Green

WIRE JOURNAL MAY 2014

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INTERNATIONAL www.wirenet.org

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CONTENTS

Volume 47 | Number 5 | May 2014

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

F EATURES

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 18 People. . . . . . . . . . . . . . . . . . 20 Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 24 WAI News . . . . . . . . . . . . . . . 26 Chapter Corner . . . . . . . . . . . 30 Products . . . . . . . . . . . . . . . . 46 Technical Papers . . . . . . 54-68 Classified . . . . . . . . . . . . . . . 69 Career Opportunities . . . . . . 69

Next issue June 2014 • Dies • Wrapup: WAI Operations Summit & Wire Expo 2014

Wrapup: wire Düsseldorf 2014 . . 32 Once again, wire Düsseldorf proved to be a hive of activity, with attendees from more than a hundred countries swarming the halls where some 1,300 exhibitors displayed a massive amount of equipment as well as products and services.

Green . . . . . . . . . . . . . . . . . . . . 38 Green is continuing to find its place in manufacturing, and while it seldom was the key selling point at wire Düsseldorf, a wide range of equipment and products were exhibited that are designed to reduce energy use, use of chemicals and more. In a way, green has increasingly become part of the basic ingredients.

T ECHNICAL PAPERS How to increase the performance of aluminum alloy rod drawing by using emulsions Stuart Duff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Increased productivity in medium voltage XLPE insulating with continuous type change Jorma Leppänen, Eero Korolainen and Pekka Huotari. . 60 Energy efficient operation of pulse-jet dust collection systems Kelly Zipsie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Cover: In ways both big and small, “green” has become a part of manufacturing...even if it doesn’t seem as if a lot has changed.

MAY 2014 | 3

CONTENTS

INSIDE THIS ISSUE IT’S COPPER WIRE ART IN A ‘MEGA’ WAY . 33

GREEN

Something unexpected and memorable always seems to turn up at Düsseldorf, and the 2014 staging was no exception. In Hall 10, A72, Mega Metal SAN ve Tic Ltd., a Turkish cable manufacturer, displayed a two-meter-tall dervish made from the company’s superfine copper wire.

Four students from Mimar Sinan Fine Arts University spent a month forming the dervish, which weighs about 150 kg and may have set a “most photographed” record.

‘Green’ can be seen in many places, and for Sandvik Hyperion, it can be found in used carbide. A typical mine will landfill about 300 kg of rock for every 1 kg of tungsten made due to the low concentration of tungsten compounds in the ground. However, recycling just 1-2 kg of cemented carbide yields the same result. That’s the basis for a recycling program that the companmy has found to be both environmentally sound and good for business.

4 | WIRE JOURNAL INTERNATIONAL

CAN BE SMART BUSINESS

. . . 38

EDITORIAL WIRE JOURNAL ÂŽ

EDITORIAL

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

The ‘green’ story continues to evolve Green is here to stay, but what exactly that means can be difficult to grasp. There is no one single green direction for manufacturing, but there are mountains of possible concepts to consider.

University of California-Berkeley Professor David Dornfeld, author of “Green Manufacturing,� put that dilemma in context. He wrote that there are so many green initiatives–from power to water to air quality–a company can follow that it can be overwhelming. He supports a common-sense approach: figure out what steps can be taken and what they cost, then start with those that have the greatest paybacks, both financially and environmentally.

One mistake some companies make, Dornfield wrote, stems from a well-intentioned instinct. “Green manufacturing doesn’t just mean recycling materials. In fact, recycling comes after other options have been exhausted. Instead, manufacturers should refuse to create waste, reduce it, reuse resources, and then, finally, recycle.�

Part of the approach can include choosing greener ways when it comes time to make investments. The good news is that there are more cost-effective options for manufacturers to consider. A range of such technology was shown at wire Dßsseldorf, some of which is included in this issue’s feature, and more in the Products section.

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli Media Production Manager | Paul Streeto Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing & Corporate Communications | Janice E. Swindells Proofreader | Livia Jacobs Publications Committee Dane Armendariz | Chemetall Ferruccio Bellina | TKT Group/President ACIMAF, Italy Malcolm Michael | AWIA Australia Don Schollin | Q-S Technologies, USA Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA Technical Advisors John Drummond | Scotia Group

Cartel activity in the wire & cable business I was disappointed by the recent report (see p. 11) that spelled out how some of the world’s top power cable manufacturers had controlled contracts from 1999 to 2009. Many people I asked for their take on the news essentially shrugged it off, saying, “Hey, that’s business.� Some observed that such activity is rampant elsewhere too.

For multiple reasons though, this story still doesn’t feel right. I thought better of the businesses. I’m not out to plunk a black hat on companies I have written about–and often admired–for years, but I’m also not willing to accept that this is what business is. It’s not. It’s what a group of people allowed it to become.

Much could be said about the activity, but strip away all the excuses, all the rationalizations, and I think that one undeniable truth emerges: it was taking the easy way out.

Mark Marselli Editor-in-chief

R. M. Shemenski | RMS Consulting, Inc.

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, $15 non-members. Periodicals postage paid at Guilford, CT 86$ DQG DW DGGLWLRQDO RI¿FHV 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. Š 2014 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 DUH RQ PLFUR¿OP DQG DYDLODEOH IURP 8QLYHUVLW\ 0LFUR¿OP 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313-761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

CALENDAR

CALENDAR May 14-15, 2014: 2014 National Electric Wire Processing Expo Milwaukee, Wisconsin, USA. To be held at the Wisconsin Center. Contact: Expo Productions, Inc., tel. 800-3675520 or 262-367-5500, cheryl@epishows.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.

June 9-11, 2014: 8th CRU Wire and Cable 2014 Istanbul, Turkey. CRU’s 8th Wire & Cable conference, to be held at the InterContinental Istanbul. Contact: CRU, tel. 44--20-7903-2444, www.crugroup.com, conferences@crugroup.com.

Oct. 28-30, 2014: Wire & Cable India Mumbai, India. To be held at the Bombay Convention & Exhibition Centre. Contact: see wire China 2014.

Nov. 9-12, 2014: 63rd IWCS ConferenceTM Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.

June 9-12, 2014: Wire and Cable Guangzhou 2014 Guangzhou, China. To be held at the China Import and Export Fair Complex, this event is co-sponsored by Messe Frankfurt. Contact: Elaine Zheng, Guangzhou Guangya Messe Frankfurt Co., Ltd., tel. 86-203825-1558, sps@china.messefrankfurt.com, www.chinaexhibition.com.

Nov. 26-28, 2014: MFSH 2014 Shanghai, China. To be held at the China (Shanghai) Inernational Exhibition, this event includes bar, wire, steel rope and more. Contact: Shanghai Aoya Exhibition Co., at 86-21-3351 8138, ayexpo@vip.163.com.

June 16-18, 2014: 15th Guangzhou International Metal & Metallurgy Exhibition Guangzhou, China. To be held at the China Import and Export Fair Pazhou Complex. Contact: MeiWen, tel.

86-1-800-2266711 or tel. 86-20-38621295, meiwen@ julang.com.cn, www.julang.com.cn.

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

June 17-18, 2014: Polymers in Cables Philadelphia, Pennsylvania, USA. To be held at the Hotel Sofitel Philadelphia. Contact: Kelly Cressman, AMI Conferences, tel. 610-478-0800, kc@amiplastics-na. com, www.amiplastics-na.com.

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

June 20, 2014: Midwest Chapter 12th Annual Golf Tournament West Chicago, Illinois, USA. The Midwest Chapter will return to the St. Andrews Golf & Country Club.

Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.

Sept. 8, 2014: New England Chapter 20th Annual Golf Tournament Ellington, Connecticut, USA. The New England Chapter will return to the Ellington Ridge Country Club. Contact: WAI’s Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

8 | WIRE JOURNAL INTERNATIONAL

Oct. 2, 2014. The Vannais Southeast Chapter’s 13th Annual Golf Tournament Conover, North Carolina, USA. The Southeast Chapter will return to the Rock Barn Golf and Spa. Contact: Art Deming, tel. 252-955-9451, art.deming@nexans.com.

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

INDUSTRY NEWS

INDUSTRY NEWS Turkish company orders bar and wire rod mill from Germany’s SMS Meer Germany’s SMS Meer reports that it has received an order from Karabük Demir Celik (Kardemir) from Karabük, Turkey, for special bar quality (SBQ) rolling mill for the production of surface-quenched and tempered rebar, straight bars, wire rod and bar in coils.

A press release said that the mill, in its first stage, will have annual capacity of 700,000 metric tons, and will have the capacity to increase to 1,400,000 metric tons per year in a second phase. The bar and wire rod mill has been designed to “produce cost-effectively even in small batches and, thus, is able to flexibly react to market demands at any time.”

SMS Meer noted the following about the three-roll Precision Sizing Mill (PSM®). It will include a walking-beam reheating furnace with a capacity of 150 tons per hour, 18 modern housingless two-high stands in H/V arrangement, shears, cooling lines, cooling bed with finishing facilities, a wire rod line with ten-stand MEERdrive® wire rod block, laying head, LCC®, coilhandling equipment and two coil compactors as well as a coiling line with two coilers and cooling facilities. It includes a wire rod outlet with a 10-stand MEERdrive block for rolling wire rod (5.5 to 25 mm), with the mill designed for a maximum speed of 120 meters per second for wire rod and 16.5 meters per second for bars. Each wire rod stand is driven individually by its own motor for lower operating costs, less roll stock-keeping and redressing, a flexible pass design and lower energy consumption.

Commissioning is scheduled for the first quarter of 2015.

nkt cables dealt with explosive issues in challenging offshore wind farm project It may have been finished a half-year late, but officials at nkt cables have to be relieved that the offshore turnkey project connecting the Riffgat offshore wind farm to the German transmission grid was finally completed in January and operational in February. The order from TenneT, the turnkey contractor for the cable system, called for the laying of 51 km of 155 kV cable, but the project was delayed, most notably by the discovery of underwater explosives.

In a June 24, 2013, story in Wind Power Monthly, nkt cables reported that the project would not be finished as scheduled in 2013 due to large amounts of World War 2 munitions detected on the seabed. “Work is ongoing around the clock by a 60-strong team clearing the material, including mines and boxes of munitions, but the situation is complicated by strong currents and turbulence, and problems

An underwater WWII bomb is detonated in the Baltic Sea in 2010. with algae,” a company spokeswoman said. “Surveys carried out in 2008 and 2010 to detect magnetic anomalies did not reveal the massive amount of munition that has to be cleared away. A further survey in early 2012 showed that a larger seabed area has to be cleared, and that the work is more difficult and complex than had been expected.”

The Wind Power Monthly story noted that this was not the first time that WW 2 ammunition had held up development of offshore wind farms, citing unexploded bombs having to be removed at the Greater Gabbard and Sheringham Shoal projects in the North Sea. There are more than 100 of these bomb and shell graveyards scattered along all of northern Germany’s coastlines, it said.

A press release from nkt cables said that a specialist company hired by TenneT “detected an unexpectedly great number of explosive objects along the cable route.” That threat had to be mitigated, and cable laying had to be stopped at one point “to ensure the complete clearance of a small cable laying corridor,” it said. The cable laying was done by nkt cables and Bohlen & Doyen, marine specialists that it works with for such projects.

“This was the first time a cable has been installed this close to an ammunition dumping area in the German North Sea,” said Alexandra Bangemann, nkt cables’ project manager for Riffgat.

There had been concerns prior to the project as it was known that the cable route was in the proximity of an ammunition dumping area, and there were also delays because the cable route had to take into account environmental protection areas, the release said. That combination of challenges led to on- and off-shore delays while carrying out work both onshore and offshore. Near-shore cable operations in the Wadden Sea National Park was described as especially difficult.

“Working with tides is always a challenge, especially with regard to HSE and emergency planning,” Bangemann said. “Seeing a barge manned with 30 people just 100 meters away from land but not being able to get them on

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

10 | WIRE JOURNAL INTERNATIONAL

EU body issues $416 million in cartel fines, appeals to decision may follow Finding that some of the world’s top power cable companies were part of a cartel that controlled bidding on major infrastructure and underground high-voltage projects for a decade, a European Union antitrust regulator has fined a number of the world’s top power cable companies and an investment bank a total of $416 million.

The EU doled out hefty penalties, led by Prysmian (previously Pirelli), which was fined $143 million, a figure that includes a joint $53 million fine with investment banker Goldman Sachs, which acquired the Italian company in 2005 but later sold its holding; and Nexans France,

fined nearly $97 million. ABB Ltd., had faced a 33 million euro penalty, but was not fined because it “was the first to inform the EU of the cartel,� the article said. The decision was denounced by a few of the 27 named companies, such as Prysmian, Nexans and NKT Holding, which either declared that they would appeal or that they are considering it.

An EU press release outlined a story of deliberate actions by the companies to control competition on submarine and underground high-voltage projects from 1999 to 2009. “Six European, three Japanese and two Korean producers of submarine or underground power cables were involved in the cartel. Several companies that took part in the infringement and later merged their activities into joint ventures are also held liable, as well as parent companies of the producers involved, because they exercised a decisive influence over them. This includes the investment company Goldman Sachs, the former owner of Prysmian. “The investigation revealed that from 1999 to the inspections carried out by the Commission in January 2009, these producers entered into mutual agreements according to which the European and Asian producers would stay out of each other’s home territories and most of the rest of the world would be divided amongst them. In implementing these agreements, the cartel participants allocated projects between themselves according to the geographic region or customer. In particular, the European companies agreed

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INDUSTRY NEWS

shore seems totally strange–but you cannot get people on and off board when there is no water around the barge– they would sink completely into the mud. ... And as safety is top priority for nkt cables, we had to find a solution that ensured a safe working environment for everybody.�

Final HV testing was carried out at the end of January, with power flowing on Feb. 12. “With Riffgat now being online, nkt cables once again showed that it is able to handle large, challenging turnkey projects with professionalism, transparency, flexibility and total dedication,� said Wolfgang Nolden, senior vice president offshore at nkt cables.

INDUSTRY NEWS

to allocate projects within the European Economic Area (EEA). The evidence in the Commission’s file shows that these agreements were in place for almost ten years. In internal communications the cartelists referred to themselves as the “R,” “A” and “K” companies, meaning European, Japanese and Korean companies.

“Whenever Japanese and Korean companies received requests from European customers, they would notify their European counterparts and decline to bid. In order to allocate projects successfully, the cartelists also agreed on price levels to be applied or exchanged information on price offers to ensure that the designated power cable supplier or ‘allottee’ would bid the lowest price while the other companies would submit a higher offer, refrain from bidding or submit an offer that was unattractive to the customer. The cartelists regularly met each other in hotels in Southeast Asia and Europe and maintained further contacts by means of e-mails, faxes and telephone calls.

“The investigation also revealed that the companies were well aware that they were breaking competition rules. For instance, in a note of a meeting, the advantages and disadvantages of entering into a cartel were discussed: ‘It would be tough unless the pie for each company increases and the merits exceed the risk of having cartel.’

“The participants were also taking precautions not to be found in possession of anticompetitive documents. By using its forensic IT technologies the Commission was able to recover several thousand documents that had been deleted by an employee of Nexans. Most of these documents were closely linked to the illegal cartel activities and relevant for the Commission’s investigation.”

Per the EU and media reports, the other companies cited were Viscas Corp., which shares a $48 million fine with Furukawa Electric Co. and Fujikura Ltd. Furukawa was separately fined an additional $12.2 million and Fujikura must pay an extra $11.2 million. J-Power Systems Corp., a joint venture owned by Sumitomo Electric Industries Ltd. and Hitachi Cable Ltd., was fined $28.4 million. LS Cable & System Ltd. was fined $16 million, Taihan Electric Wire Co. Ltd. was fined $8.5 million, Brugg Kabel AG was fined $11.7 million and NKT Holding A/S (NKT) was fined $5.3 million. Safran SA (SAF) was fined $11.7 million and must share another $170,000 fine with Silec Cable SAS, which it has since sold to General Cable. Silec and General Cable Co. share a $2.6 million fine. General Cable is suing Safran for compensation for the fine, according to Safran’s 2013 annual report. Sumitomo was also fined $3.56 million euros and Hitachi was fined $3.15 million. SWCC Showa was fined $1.1 million; and Mitsubishi $1.04 million.

In a statement, Nexans said that it would review “the voluminous decision” to decide its next course of action, which could include appeal. “The Group will evaluate the consequences of the decision for possible follow up on claims as well as the impact of this decision and other recent developments in the other ongoing competition 12 | WIRE JOURNAL INTERNATIONAL

authority investigations in the same cable sector in the United States, Canada, Brazil, Australia and Korea, which consequences as previously reported could have a material adverse effect on the results of Nexans and its financial situation.”

Prysmian said it would appeal the fine, calling the decision by European authorities “unlawful.”

NKT Holding said it would challenge the decision in court. “We do not believe that there is evidence in the Commission’s allegations. We have not in any way been involved in any form of cartels. Therefore, we disagree with the decision and we will appeal,” NKT Chief Executive Michael Lyng told Reuters.

General Cable noted that charges against its Spanish subsidiary, Grupo General Cable Sistemas, were dismissed for lack of evidence, and that it is reviewing the $2.5 million fine for Silec Cable. “This fine was based on participation that allegedly commenced well before Silec Cable was acquired in 2005 by General Cable,” it said, adding that General Cable will also seek full indemnification for the Silec Cable fine “under the previously disclosed terms of the acquisition agreement with Safran SA.”

Ducab Cable Company makes first cable delivery for UAE nuclear plants Dubai Cable Company Ltd., has made the first delivery of an order for 16 million ft of cables for use in UAE nuclear plants that are under construction in Barakah.

Multiple media reports said that the cables, ordered by the Emirates Nuclear Energy Corporation (Enec), will be used for non-class 1E power and lighting in the four units at the Barakah nuclear site. The delivery, it noted, included 324,000 ft of non-class 1E cable, which passed the 60-year operating life qualification test.

UC RUSAL reports investment in aluminum wire rod production Russia’s UC RUSAL, announced that it has made a substantial investment to produce aluminum-zirconium wire rod, a project that it said represents the first such capital expenditure for the electric power industry.

A press release said that customers have already approved the first samples of the aluminum zirconium wire rod made at its Irkutsk aluminum smelter. The $5.5 million includes R&D, equipment for wire rod production and thermal treatment, it said, noting that the company has signed a contract with Seco Warwick to supply electrothermal equipment this September, with planned production levels expected to be reached in early 2015. The project is expected to provide up to 3,000 metric tons of aluminum wire rod a year.

The release said that the project was supported by government grants it won in 2010 to develop and manufacture cable wire-rod production equipment. “RUSAL’s Engineering & Technology Centre (ETC) has developed

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sophisticated equipment and patented EC grade aluminum-zirconium alloys,’ said Victor Mann, RUSAL’s technical director, who noted that the company’s share in the Russian aluminum-zirconium wire rod market “is expected to be up to 80%.”

The aluminum-zirconium wire rod is used by grid and electric distribution companies, the release said. Using conductors made from this type of wire rod instead of traditional rod, it noted, will result in a two-fold increase in transmission capacity over existing power lines

WireCo acquires Netherlands company U.S.-based WireCo WorldGroup Inc. (WireCo), a leading producer and marketer of specialty steel wire ropes and high performance synthetic ropes, announced that it has acquired the majority of the assets of Endenburg B.V., (Gouda), a Netherlands-based company that supplies hoisting and lifting gear including steel wire ropes, shackles and high performance synthetic ropes.

A press release noted the following. WireCo will establish a crane rope distribution center at the current Gouda location called WireCo Crane Center. The new facility, located near the Rotterdam port, will allow WireCo to have turnaround times within 24 hours when needed. It will exclusively service WireCo’s distribution partners and select OEMs, focusing on Casar and Oliveira crane ropes. Endenburg’s current maritime, offshore and heavy lifting departments will continue from Lankhorst Ropes, located in the Netherlands, under the Lankhorst Ropes name. WireCo’s German fabrication and distribution center will continue to operate.

Chandler said that Marc Altena is serving as the general manager of the WireCo Crane Center. He previously had managed the distribution center of Ymuiden Stores.

Founded in 1855 and based in Gouda, Endenburg was described as a well-known supplier to the shipping, towing, construction and transport industry.

Prysmian reports submarine cable contract for 200 km of MV cable The Prysmian Group announced that it has been awarded a new contract worth approximately 30 million euros from UAE-based construction company Emirates Holding on behalf of major offshore oil and gas producer ADMAOPCO (Abu Dhabi Marine Operating Company).

A press release said that the contract is for the design and manufacture of submarine cable links for the replacement of power feeding systems to the Zakum offshore oil field, in Abu Dhabi. The Zakum oil field, it said, is the first submarine electrification project planned by ADMA-OPCO and “will be the benchmark for future projects aimed at developing and implementing a power distribution and transmission network among owned offshore oil fields, in order to increase capacity and improve reliability of their oil production facilities.”

14 | WIRE JOURNAL INTERNATIONAL

Prysmian reports that it will supply MV cable for an RIIVKRUH RLO ¿HOG SURMHFW The project will require about 200 km of XLPE (crosslinked polyethylene) insulated medium-voltage submarine cables for the distribution of energy to oil towers and platforms, plus accessories and network components, the release said. The project will be handled by the company’s offices in the UAE, using production from its plant in Pikkala, Finland. The first delivery, 70 km of cable, is set for this November, the remainder of the order by mid2015, it said.

The release said that the order “reconfirms Prysmian’s leadership role in a strategic region like the Middle East, where the Group can rely on a number of projects completed or currently ongoing including the Barzan oil field submarine power interconnection in Qatar, the first-ever submarine power transmission link serving Doha, the GCC Saudi-Bahrain submarine interconnection and the 400 kV power transmission system for TRANSCO connecting the Bahia and Saadiyat Grid Stations in Abu Dhabi.”

Nexans reports Airbus contract Nexans announced that it has further extended its longterm partnership with Airbus by winning a new five-year global contract to supply specialized hook-up, power, data and fire resistant cables.

A press release said that the contract, worth an estimated 200 million euros, calls for Nexans to supply 130,000 km of the specialized cables for Airbus modern aircraft family from the single-aisle A320 Neo to the flagship double-deck A380. It noted that Nexans has an existing 20-year partnership with Airbus that covers the supply of the hook-up, power, data and fire resistant cables that represent some 95% of the total cable requirement on an aircraft. Each airplane, it said, depending on the model, can have from 200 km to 600 km of cable.

The order, the release said, stemmed from the ability to provide lighter cables as well as improvements in on-time delivery within very short time scales as Airbus ramps up its production from 2015 onwards. It noted that this includes careful coordination and planning between Nexans’ aircraft cable manufacturing plants in France, Morocco and North America. “The proven capability of Nexans’ innovative aircraft cables to save weight was

173-km undersea cable between Italy and Tunisia has been laid Interoute and Orange Tunisie have completed the 173km Didon undersea cable between Mazaro del Vallo, Italy, and Keliba, Tunisia.

A report in $JHQFH (FR¿Q said that the cable was due to enter service this month. It said that this addition will boost the capacity and reliability of Tunisia’s international bandwidth by up to 8 Tbps per operator as well as raise end-users’ internet speeds to 100 Gbps. The cable, it said, uses Alcatel-Lucent submarine cable technology and is the first private infrastructure connecting Tunisia to another country.

UL reports further counterfeit cables Underwriters Laboratories (UL) issued a public notice in March warning consumers about a communications cable that “bears a counterfeit UL Mark for the United States and may pose a hazard.”

Media reports said that the cable’s jacket and packaging, which call the product ByteCC, identify it as Cat. 6 with

plenum ratings. However, UL warns, “This communications cable is missing required flame retardants. This may cause an increased risk of fire.”

The cable was known to be sold at newegg.com, and may have been sold elsewhere, the reports said. The packaging (box) identifies the cable as Cat. 6 Plenum Solid Ethernet Cable, UL Type CMP. The box also states the cable is 23AWG/2-pair, with a plenum (CMP) jacket, solid conductors, 400-MHz bandwidth. The box further claims UL Number E328429.

Southwire reports operational changes that includes plans for 3 plant closures U.S.-based Southwire, which has completed its acquisition of Coleman Cable, reported a number of changes in its overall operations that will take place this year and next year.

A company spokesman said that Southwire will close operations at Tappan Wire and Cable in Blauvelt, New York, which it acquired in 2010; and its manufacturing plant in York, Pennsylvania. Both closures will happen before September 30. The Coffeyville, Kansas plant will closed by March 31, 2015. On the distribution side, the company will close U.S. customer service centers in Orlando, Seattle and Salt Lake City, and one in Markham, Ontario, Canada.

MAY 2014 | 15

INDUSTRY NEWS

a crucial element. However, our attention to quality, delivery and logistics was equally important,” said Yvan Duperray, Nexans’ Aerospace Sales Director.

INDUSTRY NEWS

“This is not a reflection on our employees or their performance. Rather, it is one of the tough decisions that must be made as we work to remain strong in an increasingly competitive industry,” the spokesman said.

Management buyout reported for Windy City Wire Cable U.S.-based Windy City Wire Cable & Technology Products, LLC (WCW) has undergone a management buyout by co-founder and CEO Rich Galgano.

A press release from Harris Williams & Co., an investment bank that helped the process, said that WCW had been a portfolio company of Seidler Equity Partners.

Founded in 1994 and based in Bolingbrook, Illinois, WCW was described as a manufacturer and distributor of low-voltage wire and cable.

“Our firm has enjoyed an extraordinarily productive eight-year partnership with Rich and his management team,” said Bob Seidler, managing director of Seidler Equity Partners. “We believe WCW is well positioned to continue its pattern of expansion and innovation.”

Taihan Electric reports 3 U.S. orders Taihan Electric Wire, South Korea’s second-largest cable maker, reports that it has won three U.S. orders worth a total of $32 million.

The company said that it won a $24 million order from the Los Angeles Department of Water and Power to deliver 275 kilovolt cables, an $8 million order for supplying 230 kilovolt line to the construction of local power station in New Jersey, and a $2 million order from San Diego Gas & Electric, reported The Korea Economic Daily.

The LA project, the report said, is the largest in the U.S., using conductors with insulated cable and coated with enamel. Taihan noted that, unlike any other ultrahigh-voltage cables that use copper wire as a conducting material, stranded wire insulation cables have reduced power transmission resistance by coating enamel finish.

Prysmian reports 250 million euro windfarm contract from TenneT Italy’s Prysmian Group announced that it has been awarded a major project worth in excess of €250 million by the Dutch-German grid operator TenneT for the grid connection of offshore wind farms in Germany.

A press release said that the project calls for supplying a High Voltage Direct Current (HVDC) 320 kV extruded submarine and land power bipole connection with a rating of 900 MW and associated fiber optic cable system that includes a 29-km land route and a subsea route of 130 km. The power link, it said, will run from the land based converter station at substation Emden Ost in Lower Saxony to the converter platform BorWin gamma in the BorWin cluster, located approximately 120 km north of Germany.

16 | WIRE JOURNAL INTERNATIONAL

Cables will be installed through environmentally significant natural areas both on land and at sea, including along the Ems estuary, the release said. “This is the second grid connection project awarded by TenneT to follow this route (the route runs directly parallel to the DolWin3 project the Group was awarded last year) and highlights Prysmian’s ability to provide tailor-made installation solutions addressing customer specifications and needs in conjunction with stringent environmental requirements.”

It noted that the contract represents the seventh offshore project awarded by TenneT to Prysmian in recent years.

Prysmian is providing complete cable systems for projects in all of the four clusters designated by TenneT in the North Sea, the release said. “Following BorWin2, HelWin1, SylWin1, HelWin2 and DolWin3, the BorWin3 project, with its power rating of 900 MW, is again at the highest rated level for TenneT projects using extruded cables operating at the highest commercially available voltage level of ± 320 kV DC.” The release said that coordination of the ‘BorWin3’ project execution will be from Prysmian offices in Hamburg, using production from the Group’s operations in Pikkala (Finland) and Gron (France). The completion of the HVDC system installation is scheduled for October 2017.

Alps Wire Rope reports facility move U.S.-based Alps Wire Rope Corporation reports that the company has moved its warehouse in Columbus, Ohio, to Harrisburg, Pennsylvania.

A press release said that relocating the Columbus warehouse, used for more than 21 years, is the final move in a strategic realignment process for the company, which is now located in positions that enable Alps Wire to provide fast product delivery. Making the move to Harrisburg is warehouse manager Rocky Chapman.

Southwire’s Stuart Thorn named the 2014 Copper Man of the Year The Copper Club has named Stuart Thorn, president and CEO of Southwire, as its 2014 Copper Man of the Year.

“The (award) recognizes the exceptional leadership that Stu has demonstrated not only at Southwire, but within the industry as a whole,” said Copper Club Chairman Arthur Miele.

“Under Stu’s leadership and vision, Southwire has grown and diversified both organically and through acquisition, to become one of the largest producers of electrical cable in the world. Furthermore, Stu has been one of the most dynamic contributors to the future of our industry, serving in board and leadership positions at the National Electrical Manufacturers Association, The Electrical Manufactures Club, the Copper Development Association, and the International Cablemakers Federation, among others.”

PWM celebrates 30th at wire 2014

innovations include the portable air/hydraulic powered HP100 and HP200 machines, which provide effortless welds on wire and strip 1 mm to 5 mm and 2 mm to 6.50 mm. All PWM machines and dies are precision engineered in-house to stringent quality standards by PWM’s own team of skilled engineers and technicians.

PWM’s worldwide network of experienced agents and its U.K. team provide fast and efficient on-site support with full back-up and after-sales service. It notes that it continues to focus on R&D to offer the most advanced and comprehensive range of cold welders in the world.

For more on the company go to www.pwmltd.co.uk.

British company PWM (Pressure Welding Machines) Ltd. celebrated its 30th anniversary of service to the wire and cable industry at wire 2014, toasting the company’s continued success. Below, it describes its evolution.

PWM, based in Kent, England, designs, manufactures and supplies high-performance cold welding machines and dies to wire and cable manufacturers worldwide.

Its first machines were small, manually operated cold welders for joining fine wire and strip. The M10, M25, and M30 models for wire sizes 0.10 mm to 1.80 mm, are all still produced today.

Over the years, PWM gradually expanded its range and introduced larger, powered cold welders, including the P1500 rod welder for joining large rod At wire 2014, PWM showcased its technology and toasted 30 good years. sections up to 30 mm diameter. Recent

MAY 2014 | 17

INDUSTRY NEWS

First presented in 1962, the honor recognizes outstanding achievement and contributions to the copper industry.

“NEMA extends its heartiest congratulations to Stu for this honor. We ... are proud that a representative on our Board of Governors is receiving this prestigious award,” said NEMA President and CEO Evan R. Gaddis.

ASIAN FOCUS

ASIAN FOCUS Chinese steel company finds success in a different continent

Wenwei’s plant has annual capacity of 300,000 tons, making it the biggest steel-making company in Ethiopia.

Before Eastern Steel, there were small plants that were China is a world leader in countless categories, but prooperated by Indian, Chinese and Turkish business people, duction of steel has been problematic at best due to overwith average capacity of 20,000 tons a year. capacity, higher energy costs and lower selling prices. All Eastern Steel may seem like a giant, but in China its of which led to one Chinese man, Miao Wenwei, to find parent company, Jinfei Stainless Steel and Special Steel opportunituy elsewhere: Africa. Specifically, Ethiopia.

Company in Zhangjiagang, Jiangsu Province, is not considA series of articles by China Daily Africa outlined the ered a top steel company. It produces 600 to 1,000 tons of story of Wenwei, age 42, who chose metallurgy as his steel a day, while others, such as a close neighbor, Shagang undergraduate major, and from there went into the field.

Group, can produce 5,000 tons.

For years growth was impressive but then conditions Eastern Steel import billets from Ukraine and its customchanged. Large steel-maufacturing cities were told to cut ers are mostly Ethiopian subcontractors, and occasionally back because they used too Chinese companies. Wenwei much energy and caused too said that the quality of Eastern much pollution. Demand was Steel’s products meets China’s slowing and competition was level-II steel standards, which getting fiercer. The China Iron he explained is higher than and Steel Association reported products from small local steel that the average profit of the workshops. steel industry fell to 0.13% last One of the biggest differencyear. Among the association’s es operating in Ethipoa is that 86 members, about 34 of them there is far less competition, are operating in the red, and Wenwei said. His company’s many medium to small-sized capacity will be taken for use in steel plants are struggling to domestic needs in Ethiopia, and avoid bankruptcy. if demand grows significantly, Wenwei, chief of Eastern Steel the plant may be expanded. If Company, said that his company the local market reaches satuarrived in the Ethiopian capital, ration point, he said he would Addis Ababa, at just at the right consider exploring markets in time. Steel is in heavy demand neighboring countries. as national infrastructure buildAn inside view of Eastern Steel’s plant in Ethoipia.

As the local steel industry is ing continues apace, and the China Daily photo. weak, there are no established Ethiopian government had industrial standards, Wenwei pledged to build housing for said. Essentially, the company’s standard became accept1 million people over the next 10 years, so there was ed as a standard setter. Another factor that he said helps surging long-term demand for steel and other construction Eastern Steel is that the Ethiopia government is reluctant to materials in the foreseeable future. Beyond the better comimport steel from Europe. To maintain its dollar reserves, petitive market, utility costs were much lower. “In China, the Ethiopian government prefers to use locally produced every ton of water we need costs 8 yuan, but here it is less steel, which is also much cheaper. than 3 yuan.” Electricity is also much cheaper.

There is a challenge in terms of the logistics of running Wenwei visited the country in September 2012 to the business, but the rewards are there for those who can gather information, and by October 2013 his company’s do so well, Wenwei said. machines were already roaring in the factory, producing Han Shengjian, deputy director of the foreign trade rebar and wire rod for constructing buildings and bridges. development bureau at the Ministry of Commerce, was The employees include 50 Chinese engineers and 108 local cited in the story as saying that relocation is a trend for workers. Another big attraction is the low cost of labor. In Chinese companies, especially in labor-intensive and high China, a worker is paid 160 yuan to 200 yuan a day, while energy-consumption industries. in Ethiopia the rate is 20 yuan a day. Further, a power plant “From the late 1970s there was a relocation wave from with capacity of 230,000 kW will come on stream this European countries, and China benefited from the first and year, guaranteeing Eastern Steel a good supply of electricsecond rounds,” Han said. “Companies struggling in China ity. He noted that if the power goes off for even for a very because of a lack of workers or energy can consider Africa short time, the company can lose three to five tons of steel, a good destination.” which equals tens of thousands of yuan.

18 | WIRE JOURNAL INTERNATIONAL

Vietnamese Cable company CEO explains how his company has become a leader in its field The Vietnam Business Forum recently did an interview with Nguyen Loc, CEO of Cadivi, a leading wire and cable company. Below are edited excerpts from Mr. Loc, who explains how his company has survived the “electric ZLUH DQG FDEOH PDUNHW ZKLFK KH WHUPV D ÂłEDWWOHÂżHOG ´ Last year, like many other companies, Cadivi also faced many difficulties. But with tireless efforts of the entire staff, Cadivi achieved encouraging results.

Revenue rose 31% year on year to VND 4,500 billion, net profit reached VND 170 billion as planned.

Cadivi-branded electric cables and wires are gaining increasing trust of consumers and becoming a favourite choice for electrical works of national importance. The Council of Vietnam Enterprises Institute granted the “Trusted Quality Supplier 2013� certificate to Cadivi. We also were honoured with an ASEAN community award as well as many other certificates and awards of quality.

The strength of Cadivi’s products is affordable price and premium quality. Cadivi can do this because we deem pricing as a long-term strategy. Instead of raising prices, which may deprive of the opportunity of using Cadivi products by low-income consumers, we have

applied very strict rules to reduce costs in all phases, from material sorting to product distribution and circulation. Specifically, we focus very much on applying scientific and technical advancements and using stateof-the-art technologies to reduce input consumption, enhance productivity and improve product quality.

With this approach, in 2013, Cadivi saved VND28 billion, a record value, which helped boost productivity, stabilise prices and increase profit. As Cadivi’s products are made with lowest costs, we can fully supply the market with products of stably competitive prices and high quality.

Our difficulties mainly come from poor-quality imports, counterfeits and products of unclear origin.

Unfair competition caused our market share to shrink and forced us to consider exporting. Also, to boost sales, we do not increase selling prices and focus on developing new products with high competitiveness like underground medium-voltage cables. Being one step ahead of the industry in underground middle-voltage cables, Cadivi quickly occupied the market, starting in Ho Chi Minh City.

Finally, Cadivi always turns out products meeting both Vietnamese and international standards like Vietnam’s TCVN, the US’s UL and Japan’s JIS to meet all requirements of customers and keep up with requirements of international integration process. „

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PEOPLE

PEOPLE Ty Krieger has been promoted from vice president of operations to president of Mount Joy Wire Corporation, responsible for overseeing the daily operations of the facility and creating long-term strategies for the company’s growth. The position had been held by Tom Duff, who served as both company CEO and president, and is now continuing Ty Krieger as CEO. Krieger joined Mount Joy Wire in 2009, having more than 15 years of previous industry experience in leadership and customer service. His focus had been growing sales and serving customers. He is a graduate of New Mexico State University. Based in Mount Joy, Pennsylvania, USA, Mount Joy Wire Corporation manufactures a range of ferrous wire products.

Woywod GmbH & Co. KG announced that Tom Siedlarz of PLASTIC EQUIP, LLC, will again be responsible for sales and after sales services in the USA for complete range of PLASTICOLOR products.

The industry veteran started as a machine designer at Wire Machinery Corp. of America and later became the company’s vice president of sales. He Tom Siedlarz also served as a regional sales manager for Zumbach Electronics Corp., and co-founded Unitek North America, Inc., serving as its president, before he founded his company. He also worked as a sales representative for Amaral Automation. Based in West Haven, Connecticut, USA, Plastic Equip, LLC, represents a range of industry sectors in the U.S. and Canada, primarily related to extrusion.

obituary Terry Sieger, a much beloved industry veteran, dies at the far too early age of 66 Terry L. Sieger, international sales director at Woodburn Diamond Die, Inc., died on March 19, at the Parkview Regional Medical Center located in Fort Wayne, Indiana. He was 66 years old.

Sieger, who had worked for Woodburn for 28 years, was a very active WAI volunteer who served on multiple Association bodies. He had been named by WAI President Bill Avise as the next recipient of the President’s Award, which he was scheduled to receive at the Operations Summit & Wire Expo in May. He knew that he was the recipient before he was diagnosed with cancer just last month.

Sieger, who served in the U.S. Air Force during the Vietnam era, worked for International Harvester for 13 years, and then found a home at Woodburn Diamond Die. He was remembered for his positive presence and willingness to help out.

“To those who had the pleasure of working with him, Terry Sieger was far more than a colleague. He was a constant reminder of the importance of taking pride in what we do and

20 | WIRE JOURNAL INTERNATIONAL

in bringing some joy to those around us,” said John Rumpz, vice president of Woodburn Diamond Die. “Terry cherished his role Terry Sieger in sales at Woodburn, primarily because it gave him an opportunity to meet so many wonderful people. His selfless and positive attitude endeared him to the many individuals throughout the wire industry that were fortunate enough to know him. Terry will forever be missed, but never forgotten.”

Sieger had been an Association member since 1985 as well as a member and director of its Midwest Chapter, and had served as a member of WAI’s Board of Directors, Executive Committee, Membership Committee and the Exhibition Planning Task Force.

WAI President Bill Avise, who chose to honor Sieger this year before the news about his health were known, said that it was a very sad loss, but that he was grateful that at least Terry knew he had been chosen for the award. “Our industry lost a truly great person and friend with the passing of Terry Sieger. Very few people have contributed so much to our industry and the WAI while never asking for anything in return. It is truly an honor for me to acknowledge all that he has done for our industry and association. If everyone could be just a little bit as caring and unselfish as he was, the world would be so much better off. Terry Sieger will truly be missed.”

Sieger married his first wife, Ann F. Adams, in 1969, and she died on Jan. 2, 2000. He is survived by his wife, Lesa Hunt, who had been his companion for 13 years, marrying him on Feb. 16, 2014. He also leaves two sons, Randy and Rod Sieger; a daughter, Teresa Warnock; a brother, Mike Sieger; nine grandchildren; and numerous brothers-in-law; sisters-inlaw; nieces and nephews.

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Australia’s NBN passes on FTTP as main technology, to use more FTTN Following the win by a coalition led by the Liberal National Party in the national government in last September’s general elections, Australia’s Minister for Communications Malcolm Turnbull and Minister for Finance Mathias Cormann have instructed the company responsible for construction of the country’s National Broadband Network (NBN) to switch the program’s fixed-line technology emphasis from Fiber-To-The-Premises (FTTP) to a mix of approaches.

Media reports said that the change will include the use of fiber to the node (FTTN) rather than FTTP in most instances. The ministers informed NBN of the change in policy via a letter sent April 8. The new direction comes before the completion of a cost/benefit analysis; Turnbull had criticized the former Laborled government for settling upon the FTTP-centric approach in 2009 without completing such an analysis themselves.

Turnbull had ordered a full review of the program last year; the new NBN Co board released a final version of the review last December. The review showed the program to be 3.5 years behind schedule and likely to cost a total of AUS$73 billion, about AUS$29 billion more than estimated in the project’s Corporate Plan.

The new strategy will focus on a “multi-technology mix” for the fixed portions of the network that Turnbull described in a speech last December as comprising 26% FTTP, 44% FTTN, and 30% upgraded hybrid fiber/coax (HFC) infrastructure. This approach will decrease the total cost of the project to AUS$41 billion, Turnbull asserted in his speech. The rollout would be completed by 2020, he added.

In the recent directive to NBN Co, the ministers said the fixed-line portion of the network should be capable of providing download rates of at least 25 Mbps (and “proportional upload rates”) to all premises when the project is completed and download rates of at least 50 Mbps to 90% of fixed-access subscribers “as soon as possible.” The original FTTP-based plan had called for delivery of 100-Mbps speeds.

Nevertheless, NBN Co has been tasked with assembling a new Corporate Plan that reflects the change in strategy.

The switch puts the NBN equipment supplier roster in flux. Alcatel-Lucent won a contract in 2010 to supply GPON platforms for the roll out. As the company’s ISAM platforms support FTTN as well as FTTP, including VDSL2 vectoring, Alcatel-Lucent is likely to argue that it should remain the main broadband equipment supplier.

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FASTENER UPDATE

FASTENER UPDATE Faulty engine bolts result in recall

by BMW for 489,000 vehicles BMW has issued a recall for 489,000 vehicles worldwide due to faulty bolts in some of the company’s six-cylinder engines that could lead to failure and stalling, according to multiple reports.

Multiple media sites reported that the models in the recall include 1 Series, 3, Series, 5 Series, X3, X5, X6 and Z4 automobiles from 2010 through 2012, along with the 2012 6 Series. BMW is voluntarily offering to fix a defective bolt design that may damage the motor or cause it to fail to start. “In rare cases, bolts securing the casing of variable camshaft timing unit can loosen or snap, alerting the engine to enter into safe mode. This limits performance of the engine and lights up ‘check engine’ or ‘service engine soon’ warning indicator in instrument cluster.”

The recall began in China, but has now been broadened globally to include 156,000 cars in the U.S. The defect can be fixed with a repair, BMW said. In recent weeks BMW recalled 232,098 cars and SUVs in China for

24 | WIRE JOURNAL INTERNATIONAL

the same problem. Herbert Diess, the head of BMW’s research and development, said at a March 19 press conference that the manufacturer’s data on breakdowns and guarantee services show vehicle quality is at “a good level.” While the number of recalls has “hardly changed” in recent years, “the number of affected vehicles per recall went up.”

A BMW spokesman said that no accidents or injuries have been reported related to the fault.

USITC rules for Thai threaded rod The United States International Trade Commission (USITC) found that a U.S. industry is not materially injured or threatened with material injury by reason of imports of steel threaded rod from Thailand that the U.S. Department of Commerce has determined are sold in the United States at less than fair value.

A press release said that as a result of the USITC’s negative determination, no antidumping duty order will be issued on imports of this product from Thailand. The report will be available after May 22, 2014.

WAI NEWS

May 2014

WAI MEMBERSHIP

SPOTLIGHT

This section introduces a new :$,࣮PHPEHU HDFK LVVXH

Thomas Walker President, 3LWWVÀHOG 3ODVWLFV (QJLQHHULQJ ,QF

Q: What does your company do?

A: Pittsfield Plastics Engineering is a unique company located in the Berkshires of Massachusetts. We have been an ISO 9001:2008 certified injection molder, extruder and mold maker/mold repair operation for the past 46 years.

Q: What is your role there?

A: : As President/CEO, I secure the ongoing and future operations of the company. I play a heavy hand on sales and new product development. Every day brings a new challenge and I would not want it any other way. I guess I can say that I’ve been scratching the same itch in plastics since 1976.

Q: What do you like best about your position?

A: I would have to say the people. I’ve worked hard at creating an innovative team from the CFO right down to the shop floor. Empowering and promoting people from within gives me a sense of accomplishment. I really enjoy seeing others succeed.

Q: How has the industry most changed?

A: Over the years there has been a lot of consolidation in the wire and cable industry. Fortunately, we have not been hurt by it, but it is always a challenge in maintaining that business.

Q: How does your company remain competitive?

A: The key to our success has been listening to our customers. Pittsfield has always set out to make a better product than is currently on the market. We are constantly enhancing our reels to our customers needs.

Q: Why did you recently join WAI? A: Our company joined the WAI Plantium member program to become more proactive in the industry.

I was also asked by many of our customers to become more active. We look forward to the chapter golf outing along with other social events. There are a lot of good people in the wire industry, and that makes it eventful when we all get together.

26 | WIRE JOURNAL INTERNATIONAL

Roberto Castillo Sales Engineer CONDAT Corporation Diane Catellier Customer Care J Hamelin Industries Bill C Clapham Regional Sales Manager Keystone Steel & Wire Co Michael Crouchley Procurmt Manager Champlain Cable Corp Edward Davis Engineer Chemetall US Casey Davis Sales Engineer Siemens Industry Inc Thomas L Fitzpatrick Prod Manager Siemens Industry Inc Duane Fudge Director, Market Segment Manager Chemetall Ing Horst Gisbertz Nexans Canada Inc Ted J Gormanos Sales Manager Borealis Compounds Inc Gary Gray Gerard Daniel Worldwide

Daniel Kenji Shimizu Engineer Belgo Bekaert Arames

Richard A Hall President Champlain Cable Corp

Frederick George Simmons Nexans Energy

Kurt Hilderbrand Proc Line Eng Siemens Industry Inc

Anil Kumar Singhania Managing Director Singhania International Limited

Thomas Kern Condat Corporation Dick Kruger VP Sales/Marketing Champlain Cable Corp Dominic Kung App Tech Manager Borealis Compounds Inc Tim Lizotte VP/CFO Champlain Cable Corp Dinesh Manocha Sr Gen Mgr Mktg Grauer & Weil (India) Ltd Jack McAfee, Jr Business Manager Chemetall Jeffrey Moser Sales Manager Borealis Compounds Inc Robert Prevatt Dir of Mktg & Bus Dvlpmt Paramount Die Company David Princz Process Engineer TE Wire William F Reichert Chief Operating Officer Champlain Cable Corp Nick Roth Acctount Manager Pittsfield Plastics Eng Inc

Brian M Smith Sales Enginer Siemens Industry Inc Susan M Song ADE Borealis Compounds Inc Ben St Amour VP & GM J Hamelin Industries Harold Stotland President J Hamelin Industries Paul Szeplaki Plant Manager J Hamelin Industries Rudolf Vey Senior Scientist Chemetall Loc Vo Senior Process Engineer CommScope Thomas Walker President Pittsfield Plastics Eng Inc Ryan Walp Process Engineer Bridon American Corp Norm Worden VP of Operations Pittsfield Plastics Eng Inc

New WAI Platinum Membership Companies Borealis Compounds Inc Champlain Cable Corp Chemetall Industry leaders can contact WAI Executive Director Steve Fetteroll at sfetteroll@wirenet. org or 203-453-2777, ext. 115, to learn more about this special membership program. Such organizations actively support the Association by participating as exhibitors, advertisers, sponsors or content providers for WAIorganized events, publications and educational programs.

MAY 2014 | 27

WAI NEWS

Dale Born Mechanical Engineer Siemens Industry Inc

Louis Guillet Plant Manager J Hamelin Industries

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

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

WAI NEWS

Final leg held of 3-part webinar series on cleaning/coating of ferrous wire and rod The WAI’s first webinar “trilogy,” presented by Chemetall USA, was held Wednesday, April 23, covering specialty coatings such as salt carriers, lubricants, dry film polymers, and new technologies on the horizon.

Parts I and II presented the fundamentals of cleaning and pickling in preparation for the coating of ferrous wire and rod and the subsequent drawing operation as well as the zinc phosphate process, including control methods, what data means, and basic troubleshooting of the process.

Chemetall presenters Ed Davis, Jack McAfee, Rudy Vey, and Dane Armendariz collectively presented the information and fielded questions. The archived webinars are free to WAI members.

Interwire 2015 update wire Düsseldorf once again proved to be a very positive event for the Association. WAI, which returned to Hall 11 B25, sold 8,000 sq ft of floor space for Interwire 2015 and added some 500 new subscribers.

Sales Director Box Xeller notes that all but one of the large booths have been taken, “so if you had a big idea for Atlanta, now would be a good time to act.”

28 | WIRE JOURNAL INTERNATIONAL

New staffer at WAI Paul Streeto, who has more than 20 years of experience in magazine design and production, will now handle those duties for Wire Journal International.

Streeto, who has won awards for magazine redesign, most recently worked as a production artist/traffic manager for Air Age Media, where he handled multiple publications as well as other duties. Prior to that, he was a design and production director for Elseveier Business Intelligence, where he was involved with design and production of 11 Life Science magazines, producing 23 issues monthly. He holds a degree in journalism and communications from Penn State University. His primary duties will be WJI, but he will Paul Streeto also assist WAI Marketing Director Janice Swindells, and work on other projects as needed.

“We’re very pleased to have Paul here,” said WAI Executive Director Steve Fetteroll. “He’s already demonstrated that he is quite skillful and a very positive contributor.”

Streeto replaces Bill Branch, who left to pursue other opportunities.

CHAPTER CORNER

CHAPTER CORNER Midwest Chapter to lead off series of chapter golf tournamenst in June

Contact: Anna Bzowski, tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

The third scheduled event is for the Southeast Chapter, which on Oct. 2, 2014, will return to the Rock Barn The Midwest Chapter will once again have the honor Golf and Spa in Conover, North of being the first WAI chapter to Carolina, to hold the Vannais stage its annual tournament when Southeast Chapter’s 13th Annual on June 20, 2014, it returns to Golf Tournament. Contact Art the St. Andrews Golf & Country Deming, tel. 252-955-9451, art.

Club in West Chicago, Illinois, deming@nexans.com.

USA, to hold its 12th Annual Golf Two other chapters, the Ohio Tournament.

Valley Chapter and the Western At this time, there are still sponChapter, will announce the dates sorship opportunities available, and for their annual golf tournaments while golfers need no reminder that at a later time. taking part in the outing is a gloriAs noted before, each event ous way to spend a day, it should be offers multiple sponsorship oppornoted that the event helps supports tunities and the chapters also the chapter’s scholarship activities. welcome donations of items for Contact: Steve Fetteroll, tel. 203The time is now for golfers to exit hibernaraffles, held during the awards 453-2777, ext. 115, sfetteroll@ tion and take to the links. presentations, that help fund the wirenet.org. individual chapters’ scholarship Next up will be the New program. The events offer superb camaraderie, an England Chapter, which on Sept. 8, 2014, will return opportunity for bragging rights and come with a WAI to the Ellington Ridge Country Club in Ellington, snow-free guarantee.

Connecticut, to hold its 20th Annual Golf Tournament.

30 | WIRE JOURNAL INTERNATIONAL

WIRE DÜSSELDORF

WRAP UP Solid results seen for wire 2014 The concurrent staging of wire 2014 and Tube 2014 may have seen a modest dip in attendance, but exhibitors were largely pleased with the quality and interest of attendees at the week-long event held at the Messe Fairgrounds in Düsseldorf, Germany.

A press release from the organizers, messe Düsseldorf, said that the combined events featured more than 2,500 exhibitors over 1.1 million sq ft of exhibit space visited by some 72,000 trade visitors from 104 countries. The attendance was down just a bit from 2012, when it reported 73,500 visitors, but it was still markedly ahead of 2010, which saw attendance of 69,200. “Once again, wire and Tube recorded exhibitor growth as well as a significant increase in booked exhibition space,” said Joachim Schäfer, managing director of Messe Düsseldorf. He noted that the attendee interest level was high as many companies are planning to invest in order to position themselves for continued competition.

Per the release, about 98% of exhibitors gave the two trade fairs top marks, citing international contacts, strong buying interest, plenty of conversations and deals closed onsite as well as the anticipation of busy post-show business. The steel and NE metal industry has long been considered to be a reliable early indicator for all other industries. The entire economy benefits when this market is strong.

More than 1,300 companies from 54 countries participated in wire 2014, which accounted for nearly 640,000 sq ft of space, up 2% from 2012. From the U.S., 78 companies exhibited at wire 2014, including 33 exhibitors (from the U.S., Canada and Mexico) within the North American Pavilion, organized by Messe Düsseldorf North America and with the Wire and Cable Industry Suppliers Association (WCISA) as the sponsor.

One of the largest exhibitors, WAFIOS, presented some 30 innovations at its two stands in Halls 5 and 10. “That includes 15 new machines alone,” said Dr. Cristoph Müller-Mederer, senior executive president, sales and marketing for WAFIOS AG Reutlingen, who noted that the company was extremely pleased with the strong participation of trade visitors from all parts of the world.

Per the release, 66% of the attendees came from 70 countries outside of Germany, the majority from Belgium, France, Great Britain, India, Italy, Japan, the Netherlands, Spain, Sweden, Switzerland, Turkey and the U.S. The visitors were primarily from industry (75%), trade (11%) and skilled crafts (4%). Of major interest to the attendees were machinery for the processing of wire, steel bars and steel band (35%), end products (22%), auxiliary equipment (machinery, devices, tools, consumables; 21%), forming technology (15%) and spring making technology (11%).

Many companies reported good results, although one exhibitor observed that the industry is feeling the results of tough global economic conditions that had been slow in taking effect.

32 | WIRE JOURNAL INTERNATIONAL

Photo courtesy of Messe Düsseldorf. Also, the photo at top l, p. 33, and lower r, p. 34.

WIRE DÜSSELDORF More than 1,300 companies exhibited at wire Düsseldorf.

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Rosendahl and Nextrom reported that Wire 2014 was an intense and successful show. They said that the atmosphere and spirit at the exhibtion and their booth was enthusiastic.

“Partnerships and business relations have been intensified and they celebrated their closed deals, birthdays of col-

leagues and customers and their new developments which they had on display.” One creative touch was serving beer via two taps in a crosshead.

Wire 2014 was a definite success for Maillefer, said Juha Hiltunen, director, sales & marketing, wire & cable

Dervish at booth a work of art … and superfine copper wire Wire art is not unusual at wire Düsseldorf, but one stunning such work displayed at the MEGA Metal booth, Hall 10 A-40, was the subject of many photos. A two-meter-tall dervish made from the Turkish company’s superfine bunched copper wire stopped many attendees.

Abdullah Turgut, a board member of MEGA Metal SAN ve Tic Ltd., said that the company decided to showcase its wire, and turned to Mimar Sinan Fine Arts University.

Four students there spent a month forming the dervish, which weighs about 150 kg. Turgut said that the company wanted to “introduce to the philosophy of ‘Mevlana,’ whose doctrine advocates unlimited tolerance, positive reasoning, goodness, charity and awareness through love, which we feel is very important to emphasize in these days.”

Mevlana Celaddiin-i Rumi is a 13th century Muslim saint and Anatolian mystic known for his exquisite poems and words of wisdom, which have been translated

into many languages. The whirling dervish is linked to a dance called Sema, which is part of the inspiration of Mevlana.

The reaction to the dervish, Turgut said, was stunning. Many people came to the booth to inquire about the work, he said, which allowed them to talk to attendees about Mevlana’s philosophy. There was also much interest in it as a collectable piece of art, he observed. “If we were selling this dervish there would be a lot of people interested in buying it,” he said, adding that there is no price for it as there is no intention to sell the work.

One of the biggest challenges was sending the dervish to Germany, which required very careful packaging, Turgut said. Asked what would happen to it now, he said that it will be placed at the company’s factory.

He said that the company plans to return with a second work of art for the event in 2016. “Please come by and see our surprise in the next exhibition.”

Abdullah Turgut with the company’s dervish at wire Düsseldorf.

MAY 2014 | 33

WIRE DÜSSELDORF The Maillefer staff was kept quite busy with attendee visits during the show.

PWM greeted customers and toasted its 30th anniversary.

Mario Frigerio SpA Managing Director Emilia Tentori and Marco Dell’Oro found plenty to smile about at wire 2014.

Windak, celebrating its 20th anniversay, reported getting many good leads.

The Pittini booth left no question as to the company’s focus.

34 | WIRE JOURNAL INTERNATIONAL

WAI gathered hundreds of new WJI subscribers at its booth.

Exhibitors had plenty of options to offer attendees.

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““I expected wire Düsseldorf 2014 to be a good launching pad for new projects after a hard hitting recession, but the reality as it turned out was a mixture of hesitation to invest and great optimism,” said Ali Shehab, Cimteq.

He observed that the recession in the cable industry was delayed due to the large number of infrastructure projects started by governments to boost their counties economies as a result of the 2008 financial crises. “The end of these projects has led to the recent financial hardship among cable manufacturers and the need to reduce costs.

However, the cable industry, in general, seem to be at a turning point.” On the positive side, he said, the number of visitors investing in new factories increased a lot from 2012 and there was definitely an air of optimism in all the halls of Messe Düsseldorf.

Switzerland’s AESA Cortaillod took a different approach at wire Düsseldorf. Vice President Jean-Luc Allemann said that in addition to displaying the company’s testing and measuring technology (see p. 46), the company staged technical sessions at its booth where it could provide useful information to attendees while presenting the company’s mastery of electrical solutions.

The interactive venue, he said, allowed competing cable manufacturers to see AESA’s equipment in use as well as share some common concerns. “Our aim was also to prepare for the future with new solutions for testing cables,” he said, adding that his company had very good

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business line. “The number of visitors exceeded expectations and different markets around the world were well represented. All energy applications – low, medium and high voltage – got topmost attention,” said Juha Hiltunen, director, sales & marketing, wire & cable business line.

Windak, which has exhibited at show since 1996, celebrated its 20th anniversary at the show. Over that time, it noted that it has become one of the top suppliers of automatic packaging machinery for the cable industry. “The feedback and number of visitors to our booth was very positive. The company has a hot list of potential new projects from the show and is expecting to receive at least four new orders.”

The MFL Group was also very pleased with the results.

“We had many high level and serious discussions,” said MFL Managing Director Emilia Tentori. “New and traditional customers came to the exhibition prepared to make equipment decisions. As a result of our meetings, Mario Frigerio and Frigeco secured very important orders and requests for proposals for our ferrous and nonferrous divisions.”

“We were expecting a higher level of visitors and a more positive mood this year and were not disappointed,” said Steve Mepsted, managing director, PWM, which celebrated its 30th anniversary at the event. See p. 17. “Visitor traffic was good, particularly mid-week.

Visitor quality was also good and an improvement on 2012. Sales leads were excellent and we sold a number of the exhibition machines at the stand.”

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WIRE DÜSSELDORF AESA Cortaillod’s booth offered both equipment and sharing of technical information. visits and that he left the show with a positive sense for business going forward.

U.K.-based Meltech reported that it is now deeply involved in talking to contacts made at the show, both new and old. “The feeling leaving the halls was definitely positive, and we ourselves had our best show to date with more visitors than ever before to the stand, many of whom

came to discuss requirements for imminent projects.”

The next concurrent staging of wire and Tube will place from April 4-8, 2016, in Düsseldorf, Germany.

For further information on visiting or exhibiting at wire or Tube 2016, contact Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

MAY 2014 | 37

FEATURE

The ‘green’ side of wire Düsseldorf Not long ago, “green” was a rising star at wire Düsseldorf, only it lost its luster when suppliers saw that few customers were willing to pay more for it. Green continues to have a presence, only now the focus is more on how it can be good business, and more can be seen in the Products section that starts on p. 46. Also, one company's recycling experience.

Recycling cemented carbide a growth area At wire Düsseldorf, Sandvik Hyperion, which develops and produces wire drawing applications in hard and super hard materials, reported that recycling used carbide is a growing business and that the company has become a big player in it via its Carbide Recycling Program.

The company purchases used carbide tools and products from its customer base and converts them back into usable tungsten carbide and cobalt. It does so because recycling creates a strategic supply of raw material, while also providing a value-added service to customers. Cemented carbide, which is mainly tungsten carbide with the addition of cobalt and other binder materials, is the most common hard material used.

Manufacturing new cemented carbide products from recycled tungsten, rather than using tungsten material extracted from ore, is better for the environment. The recycling process uses up to 70% less energy and emits 40% less carbon dioxide. Also, tungsten is a rare element and increasingly difficult to extract from the world’s mines.

38 | WIRE JOURNAL INTERNATIONAL

Compare it to aluminum, which makes up about 8% of the world’s crust, and tungsten is only around 0.0001%!

Recycling is also good business practice. Currently, a typical mine will landfill about 300 kg of rock for every 1 kg of tungsten produced. This is due to the low concentration of tungsten compounds in the ground in relation to other minerals like granite and other rock formations. Alternatively, recycling just 1-2 kg of cemented carbide will yield the same result. Not only is the tungsten supply limited and difficult to retrieve, it is also unevenly distributed across the globe. So without recycling, the world’s tungsten would need to come from this small supply.

In the past, recycling was not well developed and it involved methods that only partially recycled tungsten carbide. While these methods were quick and less demanding, they could not produce the same quality tungsten carbide as material made from ore. However, the standards for products are very high and using these methods is just not good enough. Consequently, Sandvik uses a process called chemical conversion when recy-

responsible way. Sandvik is committed to sustainability.

For several years we have been following a code of conduct for environmental, health and safety management systems that forms the foundation for how they work.

Sandvik is integrating sustainability into its operations and reducing the company’s environmental footprint. The company is proud of its carbide recycling program and the sustainable, positive impact it has for the environment. www.sandvik.com

Recycling has become a way of life for cable manufacturer Superior Essex has made the environment a priority at its four U.S. communication cable plants, and the results of those efforts have already been seen. The company reports that its copper data cable manufacturing facility in Hoisington, Kansas, has achieved a 98% landfill waste diversion rate for 2013, an industry-leading environmental milestone for the cable manufacturing industry.

In simple terms, more than four million pounds of waste were recycled or reused last year at Hoisington instead of being sent to a landfill, which saved over $100,000 in landfill fees, the company reports.

“Our environmental initiative is more than just a company objective; it is an ethical responsibility to our communities and to future generations,” said Tim Waldner, President of Superior Essex International LP, a subsidiary of Superior Essex, Inc. “We have made the commitment to continuously improve the environmental sustainability of our operation and products and to lead by example.” A key focus, he said, is landfill waste diversion, defined as the prevention and reduction of generated waste through source reduction, recycling, reuse, or composting, which has been characterized as one of the best ways manufacturing companies can demonstrate genuine environmental responsibility.

The company noted the following about its overall approach. We reuse or recycle more than 50% of the waste that is generated in our

production processes for use in new production. All water used in our extrusion processes is recycled using a closed-loop system. The plastic spools used to hold our data cable products are made with 100% recycled materials. We employ mod-

A wide range of efforts has led to noteworthy environmental gains for Superior Essex. ern logistics practices to maximize the efficiency of our shipments of cable across the continent, thereby reducing energy consumption for the trucks that carry our products.

The majority of our raw material and final product packaging materials, such as wooden pallets, corner boards, spools, and boxes are either reused or recycled. Our data cable box packaging is made of up to 25%

recycled materials. Superior Essex uses non-bleached, brown boxes for Superior Essex branded data cable products. All of our box waste is returned to our supplier’s warehouse for use in future products. Our production facility lighting has been replaced with energy efficient T5 and T6 fluorescent systems, yielding a reduction in annual energy consumption of 8 million kWh. Energy consumption has been reduced by upgrading motors, compressors, and HVAC systems with energy efficient models and promoting more efficient uses of energy. The inks and adhesives used on our boxes for our premises cable products are biodegradable, and the process used to manufacture the ink itself is not harmful to the environment.

Lindsay Allen, vice president of barketing for Superior Essex, observed that while the actions are positive for the environment, they also make for good business.

Further, the company has seen all of its communications cable products become fully compliant with the RoHS 2 Directive and the REACH restricted substances list.

RoHS (Restriction of Hazardous Substances) and REACH are directives adopted by the European Union. While such compliance is not required under U.S. or Canadian law, these directives are being used

by North American agencies and companies to ensure environmental standards in the products they buy. www.superioressex.com.

MAY 2014 | 39

FEATURE

cling tungsten. It means there is full separation of tungsten from all impurities. The result is a product that is identical in performance as the one produced from ore.

In fact, there is a point in the production process where the two supply streams merge together, producing one uniform material.

Sandvik maintains full control over its raw material supply chain. The closed-loop system for all recycled products ensures they are processed in an adequate and

FEATURE

The evolution continues in finding ways to maximize waste reduction At wire Düsseldorf, Italy’s Guidetti Srl was ready to discuss recycling, noting that its range of processing systems can process wire and cable at volumes from 50 kg/h up to 3.000 kg/h.

Guidetti’s Roberto Bentivoglio and technician Bianco Vincenzo.

GET MAXIMUM WITH MINIMUM is the mission of Guidetti, which Technical Sales Manager Roberto Bentivoglio said stems from the company’s continuous focus on improving machine efficiency to reduce energy consumption, space required for installation, tool consumption, maintenance and quality of final products as well as energy savings. The systems are very environmentally friendly, having zero emissions. No water is required for processing materials, and the air is filtered so no dust escapes into the atmosphere.

Bentivoglio explained that all the factors can be seen in the company’s latest technology, which addresses two goals (cables and WEEE recycling) in one shot. “After years of testing in our factory and at customers’ sites we have reached an optimal mixture among output capacity, final products purity and energy consumption.” He said that contrary to a traditional mindset that high capacity means using big machines that take lots of power, Guidetti has developed a progressive size reduction using small/ medium machineries that work in concert to produce a very pure final separation of materials.

This approach solution has many advantages, one being flexibility as it is simple to combine different machines to optimize production to customer needs. If a system is large but is only using 60% of its capacity, that represents wasted capital dollars as well as energy, Bentivoglio said. Smaller focused systems require less maintenance than larger machines and is easier to do because there is better accessibility to parts needing replacement. In terms of power, the machines are very efficient because they are offered in in various types depending on the materials to be processed, which results in less energy needed per metric ton.

40 | WIRE JOURNAL INTERNATIONAL

Other savings, Bentivoglio said, relate to the space that is needed, which is always an industry concern. Guidetti’s compact systems require a smaller footprint. Also, the results of the overall process are better, which means that there is more value, less pollution in the metal melting process and a higher quality of final products. Finally, the percentage of metal that we save during processing is believed to be the highest available on the market.

One trend Guidetti has seen is that sales of its systems have largely been to scrap dealers, but now the company is offering its machines directly to cable manufacturers, with such clients including Yazaki, Coficab, Condumex and Oman, Bentivoglio said. A cable manufacturer can easily keep separate different kind of cables, optimizing efficiency and recovering pure insulation. Cutting out transportation means less costs and pollution, and immediate recycling means that less stock has to be piled up somewhere. Finally, this approach keeps any recycling profits inside the company and minimizes the risk of metal price fluctuations.

Guidetti sells its machines worldwide, and two years ago opened a branch in Atlanta. Up to now, that location has only been used for assembling and as a spare parts center, but in the next year it will become a manufacturing workshop able to cover production for North and South America, Bentivoglio said. www.guidettisrl.com.

Design and chemical knowledge a key to ‘greener’ cleaning and plating systems At wire Düsseldorf, Italy’s Otomec displayed the OTO H2 model (shown), the company’s newest cleaning system for metal wire, strip and bar, which is used as a complete closed-loop filtering and recycling system for all the company’s plating processes.

Otomec Srl’s Alberto Rusconi and Pietro Rusconi at wire Düsseldorf.

“Chemical products are the basis of our technology, and our desire to be a friend to the environment is the basis for our research and engineering,” Otomec Partner and Managing Director Alberto Rusconi said. He noted that there “are increasing requirements our systems have to meet for plating and cleaning related to the need for

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FEATURE

improving electrical conductor performances, preventing oxidation, and providing a better-looking final product.” He cited another system, the OTO’FF 1W MULTIPURPOSE line, a new concept reel-to-reel and reel-to-basket electroplating system for ferrous and nonferrous wire, as a good example of the company’s technology. It has electronic controls that manage all production parameters and the wire tension and the temperature and physical properties of the chemical and rinse water are monitored by sensors and recorded. Below, he discussed some of the key factors that Otomec has considered when it evolving the OTO H2’s environmental focus.

First, it is important that our customers be able to use the minimum volumes of chemical products necessary for each treatment, and to use those that have the least effect.

Otomec has worked closely with key industry suppliers to select organic compounds and “green” products that allow its systems to work without use of cyanide, fluoboric or chrome. Electronic devices automatically control inlet water pollution, organic and metal impurities are removed by carbon filters and resins. An acid-proof pump returns clean water back to the galvanic line. An evaporator concentrates waste and produces distilled water.

Protecting operators is part of the overall goals, so automatic and Plc-controlled replenishment of chemicals is used to avoid operator contact with hazardous materials by meter pumps. Tanks are sealed and insulated with thermal lining to save energy and all galvanic modules are equipped with safety lids to collect vapors and protect operators from accidental risk.

Other factors include the use of galvanic modules with a stainless steel retaining tank that helps prevent accidental spillages on the floor. To minimize the quantity of rinse water necessary for the process Otomec developed a “save-water cascade system” that consists of an automatic refilling of the chemical treatment to process contaminated rinse water at rates up to 1,500 liters per hour. www.otomec.it.

42 | WIRE JOURNAL INTERNATIONAL

This bow deserves to take a ‘green bow’ At wire Düsseldorf, the GreenBow2 was showcased at the Gauder Group booth, where it introduced the latest innovation: options for the enclose that the wires run through during processing.

Bow Technology Sales & Project Manager Sophie Rondepierre said that GreenBow2 now can be equipped with three different wire paths, depending on production requirements: spring tube for bare copper; plastic tube for plated copper (tin-, silver- or nickel-plated); and special stainless steel pipe for insulated cables (PE/HDPE, FEP). The spring and polymer tubes can be changed in five minutes, while the steel pipe takes longer.

“Concerned by enviBow Technology Sales & Project ronmental questions, Manager Sophie Rondepierre by I wanted to develop her pride and joy. a power saving bow, easy to maintain by maintenance teams. As bow breaks are less frequent with wires running inside of the bow, we can also say Greenbow2 is a sustainable product,” she said.

Below, she outlines the advantages of the technology.

The key to the GreenBow is that the wire runs inside a tube in the carbon flyer bow, making the unit exceptional in terms of reducing wind resistance. With its clean line

Sustainability focus on way to being a requirement for large EU companies Sustainability has been a key issue for larger companies in the European Union, but now it’s becoming a requirement.

Per a recent report in Sustainable Business News, the European Parliament has passed a law that requires publicly traded companies with more than 500 employees to include sustainability factors as part of their annual financial report. They must address “policies, risks and results� in relation to “social, environmental and human rights impact, diversity and anti-corruption policies� in their annual reports. Such reports are voluntarily produced by some 2,500 companies, a number that is projected to reach 7,000 by the time the law goes into effect in 2017.

The reporting, the article said, must cover environmental, social and employee-related, human rights, anti-corruption and bribery matters, describing their business model, outcomes and risks of their policies regarding these topics, as well as their diversity policy for management and supervisors. Companies will be encouraged to use standardized, recognized frameworks, such as the Global Reporting Initiative (GRI) Sustainability Reporting Guidelines and the U.N. Guiding Principles on Business and Human Rights. “GRI is proud to have played a central role during the development of the directive — providing expertise, facilitating dialogue and raising awareness,� says Teresa Fogelberg, GRI’s deputy chief executive. “This directive is the vital catalyst needed to usher in a new era of transparency in the largest economic region in the world.�

As of 2011, 95 percent of the world’s largest 250 corporations, including 86% of the largest U.S. companies, produced annual sustainability reports, up from 80 percent in 2008, according to KPMG, the article said.

Taping Equipment

Single Twist Lines

Production range: s 4APING BINDING SCREENING MACHINES WITH CONCENTRIC HEADS HAVING DYNAMIC DANCER FOR SPOOLS AND PADS s (IGH PERFORMANCE SINGLE TWIST LINES WITH HIGH SPEED BACK TWIST FEEDERS s 2EWINDING LINES WITH IN LINE MEASURING AND QUALITY CONTROL SYSTEMS s 4AKE UP AND PAY OFF UNITS FOR REELS UP TO $).

ALSO IN TRAVERSING VERSION WITH HORIZONTAL AXIS FOR PRECISION FLAT WIRES LAYING s #ATERPILLARS AND CAPSTANS FOR ANY WIRE SHAPE FOR SMALL AND MEDIUM SECTION s #ABLE PEELING MACHINES FOR LARGE DIAMETERS s !NCILLARY TESTING SPECIAL AND CUSTOMIZED EQUIPMENT

W.T.M. s.r.l.

Via Austria, 12 - 35127 Padova - ITALY Tel. (+39) 049 8705566 - Fax (+39) 049 8705599 www.wtmachinery.com e-mail: info@wtmachinery.com MAY 2014 | 43

FEATURE

FEATURE

shape and totally protected wire path, performances of double-twist machines will be enhanced and allows reducing power consumption by 3 KVA at 5000 tpm. Other advantages include the bow’s reduced noise level as well as an overall better finished product as there is less tension inside the bow and the protected wires do not suffer any from aerodynamic turbulences. Further, there is little risk of bow crashes from cable “whip� as the wire is safe inside the easily removable wearing tube.

The first Green Bow was introduced in 2004, and GreenBow2, introduced in 2009, serves larger wire sizes (630/800 double twist equipment), saving up to 30% in electrical power due to the patented technology. Rondepierre observed that the technology has proven so effective that other equipment companies have requested to use GreenBow2, which is distributed worldwide through the Gauder Group network and is available on Kinrei HK/NB560, HK/NB630, Niehoff D630, D631, Niehoff, Samp BM 630, Northampton B630, Setic TA 630Ni, TA630Ki, TC/TD630i, TC/TD 800Ni. It is under development on Lesmo DTO-800 and Setic TA560Ni. To date, GreenBow2 has been installed on more than 300 machines that collectively are estimated to annually save some 4,500,000 KWh of electricity, Rondepierre said. Founded in 2003, Bow Technology

by Gauder Group initially was developed by Setic, and over the years more and more cable makers were asking to develop SETIC bows for other machine brands, which has led to some 500 designs adapted to customer’s specificities. bowtechnology@gaudergroup.com.

FEATURE

and unwinding properties. The spools, made from 4 mm copper drawn steel wire, are supplied plastic coated in the customer’s preferred color, or in a non-coated condition At wire Düsseldorf, Italy’s NEW SPOOL Srl presented (copper-drawn wire). its line of patented wire basket spools that are 100% recyThe stable and precise BS spool provides high speed clable. The company reports that the one-way-use reels are winding which offers improved productivity and better “green” as they are easy to recyeconomy by up to 10%. The cle, and noted that what makes BS spool is easy to handle in them especially of value is the every respect. When mounting quality of the spool construction the spool to welding machine no as well as an unusual option for adapter is needed since the hole cable manufacturers: you can diameter will fit the hub of the buy the equipment used to make feed unit. The narrow tolerances them. Below, it discusses both its will guarantee the fitness from spools and its willingness to sell one spool to another. the equipment. ”What’s unusual about us Our unique wire basket spools is that we not only supply BS300 (15-20kg) and the all spools, we are willing to supnew BS200 (5kg), which was ply the equipment we use to NEW SPOOL Srl’s Marina Zadra and Technical introduced in December 2003, make them,” said company Manager Danielle Lorandini. are today used world-wide. The Chairwoman Marina Zadra. She ground for success is mainly due explained that it is not economto the exact geometry and extremely tight tolerances, which ically feasible to export spools to some regions, but as offer an outstanding stability and extremely good winding there is demand for the spools the company is willing

Company offers recyclable wire spools with a twist: you make them yourself

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44 | WIRE JOURNAL INTERNATIONAL

At wire Dßsseldorf, Germany’s Schlicht Handelsgesellschaft oHG, a subsidiary of Rolf Schlicht GmbH, displayed two dry ice shot blasting models from Deckert that are designed to serve as an environmentally friendly, multi-purpose cleaning tool for shop floors.

When it comes to cleaning tools, molds, parts and even greasy equipment, “we are of the opinion that the treatment with dry ice is the gentlest and also cleanest way because the dry ice has no residues and only the blasted particles have to be removed,� the company notes at its website. The cleaning does not damage the surface of your parts as is always a concern with other methods.

The intensity of the dry ice stream is adjustable, so that for easy cleanings less dry ice is needed than for harder Schlicht’s Simon Libera cleanings. Further, if with a dry ice model. desired, containers for cleaning with dry ice combined with abrasive agents are also available.

7KH GU\ LFH LV ŒILUHG§ DW WHPSHUDWXUHV RI Ç & cooling surface. Material on that surface becomes brittle and the interaction results in the contaminants loosening from the carrier material. The dry ice quickly evaporates without melting as carbon dioxide is one of the few gases that can assume a solid state. Four different sized models are offered, the largest being the /7 &KDPSLRQ %ODVWHU ZKLFK XVHV GU\ LFH SHOOHWV The 16 mm nuggets have double the length of 3 mm pellets, making ordering, storing and delivery of dry ice simpler.

Schicht’s Simon Libera said that one big advantage of the dry ice systems is that they allow items and surfaces to be cleaned without introducing waste products that themselves have to be removed. The models can clean porous surfaces as well as remove rust and paint. www.schlicht-handel.de. „

WHO WE ARE - WHAT WE OFFER We are a german company with generations of experience in manufacturing machines for the cable and rope industry. We develop and manufacture according to our customers‘ requirements and are the world‘s leading manufacturer for machines for CTC (continuous transposed conductors). Further we offer used or reconditioned cable and rope making machines.

Please take a look at our currently available used equipment at www.queins.com MANUFACTURING RANGE Pay-offs and take-ups, all Tubular stranders designs Rigid stranders Belt-type caterpillar capstans Planetary stranders Single- and double disc Power cable drumtwisters capstans Armouring lines Rotating caterpillar capstans Bow/Skip stranders Single/Double twist bunchers Taping heads for plastic- and steel tapes Transposed wire machines

NEW ARRIVALS - PRE-OWNED • Queins - FLR 30+36/630 mm, (24.8“), fast loading rigid stranding/screening for up to 66 wires • Henrich - self-traversing spooler for max. 1600mm (63") bobbins, max. reel weight 5,6t, specially designed for flat and profiled wires (trolley wires)

For contacts in USA:

QMS INC. Miami, Florida Tel.: +1 (305) 665-2523 Cell: +1 (305) 924-1742 Fax: +1 (305) 740-9460 info@qmsmachinery.com

QUEINS Machines GmbH Hans-Georg-Weiss-Str. 12 52156 Monschau GERMANY Tel.: +49 2472 8080 Fax: +49 2472 3014 info@queins.com www.queins.com Your best partner for new and reconditioned machines

MAY 2014 | 45

FEATURE

Dry ice: a ‘green’ shop floor tool

QUEINS Machines GmbH FEATURE

to sell its equipment, which includes the Spokecutter, which processes wire into spokes of desired lengths; the Ringformer, where the wire is fed into the bending rolls by a roller feeding device, driven by an electric servo motor; and the assembling units, which semi-automatically produce wire spools for arc welding the wire. www.newspool.it

PRODUCTS

PRODUCTS AT WIRE 2014 AS SEEN AT WIRE DÜSSELDORF

Ceramifiable technology used for HFFR sheathing compound At wire Düsseldorf, U.K.-based AEI Compounds Ltd., a supplier of cable compounds, introduced a new, innovative thermoplastic Halogen Free Flame Retardant (HFFR) compound, TP-0851, that was well received by some 250 visitors from 150 companies from 35 countries during the week-long show.

cable sheathing in certain cable constructions allows for improved cable production efficiency and faster cable termination performance.

TP-0851 sheathed cables have met the fire test requirements of BS EN 50200 for PH 120 and the enhanced BS 8434-2 with a 930°C flame and water spray with aluminum laminate tape screens. The ceramifiable technology developed for TP-0851 may have wider applications in different cable constructions. lso introduced at the show was a new line of silane-crosslinked, oil-resistant HFFR compounds, SX-0620, for railway, shipboard, oil and gas installations.

The company welcomes inquiries for technical and commercial discussions.

Contact: AEI Compounds Ltd., sales@aeicompounds. co.uk, www.aeicompounds.com.

3 new products that measure up At wire Düsseldorf, Switzerland’s AESA Cortaillod launched new testing equipment and solutions that automatically master the electrical characterization of cables and wires, as noted below.

The company reported that TP-0851 is a new ceramifiable HFFR sheathing compound for cables built to preserve circuit integrity in fire situations. It has been used successfully in emergency alarm, communication and lighting circuits, and other fire-survival cable applications are now being tested using the AEI technology.

The ceramifiable sheathing material forms a strong char during burning, providing enhanced cable fire protection and enables the cable to function in serious fire situations.

When TP-0851 is used with silicone rubber-insulated cores, the most onerous fire performance specifications can be satisfied. Traditional fire survival cable constructions using mica tapes may be eliminated. Its use for

46 | WIRE JOURNAL INTERNATIONAL

The ResTest110, a universal linear resistance bridge, is intended for cable manufacturers that produce not only bars, but also flexible braids, stranded insulated conductors and enamelled wires, among others. Measuring these cables requires additional skills and constraints,

AESA Cortaillod shares also its know-how through technological sessions and technical papers.

Contact: AESA Cortaillod, www.aesa-cortaillod.com.

Technology can measure as well as duplicate original part for production At wire Düsseldorf, WAFIOS AG displayed iQinspect, a new company-developed control function integrated in the WAFIOS Programming System (WPS) for automatically correcting errors detected in dimensional accuracy checks of bent wire parts.

The newest development of the iQinspect function now allows a user to place a target wire form or net shape

MADE IN THE UK

Stay connected All inquiries within North America for machines, spares and dies, contact:

As a specialist manufacturer of high-

Joe Snee Associates, Inc. Tel: 774-991-0504 Email: joe@jsnee.com

performance cold welding equipment for thirty years, we’ve helped thousands of wire and cable manufacturers improve productivity and avoid downtime. To find out how we can keep production up and running, call us on +44 (0) 1233 820847 or visit www.pwmltd.co.uk.

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

MAY 2014 | 47

PRODUCTS

otherwise results are not repetitive or may even be incorrect. Using integrated equipment allows mastering the uncertainties related to the connecting device, then ensuring the precision of the overall measurement, on the line or in the laboratory. The ResTest110 excels at measuring the linear resistance of bar wires and insulated conductors.

Also introduced was Cobalt+, which is used to test LAN and patch cables. Cobalt+ (balunless ATE Automatic Test Equipment) gets around the restrictions of traditional methods and opens the door to an efficient qualification of LAN and patch cables. AESA Cortaillod also proposes traditional balun equipment for LAN, xDSL, coaxial or telephone cables.

Another approach shown at wire Dusseldorf was SoftDLC for cable production monitoring. Most of the data to be processed in the cable industry are not related to quantities but to lengths, and the SoftDLC module efficiently monitors the production and managing of data for process improvements. The specifically integrated data management system allows the capture, remote visualization, evaluation and traceability of the quality and process information to suit the specific needs of this market.

PRODUCTS & MEDIA

in the TubeInspect HD measuring cell for the creation of the CNC programming data. The CNC programming data can then be transferred to the WAFIOS wire bending machine, allowing for the production of the target part.

After three or four measurement-to-production iterations, the target part has been duplicated with very little operator knowledge or experience in wire bending machine setup.

This new iQ function, which presented as part of the WAFIOS B5, a new CNC coiling and bending machine also shown in Hanover, both were presented in cooperation with Aicon 3D Systems GmbH and the proven TubeInspect HD measuring cell (pictured). In the past, the measuring cell checked and corrected tubes bent on WAFIOS tube bending machines; now, this is also possible for parts bent on WAFIOS wire bending machines.

First, the target data is exported into the TubeInspect software. Despite the name, the technology works equally well for wire. When a bent wire part is measured, the results are compared to the target data and the correction data are fed back into the WAFIOS Programming System.

After a few cycles, typically no more than three or four, the bent wire part will correspond to the target specifications and production can be started.

The IQInspect and Aicon measuring cell package is particularly profitable for manufacturers who produce small

DESIGNERS & MANUFACTURERS ISO9001 OF PAYOFF & TENSION CONTROL REGISTERED EQUIPMENT FOR WIRE & CABLE

batches of parts with complicated geometries, where short set-up times are a crucial criterion.

Manufacturers of parts that demand high dimensional accuracy will also see the benefits of this package.

Contact: WAFIOS AG, www.wafios.com.

Rod breakdown machine for large wires has limited-slip operations At wire Dßsseldorf, Italy’s EUROALPHA, a supplier of high-technology drawing machines for nonferrous wires, exhibited the company’s R3 model, an advanced limited-slip drawing machine.

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48 | WIRE JOURNAL INTERNATIONAL

6-axis lump detector introduced for inspection of optical fibers At wire Düsseldorf, Germany’s SIKORA AG introduced the FIBER LUMP 6003 MICRO, which can detect faults on a fiber surface during the drawing process at a speed of up to 3,000 m/min.

A key to the performance is related to the use of six measuring axes. Thus, shadow areas are eliminated and even the smallest faults of a height from 5 μm can be detected. The length of detectable faults is 50 μm. In combination with a double-sensor technology, punctual non-conformities can also be detected. The FIBER LUMP 6003 MICRO is designed for product diameters from 100 to 500 μm. The

PRODUCTS

The R3 model excels for drawing large round wires as well as shaped and flat wire made of copper/copper alloys, 12 mm aluminum/aluminum alloys, according to the finished wires to be produced. The key is that this rod breakdown system offers technology beyond conventional systems as outlined below.

The R3 is a multi-motor machine, with each capstan individually driven by an independent motor. This setup provides precise synchronization of the motors’ speed for limited-slip operations. The system can be used with different size drawing capstans according to the user’s requirements. It uses submerged lubrication with fully watertight operations that offer easy access to capstans and dies during string-up thanks to a sliding steel bulkhead in front of the capstans. A skin-pass and wire polishing system for final wire calibration and cleaning can be positioned before the last pull-out drawing capstan, again according to the user’s requirements. Because of the individual motors for each capstans, the model uses less energy because the motors are off if the capstans are not used. The design provides for extremely simplified and less expensive maintenance operations and the overall system has such a low noise level that no sound-proof cabinet is needed.

EUROALPHA welcomes all customers to contact it to make arrangements to see our new equipment in production, so they can compare our limited-slip drawing machine technology to similar conventional machines, as well as see some of our other advanced technology, such as our new line of high-end, top-performance bunching machines.

Contact: Bonomini Massimiliano, sales manager, EUROALPHA Srl, tel. 39-0335-1092839, massimiliano. bonomini@euroalpha.it, www.euroalpha.it.

REEL FOR DRAWING AND STRANDING

CABLE AND ROPE PROCESS REEL

CABLE AND ROPE PROCESS REEL

STRUCTURAL DRUM IN TUBOLAR VERSION

MASSIVE REEL

REINFORCED DOUBLE FLANGE REEL

HANDLING EQUIPMENT

All the necessary accessories for reels and coils handling.

ROLLING SYSTEM FOR DRUMS

TAKE APART REEL FOR COIL’S PRODUCTION

TILTING UNIT FOR REELS AND COILS

TILTING DEVICE FOR REELS

AUTOMATIC LIFTER FOR REELS

AUTOMATIC LIFTER FOR COILS

Headquarter & Production plant: GMP Slovakia s.r.o., Pribenik - Slovakia Companies of the group: GMP do Brasil Imp. Exp. Ltda, Jandira/SP - Brasil sales@gmp-slovakia.com www.gmp-slovakia.com

MAY 2014 | 49

PRODUCTS & MEDIA

REELS AND DRUMS

Metal reels for wire and cable. Process and trasport.

PRODUCTS & MEDIA

device can easily be integrated into new or existing drawing towers. It can be connected to either the SIKORA FIBER ECOCONTROL display and control system or to a line computer. In addition to the installation in drawing towers, the FIBER LUMP 6003 MICRO is also suitable for coloring lines. “The response to our FIBER LASER 6003 for the measurement of the diameter, position, vibration frequency, tension and the spinning of fibers, confirmed our decision to bring this additional lump detection device to the market,â€? said Dr. Siegmar Lampe, Sikora’s head of R&D. He said that the company responded to many customer inquiries regarding the detection of very short fault lengths from 50 Îźm. “Currently, the fiber market grows tremendously and the quality requirements are getting higher and higher. Therefore, it is a logical step for SIKORA to set a quality statement with the FIBER LUMP 6003 MICRO. The device does not only convince by its high accuracy, but rather impresses by its 100% control of smallest faults from 5 x 50 Îźm.â€?

Contact: SIKORA AG, tel. 49-421-48900-0, sales@sikora.net, www.sikora.net; and in North America, Sikora International Corp., tel.770-486-1233, sales@sikora-usa.com,www.sikora-usa.com.

Spiral system offers dependable high-speed performance At wire Dßsseldorf, Germany’s Spirka-Schnellflechter GmbH displayed its model DW 16A spiraling machine, which is used for screening coaxial cables and other screened conductors with copper or galvanized steel wires from 0.07 to 0.2 mm.

The company notes that spiraling is another form of shielding. As such, it offers an advantage over braiding with higher rotational speed, larger supply bobbins and smoother surface, translating into thinner extruded jacket. Spiraled shielding is especially useful and desired when the shielded cable must remain highly flexible and is not subject to bends around a small radius.

The DW 16A model can operate Spirka’s DW 16A spiraling machine.

50 | WIRE JOURNAL INTERNATIONAL

at speeds of up to 450 rpm, which provides optimal efficiency and output. The use of dancers on take-up and/or payoff, precise capstan control and optimally designed bobbin carriers guarantee precise braid angle control, and ensure consistent tension at low levels, essentially eliminating the occurrence of elongation. When integrated with concentric tapers, DW spiraling machines offer additional value and savings by combining two screening processes.

The system is offered in six versions: the DW 6/8/12/16 models, all to speeds of up to 450 rpm; an 18-carrier model that can run at speeds up to 350 rpm; and a 24-carrier model at speeds of up to 250 rpm. All models employ a rotor that is turned with extreme precision for balance, speed and quiet operation, making the line the spiraling unit of choice for discerning cable manufacturers. The sound cabinet, take-up/payoff and drive motor/control are all integrated. The models have variable AD drive, an adjustable traverse mechanism for accommodate reel variation, automatic central lubrication and automatic single wire and bundle breakage monitoring.

Contact: 6SLUND 6FKQHOOĂ€HFKWHU *PE+ www.spirka.com.

Lubricant line is eco-friendly solution for aluminum/aluminum alloy wire At wire Dßsseldorf, France’s Condat exhibit introduced VICAFIL TFH 1167, a lubricant for aluminum and aluminum-alloy wiredrawing.

VICAFIL TFH 1167 was developed to provide the best performance, preserving dies and drawing high quality wires without compromising simplicity of use and long-service life. The oilbased lubricant uses a low-viscosity base oil in order to improve cooling but reduce consumption by minimizing the amount of residue on drawn wire. The product includes a package of additives to limit the production of sludge, thus reducing machine maintenance and extending lubricant life. Further, no additives are required during the whole product life, so using VICAFIL TFH 1167 reduces bath maintenance costs. Thanks to its properties, VICAFIL TFH 1167 suits most drawing operations and diameters: from 0.8 mm to rod break drawn. Moreover, it can be used in either immersed or sprayed type drawing machines, without damaging equipment.

The company’s VICAFILŽ and STEELSKINŽ product ranges are designed to comply with the latest health and safety regulations for chemicals, such as REACH, biocides legislation, etc. The company has focused on providing customers with safer product while maintaining high performance levels in use.

Contact: Condat, www.condat-lubricants.com.

At wire Düsseldorf, U.K.-based Cimteq released a new product, CableMES (Cable Manufacturing Execution System), that is explained designed to transform manufacturing.

“From our studies we found that MES is underutilized in the cable industry,” said Cimteq CEO Ali Shehab, who explained the technology and its benefits as follows.

length. A factory with an annual material bill of $50 m, will saving $250 k. CableMES, with is innovative pricing, would have paid for itself in a few months, leaving the rest as profit.”

CableMES is based on one of the world’s leading MES platforms from Wonderware. It is simple to implement because it contains all the functionality needed to make cables, it contains long established analysis tools.

CableMES integrates to the company’s cable design software CableBuilder as well as numerous ERP systems.

Contact: Ali Shehab, Cimtec, ali.shehab@cimteq.com, www.cimteq.com.

Surface detection systems provides multiple manufacturing benefits U.S.-based Taymer International, Inc., had one of the busier booths at wire Düsseldorf, displaying the company’s surface defect detection equipment.

MES has the potential of truly transforming production, increasing yield, increasing performance, reducing material usage, controlling WIP and quality, and providing a platform for continuous improvement. MES controls the process of production by electronically relaying manufacturing instructions to the operators on the shop floor and collecting order progress as well as process information from machine sensors, process controllers and manual operator input. It also collects quality data from test equipment and ensures traceability of materials used in every batch.

“Let us take just one example of what it means to a cable factory,” Shehab said. “Imagine a very modest improvement in material utilization by only 0.5%, in reduced scrap, reduced give away and reduced over-

The company focused its knowledge of wire and cable industry requirements with its machine vision technology to better detect surface defects, especially in non-metallic cables such as fiber optic cables. Surface defects also play a big role in steel tube; round bar and plate manu-

MAY 2014 | 51

PRODUCTS & MEDIA

Industry software helps maximize the potential of cable manufacturing

PRODUCTS & MEDIA

facturing where a small scratch or nick can be an unacceptable defect. The result is the Surface Inspector, which comes in two models, the SI3100 and SI4100.

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 any production line. This continuous stream of real time information–especially the failure images–allows the operator to isolate causes of jacket imperfections and water soluble tape folds. This result allows you to identify the causes of surface defects and prevents customer complaints or rejects.

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 examine the defect.

Defect locations can also be recorded, this will allow for further analysis of the defects later on. The Surface Inspector will catch defects on the wires before they reach your customers or fail in the field.

Contact: Craig Girdwood, Taymer International, Inc., tel. 905-479-2614, ext. 232, craig.girdwood@taymer.com, www.taymer.com.

52 | WIRE JOURNAL INTERNATIONAL

Air-cooled extruder provides quality flow of insulation for vulcanizing line At wire Düsseldorf, Maillefer presented an air-cooled extruder, model MXI 150, that provides 300 kg/h output with a low melt temperature.

The unit ensures good medium-voltage cable durability due to the homogenous melt, resulting in high insulation quality. The MXI 150, which is easy to operate and has low maintenance needs, is part of the company’s medium voltage catenary continuous vulcanizing line, EPL 30/Enter.

EPL 30/Enter is a compact quality solution for more sustainable production. It offers affordable investment that is easy to start and maintain in different production environments.

The Maillefer medium-voltage catenary vulcanizing line is designed for continuous insulation of XLPE insulated cable cores. The conductor is insulated by proven XLPE extruders and triple crossheads. The combination of the advanced Autocure line control system, triple crosshead and X-ray dimensional measurement provides the possibility to minimize start-up scrap and material over-consumption during your cable production run.

Contact: Jorma Leppänen, Maillefer, tel. 358-40-504 8308, jorma.leppanen@maillefer.net, www.maillefernet.

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INTERWIRE 2015 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS. GEORGIA WORLD CONGRESS CENTER | ATLANTA, GEORGIA, USA

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APRIL 27-30, 2015

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TECHNICAL PAPERS

TECHNICAL PAPERS How to increase the performance of aluminum alloy rod drawing by using emulsions A comparison of emulsions and neat oil for drawing aluminum rod shows that the emulsion technology provides performance benefits and has a lower total cost.

By Stuart Duff

Within wire drawing there are ever increasing demands to be more efficient, a faster, more reliable, zero defect production to meet the demands of the current economic climate.

In terms of costs and weight, it is seen in the industry that aluminum conductors are increasing the percentage of total production, in fact over the last ten years, aluminum overhead conductor production has increased by over 300%.

However in their manufacturing process and specifically how the aluminum or alloy wire is drawn, the manufacturing method has mostly stayed in the past and not taken advantage from increased performance and changes in drawing lubricant technology.

This paper then addresses the question of how can, a factory producing aluminum wire increase their production output?

In the present situation, the majority of aluminum rod and wire drawn is drawn using neat oils, a non-soluble wire drawing lubricant, it is fair to say that most likely over 90% of the world’s aluminum and aluminum alloys are drawn using neat oils, lets remind ourselves of neat drawing oils.

Neat oils Neat oils for aluminum rod drawing can be in the viscosity range of Kinematic Viscosity (Kv40c) 100 to 500 centistokes by the method ASTM D445, the actual viscosity can be dependent on the lubricant supplier and formulation. Lower viscosity oils are typically used for intermediate and fine wire sizes where the drawing oil is of a Kinematic Viscosity (Kv40c) 30 to 100 centistokes.

Most neat oil formulations for aluminum wire drawing lubricants will use a single or combination of base oils with the properties of low sulphur and high oxidation resistance.

The base oils are value added with performance additives of lubricity, EP and antioxidant additives. The choice of raw material additive is decided upon by the development chemist and there are thousands of performance additives to evaluate and consider for use.

When a neat aluminum drawing oil is drawing rod and

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wire, it is developed to both lubricate and cool as per any other wire drawing product, lubricating at the wire/die surface and wire/capstan surface, removing and dissipating heat from the drawing process. Fig. 1 shows typical properties a drawing lubricant should be able to provide: lubricate, cool, prevent wear to dies and capstans, protect the drawn metal, protect the machine, provide a good wire surface finish, control foaming, keep the machine clean, reduce cost and reduce power consumption.

The aluminum drawing oil however, can over time become contaminated with aluminum oxides and fines from the drawing process. It can also become contaminated with moisture and free water from any leaks or contamination into the drawing oil. The fines can be abrasive to the die and capstan surface hence reducing their life, this can also affect the wire surface finish of the drawn wire due to poor dies and is costly. Additionally the fines present in the drawing oil can react with the lubricant to cause the formation of aluminum soaps and darken the color of the drawing oil, with severe contamination the drawing oil can exhibit thixotropic properties.

Fig. 2 shows a drawing oil contaminated with aluminum soaps and fines. The operating temperature and temperature control of aluminum neat wire drawing lubricant also has a direct influence on drawing performance where excessive aluminum soaps can be formed which can influence viscosity and thereby change how the drawing oil will lubricate and cool.

Lubricant viscosity increase or thickening can be caused by three principle causes: reaction of aluminum fines in the system with the lubricant to form aluminum soaps, this reaction is catalyzed by temperature, therefore the higher the drawing oil temperature, the rate of reaction is increased; contamination with finely dispersed aluminum particles, large particles can settle or be removed easily by filtration and therefore have little effect on the lubricant viscosity. Small finely dispersed particle remain in colloidal suspension, almost thixotropic effect which can

TECHNICAL PAPERS Fig. 2. A pure drawing oil, l, and one contaminated ZLWK DOXPLQLXP VRDSV DQG 多QHV

Fig. 1. Desirable properties of a drawing lubricant.

increase viscosity and reduce lubrication; and lubricant oxidation, which would be a reaction of the lubricant or particular components of the lubricant with the atmospheric oxygen. Temperature can also accelerate this reaction, particularly when bulk oil temperatures exceed 50 degrees centigrade.

Effects of water contamination The effects of water contamination into drawing oil can be both severe and costly. Free moisture can cause severe lubrication problems in the drawing die to give a scored or severely marked drawn wire. Fig. 3 shows wire scoring from the contamination of a drawing oil with water droplets into the die.

Technical support for aluminum drawing oils The technical service and support for aluminum drawing oils to determine the overall condition and suitability for continued use, are routinely as follows.

Analytical tests are carried out for: appearance; kinematic viscosity @ 40 c, cS; specific gravity@15c; acid value mgKOH/g; moisture content ppm; and ash content, % expressed as aluminum and aluminum oxide. Each test is important in its own right, but collectively gives an indication of the lubricant system condition and suitability for continued use.

Appearance. This is a primary condition check, often viewing the lubricant color, contamination of aluminum fines and their particle size. The odor will also be checked.

Kinematic viscosity. Measured to determine any increase due to aluminum fines contamination and aluminum soap content.

6SHFL多F JUDYLW\ This value is required as the viscosity is recorded by a rotary viscometer in units of centipoise. The S.G. converts the value back into centistokes and therefore can be related to the standard value of the lubricant grade.

Acid value. Indicates the degree of oxidation that is

taking place within the drawing oil, in particular the lubrication additives.

Moisture content. Measured by the Karl Fischer method, this value is very important, as moisture will have an immediate effect on the lubricants performance. Moisture will vaporise in the die due to the die temperature thereby causing a compressible gaseous area between the wire and the die.

Contact between the surfaces is highly probable which will cause heavy die wear and wire scoring; severe cases of which will stop production.

Ash content. This value records the amounts of aluminum fines and oxides circulating in the system. These can have a dramatic effect in the kinematic viscosity and can be abrasive to the dies and capstans.

The analytical tests are carried out as routine when the customer sends a sample for analyses. The frequency of which will vary from monthly, quarterly to yearly dependent on the customer and the condition of the drawing oil system.

Neat oil filtration Neat aluminum drawing oils can be temperature controlled and also filtered of oxides, aluminum, debris, soap and moisture. There are many methods and types of equipment available on the market, all have varying cost, effectiveness and

Fig. 3. Wire scoring from the contamination of a drawing oil with water droplets into the die.

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TECHNICAL PAPERS

maintenance requirements. The best system for the filtration of aluminum drawing oils is by centrifuge. A simple low cost 3 to 5 micron high speed centrifuge can remove soaps, fines and moisture from the drawing oil to extend the drawing oil life and keep the drawing oil in good condition provided the centrifuge is properly maintained.

Neat oil summary The majority of the industry use neat oils for the drawing of aluminum and aluminum alloys from rod to fine wire, the drawing oils with new performance additives can run very well and the drawing machine can have an acceptable productivity. This is provided that the drawing oil is maintained, temperature controlled and filtered, additionally the testing of a neat oil will take place in a laboratory hence real time data is not available.

The question is how a factory can increase output from the drawing machine; drawing oils can provide good performance with both, for and against arguments as to their suitability.

They also can be restrictive in increasing performance in terms of speeds of production or susceptibility to contamination. The wire industry should consider moving forwards and embrace new emulsion technology to improve the production.

Soluble oil emulsions The use of soluble oil emulsions for aluminum drawing is not a new application, however with newer types of additive and the performance that they provide, substantial benefits can be provided to the drawing company by using emulsions over drawing oils. Emulsions can be used for both EC and Alloys across all wire sizes from rod to super fine applications. The following list cites the benefits of using a drawing emulsion over drawing oils and far outweigh neat oil: low-cost purchase and investment by customer compared to neat oils; increased productivity of the wiredrawing machine; increased speed; a cleaner wire, machine and system; operator acceptability; improved heat removal; better lubricant control; improved die life and surface finish; reduced drag out reducing waste; reduced operating costs; less disposal cost; easy mainteFigs. 4 (above) and 5 (below). Comparison of cooling rates of neat drawing oil to an nance, easy filtration and easy emulsion, evaluating the cooling performance from 100Ëš& WR DSSUR[LPDWHO\ Ă›& temperature control 56 | WIRE JOURNAL INTERNATIONAL

Emulsions versus oils The heat removal of emulsions will be better than the heat removal of oil, this is clear in all quenching applications.

The same applies to a fully formulated aluminum wire drawing lubricant, where the heat removal of the emulsion is far superior.

This is considerable and an important point for the superior performance of a drawing emulsion where the emulsion is over three times as fast as the drawing oil to remove heat.

Improved heat removal can protect dies and provide an improved surface finish.

Figs. 4 and 5 show the cooling rate of neat drawing oil compared to an emulsion, evaluating the cooling performance from 100C to approximately 40C. The results are clear that the emulsion (blue line) has a faster cooling rate over the oil (red line) by a factor of over three times.

enables full speed output from the drawing machine, a clean machine and very high productivity.

In both cases, the summary points are the use of the same product for both copper and aluminum at the same concentration, there is no requirement for high concentrations for drawing aluminum alloys, concentrations typically used are at 12%. What is key is the importance of filtration and housekeeping for the removal of fines.

Housekeeping and control A soluble oil concentrate for wiredrawing will typically contain the following chemical types of additives: mineral oil, high quality, oxidation stable pure base oils; emulsifiers; surfactant detergency additives; surfactant coupling agents; corrosion inhibitors; lubricity additives; extreme pressure performance additives; bactericides, biocides and fungicides; antifoams; and water.

In a previous paper the authors commented that it is important for users to understand what soluble wiredrawing

Drawing performance Customers have proven the ability for a wiredrawing emulsion to be used for both copper and aluminum alloy rod breakdown applications, the emulsion can provide increased machine outputs, a cleaner system, cleaner wire, improved die life and surface finish as well as a clean working environment.

The authors present two case references as an example.

Case Reference A. A customer was using the same drawing emulsion for both copper and aluminum rod drawing (1350 and 8000 series). The emulsion used at a concentration of 10 to 12%. Two drawing machines supplied by a single tank of emulsion which has a filtration system, the customer using PCD dies. The filtration system and control of the emulsion is important to provide the maximum benefits to the customer. Note : the same concentration was used for copper and aluminum rod drawing with good die life and clean running.

Case Reference B. A twin-rod system running at 12% concentration for aluminum 1350 and 8000 series drawing, also using PCD dies. The drawing emulsion coupled with an excellent filtration system

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TECHNICAL PAPERS

There is, however, a drawback in terms of the reactiveness of pure aluminum with water, also seen in the aerospace industry where emulsions are used. Pure aluminum will react with water to form aluminum oxide and the reaction is exothermic hence attention to lubricant housekeeping is important and monitoring the process. The role of the lubricant is also vital to coat the fines with emulsion.

TECHNICAL PAPERS

emulsions are, as the more a person understands about the physical and chemical properties, the better they will be able to manage the emulsions effectively and appreciate why precautions should be observed and procedures followed.

Emulsion management/control and costs The aluminum wire drawing emulsion as like copper should be filtered effectively, this promotes clean running by removal of abrasive and reactive fines from the system. In aluminum emulsions it is best to use two systems, a centrifuge and also a paper filtration. A third system of a vacuum filtration could also be considered to remove the lightweight particles.

Figs. 6 and 7, courtesy of Filtertech, show the higher performance filtration systems for aluminum wire drawing emulsions.

The aluminum wire drawing emulsion should be controlled and monitored frequently for the following test parameters: appearance, odor, concentration, pH, conductivity, bacterial analysis, co-efficient of friction and cleanliness.

The testing and procedures are no different to those used for copper wire drawing emulsions, the evaluation of cleanliness of the emulsion being important to determine fines content and the effectiveness of the filtration system. Fig. 8 shows trend analysis.

The overall costs for running an aluminum drawing system can be lower when using a wire drawing emulsion, although the soluble oil is more expensive there is less required for the system. The chart (see Fig. 9) shows the big cost differences of lubricant systems comparing an aluminum drawing oil to a drawing emulsion. In terms of index cost, top up and disposal the drawing oil is more than three time expensive.

It is also true to comment that in terms of life, the oil system could if well maintained, have a longer life hence costs could be spread over time there would also be increased drag out as the oil ages and extra top up costs. There also remains a higher cost of disposal at the end of its life due to additives in the oil and the fines contamination.

Disposal techniques and costs for emulsion are decreasing also with advanced techniques of ultrafiltration and vacuum distillation which can further reduce costs by up to 85%.

Fig. 8. Trend analysis.

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20,000 Litre System Neat Oil 20KL @ Index 2.00 Top Up, 10%, 2KL Disposal, index 120 per ton

Cost 40,000 4,000 2,400

TOTAL

46,400

Emulsion 12%, 20KL, 2.4KL @ Index 3.00 Max Top Up 2.4KL Disposal, index 40/MT TOTAL

Cost 7,200 7,200 800 15,200

Fig. 9. Lubricant cost differences between oil and emulsions.

Summary This paper discussed the application for aluminum wire drawing and options for users in that they can use either an emulsion or neat oil for aluminum rod drawing and in some case the same product for all applications of copper and aluminum.

The total cost of the process using an emulsion is lower than that of neat oil and there are significant performance benefits to be gained.

Many techniques and experience are lost out of the industry through factory personnel changes, the requirement for the supplier to support the customer and highlight cost saving options is ever more important. The wire drawing lubricant is perhaps the smallest cost item in the process but remains one of the most influential. „

Stuart Duff is one of two product managers responsible worldwide for the metal manufacturing products of Q8Oils, Roloil. He has over 29 years of experience in metal manufacturing products, in particular lubricants for wire (Germ-Allcard), WXEH VWULS DQG SURÂżOHV LQ WKH Duff applications of drawing and rolling. He is also a member of the executive committee of the International Wire Machinery Association. This paper was presented at the CabWire World Conference, Milan, Italy, November 2013.

TECHNICAL PAPERS

TECHNICAL PAPER Increased productivity in medium voltage XLPE insulating with continuous type change Employing a Continuous Type Change in a CCC line is a positive manufacturing contributor for a product (medium-voltage cores) that is known for low margins.

By Jorma Lepp채nen, Eero Korolainen and Pekka Huotari.

XLPE insulated medium voltage (MV) power cables have been produced since the late 70s. Insulating and cross-linking of medium voltage cores in a CCV-line (catenary continuous vulcanizing) is a rather established technology with preheating, triple cross-head and dry curing in pressurized atmosphere. The margins for MV cables are typically low and there is a clear need to reduce costs and increase the efficiency. Type change normally means significant down time. The CV-line needs to be run down and the cross-head disassembled. It easily takes hours, or often a full shift before the line is back in operation. With continuous type change (CTC) there is no down time.

tools need to be changed. Time for this can be reduced, if another cross-head is available and already assembled, but this is seldom the case. If a thermoplastic start-up compound has been used for the change, it has to be bled out before the new start. Depending on the lead wire there might be some tens of meters of scrap before tube can be pressurized. A normal type change always means a down time of hours. It means a waste of time, nitrogen, plastics and often a waste of conductor too. Because extruders are running continuously the screws and the cross-head do not need to be cleaned so often.

Down time of a normal type change

Continuous type change is a method to change from one core to another at production speed and without depressurizing. There is no down time and only some meters of scrap. The conductor diameter can change as well as the conductor material and core outer diameter. The method consists of several key components: welding/pressed joint; crosshead tools; end seal; core positions inside the CV-tube; and automation.

A normal type change means stopping the line and depressurizing the CV-tube. If the tail of the core is used, so called after-curing is activated before depressurizing.

The tail located inside the heating section is cross-linked and cooled down. For MV cores this takes less than half an hour. When the splice-box is open, the conductor is cut and the cross-head can be disassembled. Basically only the

Fig. 1. CTC pressed sleeve jointing.

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Continuous type change

Fig. 2. Triple cross-head equipped with the CTC.

In MV CCV-line there is practically always an accumulator after the payoff stand before the metering capstan or caterpillar. It gives time to make the conductor jointing. It is also possible to reduce the speed during the payoff reel change. With different sizes of conductors, or even more so, with different materials, jointing is more challenging. The key is to well prepare the leading end of the new conductor.

See Fig. 1.

The position of a flexible core follows the equation:

where x, and y are horizontal and vertical positions, a is so called catenary factor and x0 and y0 are constants. When there are two succeeding cores with different meter weights, their positions can be calculated using the below equation

Cross-head tools The clearance between the conductor and wire guide (innermost tip) is kept small to maintain the centricity of the inner semi-conductive layer (conductor screen). Two conductors with different diameters can not be run with the same wire guide. The core of CTC is the method and technology to change tooling in production speed, without depressurizing and practically with minimum scrap. The change can be done from bigger to smaller conductors or vice versa. See Fig. 2.

End seal The CV-line may have a single or double end seal, with or without a pilot seal. The conical seal rubbers need to be flexible to operate properly with different outer diameters. The tightness can be adjusted hydraulically. See Fig. 3.

Core position inside the CV-tube Two succeeding cores with different weights per unit length (meter weight) result in core displacement, when the joint is in the catenary part of the CV-tube. The lighter travels near the top and the heavier correspondingly near the bottom.

If the ratio of meter weights is too big, one of the cores or both will touch the hot curing tube. It is possible to calculate the displacement.

Fig. 3. Flexible end seal.

CTC includes a program for analyzing core positions during the change. It can also be used to optimize position control settings during the change. See Fig. 4.

Automation Both the line speed and the heating zone profile are changed with the core. The change takes place smoothly and automatically due to the built-in function in the automation’s recipe system. It is also possible to keep the same heating zone profile for the cores and change only the speed.

CTC performance CTC is utilized for MV cores with the following specifications: MV cores 10 kV to 35 kV; conductors 50 to 300 mm2; copper and aluminium (even to 630 mm2); and ratio of meter weights of succeeding cores 0.67‌1.50.

Costs and savings per type change The use of CTC increases line availability and saves significant amounts of conductor and plastics material. It also reduces the use of nitrogen, electricity and scrap handling.

Fig. 4. Calculated core displacements (display of CAT program).

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Welding/pressed joint

TECHNICAL PAPERS Fig. 5. Recipe system (display of Autocure).

Fig. 6. Sequence of succeeding cores produced using CTC.

Table 1. Comparison of type change costs.

Table 1 shows a comparison of costs/savings with and without CTC for one MV core type change (AL 240 mm2 20 kV, 2012).

Conclusion It is possible to produce several MV cores in the same run without stopping the CV-line. This can reduce significantly the over all down time especially if the production contains frequent type changes. CTC, which can be upgraded without heavy investments, is an effective means to improve productivity.

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Leppänen

Korolainen

Huotari

Jorma Leppänen is the product manager of CV-lines at Mallefer Extrusion Oy, Finland. Eero Korolainen is a process and automation specialist at Neutro Oy, Finland.

Pekka Huotari is the process department manager at Mallefer Extrusion Oy. This paper was presented at the CabWire World Conference, Milan, Italy, November 2013.

TECHNICAL PAPERS

TECHNICAL PAPER Energy efficient operation of pulse-jet dust collection systems Dust collecting systems are an area that can be easy to overlook, but such systems can consume considerable energy without getting the desired results if not properly installed and maintained.

By Kelly Zipsie

Fabric filters are designed to control airborne particulate created from handling, moving, and transferring material in a production facility. Once installed, these filters and other environmental systems are often neglected or misused.

Although the equipment was designed to ventilate and control dust, it often contains a poorly designed ventilation system that results in a much higher dust load than necessary. Air pollution control equipment requires high levels of energy for proper operation, and equipment misoperation can result in unnecessarily high operating costs.

Energy efficient operation There are typically two components found in pulse-jet bag-houses that consume high levels of energy: (1) compressed air demand and (2) the fan the system used to convey the air from the source through the system. Fig, 1 shows

these two main energy consumers and where they are typically located in the system.

Compressed air demand and considerations Compressed air is generally an expensive plant resource since the compressor itself is the highest energy consumer in the system. There are many things that can be done to reduce the consumption of compressed air.

Compressed air pressure. By reducing the compressed air pressure to the lowest allowable level, filter bag life can be increased and compressed air consumption decreased, resulting in significant monetary savings.

Pulse valves. One of the most significant ways to reduce compressed air consumption is by converting to a larger pulse valve that cleans more efficiently at lower pressures.

This will reduce the demand for compressed air consump-

Fig. 1. Main energy consumers in the system.

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TECHNICAL PAPERS Fig. 2. A single diaphragm valve.

Fig. 3. A double-diaphragm valve.

tion. Older pulse-jet units were furnished with 他 in. single diaphragm pulse valves. See Fig. 2. These valves require much higher pulse pressures to provide adequate cleaning.

If not properly operated, the valves created compressor demands, wasting compressed air, and reducing system cleaning efficiency.

Fewer pulse-jet units, as well as rebuilds and retrofit units, are often furnished with a larger 11/2 in. diameter double diaphragm valve. This design gives a minimum coefficient of friction loss with maximum pressure energized for cleaning. An effective cleaning pulse is obtained with the double diaphragm valve at approximately 85-90 PSI, where the 他 in. diameter valve would introduce its optimum energy at 100-105 psi. Fig. 3 shows the double diaphragm valve used in the system.

Compressed air leaks. A simple 1/8 in. diameter hole within a compressed air system will pass 16.9 cfm psi, resulting in 8,880,000 cubic feet per year. If the cost of the compressed air is $0.20 per 1,000 cfm, the total cost produced by the orifice will be $1,776.00 per year. See Table 1 (Fig. 4). Inspect the pipe and connections periodically and repair any leaks, regardless of how small. By reducing the compressed air pressure to the lowest allowable level, filter bag life can be increased and compressed air consumption decreased, resulting in significant monetary savings.

Pulse valve and solenoid maintenance

Fig. 4. Energy costs of compressed air.

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Proper maintenance of the pulse valve and solenoids is essential to the economical operation of the unit. Since all the pulse valves are mounted on a common manifold tank, the tank pressure buildup is bled down each time a valve pulses, based on the solenoid on-time operation.

This pressure is used to seat and maintain a seal in the pulse valve diaphragm. If the compressed air supply to the manifold contains oil or moisture, it will create problems in the pulse valves internal orifices. The compressed air needed to seat the diaphragms is channeled to the chamber located behind the diaphragm through these orifices.

If these orifices become plugged, the equalizing pressure cannot be developed in the diaphragm. Therefore, the required manifold tank pressure will not develop. Also, when the solenoid valve is energized, the sudden change in pressure on the diagram of that valve causes the tank pressure to open the diaphragm, which releases the tank pressure for the energized time. The cleaning of the row of filters is accomplished during this time frame. If a solenoid valve or one diaphragm does not seat properly during this time, there will be a drain on the compressed air system.

This drain will cause a loss of cleaning capability in the valves mounted on the tank. Any poorly seated or broken

Pulse-On-Demand

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diaphragms or solenoids causing these leaks should be repaired as soon as possible.

Compressed air pipe size Some manufacturers furnish manifold tanks that contain a 1/2 in. coupling to store compressed air for cleaning.

In this situation, the installer generally plumbs the compressed air supply with a 1/2 in. schedule 40 pipe from

Fig. 6. Fan performance curve.

A clean-on-demand system cleans the filters only when necessary to maintain the desired differential pressure. If the collector is currently operated on a timed pulse, the system can over clean or under clean the filters. A collector with new filters will not impose as much resistance to the system as one with dirty filters. If a timed pulse is being used, the collector can be in “cleaning mode” on start up. This means the system will be pulsing clean filters. Since most filters need a dustcake to create maximum operating efficiency, there is no need to pulse filters that are clean. On start-up, the cleaning of the filters will prolong the time before an adequate dustcake is established.

In the process, this over-cleaning will damage the filters due to dust migration into the fabric, since it will build a cake or a resistance “in the fabric” instead of “on the fabric.” See Fig. 5.

Since the fan in the system will move more air due to the reduced resistance of the clean filters, the collector will be operating at a higher air-tocloth ratio than it has been designed for. This will contribute to the premature failure of the fabric due to blinding.

A Pulse-On-Demand controller will protect the fabric since the pulse will not be activated until the differential pressure has reached the predetermined set point to start the cleaning mechanism. See Fig. 6.

In the cleaning sequence, the dust removed falls downward a few feet during each pulse resulting in a rearrangement of the dustcake. This rearrangement causes the reduction in the differential pressure. The next row of bags to clean should not be the row adjacent to the one just cleaned since the space between rows is very close.

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the compressed air source. In some cases, this source can be hundreds of feet away from the collector location. The pipe size should be at least a 11/2 in. Schedule 40 to allow the pressure regain and cleaning system operation to occur as quickly as possible. This cleaning mechanism is based on the crispness of the pulse. Therefore, the pressure in the tanks has to develop up to the rated pressure. Too small of an air supply pipe will create a flow restriction that will slow the tanks ability to regain pressure. If the cleaning capability of the unit is being maximized, the pressure regain should be instantaneous.

TECHNICAL PAPERS

Fig. 8. Photohelic gauge.

Fig. 8. Photohelic gauge.

Cleaning of a pulse-jet collector in sequential Fig. 7. Recommended Pulsing rows can cause Sequence. a mechanical separation of the collected dust. The row just cleaned can now receive more airflow than the other rows. Small dust will migrate to the clean row as the adjacent row pulses. As a result, the mechanical separation of micron sizes will occur and resulting in differential pressure.

A staggered pulse sequence is recommended for cleaning. See Fig. 7. The dust should be cleaned according to the following sequence: row one, row four, row seven, until the end of the manifold. When this point is reached, the cleaning should restart at the following uncleaned row at the beginning of the manifold and follow the same sequence. Staggering the cleaning cycle ensures that no rows in the unit clean directly adjacent to a row that has just been cleaned. The dustcake has adequate time to restructure, allowing more dust to be removed on each cleaning cycle. This process will remove more material from the collector than sequential cleaning and will not create a mechanical separation of the dust.

Pulse cleaning sequence The recommended setting of the PulseOn-Demand controller should be set to maintain a differential Fig. 10. Modulating damper.

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Fig. 9. Magnehelic gauge.

pressure from 1/2 in. to a maximum of 1 in. across the filters if the gauge has two needles to indicate the start and stop setting for cleaning See Figs. 8 and 9. If the gauge has a single point instead, it will automatically operate in a 1/2 in. window around the set point. This is due to the drift on the control gauge at a single set point.

Fans and fan motors Fans and fan motors are major energy consumers. Their energy can be made an advantage if used properly. See Fig. 6. Fan selection in ventilation equipment is based on a fixed volume of air that needs to be handled within the system.

When a fan and motor are selected for the system, a differential pressure must be assumed for the dust collector in order to make an accurate evaluation. This is generally selected at 6 in. SPWG for the collector. To select the total static fan pressure requirements, an anticipated pressure drop for the baghouse is estimated. The fan can run all day in this system at a fixed volume if the collector is not part of

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the requirements and no pressure changes have occurred in the collector.

The fan can pull more air than the design volume when the resistance of the baghouse is lower than the design value of 6 in., causing excessive loading of the motor and filter bag damage. Many initial designs incorporate dampers to artificially introduce static pressure into the system to control the baghouse static pressure variations. In these cases, the damper will keep the fan operation at a fixed point on the fan curve, reducing motor load.

The fan will operate at a higher volume than designed if the system starts with a low differential pressure across the baghouse. If the fan motor power is insufficient, the overload produced will “kick out” and the fan will require a restart. To ensure overload protection, a resistance is applied to the system to reduce the air volume. This is generally accomplished with a fan damper. If the damper is a manual device, the fan amps should be monitored.

The fan amps will identify the collector resistance as it develops across the bags. The damper restriction can be adjusted to keep the fan operating at a fixed volume. It is recommended to have a modulating damper on the fan.

This damper can be modulated by either fan amps or by system pressure. This modulating system incorporates a transducer that sends a signal to the controller and an actuator on the fan damper. The signal modulates the fan damper keeping the air volume constant to prevent overloading the collector. See Fig. 10.

The only changes to the system will be the differential pressure across the baghouse since the fan air volume is controlled by pressure or amperage. If the differential pressure span is set at 1/2 in., the control of the cleaning system will actuate the pulse cleaning only as often as required to maintain this setting. See Fig. 6. This will only cause a change in pressure of 1/2 in. to the fan operation. Therefore, the fan damper will only need to control within a range of 1/2 in., which will stabilize the fan performance. The cleaning mechanism should be set up to pulse at the recommended setting of 0.10 seconds duration. The time between pulses or the off-time between

Inlet dust connection The inlet duct design into the hopper can also help improve the system performance. The air in the system

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the timer card should be set at the minimum time that the compressed air system regains maximum pressure. With these settings, the mechanical cleaning capability of the collector will be maximized.

The most energy efficient method of operating the fan is to have variable speed motors or drives which are designated to operate on static or volumetric requirements of the system. This will provide volumetric control with minimum horsepower or motor load. A variable speed motor or drive operating with a Pulse-On-Demand controller provides state-of-the-art controls and economic performance.

If the collector has more than one manifold tank with pulse valves, the cleaning of the collector can be increased by cleaning one pulse valve simultaneously on separate tanks form one timer board output. Solenoid valves require milliamperes to open. Based on these requirements, the outputs from the timer card can fire as many as eight solenoids.

This was accomplished with a total of eight manifold tans on four collectors that utilized the same exhaust fan system. The system was set to fire with the staggered sequence mentioned earlier. The off-time was set to allow maximum pressure manifold tank regain. The differential pressure was set to control within a range of 1/2 in. across the entire system. That is, the reading from the inlet to the outlet of the 4-collector system. The reading from the collector was a differential pressure of 4 in. to 4 1/2 in. across the bags. The setting on the control of the timer board output was a differential pressure of 8 in. to 8 1/2 in. across the 4-collector system. This approach eliminated six timer boards and stabilized the air throughput of the system.

Initially, the collector cleaned on-time and the pulse valves on the manifolds were fired on 2 second intervals.

After the changes, the cleaning cycle would energize for three pulses at two second intervals satisfying the differential pressure window of 1/2 in. The differential pressure regain to start the cleaning cycle took 45-50 seconds. This required less compressed air. Also, the differential pressure was satisfied pulsing three rows in all the collectors.

Therefore, the dust pulsed from the filters into the hoppers was removed before the next cleaning cycle.

This also provided an equal distribution of airflow between for the four collectors resulting in a prolonged life of the filter media. Since the amount of pulses was reduced and they stabilized the airflow, the total air volume increased and the compressed air consumption decreased. Gaining mechanical control of the system components will maximize the system operation, reduce energy cost, and improve operational performance.

TECHNICAL PAPERS

is normally delivered to the hopper of the baghouse at a speed of at least 60 fps. At these velocities, the air does not have enough time to disperse within the hopper and higher dust loads are carried to the filters. This results in a need to clean the collector more often to control the differential pressure. A change to the inlet design can disperse and slow the incoming airflow, allowing the incoming material to separate from the air stream and reduce the dust load to the filters downward. This is accomplished with ductwork or sheet metal changes. See Fig. 11.

The duct prior to the hopper is expanded downward.

This will reduce the airflow velocity and will introduce the material into the hopper at a lower speed. Another cost effective modification is to add ladder vane baffles in the hopper. The ladder vane will reduce the back pressure of the system and distribute the air in the hopper more evenly creating a uniform upward velocity across the hopper as it approaches the filter bags. See Fig. 12.

Conclusion Energy efficiency continues to be a significant operational issue in plants worldwide. Air pollution control equipment is a major energy consumer in the system and steps can be taken to ensure its proper operation to curtail unnecessary energy use.

As mentioned earlier, minor enhancements and control settings in the dust collection system can go a long way to helping you conserve valuable energy. „

Kelly Zipsie

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

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CAREER OPPORTUNITIES SOUTHWEST ACCOUNT MANAGER. Wire & Cable Distributor is seeking Account/ Product Manager for TX, LA, AL, MS, OK, TN, KS, and select accounts in GA. Travel to customers in Mexico will also be required.

Experience: 5 years in sales and 5 years in W&C industry. Must have a record of proven sales results. Must reside in one of the states in the territory and be able to work independently. Technical and marketing experience a plus. Opportunities for advancement are available. Industry leading pay and benefits will be offered. Please send resume to jhoogendoorn@ttmarketinginc.com.

M A N U F A C T U R E R ’ S REPRESENTATIVE. Established international manufacturer of drawing lubricants, pre-coatings, chemicals, equipment and tools is seeking representation in the US. Through our innovative practices and responsiveness to customer’s needs we have rapidly achieved a leading role in international markets and are currently pursuing highly motivated and results oriented reps to develop the US market. If you are enthusiastic with tremendous initiative and ambition this ground floor opportunity is right for you. Competitive commission structure and marketing support are provided. Please respond by e-mail to classified@wirenet.org.

PLANT/MANUFACTURING MANAGER. MA-based privately held custom cable manufacturer seeks manufacturing manager due to pending retirement of current one.

Extensive background and experience in Wire & Cable industry is

DEADLINES: Copy is due a full month in advance.

Contact: classified@wirenet.org for more details.

required. We are a smoke & drug free EOE offering excellent pay, benefits and room for personal and professional growth for the right candidate. Send Resume to: generalwire@aol.com.

sands of key individual contributors.

Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593, Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.

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 executives, managers, and thou-

DIES APOLLO DIA-CARB COMPANY Sells Natural/PCD diamond dies.

Fair prices/excellent lead times.

Contact Paulette, Owner/Sales Tel. # 1 (508) 226-0946 E-mail: apollodie@comcast.net

FOR SALE 1 - HACOBA Model DF24 24-Carrier Braider 2 - WARDWELL 24-Carrier Braiders 1 - NEB 72-C #2 Braider, Long Legs, Motor 1 - TRENZ 64-C Horizontal Braider 1 - STEEGER 16-C # Double Head Braider 1 - NEB 24-C CB-1 Cable Braider 15 - KINREI 560mm, 760mm D.T. Bunchers 1 - REEL-O-MATIC 24” Caterpuller Capstan 2 - FARRIS 22”, 30” Caterpuller Capstans 1 - ALLARD 36” Closer 2 - NEB 12-Wire 8” Vertical Planetary Cablers 1 - ALLARD 30” S.T. Closer 1 - DAVIS STANDARD 4.5” 24:1 Extruder 1 - DAVIS STANDARD 3.5” Rubber Extruder 1 - DAVIS STANDARD 2.5” Hi-Temp Extruder 1 - DAVIS STANDARD 1” 24:1 Extruder 1 - LESMO 1800mm Gantry Payoff, Model SPF1800 1 - SKALTEK 1600mm Payoff, Model A16-4K 1 - DYNAMEX Tape Payoff, Model TPB30-2-D

1 - ROSENDAHL 630mm 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, 18” Reels 1 - TULSA 36” Rewind Line 1 - METEOR Model ME301 3-Head Winder 1 - TEC Model DTC630 D.T. Twister 2 - ENTWISTLE 4WDT24 4-W 24” D.T. Twisters 2 - NEWMCO 16” Quadders 1 - METRONIC AlphaJet C Inkjet Printer, 2005 1 - PWM Model EP500 Rod Welder 1 - HALL Tape Accumulator 1 - WARBRICK “Chalkmaster” Talc Applicator 1 - EUBANKS Model 4000-04 C/S Machine 1 - SCHLEUNIGER Model UC3750 Cutter 1 - SCHLEUNIGER Model EC3200 EcoCut 1 - SCHLEUNIGER Model ES9320 EcoStrip 1 - SCHLEUNIGER Model HS4500 Hot Stamper 1 - SCHLEUNIGER Model CT32, CT42 Crimpers 1 - IDEAL Model STP Stripper, Part #45-930

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

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 by smaller companies. It includes a CD-ROM. Price, $95, $75 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legacy. “But it’s all wire,” proclaimed a 1950s Roebling Company brochure about its product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and aircraft strand, flat and braided wire, PC wire and strand, galvanized bridge wire, among others.

To maximize quality, the Roeblings started drawing their own wire in the 1850s, rolling bars into rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history chronicled in The Roebling Legacy. The price is $75, $50 for WAI members, plus ship70 | WIRE JOURNAL INTERNATIONAL

ping. To purchase, go to wirenet.org and click on The WAI Store.

THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 2011 135-page booth by industry expert Douglas Relyea, founder of Quality Principle Associates, a consulting firm specializing in the education and application of data analysis techniques to industrial problem solving. The list price is $45, $40 for WAI members, plus shipping. To buy, go to wirenet.org and click on The WAI Store.

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.

THE ROEBLING LEGACY. This 288-page indexed book by Clifford W. Zink presents a different perspective of the Roebling legacy. “But it’s all wire,” proclaimed a 1950s Roebling Company brochure about its product line, which included wire rope, copper magnet and electrical wire, screens and hardware cloth, aircord and aircraft strand, flat and braided wire, PC wire and strand, galvanized bridge wire, among others.

To maximize quality, the Roeblings

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

started drawing their own wire in the 1850s, rolling bars into rods in the 1870s, and making their own steel in the 1900s. Wire is the binding thread through 125 years of Roebling and American industrial history chronicled in The Roebling Legacy. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 135page indexed booth (published in 2011) was written by industry expert Douglas B. Relyea, founder of Quality Principle Associates, a New Englandbased consulting firm specializing in the education and application of data analysis techniques to industrial problem solving. 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.

ADVERTISER ............................ PAGE AlphaGary Corp . . . . . . . . . . . . . . . . . . . . .Cover 2 Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

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

July 2014 WJI • Equipment

Amaral Automation Associates . . . . . . . . . . . . 31 Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . 30 Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Borealis AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cable Consultants Corp . . . . . . . . . . . . . . . . . . 22 Carris Reels Inc . . . . . . . . . . . . . . . . . . . . .Cover 4 CM Furnaces Inc . . . . . . . . . . . . . . . . . . . . . . . . 15 Commission Brokers Inc . . . . . . . . . . . . . . . . . 69 George Evans Corp . . . . . . . . . . . . . . . . . . . . . . 52 GMP Slovakia. . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . 46 Huestis Industrial . . . . . . . . . . . . . . . . . . . . 36, 44 Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . 42, 51 IWG High Performance Conductors Inc . . . . . . 9 KEIR Manufacturing Inc . . . . . . . . . . . . . . . . . . 52 Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . 29 Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . 4 Pressure Welding Machines Ltd . . . . . . . . . . . 47 Proton Products Ltd . . . . . . . . . . . . . . . . . . 17, 37

Advertising Deadline: June 1

Queins Machines GmbH . . . . . . . . . . . . . . . . . . 45 Radyne Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 MAY 2014 | 71

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

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

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

Rainbow Rubber & Plastics Inc . . . . . . . . . . . . . 2

WTM Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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

Wyrepak Industries . . . . . . . . . . . . . . . . . . . 11, 48

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Zumbach Electronics Corp. . . . . . . . . . . . . . . . 13

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

August Strecker GmbH & Co KG. . . . . . . . . . . 19

WIRE ASSOCIATION INTERNATIONAL ADS . . . . . . . .

Teknor Apex Co . . . . . . . . . . . . . . . . . . . . . . . . . 35

WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . 25

TMS Specialties Manufacturing Co Inc . . . . . . 28

Interwire 2015 . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Sjogren Industries Inc. . . . . . . . . . . . . . . . . . . . 24

Wire & Plastic Machinery Corp . . . . . . . . . . . . 72

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72 | WIRE JOURNAL INTERNATIONAL