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After April’s successful wire 2014 in Düsseldorf, Germany, the industry turns its attention Stateside for Wire Expo. The Indiana Convention Center, Indianapolis, plays host to the show from 6 th to 7 th May. paper presentations, an exhibition and product demonstrations throughout the two-day event. Wire Expo originated in Boston in 1990 and has been hosted throughout the USA since, with exhibiting companies including suppliers to the wire, cable, fastener, formed and fabricated wire products. Companies have represented all sectors of metal and bre. Some of the exhibiting companies can be found from page 44 onwards in this issue of EuroWire . Also in this issue is news that Nexans is deploying the world’s longest and deepest XLPE cable system. This can be found on page 9. There are departures and arrivals to the executive board of the International Wire and Machinery Association also, and these can be found on page 10 and 24. Upturn in the market has also led to one UK company putting into action its expansion plans. News from Merlin Control Systems can be found on page 28. On the technological front, Condat has launched its aluminium alloy drawing oil Vica l TFH, which can be found on page 38, in addition to Wire Körner launching a new series of directly heated furnaces. A new braider from Spirka Schnell echter for medium heavy and heavy cables also grabs the headlines on page 41. Expo attention turns across the Atlantic The event incorporates technical

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8

Diary of events

9

Corporate News

30

Transatlantic Cable

9

34

Technology N ews

44 Wire Expo 2014 ▲ Feeding unit NAK 60 Z with centric materal

clampin

96

Editorial Index

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Advertisers’ Index

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Market News

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Technical Articles 56 Low Coe cient of Friction Polyole n FTTx Jacket for Improving Cable Installation in Ducts

Next Issue

By Saswati Pujari, Anny Flory, Chester Kmiec, Mohamed Esseghir, Je rey M Cogen, Elastomers, Electrical and Telecommunications Research and Development Reibungskoe zient für FTTx-Anwendungen zur Verbesserung bei der Installation von Kabeln in Kanälen Von Saswati Pujari, Anny Flory, Chester Kmiec, Mohamed Esseghir, Je rey M Cogen, Elastomers, Forschung und Entwicklung von Elektrik und Telekommunikation

Features On

63 Polyole n-Mantel mit niedrigem

• Fibre optic machinery and equipment • Rod and bar production equipment

70

,

,

,

   , «Elastomers, Electrical and Telecommunications Research and Development» 77 Revêtement polyoléphinique à coe cient de friction réduit pour applications FTTx pour améliorer l’installation des câbles dans les conduites Par Saswati Pujari, Anny Flory, Chester Kmiec, Mohamed Esseghir, Je rey M Cogen, Recherche et Développement Élastomères, Électricité et Télécommunications  ,   . coe ciente di attrito per applicazioni FTTx per migliorare l’installazione dei cavi nei condotti A cura di Saswati Pujari, Anny Flory, Chester Kmiec, Mohamed Esseghir, Je rey M Cogen, Ricerca e Sviluppo settore Elastomeri, Elettricità e Telecomunicazioni coe ciente de rozamiento para aplicaciones FTTx que facilita la instalación de cables en conductos Por Saswati Pujari, Anny Flory, Chester Kmiec, Mohamed Esseghir, Je rey M Cogen, Elastómeros, Investigación y Desarrollo Electricidad y Telecomunicaciones 91 Revestimiento de poleole na con bajo 84 Rivestimento poliole nico a basso

GettingTechnical

The e ects of heat treatment on the properties of extension springs

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Indice Español

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89 96

Nouvelles du Marché Index des Annonceurs

Notizie del Mercato

Noticias de Mercado Indice de Anunciadores

96

96

Indice degli Inserzionisti

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May 2014

dates for your diary . . .

2014

May

14–17 May: Lamiera – trade exhibition – Bologna, Italy Organisers : Ucimu-systems Fax : +39 0226 255 894 Email : lamiera.esp@ucimu.it Website : www.lamiera.net

wire Expo May 2014 6–7 May: Wire Expo – trade exhibition – Indianapolis, Usa Organisers : wire association International Fax : +1 203 453 8384 Email : sales@wirenet.org Website : www.wirenet.org

June

16–18 June: 2014 China (Guangzhou) International Metal and Metalurgy Exhibition –

trade exhibition – Guangzhou, China Organisers : Julang Exhibition Co Ltd Fax : +86 203 862 0790 Email : meiwen@julang.com.cn Website : www.julang.com.cn

September

24–27 september: wire China – trade exhibition – shanghai, China Organisers : sECrI and Messe Düsseldorf (shanghai) Co Ltd Fax : +86 216 169 8301 Email : shanghai@mdc.com.cn Website : www.wirechina.net 21–25 october: EuroBLECH – trade exhibition – Hanover, Germany Organisers : Mack Brooks Exhibitions Ltd Fax : +44 1727 814 401 Email : info@euroblech.com Website : www.euroblech.com 28–30 october: wire India – trade exhibition – Mumbai, India Organisers : Messe Düsseldorf India Pvt Ltd Fax : +91 112 697 1746 Email : info@wire-india.com Website : www.wire-india.com October

November

9–12 November: IWCS – technical symposium – rhode Island, Usa Organisers : IwCs Fax : +1 717 993 9500 Email : phudak@iwcs.org Website : www.iwcs.org

Image “SoldiersandSailorsMonument, Indianaopolis,USA” –www.bigstockphoto.com– photographer –ToddTaulman

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May 2014

Corporatenews

▲ ▲ The CS Nexans Skagerrak will lay the cable in the fjords

Nexans to deploy world’s longest and deepest 420 kV XLPE cable system

The submarine cables will be installed in the fjords in three parallel lengths to create a three-phase AC connection, rated at 420 kV. The cables will be protected by outer shells or water jetting from shore to 30m water depth. The Lurefjorden installation will have a length of 10km per phase and a maximum water depth of 200m, while the Hjeltefjorden section will set a new world record for 420 kV XLPE cable covering both length – 20km per phase – and depth – a maximum 390m. be manufactured at Nexans’ specialised facility in Halden, Norway, for delivery and installation in 2016/17. The submarine cable will

and industrial consumers in the Bergen region, which is an important growth area. It will also provide additional capacity for the grid connection of new generation resources. The total length of the new 420 kV Mongstad to Kollsnes connection will be around 30km. On land, overhead lines will carry the power. However, the majority of the route crosses two fjords, requiring the installation of submarine cables. For BKK, Nexans is providing a comprehensive turnkey service for the design, manufacture, supply and installation of a total of 90km of single-core XLPE cable. The design is based on the same field-proven technology used in Statnett’s successful Ormen Lange project, commissioned in 2006, then the world’s first 420 kV XLPE submarine cable installation.

Norway’s power supply network will get a crucial boost in reliability and capacity with the installation of Nexans’ state-of-the-art submarine cables as part of a major new connection for the utility BKK Nett AS. The new 420 kV connection between Mongstad and Kollsnes will cross two fjords – Hjeltefjorden and Lurefjorden – requiring Nexans to install the world’s longest and deepest deployment of XLPE (cross-linked polyethylene) insulated submarine cables in a contract worth around €78 million. BKK Nett AS, one of Norway’s largest utility companies, is building the new connection to reinforce the power grid in the west of the country. The new power line is essential to ensure security of supply for the forecast growth in consumption by residents, businesses

Nexans – France Website : www.nexans.com

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May 2014

News Corporate

A real Gift for distribution firm

A new generation Lubricants specialist Metalube has launched the next generation of its Lubricool™ range with an all new Lubricool™ 260 – a superfine copper wire drawing lubricant.

Before starting the work, SunGift sent out a specialist surveyor to assess the site and look at every possible option. The design team then discussed the options in detail and designed a bespoke system that included 1,000 high-quality BenQ Solar Green Triplex Panels.

 “BenQ is one of the world leading solar PV manufacturers with exceptional quality control and a proven track record,” said Gareth Walton, SunGift Energy’s business development manager, “so we can be sure that they will perform well for Gregory Distribution.”

 The solar PV system included all preparation work, setting up safety rails on the roof, installing the solar PV panels and inverters, and carrying out all associated electrical works and commissioning.

 “SunGift did an outstanding job,” added Paul Jefferson, operations director at Gregory Distribution. looking forward to supporting the IWMA in all its existing and emerging programs, designed to further the interests and opportunities of the membership at home and abroad. Mr Dawson has been involved with the wire industry since his early years, and joined Whitelegg in 1992 after travelling widely and working at the Emil Jaeger Maschinenfabrik in Germany. Although having had no technical training, Glyn’s keen mind allowed him to master the ranges of CNC controlled machines and he commissioned these all over the world. He looks forward to more involvement with the IWMA and working with the executive board for years to come.

South west UK transportation company Gregory Distribution has taken the first steps towards reducing its electricity bills, securing its energy future and boosting its green credentials following the completion of a 250 kWp solar PV system by Exeter-based SunGift Energy. The system is installed on the roof of Gregory Distribution’s temperature-controlled and ambient distribution centre in Cullompton and is equal in size to the one installed by SunGift at the Met Office. It will not only generate an exceptional return on investment of 19.3 per cent but also reduce the company’s carbon emissions by 116 tonnes per year. Gregory Distribution’s chilled and frozen warehousing operates around the clock and a significant proportion of the electricity generated by the solar PV panels will be used on site, rather than being fed back into the national grid.

 The International Wire and Machinery Association’s executive board has been strengthened following the appointment of three new members at its AGM in February. Don Neville, managing director of RichardsApex Europe Ltd; Glyn Dawson, managing director of Whitelegg Machines Ltd; and Martin van der Zwan, co-owner of Cable Tapes UK Ltd, were all appointed at meeting prior to the “Meet the Industry” luncheon at The Mere Resort, near Manchester, UK, in February. Prior to his current position Mr Neville worked extensively in the wire and cable machinery sector throughout the Far East and North America, commencing in 1990 with N o k i a - Ma i l l e f e r followed by

▲ ▲ Development chemist Naomi

Pells with the new Lubricool 260

▲ ▲ The solar PV system’s SolarMax inverters in place at the site

This addition to the Lubricool™ range uses innovative chemistry that provides significantly improved lubricity. This in turn gives a much cleaner wire, resulting in reduced wire breaks. Commenting on the new product, commercial director Douglas Hunt said:“This latest generation, Lubricool 260, outstrips any other product currently available in the market and in turn will save our customers considerable sums of money.” Metalube specialises in wire and tube drawing lubricants as well as protective greases for overhead conductors. The headquarters are in Manchester, UK, where the site incorporates offices with warehousing, laboratories and manufacturing facilities.

SunGift Energy – UK Website : www.sungiftsolar.co.uk

Trio of board appointments for international association

Martin van der Zwan began working in the cable industry in 1977 at the BICC Wrexham factory. He served his time there working originally within the factory and then moved to work study and then material control. He retired from Pirelli (now Prysmian) in 2008 and set up his own company called Cable Tapes UK Ltd with Paul Haines, his business partner, and up to date has been very successful. He is a great supporter of the association’s educational trust and believes it should strive to encourage young talent to come into the industry, ensuring it stays at the forefront of technology. He now feels that his knowledge and experience of the cable industry could be used to support other companies within this area with advice and assistance where required.

positions at both SAMP Sistemi and Niehoff Endex North America.

With

a

strong

IWMA – UK Website : www.iwma.org

background in international market development he is

▲ ▲ From left, Don Neville, Glyn Dawson and Martin van der Zwan

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May 2014

News Corporate

Advaris MES on the podium...

...and Chemetall For the second time in a row, Chemetall received the award of best supplier of the year by from ArcelorMittal Bourg-en-Bresse (AMBB) in France, the wire drawing division of ArcelorMittal. The leading global surface treatment company obtained the best evaluation in terms of safety, cost, quality, delivery, responsiveness and partnership. “We are very honoured to receive this award and consider it as a tribute to our strong customer dedication and an incentive to continuously improve our performances and services”, said Bruno Rouvier, general manager of Chemetall France. Seven out of 35 major suppliers invited to the AMBB’s Suppliers Day were esteemed for their great performance.

ISA (International Society of Automation) and the guidelines of the Association of German Engineers (VDI), which they are derived from. He also added some more stringent criteria of his own. The Advaris MES got top marks for its “manufacturing flow design” with the

In this year’s assessment and ranking of manufacturing execution systems (MES) carried out by Landshut-based industrial consultants MES Consult, Advaris from Bruchsal, Germany, has gained a place among the top eight. MES is a core element of “Advaris Cable”, the operations management system for length-based manufacturers.

functions of “product definition management” and “resources management”, as well as for its “manufacturing flow planning”. The Advaris system was also praised for its flexibility and the ease with which it can be integrated into an existing on-site system landscape. The decision to consistently base the system on service oriented architecture (SOA) also contributed to the Bruchsal company’s overall success. Two other reasons for the

Economist of MES-Consult, said: “Advaris has a very good manufacturing execution system tailored to the relevant sectors (cable, wire, litz wire, and rope). In the opinion of MES-Consult, the Advaris system could also be used in other industries with drum-based manufacturing. Klaus Thiel,

▲ ▲ Advaris CEO Dr Manfred Moser

“The impressive because the basic design includes all three main components of a sophisticated MES. The fact that the structure is based on SOA elements throughout, and makes use of modern in-memory technology, also deserves a special mention.” system is

very positive assessment by MES-Consult were the intensive advice with which Advaris supports their customers, and the fact that its systems can be implemented on site in a very short time. Advaris Informationssysteme GmbH – Germany Website : www.advaris.de

AMBB

and

Chemetall business

have

a

longstanding relationship and the award underlines this excellent cooperation.

Chemetall GmbH – Germany Website : www.chemetall.com

In his product evaluations, the MES expert adhered strictly to the standards of the

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May 2014

News Corporate

5G is heading to Europe

It’s all in the name for iDaCS

life. Huawei is one of the driving forces in making 5G a reality,” said Dr Wen Tong, head of wireless research and head of communications technologies laboratories at Huawei 2012 LAB. Huawei will invest significant research and innovation efforts in Europe within the Horizon 2020 framework and beyond, especially at the Huawei European Research Centre (ERC). As a member of the European research consortium METIS, Huawei ERC is at the forefront of 5G research by developing the key technology components of the 5G Wireless interface. The ERC is also one of the key contributors to the Advanced 5G Infrastructure public-private partnership programme (5GPPP) defined by the European Commission. Huawei predicts that the first 5G networks will be ready for commercial deployment in 2020, delivering 1,000 times the capacity of current mobile networks and reaching peak data rates of over 10Gbps.

Huawei is taking decisive action to make the fifth generation of wireless systems (5G) a reality for Europe. At the 5G@Europe Summit in Munich, Germany, participants discussed how best to join forces to speed up progress towards achieving this objective. 5G is the next generation of ultra-fast wireless networks that will power the technology of tomorrow. Huawei is investing in a tremendous research and development effort to turn this investment into technological progress for Europe, thanks to an open and collaborative approach involving industry partners, consortiums, universities and leading innovation platforms around the world. The 5G@Europe Summit provided the opportunity to discuss the challenges and opportunities involved in 5G including long-term vision and requirements, key technology drivers and innovation as well as societal benefits.

Datwyler UK Ltd became iDaC Solutions Ltd from 1 st January 2014. The name may have changed, but the products, services, personnel and direct supply model remain the same. As the sole source for Datwyler Cabling Solutions in the UK and Ireland, iDaCS will adopt a business as usual approach – continuing Datwyler’s 30 years of trading in the UK market. iDaC Solutions managing director Paul Cattell is pleased to announce that “this change enables us to re-launch the Datwyler Cabling Solutions brand as part of an integrated system of products for the data network, elevator and fire safety markets. “By increasing our solution offering to include complementary products and specialist services, iDaC Solutions can provide clients with an even greater level of flexibility and responsiveness to their changing business challenges.”

iDaCS Solutions Ltd – UK Website : www.idacs.uk.com

Huawei – China Website : www.huawei.com

“5G will have a fundamental impact on the ICT industry and on our quality of

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May 2014

News Corporate

Sikora’s number one aim is satisfaction

Sikora offers a calibration service for customers. With this calibration, the accuracy of the measuring device is verified and documented. Usually, customers require a calibration of their devices once a year. The benefit for customers is that they do not need to buy and maintain the calibration tools and equipment. This service can also be done

in order to receive a correct display of the measuring values. All devices are free of moving parts, so they are not subject to wear, which influences the measuring accuracy and keeps their accuracy for the entire lifetime. of measuring equipment to ISO 9001, For the required monitoring

Customer Sikora’s most important aim. Not only is the technology focused on this, but also the customer service. This service is diverse and includes the handling of support requests, commissioning of equipment, maintenance or repair and the supply of spare parts. satisfaction is

at the company’s headquarters in Bremen, Germany, or at certain subsidiaries. For customers with perm- anently installed equipment or those with time constraints, Sikora also offers a on-site calibration service, with a trained engineer visiting the customer’s site. Sikora technicians work in all parts of the world and customers are supported by a service specialist in Bremen or by one of the global offices in their native language. Sikora AG – Germany Website : www.sikora.net

In addition to classical service, Sikora offers device training and is now putting a focus on a calibration service for customers. With its extended service support, customers can choose from a variety of service possibilities – no matter in which part of the world the devices are installed. After the delivery of Sikora devices, adjustment is not necessary. Adjustment in this sense means the correction of the actual value to the nominal value

▲ ▲ Sikora now offers a calibration service for customers

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May 2014

News Corporate

Electro-Wire is bought by EIS

Inc, added:“We are very fortunate to join EIS and the Genuine Parts family of companies. “We look forward to building the speciality wire and cable group into a major player in the wire and cable marketplace.” GPC is a Fortune 500 company founded in 1928 and based in Atlanta, Georgia. The company had 2012 revenues of approximately $13 billion and operates in four principal segments: automotive replacement parts through its NAPA and other subsidiaries; industrial replacement parts through its Motion Industries subsidiary; business and office products through SP Richards company; and electrical and electronic process materials and supplies through EIS. EIS Inc – USA Website : www.eis-inc.com Scott’s new role Plastic extrusion-tooling manufacturer B&H Tool Company LLC (B&H) has

EIS, said: “We are very pleased to bring Electro-Wire into our speciality wire and cable business and the EIS family. Electro-Wire is one of the most successful speciality wire and cable distributors in the markets they serve. “The Electro-Wire team has built a tremendous business over the last 35 years and they will certainly strengthen EIS.”

EIS Inc, a wholly-owned subsidiary of Genuine Parts Company, has acquired the assets of Electro-Wire, Inc, based in Schaumburg, Illinois. Electro-Wire is a North American dist- ributor and contract manufacturer of speciality wire and cable products with four locations in the United States primarily serving the telecom and transit markets.

Mickey Hamano, president of Electro-Wire

Bob Thomas, president and CEO of

appointed Scott Cameron as its new engineering manager. Before joining B&H, Mr Cameron worked in the irrigation tubing industry. He brings with him 18 years of customer experience in extrusion processing, tooling design and manufacturing.

▲ ▲ New

engineering manager Scott Cameron

“Scott’s

experience engineering

in

both

and manufacturing environments is a positive

link to the growth opportunities we have for B&H Tool this year,” said Peter Neville, president of B&H. Mr Cameron holds a BS degree in mechanical engineering technology from Arizona State University and is a certified quality engineer (CQE). He will lead B&H’s engineering function in tooling design and manufacturing and participate in the design and development of extrusion tooling solutions for customer applications. He will work directly with John Ulcej, director of engineering and manufacturing for new product development. “It will be of great value to our customers contacting us to have someone who understands their issues and needs from their perspective,”Mr Ulcej said.

B&H Tool Company LLC – USA Website : www.bhtool.com

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May 2014

News Corporate

Hendrix is going green!

Cleaning up after takeover

simply shipping them back to Hendrix for recycling – at no additional cost.

Hendrix Molded Products introduces its cradle-to-cradle recycling programme for the return and recycling of its HPI polyethylene insulators products constructed using two recyclable plastics. Familiar household products that are made from high-density polyethylene (HDPE) are items such as milk, juice or water containers, liquid detergent bottles as well as margarine and yogurt cartons. Hendrix has developed polyethylene insulators that not only address the growing concern to minimise the environmental impact, but also as a means of minimising costs to customers as an incentive to do so. Unlike traditional porcelain insulators, Hendrix’s line of HPI insulators are made from high-density polyethylene, a two recyclable plastic that can be reconstructed for reuse when its product life cycle has ended. As part of Hendrix’s new cradle-to-cradle programme, customers are encouraged to dispose of insulators by sending any used HPI products to a local recycler, or by

Schlicht Handelsgesellschaft oHG, Hamburg, has taken over the distribution of its partner DCA, Germany, for dry ice shot blasting instruments. The colour dosing and cleaning systems company can now also deliver cleaning machines for the plastic, rubber and cable industry as well as for other industries for cleaning of: • tools • screws • dies and injection discs • surfaces of any kind • removal of rust on machines, etc The delivery programme involves the small unit for simple cleaning up to large machines for great areas and difficult cleaning of strongly adhesive materials. Schlicht Handelsgesellschaft oHG – Germany Website : www.schlicht-handel.de

The insulators are suited for both bare wire and covered conductors and offer an alternative solution to porcelain insulators, which are susceptible to vandalism and can be problematic when paired with covered overhead conductors. Impervious to impact damage and breakage, the insulators offer longer leakage distance and higher impulse strength. Additionally, every insulator easily withstands ultraviolet rays and offers greater track resistance due to the proprietary high-density polyethylene material.

 With the ability to resist wear and tear, including chipping, cracking or breaking, Hendrix HPI polyethylene insulators have an increased lifespan. accept any conductor or tie and can be used interchangeably with porcelain insulators.
 Additionally, the insulators

Hendrix Molded Products – USA Website : www.hendrix-wc.com

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May 2014

News Corporate

Tele-Fonika Kable secures first SheathEx order in Europe

Tee-ing off for charity S&E Specialty Polymers LLC will sponsor its second annual Play Fore Playmakers charity golf tournament on 21 st July 2014 at the Sterling National Country Club in Sterling, Massachusetts, USA. The tournament supports Life is good Playmakers, the non-profit action arm of the Life is good Corporation, and all profits from registrations, donations and sponsorships will be donated directly to the Playmakers organisation. S&E’s first Play Fore Playmakers charity golf tournament raised $14,000 to support children in need. More information on the tournament, including registration forms, can be found at www. play4playmakers. org “We were thrilled with the success of last year’s inaugural tournament and are excited to continue to improve upon it, starting this year with our goal of increasing our donation to $20,000,” said Duane Shooltz, president and COO of S&E Specialty Polymers.

Tele-Fonika Kable SA (TF Kable) is the first company in Europe to invest in BWE’s SheathEx™ technology. Based in Poland, TF Kable is the largest cable company in Central and Eastern Europe delivering its products to more than 80 countries worldwide. In 2013, the company was awarded the Special Honorary Distinction for its 500 kV cable produced at the Bydgoszcz Plant. TF Kable’s development and expansion programme included the purchase of the SheathEx line, which allowed the company to consolidate its position in the ranking of manufacturers specialising in the production of high voltage (HV) and extra high voltage (EHV) cables. TF Kable is now able to extrude a ‘seamless’ (no weld) aluminium sheath over cable. The aluminium sheath is produced from two 12mm diameter aluminium rods. The sheath is corrugated inline (helical or annular) to improve flexibility. Mr Marcin Szymański, vice president high voltage systems, said: “This investment reflects

▲ ▲ TF Kable has invested in BWE’s SheathEx™ technology

instead of lead, the cable is much lighter, environmentally friendly and less harmful to health. An aluminium sheath has good mechanical properties making it stronger and lighter than lead with higher conductivity. TF Kable also has a BWE Conform™ 350 machine. This machine is used to extrude round and sector shape solid aluminium conductor (SAC) from 2 x 9.5mm diameter aluminium rods. BWE Ltd – UK Website : www.bwe.co.uk TF Kable – Poland Website : www.tfkable.com

consistent execution of TF Kable’s strategy to expand in the EHV business. With our new SheathEx line we are able to serve our clients with a modern, reliable and economic solution for power generation and transmission systems.” As well as this first contract in Europe, BWE has supplied a further six lines to cable companies in China. All are in full production and these cable manufacturers are now able to secure large cable contracts based on the aluminium sheath being ‘seamless’. With no weld, the cable sheath is now reliable against the ingress of moisture. By using aluminium

Satisfaction is guaranteed at Madem

▲ ▲ The Madem Gulf site in Bahrain

customer satisfaction for the year 2013 proves that Madem Gulf has built a strong business partnership with our clients by providing the best strategic and quality system,” said Cristian Outeiral, operations manager. “It is also shows that the organisation is constantly improving and implementing the Integrated Management System (IMS) ISO 9001:2008, ISO 14001:2004 and green label PEFC www.pefc.org ST 2002:2010 standards.” Madem Gulf – Brazil Website : www.madem.com.br

Madem Gulf Ind recently undertook a customer satisfaction survey with 45 wire and cable manufacturing customers in Middle East, Asia and African countries. The company received 60 per cent of responses polled in three categories: bad, good and very good with 100 per cent falling into good and very good categories. The company polled the following services: claim response, quantities shipped X received, documentation, deliveries, quality inspections, performance, and packing.

“Achieving once more the score of 100 per cent

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May 2014

News Corporate

Brazil boost for lubricant specialist

our new Brazilian customers will reap many rewards from the benefits they deliver.” Metalube is a UK-based manufacturer of specialist industrial lubricants, exporting to over 80 countries worldwide. Research and development is key to its business and the company constantly invests in its technology centre based at its Manchester factory, ensuring technical excellence and innovation. Metalube Ltd – UK Website : www.metalube.co.uk

Lubricant specialist Metalube’s subsidiary in Brazil has received regulatory approval from Agência Nacional do Petróleo (ANP) for all its lubricant products. ANP is the Brazilian government agency that issues licences for all chemical products manufactured both inside Brazil and also imported. Now that Metalube Brazil has the ANP license it will be able to market products to end user clients in the wire drawing and non-ferrous tube industries in Brazil. General manager Ricardo Neves manages the company’s Brazilian operation. Ricardo has worked in the lubricant industry for the past 15 years with ITW Rocol in São Paulo state. Commercial director Douglas Hunt said: “We started our application process for this licence over a year ago and are thrilled to now be able to launch and sell our products into such an exciting market place. We will be heavily focusing our efforts on Brazil to enable the business to flourish and develop.” Mr Neves added: “We know there is fantastic potential for all the Metalube range across Brazil.

▲ ▲ Ricardo Neves, general manager of Metalube Brazil

“Our superior-performance lubricants deliver exceptional quality and we hope

New vice president RSCC Wire & Cable LLC has named Christopher Venice as its new vice president, sales,

RSCC Wire & Cable, Down Hole Metal Clad, reporting to Graeme Young, vice president/general manager of the segment. Mr Venice will be responsible for

▲ ▲ Christopher

overall sales growth for the Down Hole Metal Clad business, which manufactures the Perma-TEC™ lines of specialised downhole instrument cables for the oil and gas industry. He has held several positions within the Marmon Engineered Wire & Cable Group, most recently as vice president of new operations and supply chain infrastructure. He holds an MBA from the University of New Haven. RSCCWire & Cable LLC – USA Website : www.r-scc.com Venice, new vice president

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News Corporate

Check your cable sheathing

25 years and counting for SIF

purchased and the problem they have encountered. This should then be investigated by the supplier. With regard to the installation, ideally the problem cable should be replaced. However, if it is necessary to work around the problem, it is possible for the electrician to leave the outer sheathing in place and separate the cores by cutting down the centre line of the cable, being careful not to damage the insulation. All necessary electrical installation verification tests must then be performed. Electricians’ priority must be to ensure quality and safety. To help safeguard against the risk of installing cable which is substandard, electricians should ensure that the cable supplied is the correctly specified cable and always check the markings on the cable sheath – not just the packaging. For peace of mind, you should also insist on an independent third-party approved cable with a BASEC or HAR mark. It is important to note that the problem of unstrippable cable can happen with low smoke halogen free cables as well as PVC. BASEC – UK Website : www.basec.org.uk

and is advising manufacturers to be more vigilant in their production. Any cable batches found to have insufficient chalk should not be sold and should be returned to the supplier. Manufacturers are also advised to ensure the thickness of the sheath meets relevant standards. If the sheath is too thin cables can disintegrate when subjected to rigorous safety tests. For example, a cable sheath can fragment and break in a cold bending test if it is too thin. This problem could result in a fire, short circuit or an electric shock. Strippability can be readily checked by the electrician by feeling the free end of each reel of cable with a fingernail to see if the sheath can be lifted away from the cores. If it will not come away from the cores easily, then normal stripping of the cable should be attempted. If it is difficult to strip without damaging the insulation material, affected cable should be returned to the supplier. Installers should always make checks on each reel of cable used. If cable has been installed and then found to be unstrippable at second fix, the electrician should advise the supplier of the particular cable batches

Dr

Jeremy

Hodge,

chief

executive British Approvals Service for Cables (BASEC) advises end users and manufacturers to ensure the quality of cable sheathing before use. Europe should check their cable can be easily stripped before first fix installation. It is a simple and worthwhile check that can save time and cost later. If cable has been laid and plastering or decoration has been completed, when the installer comes to fit accessories at second fix and the cable cannot be stripped easily, there can be serious difficulties which will cost the electrician both time and money. In the cable production process, a sprinkling of fine chalk or a silicone spray is applied in between the cores of a multi core cable, which enables the sheath to be easily stripped from the cores. If the chalk runs out during production, or an insufficient amount of chalk is used, the sheath will stick to the cores and make the cable difficult or impossible to strip. Having reviewed this problem with installer organisations and cable manufacturers, BASEC is treating this problem as a serious production failure of the Electricians across

▲ ▲ iHV_PST550K15 from SIF

SIF, founded in 1989, celebrates its 25 th anniversary this year – and it is thanks to its research and development, innovation and thinking, which allows it to manufacture quality products, high value-added and technological content. This was shown at wire 2014 in Düsseldorf where the company showed its new iHV product family – the ‘i’ standing for innovative, intelligent, intuitive, illustrated and interactive, and the HV meaning high voltage. Common elements of these products are the GUI (graphical user interface) 7" touch screen with microcontroller

Board members retire

Two members of the International Wire and Machinery Association retired from the executive board at the annual general meeting in February. Terry Robinson, of XL Technologies UK Ltd, served as a board member, chairman, treasurer and a member of various sub-committees. Colin Dawson, of Whitelegg Machines Ltd, was a former chairman and elected president in 2012. Mr Robinson’s decision to retire from the board was strongly influenced by family duties. “I have enjoyed serving the association over the years and will, without doubt, miss the many friends I have made during my time at the IWMA,” he said. Mr Dawson’s place on the board has been taken by his son, Glyn, who will continue the tradition of Whitelegg Machines being a long-standing supporter of the IWMA. The company was one of the original founding members in 1970. IWMA – UK Website : www.iwma.org

▲ ▲ Terry Robinson, left, is presented with a gift on his retirement from the executive board 
by Paul Wright, board member

technology, a menu for the simple use of the device and a group of peripherals designed on function of the application.

▲ ▲ Colin Dawson, right, is thanked for his service by chairman Steven Rika

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Multihead weighers Bilwinco is a manufacturer of advanced weighing systems for fasteners. The system may be installed on existing equipment but also forms part of the new concept of IMFLEX open fire furnace that is able to save up to 27 per cent of gas consumption. FIB sa – Belgium Website : www.fib.be Savings after just a few hours The first installation of a FIB intelligent mixer in the Kiswire Group has led to an immediate success. After just a few hours of operation, the automatic atmosphere control loop system had already shown a saving of almost 5.8 per cent of gas consumption. ▲ ▲ Kiswire experienced gas savings of 5.8 per cent just a few hours after the FIB intelligent mixer began operation

Since 1955 it has delivered more than 6,000 solutions worldwide to, primarily, the automotive market, construction industry and the DIY market. The company has recently introduced a series of hardware multihead weighers.

▲ ▲ The PC interface making operation and production surveillance much easier

This provides a number of significant advantages:

• A smoother body without points of attachment which reduces risk of product mix • A compact design which reduces product damage and increases speed • A direct weighing principle giving nothing but the highest accuracy through a robust and long lasting load cell system A new advanced control with user interface through a standard PC or through a large and easy-to-use 15" touch screen, makes operation and production surveillance much easier. This new interface also allows for remote service back-up via an Internet connection, which ensures the most cost effective and efficient back-up to the Bilwinco equipment.

Bilwinco A/S – Denmark Website : www.bilwinco.com

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News Corporate

Cooperation for 100 per cent quality control

Customer demands significantly determine which new technologies are pushed by Sikora. Two years ago Maillefer raised urgent questions about the possibilities for the development of a system for the detection and sorting of contaminations in plastic pellets. The reason for the need of such a system was – and is – the continuously increasing demand for renewable energies in the international energy market. “The worldwide installed capacity has already increased from 1,250 GW (2010) to 1,700 GW (2013),” states the International Energy Association (IEA). A part of this is supplied by wind turbines in offshore wind farms. For the power transmission to the mainland, submarine cables are used, which have to fulfil sophisticated requirements due to the specific environmental conditions. Therefore, the cable structure and its production process must follow national and international standards. In these regards, the purity of the XLPE compound plays a critical role, especially with regard to the insulation: the purer the compound, the lower the risk of a breakdown. It is for that reason that the Chinese Standard for high voltage cables, for example, demands the exclusion of contaminations from 75 µm in the processed materials. A very important aspect has always been the cable joint, specifically with high voltage cables for off-shore applications. The joints where the cables are welded together are always critical. Therefore, energy suppliers want cable manufacturers to deliver large cable lengths with a minimum amount of joints, as each joint contains a potential risk for breakdowns. Consequently, the aim is to produce energy cables with long lengths with only a few joints while using highly pure rawmaterial. In order to catch possible impurities in the XLPE compound before they get into the cable, cable manufacturers use screens which are positioned directly in the melt flow after the extruder, before the crosshead and, thus, prevent the contaminations from entering the product. But these screens can get clogged by degraded XLPE, ie scorches, or excessive amount of contaminants after certain run time and then the melt pressure in the extruder may increase significantly. Finally, the production has to be stopped in order to change the screens, which in turn means that a joint is later required at that position. A solution to this problem is a system which inspects the pellets for purity before the XLPE pellets get into the extrusion process. Currently installed devices use optical measuring principles that randomly inspect pellets for contaminations. Since this is a sample check, not all of the material is controlled. Furthermore, with optics, only the outside of the pellet can be inspected, while impurities inside the pellets remain undetected. Moreover, the inspection of the raw material with existing devices is not done under clean room conditions, so that new impurities can emerge from the ambient air or as a result of the conveyor belt used. In initial experiments, various sensors were tested in order to ensure a reliable detection of contaminations with a size of 50 µm. It soon became clear that Sikora had the know-how to develop the appropriate technology to meet Maillefer’s requirements. With the newly developed purity scanner, metallic and organic contaminations not only on the surface but also inside the pellet can be detected. The system applies for XLPE compounds as they are used in the production of medium, high and extra-high voltage cables, as well as underground and submarine cables, including semi-conductive XLPE compound.

With the combination of X-ray and optical technologies, a system was developed which inspects 100 per cent of the pellets for purity before they enter the production process. Rejected XLPE pellets are reliably sorted out. The transport of the pellets is carried out via a vibrating ramp. This transport system is hermetically sealed with the result that no external impurities get into the material flow. Sikora AG – Germany Website : www.sikora.com Maillefer – Switzerland Website : www.mailleferextrusion.com ▲ ▲ The purity scanner is the result of technological cooperation between Maillefer and Sikora. From left: Member of the board Dr Christian Frank, head of R&D Dr Siegmar Lampe (both Sikora AG), and MV/HV process specialist Timo Mäkelä, of Maillefer

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Confidence in the upturn in the economy has been well and truly marked by the recent expansion of Merlin Control Systems Ltd, an ISO9001 registered company offering automation and control systems for industrial plant and machinery. Upturn sees expansion plan

New Delisi model Delisi manufactures and sells automatic wire straightening and cutting machines for diameters from 1 to 22mm, for smooth and ribbed wire. The new model HS22H with hydraulic and flying shear cut for wires from 10 to 22mm is suitable for smooth wires and, with the addition of special devices, for very short pieces. This model can also work ribbed wire. The HS22H machine has four couples of feeding rolls and rapid change of diameter. Feed speed is from 30 to 150m/min. Further features are reduced wire twisting, increased production and reduced noise. Delisi Srl – Italy Website : www.delisisrl.com

The in Brompton-on-Swale, Richmond, North Yorkshire, UK, has been providing custom built electronic systems to customers at home and abroad for the past 14 years. The recent addition of two highly experienced members of staff has meant a broader spectrum of service can be provided. company, based

Machine upgrades

refurbishment encompassing

and

all

mechanical, and electronic work are now offered in a turnkey project package. Merlin Control Systems is well known in the resistance welding field for the supply of welding controls and used welding and wire work machinery. A new spare parts and consumables department has also been opened, offering resistance welding consumables such as electrodes, current shunts and spot weld caps. A new tool room has also been added as part of the expansion project; this has facilitated the supply of copper and copper alloys in their raw form or as bespoke parts for customers‘ specific requirements. Merlin Control Systems Ltd – UK Website : www.merlin-controls.com ▲ ▲ The Merlin Control Systems factory in North Yorkshire, UK electrical

▲ ▲ Wire straightening and cutting machines from Delisi

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20 th anniversary for Tecnofil

• fully adjustable reduction scale for maximum flexibility • AC independent motors electronically controlled and perfectly synchronised • easy operator interaction with touch screen switch board • designed and successfully tested in intensive working conditions for more than three years. Tecnofil SpA – Italy Website : www.tecnofil.net ABB scoops award ABB, the global power and automation technology group, has been awarded the Zayed Future Energy Prize 2014 in recognition of its efforts to drive innovation, renewable energy and energy efficiency. The award was presented by His Highness General Sheikh Mohammed bin Zayed Al Nahyan, Crown Prince of Abu Dhabi and Deputy Supreme Commander of the Armed Forces of the United Arab Emirates at an awards ceremony in Abu Dhabi, UAE. ABB – Switzerland Website : www.abb.com

drawing speeds (up to +600 per cent), drawing die lifespan (+35 per cent) and line efficiency (+30 per cent). Best results can be achieved when drawing special materials like high/low alloy steels. In this case TBL working speed is seven times faster than traditional machines and grants flawless quality consistency. TBL is designed to be connected to a copper coating tank to manufacture welding wire of special alloys. TBL eliminates wire slip during wet drawing, reducing wire mechanical stress. Moreover, each die and block is lubricated and cooled by dedicated high-pressure water sprays. These exclusive features grant lower wire breakages, higher working speed and reduced die consumption.

Tecnofil, which specialises in the production of low and medium carbon steel wires and in the manufacture and supply of machines for the production of steel wire and wire bands, is celebrating its 20 th anniversary this year. One of the key points that differentiates Tecnofil on the market is its overall control of production and the possibility to deliver tailor-made solutions, starting from the specific needs of its clients. The machine division produces every single part of the machines, from carpentry to high precision mechanics, from electrical equipment to the software, and the test phase. The company participated at wire 2014 and presented several innovations, including the new TBL, its straight wet drawing line, designed to bring the advantages of the dry drawing system into the wet drawing process. TBL increases significantly the productivity of drawing plants while reducing the operational costs. This result is achieved thanks to the exclusive design of the machine, which guarantees higher

Other advantages of TBL include:

• user-friendly and highest operator accessibility for fastest string-up • monolithic anti-vibration steel frame • wire drawing in one direction • heavy duty bearings with exclusive waterproof system

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