Take-ups and payoffs by Wire Journal International, Inc.

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JUNE 2008

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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

Take-ups and payoffs

wire D端sseldorf 2008 wrapup 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

Volume 41 | Number 6 | June 2008

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

CONTENTS

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F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . 34 Wrapup: wire Düsseldorf . . . . 38 Technical Papers . . . . . . . 58-78 Products/Media . . . . . . . . . . 80 Classified . . . . . . . . . . . . . . 85

Take-ups and payoffs

. . . . . . . .46

Suppliers of take-ups and payoffs present some of the technology that they offer to wire and cable manufacturers.

T ECHNICAL P APERS Processing of wire from antiquity to the future Horace Pops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Leoni Histral® - The cadmium-free alternative for cable manufacturers Maik Bayersdorfer, Martin Kemethmueller, Wolfgang Steuff and Michael Scharf . . . . . . . . . . . . . . . . . . . . . . 89 Plasma: a clean and cost-effective alternative to chemical and heat treatment Igor Rogelj . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Career Opportunities . . . . . . 85 Advertisers’ Index . . . . . . . . 88

Cover: Equipment (clockwise from top) from Italy’s M+E Macchine Engineering Srl, Germany’s Queins & Co. GmbH and Sweden’s Windak AB is among the take-ups and payoffs presented in the feature that begins on p. 46.

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CONTENTS

INSIDE THIS ISSUE L OTS OF MACHINERY + BIG CROWDS = SUCCESS FOR WIRE 2 0 0 8 38 The Maillefer booth was among the busiest at wire Düsseldorf. Besides equipment, the company put on technical sessions that kept the traffic flowing.

4 | WIRE JOURNAL INTERNATIONAL

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Messe Düsseldorf’s Joachim Schafer, l, at a press conference at wire 2008. With him (l-r) are Dr. Detlev Elsinghorst (METAV) and Dr. Wolfgang Sengebusch (VDMA). See p. 39 for Schafer’s edited comments. Photo courtesty of Messe Düsseldorf.

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

The view from the top in hard (company) times

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli

How and why companies fail is a subject that could fill volumes, but what it takes to turn one around is a far different story. It’s also the subject of a recent book that one could literally say is a work in progress at Delphi Corporation. Robert “Steve” Miller, the man some say saved Chrysler Corporation in 1980 and later went on to a career in executive “rescue” positions, has summed up his experiences in “The Turnaround Kid,” recently published by Collins. The book starts off with his current challenge: Delphi Corporation. The ailing company, once part of General Motors, was saddled by legacy costs and an onerous union contract when Miller accepted the top position in 2005. When the news broke about Miller, I thought of Al “Chainsaw” Dunlap, perhaps the most infamous turnaround specialist of his era. He was also among the most despised because of how he sliced companies up. Turns out that Miller—who credits his grandfather’s management style at his logging operation for teaching him at an early age the value of honesty, hard work, risk taking and respect for workers—was far from impressed with Dunlap. “His style…was no substitute for substance,” he wrote. And that underlies the reason this piece is here and not in the media section. What is substance in a leader? For Miller, it inherently meant making painful choices and hard decisions. It meant having to work with lenders and the union, selling both Delphi and himself. It meant going into Chapter 11, greatly paring operations, working with the union to cut employees and the pay scale and, most lately, trying to get out of Chapter 11. The Delphi saga continues today and the outcome remains unknown. Delphi is but a slice of Miller’s book, most of which is about his prior experiences, including personal struggles. His experiences are memorable because they reflect how daunting it is to be responsible for a struggling company’s future, how decisions can either make or break a company and the need to factor in the human equation. As he notes in his postscript, “… very big and complex problems can be resolved when people share a goal, work hard and let their better nature come to the fore.” It also gives one a bit more appreciation for the CEOs out there who can and do take care of business.

Mark Marselli Editor-in-chief

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: $95 per year, USA; $105 per year, Canada and Mexico; other countries, $125 per year (includes air mail). Single copies: $6 in the U.S.; all other countries $7. 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. © 2008 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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by the Chicago Association of Spring Manufacturers (CASMI). Contact: Tom Renk, tel. 847-433-1335; info @casmi.org; www.casmi.org

June 23-26, 2008: 9th China (Guangzhou) Int’l Platemetal, Tubing, Bar, Wire & Setting Eqpt. Exhb. GuangZhou, China. Contact: Mei Wen, Guangzhou Julang Exhibition Design Co., Ltd., tel. 86-13902266275; meiwen@ julang.com.cn; www.julang.com.cn

November 3-5, 2008: Electrical Manufacturing Expo Orlando, Florida, USA. This event, to be held at the Gaylord Palms Convention Center, is organized by the Electrical Manufacturing & Coil Winding Association. Contact: Chuck Thurman, tel. 619-435-3629; cthurman@emcwa.org, www.electricalmanufacturing.org.

September 18-20, 2008: Cable & Wire 2008 Istanbul, Turkey. To be held at the CNR Expo Center, this event will present cable accessories, wiring harnesses, machines and electro-insulating materials, equipment and production machines. Contact: Mediaforce Fuarcilik Ltd. Sti., tel. 90-212-465-65-45; info@ mediaforceonline.com; www.mediaforceonline.com

November 9-12, 2008: 57th IWCS™ Conference and Symposium Providence, Rhode Island, USA. The IWCS returns to the Rhode Island Convention Center. Contact: Internet www.iwcs.org; phudak@iwcs.org; tel. 001-732-389-0990.

September 23-26, 2008: wire China Shanghai, China. wire China will be held at the Shanghai New International Exhibition Center. Contact: Messe Düsseldorf North America, tel. 001-312-781-5180; fax 001-312-781-5188; info@mdna.com; ww.mdna.com

November 20-22, 2008: Wire & Cable India 2008 Mumbai, India. Contact: Cheryl Fernandes, Business Fairs, Confederation of Indian Industry, tel. 91-2224931790, ext. 470; fax 91-22-24939463; www. ciionline.org

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April 25-30, 2009: Interwire 2009 Cleveland, Ohio, USA. To be held at the International Exposition Center (I-X Center), Interwire incorporates: Interwire Trade Exposition, the technical program and the WAI’s 79th Annual Convention. It addresses ferrous and nonferrous manufacturing, and electrical/data/voice segments as well as wire forming and related wire and wire products. Contact: WAI, tel. 001-203-453-2777; fax 001203-453-8384; www.wirenet.org ■

CALENDAR

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WIRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org. June 23, 2008: Sixth Annual WAI Midwest Chapter Golf Tournament West Chicago, Illinois, USA. To be held at St. Andrews Golf & Country Club. Contact Kevin Sopczak at tel. 815713-6959, kswire@aol.com or WAI’s Chip Marsh at tel. 203-453-1748, cmarsh@wirenet.org. August 7, 2008: Sixth Annual Ohio Valley Golf Tournament Solon, Ohio, USA. See p. 34. September 11, 2008: New England Chapter's 14th Annual Golf Tournament Paxton, Massachusetts, USA. The chapter will return to the Kettle Brook Golf Club. September 25, 2008: Mid-South Chapter's 7th Seventh Annual Golf Tournament Florence, Alabama, USA. The chapter will go to a new course, part of the Robert Trent Jones Trail. October 15, 2008: Western Chapter's 8th Annual Wild West Shootout Industry Hills, California, USA. The chapter will return to the Industry Hills Golf Club. October 30, 2008: Southeast Chapter's 7th Annual Golf Tournament Conover, North Carolina, USA. The chapter will return to the Rock Barn Golf and Spa. October 20-22, 2008: ITC Mexico Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, a plant tour and networking opportunities.

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INDUSTRY NEWS

INDUSTRY NEWS CommScope to close Brazil facility CommScope, Inc., reported that it plans to close its Jaguariuna, Brazil, broadband facility as part of its goal to eliminate redundancy and reduce costs. The Jaguariuna facility, which employs approximately 200 people and primarily produces broadband cable products, is expected to close by the end of September, with most equipment redeployed to other facilities elsewhere in the world, a press release said. It noted that these changes do not affect the company’s facility in Sorocaba, Brazil, or its commitment to providing technology to Latin America customers. “This is the latest step in our ongoing drive to improve our competitive position, enhance our long-term financial performance and achieve our cost-synergy targets associated with the Andrew Corporation acquisition,” said CommScope President and COO Brian Garrett. “We regret the impact on our people in Jaguariuna and appreciate their many contributions during the past eight years. However, we have an extensive worldwide manufacturing and distribution footprint that can be better utilized and more efficiently operated by consolidating facilities.” The 221,000 square-foot Jaguariuna facility was purchased in June 2000. Both the costs and the savings related to this facility closing will make up part of the projected total savings and transition costs announced in connection with the acquisition of Andrew, which was completed in December 2007, the release said. CommScope noted that it previously has told employees at its plants in Seneffe, Belgium, and Capriate, Italy (acquired from its acquisition of Andrew Corporation), that it plans to close those plants.

Melrose to buy FKI Plc, the parent company of Bridon International U.K.-based Melrose Plc has agreed to buy FKI Plc, Europe’s biggest maker of wire rope for tethering ships and oil rigs, for US$945 million in cash and shares, Bloomberg reports. The story said that the offer from Melrose Plc, an international engineering group that buys and sells manufacturers, was made to FKI, which had debt problems and faced a potential breakup. FKI has four group areas. One of those, lifting products, includes Bridon International Ltd. At Bridon’s website, it notes that the company was originally formed in 1926 from an amalgamation of wire rope producers, the earliest of which date back to the late 18th

Century. Acquired in 1997 by FKI plc, Bridon now is a major supplier to key industries throughout the world with numerous strategically positioned global operations, it states. It is unknown what the long-term plans are for Melrose, whose investments include Dynacast, the sole supplier of handles for Gillette Co.’s Mach III razors, the article said. Possible options include selling either Bridon, the lifting equipment business, or Brush, the turbo generator business, it said.

Tele-Fonika subsidiary supplying high-voltage cable for Odessa Poland’s Tele-Fonika Kable S.A. reports that TF Cable JSC, its subsidiary trade company in the Ukraine, is providing high voltage 110 kV cables for powering the regions of the Odessa District of the Ukraine. A press release said that the contract calls for providing

A view of the high voltage laboratory in the Bydgoszcz facility, where Poland’s Tele-Fonika is producing cable for Odessa. cable type A2XS(FL)2YR2Y 1x240 RM/95 110 kV (cable executed using XLPE technology according to German standards with an aluminum core with a crosssection of 240 mm²) and a length of over 10 km for the Odessa Power Plant. One of the cable sections, 1,200 m long, will be laid at the bottom of the Kagul Lake (belonging to the lagoon system of the Black Sea). The cable for this contract was made by the Bydgoszcz plant, it said.

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

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Draka to close Vigo plant in Spain

INDUSTRY NEWS

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Citing a migration of its auto customers, Draka has announced that it plans to close its plant in Vigo, Spain, that is part of its Automotive & Aviation division. The Cable Directory reported that the company was reacting to “Draka’s important automotive customers (Tier 1 harness suppliers) in Spain … relocating their production facilities to low labor cost countries in North Africa and Eastern Europe …” The closing of the plant, which has about a hundred employees, will proceed after getting approval from the Works’ Council and the Labor Authority, which will consider the legal grounds for the proposed closing.

Sonoco offers waste reduction service The Wire and Cable Reels Division of U.S.-based Sonoco announced that it has begun offering a new sustainability consulting service for wire and cable manufacturers, distributors and their customers. Sonoco Sustainability Solutions (S3) identifies ways to reduce waste materials going to landfills and increases profitability by converting waste streams into revenue streams by finding alternative uses for a facility’s previously unrecycled wastes, a press release said. S3 is a new service of Sonoco’s recycling division (Sonoco Recycling), one of the largest recyclers in the packaging industry, said Randy Lusk, general manager,

A member of the Sonoco Sustainability Solutions (S3) team inspects a company’s operations. Sonoco Wire and Cable Reels. Under the program, Sonoco experts assess a customer location’s existing waste-handling practices and develops ways to attain significant savings by reducing waste hauling charges and landfill fees. The program has resulted in reduced landfill waste by as much as 70 percent at some consumer product goods manufacturing facilities, it said. One S3 customer includes Southwire, said Cynthia Brooks, the company’s Green Initiatives Manager. “The goal of S3 is zero landfill waste,” she said. “We’re really looking

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INDUSTRY NEWS

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forward to identifying ways we can reduce our landfill waste, help the environment and possibly even positively impact our top line. This is a really exciting opportunity for creating value by enhancing our current processes.” Sonoco notes that its reel recycling program helped North American wire and cable manufacturers and distributors and their customers save some 50,000 trees and $6 million in disposal costs by recycling 150,000 wire and cable reels in 2007 for 1,200 customers in 641 cities.

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Sam Dong Co. opens Tennessee plant Sam Dong Co. Ltd. reports that it has officially opened its first U.S. plant, an 80,000-sq-ft plant in Rogersville, Tennessee, that makes specialty wire. A report about the news in knoxnews.com said that the company currently employs 60 workers and plans to add another 40 positions as the facility becomes fully operational. Sam Dong, a South Korean producer of specialty magnet wire products, bought the Rogersville plant in 2007. According to a report in www.timesnews.net, the plant, the former site of Assured Casting, had been closed in 2005. It had made aluminum castings, and Sam Dong has since retrofit it to produce specialty magnet wire products used in electrical transformers, electric motors and generators, it said, noting that Sam Dong has been in business in South Korea for 30 years and exports its products globally.

Carlisle completes its buy of Carlyle Inc.

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Carlisle Companies Incorporated announced that it has completed its $200 million acquisition of Carlyle Incorporated, a manufacturer of wire and cable harnesses, rack and panels, and cable assemblies for in-flight entertainment systems and specialty avionics applications. “We are very excited about this addition to our Tensolite division which virtually doubles the size of our wire, cable and high-end interconnect solutions business,” said Carlisle Chairman, President and CEO David A. Roberts. “The Carlyle acquisition strengthens our global reach of this critical strategic Carlisle platform.” The press release noted that Carlyle’s largest application includes both fiber optic and copper cable assemblies for in-flight entertainment systems (IFE) on commercial aircraft, and that such spending “is expected to grow dramatically through 2010 fueled by new aircraft builds and retrofit applications.” Carlyle, the release said, has annual sales of

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approximately $125 million. The company, which has facilities in Tukwila and Kent, Washington, will operate within Carlisles’ Tensolite Company division, it said.

Belden Inc. to lay off 135 employees at Richmond plant

team. It noted that C&M, which evolved from its origins as a wire salvage business, “is well positioned as a top supplier of specialized cabling solutions to Fortune 500 companies in the industrial, medical, defense, multimedia, datacom and data collection industries.”

Belden Inc. is laying off 135 workers at its plant in Richmond, Indiana, the location of its main North American operations. The news follows a recent announcement that the company will close its plant in Connecticut. According to wire reports, Belden spokeswoman Dee Johnson described the layoffs in Richmond as a “periodic adjustment” that mostly involves hourly workers. The layoffs represent a little more than 13 percent of the company’s 1,000 workers in the Indiana town. The news follows a March 25 announcement that by September it would close its plant in Manchester, Connecticut, which has 132 positions. Belden President and CEO John Stroup said at that time that closing the Connecticut plant would help it save money as Belden moved some U.S. operations to a new plant in Mexico.

Watermill Group acquires C&M The Watermill Group announced that it has acquired C&M Technologies Group, Inc., (C&M), a manufacturer of custom cable, coil cords and cable assemblies with manufacturing capabilities in the U.S. and Mexico. A press release said that C&M CEO William Mueller will continue to lead the management

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INDUSTRY NEWS

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INDUSTRY NEWS

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Steven Karol, Founder and Managing Partner of The Watermill Group, said that C&M’s “strength of engineering and component design in the manufacturing of custom cable and cable assemblies provides a strong value proposition to its customers.”

German subsidiary of General Cable awarded fiber optic contract General Cable Corporation announced that its German subsidiary, Norddeutsche Seekablewerke GmbH (NSW), has been awarded its first submarine long-haul repeatered fiber optic communications link project. The communications link will stretch through the Mediterranean Sea from Marseilles, France to Port Said, Egypt, with additional connections in Italy, Turkey and Cyprus, a press release said. The project will have a length of more than 2,600 miles and will be installed at depths of up to 11,000 feet, it said. NSW’s portion of the project is valued at approximately $40 million with cable delivery and installation beginning later this year, the release said. “NSW has been investing heavily to support the expansion of our product offering to include long-haul submarine fiber optic communications cables. We believe that this global market, which is

coming off nearly a decade of decline, is positioned to rebound throughout the world as nations increase their need for reliable communications links,” said NSW Chairman Valentin Jug.

NKT lands Dutch cable contract NKT Cables has won a contract from TenneT TSO B.V. (the transmission system operator of The Netherlands) to design, manufacture and install a 380 kV cable system in the “Zuidring” connection in the western part of The Netherlands. A press release said that NKT Cables will provide the technical, logistical and managerial aspects of this highvisibility project in the Netherlands’ transmission grid. The contract could be worth approximately US$54 million, depending on a final decision by the Dutch government about overhead lines versus cables. The project is scheduled for completion by the end of 2010.

PWM names Amaral as new U.S./Canadian distributor U.K.-based Pressure Welding Machines (PWM), a global manufacturer of cold pressure welding equipment and

Put the pressure on Repair non-ferrous wire breaks quickly and economically with a PWM cold welder. Precision engineered to provide a reliable weld every time, our low maintenance, high performance machines are clean, ‘green’ and easy to operate. Hand-held, bench and trolley-mounted models and freestanding machines available with capacities from .003145" to 1.181".

www.pwmltd.co.uk Visit us at Wire Expo 2008 Amaral Automation Booth 831 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

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dies, announced that Amaral Automation Associates, Cumberland, Rhode Island, is now its exclusive distributor for the U.S. and Canada. “Amaral Automation Associates has over 20 years of proven wire and cable experience and has the product and customer knowledge we are looking for in order to continue to expand our share of these very important markets,” said PWM Managing and Sales Director Steve Mepsted. Amaral Automation, founded in 1984 by Rick Amaral, represents Zumbach Electronics, Huestis, B & H Tool, W Gillies Technologies, Tulsa Power, Diagraph, Engineered Control Systems, Eurotherm, Bardac, Vulcan, Rosendahl/Nextrom and Star Inks. “The PWM line and the service the company provides is the hallmark of the industry and we look forward to working with the PWM team,” said Amaral Automation Sales Manager Joe Snee. He can be reached at Tel. 774-991-0504, joe@amaralautomation.com.

al production to 33,600 metric tons at its Dalian facility, the release said. In addition to its installed capacity, it noted, Fushi Copperweld also has CCS and CCA production capacity in transit as part of its three-phase relocation project of machinery to its facility in Dalian, China from its Fayetteville, Tennessee plant. The second phase, scheduled for completion by yearend 2008, calls for the refurbishment and relocation of 10,000 metric tons of CCS production capabilities, and

Fushi Copperweld expansion on target for Dalian, China facility Fushi Copperweld, Inc., announced that it has added 6,000 metric tons per year of Copper-Clad Aluminum (CCA) production capacity at its Dalian facility at the end of its 2008 first quarter. The accomplishment marks the completion of the first stage of a three-phase relocation project that will bring online an additional 22,000 metric tons of annualized CCA and CCS capacity to the facility by the end of the first quarter of 2009, a press release said. The new production capacity has increased Fushi Copperweld’s total CCA annu-

ISO 9000:2000 AS9100 Registered

Bomco Inc. 125 Gloucester Avenue Gloucester, MA 01930-2294 978-283-9000 Fax 978-283-2882 e-mail custserv@bomco.com

JUNE 2008 | 15

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Saudi order represents Gauder Group’s 700th drum twister line

the third and final phase, scheduled for completion in the first quarter of 2009, plans a further addition of 6,000 metric tons of CCA capacity to the Dalian facility. Via its wholly owned subsidiaries, Fushi International (Dalian) Bimetallic Cable Co. Ltd. and Copperweld Bimetallics, Fushi Copperweld, Inc., supplies bimetallic composite wire products, principally CCA and CopperClad-Steel (CCS) wire.

The Gauder Group reported that its Pourtier division has received an order for its 700th drum twister line for high-voltage power cables from a long-time customer in Saudi Arabia. Saudi Cable Company ordered the drum twister line, which is the biggest offered by Pourtier, designed for a take-up reel of up to four meters with a weight capacity of 30 metric tons, a press

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16 | WIRE JOURNAL INTERNATIONAL

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release said, noting that the line integrates “unique technology and the latest development for the production of high quality cables.” Saudi Cable, which has been with Pourtier-Gauder Group from the start, manufactures a complete range of cable in the Middle East area.

EU may act on rod imports from China, Moldova and Turkey The European Union announced that it would investigate whether China, Moldova and Turkey are illegally selling steel wire rod at below-cost prices that damage European manufacturers. Per the AP report, the investigation will focus on wire rods used in construction that were imported from April 1, 2007, until March 31, 2008. The EU can impose trade charges

RESPOOLING Solid and tubular wires (MIG, stainless steel, aluminium, bronze, flux cored) ROBOBINA NEW UPDATED DESIGN AND FEATURES. No operator requirement: totally automated precision layer respooler. User friendly: simple touch-screen controls. 7 Different formats: 5-15-20kg wire baskets, 15-20kg plastic spools, 20-30 kg fibreboard spools. High speed: over 35 metres per second. High production: even more than 25 spools (15kg) per hour. Precision layer or Random winding.

POLISPIRA DIGITAL FOUR VERSIONS AVAILABLE – “BASE” manual unit, “EVO” semi-automatic version, “SAW” solution for large diameter wire and “COIL” model for large coils. Economical: low cost respooling line with a full range of Gimax features Extremely flexible: the Polispira can handle many spool sizes (wire baskets, plastic spools, fibreboard spools, spoolless coils), to hold from 1 kg up to 45 kg of solid wire. Large range of wire diameters: wire from 0,6mm up to 5mm in diameter. High speed: up to 35 metres per second. Precision layer or Random winding.

OMNISPIRA Limited operator requirement: semi-automatic precision layer respooler,one operator easily handles two machines. Operator friendly: automated discharge system for finished spools. High degree of flexibility: the Omnispira can handle many spool sizes (wire baskets, plastic spools, fibreboard spools, spoolless coils), to hold from 1 kg up to 45kg of solid wire. Large range of wire diameters: wire from 0,6mm up to 5mm in diameter. High speed: over 35 metres per second. Precision layer or Random winding. Viale della Tecnica, 8 - 36050 - Sovizzo (VI) - Italy - Tel. +39-0444-376004/551790 - Fax +39-0444-536071 www.gimaxgroup.com - e-mail: sales@gimaxgroup.com

DRUM PACKING

WET DRAWING LINE

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on imports for up to five years if it finds they are being dumped on the European market in violation of global trade rules, AP reported. It is not expected that any action would happen soon. When a recommendations can be made, governments in the EU can consider if action is warranted. The case stems from complaints from the European Confederation of Iron and Steel Industries or Eurofer, after there was nearly a doubling of steel imported from China to Europe last year, the AP report said. It cited the EU’s Executive Commission as saying that a March 25 complaint from Eurofer gave evidence of surging imports from Moldova and Turkey as well. “It is alleged that the volumes and the prices of the imported product have ... had a negative impact on the market share held and the level of prices charged by the (European) industry,” the Commission said in the EU’s Official Journal, AP reported. The article noted that part of the fact-finding will include comparing European steelmaking costs with those in Turkey to help determine if that country’s exports undermine market prices. Oddly enough, because the EU does not recognize China or Moldova as market economies, since state subsidies such as low rents or cheap power may affect produc-

tion costs, it will instead compare European figures with those of another fast-growing developing economy, in this case Brazil, unless Chinese and Moldovan steelmakers can prove their governments do not subsidize them, the AP article said. China supplies about a third of the EU’s steel imports, far more than suppliers in Turkey, India, South Korea and Switzerland, the article said. It added EU officials warned of a protectionist backlash if China does not open up more to European exports, however, imports have slowed by 20 percent recently from a combination of a slowing of European growth and Chinese export controls.

Prysmian contracts include cables for Kazakhstan oil and gas facility Prysmian Cables & Systems announced that Prysmian Italy has landed orders for high-technology cables and systems in the oil and gas field in Kazakhstan, as well as contracts for creating high-voltage energy transmission networks in Italy. Prysmian Italy has won an order worth about US$16 million to design and install special on-shore high-tech-

JUNE 2008 | 19

INDUSTRY NEWS

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4/17/2008

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nology cables intended for the Kashagan oil facility in Kazakhstan, one of the largest petroleum deposits discovered in the past 40 years, a press release said. The order follows a series of other deliveries made by Prysmian Italy to Italian and foreign engineering and installation firms in Kazakhstan, for off-shore and on-shore applications worth more than US$32 million, it said. Prysmian Italy also reported that it has been awarded a “turnkey” contract worth about US$16 million for three overhead lines (one owned by ENEL and two owned by RFI), for a total of approximately 40 km of high-voltage, 132 kV cable, as part of the Urban Redevelopment Plan for the former Neri Distilleries in the municipality of Faenza in Italy, the release said.

INDUSTRY NEWS

inews.qxp

Furukawa-Draka settle patent suit Furukawa Electric North America, Inc./OFS Fitel, LLC and Draka Comteq B.V./Draka Comteq America, Inc. announced that the parties have resolved the patent disputes at issue in two different U.S. federal court cases. Furukawa, the parent company of OFS Fitel, brought the action last June, alleging that the North Carolinabased company infringes several U.S. patents related to single-mode and multi-mode optical fiber, processes for making optical fiber, and optical fiber cables. A press release noted that the Furukawa/OFS intellectual property portfolio “today includes several hundred issued U.S. patents, many assigned from the Lucent patent portfolio as part of the 2001 purchase, and more that are the result of OFS research and development efforts since 2001.” The details of the settlement were not disclosed.

Russian company reports wire advance Mechel OAO, a Russian mining and metals company, reports that its Beloretsk Metallurgical Plant subsidiary has “succeeded in mastering a unique technology to produce stabilized reinforcing wire for prestressed concrete structures used in the construction industry.” Using equipment from European manufacturer Koch–GSG, Mechel was able for the first time to implement mechanical descaling and surface preparing of 9-16 mm high-carbon wire rod in the drawing line, resulting in output of 3-8 mm high-tensile wire with 1,700-2,300 MPa maximum strength at the level of approximately 20 thousand metric tons annually. ■

IWC Used Machinery and Equipment 66 N. Buesching Road EPhone: 847-726-8910EFax: 847 726-7544 Email: grahamchri@aol.com www.iwc-machinery.com Please call for further information or to set up an appointment for inspection. 847-726-8910 or email grahamchri@aol.com put “used machinery” in the subject. LARIBEE BUNCHERS (16 in stock) Reel Capacities: 12” O.D. 50 LBS Speeds: 4000 Twists per min. Motors: 2 H.P. Traverses: 6 INCHES Wire Sizes: 33 to 22

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SYNCRO ANNEALER (2 in stock) Type “AB” Resistoneal Model AB-3M (without Spooler) Wire (Copper) Range #26-36 B&S Speed Up to 7000 ft. /Min. Annealing power 12.5 KVA Single Phase SYNCRO COARSE FINE WIRE DRAWING MACHINE (12 in stock) Type BG-16 Max size entering wire 12 Gauge (B&S) Finished wire size range 24 thru 36 Gauge (B&S) Max Finishing Speed 7000 F.P.M. (depending on material being drawn) Motor Size 25 H.P. SYNCRO DRAWING MACHINE (6 in stock) Type AG-16 Max size entering wire 14 Gauge (B&S) Finished wire size range 28 thru 36 Gauge (B&S) Max Finishing Speed 7000 F.P.M. (depending on material being drawn) Motor Size 25 H.P. In addition to the above we also have these items: ENDEX SPOOLER (15 in stock) ACROMETAL MULTI-HEAD TAKE UP (6 in stock) BARTELL BUNCHERS (12 in stock) MGS DTB 30-3000 DOUBLE TWIST BUNCHER (7 in stock)

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For a complete listing of our used machinery please call 847-726-8910 or visit www.IWC-Machinery.com

JUNE 2008 | 21

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ASIAN FOCUS

ASIAN FOCUS Belden Regional Road Show in Asia shared tech in 5 cities in 8 days Belden Singapore Pte. Ltd., a business of U.S.-based Belden Inc., reports that it has successfully completed an ambitious road show that over an eight-day period saw some 800 registered delegates in five countries attend its program about network infrastructure. The Belden Technology Seminar 2008 started April 8 at the Amara Hotel in Singapore City, then went April 9 to the Sunway Pyramid Convention Centre in Kuala Lumpur, Malaysia; April 11 to the Swissotel Le Concorde, Bangkok, Thailand; April 14 to the Shangri-la Hotel, Manilla, Phillipines; and April 16 to the Intercontintental Midplaza Hotel, Jakarta, Indonesia. This year’s seminar, ‘Unlocking Secrets of Intelligent Network Infrastructure” drew close to 800 registered delegates in the above five cities, a Belden press release said. It explained that the seminar offered IT decision makers ideas on how to implement new technologies to build an intelligent network infrastructure that will outlast two to three generations of active equipment. “Belden Technology Seminar is a platform that allows us to share our successes in developing the most advanced structured cabling systems in the marketplace,” said Goh Wei Koon, Marketing Manager for SouthEast & North Asia and South Pacific. Three main topics were presented during the seminars: the Belden IntelliMac solution that helps organizations to increase productivity and efficiency of IT service management processes as well as providing IT forensic support; Belden Data Centre Infrastructure, which highlights strategies in deploying solutions to seamlessly integrate data centre’s functional areas; and the Belden Wireless Solution, which eliminates the coverage and capacity limitations of traditional

Attendees browse through the tabletop display during the Belden Technology Seminar 2008 at the Sunway Pyramid Convention Centre, Kuala Lumpur, Malaysia.

At the Amara Hotel in Singapore City, attendees listen to presenters at the Belden Technology Seminar 2008, which visited five countries in eight days. WLAN architectures, and the need for cell planning and site surveys. IT professionals and consultants from Singapore, Malaysia, Indonesia, Philippines and Thailand where the Belden Technology Seminar 2008 traveled to were treated with the latest information. Belden partnered with Fluke Networks and Brady Corporation, both technology partners of the seminars in the solutions showcase during the events at five cities. For more details, contact Maggie Huang, Marketing Executive, S.E. & N. Asia and S. Pacific, tel. 65-6879-9800, maggie.huang@belden.com.

ASIAN NEWS BRIEFS Agreement to create Europe India Gateway A formal contract has been entered into to make the ambitious Europe India Gateway (EIG) a fiber reality. The project, estimated to cost more than $700 million, will build the first direct, high-bandwidth optical-fiber submarine cable system from the U.K. to India, the EconomicTimes reported. The goal is to “significantly enhance connection capacity and redundancy between India and the UK,” the report said. The report said that major global players in the telecommunications industry have signed on for the project, which is targeted to be operational in the second quarter of 2010. The 15,000-km system will connect 13 countries and three continents, with landings panned in the U.K., Portugal, Gibraltar, Morocco, Monaco, France, Libya, Egypt, Saudi Arabia, Djibouti, Oman, United Arab Emirates, and India. Participants, it said, include: AT&T; Bharti Airtel; BT;

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

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C&W; Djibouti Telecom; Du; Gibtelecom; IAM; Libyan Post, Telecom, and Information Technology Company; MTN Group Ltd.; Omantel; PT Comunicações, S.A.; Saudi Telecom Company; Telecom Egypt; Telkom SA Ltd.; and Verizon Business. The EIG system will also provide seamless interconnection with other major cable systems connecting Europe, Africa, Asia and North America, the report said. The system is designed to provide up to 2.88 terabits (Tbps) using DWDM to provide upgradeable transmission facilities that support Internet, e-commerce, video, data and voice.

Usha Martin seeks duty relief on some exports India’s Usha Martin Ltd. is seeking to be excluded from export duties on wire rod it sends its foreign subsidiaries. The company exports 30,000 metric tons of wire rod to its Thailand subsidiary, Usha Siam Steel Industries Public Company Ltd., which turns the rods to wire and wire ropes. Those exports will now require a 10 percent duty, which is likely to impact the margins of the Thai company, according to a report in India’s The Telegraph. The article noted that other companies are facing this same problem. JSW Steel and Tata Steel export cheap semifinished steel produced in India to overseas mills where they

are processed for sale in the developed markets. That strategy would not work if exports face a 10 percent duty, it said.

Wire rod a leader in Chinese export decline Efforts by the Chinese government to curtail exports of steel appear to be having an effect, especially for wire rod. According to wire reports, China’s steel exports fell by nearly 20% from last year for the first 2008 quarter through March, with exports of 11.39 mmt. The articles noted that Chinese steel exports have been declining since July 2007. Wire rod exports have had very notable drops because of changes in tax rebates, falling 44% due to a 15% export tax and a rising Chinese currency.

Sterlite reports power cable contracts from PGCIL Sterlite Technologies Limited (Sterlite) has won three power cable contracts from PGCIL (Power Grid Corporation of India) worth approximately US$74 million. Sterlite, which notes that it will start filling the order this August, described PGCIL as India’s single largest buyer of power transmission conductors, according to a report in newswiretoday. With the latest contracts, Sterlite’s telecom and power business order book for 2009 is worth about US$275 million, it said. ■

Can You Tell The Difference? Your Butt Welder Can. Ed Harrington, Quality & Service Supervisor

When was the last time you actually replaced a part on your Micro-Weld butt welder? Though our butt welders work harder, last longer and offer consistent high quality welds, certain parts will eventually wear out. Check your welder for worn out parts, or call the Micro-Weld Service Team. Why go any place else? Get genuine parts from folks who built your welder. All parts may look the same, but ours work better and last longer. Your welder will know the difference. You’ll know it too, because genuine Micro-Weld parts reduce weld breaks and downtime, maximize weld consistency, and increase your productivity.

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PEOPLE

PEOPLE Belden Inc. has named Steve Biegacki as vice president, global sales and marketing. He had most recently been with Rockwell Automation where he was vice president, marketing. As part of his duties at Rockwell, he helped lead the company’s globalization of its marketing function, provided leadership in Steve Biegacki defining targeted customer segments, worked to align the product portfolio with customer needs, and envisioned and realized strategic initiatives. He joined Allen-Bradley (which was later acquired by Rockwell) in 1978 and has nearly 30 years’ experience with the company in sales, business management, and marketing focused on industrial automation. He holds a B.S. degree in electrical engineering technology from ETI Technical College in Cleveland, Ohio. Based in St. Louis, Missouri, USA, Belden Inc. provides signal transmission solutions for the global industrial automation, data centers, broadcast studios, and aerospace markets.

24 | WIRE JOURNAL INTERNATIONAL

Berk-Tek, a Nexans company, has named Mike Connaughton, RCDD, as the company’s fiber product business manager, responsible for managing all BerkTek’s optical fiber LAN product activities team. He previously spent 15 years at Mohawk, a Belden Company, focusing on fiber optic product development and support. He has held various positions in technical support, sales, marketing and product management. He holds a B.S. degree in electronic engineering technology from Wentworth Institute of Technology in Boston, and achieved his Registered Communications Distribution Designer (RCDD) designation from BICSI. He will be based out of Berk-Tek’s fiber optic Mike Connaughton facility in Fuquay-Varina, North Carolina. Part of Nexans, Berk-Tek manufactures different network copper and fiber optic cable products.

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Lenze-AC Tech has named Jim Craig as the company’s new director of engineering, responsible for directing new product design, development and sustaining engineering activities at the company’s Uxbridge facility. He has 28 years of industrial automation experience, including serving as product manager, high power motor drives at Danfoss. He holds a B.S. degree in electrical engineering from Southern Illinois University, graduate work at Stanford University and has multiple patents to his credit. With its North American headquarters in Uxbridge, Massachusetts, USA, Lenze-AC Tech supplies a portfolio Jim Craig of AC Drive products. AMETEK Specialty Metal Products (SMP) has named Peter Hoctor as regional sales manager for Europe, responsible for sales and marketing of AMETEK’s full line of specialty metal products. He has more than 15 years of experience in the sales and marketing of specialty metals, most recently as sales manager, Europe, for

Reading Alloys, a manufacturer of specialty titanium alloys and highly engineered metal powders acquired by AMETEK in April 2008. He will retain his position with Reading Alloys as he assumes additional responsibilities for AMETEK Specialty Metal Products. AMETEK SMP has plants in Austria, Czech Republic, Denmark, France, Germany and the U.K. Based in Eighty Four, Pennsylvania, USA, AMETEK SMP supplies powdered metals, shaped wire and more. PolyOne Corporation has named Robert M. Patterson as senior vice president and CFO. He most recently was vice president and treasurer at Novelis, Inc. He holds B.B.A. and M.A. degrees in accounting from the University of Michigan. He succeeds W. David Wilson, who has served as CFO since PolyOne’s inception in 2000 and has been with the company and its predecessors for 30 years. Wilson plans to leave upon completing the transition. Based outside of Cleveland, Ohio, USA, PolyOne Corporation supplies specialized polymer materials. ■

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FIBER WATCH

FIBER FTTH subscribers up sharply The Fiber-to-the-Home (FTTH) Council reports that North America continues to embrace high-bandwidth as fiber connections to home grew substanially again, reaching nearly 3 million households, according to a study released today by the Fiber-to-the-Home (FTTH) Council.

FTTH Homes Connected, cumulative, North America. Chart: Fiber to the Home Council.

sharply, with more than 1.6 million homes using videoenabled FTTH. “Fiber-to-the-home providers are going full speed ahead in their efforts to deploy advanced fiber networks capable of delivering a new generation of online services,” said FTTH Council President Joe Savage. “The FTTH industry will not rest until we deliver direct fiber connections to the other 90 million North American households that still don’t have access to them.” The study showed that Verizon, having committed more than $20 billion to deploying its FiOS FTTH service, continues to set the pace in the number of connections, with more than 70 percent of the North American total. Mike Render of RVA LLC, who authored the study, noted that the number of homes receiving 100 megabit service – some 30 times the speed of what is offered by most cable and DSL Internet services today – has risen to 17,000 from 12,000 a year ago. “The 100 megabit level of service is beyond what most people would need or use today, but it’s interesting to note that some FTTH providers do offer it and that a fairly large number of subscribers have it already,” he said. The FTTH Council has urged legislators and regulators to adopt a “100 Megabit Nation” policy and reduce barriers to next-generation broadband deployment. Further information on the study, including graphs and charts, can be found at www.ftthcouncil.org.

Politics - with a fiber optic edge/pledge

FTTH: houses passed, cumulative, North America. Chart: Fiber to the Home Council. A study by RVA Market Research (www.rvallc.com) notes that there are now 2.91 million homes connected via end-toend fiber, compared to 1.48 million connections as of April 2007, for an annual growth rate of 97 percent – indicating that the number of FTTH connections continues to almost double annually. The study also shows fiber-to-the-home networks now passing 11.8 million North American homes, up from 8 million a year ago, with the percentage opting to subscribe up for a fourth straight six-month period. In addition, the number of households receiving video services over their FTTH connections continues to increase

26 | WIRE JOURNAL INTERNATIONAL

It’s time to update the old political credo promising “A chicken in every pot.” In Auckland, New Zealand, National party leader John Key has promised a taxpayer investment of US$1.5 billion over six years if he is elected. According to a report in the digital edition of The Otago Daily Times, Key said that within a year of taking office, he would meet with telecom companies to convince them to contribute the remainder of the estimated $4 billion it would cost to meet the National’s broadband target. The National party, it said, wants to see the copper wire network upgraded to a fiber cable network, an upgrade that it says would have economic benefits of between $2.7 billion and $4.4 billion a year. ‘‘New Zealand has already fallen behind our global competitors when it comes to broadband,’’ Key was quoted as saying. “‘We’ve delayed the big decisions and put off investment for long enough. Every year that goes by with us languishing behind other countries is another year of missed opportunities.’’ The ruling Labour Party, however, is not so thrilled with the proposal, the article said. Communications Minister David Cunliffe said that “National’s plan would cement telecom in as the dominant fiber network provider. The party’s plan amounted to a state subsidy for a monopoly firm, Telecom,” he said. ■

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FASTENER UPDATE

FASTENER UPDATE Uses of composites in prototype jet calls will require far fewer fasteners A new U.S. Air Force cargo plane that may go on a test flight as early as this October will see far greater use of composites as well as a marked decrease in the numbers of fasteners used. According to a report in USA Today, Lockheed Martin is building the first military cargo jet whose structure will

The U.S. Air Force is pursuing R&D to replace its venerable C-5 Galaxy transport plane with a model that uses far more composite materials and far fewer fasteners. be made of fibers, resins and epoxy, replacing metals such as aluminum and titanium that have been in use in aircraft for decades. That, the article said, will result in reducing greatly the number of parts, with 306 composite parts replacing up to 4,000 metal ones, including many fasteners. Lockheed Martin is using an existing airplane, a German-built Dornier 328J regional jet, and modifying it, the article said. The cockpit was sawed off the cockpit and workers discarded much of the rest of the plane and they will replace it with a bigger, lighter composite airframe, it said, noting the following: The top and bottom parts of the fuselage, an interior floor and reinforcing parts will all be made of composite materials. The two halves will be shaped with giant custom-made foam tools, or molds, and rest in metal frames while engineers use lasers and computer-guided cutting machines to precisely fit parts and sculpt the final shape. When ready, workers will glue the halves together and bond the new fuselage to the original metal cockpit. The numerous nuts, bolts and metal fasteners that hold current military planes together will largely not be needed. The plane, which will have some 20% to 30% of its weight cut, is being made via a $50 million contract that will have gone from concept to its first air test in just 18 months, it said.

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The article cited Project lead Engineer Mike Swanson as saying that, “This is fundamentally a different way of building aircraft. We’re going up against 70 years of traditional metal fabrication.” The USA Today story noted that non-metal parts have been used in commercial and military aircrafts for more than a decade, but this marks the first time that it will be used by the U.S. military to incorporate the latest fiber technologies and production methods in the airframe of the transport plane itself. The article said that the use of the composite materials should result in fuel savings of 20% to 30% as well as enable the plan to fly heavier payloads for longer distances. The U.S. Air Force, it said, reports that it spent $4.2 billion on petroleum in 2005, up more than onequarter over the previous year and more than the Army, Navy and Marines combined. The U.S. military currently relies on the aging transport workhorses, C-5 Galaxy, circa the late 1960s, and C-130 Hercules, which first flew in 1954, said the article, which cited one officer as observing, “There’s a high payoff for the Air Force if this works.”

Updated book offers far more parts U.S.-based MSC Industrial Supply Company reports that it has released a new comprehensive guide for the industry that offers 40 percent more fastener parts than the prior version printed in 2002. The new publication, the Fastener Source Book, presents more than 42,000 products, a press release notes. The company said that it has tripled the catalog printing and that it plans to distribute more than 50,000 copies to customers nationwide as well as allow people to view an online version at its company website in its Fasteners Solutions section. MSC Senior Director of MRO and Purchasing Greg Levy said in the release that the book will make it easier for customers to find the products they need. “The book includes many new items and technical information to assist customers in finding the right products for maintenance, repair and production. Since fastener products are used across virtually every industry segment, the Fastener Source Book will be broadly distributed to MSC’s current customer base,” MSC Product Manager Lou Cutalo, Jr., said in the release. He noted that the book contains new items, such as a full line of stainless steel fasteners, and is another step to providing customers an even higher level of service. Contact: MSC Industrial Supply Company, www.mscdirect.com or call 800-645-7270. ■

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WAI

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NEWS

Program shaping up for Mexico ITC Planning and preparations continue for WAIâ&#x20AC;&#x2122;s International Technical Conference (ITC) that will be held October 20-22 in Monterrey, Mexico, and at this point the technical program is being solidified and other elements, such as the plant tour, have been firmed up. The event, which is being organized by ANTAAC, a Mexican steel wire association, and WAI, will include a full program that will be held at the Crowne Plaza Monterrey. The August WJI issue will provide much more detail, but some of the elements that are in place include the framework for the technical program, to be presented over two days (Oct. 21-22); tabletop displays; a tour of Mexicoâ&#x20AC;&#x2122;s new Homo 3 Museo del Acero, a local steel museum; an evening fiesta at a nearby brewery; and more. The technical program is expected to include more than 20 papers on topics from the ferrous, nonferrous, and electrical segments. A complete list of abstracts will be available in the August issue of WJI, but the preliminary list of topics includes: die wear, wire rolling, graphite par-

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ticles, tensile strength calculations, wire rope fatigue strength, tire cord and bead wire, copper and aluminum rod, stranding, crosslinkable cable insulation, and analytical software for fiber networks. Other parts of the educational program, which are also still being finalized, will include presentations from senior professionals in both the ferrous and nonferrous categories.

The Crowne Plaza Monterrey will host the International Technical Conference being held in Monterrey, Mexico, this October.

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Interwire is again rated a ‘Top 200’ trade show event

WAI NEWS

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Serving the non-ferrous and ferrous industries since 1983

Interwire 2007 was one of the Top 200 Trade Shows for that year, reported Tradeshow Week, which notes that it came in at No. 181. Tradeshow Week compiles the list each year from data on trade shows in the U.S. and Canada. In 2007, there were some 3,800 such events, it noted. Each manager gets a report form after the event ends and those that are returned are considered and ranked based on net square footage accounted for at the venue.

Consumer shows are excluded from the TSW 200 rankings. However, some tradeshows are open to the general public. Such shows are included only if there are specific trade-only periods. Interwire/IFE had 152,850 sq ft of net exhibit space. Interwire has been rated a top 200 trade show by Tradeshow Week each year that a report was submitted. It has come in as high as No. 131 for 2003. The top five shows in 2007 were: 1) 2007 International Consumers Electronics Show, 1,804,070 sq ft; 2) International Construction & Utility Equipment Exposition, 1,155,000 sq ft; 3) The World Shoe Association (WSA), February show, 1,110,250; 4) MAGIC Marketplace, 1,100,885 sq ft; and 5) The World Shoe Association (WSA) Show, 1,099,750 sq ft, July show. “We’re proud of this recognition as it highlights just how big an event this is for the wire and cable industry,” said WAI Sales Director Bob Xeller.

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Poland Chapter symposium draws attendees from 14 companies A March 20 symposium at the Hotel Argentum in Gliwice, Poland, by the WAI’s Poland Chapter and the Institute of Non-Ferrous Metals (IMN) drew some 50 attendees from 14 companies. The symposium, which focused on development of technologies for nonferrous metals wire production, was further aided by scientists from Czestochowa University of Technology. The event included two noteworthy presentations: “Development of Technologies for Production of Wires from Special Alloys and Composites Based on Silver, Copper and Other Metals,” by INMET Director

WAI NEWS

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Schneider Memorial Award was presented to Dr. Stanislaw Ksiezarek. Dr. Stanislaw Ksiezarek; and “Trolley Wires for High Speed Railways,” by Prof. Tadeusz Knych, AGH University of Science and Technology, Krakow. Attendees came from Telefonika, Bipromet, WM Łabedy, Dawid, Degropol, IMN and IMET as well as scientists from the Polish Academy of Sciences, AGH University of Science and Technology, Silesian University of Technology, Institute of Welding and Czestochowa University of Technology. During the event, the Schneider Memorial Award was presented to Dr. Stanislaw Ksiezarek for his contributions in developing technology for nonferrous metals wires, including many patents, as well as his international achievements. A WAI member, Dr. Ksiezarek was among the authors who presented an award-winning technical paper at Interwire 1990, a first for the Poland authors. The symposium was made possible by contributions from IMN, whose managing director, Prof. Zbigniew Smieszek, was on the local committee for the WAI’s 1999 ITC held in Zakopane. Prof. Smieszek and Prof. Jozef Zasadzinski were chairmen of the symposium. ■

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CHAPTER CORNER

CHAPTER CORNER Ohio Valley Chapter sets Aug. 7 date for its 6th Annual Golf Tournament The Ohio Valley Chapter cordially invites golfers, be they WAI members or not, to take part in its 6th Annual Golf Tournament, to be held on Thursday, August 7, 2008, at the Grantwood Golf Course in Solon, Ohio, USA near Cleveland. The scramble format event is a great way to network with industry colleagues, entertain clients and reward employees at a player friendly course. Prizes will be awarded for the best team scores as well as for a variety of individual skills contests. The day’s top prize of $10,000 will be awarded to the golfer on hole number 7 who makes a hole-in-one on the challenging par three. Three other par 3’s will have closest-to-the-pin prizes to reward the golfers’ accuracy. Continuing on the precision theme, there is an accurate drive hole along with two long drive prizes for the big hitters. “You can have a lot of fun playing the Grantwood course,” said tournament chair Mike Caranna of

From l-r, Ohio Valley Chapter Golf Event Chairman Mike Caranna with the winning 2007 team of Mark Mathiasen, Mathiasen Machinery, Inc.; Andy Blackmore, Roteq Machinery, Inc.; Joe Brunner, Northern Cables, Inc.; and Mike Mathiasen, Mathiasen Machinery, Inc. American Spring Wire Corp. “It really gives you the opportunity to connect with people in the industry in a relaxed setting, and the prizes help add a little challenge to the mix.” Sponsorships are available ranging from the hole-in-one and skills contests to $100 corporate hole sponsors. All companies who take advantage of this opportunity get signage and acknowledgment at the course as well as recognition in the tournament wrap-up article. “Companies who sponsor the various activities of the tournament really are a big help,” said Ohio Valley Chapter President Dane Armendariz, Henkel Corporation. “We really appreciate their support and are pleased to recognize them for it.” Check-in and warm-up begin at 8:30 am with the first tee time set for 9:30 am. The awards reception and dinner

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will take place at 4 pm. Tournament fees are $120 per golfer and include greens fees, cart, lunch at the turn and the awards dinner. Deadline to register is July 31, 2008, and the registration form is available at the chapter webpage at www.wirenet.org/members/chapters/ohioval.htm. Nongolfers who want to attend and network with industry colleagues can join the reception and awards dinner for only $35. For more information, contact Mike Caranna at mcaranna@amspringwire.com; tel. 216-292-4620 or WAI’s Chip Marsh at cmarsh@wirenet.org; tel. 203-453-1748.

Last call: Midwest Chapter tourney Time is getting short to make plans to take part in WAI Midwest Chapter’s 6th Annual WAI Midwest Chapter Golf Tournament, which is set for Monday, June 23. The chapter returns to the St. Andrews Golf & Country Club in West Chicago, Illinois, for a fun day of networking and golf. The scramble format tournament will offer both team and individual prizes, with a $10,000 payout to the golfer who makes a hole-in-one on the designated par 3 hole. Other skill contests include two long drive holes and three closest-to-the-pin holes as well as the popular putting contest after the round. Fees for the event remain the same for golfers at $110, which covers the greens fees, cart, lunch at the Halfway House and the post-tourney reception and awards dinner. Non-golfers are invited to join in for the reception and dinner for only $35. Sponsorship opportunities are still available for companies and provide exposure the day of the event with signage and recognition in the tournament program as well as in the WJI wrap-up article. Exclusive sponsorships are available for the $10,000 hole-in-one and the skill and putting contests for fees ranging from $150 to $250. Corporate hole sponsorships are also available for $100 each and are non-exclusive. The pdf registration form is available online at the Midwest Chapter webpage at wirenet.org, or you can contact Kevin Sopczak at tel. 815-713-6959, kswire@aol.com or WAI’s Chip Marsh at 203-453-1748, cmarsh@wirenet.org.

New date for Southeast golf tourney The date has been changed for the Southeast Chapter’s 7th Annual Golf Tournament, which had been set for October 23 at the Rock Barn Golf and Spa in Conover, North Carolina, USA. The event will be held October 30.

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Members of Poland and India chapters active at wire Düsseldorf Among those attending wire Düsseldorf in April were members of the WAI’s Poland and India chapters, whose members took advantage of the opportunity to inspect the technology on the show floor (see wrapup on p. 38). The Poland Chapter sent a contingent to the biennial event in 2006, and for the 2008 event it had a total of 37 participants who traveled by bus. Participants were from the following 17 companies, most of which are wiredrawing businesses: Gamma Metal, Elmen, SPIE, PPHU STAL-POL, MET-Prim, EDIKOL, ECOR, Ferro-Pol, ZPHU “Wider –Bet.” Dawid Enterprise, Alwotech, Metal Union, CMC Zawiercie S.A., Premco, Eldrut, Degropol

R&D Centre and Energomontaz Polnoc Belchatow. Representing the Poland Chapter board were Prof. Bogdan Golis and Prof. Jan Pilarczyk along with a representative from Dawid Enterprise, which along with Degropol R&D provided financial support for the trip and their help is gratefully acknowledged. Also on the trip was the owner of Morionis from Vilnius in Lithuania. During the trade fair, in addition to being able to visit many exhibits, the Poland Chapter members were welcomed at the booth of Italy’s Lubrimetal, which was also celebrating the company’s 50th anniversary. Lubrimetal President Antonio Corso greeted the chapter members and spoke about his company’s history. He also noted that Gamma Metal is its representative for the Polish market. The presentation concluded with good Italian wines and Italian snacks, making for a very good visit. All participants were very pleased with this meeting and ending the trip confirmed they will to take part in similar trip in 2010. Members of the WAI’s India Chapter were among a 120-person contingent who attended wire Düsseldorf. Key planners for the trip were India Chapter President R.K. Tyagi, Treasurer Harish Jindal and Secretary Nirmil Singh. Attendees were able to meet with exhibitors and inspect new technology and services. Many attendees reported that the event was worthwhile. ■

Members of the Poland Chapter get ready to board the bus for Düsseldorf.

Poland Chapter members gather during wire Düsseldorf at the booth of Lubrimetal, where they were welcomed by company officials (at right).

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With WAI Executive Director Steve Fetteroll during a special dinner for India attendees at wire Düsseldorf are (l-r) India Chapter officers Harish Jindal, treasurer, R. K. Tyagi, president and Nirmal Singh, secretary.

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2008 Düsseldorf trade show a memorable event

ne need not see the wrapup from the organizers of the 2008 staging of wire Düsseldorf to know that the biennial event was a big success. Aside from the

considerable traffic, by mid-week, there was an unmistakable atmosphere that business indeed was being done. There was a sense of contentment in the faces of many busy exhibitors, a tone that has been reflected in the post-show comments in this wrapup.

The theme at the Sikora AG/Sikora International booth was “Join the best.” 38 | WIRE JOURNAL INTERNATIONAL

By the numbers from Messe Düsseldorf, wire 2008, which was co-located with Tube Düsseldorf and the METAV automation show, fared quite well. The combined wire and tube events featured 2,200 exhibitors, 1,129 for wire and 1,028 for Tube, occupying more than 95,000 sq m (1,022,600 sq ft). The two combined events drew 73,600 visitors from more than 90 countries. The wire event drew 40,700 visitors, up nearly 4 percent from 2006. Wire attendees came from 72 countries, with about 58 percent from outside of Germany. The largest contingents came from France, India, Great Britain and Northern Ireland, Italy, the U.S., Poland, Brazil and Belgium. See p. 36 for news on members of WAI’s India and Poland Chapters attending the event. A total of 72 companies from the U.S. exhibited,

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During wire 2008, Joachim Schäfer, Managing Director of Messe Düsseldorf GmbH, spoke at a press conference about the events, the state of the industry and Messe’s role. Below are edited comments from his speech.

An overhead view of the Niehoff GmbH booth. Equipment draws, but offering attendees a place to rest one’s feet and to enjoy refreshments and snacks is a welcome touch.

including 29 companies within the North American Pavilion, organized by Messe Düsseldorf North America (MDNA) and sponsored by the Wire and Cable Industry Suppliers Association (WCISA). Since its premiere in 1986, wire Düsseldorf has more than doubled its exhibitor figures: from 488 exhibiting companies in 1986 to 1,101 companies in 2006. The event continues to be more international, with exhibitors based outside of Germany climbing from 785 in 2006 to 814 in 2008. In 2006, 51% of wire visitors were interested in wire-manufacturing and processing machines, 38% in materials, special wires and cables and 22% in processing technology tools. “We expect that visitor interest in 2008 will (have been) similar,” a press release said. “Once again, Düsseldorf has proven to be the number one platform for the wire and tube industries,” said Joachim Schäfer, the managing director in charge of trade fairs for Messe Düsseldorf. “The exhibiting companies and visiting trade fair guests were truly enthusiastic with the results of the trade fairs. Many large and also medium-sized businesses have told me of new, promising business contacts.” The equipment features in the July and September WJI issues will include a wide range of the equipment that was displayed at wire Düsseldorf. Exhibitors: good results, a refined approach Germany’s Niehoff GmbH reported that it had its most successful participation ever at a wire trade show, with many customers and visitors from Europe and other continents. The company said it took orders for several double-twist bunching machines equipped with its new optoelectronic traversing system NBAT for double-twist

wire 2008 and Tube 2008 are stronger than ever before and there are no signs of this stopping as both fairs exceeded the very good results of the 2006 events. Europe continues to be an important supplier of wire and cable machines as well as one of the leading sales markets for these industries. Despite high cost pressure in the core countries of the EU, many companies in the wire and cable industry are continuing to invest. Beyond the mechanical engineering sector, significant customers include the vehicle industry and its supplying sectors, the energy industry as well as the areas of information and communication technology. The steel pipe/tube business, especially the pipeline sector, has the best growth opportunities beyond 2008, but wire remains a significant field. One trend wire attendees may Joachim Schäfer notice is that there will be more wire exhibitions in the areas of logistics, efficient energy utilization and environmental technology as exhibitors respond to increased environmental awareness and stricter environmental protection laws. This is an important growth area. The business volume generated by the worldwide wire and cable industry is expected to increase to US$25 billion by 2010, an economic upswing which will probably not even have reached its peak by then. Products from the wire and cable industry, for example screws, technical springs, fence mesh as well as energy and data cables, are indispensable for everyday requirements and applications. wire and Tube are among the most international events held by Messe Düsseldorf at the Düsseldorf venue. The themes of wire and Tube are intertwined with each other like a cog. Synergy effects are generated particularly for the industrial sectors of construction, iron and steel, the electronics industry, electrical sector, vehicle building as well as the supplying industry. International support for wire and Tube is provided by strong alliance partners from Italy, the U.S. and Great Britain. A glance across the expanded exhibition centre clearly illustrates that we too are also continually working on the modernization of the Exhibition Centre to offer our exhibitors the optimal platform for presenting their products. The fact that wire and Tube are the leading trade fairs for their respective sectors is an incentive for us to further extend and develop this edge. Our aim is to respond in equal measure to the needs of the exhibitors and the constantly increasing requirements of the visitors from all over the world. JUNE 2008 | 39

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Further opportunity awaits industry

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Otto Bihler Maschinenfabrik GmbH displayed its MC 120 multifunctional processing center.

bunching machines. Other exhibited equipment that was sold included an MMH50/RM121 multiwire drawing line, the latest high speed rewinding machine DSA “Niehoff System Hacoba” with spool payoffs for multiwire bundles, a double twist stranding machine with back twist payoff and longitudinal tape payoff and a 24-carrier high speed braiding machine with take-up and payoff unit. If there was a downside, Niehoff reported, it was that the addition of the third fair made it more difficult to get local accommodations, which meant that some show attendees had to travel longer than usual distances from their hotels to the fair grounds. Brazil-based Madem Reels, which noted that it has taken part in the wire show for more than 10 years, declared the event a success. “Our focus is to meet and talk with our worldwide customers and also develop new customers. This show was very good and we (met) several new customers in several countries around the world.” U.K.’s Pressure Welding Machines notched excellent sales leads for its cold pressure welding equipment and dies. “Although the show seemed less busy this year, the quality of visitors to our stand was much higher than before, with far more decision-makers in attendance,” PWM Managing Director Steve Mepsted said. Canada’s QED Wire Lines said that it had a great show, with very strong interest from Eastern Europe, the Middle East and India. “Interest from South America was stronger than expected and Asia was a little weaker than in previous years,” said QED Engineer Michael Crowle. “The North American market was reasonably quiet as expected. Overall, it was a good show with good attendance. As usual the show was well organized and the added crowds from the Metal Forming Show did not seem to be a problem. It was a little more difficult finding seating in restaurants, but it was a very good week for us.”

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Scapa Cable Solutions, part of U.K.-based Scapa Group plc, also reported a very successful week, with higher than anticipated visitor numbers and excellent visitor quality. “During the course of the week we welcomed visitors to the stand from over 50 different countries, with strong interest from the Middle East and Africa.” Swiss-based Maillefer SA summed up the event in four words: “Wow, what a show!” It said that the organizer’s Swiss-based Maillefer glowing wrapup “qualifies the spirit SA summed up the experienced at the event in four words: Maillefer stand this “Wow, what a year.” It said, “Handshakes show!” It reported sealed several that, “Handshakes multi-million dollar deals, especially sealed several multiin the energy secmillion dollar deals.” tor. The busy fiveday event saw many loyal friends and partners step into the crowded booth. (See photo on p. 4.) Beyond equipment, the Maillefer stand also drew a good crowd for its technical sessions that it put it on during the event. The company’s booth was busy and with the sessions, it was even more so. U.S.-based MGS Manufacturing’s Jim Zampogna reported that his company had “the most activity we have seen in a long time from potential customers outside the USA, thanks to the weak dollar.” He said that discussions he had were fruitful. “There are many real and active projects, especially outside the U.S., although we also met with some key U.S. customers to seriously talk about projects that should happen in the next few months.” The Eurolls Group, which is made up Eurolls SpA,

Staff at the booth of U.S.-based Wire Lab Co. were among those kept busy during the biennial trade show.

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The Eurolls Group exhibited in a big way, equipment-wise and presentation-wise, in Hall 11. In front is Tony DeRosa, Cortinovis Machinery America, with a 72 in. bow strander and an automatic loading system.

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Team Meccanica, Teurema, Vitari, Cortinovis Machinery, and the newly acquired Sictra, exhibited in a spectacular way at wire 2008, with an eye-catching, two-level structure spanning 10,000 sq ft. The stand was filled with equipment and staff from the different group companies and the company said that the efforts paid off. “It was an amazing week for all of us in the Eurolls Group,” said Eurolls Group President Renato Railz. “There was non-stop activity with attendees and a good deal of business as a result.” Germany’s Sikora AG focused on the theme “Join the best,” presenting its

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measuring technology while stressing the importance of being able to meet future needs. The concept, Sikora Chairman Harry Prunk explained, is that for manufacturers to remain competitive, they need innovative measuring devices, and Sikora is committed to being that supplier via its commitment to continuous R&D and working with customers. Discussions were held on the company’s lounge-style second floor. “Our customers immediately felt comfortable at our booth, which contributed to the

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The Esteves Group booth had an interesting overall look and marked the introduction of the company’s new name, which it noted reflects the global natural of Esteves.

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Italy’s PS Costruzioni displayed an automatic coiling line, model PS 350/6-2.

Marco Dell’Oro, U.S. sales manager for Italy’s Mario Frigerio SpA, said his company took an artistic approach to make their booth more inviting for attendees.

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MGS Manufacturing’s Jim Zampagno (2nd to left) believes the weak U.S. dollar helped send some attendees his company’s way.

further development of business connections and to make new contacts,” Prunk said, noting that visitor attendance was up 45% over the prior show. The Mario Frigerio SpA booth featured more than just equipment. The upstairs portion of the Italian company’s booth included an artistic element, with conceptual art by Mario Ronchi, designer-artist in Milan. “We also wanted to create a better environment that did not directly refer to machinery but in a very welcoming way could make the visitors feel comfortable and almost not as if they were at a wire show,” said U.S. Sales Manager Marco Dell’Oro. “The lower part of the booth was strictly related to equipment and business, while the upper section became almost a museum where conversation could be carried out with more relaxing.” The company also held a well-attended post-show wine and cheese on Tuesday and Wednesday. Dell’Oro said that the company’s booth had many good attendee visits, and that it closed contracts during the event and received good feedback about progress made by its nonferrous division, Frigeco. It also made new important and encouraging contacts for its newest group member, Cabmach, for its stranding and bunching machinery, he said. Swiss-based Nextrom Oy reported that wire Düsseldorf was “the most successful fair in the group’s history.” It said that its booth, displaying Nextrom and Rosendahl technology, was constantly crowded with attendees from the global wire, fiber and cable industry who saw a multipurpose THHN wire extrusion line, a

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Sector SZ, a high-speed coloring line OFC 52i, a Screening SZ-Strander ROSZ 120, and more. “This (was) without a doubt, the most successful fair in our history,” declared Nextrom CEO Siegfried Altmann, whose wrapup statement said that many “This is without a orders were doubt the most signed during the show. He successful trade fair noted that the in our history,” company’s “kick-point Siegfried Altmann tournament” Nextrom CEO was much appreciated, as was its customer evening that saw some “350 partners attending from 39 different nations, a memorable moment for all of us.” The Düsseldorf Fairgrounds will host wire and Tube again in 2010, the dates not yet set. At press time it had not been decided by the organizers, who had polled

FEATURE

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Attendees who stopped by the WAI booth could reserve a booth for the Interwire 2009 show in Cleveland, Ohio, as well as enjoy pastries and a cup of American-style coffee. exhibitors, whether METAV would return. Contact Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. ■

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Take-ups and payoffs

elow, 18 suppliers of take-ups and payoffs present some of the equipment they offer. For more details, visit the companies’ websites and/or contact

them by telephone.

Cortinovis Machinery America U.S./Italy Cortinovis Machinery America, part of Italy’s Eurolls Group, has offered a complete line of payoffs and takeups for many years. These field-proven machines incorporate the latest generation of servo-drive technology for traverse and winding. The machines can be supplied in a plant configuration, as a rewind application, or as standalone machines that can replace outdated existing machines. The latest developments have been in large drum twister take-ups for assembling Milliken cable constructions with machines A drum twister take-up from up to 4000 mm Cortinovis Machinery America. diameter and 30 tons. The photo46 | WIRE JOURNAL INTERNATIONAL

graph shows a drum twister take-up with external rotating capstan. The company’s complete line of payoffs and take-ups includes: gantry type (overhead type); portal type (floor traversing); single and dual open flyers; soundproof single and dual cone type flyers; cantilever type; rotating take-up (drum twisters) with external rotating capstan; and rotating take-ups (drum twisters) with integral linear capstan. Tony DeRosa, tel. 908-479-9818, cortinovis@cortinovisamerica.com.

Dynamex Corp. U.S. Dynamex, an innovator for wire and cable equipment, is mostly known for its high-speed single-twist cablers and bunchers, but it has developed a series of driven payoffs for wire on reels as well as unique, auto-splicing tape payoffs for extruders. The driven wire payoffs come in two main types: the multi-position overhung shaft type, and the stand-alone power loading pintle-support type. Many years ago Dynamex abandoned controlling tension by mechanical brakes in favor of driving/braking each reel by regenerative drives, while setting and controlling the tension by means of pneumatic dancers. The advan-

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carbon wire at speeds to 220 fpm. Custom units are available to suit any application. Features include: precise tension control, constant line speed during changeover, compact space requirements, no mechanical wear parts on tensioning device and optional spoolers from 1 lb to 8000 lb capacity. John Stevens, tel.909-476-9776, jstevens@emc-wire.com.

Fine International Corporation U.S. Dynamex Corporation’s TPX Series tape payoff. tages include improved energy efficiency, the ability to “divorce” the wire size from the reel weight, the ability to brake the reels or drive them as required, the elimination of heat generation in the plant, the elimination of replacing friction pads, and more. Each position includes a broken wire sensor for auto-stopping of the cabler, which can be selectively bypassed when that position is not in use. The standalone pintle-type driven payoff uses the same system to control the wire tension, but in addition includes power loading/unloading of the reel. The TPX Series tape payoff was developed specifically to enable uninterrupted tape supply for longitudinal taping in the extrusion process, but it can also be used in other continuous systems. This patented machine enables running a taping process continuously with unattended splicing, which until now has been considered unattainable. Ben Bravin, tel. 310-329-0399, ext. 11, bbravin@dynamexcorp.com

Engineered Machinery Group, Inc. U.S. Engineered Machinery Group, Inc., has developed and is currently producing a new line of dual block payoffs and take-ups for nonstop in-line process operations. The units feature AC flux vector drives for the pullout capstan, flyer and optional spooler. These machines are operator friendly and require minimal attention during operation. The advanced AC drives feature a unique program within its software that allows for automatic accumulation count during spool changeover. The flyer, which is driven by its own motor (no brakes or clutches), is utilized as a dancer control for the spooler take-up as well as a tensioning device for the wire. EMC offers the system in two sizes of standard machinery: a 16 in. dual block for .032 to .100 dia. high and low carbon wire at speeds up to 450 fpm, and a 22 in. Engineered Machinery Group offers a new line of dual-block dual block for .100 to .250 dia. high and low take-ups and payoffs.

Fine International manufactures a variety of take-up and payoff equipment, including a shaft-style cantilevered unit, a C-frame pintle, an O-frame pintle, a cantilevered pintle, floor-traversing portals, an overhead arm portal, and semi and automatic dual reel take-ups. Traversing reel style units are available in most configurations. Multiple reel payoff systems for cabling and extrusion applications are also available. Systems are offered for reel sizes from 250 mm to 3600 mm. The photo illustrates a 2500-mm cantilevered pintle style payoff that can be used for extrusion or rewind applicaA 2,500-mm cantilevered pintle-style tions. The pintle payoff from Fine International Corp. arms open and close using independent ½ hp AC motors. The lifting is done with a 5 hp gearmotor. The key feature of the payoff systems is the use of a specially designed low rpm motor that allows the elimination of a gearbox and provides jog forward/back, torque or dancer mode operation. This particular style can be made for reels from 1250 mm up to 3000 mm and up to 18,000 kg weight capacity. Eric Maks, tel. 508-315-8200, finesales@ gmail.com, www.fineinternational.com.

Kinrei of America LLC U.S. Kinrei of America, the distributor for Kopilowitz Engineering, Ltd., is offering a simple free standing, motorized payoff for up to DIN 800 reels that includes an integral dancer. This unit has a driven pintle that is fixed and is moved manually through the use of a hand crank. The dynamic multiwire payoff is specially designed to feed multiple wires up to 16 ends of awg 38-24 into a high-speed, double-twist buncher with line speeds up to 450 feet per minute. The tension range is from .6 to 11 lb. The integral dancer is pneumatically controlled and is designed for extremely low inertia and friction. The braking system uses a disk brake that is also pneumatically activated. All drives are AC inverters and motors are nor-

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mally Siemens AC with other brands available upon request. An operator station complete with touchscreen can be proved with the normal operator functions (start/stop, etc.), hour meter and line speed indicator. All sizes and types of payoffs, take-ups and rewinding units are also available. Mitch Jacobsen, tel. 973-6779500, mjcobsen@ A motorized payoff offered by Kinrei of America LLC. kinreiusa.com, or www. kopilowitz.com.

Maillefer SA Switzerland More than 20 years ago, Maillefer delivered the first of its successful EKP 130s to Australia. Now, a new generation EKP 1300 take-up is available that qualifies the 1300 as more versatile, more reliable and easier to operate from features such as: a 66% increase in reel range, now accepts reels starting at 500 mm up to 1250 mm; a 66% increase in cable outer diameter size Maillefer SA’s new EKP 1300 take-up. thanks to new catching device, up to 20 mm; safer and easier string up with an integrated dancer inside the take-up; upgrade potential from lifter model to conveyor model or reverse; modern and reliable components; AC motors and drives; failsafe PLC control; a new operator interface with touch screen panel; easier integration into line controls; and fewer parts for more reliable and easier maintenance. The 1300 benefits from the long proven EKP designs. Construction is robust and life time is long. Each take-up is factory tested with customer reels for quick start-ups on location. Manuel Felder, tel. 41-21-694-4111, info@maillefer.net, www.mailleferextrusion.com.

M+E Macchine

Engineering Srl Italy/U.S.

Italy’s M+E Macchine + Engineering Srl, represented in the U.S. and Canada by Morgan Koch Corp., special-

48 | WIRE JOURNAL INTERNATIONAL

izes in the design and manufacturing of payoffs and take-ups for steel and stainless steel wires M+E reports that its lines of take-ups and in coils or on payoffs can serve many ferrous uses. spools for annealing, patenting, galvanizing, oil tempering and other in-line processes, with long experience in the steel-cord industry. It also manufactures wet drawing machines for steel and stainless steel wire complete with horizontal or vertical axis spoolers. Its production range includes: payoffs from stationary spools or carriers; rotating payoff turntables for spools or carriers; horizontal or vertical spool payoff frames (option: double accumulation capstan); rotating capstan take-up frames for carriers (option: spiral laying, wire skinpass, dual size capstan); stationary capstan takeup frames for carriers (option: pattern laying, accumulation device, dual size capstan); horizontal or vertical spool take-up frames (option: double accumulation capstan); payoffs and take-ups for bead-wire and steel cord; and wet drawing units (for ultra-fine wire, saw wire, steel cord, spring wire, rope wire, staple and clips wire) complete with horizontal or vertical spoolers or its new series of full automatic spoolers with no operator intervention. U.S./Canada, Bob Strauss, straussrl@aol.com, tel. 281992-7850, www.morgan-koch.com; Italy: Marco Fusoni, tel. 39-0341-806000, info@meitaly.it.

Niehoff GmbH Germany/U.S. Germany’s Niehoff GmbH/Niehoff Endex North America offers spooling and payoff systems for many applications. Of particular note is its S-series single spoolers and ARH tangential payoffs. The S631 and S801 models are equipped with integrated dancers making them very compact and easy to install. They are well suited, for example, as takeup systems for multiwire drawing lines. A swiveling traversing roller assembly eliminates the need to turn the wire bundle before the take-up. The An ARH model from Niehoff GmbH.

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result is high quality and consistent spooling which consequently assures that the wires can be efficiently processed further down stream and at higher speeds. The S631 and S801 feature traverse and spool drives using AC servo motors as well as a hydraulic-pneumatic spool lifting table for operator-friendly spool loading and unloading. The systems cover wires ranging from 0.15 mm up to 1.60 mm and work at speeds up to 40 and 36 m/s respectively. The ARH630 and ARH800 tangential payoffs with separate drive are designed for the nontwisting payoff of individual wires, parallel wound wires in any number as well as bundles. They are also well suited for the manufacture of high-quality and geometrical strands. A pneumatic dancer maintains constant wire tension. Further features are a friendly MMI display with back tension indicator and an empty spool detection system. The ARH payoffs are available in either single (left or right hand operations) or double payoff versions. They are designed to handle individual wires with a diameter of 0.40 mm to 1.41 mm and bundles with a cross-section of 0.157 mm² to 6.00 mm² (ARH 800) with corresponding maximum lines speeds of up to 300 m/min. Frank Knobloch, tel. 856-467-4884, sales@niehoff-usa.com.

OMCG North America U.S./Italy At wire 2008, Italy’s OMCG SpA, parent company to OMCG North America, displayed its SM02 4000-lb payoff equipped with a snag ring and movable control unit for positioning outside the guarding with E stop, rotation speed and clockwise/counter clockwise dials. This allows the payoff to be located very close to the bending machine thus saving floor space. The SM02 is powered from the bending machine so when the machine E stop is activated the payoff also stops. The SM02 automatically feeds wire on demand as the bending machine requires. The dancer arm controls the speed OMCG’s SMO2 model payoff. of wire payoff. The more the arm

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moves forward, the faster the wire is fed to the machine. The arm is equipped with the long roller allowing the wire to move as the coil is reduced during production. The arm can also be equipped with two or three rollers for a larger accumulation of wire to meet long fast wire feed requirements. The tension of the dancer arm has an easily adjustable knob to meet small or large wire requirements, so smooth payoff is accomplished without kinking the wire. The arm also is a safety for any tangles that occur during payoff, in that if the arm moves too far forward without feeding wire, the payoff will shut off thus shutting off the machine. The coil-centering feature is optional and can be adjusted according to the coil diameter. This feature allows easy loading and unloading of the wire stand. Bob Sears, tel. 630-860-1016, omcg@omcg.com

PS Costruzioni Meccaniche Srl Italy Italy’s PS Costruzioni Meccaniche Srl has developed a new automation double spooling line, the PS 400/14-B, which features a double portal payoff stand and automatic pallet units. The model is now in use at a Prysmian plant in Australia. The double portal payoff enables the line to produce spools continuously, as while the first reel is

unwinding, the second portal payoff can be loaded with a new reel. Once the PS Costruzioni’s new double spooling line. first reel is empty, the operator moves the first portal payoff aside and moves the second one into place, threads the cable end and restarts the line operation. The produced spools are labeled and conveyed automatically to the axis automatic pallet units. An incremental cable marking device, using an ink jet printer, enables the cable to be cut on the 100 meter mark. The payoffs accept reels with diameter from 1,000 mm to 2,000 mm, with a maximum weight of 7 metric tons. Spool sizes range in outer diameter from 200 mm to 400 mm, with width of 100 mm to 400 mm, bore of 102 mm, and maximum weight of 45 kg. The line can accommo-

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date multipolar insulated flexible and semi-solid cables with outer diameter of 5-14 mm, and semi-solid flat cables with dimensions from 4.12 x 6.06 mm to 16.5 x 9.55 mm. Franco or Stefano Parma, tel. 39-0396-898763, ps@pscostruzioni.com.

Queins & Co. GmbH Germany Queins Managing Director M. Hoffmann notes that his company is a leading manufacturer and supplier of heavyduty payoffs and take-ups. Its product range covers columntype, cantilevertype, bridgetype, selftraversing portaltype, heavy rotating A Queins & Co. traversing take-up. take-ups and payoffs for power and telecommunication cables as well as for steel wire ropes. Standard sizes for take-ups and payoffs are manufactured in a range from 3 to 300 tons of drum weight. At the recent wire Düsseldorf show, it displayed a newly manufactured traversing take-up for a reel size of 3600 mm and a reel weight of up to 23 metric tons. The take-up is equipped with ultra-modern electrics, PLC-controlled, for precise traversing without any operator assistance. M. Hoffman, 49-2472-808-0, info@queins.com.

Rockford Manufacturing Group (RMG) U.S. Rockford Manufacturing Group, Inc. (RMG), offers an extensive variety of material payoff methods and systems to satisfy almost any size, space and speed requirement. For vertical payoff systems, RMG’s 4VPS16 series is a low-cost, compact, alternative to a power assisted turntable. The non-rotational nature of this unit reduces the force necessary to pull the wire into the production machine. This configuration is for use with up to 4.75 mm wire. The company’s line of power-driven uncoilers includes three models for large diameters that range up to 44.5 mm and coil weights exceeding 2720 kg. These units are all equipped with free wheeling clutches that allow the coil to freely unwind from the mandrel, but should the coil begin to bind, a signal increases the uncoiler roll speed to loosen it. If this automatic speed adjustment still

52 | WIRE JOURNAL INTERNATIONAL

does not eliminate the tangle, another switch stops the production process automatically. RMG offers VF controlled, directdrive turntables that respond quickly to the consumption rate variation of production A 3D drawing of RMG’s latest machines, keeping tension off the pro- unit, which has an 80 in. top plate with 6000 lb capacity duction machine’s feeding system. Powered turntables are equipped with brake resistors to dissipate the energy of the spinning coil during deceleration. These units can increase the productivity of a straightening and cutting machine as much as 40%. Equipped with production interlocks that sense the condition of the coil of wire and stop the production if necessary, powered turntables represent a safer solution to material payoff in most environments. They are capable of running forward or reverse wound coils as well as having a reversing feature for rewinding partial coils for removal. RMG can design and create a custom payoff system to address unique production requirements. Tel. 815-624-2500, mgfelm@rmgfelm.com.

SAMP USA Italy/U.S The SAMP USA family of take-ups and payoffs is one of the most comprehensive and widely accepted throughout the global nonferrous wire and cable industry. For copper and aluminum wiredrawers who seek higher efficiencies and ease of handling, SAMP offers its newest generation automatic dual spooler, the BD 800DA, for taking reels up SAMP USA’s AV1800-P system. to 800 mm in diameter. This model provides reliability with utility for high volume producers, and is flexible for loading/un-loading empty and full reels as well as floor plan configurations. Complemented by SAMP’s compact manual BD single take-up series for reels from 500–1250 mm, the IN-FS

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SIMPACKS U.S.

and IN-FG series of basket coilers and the BS 800 to BS 1250 range of static spoolers, SAMP has a precision takeup solution for requirements of bare wire manufacturers in terms of application, outlet wire size, investment budget or space considerations. For extrusion system take-ups, its AV-D automatic dual spooler line serves the widest range of insulated wire applications. For new or existing extrusion lines, the AV-D has offered take-up reel size alternatives of 500, 630, 800, 1250 and 1600 mm in diameter. The newest addition to this series is the AV 1000D, which expands the AV-D utility with a machine for 1000 mm reels. SAMP’s AV-P/SV-P group of portal take-ups/payoffs provides end-users with flexible yet highly robust solutions for either insulated or jacketed products. Its AV-P/SV-P models are available for take-up reels with barrel diameters ranging from 1800 to 3600 mm with load capabilities of 6, 10, 15 and 25 metric tons. Whether it’s bare wire, insulated wire or a jacketed cable, SAMP has the proven take-up solution for any cable and wire manufacturer. Dominique Perroud, tel. 301-2238584, dperroud@sampinc.com.

SIMPACKS offers a range of equipment for the wire and cable industry. Its dual head automatic coiler can coil or wind telephone and building wire cables, both round and flat, as well as computer cables with diameters from 1 mm/0.04 in. to 8 mm/ 0.3 in. This coiler is capable of producing six coils per minute. Controls can be chosen by the customer from brands such as Allen Bradley, Siemens, Telemecanique, Mitsubishi, Omron and more. Each system comes with PLC and color touch screen built in control, monitoring, alarms, troubleshooting and a recipe. An optional XCoupler module can exchange data between the machine and Microsoft SQL via Ethernet. Hernando Blanco, tel. 973-402-4098, sales@.simpacks.com

Skaltek AB Sweden/U.S. The development of Skaltek System X payoffs and take-ups started in1981. The system was based on the proven concept with Skaltek’s patented self-locating pintles and the adjustable portal design. In 1989 the System X had a major breakthrough and Skaltek earned the confi-

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dence to develop a complete material handling solution for a new cable plant in Norway. Today, almost 20 years later, the System X takeups and payoffs are the preferred solution by many. By rotating the reel with a standard automotive tire on the System X equipment from Skaltek AB, flange, the reel and which offers models in take-ups and the drive wheel “makes out” the gear payoffs. ratio and as a result there is no need for traditional gear boxes. Also, by driving on the perimeter of the flange, the result is twice the torque with less force. This increases the safety by eliminating a drive arm and drive pin. The position of the drive wheel in relation to the flange is always correct. A simple geometrical solution for the positioning of the drive wheel is built into the machine by means of a mechanical linkage. When the portal is raised or lowered, the drive wheel is automatically positioned. There are no adjustments required. Based on almost 20 years of experience, Skaltek knows that the system works, even with poor-quality wooden reels. From customer feedback, Skaltek knows that the tires are seldom replaced and it can sometimes take over 10 years before the tire is worn out. From 60-70 percent of Skaltek’s sales for take-ups and payoffs are for driven machines, a trend that appears to be increasing. Ralph Skalleberg, tel. 770-449-4263, rs@skaltek.com.

Serving the non-ferrous and ferrous industries since 1983 Keir Manufacturing, Inc.

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(1-828-885-8444) www.keirmfg.com email: mwalters@keirmfg.com

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connexia

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SKET GmbH Germany Within the last few years, SKET GmbH has built up a series of extremely large payoff and take-up systems for payoff and take-up products such as large steel wire ropes, umbilicals and special cables. The WT 6000/370 take-up, which was supplied to Bridon International, Gelsenkirchen, Germany, can accommodate a number of different reel sizes. The reel is accommodated shaft-free between adapters which are supported in two massive and stable designed stands. Technical parameters are as follows: reel weight, max. 400 metric tons; reel flange diameter, max. 6 meters; reel width, max. 8 meters; pulling force, max. 8 tons; linear speed, max. 30 m/min; and rope/umbilical diameter, max. 320 mm. The take-up SKET GmbH specializes in large systems. is able to work as a

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take-up as well as a payoff. The payoff version, as well the take-up version, can be integrated in large planetary closers and in sheathing lines for extrusion of ropes. The take-up can traverse on rails over long distances to ensure the utilization at different stranding machines and a loading/unloading process of the large reel without space limitation. Each take-up is equipped with electrical cabinet, operating desks/screens and PLC that can be easily connected with the PLC of the stranding machine. SKET also has available versions for 100-ton-, 160-ton, 200-ton- and 300-ton reel capacity. Michael Moesken, tel. 49- 391-4055- 835, moesken@sketvmb.de.

Tulsa Power LLC U.S. Tulsa Power LLC has recently introduced its new line of 100 K gantry systems. The units are offered in both payoff and take-up configurations. Reel capacities range from 2175 mm thru 4350 mm flange diameter, reel widths to 4572 mm and maximum reel weights to 100,000 lb. The entire structure offers easy loading and un-loading of reels with true walk-thru capabilities. The telescoping super structureâ&#x20AC;&#x2122;s portal design conforms to the size of the reel to minimize floor space requirements. Each system traverses on rails to offer material payout or take-up with no fleeting angle. Electromechanical drives are utilized to allow for up/down and in/out manipulation of the main frame during reel load/un-load sequences. Main drive systems are engineered to customers specifications and are complemented with a color operator touch-screen interface that is used to communicate parameters used by the operator in relation to the product being run, the reel being used, display status, position and fault A 3-D rendition of a system from Tulsa alarms of the Power. unit. Tulsa Power offers a wide range of wire and cable handling equipment, including shafted and shaftless payoffs and take-ups, capstans, accumulators, respoolers, coilers, eccentric and concentric taping systems, measuring systems and custom designed equipment to meet customer specifications. Jim Miller, tel. 918-584-1000, miller@tulsapower.com.

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Windak AB Sweden/U.S.

FEATURE

Windak’s new range of tire driven payoffs and take-ups offer such great flexibility that one machine can cover a large range of reels. The optional and selectable one- or two-drive units make it possible to achieve a large range of speed and tension combinations in the same machine. The system has a portal-type floor traversing design and the tire-driven design allows for much faster reel changes and, in general, higher running speeds. The models, which are very robust and have a low-maintenance design, have an Allen Bradley PLC control. Models include: UW22T, 24-28 flange dia., 17,600 lb max. wheel weight; UW25T, 36-96 flange dia., 26,400 lb max. wheel weight; and UW30T, 47118 flange dia., 39,600 lb max. wheel weight. Windak offers a traditional style drive-pin design (36 in. to 197 in., up to 40 ton) and customizes rewind lines to specs. Dan Shelander, Windak Inc., tel. 828-322-2292; dan. shelander@windakusa.com. ■ A tire-driven unit from Windak AB.

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E DA L ER WINN AWA R

Processing of wire from antiquity to the future

TECHNICAL PAPERS

TECHNICAL PAPER

Technology had a different meaning for the early days of wire production, but as this paper notes, from the most basic of technology levels the industry has continued to evolve to meet increasingly more stringent needs, a status that no doubt will continue to drive future advances for centuries to come. By Horace Pops

Discovery of copper in its native form was just one of many characteristics that signaled mankind’s emergence from the Stone Age. Because this metal was extremely malleable, it was easily hammered into crude implements such as knives, swords and other weapons. Soon thereafter methods were developed to form copper and gold into wire shapes. Although copper has been mined and fabricated into wrought forms by a myriad of techniques for aeons, the most noteworthy improvements for the production of rod and wire have been achieved only since the second half of the 20th century. Inasmuch as practices that are being implemented today are heavily linked to past developments, the present paper will address this association from both a historical and metallurgical perspective. Currently, most commercial copper wire is being manufactured globally from continuously cast rod. Consequently, a brief historical review of rod production will also be addressed herewith.

Fig. 1. Timeline for first commercial use of metals.

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Historical background of copper Humans probably started to use copper about 9000 BC, when Egyptians discovered native copper on the island of Cyprus. This metal was originally given the name “aes cyprium,” and subsequently shortened to cuprum. Consequently, the English word copper and its chemical symbol Cu soon emerged. The alchemy symbol for copper is , which is also the symbol for woman, because Venus, the goddess of love, was thought to have been born on Cyprus. The timeline for the first commercial use of copper and other common industrial metals is presented in Fig. 1. As might be expected, the first few metals that were discovered all occurred in native form. Some of the earliest known written references to mining of copper are included in the Old Testament of the Bible, and are dated about 1400 BC. Four relevant chapters and verses pertaining to such metallurgical comments are contained in Table 1. Clearly, knowledge of fire refining must have been well known at that time. Very little technical knowledge has been documented until the famous book entitled “De Re Metallica” was published in Latin by Georgius Agricola of Saxony in 1556 AD and described in detail the processing of copper ore. (It was translated into English by Herbert Hoover., the 31st president of the U.S.) The processes and methods in this book have long been superseded. During this period smelting operations were started in Germany and Wales for the elimination of sulfur. In 1869, the largest copper producer in the world was Calumet and Hecla of Michigan, which had an annual production that was less than 6,200 tons. Anaconda, in 1896, was the first mine in the U.S. that produced more than 50,000 tons a year. The twentieth century is associated with the development and large-scale mining of low-grade copper ores. Processing of wire in ancient times The first jewelry applications for wire used both native copper and precious metals such as gold and silver. Examination of archaeological wires indicates that these metals were not

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produced by normal wiredrawing methods, i.e., pulling them through a tapered hole in a die. A gold necklace that belonged to an Egyptian pharaoh who reigned about 2750 BC was produced by a hammering process that involved cutting sheets of the metal into thin strips and then hammering them into a round shape1. Inasmuch as this technique was quite crude, the wire diameters showed considerable variation over long lengths. Hammering was undoubtedly used for many centuries because Exodus, chapter 39, verse 3 states “…and they did beat the gold into thin plates, and cut it into wires, to work it…” Strip twisting was the second technique used by Egyptians in antiquity to make fine wire for jewelry. Once again, the metal sheet of copper or gold was cut into very thin strips or ribbons. As shown in Fig. 2, these strips were initially either formed directly into a tube or twisted about the ribbon axis. In both of these strip-twisting methods the strips were then formed into wire by either cold flat rolling or else drawing through some form of a crude die2. The strip-twisting technique was employed until about 1000 AD. A third precursor to modern wiredrawing also started with thin ribbons. They were drawn directly through dies made from either perforated natural stones or soft metals such as copper or iron. These ribbons transformed into tubes after about one or two passes through the die. The tubes then closed into round wires and oftentimes exhibited a seam resulting from both edges of the metal ribbon. Sometimes precious metal jewelry wires were drawn through dies made of the same material3. Since wires and dies were made of the same material, there was extremely rapid die wear and only a few draw passes were possible before dies were remelted or reworked. Unfortunately, relics

of ancient metal dies have not been recovered because they were undoubtedly recycled. A bronze wire rope was found in the ruins of Pompei after its destruction in 79 AD. However, careful examination and study of this material indicated that it was probably fabricated about 600 years earlier. There is considerable controversy whether the wires were hammered or drawn through a die. In order to produce bronzes at this time by alloying copper with tin, bellows were used on fires to obtain temperatures close to 1090°C. References to wires made in China and India suggest that they were produced during the period 2200 to 2000 BC. Wire In medieval times Medieval wiredrawing first employed a drawplate having successively smaller diameter holes to reduce the wire’s diameter. Initial evidence of such a process has been obtained from archeological finds, which are dated about 700-900 AD. Credit for this practice is usually attributed to the Vikings in Norway. In the 6th to 10th centuries it is believed that Venetians and other Italians knew about the method for drawing wires through dies in draw plates. Credit for the first written documentation of modern wiredrawing is given to a German monk named Theophilus. Somewhere between 1000 to 1100 AD he wrote a Latin manuscript that describes a conically converging die, which is similar to the tapered design currently in use throughout the wire industry. His description is also similar to the dies found in a Viking grave. The drawplate was produced from bronze, and had iron inserts for the wire dies4. After Theophilus there are many written references to the production of wire. In the Middle Ages much of the manufac-

Fig. 2. Schematic of forming wire from thin sheet strips by strip twisting (left) and block twisting (right)2. Fig. 3. Typical water powered wire drawing apparatus first used in Europe by swing drawers15.

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turing was performed by “swing drawing.” By the 13th century artisans in Germany were referred to as “Schockenzieher,” or shock drawers. The drawplate, or die, was inserted into a tree stump or block of wood. The wiredrawer sat on a swing, and upon sliding forward gripped the wire with pliers or tongs near the hole. As the worker moved backwards on the swing he pulled the wire through the draw plate. This pulling process was repeated until the wire was completely through the drawplate. A good pull was considered to be about one foot of wire per heave. For fine wire, successively smaller dies were used until the wire could be wound onto spools. Swing drawing was used in parts of Europe as late as the mid 18th century. The first major technical breakthrough in wiredrawing occurred in Nuremberg, Germany about 1350, when water power was harnessed to help perform the swing drawing process. Tongs were moved by cams on the shaft of the water wheel. A simple drawing of the water wheels that were used at that time15 is shown in Fig. 3. This practice was so successful that many water powered flour mills were converted to wiredrawing facilities commencing around 1390. Ancillary tools such as pay-offs, reels, and bobbins were adopted to simplify hand drawing and to improve productivity. Some typical tools that were used at the end of the 17th century7 are illustrated in Fig. 4. Although lubricants might have been used, their discovery was not reported until about 1650 near Dusseldorf, Germany. Human urine was found to reduce friction during wiredrawing so effectively that hard steel wire could be easily pro-

Fig. 4. Typical tools used in the 17th century to draw wire by hand7.

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duced. Stale beer was also found to be an effective lubricant. Modern analytical techniques such as chromatography are currently being used on archaeological metals to investigate the use of organics as lubricants in the wiredrawing process5. Beginnings of modern wiredrawing Steam driven machinery was utilized very slowly and gradually. Consequently, both hand- and water-driven operations were used well into the 19th century. The wire industry in the United States was established only after the American Revolution, when wire became unavailable from England. Consequently, by 1834 only three wire mills were in operation with a total annual production of 15 tons. Demand for wire increased significantly in the 19th century. After the telegraph was invented in 1820, large quantities of copper wire were needed to transmit signals in the lines. Invention of the telephone in 1876 proved to be another boon for the copper wire industry. Early telegraph and telephone lines were made of iron. Copper replaced iron for the substantial gain in electrical conductivity, but only hard drawn copper wire could be strung between poles without sagging or breaking. At that time fully annealed copper had insufficient strength to be used as a conductor for this application. Future developments of twisted wire pairs not only reduced signal loss and interference, but also doubled the use of copper. Very few descriptions concerning the manufacture of wiredrawing dies exist before the early part of the 19th century. Most of these parts were made from cast iron. In fact, cast iron wiredrawing plates similar to the one shown in Fig. 5 were still being used in the early part of the 20th century. Their holes exhibit the same shape and dimensions as those of modern wiredrawing dies. Diamond and carbide dies started being used commercially in the U.S. about 1870 and 1928 respectively. Although John A. Roebling gained nationwide fame in the 19th century for his numerous patents, developments of steel wire rope, and construction of many suspension bridges including the Brooklyn Bridge, he was also involved with a copper wire and cable company at Dollar Bay in the upper Michigan peninsular. Fig. 6 shows a photograph of this plant that was taken during the early part of the 20th century. Clearly, attention to good surface quality was of much less concern compared with modern wire products. Brass music wire for harpsichords was also produced during the 17th and 18th centuries, usually for the thicker bass strings. Most of this material was produced in Germany, France, and Sweden using red and yellow copper-zinc brass alloys. The zinc was obtained in gaseous form by the reduction of zinc oxide. It was subsequently diffused into the copper at temperatures in excess of 1000°C. Continuous rod production: historical developments Until the latter part of the 20th century, wirebars were the principal form of refined copper castings that were produced from cathodes at refineries6. Electrolytic tough-pitch copper (ETP) was the primary metal used in the production of these wirebars. The conventional design of the casting process was

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a horizontal turntable or wheel that contained numerous open tray molds arranged tangentially around the circumference. Pouring of the copper was obtained without stopping the wheel. A flat set surface on the wirebar was obtained by controlling the oxygen content, which in turn affected the cast density via gas-metal reactions. When used for rolling into rod and subsequently drawing into wire, wirebars weighed about 100 kg each and were tapered or pointed at both ends. On occasion, the set surfaces were removed by scalping to eliminate many of the cuprous oxide inclusions. The ingots were hot-rolled in air to produce finish rod. After pickling the rod in a sulfuric acid bath, large coil lengths were obtained by hot butt-welding the ends of each rolled rod coil. The major quality problems resulting from this process included many weld breaks, pick-up of numerous steel inclusions during hot rolling, short coil lengths and macrosegregation throughout the coil. In addition, the annealability differed from the tail end to the head end of the coil due to differences in air cooling during hot rolling. All of these problems were reduced significantly through the advent of continuous casting. A brief chronology of the continuous casting history in addition to major events pertaining to copper rod production is presented in Table 2. The latter part of the 19th century witnessed numerous attempts to produce both ferrous and nonferrous metals by continuous casting. Most of these methods failed because of excessive sliding friction between the initial solidified skin of the cast bar and the mold interface, which caused rupture and leakage of molten metal at this interface. The relative movement between these two components was eliminated in 1882. An endless mold was created by placement of a moving belt over the outside of a metal wheel that contained a peripheral groove. In 1948 the first commercial process was developed by Properzi for lead and zinc, and is known as the â&#x20AC;&#x153;wheel and beltâ&#x20AC;? process. A modification was adapted successfully in 1963 for copper at a subsidiary of Western Electric. Over the next several decades additional continuous casting systems were developed for copper7. These include the Contirod twinbelt caster, the 5-wheel Southwire (SCR) system, a 3-wheel design by Essex that uses a siphon tube for the transfer of molten metal and two vertical Upcast casting units by Outokumpu and Rautomead for the production of as-cast oxygen free (OF) rod. Nearly all ETP copper rod today is produced by a continuous in-line process that includes charging, melting, casting, hot-rolling, descaling, pickling to remove surface oxide scale, eddy-current testing of the finish rod, take-up and coiling. Because of the slow casting speeds for OF copper, which employs unidirectional solidification, hot-rolling cannot be performed in-line. Metallurgical principles Solidification. The commercial practice that is used for the production of ETP copper wire bars is based upon the principles of gas-metal reac-

tions in molten copper6,8. When copper transforms from a liquid to a solid state, approximately 4.1% contraction will occur. If this shrinkage is not properly treated, large internal voids or macroporosity will likely occur during solidification. To offset the shrinkage, oxygen is added to the melt and reacts with hydrogen and sulfur to form steam and sulfur dioxide as gases. Both hydrogen and sulfur can originate from the cathode as entrapped electrolyte or from the furnace combustion gases. Steam and sulfur dioxide are retained in the cast bar as internal voids. Consequently, density of the as-cast bar is less than that of wrought copper. If the voids are small in size and disbursed uniformly, they can be eliminated after about two passes through the rolling mill. Impurities. Many of the classic studies concerning the effects of residual impurities in high purity copper have been published in the technical literature just before the middle of the 20th century6 and are still quite valid. Impurities can induce a very deleterious effect upon copper by decreasing electrical conductivity and spiral elongation (SEN) of the annealed wire, raising the annealing time and temperature, and denigrating elastic springback and conformability9. Some of these same elements can also cause cracking and hot-shortness. In general, Se, Te, Pb, Bi, and S are the most harmful elements. Table 3 is a summary of the unit effects that 11 different common elements are likely to produce when added individually to copper upon the annealing temperature, spiral elongation number, and electrical resistivity9. It should be noted that when predictions of properties in commercial ETP wires are based upon chemical analyses these individual unit effects do not always agree with actual measurements in the finish wire. The reason for this discrepancy is two-fold. First, certain impurities may react with each other, such as lead and sulfur, to form insoluble intermetallic compounds. Second, and more important, is the solid state reaction of many impurities with oxygen to form insoluble metal oxides. The maximum effect of impurities upon copper behavior and properties occurs when they are dissolved in

Fig. 5. Cast iron draw plate used during the first half of the 20th century. Below it is a silicone impression of a die that was used in that period. The die has a profile similar to that of modern wire dies.

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Fig. 6. Copper wire and cable plant at Dollar Bay, Michigan, during the early part of the 20th century.

copper solid solution. As an alternative method to predict behavior, regression equations relating chemical analyses to performance have oftentimes proven quite useful. One such relation is as follows: RF = 34.7 + 0.25Pb + 2.73Bi + 2.18Sb + 4.62Te + 0.88Ni + 0.28Fe where the impurity levels are in ppm, and RF is the Rockwell F hardness annealability number for the starting rod. For this test the rod is first cold rolled to 30% of its diameter and then annealed for 15 minutes in a constant temperature bath at 275Â°C prior to hardness testing. Any Rockwell F hardness value less than 60 is considered as low annealing copper.

Oxygen. As noted in the previous section, one reason for adding oxygen to the melt is to control porosity in the ETP cast bar vis-Ă -vis controlled shrinkage during casting and solidification. Since oxygen is also a very strong scavenger for residual impurities, most of their harmful effects are easily negated. As a result of the interaction between oxygen and other elements, improvement of conductivity, annealability, and conformability may be obtained10. As an example, Fig. 7 shows the effect of oxygen content upon electrical conductivity of some coppers in the annealed state16. For commercial wires of 4-nines copper, the first 200 ppm of oxygen produces an increase in conductivity because of the scavenger effect. After the aforementioned solid-state reaction is complete, conductivity decreases linearly because of an increase in the volume fraction of copper oxides. Fig. 7 also shows that the conductivity of both OF and ETP coppers are nearly the same. Most continuously cast ETP copper rod is now produced with oxygen content in the 125 to 500 ppm range. At lower contents the propensity for hot-cracking due to hydrogen embrittlement increases because there is insufficient oxygen to tie up the hydrogen. Oxygen contents in excess of this range raise the amount of equilibrium copper oxides. Consequently, the overall ductility of the wire is decreased and the likelihood of obtaining brittle breaks during drawing will increase. Scrap. The highest quality copper rod is usually employed for the production of magnet wire (also known as winding wire), which has the most demanding requirements in the wire industry. Consequently, high purity electrolytically refined cathodes are recommended for this particular application. Compositions associated with several different commercial grades of ETP, OF, and fire refined coppers (FRTP) are listed in Table 4. In the last decade copper scrap has been used frequently for less critical applications such as building wire11.

Fig. 7. Effect of oxygen content upon electrical conductivity of annealed copper16. Fig. 8. Removal of surface oxide layers on copper rod by acid pickling or alcohol reduction. 62 | WIRE JOURNAL INTERNATIONAL

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ity, fill factors should be greater than ~ 60%. This non contact, non destructive technique works quite well at high rod speeds exiting the rolling mill. Dampening devices are usually needed to prevent excessive noise and vibrations. An ASTM standard12 describes a recommended practice to be followed. With the proviso that the defects are close to the surface and larger than several mils, the equipment is capable of detecting Table 1. Biblical references to copper and mining. seams, cracks, and inclusions. Scale removal. Because the hot cast bar is exposed to the atmosphere, a very thick scale of cupric oxide ~ 100,000Å (104 nm) forms very rapidly on the outer surface. Inasmuch as Assuming that some fire refining is used to reduce the total scale adhesion to the base metal is very poor at ~ 800°C, exfolevel of impurities, electrical conductivity in excess of 101% liation is easy to achieve. Consequently, most copper concast IACS can be achieved with this product. The percent conduclines employ high pressure pumps near the entrance of the tivity of a copper sample (%IACS) wire is calculated by roughing mill to spray the mill emulsion onto the moving hot dividing the resistivity of the International Annealed Copper bar. Although about 90% of the scale can be easily removed Standard at 20°C by the resistivity of the sample at 20°C. by this high pressure spray, further descaling is needed to Either the mass resistivity or volume resistivity may be used. achieve high quality rod. Some of the larger concast lines that Rod that is produced by a fire refining process at the La Farga are associated with copper refineries still use aqueous sulfuric Lacambra plant in Spain11 is being broken down in rod mills acid pickling solutions in line with hot rolling. On the other and then processed successfully to large wire sizes using multi hand, most concast facilities immerse the moving hot rod in drawing machines. an aqueous alcohol solution. The alcohol vaporizes at elevated temperature to form the reducing gases hydrogen and carRecent rod improvements bon monoxide. These gases react with the copper oxide scale The copper rod industry has displayed an impressive continon the rod surface to form a thin surface layer of copper. A uing improvement of rod quality over the past several schematic representation of the sulfuric acid and alcohol decades. Use of Statistical Process Control, Lean methods being used on rod to either chemically remove or Manufacturing and Six Sigma methods, among others, has reduce the surface oxide scale to copper respectively are prebeen successfully employed. Just a few examples of benefisented in Fig. 8. If the reduction process does not go to comcial developments that have occurred in the recent past are as pletion, a thin layer of reduced copper will cover a subsurface follows: layer of copper oxides. Reaction times to reduce 5000 Å (500 Non destructive Eddy Current testing. Almost every continnm) of oxide scale are several seconds. Although other organuous cast rod line employs electromagnetic (eddy-current) ic compounds can form reducing gases, isopropyl alcohol methods in-line to evaluate surface quality of the finish hot(IPA) has been the most effective organic material in the rod rolled rod. A few systems also have encircling coils surroundindustry. ing the hot rod inside the rolling mill to detect hot cracks that Measurement of surface oxides and fines. The aforemenmight form on the cast bar. In order to obtain the best sensitivtioned scales on copper rod are quite abrasive and can lead to fines generation, wear of draw dies, poor solderability, excessive wire breaks and poor adhesion of enamels on bare magnet wire. Thickness of cuprous and cupric oxides is determined quantitatively by a constant current electrolytic reduction method7,13,14. When continuous cast rod was first produced, typical oxide scales were in the 6000 to 8000 Å range. Today, most producers of rod are quite capable of manufacturing a product having surface oxide films that are less than 300Å (30 nm). Copper fines on the hot-rolled rod can be determined by gravimetric analysis17. After subjecting several different specimens to a 10x10 torsion test, the loosened fines are removed by ultrasonic vibration and subsequently weighing Table 2. Chronological history of commercial continuous casting. JUNE 2008 | 63

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after drying. The relationship between fines and surface oxides is as follows:

with copper and wiredrawing over the ages. Wire and cable industry. Consolidations, mergers and acquisitions will continue, leading to still more capacity reductions. Wf / Wr x 10-6 = 8.73 + 0.0493 x SO Globalization will not diminish, with expansion into Asia and maintenance of stability at best for North America. Many where Wf is the weight of fines, Wr is the weight of rod, and studies are predicting a steady decline of the building wire and SO is the film thickness in angstroms. Inasmuch as the oxide cable market. Low cost imports of wire products will conscale on acid pickled rod is removed chemically, the amount tribute to the U.S. trade deficit in insulated wire products. of residual fines is oftentimes less than that of alcohol cleaned Technology. Spending for research and development as a rod. percentage of revenues has been on the decline for several years, and will probably continue in this downward trend. As Prognostications and technology of the future a consequence, there is a dearth of science and engineering Arguably, the past decade has witnessed the largest number students being produced and entering the wire industry. of significant changes to the copper rod, wire, and cable However, since this has been accomplished with an accompaindustry than any other period in its history since ancient nying increase in productivity, not much change is expected in times. Table 4 presents a list of noteworthy events associated the short run. With the exodus of manufacturing to lower-cost Asian suppliers, there will be an exodus as well of technical talent. Most Asian countries are putting money and resources into their local university infrastructures, which will further usurp U.S. domestic technologies. Additional improvements in productivity will likely continue because of an emphasis upon equipment developments. Computer modeling is a very useful tool that has been available for quite some time, but has hardly been applied in this industry. However, there is considerable potential and merit for its application. Wire Association International will continue to be the focus organiTable 3. Effect of impurities upon some copper properties. zation for publication of technical articles. While the number of papers from the U.S. has been on a steady decline, those from Korea, Japan, and Eastern Europe have been increasing and are now more than 40% of the total. Although new technologies have not yet evolved from China, this situation will most likely change. Consequently, numerous technical papers are expected from this country, but not in the very near future. Competitive materials. Several years ago high-purity aluminum was being given consideration as a replacement for copper superconductors at cryogenic temperatures. This substitution does not seem likely in the near future. On the other hand, considerable commercial interest is being given to Table 4. Chemical composition of commercial ETP, OF and FRTP coppers. fiber-optic cables. Copper has been

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Table 5. A chronology of events associated over the ages with copper and wire drawing.

declining in telecommunication applications for the past several decades. Fiber has been a large factor in the long-distance networks and the short-haul trunk lines, i.e., the lines between central offices. It is now penetrating the subscriber loop portion of the telephone system, particularly the feeder link from the local office to a distribution point near the customer. Fiber optic installations will continue very strong in this area. Verizon Communications is spending close to $23 billion to rewire more than half of its copper cable telephone network so it can also sell cable TV and very fast Internet connections. This FIOS project will continue in the near future. By contrast, AT&T is upgrading its network by installing fiber cables to the edge of most neighborhoods, but they will rely on the existing copper lines to carry signals. Rod production. The concast industry appears to be saturated in North America. However, new systems will continue to be installed in China and India. Because of low hourly wages, the market in Africa has some promise for the longer range picture. From a technological perspective, surface quality improvements will continue to be a primary focus, including the reduction of copper fines and surface oxides. Although in-line eddy-current testing will continue, standards are sorely needed to help calibrate the encircling test coils. This endeavor should be a top priority to improve NDT testing. Finally, an NDT method should be developed to measure macroporosity in the center of rod and on-line. Either ultrasonics or electromagnetic acoustic transducers work very well in the laboratory and are therefore viable candidates. Copper wire. Improved surface quality will occur because of the driver to improve transmission of high-speed voice and data signals. Non-destructive testing will be used more frequently on process wire in addition to smaller sizes. Demands for better drawability and movement towards â&#x20AC;&#x153;zeroâ&#x20AC;? defects will continue. Harmonization of standards and specifications will be heavily emphasized because of increased globalization in the industry. Currently, there are max-

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imum strength requirements for magnet wire in order to optimize springback, conformability, and conductivity. In addition, a minimum strength requirement may evolve to improve formability and prevent excessive stretching of wire during high speed coiling operations. The automotive industry for decades has been considering the use of smaller diameter wires to decrease weight. It just might happen in the future. A few comments are in order concerning the need and use of 4-nines copper purity for commercial wire applications. Although 6-nines copper has been produced in small quantities, it is extremely expensive and probably unnecessary for most commercial applications such as magnet, telecommunications and building wire. Furthermore, electrical conductivity of both materials is nearly the same at ambient temperature. The primary advantage of the higher purity material is better conductivity at cryogenic temperatures, and therefore, higher residual resistivity ratios (RRR). Consequently, it does not seem likely that standards for copper wire will increase beyond the current minimum value of 101% IACS. Finally, it is appropriate to note that while the wire and cable industry has downsized considerably, nevertheless optimism seems plausible for the near future. References 1. D.L. Carroll, American Journal of Archaeology, 76 (3), 1972, pp. 321-323. 2. J. Ogden, Jewelry of the Ancient World, New York, Rizzoli International Publications, 1982, pp. 46-57. 3. C.R. Williams, Gold and Silver Jewelry and Related Objects, New York: The New York Historical Society, 1924, pp. 39-43. 4. K.B. Lewis, Wire and Wire Products, 17(1), 1942, 17-56. 5. R. Slater, “The Metallurgy of Archaeological Wire: A Tool for the Modern Metallurgist,” Wire Journal International, August 2006, pp. 58-61. 6. A. Butts, Copper, Reinhold Publishing Company, New York, 1954. 7. Non Ferrous Wire Handbook, Vol. 3, Wire Association International, 1995, 1-5; pp. 143-154. 8. A.J. Phillips, “The Separation of Gases from Molten Metals,” Trans. Am. Inst. Mining Met Engrs, 171, 1947, pp. 17-46. 9. H. Pops, “Copper Rod Requirements for Magnet wire”, Wire Journal International, May 1987, pp. 59-70. 10. H. Pops and J. Holloman, “Effects of Oxygen Concentration on the Recrystallization Behavior of Copper Wire,” Wire Journal International, May, 1994, pp. 70-83. 11. O. Guixa and M. Garcia, “Further Steps in Copper Scrap Refining and Subsequent CCR Copper Rod Production,” Wire Association Technical Conference, Stresa, 1997. 12. ASTM Standard Practice E1606, “Electromagnetic (Eddy-Current) Examination of Copper Redraw Rod for Electrical Purposes.” 13. H. Pops and D. Hennessy, “The Role of Surface Oxide and its Measurement in the Copper Wire Industry,” Wire Journal International, March 1997, pp. 50-57.

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14. G. Baker and H. Pops, “Analysis and Automation of Copper Surface Oxide Measurements,” Wire Journal International, February 1999, pp. 90-97. 15. C.S. Smith and M.T. Gnudi, “The Pirotechnia of Vannocio Biringucchio,” New York, The American Institute of Mining and Metallurgical Engineers, 1942, pp. 377-381. 16. H. Pops, “Metallurgy and Technology of Commercial Copper Electrical Conductor Wires,” Metallurgy, Processing, and Application of Metal Wires, edited by H. Paris and D. Kim, The Minerals, Metals and Materials Society, 1996, pp. 43-61. 17. H. Pops and G. Baker, “Formulation, analysis and measurement of fines,” Wire Asociation International’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008. ■

Horace Pops is president of Horace Pops Consulting, Inc., Ft. Wayne, Indiana, USA. He previously was director, metals laboratory at Superior Essex in Ft. Wayne. He joined Superior Essex in 1972 and later founded the company’s corporate metals laboratory. He holds an Sc.D. degree from the University of Pittsburgh, Pennsylvania, USA, and M.Met.E. degree from Pops Lehigh University, Bethlehem, Pennsylvania, USA, and a B.Met.E. degree from Rensselaer Polytechnic Institute, Troy, New York, USA. He is the sole or co-holder of 10 patents. Many of his papers have been published in leading technical journals. This paper, which was presented at WAI’s 77th Annual Convention. Cleveland, Ohio, USA, May 2007, won the WAI’s top award in the nonferrous division.

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TECHNICAL PAPER Leoni Histral速 - The cadmium-ffree alternative for cable manufacturers Leoni and Wieland-Werke joined forces to develop a cadmium-free alternative for cable manufacturers that has been shown to be a safe, environmentally harmless replacement material that is able to solve complex applications for the cable industry.

By Maik Bayersdorfer, Martin Kemethmueller, Wolfgang Steuff and Michael Scharf

Cable manufacturers are confronted with finding a complex solution for special applications that require specific tensile strength, flexlife behavior, temperature resistance and conductivity. In the past, copper alloys containing cadmium were appropriate materials to fulfill these high requirements. This material was used for aerospace, military, railway, robotics, medical and mechanical engineering applications when strong boundaries were needed. But in recent years, cadmium has had increasing problems with health and environmental concerns. The constraints for casting, use and disposal of copper cadmium alloys have increased and most foundries have shut down the melting of cadmium-containing alloys. In Europe, a legal guideline restricts the use of cadmium to less than 0.01%1. California and China will follow soon and prohi-

bition of cadmium seems to be a global evolution. Faced with this challenge, Leoni and Wieland-Werke this developed a new alloy2 that can serve as a substitute for conventional copper cadmium alloy. The new material, called LEONI Histral速, is at least comparable to the traditional copper cadmium alloys in terms of mechanical and electrical properties. Metallurgy of LEONI Histral速. LEONI Histral速 is made of more than 99% copper, with the residual elements in this alloy including chromium (Cr), iron (Fe), silicon (Si), silver (Ag) and titanium (Ti). The properties of LEONI Histral are not only determined by its composition. LEONI Histral is a precipitating alloy, so how it is produced is very decisive, especially the heat treatment. In general, the precipitation process needs two different

Fig. 1. Heat treatment of precipitating alloys3. JUNE 2008 | 67

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Fig. 2. Dissolved condition.

Fig. 3. Precipitated condition.

annealing steps. See Fig.1. The first heat treatment brings the elements into solution. That happens at a high temperature over the recrystallization limit1 with a subsequent quenching2. The additional elements are dissolved in the copper matrix. See Fig. 2.. The impurities in the copper cause a low conductivity. The dislocations and grain boundaries are not hindered by any particles. There is both inter- and intra-crystal forming This condition is the prerequisite for the subsequent precipitation strep. This requires a long-term heat treatment under the recrystallization temperature with smooth cooling3. That causes that the additional elements that create intermetallic phases (Chromium and Titanium-Silicides). The copper matrix becomes pure and well conductive. The hard intermetallic phases settle down at the dislocations and grain boundaries. These intermetallic phases act as a kind of barb and constrain the movements in the metal lattice. This circumstance increases the resistance of the material against mechanical stress. Fig. 3 shows that the correct heat treatment, the precipitated condition, influences the mechanical and electrical properties. Mechanical and electrical properties. LEONI Histral® is developed as a high-strength, high-conductivity copperalloy. By a special heat treatment and correct precipitation process, this material fulfills the requirements of ASTM B 6244 as well as of BS EN 20835. Details include: * Tensile strength = Rm > 60 ksi (418 N/mm²) * Elongation in 10 inch or 250 mm = Al250 > 7 % * Conductivity IACS > 83% Fig. 4 shows that the number of available materials fulfilling BS EN 20835 and especially ASTM B 6244 is very limited. At the moment, only three materials meet the requirements of ASTM B 624. All these alloys utilize the

precipitating process, and only two are cadmium-free. The strain-stress-curve of the new material represents a common behavior. See Fig. 5. It is notable that the conductivity will decrease by more than 15 % IACS if the strain reaches more than an amount of 2. During the development process for the new cadmiumfree conductor material, LEONI paid special attention to the flex life of the material. Therefore, it developed a bending test unit according to the requirements of ASTM B 4709. The two cadmium-free precipitating alloys that meet the objective of ASTM B 624 are comparable in regard to their flex life behavior. These two materials resist about 20% less cycles than CuCrCd. Applications. The application field of this material has a wide range. There are several areas in which this special product can be used. Subsequently, some examples are presented: LEONI Histral is used in the aerospace and military sectors. The above mentioned properties enable the material to serve as an appropriate conductor for system-critical applications. The material’s high-temperature resistivity widens the range of potential applications. Qualification for U.S-military specifications is ongoing at the moment. If special resistance against bending, torsion or vibration is required, LEONI Histral is very suitable. Examples for this field can be found in cars (cables between body and hatch), in dragchains of industrial machines and in robotics. The material’s excellent resistance against vibration is used in the connection between the diaphragm and the inductor in a loudspeaker. The construction for this load is a braid made of strands consisting of tinsels. The requirements concerning drop wire of a trolley system are increasing with speed and LEONI Histral is a new drop wire that provides a high-speed track solution. See

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Fig. 4. A range of copper alloys with good properties concerning tensile strength in combination with conductivity in dependence of the common standards.

Fig. 5. Strain stress curve/ strain-conductivity curve of LEONI Histral速 in a precipitated condition.

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Fig. 6. Bending test unit according to ASTM B 470 9.

cal or electronic equipment was introduced, the LEONI Fig. 7. The electrical connection between the wagons of a Group developed in cooperation with Wieland-Werke a train needs a high resistance against bending and vibrations cadmium-free copper-based high-strength-alloy called and LEONI Histral is an appropriate solution for electrifi“LEONI Histral®. cation of the mass transit in general. In the medical field, keyhole surgery is very small and This cadmium-free alloy complies with the latest enviflexible coaxial cables are needed. The new material can be ronmental standards. That is of importance for companies used as a solution for this problem, too. For most of these applications, 19 end silverplated strands are established as a kind of standard. This most common of these are AWG 24 and AWG 26. However, there is not a specific limit of construction-types at all. The wide range of the material’s properties is opening a lot of more future application areas by customized solutions. Conclusions. Already before the EU-restriction of hazardous substances (e.g. cadmium) Fig. 7. Trolley system of the European high speed train ICE. in vehicles and electri-

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selling products into the EU-market, and increasingly so as the casting of cadmium-containing alloys is becoming more and more critical. The material has special mechanical and electrical properties. An excellent high tensile strength, good conductivity, high flexlife and the product’s very good temperature resistance make the material fitting for special markets like robotic, aerospace and defense. LEONI Histral fulfills the requirements of ASTM B 624. LEONI Histral is a healthy and environmentally harmless solution for complex applications in the cable industry. References 1. EU Guidelines EU-D 2000/53/EEC, EU-D, 67/548/ EEC, EU-D 76/769/EEC, European Commission, Brussels, 2000. 2. Boegel, A. et alt.: European Patent EP 1179606, Munich, 2002. 3. Prof. Dr.-Ing. H. Horn, lecture notes, material science part Teil 8, IWS - FH Hamburg, unknown. 4, ASTM B 624 “High-Strength, High-Conductivity Copper-Alloy Wire for Electronic Application,” ASTM International, West Conshohocken, USA, 2005. 5. BS EN 2083, “Copper and copper alloys for electrical cables – Product standard,” British Standard Institution, London, U.K., 2001. 6. T.B. McCune, D.K. Sanghavi and T. Inakagi, “Conductor materials,” Hudson Wire Company, Ossining, USA, 1980. 7. N.N., Datasheet of Percon 17; Fisk Alloy conductor Inc, Hawthorne, USA, 2002. 8. N.N., Datasheet of Percon 24; Fisk Alloy conductor Inc, Hawthorne, USA, 2002. 9. ASTM B 470, “Bonded Copper Conductors for Use in Hookup Wires for Electronic Equipment,” ASTM International, West Conshohocken, USA, 2003. ■

Maik Bayersdorfer is one of the heads of the Leoni Histral® department at Leoni Draht GmbH, Weißenburg, Germany. He has worked in product development for Leoni since 2004. He earned a degree in electrical and electronic engineering from the University of Applied Sciences, Coburg, Germany. Martin Kemethmueller is the other head of the Histral department at Leoni. He has worked as an industrial engineer for Leoni since 2003. He earned an MBA/MBE degree from the University of Applied Sciences, Mannheim, Germany, and a degree in business administration from the University of Applied Sciences, Nuremburg, Germany. Michael Scharf has been product manager in the Extruded/Drawn Products Division of Wieland-Werke AG, Ulm, Germany, since 1992. He earned a degree in production engineering from the University of Applied Sciences, Ulm. Wolfgang Steuff has worked in the Wire & Strands business unit of Leoni since 2001. He is responsible for development, projects, and the internal refurbishment of the drawing dies for Leoni’s global operations. He previously was head of the cold forming department of a German copper alloy manufacturer. A Ph.D. graduate, he also holds a degree in mechanical engineering from RWTH Aachen University, Germany. This paper was presented at WAI’s 77th Annual Convention, Cleveland, Ohio, USA, May 2007.

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TECHNICAL PAPER Plasma: a clean and cost-e effective alternative to chemical and heat treatment Benefits of using plasma technology include complete degreasing, deoxidation and surface activation for better coating/adhesion, reduction of energy used for tin bath heating and lead-free tinning. By Igor Rogelj

Plasma has been used for a few decades in the industry for a range of surface treatment applications, including for the production of endless metal materials such as wire, tube and strip. The first half of this paper presents a general overview of Plasmaitâ&#x20AC;&#x2122;s heat and surface treatment for wire, tube and strip is outlined, referred to as plasma process. The second part of this paper sets out applications of plasma technology in plating processes on nonferrous materials, i.e. copper and copper alloys. Two processes are considered in more detail: hot-dip tin

plating of copper wire, tube and strip; and electroplating of copper and copper alloy wire, tube and strip. Plasma can be used to simplify hot-dip and electroplating processes and make them friendlier to the environment and operator by replacing chemical treatments. In plating, the plasma process is used to anneal or preheat material to a required temperature prior to plating and to clean and activate the surface to facilitate effective plating (inter-metallic bonding). Plasma treatment replaces pickling and fluxing in the hot-

Fig. 1. Schematic of plasma treatment process inside the heating chamber. 72 | WIRE JOURNAL INTERNATIONAL

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dip tinning process. It can also be adjusted to allow simultaneous annealing, if required to achieve required mechanical properties of the finished material. This makes the plasma process more economical and more environmentally friendly. In the electroplating process, plasma replaces acid degreasing and rinsing. The surface cleanliness of plasma-treated wire can be electroplated directly with Ni, Sn, or Ag without the need for chemical treatment. The plasma process is used to its full advantage when it performs simultaneous annealing to ensure required material softness. The ability to target required softness allows simplification of upstream wire drawing process. Final drawing becomes unnecessary when bell annealing is used because the plasma heat treatment achieves the required mechanical properties with sufficient tolerance to meet the specification of the finished product. Plasma heat and surface treatment runs inline with both the hot-dip or electroplating process. Plasma annealing is most suitable for applications that require good surface quality. It is therefore invaluable for applications that cannot tolerate surface defaults commonly caused by resistive annealing. General overview of Plasmait treatment Plasma takes many different forms. Here, plasma is generated by electrically charging a small amount of gas inside the plasma chamber. In plasma, gas particles (atoms and molecules) constantly collide and exchange energy by switching to higher and lower energy states. When colliding, some particles begin to emit light while others become ionized, divided into free (positive) ions and free (negative) electrons. Electrically charged particles make plasma different from other states of matter. Charged particles can be accelerated in the electric field to a desired speed and directed to a target. In a plasma chamber the electric field accelerates ions towards the wire surface (positive electrode) and electrons towards the edge of the heating chamber (negative electrode earth). Fig. 1 shows how the electric field in the heating chamber accelerates charged particles between the outer wall of the heating chamber and the wire. On their way to the opposite electrode, the particles collide with other atoms and molecules. The less they collide (or the less interrupted their journey is) the faster they accelerate and the larger their impact on the wire surface. To achieve high-impact heat treatment one has to apply a vacuum to the heating chamber. A plasma chamber, ensuring sufficient power/heat for the process, is filled with low-pressure inert gas to prevent a chemical reaction between the gas and the wire that is fed through the sealing system and the heating chamber, continuously thereby exposing the wire surface to ion bombardment. The effect of such bombardment is threefold: it provides efficient heating, surface smoothing and surface cleaning such as degreasing and deoxidation. The degree and type of surface treatment can be manipulated with the choice of process gas. The plasma process can improve the economics of the production process for many wire, strip and tube production applications. This is a result of process simplification through a replacement of batch annealing and introduction of an in-line process. Plasma treatment can be used as an alternative to

chemical cleaning as it achieves a high degree of surface cleanliness and outstanding product quality through accurate physical properties of the material in the end product. The outstanding cleaning and smoothing capabilities of plasma technology benefit applications in such fields as medical, aviation, aerospace and other precision wire manufacturing as well as galvanizing, extrusion, enameling, and winding/magnet wire manufacturing. General line composition of a Plasmait system A plasma annealer consists of three main components: vacuum and sealing system, power supply/heating module and cooling system with gas supply. The sealing system (Fig. 3) is deployed to maintain a lowpressure inert gas atmosphere in the heating chamber. It prevents air from entering the heating chamber and hence reduces consumption of process gas. The vacuum systems collects the dirt from the wire surface, which is deposited in the air filters. Two sealing modules are installed on each side of the heating section, which makes the use of a contactless technique and allows a range of wire diameters to be processed through the same sealing module. The small sealing module can be utilized on wire diameters of between 0.1 mm and 2 mm (0.004’’ – 0.0785”) and the large module on diameters of between 1.5 mm and 3 mm (0.06’’– 0.12”). This simplifies the process handling and shortens the downtime during the batch changeover. It takes a few simple steps and a maximum of five minutes to up-load new material and start the process. Stringing in a different sized should take no more than two minutes. The heating module (Fig. 4) is the heart of the device in which the plasma generation takes place and where the input power is computer controlled. The chamber, depending on the execution and actual power, has a length of 0.5 m – 1 m

Fig. 2. High-speed plasma wire heat and surface treatment system with two heating modules, flexible sealing system and combined (gas and water) cooling system

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Fig. 3. Sealing system module at the inlet point of plasma annealer.

(approx. 1.5 â&#x20AC;&#x201C; 3.3â&#x20AC;&#x2122;). The standard plasma chamber has a power input of 8 kW. The wire is led through the heating module where it is exposed to high-density plasma. The intensity of plasma treatment is regulated by the power supply unit, the integral part of the heating module. The cooling section (Fig. 5) is an additional element of the plasma annealer. It is used to prevent oxidation of the wire surface at the point when the wire exits the machine. The cooling section can entail water cooling, gas cooling or a combined system, depending on the type of material or surface quality requirements of the finished wire. Operational benefits of plasma process. The plasma annealing process offers considerably higher output compared to traditional strand annealing. This is due to concentration of energy in plasma, i.e. flame energy density in the plasma chamber. One plasma heat treatment line can replace five to 20 lines on a strand annealer. This makes it possible to run a plasma

Fig. 5. Views of a plasma system combined cooling section. 74 | WIRE JOURNAL INTERNATIONAL

Fig. 4. 8kW heating module in a plasmait plasma annealer.

annealer inline with drawing on a number of applications. A replacement of a tube annealer with plasma technology would allow for radical reduction in the number of processing lines, including the payoff and take-up facilities. By the same token, the potential reduction in working capital can be of great benefit to the manufacturers of expensive wires. The output of a plasma annealer is still lagging behind the outputs achieved by traditional resistive annealers for diameters larger than 1 mm. However, the surface quality of the end product achieved with plasma technology is considerably higher, which is a consequence of the surface cleaning and polishing effect during the plasma treatment. This makes plasma technology particularly suitable for applications that require uncompromising surface quality, such as enameled and plated wire. Plasma treatment is easy to operate and does not involve any hazardous chemicals nor does it release unnecessary heat into

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Table 1. Examples of plasma annealer processing and maintenance costs1.

the operator’s environment. The process is computer automated, allowing for integration into the controls of the complete production line. The plasma process is started and stopped immediately without heat-up and cool-down period. Products of different diameters and materials can be strung-in and changed over in a matter of minutes. Plasma offers low processing and maintenance costs. Its energy conversion rate [electrical power vs. heat released to the material] is between 50% and 80%, subject to application. Plasma technology benefits from low-cost processing and maintenance. The cost of operation of a plasma annealer was quantified in the four trials on copper, stainless steel and bronze wire provided in Table 1. The plasma process has all the benefits of contact-free processing, which contributes to a low cost of maintenance. Maintenance is limited to changing of oil and air filters and replacement of electrical contacts. The plasma chamber may have to be wiped with a dry cloth as required, depending on the amount of dust deposit on the inlet wire. In the case of a high degree of dirt on the wire surface pre-cleaning is required. Product quality through plasma treatment. Plasma treatment offers homogenous mechanical properties such as yield strength, tensile strength and grain size. The consistency and low deviation from the required mechanical properties can benefit many applications, in particular copper alloys and special metal processing. Plasma heat treatment can be used for full re-crystallization annealing reaching the softness usually obtained only in bell annealers. For example the elongation of plasma annealed 2mm copper wire reached 46% to 48%. Tensile strength and

yield strength of same copper wire measured 220 to 230 N/mm2 and 50 to 60 N/mm2 correspondingly. For fully annealed copper wire the tensile strength does not vary more that ± 2 N/mm. The tolerances are larger for medium annealed wire that is in the “steep curve range,” where elongation changes quickly with temperature. For example, specific mechanical properties can be targeted accurately with a plasma annealer also in the “semi soft” range. Plasma annealing on 1.5 mm copper alloy resulted in the following tolerances: Yield Strength: 405 N/mm2 ± 12 N/mm2; Tensile Strength: 510 N/mm2 ± 20 N/mm2; and Elongation: 4% ± 1%. In addition, the process control system allows for highly accurate control of wire softness during the production process. The annealing temperature can be changed during the process making it possible for wire softness to be manipulated on-line to the desired grade during the process. One of the main advantages of plasma treatment is the surface quality of the processed material. Plasma treatment is a dry alternative to acid/alkaline cleaning. Plasma does not leave acid residues on the wire surface and hence prevents subsequent surface oxidation on the wire surface. Plasma can deoxidize the surface of non-ferrous materials. Plasma treatment demonstrated the most benefits for plasma annealing/pre-heating and surface cleaning in-front of extrusion, enameling, cladding for improved adhesion of the coating; plasma annealing and acid-free cleaning inline, in front of electroplating; and plasma annealing and cleaning in front of hot dip plating. Plasma treatment for hot-dip tinning of copper. Tinning or tin plating of copper is used predominately to provide corro-

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Table 2. Comparison of traditional and PlasmaPREPLATE hot-dip tinning processes.

sion protection of copper surface. Traditionally, tin platting of copper wire is performed by running the wire through a tin bath and drying it vertically in order to allow the tin coat to dry on the copper surface. The inter-metallic bond can be achieved only if the copper surface is clean and appropriately activated. Acid cleaning or pickling has traditionally been used to preclean the wire surface. Surface activation is commonly obtained with fluxing, which is a dirty and environmentally compromising process. Table 2 compares the traditional

process of hot dip tin plating to new PlasmaPREPLATE process developed by Plasmait GmbH. The PlasmaPREPLATE process pre-heats (anneals) and cleans the wire before it enters the tin bath to allow tin adhesion on the copper surface. The PlasmaPREPLATE process can be adjusted to perform simultaneous annealing of the wire to a required softness. The wire enters the tin bath at temperature, which in turn heats the bath reducing the need for additional heating on the bath, and hence saving the energy used in

Fig. 6. A picture of Plasma module in a PlasmaPREPLATE machine, l, and a picture of PlasmaPREPLATE machine designed for hot-dip tin plating of copper wire/strip/tube.

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the process. The PlasmaPREPLATE process ensures complete degreasing and deoxidation while activating the surface to meet the conditions for strong inter-metallic bond. Superior surface cleanliness and activation allows the temperature of the tin bath to be reduced considerably compared to the temperature required in the traditional process. The bathâ&#x20AC;&#x2122;s low temperature limits solvency of copper in the bath, which in turn reduces the need for cleaning of the tin bath, saving on the cost of tin. More importantly, the bathâ&#x20AC;&#x2122;s low temperature allows the manufacturer to produce a wider range of hard finished products, which is not possible in the traditional process. Hard copper wire would inevitably soften in a bath with a temperature over 300Â°C. Traditionally, lead is added to a tin bath to improve adhesion of the coat. The PlasmaPREPLATE process improves the adhesion of the coat so lead can be omitted in the bath. This is becoming increasing important in the electronics industry due to the new regulation concerning the lead content in the consumer electronics components. PlasmaPREPLATE process can be used for production of wire, strip and tube such as capillary tube used in refrigerators, air-conditioning systems as well as for various tinned conductors that require good corrosion protection. Plasma treatment for electroplating copper. Electroplating

was introduced a few decades ago as an alternative to the hotdip process. Electroplating offers faster, single-line production as well as better control over coat thickness, i.e. usage of the plating material. The electroplating process can run at speeds of up to 15m/s. This is too slow for the process to be integrated inline with the upstream drawing lines that operate resistive annealers. As represented in the Diagram below, electroplating line runs usually independently of a drawing line with a resistive annealer. The applications such as copper alloys and those that cannot tolerate surface defects created by resistive annealing usually employ bell annealing technique. The two alternative processes are depicted in Table 3. As an alternative to the traditional processes PlasmaANNEALER can be deployed inline with an electroplating line, replacing the need for pickling and rinsing while annealing the wire to a required softness prior to plating. This configuration improves the environmental footprint of the process and releases the upstream annealing capacity. Further, the drawing operation can be placed in front of PlasmaANNEALER and inline with the electroplating line to ensure single line operation. This requires the use of a slower, but considerably less expensive drawing machine that runs at speeds up to 15m/s, the limit set by the electroplating line. In the case of copper alloys, final drawing can be abolished

Table 3. A drawing and a picture of the PlasmaPREPLATE machine designed for hot-dip tin plating of copper wire.

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Fig. 7. A picture of the PlasmaANNEALER/PlasmaCLEANER designed for annealing/preheating and cleaning of copper wire for applications such as electroplating, extrusion or cladding.

by targeting specific softness parameters with the use of PlasmaANNEALER. In this way a four-stage process of drawing, bell annealing, final drawing and electroplating can be reduced to a single line as show in in Fig. 7. This would mean that running PlasmaANNEALER inline with a plating line could avoid two sets of take-ups and payoffs, final drawing, pickling, rinsing as well as release the capacity in the upstream drawing line and bell annealer. Such a configuration can also be utilized in some extrusion and cladding applications. â&#x2013;

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Igor Rogelj is one of the founders of Plasmait GmbH, Lebring, Austria, as well as its head of sales and marketing. During his 10-year career he has held a number of sales and marketing positions in the technology and manufacturing sectors. He holds an M.B.A. degree from Manchester Business School, UK. He graduated from the University of Ljubljana, Slovenia, in 1996. This paper was presented at Wire Bologna 07, Bologna, Italy, November 2007.

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS Color concentrates have ‘green’ focus Breen Color Concentrates reports that its new ULTRALOR EF color concentrates, developed in partnership with Delphi Packard Electric Systems, have been successfully used to manufacture wire insulation that meets the demanding processes, performance and environmental requirements for halogen-free applications. ULTRALOR EF meets the performance demands of high-temperature, lightweight, halogen-free, thinwall insulation for wire and cable and has been approved by a leading automotive manufacturer for use in 2009 platform vehicles, the release said. It notes the European RoHS and WEEE environmental initiatives have been getting more momentum in the U.S, led by groups such as the U.S. Green Building Council (USBG), which wants to limit the use of halogen-containing materials. Breen Color Concentrate’s Tom Taylor observes that “the guidelines of these regulations will impact applications across numerous wire and cable markets including automotive, hospital, medical equipment, lighting equipment, fire alarm and security products.” Available in a full range of colors, ULTRALOR EF products are compatible with flexible PPE compounds for wire and cable, the release said, adding that ULTRALOR EF is made using 100% virgin material and meets the European RoHS and WEEE requirements. Samples are available upon request; conditions may vary, it said. Contact: Breen Color Concentrates, Tel. 86699BREEN, ttaylor@breencolor.com

Spare parts program a customer aid U.S.-based Davis Standard’s Extrusion Systems Group is offering a new spare parts program that it said will enable customers to buy recommended spares for recently purchased machinery under special terms. The program, a press release said, encourages customers to have spare parts on hand for those items susceptible to wear or those that are essential to maintain equipment in good working order. Davis-Standard created the program to give customers the option of stocking parts on-site, so parts are readily available to reduce potential downtime, it said. “No matter how reliable equipment is, it is still mechanical and susceptible to wear or an occasional breakdown. Offering spare parts packages up front is one way to ensure that our customers are prepared and that they get

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the most from their equipment investment,” said Jerry Warren, Vice President of DavisStandard’s Aftermarket Group. “Even if the equipment is still under warranty, customers can take the part off their own shelf, get the machine back up and running, and we will replace the warranty-covered part at no charge.” Pre-approved customers can fill out a simple acknowledgement sheet and let Davis-Standard know which option they would prefer, the release said, noting that once an order is received, the parts will be shipped. Contact: Jerry Warren, Davis Standard, at jwarren@davis-standard.com or at parts@ davis-standard.com.

UTM can process wire and fasteners U.S.-based Instron® reports that its new SATEC™ Series 2000KN universal testing machine can perform tension, compression and flexure tests on wire, fasteners and other materials. The 2000KN model, with a capacity of 2,000 kN (200,000 kgf/450,000 lbf), features a single, ultra-large test space that makes it easy to provide different stroke lengths and extended test openings to suit unique applications without costly customization, a press release said. The upper actuator design makes the testing space easily accessible, increasing efficiency, productivity and operator safety while a variable pressure hydraulic power supply reduces noise and heat generation, it said. With no need for water cooling, the 2000KN testing system from Instron is more environmentally friendly, while lower oil temperature means a longer oil life and ultimately, lower operating costs, the release said. Optional open-faced high capacity grips can be added that will make specimen loading even simpler

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and much more efficient, the press release said. Contact: Instron, tel. 800-564-8378, info_news@ instron.com, pr.instron.com.

New TPOs a better choice U.S.-based Teknor Apex Company reports that its new family of thermoplastic olefin (TPO) elastomers exceeds by a wide margin the performance and softness limitations of conventional TPOs and exhibit processing and physical property advantages over a wide range of other thermoplastics elastomers (TPEs). Tradenamed Telcar® OBC, the new TPO compounds are blends of a rigid polyolefin and INFUSE olefin block copolymers (OBC) from Dow, which Teknor Apex uses under a newly established agreement with Dow, a press release said. The Telcar OBC compounds provide far more rubberlike elasticity

(as measured by compression set at 70°C), greater tensile strength, tear strength, and elongation, and improved processability, as compared with TPOs with rubber phases of EPDM or random ethylene copolymer, it said. It added that they will be available in a much broader range of Shore A hardnesses, from the single digits to 90 and above, noting that standard TPOs are generally not available below 70. The new compounds can be used for a wide range of applications, including products from seals to hand tools (photo courtesy of Dow Chemical Company) to wire and cable, the release said. Contact: Teknor Apex Company, www.teknorapex.com.

Compound line meets ‘green’ regs PolyOne Corporation announced that it has introduced a new family of halogen-free, flame-retardant thermoplastic elastomer compounds that it said can help customers meet current and upcoming environmental regulations. The product line, displayed at Chinaplas 2008, is from GLS Corporation, a global supplier of high-performance, custom-formulated thermoplastic elastomers (TPEs) that was recently acquired by PolyOne Corporation. The line

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includes a new family of With OnFlex™-S HF TPE-S compounds that feature a unique, patent-pending formulation, with which permits customers can easily upgrade from conventional, halogenated flame-retardant TPEs without retooling or sacrificing performance, it said. The OnFlex-S HF grades are designed for injection and blow molding, and in some cases, are also suitable for extrusion, for applications including cable jacketing and insulation, the release said. GLS also showcased its low smoke, free of halogen (LSFOH) family of compounds for wire and cable applications, demonstrating the company’s focus on new technologies that enable customers to comply with increasingly stringent regulatory requirements. Contact: Manfred Taedcke, PolyOne Corp., Europe, tel. 49-7225-6802-0, Manfred.taedcke@polyone.com.

Measuring system is MID certified U.S.-based Beta LaserMike reports that it can now offer two configurations of its LaserSpeed gauges that have been certified to the requirements of the Measuring Instrument Directive of the European Community (MID). The MID LaserSpeed non-contact length and speed measurement system uses a proven technology called Laser Doppler Velocimetry to accurately measure the length and speed of any moving product or surface to an accuracy of +/- 0.125% or better, a press release said. The system also allows measurements down to zero as well as reverse speed. Coupled with a DataPro™ controller, the system delivers the accuracy, reliability and MID certification required throughout Europe. The LaserSpeed Series of measurement gauges were designed to be drop in replacements for any type of mechanical tachometer, the release said, noting that “they have proven to provide a short term return on investment of less than two months.” Savings come via increased accuracy, reduced scrap, less product give-away, reduction of charge backs from short rolls or lengths and reduced maintenance/calibration costs, it said. Contact: Beta LaserMike, tel. 973-233-9935, sales@betalasermike.com.

Welder ideal for splicing wire bundles U.S.-based Sonobond Ultrasonics reports that its SpliceRite™ Ultrasonic Wire Splicer provides strong, reliable welds in a cost-effective manner. The SliceRite welder creates perfect solid-state metallurgical bonds using the lowest possible voltage drop and minimum energy consumption, a press release said. The unit is ideal for quickly splicing wire bundles without producing arcs, sparks, or fumes, or melting the wires and eliminates the need for clipping, soldering, crimping or dipping it said. Unlike other ultrasonic wire splicers, Sonobond’s SpliceRite can easily accommodate tinned or heavily oxidized wires, the release said. The unit features a micro-

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processor controller that can store and recall up to 250 jobs, while producing welds by height, by energy, or by time, it said. The welder, available in 1500 and 2500 watts power capacity, features the patented Wedge-Reed system that combines high vibratory force with low amplitude coupling, it said. This, it added, enables the unit to direct high frequency ultrasonic energy via a welding tip to the surface between the metals to be welded. The vibratory energy disperses the oxides and surface films between the work pieces and a true metallurgical bond is then created without melting the materials, it said. Contact: Sonobond Ultrasonics, tel. 800-323-1269, www.sonobondultrasonics.com.

UV curing system is more flexible U.S.-based Nordson Corporation reports that its new, low-power Nordson® CoolWave® 2 410 UV Curing System, which was slated to be introduced at RadTech UV/EB 2008, offers substantial advantages for sectors that include wire and cable manufacturing. The CoolWave 2 410 system provides up to 420 Watts/inch (165 Watts/cm), and uses dichroic-coated temperature stable glass reflectors for cooler operation, a press release said, noting that as it has no internal gasketing it also virtually eliminates the possibility of arcing. The system provides faster identification of cause of system faults, and greater application flexibility with a range of precisely focused and flood reflector geometries for a myriad of manufacturing applications, it said. The power supply provides the capability to switch between 20 to 100% power levels in 1% increments, it said. The system has an optional internal blower that provides further system flexibility to meet installation requirements, the release said. It also simplifies installation and provides properly balanced cooling to ensure optimal spectral output and maximum bulb life, it said, adding that the system’s scratch-resistant glass reflector

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material is more heat stable than metal,easier to clean and provides longer service life. Contact: Nordson Corporation, www.nordson.com.

Expanded capabilities translates to better customer service OMCG North America reports that it has installed an Agie Wire EDM for cutting tools that has enabled it to improve both quality and time requirements for a sample submission. A press release said that the additional allows the company to design on Auto Cad 3 D and send it for manufacturing to the Agie, which can cut up to 4” thick tools plus taper tools for compound bending. The new equipment makes it easy for OMCG North America to produce complicated profiles of plate cams used to finetune the multislide forming process. OMCG North America notes that it has been providing manufacturing slide forming and CNC forming machines built by its Italian parent company, OMCG Spa, to multiple industries since 1981. Its systems can handle strip to 4 in. wide and wire to over .625 in., with blank length not a real concern, it said. Contact: OMCG North America, www.omcg.com.

Cat. 6 cable is smaller, ‘greener’ Hitachi Cable Manchester, the U.S. business of Japan’s Hitachi Cable Ltd., has introduced its Cat. 6 ECO™ line of communication cables. Manufactured at its plant in Manchester, New Hampshire, the design eliminates the use of a center filler for the cables. A press release said that without the center filler, the cable has a smaller outside diameter, about the size of a traditional Cat. 5e cable. That, it noted, can help reduce installation costs by permitting the owner to install more Cat. 6 cables per conduit or tray than could be installed if using traditional counterparts. The new construction, which is UL verified for performance and exceeds Cat. 6 requirements, is a result of knowledge gained during the development of HCM’s Cat.

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6A cable, Supra 10™, said HCM Marketing Director Steven Kenney. “We are very excited about this new product,” he said. “Not only does it offer the Cat. 6 performance that our customers require, but it does so using substantially less material. This also translates into a smaller impact on the environment when the product reaches the end of its life cycle.” Another benefit, the release said, is that HCM has further reduced the environmental impact by designing the packaging to be made with 100% post consumer cardboard. “We believe this is the most environmentally friendly Cat. 6 cable on the market,” Kenney said. Contact: Hitachi Cable Manchester, tel. 800-7720116, www.hcm.hitachi.com.

MEDIA Brochure highlight’s fastener solutions, company’s capabilities A 16-page brochure from U.S.-based Ohio Rod Products features the company’s small diameter, long length fastener solutions as well as the company’s strengths, abilities and market applications. The brochure features a full list of fastener size ranges and products including machine screws, thru bolts, ladder rods and rivets, with information provided for the various head styles and thread types available. A press release notes that Ohio Rod’s fasteners, which serve a variety of markets, including automotive, construction and lawn and garden, are custom engineered and produced to ISO 9001:2000 registered quality systems. Part of the Elgin Fastener Group, Ohio Rod Products manufactures cold-headed and threaded long-length specialty fasteners used in a wide array of durable goods and consumer product industries. Contact: Ohio Rod Products, tel. 812-689-6565, www.ohiorod.com, ohiorod@eni.com.

Bulletin introduces new cable line U.S.-based Belden Inc. has introduced new halogen-free DeviceBus® Cables, two of which are steel wire armored for use in public areas and/or demanding industrial applications. A product bulletin at www. belden-emea.com describes the new cables, which include a range of four new halogen-free 84 | WIRE JOURNAL INTERNATIONAL

cables meant for use in a global environment, suitable for indoor and outdoor usage, as well as for direct burial applications, a press release said. The cables are designed to meet both the electrical and physical requirements as laid down by ODVA, these cables comply with IEC 60332-3-24 (formerly IEC60332-3C), EN 50265-2-1 and NEC/CEC CM CL2 CM FT4 standards and regulations and enable flawless communication using the DeviceNet™ protocol and matching all existing connectivity, it said. For harsh industrial environments, Belden offers a range of armored halogen-free DeviceBus cables. The SWA (Steel Wire Armoured) versions feature an inner jacket which matches the dimensions of the un-armored types. The DeviceBus cables do not need special connectivity or cableglands and the single galvanized steel wires of the armor are applied in a tension free process and are in accordance with EN 50288-1, it said. Contact: Belden Inc., www.belden.com.

Book covers role of culture in workforce Productivity Press reports that one of its most recent books on helping companies foster a good workforce presents important management principles in a practical way. “A Culture of Rapid Improvement: Creating and Sustaining an Engaged Workforce,” by author Raymond Floyd, is intended for those leaders seeking to encourage dramatic improvement within their organizations, a press release said. It notes that management “must provide employees with a shared set of values and beliefs so that they can decide for themselves how to behave in accordance with the expectations of a nurturing and empowering culture.” Floyd, who worked in key positions at Exxon Chemical and General Motors, is generally recognized as an expert in applying Lean Manufacturing within the liquid industries, the release said. A registered professional engineer, attorney-at-law and patent attorney, Floyd’s 328-page book identifies management tasks essential for creating a culture of improvement, demonstrates the importance of engaging all participants in the drive for improvement, shows how to involve employees in achieving company-wide objectives and provides examples of specific methods that have achieved results, many times in many places, it said. Contact: Productivity Press, www.productivitypress.com. ■

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CLASSIFIEDS WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking employment positions are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership 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 Wire Journal International 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.

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 of the WJI.

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

PAYMENT POLICY: All ads must be pre-paid.

CAREER OPPORTUNITIES

required. Please send resume to sales@abcwire.com.

SALES AGENTS. Midwest Wire & Cable manufacturer is seeking for commission-based agents. Previous experience in insulated and bare copper

BUSINESS OPPORTUNITY WANTED: MERGER & ACQUISI-

TION OPPORTUNITY FOR WIRE & CABLE. Client seeking to purchase a manufacturer of insulated wire & cable conductors, receptive to a purchase, joint venture or partnership. Contact: Jim Knott at tel. 508-234-

COMMISSION BROKERS, INC. EQUIPMENT SPECIALISTS TO THE ELECTRICAL WIRE & CABLE INDUSTRY APPRAISERS • COMMISSION BROKERS • INDIVIDUAL PIECES OR ENTIRE PLANTS

FOR SALE 1 - WMCA 37-Wire, 6+12+18, 16” Planetary Line 1 - NEW ENGLAND BUTT 12-Head 16” Planetary Cabler 1 - WATSON 36” Rotating Cabler Line 1 - KRUPP 1250mm D.T. Cabler 1 - NORTHAMPTON ST1000 Cabler, 1999 1 - NIEHOFF M15 Wire Drawer, Annealer, SG45 Spooler 1 - D/S 2.5” 24:1 L/D Nylon Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extrusion Line 1 - D/S 1.25” 30:1 L/D Hi-Temp Extruder 1 - D/S 2” 24:1 L/D Extruder 2 - BARTELL 72” Shaftless Payoffs 1 - BARTELL 60” Shaftless Payoff 4 - DAVIS STANDARD, ENTWISTLE 50” Shaftless Payoffs 1 - DAVIS ELECTRIC 36” Shaftless, Model POS18-36, #6198

1 - TULSA 30” Payoff, Model PSPO-1, #2324-1, 1000lb cap, 8/90 1 - 30” Core Neutralizer Payoff 1 - NEB 18-Wire 22” Rigid Strander, L-R 1 - NEB 61-Wire 22” Rigid Strander Line 1 - D/S 36” H.S. Dual Reel Take-up, twin Motors 1 - ENTWISTLE 36” Dual Reel Take-up, Model THE 24/36 4 - D/S 30” Dual Reel Take-ups 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 7 - CLIPPER Model SP16 Dual Spoolers 2 - BARTELL 72” Shaftless Take-ups 1 - DAVIS ELECTRIC 36” Shaftless, Model TUS36 3 - TULSA/KENRAKE Model WTR-656 Respoolers 1 - ADVANTAGE Chiller, Model MK-25AM-41HBX, 9/98 1 - IMAJE Model Jaime 1000 S4 Ink Jet Printer, 10/96 41 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

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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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”)

4710/info@knottco.com, or visit www. knottco.com and click on “Available Assets, M&A Opportunities.” PERSONNEL SERVICES “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. E-mail Peter Carino or Jack Cutler pcarino@wireresources.com or

jcutler@wireresources.com www.wireresources.com. Wire Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-6223000 or 800-394-WIRE. DIES APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@wmconnect.com. 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.

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.

DIAMOND & CARBIDE DIES: PRICED TO MOVE! Take advantage of discounted pricing on new, used and recut diamond and carbide dies in standard case sizes: 2, 5, and 6. For quality dies with competitive pricing, contact Ida Pardo at info@knottco.com or by phone at 617-519-3303. EQUIPMENT WWW.URBANOASSOCIATES. COM. For New & Used Wire & Cable Equipment. Tel. 727-863-4700; fax 727-863-4711; or by e-mail at urbassoc@verizon.net. WE BUY LASER MICROMETERS. Any condition. For a quote fax or email manufacturer & model #'s. Fax 386-4262056 or e-mail johnknight@ microtex. net. Laser micrometer repairs $875.00. 1-year warranty. www.microtex.net. M

WIRE JOURNAL

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

JULY 2008: WIRE & CABLE MACHINERY—PART 1 No matter where your product is located along the wire and cable manufacturing line, you’ll finish first with a product Wire Journal International’s July advertisement in I S S U E . M A C H I N E R Y So get a head start today. Call Bob Xeller or Anna Bzowski on WJI’s sales staff today to rev up your marketing campaign with a well-placed ad message. Tel.: 001-203-453-2777 | E-mail: bxeller@wirenet.org or abzowski@wirenet.org

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BEST WARRANTY-LOWEST PRICES on high quality Rolling Ring Traverses. YR Products phone/fax: 708672-5007 or e-mail kamoline@ comcast.net. WIRE 12 GAUGE C1018 EG WIRE on carriers. Approximately 16,000 lbs. @ $0.45/lb. FOB Chicago, IL - Ph.708-2051194 or email kamoline@comcast.net. MEDIA FERROUS WIRE HANDBOOK. The most recent in a series of handbooks published by WAI, this comprehensive hard-cover book is a new, definitive industry resource for ferrous wire written by members of the Association and edited by former WAI President Robert M. Shemenski. It is a modern-day reference tool for those

working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. At 1,168 pages, the publication’s comprehensive 36 chapters cover a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and includes the evolution of ferrous steel manufacture, appendices and a complete index. List Price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Bookstore. WIRE BREAKS, by Horace Pops and Julie Steininger, 2003, 49 pages. Breakage of copper, steel, or aluminum wire is one of the most common and costly problems facing the wire industry today. To help minimize the number of breaks, drawing personnel must first be able to recognize and identify the

type and cause of material failure. With this need in mind, the following reference manual was prepared. It contains pictures of the most frequent examples of broken wires found in the wire mill and at the customer’s facility. Although some of these photographs were taken at high magnification with a scanning electron microscope, adequate visual examination of the broken ends can be made in the plant using either a magnifying glass or a low power stereomicroscope. In addition, many pictures of cross-sections are included that were obtained in the laboratory using metallographic techniques The photomicrographs do provide useful supplemental information that helps to confirm and explain the nature of the wire breaks. List Price: $15, WAI Member Price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

Surplus Assets to Ongoing Operations

Machine Tools, Die Room, Furnaces, Welders and Compressors Morgan Twin Head Bullblock, Vaughn 3HR Roughing Block, Plane Straightener, Arbour Straightener, Fly Cutoff Saw & Stringer Pointer, Steelman Bake Oven, Quincy Air Compressors, Bandsaws, Fay & Egan Lathes, Rockwell Sanders, Fay & Egan Jointer, Gantry Crane, Onan Generators & More! Sale Closing: Wednesday, 25th June 2008 at 12:00 EDT (local time) Inspection: By appointment only Location: Park Avenue East, Massena, New York, 13662, USA For further information please contact: BRYAN GOODMAN Tel:(800) 722-3334 ext. 235 Email: bryan.goodman@goindustry.com To view and bid on the lots please visit our website: www.goindustry.com and Search: Alcoa – Morgan Drawing Line (Full details and pictures can be found on our website)

GAVLICK MACHINERY CORPORATION 100 Franklin St., Bristol, CT 06010 USA Phone: 860-589-2900 Fax: 860-589-0863 email: sales@gavlick.com www.gavlick.com

Buying & Selling Used Ferrous & Non-Ferrous Wire & Cable Machinery JUST PURCHASED: • Vaughn #18 Bullblock; 30"x125hp; 1"start; late model controls-excellent • Vaughn #19 Bullblock; 30"x65/75hp; start .625" • NAIL PLANT:Wafios N-90's, N-5's, N-4's; staple with barbing; roll threading • (2) Taiwan Cheng model MDC-10L Descalers; 5.5-10mm, scale breaking, brush, coating-heating • (16) Drawing Deadblocks; Morgans, Macbees, Whitacre; all sizes; 16"-28"; 30-75HP • (9) Wire Lab Model 310 Descalers, reverse bend WIRE DRAWERS: • Vaughn model 5HRM w/30" Deadblock; (5) 40/50/69HP motors; (4) 26" blocks; start: .280" S.S.; PLC controls; excellent • Vaughn model 6/7 HIVXX; (1) 20/30HP motor 1st block; (5) 15/22.5HP motors; start block dia 20"; intermediate 14"; finish 16" + 22"; start wire .220"; 2400 FPM; PLC controls • Morgan 5BW; 5x22" blocks; start .218", finish .086", 300HP AC • Morgan 6BW; 4x26"/2 x 22" blocks; start .218", finish .076"; 300HP AC STRAIGHT & CUT MACHINES: • Shuster Model 4AV; .375"-.625"; 3' runout; new 9' track in crate; 1991 • (5) Lewis Model 1SHV-HS; .031"-.062" to .135"; 4' runout; 250-400 FPM

BUTT WELDERS: • Micro T-HD; .125"-.500" • (2) Strecker Model 2B Butt Welders; 5-16mm, new 1997 • Micro J8S, .187"-.500" • Micro J5S, .060"-.250" BAG-BAR TIE MACHINES: • (1) 3-head Bar Tie Spooling Machine • (4) Bag-Bar Tie Machines; 16 ga.; 5"-12" lgths. • (4) Bar Tie Wire Spooling Machines; 3- 3-1/2 lbs.; 16 ga. TURKHEADS: • AWM Cold Rolling Line; 4-12mm; powered rolling unit 3 x 27HP; twin payoff; 20' shear cutoff • Fenn Model 5U + 5P tandem, 28" shedding drum, 25/30HP • Fenn 6U Turkshead • Fenn 5TH Turkshead; max. sq. .437" MESH WELDERS: • Jager NS200; 102"wide, .019"-.098" wire; shear; coiler • EVG GZN/85; 90"max. width; 85"max weld width; 1,2,3,4,6,8 line spacing; cross wire 1/2" up to 4"; wire dia. 1.4-3.8mm; slitter; nibbler; coiler for rolls; excellent • Hurricane-Southwire Hinge Joint Fence Machine; wide bed; 78" x 14 line wire

WE WANT TO BUY YOUR GOOD SURPLUS EQUIPMENT. SEND US YOUR LIST. www.goindustry.com

VISIT WWW.GAVLICK.COM TO SEE OUR COMPLETE LISTINGS

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ADVERTISERS’ INDEX

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

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

A. Appiani Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Dovebid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Eurolls Group/Team Meccanica . . . . . . . . . . . . . . . . . . . . . . . . .55

Alloy Wire International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Eurolls Group/Teurema . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Fabritex Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Fine International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24, 83

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Bomco Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

FROMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . .53

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Gavlick Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Gimax Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-18

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Guill Tool & Engineering Co . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . . . . . .83

Kinrei is Kabling In fact, Kinrei is your source for the latest technology in cabling, stranding and twinning solutions. Our double twist twinners and cablers produce today’s highest performance data and communications cables. Our complete Stranding Systems output levels are 15 – 40% higher than competitive machines. And that’s just the beginning — to learn more visit www.kinreiusa.com for product details! Also representing: Donnelly High Performance ABS Reels Watson Parts and Service Company Featuring OEM Replacement Parts & Rebuilds The Kinrei HK560 Watson Machine Company • Wire Machinery Corporation of America, Inc. The Edmands Company • The New England Butt Company • Peachtree Fiber Optics

Call for a quote, 973-677-9500, ext. 143. Or e-mail shess@kinreiusa.com

Donnelly Reels KINREI OF AMERICA, L.L.C. | 26 NORTH CENTER STREET | ORANGE, NJ 07050 973-677-9500 | WWW.KINREIUSA.COM

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

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 16

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Industrial Wire & Cable Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

International Fastener Machinery & Suppliers Association . .27

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . . . . . .14

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Kinrei of America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Reel-O-Matic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Lesmo Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Sealeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Sikora AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Madem Reels USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

MAGPOWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Mario Frigerio SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Skaltek AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . .32, 54

Sweed Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Metavan/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . .83

Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . . . . . .4

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

PS Costruzioni Meccaniche Srl . . . . . . . . . . . . . . . . . . . . . . . . .25

Team Meccanica/Eurolls Group . . . . . . . . . . . . . . . . . . . . . . . . .55

RECENT PURCHASES EXRL35 (2)4 1/2” D.STD Therm III 20:1 Rubber Ext w/Rollerfeed, water cooled, 150 HP Drive, (1989) EXRL36 3 1/2” D.STD Therm III 20:1 Rubber Ext w/Rollerfeed, water cooled, 100 HP Drive, (1999) EXRL34 2 1/2” D.STD Therm II 15:1 CV Line w/D.STD. DR-30 Dual Take up, (2) 24” BW Capstans, autoclave, 3 yr old drives. EXP858/859 (2) 4 1/2” D.STD. Therm III. 24:1, EXP834/835 (2) 2” D.STD. 24:1. EXP864/864 (2) 3” D.STD. 24:1. EXP853 6” D.STD. 24:1 Therm III w/250 HP DC motor, panel. CBR977 ENTWISTLE COOK SC-48 S.T. Cabler (1983). CBR980 (2) 760mm LESMO D.T. Buncher, DTO-760MB (1998). CBR981 760mm SAMP D.T. Buncher, BM-760D. (1995) CBR965 - 50 Pair 500mm CABALLE Group Twinning Line Yr. 1992, w/ 84” rot. take up 5 head OSC/binder. CBR967 - 52 PAIR 500mm CEECO Group Twinning Line, Yr. 1992, w/1.6m Pourtier rot. take up, 7 head OSC/binder, (2) SZ OSCbinder, (2) 1.6m Ceeco portal trav. T/U. CBR968 - 84” CEECO Cabling Line w/(29) 64” S/L payoffs, (2) conc binders. CBR966 - 50 Pair 500mm POURTIER Line with 1.6m Pourtier rotating take up, 10 head osc/binder. O.A. binder. CBR949 - NEXTROM 18 Bobbin (6+6+6) Ribbon Strander, 450mm bobbins CBR927 - (10) 560mm WATSON/KINREI D.T. Twinners, 20” Dual Driven payoffs, 1998.

CBR923 - 1250mm POURTIER Drum Twister, 12-630mm Neutralizing Payoffs, Rotating Caterpuller, 1.25m Rotating Payoff. CBR948 - 48” TEC Drum Twister w/(2) Conc. Tapers. CAT420 BARTELL 48” belt caterpuller. TKU1068 CLIPPER PA-16 Dual Parallel S/T Take up. TKU1060 D.STD. DR-30 dual Take up w/AC Vector drive, mot. Traverse. TKU1061 (2) 60” BARTELL S/T take ups. TKU1062 AFA 84” take up. TKU1050 30” D.E. TAP-30 Dual take up w/ controls. TKU1043 36” CLIPPER Dual Reel Take up, PS-36 Recently rebuilt. PAY1420 HALL 72” driven S/L payoff. RWD360 CLIPPER SP-18 Dual Rewinder RWD445 CLIPPER SP-16.Dual shaft rewinder, NOKIA DUAL TAKEUPS - (2) EKP-5 2001, EKP-50 1998, EKP-100 1995. WRD835 ENDEX 18” Drop Coiler with Turntable. WRD837 (4) NIEHOFF M30 Intermediate Wire Drawing w/VG_30 annealer, 75 kw DC motor, controls. BIN131 (2) CABALLE 18 Position Kevlar servers, RKCR-250-18, 250 RPM, Year 2000, Siemens S7/300 PLC. LATE MODEL HIGH QUALITY (BRAND NAME US & EUROPEAN) WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY EX-STOCK FROM (6) USA WAREHOUSES

JUNE 2008 | 89

ADVERTISERS’ INDEX

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ADVERTISERS’ INDEX

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ADVERTISER . . . . . . . . . . . . . .PAGE Teurema/Eurolls group . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . . . . . .89

What’s your story? Messages from ads and articles that appear in Wire Journal International make great reprints and serrve as another opportunity to tell your company’s story.

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Layouts can be customized to suit your promotional needs. So, why not brand your reprints by including your logo, plant location, or the correesponding Wire Journal International cover with your reprint?

WIRE ASSOCIATION INTERNATIONAL ADS

For more information about reprints be sure to have the WJI issue month, year, and page number handy when you contact The Reprint Department at: ckeener@reprintdept.com or Tel.: 800-259-0470.

Ferrous Wire Handbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 WAI 2008 ITC: Monterrey, Mexico . . . . . . . . . . . . . . . . . . . . . . .50

When it comes to reprints, we’ll help you tell it like it is.

WIRE JOURNAL

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

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

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/Fax: 44-1223-360472 franksco@btopenworld.com

90 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

Anand Bhagwat Wire & Cable Services Pvt. Ltd. (WCS) Mobile 91-98-508-38467 abhagwat@wirenet.org

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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

email: amacoil@amacoil.com

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

connexia

Impossible is nothing EVM Automatic spooler EVM for the production of precision laid wire coils with spools which can have a capacity of up to 5 tons. This double automatic spooler is composed of two spool working stations which are the wire collection station and the wire strapping/unloading/ loading station. It is complete with all necessary devices to ensure an automatic handling of the wire, the cutting and subsequent threading of the wire, and the securing of the wire tail. All these operations improve line efficiency specially when operating with large diameter wires. The combination of all these factors guarantees a drastic reduction in down times which are normally present during the spool changeover cycle. All parameters required for the formation of the pattern laid coil, as well as production information, are set on the spooler control pulpit.

TEUREMA - Poligono Txirrita - Maleo, 10 - 20.100 Errenteria (SPAIN) Phone (+ 34) 943341919 - e-mail:teurema@teurema.com - www.teurema.com The Eurolls Group Companies are exclusively represented in North America by: Cortinovis Machinery America, Inc. - 1014A Route 173 Bloomsbury New Jersey 08804 Phone: 908-479-9818 - e-mail: cortinovis@cortinovisamerica.com - www.cortinovisamerica.com