Industry information by Wire Journal International, Inc.

WIRE JOURNAL NOVEMBER 2014

速

INTERNATIONAL www.wirenet.org

wire China wrap-up

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

WIRE JOURNAL NOVEMBER 2014

INTERNATIONAL

CONTENTS

www.wirenet.org

Volume 47 | Number 11 | November 2014

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

FEATURES

Calendar . . . . . . . . . . . . . . . . . 8 Industry News. . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 18 People. . . . . . . . . . . . . . . . . . 20 Fiber Watch . . . . . . . . . . . . . 22 Fastener Update . . . . . . . . . . 24

Wrapup: Wire China . . . . . . . . . . . 38

Chapter Corner . . . . . . . . . . . 26

Exhibitors who contacted WJI about their experience at the September staging of Wire China had nothing PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL but goodOFFICIAL things to say about the biennial event.

WAI News . . . . . . . . . . . . . . . 28 Technical Papers . . . . . . 52-64 Products . . . . . . . . . . . . . . . . 66 Classified . . . . . . . . . . . . . . . 73

Feature: Industry information . . . 42 Who would disagree that industry knowledge, both technical and management, matters? But the question is where can one ﬁnd it, and is it worth the investment of time and resources?

TECHNICAL PAPERS

Career Opportunities . . . . . . 73 Advertisers’ Index . . . . . . . . 75

Next issue December 2014 • Industry Role: Agents • Wrapup: Wire & Cable India

Improvement of ductility of aluminum wire by alternate drawing Kazunari Yoshida and Kota Doi . . . . . . . . . . . . . . . . . . . 52 High-precision roll bending of titanium alloy wire for glasses Yuichiro Sekine, Motoo Asakawa, Natsuki Kato, Yuki Takebe, Yoshinori Sasaki and Masami Matsumura . . . . . 57 New efﬁcient and ecological surface cleaning technique for ferrous and nonferrous wires Rory A. Wolf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Cover: So where does a company ﬁnd the expertise to help it up its manufacturing capabilities or provide direction for future plans? Organizations that provide technical conferences and/or management analysis believe that they can help on those matters, and more. See p. 42.

NOVEMBER 2014 | 3

CONTENTS

INSIDE THIS ISSUE A ‘platinum’ level industry webinar . . . 32

An industry tradition continues . . . . . 36

Integer Rearch’s Philip Radbourne provided expanded content during an Oct. 21 webinar that followed up the Electrical Sector report that was provided to WAI Platinum Members. Below is a slide from his presentinterest. The webinar also included further discussion by a panel of industry experts.

Robert Bache, a director at U.K.-based Bache Pallets Limited, performs the clockwinding duties at the Oct. 15 event at WAI’s headquarters in Guilford, Connecticut. Bache spoke to guests and staff about the importance of having a close relationship. He observed that in today’s world we all need a wingman, and for the U.K., “I think that there’s a wingman in America, in the USA.”

US economy seems to be showing some solid signs of growth..but also some concerns

Positive  Economy recovered from worst recession in 80 years  US consumer confidence at 7 year high  US gas prices fall to lowest since 2010  US oil extraction booming  US auto sales at record highs  US weekly jobless claims drop to 14 year low of 264,000  US unemployment at 5.9%  US budget deficit below 3% of GDP Longest run (54 months) of private sector job creation on record

Negative X Real wage growth has been modest at best X Recovery not evenly split X US Housing starts still well below 2007 peak X US still running large budget deficit X Labour participation rates continue to drop, lowest levels since 1970s X Lower US oil prices may hit fracking boom expansion X US National federal debt still at highest level in 70 years X Further potential dispute over the debt ceiling extension www.integer-research.com

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EDITORIAL WIRE JOURNAL

EDITORIAL

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

Warning: this editorial may be self-serving The feature in this issue is on industry information and where to find it, so it will surprise nobody to see that one of the sources is none other than the Wire Association International, which puts on conferences with technical papers and operation presentations. The reader can decide whether or not the feature is self-serving, but hopefully some observations will be of interest. Over years of going to technical conferences (both ours and others), it was clear that attendees came because they hope to hear from an author or two who have ideas that–direct or indirect–could help them in their own research. The ability to pose a few questions to such a speaker maybe hard to quantify on paper, but it is safe to say that the value of such a discussion cannot be replicated by e-mails or webcasts. Hold that thought. The industry has seen its share of up and down cycles, and when economic times get especially harsh, some companies stop sending staffers to such events. On one level, it’s understandable: if a company has had to cut staff, there may be reluctance to spend for travel and event fees. But, coming back to the prior premise, by not sending somebody, nobody will ever know the cost of a lost opportunity. If a timely technical advance was not found or a key contact not made, an advance that might have been achieved over time never had a chance to happen. Management can judge what is, but not the value of missed opportunities. They just never were. That dilemma was the basis for this feature. There is value in increasing technical knowledge, especially if one can make faceto-face contact and hone in on specific areas of interest. As this feature progressed, the focus expanded beyond technical papers to include other forms of industry information, from management views and operational sessions to employee training and Open Houses. The goal here was to focus more attention on technical papers– the proverbial sea of gray at the back end of the issue–that are all too easy to flip over, the incredibly smart people who present them, and the companies that may be able to benefit by that work as well as all the other sources of information. If that’s self-serving, so be it.

Mark Marselli Editor-in-chief

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail editorial@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 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 are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313-761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

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The PURITY SCANNER is a system for the 100% online inspection and sorting of plastic pellets used for the insulation of medium, high and extrahigh voltage cables, but as well for other applications such as the medical industry. Contaminated pellets are separated and sorted out, assuring that only pure pellets get into the extrusion process. The pellet inspection allows the detection of organic and metallic contamination inside the pellet as well as on the pellet surface, using a special combination of X-ray technology and an optical system. The smallest detectable particle size is 2 mil (50 µm) at a flow rate of up to 4,400 lbs/h (2,000 kg/h). • Dual inspection: X-ray and optical • Detection of contamination from 2 mil (50 µm) on the pellet surface and inside the pellet • Automatic sorting • Easy to integrate in existing feeding systems • Suitable for all kinds of transparent and colored pellets • Hermetically sealed system • Throughput of 1,100 / 2,200 / 4,400 lbs/h (500 / 1,000 / 2,000 kg/h)

See us at IWCS Conference 2014, Nov 9 - 12, Providence, RI, USA, Booth 413

CALENDAR

CALENDAR 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. Nov. 26-28, 2014: MFSH 2014 Shanghai, China. This event includes bar, wire, steel rope and more. Contact: Shanghai Aoya Exhibition Co., at 86-21-3351-8138, ayexpo@vip.163.com. Dec. 2-4, 2014: 3rd Advanced Cable Asia Shanghai, China. This conference, sponsored by Integer Research Ltd., will examine key wire & cable market developments and business opportunities in the region to help Asia based cable makers determine their R&D and investment plans. Contact: Imam Quadir, tel. 4420-7503-1265, imam.quadir@integer-research.com, www.integer-research.com. tel. 44-20-7503-1265, www.integer-research.com. April 27-30, 2015: Global Continuous Casting Forum Atlanta, Georgia, USA. This WAI event, first staged in Atlanta in 2011, will be co-located with Interwire 2015. It returns with a new format: the scope has been expanded to include aluminum. Contact: www.castingforum15.com. April 28-30, 2015: Interwire 2015 & WAI’s 85th Annual Convention Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center to stage its biennial trade show, technical programs and 85th Annual Convention. Contact: WAI, USA. Tel. 001-203-453-2777, www.wirenet.org.

June 9-12, 2015: Guangzhou International Wire, Cable and Accessories Fair Guangzhou, China. To be held in the China Import and Export Fair Complex, this even will feature the latest equipment, materials, machinery and detection instrumens in the wire an cable market for attendees from top-level executives to engineers. Contact: www.wire-cable-china. com, wire@china.messefrankfurt.com. June 21-25, 2015 Jicable 9th International Conference on Insulated Power Cables Paris, France. Held every four years, this international forum is an exchange of information in the fields of research, industrial development, installation, operation and diagnoses relating to insulated power cables and their accessories. Contact: Jicable, tel. 33-1-56-90-37-04, jicable@see.asso.fr, www.jicable.org. April 4-8, 2016: wire Düsseldorf Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. June 8-9, 2016: WAI Operations Summit & Wire Expo Uncasville, Connecticut, USA. This WAI event, which will be held at the Mohegan Sun Resort Center, will include its trade show, technical programs and WAI’s 86th Annual Convention. WAI, USA. Tel. 001-203-4532777, www.wirenet.org.

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

April 27-30, 2015: Global Continuous Casting Forum Atlanta, Georgia, USA. This WAI event, first staged in Atlanta in 2011, will be co-located with Interwire 2015. It returns with a new format: the scope has been expanded to include aluminum. Contact: www.castingforum15.com.

8 | WIRE JOURNAL INTERNATIONAL

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. www.wirenet.org.

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

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INDUSTRY NEWS

INDUSTRY NEWS Nexans holds official opening of its high-voltage power cable plant Nexans held the official opening of its high-voltage power cable plant on Oct. 8, a sunny day in Goose Creek, South Carolina, with state Gov. Nikki Haley and Nexans officials there to herald the $85 million investment in Bushy Park Industrial Complex. The 350,000-sqft plant, not far from Charleston, will eventually employ some 200 employees producing HV cable for the North American market.

state. Nexans is a company that is not only committed to producing quality products but is also committed to making a big difference in their local community,” said Haley. The company noted that the following. The plant will reinforce Nexans’ current product range in North America, adding to the existing medium voltage, low voltage, overhead transmission, industrial, building wire, electrical wire and Local Area Network (LAN) portfolios. In 2013, North America represented 14%% of the Group’s total sales, with more than 3,000 people employed. The new building was planned with health and safety a priority. There are no underground storage tanks and the substation transformers are dry to avoid potential soil contamination. Nexans has put in place additional measures to protect employees, including the lower level of the tower that was designed to serve as a shelter in the event of a hurricane.

Southwire expands building and MC cable capacity with Carrollton building

An outside view of the new Nexans power cable plant. Nexans CEO Arnaud Poupart-Lafarge hailed the initiative as “an exciting new phase for Nexans and is an important milestone for the company. … With the opening of this new plant, Nexans is best-placed to serve the major new power transmission infrastructure projects currently being planned in North America today.” Per the company’s provided details, the plant stands tall. Literally. The plant’s 427-ft continuous extrusion tower, which is described as the tallest building in South Carolina, required an air-clearance permit from the Federal Aviation Administration. The ISO 9001:2008 certified plant is equipped with the facilities for type testing cables up to 550 kV according to North American and international standards. Among those in attendance for the inauguration were South Carolina Governor Nikki Haley, Nexans Chief Executive Officer Arnaud Poupart-Lafarge and Executive Vice President Nexans North America Steve Hall. “It’s always a great day in South Carolina when the doors open to a plant that is bringing 200 jobs to our

U.S.-based Southwire is renovating an existing 650,000-sq-ft facility on 111 acres in Carrollton, Georgia, to expand its building wire and feeder metal-clad (MC) cable manufacturing capacity. A press release said that the project will enable Southwire to increase capacity and streamline its operations to support residential and commercial construction growth to meet future customer demand for building wire and feeder MC cable products. “Production has already begun at the new plant and additional equipment will be added over the coming months, making it one of the most efficient and up-to-date wire and cable manufacturing facilities in operation today. Once complete, Southwire will produce several key product lines using updated equipment and manufacturing techniques.” “This new facility delivers a number of manufacturing benefits and the property allows for further expansion as needed,” said Phil Tuggle, SVP building wire, Southwire. “Copper wire will continue to be our largest building wire category, but the market is continually demanding value engineered alternatives to copper. So not only will we get increased capacity, but we’ll do it with an extremely efficient footprint with room for future growth.”

Correction Due to an editing error, a story in the August issue about LEMO’s acquisition of Northwire, Inc. (NWI) said that in other news, a July 13 fire took place at its plant in Wisconsin. The fire did not take occur there but at a plant owned by Northern Wire LLC in Merrill, Wisconsin.

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

10 | WIRE JOURNAL INTERNATIONAL

U.S.-based RSCC Nuclear Cable (RSCC) announced that it has completed delivery of safety-related replacement cables (class 1E) for the Shin Kori Unit 3 nuclear power plant as part of a nearly $13 million award by Korea Hydro Nuclear Power (KHNP). A press release said that RSCC was competitively selected to replace cables at two APR-1400 reactors in November 2013, and this deal marks “the cable industry’s first installation of 60-year qualified nuclear cables anywhere in the world.” “RSCC is proud to have achieved this milestone in the qualification and manufacturing of the world’s highest quality cables, under the most challenging circumstances of scrutiny and delivery for KHNP,” said RSCC Wire & Cable President Steven Bonnell. RSCC noted the following. The company has delivered more than a million feet of cable to meet the urgent demand for qualified replacement cables. More than 1,000 reels of low- and medium-voltage power, instrumentation and control cables have been air-freighted from JFK Airport to Korea over the past six months. Each reel was inspected several times during and after manufacturing in the U.S. and again several times before and after installation at Shin Kori.

INDUSTRY NEWS

RSCC delivers a million feet of its nuclear cable for South Korean plant

RSCC nuclear cable prepared for shipment to KHNP. RSCC photo. RSCC passed a series of equipment qualification tests to ensure the cables will withstand the most challenging circumstances 60 years into the future. The cables installed at Shin Kori are the first ever to meet such stringent IEEE requirements, demonstrating the ability of RSCC’s cable to withstand harsh conditions that include extreme temperatures, pressures, steam, and radiation. “Shin Kori’s cables have undergone more quality inspections than any other cable in the nuclear industry and KHNP has been one of RSCC’s most conscientious

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INDUSTRY NEWS

customers in the more than 40 years that we have been supplying nuclear cables,” said Corey McDaniel, vice president Asia. The release said that RSCC cables have been installed in more than half of Korea’s reactors and in every reactor in the U.S. and most major U.S. government nuclear facilities. RSCC nuclear cables are sold internationally to countries where the highest safety standards are demanded, including the UAE, China, Taiwan, Canada, Mexico, and throughout Europe and South America. RSCC notes that it has qualified safety-related cables for more nuclear applications than any other company in the world. Per an article at www.world-nuclear.org, the existing cables had to be removed when authorities determined that falsified documentation had been provided for safety-related control cabling at four reactors. The Nuclear Safety and Security Commission (NSSC) ordered the plants closed until measures were taken that included replacing them with certified cables.

Prysmian wins Swiss rail contract for 2,800 km of signaling cable The Prysmian Group reports that it has been awarded a contract worth about US$32 million from SBB CFF FFS, a Swiss Federal Railways company, to upgrade railways infrastructure. A press release provided the following details. With 31,000 employees, 3,175 route km, more than 1 million passengers per day and 195,000 tonnes per day of freight transported each year, the Swiss Federal Railways is the largest travel and transport company in Switzerland. The cables for the upgrade will be manufactured in Germany and delivered as required through the end of 2019. The contract will be coordinated by the company’s team in Switzerland. “This award reflects customers’ trust in Prysmian’s capabilities to meet the increasing demand for the development of new infrastructures and to act as a single-stopshop where players from different industry segments can find the most viable solutions to their needs,” said John Chrupcala, director of BU Industrial at Prysmian Group. The new project, the release said, “confirms Prysmian’s technology and market leadership role in the sector of cables for the railway industry.”

U.K.’s oldest cable company sold to Canadian teachers’ pension fund Industrial turnaround specialist Melrose announced that it has sold Bridon, the oldest cable company based in England, to a Canadian pension fund for £365 million. A press release said that Bridon, whose roots can be traced back to a Doncaster rope maker in 1789, was sold to the Ontario Teachers’ Pension Plan. Melrose inherited the business when it bought engineering ﬁrm FKI in

12 | WIRE JOURNAL INTERNATIONAL

2008 for £900 million. “Bridon is an excellent example of the Melrose ‘buy, improve, sell’ model at work,” said Melrose executive Simon Peckham. “I think this is very good news for Bridon and for our customers,” said Bridon of American Corporation President Chris Dugan. “Teachers is a well-capitalized and well regarded company, and understands and supports Bridon’s strategy of technology leadership within wire rope, and will invest so we can continue to execute that strategy. Bridon’s leadership will remain intact, and we are eager to continue on our growth path.” Per its website, Bridon was consolidated in 1924 as British Ropes Limited and registered under the Bridon name in 1974. It was purchased by FKI in 1997, and classified as one of its five core businesses. The company was acquired by Melrose in 2008. The release said that Bridon has been hit by the global mining slowdown. Last year it reported sales of £266.4 million and profits of £34.1 million.

Initial okay given for deployment of sub-sea power cable from Norway to U.K. Initial approvals have been given for a project that calls for the deployment of a 730-km cable to carry up to 1,400 MW of hydro-power from Norway to the U.K.’s power grid. A report in ChronicleLive.com said that Northumberland Council’s planning committee approved plans for a sub-station and cables to be laid off the coast at Cambois and at land north east of East Sleekburn. The 730-km cable interconnector will be buried deep beneath the North Sea, it said, adding that “it is hoped over time renewable energy created from U.K. wind-farms could be sent back to the Scandinavian nation.” The project, the report said, to be ﬁnanced by the U.K. and Norwegian company Statnett, would help the U.K.’s National Grid “top up” its supplies of electricity by buying hydro-electricity to meet demand at peak times. The cable, called the NSN Link, will start off at land near the former Blyth Power Station site and will be buried underground until it meets a converter station on the coast. It will be buried in a trench in the North Sea, while new tunnels will be built on Northumberland’s coastline. The project still needs approval from the Marine Maritime Organisation for a license to install the subsea cables.

U.S.-based General Cable announced that it will provide cable for the Cincinnati Streetcar, an Ohio project in its ﬁrst phase of development that ultimately will provide

General Cable will supply cable for the Cincinnati Streetcar project in Ohio. the downtown and uptown areas of Cincinnati with 3.6 miles of track connecting key businesses and locations. A press release said that the project will offer daily transportation services 18 hours a day, from ﬁve streetcars that each have the capacity to hold up to 150

people. General Cable’s Polyrad® XT Transit wire and cable will provide the internal wiring throughout each vehicle, it said. The project, the release said, has a home ﬁeld advantage for General Cable as its headquarters are in the greater Cincinnati area. The company has been involved in many of the city’s renovation projects, such as Paul Brown Stadium, the National Underground Railroad Freedom Center, Great American Ballpark and the Cincinnati Zoo. The Cincinnati Streetcar project “is on-track to revitalize and connect communities throughout Cincinnati and beyond, promoting job growth, development and more livable communities,” it said. “Much like the Cincinnati Streetcar project, General Cable is dedicated to connecting and powering people’s lives with products that are a critical part of both local and global infrastructure.” “Energy and transportation infrastructure are vital to Cincinnati’s future, and are vital to General Cable,” said Robert W. Schuermann, General Cable’s North American vice president and general manager of specialty cables. “Being a part of a growing Cincinnati is important to us, as General Cable takes pride in knowing that our transit cable will be an integral part of this project — improving infrastructure and strengthening its economy.”

NOVEMBER 2014 | 13

INDUSTRY NEWS

General Cable along for the ride on the Cincinnati Streetcar in Ohio

INDUSTRY NEWS

General Cable reports winning award for supplying overhead conductor U.S.-based General Cable reports that it has been awarded a contract by Basin Electric Power Cooperative (Basin Electric) to supply overhead conductor for a new 345 kV transmission line in northwestern North Dakota. A press release said that the Antelope Valley Station contract, valued at $10 million, is from the Basin Electric Power Cooperative (Basin Electric), one of the largest electric generation and transmission (G&T) cooperatives in the United States. The project calls for approximately 200 miles of single circuit 345 kV and double circuit 345/115 kV transmission lines that are intended to increase capacity and enhance reliability and system stability for the region. General Cable will provide its 2312 kcmil Thrasher ACSR (Aluminum Conductor Steel Reinforced) for the project, which entails running from the Antelope Valley Station to substations near Grassy Butte and Williston, ending at the Neset substation near Tioga.

Saarstahl AG to invest US$38 million to modernize wire rod mill in Saarland Germany’s Saarstahl AG reports at its website that the company will investing approximately US$38 million for a complete upgrade of its wire rod mill at its Neunkirchen plant in Saarland, one of Germany’s 16 federal states. The company reported that the modernization of wire rod train 32 includes the latest rolling and cooling technologies. The project includes the complete recon-

Saarstahl AG will invest approximately US$38 million for a complete upgrade of its wire rod mill at its Neunkirchen plant in Saarland. struction of the high-speed section to both increase ﬁnal rolling speeds, further improvements in quality characteristics such as strength and uniformity of the microstructure, and rolling of wire with the greatest precision. The construction work will begin at the end 14 | WIRE JOURNAL INTERNATIONAL

of 2015 and will take place while production is running. Commissioning of the new rolling mill train is planned for the middle of 2016. “With this investment, we are securing our market share in the premium quality sectors for our customers in the automotive industry and mechanical engineering and are consistently pursuing our forward-looking strategy,” CEO Dr. Karlheinz Blessing said. The investment was approved by the company’s supervisory board at a Sept. 25 meeting. “After the investments which have already been decided in the rolling mills in Völklingen and in Saarbrücken/Burbach, in this year alone, the company has now initiated investments of around 80 million euro for the modernization of its facilities,” it said. The report said that the high-performance mill train 32, which has an annual capacity of almost 600,000 metric tons and which celebrated the 50th anniversary of its existence last year, produces cold-heading grades, spring steel and free-cutting steels.

Google part of consortium to deploy fiber optic cable linking Brazil and U.S. Google is part of a consortium planning to deploy a massive undersea fiber optic cable linking Brazil to the U.S. to improve Latin America’s internet infrastructure. Media reports said that the project, awarded to TE Connectivity SubCom, calls for the new cable to span 10,556 km, linking the Brazilian cities of Santos and Fortaleza with Boca Ratón in Florida. The cable will have six fiber pairs, with overall system design capacity of 64 Tbps, which will be a boon for Brazil as the country’s current internet speed currently lags behind the rest of the world. Per Valor, a Brazilian newspaper, the project, scheduled for completion in late 2016, will cost about $60 million. The reports said that the consortium also includes Uruguay government-owned telco Antel, Brazilian firm Algar Telecom and African operator Angola Cables, the latter of which had been trying to build another submarine link between Brazil and Angola that never went ahead. As a sidenote, an article by Angelica Mari in Brazil Tech/ ZDNet said that earlier this year, Brazilian President Dilma Rousseff put pressure on the European Union to build an undersea link directly to Europe to bypass the U.S. following the news that the National Security Agency had been spying on top officials, including Rousseff herself. The concept, the article said, had been desired for years, but it was not till a month after Dilma addressed a EU Commission conference that Brazilian state-owned telecom provider Telebras and Spain’s IslaLink Submarine Cables announced that the construction of the Europe-Brazil fiber optic link would go ahead. The $185 million project will link Portugal to the city of Fortaleza in the northeast of Brazil and is expected to complete within similar timescales to the Google-led U.S.Brazil link.

BT claims fiber-copper system delivered speeds of up to 1 gigabit per second

Nexans North America reports that the company is investing $15 million into expanding production at its Canadian facility in Fergus, Ontario, an action that will allow the relocation of its distribution facility in Milton, Ontario. A press release said that the expansion adds capacity in the Fergus plant as well as streamlines logistics, “thereby enhancing capabilities.” The expanded area, about 140,000 sq ft, will “include several upgrades to our logistical technology and manufacturing processes.” Signiﬁcant sums, it said, “will go into new equipment to increase our capacity in the manufacturing of low-voltage residential, commercial and industrial cables.” Those three core Fergus facility products service the Canadian, U.S. and export markets, it said. “This investment helps us to provide the level of service all customers expect, and deserve,” said Dave Hawker, vice president and general manager, Energy Division, North America. “We are focused on improving our turnaround time, order ﬁll rate as well as the other value-added services we offer, such as parallel reels, pulling eyes and custom cutting lengths.”

British Telecom (BT) reports that its research has proved that G.FAST technology can provide “ultrafast modern broadband” via a mix of fiber and copper cabletechnology. A press release said that researchers were able to see combined downstream and upstream speeds of up to one gigabit per second (1000 Mbps), a rate that it observed was not believed possible with a system that included copper cables for the last leg. Making fiber the last step for an internet connection was an “expensive, disruptive and time consuming process” that may not be necessary, it said. BT said that most of its customers are supplied by Fiber to the Premises (FTTP), an expensive method where high speed cable is laid all the way to where it is needed, and Fiber to the Cabinet (FTTC), where comparatively lengthy old-school copper connections link a fiber-connected exchange to a home or business. During the G.FAST trials, the release said, researchers achieved downstream speeds of around 800Mbps over a 19m length of copper and upstream speeds of more than 200Mbps. Speeds of around 700/200Mbps were also achieved over longer 66 m lines. BT is now planning to

NOVEMBER 2014 | 15

INDUSTRY NEWS

Nexans to expand Ontario plant, will relocate a distribution facility

INDUSTRY NEWS

study the technology at a new ultrafast broadband lab at its Adastral Park R&D center in Ipswich. “We see G.FAST as a very promising technology with significant potential. That’s why we’re putting some of our best minds on the case to assess it fully in a purpose-built facility,” said Dr. Tim Whitley, MD of Research and Innovation, BT Group said.

Keystone to upgrade Bartonville mill U.S.-based Keystone Steel and Wire Company has placed an order with Siemens Metals Technologies to upgrade the cooling conveyors of a two-strand wire rod mill in its plant in Bartonville, Illinois. The project, a press release said, includes new blowers, auxiliary systems as well as electric and automation equipment. The upgrade will enable Keystone to produce steel grades with higher tensile strengths with improved and more uniform quality, thus extending their product range, it said, adding that the new equipment is expected to be commissioned in late 2014.

Bangalore’s Suprajit Engineering reports it is acquiring Speedo Cable Suprajit Engineering, an automotive cable maker based in Bangalore, is acquiring the Speedo Cable business from India’s Pricol Limited, for an undisclosed amount. Multiple media reports said that the acquisition is being made on a “slump sale basis,” and that the company would relocate the plant and machinery from Pricol’s plant to one of its facilities in Bangalore. In addition to the speedometer cables, Pricol manufactures products such as speedometer cables, oil pumps, disc brakes, sensors, industrial gauges, vehicle security systems, etc. The Speedo Cable business was part of the non-core business of Pricol whereas it will be a key addition for Suprajit, which makes a wide variety of control cables. Suprajit has 13 manufacturing units, and the capacity to make 150 million cables for OEM and replacement segments. The company also has plans to set up a new plant in Tamil Nadu that would take its capacity to 210 million cables. It clientele include TVS Motors, Ashok Leyland, TAFE, Hyundai and Ford, among others.

UAE reports that it ranks among top 5 copper cable exporters

A report issued from the UAE’s Ministry of Economy places the country among the top five global exporters of copper cables, with copper cable exports contributing an estimated US$1 billion trade surplus. A story in Emirates 24/7 said that the value of the UAE copper cable exports grew by 102% to U.S. $1.325 billion in 2013, with export volume rising from 80,000 metric tons in 2012 to 174,000 metric tons last year (119%). Sales to one country, Saudi Arabia, accounts for 65% of the copper cable exports, it said, noting that such sales were valued at

16 | WIRE JOURNAL INTERNATIONAL

$835 million. It added that overall GCC countries collectively accounted for 75% of the UAE’s copper cable exports. Subtracting $397 million in cable imports results in a copper cable trade surplus of $923 million in 2013, it said. Ducab was singled out in the Emirates 24/7 story as being one of the most important UAE companies involved in the manufacture of copper products, including cables and wires. The report states that Ducab’s production capacity exceeded 110,000 metric tons of high quality copper products that were exported to more than 20 countries worldwide. The story cited global copper cable exports as being valued at $20.9 billion in 2013, up 4% from 2012. Russia topped the list with 14% of the market, $2.941 billion, followed by Germany, 13%, $2.718 billion; Belgium, third at $1.49 billion, and the U.S. fourth at $1.33 billion. The UAE, with a 6.3% share, $1.325 billion, came in fifth.

HELUKABEL opens office in Austria

HELUKABEL reports that it has expanded its global footprint by opening HELUKABEL Austria, which recently opened its sales office in St. Florian, just south of Linz. A press release said that the latest international affiliate, the company’s 24th, further supports the cable manufacturer’s strategy “to provide its customers with global one-stopshop capabilities for cable and wire.” Located not far from the global headquarters in Germany, HELUKABEL Austria will receive product distribution and logistics support from the automated, state-of-the-art warehouse in Hemmingen, near Stuttgart. Further, a permanent sales and distribution facility within Austria is expected in a few years, it said, adding that the new location will be overseen by Manfred Breurather, a 24-year industry veteran.

WCMA annual meeting/lunch to be held Dec. 4 in a new location

The Wire & Cable Manufacturers’ Alliance (WCMA) will hold its annual meeting and holiday luncheon on Thursday, Dec. 8, at a new location in downtown Hartford. A press release said that the event will be held at the top floor of the Hilton Homewood Suites Hotel, 338 Asylum Street. Doors open at 11:30 am with a networking and social hour. The WCMA annual member meeting will take place during lunch, with an industry presentation and announcement of the 2015 Distinguished Career Award recipients to follow. Attendees are also encouraged to support the U.S. Marines Corps Toys for Tots program by bringing an unwrapped toy or game (for ages 2-12) or write a check for any amount made out to “Toys for Tots.” Tickets are $75 a person ($95 after Nov. 24) for corporate member companies and their guests; $37 for a first-time attendee accompanied by a corporate member (limit two per company); and $95 per person for non-members. The registration form can be accessed for faxing at www.wcmainc.org. Contact WCMA Executive Director Deb Mathiasen at tel. 860-873-2311, mrcdm@ snet.net.

ASIAN FOCUS

ASIAN FOCUS Vietnam: with 93 million people, it can use a few more internet cables

somewhere between Hong Kong and Vietnam and was undergoing repairs. It cited authorities as saying that dragging local ships along the Vietnam shoreline were A recent article by Anh-Minh Do that ran in multiple responsible for the break. The possibility was also publications posed a bandwidth-heavy question: will raised that the problem was related to the cable design. Vietnam ever take its internet seriously? An article posted at www.therakyatpost.com cited “This week, and not for the first time, one of Nguyen Van Khoa, director general at FPT Telecom, a Vietnam’s major internet cables was cut by accident,” major Internet service provider in Vietnam, as saying the author wrote. “That’s in a country with only five that “the AAG cable system was built to a below-staninternet cables and over 93 million people. By contrast, dard technical design, which is the major reason Singapore, a country of just over five million people, behind its frequent fractures.” has 21 internet sea cables connecting it to the world. Do observed that the latest outage must have caused millions of dollars in losses in productivity for Vietnamese businesses across the country. “This is especially impactful for companies that depend on a strong internet line to keep in touch with business partners abroad. But it also impacts everybody in Vietnam with an internet connection. In other words, everybody’s counting minutes while their YouTube videos load.” Other issues were also raised by Do. “The central issue here is what companies like VNPT, the second biggest telco in Vietnam that manages the AAG cable, are doing about it? For a country about to enter the Trans-Pacific Partnership that is desperate for foreign direct investment and eager to be seen as a technology hub, basic needs like An Internet cable is placed undersea off Vietnam coast. Photo by internet need to be addressed. VNPT Tien Phong. is a major corporation with US$5.5 billion of revenue in 2013. It is one of This is ridiculous. This is at least the third time that Vietnam’s most important technology-related compaan internet cable has been cut in Vietnam. Last time, it nies, but it can’t even keep its cables from being cut, caused the internet to slow down to a near halt for an or at least develop contracts to build more. If Vietnam entire week before returning to normal.” can’t get basic things like internet together, how can it Per an online report in ThanhneinNews.com, internet be taken seriously? And you can forget about 4G. That service to Vietnam has long been challenging. The won’t be coming to Vietnam until 2015, at the earliest. 20,000-km Asia American Gateway (AAG) cable– which provides most international connections for Report: India’s telecom cable market local providers like FPT Telecom, VNPT and Viettel– should top US$354 million by 2019 has broken or been shut down for maintenance on several occasions since 2011. Last December, it broke “India Telecom Cable Market Forecast & at a section between the southern beach town of Vung Opportunities, 2019,” a recently published report by Tau and Hong Kong, leaving Internet connections in TechSci Research, projects that the country’s telecom Vietnam shaky for two weeks. AAG, which represents cable market, fueled by rural growth, should reach an investment of US$560 million, is the only cable US$354.23 million by 2019. connecting Southeast Asia with the U.S., with landA press release from the research-based global maning stations in the continental U.S., Hawaii, Guam, agement consulting firm cited the following about its the Philippines, Hong Kong, Malaysia, Singapore, projections. A growing number of telecom subscribers, Thailand, Brunei, and Vietnam. growing penetration of smartphones and rising demand More recently, an article in Kicker Daily News for high-speed data transmission are the major facreported that an AAG cable was breached on Sept. 15 tors propelling the demand for telecom cables in the

18 | WIRE JOURNAL INTERNATIONAL

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The Government of India is planning to connect 250,000 small government assemblies in various parts of the country to their respective district blocks for streamlining various sectors such as healthcare, education, etc. This is expected to drive the adoption of telecom cables in rural India on the back of rising number of mobile subscribers. In addition, projects like Network for Spectrum (NFS) being implemented by the Indian Army and Indian Navy are also expected to fuel the market for telecom cables in the country. In addition, the expected 4G rollout would further propel the demand for telecom cables in the country. Considering these opportunities, telecom operators are also eyeing to expand their penetration level in rural areas over the forecast period. “Increasing penetration of telecom services in rural India has emerged as the major growth driver for the Indian telecom cable market,” said TechSci Research Director Karan Chechi. “Teledensity in India is increasing continuously due to the growing demand for high-speed internet services, which cannot be catered by traditional copper cable network. ... (The) ﬁber optic cable market is expected to gain a lion’s share in India’s telecom cable market.” The report, which evaluates the future growth potential of the telecom cable market in India, provides statistics and information on market structure, market trends, market size and share, as well as market projections and demand forecasting and is intended to provide cutting-edge market intelligence and help decision makers take sound investment evaluation. It also identiﬁes and analyzes emerging trends along with essential drivers, challenges and opportunities available. For more details, go to www. TechSciResearch. n

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ASIAN FOCUS

country. With increasing data trafﬁc, expansion of telecom infrastructure has become inevitable, thereby spurring the market for telecom cables. In 2013, advanced optical ﬁber cables that are designed for high-speed data transfer dominated the market, holding over a 50% market share in value terms. The segment is expected to continue dominating through the forecast period due to rising demand for high-speed Internet on the go.

ASIAN FOCUS

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PEOPLE

PEOPLE Jason Wolken has joined T & T Marketing, Inc., as a Southwest Account Manager, with U.S. sales territory including Texas, Louisiana, Alabama, Mississippi, Arkansas, Oklahoma, Tennessee and southern Kansas. He has 17 years of experience in sales, marketing, business development, and program management. He most recently served as marketing business development manager at Intertape Wolken Polymer Group. Based in Allamuchy, New Jersey, USA, T & T Marketing, Inc., supplies a wide range of products to the wire and cable industry. WAGO has promoted Jesse Cox from regional sales manager for Oregon, Washington and Idaho to the ﬁeld applications engineer for the Paciﬁc Northwest region. He previously held positions in application support and sales at Platt Electric and Kinetic solutions. The company also promoted Eric Langhorst from regional sales manager for Colorado and Montana, to zone manager for

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the western U.S. region. He joined the company 10 years ago and previously worked in management and sales at Graybar, Indio and DST Controls. Based in Germantown, Wisconsin, USA, WAGO supplies spring pressure connection technology. The International Wire & Cable Symposium (IWCS) has named Dave Kiddoo as its new CEO. The Global Business Manager for AlphaGary, he has long been a key volunteer for IWCS, serving on its board of directors. His career began in 1981 in sales and marketing with DuPont Company, where he spent 11 year before joining Ausimont USA, for nearly two years before he joined Kiddoo AlphaGary Corporation in 1994. He holds an engineering degree from Bucknell University and has been very active over the years with trade organizations and advisory bodies. He replaces John Barteld, who is retiring after serving the organization since 2004. See p. 49 for his parting thoughts. Founded in 1987, IWCS stages an annual technical symposium, with tabletop exhibits, for wire and cable products, materials, applications and processes.

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10/6/14 3:22:21 PM

FIBER WATCH

FIBER WATCH Plans call for Indonesian JV to build fiber optic cable route along toll roads State-controlled Telekomunikasi Indonesia, the biggest telecommunication company in the country, plans to set up a joint venture with state-toll road operator Jasa Marga to build fiber-optic cables along the toll roads Jasa Marga operates. An article in The Jakarta Globe cites Telkom Chief Executive Arief Yahya as saying that the goal is to establish the joint venture by the end of 2014. The deal, not finalized but under discussion, calls for the joint venture to be equally owned by Telkom and Jasa Marga, he said. The plans call for the laying of roughly 400 km of fiber-optic cables during the first phase of construction, expected to take around one year to complete, Yahya said in the article. The project, once approved, would be capitalized with an initial investment of US$8.2 million. Jasa Marga has been scouting land in the Greater Jakarta area—including Bogor, Depok, Tangerang and Bekasi—to

22 | WIRE JOURNAL INTERNATIONAL

erect ofﬁce buildings, hotels and other real estate interests. The company hopes to use access to the toll roads it operates as leverage in its real estate deals. Arief said that the company plans to acquire satellite companies based in Hong Kong and Singapore. He declined to disclose names of the companies.

Slow fiber speeds reported in U.K. A report from Ofcom, a U.K. telecom watchdog, said that in the six months to May 2014, fiber broadband packages saw a decrease of nearly 1 Mbps, from 42.9 Mbps to 42 Mbps. An online report in thenextweb.com observed that cable broadband services, primarily provided by Virgin Media in the U.K., increased by 3.1 Mbps to 43.3 Mbps, overtaking fiber for the first time. Ofcom said much of the increase was due to the uptake of higher speed packages. “While on the surface of it, it’s not great news for fiber subscribers as it suggests services are becoming more congested, it’s also worth noting that as well as a small decrease in speed, an increase in the number of customers taking ‘up to 38 Mbps’ packages (rather than up to 78 Mbps options) also contributed to the dip in speeds,” the story said. Overall across the U.K., the average broadband speed increased by about 5% to 18.7 Mbps.

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FASTENER UPDATE

FASTENER UPDATE Fastenal acquires Av-Tech assets The Fastenal Company announced that it has acquired certain assets of Av-Tech Industries, a wholesale distributor of aerospace fasteners, electronic components, and miscellaneous aircraft parts. “We feel there is a strong opportunity for our company to continue to grow within the aerospace market,” Fastenal President Lee Hein said in a press release. “Av-Tech Industries will be a great asset in that mission and a great fit for the Fastenal team, sharing the same core values, commitment to quality, and culture of customer service.” Per the release, Av-Tech Industries, founded in 1987 in Arlington, Texas, specializes in the sourcing, distribution and fulfillment of off-the-shelf and hard to find products. The company services a wide range of customers in industries including aerospace, aviation, aircraft repair, air conditioning, automotive, window manufacturing and other commercial concerns. Av-Tech Industries’ quality systems are certified to ISO 9001:2008, AS9120 Rev. A, and Advisory Circular AC 00-56A, and compliant to MIL-I-45208A. Fastenal operates some 2,700 stores located primarily in North America with additional locations in Asia, Europe, Central and South America, and Africa. The company has 14 distribution centers in the U.S., Canada and Mexico.

24 | WIRE JOURNAL INTERNATIONAL

Threaded Fasteners opens new headquarters/distribution center Alabama’s Threaded Fasteners, Inc., recently opened its new corporate headquarters and national distribution center in Crichton. A press release said that the renovated 81,000-sq-ft warehouse, on 4.5 acres, was purchased for an undisclosed sum in 2013. The company has been operating from St. Louis St. for more than 30 years, but the new facility will also store much of the company’s inventory in a sophisticated pallet rack system where it will be ready for prompt shipment to the company’s multiple branches or directly to customers nationwide and internationally, it said. Threaded Fasteners also operates branches in Gulfport, Mississippi; Pensacola, Panama City and Tampa, Florida; Tulsa, Oklahoma; and its 60,000-sq-ft manufacturing facility in Semmes, Alabama. “Our company has been a fixture in Mobile since 1979, because of the investment and vision of its founders, Frank Martin and Steve Sholtis. Their vision to become a leader in fastener supply to the industrial market of Mobile and surrounding area has expanded exponentially now to include five branch locations in other states,” Threaded Fasteners President Billy Duren said in a prepared statement.

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CHAPTER CORNER

CHAPTER CORNER The ‘Vannais’ tourney results in 3-way tie for first

There was no lack of winners among the 106 participants at the Southeast Chapter’s 13th Annual Golf Outing, held Oct. 2 at the Jones Course at Rock Barn Golf and Spa in Conover, North Carolina. On a day roundly declared by Chapter President Art Deming to be “near perfect,” three teams tied for first with a 56, the winners determined by comparing score cards. Carding “first” was the team of Tim O’Haren, TSM Controls; and Delton Smith, Jason Watts and Danny Crouse, all “The Vannais” Leaves 3 Groups Tied For First and A Large Donation to their Scholarship Fu of Prysmian; second went to Scott Fields, There was something lucky about 13 for the Southeast Chapter as enjoyed a near perfect da Ron Burchfield th Chapter’s Annual Golf Outing on October 2. and Tim13 Poore, Southwire; and According to Art Deming, the WAI Southeast Chapter Board received resounding favorable r Andy Carden, this year’s outing asFrom the course was in near group perfectofconditions. “Timing Alabama l-r, the winning Jason Watts, Tim has everything to do While we have typically produced the event in late October, the Board Power; O’Haren, Delton Smith and Danny Crouse alongdecided to move the early the month, with partially because of availability and to try our luck with the weather,” sa and in third Chapter President Art Deming. Their wentinstincts to Jay paid off as the temperature was in the high 70s as the tournament’s shot gun 1:00p.m. Swetenburg, Sonoco Plastics; Donnie Floyd and Jeff Rudisill, both of CommScope; and Brian Berry, Progress Container. The proceeds of the tournament, named after the late Steve Vannais, a devoted chapter member, go to the chapter’s scholarship program.

From l-r, chapter board directors Jim Perdue Southwire; Chris McGill, ABB; Brooke Stonesifer, Sonoco; Tim McElhany, Tulsa Power; Woody Holland, Clinton Instruments; Art Deming, Nexans; Mike Kos, CNA; and John Dognazzi, Sikora. left to right, Jim Perdue Southwire; Chris McGill Prysmian, Br SE Chapter Board of Directors,

Stonesifer Sonoco, Tim McElhany Tulsa Power, Woody Holland Clinton Instruments, Art Dem Before Deming reminded Mike Kosplay CNA,started, and John Dognazzi Sikora. the golfers how much time and

energy Vannais had contributed to the event and there was a moment of silence. Among those in attendance was Steve’s son, Eric, who continues to volunteer his time to the event.

26 | WIRE JOURNAL INTERNATIONAL

The tournament was again held at the Jones Course at Rock Barn Golf and Spa in Conover, N Carolina. The course was in exceptional condition as Jack Fleissner PGA, Head Golf Professio team were to host of the Champions Tour Greater Hickory Kia Classic later in the month.

CHAPTER CORNER

CHAPTER CORNER Putting Contest winner Sean Whitelavich, Henderson Sales & Service, ﬂanked by Chapter Treasurer Mike Kos (left) and Chapter President Art Deming (right). Deming also thanked all the sponsors who made the day possible. Specialty Sponsors included 360 Control Technologies, Beta LaserMike, Carris Reels, Commission Brokers, DuPont, Henderson Sales & Service, J.J. Lowe Associates, Maillefer, The Okonite Company, Sikora, Sonoco Plastics, Sonoco Reels, Southwire, Standridge Color & Compounding, Technical Development Corp, Teknikor Contracting, Tulsa Power, W. Gillies Technologies, Wire & Plastic Machinery. Hole sponsors included American Kuhne, Axjo/ Windak, Chase Neptco, Clinton Instruments, DavisStandard, Gem Gravure, Guill Tool, Haynes Wire Company, J.J. Lowe Associates, Joe Snee Associates, Keir Manufacturing, Lloyd & Bouvier, Niehoff, P & R Specialty, Process Controls, Quality Machinery & Services, Rosendahl Nextrom, Sonoco Reels, Southwire, T & T Marketing, Teknikor Contracting, Wire & Plastic Machinery.

Entertainment troupe to perform at New England Chapter annual meeting You can expect a double heaping of wit and satire when the New England Chapter’s annual meeting is held Jan. 29, 2015, at the Mohegan Sun Resort Conference Center, where a troupe from Brickroad Productions will entertain attendees. The event will see the introduction of new ofﬁcers as well as camaraderie at its best. For more about the troupe, which is known for its irreverence and interaction with the audience, go to the company’s site at www.brickroadproductions.net. To register, contact WAI’s Anna Bzowski at tel. 203-453- 2777, ext. 126, abzowski@wirenet.org.  JUNE 2014 | 27

WAI NEWS

WAI Nov. 2014

MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Jeﬀ Terrell Business Development Engineer Sikora International Corporation

Q: What does your company do? A: SIKORA AG is a leading global manufacturer and supplier of measuring and control technology for the wire and cable as well as hose and tube industry. Q: What is your role there? A: I manage the Southeast and West coast of the United States in technical sales and engineering. I present various measuring and monitoring technologies to my customer to find solutions for their measuring needs. Q: What do you like best about your position? A: I enjoy working within a team of passionate and creative people at Sikora. The innovative technologies we can offer customers allows us to quickly solve their issues. Sikora stands behind the statement “Technology to Perfection.” One example of this is how all of our laser and x-ray instruments need no calibration. Q: How has the industry most changed? A: Tighter control of material usage and eliminating startup scrap has always been a focus but now there is even more emphasis on data collection and statistical processing. Sikora delivers in all areas. Q: How does your company remain competitive? A: The quality and accuracy of our measuring devices deliver added economic value to our customers. Customers have been telling me how great our service department and service engineers are. Also, our R&D group is continually working to develop new devices to expand our customers’ ability to improve their product quality. Our Purity Scanner system ensures the purity of plastic pellets with x-ray and optical verification. Our customers are saving approximately 1.5 million barrels of crude oil per year using SIKORA technology. Q: Why did you recently join WAI? A: I recently started with Sikora, a longtime supporter of WAI. I was quickly encouraged to join the Wire Association to stay informed and connected with what is happening in the wire and cable industry.

28 | WIRE JOURNAL INTERNATIONAL

Fermin Loayza Sup Engr Gem Gravure Co Inc

Johnny Frederick Fld Srv Tech Gem Gravure Co Inc

Mike Pichierri Fld Srv Tech Gem Gravure Co Inc

Michael Haggerty Fld Srv Tech Gem Gravure Co Inc

Jeff Terrell Bus Dvlp Engr Sikora International Corporation

Jason Hicks Fld Srv Tech Gem Gravure Co Inc Rathnakumara K Kemmara QA Mgr Venus Wire Industries Ltd

J Clifton Vandenburg Fld Srv Tech Gem Gravure Co Inc Richard Lee Wofford Proc Engr Bekaert

WAI Platinum Membership Companies 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.

NOVEMBER 2014 | 29

WAI NEWS

Joshua Blunk Tech Sup Engr Gem Gravure Co Inc

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

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

CONVENTION: APRIL 27-30, 2015

EXPOSITION: APRIL 28-30, 2015

A meeting this productive shows up every other year. Georgia World Congress Center | Atlanta, Georgia, USA

Industry leaders are following www.Interwire15.com for details on the largest wire and cable meeting place and marketplace in the Americas. Decidedly the most valuable use of your time...until 2017. Wire & Cable Making Machinery | Live Demonstrations | Supplies & Equipment | New Trends & Products | Global Networking | Educational Focus: Dust Control, Raw Materials, Processing, Applications, Recruiting & Retention, Manufacturing Workshop | Plant Tour: Southwire SCR | Also with WAI’s 2nd Global Continuous Casting Forum

Corporate SponSorS: PLATINUM | Sonoco ReelS and SpoolS • WiRe & plaStic MachineRy coRp. SILVER | caRRiS ReelS inc. • GeM GRavuRe co. inc. • nexanS • SikoRa inteRnational coRp. BRONZE | RichaRdSapex inc. Supporting SponSorS:BauM’S caStoRine co. • cheMSon • coMMiSSion BRokeRS inc. • heRitaGe WiRe die • lloyd & BouvieR inc. The Wire Association International, Inc. | Telephone: (001) 203-453-2777 | www.wirenet.org

PARTICIPATING EXHIBITORS A. Appiani Srl Ace Metal Inc. ADVARIS GmbH Agape Industry Inc. AIM Inc. All Forming Machinery Inc. Allied Mineral Products Amacoil Inc. American & Efird Inc. American Kuhne Inc. Anbao Wire & Mesh Co. Ltd. Assomac Machines Ltd. AW Machinery LLC Axjo America Inc. Aztech Lubricants LLC B & H Tool Co. Inc. B & Z Galvanized Wire Ind. Balloffet Die Corp. Baum’s Castorine Co. Inc. Bechem Lubrication Technology LLC Beijing Orient PengSheng Tech Co. Ltd. Bekaert Bergandi Machinery Co. Beta LaserMike/NDC Technologies Beta Steel Blachford Corp. BLM Group USA Corp. Bloom Engineering Co. Inc. Boockmann GmbH/The Slover Group Bow Technology Breen Color Concentrates Inc. Brookfield Wire Co. Buhler-Wurz Kaltwalztechnik GmbH Butt Welders USA Caballe SA Cable Consultants Corp. Cable Services & Systems Calmec Precision Inc. Candor Sweden AB Canterbury Engineering Co. Inc. Carris Reels Inc. Ceeco Bartell Products, Bartell Machinery Systems Cemanco LC Central Wire Industries Ltd. Ceramtech CERSA-MCI Chase Wire & Cable Materials Chemetall Chengdu Centran Industrial Co. Ltd. Cimteq Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc CMEC International Exhibition Ltd. CN Wire Corp. Collins & Jewell Co. Inc. Cometo Commission Brokers Inc. Condat Condat Lubricants Conneaut Industries Inc. Continuus-Properzi SpA Custom Machining & Fabrications LLC Daloo Davis-Standard LLC Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. EJP Maschinen GmbH Electron Beam Technologies Inc. EMSCO Enercon Industries Engineered Machinery Group Inc. Enkotec Co. Inc. Er-Bakir ERA Wire Inc. Ernst Koch Esteves Group USA Etna Products Inc.

Eurobend SA Eurolls Group Srl Eurowire Magazine George Evans Corp. EVG Inc. Evolution Products Fabritex Inc. Fastener Engineers - Lewis Machine Fenn LLC FIB Fil-Tec Inc. Filtertech Inc. Fine International Corp. Finoptics Inc Fisk Alloy Wire Inc. Flymca & Flyro FMS USA Inc. Foerster Instruments Inc. Fort Wayne Wire Die Inc. Fortune Machinery Fridea Srl Frigeco USA Inc./ MFL USA Service Corp. Frigerio USA Frontier Composites & Castings Inc. FSP-One Fuhr GmbH & Co. Kg Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co Inc. Genca W. Gillies Technologies LLC GIMAX srl GMP Slovakia s.r.o Granite Falls Furnace Guill Tool & Engineering Co. Hafner & Krullmann GmbH Hangzhou JR Exhibition Co. Ltd. Heany Industries Inc. Heatbath Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. HFSAB H Folke Sandelin AB Holland Colours Americas Inc. Houghton International Inc. Howar Equipment Inc. Huestis Industrial Huttner Maschinenfabrik ICE Wire Line Equipment Inc. IDEAL Welding Systems INFLEX Inc INHOL LLC InnoVites Inosym Interequip SA International Wire & Cable Machinery Association Isotek Corp. IW/Bare Wire Division IW/High Performance Conductors IWE Spools & Handling GmbH IWG High Performance Conductors Inc. Joe Snee Associates, Inc. Joe-Tools Jouhsen-Bundgens Inc. Kablosan Turkey-FBC Yayincilik Ltd. sti Kalmark Intergrated Systems Ltd. KEIR Manufacturing Inc. Keystone Steel & Wire Co. Kieselstein GmbH King Steel Corp. Kinrei of America KMK Lamnea Bruk AB Kopilowitz Engineering Ltd LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. Lesmo Machinery America Inc. Lloyd & Bouvier Inc. Lubrimetal Corp. LUKAS Anlagenbau GmbH

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M+E Madison Steel Inc. Magnetic Technologies Ltd. Maillefer Extrusion Oy Mario Frigerio SpA Mathiasen Machinery Inc. Messe Düsseldorf North America Metal Resource Solutions Inc. Metalloid Corp. Metallurgical Council of China MFL USA Service Corp. MGS Manufacturing Inc. Micro Products Co. Microdia USA Mid-South Wire Morgan-Koch Corp. Mossberg Associates Inc. Mossberg Industries Inc. Neptco Nextrom OY Niagara Composites Int’l.Inc. Niehoff Endex North America Inc. Maschinenfabrik NIEHOFF GmbH & Co KG Nimsco LLC / SB2C Numalliance North America Inc. Oklahoma Steel & Wire OMCG North America Inc. OM Lesmo Otomec Srl Ozyasar Tel Ve Galvanizleme P & R Specialty Inc. Paramount Die Co. Parkway-Kew Corp. Troester Maschinenfabrik GmbH & Co. KG Pentre Group Ltd.-Hearl Heaton Phifer Wire Inc. Pioneer USA Pittsfield Plastics Eng. Inc. PKG Equipment Inc. Plas-Ties Co. Plastic Equip LLC Plasticolor Plymouth Wire Reels & Dies Inc. Pneumatic Power Tool & Co. Polytec Inc. Pourtier Pourtier & Setic of America Precision Die Technologies Inc. Premier Wire Die PrintSafe Process Control Corp. Progressive Machinery Inc. Promostar srl Properzi International Inc. Proton Products PWM QED Wire Lines Inc. Queins Machines GmbH Raajratna Stainless Wire Inc. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reber Systematic GmbH + Co KG REDEX Reel-O-Matic Inc. Refractron Technologies Corp. RichardsApex Inc. Rizzardi Rockford Manufacturing Group Inc. Roloil Rosendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. RSD Group USA RTD Manufacturing S&E Specialty Polymers Saint-Gobain SAMP SpA SAMP USA Inc.

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WAI Platinum Member webinar provided unique perspectives on electrical sector WAI NEWS

WAI NEWS

PARTICIPATING EXHIBITORS (cont’d) SAMPSISTEMI Sarkuysan SA Schlatter Inc. Schmidt Maschinenbau GmbH Scienscope International Setic Shanghai Pudong International Exhibition Co. Sikora International Corp. SIMPACKS Sirio Wire Sivaco Wire Group Sjogren Industries Inc. SKET Verseilmaschinenbau GmbH Sonoco Reels Spirka Schnellflechter GmbH STAKU- Anlagenbau Starrett-Bytewise Measurement Systems Stolberger Inc DBA Wardwell Braiding August Strecker GmbH & Co KG Subec AB Sudhir Enterprises Sylvin Technologies Inc. T & T Marketing Inc. Talledega Castings & Machine Co. Tantec Est Inc. Tapeformers Ltd. Taubensee Steel & Wire Co. Taymer International Inc. Tecnofil SA Teknikor Teknor Apex Tensor Machinery Ltd. Tien Chen Diamond Industry Co.Ltd. Tramev Traxit North America LLC Tubular Products Co. Tulsa Power Inc. United Wire Co. Inc. UPCAST OY Vandor Corp. VINSTON US Corp. Vollmer America Inc. Vom Hagen & Funke GmbH W3 Ultrasonics LLC WAFIOS Machinery Corp. WCISA / Wire Forming Technology International Weber & Scher Mfg. Co. Inc. Welding Wire Machineries Windak Inc. Wire & Cable Technology International Wire & Plastic Machinery Corp. Wire Association International, Inc. Wire Journal International Wire Lab Co. Wire Machine Systems (WMS) Wire World WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. Woywod Kunststoffmaschinen GmbH & Co Vertriebs KG Yield Management Corp. Zumbach Electronics Corp.

An Oct. 21 webinar, “Industry Outlook - Electrical Sector,” provided bonus information to a special 16-page report that was recently sent to WAI Platinum Members. Leading off the webinar was a presentation by industry guru Philip Radbourne, director of U.K.-based Integer Research, who provided content for the Electrical Sector report. He expanded the scope in the online forum. He discussed which markets are most likely to provide the strongest future growth, the GDP performance of North America and the size of its cable market, which nonBRICS countries would likely drive the global market, consolidation of China’s cable manufacturers, and more. Integer Research, which provides consulting services as well as industry reports, also presented its annual list of top 100 cable companies, with Radbourne noting some of the more meaningful changes. He also broke down the leading states in the U.S. for cable production by revenues, which included a few surprises. Following Radbourne’s presentation, questions were posed by WAI Platinum members taking part in the hour-long webinar to panelists Neville Crabbe, Leoni; Dave Hawker, Nexans; Patricio Murga, Viakable; and Bill Reichert, Champlain Cable. The panelists and Radbourne shared their thoughts on topics that ranged from which areas offer very strong growth potential and labor matters to the fragility of some regions and the challenges of obsolescence in controls/software, and more. “We were quite pleased with the response to this ﬁrst-ever Platinum Members webinar,” said WAI Education Director Marc Murray, who noted that 27 people from 15 different companies took part. “Philip, as ever, made a very detailed and practical report. We had good questions posed and the panelists provided a good range of comments.” The WAI’s Platinum Members are a class that actively support the Association by participating as exhibitors, advertisers, sponsors or content providers for WAIorganized events, publications and educational programs. The webcast has been archived for WAI Platinum Members. For more information about the program, contact WAI Executive Director Steve Fetteroll at tel. 203-452-2777, ext. 132, sfetteroll@wirenet.org.

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

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

industry, as well as a refresher for seasoned professionals. General topics are wiredrawing mechanics, drawing dies, lubricants, and wire breaks. For the afternoon ferrous track, the topics are ferrous metallurgy, ferrous testing and properties, heat treatment, and cleaning and coating. On the nonferrous side, topics include electrical testing, two segments on extrusion, and stranding and bunching. A different feature this year will be a 45-minute question-and-answer session following the end of the last class at 4:15 p.m. Q&As had been part of past Fundamentals courses, but had been dropped previously due to scheduling concerns. The popular open discussion session makes its return in 2015.

WAI NEWS

Interwire 2015 sales/tech update More than 90% of the show ﬂoor for Interwire 2015 has been accounted for, and all the larger booths have been taken. “At this point, all we have left are smaller-size booths,” said WAI Sales Director Bob Xeller. “There still are some good locations available, but now’s the time when they start to disappear as companies that have been waiting decide to sign up. Again, there still is space available, but if you are leaning towards exhibiting at North America’s largest trade show for wire and cable, it would be good to contact us now.” In terms of the technical programs, the educational portion of the Interwire 2015 program, and WAI’s Education Committee is ﬁnalizing the popular Fundamentals of Wire Manufacturing course. The course will continue in the one-day, pre-conference format it followed at the 2014 Operations Summit and Wire Expo in Indianapolis. It is scheduled to run from 8:30 a.m. to 5:00 p.m. on Monday, April 27, 2015, the day before the start of Interwire. As before, it will include four general topics in the morning, and four each in a ferrous and nonferrous/ electrical track during the afternoon. Lunch is included. As its name suggests, the course is intended to give attendees a solid grounding in the essentials of wire and cable manufacturing. It is valuable to those new to the

Casting methods updated at WAI’s GCCF All of the major continuous casting rod processes will be represented and discussed at WAI’s second Global Continuous Casting Forum (GCCF). For the latest details go to www.castingforum15.com. Below is a short review of the types of casting technology that will be presented at the event, which is being held in conjunction with Interwire 2015. Properzi Casting Technology Though considered mature, nonferrous technologies are still subject to development aimed at improving safety

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34 | WIRE JOURNAL INTERNATIONAL

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SCR Casting Technology ® Continuous Rod (SCR ) process for continuously producing copper and aluminum wire rod. The company operates four SCR systems—one copper and three aluminum systems—in its own manufacturing facilities. This segment of the forum presents a brief history of the SCR process, a description, and recent process developments. Contirod Casting Technology ® During the more than 40 years of Contirod history, many innovations have been made along the entire process line. These include a new charging device; an improved shaft furnace combustion control system; a modular designed Hazelett caster; and individually driven, frequency-controlled drives for the rolling stands. The result of these constant improvements is today’s state-ofthe-art Contirod® process which delivers the cost-effec-

tive production of high-quality wire rod. This presentation covers important new developments and the resulting influence on process cost reduction. ®

Upcast GREENerCAST and Beyond Based on the combination of the GREENerCAST technique and new developments in® metallurgical processes and thermal mechanics, Upcast inherently clean technology has broken into areas that were considered off-limits, such as obtaining small grain as-cast structure (without grain refiners), casting 100% ETP scrap or magnet wire scrap into high-quality HCOF copper rod without harmful environmental emissions, casting new metals and alloys (including aluminum) and casting faster than ever. Rautomead Continuous Casting Rautomead Continuous Limited specializes in continuous casting equipment for copper, copper alloys, gold and silver. The copper rod continuous casting machines are specifically designed for the processing of electrolytically-refined grade ‘A’ copper feedstock to produce 8.0 mm wire rod. They may be configured to produce rod up to 22.0 mm if required. The machines are intended to be operated for long periods of uninterrupted production of continuous cast copper wire rod. There are now more than 300 Rautomead machines in operation in over 45 different countries around the world.

If You’re Changing Butt Welder Parts As Often As You’d Change Him It’s Time You Changed To Micro-Weld At Micro-Products, we realize that change is never easy. That’s why we build all our Micro-Weld parts tough. Though our butt welders work harder, last longer and offer consistent high quality welds, certain parts will eventually wear out. Use only genuine Micro-Weld parts to reduce downtime. Keep stacking the building blocks that help you get the job done and increase productivity. Also ask us about our reconditioning service. You'll save up to 40% and still get a new welder guarantee. For more information, call 1-800-872-1068, or visit our new expanded website: www.micro-weld.com Genuine Micro-Weld Parts Service Reconditioning 1886 E. Fabyan Parkway, Batavia, IL 60510 USA Phone: 630-406-9550 • Fax: 630-406-9552 • Email: info@micro-weld.com

NOVEMBER 2014 | 35

WAI NEWS

and the index of repeatability of quality while reducing transformation costs. Using Properzi lines in the production of ETP copper rod, the transformation of copper cathodes into wire rod passes on a continuous basis through melting, casting, rolling, and coiling. The most recent developments in Properzi technology, particularly the introduction of “big blocks” refractory in casting and the combination of roughing and finishing mills with new size rolling rolls, will be covered.

WAI NEWS

U.K. executive continues the tradition of clockwinding at WAI headquarters Standing in front of the clock presented to the WAI in 1948 for support during World War II by U.S. wire companies, Clockwinder Robert Bache, a director at U.K.based Bache Pallets Limited, made an eloquent speech on Oct. 15 to WAI staff and guests about the importance of the clockwinding tradition.

roof of a dormitory structure. He recalled one meeting that included a number of generals, one of whom asked what else his company did beyond storage equipment, and Bache told him about supplying the roofs for dormitories in Afghanistan. “One general went white as a sheet, and he said, ‘Will you please thank all your men, because I was in one that was hit, and I walked out.’ ” Bache said the U.S. and U.K. have had and need to continue their close relationship. “I do think with the potential problems and the actual problems this world is having at the moment (that there’s a need for a wingman), and I think that there’s a wingmen in America, in the USA, and little gestures like this go (a long way) to showing that special arrangement. America to us is very, very special.” Bache was introduced by WAI President Bill Avise, who recalled how little he knew about what his father had done as a B24 pilot in the Paciﬁc in World War II until after he passed away. “ It all gets back to how (easy it is) to let things drift away. So to be able to be here and to carry on this tradition, I’m just real proud to be part of it.”

From l-r, clockwinder John Swain (2012) and Robert Bache (2014), Bill Avise and Bill Reichert. Bache, who was accompanied by his wife, Elaine, and 2012 Clockwinder John Swain and his wife, Wendy, discussed how he and John both came to be invited to join the Worshipful Company of Tin Plate Workers alias Wire Workers of England. To be a member, he had to become a Freeman of London, which he said was a mostly charity-driven group. “Being a freeman of the city of London is not all it’s cracked up to be...I think our only bonus is that we are allowed to herd sheep across Tower Bridge,” he quipped. Through his membership, Bache said that he got to meet people in the wire industry. A considerable amount of his company’s business is exports, with customers including the U.S. defense industry, which placed an order for the

36 | WIRE JOURNAL INTERNATIONAL

Outside WAI’s headquarters, Clockwinder Robert and Elaine Bache and John and Wendy Swain. Others in attendance for the event were Tony De Rosa, Frigeco USA; Dave Ferraro, Carris Reels; Bill Reichert, Champlain Cable Corp; Andy Talbot, Mid-South Wire Co; and Richard Wagner, Insteel.

I can help WAI members learn more about copper, continuous casting, and process innovation. Q: Why did you join WAI? A: To network and connect with like-minded business professionals and enhance my career development through WAI technical programs and contacts. I also like the ability to meet many suppliers in one location.

Q: Why do you renew your membership? A: To stay abreast of the latest technologies for a competitive edge and keep in touch with friends and colleagues from around the world. I am at the point in my career that I would like to give back to the WAI and our industry by being a voice for manufacturing.

Q: What would you be doing if you hadn’t become involved in the wire industry? A: I’d be in the metals industry. I like metallurgy and molten metals.

Gary Spence VP Nonferrous Metals | Encore Wire Corp. Member Since: 1980

Q: What do your co-workers say about you? A: They think I am always trying to improve something, innovative, very knowledgeable of copper continuous casting, results oriented, outspoken, and fair.

Q: What did your most valuable WAI contact help Meet Gary Spence. One of WAI’s worldwide members. One compelling story. You’ll find Gary where innovation and old-world ethics collide. He’s continuously improving. In 43 years he’s gathered more information on copper continuous casting than most will ever learn—until April 2015, that is, when he will join a casting call of his international colleagues at Interwire for the second global continuous casting forum of his design. The encore? Aluminum will join his cast. He’s an expert. An optimistic leader. And, he’s emblematic of the knowledge base accessible through WAI. Gary’s profile reveals key themes familiar to all distinguished personalities, namely:

you do?

A: Many helped further my professional development and assisted me in achieving product and process improvements. I now have global contacts to communicate with via the Internet at anytime.

Q: Who was your mentor? A: My parents; they instilled a strong work ethic. I have also been fortunate to work for three outstanding companies all with strong, innovative leadership.

Q: Who is the most famous person you’ve met? A: I met Brooks Robinson—the Baltimore Oriole third baseman with a golden glove—at a ball game in San Francisco.

Q: What do you do for leisure? A: You can find me at a health club, on my Harley, or by the water.

MNEMONIC TIP: GARY SPENCE. GARY SPENDS TIME ON INNOVATION.

Q: What is your lifelong ambition? A: In business to be recognized as an expert by my peers. To be the best I can be at whatever I pursue.

Q: What is your greatest accomplishment? A: I am optimistic; the best is yet to come. Watch the forum bloom: www.castingforum15.com

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

EVENT REVIEW PREVIEW Dignitaries at the opening ceremony at wire China, which got very good reviews from organizing groups and exhibitors.

wire China wrapup: rave reviews By the numbers, the recent staging of wire China 2014 in Shanghai set a record, with 1,461 exhibitors presenting their latest technology for the wire, cable and tube processing industries to more than 38,000 visitors. From an exhibitor perspective (see p. 40), the quality of visitors and potential was declared quite good. A press release from the organizers, Messe Düsseldorf, said that they and their local partners–Metallurgical Council of China Council for the Promotion of International Trade (MC-CCPIT) and the Shanghai Electric Cable Research Institute (SECRI)–were delighted with reports they received from participants. “(We and our partners) are very satisﬁed with the outcome of the trade fair duo,” said Messe Düsseldorf, CEO Werner M. Dornscheidt. “We managed to not only exceed the visitor and exhibitor results from 2012 but to also

Attendees enter the Shanghai New International Expo Centre.

38 | WIRE JOURNAL INTERNATIONAL

strengthen our position as Asia’s leading wire, cable and tube trade fairs.” The release said that the event had widespread approval from industry leaders and organizations. “The trade fair’s status gained in importance,” said Arnd Kulaczewski, president/CEO, Niehoff GmbH. “All globally active wire and cable manufacturers have to be at wire China. It is not just about having a presence here but about establishing production capacity in China. wire China 2014 had a positive international response. In addition to the Chinese participants there were visitors from Southeast Asia, the Middle East, Brazil, India, Iran, Iraq, Russia, Vietnam and the U.S.” “This year the overall attendance was quite good and I think the participation of visitors was good,” said Ferruccio Bellina, president, ACIMAF. “The exhibition is growing in terms of the exhibitors and is also more attractive for the visitors. The participation of Chinese companies is very strong. And competition is growing greatly.” “The general feedback could be very positive and this is the information we will give our membership, how successful people ﬁnd the show,” said Steve Rika, chairman, International Wire & Machinery Association (IWMA). “We hope we can increase the number of members attending the next show. Compared with the event two years ago, this

U.S. exhibitors continue to have a presence. year there seems to be a lot more attendance and new visitors.” “wire China is an important trade show for us,” said Rahul Sachdev, president, Wire & Cable Industry Suppliers Association (WCISA). “The visitors come here with specific projects. The event is becoming more international and we had attendees from Asia, India and Indonesia. The North American Pavilion continues to be improved and the overall infrastructure has also been updated.”

NOVEMBER 2014 | 39

EVENT REVIEW

“wire China was distinctively better than two years ago,” said Kurt Eder, president, AWCMA. “We registered strong increase in international visitor participation, including attendees from Saudi Arabia and Iran. The quality of the visitors was also better. Overall, the behavior of the Chinese has changed. With the improved standard of living, customers can afford to buy high quality products and consequently, the copying of Western equipment has decreased. The difference between Chinese and Western quality is understood and Chinese manufacturers realize that they need to offer their customers Western quality equipment, and this increased demand for original products was obvious at wire China 2014.” “wire china 2014 went very well and we had a lot of visitors especially on the ﬁrst day,” said Heinz Rockenhaeuser, president, International Wire and Cable Exhibitor’s Association (IWCEA). “We are pleased with the four days of the show. Many international attendees want to have meetings on Saturday. Visitor groups come to this event not just to see and order products but also to decide about exhibiting in two years from now.” The next wire and Tube China will be held at the Shanghai New International Expo Centre (SNIEC) from Sept. 26-29, 2016. For further information, contact Messe Düsseldorf North America, tel. 312- 781-5180, info@mdna.com, www.mdna.com. (continued next page)

EVENT REVIEW

Exhibitor perspectives At wire China, Eurolls SpA reported great interest in the company’s cassettes and microcassettes as more companies see the advantages of rolling wire instead of drawing it. At the event Eurolls was able to reconnect with existing customers and secured several interesting orders for their products division, (cassettes and rolls), and entered new projects for their machinery divisions (rolling lines). The single largest attraction was a double-twist buncher for steel cord, a compact, easy-to-use model that is maintenance-friendly (see p. 66). “We con-

clude that this show was very successful, as the quantity and quality of visitors, from China, South East Asia, and other countries such as India, Latin America, and Europe, was important.” Elisabetta Gironda, Eurolls SpA.

Activity at the Eurolls booth.

SAMP reported stellar results at wire China.

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“wire China has deﬁnitely conﬁrmed its status as the most important international trade fair for the wire and cable industry in Asia,” said Dominique Perroud, managing director of SAMP Shanghai. “It was an even greater triumph than we expected. We had an extraordinary number of visitors

The Windak Group has seen good results since we started exhibiting at Wire China in 2008. We have seen the show grow to become one of the major events for the cable industry. We meet new and existing customers, which is obviously important, but we also get information of new trends and the general market situation. For instance, cable manufacturers in China have seen their labor costs rise and are now more interested in automatic equip-

ment, and we can show them our solutions that can help make them more efﬁcient and better able to expand their business. There was much interest from such customers at our stand for our new line QuickPack QP3 (see p. 66). Wire China showed us once again that trade shows can be very important for business development, industry knowledge and co-operation. We expect to get a few orders related to the show and ﬁrmly believe that being there is a good investment. We look forward to participating in the next holding of Wire China. Windak welcomed attendees to Windak Group. its stand.

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EVENT REVIEW

and a powerful media impact, and it also reafﬁrmed its international vocation. All this gave us an opportunity to show ground-breaking innovations from our comprehensive range of wire and cable manufacturing solutions for sustainable and efﬁcient manufacturing. We were pleasantly surprised by the interest of customers and by the quantity of new sales contacts that were made throughout the exhibition. The wire China show surely met and even exceeded all of our expectations.” SAMP presented many technological innovations, including hi-tech rod breakdown machines for nonferrous wire, double-twist bunchers and innovative spoolers. Dominique Perroud, managing director of SAMP Shanghai.

FEATURE

Industry info: where to find it Wire and cable can be tested, but industry knowledge is not so readily defined. This feature asks a few of the many providers of industry events— both technical and/or management focused—what the value is in what they do. It also includes parting thoughts from a man who has served on both ends, the role of an Open House, and more.

Information is essential, especially in a high-volume industry where even a very slight production advance can spell big returns. The flip side is that it is not so obvious that somebody who sets out to find useful information will find it, which per one popular industry theory means that such a person’s status has switched from productive to overhead (meaning, non-revenue generating). Below is an excerpted column by Scott Berkun (scottberkun.com), the author of five books on creativity, leadership, philosophy and speaking, on why an employee should want to go to a conference and why it should be a sound investment for both staffer and company. You are an asset to your company. All assets require maintenance and enhancements. If instead of being a person, you were a piece of machinery, part of the corporate budget would go towards maintaining and upgrading you. Well, despite being human, you are an asset to the company. They should be investing the same percentage of budget towards maintaining and upgrading your skills as they do for the rest of the corporate assets. Offer to train others in what you learned when you return. You can pitch your trip to a conference as a way to bring back skills and knowledge to the rest of the organization. If you have any experience in training or teaching, you can use that as your justification to attend instead of other co-workers. Get extra copies of the tutorial notes from other sessions. Trip report. Arguably one form of teaching others, the trip report is a write up of the sessions you attended, written for other folks in your group. The best trip reports make it easy for folks to dig up the right reference, or trigger people to come ask you questions. There’s rarely much value in 10-page trip report documents: no one reads them. Instead, a two- or threepage summary, with URLs and pointers to stuff for

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specific questions, gets much more mileage. Connect the value of the conference to business goals. If ease of use or customer satisfaction are company or division goals, you can claim that sending folks to conferences on those subjects will help pull in more expertise and knowledge, thus helping the business. This argument puts less of the focus on your professional goals, and more on the company. Recruiting. One of the “other” reasons to send people to conferences is to recruit for open positions. If your team has had trouble filling certain jobs, or know that new openings are coming for your group, you can offer to do recruiting work while you’re there. Professional development. If you have career discussions with your manager, tie your career goals and future development to specific kinds of training or growth opportunities that you need. This might force you to rethink which conferences you’re going to (the cool conference might not be the one that’s likely to help your career/skill growth the most). In some organizations, folks will get to go to conferences provided they are presenting or participating in a session. Ask lots of questions. Learning is a contact sport. If you don’t make your experiences engaging for yourself, you are guaranteed to be bored. Talk to speakers, paper authors, booth people, the folks sitting next to you, whoever. Ask for recommendations for books, websites or other conferences. If you don’t become an active participant in your own learning, don’t be surprised if not much of what you experience is relevant to you. Take smart notes. Think about what the notes are good for: you’re writing for the future version of you. What level of detail do you need? Attending conferences is not meant to be a vacation, but it can be both a personal boost for your productivity and career–direct and indirect value for your company–if you take it seriously and plan accordingly.

WJI: What level employees (R&D, plant manager, CEO, engineers, etc.) most beneﬁt by attending your programs? We target key decision makers responsible for their company’s strategic planning and product development as well as business development. Our Advanced Cable Asia conference is attended by senior level management or research representatives which could be CEOs, R&D managers, senior engineers, etc. It provides these senior executives with key information and contacts needed to make strategic business decisions on technology choice, R&D and future investment. Allie Gavel, Customer Service and Operations Manager - Conferences, Integer Research. The largest demographic in the audience tends to be product and process engineers in transmission of data and voice. John Barteld, CEO/Director, International Wire & Cable Symposium (IWCS). Our Polymers in Cables conference attracts every level of professionals in the cables industry. Kelly Cressman, Conference Coordinator, AMI.

Executives, general managers, and sales managers will benefit greatly from both the panel and networking portions of our Rebar & Wire Rod (R&WR) conference, but lower-level employees—especially newer hires who might be new to the steel industry—will benefit significantly as well, as it works great as a “crash course” in the mechanics, politics, and future of the long product market. Katie Memmell, Content Manager/Editor-inChief, SteelOrbis.

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Industry events: the value of face-to-face education and networking

Katie Memmell

Technical and management information providers in feature Q&A AISTech is the world’s largest annual iron- and steel-related technology conference and exposition. Its presentations cover the steelmaking process from raw materials to transporting the finished product. The AISTech Exposition features more than 500 companies, and there are unique plenary sessions and a “Town Hall” that engages industry executives in debate regarding key issues. www.aist.org

Applied Market Information LLC (AMI) serves the North American plastics market with global market research consultancy. A major publisher of both commercial and technical information for the plastics industry, AMI's annual two-day Polymers in Cables conference includes a mix of technical and market presentations of material, regulatory and technology developments. www.amiplastics-na.com

Integer Research’s Advanced Cable Asia event is a platform to discuss the opportunities and developments in Asia’s advanced fiber optic and power cable markets. It helps identify and assess new technologies and materials and help cable producers understand the most profitable areas for R&D and investment, and provides excellent networking opportunities. www.integer-research.com

The CRU Wire and Cable conference provides an insight into power, telecom, OEM and structured cabling markets, with assessments and outlooks from cable makers, end-users, policy makers, economists and analysts. www.crugroup.com

The forum SteelOrbis offers at its annual Rebar & Wire Rod conference (in conjunction with the World of Concrete expo) is focused on concrete reinforcing steel, but the assessments, outlooks and projections discussed by our panel of experts can often encompass other long products as well as other construction-related steel where end-use overlaps. www.steelorbis.com

The International Wire & Cable Symposium organizes an annual technical symposium in which papers are presented on new technologies related to wire and cable products, materials, applications and processes. It also includes Professional Development Courses, a suppliers’ exhibition and an “Executive Track” for senior managers. The IWCS is now in its 63rd year. www.iwcs.org

WAI offers technical and operations information at two conferences every year, as well as year-round through our webinars, archived resources, website, bookstore, and chapter events. In recent years, we’ve offered more practical material on the day-to-day operations of a wire and cable business as part of our Operations Summit held at our stagings of Wire Expo. www.wirenet.org

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Education of a new Encore employee: conferences part of the plan Chris Tucker joined Encore Wire in May 2012 as a process engineer. He came with a degree in mechanical engineering from the University of Texas at Tyler and a desire to excel. He also was lucky to be mentored by Gary Spence, vice president of nonferrous metals, and in January 2014 he was promoted to assistant rod mill manager, responsible for the production of continuous cast copper rod. Tucker’s story has been one of continuing development. Spence described Tucker’s path as follows. “It includes hands-on operations of all equipment, qualifying as an operator on all jobs within the rod casting facility, including our recycling operations; attending a certain amount of industry related conferences and trade shows; visiting other similar operations; actively participating in WAI on a committee; and a community leadership program–all this in addition to the daily management activities of the rod facility.” Spence said that attending trade shows and conferences “is vital to our success in keeping abreast of the most current technology, training opportunities they offer, networking with customers and suppliers, and supporting our industry trade organizations through active involvement.” He said that each year, the company probably sends 20 to 30 different people to such events, two to four each. “We do not cut back during the economic cycles. We are consistent. We must maintain a leadership role in service, quality, and low cost, and that includes going to conferences and trade shows to enhance our knowledge base, ﬁnding better, simpler, cheaper ways of managing Gary Spence our entire business. Face-to-face networking and developing relationships is critical to success.” Below, Tucker shares his thoughts on the process.

WJI: How has your post-college education gone since you left school? How has Gary been as your mentor? Tucker: I think anyone would be hard pressed to ﬁnd a better mentor than Gary. During his 45 years in the nonferrous industry he has been involved with the startup of three continuous cast of copper rod processes (Essex, Contirod, and SCR). I believe he is the only one who has ever done this and the amount of information I have gained under his leadership is something that could never be matched in a classroom. Along with sharing his copper rod knowledge, he has instilled the mindset that everything can be improved upon. I apply that to every aspect at Encore. WJI: How has it been to be a member of a WAI committee? Tucker: It has been a rewarding experience. As a part of the Paper Awards Committee, I am assigned technical papers to read and evaluate. If a paper is outside my area of expertise, I’m permitted to enlist the help of others for guidance regarding content. It’s a great way to gain knowledge and exposure to different facets of our industry.

WJI: How has the networking been? Tucker: It’s really been great. Forming relationships with those key guys who can be called up in a time of need, or to bounce ideas off of, is pivotal to success. Continuous cast of copper rod is the niche I’m in but a lot can be learned from those in the aluminum and steel industries as well. Networking is limitless.

WJI: Do you appreciate being sent to such events? Chris Tucker Tucker: I do. It shows that Encore is willing to invest in me. I believe that this ongoing experience has been win-win.

WJI: How many conferences have you been to so far? How did you prepare for them? Tucker: So far I’ve attended six conferences or trade shows including TMS, ACC, SCR User’s meeting and WAI’s Interwire and Operations Summit. At our rod facility we have a list of over 100 improvement project ideas. I review it before events and at the technical presentations and walking the exhibit ﬂoor, I look for project solutions.

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WJI: What were your expectations for the conferences? Tucker: I hope to hear technical papers that are relevant to my process or product. Even if the presentations do not pertain to my operation, I believe that as long as good networking takes place or a new improvement idea/concept is taken away and implemented, the conference was beneﬁcial.

WJI: Do you believe that going to conferences has made you a better employee? Tucker: Absolutely, not only me, but the rest of my team as well. I am able to come back and share the things I’ve learned and we are able to take those ideas and implement them into our operation.

Depending on the type of material being presented, the people in our audience tend to be process engineers, quality assurance folks, metallurgists, as well as salespeople, but also GMs and plant managers for our operations-focused information, and top leadership for some of our more strategic business topics. Marc Murray, Director of Education & Member Services, Wire Association International (WAI). Senior level decision makers/C-suite. Dominic Halahan, Head of Metal Events, CRU.

WJI: How hard is it to get good quality technical papers and/or top management representatives for presentations? We are always very pleased with the number of high level professionals that are happy to speak at our event. Speakers range from academics to technical and commercial executives from the industry. Papers are selected based on level of interest, relevance and with a view to having a balanced, exciting program. Kelly Cressman, AMI. In addition to AIST’s general Call for Papers, we have 29 technology committees that address speciﬁc process, engineering, equipment or reliability technologies associated with the iron and steel industry. These committees are responsible for soliciting and reviewing abstracts and presentations for the conference. The hard work the committee members put in is reﬂected in the steadily growing number of abstracts and papers received, including record numbers over the past two years. Ronald E. Ashburn, AIST.

FEATURE

If you are involved with the steel industry, you should be at AISTech. There is relevant information, topics, and networking opportunities for all levels of industry involvement, including producer, supplier and academic. Ronald Ashburn, Executive Director, Association for Iron & Steel Technology (AIST).

Attendees at Integer Research's 2013 Advanced Cable Asia event. Finding good quality representatives to speak at our events is not without its challenges. We receive quite a few enquiries from leading producers and suppliers to speak at the event. However, the phenomenon of severe competition and concerns about intellectual property protection make some speakers or their companies cautious about sharing too much detailed information or sending their key R&D staff to the conference. We work hard to ensure that the finished program is packed with the best of the best. Allie Gavel, Integer Research. Senior level executives are aware of the opportunity that the event offers to raise both personal and company profiles. Against this back drop we find that many executives/ companies are willing to share their views on the market and other topics of interest. Dominic Halahan, CRU. Technical papers tend to be written by operating employees as opposed to dedicated researchers, so the work must be coordinated with regular work loads. The IWCS has recognized this phenomenon and has made some adjustments in the program to ensure a full, valuable program has been maintained. After a dip in papers in the past few years, the IWCS program has returned to a consistently strong technical program. John Barteld, IWCS.

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An Open House can (and should) be more than a sales pitch Much information is disseminated at organization conferences, but Open Houses staged by suppliers can also serve as a place to learn more about technology and pose questions to experts. One such event is put on every other year by Niehoff Endex of North America (NENA), a subsidiary of Germany’s Maschinenfabrik Niehoff GmbH & Co. KG, which was founded in 1985 in Rome, New York. On October 7-8, it hosted 55 attendees to the event, which included an Oktoberfest dinner and a half day of presentations/information by representatives from Reber Systems, Schmidt Maschinenfabrik, REDEX/Bühler Würz and HFSAB, Bechem Lubricants, Fort Wayne Wire Die, RTD Manufacturing and Howar Equipment as well as Niehoff staffers from Germany. Presentations included “A New Era in Wire Drawing Lubricants,” “Manufacturing Solutions for Alternative Materials to Copper for Automotive Wires,” and “Keep your Investment Safe & Running: Beneficial Advice Maintaining Your Equipment.” Attendees had a tour of the facility, and were able to inspect equipment from a complete rod breakdown line and two vertical braiders to a new stranding process for automotive wire and an ultra-fine wiredrawing line. Below, NENA CEO Robert Wild, who welcomed Open House attendees, discusses the role of event.

WJI: How did the first Open House come to be, and what was the goal? Wild: In 1991, Niehoff built a facility in Swedesboro, New Jersey, to serve as our sales and service center for the Americas. That year, we held our first Open House, a one-day event, and the goal was to show off our latest generation equipment. We invited existing and potential customers, a mix of decision makers, owners and engineering personnel, and had a very good turnout. The Open House stayed like that for the next few stagings, and we were pleased with it.

WJI: Are the presentations always technical? Wild: One of the best presentations we had was at an Open House that featured an industry overview by Philip Radbourne of Integer Research. That kind of “big picture” information is always of interest. At the same time, our Open House format keeps evolving. We try to learn from past experience and improve where possible.

WJI: Can you provide an example? Wild: Sure. Every event has had topics of interest, but one that I especially liked was in 2012, when we had six speakers, both from Niehoff and some from other companies that we work with. They covered topics such as dies, lubricants, materials and new processes, and there was time for questions and to talk to the presenters later. Our attendees left with a better understanding of some of the more challenging technical production elements, and you could see that they appreciated what we had done.

WJI: How does one balance between the presentation of technical information and a sales pitch? Wild: Our customers deserve more than a sales pitch. When they invest time and effort to join us, they deserve a rich program with value. It is not always easy to achieve this goal but we try to combine the educational with the beneficial and walk that thin line. We think our Open House achieves that goal, and as long as our attendees continue to tell us they find our event of value, we will continue to offer it.

WJI: Is the equipment the main draw? Wild: I think that the single biggest attraction remains new technology and equipment. That makes sense when you consider that relatively few North American customers WJI: How did the Open House evolve to what it is today? travel to wire Düsseldorf, so our Open House becomes the best opportunity to introduce Wild: In 1996, the Wire our latest offerings to our Association International North American customers in scheduled an event in Cherry a relaxed setting. You have to Hill, New Jersey, and we volremember that companies are unteered to use our facility still stretched thin, especially in as a tour for the conference their engineering departments. attendees. We set up equipment We understand their challenges for this purpose. Initially our and try to offer them a program intent was only to demonstrate that helps them on their shop Niehoff equipment, but we also floor. Besides this, we look at wanted to make it even more our Open House as a way to special for attendees. We invitsay “thank you” to our cused speakers from our industry tomers on a professional and to talk, and the reaction from Attendees at the October 7-8 Niehoff Open House. personal level. attendees was very positive.

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WJI: What is the value of technical papers and/or presentations by industry leaders? Technical presentations provide an opportunity to monitor developments in the industry and to adapt strong technologies. All our presentations are vetted for their value prior to inclusion in the event and the proceedings. Changes in technology are quickly adopted by industry users, and a unique or restricted technology has less opportunity for adoption than does a technology that leads to a new standard. Often, presentations are made by industry suppliers who beneﬁt through an expansion of their respective marketplace. Academic authors beneﬁt through John Barteld recognition of their work through publication. At times, processing technologies are withheld due to a concern of losing competitive advan-

tage of a unique efficiency. Generally, the IWCS has enjoyed strong support from all quarters of industry. John Barteld, IWCS. One of our conference aims is to provide solid technical advice for Asia-based wire and cable producers to upgrade their products. Technical papers play a significant role at the event to help establish a platform for knowledge sharing and education. Hearing from industry leaders is the best way to understand the real market situation, explore business potential, and investigate and prevent possible risks presenting the market. Most of our speakers are willing to share on the topics, within their company strategy and complies with company rules. We find that industry leaders feel quite comfortable joining in and engaging in hot topics. Most recognize and value the importance of information sharing and open discussion for both market development as well as emphasizing their market leader status. Allie Gavel, Integer Research. The value is at least twofold. First, it gives people the chance to learn from others who have faced the same challenges; and second, it gives authors a chance to test their findings under the harsh light of public scrutiny. It’s satisfying as an organizer to see an attendee and an author engaged in animated discussion after a presentation. It's why we put on a conference in the first place. Panel discussions can be very effective. Roundtables can be lifeless and boring, but the right mix of panelists can result in some really frank and insightful discussions. When you go beyond technology and talk about best practices, everyone benefits. As one of our board members and active organizers has told me, “There are no secrets when it comes to this stuff.” Marc Murray, WAI. Our R&WR conference usually features presentations from both “inside” sources (executives and managers from within the steel supply chain) and “outside” sources (trade associations, economic experts, trade lawyers), giving attendees a fresh, comprehensive perspective of the market. Most executives are unwilling to share proprietary informa-

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There are fewer people dedicated exclusively to R&D, and that has limited the number of papers. With a smaller pool to choose from in general, we have to position WAI as one of the best venues to present material. Speakers choose where and when to present based on expected outcomes and reputation. People know Interwire and the Operations Summit are well-attended events where they can interact with scores of colleagues, which makes them highly desirable settings. With tighter budgets, we have to keep improving our programs to give people more and new reasons to come, both as attendees and as presenting authors. Marc Murray, WAI.

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tion, and are guarded when it comes to making solid longterm forecasts, but they tend to open up during the Q&A portion. Of all the feedback we’ve received about R&WR, “boring” has never been a complaint, and that sentiment seems goes for SteelOrbis’ other annual events, such as the IREPAS conference held overseas every spring and fall. Katie Memmell, SteelOrbis.

Kelly Cressman, l, with a colleague at an AMI event.

Technical presentations play a large role in our events, but we do try to have a nice balance between technical and market papers. Industry leaders are the key to a successful event—it beneﬁts both the presenter and the audience. Speakers are often eager to debate their point of view with colleagues, to test their hypotheses against their peers, etc. Kelly Cressman, AMI.

Manufacturing steel is technically challenging: it requires extreme temperatures, large forces and sophisticated controls, and dissemination of information for the greater benefit of the steel industry is our fundamental objective. Technical presentations bring advances to light, and identify different problem-solving methods for improving steel manufacturing. Industry leaders are aware of their responsibility to further not only their companies’ growth, but also that of the industry as a whole. They are willing to share meaningful perspectives during events like the annual AISTech Town Hall Forum, because their ideas help shape the overall effort to keep the industry moving forward. Ronald Ashburn, AIST. WJI: Regarding technical papers, what would you like to say to companies that decline to share their tech findings? A technology development has little value without commercialization. Seldom do we enjoy a sole source or committed standard situation, so the adoption of the development by others is a significant value to the developer. John Barteld, IWCS. Saying something is not the same as saying everything. I encourage companies who are reluctant to share their findings to just be selective in what they share. There’s a lot to be learned without revealing every little detail.

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John Barteld, whose career has been split between cable companies and heading two industry bodies that provide technical information, is retiring as CEO of IWCS. Below are some of his parting thoughts. Life has been a whirlwind since I joined General Cable Corporation in 1977 at age 30, as a marketing services minion, up to my retirement this month. I have been privileged to work for some of the world’s top cable companies as well as switch hats and serve as a director of two organizations that put on industry conferences with technical and/or management presentations. As a then new GCC employee, I had no sense of industry conferences or what lay ahead. I joined expecting to be part of a traditional, established American industrial company: six months later I found myself part of Pirelli Cables, a traditional, established Italian industrial company. Perhaps the most memorable and significant event was meeting Gwenn, a transfer from a Pirelli operation to headquarters, who has been my wife now for 32 years. In the early 1990s, Pirelli asked me to assist in the development of a new industrial association, the International Cablemakers Federation (ICF). It was to serve as a “meeting point” for the international industry, a venue where issues of common concern could be addressed. The ICF launched in 1992 in Vienna with strong industry support, and in 1994 I became its head. My family, which now included two young daughters and my wife, remained there until 1997. As secretary general of the ICF, I had close contact with the senior leadership of the global wire and cable industry. The ICF organized an annual conference in rotating venues around the world, largely for CEOs and other senior managers of member companies. We had notable speakers from industry, government and academia. I traveled to all corners of the world to foster member support and conference organization. I was fortunate to have a very active standing committee of industry managers. Anxious to return to an operating role, I returned to the U.S. in 1997 and joined Draka Cable as marketing vice president. Our family moved to New England where we fully expected to remain for a decade. Eighteen months later, I moved to the Middle East to become managing director of Draka’s interests in the region. We set Dubai as our new home and packed up our house, kids and dog and headed for the desert. I spent a lot of time traveling the region and visiting Draka’s European facilities. Life was good in the UAE, but 9/11 intervened and the role of Americans in the region was of concern. So, in early 2002, I returned to the U.S., responsible for Draka’s offshore and marine business. Once again, constant travel was part of the job, most of it being to Asia. By the time I departed in 2004, my rolodex was crammed full of industry contacts from all over the globe. Meanwhile, IWCS had suffered some significant setbacks due to the high tech implosion of the late 1990s

and the impact of 9/11. In 2004, IWCS was searching for renewed stability, both financially and in its mission. I accepted the CEO role, and in the passing years we modernized the operation and confirmed the IWCS role as the premier venue for industry technology. My fat rolodex proved of value as I was not shy about tapping contacts for the IWCS program. The IWCS today is an efficiently run, cost-effective organization that has achieved financial and mission stability. That has largely been due to the commitment of the industry volunteer experts on the board of directors and the symposium committee who volunteered their precious time to help IWCS continue its mission. That passion, which included the scholarship program for the next gen-

John Barteld, center, with his family.

eration of technology leadership, confirms my sense of the value of what we do. In an electronic age, the IWCS operates virtually, with no fixed office and most of information processed electronically means. I wish I could say that I fully understand all of the technology presented at IWCS, but I don’t. What I can say is that I have seen over the years how management from many of the world’s top cable companies has kept IWCS both alive and relevant. Is it altruism? A sense of obligation to give back? I don’t know, but either way IWCS is a springboard for the industry, and I am proud to have been entrusted with its care for the last ten years. What did I learn from my two separate careers? I saw that manufacturing (especially sales) and industry conferences are two sides of a complementary table: operations/ management and fostering knowledge. The first is fiercely competitive, the latter fiercely collaborative. Yet the two are related, sometimes quite closely, and each has its own unique challenges and each provides value, I also learned that no matter what one does, family matters, so make room for it in your life. And now it is time to me to leave. My rolodex now contains the coordinates of a lot of retired people, and my grandkids expect more attention from Poppy. I continue to teach at a nearby college, and will keep doing that until the students start laughing at me, but it is time to retire from the industry. It has been a great run of 37 years! NOVEMBER 2014 | 49

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IWCS CEO: a 37-year tale of mission, family and dedication

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And to be able to position your organization as a reliable expert in a particular area obviously makes you a more desired quantity. We don’t get a lot of people offering to publicly share their most spectacular failures and wasted efforts (though those are interesting too), but there is goodwill and brand enhancement in sharing successes and giving your audience reason to believe they also have the power to achieve similar success. Marc Murray, WAI. Sometimes, it is not possible for companies to share new innovations; but we do encourage them to share their experience as it helps the industry move forward. While the research may initially be conﬁdential, at some point results and innovations have to be revealed, if they are to be used in practice. Presenting at a conference also offers an opportunity for immediate debate, feedback and assessment of interest. Kelly Cressman, AMI. Conferences provide an excellent platform to share best practice and operational experience through peer-topeer debate and discussion. This two-way engagement is beneﬁcial for both the speaker and participant attending. Dominic Halahan, CRU. AIST is very fortunate – the steel industry has historically been built on sharing. Being able to talk to a peer about a problem or success, even if they work at a competitor, has been a hallmark of the steel industry’s emphasis on sustainability. Ronald Ashburn, AIST. Many companies are very cautious about IP protection. If they do have concerns, we will take the opportunity to help them build up relationships with their clients or potential partners in a more private way. There are many ways to get involved with the conference without showing all your cards. Allie Gavel, Integer Research.

WJI: Does your program include a tabletop element? If so, is it hard to balance an event schedule? We often include panel discussions and multiple streams in our events. As long as there is sufﬁcient difference in subject matter between concurrent streams it does not create any issues. All of our conferences have an exhibition. Exhibitors beneﬁt from extended opportunities to interact with delegates during breaks lunches and receptions. Dominic Dominic Halahan Halahan, CRU. AISTech’s Exposition is a major part of the conference. AISTech 2014 set all-time event records with a sold-out exhibit hall with 531 companies. Our success was recognized by Trade Show Executive’s 2014 Fastest 50 Awards

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A photo of the award-winning AISTechExposition.

& Summit with two “Grand Awards” for outperforming nearly 11,000 other shows within the U.S. in 2013. Balancing the scheduling needs of a technical conference and exposition can be a challenge. We and our conference planning committee carefully address the needs of all attendees. Our current schedule provides opportunity for each group to avoid missing out on special events, from plenary events to receptions. Ronald Ashburn, AIST. Yes. There are really two audiences who must be addressed. Encouraging the technical attendees to visit the exhibition is critical, although the exhibition also attracts supply chain individuals who do not attend the technical sessions. The differing expectations of the two audiences can be a challenge. John Barteld, IWCS. We have a small exhibition but limit stands to ensure maximum exposure and traffic for each technology supplier during networking breaks. We cover a lot of content during our two-day conference. We have two dedicated tracks. The first two sessions generally look at the latest development in the Asian cable market and opportunities emerged in specific cable markets such as China, Thailand, etc. The rest of the conference program will be split into two parts – advanced power cable and advanced fiber optic cable. We feel that this is an ideal balance for the needs of both industry sectors as well as suppliers to these sectors. Allie Gavel, Integer Research. Most attendees at Interwire and Wire Expo come for the exhibits, and the technical program audience is admittedly just one segment of that overall group. That equation flips for our international technical conference, which is focused on the papers, but also has tabletops. At the exhibitions, it’s always a challenge to balance the needs of our audiences and supporters on both the exhibit and conference side. We try to schedule things so we’re not enticing people off the show floor too much. Marc Murray, WAI. We have a table top exhibition that runs alongside our conference. Our events combine technical presentations

FEATURE

WJI: In an increasingly electronic world, do technical conferences/management perspectives have a place? They deﬁnitely do. Advanced Cable Asia 2014 is a place for senior representatives in the industry to gather together to discuss the latest market trends and issues, to learn about the latest strategies and plans, and to discuss these with suppliers and clients alike. You cannot put a value on face-to-face networking. The industry in Asia needs has an increasing demand to develop new technologies and to establish long-lasting business relationships. Allie Gavel, Integer Research.

FEATURE

with networking. The papers program and the table top exhibition work very well together. Often, innovations introduced by the papers can be seen in practice in the exhibition. Kelly Cressman, AMI.

Conferences provide an excellent and cost-effective opportunity to schedule multiple meetings with industry counterparts. Our conferences, which attract between 200-600 people from 50+ countries, provide both valuable content and the opportunity to travel to new destinations and meet potential business partners. I am not aware of any electronic communications vehicle that can do that. Webinars are good, but face-to-face remains the Holy Grail in business. Dominic Halahan, CRU. With younger participants, there is a constant challenge to relevancy. However, face-to-face interaction is not out of style. The conferences must be relevant and make efﬁcient use of the time committed by the participant. The days of the “convention” atmosphere are likely numbered, but the value of the content-driven conference remains. John Barteld, IWCS. The digital revolution should help us complement and specialize, not replace something that still has strong value and purpose. Yes, a lot can be communicated digitally, and we developed our webinars in part to take advantage of this, giving attendees a chance to get workshop-quality information without having to justify hotels and airfares. But giving up face-to-face interaction makes communication harder overall. If you can’t make those instantaneous evaluations of emotion, manner, and body language, you can’t understand your fellow human beings on an instinctive level we take for granted. Without that, you can’t develop relationships, you just have a bunch of business cards. Marc Murray, WAI.

Marc Murray

The face-to-face contact at AISTech is just as valuable as the information being presented. The ability to ask questions to presenters in the Technical Conference, of industry leaders during plenary events and of exhibitors in the Exposition gives all attendees opportunities to broaden both their networking and knowledge bases. In our present-day world of electronic communication, there is still value in shaking someone’s hand, whether it’s an old or new acquaintance. Ronald Ashburn, AIST. There is no substitute for meeting customers and colleagues face to face. Our event allows you to meet your colleague, customers and suppliers all at once rather than making several business trips throughout the year. Polymers in Cables provides excellent networking opportunities and is balanced with exceptional presentations. Kelly Cressman, AMI. NOVEMBER 2014 | 51

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TECHNICAL PAPER High-precision roll bending of titanium alloy wire for glasses A method has been proposed to reduce processing defects in titanium alloy wire used for production of eyeglass frames by shortening the distance between two rolls. By Yuichiro Sekine, Motoo Asakawa, Natsuki Kato, Yuki Takebe, Yoshinori Sasaki and Masami Matsumura Glasses were invented in the 13th century in Italy1. Nowadays, they are widely used not only to improve eyesight but also as a fashion accessory. The Fukui prefecture in Japan, which is known for making glasses, has seen production decline in recent years owing to strong appreciation in the yen, technological improvements in developing countries and the inﬂow of low-cost glass frames into Japan. Consequently, Fukui’s frame makers have been reconsidering their traditional business model, and have changed their business model to the “Production of Many Models in Small Quantities.”2-4 There are two methods for producing frames. One is to stamp sheet metal using molds and dies, and the other is to bend frame wire three dimensionally using rolls. Material waste is unavoidable in the stamping process, and molds and dies are expensive. In contrast, the roll-bending process makes it easy to change models because it uses no molds and dies. This study focuses on the latter process, which is more cost-effective than the use of molds and dies. See Table 1. Many skilled frame-makers who produce rims, an important part of the frames (see Fig. 1), work at low yield ratios owing to the new strategy of producing numerous models in small quantities. They are eager to ﬁnd a way

to produce good rims from the ﬁrst piece5-6. This report provides some suggestions from experiments that involve analysis of the actual production process through simulations and investigation of the bending process.

Experimental Method This experiment was conducted using a 3Al-2.5V titanium alloy wire that is widely used for making frames. The chemical composition of this material is given in Table 2, and its cross section is shown in Fig. 2. The rim consists of two curvatures, for which a two-dimensional shape is usually designed. Fig. 3 shows “rim curvature κz” and “lens curvature κy.” Wires undergo three-dimensional bending between rolls. Fig. 4 shows the roll arrangement. With feeding material, lens curvatures κy is given by roll No. 8 intermesh h and rotation angle θ, and rim curvature κz is given by intermesh h. In the real rim production, roll C is intermeshed in the z direction, and all of the rolls after roll C are rotated around roll C for obtaining lens curvature κy. Roll no. 8 is intermeshed in the y direction for obtaining rim curvature κz. Table 3 shows the experimental parameters (real rim production range). To investigate actual rim production, the authors searched for a relationship between intermesh h and lens curvature κy, and a relationship between intermesh h and rim curvature κz.

Analysis Method

Table 1. Comparison of two methods for producing frames.

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Calculations were performed using MSC Marc, an all-purpose software application for static implicit nonlinear elastic-plastic FEM analysis. As shown in Fig. 4, the ﬁnite elements were hexahedral primary isoparametric elements, and each roll was treated as a rigid body. The coefﬁcients of fric-

Results and discussions Fig. 5 shows the relationship between intermesh h and lens curvature κy. The wires have a constant rim curvature following the constant curvature of the lens. In this experiment, the lens curvature for each rotation angle Fig. 1. Parts of glasses. was constant. The lens curvature was unaffected by the intermeshes. In addition, the wires bent at a rotation angle of 10° were almost straight. Therefore, the wire bent at a rotation angle of 10° with no intermeshes was defined as Table 2. Chemical composition of titanium alloy the standard wire. wire.n mass%. Fig. 6 shows the relationship between intermesh h and rim curvature κz. The experimental conditions were the same as above. In these results, a smaller rim curvature, κz, was obtained with a smaller rotation angle, θ (i.e., a larger lens curvature, κy). Therefore, the rim curvatures were affected by the rotation angles. However, there Table 3. Experimental parameters (real rim were no data for lens curvatures and rim curvatures of production range). –5°, –10°, and –15°, with larger intermeshes, because the wires buckled under the feeding materials owing to a large frictional resistance between the wires and the bending rolls. These experimental results pose no problem because the range of these experimental parameters are rarely used in real rim production. Fig. 7 shows the relationship between rim curvature κz and the deviation from standard wire Δκz. The deviation from the standard wire, Δκz, has been defined as the difference in the rim curvature from the standard wire’s rim curvature. These results indicate that the deviation from the standard wire, Δκz, increased as the rotation angle Fig. 2. Cross section of titanium alloy wire. decreased (smaller lens curvature). Below, the processing of wires at various curvature values is considered. Fig. 8 shows the motion of the contact point between the wire and roll no. 8. This figure shows a portion of the entire bending roll arrangement. Wires are fed in the x direction. The wire drawn with dotted lines has no lens curvature, while the wire drawn with solid lines has lens curvature. The position of roll no. 6 is considered as the fixed end. First, twisting moment is generated by roll no. 8’s intermeshes at roll no. 7. Second, the wire with lens curvature is tilted above roll no. 7 by a twisting moment. Fig. 3. Definition of rim and lens curvatures. Third, the tilted wire is fed to roll no. 8. Finally, the tilted wire reaches roll no. 8, and the contact point between the wire and roll no. 8 moves. Figs. 9-11 explain the experimental results, which were obtained by conducting MSC calculations using Marc software. Fig. 9 shows the contact point between the wire and roll no. 8 with only the rim curvature bending. The contact point between the wire and roll No. 8 was located in the middle of the wire. Fig. 10 shows the contact Fig. 4. Arrangement of bending rolls. NOVEMBER 2014 | 53

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tion between the materials and the rolls were set to 0.02, assumed as Coulomb friction. The materials were fed by giving displacement of longer direction in the back-end.

TECHNICAL PAPERS Fig. 5. Relationship between intermesh h and lens curvature κy .

Fig. 6. Relationship between intermesh h and rim curvature κz .

point between the wire and roll No. 8 with only the lens curvature bending. Similar to the case with only the rim curvature bending, the contact point between the wire and roll no. 8 was located in the middle of the wire. Fig. 11 shows the contact point between the wire and roll no. 8 with both lens curvature bending and rim curvature bending. Here, the contact point between the wire and roll no. 8 has moved to the end of the wire. These simulation results indicate that performing lens curvature bending before rim curvature bending affected the contact point between the wire and roll no. 8. This corresponds to the concept of the moving mechanism of the contact point. In addition, the authors conducted a simulation to analyze the real operation, which was recognized as being difficult for frame-makers to simulate. Fig. 12 shows the decomposition of intermesh h into the rim curvature bending component and lens curvature bending component. The tilted wire was indented by roll no. 8, and the component of indentation h was decomposed into the rim and lens curvature bending components. Under only rim curvature bending, the rim curvature bending component is equal to intermesh h. Under both lens curvature bending and rim curvature bending, bending moment Mz, which generates the rim curvature, decreased with a decrease in the rim curvature bending component. Consequently, the rim curvatures considering lens curvature decreased. To reduce the decreased component of rim curvature with lens curvature, one should decrease twisting moment Mx. Accordingly, the distance between roll nos. 7 and 8 should be shortened to prevent them from intermeshing with the tilted wire. The mechanism of this process is shown in Fig. 13, and the arrangement for shortening the distance between roll nos. 7 and 8 is shown in Fig. 14. Fig. 15 shows the relationship between rim curvature κz and the deviation from the standard wire, Δκz, after shortening the distance between roll nos. 7 and 8. Shortening the distance narrowed the range of the deviation from the standard wire. By shortening the distance, rim curvature bending could be conducted under a smaller wire tilt. In other words, processing defects could be reduced successfully. Fig. 16 shows a comparison of the equivalent strains before and after shortening. Under roll no. 8, after shortening, the wire had smaller tilt than that before. From the status after shortening, the decomposed component of rim curvature bending could be increased because the distribution of equivalent plastic strain was nearly horizontal to the cross section.

Conclusions Fig. 7. Relationship between rim curvature κz and deviation from standard wire, Δκz . 54 | WIRE JOURNAL INTERNATIONAL

In this study, experimental and FEM analyses were used for the in-depth analysis of a manufacturing process. The real rim production process and improved

TECHNICAL PAPERS Fig. 8. Motion of contact point between wire and roll no. 8.

Fig. 9. Contact point between wire and roll no. 8 with only rim curvature bending.

Fig. 10. Contact point between wire and roll no. 8 with only lens curvature bending.

Fig. 11. Contact point between wire and roll no. 8 with lens curvature bending and rim curvature bending.

Fig. 12. Decomposition of intermesh h into rim and lens curvature bending components.

Fig. 13. Mechanism of decreasing twisting moment Mx .

methods for the high-precision roll bending production of rims were investigated and discussed. The results obtained in this study are as follows: 1. A simulation model for a real rim production machine was created and used successfully for simulations. 2. The cause of processing defects was found to be tilting of the wire owing to twisting moment Mx generated by the lens curvature under roll no. 8, while rim curvature κz was affected by the rotation angle θ. 3. Processing defects could be reduced, and rim curvature bending could be conducted under a smaller wire tilt by shortening the distance between roll nos. 7 and 8. 4. Regarding the prior finding, further investigation should be done to determine the optimum distance and to thoroughly verify this method.

References 1 K. Yamanouchi, Journal of the Japan Society for Technology of Plasticity, 45-516, 2004, pp. 13-18 2 Y. Sekine, K. Nishimura, N. Kato, M. Matsumura, Y. Sasaki, T. Tanaka and M. Asakawa, Journal of the Japan Society of Mechanical Engineers, 2012, pp. 155-156. 3 Y. Sekine, K. Nishimura, N. Kato, Y. Sasaki, M. Matsumura, H. Yagi and M. Asakawa, Proceedings of the 2012 Japanese Spring Conf. for the Technology of Plasticity, 2012, pp. 63-64 4 Y. Sasaki, M. Matsumura, K. Morishita, T. Tanaka, H. Yagi, Y. Sekine and M. Asakawa, Proceedings of the 2012 Japanese Spring Conf. for the Technology of Plasticity, 2012, pp. 65-66.

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5 Y. Sasaki, M. Otsu, K. Morishita, T. Tanaka, H. Yagi, Y. Sekine and M. Asakawa, Proceedings of the 2012 Japanese Autumn Conf. for the Technology of Plasticity, 2012, pp. 431-432 6 Y. Takebe, N. Kato, Y. Sekine, Y. Sasaki, M. Matsumura, H. Yagi and M. Asakawa, The Proceedings of the 2012 Japanese Autumn Conf. for the Technology of Plasticity, 2012, pp. 433-434.  Fig. 14. Arrangement of bending rolls (shortened version).

Fig. 15. Relationship between rim curvature κz and deviation from standard wire, Δκz, after shortening the distance between roll no. 7 and no. 8.

Fig. 16. Comparison of equivalent strains before shortening and after shortening. 56 | WIRE JOURNAL INTERNATIONAL

Yuichiro Sekine, Natsuki Kato, Yuki Takebe, and Shuzo Matsuo are students in the School of Fundamental Science and Engineering of Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the school’s mechanical engineering department. Yoshinori Sasaki is and Dr. Masami Matsumura are research fellows at the Industrial Technology Center of Fukui Prefecture, Fukui, Japan. This presentation, which was made at WAI’s 83rd Annual Convention, Interwire 2013, Atlanta, Georgia, USA, April 2013, won the Silver Certiﬁcate Award in the Nonferrous Division.

Improvement of ductility of aluminum wire by alternate drawing An alternative drawing method is proposed for producing aluminum wire for an automotive wiring harness with a comparison of the ductility between alternately drawn wires and unidirectionally drawn wires. By Kazunari Yoshida and Kota Doi

Deployment of aluminum wiring harnesses is now under consideration to improve fuel efﬁciency of cars. The speciﬁc gravity of aluminum is one third of that of copper. Therefore, by changing the material of wiring harness from copper to aluminum, it is possible to reduce the weight of wiring harness of a car by 10-40%1. Wire drawn for automobile wiring harnesses require high strength and high ductility to withstand breaking from vehicle vibration and repeated bending caused by door opening and closing. In wiredrawing, additional shearing strain accumulates in the surface part of the wire2, and the strength of the drawn wires increases due to its work hardening. On the other hand, ductility of the drawn wire decreases as the frequency of wiredrawing increases. In this study, an alternate drawing process is proposed to obtain wire of high strength and high ductility3. It is presumed that alternate drawing decreases additional shearing strain by changing drawing direction (See Fig. 1) and increases ductility, though tensile strength decreases slightly compared to that of unidirectional drawn wires, resulting in the production of drawn wires of high ductility. In this study, wires processed by alternate drawing in every pass and several passes were used. Tensile tests of those wires were conducted to examine their mechanical

properties, and then usefulness of alternate drawing for the production of aluminum wiring harness was discussed. The residual stress measurement of drawn wires and crystallographic consideration were also performed.

Material and experimental method Annealed 99.7%-purity 9.6 mm aluminum wire of in diameter was used in the experiment. Chemical compositions of employed pure aluminum are shown in Table 1. Reduction per pass (R/P) was about 20%. The deﬁnition of R/P and total reduction (Rt) are shown in Fig. 2. The drawing speed was 500 mm/min. WC dies with a six-degree half angle and petroleum-based hydrocarbon lubricant were used to draw wires. Wires of Rt = 99.77% (total pass number is 27) were processed by alternate drawing in every pass, every three passes, every nine passes and with wires processed by unidirectional drawing until its diameter became the same as that of alternately drawn wire. They were used to check usefulness of alternate drawing, and then a comparison of strength and ductility of those wires were made by conducting tensile test and crystal texture analysis by X-Ray Diffraction (XRD). Fig. 3 shows fabrication process of

Table 1. Chemical compositions.

Fig. 1. Restriction of additional shearing strain by alternate drawing.

Fig. 2. Deﬁnition of R/P and Rt in wiredrawing. NOVEMBER 2014 | 57

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each drawn wire, and Table 2 shows timings of drawing direction change in tested wire drawing. Hereafter, W1 represents a wire processed by alternate drawing in every pass, W3 a wire in every three passes, W9 a wire in every nine passes, and Wu a wire processed by unidirectional drawing.

Results and discussions Tensile tests were conducted to compare mechanical properties of the previously described four kinds of wires of Rt = 99.77%. Fig. 4 shows stress-strain curve obtained from the tests.

It can be seen that the tensile strength of W1,W3 and W9 is lower than that of a unidirectionally drawn wire, and the value of breaking strain of drawn wires is higher than that of an unidirectionally drawn wire. Targeted tensile strength value for automotive wiring harness is 160 MPa. W1, W3 and W9 meet the targeted tensile strength value. The value of breaking strain of Wu is 0.012, but that of W1 is 0.022, W3 is 0.018, W9 is 0.015. This means that ductility of alternately drawn wires has improved. The rate of breaking-strain-value increase of W1, W3 and W9 to that of Wu is improved 88% for W1, 52% for W3, and 29% for W9. This shows that ductility

Fig. 3. Fabrication process of several drawn wires.

Table 2. Timing of drawing direction change in each drawing method.

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The drawing rate of each drawn wire in tensile test was examined by observing SEM images shown in Fig. 6. Fig. 7 shows the drawing rate of each drawn wire and comparison of drawing rate between drawn wires.

Fig. 4. Stress-strain curves of several drawn wires. (Rt = 99.77%)

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of alternately drawn wires is higher than that of unidirectionally drawn wires, and higher ductility can be obtained as the number of drawing direction change increase. It is considered that additional shearing strain is restrained by drawing direction change. Then, tensile tests of drawn wires of various Rts were conducted. Fig. 5 shows the test results of tensile strength and breaking strain of drawn wires of Rt = 98.19%, 98.89%, 99.44%, and 99.77%. As can be seen in Fig. 5, ductility of alternately drawn wires is higher than that of unidirectionally drawn wires in each Rt, and difference in tensile strength and breaking strain between drawn wires which are in the same Rt value increases as the value of Rt increases. Next, observing the drawn wireâ&#x20AC;&#x2122;s fracture surface caused by tensile tests, evaluation of ductility is discussed. Fig. 6 shows SEM images of fracture surface of four kinds of drawn wires. (a) is for wires of Rt = 98.89%, and (b) is for wires of Rt = 99.77%.

TECHNICAL PAPERS

In both Rts, wires in decreasing order of drawing rate are placed as follows: W1, W3, W9 and Wu. As can be seen in Fig. 7, the change in the drawing rate of wires which are in the same Rt vale becomes large as Rt increases.

These results agree well with the results of comparison of tensile strength and comparison of breaking strain which are shown in Fig. 5. Tensile tests and observations of fracture surface made it clear that alternately drawn wires possess high ductility.

Comparison of residual stress of drawn wire by slit method Axial residual stress is also an important mechanical property for drawn wires. Axial residual stress σ of drawn wires of Rt = 95.44% and 98.19% is examined by using the slit method4. Fig. 8 shows the results. Using the mathematical scheme shown in Fig. 8(c), axial residual stress was calculated under the condition that Young’s modulus E is 70GPa and slit length is 20 mm. Residual stress increases as slit width δ increases. Fig. 8(a) shows images of Fig. 7. Comparison of drawing rates.

Fig. 10. Comparison of (111) plane in each drawn wire (RT = 99.77%). 60 | WIRE JOURNAL INTERNATIONAL

Crystallographic consideration Crystal plane orientation of each drawn wire was examined by XRD to make crystallographic consideration on the cause of restriction to ductility decrease which occurs in alternate drawing. Inakazu5 has reported a change of crystal rotation in fcc metals during drawing as shown in Fig. 9. In drawn wires, diffraction intensity in the (111) plane increases along with the increase of Rt. There seems to be a relationship between the formation of (111) plane and work hardening. Diffraction intensity of (111) plane in surface part of drawn wires of Rt = 99.77% were examined by XRD. The ratio of diffraction intensity of a drawn wire to that of the original wire was calculated by setting diffraction intensity of the original wire equal to 1. Fig. 10 shows the results. As can be seen in Fig. 10, diffraction intensity of (111) plane of drawn wires is higher than that of the original wires. And the unidirectionally drawn wire shows the strongest diffraction intensity of (111) plane. Meanwhile, for alternately drawn wires, diffraction intensity decreases as the number of drawing direction change increases. It is considered that processing by drawing direction change caused the restriction of formation of (111) plane, resulting in the improvement of ductility of drawn wires.

Conclusions Using wires which were processed by alternate drawing in every pass, every three passes, and every nine passes and drawn up to Rt = 99.77% (total pass number is 27), their mechanical properties, fracture surface, residual stress and crystal plane orientation were compared with those of unidirectionally drawn wires. The findings are as follows:  It is possible to restrain work hardening by alternate drawing. Also, accumulation of residual stress in drawn wires is restricted.  Wire processed by alternate drawing in every pass showed the highest ductility, also wires processed by alternate drawing in three passes and nine passes showed relatively high ductility.  The reason for the restriction of work hardening of drawn wires in alternate drawing is considered as follows: Drawing direction change restricts the formation of (111) plane in surface part of drawn wires. n

References 1. Furukwa Electric, http://www.furukawaas.co.jp/products/01.html#harness01. 2. K. Yoshida, “Basis of Plastic Working,” Sangyo-Tosho Publishing, 1988, p. 66. 3. S. Kikuchi, “Improvement of mechanical properties of drawn aluminum wire for wiring harnesses,” Wire Journal International, August 2011, pp. 76-80. 4. H. Sutou, “Residual stress and distortion,” Uchida Rokakuho Publishing, 1994, p. 48. 5. N. Inakazu, “Metal Drawing and Fiber Textures,” Kindai Hensyu, 1985, p. 151.

Kazunari Yoshida is a professor at Tokai University, Japan. He has served as a member of the steering committee for Japanese Wire Drawing. He holds a Ph.D. degree in engineering. He authored a prize-winning paper for the Japan Society for Technology of Plasticity and won medal awards from WAI for the best paper as well as its Mordica Memorial Award in 2011. Kota Doi is a graduate student at Tokai University. This paper was presented at WAI’s 83rd Annual Convention, Atlanta, Georgia, USA, April 2013. Kazunari Yoshida

Kota Doi

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slit of drawn wires of Rt = 95.44%, (b) Rt = 98.19%, and (c) shows comparison of residual stress. As can be seen in Fig. 8 (a) and (b), slit width δ decreases as the frequency of drawing-direction change increases. And, as can be seen in Fig. 8(c) ,the σ of W1 is the lowest of the tested drawn wires, and σ of Wu the highest, and change in σ between wires which are in the same Rt value increases as Rt increases. These results prove that alternate drawing decreases axial residual stress of drawn wires.

TECHNICAL PAPERS

TECHNICAL PAPER New efficient and ecological surface cleaning technique for ferrous and nonferrous wires Plasma surface cleaning technology can be achieved with single-head drivers that require a relatively small footprints while a multi-head setup has much potential. By Rory A. Wolf

Wiring used within industries such as aerospace, military, automotive (tire wire), electronics and fabrication/ welding require clean bonding surfaces. Ferrous and nonferrous wire materials inclusive of copper, stainless steel, nickel, aluminum and alloys benefit from surface cleaning prior to downstream processes. There has also been a meteoric rise in the development and use of greater alloyed metals, creating more demands on wire cleaning processes. Current wire cleaning techniques include acid baths, salt baths, chemical-based reactive low pressure plasmas, high energy/high frequency ultrasonic cavitation, electrical pre-annealing systems with induced atmospheres (N2 or steam), and gas-fired annealing systems with reducing gas atmospheres (0% O2 and up to 10% reductives with gas-rich burner protocols). Acid waste streams (e.g., alkalines for degreasing, phosphoric acids for removing stearate soaps), high-volume chemical or gas consumptions high electrical energy consumption, and low operating speeds characterize these processes which are intended to remove wire surface contaminants created during the drawing process. Typical contaminants removed include– but are not limited to–calcium and sodium stearate lubricants after the drawing process or lubricating oils remaining following wet drawing processes. Industrial challenges to achieving clean wires include repeated annealing cycles, the use of high film-strength lubricants in the drawing process, maintaining die life and surface finish and non-uniform anneal scale contamination. However, with the appropriate wire cleaning process, strict wire cleaning objectives can be met. An ideal systematic wire cleaning technology would feature a wet chemical-free, dry surface treatment process having the ability to remove/ablate surface contaminants; a dry, wet chemical-free process; surface activation to promote adhesion of coatings; a low footprint; low operational and maintenance costs; a long MBTF; electronic controls and a highly user-friendly control interface. 62 | WIRE JOURNAL INTERNATIONAL

One such process approaching these features is atmospheric pressure plasma technology (APPT). Evolved from low-pressure regimes, APPT has become a promising tool for cost-efficient, ecological surface cleaning of metals.

Atmospheric plasmas and metals cleaning The establishment of efficient atmospheric pressure plasma technologies to replace traditional methods to clean, create depositions of thin films, and prepare surfaces of metal substrates for processing constitutes a very critical area of current research and development. The increasing concern for the development of environmentally friendly and sustainable technologies has led to a focus on cold plasma technology which represents an efficient alternative. Atmospheric plasma treatments can remove oils from metal surfaces. This surface conditioning can also act as a preparation step for thin film deposition of monomers such as hexamethyldisiloxane or enameling to achieve corrosion protection. This interfacial layer can also be designed to favor the adhesion of additional extruded polymer layers. An ecological process, atmospheric pressure plasma “dry etching” is a technique which can be employed to clean organic oil layers from metal surfaces in an in-line, continuous manner. The surface etch rate will depend upon the physical and chemical properties of the oil, the thickness of the layer, the substrate, and on the plasma process parameters. The speed of removal of the organic layer will be accelerated by an oil with high vapor pressure and low viscosity. Of greater conduciveness will be an oil contamination layer containing hydroxyl and ester groups, and be free of heavy metal ion additives. Etch rate dependence will also concern plasma process parameters such as gas flow rate, energy density and dwell time. All of these parameters will affect substrate temperature, which is a key factor in plasma etching as well. Industrial applications have favored plasma gas mixtures consisting of oxidizing as well as reducing components.

Flame plasmas A flame plasma (Fig. 1) is formed when a flammable gas and atmospheric air are combined and combusted to form an intense blue flame. The surface of materials are made polar as species in the flame plasma affect electron distribution and density at the surface. Polar functional groups such as ether, ester, carbonyl, carboxyl and hydroxyl are contained in a flame plasma, Fig. 1. Port-based flame plasma. and these can be incorporated into the surface of amorphous materials such as polyolefins and affect the electron density of the polymer material. With metals, there is simply a deposition of these polar groups to the surface. This polarization and functionalization is made through reactive oxidation of the surface. ESCA analysis shows, for example, that oxidation depth through flame treatment is 5-10 nm with polymers, and with metals there are minimal surface-oxidative species. Flame plasma treatment’s oxidative effects–due to reactions with OH radicals in the flame–result in a highly wettable surface which is relatively stable upon aging. Practical applications of flame plasmas has established that base substrates are optimally treated by flame plas-

mas when they are positioned approximately 5-8 mm above the inner luminous ﬂame cones (known as the primary treatment zone). Line speed and burner output (BTUs/min/incremental burner length) will affect this positioning. The treatment byproducts to be exhausted from the open-air cleaning location include contamination particulates which are volatilized, vaporized or ablated, carbon dioxide, and water vapor, and small ppm of CO.

Blown ion (air) plasmas

TECHNICAL PAPERS

More recently, metal products pretreated by atmospheric pressure plasma processes have tendered new facilitations such as in automobile parts painting, manufacturing of printed circuit boards, and for improving electromagnetic interference shielding adhesions between the different kind of materials, including water-borne adhesives and paints. Surfaces are therefore activated for metal/ polymer or metal-metal composites by atmospheric pressure plasma systems. Previously, there has been little pre-established in the form of explanations relative to the surface phenomena for hydrophilic properties established by this technique for metal wire surfaces, as well as how to obtain optimized conditions for hydrophilic surface conditions using atmospheric plasma. To understand the chemical reactions and functionalization phenomena on metal surfaces, ESCA (XPS) and AFM methods are commonly used for plasma-treated surfaces under optimum conditions. Surface energy and surface aging characteristics are commonly measured either by contact angle or dyne solutions. Two atmospheric plasma regimes which are now being employed for efﬁcient bare wire cleaning are ﬂame plasmas and blown-ion air plasmas. Both feature high velocity, high density discharges which are conducive for removing wire surface contaminations at high production speeds.

This type of atmospheric air plasma system (Fig. 2) pushes pressurized air past a single electrode which discharges inside the treating head. The electrode energizes electrons which, through bombardment, create positively charged ions within the discharge chamber. The air pressure Fig. 2. Blown ion air plasma. forces the ions to accelerate and stream out of the tip of the head at high velocity toward the substrate surface. Again, through direct contact, these ions positively charge the object’s surface, increasing its surface energy, cleaning the surface of low molecular weight contaminations and making it more receptive to jacketing extrusions, inks and coatings. Because the discharge occurs inside the treating device head, blown ion systems can treat both conductive and non-conductive materials. Often, preparation of substrate surfaces typically involves mechanical, chemical or vacuum plasma cleaning techniques. While effective in removing a large range and portions of contaminations, these processes are well-distinguished by slow cycle times and capital-intensiveness. Atmospheric blown ion systems are well-suited for continuous, in-line surface cleaning of wire surfaces at higher line speeds. A second surface effect of blown ion systems can be surface roughening for organic materials such as polymers. Surface roughening can increase the surface area of substrate, yielding better potential adhesion between the substrate and the interface (ink, coating, adhesive). The third effect is chemical modiﬁcation of the surface. Ion bombardment can alter the chemical structure of the surface by breaking existing bonds, producing a more reactive surface. The treatment byproducts to be exhausted from the open-air cleaning location include contamination particulates which are volatilized, vaporized or ablated, carbon dioxide, water vapor, and small ppm of NOx.

Test protocols and results An assortment of bare metal wire materials were sourced with standard surface contamination conditions for atmospheric plasma cleaning using either a single blown ion (non-arc, zero voltage potential) plasma disNOVEMBER 2014 | 63

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TECHNICAL PAPERS Table 1. Atmospheric (blown ion, flame) plasma-induced wire surface wettability protocols. charge or a single burner flame (non-arc, zero voltage potential) plasma discharge. Plasma device treatment gaps were 6 mm for the blown ion device and 38 mm for the flame plasma device. Gap variation is specific to discharge density zones within each respective plasma. Plasma discharge dwell times (power density) were determined and applied on the basis of sufficient cleaning (wettability) levels achieved. Table 1 shows pre- and post surface wettabilities as a function of wire surface type, as are the applied plasma density wettabilities, along with protocol processing speed which is a component metric with the plasma density calculation.

Conclusions The data provides clear evidence that the high velocity atmospheric pressure plasma surface cleaning regimes of blown ion and ﬂame can efﬁciently clean a wide range of bare wire surfaces. A unique outcome is that the above levels of surface wettability were achieved with single-head devices which occupy extremely small production line footprints compared to current state chambered cleaning systems. The expectation is that employing multiple device heads (on opposite wire sides for 360º cleaning) would not only increase surface cleanliness/wettability levels, but also enable linear increases in cleaning process speed. n

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At the time this paper was written, Rory Wolf was vice president of business development at Enercon Industries Corporation, Menomonee Falls, Wisconsin, USA. He has 28 years of experience in international positions in the plastics and packaging industries, with specific experience in polymer-based flexible packWolf aging, polymer surface modification systems and printing industry segments. He holds a MBA degree from Marquette University. He is a division council member, PLACE Division, in Technical Association of the Pulp and Paper Industry (TAPPI); executive board member for the Society of Plastics Engineers (SPE); and a member of the Society of Plastics Industry (SPI). He has published 26 technical papers, 35 industry articles, and two books of the topic of plastic surface modifications by atmospheric plasma technology. This paper was presented at WAI’s 83rd Annual Convention, Interwire 2013, Atlanta, Georgia, USA, April 2013.

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PRODUCTS TECHNOLOGY Multi-block breakdown line offers longer life and less maintenance A seven-block drawing line from Italy’s Frigeco, a business of the MFL Group, that was shown earlier this year at wire Düsseldorf, offer advantages to manufacturers in terms of both efficiency and longer component life. A press release said that the system, which has a block size of 560 mm and a total 240 Kw installed, is capable of running rod sizes from 5.50 to 6.50 mm down to a finished diameter of 2.50 to 3.00 mm. The machine employs the latest Frigerio rolling cassette design, which features an improved cooling system that guarantees longer life for rollers and bearings, it said.

The breakdown machine, with the set up shown in the picture (or with various configurations of more or less blocks) can be used for production of low/medium carbon products for fences, nails and welding wire, the release said. The system is able to operate at high efficiency and high speed due to the well-known block cooling system. The model has a safety guarding system with internal lighting that allows the operator to look inside the machine during operation while the dust extraction set-up removes all the heated air generated by the process, together with dust created by the lubricant. This machine is capable of bypassing the blocks in case the required draft requires a smaller number of blocks. Also, an OTO accumulation block on the first pass is provided to help the payoff operation in case of snarls. Contact: Marco Dell’Oro, sales manager, Frigeco, www.mariofrigerio.com.

Strander can meet exacting demands, both those present and those to come At Wire China, the Eurolls Group showcased the company’s new double-torsion stranding machine for steel cord, DT-I-B80, that was designed to be able to process the most advanced product characteristic requirements.

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A press release, which noted that there was much interest in the model at the event, provided the following details. All the components were chosen to enable the machine to offer specific advantages and optimum performances. The model is easy to string up, and it is possible to adjust the number of wires processed by the high-performance pre-cabling device. Wire tension is self-setting, covered by the payoff section. The bunching section is optimized by special strand parameter control software and a special capstan design results in correct tension at any time. The model features an accurate wirebreak checking system, and it is easy to change the strand pitch and twister control device to obtain the desired cord shape. The catenary path is on rotating pulleys and the cord length is double-checked. The easy-to-maintain and operator-friendly machine uses top-level components, a simple and ergonomic design integrating load and unload spool system, constant speed and low noise production. All these attributes make it an innovation for today that will also be able to meet future steel cord production requirements, as its design will allow increasing of carbon content, production of thinner and stronger wires, with lower weight and higher tensile strength. Contact: Eurolls Group, www.eurolls.com.

Horizontal and vertical coilers offer high output on short-length coils At Wire China, Sweden’s Windak Group showcased its QuickPack QP3-H and QP3-V models, which it reports are fast coilers with high output. A press release provided the following details about the QP3-H model, a horizontal coiler, and the QP3-V model, a vertical coiler. The coilers are designed for maximum output on short length coils to 100 m lengths/coils. Both use modern servo technology for accurate and fast movements, and can be set up with four different packaging methods: binder, stretch film, shrink film or box. The Quickpack QP3-H is suitable for high-speed packaging of single conductor for round and flat products. The coil is held together with two elastic binds and with optional shrink film as final package. Specs are could ID

Low-cost compound line designed for general purpose jacketing

from 110 mm to 160 mm, OD from 120 mm to 300 mm and maximum weight of 12 kg. It targets products from 2.5 mm to 13 mm, and coil lengths from 5 m to 100 m per package. Output is up to eight coils per minute, depending on type of cable and winding length. Almost all movements in this fast single-head machine are controlled by servos with very few mechanical setting changes for different packages. Coils can be binded, shrink filmed or put in boxes, all in one complete solution. The Quickpack QP3-V is designed for high-speed packaging of single conductor round and flat products that can be packed into plastic bag, cardboard box or both solutions.

At wire China, U.S.-based Teknor Apex Company showcased a new series of low-cost Halguard® 58600 products intended for general-purpose jacketing of cable used in telecom, datacom, electrical and electronic equipment as well as infrastructure applications. A press release provided the following details about the halogen-free, flame retardant (HFFR) compounds, which it noted cost less than premium compounds but with little compromise in performance properties. The 58600 series HFFR compounds are available with Shore D hardness ranging from 47 to 53 and LOI of 40% to 45%. Like other general-purpose HFFR compounds, their ability to pass the most stringent flame tests such as UL 1685 FT4 or UL1666 depends upon the overall cable design, but they provide comparable or superior UL94 performance. They exhibit similar tensile properties and greater flexibility in comparison to competitive grades. See property details in table.) The compounds are ideal for used in subways, mass transit, cell towers and other infrastructure applications as well as internal wiring in electrical and electronic equipment.

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

Where can you buy specialized tension controls and pay-offs? Or custom pulleys with different inserts, coatings and sizes? Wyrepak Industries has the answer for all of your manufacturing needs! For more details on any of our manufacturing product solutions, call us at 800-972-9222 or email sales@wyrepak.com WYREPAK INDUSTRIES — A Huestis Industrial Company • www.WYREPAK.com

68 Buttonwood Street, Bristol, Rhode Island 02809-0718 USA • tel: 800.972.9222 or 401.253.5500 fax: 401.253.7350 2C_WYREPAKHuestis_WhereCanYouBuySpecialized_WJI_halfHoriz_VariousCombos_ShowInfoAdded_v2_09062013_press.indd 1

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Specs are coil ID from 100 mm to 160 mm, coil OD from 150 mm – 260 mm and maximum weight of 12 kg. Contact: Windak Group, www.windakgroup.com.

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options that protect cables from unwanted EMI/RFI issues, even in continuous flexing applications. A press release noted the following about the company’s flat-cable technology. The cable’s double-shielded design is comprised of an inner foil shield that provides 100% coverage and an overall tinned copper braid with 90% coverage. A durable, yet flexible PFA insulation is

“Halguard 58600 Series compounds meet the property requirements of a wide range of general-purpose jacketing applications while costing signiﬁcantly less than other Halguard compounds or competing HFFR products,” said Mike Patel, director of marketing and business development for the Vinyl Division of Teknor Apex. “To keep our customers competitive, our technical team is constantly working to create the optimal cost-performance mix.” Contact: Teknor Apex Company, tel. 401-725-8000, vinyl@teknorapex.com, www.teknorapex.com.

Line of dual-shielded flat cables can provide the ultimate EMI protection U.S.-based Cicoil reports that the company’s line of dual-shield ﬂat cable provides multi-layer shielding

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layered between each shield, which protects the inner foil shield from making contact with the outer tinned copper braid. In addition, the foil shield is isolated from damage caused by mechanical stress, vibration and continuous motion. A patented computer-controlled extrusion process allows each dual-shielded pair to be placed in a ﬂat parallel proﬁle, precisely controlling the inner component spacing, jacket thickness and the overall cable

Foaming fluoropolymer reduces costs for materials, improves processing PolyOne Colorant Chromatics has launched a new chemical foaming solution for ﬂuoropolymer wire insulation that can reduce part density while enhancing the stability and efﬁciency of the manufacturing process.

A press release said that the advanced additive, suitable for FEP, PFA and MFA polymers, enables customers to preserve electrical properties while reducing insulation thickness and raw material consumption through a con-

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shape. This ensures that each of the individually shielded pairs do not rub against each other, wear during operation and provide optimum EMI/RFI suppression. This combination of features makes Cicoil’s flat, double shielded cables an excellent alternative to single shielded or individually shielded round cables. The compact, flame retardant cable, free of contaminants and halogens, is engineered to provide uninterrupted data transmission reliability, space efficiency and consistent electrical characteristics. The proprietary Flexx-Sil™ jacket is also self-healing from small punctures and is impervious to long term exposure to water, ice, steam, UV light, ozone, sunlight, radiation, humidity, fungus, temperature extremes (-65°C to +260°C), coarse sand, autoclave and many chemicals. Cables are available in continuous lengths, break-outs, custom shapes for very tight spaces, cut to order, or as assemblies, complete with connectors of your choice, 100% tested and inspected for peak electrical performance, quality and reliability. The cables are UL and CSA recognized, CE Conforming, RoHS & REACH Compliant, Class 1 Clean Room Rated and manufactured in an automated, climate controlled environment, with strict quality and inspection controls. Contact: Cicoil, www.cicoil.com.

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sistent closed cell structure. “It’s difﬁcult to minimize the tradeoffs between thermal stability, foaming control and high processing temperatures when applying wire insulation,” said Barto du Plessis, the company’s general manager. “This new technology balances all three performance requirements and boosts productivity without the need for additional equipment investment.” The additive, the release said, provides wire manufacturers the following beneﬁts: superior foaming performance, due to maximum gas generation resulting from no premature foaming enables greater process control; tight tolerances, as enhanced dispersion of active foaming ingredients produces a consistent cell structure of 200 micron or less, so insulation thickness and density are reduced without adversely effecting electrical, chemical or thermal properties; and thermal stability, as it offers excellent heat resistance from 340-380°C supports effective homogenization of the foaming agent with high-performance polymers. Contact: PolyOne Colorant Chromatics, www.colorant-chromatics.com.

Electrolytic process is a plus for surface pretreatment of both wire and strip

Germany’s Staku-Anlagenbau GmbH, which is represented in North America by Wire Machine Systems and focuses on processes for surface pre-treatment and ﬁnishing, reports that its electrolytic phosphating (Ephos) technology has been shown to offer superior results for inline cleaning and coating of high-quality stainless steel. A press release provided the following details about the Ephos technology, which was showcased earlier this year at wire Düsseldorf. The electrolytic process is especially appropriate for high-quality stainless steel as it can be directly phosphatized without having to apply an intermediate coating beforehand. The phosphate layer can serve as a lubricant carrier for cold forming or as a bonding agent for paint or rubber coatings. The electrical potential applied from outside prevents the basic

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material from dissolving, which increases the operating life of the process baths by months and thus guarantees consistently high product quality. All systems can be equipped with optional titrolysers to guarantee on-line monitoring of the process baths. The electrolytic process reduces process times from minutes to fractions of a second, making a new in-line production installation possible. It reduces the overall in-line layout length while simultaneously increasing capacity. Ephos coating of stainless steel can be realized at speeds up to 200 fpm due to a coating time of four seconds. The coating thickness can be between 2 and 4 gr/mm², which is enough for the following rubber coating process. STAKU has already supplied Eclean (electrolytic degreasing) lines for strip to handle a width of 63 in. at speeds of 500 fpm. The higher speeds, for example, made it possible to increase the capacity of CO2 welding wire production with Ecopp (electrolytic coppering) by 50% and cut manufacturing cost in half, mostly from low disposal costs and savings in the use of precious metal. It also extends the operating life of a typical copper sulfate bath from one week to as long as two to three months. Contact: Staku-Anlagenbau GmbH, www.staku-gmbh.de, Wire Machine Systems, Inc., tel. 260-483-9269, sales@wire-machine.com, www.wire-machine.com.

U.S.-based TPC Wire & Cable Corp., has expanded its Thermo-Trex® family of cables with Thermo-Trex 500-Plus 12 AWG cord sets that are designed with a tear-resistant silicone jacket and fully-bonded silicone head providing an IP68-Rated seal against moisture.

A press release provided the following details about the cable, which it described as an ideal choice for applications where electrical connections are exposed to high temperatures up to 180°C, UV light, chemicals, moisture, dust and mechanical abuse. The new cord sets work well in industrial environments such as steel, wood, pulp and paper, oil and gas, transportation and food processing which can be unusually abusive. The product was designed to include

extra-long grounding pins to ensure first-in, last-out contact for safety, as well as stainless steel knurled coupling rings and a retaining washer that resists corrosion, and provides quick and secure assembly. The solid brass contact pins are nickel-coated and gold-plated for longer life, corrosion resistance and easier positive engagement. Customers will benefit from its excellent low voltage, low-level signal applications for use in conveyors, pumps, motor operated valves, kiln fans and hood lighting. The company notes at its website that two other notable products it offers include: Chem-Gard™ Cat. 6 Cable, a rugged industrial Ethernet cable built for performance in the harshest of environments, that has unique physical properties offering resistance to UV light, cutting, abrasion, oil and chemicals and extreme temperatures–providing superior performance to meet or exceed Cat. 6 and Ethernet/IP requirements; and Super-Trex® Basket-Crane Cable, which is designed for gravity-fed crane systems and also known as “bologna cable,” made with a heavy-duty polyurethane jacket that provides excellent protection against abrasion, chemicals and UV light, with an aramid fiber braid that supplies additional strength and support to extend cable life, making it an excellent choice for both indoor and outdoor applications. Contact: TPC Wire & Cable Corp., www.tpcwire.com.

There are many cold welder companies to choose from... So why should you buy from Huestis Industrial? a. Quality b. Performance c. Dependability d. Reputation e. Pricing

f. Delivery g. Warranty h. Customer Service i. All of the above

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www.huestisindustrial.com Air Wipes, Pay-offs, Take-ups, Buncher Pay-offs, Accumulators, Spoolers, Cold Pressure Welders, Cable Jacket Strippers, Custom Machinery 2C_HUESTIS_CPW_ManyCompaniesToChoose_WJI_halfHoriz_VariousCombos_v10_10062014_press.indd 1

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Cables ideal for harsh conditions

PRODUCTS & MEDIA

MEDIA Report covers sustainability performance of the steel industry A new report from worldsteel, 2014 Sustainability Indicators, presents the steel industry’s progress in sustainability performance over the past decade. A press release from worldsteel provided the following details. The report has 2013 results for eight sustainability indicators reported on by the steel industry. For environmental performance, in 2013, one metric ton of crude steel required average greenhouse gas emissions of 1.8 metric tons of CO2 and an energy intensity of 20.0 GJ. Material efﬁciency indicator results showed that 96.4% of materials used on-site to make crude steel are converted to products and by-products. The environmental management systems (EMS) indicator demonstrated that 90.2% of steel industry employees and contractors worked in EMS registered production facilities. For social performance, the lost-time injury frequency rate (LTIFR) was at 1.6 injuries per million hours

worked in 2013 while the employee training indicator showed that employees (at both production and non-production facilities) received an average of 7.8 training days during the year. For economic performance, investment in new processes and products in 2013 was at 8.6 % of revenue while economic value distributed (EVD) reached US$582.7 billion, or 97.3% of revenue. “Measuring performance is the ﬁrst step in making progress and having deﬁned indicators allows compa-

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nies to benchmark themselves and encourages further improvement,” said worldsteel Director General Edwin Basson, “Sustainability reporting at a global level is a major effort that the steel industry undertakes to manage its performance and demonstrate its commitment to sustainability. In 2004, 42 steel companies participated with a rise to 149 companies in 2014.” The report can be seen at the organization’s website. Contact: worldsteel, worldsteel.org.

Website provides a wealth of info on marking/coding equipment Germany’s Paul Leibinger GmbH & Co. KG has relaunched its website to make it simpler than ever for customers to ﬁnd and learn more about the company’s range of marking and coding equipment.

A press release said that the company website is now “radiating with a fresh, new design” and is clearly focused make it quick and easy to find information. It noted the following. With just a click you can get detailed information about continuous inkjet printers, camera verification systems and numbering machines as well as access to a “News” area with press releases, news and current trade show appearances. Under the “Industries” heading, visitors can find information for marking requirements and solutions for many different sectors, including wire and cable. One can also locate a company staffer to contact. Among the systems that can be found are the company’s JET3 and JET2neo models as well as information about software and accessories. The company notes that for more than six decades, it has been developing and producing numbering machines, camera verification systems and inkjet printers at its Tuttlingen location in Baden-Württemberg, Germany. Its product lines—from development to production—are all made in Germany, and sold in more than 150 countries throughout the world. Contact: Paul Leibinger, GmbH & Co. KG, info@ leibinger-group.com, www.leibinger-group.com. n

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

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

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

PAYMENT POLICY: All ads must be pre-paid. DEADLINES: Copy is due a full month in advance. Contact: classiﬁed@wirenet.org for more details.

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WIRE & CABLE REPRESENTATIVE AVAILABLE FOR THE AMERICAS. Do you need an experienced salesman in Mexico, Central and South America? If so, please conact Antonio Ayala at 1953ayala@ gmail.com.

“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 thousands of key individual contributors. Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593,

CAREER OPPORTUNITIES 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 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. OFF SHIFT MANUFACTURING MANAGER. Central MA-based privately held hi tech custom cable manufacturer seeks off shift manufacturing manager. Extensive background and experience in the wire & cable industry is required. Offering excellent pay, beneﬁts and opportunities for personal and professional growth for the right candidate. Send resume to recruit.wireandcable@ gmail.com.

Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.

DIES MILLER-MIDWESTERN DIE COMPANY. Finshed, Rough-Core and Reworked Round Drawing Dies. R7 through R18/Various Case Sizes. P: 815-338-6696 F: 815-338-0941 E: sales@millermidwestern.die.

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 - NEB 24-C CB-1 Cable Braider 7 - KINREI 560mm D.T. Twisters 1 - MGS 50” Caterpuller Capstan 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 3.5” 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 - KRUPP 37-Wire 27” Rigid Strander 1 - KRUPP 1+12 Wire 31” Tubular Strander 1 - KRUPP 1+6 Wire 26” Tubular Strander 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 - BARTELL 108” Gantry Take-up 1 - METEOR Model ME301 3-Head Winder 1 - TEC Model DTC630 D.T. Twister 1 - ENTWISTLE 4WDT24 4-W 24” D.T. Twisters 2 - NEWMCO 16” D.T. Quadders 1 - METRONIC AlphaJet C Inkjet Printer, 2005 1 - HALL Tape Accumulator 1 - WARBRICK “Chalkmaster” Talc Applicator 1 - EUBANKS Model 4000-04 C/S Machine

1 - MGS 84” Payoff, Motorized 1 - AFA 84” Portal Payoff 1 - LESMO 1800mm Gantry Payoff, Model SPF1800 1 - SKALTEK 1600mm Payoff, Model A16-4K

1 - SCHLEUNIGER Model UC3750 Cutter 1 - SCHLEUNIGER Model ES3200 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

1 - DYNAMEX Tape Payoff, Model TPB30-2-D 2 - KRUPP 54-Wire 31” Rigid Stranders Commission

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WE SELL GOOD USED DIAMOND DIES. All dies should be recut to your speciﬁcations and should be able to be recut a number of larger sizes. Your inspection should show this. Guarantee Included. For more information, reply to Box 10-1, Wire Journal International, PO Box 578, Guilford, CT., 06437-0578USA or classiﬁed@wirenet.org reference 10-1. 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.

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: 727-863-4700 or by e-mail, please send to urbassoc@ verizon.net.

MEDIA 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

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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 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 book (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

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.

shipping. To purchase, go to wirenet. org and click on The WAI Store. n 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. Published by SMA, 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 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. The price is $75, $50 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.

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

AlphaGary Corp . . . . . . . . . . . . . . . . . . . . .Cover 2

Lesmo Machinery America Inc/Tramev. . . . . . 13

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

Metalloid Corp . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . 68

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . 35

Beta LaserMike/NDC Technologies . . . . . . . . . . 1

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . 23

Cable Consultants Corp . . . . . . . . . . . . . . . . . . 27

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

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

Pressure Welding Machines Ltd . . . . . . . . . . . 13

CM Furnaces Inc . . . . . . . . . . . . . . . . . . . . . . . . 24

Proton Products International Ltd . . . . . . . 22, 40

Commission Brokers Inc . . . . . . . . . . . . . . . . . 73

Queins Machines GmbH . . . . . . . . . . . . . . . . . . 19

Esteves Group USA . . . . . . . . . . . . . . . . . . . . . 41

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

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . 69

Sealeze A Unit of Jason Inc . . . . . . . . . . . . . . . 17

Flymca & Flyro. . . . . . . . . . . . . . . . . . . . . . . . . . 15

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

Frigeco USA Inc. . . . . . . . . . . . . . . . . . . . . . . . . 25

Sjogren Industries Inc. . . . . . . . . . . . . . . . . . . . 34

Howar Equipment . . . . . . . . . . . . . . . . . . . . 68, 70

Steel Cable Reels . . . . . . . . . . . . . . . . . . . . . . . 26

Howar Equipment/Unitek . . . . . . . . . . . . . . . . . 45

August Strecker GmbH & Co KG. . . . . . . . . . . 11

Huestis Industrial . . . . . . . . . . . . . . . . . . . . 48, 71

Talladega Castings & Machine Co . . . . . . . . . 29

Inosym Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . 36, 47

Tramev/Lesmo Machinery America Inc. . . . . . 13

KEIR Manufacturing Inc . . . . . . . . . . . . . . . . . . 69

Unitek/Howar Equipment . . . . . . . . . . . . . . . . . 45

NOVEMBER 2014 | 75

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX PEOPLE

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

AlphaGary Corp . . . . . . . . . . . . . . . . . . . . .Cover 2

Vandor Corporation . . . . . . . . . . . . . . . . . . . . . 21

January 2015 WJI

Windak Group . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Wire & Plastic Machinery Corp . . . . . . . . . . . . . 9 Wyrepak Industries . . . . . . . . . . . . . . . . . . . 20, 67

• Wireless Update • IWCS wrapup

WTM Srl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

WIRE ASSOCIATION INTERNATIONAL ADS Interwire 2015 . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Global Continuous Casting Forum . . . . . . . . . 33 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . 37 Wire Foundation . . . . . . . . . . . . . . . . . . . . . . . . 65 WAI Industry Search . . . . . . . . . . . . . . . . . . . . . 76

WIRE JOURNAL

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

SALES OFFICES NORTH AMERICA

EUROPE

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

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

ASIA/ WAI INDIA OFFICE

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

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

76 | WIRE JOURNAL INTERNATIONAL

Advertising Deadline: Dec. 1