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WIREE JOU JOURNAL FEBRUARY 2015

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INTERNATIONAL www.wirenet.org

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

WIRE JOURNAL FEBRUARY 2015

INTERNATIONAL

CONTENTS

www.wirenet.org

Volume 48 | Number 2 | February 2015

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

FEATURES

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 18 People. . . . . . . . . . . . . . . . . . 20 Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 24 WAI News . . . . . . . . . . . . . . . 26 Chapter Corner . . . . . . . . . . . 38 Products . . . . . . . . . . . . . . . . 52

Packaging . . . . . . . . . . . . . . . . 40 Suppliers of reels, spools and carriers discuss how they provide value to their wire and cable customers. Cost OFFICIAL is always essential, but one constant that comes PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL through in their comments is the importance of being able to provide solutions, which makes a partner-like relationship a key focus.

Technical Papers . . . . . . 62-77 Classified . . . . . . . . . . . . . . . 78

TECHNICAL PAPERS

Career Opportunities . . . . . . 80

Economic and chemical comparisons of hydrochloric acid recovery technologies for iron pickling operations Jared Cullivan and Bryan Cullivan . . . . . . . . . . . . . . . . . 62

Advertisers’ Index . . . . . . . . 81

Next issue

AIST Paper: Interplay between grain size and austenite stability on the deformation behavior of high strengthhigh ductility combination austenite stainless steels V.S.A. Challa, R.D.K. Misra, M.C. Somani, and L.P. Karjalainen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

• Interwire 2015 preview • Global Continuous Casting Forum preview

Continuous casting of copper magnesium conductor alloys Sir Michael Nairn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

March 2015

Cover: A photo of a large George Evans Corporation reel being crafted at the company’s plant in Moline, Illinois. Artistic design by WJI Media Production Manager Paul Streeto.

FEBRUARY 2015 | 3

CONTENTS

INSIDE THIS ISSUE Move bolsters operations & tech10

A hard-hitting Reception Site. . 36

When the MFL Group decided to move its MARIO FRIGERIO and FRIGECO operations into a single facility, it decided to build the most modern facility, one able to meet the machinery supplier’s needs for the next 100 years. The result is its state-of-the-art, 320,000sq-ft facility that now houses engineering, manufacturing, assembly, sales, after-sales and service, and more.

You don’t have to be a football fan to appreciate the setting for WAI’s reception at Interwire. The recently opened College Football Hall of Fame, a $68.5 million, three-story building that includes museum-quality memorabilia and interactive and multi-media exhibits. One stunning display includes helmets from 768 college football teams, a slice of which is shown below.

4 | WIRE JOURNAL INTERNATIONAL

EDITORIAL WIRE JOURNAL

EDITORIAL

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

Conversation is the real marketplace of ideas There are plenty of reasons to attend a conference like Interwire, but one of the most appealing for me is the conversation. There’s just no substitute for the give and take of talking person-to-person. As a member of the Conference Programming Committee, I’m reminded of this every time our group discusses what sort of topics and speakers WAI events should have. We consider many suggestions, but the ideas don’t seem to take off until the conversation really gets going. Sometimes I think Interwire would be a success even if all we did was record these conversations and play them back at the show. Finding out what other people think is part of how I decide what I think. And if I can help others do the same, that’s my idea of a learning experience. That’s why I’m so pleased this year’s program will feature these kinds of conversations. We’ve scheduled several panels, including a series tracing electrical cable production from raw materials through processing and applications. We’ve gotten together manufacturers and suppliers to share their diverse perspectives on thermoplastics and thermosets, including opinions on the pros and cons of irradiation, CV, and moisture and ambient curing. I’m also looking forward to the Capital Expenditures panel, and not just because I am a panelist. I think the chance to get CFOs, engineers and equipment suppliers in the same room, all trying to speak the same language and better understand how each approaches the purchasing process, will be invaluable. Is smaller always better? How important is wear life and energy savings really when it comes to the bottom line? What about work-in-process reductions? As VP and GM for Nexans Energy Cables Div. NA, I’m focused on the electrical side of the business. But my steel colleagues on the committee have also put together good discussions, taking on topics like dust hazard abatement and hiring and retention. Perhaps the best part is we won’t really know what we’re getting until we arrive in Atlanta. The discussions can head in unpredictable directions, and I think that’s really the point of the whole event. I can’t wait to start talking about these key aspects of the wire and cable business, and I’ll bet you can’t either.

David R. Hawker WAI Conference Programming Committeee Co-chair

6 | WIRE JOURNAL INTERNATIONAL

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 71 Bradley Road, Suite 9, Madison, CT 06443-2662, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail editor@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 Madison, CT 06443, 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, 71 Bradley Road, Suite 9, Madison, CT 06443-2662, USA. © 2015 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: 313-761-4700. POSTMASTER: Send address changes to Wire Journal International, 71 Bradley Rd., Suite 9, Madison, CT 06443, USA.

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See us at Interwire, Apr 27 - 30, Atlanta GA, USA, Booth 812

CALENDAR

CALENDAR March 3-5, 2015: Cables 2015 Cologne, Germany. To be held at the Maritime Hotel, this event is organized by Applied Market Information Ltd. (AMI). Contact: Becca Utteridge, tel. +44 (0) 117 314 8111, rju@amiplastics.com, www.amiplastics.com.

June 9-12, 2015: Wire & Cable Guangzhou Guangzhou, China. This event is held concurrently with the Guangzhou International Lighting Exhibition and Guangzhou Electrical Building Technology. Contact: Messe Frankfurt, info@china.messefrankfurt.com.

March 26-28, 2015: Tel Fair 2015: International Istanbul Wire Fair Istanbul, Turkey. To be held at the Istanbul Expo Center. Contact: http://tube-wire-coil-fair.com.

June 21-25, 2015: Jicable 9th International Conference on Insulated Power Cables Paris, France. This forum focuses on research, industrial development, installation and operation of insulated power cables and accessories. Contact: Jicable, tel. 33-156-90-37-04, jicable@see.asso.fr, www.jicable.org.

April 27-30, 2015: Global Continuous Casting Forum Atlanta, Georgia, USA. This WAI event will be co-located with Interwire 2015. The scope has been expanded to include aluminum. Contact: www.castingforum15.com. April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its biennial trade show, technical programs and 85th Annual Convention. Contact: WAI, USA. Tel. 001-203-453-2777, www.wirenet.org. May 12-15, 2015: Wire Russia 2015 Moscow, Russia. To be held at the ZAO EXPOCENTR Exhibition Center at Krasnaya Presnya, this event is organized by Messe Düsseldorf North America. Contact: MDNA, tel. 312-781-5180, info@mdna.com, www.mdna.com. June 9-12, 2015: Guangzhou International Wire, Cable and Accessories Fair Guangzhou, China. To be held in the China Import and Export Fair Complex. Contact: www.wire-cable-china. com, wire@china.messefrankfurt.com.

Oct. 6-8, 2015: Wire South America 2015 São Paulo, Brazil. To be held at the Imigrantes Exhibition & Convention Center. Contact: See Wire Russia 2015. Oct. 5-8, 2015: 64th IWCS conference Atlanta, Georgia, USA. To be held at the Hyatt Regency Atlanta in Atlanta, Georgia. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, iwcs.org. April 4-8, 2016: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: See Wire Russia 2015. June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun Resort Center, will include its trade show, technical programs and WAI’s 86th Annual Convention. WAI, USA.

WIRE ASSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

March 5-7, 2015: Poland Chapter Technical Conference Zakopane, Poland. This event will be held at the Antałówka Hotel. Contact: go to the event website, www.konferencja.wip.pcz.pl, for more details. See p. 38.

April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its biennial trade show, technical programs and 85th Annual Convention.

April 27-30, 2015: Global Continuous Casting Forum Atlanta, Georgia, USA. See main listing.

June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. See main listing.

8 | WIRE JOURNAL INTERNATIONAL

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INDUSTRY NEWS

INDUSTRY NEWS General Cable Corporation sells its Philippines operation to its JV partner U.S.-based General Cable Corporation announced that it has sold its 60% interest in Phelps Dodge International Philippines, Inc. (PDP) for $67 million.

An inside view of Phelps Dodge Int’l Philippines plant. A press release said that the company sold its interest to its joint venture partner, A. Soriano Corporation. The proceeds will be used to reduce debt. General Cable plans to divest all of its manufacturing operations in Asia Paciﬁc and Africa to simplify its geographic portfolio and reduce organization complexity. Per its website, PDP produces building wire, power cable, communications cable, special cable and more. It was formed in 1955 when Andres Soriano Corporation (ANSCOR) forged a partnership with Phelps Dodge International Corporation (PDIC). The company was acquired by General Cable in 2007.

Leoni wins first order from Hyundai Germany’s Leoni reports that it has been awarded a contract from Hyundai Motor Company to provide front body cable harnesses for a period of six years. A press release said that the company will provide the front cable harnesses in Europe for certain models from 2016. The contract is Leoni’s ﬁrst order from Hyundai, which it noted is now the world’s fourth largest cable maker. The deal, which is projected to see production of 130,000 and 160,000 front body harnesses per year, is expected to produce “a double-digit million euro sales volume” over the six years, it said. Cited as a contribution to the deal was Leoni Wiring Systems Korea, which Leoni launched in recent years. “This order is a big milestone forward concerning the further globalization of our company and we are looking forward to keep growing with a solid cooperation to Hyundai in the near future,” said Dr. Andreas Brand, a member of the Leoni Management Board who is responsible for the wiring systems business. “As a

global supplier Leoni has now started its ﬁrst wiring systems project in Europe with the Korean partner targeting to become a preferred supplier worldwide.”

Hellenic Cables to provide 37.7 km of cable for innovative Greek wind park Hellenic Cables SA has won a 36.4 million euro contract from the Terna Energy Group (TEG) to provide the cable for a wind farm on St. George Island, which is located in the sea area south of Cape Sounio in Greece. A press release said that Hellenic Cables will provide 37.4 km of 150 kv high-voltage submarine cable that will be laid at depths of 230 meters. The goal is for the wind park, which will have a capacity of 73.2 MW, to be in operation by the end of the year, it said. The wind park, which has a total cost of 150 million euros, is designed to provide enough electricity to meet the annual needs of over 40,000 households.

What is unique about the project, the release said, is that it incorporates a submarine connection between the island and the continental system. “In essence, it is the ﬁrst on-shore wind park with characteristics of an offshore wind park installation, exploiting the high wind potential of the Aegean Sea, to such a large scale.” The wind park will operate as an autonomous electricity production unit, connected to the National Transmission System (NTS) via a new substation (20/150kv) on the island that is near the wind generators. Once working, it will supply energy to the NTS via a submarine cable connection ending at the Mikro Lavrio substation. TEG notes that it has total installed capacity of 640 MW, including 386 MW in Greece, 138 MW in the U.S., 86 MW in Poland and 30 MW in Bulgaria, with goals to near 1,000 MW in the coming years.

MFL Group consolidates all its Italian operations in new facility The MFL Group reports that its iconic brands, MARIO FRIGERIO, a supplier of steel wire and rope machinery founded in 1897, and FRIGECO, a supplier of machinery for the nonferrous wire and cable industry, have combined their Italian operations into a single new facility in Molteno.

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

10 | WIRE JOURNAL INTERNATIONAL

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FEBRUARY 2015 | 11

INDUSTRY NEWS

The companies previously operated out of four separate facilities. Commented MFL Group Managing Director Emilia Tentori, “We were in our first location for 100 years and we wanted to build something for the next 100 years.” Per the company, it became clear that investing in the MFL Group’s future could result in substantial synergies. That vision became reality last year when the multiple facilities and two divisions consolidated operations in a state-of-the-art, 320,000 sq ft (30,000 sq m) facility that now houses all engineering, manufacturing, assembly, machinery sales, after sales and service and administration. Previously, those funcMFL Group’s Italian operations, which previously operated in four separate tions were splintered as a total of four facilities, is now located in a single new complex. buildings were being used. Now, they are all located in a single corporate and manufacturing location. With more than a century of experience in the wire The new facility boasts a fully computerized manuand cable industry, a workforce topping 400 employees facturing floor where all Mario Frigerio and Frigeco and customers in 100-plus countries, the MFL Group machines are manufactured from raw material to finnotes that it is the only worldwide supplier of state-ofished parts. Each part can be tracked through the entire the-art machinery for the production of wires, ropes and manufacturing cycle, a process that is cutting edge. All cables. This investment, it said, has further bolstered its critical parts are statically and dynamically balanced on ability to provide customers the most advanced technical site and all parts are subjected to 100% quality control. solutions and unmatched customer service.

INDUSTRY NEWS

U.S. wind project is closer to fruition … Deepwater Wind New England was granted a right-ofway for the export cable it needs for its 30 MW Block Island wind project from the U.S. Bureau of Ocean Energy Management (BOEM), furthering its efforts to what would be the first U.S. offshore windfarm a reality. A press release said that the grant authorizes construction of a 34.5 kV bi-directional submerged transmission cable in a nine-km stretch of federal waters between Block Island and the Rhode Island mainland. BOEM also has approved Deepwater’s general activities plan, which outlines the developer’s proposed installation activities. Before starting construction, it said, Deepwater must submit a facility design report, a fabrication and installation report, and a safety management system. BOEM will have 60 days to review the plans and notify Deepwater if there are any objections. Rhode Island has already approved the on-land interconnection facilities and submerged cables in state waters. Offtaker National Grid has been chosen for the transmission facilities, valued at $75 million. The overall project, which was valued at $300 million, is to include five Haliade 150 6MW direct-drive turbines. If financing goes as planned, Deepwater expects to commission Block Island in late 2016, it said.

… while a 2nd such energy project may well have lost its headwinds Two major utilities have terminated their contracts to buy power from the proposed $2.5 billion wind farm in Cape Cod waters, a decision that could kill the controversial Cape Wind project. Multiple media reports said that National Grid and Nstar, a subsidiary of Northeast Utilities, have ended their contracts because Cape Wind missed a Dec. 31 deadline to obtain ﬁnancing and begin construction, and did not put up ﬁnancial collateral to extend the deadline. “Unfortunately, Cape Wind has missed these critical milestones,” NStar spokeswoman Caroline Pretyman said. “Additionally, Cape Wind has chosen not to exercise their

12 | WIRE JOURNAL INTERNATIONAL

right to post ﬁnancial security in order to extend the contract deadlines. Therefore the contract is now terminated.” Cape Wind has proposed a 130-turbine offshore wind farm in Nantucket Sound. If built, it would be the ﬁrst offshore wind farm in U.S. waters.

Nexans to supply largest, most complex, DEH system for Caspian Sea project Nexans reports that it has begun initial shipments to BP for what it described as “the world’s largest and most complex Direct Electrical Heating (DEH) system to date.” A press release said that Nexans will supply the complete system design, which calls for 130 km of cables with accessories for installation. The system, it said, will provide flow assurance for 10 subsea flowlines serving the Shah Deniz high-pressure gas condensate development, located in the Azerbaijan sector of the Caspian Sea. The project, valued at 100 million euros, is part of a 10-year frame agreement between Nexans and BP, the operator of the project. The first delivery consisted of DEH cables and accessories for four flowlines, the release said. The second delivery of the six remaining subsea systems is scheduled for 2016. Per the release, DEH provides cost-effective and reliable flow assurance, an important factor in ensuring successful production from Stage 2 development of the Shah Deniz field located in the Caspian Sea. DEH is a technology for flow assurance, developed to safeguard the wellstream flow through the pipeline to the platform. Alternating current (AC) transmitted from the DEH cable runs through the steel in the pipe, which heats up due to its own electrical resistance. This specific DEH system is more complex than previous DEH projects due to the multiple systems in close proximity and the unique operating environment in the Caspian Sea. The cables and accessories will be manufactured in the Nexans’ facility in Halden. “The key to Nexans’ success as a leader in DEH projects is our comprehensive systems approach that integrates the design of DEH systems, including engineering and manufacture of all the vital elements such as riser

INDUSTRY NEWS

cables, piggyback cables, protection and accessories,” said Krister Granlie, Executive Vice President, Hybrid Underwater cables Division, Nexans Norway. Nexans notes that it has delivered nine pre-qualiﬁed DEH systems in operation to date.

Bekaert completes its acquisition of Pirelli steel cord plants in 3 countries Bekaert reports that it has completed its previously announced acquisition of three Pirelli steel cord plants. A press release said that the plants, which are in Figline, Italy; Slatina, Romania; and Sumaré, Brazil, are part of an overall transaction that includes a long-term supply agreement for delivery of Bekaert tire cord products to Pirelli. The integration process of the three tire cord plants into the Bekaert Group has begun, it said. The release also noted that there are two other Pirelli plants that are also part of the deal, but those will not close until regulatory approvals are obtained in the respective countries. Those plants are located in Izmit, Turkey, and Yanzhou, China. “The integration of the steel cord activities and the long-term supply agreement will further enhance Bekaert’s status as a preferred supplier to the tire industry,” it said.

nkt cables gets additional contract from DONG Energy for wind farm nkt cables reports that it has won a contract from DONG Energy for delivery of export cable systems to the Race Bank Offshore Wind farm by DONG Energy. A press release said that the order represents the company’s 11th large offshore wind farm project since 2010, when the company ﬁrst started production of submarine cables. The latest order, it said, calls for nkt Cables to supply more than 150 km of 220 kV high voltage submarine cables. The cables, to be made in Cologne, Germany, will begin shipping for the ﬁrst project phase in 2016, and the following year for the second stage. The order, it

14 | WIRE JOURNAL INTERNATIONAL

noted, is conditional upon DONG Energy making a ﬁnal investment decision for the offshore wind farm. Export cables would bring power from the windfarm to an onshore substation, the release said. For Race Bank these would come to shore east of the mouth of the river Nene and about 6 km north-northeast of Sutton Bridge. The cables, it said. would run in a southerly direction to the connection point at the existing Walpole substation. “The award of the Race Bank project underlines that our technology, expertise and state of the art facilities in Cologne and Rotterdam is well acknowledged by the utilities. The order is a recognition of our position as a highly reliable cable manufacturer and partner for large offshore projects,” said CEO Michael Hedegaard Lyng.

Trade event report: Gulf cable market continues to show very strong growth The Gulf market has seen growth of 15% the last two years, and the future looks good, an organizer of Wire & Cable Arabia said at the recently held event at the Dubai International Convention and Exhibition Centre in Dubai, UAE. Per a report in TradeArabia News Service, Satish Khanna, general manager of Al Fajer Information and Services, said that his company’s event saw robust activity, reﬂecting the state of the market for wire and cable. “The activity … (indicates) that the industry is on a growth track in the Middle East, thanks to the construction boom and expansion of utilities infrastructure underway in the Gulf countries.” Citing a report by U.K.-based Integer Research, he noted that while overall global demand for wire and cable grew at 3.2% between 2008 and 2014, the growth rate in the Gulf region “was over 15 per cent, driven mainly by the utilities and communications network in the wider Gulf.” Khanna said that the global economy as a whole saw a mild recovery in 2014, backed by a resilient U.S. economy, but weakened by a depressed euro zone economy. Elsewhere, China, India and other emerging countries

Fenn reports solid 2014 sales of engineered machinery to 9 countries U.S.-based Fenn reports that it closed out the 2014 calendar year with exemplary sales both in and outside of North America, led by especially strong results in India, Chile and the U.K. A press release said that it saw multiple contracts for its wire processing equipment—which includes wire flattening and shaping lines, rolling mills, Turks heads and drawbenches as well as industrial products which include Torin spring coilers, swagers, and impact cutoff machines—in China, Turkey, the Netherlands, Norway, and South Korea, in addition to those mentioned above. Domestic sales, as expected were good, but international sales have continued in a growth pattern as the company’s focus on marketing its customized technology has paid off, it said. The country of India has been a key driver to the growth path, it said. One example cited was the sale of a line to an India-based company for specialty shaped wire used in the water and oil filtration industry. The press release said that Fenn has experience producing similar lines in the past, and will continue to support the growth of this industry. “We are finding that the industry values the quality, precision, and reliability of our products, and we are very pleased with the surge in business as we close out the 2014 year,” said Fenn President Paul Uccello.

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Canadian trade tribunal continues existing trade order for fasteners The Canadian International Trade Tribunal reports that it will continue an existing trade order stemming back to 2005 for dumping and subsidization of certain carbon steel fasteners originating in or exported from the People’s Republic of China and Chinese Taipei.

INDUSTRY NEWS

showed signs of a slowdown, and both Russia and Brazil were on the downswing. Meanwhile, the Gulf area has grown, citing report findings that “there is a difference of just $5 million between volume of copper cable exports of USA ($1.330 billion) and the UAE ($1.325 billion), taking the UAE to fifth position globally after (the) U.S.” Copper, mostly used for cable, now represents about $1 billion to UAE’s trade surplus. Per a Ministry of Economy report, UAE ranks among the top five copper cable exporters after USA (4th), Belgium (3rd), Germany (2nd) and Russia (1st).” Observed Jeen Joshua, Group Exhibition Manager, Al Fajer Information and Services, “Asia is the largest source of copper and aluminum imports, at over 40%, followed by the Middle East North Africa region accounting for 34%. The industry in this part of the world is getting huge attention as it forms the arteries of the real-estate and infrastructure sectors.”

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The Tribunal found that “the dumping and subsidizing of certain carbon steel fasteners from China and Chinese Taipei were likely to result in injury.” The Canada Border Services Agency, it said, “will therefore continue to impose anti-dumping and countervailing duties on these products.”

Macbee Engineering reports that it is operating again under its own name U.S.-based Macbee Engineering, which offers processing equipment for both ferrous and nonferrous sectors

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that is made in the U.S., has resumed full operations under the Macbee name. A press release said that the company, whose rights were owned by Engineered Machinery Corp (EMC), is now owned by JMS Machinery. The principal of JMS Machinery is Jonathan Stevens, who bought the rights from his dad, John Stevens, the CEO of EMC, who now is semi-retired. Macbee Engineering is now operating in Southern California, serving all Macbee, EMG and JMS Machinery customers. Its product lines include: X series modular draw lines; Vee groove take-ups and payoffs; and inverted bullblocks. Macbee Engineering can be contacted at tel. 909758-0638 or www.macbeeengineering.com. In related news, Macbee Engineering reports that it partnered with Metal Line Machinery of South Korea to supply and install a new nine-pass draw line in the U.S. Midwest. The line, which includes a nine-pass pass drawer, a cannon-type payoff, a dead block and dual-cleaning lines, can run 90 grade high carbon as well as low-carbon rod. It has tilted water-cooled blocks, a powered horizontal payoff and coil loading from back for continuous operation. Macbee Engineering will provide sales, service and parts inventory for Metal Line in the U.S.

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filmPad canPackaging be as thin as 0.001”. Flat Traverse and pyramid Flat packaging allow for longer runs per package on narrow widths. Pad Packaging Custom packages are manufactured DeWAL’s Narragansett, facilities in DeWAL’s state-of-the-art equipment allows us at to create custom packages with RI, precision Appropriate for allalso DeWAL slit12”. film and laminatedcan products. widths up to 12” and diameters up to Packages be with or without Appropriate for alland DeWAL slit film and tension control. This gives our packages customersfrom reduced increased productivity. Custom 3/8" downtime (9.525mm) 8" (203.2mm) widelaminated products. sideboards. Film lengths can be as Custom much as 20,000tofrom ft. packages 3/8" (9.525mm) to 8" (203.2mm) wide with diameters, width,using up totoday’s 14" (355.6mm). This tension control becomes a criticaldepending componentonwhen low density films in with diameters, depending on traverse width, up toand 14" pyra(355.6mm). Besides new Solid Packs, DeWAL offers traditional flat pad, high performance coaxial cables, where a slight amount of stretching will cause problems mid packages in standard and custom configurations. with signal loss.

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than 40 years.” SEQUEM, it noted, has been representing Niehoff in Belgium and Luxembourg for 10 years. The family-run business cooperates with about 30 manufacturers of machinery for the wire, cable, wire processing and other sectors of the metal working industries. It can be contacted at www.sequem.fr.

For skived, unsintered and low density PTFE film in widths from For(19.05mm) skived, unsintered and low density PTFE film in widths from 5/32" (4.123mm) 3/4" in 1/32" (0.794mm) increments. Appropriate for alltoDeWAL slit film and laminated products. 5/32" (4.123mm) to 3/4" (19.05mm) in 1/32" (0.794mm) increments. Film canpackages be as thinfrom as 0.0005" (0.013mm). Custom 3/8"can (9.525mm) toas8"0.0005" (203.2mm) wide Film be as thin (0.013mm). Custom packages up to 6" (152.4mm) wide and up to 6" (152.4mm) with diameters, depending on packages width, up to 14" (355.6mm). Custom in diameter, with or without sideboards. up to 6" (152.4mm) wide and up to 6" (152.4mm) in diameter, with or without sideboards. A report Traverse Packaging

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2015 WCMA award winners to be honored at March dinner The Wire & Cable Manufacturers’ Alliance (WCMA) will honor the eight recipients of the organization’s 2015 Distinguished Career Award at its 31st annual Awards Dinner and Investiture Ceremony on March 28th, 2015. A press release said that the event, to be held at the Connecticut Convention Center in Hartford, Connecticut, will see the presentation of the awards to: Giulio Berardesca, Exec. VP, Global Wire & Cable, Anixter International Inc.; Kevin Coderre, Technical Manager, RSCC Aerospace & Defense; Daniel DeLisle, General Manager, Alpha Gary; Don Dodge, VP Research, Calmont Wire & Cable; Vince Donaldson, VP, Sales & Marketing, International Wire Group; Marvin (Eddie)

Edwards, Jr., President & CEO, CommScope; Steve Payne, President, Advanced Digital Cable (ADC); and Robert Smith, Vice President of Sales and Marketing, Fluorogistx LLC. The WCMA continues the tradition of recognizing industry professionals that was started in the mid ‘80s by the late Dick and Harriet Callahan, founders of the Wire & Cable Clubs of America (WCCA). For information about tickets, WCMA or the Distinguished Career Award, contact Deb Mathiasen, executive director at tel. 860-873-2311 or mrcdm@ snet.net, or go to www.wcmainc.org.

Belden closes Tripwire acquisition U.S.-based Belden, Inc., reported that the company has completed its acquisition of Tripwire, a leading global provider of advanced threat, security and compliance solutions. “We look forward to offering our customers one of the most comprehensive and secure network solutions in the market today,” said Belden President and CEO John Stroup. “Tripwire technology paired with (our) application expertise across enterprise, industrial and broadcast markets will position Belden as a leader in helping customers deploy and secure the ‘Internet of Things’,” he said.

FEBRUARY 2015 | 17

INDUSTRY NEWS

A press release said that the report looks at the current and extended growth prospects by project type, project ownership and geography. It segments the market into new and upgrade projects. It covers Africa, Australia/NZ Intercontinental, Europe, SEA, and ME Intercontinental, Latin America, Trans-Atlantic, Trans-Pacific, and Others as well as the market landscape, growth prospects and a discussion of key market vendors. For more details, go to www.technavio.com.

ASIAN FOCUS

ASIAN FOCUS investigate cultural sites across the country on their fire protection measures and draft relevant technical protocols. Over the next few years, the country will invest More than a world leader in many manufacturing more in fire-protection infrastructure to prevent such fires. sectors, China also has a vast accumulation of cultural Official statistics showed that from 2010 to 2013, 52 fires sites across the country. However, electrical fires,some to cultural relics were reported to the administration. attributed to bad wiring, have caused substantial damage Per the State Administration of Culture Heritage, over to some of China’s cultural relics. 1,300 fires occurred in various ancient cities between Per mulitple media reports, on Jan. 3, in a matter of two 2009 and 2014, 40% of which are caused by household hours, the Gongchen Tower, misuse of fire, 20% by an ancient city gate tower electrical equipment malwith a history of more than function, and the rest by 600 years, was destroyed in arson, fire-playing, smoking a fire in Southwest China’s and lightning strike. Yunnan Province. No casualIn a blog in ChinaDaily. ties were reported in the fire com.cn, Leiiang Ping wrote but the tower, built in 1390 that, “As more ancient cities during China’s Ming Dynasty are being developed, the and listed as a key cultural excessive human activities protection site, was scorched. have increasingly threatened Xinhau reported that a wire their safety. To seek more fault ignited nearby flammaprofits, many developers ble materials in the southhave added modern facilities eastern corner at the top of to redecorate ancient cities, Gongchen Tower. Though the some even rearrange their cause of the fire is still under previous structures in order investigation, renovation of to make more room for rent, The Gongchen Tower was damaged by fire in January. the ancient tower as a public which not only has changed Photo by IC/www.news.cn. entertainment place has been their unique features, but largely blamed. also buried seeds of future Big antique lanterns, spot lights and a string of light risk. Like in Weishan, bars, shops, restaurants, traveling bulbs decorated inside the Gongchen Tower were claimed agencies and residential houses can be seen crowded in a as fire hazards. A team of experts will be assembled to confined space, and modern facilities in these units have assess the damage to the tower, said the local governskyrocketed the amount of power consumption, overburment. Reconstruction will begin following approvals. dening the aging wires and easily leading to short-circuit China’s State Administration of Cultural Heritage said problems. Worse still, little room for fireproof apparatus is that electrical fires are to blame for 40% of fires affecting reserved and few fire buffer zones are separated: no wonthe country’s heritage buildings. It said that it will covertly der Gongchen tower was so vulnerable to fire.”

Some cultural sites in China at risk for damage caused by electrical fires

18 | WIRE JOURNAL INTERNATIONAL

Broken undersea cable in Vietnam region leads to further internet connections woes At press time, parts of Southeast Asia were still experiencing slow internet connections after an undersea cable, part of the Asia-America Gateway (AAG) that

Vietnamese section of the 20,000-km system, that will take from three weeks to one month to repair. The cable is part of the Asia-America Gateway linking Southeast Asian countries with the United States through Guam and Hawaii. Viettel, which is owned by the military, said it has transferred its international Internet traffic to other cable networks. A Vietnamese news report said Internet traffic between Vietnam and Hong Kong, Singapore, Japan and the U.S. has been slowed. “At the moment, reason for the broken cable has not been identified, but there is a lot of maritime traffic in that area, so maybe a passing ship accidentally cut the cable,” Deputy Minister of Information and Communication Le Nam Thang said. Others have suggested that sharks have been responsible for the damage.

Canada tribunal to continue trade sanctions against China for some carbon steel fasteners Repairs to the AAG cable break were scheduled to be completed in January. Nhan Dan Online photo. links South-East Asian countries with the U.S., was cut. It was not the ﬁrst such outage for the cable, which was described as having been damaged three times last year. Multiple media reports said that Viettel Mobile, Vietnam’s largest mobile service operator, reported problems GIWC15-eng-Wire stemming from a broken cable, located in the Journal(USA)-6.775 x 4-op.pdf 1 2015-1-13 15:21:38

The Canadian International Trade Tribunal reports that it will continue an existing trade order stemming back to 2005 for dumping and subsizidation of certain carbon steel fasteners originating in or exported from the People’s Republic of China and Chinese Taipei. The Tribunal found that “the dumping and subsidizing of certain carbon steel fasteners from China and Chinese Taipei were likely to result in injury.” The Canada Border Services Agency, it said, “will therefore continue to impose anti-dumping and countervailing duties on these products.”

CMY

FEBRUARY 2015 | 19

ASIAN FOCUS

ASIAN NEWS BRIEFS

PEOPLE

PEOPLE Jon Stine has been promoted to general manager of Mount Joy Wire Corporation, responsible for overseeing production, scheduling, maintenance, quality, product and process development and technical customer services activities. He joined the company in 1992 as a process engineer and later served in different roles. Prior to that, he worked for six years at Caterpillar Stine Incorporated’s Peoria and York plants in laser engineering and heat treating, where he developed a proprietary laser welding process and installed Caterpillar’s ﬁrst production laser welder. A member of the America Wire Producers Association, he holds a B.S. degree in metallurgical engineering from the University of Pittsburgh’s School of Engineering. Based in Mount Joy, Pennsylvania, Mount Joy Wire Corporation manufactures specialty steel wire. Huber Engineered Materials (HEM), a division of J.M. Huber Corporation, announced a series of key executive changes. Chuck Herak has become president of HEM, replacing Andy Trott, who has retired. Herak was vice

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president and general manager of the company’s silica business. Prior to joining Huber in 2009, he was with Hercules (now Ashland) in positions of increasing responsibility that included general manager – coatings additives. Replacing Herak as vice president and general manager of HEM’s Silica business is David Riley, who has been vice president and general manager of Herak HEM’s ground calcium carbonate (GCC) business. He had held this position for four years, and had worked in the silica business as director of global marketing from 2008 to 2010. Replacing Riley as vice president and general manager of HEM’s GCC business is Matt O’Brien, who for the last nine years has been a key member of Huber Engineered Woods LLC, serving as CFO, and most recently as Chief Commercial Officer. He joined Huber in 2002 as vice president of corporate strategy. A division of J. Huber Corporation that is based in Atlanta, Georgia, USA, Huber Engineered Materials supplies products that include halogen-free flame retardants and fillers for the wire and cable industry.

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David Currie has been named CEO of JDR. He has nearly 30 years of experience in the global offshore energy industry, and most recently was U.K. Regional President for Aker Solutions. Prior to that he spent much of his career at FMC Technologies, where he served at senior positions that included director of global subsea operations. Based in Edinburgh, Scotland, JDR designs and manufactures subsea umbilicals and power cables that operate in harsh, dynamic, subsea environments.

OBITUARY

Industry icon and founder of Endex Inc. dies at age 96 Konrad C. Schillebeeckx, a design engineer who made substantial contributions to the advancement of the wire processing technology, died Dec. 31, 2014, at age 96. Born and educated in Belgium, Schillebeeckx resided in Colts Schillebeeckx Neck and Holmdel, New Jersey, for 13 years before moving to Manchester, New Hampshire, in 1983. Per WJI records, he entered the industry in 1951 as a plant engineer for Phillips Cable in Canada. In 1959, he joined Edmands Co. as chief design engineer. He was instrumental in developing cabling machinery. He helped transfer production of building wire from existing tubular stranders to new double-twist closers. He also helped introduce rotating take-ups and capstans that supplanted rigid stranders for telephone cable. In 1969, he was a corporate manufacturing engineer for General Cable Corp., and from 1974 to 1978 he served with Syncro Machine Co., first as general manager and later as company president. In 1978, with the help of H.W. (Pete) Petersen, he founded Endex Inc., a wire machinery manufacturer specializing in rod breakdown equipment. His focus included developing a controlled method of continuous coiling that led to the manufacture of NMB insulated conductors at higher speeds. In 1993, Endex was acquired by Bekaert Corporation, and he continued to work there as a design engineering consultant. In 1994, he received the WAIâ&#x20AC;&#x2122;s Mordica Memorial Award for his contributions to the industry. He retired in 1996, and the firm he founded has continued to operate under the name of NiehoffEndex North America. Schillebeeckx is survived by two sons, Dick and Edward; a daughter, Ingrid Schillebeeckx-Rice; three sisters, Elza, Mia and Magda Schillebeeckx; four grandchildren and four great grandchildren.

DECEMBER 2014 | 21

Report: global medical fiber optics field is to be worth US$1.33 billion by 2019 A new report from Transparency Market Research, “Medical Fiber Optics Market- Global Industry Analysis, Size, Share, Growth, Trend and Forecast 2013-2019,” predicts that the field will grow from $863.1 million in 2013 to $1.33 billion by 2019. A press release said that the field will see annual CAGR growth of 7.6% through 2019. It cited some key drivers as follows. There has been significant growth in the number of applications of fiber optics in minimally invasive surgeries as well as for advanced diagnostic technologies. The primary growth drivers were identified as X-ray imaging, light therapy, ophthalmic lasers, lab and clinical diagnostics, dental head pieces, surgical and diagnostic instrumentation, surgical microscopy and endoscopy. For more report details, go to www.transparencymarketresearch.com.

Kuwaiti group to provide fiber network

Atco, a subsidiary of the Kuwait-based conglomerate Sultan Center, has signed a $20 million contract with the Kuwait Ministry of Interior (MOI) for the supply, installation, operation and maintenance of a fiber optics network. A press release said that the network will link the differ-

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Cincinnati Bell to upgrade 2 Ohio towns with an all-fiber network

Corning announced that it has agreed to upgrade the towns of Fairfield and Bethel in Ohio to all-fiber networks. Per a story in the Journal-News, Cincinnati Bell said that Fairfield’s network will be part of a $200 million expansion plan for the company that starts this year. The project came about largely because of Fairfield’s business clientele, said Cincinnati Bell spokesman Josh Pichler. “We’ve been building out our fiber network here for the last couple of years and have about 40% of the region covered today. This coming year, in 2015, we’re going to try to accelerate that … the goal is that by the end of 2016, we’d have about 75% of the region covered.”

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FASTENER UPDATE

FASTENER UPDATE Bossard buys a majority interest in Norwegian fastener company

Report: questionable fasteners used on San Francisco bridge found to be okay

The Bossard Group, based in Switzerland, reports that it has acquired a majority interest (60%) in Norway’s Torp Fasteners for an undisclosed price. A press release, which said that the investment will boost Bossard’s position as a supplier of high-quality fastening solutions in Scandinavia, provided the following details. The Norwegian company generated an annual turnover of about $10.2 million and has 16 employees. While Bossard is acquiring about 60%, the remaining 40% will remain with the previous owners and management. “The acquisition of Torp Fasteners ﬁts ideally into this overall strategy of developing new markets and is in line with the strategic focus for the years 2010-2015. In this connection,” said Bossard Group CEO. “We are already well-established in Denmark and Sweden. Torp Fasteners will now contribute substantially to an improved market position of the Bossard Group in Scandinavia.” Per its website, The Bossard Group’s global network of companies has more than 1,800 employees in over 60 locations as well as select international partners in all regions of the world, providing continuity in the company’s operations.

Authorities say that thousands of rods and bolts on the new Bay Bridge eastern span are secure and should remain in place. Per multiple media reports, The Toll Bridge Program Oversight Committee has found that past concerns that erupted when cracks were found in 32 of some of the more than 2,000 rods and bolts on the new Bay Bridge eastern span have been allayed. The committee voted to release a draft report that advised “extra steps be taken to protect the galvanized steel fasteners” but concluded that they can “safely remain in service with continued inspection and maintenance.” The $6.4 billion project saw the thousands of rods and bolts placed throughout the span. They anchor the span’s main cable to the road deck, secure it to the top of the tower and hold down structures designed to keep the bridge from swaying excessively in an earthquake. The concern was that if the fasteners were found to be unsafe, then hundreds of the steel fasteners would have to have been replaced at toll payers’ expense. State ofﬁcials spent millions on testing and engineering plans after the failure and concerns about the safety of another 64 fasteners that were made in the same batch. The report found the rods that failed lacked a basic property that resists cracking. 

24 | WIRE JOURNAL INTERNATIONAL

WAI NEWS

WAI Feb. 2015

MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Matthew Duncan vice president Granite Falls Furnace

Q: What does your company do? A: Please don’t let the name fool you...Granite Falls Furnace produces drawn steel wire covering a vast range from low carbon, high carbon, and music grades, to black and bright annealed wire for a wide range of industries. Q: What is your role there? A: I serve as vice president of sales and operations. Therefore I work with and for everyone; customers, suppliers, and our employees thus over-seeing our strategic direction and growth. Q: What do you like best about your position? A: I love the fact that I get to work with the many different levels/roles within our customer and supply base. In my position, I get to drive the culture within our business, where I personally know each of our employees Q: How has the industry most changed? A: It seems to me, for the most part our industry has remained constant, with the same major producers, suppliers and customer base. GFF hopes to offer the suppliers and customers something new. Q: How does your company remain competitive? A: GFF is a family owned and operated business; therefore we operate with a very lean management structure that lends itself to very quick decisions and low overhead costs. Q: Why did you recently join WAI? A: I joined WAI because I believe that the information it provides is essential to our company’s continued growth and understanding of the markets we serve.

26 | WIRE JOURNAL INTERNATIONAL

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY.

• Matthew Duncan, VP, Granite Falls Furnace • Jesse Gallop, Sls Mgr, Beta LaserMike • Jesse Garcia, Sls Mgr, Plas-Ties

• David Jankowski, Gen Mgr, Whitney Blake Company • Joe McDonnell, Pres, Phoenix Systems Inc • James Predmore, Mgr, Remee Products Corp

Updated list of WAI Platinum Member Companies: • ArcelorMittal • Asarco LLC • Beta LaserMike • Blachford • Borealis Compounds Inc • CAP Technologies LLC • Carris Reels Inc • Champlain Cable Corp • Chase Corp • Chemetall / Chemetall US • Clinton Instrument Co • Coleman Cable • Condusal SA de CV • Crown Technology Inc • Davis-Standard LLC • Electric Cable Compounds Inc

• Encore Wire • Enkotec • Equistar Chemicals LP • Fluoropolymer Resources Inc • Fort Wayne Metals • Frigeco USA Inc • Gem Gravure Co Inc • General Cable • Gerdau • Hazelett Strip-Casting Corp • Insteel Industries Inc • J Hamelin Industries • Joe-Tools Inc • Leggett & Platt • Lloyd & Bouvier Inc • Mario Frigerio SpA

• Marmon Specialty Wire & Cable Group • MFL USA Service Corp • MGS Manufacturing • Micro Products Co • Mid-South Wire • Nexans • Niehoff Endex North America Inc • Paramount Die Co • Pittsfield Plastics Eng Inc • PolyOne Corp • Q-S Technologies Inc • RichardsApex Inc • S&E Specialty Polymers LLC • SAMP USA Inc

• SDI LaFarga LLC • Siemens Industry Inc • Sikora International Corp • Singleton Reels • Sivaco/Ivaco • Sonoco • Southwire Co • Standridge Color Corp • Sterling Steel Co • T & T Marketing Inc • Teknor Apex Co • United Copper Industries • Whitney Blake Co • Windak USA Inc • Wire & Plastic Machinery Corp

FEBRUARY 2015 | 27

WAI NEWS

The following individuals either recently joined WAI or became Platinum Members through their companies.

CONVENTION: APRIL 27-30, 2015

EXPOSITION: APRIL 28-30, 2015

A meeting this productive shows up every other year. GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA, USA

Industry leaders are following www.wirenet.org for details on the largest wire and cable meeting place and marketplace in the Americas. Decidedly the most valuable use of your time...until 2017. WIRE & CABLE MAKING MACHINERY | LIVE DEMONSTRATIONS | SUPPLIES & EQUIPMENT | NEW TRENDS & PRODUCTS | GLOBAL NETWORKING | EDUCATIONAL FOCUS: DUST CONTROL, RAW MATERIALS, PROCESSING, APPLICATIONS, RECRUITING & RETENTION, MANUFACTURING WORKSHOP | PLANT TOUR: SOUTHWIRE SCR | ALSO WITH WAI’S 2ND GLOBAL CONTINUOUS CASTING FORUM

CORPORATE SPONSORS: PLATINUM | SONOCO REELS AND SPOOLS • WIRE & PLASTIC MACHINERY CORP.

GOLD | CONTINUUS-PROPERZI S.P.A. SILVER | BASF • CARRIS REELS INC. • GEM GRAVURE CO. INC. • THE MGS GROUP • NEXANS • NIEHOFF ENDEX NORTH AMERICA • SIKORA INTERNATIONAL CORP. • WINDAK GROUP BRONZE | RICHARDSAPEX INC. SUPPORTING SPONSORS: BAUM’S CASTORINE CO. • CHEMSON • COMMISSION BROKERS INC. • HERITAGE WIRE DIE • LLOYD & BOUVIER INC. The Wire Association International, Inc. | TELEPHONE: (001) 203-453-2777 | WWW.WIRENET.ORG

PA PA RR T ITCI C I PI A PA T ITNI N G GE X EX HH I BI B I TI O TO RR SS A. A. Appiani Appiani SrlSrl AceAce Metal Metal Inc.Inc. ACM ACM AB AB ADVARIS ADVARIS GmbH GmbH Aeroel Aeroel SrlSrl AESA AESA SA SA Agape Agape Industry Industry Inc.Inc. AIM AIM Inc.Inc. All All Forming Forming Machinery Machinery Inc.Inc. Allied Allied Mineral Mineral Products Products Amacoil Amacoil Inc.Inc. Amaral Amaral Automation Automation Associates Associates American American & Efird & Efird Inc.Inc. American American Kuhne Kuhne Inc.Inc. Anbao Anbao Wire Wire & Mesh & Mesh Co.Co. Ltd. Ltd. Appleton Appleton Manufacturing Manufacturing Assomac Assomac Machines Machines Ltd. Ltd. AWAW Machinery Machinery LLCLLC Axjo Axjo America America Inc.Inc. Aztech Aztech Lubricants Lubricants LLCLLC B &B H& Tool H Tool Co.Co. Inc.Inc. B &B Z& Galvanized Z Galvanized Wire Wire Ind. Ind. Balloffet Balloffet DieDie Corp. Corp. Baum’s Baum’s Castorine Castorine Co.Co. Inc.Inc. Beacon Beacon Reel Reel Co.Co. Bechem Bechem Lubrication Lubrication Technology Technology LLCLLC Beijing Beijing BIHI BIHI International International Exhibition Exhibition Co.Co. Ltd. Ltd. Beijing Beijing Orient Orient PengSheng PengSheng Tech Tech Co.Co. Ltd. Ltd. Bekaert Bekaert Bergandi Bergandi Machinery Machinery Co.Co. Beta Beta LaserMike/NDC LaserMike/NDC Technologies Technologies Beta Beta Steel Steel Blachford Blachford Corp. Corp. BLM BLMGroup Group USA USA Corp. Corp. Bloom Bloom Engineering Engineering Co.Co. Inc.Inc. Bohl Bohl (SPG (SPG Packaging Packaging Systems Systems GmbH) GmbH) Bongard Bongard Trading Trading GmbH GmbH & Co & Co KGKG Boockmann Boockmann GmbH/The GmbH/The Slover Slover Group Group Bow Bow Technology Technology Breen Breen Color Color Concentrates Concentrates Inc.Inc. Brookfield Brookfield Wire Wire Co.Co. Buhler-Wurz Buhler-Wurz Kaltwalztechnik Kaltwalztechnik GmbH GmbH Burster Burster Butt Butt Welders Welders USA USA Caballe Caballe SA SA Cable Cable Consultants Consultants Corp. Corp. Cable Cable Services Services & Systems & Systems Calmec Calmec Precision Precision Inc.Inc. Candor Candor Sweden Sweden AB AB Canterbury Canterbury Engineering Engineering Co.Co. Inc.Inc. Carris Carris Reels Reels Inc.Inc. Ceeco Ceeco Bartell Bartell Products, Products, Bartell Bartell Machinery Machinery Systems Systems Cemanco Cemanco LC LC Central Central Wire Wire Industries Industries Ltd. Ltd. Ceramtech Ceramtech CERSA-MCI CERSA-MCI Chase Chase Wire Wire & Cable & Cable Materials Materials Chemetall Chemetall Chengdu Chengdu Centran Centran Industrial Industrial Co.Co. Ltd. Ltd. Cimteq Cimteq Clifford Clifford Welding Welding Systems Systems Clinton Clinton Instrument Instrument Co.Co. CMCM Furnaces Furnaces IncInc CMEC CMEC International International Exhibition Exhibition Ltd. Ltd. CNCN Wire Wire Corp. Corp. Collins Collins & Jewell & Jewell Co.Co. Inc.Inc. Cometo Cometo Commission Commission Brokers Brokers Inc.Inc. Condat Condat Condat Condat Lubricants Lubricants Conneaut Conneaut Industries Industries Inc.Inc. Conoptica Conoptica A/SA/S Continuus-Properzi Continuus-Properzi SpA SpA Custom Custom Machining Machining & Fabrications & Fabrications LLCLLC Daloo Daloo Davis-Standard Davis-Standard LLCLLC DieDie Quip Quip Corp. Corp. Domeks Domeks Makine Makine Ltd. Ltd. StiSti Dynamex Dynamex Corp. Corp. E-Beam E-Beam Services Services Inc.Inc. Ebner Ebner Furnaces Furnaces Inc.Inc. EJPEJP Maschinen Maschinen GmbH GmbH

ELCO ELCO Enterprises Enterprises Electron Electron Beam Beam Technologies Technologies Inc.Inc. EMSCO EMSCO Enercon Enercon Industries Industries Engineered Engineered Machinery Machinery Group Group Inc.Inc. Enkotec Enkotec Co.Co. Inc.Inc. Er-Bakir Er-Bakir ERA ERA Wire Wire Inc.Inc. Ernst Ernst Koch Koch Esteves Esteves Group Group USA USA Etna Etna Products Products Inc.Inc. Eurobend Eurobend SA SA Eurolls Eurolls SpaSpa Eurowire Eurowire Magazine Magazine George George Evans Evans Corp. Corp. EVG EVG Inc.Inc. Evolution Evolution Products Products Fabritex Fabritex Inc.Inc. Fastener Fastener Engineers Engineers - Lewis - Lewis Machine Machine Fenn Fenn LLCLLC FIBFIB Fil-Tec Fil-Tec Inc.Inc. Filtertech Filtertech Inc.Inc. Fine Fine International International Corp. Corp. Finoptics Finoptics IncInc Fisk Fisk Alloy Alloy Wire Wire Inc.Inc. Flymca Flymca & Flyro & Flyro FMS FMS USA USA Inc.Inc. Foerster Foerster Instruments Instruments Inc.Inc. Fort Fort Wayne Wayne Wire Wire DieDie Inc.Inc. Fortune Fortune Machinery Machinery Freedom Freedom Technologies Technologies Fridea Fridea SrlSrl Frigeco Frigeco USA USA Inc./ Inc./ MFL MFL USA USA Service Service Corp. Corp. OMOM Frigerio Frigerio Frigerio Frigerio USA USA Frontier Frontier Composites Composites & Castings & Castings Inc.Inc. FSP-One FSP-One Fuhr Fuhr GmbH GmbH & Co. & Co. Kg Kg Gavlick Gavlick Machinery Machinery Corp. Corp. GCR GCR Eurodraw Eurodraw SpA SpA Gem Gem Gravure Gravure Co Co Inc.Inc. Genca Genca W. W. Gillies Gillies Technologies Technologies LLCLLC GIMAX GIMAX srl srl GMP GMP Slovakia Slovakia s.r.o s.r.o Granite Granite Falls Falls Furnace Furnace Guill Guill Tool Tool & Engineering & Engineering Co.Co. Guney Guney Celik Celik Hafner Hafner & Krullmann & Krullmann GmbH GmbH Hangzhou Hangzhou JR JR Exhibition Exhibition Co.Co. Ltd. Ltd. Hariton Hariton Machinery Machinery Heany Heany Industries Industries Inc.Inc. Heatbath Heatbath Corp. Corp. Heritage Heritage Wire Wire DieDie Inc.Inc. HFSAB HFSAB H Folke H Folke Sandelin Sandelin AB AB Holland Holland Colours Colours Americas Americas Inc.Inc. Houghton Houghton International International Inc.Inc. Howar Howar Equipment Equipment Inc.Inc. Huestis Huestis Industrial Industrial Huttner Huttner Maschinenfabrik Maschinenfabrik ICEICE Wire Wire Line Line Equipment Equipment Inc.Inc. IDEAL IDEAL Welding Welding Systems Systems INFLEX INFLEX IncInc INHOL INHOL LLCLLC InnoVites InnoVites Inosym Inosym Integrated Integrated Control Control Technologies Technologies Interequip Interequip SA SA International International Wire Wire & Cable & Cable Machinery Machinery Association Association Intras Intras Ltd. Ltd. IP IP Automation Automation IncInc Isotek Isotek Corp. Corp. IW/Bare IW/Bare Wire Wire Division Division IW/High IW/High Performance Performance Conductors Conductors IWE IWE Spools Spools & Handling & Handling GmbH GmbH IWG IWG High High Performance Performance Conductors Conductors Inc.Inc. JoeJoe Snee Snee Associates, Associates, Inc.Inc. Joe-Tools Joe-Tools Jouhsen-Bundgens Jouhsen-Bundgens Inc.Inc. Kablosan Kablosan Turkey-FBC Turkey-FBC Yayincilik Yayincilik Ltd. Ltd. sti sti Kalmark Kalmark Intergrated Intergrated Systems Systems Ltd. Ltd. KEIR KEIR Manufacturing Manufacturing Inc.Inc.

Keystone Keystone Steel Steel & Wire & Wire Co.Co. Kieselstein Kieselstein GmbH GmbH King King Steel Steel Corp. Corp. Kinrei Kinrei of of America America KMB KMB Maschinenfabrik Maschinenfabrik GmbH GmbH KMK KMK Lamnea Lamnea Bruk Bruk AB AB Kopilowitz Kopilowitz Engineering Engineering Ltd. Ltd. Kyocera Kyocera Industrial Industrial Ceramics Ceramics Lake Lake Michigan Michigan Metals Metals Inc.Inc. LaserLinc LaserLinc Inc.Inc. Leggett Leggett & Platt & Platt Wire Wire Group Group Leoni Leoni Wire Wire Inc.Inc. Lesmo Lesmo Machinery Machinery America America Inc.Inc. Lloyd Lloyd & Bouvier & Bouvier Inc.Inc. Lubrimetal Lubrimetal Corp. Corp. LUKAS LUKAS Anlagenbau Anlagenbau GmbH GmbH M+E M+E Madison Madison Steel Steel Inc.Inc. Magnetic Magnetic Technologies Technologies Ltd. Ltd. Maillefer Maillefer Extrusion Extrusion Oy Oy Mario Mario Frigerio Frigerio SpA SpA Mathiasen Mathiasen Machinery Machinery Inc.Inc. Messe Messe Düsseldorf Düsseldorf North North America America Metal Metal Resource Resource Solutions Solutions Inc.Inc. Metalloid Metalloid Corp. Corp. Metallurgical Metallurgical Council Council of of China China Metavan Metavan nv nv MFL MFL USA USA Service Service Corp. Corp. MGS MGS Manufacturing Manufacturing Inc.Inc. Micro Micro Products Products Co.Co. Microdia Microdia USA USA Mid-South Mid-South Wire Wire Morgan-Koch Morgan-Koch Corp. Corp. Mossberg Mossberg Associates Associates Inc.Inc. Mossberg Mossberg Industries Industries Inc.Inc. Henrich Henrich Müller Müller Maschinenfabrik Maschinenfabrik GmbH GmbH Nanjing Nanjing Xiandai Xiandai Diamond Diamond Products Products Co Co LtdLtd Nano-Diamond Nano-Diamond America America Inc.Inc. Neptco Neptco Nextrom Nextrom OYOY Niagara Niagara Composites Composites Int’l.Inc. Int’l.Inc. Niehoff Niehoff Endex Endex North North America America Inc.Inc. Maschinenfabrik Maschinenfabrik NIEHOFF NIEHOFF GmbH GmbH & Co & Co KGKG Nimsco Nimsco LLCLLC / SB2C / SB2C Numalliance Numalliance North North America America Inc.Inc. Oklahoma Oklahoma Steel Steel & Wire & Wire OMCG OMCG North North America America Inc.Inc. OMOM Lesmo Lesmo Otomec Otomec SrlSrl Ozyasar Ozyasar TelTel Ve Ve Galvanizleme Galvanizleme P &P R& Specialty R Specialty Inc.Inc. P/AP/A Industries Industries Paramount Paramount DieDie Co.Co. Parkway-Kew Parkway-Kew Corp. Corp. Pave Pave Automation Automation Pentre Pentre Group Group Ltd.-Hearl Ltd.-Hearl Heaton Heaton Phifer Phifer Wire Wire Inc.Inc. Pioneer Pioneer USA USA Pittsfield Pittsfield Plastics Plastics Eng. Eng. Inc.Inc. PKG PKG Equipment Equipment Inc.Inc. Plas-Ties Plas-Ties Co.Co. Plastic Plastic Equip Equip LLCLLC Plasticolor Plasticolor Plymouth Plymouth Wire Wire Reels Reels & Dies & Dies Inc.Inc. Pneumatic Pneumatic Power Power Tool Tool & Co. & Co. Polytec Polytec Inc.Inc. Pourtier Pourtier Pourtier Pourtier & Setic & Setic of of America America Precision Precision DieDie Technologies Technologies Inc.Inc. Premier Premier Wire Wire DieDie PrintSafe PrintSafe Process Process Control Control Corp. Corp. Progressive Progressive Machinery Machinery Inc.Inc. Promostar Promostar srl srl Properzi Properzi International International Inc.Inc. Proton Proton Products Products PWM PWM QED QED Wire Wire Lines Lines Inc.Inc. Queins Queins Machines Machines GmbH GmbH Raajratna Raajratna Stainless Stainless Wire Wire Inc.Inc. RAD-CON RAD-CON Inc.Inc. Radyne Radyne Corp. Corp. Rainbow Rainbow Rubber Rubber & Plastics & Plastics continued continued

PARTICIPATING PARTICIPATING EXHIBITORS EXHIBITORS (cont’d) (cont’d) Rautomead Rautomead Ltd. Ltd. Reber Reber Systematic Systematic GmbH GmbH + Co + Co KGKG REDEX REDEX Reel-O-Matic Reel-O-Matic Inc.Inc. Refractron Refractron Technologies Technologies Corp. Corp. RichardsApex RichardsApex Inc.Inc. Rizzardi Rizzardi Rockford Rockford Manufacturing Manufacturing Group Group Inc.Inc. Q8Oils Q8Oils —— Roloil Roloil Rosendahl Rosendahl GmbH GmbH Rosendahl Rosendahl Nextrom Nextrom Technologies Technologies Roteq Roteq Machinery Machinery Inc.Inc. RSD RSD Group Group USA USA RTD RTD Manufacturing Manufacturing S&E S&E Specialty Specialty Polymers Polymers Saco Saco Polymers Polymers Inc.Inc. Saint-Gobain Saint-Gobain SAMP SAMP SpA SpA SAMP SAMP USA USA Inc.Inc. SAMPSISTEMI SAMPSISTEMI Sanxin Sanxin Wire Wire DieDie Inc.Inc. Sarkuysan Sarkuysan SA SA Schlatter Schlatter Inc.Inc. Schmidt Schmidt Maschinenbau Maschinenbau GmbH GmbH Schnell Schnell SpA SpA Scienscope Scienscope International International Setic Setic Shanghai Shanghai Pudong Pudong International International Exhibition Exhibition Co.Co. Shenzhen Shenzhen KTYU KTYU Insulation Insulation Co.Co. Ltd. Ltd. SIEBE SIEBE Engineering Engineering GmbH GmbH Sikora Sikora International International Corp. Corp. SIMPACKS SIMPACKS Sirio Sirio Wire Wire Sivaco Sivaco Wire Wire Group Group Sjogren Sjogren Industries Industries Inc.Inc. SKET SKET Verseilmaschinenbau Verseilmaschinenbau GmbH GmbH Skyline Skyline Industries Industries Sneham Sneham International International Sonoco Sonoco Reels Reels Spirka Spirka Schnellflechter Schnellflechter GmbH GmbH STAKUSTAKUAnlagenbau Anlagenbau Starrett-Bytewise Starrett-Bytewise Measurement Measurement Systems Systems Steel Steel Cable Cable Reels Reels Stolberger Stolberger IncInc DBA DBA Wardwell Wardwell Braiding Braiding August August Strecker Strecker GmbH GmbH & Co & Co KGKG Subec Subec AB AB Sudhir Sudhir Enterprises Enterprises Sylvin Sylvin Technologies Technologies Inc.Inc. T &T T& Marketing T Marketing Inc.Inc. Talledega Talledega Castings Castings & Machine & Machine Co.Co.

Tantec Tantec EstEst Inc.Inc. Tapeformers Tapeformers Ltd. Ltd. Taubensee Taubensee Steel Steel & Wire & Wire Co.Co. Taymer Taymer International International Inc.Inc. Tecnofil Tecnofil SA SA TECVIL TECVIL Teknikor Teknikor Teknor Teknor Apex Apex Tensor Tensor Machinery Machinery Ltd. Ltd. Thermcraft Thermcraft Inc.Inc. Thermoplastics Thermoplastics Engineering Engineering Corp. Corp. Tien Tien Chen Chen Diamond Diamond Industry Industry Co.Ltd. Co.Ltd. TopTop Tapes Tapes (TT(TT Okroglica Okroglica DD)DD) Trafco Trafco Cortinovis Cortinovis Sictra Sictra Tramev Tramev Traxit Traxit North North America America LLCLLC Troester Troester Maschinenfabrik Maschinenfabrik GmbH GmbH & Co. & Co. KGKG Tubular Tubular Products Products Co.Co. Tulsa Tulsa Power Power Inc.Inc. Ultimate Ultimate Automation Automation Ltd. Ltd. United United Wire Wire Co.Co. Inc.Inc. Unitek Unitek UPCAST UPCAST OYOY Vandor Vandor Corp. Corp. VINSTON VINSTON USUS Corp. Corp. Vollmer Vollmer America America Inc.Inc. Vom Vom Hagen Hagen & Funke & Funke GmbH GmbH W3W3 Ultrasonics Ultrasonics LLCLLC WAFIOS WAFIOS Machinery Machinery Corp. Corp. WCISA WCISA / Wire / Wire Forming Forming Technology Technology International International Weber Weber & Scher & Scher Mfg. Mfg. Co.Co. Inc.Inc. Welding Welding Wire Wire Machineries Machineries Windak Windak Inc.Inc. Wire Wire & Cable & Cable Technology Technology International International Wire Wire & Plastic & Plastic Machinery Machinery Corp. Corp. Wire Wire Association Association International, International, Inc.Inc. Wire Wire Journal Journal International International Wire Wire LabLab Co.Co. Wire Wire Machine Machine Systems Systems (WMS) (WMS) Wire Wire World World WiTechs WiTechs Witels Witels Albert Albert USA USA Ltd. Ltd. Woodburn Woodburn Diamond Diamond DieDie Inc.Inc. Worth Worth Steel Steel & Machinery & Machinery Inc.Inc. Woywod Woywod Kunststoffmaschinen Kunststoffmaschinen GmbH GmbH & Co & Co Vertriebs Vertriebs KGKG Yield Yield Management Management Corp. Corp. Zhejiang Zhejiang Wanma Wanma Macromolecule Macromolecule Material Material Co.Co. Ltd. Ltd. Zumbach Zumbach Electronics Electronics Corp. Corp.

N ENW E WW W E BE IBNI AN RA RF RF EREE ET OT OW W A IA IM M E ME M B EBRE SR!S ! t th he e wwi ri re e a as s so oc ci ai at ti oi on n i n i nt te er rn na at ti oi on na al l p pr re es se en nt ts s: :

WIREDRAWING WIREDRAWING DIES DIES && LUBRICANTS LUBRICANTS February February1212| 11:00 | 11:00a.m. a.m.ETET featured featuredspeakers: speakers:

Tom TomMaxwell Maxwell——Die DieQuip QuipCorp. Corp.&& David DavidGzesh Gzesh——Blachford BlachfordCorp. Corp.USA USA Details Detailsand andregistration registrationat:at:www.wirenet.org www.wirenet.org

TheThe Wire Wire Association Association International, International, Inc.Inc.

Looking for a hotel room for Interwire 2015 or GCCF?

Marketing consultant John Barteld, the former CEO/ Attendees seeking a hotel room can find one via WAI’s Director of IWCS, will be the key presenter at the website, wirenet.org, where the Interwire page drop list of Manufacturing Management Workshop, a new Interwire links includes one for reservations. session to be held from 9 am to noon on Thursday, April Just click on “hotels” and a drop list will include a 30, 2015. half-dozen hotels that WAI has negotiated with. One can The half-day workshop, to be held at the Georgia World then choose a timeframe and look at the available hotels Congress Center, is designed to provide practical tools and rates. The list includes Embassy Suites, Glenn Hotel, to wire and cable operations managers on the critical Hilton Garden Inn, Holiday Inn, the Omni and the Westin. subjects of leadership and teamwork. It will include prac(section continued.) tical tools to advance performance, and a guest panel that includes senior operations executives as well as interaction with other professionals facing similar challenges and opportunities. The new program is designed specifically for wire and cable operations managers. Below are comments Model from Barteld CJS 1000 about the focus of the workshop. “If there is one constant in an organization, it is that nothModel BJS 1000* ing is constant. In the * Model BJS 1000 is ISO9001 Technology bench mounted. All other REGISTERED Age, change models are free standing. John Barteld comes rapidly, and oftenStripping faulty cable jackets from costly cable cores demands times, out of nowhere. Dealing with issues precision and protection. Huestis Industrial Cable Jacket of leadership in an era of rapid change is Strippers remove jackets quickly and easily without damaging a challenge, but also a requirement. In this the valuable core. A protective stripping tool and rotating blade workshop, current thinking and techniques work together to lift, cut and separate the jacket from bare or in leadership are examined, with direct examples used to illustrate the challenge braided cable cores. Free-standing, bench-mounted or custom and the opportunity. The use of ‘Change models quickly remove jackets from various cable cores from Agents,’ strategies for ‘peeking around the .030"–4.0" (.76–102 mm) diameters. corner,’ to identify tomorrow’s challenges, and coping with the disruption of change For more details, or to place an order, call us at are explored.” 800-972-9222, or email us at sales@huestis.com Barteld, who recently retired after 10 years of heading IWCS. His career, which began in 1977, saw him work at General Cable Corporation and Pirelli before he was asked by Pirelli to assist the development of the International Cablemakers Federation (ICF). IFC was officially www.huestisindustrial.com launched in 1992 and in 1994 he took over its leadership. In 1997, he joined Draka Air Wipes, Pay-offs, Take-ups, Buncher Pay-offs, Accumulators, Spoolers, Cable, serving both abroad and in the U.S., Cold Pressure Welders, Cable Jacket Strippers, Custom Machinery before assuming his role at IWCS in 2004.

WAI NEWS

Former IWCS director to head Interwire management workshop

Huestis Industrial Cable Jacket Strippers Cable Core Salvage System

2C_halfISLAND_WJI_CJS_PlainAd_variousCombos_v7_08112014_press.indd 1

FEBRUARY 2015 | 31

1/8/15 5:05:03 PM

WAI NEWS

Schedule for Interwire/Global Continuous Casting Forum The March issue will have full previews for both Interwire 2015 and the Global Continuous Casting Forum. The below schedule lists the elements that await attendees. For more details and updates, go to www.wirenet.org.

MONDAY, April 27 8:00 a.m. - 6:00 p.m.

Registration Open

8:00 a.m. - 6:00pm

Exhibitor Move-in | Hall A

8:30 a.m. - 5:00 p.m.

Fundamentals of Wire Manufacturing

10:00 a.m. - 12:00 p.m.

Education Committee Meeting

10:00 a.m. - 11:30 a.m.

Exhibition Planning Committee Meeting

12:00 p.m. - 1:00 p.m.

Fundamentals Luncheon

1:00 p.m. - 2:00 p.m.

Conference Programming Committee Meeting

1:00 p.m. - 4:00 p.m.

Plant Tour Southwire Rod Mill

2:00 p.m. - 3:00 p.m.

Memorial Awards Committee Meeting

3:00 p.m - 5:00 p.m.

Board of Directors Meeting

7:00 p.m. - 10:00 p.m.

Global Continuous Casting Forum Welcome Reception

- Ventanas at Hilton Garden Inn Hotel

TUESDAY, April 28 8:00 a.m. - 5:00 p.m.

Registration Open

8:45 a.m. - 12:00 p.m.

Global Continuous Casting Forum Program

9:00 a.m. - 4:30 p.m.

Technical & Operations Program

10:00 a.m. - 5:00 p.m.

Exhibits Open | Hall A

12:00 p.m. - 1:00 p.m.

Global Continuous Casting Forum Luncheon & Speaker

3:00 p.m. - 5:00 p.m.

Member Relations Committee Meeting

6:30 p.m. - 8:30 p.m.

Opening Reception

- College Football Hall of Fame

WEDNESDAY, April 29 8:00 a.m. - 5:00 p.m.

Registration Open

8:45 a.m. - 12:30 p.m.

Global Continuous Casting Forum Program

9:00 a.m. - 12:45 p.m.

Technical & Operations Program

10:00 a.m. - 5:00 p.m.

Exhibits Open | Hall A

12:00 p.m. - 1:00 p.m.

Conference Programming Committee Lunch

12:30 p.m. - 1:30 p.m.

WAI Member Rewards & Annual Meeting (Members Only)

-Sponsored by: Lloyd & Bouvier Inc.

2:00 p.m. - 2:45 p.m.

Keynote Speaker - Mike Abrashoff - “It’s Your Ship”

4:00 p.m. - 6:00 p.m.

SE Chapter Reception - Georgia World Congress Center

7:00 p.m. - 10:00 p.m.

Global Continuous Casting Forum Dinner and Address - Georgia Aquarium

THURSDAY, April 30

32 | WIRE JOURNAL INTERNATIONAL

8:00 a.m. - 2:00 p.m.

Registration Open

8:00 a.m. - 12:30 p.m.

Global Continuous Casting Forum Program

9:00 a.m. - 12:00 p.m.

Technical & Operations Program

10:00 a.m. - 3:00 p.m.

Exhibits Open | Hall A

- Manufacturing Management Workshop

The best way to deliver an encore is to add to the cast.

Aluminum joins copper for WAI’s second Global Continuous Casting Forum April 27 - 30, 2015 | Atlanta, Georgia, USA | With Interwire 2015 Join a renowned ensemble of continuous casting practitioners, raw material suppliers, and equipment manufacturers on an educational journey from ore to more at WAI’s second Global Continuous Casting Forum. Shared sessions. Independent technical tracks. Unalloyed networking. All focused on saving money through performance-based casting technologies. www.castingforum15.com.

ADVANCE REGISTRATION FORM Convention: April 27-30, 2015 | Exhibits: April 28-30, 2015 Georgia World Congress Center | Atlanta, Georgia, USA

4. EVENT REGISTRATION (Required) *advance (on or before March 29, 2015) | *on-site (after March 29, 2015) *advance

LAST NAME

*on-site

FULL REGISTRATION PLUS NEW WAI MEMBERSHIP (BL/AEM) FIRST NAME

MIDDLE

Includes exhibits, opening reception, technical sessions & online proceedings, production solutions, keynote, and one year WAI membership.

TITLE

New Member

$425 q

$525 q

Member

$375 q

$475 q

Non Member

$475 q

$575 q

$75 q

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Includes exhibits, opening reception, technical sessions & online proceedings, production solutions and keynote.

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FUNDAMENTALS OF WIRE MANUFACTURING (Includes Exhibits) (GDS) Monday, April 27, 2015 Includes program handouts, lunch, exhibits, and production solutions. q Ferrous Track (FT) q Nonferrous/Electrical Track (NT)

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$275 q

$375 q

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$125 q

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A. Which ONE of the following best describes your company’s type of business? CHECK ONLY ONE. WIRE MANUFACTURING 10 q Aluminum & Al. Alloys (Rod/Bar, Bare Wire) 20 q Copper & Copper Alloys (Rod/Bar, Bare Wire) 30 q Steel & Steel Alloys (Rod/Bar, Bare Wire) 40 q Other Metal (Rod/Bar, Bare Wire) 50 q Electrical (Insulated Wire) 53 q Communication (Insulated Wire) 55 q Fiber Optics FASTENERS, WIRE FORMING, FABRICATING 61 q Fastener Manufacture 62 q Four-Slide Forming 64 q Hot and/or Cold Forming and Heading 66 q Spring Manufacture 68 q Wire Cloth Mesh Screening 69 q Other Forming and Fabricating Please Specify ___________________________

SUPPLIERS TO THE WIRE INDUSTRY 72 q Machinery 74 q Process, Accessories, Materials WIRE END-USER 11 q Appliance 12 q Communications (Voice/Data) 13 q Computer 14 q Construction/Building 15 q Electrical (Equip./Components/Power) 16 q Transportation/Vehicular 17 q Wire Formed Durable Goods OTHER 80 q Service Cntrs, Distrib. & Warehouses 90 q Consultants 92 q Govt., Library, Others Allied to Field

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

SOUTHWIRE ROD MILL TOUR (SR) Monday, April 27, 2015 Note: Space is limited and preference will be given to full conference registrants. Individual registrations subject to approval.

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$75 q

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MANUFACTURING MANAGEMENT WORKSHOP (MMW) Thursday, April 30, 2015 Note: Space is limited and preference will be given to full conference registrants.

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$125 q

$175 q

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$175 q

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with Full Registration

$50 q

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GLOBAL CONTINUOUS CASTING FORUM (CCF) Monday-Thursday, April 27-30, 2015 Includes Global Continuous Casting Forum AND Interwire 2015 Exhibits, Full Technical Program, and Opening Reception.

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$495 q

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$545 q

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5. TOTAL REGISTRATION FEES, U.S. $ 6. REGISTRATION FEE IS PAID BY:

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Cancellation Policy–Refund requests must be received in writing by these dates: On or before 3/18/15 – REFUND minus $25 handling fee • After 3/18/15 – NO REFUND

In addition to the 30 technical and practical presentations that are the heart of the Global Continuous Casting Forum (GCCF), the program includes the below four elements to offer both a change of pace and a little fun. • Monday: Welcome Reception. The evening before the Forum begins, all GCCF registrants are invited to a Welcome Reception at Ventanas restaurant in the Hilton Garden Inn. The venue is a short walk from the Georgia World Congress Center.

he has worked with, describe some of the early challenges, assess today’s challenges, and predict those to come. His presentation will pay tribute to practitioners before him, and recognize individuals that impacted his career from 1970 on. It will be neither “institutional,” nor politically correct. It will just be Gary being Gary, sharing his story of evolving along with the industry, which unto itself makes this a must-attend event. More details on the GCCF will be presented in the March preshow issue. For the latest details, go to the GCCF website at www.castingforum15.com.

• Tuesday: Cost-Saving Opportunities Panel. The first day of the GCCF program ends with a 90-minute panel discussion of opportunities for cost savings in the casting world. Four executives from the copper and aluminum sectors will each share a cost-saving idea with the industry. Panelists include Brian Blair, Southwire Co., USA; John Quinn, Freeport McMoRan, USA; Steve Roussel, Rio Tinto Alcan, Canada; and Carlos Sanchez, Nexans Canada Inc., Canada. • Wednesday: Keynote. GCCF attendees are invited to join the rest of the Interwire program for guest speaker Mike Abrashoff’s “It’s Your Ship.” At the age of 36, the Navy selected Abrashoff to become Commander of USS Benfold. At the time, he was the most junior commanding officer in the Pacific Fleet. The challenges he faced were staggering: exceptionally low morale with unacceptably high turnover. Few thought that this ship could improve. In many ways, the USS Benfold was actually an extreme example of the same problems facing many organizations today. This break from the GCCF schedule was devised to allow attendees a break from the regular program, and a chance to hear Abrashoff before spending the rest of the afternoon visiting the Interwire exhibits. • Wednesday: Dinner and Address. The final social event of the Global Continuous Casting Forum, held at the renowned Georgia Aquarium, features a dinner, speaker, entertainment, and prize drawings. Encore Wire’s Gary L. Spence will present “A tale of long hours and hard-earned success in 40+ years in copper continuous casting.” Spence, the man who single-handedly created the highly acclaimed GCCF in 2011, will reflect back on his more than four decades of continuous casting experiences. He will talk about the four different casting processes (wire bar, ESSEX/Properzi, Contirod, and SCR) FEBRUARY 2015 | 35

WAI NEWS

2015 Casting Forum highlights

WAI NEWS

Interwire 2015/GCCF attendees will enjoy a collegiate flavor at reception

That includes 50,000 sq ft of unique event space, including a 45-yard indoor Playing Field that can accommodate approximately 900 people for a sit-down meal and up to Interwire attendees may be very familiar with the city of 1,450 people for a reception. Atlanta, but unless you’ve been there recently there is a Guests will be treated to a personalized experience in new attraction that will the Hall through 10 be a welcome surprise augmented reality for sporting-minded displays where they attendees (and even can select video and those who aren’t!): the images of players and College Football Hall of coaches from their Fame, which will host favorite school. The WAI’s reception. journey begins with a The $68.5 million, one-of-a-kind experithree-story building, ence through the Entry completed last August, Tunnel, boasting largerhouses the national than-life images from College Football Hall 11 conference chamof Fame, which was pions that are updated previously located in each season. It winds South Bend, Indiana. its way to The Quad, The “Fan Experience” which is anchored by includes museum-qual- The WAI reception will offer a gridiron treat for attendees. the Helmet Wall preity memorabilia and sented by Southwest interactive, multi-media exhibits. The site, adjacent to the Airlines, featuring helmets from all 768 college football Georgia World Congress Center and Centennial Olympic teams. Guests check in at the registration desks in The Park, covers 94,256 sq ft designed to entertain and educate Quad to personalize their All-Access Pass credential with visitors while celebrating the traditions of college football. their favorite college football team.

36 | WIRE JOURNAL INTERNATIONAL

CHAPTER CORNER

CHAPTER CORNER Members of Poland Chapter a key force behind technical conference WAI’s Poland Chapter and the Czestochowa University of Technology (CUT) once again are organizing a biennial technical conference, the 6th International Conference on Drawing, to be held March 5-7, 2015, at the Antałówka Hotel in Zakopane, Poland.

Three key organizers of the event are Zbigniew Muskalski, Sylwia Wiewiórowska and Jan Pilarczyk, all of whom are members of both the faculty of engineering production and materials technology at CUT and the WAI’s Poland Chapter. The event will see the awarding of the prestigious Schneider Memorial Award to Prof. Jose Atienza of Madrid University and to Pilarczyk, who is retiring later this year. Muskalski is president of the 10-member Scientific Committee for the event, while Wiewiórowska is president of the Organizing Committee. For more details, go to the event website at http:// www.konferencja.wip.pcz.pl/en/index2.htm.

Reminder: March deadline draws closer for scholarship applications A presentation at a past conference in Poland. The event theme, “Modern technologies and modelling of drawing and manufacturing processes of metal products,” will be seen in technical presentations presented on steel wire and wire products, nonferrous wire and wire products and electrical wire and special products. There will also be a poster session, tabletop displays and a social program.

Members of WAI’s New England, Midwest and Southeast chapters must mail their scholarship applications by Tuesday, March 31, 2015. Non-members of WAI who have students who would be eligible for the scholarships are welcome to join WAI and their respective chapter and be considered eligible to submit an application. For more details, contact WAI Executive Director Steve Fetteroll at tel. 203-453-1777, ext. 115, or at sfetteroll@wirenet.org.

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38 | WIRE JOURNAL INTERNATIONAL

FEATURE

Packaging It's not just about making the wire and cable, it's being able to get product to customers when and where they want it, and that takes reels, spools and carriers. In this feature, such suppliers describe what they can offer as well as one manufacturer's thoughts on shipping. The Products section that follows the story presents some of the technology. Ace Metal, Inc., U.S. Since 1946, Ace Metal has worked hard to build an excellent reputation manufacturing both custom and standard wiredrawing spools for the ferrous, nonferrous and tire cord wire industries. Our spools are designed with uniform quality and precision and are also used in the batch annealing process. Spools are made from prime cold-rolled steel and are available in multiple colored finishes. We manufacture many varieties of tubular wire carriers: square base, star base, clover leaf base and circular base designs. We design, manufacture and ship our wire carriers throughout North America at economical prices. All of our products are guaranteed for quality, strength and design. We know that customers are looking for Richard Medoff, Ace Metal. durability as well as performance, and that shipping times or JIT supply is vital, so we are tailored to meet those needs. Stop by our website and see the range of what we can do for you. Richard Medoff, general manager, Ace Metal, www.acemetalinc.com. A. Appiani/Lesmo Machinery America, Italy/Canada For more than 50 years A. Appiani has manufactured standard and custom-built steel reels to DlN specifications or customer requirements. It offers steel reels for wire drawing, reels for bunching and stranding, cable reels and drums, fully machined steel reels and spools for steel cord, hose wire, saw wire and special fine wire. Also offered are collapsible take-apart reels, all B-type spools, finned flanged corrugated steel reels (cable drum), plastic and steel composite reels (ABS material reels) and reel handing equipment including reel lifters and tilters, steel pallets for reel storing and reel reconditioning machinery

40 | WIRE JOURNAL INTERNATIONAL

for B-type spools. We do this with a manufacturing process and focus that allows wire makers to maxiReels from A. Appiani. mize wire drawing and bunching machine capacity with smooth, trouble-free processing. Innovation and customer service is always the rule of the day for A. Appiani. Stop by our website for more details. Marco Appiani, managing director, A. Appiani, Srl, www.appianireels.com; Allan Brown, COO, Lesmo Machinery America, www.lesmoamerica.com. H. BÖHL/H. Boehl North America (HBNA), Germany/U.S. One size fits all does not work and the same can be said for one system fits all, especially when packaging coiled wire and/or cable. With 90 years of packaging machine expertise and technology development history, Germany’s BÖHL has packaging machines and conveyor systems that are tailored to handle the large variety of real-world customer requirements. With the ability to speedily wrap product sizes that range from small to very large, we are able to customize a packaging solution that gets the job done right without resorting to a budget-killing oversized machine. BÖHL has extensive experience packaging not only a large variety of coiled cable products but also in the design of efficient systems that are incorporated into our customers’ production workflow. Our engineers know that utilizing a great packaging machine is only half of a solution without a complete product handling system. Every customer has particular needs not only with the type and physical dimensions of their products but also with their specific requirements for throughput rate, floor space availabil-

Boxy SpA/HOWAR Equipment, Italy/Canada Experience, relationships and solutions, that is what BOXY brings to the table. Many reels are duplicates of others made, but what sets apart BOXY—in conjunction with its U.S./Canadian representative, HOWAR Equipment—is the vast experience that comes from being closely involved in the wire and cable industry for close to 50 years. See p. 60 for an example. BOXY, a world leader in reel manufacturing, has collaborated with numerous wire and cable manufacturers as well as machinery manufacturers. This network of relationships allows BOXY to continually offer renewed solutions to modern-day

Big shipping reels: deliveries can represent a 'real' challenge One U.S. company that is just beginning to deliver large reels is Nexans North America, which annually ships thousands of reels (from 12 in. to 96 in. diamters, weights to 15,000 lb) and pallets annually. It will soon be shipping high-voltage power cable from its new plant in South Carolina. These reels have diameters up to 170 in. and can weigh 70,000 lb. Below, Nexans Canada’s John de Pass, manager transportation discusses the shipping challenges. WJI: Are all reels equal (in terms of shipping logistics)? de Pass: Definitely not. In the past we shipped via LTL and truckloads (vans and flatbeds). These types of shipments are routine. Going forward with much larger reels from our HV plant will present a challenge. Nexans does have experience in these types of shipments from our former HV plant in North America and from a number of HV plants in Europe. WJI: Do you try to work with the same shippers each time? de Pass: Nexans does establish long-term working relationships with carriers. These companies become familiar with our products, have good service levels and we occur little or no damage during transport. WJI: Just how durable are steel reels? Can a jarring drop of even a few inches be enough to damage a loaded reel? de Pass: Our concern is the not the reel itself but any damage to the cable, which is quite expensive. If the reel was dropped a few inches, we might not see any damage but would definitely inspect the cable before installation. If any major damage is found, then the cable would be scrapped. WJI: Which logistics step is most likely to cause problems? Loading? Transport? Unloading? de Pass: Unloading is always the most prone to damage occurring. All our plants are familiar with loading cable shipments and have the necessary equipment to avoid any damages during that step. During un-loading, and especially at job sites, damage can occur due to either inexperience or not having the necessary equipment or proper forklifts required to properly offload the reels. On larger reels, to avoid damage, we will work with our customers, issuing clear guidelines for the handling and storage of reels.

Reels from Boxy SpA. requirements. The pace of technological change in our industry is slow, but it is still true that materials and processes are regularly changing. It is these changes that provide the need to collaborate and ﬁnd new solutions. Boxy SpA/HOWAR Equipment, www.boxy. com/www.howarequipment.com.

WJI: What types of reels are the toughest to ship? de Pass: Larger reels are always the most difficult. Reels from our new high-voltage plant will present a challenge but we are familiar with them and use transport companies that have the necessary equipment to handle them safely. For large reels, before we spec any cable we look at the final destination, what modes of transport are available, length of journey and what requirements can cause issues, such as height restrictions, weight restrictions and how many states we cross before we get to final destination. (continued on p. 42.) FEBRUARY 2015 | 41

FEATURE

ity, automation integration and operator time availability. H. Boehl North America, BÖHL’s U.S. business, provides full customer service to the United States and Canada. We are available (7 am to 8 pm EST) to ensure that our North American customers are receiving the same fantastic customer service as BÖHL customers in Europe. Also, we will continue to visit William E. Buckley, H. Boehl North America. our customers to make sure their needs are met. William E. Buckley, H. Boehl North America, www.hboehlnorthamerica.com.

FEATURE

In almost every case, large reels require special permits— which differ from state to state for over-height and overweight permits—that are governed by each individual state. WJI: How do you estimate the costs? de Pass: All shipment planning must be done prior to tendering any ﬁnal offer to a customer because we must be aware of costs and services that will be needed for each shipment in order to be successful. Once an order is received, we review all shipment options and the customer’s ﬁnal location so we are ready to ship as soon as the order is completed. We look at all modes of transport, including truck, rail and, in some cases, barges. For example, on shorter destinations there may be no other option than truck whereas on longer destinations we look at both truck and rail. In some cases if we need to deliver to a destination close to the water we would even entertain a barge operation. Always, however, costs and availability play an import part in our decision.

Carris Reels, U.S. Carris Reels creates value for its customers in many different way, some of which are very unique. One of the more obvious values of doing business with Carris is our “one call does it all” ability to supply reel packaging products. As a manufacturer, Carris provides four out of the ﬁve primary reel packaging types that can be designed and built using plywood, nailed lumber, plastics and stamped metal. Structural steel large diameter reels is the current gap in its product offering; however, that too is becoming bridged

Michael Roussel, sales manager, Carris Reels.

A Nexans reel is prepared for shipping. WJI: Why are large reels always shipped standing up? de Pass: If we laid them ﬂat, the cable weight of the top layers would crush the bottom layers. Also, when winding the cable onto the shipping reel it is done in a speciﬁc manner to keep the layers even. We do ship smaller reels lying down, but again it depends on the size and weight of the cable. As a rule of thumb, reels under 50 in. in diameter can be shipped lying down. WJI: How much can an empty large steel reel weigh? de Pass: This depends on the size of the reel but could be anywhere between 3,000 to 7,000 lb, and sometimes more on extremely large reels. WJI: Do you also ship return reels, or are most of them sold for scrap? Is the process any different if you are shipping empty reels? de Pass: On large cable reels, once the reels are delivered we no longer own them. There are two options: sell for scrap or to a refurbisher or if there is a cost advantage over purchasing a new reel, we would look at bringing it back to the factory. This option really depends on the distance the reels are from the factory. 42 | WIRE JOURNAL INTERNATIONAL

with repair services provided through a joint venture partner, J. Hamelin Industries. Unique to Carris is our ability to provide product delivery for a significant portion of our customer base. Using our own fleet of equipment and employee owner/drivers, we are able to customize shipments, albeit a full trailer or less than truckload. Finally, as alluded to when describing its truck drivers, Carris Reels is a 100% Employee Owned Company. We believe the people who create enterprise value should have an opportunity to share in it. The idea of shared ownership is the basis for internal drive and performance that is ultimately reflected in Carris’ service and product quality. Michael Roussel, sales manager, Carris Reels, www.carris.net. George Evans Corporation, U.S. Celebrating its 100th year as a metal fabricator, the George Evans Corporation has the skills and machinery necessary to create the unusual or non-standard feature that your firm may require for its next cable reel project. Our firm has a library of production tools and dies that have been accumulated over the past 75+ years of making TOROIDAL® reels that are refreshed, renewed and maintained in ready condition. Chances are good that, with modification, we already have the tooling required to do the special or standard job you require. The Dave Evans, George firm has five lasers that can cut any flat DXF shape drawn, Evans Corporation.

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FEATURE

up to .750 in. thick steel. We have added in-house machining capabilities with lathes and vertical mills, and numerous large-bed presses are available. With the many other metal products made in our facility, we have the buying power in the metal markets to gain attractive pricing. Our staff is experienced, from the front office to the factory floor, with a number of them having over 25 years in the business. Often new features wanted on reels were actually used by other firms many years ago. We can advise on the strengths and weaknesses of such features in reels. For cable projects, we can also help customers pick a reel size and design that is the least expensive, robust package. We know the questions to ask in order to deliver value for the end product. You are welcome to contact us at sales@george-evans.com. Dave Evans, president, George Evans Corporation, www.george-evans.com. Evolution Products, U.S. Evolution is a manufacturer of innovative and sustainable packaging for the wire and cable industry. We help progressive wire manufacturers save costs, differentiate their products and provide extra value to customers with packaging that can be returned and reused efficiently. Wire manufactures can now eliminate one of their customers’ most stressing packaging hassles and costs: the disposal of wooden reels and fiber drums.

We’ll teach you to implement an exciting packaging system that saves space, reduces waste, reduces handling labor, improves your green image and makes customers insist on your product. Let us help you create a successful return program to provide your customers with a solution to save them time and money, strengthen your business relationship, and ultimately increase your margin. Bill Laubach, vice president of sales and marketing, Evolution Products, www.evolutionproducts.com. Fabritex, Inc., U.S. Fabritex has an inventory of over 200 carrier sizes that we have made for a wide range of customers for various applications. Our long history of supplying the wire industry is not what sets us apart from: it’s our willingness to be partners. At Fabritex, we have 110,000 sq feet of production space that can be used to hold shortterm inventory so that our partners do not have to tie Carriers from Fabritex, Inc. up valuable ﬂoor space with carriers waiting to be used. We will hold

Productivity wins

WIRE STRAIGHTENERS • STRAIGHTENER ROLLS 44 | WIRE JOURNAL INTERNATIONAL

•

WIRE PULLERS / WEDGE GRIPS

GMP Slovakia, Slovakia GMP Slovakia has been in the reels business for years. One needs great know-how to be a world leader in manufacturing of reels and equipment for the wire and cable industry, and we have plenty of that. Every day, our experienced team helps customers ﬁnd an appropriate product to satisfy their requests, giving them the correct item for any application. Further, GMP Slovakia offers not just standard reels and drums but also customized products. Our combination of expanded resources and skilled staff is especially helpful for customers that are either new to the market or who may need advice on how to improve their production. We can provide the full package, sug-

gestions and assistance, for reels as well as handling equipment, that can help manufacturer reduce production costs. Equally important is our focus on providing high quality products and that our admirable reputation is backed by important certifications. We are certified to the ISO 9001:2008 standard for quality management systems, which is essential for customers who need verifiable assurance that their supplier’s services and products respect industry requirements from the purchasing of raw material to manufacturing of the product. Further, in December 2014, GMP Slovakia became certified to ISO 14001:2004, the standard for Environmental Management Systems, which confirms our commitment to minimize the environmental impact in our day-to-day operations. GMP Slovakia, www.gmp-slovakia.com. J. Hamelin, Canada Our company always strives to add value above and beyond the package itself. We provide this approach both for single-plant, owner-operated companies or multi-plant multinationals. Our services would normally include: reel design review; reel rationalization opportunities; review of supply chain from forecasting, order process, delivery and invoicing; and reel repair and recycling (with full integration into the supply chain). We are always looking at opportunities to take cost out of our process as well as our customers. For instance, we were able to show a multi plant and distribution center (DC) customer how it could benefit by switching away from a particular size reel as it always ended up

Driving Improvements in wire straightening This alignment marker — found exclusively on Sjogren rollers — helps optimize your straightening operation. And it’s just one of many subtle-but-significant engineered enhancements that give our components and assemblies world-beating performance. Replacement runs of any quantity, full custom engineering and fabrication, decades of specialized expertise, global distribution: rely on Sjogren to push your productivity into high gear.

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TESTING & HANDLING FEBRUARY 2015 | 45

FEATURE

carriers at our facility and release them as soon as they are needed. This just-in-time inventory service obviously reduces the lead time on orders, but it also helps reduce uncertainty for production. Further, Fabritex provides in-house painting services to help identify carriers. We can paint them to just about any paint speciﬁcations, and can also stencil a company name on the carriers to help ensure return and reuse. Dan Trier, sales and marketing manager, Fabritex Inc., www.fabritex.com.

FEATURE A J. Hamelin group shot, with V.P. Ben St. Amour and President Harold Stotland in front.

at their DC and did not have a home. By coordinating multi-plant operations to use compatible reels, they all could be re-used instead of being disposed or going to recyclers. Six-ﬁgure annual savings! We also opened a repair facility in Edmonton, Alberta, to provide repair services locally and then ship the reels direct to plants in Eastern locations. Prior to this, reels were shipped back east without being sorted, resulting in signiﬁcant freight dollars being wasted. Our customers would bear these costs in the past, and now they have been eliminated. With our network of repair facilities in Canada (Quebec,

46 | WIRE JOURNAL INTERNATIONAL

Ontario and Alberta), we are developing a new product: a collapsible steel reel that can directly go from us to cable plants and then on to their customers in Western Canada. Once empty, they can be quickly knocked down and returned for assembly in the east. Reels can be purchased or rented. Ben St. Amour, vice president, J. Hamelin, www. jhamelin.com.

HOWAR Equipment, Inc., Canada HOWAR Equipment’s product portfolio includes every type of steel reel. We can offer that range due to the great resources offered by ﬁve factories, including one of our own. Our focus remains primarily on steel reels and we are proud to offer the North American market spools from 4 in. to reels up to 200 in. for process and shipping applications. We pool our collective capabilities and competencies, with our most notable recent project the supply of all the production reels for a new U.S. factory that needed them in sizes from 16 in.

Reels offered by Howar Equipment. for wiredrawing up to 196 in. for cabling and insulation. Logistics, design and manufacturing coordination to meeting all the requirements resulted in a turn-key solution the customer appreciated. We were able to supply the large diameter reels in a seamless way where the customer received the reels fully assembled. Our local presence in North America allows us to maintain strong ties to our customer base and respond in a timely manner, and our cultural background allows us to maximize the beneﬁts of having quality oriented European partners to work with. If something goes wrong—and inevitably that can happen, no matter how good one is—we are able to respond in a timely and constructive manner through our local U.S.

Inosym, Ltd., New Zealand Specializing in steel and plastic reels that are manufactured to European and U.S. standards, Inosym can offer reels to meet all the varying needs of the modern manufacturing plants. Committed to providing our customers with world class quality reels and bobbins at competitive prices, Inosym utilizes robotics and automated machining and painting. The production processes have been developed to allow us to manufacture customer speciﬁc reels and industry standard reels with short lead times, Philip Young, Inosym.

FEBRUARY 2015 | 47

FEATURE

resources. We can deploy people directly to the factory to ﬁx the problem right on site or have brought product into our U.S. warehouse for repair to get the customer up and running as soon as possible. Our collective array of reels and service allows us to be the dependable industry solution. Chris Hauer, HOWAR Equipment, www. howarequipment.com.

FEATURE

high quality and low cost. Inosym reels were developed to provide cable and wire manufacturers with a product that was realistically priced and of high quality. We believe we are achieving this and are assisting our customers to reduce capital expenditure and increase profits. Philip Young, managing director of sales, Insoym, Ltd. Madem Reels Group, Brazil We supply 150 cable plants across the world so we have to serve all kinds of different customer needs. We mainly work with big corporations that focus on logistics, quality, service and price. If you cannot offer all these elements, you can’t have a solid partnership with your customers, and as a result, you cannot grow. We, I am proud to say, continue to grow, because we can do all that and more. We offer logistic solutions, such as just-in-time assembly inside customers’ plants. We control the inventory of reels and keep direct contact between production staff and Madem customer service. These close ties help our customers eliminate waste time and money. We offer recycling programs in Brazil and Spain, and our one-way drums are environment friendly because they are biodegradable. We work very hard with customers to customize the design to work for them at the best available cost. We also make a “green” steps focus part of our regular business: all Madem reels in Brazil, Spain and Bahrain are either FSC or PEFC certified. For a Leandro Mazzoccato, Madem global cable player, these Reels Group. “green forest-sourced” certifications are a must when exporting, along with our HT ISPM-15 certification that shows the surface of our reels have been treated to prevent the spread of insects. Our customers appear to appreciate what we do: our last customer survey in Brazil (88 customers in 20 countries) showed that 98.25% rated us as either good or very good. Leandro Mazzoccato, corporate sales & marketing director, Madem Reels Group, www.madem.com. Metavan N.V/HOWAR Equipment, Belgium/Canada With a focus on specialization and customization, Metavan features a smaller array of product line detailed to the pressed steel reels. Automation throughout the factory provides extremely short lead-times which has become a very important factor in the supply of packaging materials such as reels. Customers can rely on the assistance of Metavan for their shipping reels, typically two to three weeks, which helps customers in short supply of critically needed packaging material for the wire. Metavan and HOWAR have often created custom stocking programs for customers, whereby material is warehoused for even 48 | WIRE JOURNAL INTERNATIONAL

Reels from Metavan N.V. shorter ship times, This takes mutual communication, and the results benefit each party. Beyond making new reels, Metavan has a reel conditioning program where reels are returned directly to the factory for inspection, reconditioning and painting before returning to the final customer for re-use. Metavan N.V./HOWAR Equipment, www.metavan.com, www.howarequipment.com. Mossberg Industries, U.S. Mossberg Industries brings nearly 100 years of doing business and experience in the wire industry. We recognize the importance of continually evolving and improving to meet our customers’ needs. Mossberg recently completed a building addition in 2013 to meet growth in our molding and extrusion production. This new, clean facility holds 16 injection molding presses which we have started transferring over to new all-electric presses. We brought in two new presses in 2014 and already have added another one this year. All-electric presses save energy and cycle time while lowering scrap rates to provide competitive pricing for our customers. We also set ourselves apart with a top tier and innovative engineering team. Mossberg provides our customers many specialty products and solutions. Innovation in our product offering has been demonstrated by our being one of the first companies to move from wood to plastic exclusively. Mossberg James S. Khorshid, Mossberg was also the first to bring a true knock-down reel Industries, Inc. to the market. Other solutions include automated assembly stations, return programs and CNC machining of parts for tight tolerances. Top quality is proven by our ISO 9001 certification. Mossberg Industries thrives on offering customers a variety of innovative and quality products. James S. Khorshid, president, Mossberg Industries, Inc., www.mossberind.com.

port on-time and just-in-time deliveries to meet customer needs and expectations. Beyond freight, we can provide shipping documentation, certification, export/import support, process duties and taxes, all of which makes it easier for the customer to receive our goods with minimal hassle. The commercial and finance departments—which are familiar with all forms of international payments, terms and conditions of sale, and establishing contracts— can provide consular and chamber documentation. The cost for all of this is simply part of our commitment and service as a supplier. It enables us to create good strong relationships that last the test of time and establish meaningful partnerships, which truly represents real value. Craig Currie, technical sales manager, Pentre Group, Ltd., www.pentregroup.com. Pittsfield Plastics Engineering, Inc., USA At Pittsfield Plastics we go above and beyond to help new and current customers. We like to help out both the little companies as well as the larger companies. From start to finish on a project, we give our full attention to the customer’s needs. That requires top-notch service, and we don’t just say that, we do that. If I get a call from a customer who has a problem or is interested in a new product, they get a response promptly, and by that I don’t mean days later. For instance, I recently helped a customer that was having spool issues with another

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The Pentre Group, Ltd./Hearl Heaton, U.K. The Pentre Group, incorporating Hearl Heaton, offers the most comprehensive range of plastic, steel and wooden packaging reels and drums available from a single source supplier. With an extensive range of standard products, many available for immediate delivery, we’re the people to talk to about streamlining your production and storage, but that’s not only what we are about. Our experienced sales team understands the requirements and pressures of the wire and cable industry. It works closely with customers, old and new, to ensure their speciﬁc requirements are being met throughout the whole process, from enquiry to receipt of goods. The in-house design team consistently ﬁnds cost-effective solutions to modern-day manufacturing problems and constraints, and if there is a need for a sample, we are more than willing to discuss this. All our production team and operators make quality the norm, and not the exception. They understand/sup-

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that are custom designed to our customers’ needs. A request could be major rework or just a small design change to current product offerings (e.g. robotic drive holes, arbors, etc.). For example, one customer installing new winding equipment wanted to be able to use their currently purchased reel on both machines without time consuming and complicated equipment adjustments. We worked with the customer and equipment manufacturer to come up with a new design that met both old and new requirements, eliminating the need for multiple SKUs. Adrienne Cowen, sales & service manager, Reel Options, www.reeloptions.com.

Nick Roth, Pittsfield Plastics Engineering, Inc. supplier. I told them I had a similar product that would work for them. I scheduled a meeting for the following day. I went to their facility with sample spools, and they tested them while I was there. Our spools proved to be much stronger and eliminated all of their issues. Nick Roth, regional sales manager, Pittsfield Plastics Engineering, Inc., www.pittsplas.com. Reel Options, U.S. Reel Options helps meet our customers’ stocking plans and low-minimum orders with transportation assistance, knock-down product shipping and prompt response to issues that arise. Our customers often find freight cost reductions when they choose our knocked-down reel solution that allows them to purchase components and have them locally assembled. This improves pack density, which in turn results in freight savings and frees up needed space in their facilities. While the flanges and bolts are less expensive to ship because of their highpack density, several of our customers have been able to purchase their spiral-wound paper cores from local vendors for additional freight savings. That may mean less sales for us, but it is best for our customers, and that’s our long-term focus. Besides our broad selection of stock product offerings, we develop custom plastic products (i.e., flanges, end-stands, payout tubes, etc.)

REELEX Packaging Solutions, U.S. One of the core initiatives we focus on at REELEX® is packaging development, both with respect to advancing the REELEX system in general and working closely with our customers to design the highest performing package possible. To that end, we see ourselves as “packaging consultants,” creating, developing and testing packaging solutions that ultimately become the foundation to how our customers present their products. Perhaps uniquely, we provide all samples and package development free of charge for current and prospective customers, as every new product gives us a chance to learn as well. One shining example of our focus on development has been with Encore Wire, assisting them to bring their revolutionary new PullPro™ package to market. PullPro is a completely new and Tim Copp, REELEX Packaging innovative way to Solutions. package THHN wires, and we are proud to have worked with Encore to present THHN in an entirely new way: from concept to package size to machine settings. Tim Copp, vice president, business development, REELEX Packaging Solutions, www.reelex.com. SCR (Steel Cable Reels), U.S./Oman, India Having been in the steel reel business for over 30 years, we have had a front row seat in the evolution of wire and cable packaging industry. Past years of product development combined with intensive capital investments have helped the Cabrol Group lead the shipping reel supply chain with a capacity of over 27,000 reels. Backed by three manufacturing locations, and another in the pipeline in Houston, Texas, in 2015, we aim to con-

Reels from Reel Options. 50 | WIRE JOURNAL INTERNATIONAL

FEATURE

tinue serving our long-standing clients with the highly competitively priced reels and value added services. A recent project for APAR Industries in Big Spring, Texas, required us to dissemble 1,100 collapsible steel reels and ship them back to the cable manufacturer for reuse. Our site crew completed this project in record

Reels from SCR (Steel Cable Reels). time and received great appreciation from Isolux Corsan, the EPC company involved in the wind energy project. This project made a signiﬁcant impact to procurement costs for the clients. We also offer a lease program to our long-standing clients as a strategic model to save capital costs while combining our onsite delivery and pick-up services. Our recent foray into the oil and gas industry has helped us develop customized products for that sector as well. Most of our clients have been with us over the last decade, we look forward to coming years of growth and developing new markets. Amit Shah, CEO, SCR (Steel Cable Reels), www.steelcablereels.com.

Reels that deliver from Sonoco. up of used reels in many regions across the U.S. This program applies to polyﬁber reels as well as nailed wood. Jeffrey J. Stafford, division VP & general manager, Sonoco Reels, www.sonoco.com.

Sonoco Reels, U.S. A drive for greater productivity is the main reason some of the world’s largest makers of wire and cable bring their reel challenges to us. At Sonoco, our number one priority is safety. So productivity and safety have both driven our development of the next generation of polyfiber reels: the built-in pallet. This not only makes moving and storing wire and cable much easier, it eliminates workplace hazards. When picking a reel from a stack, operators typically have to first separate two reels’ flanges with fork tines, dismount the forklift and wedge a spacer underneath the suspended reel. This is a dangerous and time-consuming exercise. With a built-in pallet, this Sonoco polyfiber reel creates enough space under the flange for forks to lift the reels without the need for spacers. The reel also includes anti-skid stops that help center and stabilize stacks while protecting cable pigtails. Sonoco engineers are always eager to find ways to solve packaging challenges. Their goal is to streamline the processes that get our customers’ goods produced, packaged and delivered to the end user with a minimum of motion, labor, materials and time, so productivity and safety are optimized. As well, Sonoco continuously explores opportunities to stretch sustainability so that raw materials are put to the best use. Our EcoReel® recycling program, in place since 1991, has expanded to include LTL pick-

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PRODUCTS TECHNOLOGY Polyfiber reel presents a safer choice

Sonoco Reels has introduced a polyfiber composite reel with a built-in pallet that makes handling both easier and safer. The reel features a circular ring on the bottom flange with thick gussets for added strength. The ring not only affords enough space below the flange to accommodate forklift tines, it also provides a cavity in which to protect the cable pigtail on another reel below. The top flange includes stoppers that will nest within the pallet ring of another reel on top. This helps to prevent slippage when transporting multiple reels. Best of all, the built-in pallet eliminates the dangerous practice of using a spacer to separate reels when picking one reel off a stack. Fork truck operators will see improved efficiency and a reduction of the risk of injury or damage to the reel or product. Another beneficial detail on the reel’s flanges is the placement of several nail or staple guides to ensure that fasteners are driven into the thickest part of the flange. Lighter weight than steel or wood, polyfiber composite reels provide smooth inside flanges and improved weather resistance. The returnable and recyclable reels are made of a recycled plastic composite plus they are available with fiber or wood drums. Diameter sizes range from 30 in. to 50 in. The built-in pallet is now available on Sonoco’s 35-in. diameter polyfiber reel. However, interest in this feature is growing enough such that the company is receiving inquiries about the next sizes to be considered. Contact: Sonoco Reels, tel. 800-633-3962, wcr.sales@ sonoco.com, www.sonoco.com/reels.

Innovation and cost-effectiveness are a key to company’s reel design

Steel Cable Reels, LLC, (SCR) offers the industry a very innovative, practical and cost-friendly CKD reel (a complete knock down or collapsible steel reel). CKD reels have changed the customer mindset on shipping cable. We call it the CKD Advantage. CKD Reel, like the conventional welded-up reel, maintains all the NEMA speciﬁcations plus brings in the ﬂexibility of on-site assembly and dis-assembly, lower freight costs and very easy repairs and refurbishment. Years of tests for endurance, weight capacity, safety and resistance have met client requirements at all levels.

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SCR provided CKD reels with a 96-in. ﬂange for a recent project. It took less than 20 minutes to dissemble one reel at an outdoor yard with minimum equipment. This project helped our client move over to CKD reels for all its cable shipments. Our Houston facility plans to focus on supporting customers for their CKD reel needs and warehouse ready to ship reels. The location also helps us cater to the oil and gas industry in and around Texas. Our team is ready to go where the client needs us, we are now equipped to work on site anywhere in North America. Cabrol Group is the parent holding company of SCR. Contact: Victor Torres, project manager, SCR (Steel Cable Reels), www.steelcablereels.com.

A reel-less package can be a manufacturer’s best friend

At the heart of all of our packages is the REELEX® coil, a unique method of coiling wire, cable or other ﬁlamentary product that precisely lays ﬁgure-eights in a cylindrical pattern. The product freely dispenses through a payout tube without any twists, kinks, snags, inertia or tangles. Because the REELEX coil does not require rotation to dispense (unlike reels), we can do some great things with our package designs. SlingPack™ (pictured) is our newest REELEX innovation, and is a lowcost, installer-friendly package that combines the economics and speed of stretch-wrapped coils with the environmental advantages, versatility and handling ease of a cardboard box. Like our ProFlex shrink bag package, SlingPack is a user-friendly package design with a centered, easy to grasp handle, but uses a simple cardboard cutout that folds around the shrink-wrapped coil and is stapled. This allows all the great features of a box (stability, easy handling, protection) to be maintained while dramatical-

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ly reducing the per-package cost. SlingPack is a great package choice for coils weighing under 20 lbs (9 kg) and provides a unique and innovative presentation for retail or industrial applications. For more information on REELEX or SlingPack, visit our website at www. REELEX.com. Contact: REELEX Packaging Solutions, tel. 845878-7878, sales@reelex.com, www.reelex.com.

2 examples of ‘reel’ success U.S.-based Reel Options, which excels at providing customer solutions to problems, would prefer to cite examples of its expertise than just list product lines that can be seen at our website. Our custom product design team recently launched two new projects, with different customers, working closely with their capital equipment providers, to design products to meet our customer’s throughput expectations. Making that possible requires R&D, a commitment that is reﬂected in the accompanying photo. Project 1: The customer requested a reel with the end stands attached prior to automated winding. We developed a product that not only met the customer’s requirements but included all the beneﬁcial features we have in our standard Reel Options reels. Project 2: A customer requested that we design a low-cost payout tube for

their coiled boxed cable. While working with the customer, we found several areas where design improvements could be made and implemented them to great success. Both of these projects were designed, developed and have been launched in the past 15 months. We see these projects as examples of how we support our customers with productivity improvement and cost reductions that allow their production to remain in North America instead of going overseas to lower labor markets. Contact: Mark Elder, vice president, sales, Reel Options, tel. 248-762-9250, mark.elder@reeloptions. com, www.reeloptions.com.

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Wide range of steel reels cover multiple manufacturing needs Steel reels manufactured at Pentre Group’s advanced reel and spool fabrication facilities cover a wide range of both national and international standard sizes as well as bespoke customer designs, and are suitable for a variety of process and shipping applications. Using only prime certiﬁed materials, including speciﬁc grades on certain components, ensures that our reels are built to a high standard and to last. Our BP and SF type

in-process take-up reels are used for making ferrous and non-ferrous bare wire products for single and multi-ends. They are approved and recommended by all the major machine suppliers. Able to run at speeds topping 40 m/s, they are ideal for high-speed wire drawing and rod breakdown lines, as well as subsequent processes such as bunching and stranding. The robust BP design is also ideal for annealing. Contact: Craig Currie, technical sales manager, Pentre Group, Ltd., Tel: 44-1942-266-391, curriec@pentregroup.com, www.pentregroup.com.

Plastic and fiberboard spool options U.S.-based P&R Specialty, Inc., has two major product solutions, plastic spools and fiberboard spools, that offer customers multiple options to meet their wire packaging needs. The plastic spools, which meet industry specifications and standards, come in more than two dozen standard sizes, with plus custom sizes available. We offer multiple material solutions, including ABS, HIPS, PC/ABS as well as polypropylene and other resins. Our In-house tool/mold department can create a mold that meets your spool winding and packaging specifications. Our fiberboard spools are manufactured with a smooth finish to eliminate costly wire snags. They are assem-

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bled using either a galvanized steel barrel with tabbed construction or a spiral wound tube with rivets. More than 20 standard sizes plus custom size spools are available. Within those product lines are multiple variations of sizes and specifications for a variety of requirements regardless of the type, diameter and weight of the wire to be placed on the spools. Shown are two reels, one plastic, one steel, both the same size (11-3/4 in. x 3.625 in. x 5 in. w/2 in. arbor hole. Both technologies offer customers excellent options to meet their needs as well as different cost options. Everyone wants to have options, right? Contact: Vince Reidy, P&R Specialty, Inc., tel. 937-773-0263, vreidy@prspecialty.com, www.prspecialty.com.

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All purpose 3-piece plastic spools are cost-effective Mossberg Industries’ three-piece design offers an economical way to build a custom package that is flexible with an extruding core/barrel stock that allows custom traverse lengths in a variety of different diameters. Custom traverse lengths mean you don’t have to buy more spool than you need. We can design and build a custom flange specific to a customer’s requirements without incurring the tooling cost for a complete reel mold. Flanges range from 5-24 in. in diameter, with a variety of different configurations. A variety of resins are available so we can produce heavy duty cores or high performance properties on the flange to meet demanding performance requirements.

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Plastic shipping reels are an ideal replacement for plywood to enhance the image of your product. A manufacturer can ship product on plastic without the export regulations and are clean room safe if the application requires. Our reels are dimensionally consistent, with no moisture absorption and no hardware to loosen up allows for faster winding speeds. Coming in 2015: new flange designs for automatic winding equipment to further improve winding speeds.

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Reels don’t get ‘greener’ than this

Also, we plan to expand our line of knock-down style reels that easily assemble and then disassemble, without any tools, for multiple uses without damage to the components. The new sizes will offer savings to our customers on their inbound freight costs and the option to reuse for further savings. Diversity has been the key to the proven success of Mossberg’s three-piece spool product line. Contact: Mossberg Industries, Inc., tel. 260-357-514, www.mossbergind.com.

In recent years, Madem has developed new internal production lines to further bolster our reputation for providing the best wooden reel quality in the world. We have also become as green as a company can be, but not at the expense of our customers. Our three Madem Reels Group sites produce more than more than 400 containers/trucks of knock-down reels per month, and when we do that we focus on turning a profit for the company and on being kind to the environment. Green organizations such as FSC and PEFC provide voluntary global forest and forest products certification systems to promote better forest management. They directly or indirectly addresses issues such as illegal logging, deforestation and global warming, which has a widespread effect on society. We apply their principles to what we do, but again, we do so within a sound business plan. That’s why we Madem has worked very hard to control its processes, using ISO 9000 and 14000 certification requirements as a tool the last 20 years. Our goal is not to be just the biggest wooden reel player in the world, but to be the best one, and that requires a commitment to both the business and the environment. To achieve this, we must make “green” part of our culture. We do this because it is right, but also because it is smart. More and more customers ask us for green products, and we are proud to be able to tell them that we were one of the first companies in the world to offer green wooden reels. Contact: Madem Reels Group, www.madem.com.br.

Plastic reels for high-speed processes are made from the finest ABS materials Hearl Heaton, with over 40 years of experience, is a recognized leader in the design and manufacture of ABS (plastic flanged) high-speed process reels for the wire, cable, telecommunication and fiber optic industries. A business of the Pentre Group, we guarantee the quality and high specification of our reels. This is achieved using certified materials, including a special grade of virgin ABS for our flanges, selected to give maximum strength without brittleness. The remaining parts are manufactured in automated machinery producing an accurate

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and precise reel. Hearl Heaton has developed its products with both machine manufacturers and customers. This collaboration has ensured our reels meet the high standard required for modern production allowing optimal speeds to maximize output. Contact: Craig Currie, technical sales manager, Pentre Group, Ltd., Tel: 44-1942-266-391, curriec@pentregroup.com, www.pentregroup.com.

Take-apart reel is very simple to use GMP Slovakia range of products includes many different models of reels for coils production, with one of

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the most popular ones being the company’s patented EASYKOIL take-apart reel, which is exceptionally easy to use. The EASYKOIL’s inside mechanical system allows the operator to release the flange below automatically, without any intervention. All one has to do is lift the upper flange by the hooks after releasing the security lock. This reel’s model is also available in a PLUS version that works as coil lifter. This reel has four rings on the upper flange; two of them allow the opening of the reel and the other two allow the lifting of the reel. Once the lifting rings are in the free position, the barrel collapses during lifting operation and sets the coil free. All internal parts are manufactured with hardened steel. The EASYKOIL model is available in flange diameters of 800 mm and

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larger. The reel, which can be dynamically balanced, is machined on the parts that come in contact with the wire. It can be supplied with four, six or eight slots for the metal strap insertion, and can also come with circular slots in the flanges to fit cardboard barrels or with changeable flanges to accommodate coils with different width. To prevent wear problems, due to the high rotation speed, hardened changeable bushings are recommended. Contact: GMP Slovakia, www.gmp-slovakia.com.

Wire carriers come in multiple designs, all made to top quality Wire carriers from Fabritex, Inc., are made to the highest quality standards, we are ISO 9001-2008 certified which means we provide only the highest quality products. The company produces more than 200 types of carriers, so if you need it, we can supply it. We offer the standard carrier base designs (square, round, star and clover), but we also offer a patented Base Lock design. This design has been tested to be as strong if not stronger than traditional square base carriers. We offer standard and special carriers in many paint finishes as well

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as stainless steel for annealing furnaces. We can also inventory for your high-volume needs. Further, we also cut down on production time by utilizing a single plane bend and robotical welding the carrier together.

Contact: Dan Trier, Fabritex Inc., tel. 888-740-5917, dfabritex.com, www.fabritex.com.

Knock-down reel offers many benefits to wire and cable manufacturers Developed and proven over the last decade, the patented Reduction Reelâ&#x201E;˘ by Evolution Products is a durable, knock-down reel system that is simple to assemble and disassemble without tools. When palletized, the components occupy up to 80% less space than ordinary reels, increasing flexibility with manufacturing space and labor. This efficiency reduces freight and storage costs, making it beneficial to return and reuse the Reduction Reels and to convert

the savings into an earth-friendly profit center. Wire manufacturers regularly achieve 20 turns or more from A ‘platinum’ level industry webinar . . . 32 the product, drastically reducing reel and spool purchases for their customers who use the program. Integer Rearch’s Philip Radbourne provided Our Reduction Reels cores are molded from expanded durable content during an Oct. 21 webinar that followed up of and recyclable ABS plastic and fitted to the flanges the Electrical Sector report that was provided to WAI your choice of plywood, nailed wood, composite, or Platinum Below is aasslide from his presentsteel. TheyMembers. are typically used shipping reels, but interest. can also be used as slower speed processing reels for The webinar also included further discussion by a panel of industry experts. US economy seems to be showing some solid signs of growth..but also some concerns

Positive Negative transportation between operations. Common sizes Economy recovered from worst reelsX can Real be wagedeveloped growth has beenfor modest areavailable and custom at best recession in 80 years applications as small as 500 lb (226 kg) and up to X Recovery not evenly split  US consumer confidence at 7 year high US Housing starts still well below 3000 lb (1360 kg) or more. X 2007 peak  US gas prices fall to lowest since 2010 Visit www.evolutionproducts.com learn X US still to running largemore budget deficit  US oil extraction booming Xthe Labour participation rates continue about the Reduction Reel and collapsible Flex to drop, lowest levels since 1970s  US auto sales at record highs ™ Reel . weekly jobless claims drop to X Lower US oil prices may hit fracking  US boom expansion 14 year low of 264,000 Contact: Bill Laubach, Evolution Products, tel. X US National federal debt still at  US unemployment at 5.9% highest level in 70 years  US budget deficitblaubach@evolutionproducts.com. below 3% of 717-515-8591, GDP Longest run (54 months) of private sector job creation on record

X Further potential dispute over the debt ceiling extension

Laser technology can handle most An industryspecial traditionreels continues . . . . . 36 demanding requirements At George Evans Corporation (GEC), we could go a directorsize at U.K.-based Bache Pallets overRobert some Bache, of the standard reels we specialize in, but Limited, performs the clockwinding duties for this purpose, showing what we were ableattothe do Oct. for 15 at WAI’s headquarters Guilford, a event customer with big, big needsin seems moreConnecticut. appropriate, Bache to guests and details. staff about the importance of thus we spoke offer the following having a close relationship. Heengineering observed that in today’s A GEC customer referred the firm world we all need a wingman, and for the U.K., “I think TEFSCO to us to have us build a special reel for offthat there’s a wingman in America, in the USA.” shore drilling. This reel would be used repeatedly to haul in cable and pay it out as necessary while the well was being drilled. This reel has to fit within TEFSCO’s cradle without interference. It also had to be a specific size in order to maximize the amount of cable available to the well driller. This project was a flagship project for our customer, a chance for them to make inroads in a market by succeeding where other oil service firms had failed. Using our wide-bed lasers, we were able to cut precision parts that fit together easily. GEC made sure the entire traverse of the reel was available for winding by slightly splaying the flanges outward .375 in. over a 38 in. span from the drum surface to the edge of the tire. Clamping the components into place while using fixtures, gave us repeatability in our manufacturing process.

www.integer-research.com

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CONTENTS

INSIDE THIS ISSUE

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The project was deemed important enough for the cable producer to send a man to inspect the new reels. He pronounced himself “very well satisfied” with the reels he measured. The project is proceeding smoothly in the Gulf of Mexico. If that is the type of capability you are looking for, imagine ® how dependable our standard reels are. We make Toroidal NEMA (Classes I & II) reels, WECO telephone reels, structural and custom reels. They are made from steel, or aluminum for power cable, phone cables (copper or fiber optic) to your specification. Just send your drawings to us. Contact: George Evans Corporation, sales @ george-evans.com, www.george-evans.com.

HDPE reels made from recycled resins The latest technological development from Carris Reels is one-piece, injection-molded High Density Polyethylene (HDPE) reel for building wire applications. This concept delivers a product package that is stiff and tough, especially in low-temperature environments where traditional polystyrene and polypropylene type packages become extremely brittle and often exhibit catastrophic failure when dropped from a foot or less at similar low temperatures. The current package has been designed to be used on high-speed Windak winding equipment. It has a 6.5 in. overall flange diameter, 4.5 in. traverse, and barrel diameter of 2.25 in. Another key feature of this product--and all other Carris HDPE plastic reels--is the commitment to sustainability that has been built into the reel. All Carris HDPE plastic reels are manufactured from post-consumer resin that is

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derived from municipal curbside collection. Recycled resins significantly reduce the carbon foot print emissions versus their virgin resin counterparts. By their very nature, these reels are reusable or recyclable to protect future generations. Contact: Carris Reels, www.carris.net.

Finding custom solutions a specialty Boxy SpA and its North American partner, HOWAR Equipment, have continued to find cost-effective solutions for customers with special manufacturing requirements. Recently, BOXY and HOWAR were approached by a customers to supply reels for a single-twist machine. The application sounds straight forward, however, the machinery manufacturer wanted to ensure that the correct reel was going to be implemented. Many factories tend to use run of the mill reels with higher concentricity deviations, and irregular flange straightness, which cause a great amount of vibration. This impacts the speed that the machine can be run at and eventually causes greater maintenance and downtime. BOXY developed and manufactured an 84 in. reel with a machined drum which provides a very even and concentric winding surface. The flanges were specially reinforced and studied to be able to stay true under continued use and winding pressure. This is the first time that a reel manufacturer was able to manufacture such a large reel using principles from wire drawing spools. Regular concentricity on such a reel would usually be around .75 in., which means that once material is wound onto the reel, it will cause a large weight to spin unbalanced. When this happens in conjunction with high rotational speeds, a great amount of vibration will be incurred. The collaboration between customer, reel sales, machinery manufacturer and reel manufacturer yielded an unprecedented reel that allowed the cable manufacturer to take advantage of the machine’s full output capabilities without incurring maintenance issues. This is a great example of how open communication among knowledgeable individuals ensures that technological progress is made. Contact: Boxy SpA/HOWAR Equipment, www. howarequipment.com.

Handling the packaging demands of coiled wire and cable is a specialty packaging application that BÖHL machines are uniquely adept at performing as the German company has decades of experience providing the ideal solution whether the customers’ coils need to be wrapped “through the eye” or fully encapsulated. BÖHL’s versatile line of coil wrapping machines includes the W1, W2, Junior, Meister, Senior and Coil Master. With multiple product size capacities and diverse product handling capabilities in each machine line, BÖHL is able to match the best machine to the needs of our customers. When we meet with a customer the first thing we do is analyze the packaging application from the standpoint of how products are currently packaged and what the customer’s needs are for improvement. After obtaining a complete understanding of the situation we are able to offer the most economical and productive packaging solution. Constantly improving technology is the key to making BÖHL coil wrapping machines the industry leader. Our machines’ wrapping speeds are the fastest in the industry and BÖHL machines use no heat elements for package material cut-off. Customers have the option of using VCI film in order to provide the critical corrosion prevention that some products require. With the efficient use of electrical power, packaging materials, and operator time coupled with an increased throughput rate, BÖHL coil wrapping machines make a significant improvement to the production line and the bottom line. Contact: William E. Buckley, H. Boehl N. America, tel. 904-449-4981, www.hboehlnorthamerica.com.

Structural reels offer solid construction Italy’s A. Appiani Srl’s wide assortment of reels includes structural reels, Type BCS, that excel for carrying cable, wire and strand. Represented in North America by Canada’s Lesmo Machinery America, the BCS reels are made to last. The reel type can be designed for internal processes or for shipping purposes, with dimensions according to DIN standards or to customers’ specifications. The reels can be manufactured with solid flanges (BFP type), pressed “finned” flanges (BFA type) or with steel plates reinforced by rolled sections (BCS type).

Lifting pockets, partial machining and a dynamic balancing are available as option for high speed applications, in addition to central interchangeable bushes and drum twister reinforcements. The reel design is checked by our designer engineers according to the required capacity and the speciﬁc application. Capacity tests are also available upon request. The reels are supplied provided with epoxy-coating or hot-galvanization and rubber coatings for cable protection are also available. Contact: Marco Appiani, A. Appiani Srl, info@appiani.reels.it/www.appiani.reels.it or Allan Brown, Lesmo Machinery America, sales@lesmoamerica.com, www.lesmoamerica.com

Reels designed for better capacity, load distribution A popular recent addition to Ace Metal’s products is a line of metal spools that have tapered flanges that will increase the amount of wire capacity by 10% to 15% over traditional flanges. The spools, designed for manufacturers wire drawing carbon wire, stainless-steel wire, aluminum wire and/or flat wire, are available in 8 in. to 10 in. and 14 in. flange diameters. The tapered flange shape, it said, leads to a better load distribution compared to the spools with conventional right-angled flanges. The tapered flange enables easy guiding of the wire, even when the reel is nearly empty, which is especially important during production pauses when high take-off speeds are used, it said. Each wire layer of wire is given a greater number of windings than the previous layer, which leads to more capacity, from 10% to 15%. The average delivery on the reels ranges from two to four weeks, and the company will make every effort to accommodate rush orders for customers, including partial deliveries if need be so that a line not need be shut down. Our goal is to produce our product lines with quality, strength and assurance that our customers have expected from us of the last 67 years. Contact: Richard Medoff, Ace Metal, Inc., www.acemetalinc.com.

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FEATURE PRODUCTS

Coil-wrapping equipment performs both quickly and cost-effectively

TECHNICAL PAPERS

TECHNICAL PAPERS Economic and chemical comparisons of hydrochloric acid recovery technologies for iron pickling operations This paper evaluates different technologies for recovering hydrochloric acid from spent wire pickling solutions, examines various factors and presents an economic review of the operating and maintenance expenses. By Jared Cullivan and Bryan Cullivan

Metal fabrication and ﬁnishing operations involving ferrous metals require an intermediate process to remove oxides and other impurities from the surface of the ﬁnal product. The most common intermediate process is acid pickling, and hydrochloric acid is the primary acid utilized world-wide to facilitate the process (sulfuric, nitric and phosphoric acids also perform the same task). The resultant waste generated from hydrochloric acid pickling is an acidic ferrous chloride solution that is categorized as a hazardous waste product. The following is an economic and chemical comparison of the four leading technologies for reducing or eliminating said waste product: acid retar-

dation (acid sorption), diffusion dialysis, pyrohydrolysis and evaporative recovery (distillation). • Acid retardation (acid sorption). This is a sorption process by which acid bonds to the resin inside an ion exchange column while allowing the ferrous chloride and water to pass through. The column is then back washed with water to recover the absorbed acid on a batch basis. See Fig 3. • Diffusion dialysis. This is a membrane process that operates under some of the same principles as acid sorption (acid retardation) by utilizing the same separation material. Clean water (dialysate) is introduced in counter-flow on the permeate side of the membrane to absorb the acid passing through the Chemical Input (kg/hr) semipermeable surface. This is a continuous process. HCl 12.5 • Pyrohydrolysis. This is a roasting process in which FeCl2 31.25 the acidic ferrous chloride burned to produce iron H2O 164.25 oxide and hydrogen chloride gas. The hydrogen Total 208 chloride gas is then processed in an adsorption colFig. 1. Data input conditions. umn where the hydrogen chloride gas reacts with incoming water to form near-azeotrophic hydrochloric acid. • Evaporative Recovery (Distillation). This process utilizes co-flash vaporization and rectification to separate the ferrous chloride, hydrochloric acid and water from each other. Azeotrophic HCl (17–22%) is possible with this technology. The scope of the following Fig. 2. Comparison of main processes for removing oxides and other impurities. analysis is limited to waste

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Data Input Conditions: Analysis is based on a typical wire pickling operation with a spent acid bath of the following characteristics: ﬁve tons of spent pickle liquor per day (5,000 kg/day); 8% iron and 6% HCl (both by weight). See Fig. 1. Mass balance comparison of the four different technologies reveals advantages in the categories of acid recovery, metals rejection, concentrate reduction and acid concentration. See Fig. 2. Pyrohydrolysis excels in all categories which would be expected as pyrohydrolysis actively reverses the chemical reaction which takes place during the pickling process. (Eq. 1)

the pickle tank and requires addition concentration through evaporation due to the high volume. See Fig. 4. Given that the return acid concentration for these input conditions has only increased 0.2%, the maximum operating concentration of the pickle tank would 9.37% hydrochloric acid (assumes 33% HCl directly added to pickle tank and no addition concentration; it does not account for atmospheric evaporation above tank). Acid sorption provides a better return acid in terms of concentration, 8%, but does not remove the ferrous chloride as effectively as the other technologies. Only 45.2% of the total ferrous chloride is rejected as concentrate/ by-product. Distillation systems, like pyrohydrolysis, return acid at a concentration near the azeotrope (in this case 17.5%) and reduce the concentrate/by-product mass by 63.1%. Although distillation systems require more energy than acid sorption and diffusion dialysis, they require less than half the energy of pyrohydrolysis. The temperature of operation for a distillation system versus pyrohydrolysis is signiﬁcantly reduced. Pyrohydrolysis temperatures are between 650°C and 950°C while a vacuum distillation system does not exceed 80°C and an atmospheric distillation system does not exceed 120°C. In the absence of foreign contaminants that would affect the solubility (ex: zinc, chromium), ferrous chloride will begin to form a crystal when the iron concentration exceed a saturation point in a distillation system. Crystallized ferrous chloride is the preferred method of disposal for reasons that include: negligible acid content, reduced weight and higher potential resale value. Downsides to crystallized ferrous

Pyrohydrolysis differs from other technologies because instead of recovering only unbounded or “free” acid it breaks the bonds between the iron and chloride to produce iron oxide (rust) and hydrochloric acid. The acid amount in pyrohydrolysis is actually increased by almost 75%. The concentrate/by-product is reduced by 95% and is discharged as powered iron oxide (rust). It is important to note that the half reaction during the roasting process produces hydrogen chloride gas which will, in the presence of water, form hydrochloric acid. Hydrogen chloride gas to hydrochloric acid is not always a complete reaction and will require special/additional scrubbing and/or air regulatory measures to ensure clean emissions. Acid sorption and diffusion dialysis, unlike pyrohydrolysis and distillation, are not as energy intensive and have fewer components Fig. 3. Diagram of acid retardation (sorption). (see cost analysis). Literature on acid sorption and diffusion dialysis has high percentage returns on the amount of hydrochloric acid returned (not regenerated) from the spent acid stream: 80-90% for acid sorption and 80-95% for diffusion dialysis. In the mass balance from the spent pickle liquor provided showed acid recovery rates of 84.8% and 91.2% respectively. Although the recovery rate of acid is high, the quality of the acid is low (8% and 6.2%) While diffusion dialysis has less than half the contamination of ferrous chloride in its return acid, the acid concentration is often too low to be returned directly to Fig. 4. Diagram of diffusion dialysis.

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TECHNICAL PAPERS

hydrochloric acid from typical batch/continuous pickling. This paper neither discusses other chemical conﬁgurations or concentrations or alternative conﬁgurations of the four stated separation operations. Other separation techniques (reverse osmosis, electro dialysis, etc.) were not discussed due to a lack of known applications and literature. Total cost estimations are based on primary contributing factors to capital, operating and maintenance expenses.

TECHNICAL PAPERS

Cost analysis The following rates were assumed. • $3.68 per MMBtu • $0.099 per kWh • $0.00073 per Liter H2O • $85.43 per metric ton HCl at 33% by weight • $70.00 per ton lime • $0.26 per pound wastewater treatment sludge • $0.10 per pound spent pickle liquor recycling • $1.18 per gallon HCl at 33% Plant operation assumes the following for yearly calculations: • 24 hour operation • ﬁve days per week (average) • 50 weeks per year (average)

Material costs

Fig. 5. Diagram of pyrohydrolysis.

Fig. 6. Diagram of evaporative recovery. chloride include: liquid concentrate that does not crystalize, crystallization in improper locations (piping), increased equipment and maintenance costs, and additional utility costs.

The specialized resin used to facilitate acid sorption is the primary material cost. Other common replacement materials include: pump seals, and filters. Acid sorption resin material has a life span of about five to 10 years for hydrochloric acid applications. Membranes are the primary material cost for diffusion dialysis system. Other replacement materials include: Pump seals, and filters. Pre-filtration is exceedingly important in diffusion dialysis compared to other technologies as membrane will form a scale on the inside of the membranes which will restrict acid diffusion and decrease the life of the membrane. Diffusion dialysis membranes have a life span of about five years. Prefiltration is also increasingly important for acid retardation as colloidal particles have a tendency to clog resin beds thereby creating an uneven flow distribution that can affect performance. Pyrohydrolysis (See Fig. 5.) and sistillation systems do not have many regular material costs associated with

Fig. 7. Comparison of utility considerations for four discussed methods. 64 | WIRE JOURNAL INTERNATIONAL

Labor costs The education and technical ability is about the same for acid sorption and diffusion dialysis systems, requiring general knowledge of diffusivity and ion exchange, pipe ďŹ tting and pump maintenance. Distillation requires technical knowledge of operation and maintenance procedures for boilers and cooling towers as well as pipe ďŹ tting and pump maintenance. Pyrohydrolysis--due to the complex nature, number of components and high temperature conditions--requires the most extensive training and maintenance. Acid retardation although a relatively simple operation in comparison to the other technologies requires more frequent testing than diffusion dialysis and distillation and also requires more manual operations that will account for an increased labor cost.

natural gas for the direct contact roaster involved in pyrohydrolysis and the boiler operations for distillation.

Acid All four technologies return over 90% of the free acid present in the spent acid. Pyrohydrolysis goes a step further is creating additional hydrochloric acid by breaking the bonds in the ferrous chloride present. The cost associated with the acid is the cost per year of additional acid necessary for maintaining production. See Figs. 7-9.

Contamination correction There needs to be a correction for the contamination of the return acid to the pickle tank. While all four technologies are designed for the same throughput, acid sorption and diffusion dialysis actually need to have a larger throughput because the acid returning to the pickle tank is contaminated with ferrous chloride. Without a compensated cost associated with pickle tank contamination the pickle tank concentration is unsustainable. Contamination correction includes the additional costs associated with the following: utilities, material, treatment, disposal and regulation.

Utilities

Treatment

Water and electricity are required for all four technologies. Water consumption is high for acid sorption and diffusion dialysis, and relatively low for distillation and pyrohydrolysis (cooling tower and scrubber make-up water). distillation and pyrohydrolysis have additional utility cost in the form of

With the exception of pyrohydrolysis, all the technologies require additional treatment of the resulting by-product. While the amount of caustic required in neutralizing the by-product is signiďŹ cantly reduced due to the acid

Fig. 8. Breakdown of utility expense areas for process.

Fig. 9. Comparison of operating costs. FEBRUARY 2015 | 65

TECHNICAL PAPERS

their respective processes. Filters and pump seals are the only regular replacement items. Pyrohydrolysis, due to the high-temperature direct contact roaster, has reduced life span on a variety of its components. The contamination of rinse water used to facilitate adsorption is a pyrohydrolysis system will add to material costs.

TECHNICAL PAPERS

recovery, it is not negated. If the by-product from a distillation system is crystallized and the supernate from the crystallazion section is returned to the distillation unit for reprocessing no addition caustic is required.

Disposal The cost of disposal will vary greatly depending on the region, and regulation. For the purposes of this paper the following is assumed: neutralization was performed onsite, sludge was disposed of by third party, and standard regulatory requirements for F006 waste were followed. For a majority of distillation operations the concentrate by-product can be considered a co-product due to its high concentration and minimal acid content. There are a variety commercial uses for ferrous/ferric chloride in the water treatment industries and many distillation operations have been able to offload the resulting concentrate at zero or negative cost. Assuming a client is found, the disposal cost for a distillation operation is negated.

Regulation An average cost of regulation for industrial wire plants in the U.S. is tabulated for air and sewer. Acid retardation, diffusion dialysis and distillation have sewer costs associated with neutralizing the concentrate. Pyrohydrolysis has a different set of regulations associated with air quality. Due to the complexity of the regulation, changing EPA standards for air pollutants the regulatory costs are not covered in Fig. 9. Air regulation for pyrohydrolysis, however, is known to have a considerable cost associated with it implementation.

Discussion of issues related to ownership: Diffusion dialysis. This technology has not gained any traction in the steel industry. Diffusion dialysis and electrodialysis have found applications in other industries, but the cost/benefit of the technology usually directs the steel industry to the other technologies. Acid retardation. In applications such as recovering hydrofluoric and nitric acid mixtures in stainless steel applications this technology has flourished. The value of the acid (10X HCl), cost of treatment and disposal, and the lack of competition justify the complexities of operation of this technology in the HF and mixed acid applications. Significant challenges of pre-filtration to extremely low levels to avoid resin fouling, resin shrinkage causing channeling and blow-through, and constant analysis to determine proper loading and regeneration are a few of the problems noted through the years. The need to provide a complete waste treatment plant that generates sludge as the final by-product also brings into question the value of recovering a relatively cheap acid. Evaporative recovery. This method has been utilized in a variety of metals industries and the mining sector. The earlier “Atmospheric Evaporator” operated at around 115ºC

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(240ºF) necessitating the use of special plastics like PVDF to handle the corrosive hot materials. The newer products operating under a vacuum operate around 80ºC (175ºF) and can use CPVC, polypropylene, and many FRP resins for components and storage. Although the systems are relatively small and simple to operate, they cost between US$6 and US$10 per ton of spent pickle liquor to operate. The value of the recovered acid is usually greater than the operating cost, but the issue of the remaining FeCl2 concentrate still has to be addressed. There are many potential buyers/takers in North America who will use it for water treatment and flocculants, but in some cases the concentrate will have to be either treated with caustic and fed to a filter press, or sent to a treatment facility. See Fig. 6. Pyrohydrolysis. This technology is actually a small scale HCl manufacturing plant. It does not “recover” acid like the aforementioned technologies, it produces it from the FeCl2 salt. As a result, the yield of HCl from an equivalent ton of spent pickle liquor is 55-65% greater than the competing technologies. The mass of the by-product iron oxide is also significantly less than the others since the water has been removed. Another benefit of the process is the use of rinse water in the rectifier, which eliminates the need to treat the rinse with a minor increase in Fe contaminants in the recovered acid. In the wire industry it is not common that the byproduct would be of high enough quality to sell to the largest consumers of this by-product. The difficulty of operation, environmental footprint, and high capital and operating cost usually limit this technology to very large consumers of HCl who cannot have their manufacturing controlled by an outside contractor. Larger scale plants have reasonable return on investment, but smaller scale operations usually look to other alternatives.

Bibliography ESTCP Cost and Performance Report: Spent Acid Recovery Using Diffusion Dialysis. Arlington: Environmental Security Technology Certification Program. 1999. B. Chenevert, National Metal Finishing Resource Center, 2012, www.nmfrc.org. C. Brown, Nixed Acid Recovery with the APU Acid Sorption System, Ontario: Eco-Tec, 1997. C. Calmon and H. Gold, Ion Exchange for Pollution Control, Vol. I. Boca Raton, Florida, CRC Press Inc., 1997. C.G. Cushnie, Pollution Prevention and Control Technologies for Plating Operations, p. 246, Second ed., Ann Arbor, Michigan: National Center for Manufacturing Sciences, 2009. H. Dorfner, Ion Exchangers: Properties and Applications, 1977, Ann Arbor, Michigan: Ann Arbor Science Publishers Inc. DPRA Incorporated Regulatory Impact Analysis of the Proposed Rule for 180-Day Accumulation Time for F006 Wastewater Treatment Sludges, Ann Arbor: National Metal Finishing Resource Center, 1998. H.M. Freeman, Standard Handbook of Hazardous Waste Treatment and Disposal, McGraw-Hill Book Company, 1989.

The Water Information Program, Water Facts, www.waterinfo.org/resources/water-facts, March 2013. U.S. EPA RCRA Enforcement Division, Estimating Costs for the Economic Beneﬁts of RCRA Noncompliance, Washington: Ofﬁce of Regulatory Enforcement, 1997. U.S. Energy Information Admin., Electric Power Annual 2011, www.eia.gov/electricity/annual, January 2013. U.S. Energy Information Admin., Natural Gas Weekly Update, www.eia.gov/natrualgas/weekly, March 2013.

Jared Cullivan is a process engineer for Beta Control Systems Inc., Beaverton, Oregon, USA. He is the company’s lead engineer for thermochemical process automation. For the last seven years he has assisted with the design, automation, installation, and commission of hydrochloric, sulfuric and hydroﬂuoric acid recovery systems as well as membrane-based recovery processes spanning four continents. He holds a B.S. degree in mechanical engineering from Santa Clara University. Bryan Cullivan is president of Beta Control Systems. This paper was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, April 2013.

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Greiner Environmental, Pilot of the Pollution Prevention Technology Application Analysis Template Utilizing Acid Recovery System, p.18, U.S. EPA, New England, 1999. ICIS, Indicative Chemical Prices A-Z. http://www.icis.com/ chemicals/channel-info-chemicals-a-z/, Aug. 2006. H.Z. Kister, Distillation Design, McGraw-Hill Book Company, 1992. M. Mach, Hydrothermal Hydrochloric Acid Regeneration: The Cost Saving, Eco Friendly Alternative, Premium DocStoc: http://premium.docstoc.com C.G. Cushnie, Pollution Prevention and Control Technologies for Plating Operations, p. 276, Second ed., Ann Arbor, Michigan: National Center for Manufacturing Sciences, 2009. National Lime Association, Using Lime for Acid Neutralization, http://www.lime.org/documents/free_downloads/acid-neut-ﬁnal-2000.pdf, Sept. 2000, A.P. Schweitzer, Handbook of Separation Techniques for Chemical Engineers, 2nd ed., New York: McGraw-Hill Book Company, 1988. C.G. Cushnie, Pollution Prevention and Control Technologies for Plating Operations, p. 361, Second ed., Ann Arbor, Michigan: National Center for Manufacturing Sciences, 2009. J.D. Seader, E.J. Henley and K.D. Roper, Separation Process Principles: Chemical and Biochemical Operations, 3rd ed., John Wiley & Sons, Inc., 2011.

AIST TECH PAPER

TECHNICAL PAPER Interplay between grain size and austenite stability on the deformation behavior of high strength-high ductility combination austenite stainless steels By V.S.A. Challa, R.D.K. Misra, M.C. Somani, and L.P. Karjalainen There is a strong interest to understand the deformation behavior of nanograined/ultrafine-grained (NG/UFG) materials, because the basic mechanisms are expected to be fundamentally different from those operating in the coarse-grained (CG) materials1-3. The dominant mode of plastic deformation of ductile CG materials that is governed by dislocation glide is suppressed in NG materials, where partial dislocation emission from grain boundaries may operate instead4. Thus, with decrease in grain size and consequent increase in yield strength, we anticipate a gradual transition in the mechanism of deformation from CG regime to NG regime. In recent years, we have pioneered the development of a novel processing route to produce NG/UFG structure in metastable austenitic stainless steels involving cold rolling and controlled phase reversion annealing1,2,5-8. In this approach, in certain metastable austenitic stainless steel grades, heavy cold rolling of austenite at room temperature leads to the formation of predominantly dislocation-cell type martensite6. Upon annealing, the deformed martensite reverts to austenite with NG/UFG structure through a diffusional or shear-reversion mechanism depending on the chemistry of the steel5, 8. The uniqueness of this concept is that it enables us to obtain a wide range of grain size from NG to CG regime using a single set of parameters (percentage of cold deformation and annealing temperature-time sequence). NG/UFG stainless steel of Type 301LN was characterized by high yield strength and elongation, typically, 600-800 MPa and 40-30%, respectively1,2,5-8, which exceeds the yield strength of 350 MPa but has comparable elongation of ~40% of the annealed CG steel. In austenitic stainless steels, the mechanical stability of the austenite phase and strain-induced martensite transformation governs ductility. We also know that austenite grain size affects its stability, where fine grains are more resistant to transformation to martensite than the coarse grain counterpart9-11. To understand deformation mechanisms from CG to NG regime, we have used a sensitive nano/micro-mechanical technique such as nanoindentation12-19. When the indenter tip (20 nm radius in our case), is small enough to produce a highly stressed volume beneath the indenter then there is a low probability of encountering a pre-existing dislocation prior to the commencement of plastic deformation and the tested volume is scalable with respect to the microstructure12, 13. To elucidate deformation microstructures the plastic zone surrounding the indentation was studied by transmission electron microscopy. 68 | AIST Technical Paper

Experimental Procedure The starting material was a commercial Type 301LN austenitic stainless steel of ~1.5 mm thickness and having nominal composition (in wt. %) of Fe-0.017C0.52Si-1.3Mn-17.3Cr-6.5Ni-0.15Mo-0.15N. The strips were cold rolled in a laboratory rolling mill to ~62% thickness reduction and subsequently annealed in a Gleeble 1500 thermo-mechanical simulator. The annealing experiments were carried out in the temperature range of 700-900oC on strips of 120 mm x 10 mm (thickness ~0.5 mm) to obtain varying grain size. The fact that the nanoindents were to be subsequently examined by transmission electron microscopy (TEM) for microstructural evolution, the following procedure was adopted. First, 3 mm disks were punched from the experimental steels. To ensure that the nanoindents are distributed along the thin area of the disk for examination in TEM, a modification of twin-jet electropolishing and a new design of sample mounting for nanoindentation were developed. The disks were partially jet electropolished in a refrigerated electrolyte of 10% perchloric acid in acetic acid at 25 V for ~30 s to obtain a shining surface in the center part of the 3 mm disk. The procedure of placing horizontally partially electropolished disks of ~30 m thickness inside the ~4 mm diameter pits drilled on the polished basal surface of an aluminum block of diameter ~25 mm is the following: First, the ~4 mm diameter pits were partially filled with the solder. Next, the surface is polished prior to placing the partially polished disk on top of the solder. This was followed by placing invisible tape around the disk (foil specimen) to prevent its movement during nanoindentation experiments. This carefully designed approach fully supported the specimen to withstand the applied force of the nanoindenter and prevent the specimen from bending during nanoindentation experiments. Nanoindentation experiments were carried out in load-controlled mode at a loading rate range of 2 N/s and maximum load set to 0.5 mN. The nanoindenter system (MTS XP) consisted of a Berkovich three-sided pyramidal diamond indenter with a nominal angle of 65.3o and indenter tip radius of 20 nm. An array of indents of matrix 12Ă&#x2014;12 was defined with the indent gap of 10 m. After the indentation experiments, the disk were removed from the mount and final electropolishing was carried out only from the side opposite to the indented surface. Using this procedure, the area surrounding the indents, which is present along the final jet-polished hole, was electron

AIST TECH PAPER Fig. 1. (a) Scanning electron micrograph of coarsegrained (CG) steel with an average grain size of 22 μm. (b-d) transmission electron micrographs of phase reversion annealed 301 LN Type austenite stainless steel with varying grain size from ultraﬁne-grained (UFG) regime to ﬁne-grained (FG) regime (adapted from reference 2).

Figure 2: Representative bright ﬁeld transmission electron micrographs of the nanoindented region in phase reversion annealed Type 301LN NG/UFG stainless steel with average grain size of 320 nm showing (a, b) extended stacking faults, and (c, d) nanoscale twin lamellae. The arrow in (d) shows dislocations being stopped at the twin boundary (adapted from reference 2).

NG/UFG and SMG Phase Reversion Annealed Steels In Figures 2-5 we summarize electron microscopy results of the deformation processes associated with the nanoindented region as a function of grain size from NG to CG regime2. We can note from the figures that twinning is an active deformation mechanism in phase reversion annealed steels (i.e., NG/UFG: 320 nm; Table I. Mechanical properties of 301 LN stainless steel with different SMG: 757 nm). These steels indicated a high average grain. The UFG to FG regime was obtained by cold work density of twins (a few hundred atomic layers to 76% reduction followed by phase reversion annealing in the o thick of twin lamella). The high density of nanottemperature range of 700-900 C. wins must be a consequence of nucleation of new deformation twins as indenter penetrates transparent to study the deformation behavior using a into the material. Similar type of twins has been observed TEM (Hitachi H7600, 120 kV). The experimental procein twinning induced plasticity (TWIP type) steels that are dure is described in detail elsewhere2. typical of low stacking-fault energy FCC alloys20. A high fraction of extended stacking faults on {111} planes were Results also observed together with planar dislocations arrays. Based on the deformation figures, we can conclude Transmission electron micrographs summarizing the a number of observations that include high density of phase reversion annealed microstructure with varying nanotwins, planar array of dislocations on {111} planes, grain size obtained as a consequence of annealing in stacking faults, and twin boundaries with dislocation pilethe temperature range of 700-900oC for 10-100s are ups (Figure 2d, 3d) in NG/UFG and SMG (sub-micron presented in Fig.1. Also, presented in Fig. 1 is the light grained) steels. The interactions between the dislocations micrograph of the starting CG steel with average grain and the twin boundaries play a significant role in the plassize of 22 m. The average grain size was obtained tic deformation process. In general, the preferred sites for for different combination of annealing temperature and generation of dislocations are grain boundaries, which time using a number of micrographs of the type preare quite numerous in NG/UFG and sub-micron grained sented in Fig. 1 and the tensile test data is summarized (SMG) structures compared to CG structure. Once the in Table 12. FEBRUARY 2015 | 69

AIST TECH PAPER Fig. 4. Representative transmission electron micrographs of the nanoindented region in phase reversion annealed Type 301LN fine-grained (FG) stainless steel with average grain size of 2132 nm showing (a, b) extended stacking faults and planar dislocation arrays, (c) nucleation of shear bands, (d) bright field and corresponding, (e) dark field image showing strain-induced ’-martensite formation at the intersection of the shear bands, and (f) is the diffraction pattern confirming ’martensite (adapted from reference 2).

dislocations are emitted by the boundaries, they move through the grain interior and in most cases are blocked at twin boundaries2.

Phase Reversion Annealed FG Steels and Conventional CG Steels We now describe the behavior of phase reversion annealed FG steel in comparison to that of commercial Type 301 LN with CG structure. In FG steel, with average grain size of ~2132 nm (~2 µm), besides stacking faults and planar dislocation arrays, strain-induced martensite shear bands were also the dominant deformed microstructure (Fig. 4). Twins were not observed. Thus, in contrast to the deformation behavior of NG/UFG and SMG steels, nucleation of strain-induced bcc ’-martensite was an active deformation mechanism in phase reversion annealed FG structure. The average grain size of ~2 µm appears to represent the transition point or change in deformation mechanism from twinning to strain-induced martensite. Two illustrations of microstructural evolution in CG steel are presented in Fig. 5. In Fig. 5, bcc martensite was observed to nucleate at the intersection of ε-martensite shear bands (white embryos in dark ﬁeld TEM micrograph, Fig. 5c, 5d). Strain induced ’-martensite nucleated at the intersection of shear bands (Fig. 5e), and the growth occurred by repeated nucleation of new ’ lath-like embryos and coalescence of such embryos with formation of a wider lath. The shear bands and ’-martensite is barrier to dislocation motion and contribute to the strain hardening rate2. It has been previously

70 | AIST Technical Paper

observed21 that the intersections of shear bands or stacking faults provide nucleation sites for strain-induced ’-martensite. Moreover, the formation of shear bands is a necessary requirement for strain-induced martensite formation. We know that the strain-hardening behavior of 301LN austenitic stainless steel with the low stacking fault energy of ~15 mJ/m221 is enhanced by the strain-induced martensite formation, irrespective of the dislocation glide. A (hcp) marsmall content of tensite (maximum ~2.5%), was observed in a tensile strained AISI 301LN steel, that subsequently transformed partly to ’-martensite at high strains. In any case, ’-martensite was the major transformed phase (up to 40% cold rolling reduction)2.

Discussion

The strain-induced ’-martensite formation at the intersection of shear bands is an active deformation mechanism in the CG structure. This is an effective strain hardening mechanism and prevents strain localization and thereby enhances ductility, i.e., uniform elongation2. In an earlier study by the authors, ’-martensite formation was also observed in tensile testing, both in FG (average grain size ~1-2 µm) and CG conditions8. In contrast to the deformation behavior of CG structure, Fig. 2 and 3 clearly suggest that twinning replaces martensite formation, as the grain size decreases from CG (~22 µm) to NG/UFG (~350 nm) regime. There is a clear distinction and fundamental transition in the deformation behavior of NG and CG alloy in a single material, such that “twinning” contributes to the excellent ductility of “high strength” NG alloy, while in “low strength” CG alloy, ductility is also good, but due to strain-induced martensite formation at the intersection of shear bands. This is a clear case of grain size effect (and strength). We currently believe that twinning is a major factor contributing to the observed excellent ductility of “high strength” NG structure, and is a contributing deformation mechanism, while for the “low strength” CG structure, ductility is also good, but without twinning2. The occurrence of mechanical twinning in NG alloy is directly related to the high strength associated with the NG structure, which makes strain-induced shear band formation difﬁcult that leads to enhanced ductility in the CG counterpart. Deformation twinning in NG alloy and strain-induced martensite nucleation in CG alloy are microstructurally similar, i.e., both of them involve diffusionless shear of

AIST TECH PAPER Figure 3. Representative bright ﬁeld transmission electron micrographs of the nanoindented region in phase reversion annealed Type 301LN SMG stainless steel with average grain size of 757 nm showing (a) through (c) extended stacking faults, (d) nanoscale twin lamellae (also in ﬁgure (b)), and (e) pile-up of dislocations at the twin boundary (black arrow) (adapted from reference 2).

a constrained plate-shaped region in the parent crystals2. There has not been substantial research into the effects of grain size phase on austenite stability in single phase austenite alloy and the possibility that the deformation mode can change with decrease in grain size. Fundamentally, this is an important aspect of the study described here, particularly in the context of striking change in the deformation mechanism with change in grain size. The mechanism of plastic deformation must be related to the enhanced contribution of grain boundaries resulting in the increased stability of austenite in the NG alloy. This dependence can be explained due to the increased strength of NG austenite inhibiting martensite formation that involves volume expansion. This is currently believed to the reason for the transition in deformation mechanism as grain size is reduced. Thus, based on the above observations and discussion, the understanding of deformation mechanisms as a function of grain size is unclear and fragmented, and the reports in the literature are conﬂicting. The following possibilities exist to explain our ﬁndings on the change in

Fig. 5. Representative TEM micrographs of the nanoindented region in Type 301LN CG stainless steel showing (a, b) evolution of strain induced martensite at the intersection of shear bands at a loading rate of 2 µN s-1. Also, presented is the data (c) through (e) for the loading rate of 20 µN s-1 showing (c) bright field and corresponding (d) dark field image showing ’-martensite formation at the intersection of the shear bands, and (e) is the diffraction pattern confirming ’-martensite (adapted from reference 2).

the deformation mechanism from ‘strain-induced martensite’ in CG alloy to ‘twinning’ in NG alloy: (a) the austenite stability increases with decrease in grain size9-11 such that twinning is encouraged and the nature of dislocations (width of stacking faults) contributes to increased tendency to twinning changes with grain size, and (b) the enhanced Shockley partial emission in NG alloy promotes deformation twinning2.

Conclusions Using nanoscale deformation experiments we demonstrated that there is a clear distinction and fundamental transition in the deformation mechanism of NG/UFG and CG Fe-17Cr-7Ni austenitic steels such that deformation twinning contributed to the excellent ductility of “high strength” NG/UFG alloys, while in “low strength” CG alloy, ductility was also good but because of strain-induced martensite nucleated at the shear bands. This transition occurs in the ﬁne-grained regime and in the present case is at ~2 µm. The observations of twins and stacking faults imply partial dislocation mediated process, such as emission from grain boundaries, being possible in grains of size ~100-500 nm. FEBRUARY 2015 | 71

AIST TECH PAPER

We attribute the change in deformation mechanism from strain-induced martensite in CG structure to nanoscale twinning in NG structure to austenite stability, such that the decrease in grain size from CG to NG regime increases the stability of austenite.

Acknowledgements The authors (R.D.K. Misra and V.S.A. Challa) acknowledge support from National Science Foundation through grant# DMR-1261883 (Program Manager Dr. Eric Taleff). They also acknowledge Board of Regents of Louisiana through grant# LEQSF(2012-15)-RD-B-08 for material processing part of the work.

References 1. R.D.K. Misra, J.S. Shah, S. Mali, P.K.C. Venkatasurya, M.C. Somani, and L.P. Karjalainen, “Phase reversion induced nanograined austenitic stainless steels: microstructure, reversion and deformation mechanisms,” Materials Science and Technology, 29 (2013) 1185. 2. R.D.K. Misra, P.K.C. Venkatasurya, M.C. Somani, and L.P. Karjalainen, “Nanoscale Deformation Behavior of PhaseReversion Induced Austenitic Stainless Steels: The Interplay Between Grain Size from Nano-grain Regime to Coarsegrain Regime,” Metallurgical and Materials Transactions A, 43A (2012) 5286. 3. G. Saada, T. Kruml, “Deformation mechanisms of nanograined metallic polycrystals,” Acta Materialia, 59 (2011) 2565. 4. L. Capolungo, M. Cherkaoui, J. Qu, “On the elastic–viscoplastic behavior of nanocrystalline materials,” International Journal of Plasticity, 23 (2007) 561. 5. R.D.K. Misra, S. Nayak, S. Mali, J. Shah, M. Somani, L.P. Karjalainen, Metallurgical and Materials Transactions A, 41 (2010) 1543. 6. R.D.K. Misra, S. Nayak, S. Mali, J. Shah, M. Somani, L.P. Karjalainen, “On the Significance of Nature of StrainInduced Martensite on Phase-Reversion-Induced Nanograined/ Ultrafine-Grained Austenitic Stainless Steel,” Metallurgical and Materials Transactions A, 41 (2010) 3. 7. R.D.K. Misra, S. Nayak, S. Mali, J. Shah, M. Somani, L.P. Karjalainen, “Microstructure and deformation behavior of phase-reversion induced nanograined/ultrafine-grained (NG/ UFG) austenitic stainless steel,” Metallurgical and Materials Transactions A, 40 (2009) 2498. 8. M.C. Somani, P. Juntunen, L.P. Karjalainen, R.D.K. Misra, and A. Kyrolainen, “Enhanced Mechanical Properties through Reversion in Metastable Austenitic Stainless Steels,” Metallurgical and Materials Transactions A, 40 (2009) 729. 9. K. Nohara, Y. Ono, N. Ohashi, “Composition and Grain Size Dependence of Strain Induced Martensitic Transformation in Metastable Austenitic Stainless Steels”, Journal of the Iron and Steel Institute of Japan 63 (1977) 772. 10. A. Frehn, E. Ratte, W. Bleck, “Influence of temperature and strain rate on the mechanical properties and the formability of the austenitic stainless steel 1.4376 containing manganese and nitrogen,” Steel Grips, 2 (2004) 447. 11. S. Turtletaub, A.S.J. Suiker, “Grain size effects in multiphase steels assisted by transformation-induced plasticity“, International Journal of Solids and Structures, 43 (2006) 7322.

72 | AIST Technical Paper

12. L. Lu, R. Schwaiger, Z.W. Shan, M. Dao, K. Lu, S. Suresh, “Nano-sized twins induce high rate sensitivity of flow stress in pure copper,” Acta Materialia, 53 (2005) 2169. 13. R. Schwaiger, B. Moser, M. Dao, N. Chollacoop, S. Suresh, “Some critical experiments on the strain-rate sensitivity of nanocrystalline nickel,” Acta Materialia, 51 (2003) 5159. 14. B. Yang, H. Vehoff, R. Pippan, “Overview of the Grain Size Effects on the Mechanical and Deformation Behaviour of Electrodeposited Nanocrystalline Nickel − from Nanoindentation to High Pressure Torsion,” Materials Science Forum 633-634 (2010) 85. 15. H. Vehoff, D. Lemaire, K. Schuler, T. Waschkies, B. Yang, “The effect of grain size on strain rate sensitivity and activation volume - from nano to UFG nickel,” International Journal of Materials Research, 98 (2007) 259. 16. M. Jin, A.M. Minor, D. Ge, J.W. Morris, “Study of deformation behavior of ultrafine-grained materials through in situ through nanoindentation in a transmission electron microscope,” Journal of Materials Reserch, 20 (2005) 1735. 17. T. -H Ahn, C.-S. Oh, D.H. Kim, H. Bei, E.P. George, H.N. Han, “Investigation of strain-induced martensitic transformation in metastable austenite using nanoindentation,” Scripta Materialia, 63 (2010) 540. 18. R.D.K. Misra, Z. Zhang, Z. Jia, M.C. Somani, L.P. Karjalainen, “Probing deformation processes in near-defect free volume in highstrength–high ductility nanograined/ultrafine-grained (NG/UFG)metastable austenitic stainless steels,” Scripta Materialia 63 (2010) 1057. 19. R.D.K. Misra, Z. Zhang, Z. Jia, P.K.C. Venkat Surya, M.C. Somani, L.P. Karjalainen, “Nanomechanical insights into the deformation behavior of austenitic alloys with different stacking fault energies and austenitic stability,” Materials Science and Engineering A, 528, 6958-6963 (2011). 20. J. Gil Sevillano, “An alternative model for the strain hardening of FCC alloys that twin, validated for twinning-induced plasticity steel,” Scripta Materialia, 60 (2009) 336. 21. J. Talonen, H. Hanninen, “Formation of shear bands and strain-induced martensite during plastic deformation of metastable austenitic stainless steels,” Acta Materialia, 55 (2007) 6108.

Author contact information V.S.A. Challa and R.D.K. Misra: Center for Structural and Functional Materials, University of Louisiana at Lafayette P.O. Box 44130, Lafayette, LA 70504, USA (Tel: 001-337-482-6430, Email: dmisra@louisiana.edu). M.C. Somani and L.P. Karjalainen: Department of Mechanical Engineering, The University of Oulu, P.O. Box 4200, 90014 Oulu, Finland.

TECHNICAL PAPERS

FEBRUARY 2015 | 73

TECHNICAL PAPERS

Material CuETP

Fig. 2. Grooved trolley wire in CuMg0.5.

Tensile strength

Electrical resistivity

N/mm2

(min) %*

10-08 Ohm.m

360

1.777

375

1.777

420

2.155

430

2.005

445

2.155

430

2.778

490

2.778

*percentage elongation after fracture. nom. x section 100mm2

Table 1. Comparison of various copper alloys.

Material CuETP

Grooved contact wire section

Max design train speed

Contact wire tension

sq.mm 100

km/hour 160

kN 10-15

120 150

250 360

15 27

120

400

Table 2. Comparison of material performance.

74 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 3. Rautomead RS 3000/5-CuMg casting machine.

Fig. 4. Rautomead RS 3000/5-Cu-Mg casting machine layout. FEBRUARY 2015 | 75

TECHNICAL PAPERS Fig. 5. Graphite crucible.

W/m Graphite

50,000

Titanium carbide

1,000

Magnesia

Alumina

Table 4. Thermal stress resistance advantages of graphite.

Fig. 6. Graphite heating elements.

graphite crucible Bulk density Open porosity

g/cm3

1.83

Young’s modulus

kN/mm2

10.8

Flexural strength

N/mm2

21.5

Ωμm

7.7

Thermal conductivity

Wm-1 K-1

165

Coefficient of thermal expansion

10-6 K-1

2.7

Resistivity

Table 3. Properties of a graphite crucible. 76 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Fig. 7. Oxygen reduction in graphite lined system. Cu

Density at room temp

gm/cc

8.96

1.738

Density at melting temp

gm/cc

8.02

1.584

Melting temp

deg C

1085

650

Boiling temp

deg C

2567

1090

Table 5. Comparison of physical properties of copper and magnesium.

Sir Michael Nairn is chairman of Rautomead Limited, Dundee, Scotland. He co-founded the company in 1978 to market equipment for the continuous casting of nonferrous metals, with special emphasis on processing copper, brasses, bronzes and precious metals. He previously was director of Ralli Nairn International Ltd., London, and later Bowater Overseas Holdings, London. He holds an MBA qualiﬁcation from INSEAD, France. He was a governor of the University of Abertay, Dundee, for 12 years and for 10 years a governor of the New School Butterstone. This paper was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, April 2013.

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