China Outlook by Wire Journal International, Inc.

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

CONTENTS

Volume 45 | Number 6 | June 2012

F EATURE

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30 Chapter Corner . . . . . . . . . . . 32 Technical Papers . . . . . . . 44-60 Products. . . . . . . . . . . . . . . . 62 Classified . . . . . . . . . . . . . . . 68

China Outlook . . . . . . . . . . . . . . .34 The government wants to better control growth, labor costs are rising, other nations are becoming more cost-effective and some offshore manufacturing is heading back home to other countries, but for all those and other concerns, Chinese manufacturing has continued to expand and further entrench its leadership position. This feature includes commentary from U.K.-based Integer Research, which is staging its first wire and cable conference in Shanghai in November, an expert’s view of the big picture, and more.

Career Opportunities . . . . . . . 68 Advertisers’ Index . . . . . . . . . 71

Next issue July 2012 • Industry Success Stories • Wrapup: WAI Operations Summit & Wire Expo 2012

T ECHNIC AL PAPERS Extended quality control of cable insulation by color measurement during extrusion Dr. Horst Scheid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Evaluating decarburization in tool steel rod Rebecca D. Cioffi, Roger N. Wright and Steven W. Mayott . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Optimized wire coil batch pickling plant design via computer-aided modeling Wynn H. Kearns, Adam G. Kimura and Arthur Seibert . .54

Cover: There are many reasons why China has become such a dominant global force in so many manufacturing sectors, but one key was the focus on the 1978 creation of special economic zones orientated towards exports and a partial liberalization of foreign trade that led to truly stunning growth in the 1990s. JUNE 2012 | 3

INSIDE THIS ISSUE SEEING COLORS (RIGHT): NOT SO EASY . . .64

China’s growth rate may have slowed some, but statistics such as those reflected in the above chart show that the country has more than just a firm leadership role in much of the wire and cable industry; it has lots of internal demand to fuel future growth. The question now is whether that same success can be found in value-added products.

Color is not just an afterthought for cables as it serves an important role in identification. Producing good consistent colors, however, is not necessarily simple. The human eye is ill-equipped to properly interpret “color,” as the above optical illusion shows: “A” appears to be darker than “B,” but indeed they have both the same gray value.

CONTENTS

CHINA OUTLOOK: FOLLOW THE CHARTS . .34

4 | WIRE JOURNAL INTERNATIONAL

EDITORIAL WIRE JOURNAL

EDITORIAL

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

The early report from Dallas Publisher | Steven J. Fetteroll

The July issue will have the wrapup for the WAI Operations Summit & Wire Expo 2012, but I am pleased to give you an advance report on the May 21-23 event: Dallas was a winner. I feel very confident in making that claim because the overwhelming response was quite positive, and I can assure you that if attendees thought otherwise they would not have been reluctant to let us know. Yes, going to a new site helped some because Wire Expo exhibitors had the opportunity to meet new potential customers, but the real attraction was more than that. It was substantive. The goal had been to offer a program with an identity and purpose of its own so that nobody would mistake it for a small version of Interwire. To that end, the technical papers were replaced by the Operations Summit, where manufacturers and suppliers shared their expertise in areas that matter: commodity outlooks, safety responsibility, drivers for process effectiveness, intellectual property legal developments, alternate fuel options in material handling, employee involvement in sustainability, a roundtable on machinery that addressed sensitive topics such as offshore equipment, how to control energy costs, and Attendees at the Machinery Roundtable. more. One of the “and more” stories was operational excellence, featuring presentations by five manufacturers. Their stories were shared, including a few that if you just read them might seem implausible, but they came across as both real and inspirational, the “ingredients” for anyone to try to work with at their own operations. Beyond those elements, the networking was spectacular, especially at the reception at Eddie Deen’s. You can’t ride a mechanical bull on Facebook or race an armadillo, and even if you could do it virtually, it wouldn’t be the same as doing so in front of a cheering crowd of your peers. The tours of Encore Wire and Gerdau were also superbly organized, with both companies extending themselves to make the experience special. There was a lot of good activity at Dallas, and you can read more about it in the July issue, but for now I am pleased to report that the WAI Operations Summit & Wire Expo has firmly stepped outside the shadow of Interwire, and is an event unto itself that offers a unique value.

Steve Fetteroll WAI Executive Director

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 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2012 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

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CALENDAR

CALENDAR June 11-13, 2012: CRU 6th Wire and Cable Conference Vienna, Austria. To be held at the Vienna Marriott hotel, this forum is for cable manufacturers and their customers. Contact: CRU Int’l, tel. 44-20-7903-2444, conferences@ crugroup.com, www.wireandcableconference.com. Sept. 25-28, 2012: wire China 2012 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 3-5, 2012: SpringWorld 2012 Rosemont, Illinois, USA. To be held at the Donald E. Stephens Convention Center. Contact: Tom Renk, The Chicago Association of Spring Manufacturers, Inc. (CASMI), tel. 630-369-3466, fax 630-369-3773, info@casmi-springworld.org, www.casmi-springworld.org. Oct. 30-Nov. 1, 2012: Wire & Cable India Mumbai, India. This event is organized by Messe Düsseldorf. Contact: see wire China 2012. Nov. 11-14, 2012: 61st IWCS Conference™ Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. Nov. 15-18, 2012: Cable & Wire Fair Istanbul, Turkey. To be held at the CNR Expo Center, this event, organized by CNR Holding, includes cable acces-

sories, cable realignment, electrical insulation materials, equipment and machines. Contact: Esra Aydin, CNR Holding, tel. 90-0212-465-74-74/2-22, sra.aydin@cnr.net, www.cnrexpo.com Nov. 15-18, 2012: Wire & Cable Asia 2012 Shanghai, China. This new conference is being organized by U.S.-based Integer Research. See p. 36. April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention. May 2013: wire Russia 2013 Moscow, Russia. This event is organized by Messe Düsseldorf. Contact: see wire China 2012. Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: see wire China 2012. Oct. 8-13, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and its partner Grupo Cipa will stage this new fair for the Brazilian market. The new event will be held in parallel with TUBOTECH at the Imigrantes Exposicoes Exhibition Centre in São Paulo. Contact: see wire China 2012. Nov. 15-18, 2012: Cable & Wire Fair Istanbul, Turkey. To be held at the CNR Expo Center, this event has a new organizer. Contact: Esra Aydin, CNR Holding, tel. 90-212-4657474/2122, esra.aydin@cnr.net.

WIRE A SSOCIATION INTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. June 22, 2012: Midwest Chapter 10th annual golf tournament West Chicago, Illinois, USA. This event will be held at the St. Andrews Golf & Country Club.

Oct. 18, 2012: The Vannais Southeast Chapter 11th annual golf tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf & Spa.

Aug. 2, 2012: Ohio Valley Chapter 10th annual golf tournament Solon, Ohio, USA. This event will be held at the Grantwood Golf Course.

Oct. 22, 2012: Western Chapter 12th annual “Wild West Shootout” golf outing Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course.

Sept. 10, 2012: New England Chapter 18th annual golf tournament Ellington, Connecticut, USA. This event will be held at the Ellington Ridge Country Club.

April 23-25, 2013: Interwire 2013 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its trade show, technical programs and the Association’s 83rd Annual Convention.

8 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

INDUSTRY NEWS South Korea’s LS Cable & System inaugurates cable plant in India LS Cable and System India (LSCI), the India subsidiary of South Korea’s LS Cable & System (LSC&S), announced that it has completed one of India’s largest power cable manufacturing plants, a state-of-the-art plant located at Bawal in Haryana that it said will produce power cables up to 220 kV, optical ground wire and communication cables. “India is among the top five energy consuming nations in the world, accounting for 3.7% of the world’s entire energy consumption, (and) the country is investing heavily in energy projects across states,” observed LSC&S President Jongho Son. That makes it a key strategic market focus for LSC&S, which is committed to the Indian market for the long term, and this significant investment only reinforces that commitment, he said. “We are looking to grow rapidly in India and attain market leadership position in the key power and communication markets in the near to medium term. We will contribute to the growth of power and communication infrastructure sectors in India by doing projects with the best technology and leveraging years of experience in the cable business.” LSCI was established in 2008 with an initial focus on manufacturing coaxial cables and RF antennas in India, the release said, noting that the focus has expanded according to ambitious plans. Today, LSCI Managing Director Euydon Park said, the company supplies extra-high-voltage cable, OPGW, for power cable solutions, and provides broadband wire and wireless communication equipment such as BTS antennas for mobile network and G-PON, EPON for FTTH solution, to the fast growing Indian communication market.

General Cable opens plant in India U.S.-based General Cable announced that it has completed construction on its state-of-the-art manufacturing facility in Baddi, Himachal Pradesh, India, a city that was described as “one of the faster growing cities in India and quickly becoming a manufacturing hub for multinational companies.” Designed and built in compliance with Indian Green Building standards, the manufacturing facility is situated on 20 acres of land in the industrial town of Baddi, in the state of Himachal Pradesh, a press release said. Products to be developed and manufactured there include aerial transmission conductors, low-, medium- and high-voltage power cables, building wire, control, instrumentation and specialty cables. At current installed capacity, the facility, which has more than a hundred employees, is capable of generating annual revenues in the range of $100 to $120 million,

A General Cable associate monitors an aluminum rod breakdown machine at the company’s plant in India. complementing General Cable’s existing exports into the country, it said. Per General Cable, the company constructed two buildings on the site. The smaller building was designed to produce building wire. The larger multi-purpose cable plant has a 35-meter (115-foot) continuous vulcanization (CV) tower and both buildings were designed to reduce their overall impact of environment. “By designing ‘green’ from the ground up, we have seen immediate benefits in operating costs. These include energy savings of 30 to 40% and water savings of 20 to 30% when compared to other similar wire and cable operations,” said Sandeep Sood, Country Head of India Operations. “We have created a better-quality work environment for our associates, which will promote good health and safety practices and therefore increase productivity.” In attendance for the opening were more than 200 highranking government officials and business leaders as well as Mathias Sandoval, General Cable President and CEO Rest of World; Peter Campbell, General Cable Senior Vice President of Asia; and Sood. “The opening of any new facility is a significant achievement, but the quality of execution at this plant in Baddi has been exceptional,” Sandoval said. The news follows a recent announcement by General

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

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Prysmian to supply submarine power cable link for company in Vietnam The Prysmian Group announced that it has been awarded a contract by the Vietnamese utility EVNSPC (Southern Power Corporation under Vietnam Electricity) worth 67 million euro to design, supply, install and commission a submarine power cable link to connect Phu Quoc Island to the national power grid in Vietnam. A press release said that, once completed, the Phu Quoc link will be the first submarine power cable link to have been installed by a utility company in Vietnam. The Phu Quoc cable connection will use some 58 km of 3 x 630 mm² 110 kV copper, single wire, armored XLPE insulated submarine cable that “will be laid and subsequently protected,” it said. Delivery and commissioning of the Phu Quoc interconnector is scheduled for the first half of 2014. The project, it added, will help develop the island, located in the Kien Giang province in southern Vietnam and home to beautiful beaches, to be a tourist paradise. The company, the release said, has long been a supplier

of high-voltage underground cables in Vietnam, and has installed submarine cable links throughout the Asia Pacific Region, with milestone projects such as Penang Island in Malaysia, the Java-Bali link in Indonesia, Cheju Island in Korea and the Basslink interconnector in Australia. It noted that the contract was won “against stiff competition from Far Eastern manufacturers.” In related news, the release said that the Prysmian Group “is moving ahead with a major investment programme to expand production capacity and to multiply the use of innovative technologies such as HVDC (High Voltage Direct Current) cables ...” It also pointed out that its acquisition and integration of Draka has strengthened the company’s portfolio of connections to mainland grids and interarray connections between turbines, also thanks to cables manufactured at the Drammen plant in Norway.

Taihan Electric reports power cable contracts in Kuwait and Saudi Arabia South Korea’s Taihan Electric Co. has won separate contracts worth US$92 million to build high-voltage power lines in Kuwait and Saudi Arabia. A Yonhap News article said that Taihan Electric reported winning a US$48 million turnkey deal from Kuwait’s Ministry of Electricity and Water. The project calls for

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INDUSTRY NEWS

Cable that it had acquired Delphia Produtos Eletricos Ltda. (Delphia), a manufacturer of automotive ignition wire harnesses located in São Bernardo do Campo, São Paulo, Brazil.

INDUSTRY NEWS

Taihan Electric Wire to replace a 158-km-long, 132 kilovolt electricity line in the Middle Eastern country’s capital. The article said that the company also reported winning a US$4 million contract, along with a Saudi Arabian company, to construct a power substation and a high-voltage, 80-km electric line at an airport in the southern city of Jeddah over a 16-month period. Those two deals, the article said, “came days after Taihan Electric Wire won a US$40.26 million order to supply highvoltage power cables to Saudi Arabia.”

Alcatel-Lucent to build new undersea cable link for the Kingdom of Tonga Alcatel-Lucent announced that it has been selected by Tonga Cable Limited to deliver a 837-km undersea cable link between the Kingdom of Tonga and its neighbor Fiji. A press release said that Alcatel-Lucent will deploy its advanced submarine optical solution based on the OALC-5 cables, repeaters and the 1620 Light Manager (LM) submarine line terminal, which can accommodate 10G/40G/100G wavelengths in the same platform. The installation, the release said, will be performed by Alcatel-Lucent’s Ile de Ré cable ship, which is based in the region and is specialized for laying and maintenance operations. The link, the release said, will provide Tonga with access to the Southern Cross Cable, the main trans-Pacific link between Australia and the U.S. The cable will “substantially increase the availability of broadband services for Tonga’s 100,000 residents and help spur economic growth,” it said. “We are pleased to be able to play a role in strengthening Tonga’s connections with the rest of the world,” said Philippe Dumont, president of Alcatel-Lucent Submarine Networks. “This new link will further expand connectivity throughout the Pacific Islands to drive digital inclusion.” “This cable link with Fiji will create a gateway to the global economy and community, and we are confident that it will provide great benefits to Tonga’s citizens and the many visitors we welcome each year,” said Robert Bolouri, managing director of Tonga Cable Limited.

Saudi company inaugurates PVC plant Saudi Arabia-based Middle East Specialized Cables Company (MESC), a manufacturer of instrumentation and control cables in the MENA region, has recently inaugurated a new plant in Riyadh, Saudi Arabia, for producing polyvinyl chloride (PVC) products. A press release said that the 36,000-ton PVC compound plant has an advanced laboratory with an extensive range of test and measurement equipments to international standards. The plant, it said, will not only meet the PVC needs of all MESC plants, it will be able to serve and supply some of the local and international markets.

(Section continued on p. 16.)

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INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Convention Dates: April 22-25, 2013 | Exhibit Dates: April 23-25, 2013 Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2013 LEADING WIRE BUSINESSES IN THE AMERICAS. WHY INTERWIRE? When industry professionals look for new wire and cable technology they choose Interwire, the benchmark for wire business in the Americas. Information is exchanged at Interwire. Machinery is debuted, reviewed, and sold at Interwire. And the promise of international networking on the Americasâ&#x20AC;&#x2122; stage continues to excite visitors to this vital marketplace. Location: Atlanta, Georgia. Interwire returns to the city of its origin where it was introduced in 1981. Compact: 3 full days of exhibits. Interwire 2013 offers a concentrated show schedule. Operating equipment. Interwire is a machinery show. Visitors will see operating equipment. Renewed energy. Attendance at Interwire 2011 surged with a 19% uptick. Visitors came from 53 countries. More than 400 companies exhibited making Interwire the largest trade show of its kind in the Americas for the wire and cable industry. Special industry theme days to be announced. Look for presentations, technical papers, and executive discussions to orbit around three central themes related to operational excellence in the manufacture of wire and cable. Specific topics to be announced. Fully supported. Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

Learn more about exhibiting and speaking opportunities at www.wirenet.org.

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

EXHIBITING COMPANIES — As of May 2012 — Genca Guill Tool & Engineering Co. Hall Industries Hangzhou JR Exhibition Co. Ltd. Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp. Heritage Wire Die Inc. Howar Equipment Huestis Industrial ICE Wire Line Equipment Inc. IDEAL Welding Systems INHOL LLC International Wire & Cable Machinery Association (IWMA) InterWire Products IWG High Performance Conductors Inc. Joe Tools Inc. Keir Manufacturing Inc. KP America Inc. Lämneå Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. The Lubrizol Corp. LUKAS Anlagenbau GmbH Magnetic Technologies Ltd. Maillefer SA Markem-Imaje USA Mathiasen Machinery Inc. Messe Düsseldorf North America MFL USA Service Corp. - Frigerio The MGS Group MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp. Niehoff Endex North America Inc. Northampton Machinery Co. (USA) Numalliance North America OMA USA Inc. OMCG North America Inc. Paramount Die Co. Parkway-Kew Corp. Pave Automation Design Phifer Wire Inc. Plas-Ties Co. PolyOne Polytec Inc. Precision Die Technologies Inc. PrintSafe Promostar srl

Properzi International Inc. QED Wire Lines Inc. QUEINS Machines GmbH Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Redex SA Reel-O-Matic Inc. RG Attachments Ltd. RichardsApex Inc. Rosendahl Nextrom Technologies Roteq Machinery Inc. S&E Specialty Polymers SAMP USA Inc. Shanghai Pudong International Exhibition Co. SIKORA International Corp. SIMPACKS Sivaco Wire Group Sjogren Industries Inc. Smeets SA Joe Snee Associates Inc. Sonoco Reels SPX Precision Components FENN Division T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Teknikor Teknor Apex Traxit North America LLC Troester GmbH & Co. KG Tubular Products Co. Tulsa Power Inc. US Synthetic Wire Die Reel Options by Vandor Corp. Vollmer America Inc. Wafios Machinery Corp. Stolberger Inc. dba Wardwell Braiding WCISA - Wire & Cable Industry Suppliers Association Web Industries Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Technology International Wire & Plastic Machinery Corp. The Wire Association International, Inc. Wire Journal International Wire Lab Co. Wire Machine Systems Inc. WireCo WorldGroup Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Zumbach Electronics Corp.

INTERWIRE 2013 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Ace Metal Inc. AEB International Inc. AIM Inc. All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American & Efird Inc. Anbao Wire & Mesh Co. Ltd. AXIS Computer Systems Inc. Aztech Lubricants LLC Bartell Machinery Systems LLC Bekaert Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti Beta LaserMike Blachford Corp. Bogimac Engineering Boxy SpA Breen Color Concentrates Inc. Butt Welders USA Caballe SA Cable Consultants Corp. Canterbury Engineering Co. Carris Reels Inc. Cemanco LC Central Wire Industries Ltd. Clayton Industries Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. Commission Brokers Inc. Condat CONDUCTIX WAMPFLER Conneaut Industries Inc. Cortinovis Machinery America Inc. Davis-Standard LLC Die Quip Corp. Domeks Makine Ltd. Sti Enercon Industries Engineered Machinery Group Inc. Er-Bakir Elektrolitik Bakir Mamulleri A.S. Esteves Group USA Etna Products Inc. George Evans Corp. Fabritex Inc. Fine International Corp. Fisk Alloy Wire Inc. FMS USA Inc. Foerster Instruments Inc. Fort Wayne Wire Die Inc. Frontier Composites & Castings Inc. Fuhr GmbH & Co. KG Gauder Group Inc. GCR Eurodraw SpA Gem Gravure Co. Inc.

INDUSTRY NEWS

At the inauguration ceremony, Eng. Abdulaziz Al Namlah, chairman and the executive director of MESC’s Board, said that the plant will supply a steady supply of raw material that is up to the international standards. “With this upstream expansion, MESC will be adding an extra competitive advantage to its existing and potential customers globally,” he said. Part of the goal, Namlah said in the story, was for the company to gain wider brand recognition and to be seen in

the international arena as shifting from a local to a global player. He noted that MESC “has been at the forefront of manufacturing advanced specialized cables and has carved a niche for itself in this industry,” and that it has “created a world-class group positioned for further growth in the future.” Swiss-based Buss supplied and installed the production lines in the plant, which will source major raw materials from SABIC (Saudi Basic Industries Corp.) as well as other local companies, the release said. This expansion will provide additional employment opportunities and Saudi nationals will constitute more than 80% of workers in the new plant.

voestalpine acquires interest in CPA Filament GmbH voestalpine Austria Draht GmbH reports that it has expanded its activities in wire processing and acquired 54% of CPA Filament GmbH from the Steinklauber Group, a manufacturer of high tensile fine wire and cord. A press release said that “a new production facility for ultra high tensile fine wire (up to 0.08 mm) will be erected within the scope of a joint venture,” with operations beginning late this year. The project, it said, is being subsidized by the Styrian Business Promotion Agency (Steirische Wirtschaftsfördergesellschaft, SFG), thus “another future-oriented product will be manufactured in the Fürstenfeld region, which will add even more value to Styria as a prime business location.” It added that additional expansion stages are planned. The release said that voestalpine, a subsidiary of the voestaline Group’s Railway Systems Division, will provide its comprehensive expertise in materials and metallurgy technology and take advantage of synergy benefits from the proximity of its own steel plant in Donawitz with the collaboration with the Styrian Steel Association. Franz Kainersdorfer, head of the Railway Systems Division, said that the first expansion stage will provide annual capacity of about 3,000 metric tons, and will create about 40 new jobs in the region.

USITC nixes penalties for galvanized steel wire The U.S. International Trade Commission (USITC) has decided not to impose antidumping duties (AD) or countervailing

16 | WIRE JOURNAL INTERNATIONAL

SAMP SpA reports new official supplier At wire Düsseldorf, Italy’s SAMP SpA announced that it has chosen Izory ceramic products, manufactured by U.S.-based Refractron Technologies Corp., as its choice for ceramic drawing rolls and capstans. A press release said that SAMP chose Izory after extensive testing and positive customer feedback from companies that have been using Izory for years. It noted that the ceramics have a vital role as “the greatest percentage of interaction between the wire and the drawing machines is at the ceramic-wire interface.” The release said that Refractron will provide direct and indirect after-market sales support. “As an additional positive result of this cooperation agreement, existing SAMP machine owners will be able to upgrade to Izory material while enjoying excellent pricing. By producing compo-

E-mail: fukaseco@ja2.so-net.ne.jp http://www.fukase.co.jp

nents in large volume and eliminating third party mark-ups, customers will be able to increase quality at competitive pricing.” Customers, it said, can order spare ceramic parts from either SAMP or directly Izory ceramics will be used for SAMP from Refractron. technology.

Last 2 companies in South African wire mesh cartel fined $3.3 million The South African Competition Tribunal has imposed fines totalling US$3.3 million on the last two players in a wire-mesh cartel that was exposed in 2008. International Construction reports that Reinforcing Mesh Solutions (RMS) and Vulcania Reinforcing were ordered to pay penalties of US$686,000 and US$2.6 million, respectively, for their activity in the cartel, Vulcania

Sk Bldg #1 2-10-10 Makuhari-Hongo, 2- 6 -1 Hamada Mihama -Ku Hanamigawa-Ku, Chiba, Chiba Bhiba-Ken 261-0025, Japan 262-0033 Japan Tel : +81-43-276-0630 FAX Fax :81-43-276-0463 +81-43-276-0463 TEL 81-43-276-0630 JUNE 2012 | 17

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duties (CVD) against imports of galvanized steel wire from China and Mexico, finding that the U.S. industry was “not materially injured or threatened with injury by reason of imports of galvanized steel wire” from China and Mexico. The U.S. Commerce Department had claimed that Chinese galvanized steel wire had been sold in the U.S. at dumping margins from 194 to 235%, with countervailable subsidies between 19.06 and 223.27%.

INDUSTRY NEWS

from January 2006 to January 2008 and RMS from January 2004 to January 2008. In its ruling, the competition authority noted that the two companies, as the smallest players in the cartel, were not instigators and had been, in some respects, coerced to join, the story said. “As a result, the penalties were small-

er than they otherwise would have been,” it said, noting the following background information. The cartel was exposed in 2008, when Murray & Roberts, the owners of BRC Mesh Reinforcing, approached the South African Competition Commission and applied for corporate leniency. This was granted, and Murray & Roberts then singled out other companies that had been involved, including Steeldale Mesh, a subsidiary of Aveng, as well as RMS and Vulcania. In March last year, Aveng reached a US$18.7 million settlement with the South African Competition Commission over its role in the cartel. Features: In its report, the Commission notes that the agreements came about as a • Improved bow strength result of meetings that initially took (no holes) place under the auspices of an indus• Wire is out of the air try association, the South African stream Fabric Reinforcing Association, and • Bow shaped like a wing for later as a result of informal meetings improved aerodynamics involving some or all of the responand low cw factor dents. • Wear strip eliminated and replaced by wear bushings with windows for easy ABB wins Australian deal inspection and dust for power infrastructure cleaning ABB announced that it has won • Wear bushings can be orders worth around $100 million from changed while bow is Rio Tinto for 17 distribution substamounted on the rotor tions to support increased production at iron ore mines in Western Australia. Advantages: A press release said that ABB will • Lower power (amps) upgrade and install new power infraconsumption and reduced structure that will raise the voltage noise level of the existing distribution substa• Higher TPM - maintaining tions and increase the power supply to wire quality support the expansion of existing iron • Reduced elongation @ ore mines in the Pilbara region. The higher TPM project includes cables, electrical • Reduced bow breakage switch rooms, switchgear, power trans• Increased life on wear formers and ring main units as well surfaces reducing downcomponents such as SCADA (supervitimes and maintenance sory control and data acquisition), and • Wire breaks are contained protection and communication equipwithin the bow - extending ment compliant with the IEC 61850 bow life global standard. The technology, it said, will enable remote monitoring and control of power assets located at multiple sites, from Rio Tinto’s KEIR Manufacturing, Inc. Remote Operations Centre situated Phone +1.828.885.8444 in Perth, more than 1,000 km away. Phone USA 800.992.2402 ABB is responsible for the design, Fax +1.828.884.7494 engineering and supply of equipment E-mail: Sales@KEIRmfg.com needed for the upgrade and installaWebsite: www.BackBoneBows.com tion of new electrical infrastructure www.KEIRmfg.com

KEIR - BackBone™

US Patent #6,233,513 #5,809,703 and Other PatentsPending

18 | WIRE JOURNAL INTERNATIONAL

Flyer Bow

INDUSTRY NEWS

for the substations, the release said. The projects are scheduled for completion by 2013. It added that the company has previously successfully completed several similar projects for Rio Tinto.

Fujikura agrees to pay $20 million fine for past conspiracy to rig bids Tokyo-based auto supplier Fujikura Ltd. has agreed to pay a $20 million criminal fine and cooperate with the U.S. government’s ongoing investigation into price fixing in the industry. ToledoBlade.com reported that a one-count felony charge was filed in federal court in Detroit for the company’s involvement in a conspiracy to rig bids and fix prices for auto parts from January, 2006, to at least February, 2010. The conspiracy, it said, was related to Fujikura selling of automotive wire harnesses to automakers in the United States and elsewhere. The article said that Fujikura is the fifth Japanese company charged as part of the Justice Department’s investigation.

Tenova Core to supply furnace for Gran Blanc plant in Michigan Tenova Core, part of the Tenova Iron & Steel Division, reports that it recently was contracted to provide the turnkey supply of a STC® (Short Time Cycle) furnace at Grand Blanc’s wire processing facility located in Holly, Michigan. A press release said that the installation will mark the second STC furnace installation for the facility and startup is expected to take place by the end of 2012. The 26metric ton batch STC furnace will be used to spheroidize anneal and stress relieve Grand Blanc’s high-quality wire products, it said. Tenova Core will also design and supply the complete control and automation package that will feature a Level 1 and Level 2 control system, the release said. The energy efficient STC furnace provides low product variability and superior temperature uniformity, it said.

e -lin n i ble sonic a l i va ltra w a EO u o N hG W: wit ning NE a cle

Cable-recycling firm fined after its workers suffer lead poisoning A Canadian-based firm that recycles cable pleaded guilty to exposing workers to lead at Metal and Waste Recycling, one of its centers, and has to pay approximately £75,000 in fines and costs. Cabling Installation & Maintenance reports that Health and Safety Executive (HSE), Britain’s national regulator for workplace health and safety, investigated the recycler and described “an abysmal lack of care” at its facilities. It said that between October 2008 and July 2009, more than 90 workers were exposed to lead from stripping lead-sheathed copper cable that came from British Telecom after the carrier upgraded to fiber-optic cabling. Blood testing, the story, said found that 23 workers had JUNE 2012 | 19

INDUSTRY NEWS

significantly high levels of lead in their blood, including six who had symptoms of lead poisoning and two who required chelation therapy.

U.K. company reports completion of upgrade to its Hartlepool plant U.K.-based JDR Cables, a supplier of specialist high performance subsea cables and umbilical systems for the offshore oil, gas and renewables market, reports that it has completed a £30 million investment in its Hartlepool plant, bringing the company into a new phase of growth. A press release said that the investment in the plant, which employs 140 people from the local community, “demonstrates that JDR Cables is now firmly positioned as a world class supplier of subsea umbilicals and power cables to the oil, gas and renewables industries.”

BRICS business forum highlights a new submarine cable system A new submarine cable system was unveiled at the BRICS (Brazil, Russia, India, China and South Africa) Business Forum, held earlier this year in New Delhi, India. A press release said that the BRICS Cable is a 34,000-km system (two fiber pair, 12.8 Tbit/s of capacity) linking Brazil, Russia, India, China and South Africa, the BRICS economies, and the United States, noting the following. The network will interconnect with the WACS cable on the West coast of Africa, as well as with the EASSY and SEACOM cables on the East coast of the continent. This will give the BRICS countries immediate access to 21 African countries and give those African countries access to the BRICS economies. The projected ready-for-service date is in the second half of 2014. Over the last 12 months, the outcome of the market, traffic and feasibility studies carried out has demonstrated its commercial viability, showing a decent Internal Rate of Return (IRR) for this kind of project. During this period, the BRICS Governments and the telecommunications operators in these economies have been canvassed to gauge their support and the result has been resoundingly positive. The release said that, at the meeting, Andrew F.B. Mthembu, Chairman of i3 Africa and Imphandze Investments, the two South African entities promoting the project, presented the BRICS Cable, which was welcomed as a strategic project for the social and economic benefit of the BRICS countries. The BRICS Cable, it said, has been in the planning and feasibility stages since March 2011, a few months after South Africa joined the BRIC economic bloc. Currently, the BRICS countries are connected to each other via telecom hubs in Europe and the U.S., resulting in high costs, and in some instances on potential interception of critical financial and security information by non-BRICS entities, it said. “The recent discussions at the BRICS Business Summit concluded that a critical factor of success for the various initiatives relies on an advanced high-speed communication infrastructure. This also has to ensure high20 | WIRE JOURNAL INTERNATIONAL

capacity and direct connectivity between the BRICS countries to offer ubiquitous and reliable services.” A joint statement encouraged BRICS members to deepen the economic engagements among the BRICS countries, and all relevant BRICS stakeholders will work to ensure that the project is executed with speed, the release said.

Editor’s note/admission: who else did not know that BRIC was now BRICS? Okay, I’ll admit it, when I saw the last news item I came to a complete stop. BRICS? Was this a strange plural usage of the BRIC (Brazil, Russia, India and China) countries? At first I thought that maybe it was a creative marketing twist, because I had never heard of any official expansion. Since when was there an addition, and even if there were, why South Africa? Why not some other far more formidable country, such as Mexico, Turkey, South Korea and others? Was this recent news? Nope. A quick internet search turned up a Bloomberg story (Dec. 24, 2010) that said Chinese President Hu Jintao invited his South African counterpart, Jacob Zuma, to attend the BRIC’s third heads of state meeting in Beijing the next year as a member. Zuma was at that summit, and the country was also represented at subsequent BRICs meetings in France (Nov. 3, 2011) and India (March 29, 2012). For the record, the person who coined the BRIC acronym, Goldman Sachs’s Jim O’Neill, made it clear in an interview this year with Mail & Guardian that he did not favor BRICS. “It’s just wrong. South Africa doesn’t belong,” he said, noting that South Africa is not close to being a top 20 global economy, and that Nigeria, while not perfect, would have been a better choice for the continent. He suggested that South Africa was chosen for its potential as a gateway to Africa. There was on-line discussion as to whether the BRICS would further expand and outgrow the name and whether it would become more activist in its goals, and that’s the organization’s right, only in this case it would further alter what was once a perfectly good moniker. — WJI editor Mark Marselli

news in brief U.S.-based Northwire, Inc. (NWI), announced that its facilities have been certified to ISO 13485:2003, the quality management standard for the design and manufacture of wire, cable and assemblies for medical devices and related services to include contract manufacturing and original design manufacturing. The addition strengthens Northwire’s ISO 9001 certification and bolsters the company’s new customer-driven line of contract manufactured products engineered from concept-to-completion by NWI’s Lab 360. “Northwire’s ISO 13485 certification advances our steady growth in life science markets, and expands NWI’s Lab 360 engineering model that rapidly delivers customers’ require-

INDUSTRY NEWS

ments from concept-to-completion,” said Northwire President Michael Conger. ... Fortune magazine has published its 2012 most admired companies list, and worldsteel reports that nine out of the 10 companies in the metals industry category are members of the organization. ArcelorMittal, which tops the list of worldsteel members, came in second after Alcoa. The other worldsteel members in the top 10 are POSCO, Nippon Steel, ThyssenKrupp, Nucor, TATA Steel, Baosteel Group, JFE Holdings and Kobe Steel. The rankings are the result of a survey that asks business people to vote for the companies that they admired the most. Fortune magazine has been publishing these rankings since 1997. ... Umicore reports that Chinese Vice Premier Li Keqiang recently visited the company’s recycling plant in Hoboken, Belgium, as part of a two-day official visit to the EU Umicore CEO Marc Grynberg welcomed Keqiang, whose responsibilities include China’s

From l-r, Umicore Chairman Thomas Leysen, China VicePremier Li KeQiang, Prince Philippe and Umicore CEO Marc Grynberg at the company’s recycling plant in Belgium. includes economy and climate change. He was in Belgium to meet with senior figures in both the European institutions and Belgian government, and toured the facility along with HRH Prince Philippe of Belgium. Umicore, the report said, has an extensive presence in China, including nine industrial plants, five of which are joint ventures with Chinese partners. It also has four commercial offices in China as well as a regional headquarters in Shanghai. Umicore, whose product lines include wire, employs more than 2,000 people in China. ... C&M Corporation, a vertically integrated manufacturer of bulk cable, coil cords and cable assemblies, reports that its assembly facility in Sonora, Mexico, has achieved ISO 13485:2003 certification. C&M de Mexico, which manufactures for a global customer base, has 18,000 sq ft of manufacturing space and more than 125 employees. It produces coil cords and assemblies, molded and mechanical, using a LEAN manufacturing focus and cellular manufacturing concepts. The company has also been certified to ISO 9001:2008 by QMISAI Global, the registrar who performed the audits.

JUNE 2012 | 21

ASIAN FOCUS

ASIAN FOCUS 2 steel giants find that progress can be hard to achieve in India Seven years ago, both Mittal and POSCO had each announced major steel projects that appeared would dramatically bolster the steel industry in India. But hopes from those multi-billion dollar projects have largely remained on hold, as the plans have been held in check a major way. Lakshmi Mittal, ArcelorMittal’s chief executive, recently said that the company’s plans are going nowhere at this time. “We continue to experience difficulties in India. My belief is that the Indian projects may not see the light for five to 10 years,” he was quoted by Reuters as saying at the company’s annual shareholder meeting. He later told Reuters that he may have overstated the delays, but that it was likely to be at least a few years. The world’s largest steelmaker, ArcelorMittal wants to build steel plants in the states of Jharkhand and Odisha, the latter formerly known as Orissa, both with capacities of up to 12 million metric tons a year, but the plans have been delayed by local opposition and problems with land acquisition, the article said. It noted that the company has also

Activists protesting against POSCO’s project in 2011.

signed an agreement with the state of Karnataka to build a steel plant on a greenfield site with a capacity of 6 million metric tons. “Many industrial ventures in India are mired in a bureaucratic morass that dulls the country’s investment appeal and slows growth of Asia’s third largest economy,” the story said, citing obstacles such as tardy environmental clearances and complex land acquisitions, as well as populist policies that often deter development. ArcelorMittal is focusing its investments on Canada, Brazil and Liberia, but in India, it has made little headway with three prominent steel projects. “Capital is scarce, and

in India for our projects, [the] process of approvals is still going on,” Mittal previously told reporters. “I feel bad; I feel a bit concerned” about delays in the steel projects. There’s no way I can ignore India, and I am not giving up on these projects.” Not having much more success is South Korea’s POSCO, which The New York Times reported in March had appeared ready to move forward as a year earlier it had received approval from the Indian Ministry of Environment and Forests for its proposed $12 billion steel plant to be build in the eastern state of Odisha, which is rich in minerals like iron ore. However, India’s National Green Tribunal suspended that environmental approval and directed regulators to review the project again. The project, first proposed about seven years ago, has faced stiff opposition from environmental activists and forest tribes in Odisha. The article said that the decision was likely to further shake foreign investors’ confidence in India, which has recently pushed or enacted proposals seen as hostile to outside business interests. It noted that the Finance Ministry had recently proposed changes to tax laws that could leave multinational companies and financial investors on the hook for billions in back taxes that they had not anticipated. “In the POSCO case, the two-member tribunal ruled that Indian regulators had approved the project without fully taking into account its effect on its surroundings on the eastern coast of India,” the article said. “The environmental impact study for the plant, for instance, was based on just the first phase of the proposed plant, which would involve production of four million tons of steel a year, even though all other facets of the plan took into account the fact that the company would eventually expand to a capacity of 12 million tons.” The decision, the article said, highlights the difficult balance India is trying to strike between industrialization and the environment. The country has delayed or canceled several large industrial, infrastructure and real estate projects in recent years on environmental grounds, often after years of acrimonious legal disputes. Indian environment minister, Jayanthi Natarajan, said the government would have to study the decision before deciding what it would do next. She said her ministry had followed a “very strict and very, very transparent procedure,” according to the Press Trust of India. Plans call for the company to commission the plants in Jharkhand and Karnataka by 2015, while the Odisha project would go on-stream a year later, Minister of State for Steel A. Sai Prathap said in a written statement. In it, he said, “India’s economy is expanding by more than 6% a year, but that is down from highs of about 8% in recent years. More foreign investment could help India boost growth to previous levels and create jobs.”

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

22 | WIRE JOURNAL INTERNATIONAL

Belgium’s NV Bekaert SA and Malaysia’s Southern Steel Berhad (SSB) have created a partnership to combine their steel wire and ropes activities in Southeast Asia to better serve customers in the growth markets of the Association of Southeast Asian Nations (ASEAN). A press release said that the resulting joint venture, which will be known as Bekaert Southern Wire Pte Ltd., represents an enterprise value of about US$63 million. The venture will be 55% owned by Bekaert and 45% by SSB. Bekaert “will bring in the galvanized wire activity platform, which today is part of PT Bekaert Indonesia,” while SSB “will inject its interests in Southern Wire Industries Malaysia Sdn Bhd (SWI) and Southern Speciality Wire Sdn Bhd (SSW) into the joint venture.” Representatives for the two companies said the deal will benefit both manufacturers. “Developing a partnership with Southern Steel will create

a production and sales platform for our joint wire and ropes activities in Southeast Asia that responds to our ambitions for growth in the region,” said Henri-Jean Velge, Bekaert Group Executive Vice President Wire. “This joint venture will enable us to leverage our mutual capabilities and technological expertise, for the benefit of the new organization and of its customers,” said Dr. Tan Tat Wai, Group Managing Director of SSB. The activities of SSB’s wire operations encompass two production plants in Malaysia; one in Shah Alam and one in Ipoh, the release said. The product portfolio, which includes a wide range of galvanized and specialty steel wires and ropes, complements Bekaert’s existing product range of steel wires manufactured at its wire plant in Karawang, Indonesia, it said. The transaction is expected to be completed in the third quarter of 2012. The business will have its headquarters in Singapore.

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ASIAN FOCUS

Bekaert and Southern Steel announce formation of joint venture

PEOPLE

PEOPLE Citing extensive growth, P & R Specialty, Inc., reported three additions to the company’s leadership. Pat Kiernan, vice president, operations, will oversee the company’s manufacturing operations. He has more than 20 years of experience in the manufacturing industry, most of it from New United Motors Manufacturing, Inc., a joint venture between Toyota and General Motors, where he served as assistant general manager. Vince Reidy, vice president, sales, will oversee the sales and marketing strategy development and manage all sales functions. He has held senior level executive sales and marketing positions in the document, IT and packaging industries. Mike Koon, vice president, finance, will manage the company’s financial functions. He has more than 30 years of experience in the manufacturing industry and a solid record of accomplishments as a business’s CFO. Based in Piqua, Ohio, USA, P & R Specialty, Inc., manufactures fiberboard spools, plastic spools and plywood reels for multiple industries.

ence in the wireless industry, including with Andrew Corporation, Allen Telecom and Motorola. He has a B.S. degree in electrical engineering from Brown University and master’s degrees in electrical engineering from the University of Michigan and business administration from Northwestern University. Ric Johnsen will continue as senior vice president, broadband, Morgan Kurk leading the business responsible for serving cable multisystem operators and other broadband network providers around the world. He joined CommScope in 2010, previously holding senior management positions with Alcatel, OFS and AllOptic. Based in Hickory, North Carolina, USA, CommScope, Inc., is a global supplier of infrastructure solutions for communications networks.

CommScope, Inc., has reorganized its business unit management structure around its three key customer segments— Enterprise, Wireless and Broadband—and named leaders for each. Kevin St. Cyr has joined CommScope as senior vice president, enterprise solutions. He will lead engineering, R&D and product line management for the segment, which serves business enterprises around the world. Most recently he was at Berk-Tek, where he was president since 1998 and senior vice president of marketing and sales from 19961998. He previously worked for Champlain Cable, a subsidiary of Huber + Suhner, and General Electric. He holds a B.S. degree in plastics engineering from the University of Lowell and a master’s degree in business administration from the Pennsylvania State University. Morgan Kurk, who previously headed CommScope’s Enterprise segment, has been named senior vice president, wireless. He will have responsibility for product line management, engineering and R&D for the segment that serves wireless operators and OEMs globally. He has more than 15 years of experi-

Hassan Gangji has joined DavisStandard, LLC, as chief procurement officer, responsible for providing strategic direction for the company’s global supply chain function including sourcing, supplier quality, procurement, inventory management and order fulfillment. He has more than 11 years of industry experience managing supply chains, most recently for ATCO Hassan Gangji Structures and Logistics. Prior to that, he was director of supply chain at Husky Injection Molding Systems. He holds a B.S. degree in mechanical engineering from the University of Southern California, and holds an MBA degree from the Rotman School of Management at the University of Toronto. Based in Pawcatuck, Connecticut, USA, Davis-Standard, LLC, offers a wide range of extrusion technology for sectors that include wire and cable.

OBITUARY Richard “Dick” Steven Clark, the founder and president of Laurel Wire Co., died on Dec. 15, 2011, in front of his fireplace in his home in Plainville, Connecticut, USA, at age 57. Clark started in the wire industry right out of high school, working in the heat treating department at Wallace Barnes (which is now Associated Spring). He then went to work as the production planner at Stanley Industrial Components, and in 1977 he became the general manager of Colonial Spring Company. In 1978, he became the warehouse manager at Uddelholm Steel, where he stayed until he and a partner formed Laurel Wire in 1983. The business started

24 | WIRE JOURNAL INTERNATIONAL

out of his garage on Laurel Street and he expanded the business to its current location in the late 1980s. Survivors include his wife, Lucy Cocozza-Clark; children Jessica and Christopher Clark; a sister, JoAnn Snow; a brother, Walter Clark; as well as a grandchild, and his past and current “Laurel Wire family” of Kelly, Jackie, Brian, Sara, Jim and Shane, who say that “he was the best boss in the world (and he was!).”

Richard “Dick” Steven Clark

David Cole has been named sales manager of Metalube Ltd., responsible for the company’s European sales. He has more than 20 years of experience within the tube and wire drawing lubricants industry, and was described as having “a wealth of knowledge and expertise” that will make him a valuable addition to the company. Based in Manchester, U.K., Metalube Ltd. specializes in tube and wiredrawing lubricants, protective greases for overhead conductors and metal cutting fluids. Berk-Tek has promoted Phil Radics to vice president of sales. He has been with the company for 14 years, most recently serving as director of new business development. He has previously served as marketing programs manager, regional sales manager and strategic market manager, and was described as “a major contributor to Berk-Tek sales and product initiatives, such as preterminated fiber-optic cable assemblies, alliance and contractor warranty programs, OEM sales and LAN global harmonization.” Prior to joining Berk-Tek, he worked for JDS Uniphase and IBM. He holds the RCDD designation from BICSI and is a graduate of California State University Fresno as well as the U.S. Army Officer and Communications Schools. He will report to company President Paul Trunk. Based in New Holland, Pennsylvania, USA, and a business unit of Nexans, BerkTek manufactures high-performance copper and fiber optic cable in North America.

across many industries. He was described as a proven executive leader with international experience and strong business acumen. He replaces Brian Bukovec, who is departing Radix after a distinguished 36-year career to pursue other opportunities. He was appointed President and COO in January 2011 after the death of Chuck VerMerris, former owner and CEO. Based in Cleveland, Ohio, USA, Radix Wire Company is a leader in the development and manufacture of high temperature wires and cables. Beta LaserMike reported two promotions. Stuart Manser has been named sales director for the Asia region, responsible for overseeing the Asia-Pacific sales strategy and implementation, as well as working with the company’s channel partner network to increase its presence and activity in China, Japan, Korea, and South East Asia. Those responsibilities had been handled by company President Ken Wright. Manser joined the company in 1990, and has served as the U.K. and Ireland Stuart Manser sales manager, general manager of Beta LaserMike Ltd. (U.K.) and, most recently, as western USA district sales manager. Prior to Beta LaserMike, he was an engineering metrologist for Rolls-Royce Aero Engines. He holds professional qualifications in both mechanical and production engineering. Ethem Erdas has been named western USA district sales manager, and will be based in California. He has been with the company for 22 years, holding positions that include final test group leader, service manager for European operations, and most recently, product manager for wire, cable and extrusion markets. A native of Turkey, he earned his B.S. degree in electronics and computer engineering technologies at the University of Dayton. A WAI member, he has also presented technical papers, Ethem Erdas including a Silver Certificate award winner presented at the Association’s 2010 International Technical Conference in Monterrey, Mexico. Based in Dayton, Ohio, USA, Beta LaserMike is a global provider of precision measurement and control solutions.

James Schaefer, a chemical engineer who holds an MBA degree from Harvard Business School, has been named the new president of Radix Wire Company. His career began at Exxon Corporation, and he has served in a variety of senior executive and manufacturing positions with BP Oil, Ferro Corporation and M.A. Hanna, among other companies

Send People items to editorial@wirenet.org. You are welcome to include a photo (jpg, 175kB to 1-2MB).

JUNE 2012 | 25

PEOPLE

Lars Fagerholm was appointed CEO of the Maillefer group. He has broad experience from several management positions, specifically from his extensive career with Albany International, a U.S.-based global supplier of products to the pulp and paper industry. His background includes internaLars Fagerholm tional business structures, technical and manufacturing management. He succeeds Peter Roos, who stays on with the company until the end of this month. Based in Europe, the Maillefer group is a global supplier of extrusion technology.

FIBER WATCH

FIBER WATCH Optical fiber transmits 100 terabits per second (sorry, that’s not enough) There seems to be no end line in sight when it comes to transmission capabilities for optical fiber. Recent milestone transmissions of 100 terabits per second are most commendable, but industry experts believe that such staggering capacity still won’t be enough for the long run. Earlier this year at OFC/NFOEC 2012, engineering members from IEEE focused on identifying areas in the optical fiber and telecommunications industry that could be affected by advances in the consumption of data and the requirements for increased speed, a press release said. While 100 terabit data transmission has been achieved, the outlook was that, “based on traffic growth trends, fiber capacity will need to stretch even further to meet the escalating demand being created by enterprises and consumers around the world.” “Current data center technologies and architectures will be unable to cope with the rapidly increasing traffic volume, and will have to evolve to accommodate higher bandwidth and better energy efficiency,” said Dr. Leonid Kazovsky, an IEEE Fellow and professor at Stanford University. “At the same time, the rest of the network will need to evolve as well. So, we must look into future technologies, architectures and infrastructure options that can effectively create ‘express lanes’ for large amounts of traffic, the same way express lanes on our highways allow high occupancy vehicles to get to their destinations more quickly.” In a story about the needs, the release cited experts who predicted that the dramatic rise in the viewing and access of video content will be a main driver of optical fiber innovation and deployment in the next several years, not only in the provisioning of the network – but within the data center itself. “The emergence of new data centers, changes in peering arrangements and the rise of new Over-the-Top (OTT) players are creating reduced predictability of traffic in the network,” said Ori Gerstel, an IEEE Fellow and principal engineer at Cisco in Israel. “Video content provided by OTT providers like YouTube, Netflix, and Hulu and peerto-peer file sharing networks dramatically affect traffic patterns and are therefore driving the need for a more agile and simplified optical fiber network.” The release cited other engineering experts who identified bandwidth demands of consumers and enterprise as the priority issue for optical communications engineers to address. “Though fragmented right now, we see next generation

26 | WIRE JOURNAL INTERNATIONAL

optical access driving the network consolidation of residential and business services,” said Jun Shan Wey, an IEEE Senior Member and standards manager, Industry Environment, CTO Office, at Nokia Siemens Networks. “From a global perspective, Asia is really driving this. Taiwan’s government for example, is talking about giving people 1G broadband access in their homes, access which had only been previously offered to businesses.” Dr. Kazovsky and other industry leaders believe that one of the most important topics for attendees of the OFC/NFOEC to address is access networks, and the integration with wireless networks. “Some years from now, the role of copper will be much smaller than it is today, and future networks will rely mostly on fiber and wireless technologies. That is more or less a given,” said Dr. Kazovsky. “But how that will come and how optical and wireless technologies will be integrated in the future remains an open question. Substantial investments will be made in these fields, and this is an area that needs to be watched very closely. One thing is clear: companies that make the right bet will flourish.”

Saudi Telecom plans to connect 500,000 homes with optical fiber Saudi Telecom Co. (STC) aims to connect 500,000 homes in the Kingdom of Saudi Arabia with optical fiber for high-speed broadband, but a lack of spectrum is limiting the adoption of next-generation mobile services, a top executive said. A Reuters article said that Saudi Arabia’s 26.5 million people had 1.95 million fixed broadband subscriptions at the end of 2011, according to the telecoms regulator, while of these only 18,500 are high-speed fiber-to-thehome (FFTH) connections, Informa Telecoms and Media estimates. “With FTTH, we’re looking to pass 500,000 homes by the end of this year and go up to 2 million in 2013,” Jameel Al-Molhem, Saudi Telecom chief executive for Saudi Arabia, told a conference in Dubai. Slumping margins on conventional voice calls have prompted STC and Mobily and Zain Saudi to bet on soaring demand for broadband to bolster income, the article said. That strategy, it said, seems to be working as STC’s first-quarter profit rose 60 percent, while its mobile broadband revenue was up 145 percent, Bahrain’s Securities & Investment Co. (SICO) wrote in a note. Potential further growth is huge, with only 41 percent of Saudis using the internet at the end of 2010, according the International Telecommunications Union’s most recent data. Analysts say this relatively low penetration, which is barely half that of the UAE, is partly due to a lack of fixed-line infrastructure in the vast kingdom that is more than twice the size of France and Germany combined.

EU imposes preliminary AD duties on stainless steel fasteners from India

Tornado leads to cancellation of the 2012 All American Fastener Show

The European Union, which found that EU producers have suffered from unfair competition, has imposed preliminary tariffs as high as 16.5% on screws and bolts from India. A Bloomberg report said that the duties will apply to punish Indian manufacturers of stainless steel fasteners that include Lakshmi Precision Screws, Ltd., â&#x20AC;&#x153;for receiving trade distorting government aid.â&#x20AC;? The levies, it said, range from 3.2% to 16.5%, depending on the Indian exporter. Lakshmi Precision Screws faces a 13.6% duty. It noted that the duties â&#x20AC;&#x153;are for four months and may be prolonged for five years.â&#x20AC;? In the report, the European Commission found that, â&#x20AC;&#x153;EU producers such as Italyâ&#x20AC;&#x2122;s Bontempi Vibo SpA and Franceâ&#x20AC;&#x2122;s Ugivis SA suffered material injury as a result of subsidies to Indian competitors.â&#x20AC;? The trade protection is the preliminary outcome of an inquiry that the Commission opened last May after a subsidy complaint by the European Industrial Fasteners Institute on behalf of producers that account for more than 25% of EU output of stainless steel fasteners, it said.

Organizers of the All American Fastener Show report that the tornado that struck Branson, Missouri, forcing the cancellation of the May 17-18 event at the Hilton Branson Convention Center Hotel, will not prevent the eventâ&#x20AC;&#x2122;s return in 2013, although a new location is planned. At its website, a letter from organizer Heidi Volltrauer wrote. â&#x20AC;&#x153;We are currently planning the 2013 All American Fastener Show and are excited to inform you we are relocating the 2013 show from Branson to a metropolitan location in the Midwest (still in the middle of the U.S.). By moving the show to a larger city with better connecting airline flights, we trust it will be easier for everyone in the fastener industry to attend the 2013 show. As soon as plans are finalized, we will contact you regarding the location and dates for the 2013 All American Fastener Show.â&#x20AC;? Volltrauer can be contacted at tel. 877-865-8237 or by e-mail at info@allamericanfastenershow.com.

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28 | WIRE JOURNAL INTERNATIONAL

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I renew my WAI membership to stay on top of industry trends and new technology. Q: Why did you join WAI? A: To connect with people in our industry and to promote our products and services.

Q: What does your company do? A: RichardsApex Inc. supplies wiredrawing and rolling lubricants to the wire and cable industry.

Q: How did you get involved in the wire industry? A: I was looking for a challenging and exciting technical sales career...and I found it!

Q: What do your co-workers say about you? A: They think I am honest, dependable, and always asking questions.

Q: What did your most valuable WAI contact help you do? A: All of the people I have met have provided me with valuable information.

Andrew P. Helffrich

Q: Who is your mentor? A: My brother. He set a great example; he taught me hard work

V.P. Sales | RichardsApex Inc. Member Since: 2005

and fairness.

Q: What do you do for leisure? A: When I’m not at work you can find me on my bike cycling

Meet Andrew P. Helffrich. One of WAI’s worldwide members. One compelling story.

down some country road or spending time with my family.

Andrew finds connections. He knows without them life can be a slippery slope. Not an advantage unless you happen to work for a leading lubricant manufacturer, which he does. Even so, when he took the technical sales challenge at RichardsApex he also opted to join WAI. WAI is his stabilizing agent—insurance that he’ll be in the right company when selling for his company. He’s optimistic and diligent. His middle initial either stands for Postive or Persistent. Andrew skirts shortcuts. Except on his off-days when he knows which country roads will take him home.

Q: Where would you most like to visit? A: China, to see the country and learn about its history and culture. Q: What is something almost no one knows about you? A: I made a hole-in-one back in high school. Q: Who is the most famous person you have met? A: Zsa Zsa Gabor. We met once on a flight to Spain. She helped me get through customs!

Q: What is lifelong ambition? A: To learn how to play the piano and get my pilot’s license.

Honest | Diligent| Dependable | Wheeling, Not Dealing | Inquisitive | Sticktoitive | Curious | Connected | Fair And he knows that while networking yields connections, buffers are vital. An axiom for both wiredrawing and airline travel. Leave it to him, and a dazzling movie star, to keep the line rolling through customs in Spain. We’re curious whether the diamonds were a distraction? We know that the volcanic ash cloud once was. As far as the extra time in Europe? Well, for such a hard-working fellow, we’d call that fair.

Q: What is your best industry related travel story? A: Like many others in the industry, it invloved a volcanic ash cloud and a high-speed train. It meant three extra days in Europe!

Q: What is your greatest accomplishment? A: All of the long lasting relationships I have made through WAI.

MNEMONIC TIP: ANDREW HELFFRICH. STICKTOITIVE, NON-STICK SALES.

Meet your peers. Achieve your goals. Join WAI’s community at www.wirenet.org. The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

WAI NEWS

WAI

NEWS

June 21 WAI webinar: flame-retardant polymers for wire & cable applications Dr. Sitaram Rampalli, president of and principal consultant at U.S.-based Polyplast Consultants International (PCI) Inc., will present a webinar, Flame-Retardant Polymers for Wire and Cable Applications, on Thursday, June 21, 2012. Rampalli notes that his hour-long webinar, from 11:00 am to noon EDT, will focus on how to choose the proper flameretardant polymers, using a systematic approach to the selection and evaluation of polymers for a variety of applications. He provided the following observations. The increased use of wire and cable products in a variety of novel applications, as well as regulations on the fire, smoke, and toxicity of these products continue to drive the popularity of flame-retardant polymers. But, as manufacturers examine how this technology can meet their specific demands, they have found there is nothing like a “one-size-fits-all” formula for selecting flame-retardant

30 | WIRE JOURNAL INTERNATIONAL

polymers for wire and cable applications. Variables such as the type of cables, where and how they are used, fire codes, and disposal are all issues that need to be considered. The webinar will address the following topics: • Various types of flame-retardant Dr. Sitaram polymers such as halogenated and Rampalli non-halogenated types, characteristics, and their relative advantages and disadvantages; • The selection process for application to wire and cable products; • A brief overview on the test methodology involving fire, smoke, and toxicity; • Regulations governing flame-retardant wire and cable products; and • Environmental and disposal issues. PCI is a technical and scientific consulting firm specializing in assisting companies in materials selection and evaluation. Dr. Rampalli previously spent 25 years at Andrew Corporation (now a unit of Commscope, Inc.) in polymers and plastics R&D for wire and cable, connector, and anten-

WAI NEWS

na applications. He has developed and taught graduate level courses in polymer characterization and analysis and coatings technology at the Illinois Institute of Technology and DePaul University. He has published several technical papers and accumulated patents on new cable designs. He holds a master’s degree in polymer science from the University of Akron and a Ph.D. degree in chemistry from the Indian Institute of Technology, Bombay, India. He presented a two-part polymer webinar for WAI in 2010. Webinars are free for WAI members and $55 for nonmembers. For further information, contact WAI Director of Education Marc Murray at tel. (001) 203-453-2777, ext. 121, or mmurray@wirenet.org.

Interwire 2013 update: more exhibit space contracted for trade show WAI’s sales department reports that, as of press time, approximately 77% of the available floor space has been sold for Interwire 2013, to be held April 23-25, 2013, at the Georgia World Congress Center. To date, 163 booths totalling 80,700 sq ft of exhibit space have been assigned, a figure that represents 77% of the overall inventory of 104,600 sq ft that is slated for the show floor at the event. The goal is to build upon the success of the 2011 staging of Interwire at the Georgia World Congress Center. Total attendance there was 4,022, up 19%

Activity at Interwire 2011, which saw more than 4,000 attendees. from the 2009 event in Cleveland, Ohio, USA. Attendees came from 53 countries, and more than 400 companies were represented on the exhibit floor. Booth space will continue to be allocated on a first-come/first-served basis. For more details on exhibiting, contact the WAI’s sales staff at sales@wirenet.org, or call tel. 203-453-2777.

JUNE 2012 | 31

CHAPTER CORNER

CHAPTER CORNER Golfing alert: last call for the WAI Midwest Chapter’s June 22 tourney The Midwest Chapter has issued a “call for golfers” to take part in the chapter’s 10th Annual Golf Tournament, to be held on Friday, June 22, 2012, at the St. Andrews Golf & Country Club, West Chicago, Illinois. Event organizer Kevin Sopczak, ShapedWire, is encourag-

ing golfers to sign up now for the event, which will, besides the golf, offer great opportunities to meet up with friends and industry colleagues. Sopczak said that some sponsorship opportunities are still available. He can be contacted at kswire@aol.com, or contact WAI’s Steve Fetteroll at tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.

Now is the time to plan for the Poland chapter’s September technical seminar

Bragging rights will be at stake this month at the Midwest Chapter’s 10th Annual Golf Tournament, to be held June 22 at the St. Andrews Golf & Country Club.

32 | WIRE JOURNAL INTERNATIONAL

Potential attendees of the Poland Chapter’s Sept. 20-22 technical conference should act now if they wish to be at the event to be held at the Antalowka Hotel in Zakopane, Poland. This year’s event will mark the fourth such staging by the chapter. Chapter President Jan Pilarczyk said that participants will include presenters of invited papers and attendees from some 40 drawing plants and institutions from Poland, Italy, Germany, and Czech Republic, among others. The program, “High Carbon Steel Wires and Ropes: Technology and Properties,” will include the presentations, tabletops, an awards ceremony, and more. For more information, contact Jan Pilarczyk by e-mail at lj.pilarczyk@interia.pl.

insight beyond numbers

6HQDÄ Ä"@AKDÄAsia 2012 27 - 28 November 2012, Shanghai, China

Bringing together senior executives from across Asia’s cable industry, Wire & Cable PF>ÐTFIIÐAFP@RPPÐ>KAÐBPQ>?IFPEÐMOLiQ>?IBÐDOLTQEÐPQO>QBDVÐMI>KPÐ>KAÐFKSBPQFD>QBÐ QEBÐKBTÐQVMBPÐLCÐMLTBOÐQO>KPJFPPFLK Ði?OBÐLMQF@Ð>KAÐPMB@F>IQVÐ@>?IBÐQLÐEBIMÐ PF>Ð based cable makers prioritize their R&D and investment plans. This will be the complete networking and information gathering platform for Asia based cable makers looking to achieve success in competitive global markets.

Latest material applications and technology

New energy cables and power systems in China

Copper price volatility and hedging techniques

Process and manufacturing developments in speciality cables

Cables and the environment

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Green cable development in Japan and worldwide

"NM×QLDCÄ2OD@JDQRÄHMBKTCD Koo Cha-yol, CEO, +2Ä"@AKDÄ Ä2XRSDL Ding Shanhua, Chairman & General Manager, )H@MFRTÄ2G@MFRG@MFÄ"@AKDÄ&QNTO Wang Chuanbin, Chief Technical Director, Far East Cable Co., Ltd. Philip Radbourne, Director, 6HQDÄ Ä"@AKD ÄÄ(MSDFDQÄ1DRD@QBG

Carlos Risopatron, Head of Environment and Economics, (MSDQM@SHNM@KÄ"NOODQÄ2STCXÄ&QNTOÄ ("2&

Dr. Yang Risheng, Executive Representative to Chairman, )H@MFRTÄ9GNMFSH@MÄ3DBGMNKNFXÄ"N Ä +SC Ä 933 Ä

Mark Loveitt, Secretary General, (MSDQM@SHNM@KÄ6QNTFGSÄ"NOODQÄ Council

Chen Peiyun, Chief Engineer, Qingdao Hanhe Cable Co., Ltd.

You Weiren, Executive Director, 9GNMFSH@MÄ"NMCTBSNQÄ3DBGMNKNFXÄ 1DRD@QBGÄ(MRSHSTSD

Susanna Keung , Statistical Analyst/Economist, (MSDQM@SHNM@KÄ"NOODQÄ2STCXÄ&QNTOÄ ("2&

Find out more: Website: www.integer-research.com/wac-asia | Email: conferences@integer-research.com

FEATURE The Chinese success story in manufacturing has been stunning in scope the last three decades: No. 1 in seemingly countless categories, from the production of steel and beer to IPOs and purchases of Rolls Royces and most likely the number of headlines of new manufacturing ventures.

It is hard to envision China losing its collective steam, although in the 1970s-80s Japan was poised to dominate the world with its technology, a story that along with the country’s economy lost its way. The circumstances that have made China’s success possible are not constants, but while there are challenges, from inflation and environmental woes to raw materials and energy, it would take a brave person to bet against China’s capability to sustain its growth. This feature includes brief outlooks for steel wire and cable, an interview with an expert on China, a look at one of the keys to the country’s success as well as its climb on the highest profile hallmark category that exists.

Individual attributes of China success remain party-line based Perhaps the most telling indicator in the Chinese success story is not its record production levels but a single statistic: China’s percentage of GDP from the private sector went from 1% in 1978 to 70% by 2005. How could that have been possible? How does a mammoth country undergo such a dramatic shift from government controlled-companies to private enterprise? Officially, Chairman Deng Xiaoping ushered in the change, and other leaders followed, but this change in direction required millions of people to implement on a wide range of management levels. Dr. George T. Haley (see p. 38), an expert on emerging markets in China, said that realizing ambitions in China takes initiative and tenacity, but those attributes must fall in line with the Chinese Communist Party (CCP). “The thing to remember about Chinese initiative, tenacity and realization of ambitions is that whenever there is any conflict it is CCP and government initiatives that will be undertaken, CCP and government tenacity that will rule the day and CCP and government ambitions that will be realized.” In other words, individual effort can and has achieved great results in China business, but those initiatives had to be done along the leaders’ game plan. “In my view the one key individual is former Premier Zhu Rongji,” Haley told WJI. “He developed the policy position exemplified by the statement, ‘Grasping the big, letting go the small.’ Through this policy he pushed through the admission that the CCP simply could not control everything and that as it could not control everything, it should focus on controlling strategic companies, 34 | WIRE JOURNAL INTERNATIONAL

industries and technologies, and let go of the rest for private parties to control. I think people and experts that point at the private sector and argue that it has any kind of control over the economy are the same people who envision Chinese communism as being akin to Soviet communism. They are now assuming that China’s capitalism is the same as American capitalism, and nothing could be further from the truth. “Most Americans think of Chinese communism as Soviet communism, but it is actually more an evolution of Confucian political and economic theory than an imposition of traditional European communism on Chinese society,” Haley said. “For example, Confucius would have approved wholeheartedly of the suppression of the Tiananmen Square protests. His position was that only members of a government had the right to criticize the government or its policies. The merchant class (business people and investors) was the lowest class in society. Westerners often think of Confucius as similar to Aristotle or Plato, while Confucius’ belief was a philosophy of power and its use that was more akin to that of Machiavelli. He viewed the merchant class as performing many of the same functions as the government and a potential challenge to the ruling prince, hence his insistence on persecuting it. Thus, Confucius would be pleased with the business success, but he would never want that to undercut the authority of its true leaders. I think that such control in the years to come will lead to increased internal conflict as the CCP moves to restrict the growing influence of the private sector.”

Chinese cablemakers: on the rise, but still a distance to go

WJI: Were you surprised by the results for Chinese companies on your most recent top 100 list of worldwide cable companies by revenues? Armstrong: We saw some of the leading Chinese companies, such as Far East Holding and the Wanada Group, on that list, but had expected to see more. The growth in China seems to have shifted inland, and there has not been enough consolidation to propel Chinese cablemakers further up the rankings. We do expect to see more Chinese companies consolidate and join the list, but we also see some of the leading European and North American producers acquiring Chinese cable companies, in specific market segments, such as specialty industrial, fiber optic cable and submarine power cable.

FEATURE

Chinese cable companies are a collective force when it comes to production of many cables, but in terms of the world’s leaders their presence in the top 100 companies has been limited by its focus on commodity products. Below, Josie Armstrong, business manger, wire and cable, U.K.-based Integer Research, which this November is putting on its first conference in Shanghai (see p. 36), shares her observations with WJI.

Leading Chinese cable companies in terms of 2010 revenues. Chart courtesy of Integer Research. WJI: How many Chinese cable manufacturers are now showing world-class capabilities? Armstrong: There are some, such as those I cited earlier, and we do expect to see more emerge as world-class, although it won’t be easy for them to become dominant. The industry has seen major changes in Europe, Middle East and North America, where the global financial crisis accelerated changes to cable companies, and as a result they have become nimbler than ever.

GIA Study: China steel wire demand will continue growth path A new study released by Global Industry Analysts, Inc., finds that, while the steel wire industry as a whole may be suffering, China is likely to fare quite well in the coming years. Below are some excerpts from the report, which can be bought as a whole or by individual chapters, at www.strategyr.com. Steel wire is highly dependent on the buoyancy of its end-use industries. Dynamics in the construction and automotive industries determine the demand for wire products worldwide, as they represent the key end-use markets for steel wire. The global steel wire market, estimated at US$21.7 billion in 2011, is projected to reach US$27.9 billion by 2017. Asia-Pacific represents the largest market for steel wire with 2011 sales estimated at US$13 billion. Factors such as new end-use products and applications; investments in infrastructure; price; new capacity and capacity utilization; tariff and non-tariff barriers; and research and development impact the worldwide steel wire industry. Chinese PC strand wire imports into the U.S. increased significantly during 2008-10 and domestic production declined drastically. In contrast, the Asia-Pacific markets fared well during the recession and suffered only marginal losses. Asia also recovered fast from the 2009 reces-

sion due to robust domestic demand. China’s steel industry is likely to experience a slowdown due to protracted delays in the expansion plans of its steel producers. The largest and fastest growing consumer of steel and steel products in the world, China offers the potential for future growth of the steel products market, in view of the steady economic performance. In 2012, the economy is likely to be affected due to stringent policies for the property market that can influence the steel industry. In the long term, the economy will maintain its growth path, driven by huge demand emerging from its massive consumer base and expansion of infrastructure. China’s most commonly exported products include wires, fasteners, wire mesh, fences, among others. The stainless steel wire industry primarily involves small and mid-sized manufacturers that largely focus on exports. Most Chinese production is low-end stainless steel wire products,and only a few large suppliers have the wherewithal and the machinery to manufacture high-grade wires. Hebei Anping County is recognized as the stainless steel wire hub, and accounts for about 80% share of the Chinese market, in terms of value sales. Anping County is another key manufacturing hub, with products being exported to North America, Asia, Europe, and the Middle East.

JUNE 2012 | 35

FEATURE

WJI: How difficult is it for the success Chinese companies have had for commodity cable products to translate to value-added products? Armstrong: Looking at the existing potential, there are perhaps around 400 Chinese companies, from a pool of 2,000 that have the potential to emerge. More than a

thousand companies make UL1xxx series cable in China, and have the capability to make more complex products, but the key questions is, will they be able to upgrade? There is a range of new areas that have become more important, such as renewables, and those involve complex issues, and we wonder whether Chinese producers can

Preview: Wire & Cable Asia 2012; Integer focus on growth strategy Citing the need by wire and cable makers for more information to help them plan their Asian strategy, U.K.based Integer Research is staging on Wire & Cable Asia 2012, its first-ever conference in China, November 27-28 in Shanghai. See p. 33. “Wire & Cable Asia will bring together senior executives of leading cable makers from Asia and beyond to discuss and assess strategy plans for sustainable growth in the face of fast growing demand from emerging Asian markets and markets for new-types of power transmission, fiber optic cable and specialty cable,” said a press release from Integer Research, which has offices in Beijing and Tokyo. As of presstime, confirmed presenters included keynote speaker, Koo Cha-yol, CEO, LS Cable & System; Ding Shanhua, chairman and general manager, Jiangsu Shangshang Cable Group; Wang Chuanbin, chief technical director, Far East Cable Co., Ltd.; Liu Young, vice president and chief engineer, Futong Group; and Dr. Yang Risheng, executive representative to the chairman, Jiangsu Zhongtian Technology Co., Ltd.; and two Integer Research representatives: Philip Radbourne, principal; Josie Armstrong, business manger, wire & cable; and Andrea Valentini, senior analyst. The conference, the release said, will identify key wire and cable market developments and business opportunities in the region to help Asia based cable makers determine their R&D and investment plans. New technologies and materials will also be discussed and assessed in order to help cable makers improve their manufacturing capabilities, and sourcing and marketing strategies. It described the conference as a “must-attend event for networking and information gathering for all cable industry professionals looking to achieve growth and success in the fast-growing and highly competitive Asian markets.” The release cited the following topics: • An overview of key market trends and demand forecast in the global and Asian wire and cable markets. • Development of new energy cable markets and power systems in China • Innovative R&D upgrades to meet the growing

36 | WIRE JOURNAL INTERNATIONAL

demand for specialty cables in China and Asia • Copper substitution and price volatility and minimizing price risk exposure in the global wire and cable industry • Business opportunities and challenges in Asian fiber optic cable markets • Latest material applications for advanced wire and cable products • “Green cable” development in Japan and worldwide • Environmental and quality control issues in the Asia wire & cable industry One of the presentations, “Understanding emerging ASEAN markets and identifying opportunities,” will be presented by Integer Research’s Astrid Tsai, senior analyst, wire & cable. Tsai said that ideal attendees would be senior executives/decision makers from suppliers, cable makers and end-users (utility companies and telecom companies) either based in Asia or looking to invest there. “One does not need to be from a multinational company. A medium-sized company looking for a partner in China or interested in establishing itself in China is our target attendee too.” One of the key elements to be focused on at the conference is power demand, the release said. It noted that China’s power consumption in the first quarter of 2012 hit 1.17 trillion kWh, up by 6.8% year-on-year, according to a recent report by he China Electricity Council (CEC) in late April 2012. Power-strapped China will most likely face blackouts this summer and “the shortage will hit about 30 gigawatts (GW) during summer peak days and may expand to 40 GW if heat waves persist.” the CEC warned. “This, combined with Chinese investment in renewable energy sources, means that we will also focus on the power cable sector and related power systems grid development in China,” the release said. As of press time, the host site was still being finalized, and that information will be posted at the company’s website. For information on participating in Wire & Cable Asia as a speaker, sponsor or delegate, contact Astrid Tsai, conference manager for Wire & Cable Asia, astrid.tsai@integer-research.com or call tel. 44-20-7503-

WJI: Much of the world is still grappling with tough economic times: how has China fared and Josie Armstrong has the country lost some of its appeal for the industry? Armstrong: The China market remains a crucial entity for companies to consider in their planning. While the global cable market saw one of its largest absolute declines in 2009 for more than 30 years, the growth levels of the Chinese cable market have been impressive by historic standards. China remains in a capital-intensive development phase, which has helped its wire and cable industry become by far the largest in the world in terms of production and demand. Today, the Chinese cable market is twice the size of the U.S. market. That said, there are signs that economic growth and development of the coastal provinces in China have started to slow, and that the high levels of growth in fixed

investment are starting to wane. This could mean that the many cablemakers in China, especially in the building wire and power cable sectors, will face tougher competition, and will have to upgrade operations to become more efficient. WJI: What percentage of cable production in China is by domestic companies versus by outside multinationals or joint ventures? What about rising costs? Armstrong: We think more than 90% by volume is domestic Chinese, and 10% by inward investment. By value, we think it may be as high as 15% from inward investment. Logistics and transport costs seem to mean that some appliance wiring products are shifting back to the U.S., a trend known as â&#x20AC;&#x153;insourcing.â&#x20AC;? We are not seeing this trend in Europe, where we have seen a shift within the region, from Western to Eastern Europe. WJI: Are Chinese companies just as vulnerable to rising energy/raw material costs? Armstrong: Yes, they are just as vulnerable, and as demand shifts inwards in China, coastal producers will lose out to the local players in Chinese provinces in Hunan, Hubei, Henan and Guizhou.

JUNE 2012 | 37

FEATURE

respond to this development outside of China. Another issue is fire performance in Europe, and European cable makers are well ahead of Chinese producers in that category.

FEATURE

What led to the Chinese success story ... and can it continue? Dr. George T. Haley, Professor of Marketing & International Business, University Research Scholar, & Director, Center for International Industry Competitiveness at the College of Business, University of New Haven, Connecticut, USA, is an expert on emerging markets in Singapore and China. His book, The Chinese Tao of Business: The Logic of Successful Business Strategy (John Wiley & Sons), was recommended by the Wall Street Journal “as the only book on Asian business to buy.” He shared his thoughts on China with WJI. WJI: What factors were most responsible for China’s stunning rise in manufacturing the last two-plus decades? Dr. Haley: There are many reasons for China’s success over the past two-plus decades. They tend to fall into four categories: Chinese situation, Chinese policies, Chinese management and U.S. policies. Chinese situation: Early in the period China had a significant labor cost advantage, however the cost of labor is probably China’s least important advantage. The potential size of the Chinese market, and now its actual size has been important over the years.

Chinese policies: Protectionist policies, low currency valuation, significant subsidies, government pressure on foreign companies to export, and the facilitation of corporate necessities, such as approving the building of production facilities, have all contributed to China’s success. China has dominated industries almost overnight, and they are not labor intensive industries – they are capital intensive. The Chinese have gone from major importers to dominant producers and exporters in industries like steel, glass, paper, solar and auto parts within a period of two to three years. These are capital intensive industries where labor makes up between 4 to 7 percent of total cost. Closer inspection shows that China has no competitive advantage. The Chinese industries are fragmented, transportation costs to U.S. markets are high and hard to plan for, the best product and production technology is imported, and most raw materials have to be imported. Additionally, low Chinese labor costs are offset by lower labor productivity. For example, when Chinese steel exports were skyrocketing, the Chinese hourly labor cost in steel was 1/20th the U.S. cost, but U.S. labor productivity was 12 times greater than China’s. Thus China’s competitive advantage is subsidy and policy related. Chinese managerial practice: The advantage of Chinese managerial practices is simply the speed of decision-mak-

Reel-O-Matic introduces the Cat s Meow

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WJI: Have those factors changed, and if so, were they in ways that will make it more difficult for Chinese manufacturing to continue being dominant in so many fields? Dr. Haley: While China’s yuan remains undervalued, its value has drifted upward in recent years. Additionally, Chinese labor is now the third highest cost of all Asia’s

emerging markets; fuel costs have risen and are more variable and susceptible to speculation than at any other time in recent history. Chinese advantages that have strengthened over the years have been the growth in the Chinese market and the speed with which the government facilitates corporate necessities. The large Chinese population has always been given as a reason to invest, but the population has not always represented a large market. In the late 1990s and early 2000s, China’s auto market was roughly equivalent to Portugal’s, yet the market was given as the reason to invest. It is now competing to be the largest. In-so-far as facilitating corporate necessities, the central government and a few of the provinces were always good about it, but previously laggard provincial governments around the country have improved. China has recently worked to establish its own world champions and brands. The result is that foreign companies are harassed into surrendering their IP to Chinese interests, generally to state-owned enterprises (SOES), and to suffer roadblocks to their penetrating Chinese markets with competing brands. WJI: How important is it for China to continue to show heady growth rates? (Could growth rates as low as 5 or

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ing and implementation of decisions. U.S. management moves sluggishly by comparison. U.S. policy: Finally, U.S. government policies also favor foreign imports to the U.S. While China’s yuan is undervalued, the U.S. dollar is overvalued. This hurts U.S. exporters and Dr. George T. Haley benefits companies exporting to the U.S. The evidence for this is the continuing deficits the U.S. runs with virtually all its major trading partners. If the U.S. dollar was not propped up its value would drop and our trade deficit eliminated.

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6%, which would make most country leaders jump for joy, pose a problem?) Dr. Haley: Crucially important. China remains a poor country. Through most of the past two decades the majority of China’s interior provinces actually grew poorer. Growing the interior provinces’economies is now a major focus of China’s government. While Chinese Communist Party (CCP) rule used to be justified philosophically, it no longer is. CCP rule is now justified economically. There are an estimated 1800 daily protests in China; if economic growth slows, the number will grow exponentially and the CCP’s rule will be threatened. As the Tiananmen Square protest demonstrated, CCP leadership will do whatever necessary to retain power. WJI: There is a strong desire in India to be “number one,” but some huge projects have been shackled for years whereas in China the bulldozers seem to be rolling in mere weeks: is this a strength of China or a plus and minus? Can growth in China remain unfettered? Dr. Haley: Generally, as indicated above, it is strength. Being able to depend on revenue and cost estimates is

major plus for any company. The very foundation of investment decisions is net present value. Sometimes stronger government and community group oversight can be beneficial, but speed and certainty are desirable. WJI: Chinese officials have declared a desire to focus on more “high value” manufacturing: to what degree has such results been seen? What are the biggest challenges to this focus? Dr. Haley: They are moving into higher value-added manufacturing. That is the conflict in the solar photovoltaic industry. China wants to claim higher value-added manufacturing and leave lower value-added assembly and installation sectors of the industry to other countries. Heavy-handedness is a major challenge. Increasing resistance from their trading partners is another. China’s withholding rare earth materials from Japan exemplifies its heavy-handedness. The U.S. and Australia are now restarting their rare earth production and Japan is intensively researching the development of alternative technologies. The latter is exemplified by the growing protectionism in the U.S.,

Branding: China’s rise reflected in ratings, but not overall perception China may be the world leader in a myriad of categories, but one place where it has begun to fare better but still is far from dominating is the list of the world’s top value brands. The country has gone from seeing modest representation from the first BrandZ list of global brand valuations in 2006 to sixth in 2010 and 13th in the 2012 list. Per a report from Financial Times, brand valuations matter because they “provide clarity and guidance for choices made by companies, consumers and investors, and provide the signposts that help in navigating the consumer and business-to-business landscapes. The list is largely comprised of financial, technology, service, fashion, telecom and automotive businesses. The article noted that Moutai is the only Chinese name in the top 10 most popular gift brands preferred by mainland millionaires, according to the Hurun Report, the chronicle of all things the wealthy in China like to spend money on. By the numbers, the China story reads well, the Financial Times story said. China accounts for seven of the top 10 brands in Asia and it is easily the emerging market leader. “But none of the mainland’s brands are true household names with a significant global footprint. Most are ranked among the world’s most valuable brands largely, or even exclusively, because they are big in China, not because they are good at selling an image globally.” Though China has made steady progress up the rankings, “brand China” remains largely in its infancy, the article said. It noted that it analysts believe it “will be years, possibly decades, before the mainland’s brand clout catch-

40 | WIRE JOURNAL INTERNATIONAL

es up with its financial muscle.” Three that have done well are Baidu, China’s largest online search engine; Tencent, which runs the world’s largest instant messaging service; and Moutai, a spirits brand with a strategy for conquering the globe. No Chinese carmakers made the list, despite Beijing’s 30-year-old ambition to build a world class automotive industry, and Chinese consumers “almost universally tell market researchers they prefer foreign brands on every basis except price,” the article said. It noted that foreign carmakers dominate the market, with more than a 70% share; and that local automakers have lost ground the past two years “as foreign cars are seen as more reliable, stylish, impressive, and just better all-round value than Chinese-branded cars, which continue to compete mostly by being cheap.” Why do so few Chinese brands make it into the global brand rankings? Observed ServCorp China, “One reason is clearly that the free markets that enable brand evolution are still relatively new to China. Even newer is the phenomenon of brands becoming an important factor in consumer choice—price was the primary consideration guiding most purchases until recently.” A Wharton report said that a July 2011 survey of Beijing graduate students (ages 21-28) asked about perceptions of Chinese and non-Chinese brands. Responded one student, “In reality, foreign brands seem more reliable,” while another responded that foreign brands are “better in quality, though I don’t know why.”

WJI: Can Chinese manufacturers succeed in high-tech fields on their own, or is there a need to continue to partner with multinationals or companies with proprietary knowledge? Will the issue of IP theft (such as the ongoing case in the Chinese courts for American Superconductor) continue to tarnish China? Dr. Haley: IP theft will always be an issue in emerging markets. It does not pay economically for emerging market nations to recognize foreign IP. The Confucian concept of tuition makes things worse. Tuition is the practice of passing IP from one party to another by a person learning the technology from its owner. Thus, for 3000 years IP transfer has occurred through what the West considers IP theft. Chinese companies can be successful in hightech, however there are benefits to partnering with foreign companies and to pressuring foreign companies to transfer their IP to Chinese SOEs. The latter two strategies reduce risk of failure, reduce time to profit generation, and reduce cost of innovating. WJI: What if any factors have the potential to slow manufacturing in China down, and are they inevitable?

What can/should Chinese leaders be doing? Dr. Haley: The greatest threats to manufacturing growth are increasing resistance from their neighbors and trading partners, increasing labor costs, civil unrest and environmental and infrastructural issues. China’s labor costs are rising and it’s facing increased resistance from its trading partners; it’s also facing increased conflict with its neighbors. China insists that its borders and political and mineral rights should be based on old borders from one of the empire’s greatest eras. This is causing increased conflict with its neighbors, especially with the Philippines and Vietnam. Vietnam’s last war was with China, not the U.S., and both the Philippines and Vietnam have had periodic naval confrontations with China. The combination of environmental and related infrastructural problems is serious now and worsening. Eighty percent of northern China’s rivers have run dry; water pollution, air pollution and desertification are increasing throughout China; during the Olympics provinces upstream from Beijing had their water allocations reallocated to Beijing to avoid embarrassing water shortages. The government is building canals to reroute water from the Yangtze River to Beijing, an engineering feat far greater than building the Great Wall. If the CCP fails to provide the expected economic

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Europe, and even in New Zealand and Brazil, countries with free trade agreements with China.

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growth and civil unrest increases significantly, economic growth will increasingly suffer. Jobs must be created. Chinese authorities should refocus economic growth on their domestic markets, use labor intensive technology for those domestic markets to create jobs, and build the strongest environmental services industry they can. It should also quit focusing on educating large numbers of engineers, and focus on educating better engineers. The Three Gorges Dam is beset by problems foreseen by U.S. and European engineers but ignored by China’s. It is doubtful the CCP will follow this prescription. WJI: Looking out a few years, will foreign companies, such as wire and cable manufacturers, continue to be welcome to open new plants or become part of a joint venture in China, be it for local consumption or for export? Dr. Haley: Historically, foreign companies preferred entering China through joint ventures with local Chinese

China’s might can be traced back to its development parks It is a given that manufacturing has found a home in China, but the logistics of how all that worked was not. All heady numbers and flashy growth charts depend on a sound base, and for China, that has been the focus on planned development areas. Below is some information on the Tianjin Economic Development Area (TEDA), which has been ranked by the country’s Ministry of Commerce as China’s top National Industrial Park for the 14th consecutive year. Below are excerpts from a report by TEDA Investment Bureau Chief Mei Zhihong, sent to WJI, that spells out the importance of this “backdrop” that makes all the other news possible. In 1984, TEDA was established in northern China as the country’s first development area, and the entity helped make the stunning Chinese production story possible. Based in an area of about 40 sq km, TEDA is strategically mapped as part of the Bohai New Area by the central government. However, it is spread across in several regions and is not confined to one region. By 2011, it had approved 4,999 overseas projects from 61 countries and regions with a total investment of $69.9 billion. Some 82 Fortune 500 Companies have invested in 186 TEDA projects. It has complete industrial clusters involving electronics and telecom, automobile, biopharmaceuticals, food and beverage, machinery manufacturing, aerospace, new energy and new material, petrochemicals and modern service. It is responsible for about 20% of Tianjin’s annual economic output. TEDA Investment Bureau Chief Mei Zhihong said that, for all its success, TEDA must remain very competitive to 42 | WIRE JOURNAL INTERNATIONAL

companies. More recently, companies have favored going it alone. While going it alone is generally considered riskier, most foreign companies have been dissatisfied with the benefits of their Chinese joint ventures. If you can find the right joint venture partner, however, a joint venture is highly desirable. For example, GM’s joint venture with Shanghai Automotive recently became the largest auto company in China. Entering China, regardless of how, requires significant investment in due diligence. Investing on your own requires sound understanding of the business environment in each individual locale you are considering. Contrary to popular opinion, Beijing does not wield tight control over the provinces as they have tremendous independence of action in commercial affairs. Entering China with a joint venture requires due diligence for the above reasons, but also because when you choose a partner you choose the partner’s political allies and enemies. The right JV partner can make you; the wrong one can break you.

potential locating companies as it competes not just with other countries but also with other development zones that are mushrooming all over China. Initially, the zones get a lot of support, but once the development is there it is self-sustaining, and it is natural for the central government to shift the focus to less-developed areas. There are over 2,700 industrial parks of different scope; but there are only about 110 national-level industrial parks like TEDA. Typically, investors in China's industrial parks face two main costs: start-up costs, including buying land, constructing a facility, bringing in equipment and staff, and operating costs, including dealing with different government organizations, buying raw materials and arranging logistics. “A lot of places focus on the initial cost and give special prices to get companies to come,” Zhihong said. “Our initial costs are in the middle. We are paying more attention to the operational costs. We are not encouraging individual companies to come here. We are encouraging industrial sectors to be here.” TEDA, she said, offers a complete environment, including the supply chain, customers and suppliers. “Many companies making serious investment look more at these factors. That’s one of our biggest advantages.” For example, Mei said, TEDA developed a telecoms cluster by first attracting Motorola to invest, “and then working on bringing in its suppliers too, to bring down logistics costs.” Customers are most concerned about having a stable power supply, but over the years other needs have been stressed, such as creating a transparent system to make sure that companies know what is required from them by regulations, ensuring a supply of qualified

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TEDA is also finding its own solutions to challenges that are affecting the whole of China’s prosperous eastern seaboard, where breakneck development and growth now mean lower land availability and strong upward pressure on salaries as well as higher inflation rates, Mei said, adding that China’s recently imposed monetary tightening policy have made it tougher to get capital to develop land. Customers and investors are pleased with the results. “Investors are happy. It’s one of the fastest-growing development zones in China, with something like 20% a year,” said Ren Xianfang, China analyst with Global Insight in Beijing. “It’s based on much investment in heavy machinery and hi-tech infrastructure and has support from the central and local government. They are trying to move China’s industrial base from the south and east to the north to achieve more balance between the regional economies.” TEDA’s overall strategy, Zhihong said, is to move away from labor-intensive industry and towards automated high-end manufacturing. Mei cites the Danish healthcare company Novo Nordisk, which has a big plant that is operated by just 1,000 people, as an example of the kind of company TEDA is looking for. This is also how TEDA hopes to attract companies to its recently established Nangang Industrial Zone. About 200 sq km in size, Nangang is envisaged as an all-in-one port complex dominated by petrochemical industry. It has so far inked agreements with Fortune 500 Companies such as Dow Chemical and Air Liquide. Some 31 projects worth about $35 billion, including refineries and warehousing logistics, are under rapid construction.

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HANDY...

employees and providing outsourced services. “When China wasn’t yet talking about outsourcing these companies showed us how to outsource,” Zhihong said. “One company sold their IT department to someone else, who now operates it and also provides services to other companies. There are many such cases. For myself it’s a great experience to work with these companies, you learn so much.”

A ED L ER W IN N AWAR

Extended quality control of cable insulation by color measurement during extrusion

TECHNICAL PAPERS

TECHNICAL PAPER

A system developed to detect color faults has been shown to be effective even for small product geometry and fast running lines. By Dr. Horst Scheid

In today’s cable production, it is common for automotive wire production to use automatic color changing systems and automatic color batch dosing systems on extrusion lines. On such production lines a huge number of combinations of main and stripe color is used and can be preset within the line control menu. Concentricity, diameter, capacitance and spark faults are constantly measured and protocolled for quality control. Readings can be used to automatically correct extrusion para-

meters, but the correctness of cable colors is still left to the imagination and skill of the line operator, who must recognize the correct colors in accordance with relevant standards and auditing procedures. The color is checked for correctness either visually inline or after the completion of a drum by inspection of the top layer. Start and end of the color changing process is normally not monitored during running production. The scrap length is set by means of empirical values under consideration of a safety value which is longer than actually necessary. It is obvious that wrong colors cost valuable production time and result in scrapped material. The logical consequence of these considerations is to use some type of automatic inline color measurement.

Color metrics

Fig. 1. Optical Illusion: Square A and B have the same gray value, but they are interpreted by human eye as different because of differences in the adjoining areas1.

44 | WIRE JOURNAL INTERNATIONAL

For a better understanding of color measurements, it is useful to define the basics of color perception and color metrics. Just to demonstrate how difficult it can be to interpret “color” by human eyes, Fig. 1 shows two squares: A and B. A appears to be darker than B, but indeed they have both the same gray value. This (like many other optical illusions) explains why objective color specification by human eyes is nearly impossible. To describe color in physical terms, the base is a part of the electromagnetic spectrum that has wavelengths from 350 to 800 nm and will be recognized by human eyes as “color” (in ascending order violet-indigo-blue-green-yellow-orangered). A better physiological representation is the so-called color wheel (or color circle), where different circular sectors are filled with different colors. Colors in opposite sectors are

TECHNICAL PAPERS

designated as complementary, that leads to the well known RGB model as the three basic colors (red, green and blue) can be mixed to create all other colors. Mixing complementary colors 1:1 results in a neutral gray or white (additive RGB-mixing). This model is very common for camera or monitor applications, but it is a pure mathematical description without any feeling for human color perception. In 1927, Reich-Ausschuß für Lieferbedingungen, a German organization for quality assurance, arranged a color chart to serve as a reference for colored parts. That table, still used in industry, is known as the RAL Palette classic/design/effect2, but it does not include the complete continuum of color variations and thus is not suitable for an automated system. In 1931, the Commission Internationale de l’Eclairage (CIE), an international organization concerned with light and color, proposed a method for a numerical expression of colors including weight factors in order to fit a certain visual color differentiation in human perception to the same geometrical distance in the color space. This attempt was revised in 1976 and is known as the L*a*b* model (also named CIELab model)3. The color space is based on a color wheel with the main axis red-green (a* axis) and blue-yellow (b* axis) with different scalings. The outer rim defines the hue, while saturation decreases to neutral grey at the center. Perpendicular to the center is the lightness (or luminance) from absolute black to pure white (L* axis). The result is a sphere, where every visible color is represented by three coordinates (L, a and b). See Fig. 2. CIE-Lab is exactly defined only for reflected colors. For lamps, monitors or other light sources there exists a modified description named CIE-Luv. Having two different colors in the Lab sphere, the geometrical length dE (or Delta-E, ΔE) of the vector between both coordinates corresponds to the visual color deviation:

Fig. 2. L*a*b* space with two color positions (red and blue) with the resulting difference vector dE.

Eq. (1) The smaller ΔE, the less is the visible difference between

Fig. 3. Simulated 2-colored wire in the scan field. The upper part is a view into the longitudinal direction with the sensor at the top and its aperture indicated as a cone. The lower part shows the sensors “camera view” at the same coincidental time (with the average color values at the right side).

Table 1. Statistical color blindness among industrial nations population, separated between male and female.

Table 2. Testing with different wire types under various quality criteria. JUNE 2012 | 45

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these colors. According to the special scaling of the model, the percepted and calculated deviation is the same and independent of position within the sphere. In other words, the Lab model is a mathematical description of color differences interpreted by human eye that is all the same whatever color is compared. Statistical tests based on CIE-Lab showed that ΔE values greater than 10 are noticed by humans as a significant color deviation. Many people can differentiate colors down to ΔE≈4, but very few people can see differences between 2 ≤ ΔE ≤ 4. Below ΔE≈2, the eye’s receptors resolve only one single color. An additional problem is (partial) color blindness. Table 1, taken from studies among industial nations population groups4, shows that around 5% of men have green-weakness (deuteranomaly), so they are poor at discriminating small differences in hues. Only objective automatic color control can avoid faults caused by that.

Technical requirements and problems caused by wire geometry and processing

Fig. 4. L*- / a*- / b*- channel of a yellow cable during a 15-minute period. The small plots are the corresponding histograms for each channel. FWHM of the histogram plots is L*»2, a*»1.25, b*»1.5.

Color measurement on the basis of CIE-Lab is the current state-of-the-art for the paint industry or graphic art applications, with tolerance values sometimes as low as ΔE < 1. Conditions for such exact measurements are plane objects, a scan spot with a diameter of some 5-10 mm and a sampling time in the order of 100 ms on a motionless object, but all these conditions are definitely not given at an extrusion line. That’s why an inline measurement has to consider the following points: With a very short sampling time an averaging over a certain number of single shots eliminates local deviations. This is justifiable as color changes in extrusion have a relative long

Fig. 5. Left: DE calculated from data in Fig. 4 (with setpoints 87.62/-66.04/39.10). Right: Histogram of DE with a binning of 0.05. Average DE = 0.89. 46 | WIRE JOURNAL INTERNATIONAL

Typical applications and inline measurement test results. Different production setups have been tested to cover most typical applications. See Table 2. The first test with single color wires was to verify the aim of a resolution of at least ΔE≈3, so the result would be same or better than checking by human eye. Fig. 4 shows a detailed yt-plot from a measurement period of 15 minutes for all three L*a*b* coordinates of a yellow wire. The histogram maxima (88/-66/39.25) correspond very well to the average values (87.62/-66.04/39.10) that have been used to calculate ΔE according Eq. (1). Due to the above mentioned jitter and surface variations, the FWHM value of the luminance channel L* is higher than that of the pure color channels a* and b*. The histogram of all ΔE values in Fig. 5 depicts a maximum of around 0.75 (average value 0.89) and shows that the system has a minimum resolution of ΔE=1. No values higher than three are recorded, so a thres-

Fig. 7. Raw data with stripe: well recognizable changes in a*- and b*-channel are seen when the stripe is moving through the scan field.

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transition time caused by mixing effects in the barrel. Object movement (Jitter) has to be minimized at the sensor position. This is important for the object-sensor distance ds (illumination reduces with ds2) as well as for transversal movement, where the object is leaving the scan spot partially or completely. The wire geometry is detected as a side view on a cylinder surface. This results in a color variation from the cylinder center view towards the cylinder border. This effect is additionally influenced by the surface roughness. As both conditions Fig. 6. Forced color fault by putting blue master batch into the barrel feeding. cannot be changed, the final color value cannot be interpreted as an absolute measurement but hold could be set to values of five to seven for color fault as relative measurement with high reproducability. alarm. Normally, one line runs different conductor/insulation diaPutting one grain of blue masterbatch into the feeding meters. The device should be able to work with various geoof the screw had a significant effect, as the ΔE value rose to metries (over a certain range) without mechanical preparati≥ 10 (middle of Fig. 6) for one to two minutes. The smaller on or sensor recalibration. increase of ΔE some three minutes later may have been cauOne more challenge is the measurement in a production of sed by some blue residue that was still on the screw for a cercolor coded wires (one or two stripes). As the final color is tain time. Only the main deviation, however, was found later established after the cooling down of the polymer, sampling by visual inspection. has to be done behind the cooling trough. Caused by rediThe second step was to measure on a stripe coded wire. For recting wheels and the product itself (particularly stranded a separation of both colors from the raw signal, statistical conductor), the wire can turn around the longitudinal axis in methods are used as the portion of main and stripe color in an irregular way. Therefore the sensor detects sometimes the the scan field is variable. Fig. 7 shows the raw L*a*b* plot of main color, sometimes the stripe color, or both at the same a wire with a main blue and green stripe. As the longitudinal time in the scan field. Fig. 3 gives an impression of the senwire rotation speed changes, the residence time of one color sor’s view on a two-colored wire. With sophisticated mechanics the wire turning can be changed to be more regular and used for main and stripe color detection with only one sensor.

TECHNICAL PAPERS

color at the stripe borders. This is limiting the color separation as there is more mixing between the main and the stripe color at smaller geometries. In Table 2, the third setup shows a clear indication of a stripe missing. To force this fault during production, the stripe co-extruder was switched off for about 40 seconds. Fig. 8 illustrates the result in the raw data (only for color channels a* and b*) during normal production. The values toggle between the main and stripe color. After the co-extruder was off (at 10 seconds on x-scale), the stripe signal slowly disappears towards the main color simultanously to the decreasing stripe width. After around five Fig. 8. Stripe missing test: only shown on the a*- and b*seconds, the raw signal moves only within the channel. Co-extruder was switched off at x-scale position 10s main color tolerances. The co-extruder was and switched on again at position 50s. switched on again at around 50 seconds on xscale and stripe signal ramped up in five seconds to normal condition. The last setup in Table 2 shows the stripe to main ratio. As the sensor only detects the averaunder the sensor position cannot be predicted. A turn mechage color in the scan field, it is not possible to measure the strinism was used to make the rotation more regular and to ensupe width directly. In case of a constant longitudinal product re that both colors come into the scan field within a time rotation, the time interval of main tm and stripe ts color found period shorter than the alarm time. in their tolerance interval can be integrated for certain time T With very small wire geometry (<1.5 mm diameter) and/or and the resulting time ratio: with a small stripe width, even when the stripe position is in the scan field middle, the sensor detects a bit of the main

Fig. 9. User interface of the color measurement. In the upper middle, a schematical cross section of the wire shows detected main and stripe color. The lower middle shows the status transferred to the PLC (green = both colors in tolerance, yellow = one is missing/out of tolerance and red = double fault or wrong recipe. At the right, actual color info is displayed. 48 | WIRE JOURNAL INTERNATIONAL

Fig. 10. Prototype of Siebe color measurement system during test at a customers line. Installation between spark test and lump camera. IPC at the top, below â&#x20AC;&#x153;turn mechanicsâ&#x20AC;? and sensor (under light cover).

Actual device specifications and forthcoming development The user interface of the device should be quite easy to control for the line operator without losing setup flexibility or detail information, comparable with inline wire centricity measurement. Based on an IPC, control of the sensor is completely transparent for the user. A non-contact measurement reduces the risk of sensor damage. Very often the wire isn’t completely dry while passing the device. This caused contamination of the sensor surface but could be solved by installation of a permanent compressed air blowing over the sensor. To protect the optics during production start/stop and bare wire running, the sensor is moved into a safe position until normal production. Temperature compensation is done automatically. As already mentioned, colors are detected as relative measurement, so the system needs a teach-in for each geometry/color combination. This is done once after the wire runs in good production and the detected reference can be stored for further production of this wire type. Any number of recipes can be stored. Until now the recipe database is very simple and should include search functions in future software. Connection to the line PLC should be possible via simple digital 24V signals (signal status and device enable) where fault messages are implemented to the coil protocol like spark or diameter faults or with a more complex network communication via TCP/IP to have access to the recipe database or to support host computer link. Fig. 9 shows the main screen, which includes the most important information for the line operator. Additional windows can display more details, like separated L*/a*/b*- channel measurement, various signal history or trend informations. For later evaluation, a subsample of raw data is stored on the IPC hard disk. To be independent of all production lighting conditions, the scan field is covered and illumination is done by an internal LED light source. See Fig. 10. According the higher luminance variation compared to a* and b*, a modification of Eq. (1) should be tested:

Eq. (2)

References 1. E.H. Adelson, MIT, 1995. 2. https://www.ral-farben.de/492.html?&L=1 3. Joint ISO/CIE Standard: CIE Colorimetry, Parts 1-5, ISO 11664-1·5/CIE S014-1·5/E:2006-2007. 4. M. Okabe and K. Ito, color blind barrier free, 2008-0215, http://jfly.iam.u-tokyo.ac.jp/color/

Dr. Horst Scheid is the R&D manager for Siebe Engineering GmbH, Wied, Germany, where he focuses on foam extrusion, new extrusion processing techniques and enhanced inline quality control. He joined the company in 1995. Prior to that he worked in the injection moulding machinery research Scheid group at Arburg in 1986, and in 1990 he joined the COSY beam accelerator group in Juelich Nuclear Research Centre. He studied solid state physics at the university of Saarbruecken. and received his doctoral degree in Nuclear Physics from the University of Bonn. This paper, which was presented at WAI’s 81st Annual Convention, Atlanta, Georgia, USA, May 2011, won the Urban J.H. Malo Memorial Award for the best paper in the electrical division.

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should be almost same as the geometrical ratio. First trials under optimum conditions gave almost satisfying results with T>10s, but scan field size, jitter and rotation irregularities are still a challenge for an evaluation with high evidence.

While Eq. (1) represents a circular error distribution, the modification is an elliptical distribution with enhanced tolerance in the L* channel (for f > 1). Technical aspects are almost solved, and the main focus now is the improvement of device interface and handling. This needs feedback from the wire and cable production companies. Another point of discussion should be the combination of stripe and main color. For example, a cable with a main red color with a brown stripe is difficult to separate, both for an automatic device as well as for a line operator. This is not a problem in color measurement itself, but a possible improvement of quality control by a simply redefinition of color pairs with high ΔE.

TECHNICAL PAPERS

TECHNICAL PAPER Evaluating decarburization in tool steel rod Temperature had the largest effect on depth of decarburization at all heat-treating atmospheres, with samples heat-treated at 1000°C showing both the largest decarburization depth and the largest hardness gradient.

By Rebecca D. Cioffi, Roger N. Wright and Steven W. Mayott

Decarburization involves the loss of near-surface carbon content in steels upon exposure to oxygen at high temperatures. It commonly occurs during the hot processing of steel in air, and its prediction is important to quality control in hot metalworking operations such as forging and rolling. Loss of near-surface carbon content in steels can ultimately decrease the strength—and therefore hardness—of the steel, and cost additional time and money to a company to remove this weakened surface material from the workpiece1. Fick’s Second Law and the diffusion of carbon in iron provide the basis for elementary models of decarburization, but such models can overestimate the depth of decarburization in alloys with stable carbide formers. Tool steels in particular are highly alloyed steels, with several stable

Table A. Chemical composition of M48 tool steel.

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carbide formers present in their composition that can change the decarburization process significantly in comparison to other alloy steels. As the rate of carbon reacting with oxygen at the surface exceeds the rate of iron-oxide scale formation at the interface between the steel and the atmosphere, decarburization begins. Carbon is drawn from more interior depths as this reaction between carbon and oxygen continues to occur1. In M48 tool steel, stable carbides are able to form from elements such as tungsten, vanadium, molybdenum and chromium, reducing the content of carbon within the sample that is available for diffusion to the surface of the sample and to react with ambient oxygen at the surface. The iron-iron carbide phase diagram is, of course, somewhat inadequate for prediction of the temperatures of phase transformations, and locations of phase regions, when several alloying elements are present. Additionally, from a kinetic perspective, because the process of carbides dissolving into the austenitic phase is a

Table B. Decarburizing heat treatments undertaken.

Experimental procedure A study was conducted on M48 tool steel rod to determine the effects of oxygen concentration and temperature on depth of decarburization. Table A displays the chemical composition of the M48 tool steel examined in this study. The primary issues under consideration in this study were: (1) the discrepancy between the theoretical depth of decarburization predicted using the error function, and values determined by measuring depth of decarburization in micro-hardness data collected; and (2) the effects of oxygen concentration on measured depth on decarburization. The M48 tool steel samples (in the as-received condition) were in the form of long rods, measuring 0.64 cm in diameter. Samples approximately 6 to 8 cm long were heattreated using a Eurotherm 2404 controller/set point programmer and a Lindberg tube furnace heating unit in air, 14% O2, and 7% O2, at 800°C, 900°C and 1000°C. The samples heat-treated in reduced oxygen atmospheres were exposed to 14% or 7% O2 (balance N2) flowing at 14 kPa. After reaching the target temperature (800°C, 900°C or 1000°C), samples were held for two hours before cooling down at a constant rate. Samples were removed from the furnace when they reached a temperature of 300°C, since it was determined that large-scale decarburization would not occur at this temperature. The 10 decarburization conditions that were carried out on samples are shown in Table B. The 10th condition shown in Table B served as a control. In this condition, a tool steel sample was heat-treated at 900°C in a compressed air flow of 14 kPa. This was done to determine if flowing versus non-flowing air in the

Fig. 1-a. Micro-hardness data for sample 1, following heat treatment at 788°C in air.

heat treating environment had any effect on decarburization depth at a given temperature. After undergoing heat treatments, samples were cut approximately 1.9 cm from the end and were mounted in epoxy. After the epoxy hardened, samples were polished and etched with 2% nital. Micro-hardness testing was conducted in the tool steel samples using a Vickers hardness testing apparatus. Using a 100gf load, 25-30 indents were made in the sample beginning at a location approximately 0.06 mm from the tool steel surface, and moving inward linearly at a distance of approximately 0.08 mm or 0.12 mm horizontally between indentations. The Vickers Hardness Number (VHN) for each indent was determined using the standard formula for calculating Vickers hardness values. Metallographic analysis of the samples was carried out using a LECO Olympus PMG 3 microscope. Micrographs were taken at 50x, 100x, and 200x, magnification. The microstructure and decarburization pattern were analyzed using AnalySIS® software, and comparisons were made between decarburization patterns in all ten samples.

Results Part 1: Micro-hardness data results. The most significant changes in the hardness gradient occurred as the heattreating temperature was increased in each of the samples. The samples heat-treated at 1000°C showed the most significant hardness gradient from the surface to the bulk of the material. Figs. 1-a through 1-f show the micro-hardness for a selection of tested samples. For samples heat-treated at 788°C in air and 800°C in reduced oxygen atmospheres (14% and 7% oxygen content), a very slight hardness gradient was observed in the micro-hardness data. This indicates that the decarburization process had not begun to occur on a large scale when samples were held at this temperature for two hours. There appears to be little observable change in hardness gradient between samples heattreated in air and in reduced oxygen environments, at a temperature of 788°C and 800°C. Samples undergoing heat treatments at 900°C had inter-

Fig. 1-b. Micro-hardness data for sample 4, following heat treatment at 900°C in air. JUNE 2012 | 51

TECHNICAL PAPERS

thermally activated process, dissolving these carbides of several different elements may delay the process of decarburization as the material enters the austenitic phase region and carbon is being rearranged. This limits the thickness of the decarburized layer present in samples heat-treated at high temperatures when compared with low-alloy steels.

TECHNICAL PAPERS Fig. 1-c. Micro-hardness data for Sample 6, following heat treatment at 900°C in a 7% oxygen atmosphere.

Fig. 1-d. Micro-hardness data for Sample 7, following heat treatment at 1000°C in air. This sample has a substantially higher hardness gradient than Samples 1 and 4.

esting hardness patterns as the oxygen content in the heat treating environment was decreased. Sample 4 (900°C, air), shown in Fig. 1-b, shows a small region near the surface of the sample with relatively low hardness values. The hardness abruptly increases at about 0.15 mm from the surface of the sample and then slowly decreases as the bulk of the material is appproached. In Sample 5, the hardness pattern shows a very small decarburized zone and a relatively constant hardness throughout the sample. The hardness profile of Sample 6 is similar to that of Sample 4, except in this sample there appears to be no decarburized zone. Instead, hardness actually decreases slightly as the bulk hardness of the sample is approached. Part 2: Micrographs showing the near surface region of five representative samples. Metallographic analysis of the samples revealed the extent of near surface decarburization in each of the samples and showed visible changes in size of micro-hardness indents moving inward to the bulk material of the sample. Micrographs showing the near surface micro-structure of representative Samples 4, 6, 7, 8 and 10

are displayed below in Figs 2-a through 2-e. These samples are representative of the trends seen in the heat-treated samples.

Fig. 1-e. Micro-hardness data for sample 8, following heat treatment at 1000°C in a 14% oxygen atmosphere.

Fig. 1-f. Micro-hardness data for sample 10, heattreated in compressed air flow at 900°C.

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Discussion The micro-hardness data show that in M48 tool steel, temperature, not oxygen concentration, had the greatest effect on the depth of decarburization. As previously discussed, the stable carbide formers could have a significant effect on both the rate of phase change and the rate of decarburization in tool steel. As the heat-treating temperature was increased, the data showed that decreasing the oxygen concentration had little effect on the depth of decarburization in the samples, especially for those heattreated at 1000°C. At 800°C, varying oxygen concentration had little if any effect on the hardness profile of the tool steel. This trend could most likely be attributed to the fact that full scale decarburization had not yet begun at a temperature of 800°C.

TECHNICAL PAPERS Fig. 2-a. Sample 4 (900°C in air) etched surface region and micro-hardness indents following heat treatment. The samples heat-treated at 900°C showed consistent, yet unpredicted results in the near surface region. Samples 4 and 5 (air and 14% oxygen at 900°C) showed a decarburized region very close to the surface of the steel, but an increase in hardness immediately following the decarburized region in comparison to the bulk hardness of the material. Samples 7, 8, and 9, heat-treated at 1000°C, had very similar hardness patterns. Oxygen concentration appeared to have little effect on depth of decarburization and hardness pattern in all samples heat-treated at 1000°C. A sample heat-treated in compressed air, flowing at a pressure of 14 kPa showed a hardness pattern similar to Sample 4, but with a smaller depth of decarburization and hardness gradient in the near surface region. See Figs. 1-b and 1-f. This result suggests that air flowing over the sample at a constant pressure of 14 kPa produced a slightly smaller decarburization depth than a sample heat-treated in

Fig. 2-d. Sample 8 (1000°C in 14% O2) etched surface region and micro-hardness indents following heat treatment. There is little difference between the near surface appearance of this sample and Sample 7.

Fig. 2-b. Sample 6 (900°C in 7% O2) lightly etched surface region and micro-hardness indents following heat treatment.

Fig. 2-c. Sample 7 (1000°C in air) etched surface region and micro-hardness indents following heat treatment. Note the higher hardness of the indent located in the gray oxide region compared with decarburized region located just to the right of the oxide.

Fig. 2-e. A micrograph of Sample 10, a sample heat-treated at 900°C in compressed air flow of 14 kPa. JUNE 2012 | 53

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Table D. Theoretical and measured depth of decarburization for M2, MX, M48 tool steels, and 5160H and 6150H low alloy steels (5). The theoretical depth is calculated on the basis of (C/Co = 0.9). Table C. Estimated depths of decarburization for samples 1-10.

air at atmospheric pressure for the duration of the heat treatment. This could partially explain why the depth of decarburization decreased in the reduced oxygen samples, but this result is not significant enough to conclude that flowing versus non-flowing air is the primary factor in the decarburization depth results obtained for the reduced oxygen samples. This is primarily something to keep in mind when considering the change in hardness gradient of the air samples to the reduced oxygen samples. Despite the consideration of Sample 10 in relation to Samples 4, 5 and 6, it is still clear that temperature had the most significant impact on depth of decarburization. The estimated decarburization depths for all samples are displayed in Table C. Oxide layer presence. The presence of an oxide layer on the atmosphere-steel interface is thought to play an important role in the decarburization process. The literature generally reports that an increase in scale depth will result in a decrease in depth of decarburization1-4. In this study, the oxide layer that formed at the surface of the steel was not considered in great detail. However, a visible oxide scale was present in several of the samples considered, although it is present in varying thicknesses and appearances for many of the samples. The most significant oxide layer appears in Sample 7 (1000°C, air), Sample 8 (1000°C, 14% O2) and Sample 9 (1000°C, 7% O2). Measurement of this oxide scale would be difficult in these samples due to the non-uniformity of the scale thickness in the samples and their circular cross-section. See Figs. 2-c through 2-d for the visible oxide layer present in Samples 7 and 8. Discrepancy between estimated vs. measured decarburization depth. One of the main issues under consideration in this study was the discrepancy between the estimates of depth of decarburization predicted using Fick’s second law and the actual measured depths of decarburization. The equation used to calculate theoretical depths of decarburization is:

54 | WIRE JOURNAL INTERNATIONAL

C/Co = erf {x / [2(Dt)½]}, where “erf” denotes the error function, “C” is the carbon concentration at depth x and time t, “Co” is the initial carbon concentration (t = 0) and “D” is the diffusivity of carbon in austenitic iron. As noted initially, stable carbide formers in tool steel contribute to the inadequacy of Fick’s second law and the error function in predicting an accurate depth of decarburization. Table D displays comparisons between calculated and measured decarburization depths for tool steels and several other steels Note that the three M48 examples from the present study display decarburized layers well below the theoretical depth, unlike the comparisons cited for the other steels.

Conclusions In this study, the following conclusions were made: Temperature had the largest effect on depth of decarburization at all heat-treating atmospheres. Samples 7, 8 and 9, heat-treated at 1000°C, showed the largest hardness gradient and depth of decarburization of any of the samples. Decarburization did not begin on a large scale at a heattreating temperature of 788°C in air or reduced oxygen heat-treating environments. At 900°C, the decarburization depth decreased with decreasing oxygen concentration from air to 14% O2, but in 7% O2, there was actually no visible depth of decarburization. Instead, the near surface region was harder than the bulk material. An error function calculation (without addressing an oxide scale) was carried out on the air samples at 800°C, 900°C and 1000°C. The estimates for decarburization depth differed significantly from the measured depths of the samples, consistent with the concept that stable carbide formers in tool steel partially inhibit decarburization depth from reaching the value predicted using a model for diffusion of carbon in austenite.

Acknowledgment

1. S.W. Mayott, “Analysis of the Effects of Reduced Oxygen Atmospheres on the Decarburization Depths of 300M Alloy Steel,” Master’s Thesis, Rensselaer Polytechnic Institute, 2010. 2. N. Birks, G.H. Meier and F.S. Pettit, “Introduction to the High Temperature Oxidation of Metals, 2nd Edition,” 2006, Cambridge University Press, New York, pp. 23, 8386, 151-157. 3. J. Baud, A. Ferrier, J. Manenc and J. Bénard, “The Oxidation and Decarburizing of Fe-C Alloys in Air and the Influence of Relative Humidity,” Oxidation of Metals, 9, 1975, pp. 69-97. 4. R.D. Stout and T. Aho,” “Surface Effects Accompanying the Heating of Carbon Tool Steel in Oxidizing Atmospheres,” Controlled Atmospheres. Proceedings of the 23rd Annual Convention of the American Society for Metals, Philadelphia, PA, USA, 1941; American Society for Metals, Cleveland, OH, USA, 1941. 5. R.N. Wright, Unpublished research, Rensselaer Polytechnic Institute, 2010.

The support of the Forging Industry Educational and Research Foundation, Crucible Materials Corporation, and the Rensselaer Polytechnic Undergraduate Research Program is gratefully acknowledged.

Rebecca D. Cioffi received her B.S. and M.S. degrees in materials science and engineering from Rensselaer Polytechnic Institute, Troy, New York, USA, in 2012 and is currently pursuing a doctoral degree at Rensselaer. Roger N. Wright is Professor of Materials Engineering at Rensselaer, having been a faculty member since 1974. Steven W. Mayott received a B.S. degree in materials engineering from Rensselaer in 2009 and an M.S. degree Cioffi from Rensselaer in 2010. He is currently a metallurgical materials engineer in the welding and materials engineering department at General Dynamics Electric Boat in Groton, Connecticut, USA. This paper was presented at WAI’s 81st Annual Convention, Atlanta, Georgia, USA, May, 2011.

Wright

Mayott

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References

TECHNICAL PAPERS

TECHNICAL PAPER Optimized wire coil batch pickling plant design via computer-aided modeling Use of computer-aided modeling has been found to be far superior to linear approximation for designing a pickling plant system as the latter method is not able to accurately take into account aspects that are needed for optimum results. By Wynn H. Kearns, Adam G. Kimura and Arthur Seibert

Wire coil batch pickle systems use a configuration of acid, rinse and coating tanks to clean and treat stainless and carbon steel wire and wire rod in coil. Between one and four overhead travel unit cranes are generally used for a 100-meter line. The process line is designed to meet customer requirements such as pickling process time, factory space constraints, and throughput capacity. System design focuses on two main design components driven by customer requirements: the movement of coils through the treatment process per the exact customer-specified steel grade recipe; and minimizing the movement of the product transfer hooks. Other considerations to determine the best loading and unloading design include the customer’s real estate, product flow constraints and line capacity. Below are highlights of some other factors that can affect the design. Multiple steel grades. Often, the customer will require multiple steel grades to be factored into the calculation of the throughput capacity. A low-carbon and a high-carbon recipe may be needed or a ferritic and an austenitic recipe for a stainless line. Sometimes, as many as 100 different steel grades, each requiring a unique treatment recipe, must be considered when determining the capacity potential of the design. Different grades can dramatically affect how one calculates capacity and mixing grades can introduce a large inefficiency into the product flow. Estimating the effect of a combination of grades is very difficult to determine with high accuracy without modeling. Drip waiting time. This is the time a coil batch is suspended above the tank to allow excess liquid to drain off. For example, each coil of 5.5 mm wire can carryover 20-50 liters of liquid according to the surface area and drip waiting time. A low drip wait time will create higher chemical consumption and generate excess rinse water. When the coil batch is suspended in the air, held motionless by the travel unit crane, the travel unit is 100% used, and no other travel units can pass over this point until it has moved, which can create traffic interference problems between other travel units.

56 | WIRE JOURNAL INTERNATIONAL

Internal doors interlocked with system. Internal doors are an intricate line design part. They create separation between certain acid fumes requiring isolation, provide protection over spray rinsing areas and keep negative pressure in the fume hood for proper fume exhaust collection and treatment. They are interlocked with the line’s transport system, adding more complexity to the flow of batch coils. Travel units must wait for the doors to open and close before passing through. Product flow. Depending on space constraints, loading and unloading may be on the same side, opposite sides or completed at the same area. After coil batches are processed, the product transfer hooks must be brought back to the beginning loading point to create a handling circuit loop. This step has the potential to create product flow interference as the coil batches are moving in one direction while the transfer hooks are moving in the opposite direction against the product flow. Cascade and parallel tank configurations. The processing tanks can be arranged in a static, cascade or parallel configuration where the processing of coil batches occurs in a series or paralleled sequence. The choice depends on treatment time, as steps like pickling and phosphating can take longer than steps such as rinsing, passivating, or coating. The time excess can be 10:1, with pickling taking 10 times the rinsing time. Thus, line configurations create higher/lower utilization times of the handling system due to the higher or lower number of coil batch deliveries and retrievals that are required.

Linearized approximation methodology As one considers the complexity, it becomes clear that the nature of a batch wire line system is highly nonlinear. An analysis shows that the system does not fulfill the principles of superposition or scaling used to study a system in a linearized approximation methodology. A system that uses one travel unit to transfer the coil batches between the tanks (see Fig. 1) will produce a throughput capacity C1. If a second travel unit is added, it has potential to produce a maximum capacity C2. Likewise a third, fourth,

TECHNICAL PAPERS Fig. 1. Travel unit quantity and capacity.

Fig. 2. Breakdown of batch sequence period.

and fifth unit will produce C3, C4, and C5 capacities respectively. The relationship between the capacity and number of travel units is clearly nonlinear as doubling the travel units does not necessarily double the designâ&#x20AC;&#x2122;s capacity potential. Consider a fixed length of track in which a variable number of travel units execute tasks. If the track is 100 meters and more travel units are added to increase the capacity potential, one will see that the capacity approaches a threshold limit where they begin to interfere with one another and capacity is compromised, and the utilization of each travel unit is sacrificed as they hinder each other. Based upon this, how does one know what quantity of travel units will produce the optimum results? Even assuming that the optimum number of travel units has been selected, how does one verify that the target capacity can be met with the proposed system design? One common method is using linear approximation as a linearized model can provide an estimate of the system potential by identifying the section of the system that has the lowest rate of production: the bottleneck. This is the point in

system space where the entire system production is limited to the speed at which this section can process the product. For coil batch pickling, this often is the pickling tanks as they have the longest processing times. Consider how one estimates the capacity through linear approximation. Determining the sequence period is the key to estimating a designâ&#x20AC;&#x2122;s capacity potential. The sequence period is the time from when the recipe time starts to the point where the next coil batch is brought in and the recipe time again begins. See Fig. 2. One can see that the period repeats itself again and again. To determine how many sequence periods can fit into a specified time frame, one would assume no time variations for the sequence events. However, the reality is that there will be time variations, such as for manual transportation lines where an operator directs the crane via a remote control or is sitting in a cab. The majority of the sequence period is comprised of the tank immersion time, Trecipe, which is usually driven by the

Fig. 3. Static cascade tank configuration.

Fig. 4. Parallel tank configuration. JUNE 2012 | 57

TECHNICAL PAPERS

type of steel grade being pickled. Various tank configurations can lend themselves to help reduce this time so that an overall sequence period is lower. Fig. 3 displays a cascade configuration of tanks that will require a higher travel unit utilization and more handling operations. The batches are required to go into each tank one by one until one acquires a total process time of Tprocess. The parallel pickling configuration has much fewer handling operations, so one would expect to see lower utilization of the travel units compared to that of the cascade setup. Fig. 4 displays the setup where incoming batches are only required to go into one of the tanks. The batch will remain in the tank until the entire treatment time requirement has been satisfied. Afterwards, there is no need to be cascaded into the next pickle tank. As a result, the sequence period in this setup will be smaller since fewer transfers are required. Fig. 5 shows a breakdown of the highest processing section, displaying all the time elements required to execute one sequence period. This sequence is centralized around Tank T2. Once the required time in Tank T2 has been satisfied, it will be transferred to Tank T3. The batch in Tank 1 will then be transferred into Tank T2. Now that the various components of the sequence are broken down, an expression that gives the time required for the sequence period, TSequence, can be written down and calculated as: Tsequence = [Trecipe + T1st

T1st

transfer

wait

+ T2nd

+ wait

Tlift

+ T2nd

Tdrip transfer]

where, Trecipe T1st wait Tlift Tdrip

= the required tank immersion time = the time between the finished tank process time and arrival of travel unit to remove batch = the time required to lift coil batch out of the tank = the time allotted for the coil batch to drip over the tank

Fig. 5. TSequence components. 58 | WIRE JOURNAL INTERNATIONAL

T1st transfer

= the time to transfer the batch, after dripping, to the next tank T2nd wait = the time between the request for the next coil and the travel unit arriving to accomplish the task T2nd transfer = the time to transfer the next ready batch into the initial tank

Once the sequence period is determined, the rate of production, Prate, can be calculated to give the number of batches the pickle line can produce on an hourly basis. From this, the annual production rate, Pannual, can be determined as tons of steel produced per year.

Annual Production Estimate = Pannual = (Prate . h.w) = P tons steel/year where, h = the amount of annual hours to be used for production w = the weight of one batch (minus the transfer hook weight)

Inaccuracies of linear approximation Linear approximation can be a useful guide tool for directing design and early layout decisions, but it has unavoidable shortcomings that cannot be accounted for, even in a single travel unit configuration. Generalized assumptions could prove disastrous later, and the designer must be assured that a travel unit is always ready and available to accomplish any batch moving task, otherwise the potential exists for overpickling. The equation TSequence accounts for some undefined amount of waiting time, T1st wait and T2nd wait, for which the travel unit is occupied and cannot immediately remove the coil batch when needed. This account of lost time is not consistent throughout the processing of coil batch products. Different aspects of the system have time varying dynamic affects that cannot simply be accounted for with this method-

Fig. 6. Three dimensional view of CMI pickle line computer model.

TECHNICAL PAPERS Fig. 7. Two dimensional view of CMI pickle line computer model.

Fig. 8. Simulation output data log.

ology. Further, when concepts such as the returning of product transfer hooks are considered, another layer of complexity is added to the simplified linear model. Thus, a time-based model is needed in order to overcome these complexities.

CMI Chemline has developed a proprietary computer modeling software in partnership with a software design house that can simulate the design of a wire coil plant in real time. Similar to applications used for airport terminal planning, the time-based computer model allows complete design analysis of the layout and process treatment times of both new and revamped batch wire pickling plants. Creating a simplified model of the pickling line system helps a designer better understand the dynamic complexities associated with the system as well as to observe how specific component parts interact over time. Such dynamic complexities cannot be perceived with mathematical annotation, therefore this analytical simulation approach is far superior to linear approximation. It can evaluate a lineâ&#x20AC;&#x2122;s capacity potential as well as other internal system parameters, such as how many product transfer hooks are needed, process tank size and arrangement, and travel unit quantities. The software provides an accurate analysis of the equipment and process design combination results and can generate a detailed task order list of all executed tasks performed by the travel units so a preliminary functional description and event schedules can be provided to assist in the control system design and implementation. Fig. 6 gives a three dimensional view of the simulation running. Fig. 7 shows a two-dimensional view of the process line. This is the main work window in which the model is developed and analyses are performed. This study was done to

evaluate the quantity of travel units needed in the design. Both Figs. 6 and 7 are models of the classic CMI U-Shape pickle line used in the Chinese markets for carbon and stainless steel. The line has loading/unloading sections on the same side, but at different location points. A cross-rinsing tank joins the top, serving as an entry line to the bottom exit line. Fig. 8, an output window, displays simulation data detailing items such as the time a coil batch was placed into a tank, the length of the stay in the tank, when it was taken out, and other details of the specified recipe time. As noted earlier, the loading/unloading of batch coils in and out of a line typically is the driving factor for the system layout. Four basic pickle line types are evaluated via simulation capabilities. Fig. 9 shows Straight Line Design A, where loading and unloading is done at one end of the line. The location point of coil batch loading is the same point of batch unloading. Typically, this design is used for lower capacity needs and where real estate is limited to a single column row. Fig. 10 shows Straight Line Design B, where loading and unloading is done on opposite ends of the line (entry end/exit end.) This design often has more capacity threshold than Design A. Fig. 11 shows a U-Shape Design, with loading and unloading done on the same side of the line, but an entry point and exit point are still defined in the layout. Traffic congestion between travel units and returning product transfer hooks is minimized. The Twin Parallel Design, shown in Fig. 12, is a hybrid of the other line layouts employing the loading and unloading on opposite sides. In this case, coupling it with another line parallel creates additional capacity. When generating a model, one must have a thorough understanding of what parameters are going to be implemented in the design. For example, the lifting and acceleration

Fig. 9. Straight line design A.

Fig. 10. Straight line design B.

Time-based computer model

JUNE 2012 | 59

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Fig. 11. U-shape design.

speeds of equipment such as travel units, the mechanical dimensions of the tanks via hook length, and the lifting heights based on the coil diameter and the site elevation must first be specified. Fig. 13 shows the continuous improvement process for how CMI answers the inquiry of the customer and indicates at what point the aid of the computer model is involved in the process. One of the most helpful aspects of computer-aided system modeling for batch wire lines is identifying a system’s limiting factors as it allows the designer to perform additional analyses to minimize bottleneck process rates and realize an optimum design. Through computer-aided system modeling, one has a deeper system understanding and insight, which allows for increased accuracy in equipment specification and design verification. This has proven to be an invaluable tool and source of information when pursuing the development of successful wire batch pickle lines.

Bibliography Fig. 12. Twin parallel design.

Gener Bellinger, Modeling & Simulation an Introduction. System’s Thinking. [Online] 2004. [Cited: 12 22, 2010.] http://www.systems-thinking.org/modsim/ modsim.htm. DP Johnson, DP. 2005. Theory of Constraints. Dealing with Production Bottlenecks. 2005.

Kearns

Fig. 13. Design procedure. 60 | WIRE JOURNAL INTERNATIONAL

Kimura

Wynn H. Kearns is sales manager responsible for business development in North America for CMI Industry Americas Inc., Salem, Ohio, USA. He earned an MBA degree from Ashland University, a master’s of science degree from Southern Illinois University, and a B.A. degree from Miami University. Adam Kimura is electrical engineer/R&D project manager for CMI. He earned a B.S. degree in electrical engineering and German from the Ohio State University. Arthur Seibert is project design manager at CMI. He has 35 years’ experience with design, commissioning, and service of wire coil, strip, and tube pickling lines. He was a leader in the design of the first automated wire coil lines installed in Sweden in 1978 and later in Korea, Taiwan, and the USA. This paper was presented at WAI’s 81st Annual Convention, Atlanta, Georgia, USA, May 2011.

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS XLPE can serve double-duty for photovoltaic wire and cable U.S.-based PolyOne reports that it has introduced new ground-breaking new technology for photovoltaic (PV) wire and cable called Syncure™ Solar. Available globally, this UVresistant, cross-linked polyethylene (XLPE) system provides high-performance, UL 4703 and VW 1-compliance in one material, eliminating the need to use two separate insulation and jacketing formulations, a press release said. It added that the product also provides customers a new option for improving efficiency, complying with RoHS requirements, and meeting sustainability goals. Syncure Solar, the release said, promotes the use of alternative energy by simplifying the wiring of PV systems as it complies with the stringent UL 4703 standard for PV wire as well as the UL 44 standard for interior wiring, so it can be used seamlessly from the outside to the inside of a building in USE-2 (Underground Service Entrance) applications, thereby streamlining installation. This, it noted, eliminates the need to create a junction between interior and exterior wiring or cabling. Syncure Solar is also a one-material solution, requiring just one pass through the extruder (versus the industry norm of two) for simplified logistics, reduced cycle time, and overall systems cost reduction, the release said, adding that the combined insulation and jacketing allows for a thinner coating (60 mil versus the typical 75 mil). Further, it comes in two colors, natural and black, with comparable performance, it said, adding that the company also offers color concentrates to provide a range of color options for easy, visual differentiation of wire and cable. Contact: PolyOne Corporation, www.polyone.com.

Electronic cables are very dependable, even in the most extreme environments U.S.-based General Cable has introduced EXZEL™ high-endurance electronic cables, an addition to the Carol® Brand line, that it reports has been engineered “for extreme environments where unparalleled performance is critical

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and cable failures are not an option.” A press release described EXZEL as perfect in applications where oil, liquids, vapors and other harsh substances can attack the jacketing of conventional “round gray” PVC electronic cables, ensuring it can withstand cruel and usual punishment. The cables are also offered in Low-Smoke, Zero-Halogen (LSZH) constructions, which produce low amounts of smoke and acid gas during a fire, while maintaining the same flame requirements, electrical performance and longevity as traditional cable constructions. The EXZEL high-endurance electronic cables, which are UV-resistant and contain sequential footage marking, are ideal for enabling critical signals in the following markets and applications: manufacturing, food and beverage, semiconductor, utilities, military, process and medical diagnostics, it said. The standard EXZEL cable, the release said, can also be customized to meet a customer’s unique application requirements, with specifications focused on: jacket colors, conductor count and construction, shielding options, composites, gauge sizes, insulation and jacket construction and armoring. “Whether you need an unshielded multi-conductor or multi-pair construction, or require the highest available shield coverage for maximum EMI/RFI resistance, General Cable will deliver quality-manufactured EXZEL cables, as well as exceptional technical sales support and service,” said Jeff Later, Vice President of Sales, Carol® Brand Electronic Products. Contact: General Cable, www.generalcable.com.

Cable maker takes ‘360’ approach U.S.-based Northwire reports that its new “Lab 360” contract manufacturing platform is a customer-focused engineering model that allows the company’s engineers to engage with customers through every process stage to make sure that their requirements are met. A press release said that Lab 360 has collaborative phases that start early in the process at the idea or concept stage. Essentially, the company’s certified

New fluidized-bed technology uses up to 15% less energy Germany’s Wire Körner announced that its new fluidizedbed furnaces can reduce energy consumption by up to 15%

and ease maintenance costs for a low investment. A press release said that the company’s innovative furnaces have no distributor pipes or tiles, and that it is designed for the combustion gas to be mixed outside the furnace to guarantee uniform temperature distribution and reduced emissions. The press release, issued before wire Düsseldorf, said that two of the units would be operational before the show was held the last week of March. Those two orders, it noted, were placed after the company introduced the new fluidized-bed furnace at wire 2010. The first furnace, it said, was being commissioned at a customer’s site in Turkey, while the second one was being installed in Ecuador. The patent-pending furnaces, the release said, dispense with distributor elements typically used in conventional designs, and “markedly reduces flow resistance of the com-

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experts translate customer requirements through disciplined process phases that can include: research and development, new product development, prototype, pilot models, clinical trials, low volume through high volume production, lifecycle innovation, and logistics. Rapid solutions for connectors, assemblies and contract manufacturing are available upon request, quotes are issued in 24 hours or less and custom products are delivered in five days, it said. The program, the release said, introduced earlier this year at the Pacific Design and Manufacturing Show, represents an engineering response to requests from customers for onestop contract manufacturing. “Lab 360 leverages Northwire’s professional certifications in Six Sigma, Lean, and Project Management to deliver precise customer requirements and enhance the hallmarks of our forty-year history of service excellence, quality, and rapid response,” said Northwire President Michael Conger, who noted that the company’s certifications include ISO 13485:2003, ISO 9001:2008, and ISO 17025 Qualified. Contact: Northwire, www.northwire.com.

PRODUCTS & MEDIA

bustion gas inside the furnace,” it said. Thus, blower capacity can be about 20% less than competing designs, and the overall simplified furnace design further reduces capital costs, it said, noting that the new design no longer requires a stand-by blower. “As the combustion gas is premixed outside the furnace, the new design achieves a uniform fuel-air mixing ratio throughout the fluidized bed and a homogeneous temperature distribution over the width and length. This results in higher combustion efficiency and lower emissions of unburned hydrocarbons,” it said. Contact: Wire Körner, tel. 49-2331-800-68-0, info@wirekoerner.com, www.wirekoerner.com.

TR-XLPE upgrade offers longer life for medium-voltage power cables U.S.-based Dow Electrical & Telecommunications (Dow E&T) announced that it has made a small but powerful change in the formulation of its market-leading tree-retardant crosslinked polyethylene (TR-XLPE) for medium voltage (MV) power cable insulation that will result in an enhanced level of performance for underground (UG) cable manufacturers, installers and utilities. A press release said that DOW ENDURANCE™ HFDC-4202 EC now offers: longer expected life than existing TR-XLPE products; improved performance in wet UG operations through enhanced tree-retardant technology; reduced strip force, with Dow E&T insulation shields, allowing for easier and cleaner termination and splicing of cable during installation; improved manufacturing robustness which ensures improved cable quality; and ability for continuous operations at 105°C cable rating, with Dow E&T semiconductive shields.

“Over time we’ve demonstrated that proper material selection is critical to the performance of the cable in field applications,” said Nathan Jeppson, Global Power Platform Leader, Dow E&T. “Equally important is high-quality cable manufacturing. As part of our Dow Inside program, we’ve worked closely with select cable manufacturers during the one-year ICEA S-94 cable qualifications that are now complete. Based upon these results, we are confident that DOW ENDURANCE HFDC-4202 EC delivers excellent performance.” The upgraded product, the release added, is also undergoing testing according to the European CENELEC HD 620 specification and is expected to meet the highest requirements of the long term wet-aging test. Contact: Dow Electrical & Telecommunications, www.dow.com/electrical.

Laser cross welder makes use of thinner gauge material possible The machinery business unit of Germany’s Nexans has developed a new laser cross welder to buttweld thin metal strips to allow continuous production of cables, tubes, etc. A press release said that the ability to produce a repeatable, highquality butt weld for thin strip material, such as stainless steel 0.05 mm thick and from 5 mm to 170 mm wide offers considerable economic savings. The welder it said, is both compact and mobile, and a laser integrated

Sheaves - Pulleys Cable Guides ProcessSheaves.com 866-344-6774 64 | WIRE JOURNAL INTERNATIONAL

Company line of Cat. 5 cable now includes industrial Ethernet U.S.-based Alpha Wire has added industrial Ethernet to its family of Xtra-Guard high-performance cables, with new Cat. 5e cables that it said enable Ethernet communications with the durability and temperature range of Alpha’s XtraGuard 4 jacket, making it a perfect solution for demanding applications. “The idea to use our XtraGuard 4 jacket on an industrial Ethernet cable came from customers who needed a flexible and routable Ethernet cable that could withstand extreme environments,” said Tim Howlett, the company’s director of marketing. “We decided to take it a notch further by offering zero minimums on this line, with put-ups as small as 500 feet.” The new cables are available in a choice of unshielded, foil shield, or Supra-Shield® foil/braid. Alpha Wire’s SupraShield uses a combination aluminum/polyester/aluminum foil and tinned copper braid that offers exceptional EMI performance and flexibility, the release said, noting that the cables are UV- and fluid-resistant, meet UL 1666 Riser and CSA FT-4 flame tests and are suitable for use in NFPA 79 applications. The connectivity cable, it said, is available in a temperature range of -50°C up to +125°C on FEP-insulated conductors and -50°C up to +105°C on polyethylene-insulated conductors, and the TPE jacket is available in black with standard lengths of 500 and 1000 feet. Other colors, including red and teal, are available as special orders. The company’s website can be used to download data sheets, access search filters and place free sample requests. Contact: Alpha Wire, tel. 800-522-5742, www.alphawire.com.

Dual-head ultrasonic wire splicer is both quick and very cost-effective U.S.-based Sonobond Ultrasonics, Inc., reports that the company’s dualhead SpliceRite™ ultrasonic wire splicer can process stranded copper wire bundles with crosssectional areas up to 100 sq mm all in one pulse for rapid, reliable and costeffective assembly of wire harnesses. The equipment, which was scheduled to have been displayed at the recent the 2012 National Electrical Wire Processing Technology Expo, “is unequalled in its handling of large wire bundles,” Sonobond Vice President Melissa Alleman said in a press release. The splicer, it said can reliably weld stranded copper wire bundles having cross-sections of 48- to 100-sq mm, and can accommodate lightly tinned or oxidized wires up to 60-sqmm without pre-cleaning. “No other ultrasonic metal

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within the unit’s lower part allows it to be easily rolled between production lines. The two strip ends are manually fed into the cross welder and clamped in position; the strip ends are then cut and positioned for the welding process, and upon activation the welding process will start and create a weld seam using one of 50 programmable, customized sets of parameters, it said. TIG welding for thicker material is available, and the whole machine is certified as LASER CI.1, thus eliminating the need for protection glasses during operation, it said. Test welds using clients material can be arranged on request. The system is represented in the U.S. by Cable Consultants Corp. Contact: Nexans, tel. 49-511-676-3163, www.nexans.com; and in the U.S., Cable Consultants Corp., tel. 704-375-9313, tel. 914-834-8864, fhardy@cableconsultantscorp.com.

PRODUCTS & MEDIA

welder can accomplish these splices in a single pulse. All this makes the (system) ideal for fast, dependable, cost-efficient ultrasonic splicing of the heavy-duty cables used in wire harnesses for cars, trucks, trains, industrial machinery, and similar applications,” it said. Ultrasonic metal welding, the release said, is now a wellaccepted and frequently used method of assembling wire harnesses, as it creates solid-state metallurgical bonds with high conductivity without the need for filler metal materials and without clipping, soldering, crimping, or dipping. However, the Sonobond system is unique in that its two ultrasonic transducers and couplers—one above and one below the weld area—plus a set of pneumatically driven jaws, gather the wires tightly to a preset width and then the upper tip descends to complete the compressing of the bundle followed by the use of ultrasonic power in a cost-effective process that produces no waste, consumes only minimal energy, and is environmentally friendly. Contact: Melissa Alleman, Sonobond Ultrasonics, Inc., tel. 610-696-4710, info@sonobondultrasonics.com, www.sonobondultrasonics.com.

Vinyl compound line to use Dow ECOLIBRIUM™ plasticizers U.S.-based Teknor Apex Company reports that it is supplying innovative vinyl compounds made possible by an agreement it has entered into with Dow Electrical and Telecommunications (Dow E&T), a unit of The Dow Chemical Company. A press release said that Teknor Apex is using Dow E&T plasticizers made from renewable resources that provide the performance advantages of conventional vinyl, have a smaller carbon footprint than alternative plastics like polyolefins or polyurethanes, and may be more cost-efficient than “green” biopolymers. The new BioVinyl™ line of flexible vinyl compounds incorporate phthalate-free DOW ECOLIBRIUM™ biobased plasticizers that are manufactured using plant byproducts by Dow E&T per a joint collaboration agreement that has given Teknor Apex exclusive rights to use them in North America for certain applications that include some wire and cable products. Traditional plasticizers are based on petrochemical feedstocks. “In replacing petrochemical-based products, ECOLIBRIUM bio-based plasticizers can help reduce greenhouse gas emissions by up to 40%,” said Thorne Bartlett, new business development director, Dow E&T, which has estimated a net reduction of 0.7 lb of carbon dioxide emissions for every 1.0 lb of compound made with diisononyl phtha-

66 | WIRE JOURNAL INTERNATIONAL

late (DINP) as compared with compounds made with biobased plasticizer. “In the case of a 1-million pound (450 metric ton) application for flexible vinyl compound, the reduction in emissions would be equivalent to removing 63 automobiles from the road on an annual basis, or 35,600 gallons of gasoline consumed,” he said. BioVinyl compounds are even less dependent on fossil fuel-based feedstocks than conventional flexible vinyl, observed Louis R. Cappucci, vice president in charge of the Vinyl Division of Teknor Apex. “Vinyl compounds incorporating DOW ECOLIBRIUM Bio-Based Plasticizers will actually be 60% based on renewable resources, since half of the PVC polymer is derived from seawater and typical plasticizer loadings are 33%,” he said. Contact: Teknor Apex Company, www.teknorapex.com, www.dow.com/ecolibrium.

Rigid stranders offer high production speeds for power cables India’s Associated Engineers & Industrials, Ltd. (AEI), reports that ASRB/E, its latest line of rigid stranders, represent integration of top quality mechanical craftsmanship with the latest generation control systems. A press release said that the company, which has 40 years of experience in making high technology stranding machines for the production of medium-, highand extra-high voltage power cables, produces all machined parts in-house to control quality at all stages in true machinery manufacturing tradition. The intelligent stranders incorporate features such as electronic-shaft synchronization (including during power failure), individual wire break detectors, auto-regulated pneumatic bobbin brakes, motorized pintles, remote diagnostics and fully automatic floor/trolley loading devices. The release said that other recent innovations include trapezoidal wire (TW) heads for the manufacture of new generation preshaped wire conductors and a completely redesigned prespiral sector heads for production of higher precision Milliken conductors for 2500 mm2 x 400 kV EHV cables. “AEI’s strength lies in the complete understanding of customer requirements and its ability to offer stranders with various options to suit the exact production needs,” it said, noting that three-quarters of the company’s production “is based on repeat orders, a testimony of our customers’ satisfaction and their confidence in our machines.” Contact: L.S. Jain, Associated Engineers & Industrials, Ltd., e-mail info@aeimachines.com, www.aeimachines.com.

Video cites a century of stainless steel The International Stainless Steel Forum (ISSF) reports that it is offering a video, 100 Years of Stainless Steel, that can be downloaded online. The video, a press release said, marks the centenary anniversary of the discovery and commercialization of stainless steel. As well as covering the history of stainless steel and its alloying elements, the video features many applications for the remarkable material, from its early days through today. It notes that demand for stainless steel has increased 10-fold in the 40 years since 1970, and explains why the industryâ&#x20AC;&#x2122;s long-term growth rate remains above 6%. The video was prepared by ISSF in partnership with members of the Team Stainless Network which includes: ISSF, Euro Inox, the International Chromium Development Association (ICDA), the International Molybdenum

Association (IMOA), and the Nickel Institute. The video was scheduled to have been shown at the 100 Years of Stainless Steel travelling exhibition that was to start its journey around the world in Beijing, China, on May 15. The video can be accessed in English and Chinese versions at www.stainlesssteelcentenary.info. Contact: International Stainless Steel Forum, www.worldstainless.org.

NEMA publishes magnet wire standard The National Electrical Manufacturers Association (NEMA) has published ANSI/NEMA MW 1000 Magnet Wire, a publication for general requirements, product specifications and test procedures for the manufacture and packaging of magnet wire. A press release said that the standard is designed to present in a concise and convenient form all existing NEMA standards for magnet wire. It contains definitions, type designations, dimensions, constructions, performance, and test methods for magnet wire generally used in the winding of coils for electrical apparatus. It may be viewed at www.nema.org/stds/mw1000.cfm. A hard or electronic copy ($112) can be bought at global.ihs.com, or at IHS, tel. 800854-7179 (U.S.) or 303-397-7956 (international). Contact: National Electrical Manufacturers Association, www.nema.org.

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MEDIA

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

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

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

PAYMENT POLICY: All ads must be pre-paid.

WANTED: AGENTS MANUFACTURER SALES REPRESENTATIVES. Established US Manufacturer of welded wire mesh products looking for sales agents in the following global regions, Africa, Asia, Central America, the Caribbean, Europe, Middle East, North America and South America. Must work with complementary product lines in marine, fencing, fence security, cage, construction, farming/agriculture or reinforcement mesh.

DEADLINES: Copy is due a full month in advance. Contact: classified@wirenet.org for more details.

For more information, please contact: jobs@riverdale.com.

losales@msn.com or you can call: 802.368.2555

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PERSONNEL SERVICES

MANUFACTURER’S REPRESENTATIVE. The Metallo Sales Group is seeking additional lines to represent in the wire industry. Our current lines are; copper alloy, wire, strip, rod and bar. We have extensive experience in manufacturing and sales in the ferrous and nonferrous wire industry. For more information please contact us at: metal-

“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors and managers.

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

FOR SALE

1 - NIEHOFF Model SPH801.1.G.E.A Automatic Spooler 1 - NEB 12-C #2 Braider, Long Legs, Motor 3 - TMW 24-Carrier Cable Braiders, 6” Horn Gears 1 - EDMANDS 18-Wire, 6+12, 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - PIONEER 50” Caterpuller Capstan, new belts 1 - CONAIR 39” Continuous Belt Caterpuller Capstan, Model 6-39 3 - DAVIS STANDARD 3.5”, 4.5” 24:1 L/D Extruders 1 - D/S 2.5” 24:1 L/D Hi-Temp Extruder 1 - D/S 2” 30:1 L/D Hi-Temp Extruder 1 - SKALTEK 1600mm Motorized Payoff, Model A16-4K 1 - HALL 40” Motorized Payoff w/Dancer 1 - CLIPPER DF6 Dual Cone Flyer Payoff (24” Reels) w/Reel Jacks 1 - ROSENDAHL 630mm Parallel Axis Dual Reel Take-up, never used 1 - CLIPPER Model SP16 Dual Spooler

1 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-up, 1997 1 - SPHEREX 18” Dual Reel Take-up, refurbished 2 - AL-BE Model MS12 Respoolers, 12” Reels 1 - REEL-O-MATIC Model PRR1 Rim Drive Powered Reel Roller 1 - REEL-O-MATIC Model RD-5 Rim Drive Take-up w/Coiling Head 1 - WEMCO 84” Take-up, Model 8284B, w/Mobility Package 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4-Wire 24” D.T. Twisters, Model 4WDT24 1 - FINE Preheater, Model IP4000-180-1, 2007 1 - EUBANKS Model 4000-04 Cut and Strip Machine 1 - EUBANKS Model 9800-03 Cut & Strip Machine 1 - GETTIG Tape and Labeling System 1 - CARPENTER 3-Head Stripper, Model 74-C 3 - CARPENTER Strippers, Model 70-B 1 - MICRODIA Crosshead, Model M9000/10XFL 1 - DCM Electronic Switching System, Model ES-350PC

Contact: Martin Kenner

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

68 | WIRE JOURNAL INTERNATIONAL

Contacts: Peter Carino, pcarino@ wireresources.com or at www. linked in.com/in/petercarino1, or Jack Cutler, jcutler@wireresources.com. Wire Resources Inc, 522 E Putnam Ave, Greenwich, CT 06830, tel. (203) 622-3000 or (800) 394-WIRE. Visit our website at www.wireresources. com.

DIES APOLLO DIA-CARB COMPANY. Sells Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508-226-1508 or by e-mail at apollodie@ comcast.net.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, color-o-meters and pointers). Tel: 727863-4700 or by e-mail, please send to urbassoc@verizon.net.

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

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MACHINERY FOR SALE: CENTRIFUGES. Wire drawing coolant filtration - New and Used. Fully Automatic for Aluminum Wire, Copper Wire. MARS TECH PH: 845-6383100 email: sales@marstechusa.com

PURGING COMPOUNDS AMERICA’S OLDEST SUPPLIER. Since 1948, we’ve supplied millions of pounds so we know a little bit about JIT deliveries and customer satisfaction. We sell for less because our costs are less. BUY SMART – WE DO. Alan Plastics Co., Inc. PH: (781) 828-0700. FX: (781) 828-2087. Contact: E-mail: Alplas@aol.com www. Alplastic.com.

MEDIA ELECTRICAL WIRE HANDBOOK SET. Focusing on the special needs of the insulated wire and cable industry, these books examine materials, equipment, and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables, communication cables, magnet wire, heater wire, and other applications. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables.

While the updated handbook includes the latest information available, this new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. TPrice $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore. THE SMALL SHOP. This book, 327 pages, was written by Gary Conner, the author of Lean Manufacturing for the Small Shop, describes six sigma and how it is used in smaller companies. Published by the Society of Manufacturing Engineers, it shows the relationship between continuous improvement, lean, and quality, and focuses on implementation for operators, managers, and owners. It explains how continuous improvement tools support each other and how they can accomplish what just one or two tools by themselves cannot. The book includes a supplementary CD-ROM. Price, $95, $75 for WAI Members. To purchase, go to wirenet.org and click on The WAI Bookstore. THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legancy. “But it’s all wire,” proclaimed a 1950s Roebling Company brochure about its diverse product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and

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

aircraft strand, flat and braided wire, prestressed concrete wire and strand, galvanized bridge wire, and many other products. To maximize quality, the Roeblings started drawing their own wire in the 1850s, rolling bars into their own rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history chronicled in The Roebling Legacy. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore. SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this new (published in 2011) 135-page, indexed softcover book was written by industry expert Douglas B. Relyea, founder and senior partner of Quality Principle Associates, a New England-based consulting firm that specializes in the education and application of data analysis techniques to industrial problem solving. The book delineates the process capability study, a powerful tool that, when understood and implemented, provides benefits to every department within a manufacturing organization. With easy to read, step-by-step flow diagrams on how to perform process capability studies and measurement process analyses, the book’s coverage includes: the benefits of statistical process control

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WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION

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over statistical product control; real-world industrial examples and case studies illustrating how to use the techniques; ways for management to determine if the investment in process capability studies is providing an appropriate return; methods to correct lack of stability and capability once either condition has been identified, such as the ANOVA technique and the simple three-factor designed experiment; and a flow chart that enables machine operators to execute a process capability study without interfering with productivity. A great deal of information is available on the technical concepts of the process capability study, much of it emphasizing the mathematics. This book shows you how to use the process capability study to increase return on investment from your statistical process control/Six Sigma effort and make your company more competitive. The list price is $45, $40 for WAI members.To purchase, go to wirenet.org and click on The WAI Bookstore. STEEL WIRE TECHNOLOGY, 4TH EDITION. This 348-page indexed book by Per Enghag, published in 2009, represents a bridge between theory and practice, providing useful information as well as new material for both veteran wire industry people as well as mechanical engineering students. The newest edition includes two new chapters: Roller Dies, and Modeling and Simulation. Other topics include: wire rod preparation and scale removal; drafting; tribology, lubricant carriers and lubricants; wiredrawing machines and other wiredrawing machinery; drawing dies and die preparation; wire cleaning; material behavior in a die; heat treatment; drawing force and power; surface coating; work hardening; and wire testing. Some chapters have been updated to present new production and testing methods. The Steel chapter, now Steel and Steel Standards, includes a review of global steel standards. The Heat Treatment chapter now includes oxygen potential data (Ellingham diagrams) as well as thermodynamic principles. Diffusion processes have been introduced and utilized for decarburization calculations. The book is useful as a practical resource for technicians, supplementary reading for students in mechanical engineering, or as course literature within a company. Author Per Enghag has more than 30 years of experience in metals. After starting his career as director of The Swedish School of Mining and Metallurgy in the 1960s, he moved to steel wire products producer Garphyttan in the 1970s. He has operated his own company, Materialteknik HB, in Ă&#x2013;rebro, Sweden, since 1980. The price is $110, $95 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Bookstore.

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

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

Fushi Copperweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .63

Gauder Group/Daloo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Bergandi Machinery Co . . . . . . . . . . . . . . . . . . . . . . . . . . .67

GCR Eurodraw SpA . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

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

Howar Equipment Inc/GMP Slovakia . . . . . . . . . . . . . . . .21

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16, 30

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 4

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Nano-Diamond America . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .68

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Cuprom SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Parkway-Kew Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Daloo/Gauder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .43

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

PRO-pHx Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .41

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Reel-O-Matic Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Equipment Sales | Equipment Purchasing | Reconditioning Services www.wireandplastic.com | Info@wireandplastic.com

JUNE 2012 | 71

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE Schlatter North America . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

August 2012 WJI

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

• Power Cables • Preview: wire China 2012

August Strecker GmbH & Co KG . . . . . . . . . . . . . . . . . . .39

Advertising Deadline: July 1, 2012

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

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . .4, 32 Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Wire & Cable Asia 2012 (Integer Research) . . . . . . . . . . .33 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .71 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .12

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 WAI webinar: flame-retardant polymers . . . . . . . . . . . . . .70

WIRE JOURNAL

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

NORTH AMERICA

EUROPE

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

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

72 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International Spitzwegstraße 4 82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

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

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

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

email: amacoil@amacoil.com

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