Ancillary equipment & parts by Wire Journal International, Inc.

WIRE JOURNAL JUNE 2010

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

Ancillary equipment & parts

wire D端sseldorf 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

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

CONTENTS

Volume 43 | Number 6 | June 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 wire Düsseldorf wrapup Fastener Update . . . . . . . . . 28

. . . . . . . .34

Despite a late showing of a volcano with an attitude, the world’s largest wire and cable event went quite well.

WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . 33 Technical Papers . . . . . . . 66-76 Products/Media . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . 83 Career Opportunities . . . . . . 83 Advertisers’ Index . . . . . . . . 86

Next issue July 2010 WJI • Equipment: Part 1 • Wire Expo 2010 wrapup and co-located event summaries

Wire Link Scholar report . . . . . . . .42 Peter Funk of Talley Metals, the 2010 Wire Link Scholar, recalls his two-week stint that saw him attend wire Düsseldorf and tour a range of U.K. companies.

Ancillary equipment & replacement parts . . . . . . . . . . . . . . . . . . . . .46 Big capital equipment may grab the most attention, but the wire and cable industry relies on a litany of ancillary equipment and replacement parts to keep going. This feature presents an assortment of such products.

T ECHNICAL

SECTION

Continuous casting technology and introduction to bar porosity detection infrared system Kiran Manchiraju and Victor Rundquist . . . . . . . . . . .66 Factors that influence ink adhesion on wire and cable substrates Mark Spencer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Cover: A gathering of industry suppliers at Wire Expo 2010, which included many of the companies that supply ancillary equipment and replacement parts that are in the feature that begins on p. 46.

JUNE 2010 | 3

INSIDE THIS ISSUE DÜSSELDORF 2010

WRAPUP

. . .34

W IRE LINK SCHOLAR

REPORT

. . . .42

CONTENTS

W IRE

To personify a trade show, one could say that a collective sigh of relief could be heard from wire Düsseldorf exhibitors, who appeared quite content with results at the world’s largest event for the wire and cable industry. Then again, one might also have heard some less-than-kind comments about volcanoes.

4 | WIRE JOURNAL INTERNATIONAL

Peter Funk of Talley Metals, here with WAI Executive Director Steve Fetteroll at WAI’s booth at wire Düsseldorf, shares what he saw and learned during his two-week trip as the 2010 Wire Link Scholar. As he reports, his education came about both at the trade show floor as well as at his visits to U.K. companies.

EDITORIAL WIRE JOURNAL

EDITORIAL

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

Change can be an industry-wide force Publisher | Steven J. Fetteroll

It is curious that we no longer hear the phrase “Resistant to Change.” I suspect that in our current political and economic state, most people and businesses would welcome a change. At any rate, change is not only inevitable but it should be the norm as it forces us to look for innovative opportunities to improve. I have visited numerous copper companies and wire and cable businesses in the U.S., Europe and China, and networked with people in other countries. In addition to building new friendships, I have witnessed the global desire for innovation and continuous improvement. Beyond a desire for change, the people I’ve met also seem to share my belief in the value of relationships, partnerships, friendships and collaboration, all of which are elements that are important to change. Everyone wants our industry to be successful. They also want to see Wire Association succeed, for it represents the industry on multiple levels. Change may not always be easy to see, but I am seeing it happen at WAI and you will see the results with an Interwire program in 2011 that is indeed alive with possibilities. The Association understands that people want to network and participate with other industry professionals who share common interests, challenges and goals. That it needs to provide a great conference program that brings people from around the world together. Interwire 2011 will be that conference. Extensive work has already gone into the planning, including the show location, networking opportunities, conference speakers, executive discussions, technical papers and exhibits. One new program will introduce operational papers that address day-to-day challenges our businesses encounter. There will be roundtable discussions on subject matters from experts around the world, suppliers exhibiting new and innovative machinery and supplies, and the opportunity to see friends and colleagues and enjoy face-to-face networking. Businesses are cautious about investing, but I believe that there is a huge potential ROI by actively participating in our Wire Association and its trade conferences. It’s also an opportunity for industry veterans to give back by sharing and mentoring our new members. I am optimistic that our Association will emerge from this economic downturn stronger and even better prepared for the future. Our focus must be on being better, not necessarily bigger. You can help both by attending Interwire 2011 and by being an active participant. Let’s bring about change. Let’s make Interwire 2011 a global event to be remembered!

Gary L. Spence Vice President Nonferrous Metals Encore Wire Corporation

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

6 | WIRE JOURNAL INTERNATIONAL

»To be the leader »To be the leader you must have followers.« you must have followers.«

Do you want to know more? www.sikora.net Do you want to know more? www.sikora.net

Jhonathan Ruiz, Sales & Service Engineer SIKORA International (USA) Jhonathan Ruiz, SalesCorporation & Service Engineer SIKORA International Corporation (USA)

X-RAY X -R RA AY 6000 X X-RAY -R RA A 6000 Online Onli ine Y wall thickness, ecce eccentricity, entricityy,

LASER R Series 6000 LASER R Series 6000 Online du dual-axis ual-axis high frequencyy

Onli Online ine wall diameter thickness,measuring ecce eccentricity, entricity ovality oval ity and meas uring y, oval ity and diameterlines measuring ovality measuring system syste em for jacketing syste em for jacketing lines system

Online du dual-axis ual-axis highsystems frequency diameter measuring forry diameter systems jacketing measuring and insulating linesforr jacketing and insulating lines

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CALENDAR

CALENDAR Sept. 21-24, 2010: AWPA Government Affairs Conference Washington, DC, USA. To be held at the Hyatt Regency on Capitol Hill. Contact: Heather Outhuse, American Wire Producers Association (AWPA) at tel. 703-2994434. For more details, go to www.awpa.org. Sept. 21-24, 2010: wire China 2010 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities. Contact: WAI, tel. 203-453-2777, www.wirenet.org. Oct. 27-Nov. 3, 2010: K 2010 Düsseldorf, Germany. This event for the plastics and rubber industry will be held at the Düsseldorf Fairgrounds, Halls 1-17. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. Organized by Messe Düsseldorf and the the Confederation of Indian Industry (CII), this event will be held at the Bombay Exhibition Centre in Goregaon. Contact: CII, tel. 91-22-24931790, www.cii.in/. May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. Contact: WAI, tel. 203-453-2777, www.wirenet.org. June 19-23, 2011: JI Cable Versailles, France. This international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1Cable 11, www.jicable.org. ■

W IRE ASSOCIATION INTERNATIONAL E VENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. June 21, 2010: WAI Midwest Chapter 8th Annual Golf Tournament West Chicago, Illinois, USA. This event will be held at the St. Andrews Golf & Country Club. See p. 33.

October 14, 2010: Southeast Chapter 9th Annual Golf Tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf and Spa. See p. 33.

August 5, 2010: WAI Ohio Valley Chapter 8th Annual Golf Tournament Solon, Ohio, USA. This event will be held at the Grantwood Golf Course. See p. 33.

October 25, 2010: Western Chapter 10th Annual Golf Tournament Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course. See p. 33.

September 16, 2010: New England Chapter 16th annual Golf Tournament Boylston, Massachusetts, USA. This event will be held at the Mount Pleasant Country Club. See p. 33.

March 3-5, 2011: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland. WAI’s Poland Chapter members are among those organizing this event. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl, www.konferencja.mim.pcz.czest.pl.

Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities.

8 | WIRE JOURNAL INTERNATIONAL

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

*2,1*)253(5)(&7,21 www.eurollsgroup.com

Straightening machines

Multiwire drawing machines

Cold rolling lines with cassettes

PC strand machines

Spooling equipment

WIRE MACHINERY DIVISION

INDUSTRY NEWS

INDUSTRY NEWS Madem Reels U.S.A. closes, operating assets sold to Sonoco Madem Reels U.S.A. has ceased its manufacturing operations in Chattanooga, Tennessee, and sold its operating assets to Sonoco Reels and Spools. A press release from Madem Reels U.S.A. President Leandro Mazzoccato said that the company, which started business in the U.S. in 2007, ceased manufacturing operations on April 30. “Our U.S. company has experienced the significant effects of the economic downturn that started shortly after we began operating (there). These events have made it impossible for our Chattanooga operations to achieve sufficient profitability.” The company is paying back to Hamilton County and the city of Chattanooga approximately $160,000 in tax benefits received through its PILOT Agreement with the city, county and related entities. A press release from Sonoco Reels and Spools confirmed that it has agreed to acquire the U.S. nailed wooden and plywood reels manufacturing assets of Madem Group, a Brazilian-based wooden reels and wood products company. The deal includes state-of-the-art automated nailed wood flange assembly lines and related inventory. It added that Sonoco also has entered into a supply agreement in which Madem will supply Sonoco with wooden and plywood flanges that it will use to supplement the company’s domestic production requirements. According to reports in the Chattanooga Times Free Press, the Madem Reels facility, more than 143,000 sq ft in size, opened in 2007 with a work force of 25 machine operators and material handlers and almost tripled in size in its first year alone. The company reported that it had employed up to 80 people, it said.

Niehoff opens new factory in Germany On April 7, Germany’s Niehoff GmbH officially opened its new factory for producing wire and cable machinery in Schwabach, a larger facility that was built to be both cuttingedge and energy-efficient. The plant, which is near Nuremberg and close to the company’s headquarters, was built on a greenfield site with direct access to European highway E 50 (Paris to Prague). A press release said that production now has much more space (170,000 sq ft than before), enough to sustain a throughput of 100 drawing lines a year. The company manufactures machinery and lines for drawing, annealing, galvanic electro-plating, bunching, spooling, rewinding and braiding of nonferrous wires, as well as machines for stranding, coiling and spooling of insulated data and special cables. In addition to the production space, the new plant includes 15,000 sq ft on three floors that is dedicated to offices and

An inside view of Niehoff’s new facility in Schwabach, Germany. auxiliary rooms. The 40-ft-high production areas and the office and other rooms all have radiant heat ceilings and airconditioning systems as well as a sensor-controlled natural lighting system, it said. The building was designed with an efficient process flow that includes the assembly department, a cutting-edge paint shop, a test rig and testing area, the packing and shipping department, offices, recreation rooms, building services and training workshops for Niehoff apprentices. The building makes use of “low-energy standards,” and features the latest in plant design, building management technology, and energy efficiency. “The investment in the new factory and its equipment gives Niehoff one of the vital assets it needs to maintain its technology leadership position,” the release said. It added that, based on future business conditions, a second building phase could see the addition of another 80,000 sq ft of production area.

Leoni acquires both an order and a plant in Romania to produce it Germany’s Leoni AG reported that it has been awarded a wiring harness contract that it will produce at a plant that it acquired from AEES Power Systems Group, which as part of a restructuring to its European businesses divested the operation in northwestern Romania. A press release explained that the order and the plant acquisition were both related to consolidation by AEES Power Systems, which is a supplier to the automotive industry. “In connection with that restructuring, Leoni was asked to continue with the supply of cable harnesses for batteries and chassis to two truck manufacturers. For this purpose

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

10 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

Leoni has acquired the manufacturing assets and taken over 375 employees. The company was therefore able to secure production and delivery without any interruption for the customers out of the existing plant in Beiu starting April 1.” With the new project, Leoni has increased its market share in the commercial vehicles harness business, which has recently begun to recover after a deep slump in 2009, the release said. “We are very pleased that we thus were able to ensure undisrupted supply of these absolute vital parts to two very important clients,” said Uwe H. Lamann, a member of the Executive Board responsible for Leoni’s Wiring Systems Division.

Nexans reports winning a major underground cable contract in Dubai Nexans reports that it has been awarded a 90 million euro turnkey contract from DEWA (Dubai Electricity and Water Authority) to construct Dubai’s first Extra-High-Voltage (EHV) underground cable system operating at 400 kV. The project, a press release said, will play a key role in DEWA’s plans to upgrade its power transmission infrastructure to meet the constantly increasing demand for electrical power created by the rapid expansion of Dubai Emirate. DEWA is currently constructing a new 400/132 kV substation at Mamzar Beach. The Nexans project, it said, will link this substation to two existing high-voltage substations at Mushriff and Nahda with several km of 400 kV XLPE cable circuits installed below the streets of Dubai in specially constructed concrete tunnels, complete with ventilation and fire protection systems. The turnkey contract includes the supply and installation of around 60 km of 400 kV XLPE cable and associated accessories, as well as the construction of the underground cable tunnels. The 400 kV XLPE cable, to be manufactured by the Nexans facility in Charleroi, Belgium, will feature a 2500 sq mm conductor with enamelled copper wire, the release said. The contract is scheduled for completion within 18 months. In other news, Nexans reported that it has completed an offshore cable contract for the conversion of ESPIRITO SANTO FPSO, a Floating Production Storage and Offloading vessel serving the BC-10 deep water field development in the Campos Basin offshore Brazil. Working under a tight delivery schedule, the Nexans factory in Lyon (France) manufactured over 500 km of specialized halogenfree, fire-safe offshore cable for the FPSO conversion project carried out by SBM Offshore in Singapore. The cables included high-voltage 12/20kV rated power cables as well as low-voltage power, control and instrumentation cables designed specifically to SBM Offshore’s requirements. It added that the company has also secured a new contract to supply the cables for the Jubarte FPSO, which will serve the BC-57 deep water field development, also in the Campos Basin. Those cables will be supplied by the Nexans Ficap manufacturing facility in Brazil.

JUNE 2010 | 11

INDUSTRY NEWS

U.S. wind farm project gets fed okay

face of the water. The base of the wind turbine towers will be 16 feet in diameter. Cape Wind will be rated to produce up to 468 megawatts of wind power as each wind turbine will produce up to 3.6 megawatts. Maximum expected production will be 454 megawatts. Average expected production will be 170 megawatts, which is almost 75% of the 230 megawatt average electricity demand for Cape Cod and the Islands of Martha’s Vineyard and Nantucket. Cape Wind will be 5.2 miles from Point Gammon, a private island in South Yarmouth; 5.6 miles from Cotuit; and 6.5 miles from Craigville

It was a lengthy battle, but a plan to establish a wind farm (Cape Wind) in Nantucket Sound off the coast of Massachusetts has gotten federal approval from U.S. Secretary of the Interior Ken Salazar, marking the first such offshore project in the U.S. “Secretary Salazar’s decision to approve Cape Wind has launched the American offshore wind industry,” said Cape Wind President Jim Gordon, whose organization has fought a nearly decade-long battle for approval. “Going first is never easy and Cape Wind is proud of the role we played in raising awareness for what will become a major component of our energy future and in helping the United States develop a regulatory framework for this new exciting industry.” Cape Wind is a project being developed by Energy Management Inc. (EMI), a Massachusetts-based energy company. It will be located in a shallow area of water toward the center of Nantucket Sound called Horseshoe Shoal, which has strong, consistent winds; is located in protected shallow water; has close proximity to landfall and electrical interconnections; and is out of way of shipping lanes and commercial boating traffic. “What enabled Cape Wind to reach this crucial milestone is the steadfast support A projected view of what the Cape Wind project will look like from one of leading environmental, labor, health and of the nearest land points, Craigville, a distance of about 6.5 miles. trade organizations and the support of the One objection to the project was that the wind farm would ruin the overwhelming majority of Massachusetts citi- aesthetic beauty of the area. The project developers note that the wind zens who have repeatedly made their voices turbines will not be noticeable more than a half-inch above the horizon. heard,” Gordon said. “While this project was Image courtesy of Cape Wind. exhaustively analyzed and debated and even with Federal and State approvals demonstrating the significant environmental and economic benefits of Cape Wind, we recognize Beach on Cape Cod. Cape Wind will be 9.3 miles there are some local opponents who disagree with from Oak Bluffs and 13.8 miles from the town of Secretary Salazar’s decision. We appreciate their involveNantucket. Cape Wind will be farther away from the ment in helping to shape the project and we now reach nearest home than any other electricity generation facility out to ask them to join the community and country in in Massachusetts. From the closest beach on Cape Cod, ushering in a new era of environmental stewardship, in clear conditions, the wind turbines will appear one energy security and prosperity.” The goal, Gordon said, half-inch above the horizon. is to begin construction before the end of the year. Aside from the location of the wind farm, one objection Per the company, the project calls for some 130 offto the project has been the cost for the electricity it genershore wind turbines to be placed at the wind farm, which ates. A recently signed contract calls for National Grid, would provide most of the electricity used on Cape Cod a local power provider, to pay 20.7 cents a kilowatt hour and the Islands. The wind turbines will be arrayed in a for 50 percent of Cape Wind’s energy when it first comes grid pattern of parallel rows. Within a row, the wind turonline in 2013. That price would increase by about 3.5 bines will be .34 nautical miles apart (about 6 football percent a year for 15 years. The price, which includes a fields); the rows will be .54 nautical miles apart (about state-mandated renewable energy subsidy of 6.1 cents nine football fields). per kilowatt hour, is well above the current market price The towers, from the surface of the water to the center for electricity from conventional power sources. National of the blades, will be 258 feet tall. The lowest blade tip Grid currently pays 8.11 cents per kilowatt hour for the height will be 75 feet above the surface of the water and power alone, not counting distribution or transmission the highest blade tip height will be 440 feet above the surcharges, according to the company’s website.

12 | WIRE JOURNAL INTERNATIONAL

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INDUSTRY NEWS

McDermott subsidiary reports a project first in Asia Pacific market U.S.-based McDermott International, Inc. notes that its J. Ray McDermott, S.A. (J. Ray) subsidiary has been awarded its first Subsea Infrastructure, Umbilicals, Risers & Flowlines (SURF) project in the Asia Pacific market.

J. Ray will supply PetroVietnam Exploration & Production with new production and export lines, and the umbilical and subsea cable, including the engineering and installation, a press release said. The project, the release said, includes tie-in, testing and pre-commissioning of two 2.2 km flexible flowlines, replacement of two 2.3 km export flowlines and umbilical, installation of a subsea cable and 4.8 km of insulated flexible flowlines.

Broken Wire & Spool Monitoring B M System for Cabling Machines M Fail F ail S Safe afe ssystem ystem ffor or d detecting etecting w wire ire b breaks reaks b before efore tthe he fforming orming d die. ie. NO NO SLIP SLIP R RINGS INGS • • • • • • •

Ena b le / disable Enable di sa ble by by position position Operator O p e ra t or safety saf et y override override Alarm A larm o on n wire w i re break break Alarm A larm o on n low l o w diameter diameter S po o l diameter di a me te r feedback feedback Spool Left L eft o orr right r i gh t hand h a nd rotation rotation Configured C o nf ig u r ed to to customer cu sto mer requirements requirements

4GƀGEVKXG UGIOGPVU OQWPVGF VQ VJG V URKPURKPdle brake disk act as a target for fo or optical position sensors mounted outside outs side the machine’s rotation

• HMI touch screen operator int interface terface • Siemens hardware platform

The system can be custom engineered for most rigid frame and planetary cabling a machinery with any num number mber of spool positions

BW701 BROKEN BRO OKEN STRAND DETECTOR DETECT TOR for Stranding Strandin ng & Bunching Machines Machin nes BW701 Strand Stra and Detection System detects missing co conductors onductors or strands cting die. The machine operator sets the he expected number at the collec collecting th o the detector control interface. The opt tical sensor continu of strands on optical continu-count ously counts countts the strands each revolution. If the co ount is less than the setting, the detection system stops the machine and alerts the the operator with highly visible 30mm LED indicator indicattor lights.

Strand input setting 1-99

Product Fea Features: atures: • Effectivelyy detects any material type of any color • Digital display disp play provides feedback with codes for m monitoring onitoring u up p tto o3a additional dditional ssensors ensors a and nd sstrand trand ccount ount Ŗ 'CUKN[ TGVTQ TGVTQſV QſV VQ GZKUVKPI GSWKROGPV • Compact operator o Interface (9 x 6 x 3 inches) • Internal relay relay y connects to existing g stop p circuit • Universal supply s voltage (100-240VAC 50/60 Hz) • Separate on/off o control • Highly visi visible ble LED indicator lamps

Laser Sensor Assembly Effective E with any color strand o bare conductor. Simple to or install. Requires no adjustment after initial set-up.

Yield Y ield M Management anagement C Corporation orporation Tel: +1 (413 (413)-283-7773 )-283-7773 Fax: +1 (413)-283(413)-283-7778 -7778 E: bbrow bbrown@yieldmanagementcorp.com wn@yieldmanagementcorp.com m www.yieldmanagementcorp.com www w.yieldmanagementcorp.com

14 | WIRE JOURNAL INTERNATIONAL

KEIR Manufacturing buys the wire products business of Kamatics U.S.-based KEIR Manufacturing, Inc., reports that it has completed the acquisition of the wire products business unit of Kamatics Corporation, a Kaman company. A press release said that wire products production will be relocated from the Kamatics plant in Bloomfield, Connecticut, to the KEIR facility in Brevard, North Carolina. The purchase includes only the assets and intellectual property of the Kamatics wire products business unit. Kamatics designs and manufactures composite flyer bows for efficient stranding and bunching of wire. At Interwire 2005, Kamatics introduced the BackBone® flyer bow design with improved strength, efficiency and productivity. “The Kamatics composite flyer bow acquisition combines two highly regarded manufacturers with brand name recognition into one company,” KEIR President David Watkins said in the release. “This expansion is consistent with our belief in building strong business relationships and greatly broadens our state-of-the-art technical product offering,” Watkins said. “KEIR has been a leader in new product development and innovation (and) the Kamatics wire products line is a natural fit. The industry can expect good things to come from KEIR.” KEIR supplies engineered technical ceramic products that for the wire and cable industry include ceramic guides and the Frontiersman™ line of air wipes. The company notes that it currently has more than 1,500 customers in 18 countries.

www.mademreels.com | sales@mademreels.com Manufacturing Plants: BRAZIL | SPAIN | ROMENIA | BAHRAIN

INDUSTRY NEWS

EU extends duties for Chinese products Citing apparent attempts to evade EU import tariffs by shipping steel ropes and cable through South Korea, the European Union has extended definitive antidumping duties on those products. Steel Orbis reported that The European Union (EU) has extended the antidumping (AD) duty on imports of steel ropes and cables originating from China to products shipped through South Korea following an anti-circumvention investigation. It said that the European Commission (EC) imposed duties up to 60.4 percent on steel ropes and cables

originating from China since 1999 through EC Regulation No. 1858/2005. In a notice published in the EU’s Official Gazette, the EU’s executive body said, “It was concluded that the definitive antidumping duty imposed on imports of SWR (steel wire rope) originating in China was circumvented by transhipment via the Republic of Korea.” Reuters reported that while imports of the product from China fell almost to zero after it imposed the duties in 1999, total annual imports from South Korea had increased between 1999 and 2008 from 11,123 metric tons to 48,214 metric tons. Europa reported that the European Anti-Fraud Office (OLAF) discussed the situation at a recent seminar hosted by the Dubai Chamber of Commerce and Industry (DCCI) and believes that such evasion efforts must be addressed. “European Union antidumping duties are levied in order to protect European companies from unfair competition. Evading them harms the EU economy and EU taxpayers,” said OLAF Director General Franz-Hermann Brüner, adding that international cooperation “is an essential tool in the fight against this type of fraud.” The Europa story notes that a recent joint OLAF-UAE investigation focused on alleged fraudulent supplies of Chinese steel wire ropes via Dubai to Spain in the European Community. “The European importer falsely declared the goods as UAE-product. ... The evidence collected by OLAF in the joint investigation in the UAE enabled the Spanish authorities to recover several million euros of import duties.”

Fushi Copperweld ups production of copperclad steel wire in Asia China’s Fushi Copperweld Inc., a global manufacturer of copperclad bimetallic wire, reports that it has completed the expansion of its Dalian facility to produce an additional 8,200 metric tons of production capacity per year for its patented Copperweld® copperclad steel (CCS) wire. A report in PR Newswire said that the expanded production

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marks the completion of the final stage of a three-phase capacity relocation project from its U.S. facility in Fayetteville, Tennessee, that resulted in 20,200 additional metric tons of annualized copper-clad aluminum (CCA) and CCS capacity coming online to its Dalian facility (Fushi International Bimetallic Cable Co. Ltd.). “The completion of this major expansion of our production capabilities marks an important step forward in optimizing our Dalian plant to meet our customers’ demands for quality and response time,” said Joe Longever, co-CEO of Fushi Copperweld. “The new Copperweld® production lines, which utilize our industry-leading proprietary cladding technologies, signify the first large-scale production of copperclad steel not only within China, but in all of Asia,” Longever said. The change “will better enable us to serve additional worldwide growth sectors, such as transportation, electric utility, and telecom industries.” The additional CCS production capacity increases Fushi Copperweld’s total annual wire and cable production at its Dalian factory to 48,200 metric tons, nearly double the plant’s previous capacity, the report said.

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ITC: rod order continues The U.S. International Trade Commission (ITC) has decided to continue an existing antidumping order on stainless steel wire rod from five countries. The ITC found that ending the order would likely to lead to continuation or recurrence of material injury within a reasonably foreseeable time, Steel Orbis reported. As a result of the ITC’s affirmative determinations, the existing orders on imports of this product from Italy, Japan, Korea, Spain and Taiwan will remain in place, it said. The action comes under the five year review process required by the Uruguay Round Agreements Act.

News in brief RAD-CON, a U.S.-based supplier of industrial furnaces, has been honored with the coveted Presidential “E” Award for sustained excellence in exporting. The Presidential “E” Awards are the highest U.S. government honor for growing U.S. exports, strengthening the economy and creating American jobs. Secretary of Commerce Gary Locke presented RADCON with the award at a ceremony held May 13 at the U.S. Department of Commerce in Washington, D.C. Pictured

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CON vice president, sales and projects) and Gary Locke (Secretary of Commerce). â&#x20AC;&#x153;I want to congratulate you on your achievement, and for supporting critical export-related jobs for American workers,â&#x20AC;? Locke told the recipients. â&#x20AC;&#x153;President Obamaâ&#x20AC;&#x2122;s National Export Initiative was designed with one overriding goal: to get people back to work in jobs that provide security, dignity, and a sense of hope for the future. It is businesses like yours with a proven record of success that are going to help us meet or exceed that goal.â&#x20AC;? A total of 22 companies received the â&#x20AC;&#x153;Eâ&#x20AC;? banner this year.

C&M Corporation, a custom builder of bulk cable, coil cords, and cable assemblies, has announced the appointment of J.R. Jordan Sales as their representatives in the Southeast, covering Georgia, Alabama, Tennessee, and the Carolinas. Jim Jordan, the owner of firm, brings over 20 years of experience in the wire and cable and power supply cord industry with focus in the wiring harness, lighting, and telecom marketplaces. C&M is headquartered in Wauregan, Connecticut, and offers manufacturing options in the U.S., Mexico, and China. â&#x20AC;Ś U.S.-based CommScope, a global leader in infrastructure solutions for communications networks, reports that it has added its 100th customer location to CommScope Advantage Inventory ManagementÂŽ

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(AIM) 2.0, a CommScope-managed, automated inventory management program offered to broadband cable customers that helps them run efficient distribution centers and other warehouse facilities. The program enables cable operators to increase inventory turns, improve operational efficiency and ensure adequate stock. â&#x20AC;&#x153;We estimate that the AIM program has resulted in approximately $10 million in combined cash flow savings for our customers at their participating locations,â&#x20AC;? said Ric Johnsen, senior vice president, CommScope Broadband Solutions. â&#x20AC;Ś U.S.-based Seco/ Warwick reports that it will provide a muffle-type wire annealing furnace to ESAB Welding & Cuttingâ&#x20AC;&#x2122;s plant in Hanover, Pennsylvania, USA. The system, it said, will be designed to process stainless steel wire, and will include state-of-the-art safety features and updated ceramic insulation system to reduce energy costs. Seco/ Warwick will provide the furnace design, manufacture and installation. â&#x20AC;Ś Tyco International Ltd. announced that it plans to pursue a tax-free spin-off of its Electrical & Metal Products business that it

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would like to see completed in the first half of fiscal 2011. “Electrical & Metal Products is a high-quality business with well-recognized brands, a strong management team and an outstanding reputation in its markets,” said Tyco Chairman and CEO Ed Breen. The Electrical & Metal Products business designs, manufactures and sells galvanized steel tubes and pipes, electrical conduit, armored wire and cable, and more. … LaserLinc conducted a three-day technical training seminar at its Fairborn, Ohio headquarters for local,

Attendees at LaserLinc’s three day technical seminar. national, and international sales and support personnel. The sessions focused on powerful new software features such as Fast Fourier Transform (FFT), Structural Return Loss (SRL),

20 | WIRE JOURNAL INTERNATIONAL

and Excel-based reporting, as well as new wall thickness and OD measurement equipment. Pictured are: Back row, left to right: Peter Zafiro, Joel Kenyon, Earl Seagrave, Jim Beard, Don Gruber, Joshua Lansford, Kurt Andrews, Dale Christopher, Doug Gardner, Jeff Kohler, Dan Dixon; Front row: John Mumaw, Jack Weiss, Tom Shoup, Chris Van Auken, Marc Waldron, Paul Miller, Mark Mugavero, Susan Murphy, Connie Lee, Robert Wexler. … U.S.-based Delphi was honored with the Premier Automotive Suppliers’ Contribution to Excellence (PACE) Award from Automotive News during the 16th annual awards ceremony in Detroit. “It is a great honor for Delphi to win two of the industry’s most prestigious awards for innovation,” said Andrew Brown Jr., Ph.D., Delphi executive director and chief technologist. Delphi won for its Multimode Electronically Scanning Radar and its Direct Acting Piezo Injector, in which the fuel injector needle is directly activated by the Piezo stack, eliminating the hydraulic circuit and its associated lag and energy consumption. The company was also honored with a finalist award for its halogen-free cable. ■

ASIAN FOCUS

ASIAN FOCUS A wireless link can be seen in 2 stories of broadband service in Asia Two separate stories, one in India and the other in China, highlight the potential role that wireless may have in meeting broadband demand. In both instances, the need for broadband was not the issue, but the reasons for favoring wireless technology suggests that landline wiring may find limitations in emerging countries. In India, wire reports say that the Department of Telecom (DoT) is now considering building wireless networks as part of its plans to bring internet to the masses. “This is in total contrast with its earlier plan to lay a 5 lakh km optic fiber cable (OFC) network using resources from the Universal Service Obligation Fund (USOF) to improve broadband penetration in the country. That plan had derived from an interministerial committee from six ministries in addition to the A wireless router. Planning Commission,” one report said. A story in the Economic Times said that the DoT has pointed out three disadvantages with building the abovecited OFC-based network for broadband. It said that laying optical fiber cable may take more than a decade to complete; that the broadband access spectrum was being auctioned in the upcoming airwaves sale process and rollout of services on this platform could not wait for OFC to be laid; and that OFC costs more and lacks the speed of deployment and feasibility available on wireless. The article cited the DoT as finding, “Wireless is an intelligent pipe stream. Bandwidth allocation can be apportioned among different uses dynamically and can be varied as per changing demand at a nominal cost. Contrary to this, OFC is a dumb pipe and managing OFC is very expensive. Wireless backhaul would be quicker and faster in deployment, reliable and easy to maintain. It will be scaleable at low costs when demands initially are perceived to be low.” The Telecom Regulatory Authority of India (TRAI) noted that as of January 2010, India had only about 8 million broadband users compared to 546 million mobile users, the article said. “While mobile growth has exceeded all targets and projections, the country is unlikely to even achieve 50 percent of its target of having 20 million broadband connections by 2010-end. Meanwhile, successful bidders for the broadband wireless spectrum are expected to immediately launch services providing the much needed thrust to increase broadband penetration. In fact, the DoT too has estimated

that with three WiMAX operators, it could provide 300 Mbps data connectivity which could accommodate 12,000 subscribers with 256 Kbps minimum speed or 1,500 subscribers with 2 Mbps speed.” A second article, in China Daily, highlighted plans by major telecom companies in Beijing to raise the speed of their Internet services, with China Unicom aiming to top 20 Megabytes per second (Mbps) before the end of 2012. It notes that there currently are four major Internet service providers in Beijing: China Unicom, China Telecom, China Mobile and Gehua CATV Network, and that most of their customers use Internet services at speeds of 1-2 Mbps. (China Mobile notes that its 500,000 base stations for wireless now cover 98% of the population, but that service at this time is not sufficient for mobile Internet use.) What is not in question is the demand to increase Internet speeds. China Telecom notes that it wants to increase speeds to above 4Mbps around the country before the end of 2010, and up to 20 Mbps in some high-profile cities, such as Beijing and Shanghai, in newly built communities. The company, the article said, has invested about US$2.4 billion for renovating existing copper cables and laying optical fiber alternatives since 2008. Despite progress, the article said that China’s Internet connection speeds are dragging behind neighboring counties. It cited Wu Hequan, vice-president of the Chinese Academy of Engineering, as saying at the China Internet Conference 2009 that “China’s average bit transfer rate was only 1.8Mbps, less than one-10th of South Korea’s and 50 times slower than Japan.” The article said that most Chinese cities have the infrastructure in place to provide Internet speeds of 4 Mbps, with large cities like Beijing and Shanghai capable of 100 Mbps after an optical fiber project is completed in one or two years. That service is much better than similar copper wire systems, but the costs for fiber optics is too high for some customers, it said. China Unicom, the article said, charges about US$350 a year for a 4 Mbps Internet connection, but nearly double that for an 8 Mbps connection, it said. The result is that some existing systems are too old to upgrade and some customers want but cannot afford a higher level service, all of which makes wireless a more attractive option, especially if 4G technology is able to overcome problems with lost connections. Further, improvements in wireless continue at a high rate, all of which makes the outlook brighter for more wireless use.

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

22 | WIRE JOURNAL INTERNATIONAL

DPI starts cable trials at new plant Diamond Power Infrastructure (formerly Diamond Cables), an Indian supplier of power transmission and distribution technology, announced that it plans to manufacture low tension (LT) and high tension (HT) cables at its new unit in Village Vadadala, Taluka Savli, District Vadodara. The company’s existing HT cables capacity of 2,800 km a year will increase to 5,600 km while the company’s LT cable capacity “will take a quantum jump” to 33,800 km a yearfrom 25,000 km. The company has invested in ongoing expansion projects of HT and LT cables. At 100 per cent capacity, the estimated sales of the company’s expanded HT and LT cables plant is expected to generate sales of over Rs 950 crore. The company’s expansion projects for manufacture of extra-high voltage cables is in an advanced stage of commissioning and was expected to have started production this month and a 48,000 MT tower project was also scheduled to have been commissioned.

CADIVI supplies electric wire to Spratly Islands Vietnam’s CADIVI reports at its website that it has supplied electric wire and cables worth about US$430 million ND for the 2nd stage of fresh power projects on Spratly

Islands. Per Wikipedia, the Spratly Islands are a group of more than 750 reefs, islets, atolls, cays and islands in the South China Sea between the Philippines, Malaysia, Brunei, Vietnam and China. The products were CVV, CXV/SWA with nominal areas from 6 to 25 sq mm at the total length of 114,820 meters and they will be installed on the Namyit, Sin Cowe, Sand Cay Islands, Electrical wire made by CADIVI. South Reef and Petley Reef. Vietnam Electric Cable Corporation, formerly named Vietnam Electric Wire & Cable Corp. (CADIVI) is part of Vietnam Electrical Equipment Corporation, an enterprise under the Ministry of Industry and Trade. It specilizes in producing various kinds of electric wires and cables to supply in National Economy as well as daily consumption of electric power and for export. ■

JUNE 2010 | 23

ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE Corporation is a global producer of copper, aluminum and fiber optic wire and cable products for the energy, industrial, specialty and communications markets.

Brian E. Moriarty has been promoted to vice president, U.S. sales, for General Cable Corporation, reporting to Gregory J. Lampert, executive vice president and president and CEO, General Cable North America. In addition to leading efforts in maximizing sales opportunities in existing markets and identifying and driving growth Brian E. Moriarty in new markets, he will focus on strategic customer partnerships. He has more than 17 years of experience in sales leadership, the last two leading General Cable’s Specialty Sales and Global Oil & Gas Sales Teams. He began his sales career with the Stanley Works in 1993, rising through the ranks with several assignments throughout the U.S. In 1998, he moved to Krone/ADC Telecommunications where he held several sales management positions, which culminated with him assuming overall responsibility for their North American Enterprise Sales. He holds a B.S. degree in management from St. Louis University. Based in Highland Heights, Kentucky, USA, General Cable

Jay Luis has been named marketing manager, worldwide, for Beta LaserMike, responsible for developing and implementing the marketing strategies to drive demand generation, revenue growth and brand development across the U.S., European and Asian markets. He has more than 19 years of international marketing experience. Most recently he was vice president of marketing at Seapine Software, a leading provider of application lifecycle management solutions, where he led a global marketing organization. Previously, he Jay Luis held the director of marketing communications position at Barco, and prior to that he served as partner and vice president at OIA Marketing Communications. He holds an Associate of Science degree in electronic engineering from Sinclair College, a B.S. degree in physical science from Capital

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University, and has attended the University of Dayton, School of Law. Based in Dayton, Ohio, USA, Beta LaserMike is a global supplier of precision measurement and control systems for a wide range of non-contact measurement applications, including wire and cable. Hitachi Cable Manchester (HCM) announced that Ed Ratti has joined the company in the newly formed position of federal sales manager. He has more than 30 years of industry experience, holding such positions as vice president of sales for Teledyne/CommScope and regional positions with ADC Corporation. Most recently, he was a partner for over six years for a rep group, ANPG, covering the Maryland, Virginia and Washington, D.C. territory. A Vietnam veteran, he will be responsible for building HCM’s relationships with various government agencies and the military branches of the United States. The company also named John Joyce as its new central regional manager. He has 20 years of experience in sales, marketing and business development across a diverse range of technology and distribution companies, including as vice president of sales for Convia Corporation and 14 years before that with Hubbell Premise Wiring, where he covered a 17-state territory. In his new role, he will be responsible for the management of six rep firms, which include 15 states along with Canada. He will also assume the responsibilities as the national account manager for strategic distributors within his territory. Based in Manchester, New Hampshire, USA, Hitachi Cable Manchester, a business of Japan’s Hitachi, manufactures high-performance copper and fiber optic communication cables. Draka Cableteq USA has named Gerry King as its national sales manager-Canada, responsible for the fire protection, downhole reservoir management, industrial, utility and water markets for Canada. With offices based in Brantford, Ontario, he will be accountable for developing enduser relationships and working with a network of distributors to serve multiGerry King ple market needs. He has more than 20 years of wire and cable experience and has a deep understanding of Draka Cableteq’s specific markets. Part of Draka Holding NV, Draka Cableteq notes that it is North America’s largest manufacturer of custom, engineered cables for specialty applications. Gerdau Ameristeel Corp. said that Terry Sutter, vice president and COO, has left the company for personal reasons. No further details were provided. Tampa Bay Business Journal reported that Sutter was named vice president and COO in June 2007. ■

JUNE 2010 | 25

FIBER WATCH

FIBER WATCH Japan’s NTT achieves record signal transmission over single optical fiber ... Japan’s NTT was able to achieve 69.1 Tb/s transmission by applying wavelength division multiplex (WDM) of 432 wavelengths with a capacity of 171 Gb/s over a 130mile long cable. The terabit optical transmission was the highest ever recorded in the transmission field, and will prove beneficial in the construction of high-capacity optical backbones for the future, a press release said. In NTT’s experimental setup, a 171Gb/s signal per wavelength is generated by the combination of the 16 QAM format (quadrature amplitude modulation) with polarization division multiplexing in the transmitter. The 16 QAM signal is generated by combining two QPSK (quadrature phaseshift keying) signals with an amplitude ratio of 2:1 in the QAM modulator. Four hundred and thirty optical signals from 1527 to 1620 nm with a wavelength spacing of 25 GHz are multiplexed to generate a 69.1 Tb/s signal. What does all of the above mean? Consider that the smallest unit of measuring data is an octet, which is eight Records may be impressive, but bits. A bit is a binaespecially for electronic ones they ry digit of either 1 quickly become old news. In 2006, or 0. a team led by Prof. Hans-Georg • 8 bits = 1 byte. Weber in Germany transmitted a • 1000 bytes = 1 data signal at 2.56 terabits per sec- megabyte (MB). In ond over a 160-kilometer link, the the late 1980s, a equivalent of the contents of 60 home computer DVDs. Japan’s NTT recordhas might have a single blasted that performance more hard drive with a than 25-fold. capacity of 20 MB. This is also the size of a decent (but not excessively large) digital photo today. • 1024 MB = 1 gigabyte (GB). As home computer got more powerful, computers were sold with average capacity in the hundreds of GB. If you use an e-reader, a typical e-book may be about 1 MB. A 32 gigabyte reader could thus (theoretically) store 32,768 books. • 1024 GB = 1 terabyte. A 1 terabyte hard drive could store 250,000 4 MB digital photos. It also holds the same amount

26 | WIRE JOURNAL INTERNATIONAL

of information as 6-1/2 netbook computers with 160-gig hard drives. Looking forward, as one must do with technology, it is unlikely that the terabyte marks the end, and indeed, there is already the “next generation” on the sidelines waiting to be called. • 1024 terabytes = 1 petabyte. A future generation will surely find applications to test these heady electronic waters. In the release, NTT said that data traffic on optical networks is increasing rapidly because high-volume content such as a high definition image is now frequently transmitted over the Internet. NTT Labs is researching and developing future optical backbone networks to cope with the rapidly increasing data traffic, with which the data will be accommodated efficiently, and high-capacity, long-distance transmission will be realized.

...but copper cabling manufacturers are not planning to quietly fade away While optical fiber continues to reach ever-more impressive electronic heights, Alcatel-Lucent reported in April that its research arm, Bell Labs, has successfully demonstrated a technology that boosts the transmission speeds achievable over just two digital subscriber lines (DSL). In a lab test of “DSL Phantom Mode,” Bell Labs achieved downstream transmission speeds of 300 Megabits per second (Mbps) over distances up to 400 meters (or 100 Mbps at 1 km), a press release said. “At these speeds, service providers will be able to maximize the ability of the existing copper infrastructure—widely deployed around the world—to satisfy demand for bandwidth-intense residential triple-play and business services, for years to come.” At its core, the release said, DSL Phantom Mode involves the creation of a virtual or “phantom” channel that supplements the two physical wires that are the standard configuration for copper transmission lines. Bell Labs’ innovation and the source of DSL Phantom Mode’s dramatic increase in transmission capacity lies in its application of analogue phantom mode technology in combination with industrystandard techniques: vectoring that eliminates interference or “crosstalk” between copper wires, and bonding that makes it possible to take individual lines and aggregate them, it said. “Alcatel-Lucent Bell Labs’ DSL Phantom Mode lab test adds a whole new dimension to the ongoing ‘100 Mbps for all’ debate, the release said. The fact that existing copper loops can facilitate 300 Mbps at 400 meters reshapes the whole next-generation broadband competitive environment—and will open up a wide range of new business opportunities for ‘traditional’ DSL players, it said. ■

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FASTENER UPDATE

FASTENER UPDATE Oak Hill to acquire Hillman The Hillman Companies, Inc., announced that it has agreed to be acquired by Oak Hill Capital Partners, a private equity firm, for approximately $815 million. A press release said that the purchase of Hillman is through its owners, Ontario Teachers’ Pension Plan and certain members of company management, and added that the deal “is in partnership with Hillman’s current management team, led by CEO Mick Hillman.” Based in Cincinnati, Ohio, USA and founded in 1964, The Hillman Group is a value-added distributor of more than 60,000 SKUs, consisting of fasteners, key duplication systems, engraved tags and related hardware items to over 20,000 retail customers in the U.S., Canada, Mexico and South America. At its website, Hillman notes that it has 12 distribution/manufacturing facilities located throughout the U.S., Canada and Mexico. Those combined facilities can accommodate more than 5,000 orders and 225,000 lines per day. Hillman employs more than 1,700 individuals across the nation, and its sales/service organization numbers more than 700 people, including sales personnel, field representatives and managers. “We are extremely pleased to partner with Oak Hill Capital,” Hillman CEO Mick Hillman said in the release. “We believe Oak Hill Capital will be a value-added partner because they understand our company and the industry, and they believe in the growth opportunities for our business. (They have) a tremendous reputation and a long history of making successful investments in partnership with management.” The deal, which is subject to regulatory approvals and customary closing conditions, is expected to close in the second quarter of 2010.

Holo-Krome plans to expand focus U.S.-based Holo-Krome Fasteners, a domestic manufacturer of socket head fasteners for more than 80 years, reports that it plans to expand its manufacturing scope to include cold-headed specials for industries requiring “Made in the USA” products in critical applications. “With new ownership backing us, we now have more resources available to aggressively pursue growth opportunities,” Holo-Krome Director of Operations Tim Thompson said in a press release. “This will allow us to fill gaps in our current offering with new product categories and potentially new materials and continue to do it all right here in the U.S.” He added that the company’s goal is “to be not only the dominant supplier of domestic socket fasteners for industrial distributors but also the dominant supplier of special fasteners and a key supplier of military grade fasteners.” He noted that all Holo-Krome fasteners are DFARS certified, and that last October Holo-Krome qualified as a QSLM Class 2 provider of fasteners to the Defense Logistics Agency (DLA).

28 | WIRE JOURNAL INTERNATIONAL

“While other U.S. manufacturers are shutting down or moving operations offshore, we’re looking forward to growing the Holo-Krome brand with all of our distribution partners and taking our heritage of “Made in the USA” quality to a new level.,” said Holo-Krome National Sales Manager Charles LaBove.

Founded in 1929, Holo-Krome is a business of the Fastenal Group, which acquired it from Danaher Corporation in 2009. Holo-Krome notes that it was organized around what was a revolutionary idea at the time: the manufacture of socket screws by metal forming, or heading, rather than machining.

Report covers a range of global trends that could impact automotive fasteners BizAcumen Inc. reports that its report, “Automotive Fasteners: Global Trends,” looks at a range of factors that it says collectively represents important factors that are driving the field. In a press release, the company observed that automotive fasteners are important because of the increasingly complex nature of vehicular designs, which is expected to result in demand for even stronger, improved and durable fasteners. Technological improvements, it said, have played a critical role in transforming fasteners into multi-purpose highly engineered automotive components. Based on those needs, chemical fastening methods (including adhesives) and “snap-fit” or self-securing fastening solutions are emerging as popular choices, the release said. These and other market data and trends are presented in the report, which it said presents comprehensive geographic coverage and vertical market analyses. Chapters cover topics such as global production and specific major trends and issues, from lengthening warranty periods to changing requirements in fastener finishes. The report includes research methodology, a market overview, market trends and drivers, product facts, corporate developments, market estimates and forecasts by region, 20 market data table and graphs and more. The regional coverage, it said, includes the U.S., Canada, Japan, Europe, AsiaPacific, Latin America and Rest of World. Contact: BizAcumen, www.bizacumen.com. ■

WAI

NEWS

WAI NEWS

WAI Q&A This occasional section will discuss a topic of general interest involving WAI. This one is with WAI President Dane Armendariz. What has WAI learned since the India subsidiary was established in 2006? Armendariz: I was fortunate WAI President to be involved with this project Dane Armendariz early on, and I think the Association has learned a lot since it started. We entered with a broad agenda, understanding that India represents a large and rapidly developing market. Our goal was to figure out how our educational mission could best serve the countryâ&#x20AC;&#x2122;s industry. We were fortunate to have the India Chapter in place and a talented managing director on the ground to get us started.

Like other businesses, we also found that, while India offers much in potential, it is a challenging region, with a labyrinth of rules and regulations that are not so easy to understand at times, let alone comply with. India is also decidedly different from North America or Europe in that the industry is largely domestic in ownership and the markets served, with a lot of production taking place at the small company level. That is a positive, as it means there is a strong appetite for educational materials and industry information, but it also means that we have to be very good at both establishing contacts there and providing value. What is WAIâ&#x20AC;&#x2122;s current objective with regard to the operation in India? Armendariz: Our goal at this time is to be a valued source for industry information and education in this expansive market. The key to that is our newly redesigned and expanded quarterly publication, Wire Bulletin, which is written and published in India for the

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30 | WIRE JOURNAL INTERNATIONAL

What will be next for WAI? Armendariz: It’s hard to say now what might be next, but the immediate goal is to expand Wire Bulletin in terms of readership and frequency. We will continue to produce educational programs in India and, over time, we hope to add more members. Much like the early days of WAI, which is now 80 years in evolution, we want to see a steady increase in activity. This project started out as a concept and to a degree it’s been an education for us as

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WAI NEWS

Indian industry. Our new editor, Huned Contractor, has done a good job of getting to know the industry and ensuring that Wire Bulletin works. This is an extraordinary vehicle for helping us in India. We believe that it is the first publication in the country that is totally dedicated to the wire and cable industry, and we feel confident that it won’t take but another year or so for our qualified circulation in India to number in the thousands. Huned was at wire Düsseldorf, where he got to experience the scope of the industry and meet dozens of Indian exhibitors as well as some exhibitors outside India who are interested in getting better known there. He has decades of publishing experience and knows how to talk to people, which makes him a very strong asset for us.

WIRE BULLETIN Editor Huned Contractor displays his most recent issue to WJI Editor Mark Marselli at WAI’s booth at wire Düsseldorf. well, but I think we are definitely getting better at it. At our Board of Directors meeting in Milwaukee it was decided to begin evaluating other areas we should consider placing an office to serve the global market. Hopefully, there will be more to report on this in a future issue. ■

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Business Information (required) A. Which ONE of the following best describes your company’s type of business? WIRE & CABLE MANUFACTURING 10 ❏ Aluminum & Aluminum Alloys (Rod/Bar, Bare Wire, Both ) 20 ❏ Copper & Copper Alloys (Rod/Bar, Bare Wire, Both) 30 ❏ Steel & Steel Alloys (Rod/Bar, Bare Wire, Both) 40 ❏ Other Metal (Rod/Bar, Bare Wire, Both) 50 ❏ Electrical Wire & Cable (Insulated Wire) 53 ❏ Communications Wire & Cable (Insulated Wire) 55 ❏ Fiber Optics

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NOTE: All checks must be in U.S. Dollars drawn on a U.S. bank. Credit card payments are preferred for members from outside the U.S. and Canada. If a check or credit card is not used, a wire transfer may be sent in U.S. dollars. For instructions, contact the WAI Membership Department at membership@wirenet.org or by phone at (001) 203-453-2777. Your membership dues may be deductible as an ordinary and necessary business expense, not as a charitable contribution. Membership in The Wire Association International, Inc. is held by the individual, not the company, and is continuous unless cancelled in writing. Membership is not transferable. Dues are non-refundable and are billed annually based upon the member’s anniversary date. Annual dues are set by the WAI Board of Directors, and are subject to change.

June 2010 International Technical

Conference Proceedings

Dates set for 5 chapter golf tourneys Dates have been set for upcoming golf tournaments for WAI’s five U.S.-based chapters, all of which will offer a range of skills contests, a reception and dinner as well as superb networking opportunities. Each event also includes a range of sponsorships, from individual skills contests to the ever-elusive $10,000 hole-in-one. The first one up is the WAI’s Midwest Chapter, which will hold its 8th Annual Golf Tournament on Monday, June 21, at the St. Andrews Golf & Country Club in West Chicago, Illinois. For more details, contact Robert Sears, North America OMCG, at tel. 630-5619512, omcgtech@netzero.net. Next up is the Ohio Chapter, which will return Thursday, August 5, to the Grantwood Golf Course in Solon, Ohio, for its 8th Annual Golf Tournament. For more details,

Ohio Valley Tourney Chairman Mike Caranna, l, with the 2009 winning team (l-r) of Mike Swift, Vincent Griffin, Dave Simpson and Chris Winkel. contact either Rob Fulop, Wire Lab Co., at tel. 216362-0800, r.fulop@wirelab.com, or Michael Caranna, American Spring Wire Corp., at tel. 3216-292-4620, mcaranna@amspringwire.com. The action then goes to the Mount Pleasant Country Club in Boylston, Massachusetts, which will host the New England Chapter’s 16th annual golf tournament

on Thursday, September 16. Contact Mike McKee, Lloyd & Bouvier Inc., tel. 978-365-5700, mikem@lloydbouvier.com. The following month, the Southeast Chapter will return Thursday, October 14, to the Rock Barn Golf and Spa in Conover, North Carolina, which will host the chapter’s

The 2009 Southeast Chapter winners: CommScope’s Jason Morrow, Hefner Reels’ Scott Ferguson and Tulsa Power’s Tim McElhany. 9th Annual Golf Tournament. Contact Steve Vannais, Davis-Standard Corporation, tel. 704-799-2258, svannais@davis-standard.com. The final outing is for the Western Chapter, which is scheduled to return Monday, October 25, to the Los Verdes

The team of Paul McLaughlin of NEPTCO, center, and F. Camarena Inc.’s father-son duo of Fred Camarena Sr. and Fred Camarena Jr., proved victorious at the Western Chapter’s 9th annual Wild West Shootout in 2009.

The 2009 winning team (l-r) at the 15th Annual New England Chapter Golf Tournament: Mark Mathiasen, Pat Staffiere, Steve Navarette and Phil Dupuis.

Golf Course in Rancho Palos Verdes, California, for its 10th Annual Golf Tournament. Contact: Michael Howard, Coast Wire & Plastic Tech., tel. 310-639-9473, michael.howard@coastwire.com. ■

JUNE 2010 | 33

CHAPTER CORNER

FEATURE

wire Düsseldorf 2010 wrapup By the end of the week, there was little doubt that wire Düsseldorf had once again been the wire and cable industry’s stalwart event. The approximately 35,000 people the organizers report attended the 2010 staging of wire Düsseldorf did not set a record, but it was a very respectable showing, and given the state of the global economic situation, it was very strong indeed, enough to lend hope that there may be better times ahead. Speaking at a press conference during the event, Messe Düsseldorf Managing Director Joachim Schäfer highlighted the importance of the wire and tube events to their respective sectors. “Global contacts are formed and orders placed here for the years ahead. The trade fairs are therefore taking place at precisely the right time,” he said, noting that companies “are now investing again in order to get ready for future competition or to re-position themselves.” A post-event press release confirmed that a majority of

exhibitors from both wire 2010 and its sister event, Tube 2010, who responded to a survey, reported that the quality of the visitors had increased again and were pleased with their participation. “Overall, the attendees gave the products on exhibit top marks and rated their visit as successful,” it said. “The results showed that the positive mood among the 2,400 wire and tube exhibitors (compared to 2,200 exhibitors in 2008) and 69,200 visitors from over 100 countries was the result of constructive talks, avid purchasing interest and actual deals as well as optimistic post-show expectations which characterized the atmosphere at both trade fairs,” the release said. The exhibitors showcased the latest machinery, equipment and products from the wire, cable and tube processing industries on 1.07 million sq ft of net exhibit space, it said. By the numbers, wire 2010 fared quite well. A total of 1,219 companies from 52 countries presented their inno-

Large displays of equipment, such as at the Niehoff GmbH booth, drew a lot of attendee attention at wire 2010.

34 | WIRE JOURNAL INTERNATIONAL

Organizers report that the majority of exhibitors were pleased with attendee quality. vations on 559,700 sq ft of net exhibit space, an increase of 7.3% compared to the 2008 staging, the release said. From the U.S., 78 companies exhibited at wire 2010, including 30 companies within the North American Pavilion, organized by Messe Düsseldorf North America (MDNA) and sponsored by the Wire and Cable Industry Suppliers Association (WCISA). The overall view from exhibitors was favorable. “The stand was busy throughout the show, and the fair proved an excellent opportunity to meet clients and make new contacts,” said Pave Automation Managing Director Tony Perna, who said that his U.K.-based company had a lot of visitors from Europe and the Baltic states, as well as from India, who were looking to acquire reliable, high output, low-cost wire forming units for a variety of applications. “The event provided an ideal platform to showcase our innovative (technology) and we obtained some solid leads and requests for trial runs.”

Speaking at a press conference during wire 2010 were, from l-r: Markus Mohaupt, general manager, economics and research, IKB Deutsche Industriebank AG; FriedrichGeorg Kehrer, director wire 2010, and Joachim Schäfer, managing director of Messe Düsseldorf.

The 2010 staging of wire Düsseldorf will long be remembered for coming through as a good event in a down period, but it will also be recalled for the horrendous travel delays that were caused by a volcano in Iceland that chose a bad time to become active. The industry, which includes many veteran travelers, was cast into unfamiliar turf. Some people fled to Italy and Spain, where flights out were still possible, while others chose to wait it out in Düsseldorf. Uncertainty reigned and woe to those who did not have access to an Internet connection as well as a robust company credit card, because post-show travels proved to be vexing logistics-wise as well as expensive. Below are just a few of the many stories of attendees trying to head home. Glenn Davidson and Ed Bouffier, Fisk Alloy Thursday, April 15. Word of the volcanic ash begins to spread through Düsseldorf. Friday, April 16. We are officially notified our flight from Düsseldorf the next day was canceled. Our travel agent advises us to start heading south as the best option to fly home. We booked a return flight from Zurich on Monday, April 19. Ed Bouffier enjoying an alt Saturday, April 17. We during his extended stay in begin traveling south via Nuremberg. automobile to Nuremberg for a one-night pit stop. Later, we are notified our Zurich flight has been canceled. Our travel agent says she can book us on a flight from Rome back to Philadelphia on Wednesday, April 21 (Newark was original return point). Sunday, April 18. We attempt to travel by train from Nuremberg to Rome through Munich, but the trains are sold out for days. We enjoy a gorgeous day and another night in Nuremberg. Monday, April 19. Our European sales person, Mrs. Petra Panaget, drives us from Nuremberg to Innsbruck, Austria, a three- to four-hour drive. From there, we have to take two trains and get in Rome at 11 pm. Tuesday, April 20. Spend the day touring Rome. Wednesday, April 21. Finally fly home. Thursday, April 22. Back to work, and it seems like we were never gone! Patrico Murga, Viakable/The Cable Sector of Xignux Our Saturday flight from Düsseldorf to Madrid on Saturday morning was cancelled, but I heard that the

JUNE 2010 | 35

FEATURE

Düsseldorf escape: attendee accounts

FEATURE

(Escape from Düsseldorf cont’d.) Madrid airport was still open and my wife, Diana, and I could fly back to Mexico. I went to the train office but no seats were available for the next two days to Madrid. I called a friend, Willibert Dautzenberg from Queins, and he helped us get a rental car. We were joined by a German friend, Klaus Offermann, a former Queins employee who still works some trade shows for them. We decided to drive to Zurich (600 km) to catch a flight to Madrid. It took six plus hours to get there on Saturday night, just to learn that, as we were driving, that airport had also been closed. On Sunday morning, we heard that the Zurich airport would be closed to at least Monday, so we tried to get

The volcano made for some quick friends. From l-r during an on-the-road break are Klaus Offermann, Ignacio, Nicolas and Diana and Patrico Murga.

train tickets to Rome, hoping to catch a flight there to Madrid, but no tickets were available. While there, we met and teamed up with two men, Ignacio from Spain and Nicolas from Argentina, who also wanted to get there. The five of us were lucky enough to find a rental van and on Sunday at 2 pm we started the 1,100-km ride to Barcelona, and reached it at 2 am. We returned the van and said goodby to Nicolas and Ignacio. We slept for three hours and went to the Central Train Station in Barcelona. We took the fast train (AVE) to Madrid, a distance of about 650 km. This train runs at 300 km/hour and we soon reached Atocha, downtown Madrid train station. From there we made it to the Madrid airport, where we got seats on the Iberia flight that left at1 pm for Mexico City. Finally, we were heading back home.

Activity at the Karl Fuhr GmbH booth.

“The show was excellent for us. We had very little downtime,” said Al Kozlowski, Paramount Die Company. Equipment is the main attraction, and the July and September WJI issues will present systems that were on display, but there were many product introductions. Dow Wire & Cable showed its DOW ECOLIBRIUM™ biobased materials, a new family of phthalate-free plasticizers for insulation and jacketing that is made from nearly 100% renewable feedstocks. DuPont presented new fluoropolymer foam resins for enhanced wire and cable applications and renewably sourced and halogen-free materials for jacketing and insulation. WJI’s July Products section will include some products introduced at the show. As ever, there was plenty for attendees to see, and according to Messe Düsseldorf, people came from 70 countries, 63% from countries other than Germany, the release said. The majority of the visitors came from Great Britain, France, the U.S., Italy, India, the Netherlands and Spain as well as from Brazil, Turkey, Austria, Switzerland, Belgium and Poland. Visitors primarily represented the industry (81%) followed by trade (8%) and skilled crafts (3%). The visitors, the release said, were mainly interested in

Chris Messina, RAD-CON Standing around a table at the Uerige in the Altstadt on Monday night with a group of Americans, we sipped our beers and lamented about being stuck since the weekend. Our hope for a departure was dim, and this informal Robert Gent, AG Attachments, displayed a special tape former. 36 | WIRE JOURNAL INTERNATIONAL

FEATURE

(Escape from Düsseldorf cont’d.) gathering was the after-party of WCISA’s 2nd “Night Out,” an event for members before wire shows. This one, organized for stranded North Americans, was a perfect time to swap stories. Some of us had flight reservations for the middle of the week, some reservations were for more than a week away, and nobody really knew when any flights would be allowed. As time went on, even the most ludicrous ideas were considered, including an ocean voyage on the Queen Mary 2 that could get us to New York in seven days, if we could only figure out how to get to Southampton, U.K. Our group had decided to sit tight in Düsseldorf, too cheap or too lazy to chase the hole in the volcanic ash cloud by venturing to southern Europe. After stories of people spending thousands of euros for taxi rides (trains were packed), only to be stuck in a different city, we reasoned that there was no use in trying to outguess Mother Nature—and after all, there are worse places to be stuck. I had to endure my wife’s accusations of complacency, “You’re not trying real hard to get home, are you?” Finally, my travel agent called to say, “Pack your bags.” I got on a Lufthansa flight the next morning (Tuesday, April 20), but my partner David Blackman had to stay until at least Wednesday. The next morning, I arrived at a deserted Düsseldorf airport. Nearly all flights were cancelled, but mine was one of the four that was still on. After some trouble with the ticket, and having to commit to pay $4,000 for my coach seat (which was later refunded), I finally had the coveted boarding pass. Oddly, this flight had 60 empty seats on it! Many fellow passengers that were on board did not even have a reservation on this flight, they went to the airport just in case, and were rewarded. It turns out that the cancelled domestic flights that feed the transatlantic ones, and the difficulty of moving around Europe, left the flight less than full. We dared not cheer until the plane touched down at O’Hare. Billy Harold, CN Wire Corporation While drowning my sorrows with some alt beer at the hotel bar I overheard someone say that he planned to drive to Madrid. As that’s where I was planning on heading, only I had had no luck getting a rental car, I saw opportunity. I politely interrupted his conversation to ask if he had room for another. It ended up that he did and off we went Monday morning. While taking my turn driving, I routinely hit 180 km/hr, but we made it safely to Madrid on Tuesday afternoon after I got a ticket for talking on a cell phone while driving (23 euros on the spot) and a speeding ticket in France (I was flashed by a high speed camera south of Bordeaux. It almost blinded me!) that I am still waiting to receive from the rental company.

38 | WIRE JOURNAL INTERNATIONAL

Wafios AG once again had a major presence at the show.

machinery and equipment for wire production and processing (44%), materials, special wires and cable (41%), test technology (22%), measurement, control and regulation technologies (19%) as well as in tools for process engineering (20%). A slight increase in the number of executives was recorded. Speaking at a press conference during the event, wire 2010 Director Friedrich-Georg Kehrer discussed the role of the industry. From steel ropes to cables, “the products of the wire and cable industry are practically ubiquitous,” he said. Further, he insisted, one cannot overestimate the technical and economic importance of these products for the development of modern society. He noted that some 16,000 different products alone are made from steel wire. When one then adds in all the wires made of nonferrous metals, such as copper and aluminum, which are indispensable in the areas of energy and telecom technology, the true scope of the industry can be appreciated. “Of course, the current economic situation also affects the wire and cable industry, especially because about 60% of its product volume supplies the automotive industry,

SAMP USA’s Dominique Perroud, r, was ready to talk about his company’s new technology.

FEATURE At WAI’s booth, Anna Bzowski talks with Ayman Ibrahim El-Nagouly, whose company, Egyptian Galvanized Steel Plant Co., reserved a booth for Interwire 2011.

Fine International’s Erik Macs is interviewed by local media at the show. He and many others would soon have quite another story to tell due to a volcano in Iceland.

which has been rattled seriously by the crisis,” Kehrer said. “Nevertheless, the industry shares an optimistic outlook, which is also reflected in the increased number of exhibitors at wire. More than ever before it is important now to show one’s flag and be present on the market.” Kehrer said that the 2010 show stressed logistics, efficient use of energy and environmental technology. “Thus wire reacts to the increased environmental awareness and

tougher legislation in the area of environmental protection,” he said. Combined with the need for further innovation, modernization of power networks and infrastructure expansion, the wire industry will be bolstered, he said. The next concurrent staging of the wire and tube events will take place in Germany on March 26-30, 2012. Contact: Messe Düsseldorf North America, tel. 312-7815180, info@mdna.com. ■

40 | WIRE JOURNAL INTERNATIONAL

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FEATURE

Wire link report: an on-the-road industry education

The first meeting was an educational experience. I had Every two years the Wire Foundation selects a young been asked by our cold drawing manager to look at new die industry professional from the U.S. to represent the WAI as maintenance equipment, and one stop was to the booth of the Wire Link Traveling Scholar. The Scholar then has the Die Quip Corporation, a U.S. company, where I was greeted opportunity to attend wire Düsseldorf and tour manufacturby Tom and Scott Maxwell. They were very patient in ing facilities in the United Kingdom during a two-week trip. explaining the basics of die maintenance as well as their The following year, a U.K. scholar is selected to attend equipment and potential improvements to our practices. It Interwire and tour U.S. manufacturing facilities. The scholarwas clear that Tom and Scott ship is jointly funded by wanted not just to sell their Worshipful Company of Tin equipment but to educate cusPlate Workers alias Wire tomers on all things related to Workers of England, and the die maintenance. For Wire Foundation. I was fortuinstance, they explained the nate to be selected as the Wire benefits of various cleaning Link Traveling Scholar for and maintenance techniques 2010. For the record, I’ve in relation to die material as worked the last three years as well as geometry. a process engineer for Talley The second visit was with Metals, which is a division of Andrea Canepa of Henkel Carpenter Technology Corporation, which is a supCorporation and is located in plier to my company. Andrea Hartsville, South Carolina. actually helped set up Talley’s My trip began with the wire cleanox cleaning process, Düsseldorf show. Every two which I currently manage, so years the organizer, Messe this was a perfect opportunity Düsseldorf, hosts the world’s Peter Funk with Andy Walker at the Corus ACP plant. for me to go over some of the largest wire and tube show. I fine points. Andrea helped me had been warned about the better understand the nuances size of the show and I had of the original process development, and that’s quite helpful read the Wire Journal International’s pre-show edition, but as I further refine the tank parameters and recipes. Andrea nothing could prepare me for the vastness and extravagance and I also discussed strategies for increasing efficiency on of the event. Hall after hall was packed with capital equipseveral of our more difficult alloys. That meeting helped me ment, ancillary equipment, testing and measuring systems, better appreciate the value in visiting the booth of a supplier. reels and spools, marking equipment, dies, lubes, software I already knew Henkel the company, but from that discusand much, much more. The aisles were crowded and everysion I learned more about the history of my process as well where you looked it appeared that sales staffs were busy. as got some new ideas to take home. Anything you could ever want was there and the hardest part After covering as much of the wire Düsseldorf as I could was to figure out where to go next. During my two days in two days, I was off for Sheffield, England. Sheffield in its there, I learned that shows like these offer great opportunities day was the epicenter of English steel manufacturing and the to explore new technologies, but also to spend time with cur“birthplace” of stainless steel. Today, the steel industry there rent suppliers. I had many good visits with exhibitors, but has been reduced in size due to changes in the technology two in particular stood out.

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FEATURE

and the economy, but steel still has strong roots in this town. In the footprints of these once colossal mills, manufacturers from many different industries now blossom. Perhaps the best example of these changing times in Sheffield is Gripple Limited, a market leader in wire joiners and tensioners that are designed to suit a huge range of applications, across many different industries. I had the pleasure of touring Gripple’s Sheffield manufacturing facility with Training & Development Coordinator Sharon Hackett. The facility is located in a former gun works that dates back to 1854. Prior to Gripple, the building had sat unused for sometime. Gripple took ownership of the building, which was renovated to a state-of-the-art manufacturing facility. This is a bright vibrant facility with vast open floor plans and art work hanging from the original steel girders. Most manufactures do not spend such time and effort on the beautification of their facility, but Gripple sees the facility’s design as a way to inspire the creativity and innovation that the company was built on. Gripple’s creativity is also evident in their manufacturing equipment. Instead of accepting whatever they can find “off-the-shelf,” Gripple’s engineers work with equipment manufacturers to create bespoke equipment using common parts. The evolution of their manufacturing process and continuous improvement efforts is on display in each machine. The Kelham Island Museum in Sheffield gave me a glimpse into the life and times in Sheffield during the Industrial Revolution. After a flood in 2007 left the museum devastated, a two-year renovation project was put into action. The results are incredible! The museum serves to educate its patrons on the steel-making process as well as the role steel played in the cultural development of Sheffield. The two highlights for me were the 12,000 hp River Don steam engine and the Little Mesters Street. The huge River Don engine was built in 1905 and used in production of armor plate rolling until 1978. Today it can be seen “in steam” Monday thru Thursday at the museum. The Little Mesters Street is a recreation of a typical Victorian Era Sheffield Street. The Little Mesters were a network of craftspeople that operated out of rented workshops in support of the cutlery and toolmaking industries, for which Sheffield was known. Here, street patrons can observe a hand forger and a grinder. These are two of the few remaining craftspeople in Sheffield. Another experience in Sheffield that brought the history of this city into context was the business of Ernest Wright & Son Limited. The company was established in 1902, but dates its origins back even further to Walter Wright. My tour was given by Nick Wright, who is of the fifth generation involved in this business. Walter Wright was a renowned Little Mester who specialized in the finishing of scissor blades. The skill earned him the title of “Master Scissor Putter-Togetherer.” That title is still used today for fully apprenticed craftspeople of this specialty. The company is

Replete with the overhead cow, the Gripple Limited facility in Sheffield was not your ordinary plant. carrying on the Sheffield tradition today using the hand-finished techniques of Walter Wright to produce extremely high-quality scissors and shears. After watching the scissor putter-togetherer, painstakingly test and adjust each pair of scissor blades, the experience of opening up a pair of scissors will never be the same! It was a very special experience to witness the talent and skill of craftspeople at Ernest Wright & Son as they carry on the age-old tradition of scissor finishing. Continuing on the historical theme, my next tour took me to Fox Wire, which dates back to 1851. Fox Wire is a colddrawing facility that has its basis in stainless steel, but in recent times has used the knowledge and talent to move the company into many different markets. It was very interesting

The Sheffield area proved especially memorable area.

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accidentally with a visit to my host’s office. Darryl Lomis, to see stainless and nonferrous products being run side by my host in Sheffield, is a business advisor for Metskill. side. Fox Wire is a clear demonstration that, even in more challenging markets, strong companies can find a way to con- Metskill works with companies in the metals industries to develop engaging apprenticeship programs and attract young tinue to move forward. people to these programs. In this day and age, the stereotypes While in Sheffield, I also toured the manufacturing facility of heavy industry do not serve its employers in attracting the of Betafence, which makes a huge range of products. As the best and brightest at all levels of the company. Metskill acts name suggests, the bulk of the facility is dedicated to welded to overcome those stereotypes and demonstrate the promising and woven fencing products, but they also make staples and and fulfilling careers that can be had in the metals industry. barbed wire. I found the barbed wire machinery fascinating. Metskill is not only a recruiter, but also helps facilitate the At production speeds it is difficult to pick up on all of the movements, but the operator was nice enough to slow it down training of these young individuals. Metskill will interview the young candidates to make sure they are fit for the indusso that I could see the amazing mechanics that goes into try. Once they have determined that the candidate is worthy making a product that to the untrained eye seems so simple. of the program they will begin Within the past couple of years, training the young candidate in this facility was able to reduce its basic industrial skills such as footprint by half through Lean safety and interpersonal comManufacturing principles and munication. The candidate will investments in new equipment then get placed into an apprenwithout decreasing their volume or tice position at a participating range of products. The remaining company. From that point the space will now be used for new program is custom tailored to business opportunities that will the candidate. The apprenticebenefit both Betafence and ship can lead to a machine Sheffield. operator position, technical An opportunity to tour a supervisor, or even to a fully Vauxhall automobile facility took accredited engineering degree me from Sheffield to the coast of WAI Foundation President John Drummond and program. It is easy to see the the Irish Sea, to a town called Peter Funk at the awards ceremony at Wire Expo. linkage from the Little Mesters Elsmere Port. I always enjoy seeto this program, once again ing automotive facilities because demonstrating how history plays an active role in Sheffield the competition for quality and cost has forced the manufacmanufacturing. turers to refine their processes into works of art. I really Although training and apprenticeship came up at all of enjoyed Vauxhall’s implementation of an Andon system. An my visits, my conversation with Andy Walker at Corus Andon system is a Lean Manufacturing tool for directing the ACP was memorable because he had just led an effort to attention of employees to a particular line or area. This can convert Corus ACP’s training documentation and Standard take the form of a big scoreboard or a light at each workstaOperating Procedures into more user-friendly documents. tion. Vauxhall used both of those signaling methods, but it Prior to Andy’s undertaking, the documents were formatted also used sounds. Each work center has its own unique and stored in a way that did not allow pictures, thereby sound, and far from a typical warning siren they could be relying only on text to describe the necessary steps. either a theme song from a TV show, the latest top 40 hit or just a generic jingle. This sound alerts the shift supervisor that Updating, reformatting, and adding pictures to all the existing documents would have taken Andy many years to coma work center has a need, and which work center it is. This plete by himself. Instead, he recruited the efforts of operaallows the operators in each work center to stay focused on tors in each area, and had them scrap the old procedures so their job task and continue to operate while the shift supervithe resulting documents would be their own product. Andy sor addresses the issue. explained that this step was vital because it created ownerAlthough many of the businesses I visited were not in ship among the operators of the information in these docudirectly similar businesses as Talley Metals, the basics of manufacturing are still the same. Seeing processes outside my ments. The resulting documents were used to create qualification tests for each procedure. These tests required written experience allowed me to witness the overarching principles “essay formatted” answers and covered not only the of manufacturing, without getting caught up in the nuts and bolts of equipment details. This allowed me to discover sever- “hows” but the “whys.” Andy emphasized the “why” portion of the test as being most the important yet also al best practices to bring back to Talley. One theme that the most often overlooked. These tests ensured manageseemed to resonate throughout my visit was training. ment that each operator was knowledgeable about the My first introduction to the emphasis on training happened

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I would like to thank the Wire Foundation, the Wire Association International, and The Worshipful Company of Tin Plate Workers alias Wire Workers of England; specifically John Drummond, Steve Fetteroll, and Bev Page for their involvement and support of the Wire Link Scholarship. I would also like to thank the following people for their time and hospitality at their facilities: Bob Flear at Metskill; Sharon Hackett at Gripple; Neil Dimelow at Fox Wire; Andy Walker and Gary Phoenix at Corus; Kevin Steers at Betafence; Nick Wright at Ernest Wright Ltd.; and Phil Milward at Vauxhall. This report wouldn’t be complete without mentioning the fantastic job Darryl Lomis did in arranging my visits in England. Somehow Darryl was able to pack together seven facility tours and the better parts of a 1,000 year old culture into 14 days. And finally, I want to thank my employer, Tally Metals, for allowing me to take advantage of this wonderful opportunity. I believe this experience will be something that helps me throughout the rest of my career. ■

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procedure as well as the process, thus creating a safer work environment. When I look back at my trip, I realize that while I understood my role, my “slice” of the wire and cable industry, I never sensed how many other “slices” exist, both in terms of the types of challenges that companies elsewhere face, the way they respond, the decisions they have to make about their future and how vital the employees are in making positive change happen. The experience, for me, indeed was an education, one that books alone could never provide. I can hardly believe that the trip was only two weeks in length. My knowledge of wire manufacturing and industry in general grew by many years in just those two weeks. At wire Düsseldorf I was able to learn about the latest technologies in the industry. By my travels in England, I was able to learn new concepts that I hope to apply to Talley. I found the living history of Sheffield fascinating. Seeing the traditions being carried on by the likes of Nick Wright of Ernest Wright Limited and the evolution of Gripple & Fox Wire, it is hard not to root for a place like Sheffield.

FEATURE

Ancillary equipment & parts wo years ago, WJI presented its first feature solely for ancillary equipment and

replacement parts. The idea was to offer a venue for industry essentials that are

not the big-ticket capital equipment or commodities such as dies, compounds, lubes and reels and spools. Here, it returns to that theme, presenting a wide range of these less heralded yet essential products, many of which were exhibited at Wire Expo 2010.

Allen-Bailey Tag & Label, Inc./U.S. Tags and labels can be a nuisance, especially if you don’t have them when you’re ready to ship your product. Tags and labels serve a vital role to the wire, cable and steel industries. These can range from a simple shipping tag or label to a product ID tag to a thermal transfer imprinted

ing line of durable, synthetic materials for thermal transfer and laser imprinting. Don’t wait until the last minute to think about your tag and label requirements. Your customer may be relying upon the information contained on your label. Call us, we make it easy, we’re the Nuisance Eradicators. Richard Phelps, sales@abtl.com.

Amacoil Inc./U.S.

Allen-Bailey Tag & Label’ s Richard Phelps and Rob Tesauro. label or to a tag containing important production measurements, barcodes, batch ID info, etc. All of these products can be made with heavy-weight papers as well as a grow-

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The new Amacoil-Uhing AVS system is a software-based traverse winding system that uses sensors to monitor and coordinate spool rotational speed relative to accumulation of material at the spool flanges. Sensors monitor both the line feed speed of the wire (or other material) and the spool rotational speed. When a dent or bulge in the level wind is detected, the AVS will slightly increase or decrease the spool rotational speed as needed in relation to the material feed speed. At the same time, another sensor detects the position of the traverse and transmits the information to a controller which integrates it with the above-described process. The AVS then adjusts the traversing width accordingly. This continual sequence of balancing spool rotational speed with line feed speed and traverse position results in a smooth, level wind. The AVS may be used with Uhing traverses and with most other level winding traverse drives including ball screws and other types of linear actuators and timing belts. The Uhing AVS system is suitable for wire diameters of 0.2 to 5 mm and spool rotational speeds of 3,000 rpm (max.). Because it corrects the level wind at the reversal points, the AVS can be used with spools having

Amacoil Inc.’s AVS traverse winding system. bi-conical flanges or bent or damaged flanges. There are no optical sensors so dirty work environments do not pose an obstacle. Up to ten programs may be stored in the AVS system with preset button access. Bob Eisele, www.amacoil.com.

B&H Tool Co., Inc./U.S. A leader in plastic extrusion tooling, U.S.-based B&H Tool has found great success by close collaborations with its customers. One example is the following testimonial from Northwire Inc., a U.S.-based designer and manufac-

B&H Tool Co., Inc. President Peter Neville. turer of technical and retractile cables that wanted to improve its handling of color changes. Northwire ships cable in five days with no minimum order length or quantity. As it focuses on custom cables with no minimum required, it has short production runs and frequent color changes, as often as hourly. Color integrity, especially for medical cables, is critical, so polymer waste from frequent changes is a major cost factor. Wire scrap, of course,

Bock Maschinenfabrik GmbH/Germany Howar Equipment/Canada Wire pointers and string-up equipment from hand operated to heavy-duty powered units are designed and manufactured in Germany by Bock. Heavy concentration is placed on durable and precisionbased wire pointers which stand the test of time. The rollers are made of a special steel alloy which has proven effective and operational after more than 10 years of factory use. A key piece of equipment supplied with many of today’s wiredrawEquipment from Bock GmbH. ing machines is the EZM type wire pointer, which has a string-up capstan for the quick and easy die string-up that is needed on today’s multi-wire machines. The units come with a wide range diameter roller set and are often mounted on casters for easy maneuvering in the factory. The complete line also includes additional wire feeders and straightening equipment that can aid in setting up wiredrawing machines when large rod diameters and products are being processed, where the workers need additional aid to handle the material. www.bock-mf.de or www.howarequipment.com.

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includes the cost of copper as well as plastic. Frequent changeovers also cost cycle time as the process includes purging, cleaning material from the crosshead, rethreading copper wire into the crosshead again after cleaning, changing the die tooling, and starting up again. In January 2008, Northwire partnered with B&H Tool, its sole supplier of tooling, to optimize its processes. By the next month, B&H had engineered and prototyped a new crosshead design. The new crosshead assembly was tested at Northwire on a number of conventional thermoplastics and blends. In each case, it dramatically reduced scrap during changeovers, in some cases by as much as 20%, says Kevin DePratter, Northwire’s director of R&D, Northwire now has the new technology on all its crossheads. It also improved cycle time and productivity. Northwire is producing custom cables, three shifts, five days a week. “B&H’s collaborative approach to this project became the key to its success,” DePratter said. Peter Neville, www.bhtool.com.

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Boockmann GmbH/Germany The Slover Group/U.S. At Wire Expo 2010, Boockmann GmbH, represented by The Slover Group in the U.S., exhibited its HELICORD technology, which is one of the most versatile processes currently in use in the wire industry. Based on a push-pullcontrolled textile cord wrapped around a wire or cable, it has been proven successful in various applications in

Technology offered by Boockmann GmbH. cleaning round wire, strands and insulated cables, as well as in applying different types of additives, e.g. corrosion inhibitors, strip aids, adhesion enhancers or welding wire finishes, supplied by Boockmann. The main advantages of HELICORD as compared to other cleaning technologies are the multiple 360° contact between the wire or cable and cleaning medium, the cleaning medium being constantly refreshed, and efficiency of the process being independent from wire speed. Being designed only for small diameters in the beginning, the HELICORD machines are now equipped with stronger motors capable of higher friction for cleaning and bigger looping units suitable for larger diameters. A very successful application is abrasive removal of stearates and thin oxide layers at drawing speeds in order to increase productivity, and prepare wire for plating (e.g., copper on ferrous, or silver on copper alloys), where chemical and other processes often cause health and environmental issues, or high costs for proper disposal of used chemicals. In the cable industry, removing particles from conductors is well-known to decrease the number of blow-outs and failures in high voltage tests, reduce the risk of extruder head clogging and wire breaks, and increase bandwidth. info@boockmann.com; The Slover Group, richard_slover@slovergroup.com.

Cometo snc/Italy Lesmo Machinery North America/Canada Italy’s Cometo snc, represented in the U.S. by Lesmo Machinery North America, supplies drawing die holders for improved wiredrawing. Fixed and rotating die units are available with direct cooling of the die through the brass 48 | WIRE JOURNAL INTERNATIONAL

die holder, reducing drawing temperatures. Rotating die holders reduce uneven die wear through their continuous rotation. They maintain a perfectly round wire finish while direct cooling of the die reduces drawing temperatures, thus allowing for increased drawing speeds with lower incidences of wire breaks and reduced die wear. Cometo offers different models for wire from 1 to 20 mm, other sizes available upon request. Fast and slow rotating models are available, from standard models with speeds from 4 rpm up to 48 rpm. Different motor speeds are also available upon request. The wire is continually lubricated by lubrication boxes that are available in long and short configurations for grease, oils and powders, and are attached to the rear of the die holder to assist in their continuous lubrication of the wire, reducing friction on the die. Cometo die holders accommodate a wide range of die sizes with single, double and even triple die capabilities. Different installation options are available for vertical or horizontal assembly of the units. The rotating die boxes provide improved performance, die life and wire quality, and are easily integrated into existing machinery. They provide: direct cooling Die holders from Italy’s Cometo snc. of die (prevents heat accumulation on wire); continual wire lubrication (large type lubrication boxes); increased drawing speed via improved lubrication and reduced temperatures; longer die life from rotation and improved lubrication; less machine downtime (due to wire breaks and die change); easier access for maintenance; and easy integration into existing machinery. www.cometo-italy.com; Allan Brown, sales@lesmoamerica.com.

CTS East/U.S. CTS East is located in the industrial heart of New Jersey. CTS is both a thermal spray company and a manufacturer of machinery components for the wire industry. CTS East specializes in the manufacture of capstans, sheaves and pulleys. These components are coated with chromium oxide, tungsten carbide, aluminum oxide or numerous other thermal spray coatings which provide increased wear life and protection against corrosion and erosion. The combination of CTS East’s thermal spray capabilities,

Force Measuring Systems AG/Switzerland FMS USA, Inc./U.S. John Dyer, John Kim and Mauro Buonarota at the CTS East booth at Wire Expo 2010.

Wire and cable makers now have an affordable way to monitor and control tension in individual wires on rotating machines. FMS technology called Radio Transmitted Tension Monitoring (RTM) can be easily applied on most planetary or tube stranders, bunchers, twisters, or any

machining, grinding, and milling operations, along with strict quality control and a metallographic lab, guarantee a finished product coated and manufactured to our customers’ exacting specifications. John Dyer, jdyer@cts-inc.net.

Die Quip Corp./U.S. Die Quip Corp. offers an extensive line of tools for working with wire, rod, bar, rope and cable from the world’s top manufacturers, including Krenn and Knipex. These ergonomic tools are designed to make cutting fine wire to 2 in. steel bar faster, easier and safer. Die Quip’s

Steve Leibold at the FMS USA booth at Wire Expo 2010..

From l-r, Krenn Sales Manager Klaus Weidenfelder, Die Quip Corporation President Tom Maxwell, Jr., and Knipex Tools LP Sales Manager Randy Booth. webstore has manual as well as powered tools at competitive prices to meet customer needs. Die Quip proudly featured the Knipex line of wire stripping, crimping and terminal end tools at the recent Wire Expo 2010 show in Milwaukee. These tools are designed to produce precise and accurate stripping and crimping pressures with less

rotating machinery. It digitally monitors tension in real time on up to 32 individual positions and displays the values on a PC screen. RTM pays for itself typically in one to two years by reducing material breaks and eliminating overstressing and excessive slack in wires and cables. The radio-transmitted system avoids the many drawbacks of mechanisms such as slip rings (cost, wear, signal noise, installation issues, etc.) and telemetry systems (unidirectional analog data transmission, multi-positional prohibitive cost, etc.). The technology can be configured in various ways to handle nearly any tension measurement or control task. The monitoring system is comprised of tension sensors, tension measuring amplifiers, a bus system with radio transceiver, and software. A wide range of tension sensors is available for any tension requirement, and if closed-loop control is required, digital controllers are used instead of measuring amplifiers. The RTM system can easily be used with existing equipment as it bolts down in a small footprint, utilizes standard FMS load cells and amplifiers, and runs on PC software so a new PLC installation is not required to utilize the system. Steve Leibold, fmsusa@fms-technology.com.

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operator fatigue. The tools are now featured along with our cable cutting tools for ACSR We also offer the Krenn line of quality manual, electro-hydraulic, hydraulic and pneumatic steel cutters. These are the right tools to cut aluminum, stainless steel, copper, carbon steels and spring grades of wire. Krenn’s new high tensile blades for the R-serial bolt cutters offer longer cutting life than the original blades and traditional bolt cutters for spring grades or high carbon steel. Tom Maxwell, Jr., tmaxwelljr@diequip.com.

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Frontier Composites and Castings, Inc./U.S. In business since 1992 as a manufacturer of flyer bows, Frontier Composites has become the best friend of many maintenance departments. Being the manufacturer of some 80 different model sizes makes Frontier the logical choice

high speed applications. Optional metering valves are available for balancing the air flow between the front and rear jets for the most beneficial mix for each product application. The down drafter is available from 1/16 in. to 1 in. This unit also employs the “air miser” jet system that reduces the air usage and consumption. New for 2010 is the Huestis shaft-less series of take-ups and payoffs. They were designed to address the circuit-size market that has been ignored for years. These units have the ability to handle a package from 12 in. to 36 in. and weights up to 2,500 lb. Options include hydraulic, pneumatic and electric versions tailored to the customers’ needs. They have a small footprint, making them ideal for movement between production lines as well as being very affordable. Also new for 2010 is the line of Huestis Industrial cold welders. They

Erwin Kish (l) and James Howe, Frontier Composites and Castings, Inc., at Wire Expo 2010. for anyone in a rush. Bows can be carbon fibre or fibreglass with Kevlar used where desirable. Aluminium or steel bows can also be supplied on a custom basis. Frontier’s products are the result of a collaborative effort with composites engineers of many years experience. The company also keeps a wide range of bow hardware in stock at all times, sufficient to satisfy the individual needs of most customers. This enables Frontier Composites to deliver to any plant in North America in from one to three days, with a few dimensional exceptions. This makes it possible for purchasing agents to respond to the rush demands of a maintenance department which is striving to maintain production schedules, with the knowledge that these demands will be met. James Howe, info@frontiercomposites.com.

Huestis Industrial/U.S. Huestis Industrial has launched new product lines that are cost-effective solutions that will give customers a competitive edge. Huestis air wipes continue to be industry leaders for air consumption, reducing compressed air usage, electricity and carbon-based emissions. New for 2010: the ceramic “Air Miser” air wipe, which features a full-length, replaceable ceramic insert that provides wear resistance and protection from misalignment and human error. Like the original “air miser” it provides efficient drying with low air consumption. It will be available in the most popular sizes for 2010 and expanding up to 1 in. for 2011. Also, the “Down Drafter” air wipe, an all-new device that has drying jets front and rear with a bottom drain in the center. The drain is threaded for a fitting and pipe or hose to capture and return the process liquid to your system. Multiple wipes can be coupled in line with greatly reduced blowback, thus aiding in effective drying at high speeds. This wipe is also more effective than the standard air miser for 50 | WIRE JOURNAL INTERNATIONAL

Howard Fancher, Huestis Industrial, had multiple new products to talk about at Wire Expo 2010. will handle all needs from superfine to rod breakdown in hand-powered manual units, as well as electric/hydraulic welders for the largest sizes, making perfect welds timeafter-time, backed by the Huestis quality and warranty for one full year. Howard Fancher, sales@huestis.com.

JoeTools/U.S. JoeTools, a designer and manufacturer of a wide range of crossheads and tooling, has recently unveiled two remarkable new heads that can significantly reduce production costs in extrusion processing. JoeTools’ new Switcher™ crosshead accomplishes this with a unique color inversion system that allows wire and cable processors to extrude 2 different colors consecutively without interruption. This unique system features a fixed center, dual-layer crosshead with a manually controlled switch valve, able to invert compound from two extruders onto the inner and outer layers of the applied insulation. So, as the production quantity of the first color is completed, the operator simply switches the color valve to transpose the inner and outer layers, and the next production run begins. This process eliminates the set up time and bulk of scrap material that is traditionally involved in extruding the second color run. So, there is almost no waste in material or time, but a substantial gain

JoeTools Switcher and Scooter heads may be new opportunities for wire and cable processors to reach their goals. Joe Dixon, www.joe-tools.com.

Kamatics Wire Products/ KEIR Manufacturing, Inc./U.S. On March 23, 2010, KEIR Manufacturing completed the acquisition of the Wire Products business unit of Kamatics Corporation, a Kaman Company. In 1990, Kamatics introduced a unique high-performance composite flyer bow by combining aerospace proven technology and a revolutionary tri-axial braiding process. Since 2005, it has been offering a new innovative solution for wire processing, called BackBone™ Bow, which is designed to incorporate all the positive features of an enclosed bow without any of the negatives associated with operating a totally enclosed flyer bow. The semi-enclosed BackBone Bow gives the customer the increased reliability and performance needed in today’s competitive environment. The hexagonal shaped wear bushing can be made with different material types for bare copper, aluminum, steel plated and insulated wire processing. This opens up the problem solving options not available with the standard wear strip and ceramic or carbide guide combination. Unique qualities of the BackBone

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in productivity and lower operating costs. Plus, the manually operated switch valve makes the Switcher extremely reliable. Not only is it easy and sure to operate, it eliminates any downtime or costs that could result from the complexity of hydraulic or pneumatic controls. Another product JoeTools introduced this year is the Scooter™ crosshead. Designed to convert a single-layer crosshead into a unique single-secondary crosshead, the Scooter is an economical alternative for dual-layer applications. Its unique adaptable design allows the Scooter to connect with existing single-layer primary heads, producing excellent results at minimal costs. With rising demands to control Joe Dixon at the JoeTools booth at expenses, the Wire Expo 2010.

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Bow include: improved bow strength, I-beam construction for significantly improved bow stiffness; wire positioned out of the air stream; and an aerodynamic shape for improved speeds with lower amperage draw. The wear bushings can be made from ceramic, steel A close up of a composite (58-60Rc) and many BackBone™ bow offered by other materials or KEIR Manufacturing, Inc. coatings. This improved design offers improved support of difficult-to-make products and prevents the wire from pinching between the guide and the wear strip. Advantages include: improved wire quality, higher tpm, less bow breakage, lower power (AMPS) consumption, a dimpled wear surface which reduces friction, reduced downtime and maintenance, quick and easy assembly and change-out of wear bearings. Mike Walters, sales@keirmfg.com; www.backbonebows.com.

KEIR Manufacturing, Inc./U.S. KEIR is a manufacturer of technical ceramics and other highly engineered products serving a variety of industries. For the wire and cable industry worldwide, KEIR’s products include high purity 99.8% Alumina Ceramic Guides, Frontiersman™ Air Wipes, and Composite Flyer Bows.

Keir Manufacturing Sales and Marketing Director Mike Walters. KEIR is dedicated to making products that enable industry to run more efficiently and productively through the application of advanced materials. A prime example would be our Frontiersman™ Air Wipes. As industry was becoming more frustrated finding a permanent solution to completely

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drying wire with increasing line speeds, KEIR developed a dependable, simple, and cost-effective new design. What makes it so unique? KEIR’s design relies on the controlled use of compressed air that is allowed to decompress to atmospheric pressure within a carefully sized chamber. The air accelerates to nearly the speed of sound in a thin layer surrounding the wire. This release of kinetic energy, stored when the air was compressed, does far more work than other systems that rely on high volumes of air. The wire path is lined with high density ceramic material for long life. The configuration of the ceramic keeps the wire centered within the airflow. KEIR offers two designs that incorporate the same proprietary concept. One, primarily for bare wire, consists of a polymer mounting block with a high density, wear resistant ceramic insert that is hand pressed into the mount and is sealed with O-rings. The other, a split, clamshell design (see photo) for jacketed wire or cable, opens to allow welds or extrusion bulges to pass through without damage. It can also be used where it is not practical to thread the wire through an air wipe when setting up the line. Mike Walters, sales@keirmfg.com.

Knipex Tools LP (See Die Quip Corp.)

Werkzeugfabrik Albert Krenn (See Die Quip Corp.)

Kyocera/U.S. When you hear the name Kyocera most people think of phones and copiers, but Kyocera is also a global leader in technical ceramics and was in on the onset of the transition of metal to ceramics in the wiredrawing industry.

John Fairchild and Don Costa, Kyocera Industrial Ceramics. Kyocera’s zirconium oxide (KZ70) is the best material for wet wiredrawing. There is none better. We have been producing KZ70 material from powder to final finishing since the early 80s in our North Carolina facility with the full

Magnetic Technologies, Ltd./U.S. Magnetic Technologies has expanded and upgraded its line of “pancake” style magnetic brakes that are just right for those hard-to-fit places, like tubular stranders. The most popular “pancake style” brakes will retrofit the Bartell B-62 and B-64 tubular stranders. The name of the brake

FEATURE

range from rod breakdown to superfine. We can manufacture rings up to 610 mm. Before that some people used alumina, which was better than metal but not as good as zirconium oxide. We manufacture OEM type replacement rings, cones, capstans as well as pulleys and guides. We can also provide the before and after sales service necessary to ensure proper size, application and run ability of the product. Kyocera is a leader in innovation of new products for the industries we serve. I am holding a new product that is being tested in the rod casting operation. This is a new version of silicon nitride that has the ability to withstand the high temperature of the new cast rod. This product was designed for casting stainless steel pipe and is proving to be a superior product in copper rod casting. Current testing position is the first on a rod casting mill line. This is proving to be very successful showing no signs of wear or copper build up. Don Costa, don.costa@kyocera.com.

Howard Schwerdlin at the Magnetic Technologies Ltd. booth. stems from its description. Most magnetic brakes are two to five inches thick and house the bearings, magnets and a rotor. The problem in tubular stranders, however, is the lack of space. To retrofit a tubular strander, one needs to shrink the brake to a half-inch thick. The O.D. is not as important as tensioning a spool that can be 5-12 inches in diameter,

The world’s ONLY one-stop wire tooling source… Inch Series Straightener

European Style Straightener

Sjogren also offers: • 5 Additional Styles of Roll Straighteners • Roll Replacement for ANY Style Straightener • 4 Styles of Wedge Grips and Replacement Parts • 3 Styles of Wire Guides • 3 Styles of Magnetic Brakes & Clutches Sjogren Industries, Inc. Tel: 1-508-987-3206 Fax: 1-508-987-1965 Email: sales@sjogren.com

JUNE 2010 | 53

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

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

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

Special industry theme days to be announced. Look for presentations, technical papers, and executive discussions to orbit around these central themes: Energy | Environmental | Safety Issues Metals | Materials | Machines Best Practices | Operational Excellence Fully supported. Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

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

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

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

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

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

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

A. Appiani Ace Metal Inc. AFL AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne AW Machinery LLC Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp. Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp. Bogimac Butt Welders USA Caballe SA Cable Consultants Corp. Carris Reels Inc. Cemanco LC Chase Coating and Laminating Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp./Er Bakir Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp. Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Daloo Machinery Davis-Standard LLC Dem Costruzioni Speciali Srl Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Egyptian Galvanized Steel Plant Co. EJP Maschinen GmbH Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl EuroWire Magazine George Evans Corp.

FEATURE

After each WAI WEBINAR one question remains...

WHAT’S ON THE HORIZON?

but the width is critical. What Magnetic Technologies did was redesign its brake with many planetary magnets surrounding the rotor to reduce the width by half. They then designed a heavy duty bearing structure, specifically for rough day-to-day service, to fit tubular stranders. Typically, the spool in a tubular strander is supported on either end by seating in the outside rails of the strander. Magnetic Technologies made its bearing structure do the same. The result is a very accurate drop-in magnetic tensioning system to replace the old “rope brake.” Companies today have found tubular stranders to be very good for stranding hard alloy wire, and this brake gives them the ability to tension fine and very fine wire. Magnetic Technologies has also added a series of accessories and niche products to complement its basic line of brakes and clutches. These accessories include: universal drive plates that clamp on the payoff shaft instead of using set screws; cones, plugs and adaptors to help “bush up” shafts to fit various reels on payoff shaft; and a quality line of stainless steel FastLocks® that clamp better and last longer than competitive designs. Howard Schwerdlin, www.magnetictech.com.

Macxess International/U.S. Low tension and wire pulley load cells offered by MAGPOWR, a business of MAXCESS, are specifically designed to indicate tension in wire applications. LC500G model load cells are perfect for monitoring low tension (as little as 500 grams) in fine wire coiling processes. TS wire pulley load cells are available for heavier loads (up to 500 lb). Each load cell is ruggedly constructed with built-in mechanical overload stops in both force directions. A full

THE ANSWER IS CLOSER THAN YOU THINK. technical and economic topics | wiredrawing mechanics | market trends | manufacturing processes | best methods AND MORE Find out about WAI’s popular online learning series at:

www.wirenet.org/events/webinars/index.htm The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

56 | WIRE JOURNAL INTERNATIONAL

Darren Irons at the MAXCESS International booth. Wheatstone bridge arrangement of four foil strain gauges is also incorporated into each load cell for the most accurate means of measuring web tension, and all load cells incorporate a dual-beam construction design to ensure linear output under all loading conditions. Automated tension control is an easy way to reduce scrap on uncoilers/recoilers, stranders, or any other wire manufacturing

FEATURE

process. Cygnus tension control is easy to use and install, with powerful features that can improve the overall consistency of our product by monitoring and adjusting tension as required, without operator intervention. Darren Irons, dirons@magpowr.com.

O.M. Frigerio/Italy Howar Equipment Inc./Canada Italy’s O.M. Frigerio, represented in the U.S. by Howar Equipment, designs and manufactures mechanical descalers to be installed in-line with wiredrawing equipment. The mechanical descalers differ from others by their use of specially rotating wire brushes that also revolve around the wire as well as having the brushes rotate. This type of a wide brush orbital + rotating brush system offers the ability to clean wire at high efficiency while running at line speeds up to 1000 ft/min. The descalers are designed to work with ferrous wires from 3-14 mm and feature a durable tungsten carbide fused reverse-bending roller assembly that breaks the rough scale initially, and then in the subsequent brushing pass, cleans the wire to a pristine finish ready to enter the drawing machine. Going into the

O.M. Frigerio offers a range of equipment and accessories. wiredrawing machine, we recommend and offer a comprehensive line of rotating die holders that are designed to further increase the productivity of the drawing line by eliminating oval die wear and improving wire finish. O.M. Frigerio, www.omfrigerio.it; Chris Hauer, www.howarequipment.com.

Manufacturers of both

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

JUNE 2010 | 57

FEATURE

Get inspired by WAI’s convenient, interactive

EMERGING WEBINAR SERIES.

O.M. Lesmo/Italy Lesmo Machinery North America/Canada Italy’s O.M. Lesmo, represented in the U.S. by Lesmo Machinery North America, has been using carbon fiber material in our double-twist, Mono Bow designs since the mid-70s, long before it became fashionable with the tuner generation. Its bow design goal has been to increase machine performance (speed and reliability) while maintaining product quality. One key to bunching, stranding and cabling at higher speeds in double-twist take-up applications is to find the optimal wire path. In the bunching and stranding of smaller section, bare products, a U-shaped eyelet is utilized to string up the machine. During operation the input wire payoff(s) and take-up tensions are adjusted so the product forms correctly and rides in anti-friction coated, flexible, blued-steel wear strips. The stranding of larger cross sectional area products, such as 19 wire or 37 wire products, also requires input and take-up tensions adjusted for the correct wire path, while the heavier product calls for a circular-shaped eyelet and during operation the strand may be in contact only with a few of the first and last eyelets. The strand optimally floats through the

The Mono Bow from Italy’s O.M. Lesmo.

FREE TO MEMBERS. technical and economic topics | wiredrawing mechanics | market trends | manufacturing processes | best methods AND MORE Find out about WAI’s popular online learning series at:

58 | WIRE JOURNAL INTERNATIONAL

rest of the bow. When you purchase a bow from O.M. Lesmo, you not only get carbon fiber technology with the strength of steel at 40% of the weight, you get a bow designed specifically for making your strand or cable on our machine. The bows we supply for our machines are purposely designed with the dynamic balance of the machine and the optimal geometric wire path for the product in mind. We have a wide range of ceramic and tungsten carbide eyelet sizes, plus special rollers used for cabling taped products. If your application changes from bare wire strands, roped, insulated cabling, taped or heavier products we have the solution to re-fit our machines with the leading Mono Bow technology. Our technical experience can provide you with the products and services to maintain the best performance. If you want competitive pricing, delivery from stock, and technical support we are always ready to respond. Allan Brown, sales@lesmoamerica.com.

Parkway-Kew Corp. (PKC) has historically been known for the restoration, coating, and fabrication of blocks and capstans for the ferrous and nonferrous industry. Drawing on nearly 60 years of experience enables us to help companies improve quality, and increase production speeds in

Robert Galperin and Mark Patrizzia at the Parkway-Kew Corp. booth at Wire Expo 2010.

their drawing process. The recent addition of a proprietary CNC Machining process, along with robotic technology allows us to provide more solutions to the industry. PKC can now work with such materials as: solid carbide, HWGP (ceramic impregnated UHMW green plastic), and our line of fused tungsten carbide coatings, allowing for alternative cost effective solutions and longer wear life. PKC now repairs and fabricates dancers and guide rolls, pulleys, sheaves and step cones. Dancer and guide rolls are available from stock for many of your newer high-speed drawing equipment, such as from Morgan-Koch and Frigerio, as well as a variety of parts for Niehoff, and Bongard down-coilers. PKC also offers a number of innovative solutions to your wet drawing and fine wire needs. Wet drawing rings can be resurfaced or fabricated from existing steel rings. Solid ceramic rings can be reground or furnished new. Our new solutions for stepcones include: resurfacing, fabrication of coated parts, and long life solid carbide replaceable rings. These new products and capabilities make PKC your: â&#x20AC;&#x153;One Stop Shopâ&#x20AC;? for all your ancillary part needs. Mark Patrizzia or Robert Galperin, sales@parkwaykew.com.

WET WIRE? Try Frontiersman Air Wipes Frontiersman Air Wipes dry quietly with minimum compressed air. With replaceable, wear resistant ceramic inserts, the Frontiersman Air Wipes last longer.

We also manufacture ceramic guides and components.

KEIR Manufacturing, Inc. Tel: +1 828.885.8444 U.S.: 800.992.2402 Fax: +1 828.884.7494 USA Email: Sales@KEIRmfg.com

www.KEIRmfg.com Your Specs! Fast, Personal Service and Great Value!

JUNE 2010 | 59

FEATURE

Parkway-Kew Corp. (PKC)/U.S.

INTERNATIONAL TECHNIC AL CONFERENCE

M O N R E Y

Photos courtesy of the Monterrey Department of Tourism.

T E R Wire and Cable Technical Program Tabletop Exhibits | Networking

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

Venture to a place where wire and cable best practices and technological answers are much more than theory. And leave with ideas you can put into place immediately. Join WAI and educational sponsor ANTAAC for the 2010 International Technical Conference that will leave you both informed and inspired. Learn more at www.wirenet.org or contact WAI’s educational director, Marc Murray at mmurray@wirenet.org; Tel.: 001-203-453-2777, ext. 121. To register complete and return the form at right. Conference organized by:

The Wire Association International, Inc.

LEARN

AT:

Asociación Nacional de Transformadores de Acero A.C.

W W W. W I R E N E T. O R G

INTERNATIONAL TECHNIC AL CONFERENCE

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

CONFERENCE REGISTRATION FORM 18-20 O CTOBER 2010 | M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL ▲ Last Name

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[

] Early Registration Fee Before September 27 USD$ Only

First Full Registration Includes: Technical Program, luncheons, reception, and breaks

Additional Full Registration First Full Registration Plus WAI Membership Includes: Technical Program, luncheons, reception, and breaks Plus one-year WAI Membership

Regular Registration Fee After September 27 USD$ Only

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❑ $280

❑ $210

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REGISTRATION FEE IS PAID BY: ❑ Check enclosed in US dollars payable to The Wire Association International, Inc. ❑ Visa ❑ MasterCard ❑ American Express Fax registrations must use credit cards for payments of ALL meeting fees. Fax No.: (001) 203-453-8384

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Single Day Registration Includes: Monday OR Tuesday Technical Program, luncheons, reception, and breaks Check one: ❑ Monday ❑ Tuesday

Facility Tour Wednesday 20 October Space is limited - preference will be given to full registrants

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Signature Cancellation Policy: Refund requests must be received in writing by October 6, 2010 to receive a full refund. No refunds after October 6, 2010.

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FORM TO: The Wire Association International, Inc.

1570 Boston Post Road | P.O. Box 578 Guilford, CT 06437-0578 USA

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THE

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www.wirenet.org for conference updates as they become available. Contact WAI sales to learn more at: (001) 203-453-2777, ext. 119 or 126.

HOTEL RESERVATIONS: www.tinyurl.com/ITCONFERENCE2010 Conference organized by:

The Wire Association International, Inc.

Asociación Nacional de Transformadores de Acero A.C.

FEATURE

Rainbow Rubber & Plastics Inc./U.S. Rainbow Rubber & Plastics, Inc., has been a supplier to the wire and cable market for over a decade, solving the problems with caterpuller, capstan and haul-off belts. The company’s single-piece construction has no seams or splices, which eliminates common belt failures that have plagued manufacturers for years. Short belt life, cover separation and tracking issues can be reduced by using the proper belt structure and rubber compound. All of Rainbow Rubber & Plastics’s belts are designed specifically for the wire and cable industry. It has developed compounds that address problems with oil on the armoring lines and wear issues on CV lines as well as a belt structure with a breaker fabric that eliminates lengthwise splitting issues. Breaker fabric is a ply of fabric inserted in the middle of the belt that dissipates the down pressure across the entire width of

Mark MacKimm at the Rainbow Rubber & Plastics booth. the belt. This reduces centerline pressure that cause belts to wear and split. Combined with Rainbow Rubber & Plastics’ technical experience, manufacturers can be assured that they have the proper belt the first time, a basis that has helped the company gain customers such as Southwire, Okonite, Nexans, General Cable and Tyco, to name a few. Rainbow Rubber & Plastics, a leader in belting for the wire and cable industry, also offers on-site surveys and technical assistances to help reduce belt expenditures and increase machine up time. Mark MacKimm, mackimm@rainbowbelts.com.

Jason Rodd at the Refractron Technologies Corp. booth, a first-time exhibitor at Wire Expo. opment. Our industrial zirconia products benefit from our use of medical grade powder of very high purity. Our cost competitiveness is reflective of our vertical integration. Our manufacturing begins at raw powder processing and continues all the way to final polishing. Our understanding of the complex production nature of Mg-PSZ zirconia allows us to produce goods that allow greater performance and longevity. Whether you company is in need of replacement capstans or rollers, or if you have a unique problem, we look forward to helping you meet your challenges. We are also in the process of adding pulleys, eyelets and guides in numerous sizes. We look forward to being the wire industry’s ceramic expert. Jason Rodd, jrodd@refractron.com.

Sealeze, a unit of Jason Inc./U.S. Sealeze manufactures a range of brushes in Richmond, Virginia, that are used in a variety of areas in wire drawing

Refractron Technologies Corporation/U.S. Refractron Technologies Corp. focuses on providing its customers with the highest quality products, excellent value and superior customer service. Refractron has been working with wire customers to understand the specific needs of the wire industry and to educate both wire manufacturers and machine producers that all ceramics are not equal. We are continuously adding new parts in response to customers’ needs. We are also working with our customers to develop parts that have never been made with zirconia before, in order to solve long-standing wire production challenges. At Refractron, we have an extensive history in zirconia devel62 | WIRE JOURNAL INTERNATIONAL

Michael Jordan at the Sealeze booth. and forming operations to increase process effectiveness and efficiency. By removing excess scale or lubricants, the brushes improve drawing and bending machine perform-

Sjogren Industries/U.S. Why choose Sjogren Industries? For over 80 years, Sjogren Industries has remained a leading provider of quality machinery, tooling and accessories for the wire and cable industry. It offers the most respected line of quality precision wire tools in the market used for the handling and preparation of wire, rod or bar including: modular roll straighteners, a comprehensive line of roll straighteners along with replacement parts and precision grooved rolls. Our modular units, both two-plane standard and EC styles,

or tension control problems in material payoff or windup applications; wire roller guides; units for guiding wire in process lines; wire testing quality control equipment and accessories; torsion twist tester and wrap testing machines; and replacement grips for OEM tensile testing machines. All products are manufactured on-site in our Massachusetts plant, which makes it convenient and cost-effective “One Stop Shopping” for customers to order everything at once in one place. Jim Jolda, sales@sjogren.com.

Unitek GmbH/Austria Howar Equipment, Inc./Canada Austria’s Unitek GmbH, represented in the U.S. by Howar Equipment, manufactures a line of high precision and high concentricity fixed-center single and multi-layer crossheads for thermoplastic and fluoropolymer thermoplastic materials. The high precision designs can achieve the highest concentricities and hold them for extended service life. PVC heads are documented to last up to 50,000 hrs. Unitek manufactures a complete line of fixedcenter crossheads capable of producing up to 120 mm over-insulation cable diameters. With special tool designs,

Sjogren Industries’ Jim Jolda explains the finer points of a roll straightener during a Production Solutions presentation he made at Interwire 2009. combine a vertical and horizontal straightener, mounted in tandem which is an industry wide tried and true formula for straightening and or back tensioning of wire and cable. Two-plane standard units combine horizontal and vertical sections on a common base plate. EC modular style units can be supplied in 5, 7, 9, 11 or 13 roll units with two planes connected using specially configured brackets. Our precision grooved rolls deliver the tightest tolerances in the industry and can be manufactured for any application upon request. Additional straightener styles are available for a variety of applications as well as wedge grips, assemblies and replacement parts; three styles of puller assemblies for all wiredrawing machine applications; magnetic tensioning brakes and clutches; unique solutions for managing torque

JUNE 2010 | 63

FEATURE

ance and reliability, extend die life, improve uniform lubricant adhesion, and optimize surface finish and brightness. Additionally, when used in conjunction with chemical descaling, they can speed processes and lower costs by extending the life of the bath. Sealeze has been manufacturing brush solutions for industrial applications for over 30 years. The company’s brush products are found in applications ranging from shielding on machine tools to guides on conveyor systems. The custom-forming capabilities enable them to make shapes and designs specific to the needs of the application. Michael Jordan, industrial@sealeze.com.

FEATURE

a variety of materials and applications can be handled. In addition to the crossheads, peripheral equipment such as bypass valves are offered efficient purging of material and changing of product, which keeps the head clean during tool changes. Unitek is also a leader in automatic color change technology that allows A schematic of Unitek GmbH production lines to technology. change colors within 50-100 ft while at full line speed. More than 16 systems are available for various applications in automotive, building wire and communication cables. Unitek GmbH, office@unitek.at; Howar Equipment, www.howarequipment.com.

wire) in Korea for over 25 years and is also well known in Japan, Europe and Asia. The company also receives good feedback from the US market, with a US sales office in California that provides better service and quick response as well as better price. The thermal spray coatings WH precision uses are: powder flame spray coating, HVOF (High Velocity Oxygen Fuel), plasma spray coating and Rokide rod spray, wire spray coating. Powder flame spray coating is widely used for hard facing of steel, cast iron and some types of ceramic coating work. A high-speed HVOF spray coating provides high adhesion strength, and low porosity. This is the most suitable for spray coating of metal line powder, such as tungsten, carbide, and chrome carbide. Plasma spray coating is the most reliable technique for metals, nonmetals, nonmetallic carbides, oxides, borides and nitrides, and may also be used with organic plastics or glass. A Rokide spray coating can provide a thicker coating than plasma spray. Wire spray coating (metalizing) is highly efficient and creates a coating thickness from 0.7 mm to 2.5 mm. The company also offers hard facing and overlay welding. Jason Chung, jason.chung@whprecision.com.

Wire Lab Company/U.S. Whanghae Precision/South Korea Based in South Korea and with an office in the U.S., Whanghae Precision manufactures capstans and capstan rings, cone drums and guide rollers as well as pump sleeves, bearings, impeller & wear rings. The company offers different spray coating technologies that are designed to provide protection for from high temperature, wear, corrosion, erosion and oxidation. Specifically, it offers thermal

Whether the need is for basic low-cost mechanical descalers for the production of industrial quality wires, or an advanced automatic brush descaling system for applications demanding the highest quality drawn wire, WILCO has a system built specifically for your needs. For over 40 years, Wire Lab Company has specialized in the manufacture of durable, high quality mechanical descaling systems. Quality yet economical mechanical descaling machinery that can withstand daily operation in the wire mill is not a bolt-on accessory, the same way the descaler does not have to be larger than the wire drawing machine itself. All WILCO systems are made using the best quality, durable components. Solid 1 in. plate steel machine frames, hardened alloy steel sheaves, solid tungsten carbide wear components. WILCO descalers are the best overall value in mechanical descaling machinery today. Even when used on rods up to 12.7 mm in diameter, WILCO descaling machinery will perform day-in and day-out. Operatorfriendly control systems make WILCO descalers some of the easiest to use. Even our advanced brush descaling system, by incorporating PLC controls, does not require oper-

From l-r, Joan Park, Jason Chung and SangHoon Lee, of Whanghae Precision, a first-time Wire Expo exhibitor. spray coatings that include metals, nonmetal, ceramics, carbide, plastics and their compounds, as well as the same materials as the basic material are coated for basic material enhancement. WH Precision has supplied parts to 90% of wire companies (i.e. KIS wire, HyoSeoung, LS cable, JS

64 | WIRE JOURNAL INTERNATIONAL

Wire Lab Companyâ&#x20AC;&#x2122;s Rob Fulop and Al Luikart.

Witels Albert USA/U.S. Witels Albert’s AS PO series of straightening modules are able to provide the flexibility required by manufacturers today. There is a trend to produce and process highstrength materials with large diameters between 10 mm and 40 mm. The straightening of such materials requires straighteners that have more than five straightening rollers per plane and combine features such as high-speed closing and opening with the adjustability of all rollers. While a higher number of rollers is recommended because of the high material strength, the other features are indispensable for good handling of the process material and for ensuring an identical zero line for different diameters. Using the newly developed straightening modules of the AS PO series, it is possible to build straighteners that meet all the requirements because the modules themselves are already designed and configured to this end. The straightening module AS 1-20 PO, which holds an adjustable straightening roller, will be presented by way of example. Roller adjustment is performed using a hydraulic cylinder whose piston moves the built-in roller component against a stop that can be adjusted to a defined position. The defined adjustment of the stop is provided by a mechanical position display and is performed manually with low force. Alternatively, it is possible for the stop to be adjusted by means of an electromotive Witels Albert USA’s Bob Flower with drive using a brochure showing some of his comrelated hardware pany’s latest technology. and software. Mounting several AS 1-20 PO straightening modules on a sub-plate creates a straightener with high-speed opening and closing capability and rollers that can be individually adjusted to defined positions. Configurations with a larger number of straightening rollers for retrofitting singular or in groups are conceivable. Variable configuration of the roller pitch is also possible, thus enabling the straightening process to be

adapted to both the diameter and the strength of the process material. Through this expansion of the straightening range it is possible for example to process not only wire but also tube with great cost effectiveness in large as well as small batch sizes. Bob Flower, info@witels-albert-usa.com.

Yield Management Corporation/U.S. Yield Management Corporation (YMC) specializes in braiding machinery and accessories that improve the quality and production efficiency of braided cable. YMC supplies “deflector-less” rotary braiding machines that use Wardwell bobbins and increase the range of braid wire from diameters as small as 44 AWG to strands with high end count up to 12 ends. The deflector-less braider is avail-

Yield Management Corporation (YMC) specializes in braiding machinery and accessories that improve the quality and production efficiency of braided cable. able as a complete machine or as a retrofit head to existing Wardwell frames. The braider is available in 16, 24 and 36 carrier models. A second unit offered by YMC, a Low Bobbin Detector (LBD), delivers significant improvement in cable shield quality, consistency and productivity. The LBD also contributes to material savings, reduction in finished goods scrap and increased productivity. It stops the machine just before a bobbin is completely depleted, reducing braid defects that contribute to failed spark tests in jacketing and finished goods scrap. YMC manufactures LBD models for maypole, lever arm and rotary braiding machines as well as tubular stranding machines and cabling machines. The system is designed to be easily retrofitted to existing equipment and has optional features that position the empty bobbin to the front of the machine, increasing operator efficiency. YMC also offers Wardwell replacement parts, stocking the most common Wardwell spare parts for immediate delivery. Many parts have been improved to offer longer life and improved braiding productivity. YMC also offers a “fail safe” wire break detection system for cabling machinery. See page 78 in the Products section. Robert Brown, sales@yieldmanagementcorp.com. ■

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ator adjustment of the wire brush pressure. Simply select the brush pressure desired based on wire rod condition and the WILCO Brusher automatically maintains the setting. The WILCO controls constantly monitor brush condition and automatically adjust to account for wear producing a consistently very clean mechanically descaled rod. Robert L. Fulop, e-mail@wirelab.com.

TECHNICAL PAPERS

TECHNICAL PAPER Continuous casting technology and introduction to bar porosity detection infrared system A number of reasons can cause wire breaks, but one primary cause is bar porosity, which can be traced to the casting process conditions.

By Kiran Manchiraju and Victor Rundquist

The Southwire Continuous Rod (SCR) process was developed in 1964 and since its introduction there has been a significant increase in the production of electrolytic tough pitch (ETP) copper by the continuous casting and rolling process. See Fig. 1. Dramatic improvements in process control and plant productivity have been the main contributors to the ETP production increase. There has also been a significant decrease in the number of wire breaks and inclusions when this rod was processed into fine wire. A total of 80 SCR systems have been installed throughout the world. These systems are designed for production rates ranging from 7 to 54 metric tons of copper rod per hour. The size of the casting wheel is the main factor in determining the maximum production rate of a given system. Casting parameter concerns. Gas porosity during casting of copper is a major problem and can have a negative impact in the quality of the finished rod. Voids in the cast bar can be especially detrimental to processing rod into fine wire. The wheel-and-belt cast system provides a great

Fig. 1. Overview of SCR process. 66 | WIRE JOURNAL INTERNATIONAL

mechanism for the escape of these evolved gases during the solidification process. However, it is important to maintain proper casting parameters to facilitate the evolution of these gas bubbles. Casting parameters that influence the evolution of these gases and voids include: maintaining appropriate levels of oxygen to prevent hydrogen porosity; ensuring the casting wheel and belt are coated uniformly with the de-molding agent (soot) to prevent the macro and micro porosity in random areas of the chill zone; using cathode that does not contain excess amounts of entrapped organic compounds, which lead to dissolved gases in the molten copper; using an appropriate casting rate to allow dissolved gases sufficient time to escape upward before solidification; entrapment of atmospheric gases (nitrogen and oxygen) from turbulence of flowing copper that can result in macro and micro-porosity; and avoidance of inadequate cooling that, coupled with an inappropriate casting rate, can lead to vacuum voids in the cast bar.

The primary components to a cast system are the shaft furnace, casting wheel, bar handling line, rolling mill, pickling line and coiler. The wheel and belt casting portion of the casting system are described below in greater detail1. Wheel-and-belt casting. The SCR system is a wheel-andbelt casting system that consists of a water-cooled copper casting wheel and a flexible steel band. See Fig. 2. The casting wheel has a groove in the outer periphery and the flexible steel band goes approximately half way around the casting ring to enclose the casting groove. The casting groove in the wheel and the flexible steel band that encloses the casting groove form the mold cavity. A tundish, pouring spout and a metering device that is mounted on the casting machine deliver molten copper into the casting groove as the wheel rotates. A parting agent/mold coating (generally soot) is applied to the wheel and steel band just before the pouring point, which is at the intersection of the presser wheel and casting band. The molten metal is held in place by the steel belt until completion of the solidification process. As the wheel turns the copper solidifies. The solidified copper, with the help of the stripper shoe, exits the wheel. The wheel is then wiped and a soot coating is reapplied prior to the introduction of fresh molten copper.

in the micro-structural characteristics between the wheel side and band side at this time. Zone-III: It is sufficient to say for the purpose of this paper that in Zone III, solidification should be complete approximately 75째 beyond the end of zone II. The two assumptions made to arrive at this conclusion are: first, elimination of superheat in zone III; and second, the rate of heat extraction is essentially constant throughout the solidification process. Zone-IV: Zone IV results in further cooling of the solidified bar.

Solidification mechanism Solidification of copper in the mold can be divided into four distinct zones2-3. See Fig. 3. Zone-I. Flow of metal from the tundish into the casting cavity produces convection forces that result in a counterclockwise metal flow toward the band side and down towards the wheel side. Under these conditions the dendritic growth is inclined away from the walls of the band and wheel. It is important to note that the solidification in single phase and binary alloys (such as the ETP copper) occurs perpendicular to the interface and hence the principles of solidification in single phase and binary phase alloys that are well understood cannot be applied here. Zone-II. As the mold orientation changes the convection forces reverse the flow to a clockwise direction that in turn results in a change in the direction of the dendritic growth. See Fig. 3. It is tentatively concluded that the combination of a horizontal orientation of the mold and the elimination of superheat suppresses the convection forces within the liquid metal. This in turn leads to a more equiaxed grain structure on the band side of the caster. However, it is important to note that on the wheel side this transformation from a columnar to an equiaxed structure is less pronounced. No theoretical support is being offered for this difference

Fig. 2. Continuous casting setup.

Fig. 3. Cooling zones. JUNE 2010 | 67

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Wheel-and-belt cast technology

TECHNICAL PAPERS

Gas porosity theoretical model This subsection examines in greater detail the mechanisms that result in bar porosity. Generally, porosity in the cast bar is due to evolution of gases and or due to the aspirated gas from turbulence during the flow of molten copper into the casting mold. Unless the casting process provides a mechanism for the escape of these gases prior to solidification there will be gas porosity in the solid metal. One of the major advantages of the wheel-and-belt casting system is that it provides a mechanism for the escape of these gas bubbles. Gases in molten metal will travel upwards through the molten pool and be released into the atmosphere; however, if proper casting parameters are not maintained, gas bubbles may be trapped in the solid metal, forming gas porosity. The first part of this subsection deals with gases present in molten copper that are evolved during the solidification process. Secondly, gases entrained in the casting due to the turbulence will be discussed. There is a decrease in solubility or a change in equilibrium that results in gas separation from a liquid phase during solidification. Separation of gas bubbles takes place where the total pressure of the gases in the liquid exceeds atmospheric pressure and the hydrostatic pressure of the liquid metal. Voids created by different gases have a different appearance because each gas has a different diffusion rate within the molten copper. For example, hydrogen in molten copper separates in the form of coarse cavities for a given rate of heat extraction. A detailed analysis of the void formation in molten copper is beyond the scope of this paper, but is appropriate to briefly outline the influence of different gases present that gives rise to gas porosity4. Oxygen. Molten copper in contact with the atmosphere will dissolve a certain amount of oxygen. Oxygen reacts with most elements to form gaseous compounds, which in

turn could result in gas porosity. Hydrogen. Sievart5 demonstrated that the solubility of hydrogen in molten copper is proportional to the square root of the pressure. Based on the data by Sievart et al5, it can be concluded that hydrogen alone will not be the primary cause of gas bubbles. The high diffusivity and high solubility of hydrogen in molten copper at elevated temperatures prevents the formation of gas cavities by hydrogen alone. Generally, raising the amount of dissolved oxygen to drive off the excess hydrogen mitigates hydrogen porosity. Steam. Hydrogen in combination with oxygen is a more likely cause of gas porosity in molten copper. Steam is not soluble in either liquid or solid copper but its components (hydrogen and oxygen) are more soluble in the liquid metal. This results in separation of steam during solidification. It is important to note that excess evolution of hydrogen as H2O during solidification exhibits micro and macro porosity. Other gases. There is some evidence that other gases such as nitrogen, carbon dioxide, hydrogen sulfide and other hydrocarbons, could also cause gas porosity. Usually the gas forming elements come from the charge material (cathode), the furnace atmosphere or elements in direct contact with the molten metal. Aspirated gas during pouring. As molten copper flows into any mold, gas that is primarily oxygen and nitrogen is trapped as gas bubbles inside the molten pool. For the gases to escape, three mechanisms deserve special mention. 1) The gas bubbles have to reach a buoyancy force that reverses their direction and enables them to accelerate to terminal velocity. Once terminal velocity has been reached, the bubbles will be expelled from the point of pouring. It is

Fig. 4. Cross sections of the bar (cut from each half and placed side by side). Samples have been placed a little bit apart to approximate the width of the saw cut and the milling of the two halves of the sample. The machine side is on the right of the image. There is a slight re-melt line on the upper right side of the sample. The cooling is reasonably uniform with the width of the centerline void apparent in the photo.

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Fig. 5. Interior of the void, wheel side up.

Infrared technique A system that detects porosity, during the continuous casting (CC) of copper bar has been developed. This system uses an infrared camera that measures surface temperature as the copper bar exits the casting wheel and after the

Fig. 8. Bar with porosity and section on surface showing less heat due to the presence of porosity and associated temperature profile.

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important to note that the buoyancy force required to cooler. The temperature profile, without porosity, is parareverse the direction of the bubble is a function of time, i.e. bolic in shape. See Fig. 7. When a void is present in the bar excessive casting rates could prevent the bubble from the temperature profile changes. See Fig. 8. Further, a stareaching the necessary buoyancy. tistical algorithm that uses the temperature profile to accu2) If the terminal velocity of the gas bubble is slower than rately predict the size and distribution of voids in the copthe casting speed it must coalesce with other bubbles to per bar has been developed. achieve the buoyancy force necessary to evolve from the Methodology. The camera was mounted in an environmolten pool. Therefore, in a vertical casting position, as the mental enclosure on the casting machine. See Fig. 9. The casting speed increases the depth the gas bubble reaches computer and monitor were mounted in the casting control also increases, this in turn would increase the size of the room. The camera was focused onto the bar and data was bubble needed to escape. recorded continuously. Infrared technology to detect bar porosity. Infrared techThe speed of the casting machine was varied and the data nology that detects voids during continuous casting of copfrom the IR system were recorded. Bar samples were colper has been developed. This is a non-destructive technique lected at each of the casting speeds. After cooling, the samthat detects the presence and size of the void in copper bar. ples were sawed in half, longitudinally. A micrometer was Drawability into fine wire. Problems associated with used to count and measure the dimensions of all of the drawing into fine wire are heightened by the presence of voids in each bar. The total length of bar samples was flaws such as inclusions, surface defects, mechanical damage or voids in the copper rod. These flaws are typically introduced during the casting or rolling process. Particularly in fine wire drawing (<25 gauge) the presence or absence of voids in the copper rod determines its drawability. Voids in the center of the copper rod could result in central burst breaks. Central burst breaks originate in the center of the wire and propagate towards the surface of the wire in a 45째 angle. This results in a cup-and-funnel shaped void in the cen- Fig. 6. Cross section of cast bar with surface cooled. ter of the wire. Two mechanisms have been identified that cause central burst breaks: 1) Abnormally high tensile forces cause central burst breaks. Inappropriate die angles that result in excessive centerline tensile forces lead to cup-and-cone failures. Using drawing dies with an appropriate design can eliminate this problem. A discussion of the die design is beyond the scope of Fig. 7. Bar with section on surface re-heated from internal energy and this paper. associated temperature profile. 2) Voids present in the center of the bar also lead to central burst breaks. Fig. 4 shows typical centerline voids in the cast bar. Fig. 5 illustrates the advancing dendrite bridging the liquid gap.

TECHNICAL PAPERS

Table Ia. Correlation data for selected production rates: 1. Speed of casting machine in ft/min 2. Flaws as measured in the bar with a micrometer 3. Output of the IR flaw detection system 4. Difference = IR - Measured

recorded as a percent of production with a flaw (See definition). These voids were classified as, small (>.0007 sq in.) medium (>.0019 sq in.) and large (>.0035 sq in.). Tables Ia and Ib summarize the data obtained from the experiments carried out at SCRM. Table Ia is the raw data from the experiments. Table Ib is the same data with the flaw size distribution and noise correction factor included.

Results and discussion Analysis of the data summarized in Tables Ia and Ib indicates that the percentage of flaws detected by IR closely matches the flaw count by actual measurement. It is tentatively proposed that the difference between the actual measurement and the IR is attributable to the noise in the IR detection technique. Fig. 10 shows the total number of flaws counted in each day during a typical five-week period. The two spikes in flaw counts occurred at the end of a run. Due to the paucity of data, no conclusions can be made at this time except to note that the decrease in flaw count appeared to coincide with any changes to the set up of the caster. Usually, set up changes includes one or more of the following; new or refurbished casting wheel, new casting band, a new tundish and spout. The only theoretical support for this decrease in

Table II. IR Data by coil for fine wire drawability

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Table Ib. Noise corrected data: 1. Feet per minute

flaw count after a new set up is to note that any change in the set up would lead to improved/uniform cooling which in turn would reduce flaws during the casting. Four coils produced at elevated casting rates (higher than the normal casting rates for fine wire) were processed at SCRM and were drawn into fine wire (<25 gauge). The flaws detected by IR were classified as small, medium and large. Surface quality of the coils was determined by twist tests. Based on the IR and twist data it was determined that these coils were fine wire quality. All four coils reported no problems in the wire drawing process. Based on the excellent drawability into fine wire of these test coils, it is tentatively concluded that the Infrared system is capable of detecting porosity within the bar. See Table II.

Conclusions Porosity in cast copper bar as a function of casting parameters has been studied. The views advanced, in previous work, with supporting data from the present work indicate that there is an inextricable link between the casting conditions and the emergence of porosity in the cast bar. A review of the causes of wire breaks has revealed that while breaks can result due to a variety of reasons, the most notable cause for the wire breaks is due to centerline porosity in the bar. This work has demonstrated that during casting of copper, dissolved gases and aspirated gases (due to turbulence) will trap gas bubbles inside the molten pool. Unless the casting process provides a mechanism for the escape of these gases prior to solidification there will be gas porosity in the solid metal. A system that detects porosity during the continuous casting (CC) of copper bar has been developed. This system uses an infrared camera that measures surface temperature as the copper bar exits the casting wheel and after the cooler. A statistical algorithm using the temperature profile from the IR camera has been developed. The temperature profile, when fitted

TECHNICAL PAPERS Fig. 10. Chart of day vs. total # of flaws.

Fig. 9. Camera mounted on casting machine.

to an nth degree polynomial and evaluated by analyzing the residuals at peak temperatures, reveals porosity less than 1/8th of an inch in diameter. Several test coils were run at SCRM at higher bar speeds and IR data compiled. Coils that showed minimal porosity evidenced by the IR data were processed into fine wire. Based on the excellent drawability into fine wire of these test coils, it is tentatively concluded that the infrared system is capable of detecting porosity within the bar. Future work on the system will be done to refine the size of the flaw being detected. This refinement will consist of deciding what size flaw causes problems in the drawing process as well as attempting to detect smaller flaw sizes. Different algorithms will be implemented and the same set of experiments performed to determine their reliability. ■

Manchiraju

Rundquist

Kiran Manchiraju is director of business and product development for the Southwire Continuous Rod Division of Southwire Company, Carrollton, Georgia, USA. He began his U.S. wire industry career in 1994 at Nichols Aluminum, and in 1996 joined Southwire’s plant in Macon, Georgia, where he started as a quality/technical manager and was later placed in charge of plant operations. He also served as chief metallurgist, providing engineering/technical support to all four corporate divisions, and in 2006 was promoted to his current position. He holds Bachelors and Masters degrees in physics from India, an MS degree in materials science and engineering from the University of Kentucky and an MBA from Georgia State University. Victor Rundquist is an SCR development engineer for Southwire Company SCR Technologies, Carrollton, Georgia, USA. He has been with the company since 2006. He previously worked in the electrical engineering department of Auburn University, Auburn, Alabama, USA, and for the NASA Ames Research Center, Mountain View, California, USA. He holds an M.S. degree in electrical engineering and a bachelor’s degree in wireless engineering, both from Auburn. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009. JUNE 2010 | 71

TECHNICAL PAPERS

TECHNICAL PAPER Factors that influence ink adhesion on wire and cable substrates This paper presents a guide meant to provide a basic understanding of the fundamentals of the ink marking process for wire and cable products, including the types of available technolgy, limitations and options.

By Mark Spencer Wire and cable are coated with insulation designed specifically for protection against external elements. Depending on the final product application, these extruded coatings are inherently designed to be chemically resistant, impervious to water, gasoline, oil, UV sunlight, abrasion, temperature and flammability, just to name a few. As a consequence, the last and most often overlooked consideration for jacketing or insulating material is product identification. Unlike most printing applications, the printing environment is not controlled. The product is continually moving, often at high speeds, twisting and turning. It is often irregular in shape, and is subject to temperature variations, and exposure to moisture as well as contact with talc, guide sheaves, pulleys and measuring devices. Further compounding the problem, the extrusion line is often variable as one can extrude one compound during the first shift and change to an entirely different compound for the second shift. Most extruded insulations are, by design, resistant to chemical and environmental attack and therefore inherently resistant to ink adhesion. This paper presents some of the challenges one faces when trying to get ink to adhere to a surface that is designed to repel the elements, but first it will provide a basic understanding of the forces at work.

those in the body of the liquid. The result is the creation of a surface film or tension. As a result, all of the molecules at the surface are subject to an inward force of attraction, in concert with a driving force to diminish the surface area, thereby causing the liquid to squeeze itself together until the lowest possible surface area is achieved. Decreasing the surface area of a mass of liquid is always spontaneous. To increase surface area, a certain amount of energy must be added. It is these forces that must acted on for proper ink adhesion to occur. Measurement of surface tension of a liquid. Surface tension can be expressed as the force along a line of unit length, where the force is parallel to the surface but perpendicular to the line. Contact angle measurements can be used as a reference to determine the “wettability” of a liquid to a solid surface. Wettability can be defined as the contact angle between a droplet of liquid in thermal equilibrium on a horizontal surface. It can also be expressed as the ability of a solid surface to reduce the surface tension of a liquid in contact with it, thereby causing the liquid to spread over or “wet” the surface. See Fig. 2. The smaller the contact angle the greater the wettability or surface energy of the surface. Surface tension measurements are expressed in dynes/cm.

Properties of liquid ink Surface tension. This is the property of how a liquid will behave at the surface. It governs the shape that the liquid can assume and the degree of contact a liquid can make with another substance. In the body of the liquid, each molecule is pulled equally in all directions by neighboring liquid molecules. These are referred to as cohesive forces. At the surface of the liquid, the molecules are pulled inward by the cohesive forces located deeper inside the liquid and are not attracted as intensely by the neighboring molecules at the surface. See Fig. 1. The molecules at the surface, by not being completely surrounded by molecules on all sides, are more strongly attracted to those like molecules at the surface in conjunction with 72 | WIRE JOURNAL INTERNATIONAL

Fig. 1. Diagram showing the surface tension of a liquid.

Relationship between ink and substrate Surface energy of the substrate. Substrates with higher surface energies are more receptive to ink adhesion. As the industry moves progressively to substrates with lower surface energy, external processes are required to increase the surface energy required to make the substrate more receptive. Examples of solid substrates with higher and lower surface energy include: metals and metal oxides, >100.0; polyimide, 40.0; polyvinylchloride (PVC) rigid, 39.0; polyethylene HDPE, 33.0; polypropylene PP, 32.0; polyethylene LDPE, 31.0; and polytetrafluoroethylene PTFE, 18.0-20.0 The surface energy of the substrate must be greater than the corresponding ink for adhesion to occur. It is this relationship between the solute (ink) and the substrate (jacketing or insulating material) that determines the attraction between these two surfaces. For instance, water has a high surface tension (72 dynes/cm) and PTFE has a low surface energy (18-20 dynes/cm). If a drop of water is placed on a flat PTFE surface, the drop will not flow out on the surface, but will tend to bead up. The attraction between the water and the PTFE is so weak that there is little force to pull the water toward the PTFE. This example can be used to explain the relationship between surface tension of inks in relation to the surface energies of the insulating or jacketing materials.

In general terms, in order to optimize adhesion, the dyne level of the substrate must exceed that of the ink by a minimum of 2 dynes. Since most conventional solvent-based inks have surface tensions in the range 35-38 dynes, adhesion will occur spontaneously on substrates, like PVC, that exhibit higher surface energies. Conversely, substrates with lower surface energies, like HDPE, may require external treatments to increase the surface energy of the substrate, making it more receptive to the ink. Testing methods such as contact angle measurement, cotton swab applicators, wire wound rod applicators or dyne test pens are available to determine the surface energy of a substrate. However, these test methods are more suitable for controlled use under laboratory conditions as opposed to use by wire and cable manufacturers, due to misuse, associated health risks, potential for cross contamination and test accuracy.

Ink formulation Printing inks, dyes, and extenders. Inks are primarily composed of solvents, pigments and resins. A pigment provides color and opacity while imparting abrasiveness and resistance to heat, light and solvents. Resins are binders that provide adhesion and film properties to the ink. Solvents are the carrier that makes the ink liquid, leaving the jacketed surface shortly after application via evaporation. Solvents also stabilize the ink and promote adhesion by means of a superficial chemical attack on the substrate. It is the custom blending of pigments, resins and solvents, in addition to special additives, that provides inks that are method and product specific. The majority of inks used in wire and cable applications are pre-mixed and formulated by the ink manufacturer. The printing operators must rely on the ink manufacturerâ&#x20AC;&#x2122;s expertise to develop formulations that will provide the appropriate ink application, solvent evaporation and adhesion of the pigment-resin system to the cable surface.

Fig. 2. Diagram showing surface tension measurement of a liquid. JUNE 2010 | 73

TECHNICAL PAPERS

This is the force in dynes required to break a film of length 1cm. Examples of liquids with high and low surface tension: (measured at 20Â°C) include: mercury, 465 dynes/cm; water, 72 dynes/cm; acetone, 23 dynes/cm; ethyl alcohol, 22 dynes/cm; and methyl ethyl ketone, 20 dynes/cm Liquids with high surface tension have higher contact angles than liquids with lower surface tension. In a majority of cases, the challenge is to lower the surface tension of the ink, making it more receptive to the cable surface. As a result, solvent-based inks, because of their lower surface tension, are more commonly used in wire and cable applications. Solvent-based inks are also more volatile, allowing faster evaporation rates that improve the dry time of the ink. As a consequence, solvent-based inks tend to release more VOCs (volatile organic compounds) into the atmosphere. Water has a high surface tension, which means that it is strongly attracted to itself as opposed to the surrounding surfaces. As a result, water-based inks, having an initial higher surface tension than their solvent-based counterparts, require the addition of solvents and special additives to reduce the surface tension required for bonding and film adhesion to the cable surface. For instance, water has a dyne level of 72, but adding 10% ethyl alcohol to water will reduce the dyne level from 72 to 47. Water-based inks inherently have slower dry times because the solvents used in water-based systems are generally less volatile.

TECHNICAL PAPERS

The interaction that occurs at the surface of the ink, known as the liquid, solid, air interface, is different than that which occurs within the body of the liquid. The body of the ink must therefore be maintained as a homogeneous mixture, making available to the surface all of the components necessary for ink application, ink adhesion and ink contrast to occur. Because of this, ink formulations for wire and cable uses must be method and product specific: Gravure inks are specific to contact printing, inkjet inks are specific to inkjet printers, band-marking inks are specific to spray markers, and liquid dyes and solid colorants are specific to color coding. Whenever inks are blended, complex interactions occur. As an example: concentrations of organic solvents, alcohols and surfactants used to lower surface tension often have an adverse effect that can reduce the adhesive qualities of the ink. These adverse effects must be counteracted either by varying the concentrations or by the addition of additives or stabilizers. Therefore, ink formulations should be considered as a balancing of desired attributes custom blended for a specific printing application.

Ink application methods In all cases, whether printing in-line during extrusion or off-line during re-spooling, jacketed wire or cable must be clean, dry and free of moisture and impurities. There should be no barrier between the ink and the corresponding substrate. Printing inks and extenders must be used in accordance with their intended purpose, according to the manufacturerâ&#x20AC;&#x2122;s recommendations and specifications as outlined on the label regarding handling, mixing, storage, exposure, flammability, compatibility and disposal. Contact printing (Gravure). In this printing method, the periphery of an engraved print wheel, revolving in a bath of ink, is wiped clean by use of a â&#x20AC;&#x153;doctor blade.â&#x20AC;? Ink that remains in the engraved surface is then transferred directly to the cable. The surface of the print wheel is optimized to prepare the ink for application to the cable surface. The wheel surface is smooth, polished and industrial chrome plated for a very low coefficient of friction to facilitate ink release. The engraving is very precise, composed of a series of cells that transfer specified amounts of ink to the cable surface. The engraving cell size, depth and pattern are selected based on many factors that include the type of insulating compound, its surface energy, texture and hardness. The contact between the print wheel, doctor blade and cable surface reduces the surface tension of the ink, increasing the surface area between the ink and the cable, providing a smooth application of the resins and pigments. This allows the solvents to evaporate, thereby improving the dry time required for ink adhesion to occur. Cable jackets with high surface energy, like PVC (39 dynes/cm), may be more receptive to superficial attack, allowing the components in the ink to bond to the cable surface, exhibiting excellent adhesive properties. On the opposite end, PTFE (19 dynes/cm), exhibits such low surface ten-

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sion that inks can only be applied to the cable surface. For these applications the engraved wheels must have a tightly formed radius that allows the wheel to more closely conform to the outside diameter of the insulated wire or cable jacket. For cable jackets with irregular surfaces, Gravure printing methods are employed by transferring ink from a print wheel to a silicone or EPDM transfer roll, which in turn conforms to and releases ink to the cable. In all cases, Gravure inks used in contact printing must be thoroughly mixed prior to use to optimize ink transfer, contrast and adhesion. Viscosity must be maintained by periodic addition of solvents/extenders manually or via a viscosity control system. Continuous inkjet (CIJ). Unlike Gravure printing, inkjet is a non-contact method of continuous marking that employs an entirely different technology. A stream of ink is continuously circulated and acted upon during the printing process. The inks used in inkjet printers are far more sophisticated than those required for Gravure printing. The inks are finely milled, allowing them to pass through the print head and recuperation gutter. The inks are conductive, which allows the charged droplets to be deflected to form characters. The ink components are continuously monitored in order to assure that the components are maintained in a homogeneous suspension. Additive is automatically dispensed to maintain viscosity at fixed levels. An ink chamber in the print head contains a small nozzle and a vibrating crystal. As the pressurized ink flows through the chamber toward the nozzle, the vibrating crystal changes the shape of the ink stream from a solid stream to a series of droplets that are marginally connected. As the ink stream leaves the nozzle, the stream breaks into individual droplets that continue down the print head through a set of charge plates. Since CIJ inks are conductive, the ink droplets can be deflected by changing the electrical current on the charge plates. The droplets needed to form the desired characters are deflected. The remaining droplets, not charged, fall directly into a small vacuum tube at the bottom of the print head and are returned by a vacuum tube to the ink container. The size of the droplet varies and is dependent on the modulation of the vibrating crystal, nozzle size, and ink pressure. In CIJ printing, all of the attributes of the ink, including the ink adhesive properties, are contained within the individual ink droplet. The parameters associated with CIJ ink application are dependent on the size of the drop, the velocity of the drop, the number of drops and the throw distance of the drop. It should be noted that the volume of ink released from an individual cell of a print wheel is many times the size as compared to a single droplet of ink from a CIJ printer. CIJ ink droplets are extremely small and can fire at high rates in excess of 60,000 drops per second. Color coding. This is method of applying a liquid dye, pigmented dye or solid colorant to the outer surface of insulated wire, cable or braided products. Color coding requires the use of an immersion-type applicator or dye pot. The dye pots are supplied with wiper systems that control the amount of coat-

Factors influencing ink adhesion Contaminants. Any impurities, including moisture, that exists on the cable surface at the time of ink application. Ink selection. This should be done in accordance with the type of printing equipment used and the ink manufacturer’s recommendations. Inks are product specific and selection is based on the application method, substrate type and its location within the extrusion line or re-spooling operation. Factors that directly impact ink performance include: selecting an incompatible extender, improper mixing, improper storage, ink contamination or use after expiration date. Ink temperature. Ink temperature should always be maintained at ambient temperatures. As ink temperature increases, solvent evaporation accelerates, requiring additional solvent to maintain viscosity. Viscosity. Viscosity is the resistance of a liquid to flow at a given temperature. Unless solvent is replenished, the result is an increase in the pigment to solvent ratio, adversely affecting the flow characteristics of the resin and application to the cable surface. Plasticizers. These are additives used to increase the softness or flexibility of the cable jacket. They tend to exhibit lower surface energies and can negatively influence ink adhesion by migrating to the cable surface before or after ink application. Substrate surface. Textured or porous substrates have a larger surface area than nonporous smooth surfaces. A larger surface area will increase the number of sites available for chemical bonding and also accelerate solvent release. Polymers. Polymers with higher surface energy, like PVC, are more receptive to ink adhesion than polymers like LDPE, that have lower surface energy. Print speed. Ink selection should be made in accordance with line speed and temperature of the substrate. With an increase in line speed, there is a corresponding decrease in duration or exposure time for the ink application and subse-

quent solvent release from the cable surface. Extenders are available to either increase or decrease the evaporation time based on the speed and temperature of the product. Auxiliary equipment. Guide rollers, sheaves, footage markers, take-ups, re-wind equipment or a cooling trough located immediately after the printing process may not provide the necessary space required for proper ink adhesion to occur.

Factors that could improve ink adhesion For the remaining compounds, external forces must be applied, in varying degrees, most often related to the dyne level of the substrate. Below are further considerations and types of processing elements that can be used. • Slowing down the line speed will increase the exposure time of the ink, thereby improving ink adhesion on those substrates that are more receptive to chemical bonding. • Increasing the surface temperature of the substrate will increase its surface energy. By locating printing equipment in-line during extrusion, inks will be exposed to substrates with higher surface temperatures. In the case of band marking, this is automatic due to the band markers’ location in close proximity to the extrusion head. Both contact printing and ink jet marking are normally done after the first or second water trough, at a point where the substrate is warm or ambient as opposed to hot. In these locations, air wipes accelerate compressed air and direct it toward the cable surface to remove excess moisture. Depending on product application, type of substrate and ink being used, contact printers or inkjet markers can be relocated to areas closer to the extrusion head. • When printing off line or at ambient temperatures, the addition of a heat tube or oven can be utilized. The heat tube or oven can be located prior to, immediately after or in both locations relative to the printing apparatus. The effect of the substrates’ exposure to temperatures generated by the heat tube or oven are related to the type of ink used, its method of application, the type of substrate, its corresponding surface energy, the speed of the production line, the length of the heat tube or oven and the heat tube or ovens temperature setting and proximity to the substrate. • Sintering is required when ink no longer has the ability to adhere to the surface of the substrate, normally because the surface energy of the substrate is so low. This requires the use of a sintering oven, where the temperature is elevated to a point typically just below that of melting, that allows the suspended components of the ink to bond or fuse directly to the substrate surface. The parameters for application and exposure are similar to those outlined under heat tube and ovens. • Corona treatment is a form of surface treatment that is located in-line, just prior to the inkjet or contact printer for pre-treating substrates with low surface energies. A high voltage electrical discharge is created in the area surrounding the surface of the cable forming a field of highly charged electrons. These charged electrons react with and break the molecular bond at the surface of the substrate, temporarily increasing the surface tension of the substrate and improving its wettability.

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TECHNICAL PAPERS

ing applied to the surface. Being a coating or saturation process, the product must be constantly moving to prevent overexposure to the solvent or resin system. The immersion time is controlled by the line speed, the volume of dye in the pot and the sheave arrangement in the applicator. Reducing the immersion time and increasing the number of passes improves color contrast. Extenders are used to maintain and to control the viscosity. Band marking. Band marks are continuous colored bands located 360 degrees around the circumference of the insulated wire. Band marking is performed in the extrusion line, in close proximity to the extrusion head. This is a spray application using single- or double-disc drums revolving in conjunction with oscillating nozzles. Inks are specially formulated for these applications. Since band marks are normally applied near the extrusion head, where temperatures are elevated, water-based inks are often used because there is sufficient dry time for the solvents to draw off of the surface.

TECHNICAL PAPERS

• Plasma treatment is similar to corona treatment, with the exception that the environment surrounding the surface of the cable is more highly charged with oxygen ions, further increasing the reaction rate, making inks even more receptive to the surface of the substrate. • Gas flame plasma treatment can be used to form a plasma field is formed when flammable gas and air are combined to form a flame. Exposure to the flame polarizes the surface molecules of the substrate through oxidation, making the cable surface more receptive to ink adhesion and wetting. The dyne enhancement effects achieved through flame treatment are generally longer lasting than those of other treatments. Some of the variables associated with gas flame treatment include the exposure time of the flame to the substrate, the distance of the substrate to the flame, the composition of the air gas mixture and the intensity of the flame.

Conclusion This paper was intended to provide some basic understanding as to the variables associated with ink application on wire and cable substrates. It is meant to provide basic information regarding methods of improving ink adhesion and its limitations on certain substrates. Certain wire and cable constructions must pass stringent testing to assure that ink adhesion is permanent for the intended purpose of the product involved. The interaction between the chemistry of the ink, the formulation of the compound and the method of application all play a pivotal role in the adhesion of the ink to the substrate. It is critical to be in contact with the ink, compound and equipment manufacturers for assistance whenever having difficulty with ink adhesive issues. ■

Spencer Mark S. Spencer is one of the principal partners at W. Gillies Technologies LLC, Worcester, Massachusetts, USA, serving as executive vice president and as a member of the RSD Technik GmbH Group. He has more than 30 years’ experience in the printing industry for wire and cable applications. He began his career in the family business at Duncan M. Gillies Co. Inc. before it joined with Germany’s Wetzel GmbH to form W. Gillies in 1996. He held various positions within the company, experiencing all levels of management, before leaving day-to-day operations in 1997 as an officer of the company and vice president. He received his B.S. degree from Springfield College, Springfield, Massachusetts, USA. He has been a member of the Wire Association International for more than 25 years and has served as officer, president, and member of the Board of Directors for its New England Chapter. He was a member of its Conference Programming Committee and is part of the Exhibition Planning Committee and the Member Relations Committee. He also serves on WAI’s Board of Directors. This paper was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009.

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THANK YOU WAI acknowledges the following CONTRIBUTORS to the WIRE EXPO 2010 TECHNICAL PROGRAM The educational program at Wire Expo 2010 was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission.

AUTHORS/PRESENTERS

Motoo Asakawa José Miguel Atienza Friedrich-Wilhelm Bach Bae Jong-Gu Ban Deok-Young Sanjiwan Bhole Dirk Bormann Ryszard Budzik Dorota J. Byrska Casey Clayton Thomas Clerkin Thomas Crafton Hubertus Damm Jeff Dewberry Romayne DuPraw Manuel Elices Rick Elmer Ehtem Erdas Jacob Friedman Sandy Fulton Masoud Garshasb Javier Gil Sevillano Bogdan Golis

Ken Hardin Richard E. Hoffmann, Jr. Eric P. Hummel Naoyuki Katsuoka Shunichi Kikuchi Masaki Kitazawa Peter Kordt George Krauss Mark Kristoff Ramona Krogman Paul Kulongowski Daisuke Kurihara Piotr Kustra Marcin Kwapisz Neil Lowdon Łukasz Marchewka David K. Matlock Joe Memmott Andriej Milenin Justin Mortimer Kotaro Nishimura Chikahiro Ohkubo Yohei Ohno Ed O’Neal

Tomoko Osada C.G. Park Ryan Pennington Jan W. Pilarczyk Horace Pops Valery Rudnev Yoshio Saiki Scot Sandoval Jan-Marten Seitz Sonomi Shirasaki Bruce Stobbe Andrzej Szymonik Yasutoshi Takemoto Yuichi Tanaka Tadashi Tashima Jeffrey T. Tyl Thomas W. Tyl Walther Van Raemdonck William Wilson Rafał Włudzik Rory A. Wolf Y.S. Yang Akihisa Yokoyama Kazunari Yoshida

MODERATORS

Dane Armendariz Masoud Garshasb Tracy Gooding Rick Gordon Scott Higgins Erik Macs Don Schollin Mark Spencer Andrew Stromer Bhaskar Yalamanchili COURSE INSTRUCTORS

Joe Domblesky Keith Donahue Bob Glodowski Horace Pops David W. Riley David Trautner GUEST SPEAKERS

Dale King Horace Pops Jennifer Rodgers

PRODUCTS & MEDIA

PRODUCTS & MEDIA PROD DUCTS Extension cord meant to stay plugged U.S.-based Coleman Cable, Inc., has introduced an updated line of locking extension cords that are designed to keep tools plugged in, eliminating the frustration and hassle of power loss. When connected to a tool or other electrical device, the cords provide a positive lock and can be disengaged only by choice, a press release said. The locking extension cords are ideal for job sites, workshops and outdoor everyday usage, it said, noting that the UL-listed cords have a SJTW jacket that provides rugged durability and resists moisture, abrasion and prolonged exposure to sunlight and the elements. The cords are available in 14 and 12 gauge and come in lengths of 50 ft and 100 ft. Contact: Coleman Cable, Inc., www.colemancable.com.

Non-contact eccentricity gauge precisely locates insulated wire U.S.-based Beta LaserMike reports that its non-contact CenterScan 2010 gauge uses an optical measurement system, based on its proven AccuScan technology that precisely determines the location of insulated wire. A press release, which said that the rugged CenterScan 2010 gauge uses a driver coil set and detection system constructed of optical and magnetic sensors to detect if the core of insulated wire and cable moves off-center, noted the following. The driver induces alternating current into the conductor to produce a magnetic field along the wire. This induced magnetic field is detected by highly sensitive coil sets strategically located around the wire to determine precise location of the conductor, and that location information and diameter measurement are used to determine the orientation of the conductor and the center of insulation to provide concentricity, eccentricity and angle measurement. Then, via various communication means, the data go to either a Beta LaserMike-provided controller,

78 | WIRE JOURNAL INTERNATIONAL

such as the DataPro 5000, or a third-party device for integrated process control. While the factory-calibrated Centerscan 2010 offers higher EMI resistance, less sensitivity to wire positioning within measurement area, multiple Fieldbus choices and a compact profile), it also offers multi-function measurements (eccentricity, flaw detection, diameter, ovality); flexible communication for easy integration; robust, compact design for reliable operation under harsh conditions; optional ultra-bright integrated display; and integrated air purge for extended operation, the release said. Contact: Beta LaserMike USA, tel. 937-233-9935, www.betalasermike.com.

Fail safe system detects wire breaks in both stranding and cabling lines U.S. based Yield Management Corporation (YMC), which has released a new product for detecting wire breaks in stranding and cabling machines, reports the following information about the technology. The system monitors individual spool rotation using optical sensors mounted outside the machineâ&#x20AC;&#x2122;s rotation and detects a non-rotating spool in less than 1.5 meters of product travel, stopping the machine before the broken wire reaches the next section. This fail-safe detection method significantly improves productivity and product quality. The product, which can be custom configured for most planetary and rigid frame and planetary cabling machinery, uses a Siemens hardware platform and an HMI that provides the operator interface for initial set-up and continuous monitoring. Once configured, no other inputs are required, and the system continuously monitors each spool, unaffected by machine speed. It is simple to maintain and operate as it does not rely on slip rings or expensive radio frequency transducers. Rather than monitor the collecting die, the company notes that the YMC system monitors spool rotation and detects wire breaks, often before the wire end reaches the collecting die, making for easier cable repair and improving product quality and productivity. The technology offers great cost savings to manufacturers of power cables or underground cables who require minimum continuous lengths as well as those who strand non-conductive materials, such as glass fiber, where conventional wire break detections systems fail. Contact: Yield Management Corporation, tel. 413283-7773, bbrown@yieldmanagementcorp.com.

A new line of Resilience™ cables from U.S.-based Northwire, Inc., has been designed for use in the nacelle of the wind turbine for low-voltage control, data, communication and exposed-run power applications. The cables, a press release said, are UL and Wind Turbine Tray Cable (WTTC) approved and NFPA 79 (12.2.2) rated for constant flex and high performance. The cables have long torsional and bend flex-life and have exceeded Northwire’s cold-bend test at temperatures as low as -40°C, it said, adding that they are also highly oil-resistant (Oil Res I and II) and are FT4 flame-rated. The cables, sizes 6 to 18 AWG, are available in AWM 300V, 600V and WTTC-rated 1000V standard configurations with a myriad of options for customization to support evolving technology, it said. They are also TC-ER (tray cable, exposed-run) rated and WTTC UL 2277 compliant. The cable can be designed to ship in five days with no minimum order length or quantity. Northwire notes that it is a member of numerous industry

bodies, including the Fieldbus Foundation, ODVA (Open DeviceNet Vendor Association), PTO (Profibus Trade Organization) and MCAA (Measurement Control and Automation Association), eMerge Alliance, AWEA (American Wind Energy Association), among others. Contact: Northwire, Inc., tel. 715-294-2121, www.northwire.com/resilience.

Crosshead designed specifically for use with high-flame retardant fillers Austrian-based Unitek, represented in the U.S. and Canada by Howar Equipment, Inc., reports that its engineers, in collaboration with solar cable customers, have developed a proprietary crosshead designed to work well for compounds with high-flame retardant fillers. A press release explained that such compounds are becoming more prevalent in use, in particular for applications such as solar power cables that are in strong demand because of the increased focus on green technologies. However, conventional crosshead designs have diffi-

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

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JUNE 2010 | 79

PRODUCTS & MEDIA

Cable designed for harsh environments

PRODUCTS & MEDIA

culties processing these compounds, it said, noting that Unitek has focused on this challenge through compound flow analysis, design and trials. The result is that a newly designed crosshead has been developed, installed and is producing cables for the solar industry, it said. “With today’s demand growing for ‘green products and services,’ companies have to look toward new and exotic compounds to meet these needs,” the release said. The new crosshead, which embodies the durability and precision that are the foundation of Unitek’s lines of crossheads, does just that, it said. Contact, Andrew Stromer, Howar Equipment, Inc., tel. 905-265-8912, sales@howarequipment.com, www.howarequipment.com.

Continuous ink-jet printer offers cable makers high-resolution marking U.S.-based ID Technology reports that its ci1000 micro continuous ink-jet printing system for applying high-resolution, high-speed identifying marks, lot and date codes to any surface works well for wire and cable. A press release said that the non-contact printer provides near-letter quality print resolution as the micro printhead can accurately produce fine characters as small as .025 in. at speeds up to 1755 ft/min. The system includes a single electronic board with surface-mount technology and a dual 32 bit processor architecture for an operating platform that can offer standard fonts in hundreds of different printing formats, it said. It can provide WYSIWYG field drag and drop message formatting with an integral graphic WYSIWYG graphic editor, while standard memory stores in excess of 1000 messages with the ability to print up to five lines of text, it said. The printer has a “smart” printhead and the ink system components critical operating settings are automatically adjusted dependent on the environment to maintain optimum print quality, the release said. Designed for a global market, the ciSeries systems feature multiple language formats that make possible multi-national characters as well as custom graphics, it said. Contact: ID Technology, tel. 888-438-3242, www.idtechnology.com.

TPU meets tough safety standards for both IT and consumer electronics Huntsman Polyurethanes, part of Belgium-based Huntsman Advanced Materials (Europe) BVBA, reports that it has developed a new fire-retardant, halogen-free thermoplastic polyurethane (TPU) that complies with current safety standards for cable jacketing materials used in the IT and consumer electronics sector. Introduced at wire 2010, the TPU, designated IROGRAN®

80 | WIRE JOURNAL INTERNATIONAL

A95P5003DP, complies with key criteria set out in the European RoHS directive and US VW1 standard, a press release said. It noted that the low-smoke TPU meets demands for a durable cabling material that is free from hazardous substances. The product can be extruded at high speeds on conventional PVC processing equipment and has a good surface quality, which makes it ideal for use in both cable power systems and injection molding for electronic devices including plasma screens, mobile phones, MP3 players, digital cameras and laptops, it said. The new TPU can be used wherever maximum mechanical strength, high tear resistance and mechanical reliability are a must, the release said, adding that it can be used for extrusion and injection-molding applications that include wire and cable, hoses, tubes and more. Contact: Franz Michel, Huntsman Polyurethanes, franz_michel@huntsman.com, www.huntsman.com.

Multiple technologies led to creation of energy-saving diffusion furnace Austria’s CPA Wire Technologies GmbH, a sister company of the control technology, MES, and galvanic control system provider, CPA Computer Process Automation GmbH, has introduced a patent-pending, two-phase crossflow convection diffusion furnace for brass plating. The AEOX furnace system, a press release said, can save up to 40% of specific energy consumption per kg of wire. It noted that the system provides multiphase recuperation by pre-heating of the combustion air while cooling the exhaust gases as well as recuperation of the heat drag-out by the hot wires. The air in the furnace is heated by either gas burners or electric heating elements that circulate at high velocity in cross direction of the wire and heat the wire very fast due to the good heat transfer through the generated high convection ratio, it said. The temperature is held constant in a subsequent recirculation furnace with longitudinal flow until the total microstructure transformation of the copper/zinc layer to brass is reached, it said. The applied air velocities usually add up to 25-30 m/sec. For the recirculation of hot furnace gases, a special fan for temperatures over 800°C is applied. That is in addition to the monitoring function of all electrical parameters and the lubricant supply with a

PRODUCTS & MEDIA

flow, pressure and oscillation documentation via the process control and diagnosis system IMPERIO by CPA. This enables a fast remote diagnosis and maintenance support via the internet in case of malfunctions. As an option, redundant fans, burners and control systems are also offered. The release noted that CPA’s new Do It Yourself (DIY)Plug & Play concept extremely simplifies the erection and commissioning of the modularly designed furnaces. Contact: CPA Wire Technologies GmbH, www.cpa.at.

Technology improves excess fiber length control for dry cable designs Austria’s Rosendahl GmbH reports that its newest generation loose-tube, secondary coating line supports excess fiber length (EFL) control for even small product dimensions. A press release said that one of the keys is the use of the company’s “clenching process” technology (Clenching Caterpillar NCA 210) within its RL-R/OFC40 secondary coating line for either fiber optic loose tubes or dry tubes production. It explained that there is more interest in totally dry fiber optic cable (FOC) designs instead of traditional jelly-filled designs as the dry designs are easier to work with, especially for fiber splicing. The dry tube designs, it noted, use swellable materials, such as superabsorbent powders (SAP) or swellable yarns, but the production of loose tubes without jelly filling can cause tube diameter variations and in the worst case a collapsing of the tube after the extrusion head. To counter such problems, the release said, Rosendahl has introduced a clenching concept that compensates the EFL increase as low EFL is required for producing compact dry loose tube FOC designs. The clenching caterpillar, installed in front of the mid span capstan inside the tube cooling section, ensures a very low tube tension during the tube crystallization process, and reduces post shrinkage (REL) of the produced buffered tube. The clenching caterpillar has to meet specific demands related to long-term stability within a challenging environment, the release said, adding that recently carried out design improvements ensure a long term reliability of the production process. The NCA 210 model is also suitable for the upgrade of existing Nextrom OFC40 & Rosendahl RL-R buffering lines, it said. The patented clenching concept provides: an integrated EFL process control system for both jelly filled and dry buffered tubes; tube diameter control system; specific

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PRODUCTS & MEDIA

clenching caterpillar design to cover demanding surrounding conditions; and a modular concept, also suitable for the upgrade of existing buffering lines. Contact: Rosendahl GmbH, www.rosendahlaustria.com.

MEDIA Website now offered in Chinese too U.K.-based Rautomead Limited reports that it now has a Chinese language website to provide information about its continuous casting technology for nonferrous metals that can be found at www.rautomead.net.cn. â&#x20AC;&#x153;The website is hosted on a server in China and will facilitate access to Rautomead product information to those using Chinese characters in their search engines,â&#x20AC;? said Rautomead Sales and Marketing Manager Guy Henderson, who noted that the goal is to make information available to important growth markets. He noted that the Chinese website follows the introduction of a company website in Russian (www.rautomead.ru), hosted in Russia,

PAYOFF & TENSION CONTROL

that has resulted in an increased level of inquiries since it went active last July last year. The websites present information about the companyâ&#x20AC;&#x2122;s graphite crucible technology that provides compact and easily integrated melting and casting solutions for producing the highest quality oxygen-free copper wire and cable, copper alloys and precious metals, the release said. It includes details on the companyâ&#x20AC;&#x2122;s fully automated casting machines, which are offered in sizes able to produce quantities from 5,000 to 30,000 metric tons a year as well as for smaller scale CuOF and CuAg wire rod production, including a new model range designed for 1,000 to 3,600 metric tons per year. Contact: Rautomead Limited, tel. 44-1382-622341, sales@rautomead.com, www.rautomead.com. â&#x2013;

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CAREER OPPORTUNITIES PRODUCT DEVELOPMENT ENGINEER. Prestolite Wire LLC, a world leader in the production of automotive, appliance, and industrial wire, is seeking a highly motivated, hands-on, team player for the position of Product Development Engineer. Candidates should have a Bachelors degree in an engineering discipline, understanding of wire manufacturing, compounding and ability to work within cross-functional environments to gain consensus and cooperation. Essential responsibilities include product design, material selections, execution of trials, hands on testing, design of product for manufacturability and productivity improvements. We offer a challenging work environment, as well as competitive compensation and benefits program, including 401(K), medical, dental and vision insurance. Confidential resumes and salary requirements will be accepted at Prestolite Wire LLC, Attn: Human Resources, P.O. Box 1632, Paragould, AR 72450 or can be faxed to 870-239-6165. EEO/M/F/H/V.

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BLIND BOX? YES____ NO ____

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

Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, or visit the Wire Resources website at w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave, Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE.

DIES 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. AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com. Send inquiries to ajexturner@ gmail.com/sales@ajexturner.com A-

53, G.T. Karnal Road, Delhi-33 India. Ph: 0091-9811078882 (Ravi Bansal). SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat

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.

Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment. Available (Cleaned, painted & checked operational) Buttwelders: Micro Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9. Babcock Models CBW-2, CBW-10 & CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equipment. Please contact by telephone at #727-863-4700 or by e-mail at urbassoc@verizon.net.

WIRE PLANT SOUGHT WANTED LRPC PLANT, 10,000 tons capacity per year. With or without wire drawing. Please contact M. Sarkar, e-mail at msarkar@mikisteel.co.in, mobile no+91-9342543555.

MEDIA

Serving the non-ferrous and ferrous industries since 1983

84 | WIRE JOURNAL INTERNATIONAL

ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The original version remains available while the revised Electrical Wire Handbook is divided

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. List price: $15, WAI member price: $10. To purchase, go to wirenet.org and click on The WAI Bookstore. FERROUS WIRE HANDBOOK. This comprehensive WAI hard-cover book is a 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 top-

ics 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. INTRODUCTION TO EXTRUSION SET (DVD). This video series (total running time of 1 hr., 45 min.) by extrusion expert Tom Black includes Part 1, Materials & Equipment (50 min.), and Part 2, Extrusion Processing (55 min). List Price: $425, WAI Member Price: $325. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

WIRE JOURNAL

INTERNATIONAL

2 PREVIEWS. 1 ISSUE. N0 DOUBT. AUGUST 2010 | WIRE CHINA PREVIEW | ITC PREVIEW The only reservation you should have about advertising in the August issue of Wire Journal International is the one you’ll need to reserve ad space. Your prospects are certain to take a second look at your marketing message as readers delve into a double preview issue covering wire China and WAI’s International Technical Conference in Monterrey, Mexico, this coming October. Ad reservation deadline: July 1, 2010

Contact the WJI Sales Team to reserve your space today. Bob Xeller | ext. 119 | bxeller@wirenet.org or Anna Bzowski | ext. 126 | abzowski@wirenet.org

JUNE 2010 | 85

CLASSIFIEDS

into three separate handbooks: Part 1 Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The handbooks provide basic information to those people working in the wire and cable industry. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore.

ADVERTISERS’ INDEX

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

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

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Chase Coating & Laminating . . . . . . . . . . . . . . . . . . . . . . .19

Alumoclad de Mexico SA de CV . . . . . . . . . . . . . . . . . . . .21

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83

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

CPA Wire Technologies GmbH . . . . . . . . . . . . . . . . . . . . . .41

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .20

Domeks Makine Ltd Sti . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Appiani/Lesmo Machinery America Inc . . . . . . . . . . . . . .16

ELOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

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

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Bock/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . .30

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .59

Gauder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

W Gillies Technologies LLC . . . . . . . . . . . . . . . . . . . . . . . .24

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

GMP Slovakia/Howar Equipment Inc . . . . . . . . . . . . . . . . .81

If you haven’t seen the latest WAI Connection online...

WAI moves information The Wire Association International (WAI), Inc., delivers The WAI Connection, its comprehensive online newsletter, to our members twice each month. Featuring the latest WAI, Chapter, and industry news—as well as late-breaking event and people items—it’s a great way to stay informed about the industry. But if we don’t have your most current e-mail address, we’re both missing Connections! A quick e-mail message is all it takes to help us deliver The WAI Connection directly to you. But without your update, you may miss out.

Stay in touch with WAI Please contact WAI at membership@wirenet.org to update your address and any contact information that may have recently changed. Because when you move, so does WAI.

...you may be in the dark about late-breaking industry news.

86 | WIRE JOURNAL INTERNATIONAL

Enlighten us with your updated e-mail address today! The WAI Connection is an online publication of The Wire Association International, Inc.

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

Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Madem SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Howar Equipment Inc/Bock . . . . . . . . . . . . . . . . . . . . . . . .30

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .84

Howar Equipment Inc/GMP Slovakia/ . . . . . . . . . . . . . . . .81

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Howar Equipment Inc/Unitek . . . . . . . . . . . . . . . . . . . . . . .40

Nextrom Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 31

OM Lesmo/Lesmo Machinery America Inc . . . . . . . . . . . .20

Jinyoungtech Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

JoeTools Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .18

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .11

Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Rautomead Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Lesmo Machinery America Inc/Appiani . . . . . . . . . . . . . .16

Rosendahl Maschinen GmbH . . . . . . . . . . . . . . . . . . . . . .13

Lesmo Machinery America Inc/OM Lesmo . . . . . . . . . . . .20

SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MONROE & MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS WRD897 BEKAERT KDA 9 Die Tandem Rod Machine, Yr. 1995 WRD899 BEKAERT KDM-14/GKM/OBK 14 Wire DWG Line w/800 mm Spooler, Annealer, Yr. 1991 BRAIDERS: WARDWELL 16C/24C Wire/Textile Braiders (500+) New Speedmaster 150 Heads (30). BRAIDERS: SPIRKA 16C/24C OMA Hi Tech 16C/24C, NEB, TMW Braiders. EXTRUDERS: DAVIS STD. 1 ¼”, 1 ½”, 2”, 2 ½”, 3 ½”, 4 ½”, 6” 24:1 Air cooled Extruders. DUAL TAKE UPS: CLIPPER PA-16, PA-24, PA-30, PS-24, PS36, PS-50 Dual Parallel Axis. CBR983 WATSON/NEB 61 Wire 22” Rigid Strander. EXPL351 NEXTROM 80 mm 24:1 Ext Line w 500mm Split Capstan, S.S. trough, 1200 mm BCA-12 Belt Cat (New). Yr Mfg 1999. CBR1050 DYNAMEX 30” S.Twist Cabler w Controls, Yr Mfg 2000 .

CLR220 REELEX D1500 Dual coiler w/controls Yr Mfg 1999. CBR984 WATSON 19 wire 22” Planetary cabling line (still installed). WRD831/WRD678 SAMP 8 wire MT8.2.4.21 drawing machine/SAMP 14 wire MLS/5.T.14. CBR957 COOK 48” BH-48 S.T. Cabler, Cook BH-36, BH-30, BH-24, BH-22, BH-16. TKU1149 NEXTROM Take ups EKP-63 Yr. 2000 Never used.(4) EKP 50, Yr. 1998, TKU1118-1121/EKP-5, Yr. 2001 (2). WRD890 (3) SAMP TR2TP Wire Drawing/Annealing /Preheating Yr. 2000 Never Used. CBR998 (8) SETIC 630mm PA630i D.T. Twinners, 1998. CBR1000 84” CABALLE/KALMAR/POURTIER Drum Twisting Line, 1990’s. CBR995/CBR989 630mm MGS & TEC, D.T. Twinners. MGS/BARTELL Payoffs: 60”, 72”, 84”, 96”. Take ups 60”, 72”, 84” 96” (some rebuilt).

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

JUNE 2010 | 87

ADVERTISERS’ INDEX

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

ADVERTISERS’ INDEX

August 2010 WJI ADVERTISER . . . . . . . . . . . . . .PAGE Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . .23 Unitek/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . .40 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Witels Albert USA Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Wyrepak Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

• Wire China preview • Monterrey ITC preview • Mexico regional outlook ADVERTISING DEADLINE: JULY 1, 2010

Yield Management Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .14 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54-55 WAI Webinars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56, 58 WAI Monterrey ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-61

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

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

India Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org

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

ZUMB.707.0099.U_WJ

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