Interwire Wrapup by Wire Journal International, Inc.

WIRE JOURNAL JUNE 2013

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Interwire Wrapup Testing & Measuring Equipment

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WIRE JOURNAL

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

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

CONTENTS

Volume 46 | Number 6 | June 2013

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 24 Fastener Update . . . . . . . . . . 26 WAI News . . . . . . . . . . . . . . 28 Chapter Corner . . . . . . . . . . . 34 Products. . . . . . . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . . 83 Career Opportunities . . . . . . . 83 Advertisers’ Index . . . . . . . . . 87

Wire Link Scholar report

. . . . . . . . .36

The 2013 Wire Link Scholar, William Binnie, an engineer for U.K.-based Kiveton Park Steel, Ltd., recalls his busy two-week trip in the U.S.

Wrapup: Interwire 2013 . . . . . . . . . .40 The overall tone was quite positive at Interwire 2013, which saw more than 4,000 attendees take part in North America’s largest trade show for wire and cable.

Testing & Measuring Equipment . . . .54 This feature presents a range of testing and measuring equipment that was displayed by exhibitors at Interwire 2013.

T ECHNICAL P APERS

Next issue July 2013 • Equipment

Mordica Lecture: The importance of package size in the manufacture of steel tire cord Thomas W. Tyl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 IWCS Paper: Analysis of advanced solution for unscreened cables for high data rate digital communications Dr. Christian Pfeiler and Denis Molin . . . . . . . . . . . . .72

Cover: Michael Cirone, global vice president of sales and marketing, New York Wire, front right, was among the attendees who came with a shopping list to Interwire 2013 at the Georgia World Congress Center. Photo by Terence Rushin, Southwire Company.

JUNE 2013 | 3

INSIDE THIS ISSUE CONTENTS

GOING BACK HOME...TO ATLANTA . . . . . .40

Atlanta once again proved to be an able host for Interwire. The 2013 staging of the Association’s biennial event drew more than 4,000 people, the largest such gathering for the wire and cable industry in the Americas. The event included the trade show, conference programs, social events and offered a slew of opportunities.

4 | WIRE JOURNAL INTERNATIONAL

INTERWIRE: A ‘HANDS-ON’ EXPERIENCE . . .40 At Interwire, US Synthetic’s Todd Mick (l) speaks with attendees as Jonathan Sands of Dayton Superior gets a closer look at a die. Many exhibitors reported that they had good meetings during the trade show, which was held April 23-25 at the Georgia World Congress Center.

EDITORIAL WIRE JOURNAL

EDITORIAL

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

Interwire: solutions, opportunities and more The 2013 Interwire Trade Exposition proved once again to be the market and meeting place for our very diverse wire and cable industry. The wrapup of the event begins on p. 40, and I encourage you to review it, but in this space I’d like to share some personal impressions that put the event in context for me, and maybe will for you as well. Everyone attends Interwire with an agenda, that most often being finding solutions or opportunities. This is true for wire and cable manufacturers as well as suppliers, regardless of the industry you serve or the position you hold in your organization. In the simplest of terms, if you are not delivering solutions, then you better be generating opportunities. As executive director, I am not a traditional attendee with immediate needs, and as a result my perspective was unique. My vantage point allowed me to look at the many parts that collectively make up Interwire as the event was going on. Below is my take of what happened at the Georgia World Congress Center in Atlanta, how that translates to the industry, and why I left feeling so optimistic. • I saw the strength of the industry in the attendee base, which included many key decision makers from plants, both large and small, throughout North America. • I saw exhibitors working diligently to attract customers to their booths, using social networking and product innovation. • I saw presenters and panelists sharing their experience on topics— such as Lean, recruitment and work safety—that matter to both employees and their companies. • I saw manufacturers exploring booths of companies that are not their current established suppliers to see what they may be missing. • I met some of the many young professionals who made the most of the educational courses and greatly expanded their network by participating in Q&As, hallway conversations and the social events. • I saw all the facets of the wire and cable industry together, under one roof, sharing ideas, and contributing to the advances that will define our industry going forward. I hope everyone was successful in their pursuit of solutions or opportunities, and I thank everyone for their participation.

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 editorial@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. © 2013 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 25-28, 2013: wire Russia 2013 Moscow, Russia. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Sept. 17-19, 2013: wire Southeast Asia Bangkok, Thailand. Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Sept. 19-22, 2013: Cable & Wire Turkey Istanbul, Turkey, To be held at the CNR Expo Center. Contact: tel. 90-0212- 465-74-74/3227, re.koc@cnr.net, www.cnrexpo.com. Oct. 1-3, 2013: wire South America 2013 São Paulo, Brazil. Messe Düsseldorf and Grupo Cipa will stage this event at the Imigrantes Exposicoes Exhibition Centre. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. ov. 4-5, 2013: Cabwire World Conference Milan, Italy. To be held at the Palazzzo Turati, this technical conference is again being put on by ACIMAF, CET, IWCEA, IWMA and WAI. For more details, go to www.cabwire.com. ov. 10-13, 2013: 62nd IWCS ConferenceTM Charlotte, orth Carolina, USA. To be held at the Charlotte Convention Center. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.

April 7-11, 2014: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. May 6-7, 2014: WAI Operations Summit & Wire Expo Indianapolis, Indiana, USA. This WAI event will be held at the Indiana Convention Center, including its trade show, technical programs and WAI’s 84th Annual Convention. It will be co-located with AISTech. June 16-18, 2014: 14th Guangzhou Int’l Metal Plate, Bar, Wire, Metal Processing & Setting Eqpt Exhibition Guangzhou, China. Contact: Guangzhou Julang Exhibition Design Co. Contact: tel. 86-20-38621071, expo@julang.com.cn, www.metalchina-gz.com. Sept. 24-27, 2014: wire China 2014 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. Oct. 28-30, 2014: Wire & Cable India Mumbai, India. This event will be held at the Bombay Convention & Exhibition Centre. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

W IRE ASSOCIATION INTERNATIONAL E VENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org.

June 21, 2013: Midwest Chapter 11th Annual Golf Tournament West Chicago, Illinois, USA. The Chapter will return to the St. Andrews Golf & Country Club. Contact: Steve Fetteroll at tel. 203-453-1748, sfetteroll@wirenet.org. Aug. 1, 2013: Ohio Valley Chapter 11th Annual Golf Tournament Solon, Ohio, USA. The Chapter will return to the Grantwood Golf Course in Solon, Ohio, USA. Contact: Ron Fulop at r.fulop@wirelab.com. Sept. 9, 2013: ew England Chapter 19th Annual Golf Tournament Ellington, Connecticut, USA. The Chapter will return to the Ellington Ridge Country Club. Contact: John Rivers, tel. 860-896-476, johnr@dms-inc.com.

8 | WIRE JOURNAL INTERNATIONAL

Oct. 21, 2013: Western Chapter 13th Annual Wild West Shootout Fontana, California, USA. The Chapter will play at the Sierra Lakes Golf Course. Contact: John Stevens, tel. 909476-9776 or jstevens@emc-wire.com; or WAI’s Steve Fetteroll at tel. 203-453-1748, sfetteroll@wirenet.org. Oct. 24, 2013. The Vannais Southeast Chapter 12th Annual Golf Tournament Conover, orth Carolina, USA. The Chapter will return to the Rock Barn Golf and Spa. Contact: Art Deming, tel. 252-955-9451, art.deming@nexans.com. May 6-7, 2014: WAI Operations Summit & Wire Expo Indianapolis, Indiana, USA. See main listing.

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INDUSTRY NEWS

INDUSTRY NEWS Leoni expands globalization focus by establishing a 2nd plant in India Germany’s Leoni AG announced that it has continued its global expansion strategy this year by establishing its second plant in India, near Pune, to serve automotive, energy and rolling-stock customers. A press release said that manufacturing of standard cables for the automotive industry had started earlier this year at the plant, which has a production area of around 15,000 sq m. The plant will eventually also produce automotive special cables, it said. The company plans to invest about 11 million euros by the end of the year for equipment and the facilities, which will have a workforce of about 140 employees. It noted that projections call for the Indian automotive market to annually grow about 12% until 2016, reaching 5.8 million locally produced units per year.

Jürgen Kniffki, managing director Leoni Kabel Holding GmbH, (left) and Pushpendra Singh, managing director of LEONI Cable Solutions (India) Private Limited, at the opening ceremony of the company’s second plant in India. “India promises attractive medium- and long-term growth prospects for several of our targeted industrial markets,” Leoni AG President and CEO Dr. Klaus Probst said in the release. “Opening this new plant...is an essential move to better serve local customers and to drive our globalization in India and close-by countries.” He noted that the plant offers multiple advantages, such as better logistics, use of local cost structures and avoidance of import duties. While best known for automotive wiring, Leoni will also commence local production of cables and cable systems for the renewable energy market in order to serve the rising demand in this field, the release said. Longterm plans, it added, include installing electron beam

equipment by 2015 to manufacture the latest generation of very robust and durable cables for solar and railway applications. It said that Leoni plans to export a major portion of such products to other countries. Leoni opened its first plant in India in 2010, an engineering office and a manufacturing facility for automotive wiring systems that is also located in the Pune area, the release said.

Ericsson to exit telecom cables, will sell power cable unit to nkt cables Citing overcapacity in the telecom cable market and more activity going to Asia, Sweden’s Ericsson announced that it is ending its telecom cable operation within its Networks business unit in Europe, a decision that primarily impacts its operations in Hudiksvall and Stockholm in Sweden. A press release said that Ericsson—which weeks earlier announced the sale of its Swedish power cable manufacturing operations to nkt cables—plans to cut Hudiksvall by 318 positions and to reduce the Stockholm workforce by 36 positions. As one wire story observed, Ericsson has essentially left cable making entirely. The company did not respond to a WJI query on that status as of press time, but it was clear that Ericsson was not optimistic about cable manufacturing given the sector’s current conditions. “As the market for copper cable has declined and the market for fiber cable has grown over the last years, the production has shifted towards Asia, where the majority of the business volumes for fiber cable are found,” the release said. It noted that in Europe there is more production than demand for both copper and fiber cables. “The decision is based on the fact that Ericsson’s production of telecom cables is small from a global perspective, and that we also have a small market share,” said Tomas Qvist, head of special products in the Networks business unit and head of human resources for Ericsson in Sweden. “Unfortunately, our production has not been operating at full capacity for a long time and has struggled with profitability.” nkt cables had previously announced that it had agreed to buy Ericsson’s power cable operations, a move that it said would strengthen the company’s position in the market for medium- and low-voltage cables in the Nordic region. A press release said that the Swedish operations in Falun, which have approximately 320 employees, include production facilities and a development department as well as sales and administration offices. The factory’s location and product portfolio will be complementary to nkt cables’ factory in Asnæs, Denmark, thereby creating a cost-efficient production and logistics set-up for servicing

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

10 | WIRE JOURNAL INTERNATIONAL

Prysmian Group wins U.S. submarine cable contract worth $100 million Italy’s Prysmian Group reports that it has won a new turnkey contract worth more than $100 million for the supply and installation of submarine cables for a section of ExxonMobil’s existing offshore operations in the U.S. A press release said that the project calls for the replacement of some 50 km of submarine power cables with increased capacity 40 kV EPR submarine cables designed for water depths of up to 450 meters. The cables, it said, will supply electric power from the existing shore-based generating plant to offshore platforms. The cables will be supplied by Prysmian’s plant in Drammen, Norway, with installation done by the company’s laying vessel, the Cable Enterprise. “We are very pleased to undertake this cable replacement operation,” said CEO Prysmian Powerlink Marcello Del Brenna, who noted that the company has previously supplied and installed other sections of ExxonMobil’s subsea power network in the U.S. The release said that Prysmian has been taking part in the development of some of the most strategic submarine power interconnections worldwide. It noted that the Group is currently involved in other U.S. projects, such as the execution of the Hudson Transmission Project, which will bring clean power to about 600,000 new homes in Manhattan, New York, and that it has been commissioned for the TransBay Cable Project in San Francisco.

Alcatel-Lucent and consortium to build 8,000-km subsea cable system Alcatel-Lucent announced that it will work with a consortium to deploy a new 100 Gigabit-per-second (100G) submarine cable system to connect Oman, the United Arab Emirates, India, Sri Lanka and Malaysia. A press release said that Alcatel-Lucent will work with a consortium of Vodafone Group, Dialog Axiata, Emirates Telecommunications Corporation (Etisalat), Reliance Jio Infocomm, Omantel and Telekom Malaysia to create the Bay of Bengal Gateway (BBG) cable system. It said that the project “will enhance the robustness and reliability of international connectivity into and out of the countries via landing points in Barka (Oman), Fujairah (United Arab Emirates), Mumbai and Chennai (India), Ratmalana (Sri Lanka), Penang (Malaysia) and Singapore.” The BBG consortium, the release said, will integrate Alcatel-Lucent’s latest innovations in subsea communications. Alcatel-Lucent will install cable and repeaters and manage the cable system via its end-to-end submarine network management system as well as be in charge of

project management, system design, marine operations and system commissioning, it said. The release said that commercial operation of the system should be working by the end of 2014, offering ultrahigh capacity, underpinning the continued growth of new applications and services in the Middle East, the Indian sub-continent and the Far East. “BBG, the first system to be lit as 100G on Day 1, will be a step change in capacity on this important route,” said Edward West, chairman of the BBG Interim Procurement Group.

Nexans wins record DEH project Nexans reports that it has been awarded a 25 million euro contract by Subsea 7, a global supplier to the offshore energy industry, to design and manufacture a direct electrical heating (DEH) system that, when completed, will feature the world’s deepest such deployment. A press release said that Subsea 7, which supplies seabed-to-surface engineering, construction and services, will use the DEH system for subsea pipelines serving the Lianzi oil field development located in a unitized offshore zone between the Republic of Congo and the Republic of Angola. The Lianzi field, which is operated by Chevron Overseas (Congo) Limited, ties back to the Benguela Belize Lobito Tomboco (BBLT) platform located in Angola Block 14, it said. “With a water depth between 390 and 1,070 meters, this will be the world’s deepest DEH system,” it said. The contract calls for Nexans to deliver a complete system, including DEH riser cable, armored feeder cable, a 43-km-long piggyback cable and associated accessories for connection to the pipeline, the release said. The cables for the Lianzi DEH system will be manufactured at the Nexans factory in Halden, Norway, with delivery set for the summer of 2014, it said. The release described DEH as follows. “Alternating current (AC) transmitted from the DEH cable runs through the steel in the pipe, which heats up due to its own electrical resistance. By controlling the current, the pipeline inner wall can at all times be maintained above the critical temperature for wax and hydrate formation. The DEH system eliminates the need for chemical injection, pressure evacuation or other flow assurance methods that might have environmental or operational challenges.”

Subsidiary of Insteel Industries acquires assets of Tatano Wire U.S.-based Insteel Industries, Inc., announced that its wholly owned subsidiary, Insteel Wire Products Company, has purchased all of the concrete pipe and box culvert reinforcement production equipment and certain related assets of Tatano Wire and Steel, Inc. Tatano is a producer of welded wire reinforcement and wire products located in Canonsburg, Pennsylvania. Insteel currently manufactures concrete pipe and box culvert reinforcement products at six facilities located in

JUNE 2013 | 11

INDUSTRY NEWS

the Nordic market, it said. Ericsson’s energy business, it said, “is an important supplier of low-voltage products to the wholesalers and installers in Sweden, and a significant portion of revenue also comes from innovative specialty power cables.”

INDUSTRY NEWS

Arizona, Florida, Missouri, North Carolina, Pennsylvania and Texas. Per a story in the Observer-Reporter, Charles Tatano started Tatano Wire & Steel in Houston in 1990, making wire mesh. He had previously worked for 30 years at the Forbes Steel & Wire Corp. plant, and in 1992 he bought the Canonsburg plant. Insteel notes that it is the nation’s largest manufacturer of steel wire reinforcing products for concrete construction applications.

Neo Industrial Group sells 2 Russian cable companies to unnamed buyer The Neo Industrial Group, a Finnish entity that invests in industrial companies, announced that it has sold two cable companies to an unnamed buyer. A press release said that the two companies are OAO Expokabel and ZAO Reka Kabel, the Group’s cable manufacturing companies in Russia. OAO Expokabel manufactures special cables for the marine engineering, oil and gas industry as well as for nuclear power plants, while ZAO Reka Kabel specializes in manufacturing mediumvoltage cables. The main market area for the companies is Russia, it said. Reka Cables, Ltd., based in Finland, will continue selling and marketing Finnish-made cables in Russia and CIS countries through its subsidiary in Russia, the release said. The agreement, it said, has no effect on the operation of Reka Cables, Ltd. Per the company’s website, Neo Industrial acquired Reka Cables, Ltd., in 2007, and that same year it acquired a share of Nestor Cables, Ltd., a manufacturer of fiber optic cables. In 2008, Neo Industrial acquired a majority share of the Russian OAO Expokabel to strengthen Neo’s Russian business operations.

Belden reports reorganization of units Belden recently announced that the company is now organized across four global business segments: Industrial Connectivity Solutions, Industrial Information Technology (IT) Solutions, Enterprise Connectivity Solutions, and Broadcast Solutions. A press release said that the newly defined operating segments are a result of the company’s “purposeful transformation to a global provider of comprehensive signal transmission solutions.” It said that the new “solution-oriented” alignment further strengthens Belden’s ability “to quickly capitalize on new market opportunities and provide complete connectivity solutions to a growing customer base around the world.” The four operating segments, the release said, are now operating as described below: Industrial Connectivity Solutions. This segment is responsible for high-performance industrial cable and connector products that transport mission-critical signals enabling reliable network communication and machineto-machine connectivity for industrial automation

12 | WIRE JOURNAL INTERNATIONAL

machine building and automotive production applications. Christoph Gusenleitner now leads this business segment. Gusenleitner was previously EVP, EMEA Operations and Global Connector Products. Industrial IT Solutions. This segment is responsible for high-performance, reliable and secure hardware and software systems that address the mission-critical networking demands of the discrete and process automation industries worldwide. This segment is led by Dhrupad Trivedi. Previously, he served as vice president of Strategy & Corporate Development for Belden. Enterprise Connectivity Solutions. This segment is responsible for efficient network infrastructure systems that transport voice, video and high-speed data in enterprise IT applications for data centers, healthcare, finance, and education markets. Glenn Pennycook enters a new role as leader of Enterprise Connectivity Solutions. Pennycook was previously president of Enterprise Solutions at Belden. Broadcast Solutions. This segment is responsible for advanced hardware, software and connectivity systems for media companies to create, manage and deliver highquality content around the world. This portfolio of businesses will continue to be managed by Strath Goodship, Dave Jackson and Jimmy Rayford. “This announcement marks another key milestone in the transformation of our business,” Belden President and CEO John Stroup said in the release. He noted that Denis Suggs, EVP, Americas Operations & Global Cable Products, has decided to pursue opportunities outside of Belden. He will continue at Belden through July to allow for an orderly transition. “We thank Denis for his solid performance over the past six years, and appreciate the strong team he has assembled. We wish Denis the best in his future endeavors.”

Canadian tribunal begins review of wire from China, Israel and Spain The Canadian International Trade Tribunal announced that it has begun an inquiry regarding the dumping of cold drawn carbon or alloy steel wire originating in or exported from China, Israel and Spain, and the subsidizing of the above mentioned goods from China. A press release said that the final injury inquiry was initiated further to a notice received from the Canada Border Services Agency stating that preliminary determinations had been made respecting the dumping and subsidizing of the above mentioned goods. On Aug. 20, the Tribunal will determine whether the dumping and subsidizing have caused injury or retardation or are threatening to cause injury to the domestic industry, it said. The inquiry focuses on “the dumping of cold-drawn carbon or alloy steel wire, of solid cross section with an actual diameter of 1.082 mm to 12.5 mm, plated or coated with zinc or zinc alloy, whether or not coated with plastic, excluding flat wire,” the release said.

INDUSTRY NEWS

Nexans wins contract for supply of underground power cables for Beijing Nexans reports that it has been awarded an 11 million euro contract by the State Grid Corporation of China (SGCC) to supply a high-voltage power cable system that will help the Beijing Electric Power Corporation support the future development and extension of the power transmission infrastructure in China’s capital city. A press release said that the new powerlink in the Haidian district, known as the “pilot project,” will be Beijing’s first intra-city installation of 500 kV cables using state-of-the-art XLPE (cross-linked polyethylene) insulation. Nexans will design, manufacture and install a 7-km circuit that will be laid in an underground tunnel, including the supply of all the related high voltage power accessories such as joints and terminations, it said. The single-core XLPE cable will feature Nexans’ largest copper cross section to date (2,500 sq mm). A total of 21 km of cable will be laid as three separate seven-km lengths, one for each phase of the 3-phase electricity supply, it said. The project is set for completion by the end of 2014.

WCMA honors 8 industry notables The Wire and Cable Manufacturers’ Alliance, Inc., (WCMA) recently honored the eight 2013 recipients of its Distinguished Career Award at an April 13 ceremony in Hartford, Connecticut, attended by 300 guests, nearly 200 of those in the wire and cable industry, representing 65 different companies.

A press release said that the award winners, honored at the banquet at the Connecticut Convention Center, included: John Berlin, group president, Carlisle Interconnect Technologies; David Ely, president, Fluoropolymer Resources, LLC; Daniel Jones, president/CEO, Encore Wire Corp.; David McDonald, president, Cable USA; Peter Page, president/general manager, Times Microwave Systems; David Richards, COO, RichardsApex, Inc.; Daniel Rubadue, COO, Rubadue Wire Co., Inc.; and John Valentine, special projects, Belden/Alpha Wire. The award recognizes wire and cable industry professionals who have made significant commercial or technical contributions over a minimum 25-year industry career. Nominations for the 2014 awards are now being accepted on the WCMA website at www.wcmainc.org. For more details, contact WCMA Executive Director Debbie Mathiasen at tel. 860-873-2311, mrcdm@snet.net.

P&R Specialty expands operations, adds models to its product lines P & R Specialty, Inc., a U.S. manufacturer of spools and reels for the wire and cable industry, reports that it has expanded its production facility and added new products to its wood reel and plastic product lines. “P&R Specialty has enjoyed consistent revenue growth for the past 30 years and that growth trend continues in 2013,” said company President Greg Blankenship. “We continue to grow with our long term customers, but we are also winning new customers in new markets. This growth created the need for more space and we recently added 15,000 sq ft of manufacturing and warehouse space, giving us a total of 115,000 sq ft of production and warehouse space at our two-facility campus,” he said. A press release said that P&R recently added nailed wood reels to its wood reel product line and 6 in. and 12 in. plastic reels to its plastic spool product line for the fine wire market as well as a plastic utility spool for use in multiple markets. “These product additions were driven by our entry into new markets and to support our existing customer base where we can now be a one-source partner for multiple solutions,” Blankenship said.

PolyOne joint venture opens production plant in Saudi Arabia

The 2013 Distinguished Career Award winners were: l-r, front row: John Valentine, Belden/Alpha Wire; Peter Page, Times Microwave Systems; Daniel Rubadue, Rubadue Wire Co., Inc.; and David Ely, Fluoropolymer Resources, LLC. Back row: David McDonald, Cable USA; John Berlin, Carlisle Interconnect Technologies; David Richards, RichardsApex, Inc.; and Daniel Jones, Encore Wire Corp. Photo courtesy of Mike D’Agostino, Casson-Foster Photographers.

14 | WIRE JOURNAL INTERNATIONAL

U.S.-based PolyOne Corporation reports that Juffali PolyOne Masterbatch Co., Ltd., its joint venture with partner E.A. Juffali & Brothers Limited, has officially opened a new production plant in Jeddah, Saudi Arabia. A press release said that the new facility will produce specialty color concentrates with a potential for future expansion into other product lines. A company spokesman said that the wire and cable industry is part of the target market for that new production. The release said that PolyOne offered its formulation technology and material science to the joint venture while Juffali brought its local expertise in the region.

U.S.-based Pelican Wire Company, Inc., announced that the company has been named the Southwest Regional Manufacturers Association’s (SRMA) Manufacturer of the Year, recognized for its Pelican Wire President Ted Bill high quality received the award from SRMA wire and cable President & CEO Betsy Allen. constructions sold in high performance critical applications in diverse industries, including the aerospace and medical fields. Further, three company employees (Martha Langston, Angel Santana, and Kathleen Wilson) were nominated for Manufacturing Employee of the year, and Langston was named a winner in the Administrative category. “It was

wonderful winning this award. … We are so proud of our team of employee owners,” said Pelican Wire President Ted Bill. Pelican Wire was founded in 1969 by Larry From l-r, Pelican Wire’s Kathleen Bill, Theresa Bill and Edward Wilson, financial analyst; Angel Santana, head extruder operator; Hobart in and Martha Langston, Illinois, and manufacturing manager. relocated to Naples, Florida in 1976. The 33,000-sq-ft production facility has manufacturing capabilities that include extruding, wrapping, serving, and stranding wire. Pelican Wire specializes in fine gauge resistance, thermocouple RTD and custom wire and cable. SRMA, a professional organization, represents 3,600 companies that manufacture products for local, national and international markets.

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INDUSTRY NEWS

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Taiwan’s Formosa Plastics Group has placed an order with Germany’s Friedrich Kocks GmbH for a three-roll Reducing & Sizing Block (RSB) for the company’s Vietnamese subsidiary, Formosa Ha Tinh Steel Corporation. A press release said that the RSB will be installed in the combined wire rod and bar mill of the new integrated steel mill project in the Vung-Ang Economic Zone of the Ha Tinh Province. The plant, it said, will have annual total capacity of 15 million met™ ric tons, making it be the largest integrated steel mill in the ASEAN (Association of Southeast Asian Nations). It noted the following. The 370 mm RSB will be operated as a finishing block in the new 600,000 t/a rolling mill for special bar qualities. The RSB will have four stand positions and is designed for controlled rolling at Try Try any competitor com mpetitor ﬁrst, and measure meassure temperatures down to 750°C. The threeroll block rolls round bar in coils from air usage, usage noise, no oise and drying effectivity. effecttivity. 20 mm to 55 mm. The RSB allows Then try ours for 30 days; if you’re not rolling out of only one pass series with just five feeders from the roughing and have convinced it’s the best air wipe you have intermediate mill. Due to the “free-size” ever used, return it for a full refund! nd! rolling capability, any desired finished dimension within the complete dimenHuestis sional range can be produced in any Air Miser™ desired sequence with few roll sets and Air Wipes just a few stand changes. “Implementing the three-roll, heavyduty RSB into their new wire rod and bar mill, Formosa Ha Tinh Steel Corporation will have at hand the most advanced tool for a trouble-free, economic production of top quality SBQbar,” the release said.

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Gerdau executive: too much excess capacity in the global steel industry Speaking during a conference call about Gerdau’s financial results, André Gerdau Johannpeter, CEO of the Brazilian steelmaker, said that projected modest growth in global steel demand this year will not be enough to absorb the industry’s excess capacity. Steel Orbis reported the CEO as saying that about 27% of the steel sector’s installed capacity will not be used this year, compared to an average of 17%. It

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INDUSTRY NEWS

noted that the World Steel Association estimates that global steel use is expected to reach 1,454 million metric tons in 2013 and 1,500 million metric tons in 2014, up 2.9% and 3.2%, respectively. Global consumption rose 1.2% in 2012 to 1,413 million metric tons (mmt). “The steel industry’s main challenge is excess capacity,” the CEO was quoted as saying. “The difference between the sector’s installed capacity and current global steel production this year is expected to reach 590 mt, compared to 545 mt in the previous year.”

Taiwanese company orders RSB block from Friedrich Kocks GmbH

INDUSTRY NEWS

Recall for Home Depot Cat. 6 cable The U.S. Consumer Product Safety Commission (CSPC) has issued a recall for CE Tech brand riser cable sold in 1,000-ft boxes at Home Depot between January and February 2013. A press release said that the riser cable “does not meet fire resistance standards for riser cable, posing a fire hazard.” The CPSC says about 11,300 units of the cable are

subject to the recall. “This recall involves 1,000 ft CE Tech riser cable sold in boxes of 1,000-ft lengths for use...between floors of a building as data cable. This type of cable must self-extinguish in a fire. The cable is ... marked (UL) E316395. The cable’s box is blue and black and is marked CE Tech 1,000 ft. riser cable, Cat 6 23-4.” The CPSC said that the cable was sold exclusively at Home Depot, which did not respond to queries from WJI as to how the company chooses its suppliers of electrical cable.

Cable from Cerro Wire chosen for U.S. tractor plant construction U.S.-based Cerro Wire LLC reports that the company’s SLiPWire® THHN cable was chosen for the construction of the new Kubota Industrial Equipment (KIE) plant in Jefferson, Georgia, USA. A press release said that the cable was selected as part of a joint decision by Kubota Industrial Equipment, its contractor, Cedartown Electric; the electrical distributor, Gexpro; and distributor, Electrical Products, Inc. (EPI). The release said that the company’s value-added features, including SLiPWire’s self-lubricating polymer and True Sequential Footage, made the installation process smoother and quicker, while maintaining low cost.

Houston Wire & Cable opens distribution center U.S.-based Houston Wire & Cable Company (HWCC) reports that it has opened a new distribution center in the Minneapolis-Saint Paul area of Minnesota. A press release said that the strategic expansion supports HWCC’s “ongoing commitment to Right Product, Right Place, Right Time®.” The new distribution center will further its efforts to provide customers with the best possible service, through standard same day shipment or willcall pickup, it said.

18 | WIRE JOURNAL INTERNATIONAL

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

WAI acknowledges the following contributors to the Interwire 2013 technical program. The conference program at Interwire 2013 was the result of the combined efforts of dozens of experts, volunteers, and special guests.This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission.

Authors / Speakers Justyna Adamczyk Chuck Amori Motoo Asakawa José Miguel Atienza Michaela Boockmann Troy Carr Mike Casey Michelle Crockett Bryan Cullivan Jared Cullivan Daniel J. Cunningham Emmanuel De Moor Kota Doi Primoz Eiselt Manuel Elices Lisa Evans Bradley Exoo Rob Fulop Oliver Funke Paul Furtado Marek Gała Francisco Gálvez Juan Carlos González Villar David Gow Marco Graziani Albert Groothedde Alois Ulrich Gruber David P. Gzesh Bernhard Hanusch Hiroshi Iwanaga Magnus Jarl Victor Jenkins Helena Johansson-Cider Mats Josefsson

Chaitanya Joshi Tomio Kanno Natsuki Kato Ryuta Kawaguchi Artur Kawecki John Keane Grzegorz Kiesiewicz Tadeusz Knych Shinnya Kojima Kinga Korzén Piotr Kustra Paweł Kwasniewski Joakim Larsson Steve Leibold Yafeng (Alvin) Lian Timm Lux Andrzej Mamala Kiran Manchiraju Masami Matsumura Shuzo Matsuo Joe Memmott Andriej Milenin Stephanie L. Miller Zbigniew Muskalski Michael Nairn Keita Nakazima Ralph Noonan Yohei Ohno Jan W. Pilarczyk Juliusz Poltz Horace Pops Christian A. Regalado Jean V. Reid Igor Rogelj Benjamin Ross

Gary Royal Victor Rundquist Roy St. Andre Kota Sakumoto Yoshinori Sasaki Yuichiro Sekine Barbaros Serbetçi Takahiro Shirakawa C. Ian Sidders Marek Sieminski Eliza Sieja-Smaga Beata Smyrak Kenta Suga Maciej Suliga Yuki Takebe Mark Thackeray Kuzuki Tsurumi Jeffrey Tyl Koji Umezu Jane Van Philippe van Bogaert Tim Wampler Kotaro Watanabe Yuma Watanabe Kimberly Watson Wolfgang Weidenhaupt Sylwia Wiewiórowska Rory A. Wolf Kevin Wolff Roger N. Wright Yoshiro Yamada Kazunari Yoshida Verna Young Peter Ziger Kelly Zipsie

Moderators Bill Avise Anand Bhagwat Neville Crabbe Mark Garretson Tracy Gooding C. Richard Gordon David Hawker Tom Horn Bill Jarae Steve Jones Erik Macs Steve Montague Tom Moran Don Neville Dale Olp Brian Parsons Horace Pops Gary Spence Andy Talbot Bo Vandromme Richard Wagner Bhaskar Yalamanchili

Course Instructors Anand Bhagwat Joseph P. Domblesky Keith Donahue David P. Gzesh Horace Pops

Guest Speakers Jeff Justice Hines Ward

ASIAN FOCUS

ASIAN FOCUS Asian presence on Forbes annual list of billionaires includes 1st from Vietnam Asia’s fortunes have continued to rise, led by China, as reflected in the ultimate scoring card—Forbe’s annual list of billionaires—which shows Li Ka-shing of Hong Kong once again the richest person in Asia, ranking #8 on the 2013 list of 1,426 billionaires worldwide. Ka-shin saw his fortune jump $5.5 billion to $31 billion from the prior year, Forbes reported, noting that shares of his biggest holdings all rose 10% or more, and that he received 2012 dividends of $860 million. The second richest person in Asia was Mukesh Ambani, an oil and gas magnate in India, who came in 22nd at $21.5 billion from his huge Reliance Industries group, followed closely at #24 and #26, respectively, by Hong Kong property stalwarts Lee Shau Kee (Henderson Land, $20.3 billion), and the Kwok brothers Thomas and Raymond (Sun Hung Kai, $20 billion). India’s Lakshmi Mittal was #41, at $16.5 billion; New World shipping founder Cheng Yu-tung of Hong Kong was #45, at $16 billion; and #58 was Thailand’s Dhanin Chearavanont, head of the Charoen Pokphand food and industrial conglomerate, at $14.3 billion, double from the prior year. Yet the most interesting addition to the list may have been a newcomer, Pham Nhat Vuong, a 44-year-old man from Vietnam who came in at #974, at $1.5 billion. Pham, the first person from the country to ever make the list—which has been kept for 27 years—earned the slot based on his 53% control of real estate developer Vingroup, a press release said. It noted that Pham, a Soviet-trained mathematician and economist who launched a Vietnamese restaurant in the Ukraine and turned it into an instant noodles company, sold it in 2010 to Nestle for $150 million. He had also invested in real estate in Vietnam, including in a luxury resort hotel and then a Hanoi office tower. Forbes provided the following information: “Pham was born in Hanoi in 1968, the same year as the Tet Offensive, the most momentous year in the war that still shapes Vietnam today. His father served in the North Vietnamese air defense force; his mother ran a sidewalk tea stand. While the North won the war and united the country, they lost the economic battle; the national finances were in ruins, and the country’s leaders were married to rigid fiveyear plans, with few allies outside of Soviet Russia. Pham’s family at one point survived solely on his mother’s meager earnings. ‘My dream at the time wasn’t big,’ says Pham. ‘I just wanted to support my family.’ “Pham escaped his circumstances through books. He proved himself something of a math prodigy, earning a scholarship to study the economics of raw material extraction at the Moscow Geological Prospecting Institute. Just as

the timing of his birth was fateful, so was his 1993 graduation. The collapse of the Soviet Union had given way to a swirl of chaos, crime and opportunity. And back home, Vietnam had begun experimenting with Doi Moi, marketbased reforms within the ongoing socialist structure. “After marrying his college sweetheart Pham decided to remain abroad to try to take advantage of postSoviet opportunities. The young couple made their way to another nation struggling in its capitalistic infancy, the Ukraine. Pham’s first venture harkened back to his mom’s tea stand: After scraping together $10,000 from family and friends, he Pham Nhat Vuong opened a Vietnamese restaurant in the Ukraine. Sensing a demand, he also began making and drying ramen noodles using a production line he imported from Vietnam. The concept of instant noodles was completely new to Ukrainians–and an instant hit. Recalls Pham, ‘Ukrainians were very poor...and very hungry.’” “Today, the price of Vingroup’s shares—and ultimately Pham’s net worth—doesn’t necessarily correlate with the health of the company, which carries $1 billion in debt. Nearly 50% of Vietnam’s public companies are lumbering and grossly inefficient concerns formerly run by the state. Vingroup is one of the few listed companies without a communist heritage. Thus, two key foreign Vietnam-centric funds, Deutsche Bank’s MSCI Vietnam IMI and the Van Eck Market Vectors ETF, load up on it, to the tune of 16% and 7% of their indexes, respectively. These outside forces are as responsible as anything for driving Pham’s new billionaire status. “Pham is now in the process of raising money from several ‘strategic investors,’ with the ultimate goal of listing his firm on Singapore’s stock exchange, which would legitimate its stock price–and represent another milestone: the first Vietnamese company to be listed overseas. “Ultimately, Pham understands that achievements like this will serve as his legacy in the increasingly capitalistic country where his mom supported him making tea. He dreams of transforming the streetscapes of Hanoi and Saigon into something resembling Hong Kong or Singapore. ‘If I could do that, even if it cost me a few billion, I would be happy,’ he said. ‘I would leave something behind. You can’t bring money with you when you die.’” Forbes reported that China, the world’s second-largest economy, placed 122 people on the list, behind the U.S.,

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

20 | WIRE JOURNAL INTERNATIONAL

ASIAN NEWS BRIEF China National Offshore Oil Corporation orders umbilicals and power cable for subsea project The China National Offshore Oil Corporation (CNOOC) has given a contract for a major subsea umbilical to JDR, a provider of technology connecting the global offshore energy industry, that requires electric submersible pump (ESP) power cables. A press release said that the main production umbilical is thermoplastic, designed for dynamic subsea environments. It incorporates a hydraulic control system to control subsea trees and deliver injection chemicals into the wellstream to reduce hydrate formation. Each ESP power cable, it said, includes three 3-phase power circuits that are capable of

serving three identical ESPs in this eight-well field. CNOOC has used the full range of JDR’s capabilities to meet their objectives on this major project, said Paul Gahm, JDR vice president of sales and marketing. He noted that JDR is one of the few companies “capable of delivering such a complex project, due to our specialist engineering team and strategic investment in large-scale umbilical manufacture at our U.K. plant in Hartlepool.” JDR has designed CNOOC’s umbilicals to maximize reliability, minimize project cost and provide the customer with future-proofing options, Gahm said. “For example, we produced the ESP power cables on our vertical lay-up machine (VLM) in Hartlepool. This enables us to provide ultra-long length electric power cores, which significantly reduces the number of core splices required. And the design approach we have taken will support future field expansion, with the ability to serve up to four additional wells. We loaded out the project, via transpooling, straight onto a heavy lift vessel via the deepwater port alongside our Hartlepool plant.”

JUNE 2013 | 21

ASIAN FOCUS

which was first with 442 billionaires.The richest Chinese person, Wahaha beverage owner Zong Qinghou, came in 86th with $11.6 billion, up from $6.5 billion a year ago. Forbes notes that its “does not include royal family members or dictators who derive their fortunes entirely as a result of their position of power, nor do we include royalty who, often with large families, control the riches in trust for their nation.”

PEOPLE

PEOPLE Tulsa Power has bolstered its engineering department with a number of key hires. Gary Thompson was named engineering manager. He has more than 19 years of industry experience and has a strong background in new product development. He holds B.S. and master degrees in mechanical engineering from Washington State University. Gene Bell has joined the companyâ&#x20AC;&#x2122;s controls engineering team. He has more than 26 years of experience that includes significant servo experience and is well versed in control platforms and brands. Three mechanical design engineers were also hired. Jim Mascola has more than 20 years of machinery design and product development experience. He holds seven current patents and a mechanical engineering degree, and has had Lean Manufacturing, quality and Finite Element Analysis training. Shelby Coulter has extensive experience in mechanical design and new product development of machinery. He has a B.S. degree in mechanical engineering from Oklahoma State University. Jack McCready is a recent graduate of the University of Tulsa, where he earned degrees in mechanical engineering. Based in Tulsa, Oklahoma, USA, Tulsa Power supplies a wide

22 | WIRE JOURNAL INTERNATIONAL

range of material-handling equipment and related technology for industries that include wire and cable. Joe Stagon has been promoted to general manager of the Wire Division of Loos & Company. He has spent the majority of his career in the wire and wire forming industry, joining the company as assistant manager of the wire mill just over two years ago. He previously had been in charge of the coiled pin, cold heading and Joe Stagon CNC Machining Division of Spirol International, and before that was a manager at Hoover Precision Products, where his focus was in cold heading, wire drawing and shaped wire products. Mike Fredrickson has been promoted to sales manager Mike Fredrickson of the Wire Division of Loos &

position, where she covered Ohio, Michigan, Indiana and Toronto. Operating out of AlphaGary’s U.K. facility, Richard Day is the new European Sales Manager. He has more than 25 years of commercial management experience in the compounding business, most recently with AEI Compounding. Based in Leominster, Massachusetts, USA, AlphaGary Corporation supplies compounds, colorants and insulation to industries that include wire and cable.

AlphaGary Corp. announced key personnel changes as part of its ongoing restructuring plan following its acquisition by Mexichem. Chuck Hayes has been named plant manager at the company’s Pineville, North Carolina, facility. He had been plant manager at AlphaGary’s now consolidated facility in Bayshore, New Jersey, and was part of the transition team. He previously worked for Roscom. On the commercial side, Rick Peiczarka was named national sales manager. He joined the company in 2007 as Southeast Regional Sales Manager and previously had worked for Clariant. Denise Wallace has been rehired by AlphaGary to replace the Southeast Regional Sales Manager position. She started at AlphaGary in 1990 and held various marketing and sales positions at the Leominster headquarters before taking the Midwest sales

ABB reports that its CEO, Joe Hogan, has decided to leave the company for private reasons. Before joining ABB, he was CEO and president of General Electric’s GE Healthcare unit from 2000 to 2008. From 1985 to 2000, he held various positions at General Electric. No date has been set yet for his departure, and he will continue to lead ABB until a successor is announced. Hogan joined ABB in 2008, and during his tenure the company invested about $20 billion in acquisitions—including Baldor and Thomas & Betts and, in April this year, solar energy company Power One—and in R&D to help secure ABB’s position in power and automation technologies for utilities and industry. Based in Switzerland, the ABB Group of companies operates in around 100 countries and employs about 145,000 people.

JUNE 2013 | 23

PEOPLE

Company. He has some 30 years of experience in the wire, wire rope, and cable assembly industry, starting with the company in the early 1980s as a wiredrawing operator. He rose through the production and sales ranks, serving as a product manager and as an account manager for the Eastern Region for the Wire Rope and Cableware® Divisions of Loos & Company. Based in Pomfret, Connecticut, USA, Loos & Company manufactures a wide variety of wire, aircraft cable and wire rope.

FIBER WATCH

FIBER WATCH Prysmian Group reports opening of an optical fiber plant in Romania

Utah municipality chosen to be 3rd location to be a ‘Google Fiber City’

The Prysmian Group announced that it has opened a new plant for the production of optical fiber cable in Slatina, Romania, which it noted “has become one of the centres of excellence in Europe for the optical communications cables industry.” A press release said that the Slatina factory celebrates its 40th anniversary this year, having started its manufacturing activity in 1973 with production of energy cables. In 2009, it introduced the first module for the production of optical fiber cables, and today the factory has a significant number of Quality Certifications, such as ISO 9001, ISO 14001, IMQ. The new plant, the release said, will triple its production, from 500,000 km up to 1.5 million km of cable a year, with the potential of reaching 3 million. “The investment in the new facility in Slatina is part of a major plan to further reinforce the Group’s competitiveness in this fast-changing market,” Prysmian Group CEO Valerio Battista said. “Many developments are taking place in the current telecoms market. New players and services are appearing and evolution in broadband, double-play and triple-play services is dynamic. For this reason, as one of the major players in the telecom cable industry, Prysmian Group is continuously investing in this strategic sector in order to offer innovative technological solutions for the development of telecoms networks.” The Slatina plant stretches across almost 100.000 sq m, with a covered area of around 42,000 sq m, the release said. This will create a total yearly production capacity of 30,000 tons of energy cable (from high-voltage cables up to 110kV and building wires, to power and instrumentation and control cables), almost 1,500,000 km of optical cable and 500,000 km of copper telecom cable (covering almost all possible demand for both optical fiber and copper telecom cables types), employing over 400 people, it said. Prysmian Group notes in the release that it is a global market leader in communication cable manufacturing, with 11% market share and 24 production facilities worldwide. Investment in new production facilities and technology for product and service innovation will help the Group support operators in the development of a modern telecoms network, with the aim to share information everywhere through faster, flexible and cost-effective deployments, it said.

Google announced that Provo, Utah, will become the third Google Fiber City, providing gigabit connectivity to one of the nation’s innovation hubs. Once formally approved as expected, it will join Kansas City and Austin, Texas in being able to get access of up to 1 gigabit per second, a rate reported as being 100 times that of the average American Internet user’s service. “Utah is already home to hundreds of tech companies and startups, and many of them are based in Provo. In fact, the Provo area ranks second in the nation in patent growth, and is consistently ranked as one of the top places to live and do business in the U.S.,” Kevin Lo, general manager of Google Fiber, said in a blog post. Lo said that the three cities all have a burgeoning tech community. Besides the ultra-high internet speeds, Google notes that it offers a Fiber TV service that lets customers watch all shows in HD, record up to eight shows at once and store up to 500 hours of HD video in the cloud. Customers can watch across several devices, including cell phones and PCs.

24 | WIRE JOURNAL INTERNATIONAL

Corning Incorporated to supply optical fiber to run from Miami-to-Atlanta Corning Incorporated announced that it has been selected as the optical cable supplier for the Miami-to-Atlanta segment of Allied Fiber’s network-neutral system build. A press release said that the 754-mile, Miami-to-Atlanta route should be completed by the end of 2013. Corning, it said, will supply its 528-fiber SST-UltraRibbon™ cable containing Corning® SMF-28e+® and Corning® LEAF® optical fibers. Corning’s SMF-28e+ is a comprehensive single-mode fiber for metro and access networks while the LEAF optical fiber is optimized for long-haul and metro networks. The network-neutral system is intended to provide an abundant supply of next-generation fiber available for lease, as legacy backhaul network infrastructures can no longer support the exponential growth occurring in the industry, the release said. The end users for these physical-layer services include submarine cable systems, large wire line and wireless carriers and network operators, private enterprises, cooperatives, cable television companies, and data center operators. “Allied Fiber worked closely with Corning to develop a custom-designed 528-fiber ribbon cable optimized for the unique network design we are deploying throughout the U.S.,” said Jason Cohen, president and chief operating officer, Allied Fiber. Planned future phases of the Allied Fiber network will encircle the U.S., with more than 11,500 route miles, the release said.

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FASTENER UPDATE

FASTENER UPDATE U.S. Navy study results in some long unused fasteners sailing into the sunset The Naval Sea Systems Command reports that it has completed a fleet-wide fastener study, identifying and recommending the removal of thousands of fasteners from the Navy supply system. A press release said that the 16-week supply system review identified 108,000 dormant fasteners (fasteners with no contract, requisition or maintenance history in the past five years) and 3,200 duplicate fasteners, where two or more identical fasteners had different stock numbers. The study included input from in-service engineering agents, technical warrant holders, program offices, shipyards, shipbuilders, the Defense Logistics Agency and OEMs, it said. “This fastener deep dive focused on basically anything used to secure two things together on a ship,” said Bill Moss, Commonality Project Management Team lead with NSWC Carderock’s Ship Systems Engineering Station (SSES) in Philadelphia. “This includes all the nuts, bolts, rivets, and pins.” The release said that it costs between $200 and $500 a year to maintain a stock number. “The savings may seem

small, but when taken in context to the number of dormant and duplicate [stock numbers], the cost escalates rapidly,” said Tessa Kashuba, a member of the Commonality Project management team. At the same time, she noted in the release, “we have to be careful when we remove an item because we don’t want to eliminate something that’s still needed. For example, we may discover a fastener that hasn’t been ordered in a number of years, but then find out a ship is coming into an availability period that may require that fastener.” The study also included shipbuilders and shipyards to familiarize them with NAVSE’s Virtual Shelf, an electronic repository of standard architectures, design guidelines, specifications and parts lists for ship systems, the release said. “Shipbuilders may go directly to vendors to purchase fasteners during ship construction,” said Dana Melvin, Commonality Project team member. “The fasteners they purchase may not have a [stock number], and must be added into the system if there isn’t a comparable fastener available. Our goal is to get the builders to use fasteners that already have [stock numbers].” For more information about the Commonality Program, visit https://acc.dau.mil/commonality.

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26 | WIRE JOURNAL INTERNATIONAL

WAI NEWS

JUNE 2013

WAI MEMBERSHIP

SPOTLIGHT

This section introduces a new WAI member each issue.

Thomas Clerkin Principle Comet Wire USA

Q: What does your company do? A: Comet Wire is a startup focused on developing new products for the wire industry. Our primary emphasis is flexible copper products in the 12-22 AWG range. Q: What is your role there? A: CEO or sanitation engineer, depending on who you ask. Essentially, I represent the many garage inventors across the industry. Q: What do you like best about your position? A: Creative problem solving and new product development. It’s one thing to say you can “do it better,” it’s quite another to go out and make it happen on your own dime. Inventing the next new thing always takes much more time and money than expected. A typical corporation can leverage its staff and resources to solve problems and generate profits. In a startup, each decision point directly affects your business viability. It’s a constant challenge to balance technological improvements with limited resources. Another take away: just having the idea is not good enough. The wire industry is full of hands on, no nonsense individuals. People like that need to see tangible products and test results before they take you seriously. Q: How has the industry most changed? A: For the entrepreneur in all of us: accessing capital through crowd funding resources like Kickstarter.com; mining collective experiences through crowd sourcing sites like crowdspring.com; and on-demand low-volume manufacturing with 3D printing technologies. Q: How does your company remain competitive? A: So far it hasn’t been, and 2013 could be my make or break year. I believe that promoting the best engineering ideas to remain competitive will ultimately succeed, and that continues to be my focus. You can find out more by contacting me at thomas.clerkin@welchallyn.com. Q: Why did you recently join WAI? A: I want to stay connected to the technological advances in the industry. I also like the access to industry contacts and wire processing technologies.

28 | WIRE JOURNAL INTERNATIONAL

Moises Acosta Process Development Engineer Oxford Instruments Inc Michael Anderson Plant Engineer Encore Wire Corp

Michael Colella Vice President North American Sales National Standard

Ryuta Kawaguchi Graduate Student Waseda University

Michael Crouch Senior Process Engineer General Cable Corp Phil Crouse Senior Vice President WireCo WorldGroup Boleslaw Czabaj Development Engineer Oxford Instruments Inc Alejandro Dantus General Manager La Metalica SA de CV

Matt Badman Engineer Sumiden Wire Products Corp Michael Benavage Technical Support Engineer Bridon American Corp Mark Bennett Process Manager Encore Wire Corp Joseph Biesiada Plant Engineer American Spring Wire Corp Jay Burleson Operations Support Manager Southwire Co Michael Carter Process Engineering Corning Cable Systems

Tadeusz Knych Professor AGH University of Science & Technology Kinga Korzen Doctoral Candidate AGH University of Science & Technology Kyle Kroening Plant Manager General Cable Corp Kim Kyung-Ho Engineer Chosun Welding Company icholas G Lance Research & Devolpment Technician Rhenium Alloys Inc

Brian Edward Gauquier Technical Sales Rep Vanderbilt Chemicals John W Golden Senior Partner The Go Group LLC Dean Hemenway Worldwide Quality Administrator Gerard Daniel Jonathan L Hinton Production Manager Southwire Co

Eloy Cavazos Villacero

Michael A Howard Process Engineer American Spring Wire Corp

Thomas Clerkin Principle Comet Wire

Chaitanya Joshi President C Tech Corp

Joy Langford Business Research Analyst General Cable Corp GilJae Lee Chosun Welding Co Brandon Linne Electrical Engineer Southwire Co Piotr Mazurkiewicz Project Manager Sonion Polska Sp z o o Brian McMillan Technical Sales Engineer Johnstown Wire Technologies Inc

WAI NEWS

Michael Kammerdiener Encore Wire Corp Project Engineer

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

The following individuals recently joined Wire Association International.

Michael Coda Purchasing Agent Hariton Machinery Co Inc

Carlos Medina Plant Manager Trans Cable International Vivek Mehta Managing Director SAI Extrumech Pvt Ltd

JUNE 2013 | 29

James Ruch Continuous Improvement Engineer Oxford Instruments Inc

Justyn V Miller Compound Manager Plastics Southwire Co

Jason D. Rush Manufacturing Manager Southwire Co

Lucas orris Management Associate Marketing Gerdau Ameristeel Corp

Rosalie Suzanne Schaefer Senior Production Manager Marubeni Specialty Chemicals Inc

Rocky P Pace Manufacturing Engineering Supervisor Sandvik Wire and Heating Technology Corp

Frank L Schaff Chairman Mapes Piano String Co

Chris Palisch Process Engineer Alan Wire

Patrick Sheean Continuous Improvement Coordinator Fort Wayne Metals Research Products Corp

Inocencio David Parazo Production Engineering Staff - Copper International Electric Wires Phils Corp Brad Pentzien Marketing Manager Hallstar USA Daniel Perez Maintenance Manager Conductores Monterrey SA de CV Mexico Betty B Reynolds Material Procurement/Office Manager Carris Reels John Rhoads Operations Manager Encore Wire Corp Tristan Rice Process Engineer Southwire Co Thomas M Rogers Plant Manager Krueger Steel & Wire Co

Dr Eliza Sieja-Smaga AGH University of Science & Technology Lane Simmons Electrical Engineer Southwire Co Jerzy Slusarz Sonion Polska Sp z o o Landon Smith Process Engineer Southwire Co Joseph Stagon General Manager Loos & Co Inc Brian Stirnaman Wire Operations Keystone Steel & Wire Co Greg Thompson Supervisor Southwire Co

30 | WIRE JOURNAL INTERNATIONAL

David Vance Maintenance Manager Southwire Co Hugo Vela Fabrication Manager Coleman Cable Inc Yuma Watanabe Roll Bending Tech Waseda University Darrel Wheeler Oklahoma Steel & Wire Greg Yorker Technical Support Engineer Bridon American Corp

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

WAI NEWS

Vance Allen Merritt Quality/Technical Manager Bekaert Corp - Rome

NEWS

Committee Sp tlight This occasional section will provide readers a better idea of the activities of WAI’s committees and its board of directors.

WAI’s Exhibition Planning Committee

Inosym Inos sym R eellss

The Exhibition Planning Committee (EPC) is charged with the responsibility for providing strategic planning and to recommend specific actions to improve the value of both Interwire and Wire Expo trade shows. The past two years, the EPC has recommended to the Board of Directors (BOD) the following venues: Dallas for the 2012 WAI Operations Summit & Wire Expo and Interwire 2013 to remain in Atlanta at the Georgia World Congress Center, both of which happened and turned out to be good choices. At its meeting at Interwire, the EPC proposed that Interwire remain in Atlanta for 2015 and 2017. The WAI’s BOD later voted in favor of that recommendation. “A lot of

work goes into choosing sites for WAI’s trade shows, and it’s not easy to find one that everybody will agree with, but we do try to find one that will be in the overall best interest of all exhibitors as well as attendees,” said EMC Chairman Jan Sorige. “For now, Atlanta is a well-regarded location for Interwire.” The EPC previously recommended/approved that the WAI Operations EPC Chairman Summit & Wire Expo be held in Jan Sorige Indianapolis for 2014, which the BOD also agreed with. The EPC is currently reviewing site selection venues for 2016. Las Vegas had a lot of support, but there was a desire to learn more about (continued)

Inosym Ltd. Ph: +64 21 353 634 Fax: +64 3 341 6668 Email: inosym@inosym.com Web: www.inosym.com JUNE 2013 | 31

WAI NEWS

WAI

The technicians Networking with and new people in the suppliers I’ve industry is the met at WAI’s most valuable shows have asset of WAI helped me membership.” improve our Dick Pechie process.”

WAI helped me branch out into a new career.” Kevin Sopczak

Meeting people I’ve met many through WAI influential is the key to leaders taking you through WAI somewhere including a exciting in your U.S. President.” life and career.” Mark Spencer Lori Parent

I do business internationally and value the friendships I’ve made over the years through WAI.” Mark Mathiasen

Roberto Duralde

I joined WAI to interact with customers in a friendly environment when they are not having issues.”

WAI’s global resources can help me reach Venice. Venus is another story.” Mike Walters

I renew my WAI membership to keep up-to-date with machinery and process developments.” Peter Stewart-Hay

Paul Kulongowski

DISCOVER WAI. Some things you know as well as your name. Other times it takes a little searching to find—or learn— what you need, especially if you are new to the wire and cable industry or plan to keep pace with its innovative advances. Wire Association International (WAI) is the place to start. As a WAI member it’s easy to stay informed. Likewise, you won’t have to dig too deeply to uncover the industry’s rich history and accepted certainties.

WAI members rank NETWORKING as the #1 reason to join.

When you consider that wire making can be traced on one timeline from the golden threads in ancient Egyptian jewelry—through telephony, countless creature comforts, and modern infrastructure— toward yet unimagined applications, you can appreciate your vital role in the wire manufacturing continuum. WAI members represent a living history of the industry. Whatever your direction, if you earn a living with wire, cable, supplies, or equipment you’ve earned a place in WAI’s global network.

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY. L E A R N

M O R E :

w w w . w i r e n e t . o r g

WAI NEWS As ever, “location, location, location” was a prime topic of discussion at the EPC meeting. other possible alternatives. A final recommendation is expected by year’s end. The EPC has also reviewed/revised and made recommendations to the Board of Directors regarding changes to the allocation process of the Points System, which were based on input from its members. The system was initiated many years ago to provide a fair way of treating “seniority” for exhibiting companies participating in WAI’s tradeshow venues. EPC Committee Members Lou Arcuri, Tri Star Metals LLC William Bigbee, Encore Wire Corp Carolyn Edwards, Zumbach Electronics John Dabbelt, Fort Wayne Wire Die Jeff Dewberry, Southwire Co Larry Fitzgerald, Davis-Standard Corp Rob Fulop, Wire Lab Company Robert Galperin, Parkway Kew Corp Marco Gerardo, SAMP/USA Inc Monica Lepper, Esteves Group Jay Luis, Beta LaserMike Sue Lynch, Sikora USA Tom Maxwell, Jr., Die Quip Corp Richard Pechie, Vollmer America Inc Rahul Sachdev, Wire & Plastic Machinery Bob Sears, North America OMCG, Inc Dan Shelander, Windak Inc Terry Sieger, Woodburn Diamond Die Inc Joe Snee, Joe Snee Associates Mark Spencer, W Gillies Technologies LLC Chairman Jan Sorige, Enkotec Co Inc Edmond Torbey, Niehoff Endex North America Ludovic Vallet, NUMAMERICA Inc Executive Committee Liaison Anthony DeRosa, Cortinovis Machinery America WAI Liaison Bob Xeller

JUNE 2013 | 33

CHAPTER CORNER

CHAPTER CORNER Western Chapter golf tourney date set With the WAI’s Western Chapter setting Monday, Oct. 21, as the date (see below) for its 13th Annual Wild West Shootout, the golf schedule is now complete for five Association chapters. First up will be WAI’s Midwest Chapter, which on Friday, June 21, will hold its 11th Annual Golf Tournament at the St. Andrews Golf & Country Club in West Chicago, Illinois. For more details, contact Bob Sears at bswire@ flash.net or WAI’s Steve Fetteroll at sfetteroll@wirenet.org. The Ohio Valley Chapter will hold its 11th Annual Golf Tournament on Thursday, August 1, when it will return to the Grantwood Golf Course in Solon, Ohio, USA. For more information, contact Ron Fulop at r.fulop@wirelab.com. WAI New England Chapter will host its 19th annual Golf Tournament on Monday, Sept. 9, when it returns to the Ellington Ridge Country Club in Ellington, Connecticut. For more information, contact John Rivers at tel. 860-8964761 or johnr@dms-inc.com or WAI’s Anna Bzowski at tel. 203-453-2777, ext. 126, or abzowski@wirenet.org. The chapter notes that the on-line registration will soon be up,

and that a limited number of new sponsorship opportunities will be available. The Western Chapter will stage its 13th Annual “Wild West Shootout” on Monday, October 21, at the Sierra Lakes Golf Course in Fontana, California. For more details, contact Shootout Chairman John Stevens at tel. 909-476-9776 or by e-mail at jstevens@emc-wire.com, or WAI’s Steve Fetteroll at tel. 203-453-1748, sfetteroll@wirenet.org. The Vannais Southeast Chapter’s 12th Annual Golf Tournament will be held Thursday, Oct. 24, at the Rock Barn Golf and Spa in Conover, North Carolina. The tourney will start at 1 pm with a shotgun start at the Jones course. For more information, contact Nexans’s Art Deming, tel. 252-955-9451, art.deming@ nexans.com.

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REPORT

Wire Wire Link Scholar William Binnie, Assistant Quality/Development & NDT Engineer at Kiveton Park Steel, Ltd., in Sheffield, U.K., was the 2013 Wire Link Scholar. The award, offered in alternative years to a U.K. and American professional in the wire and cable industry, provides a two-week, allexpenses-paid opportunity to visit and learn the industry on the other side of the Atlantic. The scholarship was created by the Worshipful Company of Tin Plate Workers alias Wire Workers in the U.K. and the Wire Association International in America. As the 2013 recipient, Binnie toured companies in U.S. and attended Interwire 2013 in Atlanta. He submitted this report on his visit. The experience and knowledge I gained visiting the U.S. as the 2013 U.K. Wire Link Scholar has been absolutely brilliant. It has been a memorable trip, one that I will remember forever. I began my trip as a weekend tourist. Late Friday I arrived at Chicago O’Hare International Airport and spent that night and the next two days exploring the city. I headed to the Navy Pier, an amusement park that is home to a 150-ft-tall Ferris Wheel, a musical carousel, lots of colorful places to eat and more. On my way back to the hotel I stopped by at a place where I was properly introduced to a deep-dish Chicago-style pizza, which was great. Saturday morning, armed with a city pass, I visited the Museum of Science & Industry, the largest science museum in the Western Hemisphere, then the Shedd Aquarium, where I saw incredible displays of fish and jellies. I walked to the Willis Tower, where in 60 seconds the elevator took me up 103 floors to a stunning view. It was a good start to the trip. Sunday morning I headed to the Field Museum of Natural History. I was quite impressed by the most complete T-Rex ever discovered. It was huge! From there, I went to the Adler Planetarium, where planets and galaxies came to life and one could follow all the Apollo missions. The last thing I did was walk through and around Chicago itself, including its “magnificent mile” and State Street, tourist “musts.” Chicago definitely makes my top five list of memorable places I have visited.

36 | WIRE JOURNAL INTERNATIONAL

William Binnie with Merit Steel Plant Manager Jamey Ford (l) and Superintendent Dan Rosenbaum. Monday morning I met up with John Drummond, the principal of the Scotia Group, Inc. On behalf of the WAI, John would be my tour guide for the remainder of my two weeks in the U.S. We headed out to ArcelorMittal’s Global R&D Center in nearby East Chicago, Indiana. Staff Engineer David Price showed us around the center and then took us to the main plant, where they cleaned, coated and galvanized sheet steel. I was impressed by the huge amounts of steel kept “in the loop” by accumulators that stretched to the top of the building, a whopping 100 ft high. From there we went to Merit Steel, part of Leggett & Platt, based in Kouts, Indiana, and met there with Plant Manager Jamey Ford and Superintendent Dan Rosenbaum, who showed us around the various processes for cleaning and drawing wire. The similarities with my company were evident in the acid cleaning and pickling plant which we also have. The process was different as Merit Steel draws through multiple die blocks for one finished product whereas we draw through one or maybe two at most due to the amount of reduction we do. The wire produced at this plant would be going to our next tour, in Kendalville, another Leggett & Platt facility that specializes in springs and spring assemblies for mattress-

REPORT

es and chairs. There we met with Plant Manager Mike Kirkhoff, who showed us the process line. He explained how the company’s Lean Manufacturing practices were used, including some that he had helped influence. One such example was converting the labelling system so only one label is printed instead of multiple labels for each product. Some of the springs the plant makes goes to Smith Brothers in Berne, Indiana, which was our first tour the next morning. We met with company President Steve Lehman and his colleagues, who took us around their facility. They make high-end sofas, recliners and custom chairs. They have around a thousand different fabrics and 150 plus leathers to choose from. Employees use software to optimize material and precisely match a pattern using CAD. Their assembly area uses “cells” to increase productivity and quality while maintaining that built-by-hand philosophy. Next we went to Fort Wayne Metals to meet Engineering Manager Patrick Sheean, who gave us a plant tour. The company makes the smallest stainless steel wire I have ever seen. It was incredible to see how ultra-fine wire is made for end products such as pacemaker wires, etc. Fort Wayne Metals has fully taken on Lean Manufacturing with continuous improvement programs throughout the plant. I saw one particular steel alloy that transforms at certain temperatures. I got a sample bracelet made from it that I wear to this day! Patrick then took me to Fort Wayne Wire Die, Inc., where I meet Regional Sales Manager John Dabbelt. John explained to me the geometry and material used to make wire dies. He explained how they could cut a hole in diamond as small as 0.0005 in., which is a lot less than the diameter of the average human. John and I later went to John Drummond’s house, where everyone we had met with that day came round for dinner, which was really nice. Wednesday was an off day for plant tours, and we went to the USAF Museum in Dayton Ohio. The base was enormous and had four main hangars where planes are stored. On a separate area of the base they keep the presidential planes and prototypes. This was a real treat as I enjoy aviation, and I got to see a “Mosquito” plane that my grandfather, William Binnie, flew in World War II. Thursday morning, we headed out to General Cable Corporation’s plant in Lawrenceburg, Kentucky, where I met with Plant Manager Brett Ostrowski and Brian Cain. They took us on a tour of their plant, where they make telecom cables. I was impressed not just by their process but by their focus on worker safety. One of the most impressive areas I saw was where they did final testing of the large diameter cables, with up to 4,800 wire ends tested end-to-end. We then headed to Beneke Wire Co., in Louisville, Kentucky, and met with Vice President of Manufacturing Ken Downs, who along with a colleague showed us around his plant, which draws, cuts and straightens aluminum wire for end uses such as fasteners. I saw a lot of similarities to our plant, although we don’t have a company and leisure facilities. The three of us then

From l-r, William Binnie with General Cable’s Brett Ostrowski and Brian Cain, and Scotia Group’s John Drummond, president of the Wire Foundation. went to lunch at a restaurant at Churchill Downs, where I sampled some traditional Kentucky cuisine. That afternoon, John and I went to a Corvette museum and saw an original 1953 Chevy Corvette that was gorgeous. It was fun to walk through the museum and follow the changing shape of the cars through the years. Friday morning, we went to the Dickson, Tennessee, plant of Sumiden Wire Products Corp., which is part of the Sumitomo Electric Group. There I met with President Brian Burr, who showed me the company’s various operations. I was impressed with level of atmospheric control they have, which is critical for a consistently quality product and makes for comfortable working conditions. Sumiden draws, anneals and coats stainless steel wire for many applications. I liked their system for identifying finished product with different color straps and bases. They also have a facility for PC strand, which was something I have never seen made before. It was amazing to watch so many strands of wire all come together to form one product. We then went to Mid-South Wire, where I met General

Mid-South General Manager Andy Talbot outlined his company’s operations to William Binnie.

JUNE 2013 | 37

REPORT

We then went to Mid-South Wire, where I met General Manager Andy Talbot. I saw a lot of similarities there to my company as it also draws low-carbon steel. I was impressed by the company’s size. It even has a barge that brings steel in, unloading 14 coils at a time. The acidcleaning plant was impressive. In 2009, a new acid recovery system from Scanacon was installed that does not use crystallizers. I think that we could implement such a system for our cleaning facility. The galvanizing wire manufacturing process was mesmerizing. The work is all done on one line, from annealing to cleaning to coating. This was the last plant tour of the week and I really enjoyed seeing all the different areas of the industry. Saturday morning we went to Lynchburg, Tennessee, for a tour of the Jack Daniel’s Distillery, a “must” for any whiskey drinker. We saw how they make Jack Daniel’s old No.7 sipping whiskey. My favorite part was seeing how the whiskey soaked into the barrel and left a “sock line” Visiting the grounds of the Jack as to how much it had been weath- Daniel’s distillery in Lynchburg, Tennessee. ered. Then we went to Chattanooga up to Point Peak, a Civil War battle site. You could see for miles and the views were incredible. We finally made our way to Atlanta, where I would attend Interwire 2013. While out for dinner, we were joined by one of John’s friends from Germany, who was exhibiting at Interwire. I had the biggest New York strip steak I’ve ever seen and it was cooked to perfection. Sunday, I explored downtown Atlanta, walking through Olympic Park. I also saw the Georgia World Congress Center, where I would spend most of the following week. Monday morning, the first day of the event put on by the Wire Association International, I attended the first two sessions (measurement, ferrous metallurgy) of the Fundamentals of Wire Manufacturing program and left having learned something at both. That afternoon, I went on the KIA plant tour. All I can say is WOW. I have never seen so much structure to a business and plant. The company gets deliveries on the hour, every hour, all in production order as they are unloaded. They make a new car every 57 seconds! Some of the most impressive areas were the stamping operations. They exchange dies for the

38 | WIRE JOURNAL INTERNATIONAL

Want to be a Wire link Scholar? The WAI is accepting applications for the 2014 Wire Link Scholar. Candidates must be under 35 years of age, have been employed in the industry for more than two years, be able to travel to Europe for two weeks in April 2014, and at the time of application be a member of WAI. For more details, e-mail WAI Executive Director Steve Fetteroll at sfetteroll@wirenet.org.

stamps in six minutes, which is more impressive when you consider that these dies are the size of a car themselves. That evening, I went out to dinner with WAI past presidents at a great Italian restaurant called La Grotta. The food was fantastic and the company to match, and we were the last ones to leave. On Tuesday, I met up again with Patrick Sheean from Fort Wayne Metals. He walked me around the show floor and helped me better understand parts of the wire industry outside my company’s scope. I appreciated his help and we have since kept in touch. The WAI Member Rewards ceremony was held on Wednesday, and it was there that I received my award from John Drummond. I had to say “thank you” in front of more people than I have ever spoken to before, and it was a bit nerve racking but a great experience nonetheless. I also became an “assistant” for Jeff Justice, a humorist at the presentation. Throughout the Speaking during the Member rest of the week I was either on the show floor Rewards event at Interwire. exploring different companies or sitting in on the technical sessions. I met up with a Scanacon representative at Interwire and talked further about its technology, which I planned to discuss in-house when I returned to my company. Friday came quickly, and with it my final plant tour. We went to Southwire Company’s plant in Carrollton Georgia. There, I met up with Plant Manager David Hutcheson, who took me around. I saw copper cathode being loaded into the furnace and heated to form liquid copper that is transported to a wheel and belt that forms the cast. From there it goes through final reduction into a round product about 5/16 of an inch. I was amazed how such a large operation could be run by just five or six people. The plant was exceptionally clean and tidy and I know how hard those places are to keep well. I also saw

William Binnie looking down at the exhibit floor at Interwire 2013 from the WAI show office. the building wire plant where they form wire into end-use products. I found the machines that wind copper wire into a final product no bigger than an inch in diameter to be very complex. Here too I was impressed with the tidiness and cleanliness of the operation. Everything has a place and everything was in its place. Everything I saw

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JUNE 2013 | 39

REPORT

stemmed from the company’s focus on continuous improvement, which obviously is working quite well. So that was my trip, which officially came to an end on Saturday. I had seen large companies and small companies, products I was familiar with and others I had no prior knowledge of, but what I could see was that each one had evolved its methods to succeed in a competitive field, just as my company has. I had one last walk around Atlanta and the Lennox shopping mall, then went to the airport to head back to the U.K. I have been to the U.S. before, but this was my most memorable trip, made possible by a long list of people. I would first like to thank The Worshipful Company of Tin Plate Workers Alias Wire Workers and the Wire Association International for their continued scholarship program support, and my employer, for not just allowing but encouraging me to part of this program. Also, all those involved in organizing the trip, most notably WAI’s Steve Fetteroll and the U.K.’s Darrly Lomas, and especially to John Drummond for being my tour guide/educator for the two weeks. I learned so much from him and from those who I met along the many different visits that I know the knowledge I have gained will further my career in the wire industry for many years to come.

Interwire wrapup

WAI President Richard Miller told the luncheon audience on Tuesday that Interwire had achieved its mission.

The overall tone was positive at the Georgia World Congress Center in Atlanta, Georgia, USA, where the Wire Association International’s Interwire trade show, educational programs and related events offered a myriad of business possibilities, new technology ideas and networking opportunities. Visitors from 59 countries, topping 4,050 industry professionals, participated in the industry’s largest wire and cable marketplace in the Americas. Based on surveys, key influencers and purchasers from more than 300 wire and cable manufacturing operations were represented, with some 80% reporting expected capital equipment expendi-

tures of more than $50,000 in the next 24 months. The collective events, which began on Monday, April 22, with a golf tournament, a well-attended tour of Kia Motors, the one-day Fundamentals of Wire Manufacturing program and various WAI committee meetings, kicked into high gear on Tuesday, April 23, with the start of the full technical program, the opening of exhibits and a keynote speaker luncheon. Speaking at the luncheon, WAI President Richard Miller said that Interwire had met its goals. “The exhibit floor opened this morning with some 400 suppliers ready to give us solutions to the challenges facing the industry.

Discussions at the OMCG booth, which showcased a new MINIMALIST CNC system.

40 | WIRE JOURNAL INTERNATIONAL

Many companies sent teams of staffers to explore the show floor.

WAI 1st VP Bill Avise with Jeff Tyl, who accepted the Mordica Memorial Award on behalf of his late father, Thomas Tyl. See p. 64 for the Mordica Lecture. The same is true with the educational program that is full of practical and technical information, again to help the industry. As you can see from the audience in this room, the attendance is excellent. From our advance registration, we know that there are representatives from more than 300 different wire and cable operations. This is the dynamic that we envision when we plan the show. The Wire Association’s charge is to create a marketplace of innovation, advancement, and information sharing for the industry. Interwire is that resource.” Miller also thanked Nick Nickoletopoulos, WAI’s 2012 president, for his service, as well as Dave Gemelli, Gem

Erik Macs was honored with the WAI’s Donnellan Memorial Award.

Photos by Terrence Rushkin, Southwire Co. and Mark Marselli, WJI. Find more photos at WAI’s Facebook page.

Instructor David Gzesh discusses lubricant technology during the Fundamentals of Wire & Cable Manufacturing sessions.

JUNE 2013 | 41

Wire & Plastic Machinery’s Rahul Sachdev (l) reported that he was busy throughout the show.

Representatives from hundreds of wire and cable companies were at Interwire 2013.

On the floor Attendee Richard Macary, l, Hagar Inc., had questions.

Conair Product Manager Alan Landers discusses the fine points of his company’s blending and extrusion technology.

42 | WIRE JOURNAL INTERNATIONAL

A “tower” display at the Sonoco booth.

Gravure, for his sponsorship of keynote speaker Hines Ward, the former Pittsburgh Steeler star, who shared his story with the audience. The football great, who also enjoyed success outside the gridiron, winning the 2011 Dancing with the Stars competition, Ward explained his â&#x20AC;&#x153;W.A.R.D.â&#x20AC;? rule, which stands for â&#x20AC;&#x153;Will Always Rise Above Difficulty,â&#x20AC;? a motto he has lived by and encouraged others to follow no matter what the setting. His mom was his inspiration, he said, and he learned to always find a positive in a negative situation. He came across as a very likeable and wellmeaning person, something that some of the Steeler fans in the audience already knew. The show floor appeared more active than the 2011 staging, with many representatives from manufacturers looking for better and more cost-effective ways to improve their processes. See p. 44 for some exhibitor comments. The educational program included more WAI President Richard Miller encouraged attendees to explore â&#x20AC;&#x153;the marketplace of innovation, advancement and information sharingâ&#x20AC;? Interwire offers.

(continued on p. 49)

Wire Russia June 25 - 28, 2013

MANUFACTURING RANGE NEW ARRIVALS - PRE-OWNED â&#x20AC;˘ Queins - Rigid stranding cages, 30+36 bobbins 630 mm (24.8") Tubular stranders â&#x20AC;˘ Cortinovis - Planetary strander, 6+12 bobbins 450 mm (17.7") Rigid stranders â&#x20AC;˘ Kraft - Planetary armouring line, 60 bobbins 400 mm (15.7") Planetary stranders â&#x20AC;˘ Queins - Planetary armouring cage 84 bobbins 400 mm (15.7") Power cable drumtwisters â&#x20AC;˘ Stolberger - Rotating pay-off for drumtwister 2500 mm (88.4") â&#x20AC;˘ Lesmo - Automatic single spooler for bobbins 630 mm (24,8"), incl. accumulator Armouring lines Bow/Skip stranders For contacts in USA: Single/Double twist bunchers Pay-offs and take-ups, all designs QMS INC. Belt-type caterpillar capstans Miami, Florida Single- and double disc capstans Tel.: +1 (305) 665-2523 Rotating caterpillar capstans Cell: +1 (305) 924-1742 Taping heads for plastic- and steel tapes Fax: +1 (305) 740-9460 Transposed wire machines info@qmsmachinery.com &* ')! #** +) . '&* " , . $ . - . #& ' (, #&* '%

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Interwire perspectives: exhibitors Interwire again proved a valuable showcase for demonstrating our electro/pneumatic EP500 rod welder and M101 portable cold welder, as well as our smaller manual machines. The atmosphere was buoyant and visitor traffic to the booth was certainly up on the 2011 show. We noted a significant increase in the rate of enquiries from customers and new prospects and came away with a good number of solid sales leads. Steve Mepsted, managing director, Pressure Welding Machines. If you go by the sheer number of visitors we get at our booth, Interwire is not cost-effective for the Gimax Group, but it is worthwhile on another level. The U.S. market is important to us, as much as the European market, and our presence at the show is a confirmation to our U.S. customers that we are always there for them, always strong! Enrico Romagnolo, sales and marketing manager, Gimax Group. We expected to do well at Interwire 2013, as word of the unique benefits of our Nano-Dies has now reached a lot of key people in the industry. We got some excellent leads, and each new lead is valuable as it represents an opportunity. We also got some new ideas to consider, and every new idea is valuable until proven otherwise. Any way you look at it, that made our participation an excellent business investment. Doug Thornton, president, Nano-Diamond America. Our customer sector is in an expansion mode, and we definitely had a lot of visitors, existing and potentially new customers, more than in past shows. I have quite a few quotations to make, although it will take some time to see if they directly result in sales. As a supplier, we feel that we need to exhibit our processing technology at this show because it is the largest in North America. We also believe that suppliers who actually run machines draw the most attendees, and I think thatâ&#x20AC;&#x2122;s why we had one of the busiest booths at the show. Jim Zampogna, vice president sales and marketing, MGS Manufacturing, Inc. We expected to see a significant turnout of decision makers at Interwire 2013 as the industry as a whole appears to be doing better than 2011, and we were very pleased with the results. Interwire continues to be a great venue for meeting all of our existing customers and potential new ones. Ron Reed, principal, Lloyd & Bouvier, Inc. This Interwire was especially successful for us! Co-located with Axjo America, Windak showed new packaging solutions and new modern spool designs. Visitors could see our AR18-DB line (the latest dual-head automatic reeler, developed for automatic packaging of cable and wire products on spools and reels between 216 mm and 460 mm in 44 | WIRE JOURNAL INTERNATIONAL

overall diameter) winding and palletizing processes. We collected several new prospective contacts and expect to receive new orders. We would like to say thanks to all the new visitors and to our clients for attending our stand. We will be very glad to see you at Interwire 2015! Olga Berlinberg, Project & Marketing Manager, Windak. Interwire 2013 once again showed that there is great interest in the American market for Rosendahl and Nextrom products. Our team welcomed visitors from various countries in the Americas as well as customers from Europe, Asia and the Middle East. Rosendahl solutions for automotive and high performance datacom applications attracted a substantial number of visitors while the Nextrom team received very positive feedback on the solutions presented for the preform fiber and fiber optic cable area. Rosendahl/Nextrom. The show was very worthwhile for us on many levels. We expect to see existing customers and suppliers and occasionally a new potential customer, but the best part is that everyone is in one place. In three days, I saw dozens of customers, including international, whereas it might have taken me months to see this many. This is very valuable and costeffective. We even met a new potential supplier, which is terrific for us as a distributor. Also, T&T is spread out geographically, so it was good to be there with colleagues and to squeeze in our own business meeting. Tom Jordan, president, T&T Marketing.

... and attendees We make an effort to send as many employees as feasible to every Interwire. This year we sent 17, including many factory employees. It is a rare opportunity to network with so many professionals Pelican Wire President Ted Bill in the industry as on the show floor. well as learn about new products and services that our vendors are offering. It really helps us think outside the box and gives our employees a boost of motivation. This yearâ&#x20AC;&#x2122;s show did not disappoint! Ted Bill, president, Pelican Wire. I was one of three people from New York Wire who attended Interwire. We had set up meetings before we got to Atlanta, and we also stopped by to see many other exhibitors while we were there. We had excellent meetings and I would say that we have more follow-up before we make some buying decisions. Overall, Interwire was a very good use of our time. We were Michael Cirone able to meet with many customers and vendors at one time/ place instead of making multiple trips. Michael Cirone, Global VP Sales and Marketing, New York Wire. I attended Interwire 2013 representing my firm, which provides financial advisory services to the wire industry. Interwire was a terrific opportunity to meet with several existing clients and folks I have done business with over the Paul Beffer, r, at the reception. years. For a small firm like ours itâ&#x20AC;&#x2122;s a good place to meet a diverse group of potential clients. I found at least three companies that are in need of our services in the next year or so. Paul Bedder, partner, Raindance Strategic Partners.

JUNE 2013 | 45

EXHIBITS • TECHNICAL PROGRAM • PLANT TOURS • NETWORKING

May 6-7, 2014 Indianapolis Convention Center | Indianapolis, Indiana, USA Co-located with AISTech 2014 - The Iron & Steel Technology Conference and Exposition

Visit www.wirenet.org for details.

Keynote speaker and football great Hines Ward shared his belief in rising above during the luncheon on Tuesday.

Gem Gravure Company President Dave Gemelli and son Paul Gemelli with Hines Ward.

Speaking at the Member Rewards Meeting was Ron Reed, Lloyd & Bouvier, which sponsored the first-time event.

2012 WAI President Nick Nickoletopoulos with current President Richard Miller.

WAI Foundation President John Drummond presents a plaque to Wire Link Scholar William Binnie. See p. 36.

JUNE 2013 | 47

From l-r, Fundamentals of Manufacturing instructors David Gzesh, Blachford Corp.; Joe Domblesky, Marquette University; Keith Donahaue, Zumbach Electronics Corp.; Horace Pops, Horace Pops Consulting; and Anand Bhagwat, Minova International. Below, l-r, moderator Neville Crabbe, Leoni Wire, with Lean Manufacturing panelists Mark Thackeray, General Cable; Roy St. Andre, EIS Wire & Cable Co.; and Victor Jenkins, Nexans.

Educational

The educational programs included some three dozen technical papers, three panel discussions and two presentations (health care and OSHA).

48 | WIRE JOURNAL INTERNATIONAL

Benjamin Ross spoke on how to prepare for an OSHA inspection.

Ralph Noonan, Etna Products, discusses lubricant concerns during his Production Solutions presentation.

Samples are inspected during a presentation.

than 50 individual presentations, including 40 papers, three discussion panels (Lean, recruiting and safety), two guest speakers (health care reform and OSHA) and two theme sessions (acid recovery systems and mechanical descaling options). Overall attendance was good, with some topics such as Lean Manufacturing and a session on dies drawing as many as 40 people. With the introduction of the Operations Summit in 2012, WAI’s 2013 Interwire program offered a contrast, return-

ing the focus to the technical side. While the Operations Summit will continue to focus on practical topics relevant to the daily operations of a wire business, Interwire focuses on the technical and includes elements of both types. “It was a valuable learning process,” said one attendee, responding to a post-show survey. “I am fairly new to the industrial business and found it very educational.” Said another: “Very helpful—got good ideas on several solutions that I am working on.”

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A thousand people attended the reception at the Omni Hotel Atrium.

The day’s events provided plenty to talk about.

social

Kinga Korzan, a doctoral student at Poland’s AGH University, and Wire Link Scholar William Binnie with Jeff Justice at the WAI Member Rewards event.

Past New England Chapter President Mark Mathiasen joins students from Tokai University for a group shot.

From l-r, the winning golf tournament team of Jim Perdue, Tom Heberling and Brandon Bennett, all of Southwire Co., and Brooke Stonesifer, Sonoco.

QED Wire Line’s Michael Crowle, center, once again proved to be the fleetest of foot in WAI’s 5K Industry Run, sponsored by Leoni Wire.

50 | WIRE JOURNAL INTERNATIONAL

Tuesday night, the WAI once again hosted a muchappreciated reception, returning to the Omni Hotel Atrium, where a thousand people enjoyed the setting, refreshments and company. The momentum continued on Wednesday, starting off at 9 am with the first-ever WAI Member Rewards event, which included the WAI’s 83rd Annual Meeting of Members. It began with recognizing the winners of the WAI’s Mordica Memorial Award—which went to the late Tom W. Tyl, accepted by his son, Jeff Tyl, who presented the Mordica Lecture that starts in this issue on p. 64—and the Donnellan Memorial Award, which went to Erik Macs, vice president of sales and marketing for Progressive Machinery, Inc. Wire Foundation President John Drummond also introduced the 2013 Wire Link Scholar, William Binnie, whose report of his two-week visit to the U.S. starts on p. 36. Entertainer Jeff Justice took over, and his “presentation” on stress in the workplace was far from technical but ever so on-target and funny. The event, sponsored by Lloyd & Bouvier, also included a slew of prizes being raffled off, making for a great start to the day’s full exhibits schedule and tech program conference. That same day, the WAI’s Southeast Chapter took advantage of the setting to hold a reception, during which it announced the winners of its scholarship program, which will be cited in the July WJI issue.

WAI 1st V.P. Bill Avise at the luncheon on Tuesday.

Take a closer look

There are a lot of cold welders out there that look like PWM’s, but aren’t. Our machines and dies are designed and made by us, inhouse, so we have complete quality control throughout the manufacturing process. We believe that makes for a better end product, and so do the thousands of manufacturers who use our machines worldwide.

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Joe Snee Associates, Inc. PO Box 236, Seekonk, MA 02771 Tel: 774-991-0504 Email: joe@jsnee.com

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Pressure Welding Machines Ltd Tel: +44 (0) 1233 820847 Fax: +44 (0) 1233 820591 E-mail: pwm@btinternet.com www.pwmltd.co.uk

JUNE 2013 | 51

The WAI Board of Directors covered topics that ranged from future directions and budgets to websites and membership.

committees Membership Committee co-chairs Tom Heberling, Southwire, and Tim Wampler, General Cable, led talks.

The Exhibition Planning Committeeâ&#x20AC;&#x2122;s discussions included the first-ever trip to IndianapoIis in 2014, and more.

52 | WIRE JOURNAL INTERNATIONAL

WAI Executive Director Steve Fetteroll spoke at the American Wire Producers Association (AWPA) meeting The final day, Thursday, April 25, got off to an early start with the WAI’s 5K Industry Run, sponsored by Leoni Wire. It was a high-visibility day for the runners in their day-glo yellow race shirts, but once again, QED Wire Line’s Michael Crowle proved to be the fleetest of runners, topping the field of 19 in the charity run. The event was followed at 10 am by the resumption of the technical programs and exhibits. Before Interwire 2013 even started, Jim Perdue, Tom Heberling and Brandon Bennett, all of Southwire Co., and Brooke Stonesifer, Sonoco, had won the Interwire Golf Tournament following a card review. The foursome shot an 18-under-par 54 that had been matched by the team of Doug Herrick, Chase Corp, Mark Wisenhunt and Richard Miller, both of Southwire Co., and Mike Gil, Microtek Medical. Kudos also go to Bill LaCount, Falcon Fine Wire, who won the 50-50 pot money and gave it to the Vanderbilt Cancer Research, the event charity. The event, held at the Whitewater Creek Country Club and organized by Jeff Swinchatt and Margie Thacker, Sikora International, raised about $5,000. The WAI was joined in Atlanta by the American Wire Producers Association (AWPA) and the Wire Fabricators Association, which also held meetings at Atlanta. Interwire was sponsored by: Sonoco—Platinum Level; Continuus-Properzi SpA and ExxonMobil Chemical—Gold Level; BASF Polyamide and Intermediates, Carris Reels Inc., Chemson Inc., Gem Gravure Co., SIKORA International Inc., Tenold Transportation, and Wire & Plastic Machinery Corp.— Silver Level; and Lloyd & Bouvier Inc., RichardsApex Inc., and Standridge Color Corp.—Bronze Level. Interwire was also supported by: Amacoil Inc., the American Wire Producers Association (AWPA), Baum’s Castorine Co.; Carris Reels Inc.; Commission Brokers Inc.; Gem Gravure Co. Inc.; The InterWire Group; LEONI Wire Inc.; Lloyd & Bouvier Inc.; RichardsApex Inc., SIKORA International Inc.; Skaltek Inc., Sonoco, and the WAI Southeast Chapter. Interwire will return to Atlanta on April 28-30, 2015.

JUNE 2013 | 53

FEATURE

Testing & Measuring Equipment nterwire 2013 featured equipment, products and services from more than 400

companies. Below, suppliers of some of the testing & measuring technology that

was on display in Atlanta highlight their offerings.

ACM AB Sweden Howar Equipment, Inc. Canada At the Howar Equipment booth at Interwire, ACM displayed its KSM off-line measuring and data evaluation system, which can provide cable manufacturers with accurate and clear information how much excess insulation cost ($$$$) each of the product carries by providing you with a simple report. The KSM system has four main components: a measuring system with backlit sample car-

replacing measuring microscopes, pin gauges and shadowgraphs. The KSM system displays results within 0.2 to 2 seconds, depending on the complexity of the slice. More than 200 KSM systems for cables, tubes and profiles are now in full operation, and in actual usage they have shown to provide typical repeat accuracy of 0.004 in. (0.01 mm) or better. Using the KSM database, statistics and analysis program, managers and engineers will be able to assess the data and begin determining the root

An ACM table showing potential insulation savings that can be realized by precise off-line measuring and evaluation. rier and digital imaging cameras; measuring software that carries out the actual measurement at unprecedented accuracy and repeatability and stores them in a ASCII based database. The Database Software allows for instant comparison of the measured sample values with specification data, with over insulation cost, trending, Cpk and Sd available. The new Analysis Software (KSMEval) allows a user to precisely determine which products have the largest over-dimensional cost. One can clearly see that the measured product length ACM141RGA of 18,000 meters carries an over-insulation value of US$805,526 while the next highest product’s over-insulation value is $62,329, making it clear that the focus of your cost improvement studies should be on the first product. KSM units have a dramatically higher repeat measuring accuracy and are

54 | WIRE JOURNAL INTERNATIONAL

causes of dimensional fluctuation and subsequently the cause of over-insulation. Stefan Askenfors, ACM, www.acmab.com; Willy Hauer, Howar Equipment, Inc., www.howarequipment.com.

AESA Cortaillod Switzerland During Interwire, AESA Cortaillod demonstrated two aspects of its market offering: one typically oriented “test equipment” and the other one “data management.” Industrial Cable Testing Equipment. Industrial cables have to meet specific norms and constraints. GAIA ensures LF-HV-IR test requirements. Now, AESA introduces SemaCare, which combines in a single system several automatic measurements, such as LF param-

of the system is Beta LaserMike’s DataPro 5000 controller that provides a control interface to the gauges and enables manufacturers to automatically and rapidly perform system setup, and monitor and control all the dimensional aspects of the cable production process. This degree of product control offers many bottom-line advantages: • Reduced start-up time: accurate monitoring of cable eccentricity helps manufacturers tightly control die centering during extrusion process • Decreased material usage and give-away: closed-loop control continuously monitors cable dimensions and automatically adjusts extrusion process parameters in real time to ensure product meets target specifications • Improved product quality: continuous collection and analysis of SPC data identifies and improves process trends • Optimized data management: networked/integrated measurement and control enables operators to closely monitor product sizes via real-time trend charts, comprehensive reporting, data logging and alarming

AESA Cortaillod’s Dennis Milz and Jean-Luc Allemann at the company’s booth. Specific Cable Management System. Today it is essential to have software to efficiently manage the business, but the tools available on the markets are general or incomplete. AESA Cortaillod proposes CIQ3.0, a specific data management system for the cable industry. This application allows the capture of product data at the quality stations as well as the process data directly on the production lines. Data are stored in one centralized database that allows traceability, evaluations, complete reporting and exportation to the ERP. AESA Cortaillod has developed strong partnerships to extend its offering to cable design and costing, warehouse management or production order management and planning as example. AESA Cortaillod, www.aesa-cortaillod.com.

Beta LaserMike U.S. At Interwire, Beta LaserMike took a different approach at exhibiting its end-to-end system solution for in-process measurement and automated quality testing of cable: we actually showed it end-to-end in a mini-line, where attendees could see how each of our gauges fit into the total process. “It’s hard to get the same sense when you see the individual measurement components,” said Jay Luis, worldwide marketing manager for Beta LaserMike. The in-process measurement system integrates Beta LaserMike’s wire Preheater, AccuScan diameter and ovality gauge, CapScan capacitance gauge, CenterScan eccentricity gauge, 3-axis LN3015 Lump and Neckdown detector, Spark tester, LaserSpeed length and speed gauge, SRL Pro structural return loss prediction/analysis system, and LayScan lay length measurement system. At the heart

Beta LaserMike provided an end-to-end view of its technology at its booth. Beta LaserMike also showcased its off-line measurement and testing solutions, including the BenchMike sample/part inspection system as well as DCM cable testing systems such as the ES-2G for quality testing four-pair category cables up to 2 GHz. Jay Luis, worldwide marketing manager, Beta LaserMike. www.betalasermike.com.

bogimac nv-sa Belgium At Interwire, bogimac showed its full portfolio of fatigue test equipment and services. To validate high value flexible wire, cable and rope today, one must test beyond the legacy static failure method on material fatigue under conditions that are close to the real usage. This subject was presented during the technical confer-

JUNE 2013 | 55

FEATURE

eters (R=Kelvin), HF parameters already from 1kHz by points or swap, and additional tests such as validation of a cable on the field or location of a default. It helps to handle short or rigid cable ends, support large wire diameters and manage intermixed compositions (single, pairs, triads, quads). SemaCare is modular and can test up to 128 conductors at once.

FEATURE

ence at Atlanta by bogimac, which presented a paper entitled, “Validation of your high-value wire and rope products on material fatigue with state-of-the-art- bend-rotation and bend-over sheave test equipment.” While optimizing a product for high cycle survival, it is important to avoid fatigue test overloading for faster results. The reason for that is because comparing variants on static failure as well as on an overloaded fatigue test will in most A bogimac fatigue tester. cases reject the solutions that are really needed. Modern fatigue test equipment therefore has to supply high-speed performance to enable fast decision in case of the required lower load but high cycling counts of modern product validation. The sample behavior is also continuously monitored on elongation, thermal behavior, noise and dissipated power. With early warning watch functions, it is possible to stop the test in the early stage of sample degradation so that the real origin of the failure can be observed more easily. bogimac supplies high speed Hunter-like bend-rotation fatigue testers for pure reverse bending of wire cable and cord, as well as the different types of bend-over-sheave testers for cord, rope and related tire and rubber reinforcements. Philippe van Bogaert, CEO, bogimac nv-sa, www.bogimac.com.

Clinton Instrument Company U.S. At Interwire, Clinton Instruments showcased two new products for the wire and cable industry. The first is a new calibration system, Model STCAL. This equipment allows in-plant technicians to easily and accurately calibrate their spark test equipment’s output voltage. The system comprises accurate voltage standards and a proprietary voltmeter. The user interface is a tablet computer, which will walk the technician through the calibration of all Clinton spark tester models, step-by-step, with clear diagrams and photographs. Automatic calibration is offered on Clinton’s newest equipment and all future models. Just make the connections and the STCAL does

56 | WIRE JOURNAL INTERNATIONAL

Clinton Instrument Sales Manager Woody Holland with the company’s new AC-30AS model. the rest! For older equipment, the STCAL will take voltage readings automatically and prompt the technician to perform the required adjustments. The STCAL will also calibrate other brands of spark testers through the use of custom profiles, which are easily input and configured through the user interface. The other new product is a high-powered addition to our spark tester line, the company’s AC-30AS model, which is shown in the photograph. This is a 30kV, 60cycle unit for testing large power cables and other large cable products, up to eight inches in diameter! The AC30AS has a unique self-tuning transformer design, which maximizes test voltage capability, while maintaining a safe level of output current. Clinton Instrument Company, www.clintoninstrument.com.

Force Measuring Systems AG Switzerland FMS USA, Inc. U.S. At lnterwire, FMS Force Measuring Systems launched the company’s newest Radio Transmitted Tension Monitoring system, the RTM X42. Through continuous development work on the RTM system, wire and cable manufacturers now have an affordable way to accurately monitor and control tension in individual wires on most planetary or tube stranders, bunchers, twisters, or other rotating machinery. The RTM X42 monitors tension, in real time, of up to 42 individual strands. Actual tension values can be provided as an analog signal (0-10VDC or 4-20mA) per channel, brought into a PC for processing (graphical display, data logging, high/low- tension alarms, etc.) with our standard software, or provided to an existing PLC (via bus communication). The tension sensors are specifically designed for rotating applications, and thus are compensated for both centrifugal and Coriolis forces to very high accelerations. A wide range of sensors are available to suit most any application. With increased production rates, faster changeovers, and improved product quality, RTM X42 investment payback period is typically quite

The latest introduction from LaserLinc, which exhibited at Interwire, is the SmartLinc™ processor, a device for direct interface from LaserLinc’s laser micrometers to control systems. The SmartLinc processor integrates easily into the line control system communicating via Ethernet or serial port to the PLC. A single unit provides a communications link for one, two or three of LaserLinc’s full line of single, dual, and triple-axis laser scanning micrometers. To simplify communication management, the processor transmits data to the PLC at user-defined intervals and to user-specified locations in the PLC via tags. Once configured and integrated, the SmartLinc provides unattended and reliable operation. No ongoing monitoring is required. Easy-to-use configuration and diagnostics tools enable the user to access and manage all SmartLinc devices over the plant network, or by Ethernet cableconnection from a laptop directly to a SmartLinc device. LaserLinc is a preeminent manufacturer of accurate and adaptable non-contact laser and ultrasonic systems for OD, ID, wall thickness, eccentricity, and concentricity across many industries including wire, cable, medical and other tubing, hose, pipe and fiber. LaserLinc’s systems can provide a time-to-payoff in months, even weeks by reducing scrap and waste, shortening startup times, ensur-

FMS Director of Sales Steve Leibold. short. The technology may also be used to open new markets for a manufacturer whose customer demands documented and verifiable manufacturing conditions. Steve Leibold, director of sales, FMS USA, Inc., www.fms-technology.com.

Innovation meets Tradition

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JUNE 2013 | 57

FEATURE

LaserLinc U.S.

FEATURE

signal conditioning offer unmatched reliability and performance, separating it from other “so-called” laser speed sensors. Polytec offers a full suite of solutions for applications on extrusion lines, rewinders, buffering lines, input to printers and more. This includes sensors to measure zero and reverse speed for tracking complete process motion, regardless of direction. Setup and integration to counters and PLCs is easy with the standard encoder output, while the encoder pulse resolution is completely scalable by the user to meet application requirements. Polytec is a global company with its core-competence being laser Doppler measuring techniques, making it a performance leader in the field of non-contact length and speed measurements. Its technology can improve yield, production throughput and customer satisfaction with better, more accurate and reliable length measurements. Replace contact wheels with the LSV non-contact encoder. Polytec, Inc., Peter Nawfel, product manager, www.polytec.com.

Proton Products International, Ltd. U.K.

LaserLinc’s new SmartLinc™ processor. ing product quality, and through process improvement and optimization. Robert Wexler, communications director, LaserLinc. www.laserlinc.com.

Interwire 2013 was by far our best showing ever, as all our new and improved products were on display for existing and potentially new customers to discern our products’ performance and capabilities. The non-contact speed and length gauge SL and SLR3060 gained wide praise from multinationals and SME cable makers, many of whom are hooking up the gauges to inkjet markers to

Polytec, Inc. U.S. At Interwire, Polytec showcased its non-contact LSV Laser Length and Speed Sensors. The sensors provide better accuracy, repeatability and long-term consistency than traditional contact encoder wheels, without the need for routine maintenance or calibration. The LSV’s rugged construction, unique optical configuration and advanced

Grant Latimer, Proton Products, at the company’s booth.

Polytec’s Izabela Mijic and Peter Nawfel at the company booth at Interwire.

58 | WIRE JOURNAL INTERNATIONAL

print exact cable lengths and save hundreds of thousands of dollars per year in materials. The SUPER FAST range of CCD diameter gauges was also very well received. They measure cables at 10,000 times per second per axis, which takes diameter gauges into a new era. A diameter gauge that can truly double as a lump and neck detector, all in one package, represents added value. Saving our customers money, providing best in class solutions and providing after sales care and attention is what we are all

The compact high-performance rotor EC15 for non-contact testing of round materialsâ&#x20AC;&#x201D;such as wires, rods, bar stocks and pipes with diameters ranging from 1.5 mm to 15 mmâ&#x20AC;&#x201D;is capable of detecting surface longitudinal and

FEATURE

about. At Interwire, Proton welcomed FASI Inc. from Ohio at our booth. FASI has represented Proton for 18 months, providing best in class service and technical support. Each of the guys at FASI has 20-plus years of laser gauging experience, providing setup, training, maintenance and calibration services to all Proton customers in the U.S. I would like to thank all our existing and potential customers who stopped at our booth: we get a real kick making these products and itâ&#x20AC;&#x2122;s great to hear your stories of how the gauges save your material, monitor your quality, reduce your downtime and so on. Thanks! We really appreciate it. Grant Latimer, Proton Products. www.protonproducts.com.

Rohmann LP U.S./Germany At Interwire, Rohmann LP highlighted its eddy-current based non-destructive materials testing technology. The ELOTEST IS500 eddy current test instrument is a stateof-the-art unit for in-line applications. The compact design in an IP 54 class housing combined with configuration flexibility is the perfect instrument for production line applications. In combination with accessories such as dual and multi-sorting gates, EC-15 rotors for wire inspection and probe arrays, the ELOTEST IS500 will provide solutions for a broad range of eddy current in-line inspection tasks in the bar, tube and wire industries.

Rohmann LPâ&#x20AC;&#x2122;s Dietmar Griem at the companyâ&#x20AC;&#x2122;s booth at Interwire. traverse discontinuities with a defect depth of 20 Îźm, depending on the surface conditions of the material. It has a compact construction that allows the rotor to be very easily integrated into existing test tracks or transport

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FEATURE

lines. The rotor is equipped with dirt protection (labyrinth seal), precision bearings and a non-contact, maintenancefree test signal transmitter that is operated at 3,000 rpm with a 24VDC motor. See our application videos at http://www.youtube.com/user/RohmannGmbH. Rohmann LP, www.rohmann.com.

Sikora internationmal Corp. U.S. During Interwire, Sikora’s booth reflected the continuing advances that the company has made in technology for wire and cable companies. One impressive area has been for its X-ray technology for wall thickness measurements and the refinement of diffraction analysis for the measurement of product diameters. That was possible

6000 device that brings this capability to jacketing and insulating lines within a variety of market segments. While other technology is less expensive, the ROI on this Sikora technology is far greater. Many of our customers have learned, “it is not what you spend on the device, it is the return on the investment” that matters. When Sikora decided to make the “next generation” diameter gauge, the company again showed its true pioneer spirit. It adapted the Fresnel diffraction principle into the edge determination of round products, a revolutionary advance for measuring wire and cable without mirrors, motors and costly calibration requirements. This created a new cost of ownership picture to diameter measurements, all at a competitive cost. One key to Sikora’s success is that these techniques require no calibrations. Manufacturers want to make cable. They do not want—nor should they pay for—their maintenance staff to calibrate measurement equipment. With Sikora, we give you back that time it took you to keep that older technologies working. We continue to be the measurement experts so you can be the experts in wire and cable production. Jeff Swinchatt, president, Sikora International Corp. www.sikora-usa.com.

Taymer International, Inc. U.S.

Sikora International Corp. President Jeff Swinchatt.

because Sikora pioneered technologies that brought X-ray to CV applications. Our experts were motivated by the contributions the technology could make for our customers, and by embracing this technology, Sikora arrived at the X-RAY 8000 NXT, which for the most part is standard equipment for medium- and high-voltage production lines around the world. It then developed the X-RAY

At Interwire, Taymer showcased one of today’s most significant quality assurance systems this year, the Surface Inspector 3100 (SI3100). Ensure your product is defect-free. The Surface Inspector is the only tool that can capture, analyze and judge every square millimeter of your product—cable jacket, pipe, tube, bar stock or water soluble tape. It is the most thorough method of detecting surface flaws available. Its most compelling benefit is allowing you to be sure the product you are sending to your customers meets your high standards and is without any surface defects. Reduced defects. The Surface Inspector provides the operator with up-to-the-second digital image feedback of the current jacket, bar or water soluble tape quality on

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Vollmer America U.S.

A Surface Inspector model from Taymer International. any production line. This continuous stream of real time information—especially the failure images—allows the

At Interwire, Vollmer America showcased continuous thickness and width gauges for use on wire mills running flat and shaped wires of steel, stainless steel, copper, brass and aluminum. For more than 45 years, Vollmer has made it a priority to provide wires guides in the gauge heads that ensures accurate measurement. Recently, we developed a Vollmer Touch Screen (VTS) version of the gauge that works with digital probes and panel PC with remote I-O. The device allows the thickness to be measured up to 6 mm thick and 20 mm wide

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operator to isolate causes of jacket imperfections and water soluble tape folds and improper cable coverage. This will result in reducing jacket defects before they result in scrapping of product or worse, customer complaints or recalls. Quality Assurance. Using the Surface Inspector, you can capture images of your printed cable, save the images to disk and print them out to include in your quality reporting both internally and to your customers. The Surface Inspector’s display also makes it easy for engineering and production supervisors to document where the jacket has defects and how the water soluble tape is being properly wrapped to the fiber optic cable. Taymer International, Inc. www.taymer.com.

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without the need for micrometer settings or manual offsets. The measurement transducers still use the proprietary long lasting diamond contacts or blades and special guides but also supply built in software and hardware for Profibus and Ethernet link to mill drives and controls. The

electronics is capable of working up to eight gauge sets at once which greatly reduces the cost and interface complexity when multiple gauges are used on tandem mill applications. The system includes digital readings of error or absolute value and has a built in trend display to show the gauge variation over a section of the wire. The gauges are also compatible with our recording, SPC and feedback control systems that are usually part of the mill configuration. Dick Pechie, vice president, Vollmer America. www.vollmer-gauge.com.

Zumbach Electronics Corporation U.S.

Vollmer America Vice President Dick Pechie at the company’s booth at Interwire.

With the MSD (Multi-Sensor Diode) diameter gauges, Zumbach introduces a new series of measuring heads for on-line diameter and ovality measurement and control and lump/neckdown detection capability. The new solution complements the time-proven and high-precision laser diameter measuring heads of the ODAC® series. The MSD models are available up to 200 mm measurement field and were developed to offer a lower-cost, yet technically suitable alternative for applications not requiring the same precision of the ODAC® series. The unique multi-sensor diode technology enables

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a precise measurement of two axes for the entire measurement range and of four axes for (typically more-precise) smaller products in the measurement range (four-axes range varies with each MSD model). Built-in external light filters prevent ambient light from affecting the measurement performance in the production environment. For hot-rolling mills of rod, bar and tube, Zumbach introduces its Steelmaster Rotation (SMR) system to provide highly precise, and rapid, full cross-sectional measurement. The SMR uses a unique power and signal transmission concept to enable rotation of the measurement heads without mechanical friction or slip-rings. The SMR uses up to 6000 synchronized measurements/second and rotates up to 100 RPM to provide up to 10 full crosssectional measurements per second. Zumbachâ&#x20AC;&#x2122;s proven EPM (Enhanced Profile Measurement) software calculates and displays quasi-true profile for standard round and oval, asymmetric, and polygonal shapes. Additionally, Zumbachâ&#x20AC;&#x2122;s proven FPS (Full Profile Synthesis) software provides an accurate measurement and display for threeroll blocks. Zumbach Electronics Corporation, www.zumbach.com. Zumbach Electronics AG General Manager Sven Naegeli by an MSD model at Interwire.

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MORDICA LECTURE The importance of package size in the manufacture of steel tire cord By Thomas W. Tyl

Thomas W. Tyl, the winner of the WAI’s Mordica Memorial Award, died July 11, 2011, at age 55. This presentation from his work was made at Interwire 2013 by his son, Jeff Tyl.

In the highly competitive world of steel tire cord manufacturing, package size can play a remarkably major role in the success or failure of a steel tire cord-manufacturing venture. Twenty-five years ago, 12-kg payoff spools were common for outside positions of twisting machines and 3/4 metric ton (MT) take-up spools or “spiders” were common after the first drawing operation. First advances to increase package size came from relatively obvious benefits of reducing labor by reducing the number of times in a day that payoff and take-up carriers require changing. For example, increasing a 12-kg payoff spool to a 36-kg payoff spool reduces by 2/3 the number of times per day that payoff positions require change, resulting in a possibility to

Table 1. A 100 MT/day manufacturing plant. reduce labor greatly. However, increasing package size can have much more profound effects on manufacturing than a reduction in labor costs when very large carriers are utilized throughout an entire manufacturing process. Reduction of waste (particularly at creel ends) increased equipment utilization (up time), virtual elimination of wire

Fig. 1. Value of material at different stages in the production process as a percentage of finished stock value. 64 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS Table 2. Time spent changing carriers at a 100 MT/day manufacturing plant. and filament welds, decrease in breakage at wet drawing and twisting, improved drawing performance, reduction or elimination of partial fine drawing pay-off and take-up spools and more consistent product quality are some benefits that can combine to add as much to profitability as reduction in labor costs. It is common to determine the amount of material placed on a carrier based on length (meters). This document will suggest that a preferred method applies material on a takeup carrier capable of carrying the weight of an entire coil through the entire manufacturing process regardless of continuous length, at least through the final patenting process.

offs and take-ups in a plant should be designed to hold 2.5 MT of material at least through fine patenting and plating take-up. Of premier importance is that carrier size be designed to eliminate welds in material at each process step, and this becomes more important as material flows further down the process river. As we shall see, eliminating welds is an obvious influence on breakage at several process steps as well as drawing performance. The importance of minimizing breakage at all process steps during the manufacture of steel tire cord cannot be over-emphasized; minimal breakage should be one of the premier measures of a plant’s capability.

Machine and operator utilization – rod mill Overall philosophy The only correct manufacturing philosophy for steel tire cord is to design upstream processes to absorb waste by controlling them as tightly as possible; it is always a nebulous bad idea to “pass” waste downstream. The reasoning is that the value of upstream waste is a fraction the value of downstream waste; it is far less expensive to scrap product before adding value. For example, the value of material after fine patenting and plating in a steel tire cord plant running a variety of products averages about 57% the average value of finished cable. See Fig 1. In fact, it is advantageous to represent waste as a percentage of finished stock value (% FSV) to help drive home this importance. The second reason is that by tightly controlling upstream processes, technical requirements for downstream processes are more easily obtainable; fine drawing and twisting performance will naturally improve and the “window” of acceptable finished product technical parameters will appear larger and easier to acquire. At first glance, it may appear that package size is relatively unimportant to obtain high quality upstream product, but this too is flawed logic. The minimum package size for a steel tire cord plant should be the maximum 5.5 mm coil size available. For example, although the most common coil size is 2.0 MT, the current maximum coil size available is about 2.5 MT. This means that the take-up and payoff size design should accommodate a weight of at least 2.5 MT at most processes. As shall be described, this does not indicate that every carrier be filled to hold 2.5 MT of material, but many pay-

As previously stated, the obvious reason to increase package size is to reduce labor, an additional benefit is to increase machine utilization. Consider a rod mill consisting of the following operations: first drawing, first patenting, second drawing, second patenting. Table 1 shows the difference in the number of carrier changes and welds for a plant with small carriers and another with large carriers where the use of large carriers reduces the number of changes and welds by a whopping 61%. Table 2 shows the difference in the amount of time a machine operator spends per day changing carriers in the same 100 MT per day plant with small and large carrier sizes, making the listed assumptions for operator and machine down time in minutes. Table 3, similar to Table 2, shows the difference in the amount of time a machine operator spends per day making welds in the same 100 MT per day plant with small and large carrier sizes, making the listed assumptions for operator and machine down time in minutes. Comparing Table 2 and Table 3, the total amount of operator time for small packages is about 294 hours to make welds and change carriers while the total amount of time required for the large-package operators is about 113 hours. If we assume that other tasks take about 300 operator hours regardless of carrier size (not a fair assumption as large carriers require less material handling) small package operators spend 594 hours per day working and large package operators spend about 413 hours per day completing the same tasks. If 80 operators are assigned to the small

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TECHNICAL PAPERS Table 3. Time spent making welds at a 100 MT/day manufacturing plant. package rod mill the large package rod mill should conservatively require about 80 x 413/594 = 56 machine operators, a reduction of about 24 biomechanical labor units per year. In a developed country this can be about $1.75 million per year in labor savings.

speed that precludes dynamic strain aging; strain aging can dramatically reduce torsional properties even if the strain aging occurs before a heat treating operation (effects of strain aging are not negated by patenting).

The anatomy of a weld Drawing performance Drawing performance, either wet or dry, will improve by (1) eliminating welds and (2) keeping the machine running at a specified speed until the die set reaches a die change tonnage (or meter) limit. For dry drawing, a weld made immediately prior to the drawing operation introduces an abrasive surface to the drawing dies, reducing die life and causing dies to “open” or increase in diameter. This means that it is to the advantage of the machine operators and product quality to “polish” ground weld surfaces to near the surface quality of the incoming rod. These influences are more pronounced in wet drawing since brass, which acts as a lubricant, is removed from the wire’s surface during welding. However, of greater importance than the actual weld to improved drawing performance is the ability to run drawing machines at constant speeds for extended time without interruption and removing welds at the machine take-up (a large percentage of fine drawn welds break during twisting, pushing waste downstream to a higher valued process). Finite Element Analysis (FEA) studies of the drawing process consistently show that drawing above a lower threshold speed and below an upper threshold speed reduces friction and these studies reflect actual drawing studies. With regard to upper drawing speed limits, whether dry or wet, it is extremely important to draw at a

Fig. 2. Schematic of 5.5 mm rod weld. 66 | WIRE JOURNAL INTERNATIONAL

Steel tire cord rod is a highly technical wrought alloy near or at the top of the steel pyramid. A weld is essentially a casting. Differences between castings and wrought steels, although numerous and well known, are beyond the scope of this publication; suffice it to say that a wrought steel for tire cord applications is orders of magnitude higher in quality than a cast material. A weld in steel tire cord material consists of the actual butt weld, the heat affected zone (HAZ) created by welding and annealing and the surface damaged area related to removal of flashing from the butt weld area. This means that there are three areas to introduce a defect during the welding process: in the weld, on the wire surface and in the HAZ. For purposes of this document, a welded 5.5 mm rod will represent a general steel tire cord weld and everything that is true for a weld in 5.5 mm rod holds true for welds at any other process step, even final cable. Review of proper welding and annealing techniques are extremely important but are beyond the scope of this text; assumed is that welding techniques are well defined and ingrained in every teammate trained to make welds. Fig. 2 defines schematically the three areas of a weld. Major common weld area defects include voids, underfill, scale or slag entrapment, misalignment and improper annealing. While most of these defects are avoidable, the

TECHNICAL PAPERS

Table 4. Potential weld breaks per MT based on material length.

microstructure in the area of a weld, including the actual weld and HAZ, is not suitable for steel tire cord manufacture. Prior to annealing the microstructure near the buttweld likely includes martensite, upper and lower bainite, coarse and fine pearlite and spherodite. Subsequent to annealing, the microstructure can include tempered martensite, upper and lower bainite, coarse and fine pearlite and spherodite. The only way to correct the local microstructure is to patent the material meaning austenization followed by controlled cooling. Although in many cases welds are classically patented (generally welds made during or immediately after dry drawing), welds made prior to dry drawing likely suffer irreparable damage during dry drawing. To ensure removal of all possible defects removal of the entire weld including the HAZ (from annealing clamp to annealing clamp) is necessary. Although it is common for defects induced during welding to pass through subsequent drawing process without incident, they commonly do not survive the twisting operation and commonly do not survive any number of bending operation like straightening and directional changes by pulleys or guide dies. Proper selection of package size can help eliminate all welds prior to twisting without creating significant amounts of scrap while resulting in general downstream performance that greatly exceeds that of material containing welds.

Steel tire cord plant layout For the purpose of this paper, one can divide the steel tire cord layout process into three parts: coil payoff through fine patenting and plating (FPP) take-up; fine drawing, twisting and spiral wrapping; and rewinding, inspection and final packaging, as outlined below.

Coil payoff through FPP take-up FPP is arguably the most critical part of the steel tire cord manufacturing process. Quality of plated stock will greatly affect wet drawing and twisting performance as well as performance of the final product in the customer’s facility. Commonly overlooked from a quality standpoint, influence of package size and method of allocating material to a carrier, e.g. by length versus weight, on final product quality is difficult and often impossible to trace back to the source. It is difficult to trace a weld at FPP to a break during the twisting process; it is all but unimaginable that a

ten-gram weld during the first plant process can be responsible for many kilograms of scrap at the twisting process. Further, at each processing step the weld area can be used for statistical sampling of material properties without introducing “cuts’ in packages of material; all samples are removed from the top of a carrier. For example, at drawing operations the weld area can be used to measure diameter and ovality for every carrier. At FPP, the weld can be used to measure brass properties, diameter and ovality without concern for the weld. Typically, rod coils weigh about 2.0 MT although coils weighing as much as 2.5 MT are available. The word “about” in the previous sentence has great significance with take-up carrier capacity based on length. Since no two coils are exactly the same weight, each take-up carrier for the first drawing process will introduce an average of one weld per carrier. Subsequent operations add either one additional weld when length targets remain the same, more than one weld per carrier when length capacities are larger and less than one weld with subsequent carriers scheduled for shorter lengths. In general and depending upon actual carrier sizes utilized, with carrier capacities based on length, every carrier used at fine drawing (FD) pay-off contains between two and five welds, assuming that no process upsets occur prior to twisting. Consider Table 4. Using data from Tables 1–3, it shows the number of potential twisting breaks due to welds for the small and large carrier capacities, based on length (large carrier welds cut out). For a quality steel tire cord manufacturer, even a 25% breakage rate due to rod mill welds is not acceptable (2.13 potential breaks/MT). Table 4 clearly indicates an additional advantage of larger package size to reduced staffing: reduced potential to twisting breakage due to welds. Steel rod manufacturers are limited in coil size somewhat by billet or bloom size but mainly by Stelmor take-up tub size. Changing the Stelmor take-up size is relatively expensive but every steel tire cord manufacturer should pressure rod suppliers to increase coil size at every opportunity. In fact, rod price should inversely reflect coil size meaning not that manufacturers with larger coils be paid a premium but rather that rod manufacturers with smaller coils size should offer a discount since in-process costs to convert their material is significantly higher due to smaller coils. In fact, this is an excellent case for individual coil weight sta-

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tistical monitoring via simple means like X-bar R charting. Significant discounting or rejection of coils falling below a statistically predetermined weight limit should be mandatory. This technique also serves as a measure of rod supplier quality when Ppk values are determined for a set period. The take-up of the first drawing operation should match pay-off size. Forward-looking steel tire cord manufacturers insist that pay-off and take-up design include capacity for a 3.125 MT weight. The amount of material placed on the take-up should mirror the weight of material at the pay-off. Regardless of take-up carrier capacity, weights equal in magnitude to the coil size on take-up carriers will help ensure elimination of welds. Removal of the weld and HAZ joining the tail of one coil to the head of the next at the take-up is mandatory. This will result in very small amounts of waste and will significantly reduce breakage during subsequent operations. For example, if the weld and HAZ account for 50 mm of 5.5 mm rod, less than 5 grams of scrap material per coil processed will result; a small price to pay for improvement of downstream performance. One caveat is that extremely small coil sizes, like one MT, should be avoided with great fervor since small coils will dramatically influence plant performance; it is not likely that a rod manufacturer with a one MT package size can offer a large enough discount to absorb increased downstream processing costs. If the first operation is direct drawing, meaning that only one process step exists between coil receipt and fine patenting and plating with no intermediate patenting, coil weight and take-up size become more important. When an intermediate patenting operation exists, welds are heat treated two times and weld defects related to annealing can

Table 5. Machine doffs for various speeds and packages, 1.5 mm product.

Table 7. Machine doffs for various speeds and packages, 1.0 mm product.

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become less important. For direct drawing, initial drawing strains are higher and only one heat-treating operation, namely fine patenting and plating, exists before twisting making weld reduction critical to twisting performance. It is not a far stretch of the imagination to state that eliminating welds as described above will reduce twisting breakage by one break per coil. Since the most common coil size is two MT, twisting breakage will generally decline by Â˝ breaks per MT at the cost of five grams of scrap, quite a profitable trade-off. Further, consider labor savings described by various carrier sizes shown in Table 5. Clearly, the most efficient plants are able to draw steel at the highest speeds. It is obvious that a plant that can run 1.5 mm product at 20 m/s has a huge advantage in throughput, labor and product quality utilizing a 2.5 MT versus 1.0 MT package size. In fact, an operator should be able to run an equivalent number of machines as an operation with 1.0 MT package size running 10 m/s, but at twice the productivity. Intermediate Patenting. Take-up package size, based on weight not length, for intermediate patenting should be identical to that of break down drawing meaning that a well-designed operation will utilize a carrier capable of holding 3.125 MT of intermediate patented material and that material transferred from pay-off to take-up will be on a one-to-one basis. This technique introduces no new welds during intermediate patenting with welds removed at the take-up. Table 6 shows the number of doffs per position per hour for various package sizes and DVs (diameter times velocity) for 2.3 mm product. Table 3 shows that comparing a 1.5 MT package size at DV = 50 to 2.5 MT package size at DV = 90 results in a

Table 6. Machine doffs for various speeds and packages, 2.3 mm product.

Table 8. Machine doffs for various speeds and packages, 2.0 mm product.

Fine drawing, twisting and spiral wrapping Fine Drawing. Determined by the type of twisting process, carrier size for fine drawing generally falls into one of two categories: outside spools for twisting that have no weight restriction and inside spools for twisting whose size in part limits the required machine speed. Recommendations for outside spools should be obvious 1:1 by weight based on FD payoff weight. Superficially,

inside spool size affects machine output since larger inside spools create a larger catenary resulting in slower machine speeds. However, having essentially “infinite” size outside spools compared to inside spools, based on plant preference determination of inside spool size has relation to down time to change inside spools and labor costs. Key is that outside spools’ holding as much as 2.5 MT of material will run for an exceptionally long time and when staged so that they do not run out at the same time result in dramatically reduced creel end waste. For a stranded construction like 3+2 x 0.35 ST producing about 900 kg per day, each outside spool can account for less than one cable weld per MT of cable produced with essentially no creel end waste. In addition, using 250 kg inside packages and 2500 kg outside packages, inside positions would need to be changed about every 1.5 days and one outside position would require doffing about every 4.6 days. Using a 2.5 MT take-up, the take-up would doff every 2.8 days. Twisting. Also determined by the type of twisting process, carrier size for cabling falls into one of the same two categories: outside take-up and inside take-up spools. Many plants fall into the trap of using the final customer package, like a B-80, for outside and inside take-ups. Although placing the material directly on the customers’ preferred carrier seems attractive, high speed, twist adjusting automated rewinding equipment is available. These rewinders are more capable of detecting broken filament, which is very difficult when the twisting take-up is inside the machine, and for automatically correcting twist. Therefore, there are great advantages for using very large package sizes for outside cabling take-ups followed by running the cable through an automated rewinder. This also greatly improves cabling machine efficiency since machines can be run for days before changing the take-up spool, the most common reason for down time when the customers’ carrier is used on the take-up. Inside cabling take-up spool size limits machine speed similarly to inside pay-off positions on twisting machines, should be determined based on labor costs, and required change-out time. However, it is generally preferred to use the largest spool possible and rewind the material on an automated rewinder as previously described. Keep in mind that for the final product, the larger the pay-off spool the smaller the percentage of creel end waste. For example, if three welds are allowed per B-80 then the maximum amount of creel end waste should not exceed about 10 kg regardless of the package size. If the package size is 200 kg, this is 5 %FSV while if the package size is 2.5 MT this is 0.4 %FSV. Table 9 shows the productivity per year for different take-up sizes and different processing speeds assuming ten minutes to change a take-up carrier. Clearly, considering only the take-up position the largest benefit to productivity is increasing the take-up size from a B-80 to any other size listed. For example, for the slowest machine speed 12 MT per machine per year are gained by changing to a 250 Kg carrier; the difference is almost 50 MT per year per

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similar number of doffs per hour with improved productivity of 1 MT per position per hour. Intermediate Drawing. Take-up package size for intermediate drawing should be identical to that of break down drawing and intermediate patenting, meaning that a welldesigned operation will utilize a carrier capable of holding 3.125 MT of intermediate drawn material and that material transferred from pay-off to take-up will be on a one-toone basis. This technique will also not introduce welds during processing. Table 7 shows the dramatic improvement in productivity using large package sizes at high speeds. The average operator would change the take-up and payoff twice in a 12-hour shift per machine, allowing the operator to run a minimum of 12 machines at very high productivity. Fine Patenting & Plating (FPP). Take-up package size for FPP should be identical to that of break down drawing, intermediate patenting and intermediate drawing, meaning that a well-designed operation will utilize a carrier capable of holding 3.125 MT of FPP material and that material transferred from pay-off to take-up will be on a one-to-one basis. This technique used during FPP will introduce no new welds. Table 8 shows the number of doffs per position per hour for various package sizes and DVs (diameter times velocity) for 2.0 mm product. Table 8 shows that it would be very difficult to manage a high-speed line with a package size smaller than 2.5 MT where a 2.0 mm product is doffed about every 9.5 hours. For a 60 end line, smaller package sizes force the inefficiency of lower line speeds. Partial FPP Pay-Off Carriers. Realistically, there will be times during manufacturing when the violation of the 1:1 ratio by weight with large package size occurs such as process upsets and code changes at FPP. Referring back to prior text, by far the safest place to make a weld is immediately before a patenting operation, where although a small section of cast material exists at the weld, after patenting the microstructure of a well-made weld will not differ from the base material, fine pearlite. Partially full carriers containing material of identical heats and diameters welded into a continuous length on one or a few positions to make one FPP take-up carrier of similar size to normal production material will reduce to the lowest level potential for twisting breaks due to welds. For other process upsets at other than FPP, partial carriers can be segregated through the process and consolidated with material of the same heat and diameter at FPP as described above resulting in minimal risk of twisting weld breaks.

TECHNICAL PAPERS

Table 9. Relative productivity per year.

Table 10. Relative productivity per year.

machine for the fastest speed. The numbers become huge when a plant has, for example, 100 twisting machines. And of course, the increased productivity is obtained with less labor and essentially no take-up creel waste. Table 10 shows the productivity per year for different pay-up sizes and different processing speeds assuming 10 minutes to change outside positions and 15 minutes to change inside positions for 3+2 x 0.35 ST cable. Benefits of larger package sizes improve the larger the package size becomes. For example, for the slowest machine speed about 20 MT per machine per year are gained by changing to a 250 Kg carrier; the difference is more than 80 MT per year per machine for the fastest speed. And again, the increased productivity is obtained with less labor and far less, or no payoff creel end waste.

Rewinding/spiral wrapping Although rewinding adds an additional processing step, it also adds several orders of magnitude to product quality. Enormous improvements in product quality follow from the ability to dynamically correct twist, exactly control length and essentially eliminate creel end waste. Highspeed rewinders can be automated for doffing cycle, twist measurement and spool length, virtually eliminating additional labor. Further, rewinding does not affect plant output if it is wisely not chosen as the plant bottleneck (the plant bottleneck should always be located at the operation with the greatest number of machines). Discussions for spiral wrapping are similar to those for twisting.

Conclusions Choosing a large carrier or package size is critical to plant productivity and product quality. Building large package size into a new plant is relatively inexpensive and the payback is very short. Converting an existing plant to large package size can be critical to the plant’s survival, especially where labor costs are high and product quality requirements are superior.

References T.W. Tyl, Tire Wire Technology, LLC, USA, “Control of Strengthening Mechanisms in the Manufacture of Steel Tire Cord.” Presented at the 2005 WAI 75st Annual Convention, Atlanta, GA USA, Printed in Wire Journal International, Feb. 2006, pp. 122-128.

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R.P. Schenk, RichardsApex, Inc., and T.W. Tyl, Tire Wire Technology, LLC, USA, “Control of Wet Drawing Lubricant in the Manufacture of Steel Tire Cord.” Proceedings of The Wire Association International, Inc. Prague, Czech Republic, Oct. 2005. T.W. Tyl, Tire Wire Technology, LLC, USA, “Control of Cable Twist in the Manufacture of Steel Tire Cord,” Presented at WAI’s 76st Annual Convention, 2006, Boston, MA USA, Printed in Wire Journal International, Nov. 2007, pp. 72-75. T.W. Tyl, Tire Wire Technology, LLC, USA, “Liquid Quenchant Fluidized Bed Technology in the Manufacture of Steel Tire Cord.” Presented at the 2006 International Technical Conference, New Delhi, India. T.W. Tyl, Tire Wire Technology, LLC, USA, “Thermodynamic Wire Transformation Process in the Manufacture of Steel Tire Cord.” Presented at the WAI’s 77th Annual Convention, 2007, Cleveland, Ohio, USA. T.W. Tyl, Tire Wire Technology, LLC, USA, “Steel Patenting Technology in the Manufacture of Steel Tire Cord,” Presented at the 2007 International Technical Conference, Bologna, Italy. T.W. Tyl, Tire Wire Technology, LLC, USA, “Recent Global Trends in Steel Tire Cord Technology.” First Annual Symposium on Wire Research and Technology, WIRETECH 2008, Research & Development, Global Wires & Technology Group and Wires Division, Tata Steel, North Point Learning Centre, Khandala, India, Jan. 22-23, 2008 M. Zelin, “Microstructure Evolution in Pearlitic Steels During Wire Drawing,” Acta Materialia, 50-2002, 4431.

Jeff Tyl with his wife Lesley, mother Shelley; and children Braydon and Holt Tyl.

Jeff Tyl presents the 2013 Mordica Memorial Award at Interwire 2013. JUNE 2013 | 71

TECHNICAL PAPERS

Thomas W. Tyl, the late principal of Tire Wire Technology (TWT), LLC, and the winner of the WAI’s Mordica Memorial Award, died July 11, 2011, at the far too early age of 55. The award honors individuals for their technical contributions to the wire and cable industry, and Tyl was known for his industry knowledge as well as his colorful stories and ready wit. He worked for The Goodyear Tire & Rubber Company in key positions from 1989 to 2003 before starting his consulting company, which provided expertise on saw wire, tire cord, bead wire, hose wire, music wire and conveyor belt reinforcement, and other steel wire products. Tyl was the inventor of seven new technologies, with patents pending in the U.S. and other countries. He held an M.S. degree in metallurgical engineering from Carnegie Mellon University, an M.B.A. degree in manufacturing management from the University of Pittsburgh, and a B.S. degree in materials science from orth Carolina State University. He authored 18 technical papers and articles in WJI, including a thought-provoking piece, “The Role of Culture (Mindset) in Technology,” in the Dec. 2008 issue. Tyl’s presentation at Interwire was made by his son, Jeff Tyl, who is the principal of Jigsaw Technology. He was accompanied by his wife, Lesley; mother, Shelley; and children, Braydon and Holt.

TECHNICAL PAPERS

TECHNICAL PAPER

72 | This presentation appeared in the Proceedings of the 61st IWCSâ&#x20AC;&#x2C6;Conference

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TECHNICAL PAPERS 74 | This presentation appeared in the Proceedings of the 61st IWCSâ&#x20AC;&#x2C6;Conference

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TECHNICAL PAPERS 76 | This presentation appeared in the Proceedings of the 61st IWCSâ&#x20AC;&#x2C6;Conference

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PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS Straighten-and-cut system can enable torsion-free production At Interwire 2013, Germany’s Eurobend GmbH showcased the company’s expanded MELC line of straightening and cutting machines, all of which are based on the company’s hyperbolic roller rotor straightening method that was invented and developed by its R&D department 25 years ago. A press release said that the latest addition to the MELC family of machines, which has three main categories, is the MELC 40 MONOLINE. This system, it said, has a patented unique anti-twist, twinroller system that ensures torsion-free production of wire/re-bar, and can process up to 40 mm coiled material. Eurobend also offers the MELC FLEXI-LINE series, with up to six automatically interchangeable coils, processing from 4 mm to 20 mm, and equipped with a patented convergence guide system for automatic diameter/coil changes in less than two seconds. Extremely fast and automatic coil changes enable the process of different diameters in the same batch without complicated collection systems. The third line is the MELC POLY-LINE Series, which has systems with up to six independently operating lines, achieving production speeds up to 500 m/min. Contact: Eurobend GmbH, tel. 49-911-9498980, www.eurobend.com, info@eurobend.com.

Furnace excels for processing of steel wire and brass-plated wire At Interwire 2013, Austria’s CPA Wire Technologies GmbH shared the latest information on the company’s AEOX furnace, designed especially for steel wire austenitization, diffusion annealing and stress relieving. A press release described AEOX as an energy-efficient, combustion optimized recirculation convection furnace with cascaded and extensive heat recuperation that is characterized by optimum insulation. In contrast to the high energy consumption of conventional industrial furnaces, AEOX furnaces are designed with air convection technology to preheat the combustion air delivered to the burners by using the flue gas-heat content, it said. AEOX is also perfectly suited to process brass-plated wire from the company’s CELLTRAC plating line as it 78 | WIRE JOURNAL INTERNATIONAL

transforms the applied brass layers into homogenous brass by diffusion annealing, the release said. CELLTRAC, it noted, is a cost-saving, multi-cell electrolytic brassplating system with separated plating cells for each wire in each plating bath and individual current supply for each wire, which leads to homogenous brass layer on the wire surface. To complete the triumvirate for high-quality steel wire production, the company’s LINNOX wet drawing machines were developed for drawing high-strength steel wires free from residual stress down to a final wire diameter of 0.06 mm. Energy and economic efficiency are very important, and not just for the steel wire industry, said CPA Sales Director Robert Zachar. “Thus the new AEOX heat treatment technology, which saves up to 40% of energy and effectively reduces emission losses, is on the rise.” Contact: Robert Zachar, CPA Wire Technologies GmbH, r.zachar@cpa.at., www.cpa.at.

New extruder generation technology results in less power consumption At Interwire 2013, one of the focuses for Austria’s Rosendahl was how the company had improved the power consumption of its ROEX extruder technology to save from 15% to 25% for comparable production lines. A press release said that Rosendahl’s R&D was able to improve energy use through the following modifications. The drive has been modified from DC technology to state of the art A/C power technology and by omitting the thyristor rectifier, which it noted caused enormous wastage due to reactive power. By converting to a direct

Wire range serves multiple fields At Interwire 2013, U.S.-based Phifer Incorporated, an international leader in the manufacture of aluminum round wire with more than 60 years of experience, displayed its range of American-made drawn wire products.

A press release said that Phifer has some of the most diverse capabilities in the industry, producing custom wire from numerous alloys in diameters from .11 mm to 11.1 mm for a wide variety of applications. The company’s aluminum wire (.127 mm, .16 mm, .254 mm and .32 mm) is used all over the world as coaxial cable braid shielding, shipboard cable armoring and hose braiding, it noted. Newer products, it said, include copper-clad aluminum, low-carbon steel and bronze wire from .127 mm to .50 mm, with available packages for fine diameter wires that include numerous returnable and disposable spools from .34 kg to 14 kg. Phifer also offers aluminum wire in larger diameters (.81 mm to 11.1 mm) for wire forms, food packaging clips, automotive molding reinforcement, vacuum metallizing and more. Innovative machinery has expanded and improved Phifer’s selection, especially for manufacturers of rivets, staples and other fasteners, it said, adding that chemical processing and cleaning is offered for improved

appearance and enhanced performance. The company also offers new precision-winding capabilities for aluminum thermal spray and metallizing applications. Packages include coils and stem carriers from 14 kg to 680 kg, fiberboard drums, and more than 40 spools and reels. Contact: Phifer Incorporated, www.phifer.com.

Jacketing technology intended for food and beverage industry U.S.-based General Cable Corporation has introduced GenClean™, a proprietary new cleanable jacket technology for rubber portable cord used in the food and beverage industry. A press release said that cables manufactured by General Cable with a GenClean jacket permit organic remnants to be more readily removed in a wash cycle, which would substantially reduce the environmental conditions conducive to microbial growth. For water wash-down, water temperatures up to 212°F (100°C) are acceptable, it said, adding that the maximum temperature for operation in water is 140°F (60°C). GenClean, the release said, is abrasion-, cut-, heat-, flame-, sunlight- and chemical-resistant, built to withstand daily abuse, temperature extremes (-50°C to 105°C) and high-stress industrial environments. General Cable will produce a test sample based on the required size and conductor count. Currently, GenClean technology is being offered with the company’s full line of Carol® Brand Super Vu-Tron® Supreme products, which include a high-visibility yellow jacket, it said, adding that there are other cable constructions and colors that will be available as Make-to-Order items. Contact: General Cable Corporation, tel. 859.572.8525, www.generalcable.com.

Optical fiber has top attenuation and improved macrobend performance U.S.-based Corning Incorporated has introduced its latest single-mode optical fiber innovation: Corning® SMF28® Ultra fiber, a new, premium single-mode optical fiber that it described as the first in the market to combine the benefits of industry-leading attenuation and improved macrobend performance in one fiber. A press release said that the new fiber, designed for high performance across the range of long-haul, metro, access and fiber-to-the-home (FTTH) network applications, is fully backward compatible with the installed base of legacy single-mode optical fibers. “SMF-28 Ultra fiber changes the game when it comes to choosing the right JUNE 2013 | 79

PRODUCTS & MEDIA

screw drive via a planetary gear motor, mechanical losses were reduced. The planetary gear is directly driven by four symmetrically aligned motors. Material output was able to be “massively increased” by optimizing the process unit (screw and feeding sector). Further gains were realized through additional electrical power consumers, such as the heating and cooling section. A new design of the heating elements, in combination with the cooling channels and fans, allowed substantially faster reactions of the extruder temperature control. These changes resulted in precise control as well as reduced power consumption of the heating and cooling section. “Needless to say, further machines of the Rosendahl extrusion lines were subjected to measures to increase efficiency,” the release said. Contact: Rosendahl GmbH, www.rosendahlaustria.com.

PRODUCTS & MEDIA

single-mode fiber for your network. Previously, network operators had to choose whether to improve the attenuation or macrobend performance but now they can have both,” said Corning’s Barry Linchuck. “This unique combination is made possible through revolutionary process innovations developed by Corning that deliver lower attenuation and improved macrobend performance with no design trade-offs.” The improved attenuation of SMF-28 Ultra fiber provides additional margin that can be used to extend spans, lengthen the distance between regenerators, increase the allowable number of cable-cuts or allow for the broader use of pre-connectorized solutions, the release said. The improved macrobend performance provides greater margins for bends that regularly occur in the field during installation and maintenance, and allows for the design and deployment of smaller and lighter cables which can improve duct utilization, enable smaller enclosures, or

80 | WIRE JOURNAL INTERNATIONAL

reduce pole/tower loading in aerial deployments, it said. The macrobend performance is delivered with a 9.2 μm mode-field diameter that is equivalent to the majority of standard single-mode fibers on the market today and allows for seamless integration into existing networks, it said. Contact: Corning Incorporated, www.corning.com.

New wire excels for production of high-quality reed switches Sweden’s Sandvik reports that it is now offering a new wire, Safeni 52, that has precisely the right material characteristics and a new level of feedability that contributes to higher throughput with less downtime, all of which are pluses for manufacturers of reed switches. A press release described Sandvik’s Safeni 52 as a soft magnetic iron-nickel alloy with high magnetic permeability, low coercive force, and a low content of non-metallic inclusions. Its thermal expansion is compatible with glass used in reed switches, it said, so reed switch manufacturers “can rely on consistently high surface quality, which contributes to the wire’s excellent feedability.” The wire, the release said, runs through equipment cleanly, contributing to higher production throughput with increased uptime as well as high end-product quality and reliability. The package is designed to reduce tangled

Coating system represents a 2-in-1 approach for fasteners DĂśrken Corporation USA, the U.S. business of Germanyâ&#x20AC;&#x2122;s DĂśrken MKS-Systeme GmbH & Co. KG, has introduced DELTA-PROTEKTÂŽ KL 105, a new coating

that provides a two-in-one approach for coating a range of fastener materials such as nuts, bolts and screws. A press release said that the coating provides anti-corrosion properties and with its integrated lubricant, a low coefficient of friction. The coating, it said, is applied using either the dip-spin, dipcoat, spray-immerse or spin-coat process, and dries at a temperature of 190Â°C and 235Â°C. Further processing and corresponding energy consumption are avoided and there is no time-consuming material change and handling necessary, it said. The release said that DELTA-PROTEKT has achieved more than 1000 hours without rust in the salt spray test (DIN EN ISO 9227) and has a coating thickness between 8-10 Îźm. The coefficient of friction (COF), it noted, has achieved a mean value of 0.15Îź tot depending on the coating. The capability of reduced COF was added to comply with the specifications of OEMs in mind, as up to this introduction a multifaceted approach was only possi-

ISO ISO9001 9001 REGISTERED

DESIGNERS DESIGNER RS & MANUF MANUFACTURERS FACTURERS A OF P PAYOFF AYOFF O & TENSION CONTROL EQUIP EQUIPMENT PMEN NT FOR WIRE & CABLE CABLE

W yrepak Industries Industries offers Wyrepak offers high high solutions for for quality machines machines and and solutions quality wire and cable companies comp panies as well as other industrial applications. applications. From tension tension controls, controls, pay-offs, pay-offs, pulleys, pulleys, and custom custom sheaves, sheaves, bobbin bobbin winders winders and Wyrepak applications â&#x20AC;&#x201D; Wyr repak does it all! For more details on anyy of our manufacturing product solutions, call uus at 800-972-9222 or email sales@wyrepak.com sales@wyrepak.c y p com WYREPAK WYREP PAK A INDUST INDUSTRIES RIES â&#x20AC;&#x201D; A Huestis Indus Industrial strial Company s WWW 792%0!+ COM s WWW 792%0!+ COM "UTTONWOOD 3TREET "RISTOL 2HODE )SLAND 53! s TEL OR FAX "UTTONWOOD 3TREET "RISTOL 2HODE )SLAND 53! s TEL OR FAX

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PRODUCTS & MEDIA

pails and the wire exhibits remarkable straightness with little cast or helix, it said. A company spokesperson said that the alloy is melted and hot rolled at the companyâ&#x20AC;&#x2122;s mill in Halstahammar, Sweden, and that the wire is produced at its plants in Sandviken, Sweden, and Connecticut, USA. The wire is available from .0039â&#x20AC;? to .4724â&#x20AC;? (0.10 mm to 12.0 mm). The normal lead time for these items is 6 to 8 weeks. Contact: Sandvik Wire and Heating Technology AB, www.sandvik.com.

PRODUCTS & MEDIA

ble with cost-intensive multi-coat systems, it said. The coating, the release said, was awarded the German Material Efficiency Prize by the Federal Ministry and has been approved by a variety of automotive, construction and agricultural OEMs. Contact: Dörken Corporations USA, tel. 517.522.4600, www.doerken-mks.com.

2-part silicone potting compound is usable for compliance with UL 94 VO U.S.-based Henkel Corporation has introduced Loctite® SI 5640™, a two-part, self-leveling silicone compound designed for electrical and electronic potting applications that require UL 94 VO compliance. A press release said that the compound, designed to ensure the integrity of electrical components by sealing against corrosion and outdoor contaminants, has low viscosity silicone that offers strong adhesion to plastics and resists 85C/85% RH aging conditions. The compound is flame retardant when applied in thicknesses as low as 6 mm and can gel in just five minutes, making it ideal for high throughput in automated processes that require fast

cure times, it said. The material is meant for a wide range of electrical uses from solar panels/wiring and signage/ displays to speakers and appliances as well as to pot and seal internal electrical components, including wires. The compound offers 30 shore A hardness and elongation greater than 100%, the release said. The silicone is available in a 490 ml dual-cartridge package or in five gallon and 55 gallon drums for high volume production environments. The components must be combined in a 10:1 mix ratio to ensure proper cure. Contact: Henkel Corporation, www.henkelna.com/silicones.

WITechs W ITe h Wire Technologies g

ROD / WIRE COA COATING AT TING

HSBE 3201 rod cleaning and coating mac machine hine for liquid lubricant carrier in-line cleaning with liquid. carrier-coating with inorganic salt mixture instead of pure bora ax. borax. coating and drying at infeed-speed up to 4 m/s. extensive control and monitoring g panel for a safe production process.

www.witechs.de www .witechs.de www.morgan-koch.com www .morgan-koch.com m

82 | WIRE JOURNAL INTERNATIONAL

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CAREER OPPORTUNITY

DIES

MACHINERY

OW N E R / O P E R ATO R RETIRING: Small electronic wire & cable manufacturing shop for sale. Great opportunity for self starter. Los Angeles, CA. Please contact: Danethecable-expert@yahoo.com.

APOLLO DIA-CARB COMPANY Sells Natural/PCD diamond dies. Fair prices/excellent lead times. Contact Paulette, Owner/Sales Tel. # 1 (508) 226-1508 or 1 (508) 226-0946 E-mail: apollodie@comcast.net

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.

AGENTS WANTED. Agents are required for open areas for Delisi Srl, a leading Italian manufacturer of wireworking machines. Delisi sells worldwide and is looking for qualified sales representatives for the company's automatic straightening and cutting machines and automatic stirrup-bending machines. For information, please contact delisi@delisisrl.com or visit us at www.delisisrl.com.

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

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

FOR SALE 1 - CEECO 37-Wire 31” Rigid Strander Line 2 - WARDWELL 24-Carrier Braiders 1 - NEB 72-C #2 Braider, Long Legs, Motor 2 - NEB 48-C #2 Harness Braiders, Motors 1 - NEB 16-C #2 Harness Braider, Motor 1 - NEB 12-C #2 Braider, Long Legs, Motor 3 - TMW 24-Carrier Cable Braiders, 6” HG 1 - REEL-O-MATIC 24” Caterpuller Capstan 1 - FARRIS 22” Caterpuller Capstans 1 - ENTWISTLE 30” Closer, Model STC-30 1 - EDMANDS 18-Wire 16” Planetary Cabler 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - SICTRA Rod Breakdown Line 1 - DAVIS STANDARD 3.5” Rubber Extruder 1 - DAVIS STANDARD 2.5” Hi-Temp Extruder 2 - DAVIS STANDARD 1.5” 24:1 L/D Extruders 1 - HALL 40” Motorized Payoff w/4F12 Dancer 1 - DYNAMEX Tape Payoff, Model TPB30-2-D 1 - ROSENDAHL 630mm P/A Dual Reel Take-up 1 - NOKIA Model EKP50 P/A Dual Reel Take-up

1 - SPHEREX 18” Dual Reel Take-up, refurbed 1 - CLIPPER Model SP16 Dual Spooler 1 - AL-BE Model MS12 Respooler, 14” Reels 1 - WEMCO 84” Take-up, Model 8284B 1 - REEL-O-MATIC SP-HJ/K5 Take-up 1 - REEL-O-MATIC ILB12X Dual Respooler 1 - METEOR Model ME301 3-Head Winder 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4WDT24 4-W 24” D.T. Twisters 1 - KENRAKE Model TWD101 Twister 1 - FORMULABS ‘Codemaster 5’ Spiral Striper 1 - FARRELL Banbury Mixer, 7.5HP Motor 1 - METRONIC AlphaJet C Inkjet Printer, 2005 3 - PWM Model EP500 Rod Welders 1 - EUBANKS Model 4000-04 C/S Machine 1 - SCHLEUNIGER Model UC3750 Cutter 1 - SCHLEUNIGER Model EC3200 EcoCut 1 - SCHLEUNIGER Model PF2000 PreFeed 1 - SCHLEUNIGER StripCrimp750 1 - IDEAL Model STP Stripper, Part #45-930

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

JUNE 2013 | 83

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MEDIA THE SMALL SHOP. This book, 327 pages, by Gary Conner, the author of Lean Manufacturing for the Small Shop, describes Six Sigma and how it is used bysmaller 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 includes a supplementary CD-ROM. Price, $95, $75 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store. PROCEEDINGS OF WAI’S 81ST ANNUAL CONVENTION. These proceedings of WAI's 81st Annual Conv., Interwire 2011 Georgia World Congress Center, Atlanta, Georgia, USA. Available only on CD-ROM, this is the Conference Proceedings of technical papers presented during the event.

The price is $90, $75 for WAI members. To purchase, go to wirenet.org and click on The WAI Store. 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 set is divided into three separate handbooks. Part 1 is Wire and Cable Production Materials; Part 2 is Wire and Cable Production Processes, and Part 3 is Types of Cables. Parts 1 and 2 are now available. The price is $99, $59 for WAI members, plus shipping. To purchase, go to wirenet.org and click on the WAI Bookstore.

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SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 135-page indexed booth (published in 2011) was written by industry expert Douglas B. Relyea, founder of Quality Principle Associates, a New England-based consulting firm specializing 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 in 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 includes: the benefits of statistical process control over statistical product control; real-world industrial examples and case studies showing 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. The list price is $45, $40 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

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Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .51

T. Fukase Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Pro-pHx Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

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

Proton Products Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 23

Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Queins Machines GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17, 34

REELEX Packaging Solutions . . . . . . . . . . . . . . . . . . . . . . .5

Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

SAMP USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

IWG High Performance Conductors, Inc . . . . . . . . . . . . .35

Sheaves Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

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

JUNE 2013 | 87

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Joe Snee Associates . . . . . . . . . . . . . . . . . . . . . . . . . .26, 62 Steel Cable Reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 August Strecker GmbH & Co KG . . . . . . . . . . . . . . . . . . .57 TMS Specialties Mftg Co Inc . . . . . . . . . . . . . . . . . . . . . . . .4 WAFIOS Machinery Corp . . . . . . . . . . . . . . . . . . . . .Cover 3 WiTechs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .45

August 2013 WJI • Brazil Outlook • previews: wire South America wire Southeast Asia • wrapup: wire Russia Advertising Deadline: July 1, 2013

WTM Wire Technology & Machinery Srl . . . . . . . . . . . . . .53 Wyrepak Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . .59, 81 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . . . . . . .9

WIRE ASSOCIATION INTERNATIONAL ADS WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Save the date: WAI Operations Summit & Wire Expo 2014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 WAI Webinars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

WIRE JOURNAL

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

ORTH 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

88 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI I DIA 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