.S. companies selected to join the Dow Jones Sustainability World Index (DJSI World). The program, started in 1991, has helped U.S. electric utilities and wire and cable manufacturers save approximately 50,000 trees and $6 million in disposal costs in 2008 by recycling more than 150,000 wire and cable reels, it reported. “We are working to help close the loop for U.S. electric utilities and other reel users by offering the largest and most comprehensive reel recycling program in the country which serves 1,200 end users in 650 cities in the United States and Canada,” said Randy Lusk, Sonoco Reel & Spool’s manufacturing director, reel and molded wood operations. He noted that customers can reduce landfill costs by using wood reels that can often be recycled three or four times. Sonoco’s reel recycling program, which began with electric utilities primarily in the southern United States and then expanded nationwide, is especially economical for larger companies with the infrastructure to use and dispose of a significant number of reels, the company reports. Other North American businesses that use wire and cable reels have also begun using the service, said Wendy Williams, Sonoco’s reels recycling operations manager. “Telephone and cable television companies are consolidating and centralizing their operations, and recycling reels is a good fit for them. Unfortunately, though, not all reels are being recycled in North America yet. This puts the environment at risk and is a

46 | WIRE JOURNAL INTERNATIONAL

lost cost benefit for reel users. Our goal is to work with wire and cable manufacturers, utilities and other reel users to close the gap and recycle every reel.” A similar success story is reported by U.S.-based Carris Reels, which company-wide recycles 140,000 reels a year, and its partner, J. Hamelin Industries of Montreal, Canada. They have expanded the reel-recycling program located at the Carris nailed-wood plant in Enfield, Connecticut, which in its first six full months of operations in 2009 saw more than 2,000 recycled reels delivered to customers throughout New England, the Midwest and the South. “Using the expertise of its sister company in Canada, we are repairing much more product in Enfield. We have tripled the activity in recycling in the past six months by identifying more sources of used reels, process refinement and development of customer base,” the company reported. “We’ve integrated new reel manufacturing along with recycled where we have recycled reels to complete an order.” Besides helping recycling, it noted, the efforts have also mitigated job loss during a period of overall reduced order levels for new reels. A press release noted that J. Hamelin has been repairing wood reels for the Canadian industry for more than 35 years,

Carris Reels’ recycled reels program has flourished, bolstered by its partnering with J. Hamelin Industries. processing 750 reels a week at its Canadian facilities. It notes that two of every three wood reels used in Canadian wire and cable plants are repaired. At Enfield, incoming reels are graded and recycled, then shipped to wire and cable producers. Wood waste is used in co-generation, converted to shavings for livestock or creation of steam for heat, which maximizes the use of the resource. J. Hamelin notes that partnering with Carris has helped both companies. “We believe that the opportunity exists today to extend this successful model, one that is very much a “green solution” to customers throughout North America.”

Visit us at Wire Expo booth #411

FEATURE

cled), wood/metal process reels and hardboard, Carris offers a package designed specifically for the application, weight, handling and transportation methods. Total cost is minimized through flexibility in manufacture using this host of materials. Recycling is a focus (see p. 46). At Carris Reels, each employee has a direct stake in the long-term success of the business. This drives productivity, creativity and sense of ‘membership’ in the Carris Community of Companies. When customers succeed, Carris succeeds, and so do all the employee-owners. www.carris.com.

George Evans Corporation Since 1939, The George Evans Corporation has provided the wire and cable industry with durable, cost-effective and fully recyclable Toroidal® steel fluted reels. The company’s Toroidal corrugated steel reel is recognized for its excellence and versatility, and includes Western Electric Reels, NEMA Class I & NEMA Class II Reels, and GEC Custom Designed Reels. Western Electric reels come in flange sizes from 30 in. to 96 in. The NEMA reels, primarily used for shipping power transmission cables, are specifically designed for differing rated weight capacities, from a 42 in. reel with 1,956 lb capacity to a 108 in. reel with 40,000 lb capacity. The company’s structural reels are preferred when the tooling does not exist for a required size and the volume does not justify the cost of new tooling. They are the preferred design for use with wire rope. These more expensive reels are preferred when the tooling does not exist for a required size and the volume does not justify the cost of new tooling. GEC’s custom designed reels are made in the company’s fully equipped steel fabricating shop that now includes (three) lasers and a robotic welder. These can be special sizes (up to 145 in.) and reinforced for use in process applications, include an extra long or short traverse, be used as heavier or lighter duty reels, have divided traverse secReels from The George Evans Corp. tions, special drums, arbor holes, or drive holes. GEC can offer more because it is a full-line custom metal fabricator that gains advantages from its large amount of steel purchases for all of its product lines. www.george-evans.com.

48 | WIRE JOURNAL INTERNATIONAL

Fabritex Inc. Fabritex Inc. is a metal fabrication company that has been serving the needs of the wire industry for over 20 years. In that time it has developed a catalog of over 100 wire carriers in all shapes and sizes. It also offers customers stem packs, annealing carriers, payoff solutions, and accessory pieces. Fabritex has the tools and knowledge to not only make wire carriers, but to proCarriers from Fabritex. vide custom solutions for packaging needs. It is the company’s experience and expertise that sets it apart from the competition. In an effort to help customers keep tabs on their investments, Fabritex is proud to offer a full paint line to help distinguish a their carriers from their competitors. Painting the carriers makes it easier to track where they are shipped and when they are returned as well as to identify which shipments go to which customers. Fabritex’s latest innovation, the Base Lock® carrier, represents an improved design of the traditional square base carrier, with added strength and durability. The real advantage comes from a streamlined production process that minimizes costs and decreases production times. The Base Lock carrier will fit most payoffs designed for a square base carrier. By using state-of-the-art automated bending and welding equipment, this high-quality carrier is rapidly reproduced. In today’s tough economic climate, speed and price are of the utmost importance. Fabritex is committed to being a partner, not just a supplier, helping a customer’s business thrive. One way to do that is to keep “nuisance costs” to a minimum, and the company believes that its line of the Base Lock carriers do just that. www.fabritex.com.

GMP Slovakia/Howar Equipment Slovakia’s GMP-Slovakia, with its North American partner Howar Equipment Inc., supplies high-quality wiredrawing and stranding reels, but it also focuses on an often-overlooked but very important aspect: providing the most appropriate reel. Failure to do so can cause detrimental effects on the final product and the machinery that it is being used in. Following are recommendations for some specific uses: Bunching + stranding: Use sturdy pressed steel reels that will fit well in the machinery and provide a uniform and defect-free wire package. Wiredrawing: For these higher speed applications, a double wall or fully machined reel is available that provides close tolerance and precise geometry which will ensure a uniform package and spooling. Insulated

Visit us at wire DĂźsseldorf - booth #12A52

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Visit us at Wire Expo booth #302

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FEATURE

wire: Various different reels are available where the importance lies in a good flange parallelism and surfaces that will not damage the insulation of the cable. Cabling: A sturdy reel that will withstand the heavy weight and often elevated rotational stresses (drum-twister) that the reels are subjected to. Corrugated flange and structural steel reels are available for these applications. Reel-less packaging: For a package that ships only the wire, we can offer take-apart reels that will be the mechanism to wind and then package the wire coil. Its Easykoil PLUS reel also acts as a coil lifting device, and is extremely quick and easy to assemble and disassemble. Handling: A complete line of safe handling equipment has been

designed to aid the operators with lifting, tilting and maneuvering reels and wire coils. www.gmp-slovakia.com, www.howarequipment.com.

H채fner & Krullmann GmbH H채fner & Krullmann GmbH is a leading European spool and reel manufacturer that has specialized in the design and production of spools for more than 75 years. Its product range covers over 1,400 different spool types with flange diameter from as small as 40 mm up to 1000 mm. The products cover application

An easy-assemble reel from H채fner & Krullmann GmbH.

We Make It Smart Micro-Weld Built For Better Productivity

A smart butt welder should be designed to help you process wire, rod or cable in the most efficient and cost-effective manner possible. And that's what our Micro-Weld butt welders do. For over 80 years we have been designing and building butt welders that offer rugged construction, heavy duty mechanical and electrical components, and easy operation to offer consistent and precise high quality welds. Micro-Weld. Smart butt welders made tough and dependable. Find out how these smart butt welders are helping customers boost their productivity all over the world. Call 1-800-872-1068, or visit www.micro-weld.com Visit Booth #815 Wire Expo 2010 May 12/13 Milwaukee, WI

Micro-Weld

1.Easy Operation 2.Precise

1296 Mark Street Bensenville IL 60106 USA Phone: 630-787-9350 Fax: 630-787-9360 www.micro-weld.com

50 | WIRE JOURNAL INTERNATIONAL

3.Dependable 4.Tough 5.Better Productivity

Visit us at Wire Expo booth #313

INVEN INVENTORS NTORS AND MUCH MORE E 4

CCR LINES Aluminium CCR Rod Lines Aluminium Alloy CCR Rod Lines Copper CCR Rod Lines Copper Rod from 100% Scrap

WMD Wire Machinery Division (RTM-OTT) Drawing Lines for HC-LC-Stainless Steel-AS Wire PC Strand Lines PC Wire Lines Steel Ropes Lines

INGOT CASTERS Wheel & Belt Track & Belt

PROPERZI MICROROLLING® Microrolling

www.properzi.com · hq@properzi.it HEADQUARTERS Continuus-Properzi Continuus-P Pro operzi S.p.A. S p A. S.p. V ia Emilia Km m 310, Via 26858 Sor dio o (LO), ( LO ), Italy Sordio Phone: +39. 02. 988 49 21 Fax: +39. 02.. 981 03 58 hq @ properzi.it properzii.it

FRANCE DIVISION Properzi Properzi France Parc d’activité du Vert Vert e Galant Parc Avenue v 78 Avenue du Château F 27745 Saint Ouen l’Aumône, France Phone: +33. 1. 34 32 34 80 Fax: +33. 1. 34 32 34 89 properzi.fr info @ properzi.fr

USA BRANCH Properzi Pro operzi International, Interna ational Inc. ational, Inc. nc Ridgebrook Road R 909 Ridgebrook Suite # 102 d 21152, USA Sparks, Maryland Phone: +1. 443. 212. 4320 2 905 5. 4320 Fax: +1. 866. 905. properzi.us s info @ properzi.us

FEATURE

areas such as inexpensive shipping reels, cable reels, oneway spools, MIG reels, braiding and tape reels, to name a few. It offers process reels that meet DIN requirements, reels for cabling and stranding as well as custom reels for extending the areas of applications. Häfner’s latest product family, DEMOPAC® packaging reels for the cable industry, allows two halves to be stacked and transported in an innovative space-saving way, before assembling with an easy twist by hand. Two different halves allow for a combination of three alternative winding widths, all of them designed for automatic winders. Some specific interesting products include: MIG wire reels for automatic winding; 500-mm delivery spools for enamelled copper wire; precision delivery spools for the photovoltaic industry; dismountable flanges and barrel up to 1000 mm for metal tapes, stampings and tubes; and germ-free spools for medical technology. All products are manufactured from environmentally friendly plastic raw materials that are suitable for recycling. www.hafner-spools.com.

Inosym Ltd.

Visit us at Wire Expo booth #902

Reaching new levels of excellence for composite bows.

At Frontier we pride ourselves on the quality of our products and the exceptional level of service and support we povide to our customers.

115 Cushman Road, Unit 8 St. Catharines, Ontario Canada L2M 6S9 Tel 905 685 3633 Fax 905 685 3482 Email info@frontiercomposites.com

www.frontiercomposites.com

52 | WIRE JOURNAL INTERNATIONAL

Inosym Ltd., a New Zealand-based worldwide supplier of reels and spools to the wire and cable industry, offers an extensive range of reels and spools suitable for all types of manufacturing processes. This includes fine wire drawing, high-speed extrusion and layup-stranding operations. With customers in more than 40 countries, Inosym is truly an international reel and spool supplier. The company’s ability to work with customers to offer flexible designs at costeffective prices is becoming a trademark of its quality service. To complement the existing steel and ABS plas- Reels from Inosym Ltd. tic product range, Inosym has developed a wire drawing and bunching plastic reel. It is an ABS reel designed for high run speeds of up to 3000 rpm for use in wiredrawing, bunching, stranding and transportation, The key advantage is that this reel weighs a third of equivalent standard mild steel reels. That offers benefits for machine loading, reducing machine wear, operator handling and transport, storage and environmental durability. The reels come in a number of sizes and dimensions, from standard 7 in. to 28 in., with bores of 5 in. and various traverse widths. www.inosym.com. U.S. reps: USA/Canada North East, North Central, Technical Marketing Services, tmspat@cox.net; U.S. Southeast and South Central, Technical Development Corporation, irv.baston@technicaldevelopment.com; and U.S. Southwest, camarena@worldnet.att.net.

Visit us at Wire Expo booth #619

FEATURE

IWE GmbH/Wire Machine Systems Germany’s IWE GmbH, represented in North America by Wire Machine Systems, has six decades of experience manufacturing precision reels. IWE offers a complete line of reels, including reels for drawing, annealing, stranding and other processing and shipping applications. Its reels, which are built to withstand today’s tough industrial environments and able to be run at high speeds, can be ordered as standard products or customized for specific needs. In addition to its line of

An assortment of precision reels that are offered to the wire and cable industry by Germany’s IWE GmbH.

On-line WJI Extra special: equipment for the last step Beyond spools and reels, packaging solutions include equipment that can process product and prepare it for shipping. This page, which presents a half dozen such suppliers, can be found at www.wirenet.org by clicking on “Wire Journal International,” and then “Wire Journal Extra,” then “April.” There, this same page will launch information, including links to video, for these companies. Gimax Srl Gimax Srl, the main company within Italy’s Gimax Group, offers a full range of fully or semi-automated respooling lines and drum packers for ferrous and nonferrous wires. Other products include wet drawing and coppering for steel wire, drawing/shaving/cleaning lines for aluminum wire, and individual payoffs and take-ups of various sizes, as well as customized product handling/ packaging systems. www.gimaxgroup.com. Niehoff GmbH Germany’s Niehoff GmbH, which supplies a wide range of equipment, from wiredrawing systems to rod breakdown lines and more, also offers the Niehoff Packaging System (NPS). The NPS is an efficient, safe, reliable and economic handling system for wires, bunches, strands, conductors and cables. It has a dominant share of the automotive market in Europe, replacing alternatives such as cardboard barrels, boxes and disposable packaging. The company’s North America business is Niehoff Endex North America. www.niehoff-usa.com. MGS Group The MGS Group (MGS-Hall-Northampton) provides its customers the highest level of automation and technology for product handling and twisting systems, customized to optimize individual applications, using comprehensive design and engineering capabilities, with equipment

54 | WIRE JOURNAL INTERNATIONAL

ruggedly built for decades of reliable, consistent service. Products include take-ups, automatic packaging systems with robotic handling of reels. www.mgshall.com. PS Costruzioni Srl Italy’s PS Costruzioni’s technology is used around the world and depended on by industry leaders because of its reliability. A family business with a heritage of knowhow and a willingness to experiment, it offers a wide range of packaging equipment that includes automatic coil winding lines, automatic spool winding lines, automatic coil and spooling lines as well as rewinding lines, semiautomatic lines, and now, rewinding lines, all of which are designed to provide high-speed processing technology that ensures a final product that is ready to ship to customers. www.pscostruzioni.com. Skaltek AB Sweden’s Skaltek AB’s innovative philosophy is reflected in teh company’s management and the equipment it produces to create its Skaltek Mini Pac Pure, the Skaltek Midi Pac Pure and the Skaltek Big Pac packaging solutions. Skaltek is known for many innovative solutions for payoffs and take-ups, two of which include the company’s patented self-locating pintles and tire drive. These solutions offer better ways, more cost-effective solutions, to cable makers worldwide. www.skaltek.com. Windak AB Founded in 1993, in Stockholm Sweden, Windak AB maintains offices in Hickory, North Carolina, Sydney, Australia and Tallinn, Estonia. Windak offers a wide range of both standard and customized products. Material handling solutions include palletizing and pallet handling equipment. Packaging solutions include coiling and spooling equipment for wire and cable, tubing and other flexible products. www.windak.se.

FEATURE

reels, it offers reel handling equipment that includes lifting and tilting devices, wire carriers, customized pallets and other special designs. www.wire-machine.com, www.iwe-reels.com.

J. Hamelin Industries J. Hamelin Industries, a leading Canadian supplier of wood and plywood reels, marks 2010, the Olympic year, as one with many challenges and opportunities. A year has passed with our new partner, Carris Reels, and many operational synergies have been realized. J. Hamelin now offers a broader range of products to its Canadian customers, servicing its growing northeast U.S. customer base from a Carris facility in Enfield, Connecticut.

Canada’s J. Hamelin Industries has made reels as large as 168 in. in diameter that can carry up to 35 tons.

Visit us at Wire Expo booth #807

Hamelin has manufactured wood reels for over 70 years. The company produces all its nailed-wood reels from its plant just north of Montreal and can ship to the U.S. and offshore from there. It also has rail access throughout Canada. As part of its wood reel offering, the company produces many large diameter reels, with large weight capacities. It often supplies reels that are 118 in. in diameter, each carrying 18 tons, and it has built reels as large as 168 in. in diameter that have carried up to 35 tons. The advantage over steel is the company’s ability to quickly design and build these reels and arrange for delivery to cable sites. Furthermore, they are competitively priced. With Carris’ extensive network of assembly operations J. Hamelin has been able to identify opportunities that can now be met from these locations. Hamelin has been repairing returnable wood reels for the Canadian market for more than 25 years. See p. 46. With strategically located hubs for reel consolidation and the “tracking capabilities” through bar code and sophisticated proprietary applications, J. Hamelin and Carris can provide North America wide solutions. www.hamelin.com.

L-S Industries U.S.-based L-S Industries, Inc., provides much of the industry with a variety of light-duty and protective wraps for wire and cable shipped and stored on reels. The com56 | WIRE JOURNAL INTERNATIONAL

FEATURE

pany’s light-duty wraps protect the wire or cable from the elements and dust, and some even serve as brand advertising with a printed logo. Reels with protective wraps from The protective L-S Industries. wraps protect wire or cable from damage during shipping and are much easier to apply than wood lagging. The company also provides ancillary reel packaging products, such as drum liners, flange protectors, and printed placards for metal spoke reels. It has also developed a small reel made from lightweight, recyclable corrugated plastic that is perfect for installers due to its light weight.www.l-si.com.

Metavan NV/Howar Equipment Belgium’s Metavan NV, represented in North America by Howar Equipment, has created a niche market for itself by specializing in a product that has widespread use in the wire and cable industry: pressed steel reels. These reels have been in greater demand as the integration of automation requires a product that allows for increased efficiency and reliability at a competitive price. Metavan supplies pressed steel reels for final packaging and shipping requirements, specializing in lightweight one-way and multi-way units.

Madem Reels Group Brazil’s Madem Reels Group is a leading reel manufacturer, producing approximately four million reels a year at its manufacturing plants in Brazil, U.S., Spain, Romania and Bahrain. The company has more than 20 warehouses worldwide and supplies high-quality Heat Treated (HT) reels according to ISPM 15 and made of renewable pine. Madem covers all production steps, from the forest to the sawmill to the plywood mill and to the reel plant, using logistic solutions. Its monthly production is around 500 truckloads that supply more than 100 customers in more than 40 countries. Madem is ISO 9000 and ISO 14000 certified. One interesting new product is the company’s wooden cable drum kit, which allows customers to easily Stacks of collapsible reel parts from assemble the Madem Reels. drums. All parts (flanges, staves and hardware) are inside the unit, which: allows for justin-time assembly, requires less forklift movement and storage space, makes for easy inventory control and reduces logistic costs. Another is a locking steel bushing that replaces the square steel bushing. It has a locking system that prevents the bushing from moving and while it is less expensive than normal bushings, it provides the same strength. The company has also introduced plywood reels with a plywood barrel. This flexible plywood barrel, made by Madem, is less expensive than fiber barrels. www.mademreels.com.

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These reels are a staple for many bare steel and copper wire manufacturers. Metavan offers common sizes, such as the 30 in. (760 mm) reel, but it also can supply them in 55, 80, 95, 120 and 145 lb weights. The lightweight version is often used as a one-way shipping reel, supplied either bare or powder-coated. The 120-145 lb reels are predominantly used as in process and returnable shipping reels. These reels can generally be made in two to five weeks as most of the material is standard and stocked inhouse. By focusing the company’s resources around the specific requirements of pressed steel reels, Metavan has established itself as a reputable manufacturer that consistently delivers a high-quality product. Its goal was never to manufacture everything, but to focus on a selected product range to the best of its abilities. sales@howarequipment.com.

Mossberg Industries U.S.-based Mossberg Industries and R-2 Systems have developed many exclusive packaging programs that protect customers’ interests and positions in their markets. Research and development takes a commitment of time and capital. Any molder can be a “me too,” but it takes a team effort to reach beyond and find proactive solutions for customers. Customers searching for packaging solutions are concerned about: cost reduction, improved efficiencies/scrap reduction, safety and reducing disposal costs. One good example of addressing such concerns is the company’s Gen II 48 in. reel. Customers had expressed concerns over the safety of splintered wood reels and the nails that can damage expensive cable. The R-2 Division of

Pittsfield Plastics Engineering, Inc.

Customers can also easily disassemble them and return the components for reuse, thus providing more cost savings. www.pittplas.com.

REELEX Packaging Solutions, Inc. As the sole provider of REELEX® tangle and twist-free reel-less packaging technology, U.S.-based REELEX Packaging Solutions, Inc., licenses the technology itself as well as manufactures the specialized coiling machinery necessary to package products. Sometimes known as a “pull box” package, REELEX is a patented method of winding cable or any cord-like product in such a way as to result in a reel-less, self supporting coil. This unique coil dispenses through a payout tube from the inside out without twists, tangles, snags or overruns. Sold under various brand names by leading wire and cable manufacturers, REELEX has become a staple for “last-mile” lengths of structured cabling such as Cat. 5e/6 cables and coaxial cables, and is quickly becoming the preferred package for many other types of products, like fiber optics, building wire, plastic tubing, and more. REELEX benefits every component in the sup-

Visit us at Wire Expo booth #206

U.S.-based Pittsfield Plastics Engineering, Inc., which recently expanded its plant in Pittsfield, Massachusetts, by 30%, is not only a domestic spool and reel supplier, it has an in-house mold making and repair shop. Customers with unique packaging issues can find help from Pittsfield because it can design a reel that meets specific needs. The company’s broad product

The new Break-Down Reel from Pittsfield Plastics, Inc. line of spools and reels includes its new patented Break-Down™ Reels. These reels can be shipped unassembled, saving on freight, and they are easily assembled without tools in 10 seconds.

APRIL 2010 | 59

FEATURE

Mossberg Industries developed a three-piece, heavy-duty, all plastic reel that can be shipped knocked down and assembled without any tools. The increased cost to dispose of wood reels has converted customers to all plastic reels that can withstand weather conditions and still be structurally sound for up to 200 uses. Mossberg Industries’ Jerry Understanding your cus- McCann, by a company reel. tomer’s application and handling methods determines the appropriate package. Experience is the key toward developing a packaging system that meets the customer specific requirements and the ability to offer innovative ideas. Mossberg’s in-house 3D design capabilities can quickly turn an idea into a model and then into quality production parts that meet the customer’s expectations. www.mossbergindustries.com.

FEATURE

plastic spool/reel sizes, from small precision spools for wire as fine as 56 AWG to the Reel Tough® 30 in. reels capable of carrying over 1,000 lb. Wire producers around the world have relied on Sonoco Crellin’s family of plastic spools and reels for more than five decades. Regardless of the challenges, Sonoco Crellin along with EconoReel offers the right solutions, from a low-cost utility spool to the most accurate, precision Reel Tough product for demanding, high speed applications. Further, Sonoco Reels (formerly Baker Reels) offers a complete selection of nailed wood, plywood, steel and

A range of products from REELEX. ply chain, as the packages are easy to handle, stack and palletize, are lighter than reels and spools, produce less waste and can be manufactured using environmentally friendly materials. The most popular packaging option, the cardboard REELEX box, has always been a comparatively eco-friendly package, as paperboard is compostable, recyclable and can be manufactured from postconsumer materials. Now, it is plastic-free as it has payout tube replacements made from the same paper fibers as the rest of the box. A new REELEX II® tube design brings eco-friendly disposable packaging to structured cabling products like Cat. 6//coaxial cables, fiber optics and more. As opposed to spools and reels that use multiple (and often environmentally hazardous) material types, these new tubes allow the entire empty package to be manufactured from a single material that is compostable, renewable, recyclable and can utilize post-consumer sources, thus offering a true sustainable packaging system. www.reelex.com.

Sonoco Reels and Spools Sonoco Reels and Spools, one of the world’s largest manufacturers of plastic spools and reels, was bolstered by its 2009 acquisition of EconoReel. Sonoco now offers EconoReel’s low-cost utility spool options that, coupled with Sonoco Crellin’s broad product line, offer the most extensive selection. This includes a complete range of

In addition to its line of wood reels, Sonoco offers a wide range of options. engineered composites. “Sonoco” is one great company with one common goal: to provide the engineering expertise, manufacturing capabilities and sales support to meet customer requirements for plastic, wood, steel, engineered composites spools and reels. www.sonoco.com, www.sonoco.com/reels.

Visit us at Wire Expo booth #502

60 | WIRE JOURNAL INTERNATIONAL

Eurolls Group at Wire D端sseldorf 2010 Hall 11 - Stand D40 12 - 16 April 2010 Visit us at Wire Expo booth #409 www.eurollsgroup.com

WIRE MACHINERY DIVISION

FEATURE

Vandor Corporation/Reel Options® U.S.-based Vandor Corporation was founded in 1973 and built a modern 125,000-sq-ft manufacturing facility in 2002. Its EnviroMold trademark is synonymous with environmentally responsible plastics production as all its products are made with 100% recycled and recyclable post consumer plastics. The company’s established products include: E~Z Brake® Boxed Reel Systems, which reduce/eliminate backlash tangles during despooling; EnviroMold STAPLED® and DEAD~BOLT® plywood replacement reels; paper-die-cut corrugated and chipboard reels, serving cordage and electrical connector industries; and three-flange reels for the fiber optics industry. New for 2010: leading designs driven by customers; CNC plywood cutting capabilities, featuring a specially designed cutting, routing and sanding system, that able to cut more than seven million plywood reel flanges per year, nearly 300% more than typical CNC cutting equipment; a plastic extrusion system that produces plastic cores for the EnviroMold Product line (mono-material plastic reels) including new utility sizes, as well as plastic cores with current EnviroMold plastic and plywood

A range of reels supplied by Vandor Corporation. flanged reels; and EnviroMold Utility Spools, a monomaterial design that is low cost and provides superior strength for 6.5 in. or 10. in. flange diameters. Products are sold in North America and Asia either directly or through a growing number of strategic manufacturing partner locations. www.reeloptions.com. ■

Visit us at Wire Expo booth #113

Manufacturers of both

‘HUSH’ & ‘LOCK ON’ PULLING IN DOGS T: +44 (0)1527 570977 F: 882423 E: sales@locton.co.uk www.locton.co.uk

62 | WIRE JOURNAL INTERNATIONAL

Radyne is the leading name in wire, cable and strip thermal processing solutions. Whether the requirement is for a complete turnkey system, an upgrade or an addition to an existing wire processing line, Radyne offers the ability to improve your heat treatment process, providing long term benefits and cost savings. Visit Booth #813 at Wire Expo 2010 and discuss metallugy and application soultions with Radyne’s Professor Induction, Dr. Valery Rudnev, FASM.

Focusing on: • High speed spring wire line in excess of 700 ft/min - Producing up to 3 tonnes/hr. on diameters of 4-14mm • Bright annealing of copper and stainless steel • In-line heating for strip and shaped wire • Continuous hardening, tempering and annealing • All wire heating applications • Power & frequency: 3kW - 2000kW @ 250Hz - 800kHz

For more information, call 800/236-8360 or visit www.radyne.com

Leading Manufacturers of Melting, Thermal Processing and Production Systems for the Metals and Materials Industry Worldwide.

Radyne Corp., 211 W. Boden St., Milwaukee, WI 53207

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Convention Dates: May 2-5, 2011 | Exhibit Dates: May 3-5, 2011 Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2011 IS ALIVE WITH POSSIBILITIES. IT IS RENEWED, INVIGORATED, AND TAKING A NEW TACK. WHO’S AT THE HELM? Senior executives from more than 25 key corporations are skillfully guiding major changes to the show. Their interest in Interwire—the largest wire and cable marketplace in the Americas— is resolute. Interwire affects their business and is clearly worth their personal time. The result is a series of carefully considered and nimbly integrated transformations to better Interwire. WHAT’S DIFFERENT? Location: Atlanta, Georgia. Relocated and familiar, Interwire returns to the city of its origin where it was introduced in 1981. Compact: 3 full days of exhibits. Interwire 2011 offers a concentrated show schedule. More operating equipment. Interwire is a machinery show. Visitors can count on more operational equipment in 2011. Renewed energy. Exhibitor participation is on the upswing showing a 14% increase between the 2007 and 2009 events. Networking opportunities, ranked as the #1 reason to attend the show, will be part of the landscape. Expect to see production solution demonstrations and other attendance-building activities on the exhibit floor.

Special industry theme days to be announced. We’re focusing on specific industry sectors that use wire and cable. Look for presentations, technical papers, and executive discussions to orbit around these central themes. Fully supported. Show management continues to work with the U.S. Department of Commerce and its International Buyer Program to interest a growing number of international participants in the show. Work with supporting sponsors, allied organizations, and educational supporters is ongoing to enhance the Interwire experience.

“Having all or most of the vendors in one location for a face-to-face has always had unmeasured value and still does, especially when times are tougher for travel and the like. Our company believes in the future of the business and that means get out there and find out what is going to take us into new future markets. I’ve already recommended that we return in 2011.” Ed Kozlowski, Senior Design Engineer W.L. Gore & Associates

SAVE THE DATE: MAY 2-5, 2011 AND LEARN MORE ONLINE AT WWW.WIRENET.ORG Interwire 2011 is organized by The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF MARCH 2010 Flyro FMS USA Inc./FMS AG Foerster Instruments Inc. Fort Wayne Wire Die Inc. Fortune Machinery Frontier Composites & Castings Inc. Fushi Copperweld Garg Sales Co. Ltd. Gauder & Co. Gauder Group Inc. Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co. Inc. Genca/Canterbury Engineering W. Gillies Technologies Gimax SRL Guill Tool & Engineering Co. V. Hagen & Funke Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Huestis Industrial Huettner Maschinenfabrik GmbH ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC Inosym Intras Ltd. Italian Trade Commission IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA - International Wire & Machinery Association JMS Machinery Joe-Tools Kalmark Ltd. Kieselstein GmbH Ernest Koch GmbH & Co. KG Albert Krenn Friedrich Krollman GmbH & Co. KG Lamnea Bruk AB LaserLinc Inc. Leoni Wire Inc. OM Lesmo Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates LUKAS Anlagenbau GmbH M + E Macchine + Engineering Madem Reels USA Inc./ Madem SA

Magnetic Technologies Ltd. Maillefer SA Mapre Belgium SA Merritt Davis MFL USA Service Corp. Frigerio The MGS Group (MGS-HallNorthampton) MGS Manufacturing Inc. Micro Products Co. Millennium Steel & Wire Inc. Morgan-Koch Corp. MPI Machines Ltd. NEPTCO Inc. Nextrom Oy Niehoff Endex North America Inc. NUMALLIANCE Oklahoma Steel & Wire OMA SRL OMA USA Inc. Paramount Die Co. Parkway-Kew Corp. Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plymouth Wire Reels Pourtier - Gauder Group Precision Die Technologies Inc. Properzi International Inc. Proton Products QED Wire Lines Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic RichardsApex Inc. Rizzardi Rosdendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. SAMP SpA SAMP USA Inc. SAMPSISTEMI Schlatter Inc. Schunk Graphite Tech Setic SAS Sictra Srl SIKORA International Corp. SIMPACKS Sirio Wire Srl Sjogren Industries Inc. SKET Verseilmaschinenbau GmbH

Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stema/Pedax Stolberger Inc. (dba Wardwell Braiding Co.) Stolberger KMB Maschinenfabrik GmbH T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Teknikor Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Traxit North America LLC Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. United Wire Uniwire International Ltd. US Reel US Synthetic Wire Die Vandor Corp. Vitari SpA Vollmer America Inc. Wafios Machinery Corp. WCISA - Wire and Cable Industry Suppliers Association Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2012/Messe Düsseldorf North America The Wire Association International, Inc. Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Wyrepak Industries Inc. Ya Sih Technology Yield Management Corp. Zeus Zumbach Electronic AG Zumbach Electronics Corp.

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Ace Metal Inc. AFL AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne A. Appiani AW Machinery LLC B & H Tool Co. Inc. Balloffet Die Corp. Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp. Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp. Butt Welders USA Caballe SA Cable Consultants Corp. Carris Reels Inc. Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CN Wire Corp./Er Bakir Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp. Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Daloo Davis-Standard LLC Dem Costruzioni Speciali Srl Die Quip Corp. Dynamex Corp. EJP Maschinen GmbH Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl Eurowire Magazine George Evans Corp. Fabritex Inc. FIB Belgium SA Filtertech Inc. Fine International Corp. Fisk Alloy Conductors Flymca

European developments in the reaction to fire testing of cables

LV E R ATE C I F I T CER AWA R

TECHNICAL PAPERS

TECHNICAL PAPER

Progress continues in the wire and cable industry in terms of current and pending directions for cable manufacturers for issues related to fire performance.

By Terence Journeaux

This paper gives an overview of the current status and possible future direction in the way that regulators, specifiers and cable manufacturers address reaction to fire performance when cables burn. Specifically, it addresses the situation in the European Union. It is not intended to provide a detailed description of the test methods used or a discussion as to their validity. The cable industry has had a long history, back to the 1960s, in the development of test methods and products designed to lessen the hazards resulting from burning cables. The industry was one of the first in the electrotechnical sector to develop tests for the assessment of the reaction to fire performance of its products and has continued to refine and improve these methods over the years. Standards covering flame spread, heat release, opacity, corrosivity and toxicity of fire effluent are today in use, and

the industry continues to sponsor research into the improvement of the fire performance of its products and the definition of appropriate test methods. The fire area has had a longstanding commitment to international standards through the IEC (International Electrotechnical Commission) and many national and regional standards, e.g. EN (European Standard) are based on the IEC publications. Within this international framework, there are differences from region to region and country to country in the way that the hazards of cable combustion are approached and the applications for which established test methods are referenced. The industry therefore provides products with a wide range of reaction to fire performance to reflect the varying end user requirements.

Historical development Much of the early work relating to improvements in the fire performance of electric cables was carried out in the 1970s and 1980s1-3. A four-stage approach was taken to: minimize the hazard by restricting the amount of burning and reducing the propagation of fire along cable runs; minimize smoke emission that obscures exits for escape; minimize emission of acid gas that leads to corrosion of equipment; and minimize emission of harmful fumes leading to incapacity or irritation and prevention of escape by people. It was recognized that these factors would assume varying levels of importance according to the particular market sector and typical installation condition considered4. The cable industry also was aware that it would need to develop its own tests to properly assess the performance of its products. Although this early development led to a series of tests that could be said to lack integration, the approach when taken as a whole still sits well with current thinking. Another important consideration was that large scale

Fig. 1. Schematic of prEN50399 test apparatus. 66 | WIRE JOURNAL INTERNATIONAL

Current situation The relevant IEC test standards have remained largely unchanged over recent years but have been subject to ongoing refinement5-8. For example, IEC 332-3 has developed into a multipart standard with each part covering a different installation condition or time of exposure to the fire source. The principles established in the early development of these standards still serve cable manufacturers and users well and the IEC standards are adopted in many countries. Based on the use of these tests, one can find in the market: Reduced flame propagation (RP) cables. These cables, when installed in vertical bunches in accordance with the recommended procedures, do not propagate fire more than a limited distance from the source. Such cables have been well established in the market since the 1970s for cabling in areas where, because of installation conditions, e.g. vertically mounted bunched cables, risk of fire propagation is high. They are tested to the various parts of IEC60332-3. Low-smoke cables. These cables have limits on smoke evolution when assessed in the 3m cube smoke chamber with performance limits chosen to give visibility over a 10 m distance. They were introduced because cables containing conventional sheathing materials based on PVC were seen to give off large amounts of dense smoke when affected by fire. Such cables have been manufactured since the 1970s, but it was not until advances in cable making material technology in the 1980s that cost-effective designs became widely available on the market. They are tested to IEC61034-2. Generally, cables of this type also combine the properties of low-corrosive gas emission and are manufactured using “halogen-free” materials. Low-corrosive gas-emission cables. These cables have limits on acid and corrosive gas emission that are verified by burning samples of materials in a bench tube furnace. They were first introduced when users began to raise concern over the large amounts of acid gas emissions from burning reduced propagation PVC cables. This corrosive and irritant gas had been seen to have devastating effects on electrical panels and instrumentation exposed to cable fire effluent9,10. The acid gas emission test of IEC60754-1 and/or the indirect corrosivity test of IEC60754-2 may be used. Products meeting the requirement of less than 0.5% acid gas emission per IEC60754-1 are often referred to as “halogen-free.” In some product standards, an additional test for fluorine content (IEC60684-2) is required. Cables having low emission of toxic gases are generally restricted to specific applications where end users have imposed such a requirement. Such cables are particularly found in the rail sector. Users have their own “toxic emis-

sion” standards ranging from a simple restriction on certain elemental groups to indices derived from an analysis of the gases evolved and weighted to the known mammalian toxicity factors of the gases present. The lack of general use of toxicity testing for cables may be explained by early work carried out in the U.K. which concluded, “From this brief excursion into consequences it appears that the acidic gas concentrations likely to cause harm to people and plant are similar” 11,12. Current work13 continues to demonstrate the large contribution of hydrogen chloride (HCl) as a fire hazard. Some interesting new work studying the effect of important irritant gases on animal lungs14 has also found that HCl and PVC smoke inhalation caused Fig. 2. prEN50399 an acute effect with a rapid apparatus.

Fig. 3. Typical SPR and HRR curves.

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TECHNICAL PAPERS

tests should be developed, wherever relevant, to assess performance of the total product in something approaching an “as installed” condition. International work concentrated on the development of test methods so that these could be adopted as an “add on” to product standards so the widest possible levels of fire performance could be achieved across the full range of product types.

TECHNICAL PAPERS

rating the performance characteristics of reduced flame propagation and low emission of smoke and harmful gases. Although the existing suite of IEC TC20 standards allows a basic overall approach to fire safety when combining the various elements (it is common for product standards to call up IEC60332-3, IEC61034, IEC60754-1 and/or IEC60754-2), recent developments have been towards a more integrated approach with test standards that have the potential to measure flame spread, heat release, smoke obscuration and combustion gas release.

European reaction to the CPD fire classification Of particular importance to the European market is the develop1. For the product as a whole, excluding metallic materials, and for any external component (i.e. ment of prEN5039915,16, a test sheath) of the product. standard based on the apparatus of 2. s1 = TSP1200 ≤ 50 m2 and Peak SPR ≤ 0.25 m2/s IEC60332-3-10 with the addition s1a = s1 and transmittance in accordance with EN 61034-2 ≥ 80% of an exhaust duct equipped to s1b = s1 and transmittance in accordance with EN 61034-2 ≥ 60% < 80% measure heat release rate and s2 = TSP1200 ≤ 400 m2 and Peak SPR ≤ 1.5 m2/s smoke production rate. The stans3 = not s1 or s2 dard has been developed to sup3. For FIPEC20 Scenarios 1 and 2: d0 = No flaming droplets/particles within 1200 s; d1 = No flaming port the classification “Classes of droplets/ particles persisting longer than 10 s within 1200 s; d2 = not d0 or d1. reaction-to-fire for electric 4. EN 50267-2-3: a1 = conductivity < 2.5 μS/mm and pH > 4.3; a2 = conductivity < 10 μS/mm and cables” per an October 2006 pH>4.3; a3 = not a1 or a2. No declaration = No Performance Determined. Commission Decision amending 5. Air flow into chamber shall be set to 8000 ± 800 l/min. Decision 2000/147/EC impleFIPEC20 Scenario 1 = prEN 50399-2-1 with mounting and fixing as below menting Council Directive FIPEC20 Scenario 2 = prEN 50399-2-2 with mounting and fixing as below 89/106/EC as regards the classifi6. The smoke class declared for class B1ca cables must originate from the FIPEC20 Scen 2 test. cation of the reaction-to-fire per7. The smoke class declared for class B2ca, Cca, Dca cables must originate from the FIPEC20 Scen 1 formance of construction prodtest. ucts. It defines the test methods 8. Measuring the hazardous properties of gases developed in the event of fire, which compromise the “FIPEC20 Scen 2” and “FIPEC20 ability of the persons exposed to them to take effective action to accomplish escape, and not Scen 1” given in the Commission describing the toxicity of these gases. Decision. See Fig. 4. Although the prEN50399 test equipment is based upon the preexisting IEC60332-3 series, results from the two procedures decline in the lung physiology parameters. This work are not comparable because the prEN50399 procedure is would appear to support a cable industry position to offer based upon a standardized “worse case” cable mounting as for particular applications products not releasing important adopted in the decision, whereas the IEC procedure is irritant gases (i.e., HCl from PVC compounds) due to the based upon an “as installed” cable mounting. Smoke proability of such gases to hinder escape and damage lungs duction is measured in the dynamic prEN50399 test but the and reinforce the position of “acidity” as an indicator for resolution is such that the test is not capable of measuring important irritant toxic effects. the low levels of smoke associated with state of the art lowThe generic description Low Fire Hazard has been adoptsmoke cables for metro applications and the like. Thus, the ed by European cable makers to describe cables incorpoIEC(EN)61034-2 method is included to assess the highest Fig. 4. Classes or reaction-to-fire performance of electric cables.

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class. Acidity is assessed using the existing EN50267-2-3 method which is technically equivalent to IEC60754-2. With the publication of the Commission Decision, the question as to the availability of classified cables becomes relevant. Although all the required test methods are available, at least in draft form, there can be no CEmarked cables under the Construction Products Directive (CPD) for their reaction to fire performance on the market until all the standards required to support such marking are available. In order to enable Notified Bodies to issue certification of product conformity, Fig. 5. Typical output curve of toxic gas production in an EN50399 test. it is necessary to prepare European Harmonized Product Standards (ENs) and other supporting standards under mandate of the European Commission. CENELEC has to develop and publish these standards and until that happens, it data necessary for classification can be obtained. The final is not possible to officially issue any certification for CE draft standard is ready for formal vote in CENELEC. Marking under the CPD for reaction to fire performance of As part of the test method development, more than 20 cables. laboratories have taken part in a proving round robin and Mandate (M/443)17 for cables concerning standardizarepeatability and reproducibility were found to be compation work for harmonized standards was given to rable with other large scale tests such as the SBI. CEN/CENELEC in June 2009 with a scope covering Considerable experience, including more than 200 tests on power, control and communication, and optical fiber cables cables representing generic constructions widely used in for use in buildings and other civil engineering works subEurope, has been obtained with the test method during the ject to regulation (all voltages included). For performance CEMAC II project. This has brought together cable manucharacteristics, the scope covers reaction to fire, resistance facturers, research and testing laboratories and research to fire and dangerous substances. CENELEC has accepted establishments in the implementation process in order to the Mandate in principle and were expected to have subcreate the technical background. mitted a detailed response with a work program in March A specific objective of the CEMAC II project was to 2010. It is expected that the first phase of the work will develop rules and procedures for extended application of focus on those documents needed to support marking for test results (EXAP) that define which constructions should reaction to fire, but it is unlikely that these will be completbe tested in order to obtain classification for a defined famed before late 2011. ily of cable constructions. The final report was submitted The Harmonized Product standard is the key to CE to the sponsors at the end of 2009 and is expected to be marking under the CPD, but development of such a stanmade publicly available during the second quarter of 2010. dard presents a difficult problem as there are many diverse Definitive documented Rules for extended application cable types and the CPD only applies to their reaction to (EXAP) are necessary to prevent a situation where every fire, resistance to fire and dangerous substances, with other individual cable design has to be tested for classification. It safety parameters covered under the Low Voltage Directive is necessary to establish which cables need to be tested to (LVD). A solution of a performance-based standard that gain approval for a product range through rules which can be applied to any cable type and specifically covering enable tests on defined products within a family to be aspects under the CPD is under consideration. extrapolated to other similar constructions within the famThe Classification standard is an important administraily. The EXAP rules have been developed by the CEMAC tive document that links test results to a classification and II research project and will be published by CENELEC. includes information on the tests to be carried out, the number of tests for classification, the assessment of results Possible future developments and the classification criteria. It has been agreed in principle by CEN and CENELEC that cables will be included as It is clear that the European cable industry will be heavian amendment to the existing EN 13501-1 so that all prodly involved with the new integrated reaction to fire test ucts under the CPD are included in one document. approach of EN50399. Together with the other European The Test method standard (EN 50399) ensures that the classification test requirements, this will require consider-

TECHNICAL PAPERS

able effort in the development of products to meet the various Euroclasses. It is likely that EN50399 will be considered by IEC at the next major review of spread of flame test methods, which is due to held during 2012–2015. Although at present there is an absence of any strong regulatory of user-driven impetus, the industry is beginning to consider suitable product tests to measure effluent and provide data that could be used in fire safety engineering studies, such as escape modeling. The integrated EN50399 test could provide a good basis if further equipped to measure effluent quantity and quality. The development of real time FTIR techniques for measuring effluent has led to some preliminary work being carried out to determine if it is possible to measure effluent quality during the EN50399 test. Presentations at a 2009 Europacable seminar18-20 suggest that it was feasible to measure effluent from the EN50399 test using FTIR techniques, to use such techniques to investigate the smoke effluents and to use the input in a simulation of critical evacuation conditions in order to compare the use of different cable types. Determination of a FED and FEC index according to ISO TS13571 during the test could provide a useful measure. Using such techniques, it was concluded from the simulation study that whereas critical conditions for some of the occupancies were achieved for the design fire when considering standard (PVC-sheathed) cables due to the production of irritant gases (HCl, acreolin, formaldehydes) and smoke (reduction of visibility below 10 m), critical conditions were not achieved for any occupancy when considering Low Fire Hazard cables.

Conclusions By reacting to the requirements of its customers with regards to the reaction to fire performance, the cable industry continues to offer a range of products with different levels of performance consistent with users needs for particular applications and installation conditions. Principles established more than 20 years ago to control the burning, smoke emission and emission of the most important corrosive and irritant gases remains valid today, although refinement and improvement in methodologies have been achieved in the intervening years. The advent of new requirements based on integrated tests involving heat release has been, and will continue to be a major challenge particularly in Europe. The effects of the new European regulatory framework for the classification of a cable’s reaction to fire performance will be a major change from the existing voluntary position. Just how the European classification and CE Marking of fire performance under the CPD will affect the cable market is difficult to predict. Implementation is strictly a national matter and while some countries that do not now regulate for the reaction to fire performance of cables have no intention of regulating in the future, other countries have indicated an intention to use the classification in regulation. However, which Euroclass is specified for any particular application is again a national matter. 70 | WIRE JOURNAL INTERNATIONAL

At a European level, it is likely that the cable industry will continue to be required to supply many different levels of performance, although in time one may expect to see users moving towards the higher classes as cost-effective cable designs become available. Comparison of prEN50399 tests with results from existing IEC tests is difficult due to the different conditions selected for the tests and the multi-criteria approach of the classification. Experience gained from the CEMAC II project has shown that prEN50399 results are in general greatly influenced by cable size: the smaller the cable, the more onerous the test. Results for larger power cables (conductor sizes greater than 35 mm²) can generally be predicted from IEC60332-3-24 (Category C) test results as the mounting in each test is similar, but no such relationship exists for smaller cables due mainly to the totally different mounting in each test. Recent work has demonstrated that real time measurement of effluent in a large scale fire test (such as prEN50399) is possible and that such results can be used as input into modeling studies. However, it is clear that further work would be necessary before any standardization could take place. Through its ongoing and demonstrated ability to invest in research, the cable industry will be in a good position to meet the challenges resulting from any new regulatory or end user demands on the fire performance of its products.

References 1. C. Zanelli, S. Philbrick and G. Beretta, “Cavi e pericolo di incendio,” Cired, London, 1973. 2. S. Philbrick and J. McConnell, “Cables having improved fire performance,” Jicable 84, Versailles, 1984. 3. T. Journeaux, G. Beratta and P. Gautier,” “Development of cables with improved fire performance characteristics,” Jicable 87, Versailles, 1987. 4. T. Journeaux, “The development of new standards for offshore cabling,” PRI Conference Polymers for Offshore Cabling Proceedings, London, 1987. 5. IEC Standard IEC60332-3-10: 2000 + A1, 2008 Tests on electric cables under fire conditions – Part 3-10: Test for vertical flame spread of vertically mounted bunched wires or cables, Apparatus. 6. IEC Standard IEC 60754-1:1994, Test on gases evolved during combustion of materials from cables, Part 1: Determination of the amount of halogen acid gas. 7. IEC Standard IEC 60754-2:1997, Test on gases evolved during combustion of electric cables, Part 2: Determination of degree of acidity of gases evolved during the combustion of materials taken from electric cables by measuring pH and conductivity. 8. IEC Standard IEC 61034-2: 2005, Measurement of smoke density of cables burning under defined conditions, Part 2: Test procedure and requirements 9. J. Gibbons and G. Stevens, “Limiting the corrosion hazard from electrical cables involved in fires,” Fire Safety Journal, 15, pp. 183-190, 1989.

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10.Telecom Australia, Design standards Branch, HQ Fire loss report, 1987. 11. G. Stevens, “The appraisal and significance of acidic gas emissions from burning electric cable materials,” 5th BEAMA International Electrical Insulation Conference, Brighton, 1986. 12. T. Journeaux, “The development and manufacture of Sizewell B cables,” Proceedings, IEE International Conference on control aspects of the Sizewell B PWR, pp. 74-79, London, 1992. 13. T. Hull, A. Stec and K. Paul, “Hydrogen Chloride in Fires,” IAFSS 9th International Symposium, Karlsruhe, 2008. 14. T. Hertzberg, P. Blomqvist and L. Lastbom, “Influence of HCl and PVC-smoke on isolated and perfused guinea pig lungs,” SP Fire Technology Report 57, 2006. 15. T. Journeaux, “Development in regulatory classification methods that will affect the European cable industry and its suppliers,” Flame Retardants 2008, Interscience Communications Ltd., London. 16. Draft prEN 50399: Common test methods for cables under fire conditions, Heat release and smoke production measurement on cables during flame spread test, Test apparatus, procedures, results, CLC TC20/Sec1577/INF June 2008. 17. European Commission, Mandate to CEN and CENELEC concerning the execution of standardisation work for harmonised standards on power, control and communication cables M/443, Brussels, May 2009. 18. P. Johansson, P. Blomquist and B. Sundstrom, “Feasibility study of supplementary FTIR measurements in tests with electric cables according to Commission Decision 2006/751/EC, FIPEC20Scen1 (prEN50399),” “Safety during fire,” Europacable, Brussels, 2009. 19. S. Messa, “Investigation into the smoke effluents of burning cables,” Safety during fire, Europacable, Brussels, 2009. 20. P. Van Hees and D. Nilsson, “Simulation of critical evacuation conditions for fire scenario involving cables and comparison of different cables,” Safety during fire, Europacable, Brussels, 2009. ■

Journeaux Terry Journeaux has been working as a technical and marketing consultant of Prysmian Cables and Systems Limited since he retired at the end of 2008. After graduating from the University of Sussex, he obtained nearly 40 years of experience working in the cable industry in various quality, technical, commercial and marketing roles. Much of his career has been closely involved in the development of fire performance cables and markets. His expertise in the fire area has been recognised by appointment as a member of the EC Expert Group on Fire and Convenorship of IEC TC20 WG18 “Burning characteristics of electric cables” and CLC TC20 WG10 “Fire performance tests for cables.” He was Project Leader for the now completed major Europacable funded CEMAC II project “CE-Marking of Cables.” This paper, which was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009, won the Silver Certificate Award in the Electrical Division.

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TECHNICAL PAPER Influence of angles of approach and bearing parts of dies on mechanical properties of drawn steel carbon wire Test of 13 different die variants found substantial differences on the resulting mechanical properties for drawn steel carbon wire. By Jan Krnac, Rafał Włudzik, Jan W. Pilarczyk, and Robert Kruzel

Recently, the influence of the approach zone and the bearing part of a die on longitudinal residual stresses and mechanical properties of high-carbon steel wire has been investigated and published1-2. In the research, different die types have been used, such as concave, convex and conical with a cylindrical and conical bearing part. The longitudinal residual stresses have been tested both in the laboratory (electrolytic etching) and by numerical analysis of a drawing process (Drawing 2D software). It has been found that the lowest values of residual stresses on the wire surface were for wires drawn in concave dies with a conical bearing part. The research considered only one value of the slope in the conical part, and because of difficulties in manufacturing concave dies it is worth searching for a way to achieve a drop of residual stresses from using typical conical dies with a modified bearing part. It also has been proven3 that the length of bearing part (related to the wire diameter at the die exit) has a remarkable effect on residual stresses. Longitudinal residual stresses significantly affect the fatigue strength of wires and their resistance in torsion tests. This work investigates the effect of three variables: die angle; bearing conical part slope; and the relative length for the above-mentioned properties. This was carried out to find a set of the parameters for which the highest mechanical and technological properties can be obtained.

Table 1. Chemical compositions of steel used in tests. 72 | WIRE JOURNAL INTERNATIONAL

Test materials and tools To estimate the effect of previously mentioned die parameters, 5.5 mm wire rod (C56D carbon steel) was used for drawing after pickling and a lubricant carrier coating. Table 1 shows the chemical composition of the wire rod. A drawing process has been performed on the 5.5 mm wire rod in two passes (4.9 mm, then 4.4 mm), with the latter process using dies with different die angle α, a slope in bearing part β and the relative length of the bearing part Lk. The last draw speed is 1 m/s. In total, 13 dies were manufactured to the parameters shown in Table 2. For the 4.4-mm wires with parameters cited in Table 2, mechanical properties such as total elongation A100, yield strength R0.2,

Table 2.Values of die angle α, bearing part angle β and relative length Lk/D of dies used in the work.

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tensile strength Rm were determined as well as technological ones: number of twists Nt, number of bends Nb as well as rotational beam tests number of cycles to failure. Fig. 1 shows the scheme of rotational beam test. The amplitude stress the rotational beam test was calculated from the equation:

Eq. (1)

where: f = arrow of deflection: f = 25 mm d = wire diameter: d = 4.4 mm E =Young’s modulus: E = 200,000 MPa l = specimen length: l = 440 mm Fatigue tests were performed for the wires for the value of the amplitude stress equal 680MPa. For estimation of the effect of aging process on fatigue resistance at this stress, numbers of cycles to failure were estimated after 30 and 90 days aging after drawing process.

Research results Mean values of mechanical properties (Rm, R0.2, A100) and technological ones (Nt, Nb) for the 4.4 mm and the values of number of cycles to failure N of those wires determined in a rotational beam test are placed in the Table 3. From that data, Figs. 2- 4 were prepared. Fig. 2 shows the relation of elongation A100 to the type of die used in drawing. From Fig. 2 and Table 3 it can be stated that the highest value of elongation of the 4.4 mm wires (5.5%) can be obtained for variant eight, which corresponds to die angle α = 10°, bearing angle β = 5° and the length of the bearing part to the wire diameter L k/d = 1.5. The smallest value of elongation is for variant five (α = 2°, β = 0.25° and L k/D = 1.5) and equals 3.9%. The difference is statistically significant. A relatively high elongation value (5.2%) can also be obtained for drawing wire in a die constructed according to variant four (α = 10°, β = 5° and Lk/D=0.1). Fig. 3 shows the relation of the number of twists Nt and number of bends Nb for 4.4 mm wire drawn in dies with different shapes. On the basis of Fig. 3 and Table 3 it can be stated that the highest number of twists (45 and 44.5) are from the wires drawn to variants six and 10, which corresponds to the following dies parameters: in the former case (α = 10°, β = 0.25° and L k/D = 1.5) and in the latter (α = 4°, β = 3° and L k/D = 1.5). The lowest number of twists (32.3)

Table 2.Values of die angle α, bearing part angle β and relative length Lk/D of dies used in the work.

Fig. 1. Scheme of rotational beam tester and distribution of bending moments in tested wire.

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TECHNICAL PAPERS Table 3. Mechanical (Rm, R0.2, A100) and technological (Nt, Nb) properties of wires with diameter 4.4 mm; steel C56D.

Fig. 2. Relationship of values of elongation A100 for wires with diameter 4.4 mm drawn in dies with different shapes.

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were found for wires drawn according to variant two (α = 10°, β = 0.25° and L k/D = 0.1) and it is more than 39% lower than the number of twists for wires drawn in dies made according to variant six. The 4.4 mm wire drawn in dies constructed according to variants six and 13 had the highest values for number of bends (24.7 and 24.8). The values for variant 13 are α = 10°, β = 3° and L k/D = 0.5) The lowest number of bends (20) were found for wires drawn in dies constructed according to variants eight and 12 (α = 10°, β = 5° and L k/D = 1.5) and (α = 5°, β = 2° and L k/D = 0.5). It is about 24% lower compared with number of bends of wires drawn according to variants 6 and 13. Comparing the effect of applied differences in the dies construction, it can be stated that the effect is stronger for the number of twists than for the number of bends of considered wires. Fig. 4 shows the relationships of tensile strength and yield strength of the 4.4 mm drawn wires for different variants of dies used in the work. From Fig. 4, it can be stated that dies with different approach and bearing angle and bearing length were more influenced by the variation of the yield strength (from 1018 to 1115 MPa: difference 97MPa) than on tensile strength (variation from 1205 to 1260MPa: difference only 55 MPa). The highest value of wire yield strength (1115MPa) for the 4.4 mm wire was obtained by drawing in the die constructed to variant 7 (α = 2°, β = 5° and L k/D = 1.5) and the lowest by a die constructed to variant 4 (α = 10°, β = 5° and L k/D = 0.1). The highest value of the tensile strength (1260

Fig. 3. Relationship of number of twists Nt and number of bends Nb of wires with diameter 4.4 mm for variants of dies parameters used in the research.

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MPa) for the 4.4 mm wire was obtained by a die constructed to variant 9 (α = 2°, β = 1.5° and L k/D = 1.5) and the lowest for variant 4. This variant wire also exhibited the smallest yield strength level. Table 4 shows the results of rotational beam tests (numbers of cycles to failure) performed at bending stress 680 MPa for the 4.4 mm wires drawn to the 13 variants for different die and bearing angles as well as in relative length of the bearing part. Tests were done after 30 and 90 days of natural aging to determine the effect of this process on wire resistance to fatigue failure. Using data from Table 4, Fig. 5 shows the results of cycles to failure for the 4.4 mm wires. From Fig. 5 and Table 4 it can be stated that for almost all variants of drawing (except 1 and 12), the number of cycles to failure for the Fig. 4. Relation of tensile strength Rm and yield 4.4 mm wires was higher for those aged 90 days than for those strength R0.2 of drawn 4.4 mm wire for different aged 30 days. variants of parameters of dies used for drawing The highest number of cycles to failure of the 4.4 mm wires the wires. after 30 days of aging was for wires drawn to variant 6 and variant 9, which was equal respectively at 31,657.5 and 30,084.5 cycles. The lowest number of cycles to failure was for wires drawn to variant 3, which was equal to 18,828.5 cycles. Comparing to variants 6 and 9, this was 68% and 59% worse for the number of cycles to failure. Wire bending can be regarded as a fatigue test with a low frequency (a small number of cycles to failure, Nb) and a high value of deformation amplitude. Considering that wire has a diverse application, and the use of wire is determined by its properties, the following properties come to the foreground: the nominal tensile strength (Rm), the number of twists (Nt) and the number of bends (Nb). Instead of using the three above-mentioned quantities, an idea was conceived to defined the properties of wire by a single index. Work undertaken by Prof. B. Golis, concerning primarily rope wires and spring wires, has resulted in the development of new methods for the determination of the properties of wires and ropes by theoretical means based on the properties: (Rm, Nt, Nb) [5÷7]. The effect of the factors (Rm, Nt, Nb) on the properties, as well Table 4. Number of cycles to failure of 4.4 mm wire (steel C56D) drawn in dies as their inseparable character, with different shapes of approach and bearing parts determined at the bending provided the basis for developstress 680 MPa.

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ing new indices:

Eq. (2)

The index Wb defines conventionally the tensile strength value per one wire bend.

Eq. (3)

Fig. 5. Dependence of number of cycles to failure of wires with diameter 4.4 mm drawn according to 13 variants of dies differing in approach and bearing angles and relative bearing length.

where: Rm = nominal tensile strength, MPa Nb = number of wire bends. The Wt index conventionally tells what the tensile strength value per one wire twist is.

Eq. (4)

where: Rm = tensile strength, MPa Nt = number of twists. The sum of the two above indices substitutes for the basic wire properties (Rm, Nt, Nb) equals:

Eq. (5)

Table 5 shows the values of indices W (Wt, Wb). On the basis of earlier published papers5-7, it has been found that for a lower value of W, the number of cycles to failure of tested wire are higher.

Conclusions

Table 5. Values calculated Wb, Wt and W for tested variants.

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The highest numbers of twists Nt and bends Nb were exhibited in 4.4 mm wires that were drawn in dies with a die angle equal to 10°, angle β in a conical bearing part equal to 0.25° and a relative length of this part Lk/D= 1.5. Further, those properties were higher than for those drawing variants for which the lowest values of Nt and Nb were observed respectively 39% and 24%. The influence of considered parameters of dies for tensile strength and yield strength is less pronounced than their influence on the number of bends and the number of twists. The differences are, respectively, only 4.5% for the tensile strength and 9.5% for the yield strength – the comparison for variants with the highest and the lowest values of those mechanical properties.

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The highest number of cycles to failure in the rotational beam test at bending stress 680MPa was for 4.4 mm wire made to variant 6 (α = 10°, β = 0.25° and L k/D = 1.5) and it was equal to 36,541.5. This was 87.5% more than for the number of cycles (19,481 ) for wire drawn to variant 3 (α = 2°, β = 2° andL k/D=0.1). The lowest value of indicator W was found for wire drawn to variant 6, which means that the best quality wire can be obtained if the die parameters are as follows: α = 10°, β = 0.25°; L k/D=1.5

References 1. B. Pikos, J.W. Pilarczyk, A. Milenin and J. Krnac, “Longitudinal residual stress of high-carbon steel wires drawn in sigmoidal, convex, concave and conical dies,” Proceedings of Wire & Cable Technical Symposium, 77th Annual Convention, Cleveland, Ohio, May 2007, pp. 247-257. 2. B. Pikos, J.W. Pilarczyk, B. Golis, R. Włudzik, and J. Krnac, “Effect of drawing in sigmoidal, concave, convex and conical dies on mechanical properties of high carbon steel wires., 2007 Conference Proceedings, International Wire & Cable Conference, November, 2007, Bologna, Italy, pp. 216227. 3. P. Renz, W. Steuff and R. Kopp, “ Possibilities of influencing residual stresses in drawn wires and bars,” Wire Journal International, January 1996, p. 64. 4. F. Knap , R. Kruzel and L. Cie lak, Ci gnienie drutów, pr tów i rur, Seria Metalurgia nr 36, Wydawnictwo Politechniki Cz stochowskiej, Cz stochowa 2004 (in Polish). 5. B. Golis, W. Waszkielewicz, R. Budzik and J.W. Pilarczyk, “Indicators of quality of wire and ropes in wire industry,” Wire Journal International, October 2005, p. 73. 6. W. Waszkielewicz, H. Dyja, B. Golis, J.W. Pilarczyk and R. Budzik, “Application of new indicator for strength characteristic of steel ropes,” Wire Journal International, November, 2005, p. 83. 7. B. Golis, J.W. Pilarczyk, Z. Błazejowski and Z. Muskalski, “Theoretical possibilities of determination of a fatigue strength of ropes on the base of wire properties,” 2003 Conference Proceedings of The Wire Association International, Wire & Cable Technical Symposium, 73rd Annual Convention, Atlanta, Georgia, USA, May 2003, pp. 41–57. ■

Krnac

Włudzik

Pilarczyk

Kruzel

Jan Krnac is a technologist in the wire mill at Zelazarny a Dratovny Bohumin, Bohumin, Czech Republic. Rafał Włudzik is a candidate for a doctoral degree in the department of metallurgy and materials engineering at Czestochowa University of Technology (CUT), Poland. He is studying central bursting in wiredrawing. Jan W. Pilarczyk is a professor in the Department of Materials Processing Technology and Applied Physics at CUT. He works on the development of new technology for wire drawing and metal products. He is the author or co-author of more than 170 papers and is president of the Poland Chapter of WAI. He holds a Ph.D. degree and a S. Sc degree from CUT and in 2004 won the WAI’s Mordica Memorial Award. Robert Kruzel is a lecturer in the department of materials processing technology and applied physics at CUT, where he earned his Ph.D. degree. He has authored or co-authored more than 80 papers. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009.

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TECHNICAL PAPER Material savings by utilizing in-line dimensional measurement and control Advanced gauging technology can enable wire and cable manufacturers to not only save money by using less unnecessary materials, but to improve their product quality. By Kevin Weaver

In-line measurement is a requirement for many extrusion lines. The objectives of such measurement systems can vary from a simple quality control tool to a completely integrated closed loop control system. This paper will explain the different measurement technologies that can be used in the wire and cable industry, taking a strategic look at how the implementation of such systems will result in significant material and scrap savings. Prior to implementing a control system, the correct technology needs to be chosen. These include: Laser/Infrared—all applications; Ultrasonics—jacketing lines (cable/fiber, etc.), insulating lines and multi-layer applications; Inductance—primary lines and insulating lines; and X ray—CV lines. Below is more information on each type of technology.

measurements. The illustration shows the ovality measurement of a product that is rotated through a two and three-axis diameter scanner. The three-axis scanner will always identify the ovality problem regardless of position. Oscillating laser scanners for profiles and non-rounds. By rotating the scanner +/- 10 degrees while taking measurements at a very fast rate (2400 scans per second) the laser can measure the “sweet spot” regardless of alignment and twisting. See Figs. 3 and 4. Angled stands for measuring corrugated and armored cable diameters. Finding the peaks on spiraled products presents a challenge for laser scanners. The shadows will find a peak on one side but will find a valley on the opposite side. By measuring at an angle, this can be overcome. By measuring at an angle with single-axis

Laser/Infrared technology Optical systems using lasers and infrared light sources are used to measure outer dimensions. Most utilize a shadow principle to establish extremely repeatable results. See Fig. 1. Laser advances: 3-axis measurement heads. Fig. 2 shows the effects of rotating an oval product through a two- and a three-axis diameter scanner. The three-axis scanner dramatically improves accuracy and stability of the

Fig. 1. Results of laser/infrared”shadow scan” technology. 78 | WIRE JOURNAL INTERNATIONAL

Fig. 2. Comparison of results for a 2-axis and a 3-axis diameter scanner.

Fig. 3. An oscillating laser scanner.

scanners, the peaks of the corrugations can be seen. Fig. 5 shows a two-axis configuration that can be adjusted to match the corrugation angle and direction.

Ultrasonics technology Advancements in ultrasonics have improved performance and reliability. Improvements include transducers and fixture technology. Measuring jackets over uneven contructions becomes more commonplace. Using specially designed transducers allows for a cleaner signal attenuation, however, covering a large diameter range becomes challenging. Fig. 6 shows an open design, noncontact transducer holder, which allows for the focus point to be adjusted for each productâ&#x20AC;&#x2122;s diameter. Fig. 7 shows the basic principle of ultrasonic measurement, Signal processing technology. Even with optimum transducers, the signals can become â&#x20AC;&#x153;noisyâ&#x20AC;? due to the irregularities. As shown in Fig. 8, signal processing technology can clean up such noise, making for a solid and reliable measurement: Advances in ultrasonics calibration. To compensate for different materials at different temperatures, a calibration must be made for the ultrasonics. The value that is changed is the sound velocity (i.e. calibration factor). To make this calibration, an offline validation must be made on the

Fig. 5. An angled scanner unit.

Fig. 6. A non-contact transducer holder.

Fig. 7. The basic principle of ultrasonic measurement technology. APRIL 2010 | 79

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Fig. 4. Comparison of measuring range for single head and x/y head models.

TECHNICAL PAPERS Fig. 8. A depiction, left, of typical “noisy” signals and, right, of those conditions corrected by signal processing technology.

ultrasonically measured product. Although effective, a new technology, called DiaCal, can establish the average wall thickness by use of two diameter scanners before and after the cross head. See Fig. 9. The values are tracked from one scanner to the other to ensure “same spot measurements.” This resulting value is then applied to the ultrasonic cross section resulting in a calibrated sound velocity for all measurement points.

X-ray technology For production lines where cooling troughs are not used (such as CV steam/nitrogen lines), x-ray technology can be used. Fig. 10 shows how x-ray absorption is used to determine the various wall thicknesses. Inductance. By inducing a low current on the conductor, the ODEX measurement system can determine the position of the conductor. See Fig. 11. The laser portion of the system can then determine the position of the insulated wire. With this information, the concentricity can be established.

Fig. 9. “DiaCal” ultrasonic calibration technology. 80 | WIRE JOURNAL INTERNATIONAL

Closed-loop control Once the method of measurement is established, the system’s processor can be configured to perform closedloop control. To ensure the maximum savings potential, the contoller must be configured to have a fast response. Additionally, the controller should be based on “final” dimensions. This goal can present challenges since the actual final dimensions can only be measured at the end of the line. If the measurement device was simply placed at the end of the line, the control loop would be quite slow and ineffective. To explain the slow controller response, consider the following example: a jacketing line, line speed 250 ft per minute, and a length of line 500 ft. If the measuring device was placed at the end of the line

Fig. 10. Presentation of x-ray technology.

TECHNICAL PAPERS

where the product has been cooled and any shrinking of the jacket is complete, the delay time from the point of change (the cross head) to the measuring point (500 ft ÷ 250 ft per min) would be two minutes. To analyze the controller’s capability, a “statistical rule of thumb” is that a controller cannot improve standard deviation in less than 10 times the length of the delay. Using the above example, this means that any variation inside of 20 minutes (10 x 2) cannot be improved. Therefore, the controller’s only function will be to prevent long term drift. To achieve material savings, it is important to understand that the first goal is to reduce standard deviation. To improve the situation in the above example, the scanner can be placed at the front of the line. Using the prior example again, it is now possible to use a measurement point located two feet from the crosshead. In this case, the delay time is dramatically improved from the two minutes for the end of the line. The new location results in 2 ft ÷ 250 ft per minute = 0.5 seconds. In this example, the controller will take care of any short-term variation outside of five seconds. This controller can now effectively make a significant improvement as shown in Fig. 12. Although the short-term variation has been significantly improved, the issue of shrinkage has to be considered. An offset can used and be effective but changes due to such variables as material, cooling, tension, etc., have to be considered. In most applications, these variables are enough to warrant a second loop to the controller. This is called a dual loop system. In a dual loop system, both the “hot end” measurement point and “cold end” measurement points are utilized. The system takes the readings from the hot end and constantly compares them to the readings at the cold end to establish an accurate offset. These values are shifted to ensure “same spot” comparison. In this case, the benefits of controlling based on the hot end measurements are realized, but with the accuracy of the cold end measurements. This control strategy can be taken a step further for jacketing applications. To realize the highest potential savings the desired controlled parameter is the minimum wall. This minimum wall value can be established using a combination of ultrasonics and laser. The “Dia-Cal” technology is used to not only calibrate the ultrasonics, but

Fig. 11. Working principle of ODEX measurement system.

will calibrate the ultrasonics based on the cold values in the same way the dual loop controller is described above.

Controller tuning and results With any controller, not only is establishing the correct control strategy important, but setting up the controller properly can make all the difference. A controller can be set up to be as aggressive as the process can tolerate. The more the process is statistically “in control,” the better a controller can perform To account for unexpected events in a process, a controller can utilize statistics to tune it. As an example, the self-tune function will adjust the controller’s gain to compensate for screw wear. This can work both ways. If a screw is replaced, the controller will become more aggressive automatically and therefore more effective. Now that accurate measurements have been established, and the controller strategy has been optimized, yet another function can be utilized to improve material savings. Since a product’s key characteristic has a tolerance and a nominal, the typical controller would be set to target the nominal as the controller’s set point. Most likely, these nominal and tolerance values were established based on the line’s performance with the lower tolerance in mind. In other words, somebody at one point established the set point with the logic that this is where the operator needs to target to play it safe to ensure the lower tolerance is not

Fig. 12. Comparison of controller efficiency. At left, a two-minute time lag and at right, a half-second period. APRIL 2010 | 81

TECHNICAL PAPERS Fig. 13. Chart showing potential savings that can be realized by being able to use a lower “set point” based on advanced controller technology.

violated. It is assumed, these parameters were established with a statistical study of some sort. In the real world, these nominals are rarely adjusted. The results are parameters that are unnecessarily paddded. Further, operators often add their own padding, targeting the upper side of the tolerance level to ensure the low tolerance is not violated. The final element of a solid controller will take the above situation into consideration. By enabling statistics to determine the correct nominal, all factors can be taken into consideration in real time. Zumbach Electronics uses a CPK pilot to perform this function. By entering the desired CPK level, the controller can determine the capabilities of the line. Once this is known, the controller will adjust the nominal value as low as possible, maintaining the desired CPK level. Fig. 13 illustrates how a process will react with CPK pilot enabled. With an improved standard deviation, the set point will be adjusted considerably lower, resulting in a high perecentage of material savings while maintaning the desired CPK.

Summary Gauging systems have become faster, smarter, more reliable and less expensive in recent years. With the demands placed on today’s processes, this is welcome news for cable manufacturers that can use these tools to further improve their process and product quality. For wire and cable manufacturers to thrive in the future, it will be imperative to incorporate advancements in gauging and control to compete and ensure profitability. ■

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Weaver Kevin Weaver is vice president, application and sales engineering, at Zumbach Electronics Corporation, Mount Kisco, New York, USA, a manufacturer of precision measurement and control systems for products that include wire and cable. He joined the company 10 years ago, and served for six years as a service manager and three years as an area sales manager. In his current position, he is responsible for directing projects and defining solutions for customers. He previously worked for 10 years at Georgia Pacific, where he held positions from automation engineering to plant management. He holds a degree from Delhi University in electrical technology. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009.

INTERNATIONAL TECHNIC AL CONFERENCE

M O N T E R R E Y Photos courtesy of the Monterrey Department of Tourism.

18-20 O CTOBER 2010 M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL

CALL FOR PAPERS Abstract Deadline: 17 May 2010 | Author Notification: 14 June 2010 Manuscript Deadline: 2 August 2010

WAI is seeking technical article authors and speakers to share their recent research findings at the 2010 Wire and Cable Technical Conference in Monterrey, Mexico, in October. We are looking for the best and the brightest ideas that will engage an international audience and serve as the building blocks to a leading educational program for 2010. Picture yourself sharing your work and conclusions on almost any topic that relates to the ferrous, nonferrous, electrical, or fiber optic segments of the industry. General papers are also welcome. Have an idea? Just outline your thoughts in abstract form on our convenient online submission page and we’ll let you know if your proposed paper will fit into the developing conference agenda. Accepted authors have a chance to have their work published in the industry’s leading Wire Journal International magazine. Share your vision of the industry’s future in your own terms. Contact us today.

SUBMIT YOUR ABSTRACT ONLINE: 1. Log on to www.wirenet.org. 2. Click the horizontal tab named “Technical” on the main page. 3. Select the “Call for Papers” tab from the drop-down menu. 4. Complete and submit the abstract form.

For more information contact: Marc Murray, Director of Education, The Wire Association International, Inc., 1570 Boston Post Rd., P.O. Box 578, Guilford, CT 06437-0578 USA, Tel.: (001) 203-453-2777, Fax: (001) 203-453-8384 ext. 121, E-mail: mmurray@wirenet.org. Conference organized by:

The Wire Association International, Inc.

Asociación Nacional de Transformadores de Acero A.C.

PRODUCTS & MEDIA

PRODUCTS & MEDIA PROD DUCTS Crosshead provides more productivity U.S.-based JoeTools reports that it has unveiled a remarkable crosshead, to be displayed at Wire Expo 2010, that is designed to increase productivity and reduce the material costs in wire and cable manufacturing. The new Switcher™ Crosshead has a color-inversion system that allows processors to extrude two different colors consecutively without interruption, a press release said. The process eliminates the bulk of scrap material and setup time that traditionally is part of a second production run, thus maximizing operational efficiency, it said, adding the following. The model’s fixed-center, duallayer design offers a unique flow valve, able to invert compound from two extruders onto the inner and outer layers of the applied insulation. As the production quantity of the first color is completed, one just switches the color valve to transpose the inner and outer layers and the next production run begins. Depending on the line speed, switch-over time takes as little as 10 to 21 seconds, so there is almost no waste in material or time, but a substantial gain in productivity and lower operating costs. The crosshead also features a manually controlled color switch valve that is easy to operate and very reliable, eliminating any problems that could result from the complexity of hydraulic or pneumatic controls, the release said. The new crosshead, it said, “is expected to play an essential role in the growth of wire and cable manufacturing as processors look for new opportunities to achieve higher returns.” Contact: JoeTools, tel. 770-832-7866, sales@joe-tools.com, www.joe-tools.com.

Extruders added to product line Belgium’s Gauder Group s.a. reports that its range of products has been expanded with the addition of new multi-compound extruders from Mapre. A press release observed that market demand for extruders has increased and that there is a lack of appropriate second-hand extruders. In response, Gauder, a stocking expert in resale solutions, has added heavy-duty, reliable Mapre equipment to its scope of sales, it said. The Mapre extruders range from 38 up to 150 mm with L/D ratio 25, and are able to process high-friction material such as

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HFFR/LSF0H as well as well-known PVC/PE/ XLPE/PA/PUR compounds, it said. The extruders, it added, are maintenance-free, offering perfect melt homogenization and high linear output. The Mapre extruders, the release said, are suitable to be integrated either in existing insulation and sheathing lines or combined with new or second-hand machines, from customer workshop or selected within the Gauder Group. They are available at a cost-effective price and with a guarantee of high-quality production and service. Contact: Henri Bonhomme, Gauder s.a., tel. 32-4-367-87-87, sales.mapre@gaudergroup.com, www.gaudergroup.com.

New model further expands the range of measuring systems for profiles Zumbach Electronics Corp., the U.S. business of Swissbased Zumbach Electronics AG, has added a new, ultramodern profile measuring system to the company’s PROFILEMASTER® family of products. The non-contact PMM 80 model uses a combination of the Light Section principle and Machine Vision to achieve the best price/performance ratio for all profiles, tubes, cables made of plastic, rubber, metal, steel and other materials, a press release said. Able to be used either on-line or off-line, the PMM 80, it noted, is a compact, industrialproof and cost-effective system that is designed to: increase the quality and accuracy of end products; improve process control and reduce scrap; save on raw materials use and postprocessing costs; be easy to install on existing production lines; and provide seamless integration of the PC-based system with a network. It also cited the following attributes: measuring field, within 80 mm; min. product dimension, up to 2 mm; repeatability, up to +/- 0.002 mm; measurement rate, up to 5/s (option: 20/s); and line speed, unlimited. The company notes that its PROFILEMASTER line offers practically unlimited profile applications due to the diverse models that are offered and the corresponding

Power cable line for big cross-sections merges SZ stranding and sheathing Austria’s Rosendahl GmbH announced that it has achieved a technical advance in power cable production with patent-pending technology for strand sector shaped conductors that combines SZ stranding with a sheathing process in one line. A press release said that being able to go from single insulated sector conductors to a finished power cable offers a lot of advantages for manufacturers, including low investment costs and reduced operating costs. The equipment, it said, makes this feasible for producing low-voltage cable up to 1 kV with a cross section up to 240 sq mm of each single conductor. The finished power cable on the take-up reel reflects just how well this set-up works, it said, noting the following. As the SZ technology has no heavy mass in rotation, the working principle is not the same as that of conventional helical stranding systems. The payoff and take-up stands

in the line are stationary reelers that need no special foundation. The non-rotating reeler also helps to improve the line efficiency due to a very fast and simple reel loading and unloading cycle. As the reel does not have to be transferred between the stranding and the sheathing process, time and space saving is guaranteed. There is also no limitation for the size of take-up, which helps to get a long product length on bigger take-up reels. The advantage of non-rotating machinery also allows a very safe working area for the operators and reduces the maintenance efforts. Contact: Rosendahl Maschinen GmbH, tel. 43-3113-5100-0, office@rosendahlaustria.com, www.rosendahlaustria.com.

Visit us at Wire Expo booth #716

June issue: ad deadline May 1 • wire Düsseldorf wrapup • Ancillary equipment/products

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accessories that enable them to continuously profile any shape and any material. Contact: Zumbach Electronics Corp., tel. 914-241-708, sales@zumbach.com, www.zumbach.com.

PRODUCTS & MEDIA

Core wire excels for ACSS/ACSR uses Based in North America, Alcan Cable, part of Alcan Engineered Products, a business unit of Rio Tinto, has introduced Ultra HS™ steel core wire for use at maximum benefit with Aluminum Conductor Steel Supported (ACSS, ACSS/TW) and Aluminum Conductor Steel Reinforced Self Damping Conductor (ACSR/SD) products for power transmission line applications. A press release noted the following about the product. Conductors with Ultra HS core wires provide the lowest sag possible on steel core transmission lines operating at temperatures up to 250°C. For Self Damping Conductors, the higher strength steel core increases their rated breaking strength and offers lower sag while still providing its usual vibration protection, up to operating temperatures of 100°C. With standard ACSR, Ultra HS steel core wires will provide a stronger conductor that can be installed within the usual tension limits used to prevent vibration damage. The new steel core wires are manufactured to ASTM B 958 standards and are available for a wide range of transmission cables. The lower sag properties of the steel core wire for transmission lines saves on tower height, said Alcan Cable

Visit us at Wire Expo booth #106

Business Development and Marketing Director Howard Atkins. “There are cases where standard steel core wire in ACSS will not provide the necessary sag profile. Our new Ultra HS steel core wire gives our customers another option.” Contact: Alcan Cable, www.alcancable.com.

Spring coiler offers high speeds for a wide range of product sizes Taiwan’s HTC, represented in the U.S. by Forming Systems, Inc., has introduced a new model, the HTC45EX high speed coiler/extension spring machine, that can process wire from 1.8 mm to 4.6 mm. A press release said that the HTC45EX combines the HTC 45CF-III CNC automatic coiling machine with the EX looping station for high-speed production to many German and English extension spring requirements. The system, which uses seven servo axes, coiling at high

Visit us at Wire Expo booth #602

e-mail Dave.Evans@george-evans.com

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Few cold welders are this versatile

Resin is UL-certified for AC power cord U.S.-based SABIC Innovative Plastics reports that its flame-retardant (FR) Flexible NorylTM resin is one of the first non-halogenated materials to be used in AC power cords meeting stringent Underwriters Laboratories (UL) 62 TPE 90C and 105C safety standards. A press release said that the resin, available in three specialized grades for different AC power cord configurations, provides outstanding FR performance that meets global environmental regulations and delivers excellent flexibility with a high-quality surface finish. The product can help wire and cable producers achieve environmental sustainability goals, differentiate their products, and create reliable, high-performance power cord solutions, it said. Global OEMs are pushing AC power cord manufacturers to deliver top-performing products that are highly efficient, cost effective, safe and compliant with increasingly tough requirements for PVC, phthalate, and halogen-free cable systems, the release said. The product, it said, has been proven in the Japanese market, meeting Den-An-Ho legal requirements. Contact: SABIC Innovative Plastics, www.sabic-ip.com.

Laser marking machine meets many exacting requirements Franceâ&#x20AC;&#x2122;s LASELEC, a specialist in cable-marking equipment, notes that it is the only company on the market to offer two comprehensive and upgradeable ranges of UV laser wire-marking machines that meet the requirements of the aerospace, rail, rally and Formula One racing-car industries. A press release said that the company has developed special equipment for the cable and wire industry, the highly advanced MT 200 inspection station, which both marks a cable using a UV laser and produces an analy-

Fast, reliable and easy to operate, our portable HP100 air/hydraulic machine can be wheeled quickly to the work area, saving effort and reducing downtime. The solid steel welding head can be easily detached to fix breaks in confined spaces and the HP100 is also available with an automatic setting, offering you effortless welding at the touch of a button. With no set up time required and a strong consistent weld guaranteed every time, you'll be ready to roll in minutes. To find out more about our portable cold welders, call +44 (0) 1233 820847 or visit www.pwmltd.co.uk PWM. Precision you can depend on.

Wire Expo 2010: booth 109 Amaral Automation Associates All inquiries within North America for machines, spares and dies, contact: AMARAL AUTOMATION ASSOCIATES PO Box 7816, Cumberland, RI 02864 Tel: 401 405 0755 / 774 991 0504 Fax: 401 405 0757 E-mail: joe@amaralautomation.com www.amaralautomation.com Pressure Welding Machines Ltd Bethersden, Kent England TN26 3DY Tel: +44 (0) 1233 820847 Fax: +44 (0) 1233 820591 E-mail: pwm@btinternet.com Welders and dies available from PWM or authorised distributors only.

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speed with an automatic looping, almost doubles the production speed of forming and looping performed on conventional spring formers, it said, adding that when the EX looping attachment is not in use, the machine provides the added function as a standalone high-speed 4.5 mm camless CNC coiling machine. The system is to be displayed at wire DĂźsseldorf. Contact: Forming Systems, Inc., tel. 269-679-3557, info@formingsystemsinc.com.

Long Products Supply Chain Symposium Where the Long Products Industries Meet in 2010

MAY 10-11, 2010

PFISTER HOTEL, MILWAUKEE, WI

The most cost-effective business meeting you will attend all year!

Industry Experts and a Knowledge-Packed Program

The Long Products Supply Chain Symposium will provide the information your company needs for strategic decision-making in 2010. Are you President, CEO, COO or Sales Executive in the Long Products Industry? Are you a Rod, Bar or Wire Manufacturer? A Wire Product, Fastener or Wire Fabricator? A Supplier of equipment or services to the Supply Chain? You don’t want to miss this opportunity to meet with your vendors, customers, and peers, all in one place, and hear what the experts in this insightful program have to say about the state of the industry and the economy.

The Symposium program has been crafted to provide you with speakers you know and trust and others you’ll be glad you met. Hear from these individuals as keynote speakers and panelists as they share their expertise with you. US Economic and Manufacturing Policy Jay Timmons, Executive VP, National Assn. of Manufacturers Charles Blum, Director, Coalition for a Prosperous America & Fair Currency Coalition Thomas Danjczek, President, Steel Manufacturers Assn.

This event is made possible by the generous support of our Sponsors: INDUSTRY LEADERS Charter Steel King Steel Corporation ArcelorMittal Long Carbon North America American Metal Market SteelOrbis Evraz Rocky Mountain Steel Members of associations representing all parts of the supply chain will be at the Symposium. Are you a member of any of these Gold Sponsor Organizations? GOLD SPONSORS American Institute for International Steel (AIIS) Asociación Nacional De Productores De Acero (ANTAAC) Chain-Link Manufacturers Institute (CLMI) Cold Finished Steel Bar Institute (CFSBI) Concrete Reinforcing Steel Institute (CRSI) Industrial Fasteners Institute (IFI) Spring Manufacturers Institute (SMI) Steel Manufacturers Association (SMA) Wire Association International (WAI) Wire Fabricators Association (WFA)

David Phelps, President, American Institute for International Steel Kurt Fowler, Managing Director, SteelFacts The Manufacturing Economy In The US and The World John J. Ferriola, Chief Operating Ofﬁcer, Nucor Clare W. Zempel, CFA, Principal, Zempel Strategic Edwin Basson, VP, Commercial Coordination, ArcelorMittal Michelle Applebaum, Michelle Applebaum Research Kenneth Simonson, Chief Economist, Associated General Contractors of America G. Mustafa Mohatarem, Chief Economist, General Motors Corporation Supply Chain Outlook James Kerkvliet, VP of Commercial Sales, Gerdau Ameristeel H.O. Woltz, III, Chairman and CEO, Insteel Industries, Inc. Matthew Brace, Executive VP of Sales & Marketing, CMC Americas Jack Lynch, Sales Manager, Charter Steel

Watch for more information about the Symposium from your organization, and register today at www.awpa.org.

Cable performance verified by lab U.S.-based Andrew Solutions, a business of CommScope, reports that the performance of its HELIAX® 2.0 FXL smoothwall cable has been verified by Telab B.V., a third-party independent laboratory specializing in testing and international certification of electronic, electrical, and machine equipment. The aluminum cable for wireless networks is the first

one that Telab has verified as passing 10 rounds of environmental testing, proving its durability in extreme temperatures, a press release said. The cable’s solid triplebonded construction also demonstrated superior crush resistance while surpassing or meeting the electrical performance specifications set by Telab for 26 other trials, it said. It noted that Telab, a leading test lab in China, conducted multiple stress tests on HELIAX FXL based on the China Communications Standard Association’s YD/T 1092-2004 standard for requirements for coaxial cable used in the nation’s wireless communications industry. Specifically, the release said, HELIAX FXL passed 10 cycles of rising then decreasing temperatures, from 25°C to 80°C and back to 25°C, with negligible degradation in attenuation and VSWR (Voltage Standing Wave Ratio), key performance metrics for wireless cable; the cable showed flat panel strength 40% higher than expected; passed an accelerated salt fog trial, exhibiting the cable’s resistance to corrosion; and displayed superior results in PIM (Passive InterModulation) testing at the 900 MHz band, exhibiting -163 dBc when the expected range is 140 to -150 dBc. A lower PIM reading means less likelihood of interference signals in the receive band. Contact: Andrews Solutions, www.andrew.com.

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sis report. The machine is very simple to use and enables users to check the “markability” of the cable and carry out periodic controls during production, it said. The machine, which has low maintenance requirements and low operating costs, uses innovative, reliable technology that complements the company’s ULYS MODENA and MRO 200 series of wire markers, it said. Direct marking with a UV laser, which has replaced heat-shrink sleeve application, reduces the weight of cabling, which in turn reduces the weight for appliances and other end use products while helping control rising energy costs, it said. LASELEC Inc. is the company’s U.S. office. Contact: LASELEC Inc., infousa@laselec.com, www.laselec.com.

PRODUCTS & MEDIA

MEDIA Upgraded website offers easy use U.S.-based Coleman Cable, Inc., has unveiled an upgraded website (www.colemancable.com) that it notes has been designed to improve the site’s ease-of-use. A press release said that customers can now perform custom searches using a Google™-type search functionality. The new and improved catalog section features user-friendly product navigation, easy to locate product data sheets and a request-more-information link on each catalog page. The redesigned website has a fresh look which integrates the websites of its Copperfield and Woods acquisitions, provides support links for online training, lit-

erature downloads, FAQs and technical information. “We developed a website that provides solutions and product information 24-7 for distributors and end-users when and where they need it,” said Kathy Jo Van, Coleman Cable Executive Vice President, Retail Group. Contact: Coleman Cable, Inc., www.colemancable.com.

Report focuses on life assessment of plenum space communication cables

The Society of the Plastics Industry, Inc. (SPI) reports that the Wire and Cable Section of its Fluoropolymers Committee has issued a new report, “Life-Cycle Assessment of Plenum Space Communication Cable,” that compares the life-cycle environmental impacts of FEP-insulated plenum-rated communication wire cable to a PE-insulated rise-rated communication cable encased in a metal conduit in plenum space. The 111-page, peer-reviewed report examines the full lifecycle of the products being evaluated from material acquisition to manufacturing, use and end-of-life, a press release said. It noted that the report supplements a 2008 U.S. EPA report. Intended for electrical engineers, architects and building owners, the report should also be of value to cable manufacturers, it said. The report can be downloaded for free at http://www.plastics industry.org/goto/2009lcareport. Visit us at Wire Expo booth #112 Contact: SPI, www.plasticsindustry.org, and the Fluoropolymers Committee at www.datacable.org. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY

COMMISSION BROKERS, INC. APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE HALL 500’ Vertical Accumulator, 1997 NEB 64-Carrier, 48-Carrier CB-1 Braiders WARDWELL 24-C Speedmaster Braiders WARDWELL 12-Carrier Braiders NEB 12-C, 44-C, 96-C #2 Braiders WATSON 36” Rotating Cabler Line NORTHAMPTON 800mm, 630mm D.T. Twisters 21 - BEKAERT Model DTK630M (11), Model DTK450D (10) D.T. Bunchers 4 - NEW ENGLAND BUTT Model C62 12-Wire 8”, Model C58 6-Wire 6”, Compact Vertical Planetary Cablers 1 - CEECO 6-Bobbin 60” Closer Line 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - VITECK 24” Horizontal Belt Wrap Capstan 1 - SYNCRO FX-13 Rod Breakdown, 400HP Motor, 1978 w/36” Deadbloc Coiler 1 - BEKAERT Model KDA Rod Breakdown, 1995 w/36” Deadbloc Coiler 6 - BEKAERT Model KDM-8, KDM-14 MultiWire Drawer Lines 10 - ENTWISTLE 4.5” 20:1 and 24:1 Extruders 1 4 2 7 6 1 4

DAVIS STANDARD 3.5” 24:1 Extruders D/S 2.5” 24:1 L/D, 2” 30:1 L/D Hi-Temp Lines ROYLE 4.5” 20:1 CV Lines TULSA 24” Motorized S/L Payoffs, Model HSPO-1 3 - MGS 18-Bay 10” Tubular Stranders 2 - BARTELL 12-Bay B64, B62 Tubular Stranders 5 - DAVIS STANDARD 36”, 30” Dual Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 5 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - DAVIS ELECTRIC Model CRS30 Respooler 12 - ENDEX and SYNCRO Barrel Packers 2 - TEC Model 24STC Hi-Speed Twisters 1 - TEC 24” D.T. Twister 1 - AUTOJECTOR Model HCS-40 Injection Molder 90 - BATTENFELD Injection Molders 6 - FILTERTECH Filtration Systems, SCF4-1600, SCF4-2000, SCF-10, SCF6-4800 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels 2 2 2 2

Contact: Martin Kenner

COMMISSION BROKERS, INC. P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

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Website has more interface capacity U.S.-based Sylvin Technologies announced that its new website that has vastly improved customer interface and is much faster with direct download capabilities. A press release from the custom vinyl compound manufacturer said that the website is a great source of information for prospective customers as well as our current customers. It said that the website improvements, especially in terms of content and design, were greatly influenced by surveys and customer feedback. Contact: Chris O’Connell, Sylvin Technologies, at tel. 800-462-4781, e-mail chris.oconnell@sylvin.com. ■

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. Limit: one ad per issue, three ads per year. This benefit is not transferable to nonmembers or to companies.

days after receipt. Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA.

CLASSIFIED AD RATES: • $1.30 per word for WJI and on-line classifieds at wirenet.org (20 word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

PAYMENT POLICY: All ads must be pre-paid.

BLIND BOX INFO: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

POSITION WANTED PROFESSIONAL WITH 35 YEARS EXPERIENCE in the wire & cable and plastics industry is seeking a new opportunity! Prior positions held include Machine Operator, Plant Manager, Process Engineer, VP Operations and Sales Manager. Knowledgeable of all aspects of wire & cable manufacturing operations and machinery. Highly skilled in the extrusion process of low & high temperature materials. Excels with new challenges & projects. Highly motivated, hardworker, and very detail-oriented. Has earned the respect of colleagues, managers, and workers alike to bring very effective leadership to any workplace. Interaction in the industry has resulted in an excellent matrix of friends & colleagues. For complete resume, respond to waiblindbox64@comcast.net with contact information. Thank you. CAREER OPPORTUNITIES PLANT MANAGER. Employee Owned L.A. Mfg. Co. in Custom Wire & Cable Products is seeking an experienced Plant Manager who offers strong manufacturing leadership. Will supervise approx. 10-15 subordinate supervisors who supervise approx. 50-100 employees during two shifts. JOB KNOWLEDGE AND EXPERIENCE REQUIREMENTS • Experience. in Wire & Cable

DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue.

Manufacturing • Experience in Quality functions and Equipment • Working understanding of UL, CSA & Military Standards • Exhibits strong skills in the areas of production scheduling and inventory management • Proficient in computers • Must write business correspondence and be able to communicate with all levels of the organization • Excellent People Management skills • Capable of implementing effective employee training programs • Safety Awareness • Strong organizational skills • Involved in the personnel selection of staff, terminations, transfers and procedures • Directs and coordinates activities of production department(s) in processing materials or manufacturing products • Performs other associated duties as assigned EDUCATION REQUIRED: • Bachelor’s Degree or 6-8 years of work related experience in wire & Cable manufacturing and/or training; or equivalent combination of education and experience. • Bilingual English/Spanish preferred Salary to commensurate w/exp. Benefits: Health & Life Insurance and Retirement. Send resume w/salary history to National Wire & Cable Corporation Attn. HR P.O. Box

31307 L.A., CA 90031 or by e-mail at svasquez@nationalwire.com, Job code NWC630-10-01. EOE M/F MACHINE OPERATORS AND TECHNICIANS (FOREMEN). SARK, a leading copper wire manufacturer, seeks experienced machine operators for its U.S. facility in Albany, New York. Competitive pay rate. Fax resumes to 518 453 4166 or e-mail to vpresident@sark-usa.com. MANUFACTURING PROCESS ENGINEER. MMI Products, Inc., a wholly-owned group of the CRH/Oldcastle network of building products companies, is seeking a Manufacturing Process Engineer for its Ivy Steel & Wire Headquarters located in Houston, Texas. Ivy Steel & Wire is a premier manufacturer of Welded Wire Reinforcement (WWR) and wire used in the concrete construction industry. Generally responsible for monitoring all primary facets of activity within and between the plants; supports S&OP efforts collectively between sales and manufacturing; for compiling summary reports of performance; for making recommendations for improvement in both equipment and processes; for preparing statistical comparisons between plants; for developing efficiency studies and making recommendations for improvement; for making recommendations for equipment and/or process improvements; for assisting plant

APRIL 2010 | 91

CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

managers in developing capital spending requests and monitoring the capital spending program against budgetary guidelines; for working with corporate personnel on such issues as safety and environmental matters; for assisting plant managers in developing annual budgets; for generally assisting plant managers and/or conducting special projects deemed critical to the company’s future. Requirements: • BS in Engineering and MBA or MS preferred. • Lean Manufacturing - Six Sigma Black Belt preferred • Minimum of 5 years work-related experience is required • Experience with ERP systems and projects • Strong knowledge of Excel • Knowledge of costing methodologies, general accounting principles • Strong metallurgical background • Background in electronics, industrial,

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org. For more details, you can call her at 203-453-2777, ext. 116.

automotive or aerospace preferred. Only qualified candidates should send resume to us by e-mail at hradministtor@mmiproductsinc.com. Visit our company’s website at: www.mmiproductsinc.com. EOE.

no@wireresources.com or Jack Cutler at jcutler@wireresources.com, or visit the Wire Resources website at w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

PERSONNEL SERVICES

DIES

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence. Contact: E-mail Peter Carino at pcari-

DS HAI, LLC IS A NEW DIAMOND DIE MAKER based in Connecticut. We can supply high quality Diamond and PCD dies at very competitive prices, to wire manufacturers anywhere in the USA. DS Hai also provides very competitive Recutting Services. We are looking for sales agents to assist our growth. Attractive commissions. Please contact Shimon Farjoun at Simonfar@yahoo.com or by telephone at 860 884 1270. AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com. Send inquiries to ajexturner@ gmail.com/sales@ajexturner.com A53, G.T. Karnal Road, Delhi-33 India. Ph: 0091-9811078882 (Ravi Bansal). MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654.

Serving the non-ferrous and ferrous industries since 1983

92 | WIRE JOURNAL INTERNATIONAL

APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com. MACHINERY EQUIPMENT FOR SALE. â&#x20AC;˘ St-Cut Shuster model 3AV, 20â&#x20AC;&#x2122; Bed 1960 â&#x20AC;&#x201C; cut .500, $25,000 â&#x20AC;˘ St-Cut Shuster model, 21â&#x20AC;&#x2122; bed 1960 â&#x20AC;&#x201C; cut 312 , $15,500 â&#x20AC;˘ St-Cut Shuster model, 10â&#x20AC;&#x2122; Bed 1960â&#x20AC;&#x201C;cut 312, $12,500 â&#x20AC;˘ St-Cut RMG 2007 model, 28 s/n 0706325 20â&#x20AC;&#x2122; Bed

cap .192-.500, $65,000 â&#x20AC;˘ St-Cut RMG 2007 model, 14 s/n 0711340 12â&#x20AC;&#x2122; Bed cut .144, $20,000 â&#x20AC;˘ St-Cut Lewis model 8F s/n 144 20â&#x20AC;&#x2122; Bed cut .375, $20,000 â&#x20AC;˘ St-Cut Wafios model R3 s/n 26105819 20â&#x20AC;&#x2122; Bed cut .312, $20,000 â&#x20AC;˘ St-Cut Lewis model 8C s/n, 20â&#x20AC;&#x2122; Bed cut .375, $20,000. Contact: Jean-Marc Perron, tel. 450-447-5000, ext. 23. WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment. Available (Cleaned, painted & checked operational) Buttwelders: Micro Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9. Babcock Models CBW-2, CBW-10 & CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equip-

ment. Please contact by telephone at #727-863-4700 or by e-mail at urbassoc@verizon.net. PURGING COMPOUNDS AMERICAâ&#x20AC;&#x2122;S OLDEST SUPPLIER. Since 1948 weâ&#x20AC;&#x2122;ve supplied millions of pounds so we know a little bit about JIT deliveries and customer satisfaction. We sell for less because our costs are less. BUY SMART â&#x20AC;&#x201C; WE DO. Alan Plastics Co., Inc. PH: (781) 828-0700. FX: (781) 828-2087. Contact: E-mail: alplas@aol.com, and via the Internet at www.alplastic.com. â&#x2013;

MEDIA

ONLINE AUCTION SALE of equipment from the BANKRUPTCY of

HYDREX MATERIALS B.V.

MYRON BOWLING

Professionals in Hydrostatic Extrusion

0,!.4 #,/3%$ p !"3/,54% !5#4)/.

Waalwijk (The Netherlands)

$%,0() !54/-/4)6% 3934%-3 ,,#

Complete production facility for aluminium - copper magnesium - brass - special alloys rods, tubes, profiles, cladded products, superconductors, wire on coils etc.

HYDROSTATIC EXTRUSION PRESS â&#x20AC;&#x153;ASEAâ&#x20AC;? Quintus - QEH40 cap. 4000 T (40 mn) horiz. hydrostatic extrusion press â&#x20AC;&#x153;ASEAâ&#x20AC;? 1250 DT, cap. 1.250 T (dismantled); 2 inline high frequent induction billet furnaces â&#x20AC;&#x153;I.A.S.â&#x20AC;? (2001); COMPLETE AUTOM. COOL-DOWN RUNOUT FEED CHANNEL SYSTEM â&#x20AC;&#x153;METALLTECâ&#x20AC;? (2007); STRAIGHTENING & STRETCHING LINE â&#x20AC;&#x153;Metalltecâ&#x20AC;? (2007); saws a.o. â&#x20AC;&#x153;MEPâ&#x20AC;? Cobra 350 SX (2007); stretch reducing rolling mill; straightening assembly machine; large quantity of machine / spare parts, measuring equipment & tooling;

CLOSING: Wed 12 MAY

from 14.00 hrs CET

Bidding only on the Internet Viewing: Fri 7 May and Mon 10 May : 10.00 - 16.00 hrs CET

INTERMEDIATE SALES RESERVED ! Photos and Catalogue on our website

www.TroostwijkAuctions.com

)NDUSTRIAL 0ARK $R IN #LINTON -3

WED. APRIL 21st & THURSDAY APRIL 22nd "5.#().' (10) BEKAERT Model DTK630M D.T. Bunchers w/SLC 5/04 CPU'S p BEKAERT DTK630DB D.T. Buncher w/SLC 5/04 CPU'S p (10) BEKAERT DTK450D D.T. Bunchers w/SLC 5/04 CPU'S %8425$).' (10) ENTWISTLE 4.5â&#x20AC;? 20:1 & 24:1 Extrusion Lines, (3) w/1.5" 20:1 Striping Extruders p (2) ROYLE 4.5â&#x20AC;? 20:1 CV Lines, ENDEX & SYNCRO Barrel Packers 7)2% $2!7).' SYNCRO FX-13 Rod Breakdown Line, 400HP Motor w/36â&#x20AC;? SYNCRO Deadbloc Coiler p 1995 BEKAERT KDA Tandem Rod Breakdown Line w/36â&#x20AC;? SYNCRO Deadbloc Coiler p (4) BEKAERT KDM-8 21-Die MultiWire Drawer Lines, GKM Annealers, OBK 800mm Spoolers (upgraded to AC Drives & Digital DC Annealers in 2007) p (2) BEKAERT KDM-14 21-Die MultiWire Drawer Lines, GKM Annealers, OBK 800mm Spoolers (upgraded to AC Drives & Digital DC Annealers in 2007) -)3#%,,!.%/53 (3) VITECK SDV-48 Dancers, 14" Sheave Wheels p COULTER McKENZIE Barrel Pack Packaging Line p SYNCRO Barrel Pack Packaging Line p (10) ENTWISTLE 24" Split Capstan Assemblies w/Double Pass Water Trough p (6) FILTERTECH Filtration Systems p (2) SYNCRO Pointer/Stringers p (4) MICRO J7C, GP Butt Welders p (12) IDEAL LSH004 Welders p (126) 460mm Steel Reels p (82) Wire Carriers p "!44%.&%,$ 4 ).*%#4)/. -/,$).' -!#().%3 4%2-3 Cash or company check. Buyer's Premium: 12% Onsite, 15% Online. Visit www.myronbowling.com for complete details.

MYRON BOWLING AUCTIONEERS 0 / "OX p 2OSS /HIO www.myronbowling.com

0%2&%#4)/. 0,!.4 ,)15)$!4)/.3 ,,#

www.pplauction.com

MS Auction Co. Lic. #467F, MS Auctioneerâ&#x20AC;&#x2122;s Lic. #466.

APRIL 2010 | 93

CLASSIFIEDS

SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com.

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

Ace Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Alumoclad de Mexico SA de CV . . . . . . . . . . .53 Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . .Cover 3 AWPA Long Prod. Supply Chain Symposium . .88 Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . .28 Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . .1 Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Bongard Trading GmbH . . . . . . . . . . . . . . . . . .59 Cable Components Group . . . . . . . . . . .Cover 2 Cable Consultants . . . . . . . . . . . . . . . . . . . . . . .56 Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . .2 Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Commission Brokers Inc . . . . . . . . . . . . . . . . .90 Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . . .61 George Evans Corp . . . . . . . . . . . . . . . . . . . . . 86 Fabritex Incc . . . . . . . . . . . . . . . . . . . . . . . . . . .24 FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Fort Wayne Wire Die Inc . . . . . . . . . . . . . . . . . .49 Frontier Composites & Castings Inc . . . . . . . .52 GCR Eurodraw SpA . . . . . . . . . . . . . . . .15, 17, 19 W. Gillies Technologies . . . . . . . . . . . . . . . . . . .34 Guill Tool and Engineering Co Inc . . . . . . . . . .62 Howar Equipment Inc/Bock . . . . . . . . . . . . . . .20 Howar Equipment Inc/GMP Slovakia . . . . . . . .25 Howar Equipment Inc/Metavan . . . . . . . . . . . .28 Howar Equipment Inc/Unitek . . . . . . . . . . . . . .26 Huestis Industrial . . . . . . . . . . . . . . . . .22, 31, 39 IWE/Wire Machine Systems . . . . . . . . . . . . . . .12 Jinyoung Tech Co Ltd . . . . . . . . . . . . . . . . . . . . .9 Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . .86 Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . .55 Lesmo Machinery America Inc/A. Appiani . . .30 Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . .62

WIRE JOURNAL

INTERNATIONAL

THINK OF IT AS A STAGE FOR THE UNDERSTUDY JUNE 2010 | ANCILLARY EQUIPMENT/REPLACEMENT PARTS It’s true that the supporting roles in wire making are as important to the manufacturing process as capital equipment. So, if you offer ancillary products that act as critical performers in wire production, your turn in the limelight is coming in the June issue of Wire Journal International. Back by popular demand, this feature article will focus on the wide range of equipment—from air wipes to cable strippers, and replacement parts—that is essential to keep the industry working. Help your customers avoid the drama of searching for support when they need it most. We’ll help you take the lead in June. Other coming attractions: wire Düsseldorf Wrapup Contact the WJI Sales Team to reserve your space today. Bob Xeller | ext. 119 | bxeller@wirenet.org or Anna Bzowski | ext. 126 | abzowski@wirenet.org

94 | WIRE JOURNAL INTERNATIONAL

ADVERTISER . . . . . . . . . . . . . .PAGE

Madem SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Mathiasen Machinery Inc . . . . . . . . . . . . . . . . .92 Micro Products . . . . . . . . . . . . . . . . . . . . . . . . .50 Myron Bowling Auctioneers . . . . . . . . . . . . . . .93 National Electrical Wire Processing Expo . . .96 Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . .41 NIMSCO LLC/SB2C . . . . . . . . . . . . . . . . . . . . . .60 Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . .43 Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . .16 Pressure Welding Machines Ltd (PWM) . . . . .87 Properzi International Inc . . . . . . . . . . . . . . . . .51 PS Costruzioni Meccaniche Srl . . . . . . . . . . . .29 Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . .37 Radyne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Rautomead . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Sanxin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 SCR Holdings . . . . . . . . . . . . . . . . . . . . . . . . . .62 Sikora International Corp . . . . . . . . . . . . . . . . . .7

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . .89 Sonoco Reels and Spools . . . . . . . . . .27, 33, 35 August Strecker . . . . . . . . . . . . . . . . . . . . . . . . .23 Talladega Machinery & Supply . . . . . . . . . . . . .4 Trootswijk Veilingen b.v. . . . . . . . . . . . . . . . . . .93 US Synthetic Wire Die . . . . . . . . . . . . . . . . . . . .47 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . .5 Wire & Plastic Machinery Corp . . . . . . . . . . . .95 Wire Machine Systems/IWE . . . . . . . . . . . . . . .12 Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . .20 Zumbach Electronics Corp . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS Wire Expo 2010 . . . . . . . . . . . . . . . . . . . . . . . . .42 Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . .64-65 Monterrey ITC: Call for Papers . . . . . . . . . . . .83

Wire Düsseldorf: Hall 9 Booth F21-01

Wire Expo: Milwaukee May 12-13. Booth Number: 218 WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS EXPL351 NEXTROM 80 mm 24:1 Ext Line w 500mm Split Capstan, S.S. trough, 1200 mm BCA-12 Belt Cat. Yr Mfg 1999. CBR1050 DYNAMEX 30” S.Twist Cabler w Controls, Yr Mfg 2000 EXP974 GENCA dual vertical 1 ½” 24:1 Co Extrusion w ribbon cable dies. CLR220 REELEX D1500 Dual coiler w/controls Yr Mfg 1999. CBR1049 (3) LESMO 760 mm D.T. Bunchers, Yr. 1998, w/Siemens PLC & Simoreg Drive, Mistubushi A500 drive. CBR1048 SAMP 760 mm D.T. Buncher Model BM/760D, Yr. 1997 w Samp drives, PLC TKU1168 SKALTEK U12P4K, 1.2m Portal Take up with Uhing Traverse CBR984 WATSON 19 wire 22” Planetary cabling line (still installed) MSC1737/MSC1225 (2) NEXTROM Jelly Metering System, Model JFS, Year 2000

WRD831/WRD678 SAMP 8 wire MT8.2.4.21 drawing machine/SAMP 14 wire MLS/5.T.14 CBR957 COOK 48” BH-48 ST. Cabler (still installed) TKU1149 NEXTROM Take ups EKP-63 Yr. 2000 Never used/(4) EKP 50, Yr. 1998, TKU1118-1121/EKP-5, Yr. 2001 (2) WRD890 (3) SAMP TR2TP Wire Drawing/Annealing /Preheating Yr. 2000 Never Used. WRD887 820 mm SAMP Drop Coiler, Model AS/3-820, Yr. 1999 CBR998 (8) SETIC 630mm PA630i D.T. Twinners, 1998. CBR1000 84” CABALLE/KALMAR/POURTIER Drum Twisting Line, 1990’s. CBR995/CBR989 630mm MGS & TEC, 800mm NMC D.T. Twinners. MGS/BARTELL Payoffs: 60”, 72”, 84”, 96”. Take ups 60”, 72”, 84” 96” (some rebuilt) RWD359 2.6m SKALTEK Rewind Line. A264K P/O, S60/L100 line controls., meas. mach. Guide roller assy. U26T T/U.

ALWAYS LOOKING TO BUY/TRADE GOOD SURPLUS MACHINERY PREOWNED HIGH QUALITY WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY AVAILABLE EX-STOCK FROM SIX US WAREHOUSE LOCATIONS.

APRIL 2010 | 95

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed. FEATURES • Zero backlash. • Automatically synchronizes pitch with take-up reel rotational speed. • Traverse drives with up to 800 lbs. axial thrust. • Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed. • One inexpensive, unidirectional motor drives both the traverse and take-up reel. • Free movement lever – no need to "jog" system on and off to position linear drive. • Options and accessories for every winding situation. • Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

Visit us at Wire Expo booth #120

email: amacoil@amacoil.com

www.amacoil.com AMACOIL, INC. PO Box 2228 • Aston, PA 19014 • Phone: 610-485-8300 • Fax: 610-485-2357

ZUMB.707.0099.U_WJ

Innovative Measurement Solutions For Cost-Effective Productions

6ISIT US AT

New ODAC速 Gauges & USYS Processors with The Latest Technology Features: s #33 #ALIBRATED 3INGLE 3CAN s .ARROW "EAM s (,& (IGH !CCURACY ,ARGE &IELD s 5393 2EPORT -ANAGER s 5393 7EB 3ERVER s 5393 $ATA ,OG s /$!#速 -ANAGER

Visit us at Wire Expo booth #401

!PRIL Booth 5 C27 6ISIT US AT

!PRIL Booth 11 D43

!SK US FOR ADDITIONAL INFORMATION askme@zumbach.ch 3WITZERLAND !RGENTINA "ENELUX "RAZIL #HINA &RANCE 'ERMANY )NDIA )TALIA 3PAIN 4AIWAN 5+ 53!