EuroWire January 2023

The International Magazine for the Wire & Cable Industries

Continuous Rotary Extrusion

RAYEX® D Dynamic X-Ray Measuring System

Benefits: Newest generation of measuring algorithm offers readiness for measurements within a few seconds Micro focused x-ray beam ensures highest precision Smart sensors with embedded processor available with the gauge New generation of long life x-ray sources available Parallel scanning of both measuring axes Easy maintenance due to modular system design

Zumbach Electronic AG | Hauptstrasse 93 | 2552 Orpund | Schweiz Telefon: +41 (0)32 356 04 00 | Fax: +41 (0)32 356 04 30 | sales@zumbach.ch | www.zumbach.com

FOCUSED ON CONTINUOUS EXTRUSION FOR 20 YEARS

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CONTINUOUS EXTRUSION SERIES Machine type Cross section Max Width / Diameter MFCCE300 MFCCE350 MFCCE400 MFCCE450 MFCCE550 MFCCE700 5-200mm² 20-1000mm² 100-2400mm² 100-3000mm² 400-6400mm² 600-9000mm² ≤ 50mm / Φ 25mm ≤ 100mm / Φ 40mm ≤ 170mm / Φ 80mm ≤ 210mm / Φ 90mm ≤ 325mm / Φ 130mm ≤ 425mm / Φ 140mm

for producing copper bus bar, copper strip billet, round bar and various sections MFCCE550 / MFCCE700

HYDRAULIC DRAWING SERIES

Hydraulic Drawing Drawing force 50T/100T Efficient drawing length ≤12m Product width 30-350mm Product thickness 3-30mm

Hydraulic drawing & straightening Drawing force 50T/100T Straightening tension 100T/150T Efficient drawing length ≤12m Product width 30-350mm Product thickness 3-30mm

Scroll Automatic Drawing Product width 10-120mm Product thickness 1-6mm Drawing speed 5-18m/min Coil inner diameter Φ500mm Max coil weight Φ1200mm

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Director: Mr Xiao Chun, Qu Cell: +86 137 0162 4291 E-mail: director@shyjdg.com

Sales Manager: Mr Raymond Cell: +86 139 0175 4334 E-mail: sales@shyjdg.com

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Forging ahead with green steel Whilst car manufacturers are actively exploring hydrogen-based technology, companies are also looking at ways of using the fuel and electricity from renewable sources to produce steel. This has led to SMS group providing technology and equipment for the H2 Green Steel project in Sweden, which will produce green steel as early as 2025. The project will see SMS supply process equipment from iron making to the finished steel products of the world’s first industrial-scale steel plant based on hydrogen and electricity from renewable sources. “Our aim at H2 Green Steel is nothing less than to pioneer an industrial revolution in the steel industry,” said Maria Persson Gulda, CTO of H2 Green Steel. “We want to use existing technology, modify it and integrate it in a different way to make green steel a reality today, not in the distant future. We have jointly designed the plant to make a significant CO 2 reduction throughout the whole steel plant in a way that will set our steel plant apart from others in the market. “We have chosen SMS group for this project because we believe in their capabilities, which have been demonstrated in numerous industrial projects around the world.” With total order volumes for SMS exceeding €1bn, Burkhard Dahmen, CEO of SMS group, said: “We are very proud to supply the technology for the world’s first large-scale all-green steel plant. This is not only an important step for H2 Green Steel, but also an excellent opportunity to underline our competence and mission in green steelmaking.” Located in Boden in the Norbotten region of Sweden, the plant is expected to be producing green steel in 2025 before increasing volumes in 2026. The full story can be found on page 8.

Editor ....................................................................................... David Bell

Editorial Assistant .......................................... Christian Bradley

Design & Production ............................................... Lisa Wright

Advertising/Marketing ........................................ Jason Smith UK, Italy, ROW, USA & Canada Linda Li 中国 James Woodburn Worldwide

Advertisement Coordinator .............................. Liz Hughes

Accounts Manager ......................................... Louise Jennings

Subscriptions ......................................... Louise Jennings

Founder .......................................................................... John C Hogg

Europe

Advertising/Marketing & Editorial Intras Ltd PO Box 6828

Warwick, CV34 9SP, UK Tel: +44 1926 334137 Fax: +44 1926 314755 eurowire@intras.co.uk www.read-eurowire.com Intras USA – Doug Zirkle Danbury Corporate Center 107 Mill Plain Road Danbury, CT 06811, USA Tel : +1 203 794 0444 doug@intras.co.uk

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US copies only : EuroWire (ISSN 1463-2483, USPS No: 022-738) is published six times a year, January, March, May, July, September and November by Intras Ltd and distributed in the USA by Asendia USA, 701 Ashland Ave, Folcroft PA. Periodicals postage paid at Philadelphia, PA and additional mailing offices. POSTMASTER : Send address changes to EuroWire, Intras Ltd, C/O 701 Ashland Ave, Folcroft PA 19032. This publication and its full contents of layout, text, images, and graphics is copyright protected. No part of this publication may be reproduced in any form or by any means, electronic or mechanical including photocopying, recording or any other storage or retrieval system without the publisher’s written permission. The publisher, owners, agents, printers, editors and contributors cannot be held responsible for and hereby exclude all liability whatsoever for errors, omissions or the accuracy and claims printed or inferred in the editorial or advertisements published in this, previous or subsequent editions or for any damages, costs or losses caused thereby. EuroWire reserves the right to edit, reword and subedit all editorial submissions in accordance with editorial policy. EuroWire expressed graphically or by text is a registered name and style trademark of Intras Ltd, UK. All matters relating to this Disclaimer are governed by the laws of England. EuroWire is published six times per year and incorporates the title and publishing rights only of the former series of publications known as ‘ Transfil Europe ’. EuroWire is circulated to engineers, managers and personnel in the wire, cable, fibre optic and wire product industries upon receipt of a completed subscription form. An annual subscription is available from Intras Ltd, UK, at Euros 140.00, £120.00, US$195.00.

Also in the January issue of EuroWire , we take a look at some of the Chinese companies making a big noise in our industry, with the return of our popular ‘Focus On’ series on page 34. This year we will be focusing on companies from Germany, Italy, the UK, USA and Turkey.

David Bell Editor

Front cover courtesy of ASMAG showing ASCON Continuous Rotary Extrusion For more details: www.asmag-group.com/ascon

Continuous Rotary Extrusion

All rights reserved © 2023 Intras Ltd ISSN 1463-2438

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January 2023

Contents January 2023

8

41

Corporate News

EuroFasteners

ISSN: 2633-9714 online

ISSN: 2633-9706 print

EF 3/43

Corporate News

EF 6/46

Products

22 Technology News

www.read-eurofasteners.com

Photo by Gregor Schram, Unsplash

31 People

Technical Article 49

Copper and aluminium power cables: cost-benefit analysis By Nagi Ahmed Nagi Abdulmagid, technical manager, alfanar cables company

Focus on China 34

Editorial Index 52

Advertising Index 52

Photo: ZLi Yang • Unsplash

wire India 2022 Review 39

Photo: Raj Rana • Unsplash

6-8 March 2023 Cables (AMI event) Trade Exhibition Cologne, Germany Organisers: AMI www.ami-events.com 7-10 March 2023 Global Industrie Trade exhibition Lyon, France Organisers: Global Industrie www.global-industrie.com Diary dates

Next issue

■ Focus on Germany

■ Reels, spools and winding

■ Wet and dry lubricants

■ Getting technical Dispel the myths of fibre optic installation to future-proof 5G connectivity

9-11 May 2023 Interwire Trade exhibition Atlanta, Georgia, USA Organisers: Wire Association International www.wirenet.org

9-11 May 2023 Made In Steel Trade exhibition Milan, Italy Organisers: Siderweb SpA www.madeinsteel.it

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10-13 May 2023 Lamiera Trade exhibition Milan, Italy Organisers: CEU-Centro Esposizioni Ucimu SpA www.lamiera.net 18-20 May 2023 China (Guangzhou) International Metal and Metallurgy Exhibition Trade exhibition Guangzhou, China Organisers: Guangzhou Julang Exhibition Design Co Ltd www.julang.com

Subscribe today!

Continuous Rotary Extrusion

Visit us online at: www.read-eurowire.com

As with all shows, and with the continuing coronavirus pandemic, please check to ensure the event is going ahead

Corporate News

SMS group will supply process technology for the green steel production plant

Landmark green-steel project in Sweden showcases SMS technology

also an excellent opportunity to underline our competence and mission in green steelmaking.” The H2 Green Steel site in Boden in the Swedish Norbotten region is expected to produce green steel by 2025, ramping up volumes in 2026. Mr Dahmen added, “Hydrogen-based green steel is the future of primary steelmaking, and we are all working at full speed to deliver the key technologies to start a new era of steelmaking. We are excited to continue our partnership with the H2 Green Steel team and looking forward to the joint realisation of this lighthouse project.” SMS group GmbH www.sms-group.com H2 Green Steel www.h2greensteel.com

we believe in their capabilities, which have been demonstrated in numerous industrial projects around the world.” SMS group, together with fully owned Paul Wurth and its consortium partner Midrex, will provide a Midrex® direct reduction plant, the EAF-based melt shop and a CSP® Nexus casting and hot rolling plant, as well as an advanced cold rolling and processing complex for the production of a broad product mix, including advanced high-strength steel and automotive steel grades. Car manufacturers have already signed agreements with H2 Green Steel for the supply of green, high-quality steel. The total order volume for SMS group exceeds €1bn. Burkhard Dahmen, CEO of SMS group, commented, “We are very proud to supply the technology for the world’s first large scale all-green steel plant. This is not only an important step for H2 Green Steel, but

Steel and metals plant engineering company SMS group has been selected to provide technology and equipment for the H2 Green Steel project in Sweden. The agreement will see SMS group supply process equipment from iron making to the finished steel products of the world’s first industrial-scale steel plant based on hydrogen and electricity from renewable sources. “Our aim at H2 Green Steel is nothing less than to pioneer an industrial revolution in the steel industry,” said Maria Persson Gulda, CTO of H2 Green Steel. “We want to use existing technology, modify it and integrate it in a different way to make green steel a reality today, not in the distant future. We have jointly designed the plant to make a significant CO 2 reduction throughout the whole steel plant in a way that will set our steel plant apart from others in the market. We have chosen SMS group for this project because

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January 2023

Stranding Wire & Cable with Large Cross Sections up to 500 mm²

The new machine types D 1252 , D 1602 and D 2002 for the production of conductors and conductor ropes for energy cables with cross sections between 6 and 500 mm² like all machines of the D series contain all crucial features modern bunching and stranding machines have to offer. But we don’t just settle for that. In the D machines all machine data are transferred via telemetry. An automatic traverse unit enables perfect winding and paying-off from the spool. Sensors monitor the production process without interruption. Additionally, the wires can be compacted. And the list could be continued. The new larger machines of the D series can produce class 2 conductors (round standard and compacted) as well as sector-shaped conductors with 90° and 120° (Cu and Al). They are capable of producing class 5 & 6 flexible conductors as well as automotive/battery cables according to IEC 60228 and insulated conductors of diameters up to 25 mm, even in layer construction. Benefit from all advantages the machines offer: a perfectly reproducible product quality, minimum materials usage and energy consumption as well as outstanding efficiency – for your fast return on investment.

Convincing Quality

Innovative Solutions

Worldwide on Site

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Maschinenfabrik NIEHOFF GmbH & Co. KG Walter-Niehoff-Strasse 2, 91126 Schwabach, Germany Phone +49 9122 977-0/Fax +49 9122 977-155 info@niehoff.de

www.niehoff.de

Corporate News

Industry to mobilise at Global Industrie Lyon 2023

has supported companies looking for new talent by implementing several complementary tools. Dedicated to training, employment and professions, the GI Avenir space is an essential element of Global Industrie. School students, job seekers and people undergoing professional retraining can obtain information there about the different professions in industry, the sectors that are recruiting and the jobs of the future. To present their job offers, companies’ HR departments will benefit from an online recruitment platform, job dating sessions, etc. The promotion of jobs in industry will also be at the centre of the Golden Tech industrial competition. For four days, the show will celebrate the people who embody industry today in different professions, giving them an opportunity to demonstrate their know-how, challenge themselves and represent their companies. All professionals can register online and be part of the selection process at www.goldentech.fr.

France’s largest showcase for industrial innovation, Global Industrie, will bring together all sectors of industry from 7 to 10 March 2023 at Eurexpo Lyon. Directly impacted by the current international situation, French companies and production chains will find solutions and know-how to help them meet challenges, whether environmental, energy-related, societal, job-related or linked to reshoring. The 2,500 exhibitors will include solution providers, service providers, subcontractors, manufacturers and distributors, divided into 15 zones. “Global Industrie wants to enable manufacturers to capitalise on the big issues of the moment, by offering them technological pathways and avenues for reflection, and to help French industry to emerge stronger,” said Sébastien Gillet, director of Global Industrie.

For 2023, the theme of the Golden Tech competition is the “hydrogen-powered car”. The test subjects, devised in collaboration with professional partners and revealed one hour before the test, will concern the design, storage or distribution of these vehicles. Contestants will have two hours to answer, before being evaluated by a jury of experts. The results will be announced on 10 March, and the winner in each category will receive a cheque for €1,000. In line with the automotive theme of the competition, the Golden Tech area will present some exceptional concept cars, such as the hydrogen prototype for the 24 Hours of Le Mans motor race. Global Industrie https://global-industrie.com

Since its creation, Global Industrie

MPD & EPD Revolutionary product

Wire surface = ND Dies 01/

02/ < 1.0mm shaped dies 03/

Dies life > PCD Dies

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Corporate News

Sustainability is the watchword for MACH 2024 MACH 2024 is set to the most sustainable in the event’s history. With challenges mounting for the UK’s engineering based manufacturers, the Manufacturing Technologies Association – organiser of the event – is taking a proactive approach to the current situation, promoting a green agenda while offering exhibitors cost-effective solutions for stands. James Selka DL, CEO of the MTA, said, “Let me be clear, this not a greenwashing exercise. As a not-for-profit enterprise with a strong ethos for socially responsible business decisions, the MTA is adopting the AEO guidance into its way of working as it is the right thing to do, both ethically and financially. replacement programme, zero waste to landfill policy and recycling sent to a plant just sevenmiles from its campus to reduce unnecessary transport miles.

Examples of show readiness will include the use of lightweight materials, so more can be stored in fewer vehicles, reducing transport emissions; the encouragement of electric commercial vehicles; the re-use of show fabrics and carpets; the adoption of low-energy LED lighting; the use of solvent-free ink; and, where possible, the re-use or hiring of stand furniture and fittings. Mr Selka commented, “This is the first time we will be offering this show-ready service and aside from the environmental benefits, it also means exhibitors can budget better, as it enables them to fix and spread the cost of both stand space and stand build. This will also facilitate better cash flow and a lower administrational burden on their staff.” Manufacturing Technologies Association www.mta.org.uk www.machexhibition.com

“We are working on a number of initiatives for the 2024 exhibition, both planned and in place, and while we are by no means fully there yet, the influence on the show will be considerable and set the tone for future events. Exhibitors and our host venue, the NEC in Birmingham, are supportive of the changes we are making, and I thank them for their help.” Examples of the sustainability approach include the re-use of the MTA exhibition stand from MACH 2022; the development of a ‘Green Mark’ badge for exhibitors adopting re-used stands; and, as far as possible, a digital-only approach to marketingmaterial to reduce unnecessary printing. Other initiatives are set to follow, while the NEC’s own plan includes an LED light

This approach is in keeping with recom mendations from the Association of Event Organisers (AEO), which has published guidance for venues, contractors and or ganisers to promote more sustainable events, not only in terms of environmen tal impact, but also true sustainability for encouraging talent and diversity, greener events and social responsibility.

The Imagineering Foundation at a previous MACH event

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Corporate News

Trade show yields substantial new orders Davis-Standard exhibited at the K 2022 event in Düsseldorf, Germany, in October, making quality leads and taking multiple customer orders. The company’s team reported a high level of excitement throughout the show, with customers arriving to discuss new projects and industry trends, and to actively participate in live demonstrations of new technology such as DS Activ-Check™ and the EDI® Prodigi die. synergy among our Davis-Standard team from different locations,” said Giovanni Spitale, Davis-Standard‘s president/CEO. Visitors showed interest in equipment for composite and micro-duct tubing lines for heating and plumbing, EV battery tempering pipes and hoses, greater automation for irrigation lines, sheet for EPET and multi-layer processes, and BOPP films, among others. Customers were focused on solutions that boost efficiency, improve recyclability, increase production capacity, and align automation and “This K show was exceptional in terms of foot traffic, customer engagement and the

digitalisation with personnel availability and capabilities. The DS Activ-Check cloud-based solution for preventative maintenance and process optimisation was highlighted, along with the Davis-Standard systems integration of the EDI Prodigi die, providing more response and automatic profile control for cast film, sheet and extrusion coating applications. Davis-Standard, LLC www.davis-standard.com

Lamiera 2023 The 22 nd edition of Lamiera – the international exhibition for sheet metal processing and sheet metal forming machines and related technologies – is scheduled to take place at fieramilano Rho, Milan, Italy, from 10 to 13 May 2023. In addition to sheet metal processing and sheet metal cutting machines, systems and equipment, tubes, sections, wires, metal structural work, presses, dies and moulds, the trade show will focus on six technological themes that are having an impact on the sector: • Fabbrica future (factory of the future) • Saldatech – the world of welding • Fastener industry • Heat and surface treatments

• Metrology and testing • Technical subcontracting and services

Lamiera will also feature a programme of in-depth cultural thematicmeetings arranged by the organisers and the exhibitors. The trade show will take place in partial conjunction with Made in Steel, the exhibition dedicated to the production chain of steel, which will be held in the halls next to those occupied by Lamiera, enabling attendees to visit the two separate but complementary events on one trip. Ucimu-Sistemi Per Produrre www.ucimu.it www.lamiera.net

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QUALITY IS EVERYTHING

The UPCAST ® continuous casting technology has been a jewel since its birth – a result of technical innovation and process know-how. The legacy continues: consistent high quality is still everything.

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Corporate News

Joint hydrogen project on an industrial scale Green hydrogen is key to decarbonising industrial products and processes, particularly in areas that are difficult or impossible to electrify. Polyolefin solutions provider Borealis and Austrian energy company Verbund have initiated a decarbonisation project that will use green hydrogen to produce fertilisers, melamine and technical nitrogen on an industrial scale, in a more sustainable way. The joint project, taking place within the framework of the pan-European IPCEI (Important Projects of Common European Interest) process, entails the production of green hydrogen at a 60 MW industrial electrolysis plant using electricity from renewable sources and deionised water. The green hydrogen will be used to produce fertilisers, melamine and technical nitrogen at Borealis operations in Linz, Austria. The oxygen generated by water splitting in the course of the electrolysis process will be used directly in production. The electrolyser will also provide grid services for the transmis sion network. The electrolysis plant is scheduled to commence operation in 2025, with projected annual CO 2 emissions reduc tions of up to 90,000 tons. “Green hydrogen is a crucial lever in driving the energy transition,” said Verbund CEO Michael Strugl. “One of our strategic goals is to establish Verbund as a key hydrogen player. As a partner to industry, we are implementing joint projects that contribute to

Borealis and Verbund are planning a green hydrogen project in Linz, Austria

Photo © Borealis

the decarbonisation of industrial processes and the achievement of climate targets.” Thomas Gangl, CEO of Borealis, commented, “We are pleased to continue the successful cooperation with Verbund in Linz in order to jointly develop solutions for the energy transition. “For Borealis, green hydrogen is an alternative to natural gas in ammonia production, and using it will lead to a reduction in CO 2 emissions. This joint effort is another example of how we are reinventing essentials for sustainable living.” With its approval of IPCEI projects in mid-September, including the green hydrogen project between Borealis and Verbund, the European Commission has given the green light for a series of hydrogen projects in Europe. Borealis AG www.borealisgroup.com Verbund AG www.verbund.com

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Supermac – Global Solution Provider in Extrusion and Process Technology along with IIOT applications r c l l l ti r i r i tr si r c ss c l l it II lic ti s

Supermac Industries established in the year 1974 is a leader in manufacturing of high end systems and process technology for the wire & cable in Power and telecom sector and related Industries. The ISO 9001 and CE certified company specializes in offering customized and tailor made solutions to fulfil specific needs of the variety of customers all across the globe. With a highly skilled design team, with the best of manufacturing and highly talented commissioning team, trained experts in cable processes and technology, we offer design to process expertise to bring in the best product for you. Supermac Industries established in the year 1974 is a leader in manufacturing of high end systems and process technology for the wire & cable in Power and telecom sector and related Industries. The ISO 9001 and CE certified company specializes in offering customized and tailor made solutions to fulfil specific needs of the variety of customers all across the globe. With a highly skilled design team, with the best of manufacturing and highly talented commissioning team, trained experts in cable processes and technology, we offer design to process expertise to bring in the best product for you. Supermac has expertise providing on line commissioning from remote. Post commissioning customer service support is provided Supermac has expertise providing on line commissioning from remote. Post commissioning customer service support is provided

IIOT screen IIOT screen

from both on site as well as from remote. In our endeavour to conform to industry 4.0 norms, Supermac has taken strong strides forward in implementing several digital initiatives and can provide IIOT enabled extrusion lines supported by Siemens Mind sphere software from both on site as well as from remote. In our endeavour to conform to industry 4.0 norms, Supermac has taken strong strides forward in implementing several digital initiatives and can provide IIOT enabled extrusion lines supported by Siemens Mind sphere software The company has three established and running units near New Delhi and are adding another unit under our expansion program. The company has three established and running units near New Delhi and are adding another unit under our expansion program. The state-of-the art facilities are equipped with international and indigenous machinery to carry out the process of manufacturing as per the customer’s requirements. Supermac has strategic partnership with German Companies – M/S Scholz to cover CCV Lines, M/S Rubicon to cover Rubber extrusion Lines and Simpack USA for Coiling machines and Solutions. The state-of-the art facilities are equipped with international and indigenous machinery to carry out the process of manufacturing as per the customer’s requirements. Supermac has strategic partnership with German Company – M/S Scholz to cover CCV Lines, and Simpack USA for Coiling machines and Solutions.

High speed building wire line High speed building wire line

Supermac specializes in the following areas: • State of the art CCV Line with Super ac specializes in the following areas: • State of the art CCV Line with

• Rubber extruders for Insulation and sheathing materials • Silicone extrusion lines with infrared vulcanization system • Cat 5.6 and 7 Lines • FTTH drop cable lines • Fluoropolymer – FEP, PTFE /ETFE Lines • Loose tube/Secondary coating lines for fibre optics • Extruders for variety of applications – up to 175 mm • Cross-Head Single/Dual/Triple • Haul-Off Caterpillar • Capstan • Take-up and pay-off of all types and sizes and as per requirement above 4.5 meters and 40 MT • Rubber extruders for Insulation and sheathing materials • Silicone extrusion lines with infrared vulcanization system • Cat 5.6 and 7 Lines • FTTH drop cable lines • Fluoropolymer – FEP, PTFE /ETFE Lines • Loose tube/Secondary coating lines for fibre optics • Extruders for variety of applications – up to 175 mm • Cross-Head Single/Dual/Triple • Haul-Off Caterpillar • Capstan • Take-up and pay-off of all types and sizes and as per requirement above 4.5 meters and 40 MT

Scholz Vulcanization system for Power Cables up to 132 KV XLPE and 33 KV for Rubber • Specialized Medical Tubing extrusion lines • Proven Triple Extrusion Line for SIOPLAS (XLPE) cables • High speed Insulation Line and Sheathing Line for House Wiring & Control Cables and medical equipment sector. • High output and best in class Insulation Line and Sheathing Line for Power and Optical fiber Cables. • HCV insulation and sheathing line • Hybrid and composite CCV lines for both XLPE and Rubber. Scholz Vulcanization system for Power Cables up to 132 KV XLPE and 33 KV for Rubber • Specialized Medical Tubing extrusion lines • Proven Triple Extrusion Line for SIOPLAS (XLPE) cables • High speed Insulation Line and Sheathing Line for House Wiring & Control Cables and medical equipment sector. • High output and best in class Insulation Line and Sheathing Line for Power and Optical fiber Cables. • HCV insulation and sheathing line • Hybrid and composite CCV lines for both XLPE and Rubber.

Supermac CCV Line Supermac CCV Line

www.supermacindia.com www.supermacindia.com

SUPERMAC INDUSTRIES (INDIA) LIMITED SUPERMAC INDUSTRIES (INDIA) LIMITED

UNIT-I : Plot No-2, Sector-6, IMT Manesar, Gurgaon Haryana, INDIA Ph.: +91-0124-4690500 | Fax: +91-0124-4690501 E-mail: jasvinder@supermacindia.com, vkohli@supermacindia.com UNIT-I : Plot No-2, Sector-6, IMT Manesar, Gurgaon Haryana, INDIA Ph.: +91-0124-4690500 | Fax: +91-0124-4690501 E-mail: jasvinder@supermacindia.com, vkohli@supermacindia.com

OFFICE : A-28 & 29, NARAINA Industrial Area Phase-1, New Delhi-110028, INDIA Ph.: +91-11-45574317 E-mail: office@supermacindia.com OFFICE : A-28 & 29, NARAINA Industrial Area Phase-1, New Delhi-110028, INDIA Ph.: +91-11-45574317 E-mail: office@supermacindia.com

UNIT-II : Plot No. 18-19, Sector-2A, IMT Manesar, Gurgaon, Haryana, INDIA UNIT-II : Plot No. 18-19, Sector-2A, IMT Manesar, Gurgaon, Haryana, INDIA

Corporate News

Sonobond becomes part of Inductotherm Group Janet Devine, president of Sonobond Ultrasonics, Inc, has stated that becoming part of the Inductotherm Group will provide customers with increased resources and benefits. Although Sonobond has been a wholly owned subsidiary of Inductotherm Group’s parent company for more than 30 years, Sonobond and its customers will now have greater access to advanced power supply technologies, global service resources and expanded supply chain resources. The launch of Sonobond’s new website is the first of many changes for the company. According to Ms Devine, “Our new brand logo and website represent a lot more than a new design. They signify our direct connection to more than 40 companies that offer advanced technology and manufacturing resources that will enhance our ability to deliver the innovative products our customers have come to rely on. “We wanted to take advantage of all the advantages and benefits Inductotherm Group provides for our customers, as quickly as possible, so transitioning our marketing materials to our new ‘Inductotherm’ look will continue after our new website has launched.” In 1960, Sonobond Ultrasonics (then known as Aeroprojects) invented ultrasonic metal welding. The company received the first patent issued for this technology, awarded for its Wedge Reed system. Since then, Sonobond has continued to develop ultrasonic welders for non-ferrous metals.

Sonobond’s Dual Head SpliceRite ultrasonic wire welder

The company’s Dual Head SpliceRite TM is an ultrasonic wire welder that can join tinned wire of up to 60mm 2 cross-sectional area. It can also produce high strength, highly conductive splices of stranded copper wire of up to 100mm 2 cross-sectional area. Sonobond Ultrasonics, Inc https://sonobondultrasonics.com

Webinar to help advance design and manufacturing digitisation

Cimteq by UL Solutions, a design support and manufacturing software provider for the global wire and cable manufacturing industry, has announced its latest webinar, “Achieve a 25% Increase inProductivity byDigitalisingDesign andManufacturing Processes.” The webinar, part of an ongoing series, highlights how going digital can help wire and cable manufacturers optimise their product development and manufacturing processes while enhancing product safety and compliance. Featuring Hamada Khalifa, commercial technical lead at Cimteq by UL Solutions, and guest presenter Amanda Shehab, specialist industry consultant and former director at the company, the webinar covers a variety of topics, including: • Process design – enhancing asset efficiency through OEE calculations • Material requirement planning – material control • Manufacturing execution – machine setup efficiencies, defining parameters “We look forward to helping empower wire and cable manufacturers on their journey to digitisation,”Mr Khalifa said. “The webinar will help manufacturers to address immediate opportunities and challenges and allow us to look at ways we can help empower them to improve their manufacturing and business processes.” Cimteq by UL Solutions www.cimteq.com

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Corporate News

Major role for aluminium in journey to net zero The UK’s aluminium industry has a “once in a generation” opportunity to drive sustainability, the circular economy and the transition to net zero (carbon neutrality), according to a sector expert. to be bolder when looking at increasing domestic capacity, to support demand from the automotive, aerospace, con struction, packaging, rail and shipbuilding supply chains.

“We’ve come through Covid-19 and Brexit, and I’m pleased to say the impact of the aluminium industry in the UK is growing once again and we stand on the verge of something really exciting … if we have the courage to lead the way in supporting sustainable manufacturing and the journey to net zero,” explained Mr Jones. “Demand is definitely out there but, as it stands, we only have one primary smelter on our domestic shores and that will just not be enough going forward …we need to build supply chain independence at both the source and downstream in the producers of castings, extrusions and profiles.” ALFED’s Net Zero Report highlights that 8g of carbon emissions are saved every kilometre for each 100kg reduction in a car’s mass, thanks to aluminium

Tom Jones, CEO of the Aluminium Federation (ALFED), made the statement following the organisation’s latest report, which reveals that more than 39,000 people are directly employed in this manufacturing discipline, with a total GVA (gross value added) of nearly £3bn. Undertaken in partnership with the Fraser of Allander Institute, the document goes on to use an economic model that predicts the sector’s real value to be closer to £7.4bn, supporting 104,000 full-time jobs considering the indirect impact of the material. Mr Jones believes that aluminium’s light weight properties and easy recyclability will help UK manufacturing on the route to net zero. However, he also warns that both the government and the sector need

Tom Jones

driven lightweighting. Mr Jones added, “There’s up to a 50 per cent reduction in a building’s energy consumption with intelligent facades using aluminium systems and a 40 per cent decrease in foil thickness of packaging achieved by using this versatile material. These are just three examples. There’s countless more and this is beginning to sway the thinking of automotive designers, architects and specifiers and those responsible for the safe transit of goods.” ALFED www.alfed.org.uk

Emerging 5G and EV infrastructure opportunities In meetings held during IWCS 2022, designers and engineers from Web Industries outlined how contract manu- facturers can help telecom, power and energy, technical textiles, medical and transportation industry professionals roll out 5G, broadband and electric vehicle (EV) technologies. Web Industries high-capacity spools enabled the cable producer to extend the length of its production runs. nent manufacturing services that we offer while explaining new capabilities and capacities that we brought online during the pandemic.”

“The event was a great reminder that the wire and cable industry is a key enabler for many critical current and future initiatives, like the ongoing global 5G and EV charging network build-outs,” said Dante Ercoli, Web Industries director of sales for industrial markets. “It presented a unique opportunity to reconnect with our customer base and reinforce the wide range of customised formulation, extrusion and cable compo-

As a provider of contract converting and turnkey manufacturing services, Web Industries supports wire and cable companies in accelerating their speed to-market for new products, clearing up sourcing and supply chain problems and freeing in-house assets and personnel to focus on core business activities. Web Industries, Inc www.webindustries.com

Among the meetings’ highlights was a success story involving a major producer of data cables. With the assistance of Web Industries, the cable company increased its manufacturing throughput by 325 per cent, while virtually eliminating defects in its shielding tape production. In addition,

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Corporate News

Strong attendance at IWCS 2022 in-person event, after three years apart

IWCS welcomed attendees to the 71 st annual Cable & Connectivity Industry Forum, in Providence, Rhode Island, USA, in October. Due to the Coronavirus pandemic, the event was conducted virtually in 2020 and 2021. The show’s organisers stated that the high attend- ance and energetic networking in Providence illustrated the industry’s excitement for the ability to network in-person again. More than 860 guests representing 23 countries gathered at the Rhode Island Convention Center for four days of networking and learning. Attendees shared cutting-edge research, technologies and products that are helping the industry advance aspects of the connected global society. The event included all of the traditional IWCS elements: technical symposium, executive session, supplier exhibition, professional development courses, plenary luncheon, welcome reception and several networking breaks. Two

NEW

The 2022 IWCS plenary luncheon with keynote speech

panel discussions, on the topics of career development and celebrating women in historically male-dominated industries, were added to the programme. The 2023 IWCS Cable & Connectivity Industry Forumwill be held at the Gaylord Palms Resort & Conference Center in Orlando, Florida, USA, from 17 to 20 September. IWCS, Inc https://iwcs.org

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Cold-Rolling Wire Drawing Wire Stretching

Winners of Kabel Stars scholarship programme announced

Wire and cable manufacturer RR Kabel, part of RR Global’s US$1.25bn conglomerate, has announced the Kabel Star Scholarship Program winners in Maharashtra, India. Of the 1,012 winners across India, 142 were from Pune and 111 were from Mumbai. The scholarship programme is an initiative for the children

...for more information go to www.schlattergroup.com or scan the QR-Code

Some of the scholarship winners

Kirti Kabra, director, RR Global, said, “I would like to congratulate all the winners of the Kabel Stars Scholarship Program for achieving this milestone in their lives and taking them a step ahead towards their goals. We at RR Kabel consider electricians an integral part of our community, and our initiatives are dedicated to contributing to this community’s well-being.” RR Kabel www.rrkabel.com

of electricians who have passed their tenth-grade exams in the given year. It is part of the brand’s vision of an empowered and educated India. RR Kabel has invested more than 10mn rupees towards the higher secondary education of the electricians’ children under this scholarship programme. The selected students will each receive a scholarship worth 10,000 rupees.

Talking about the scholarshipprogramme,

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Corporate News

World-first magnesium extraction process production

With its patented hydrometallurgical extraction and thermal reduction process, the plant will harvest magnesium metal from a fly ash resource – a waste stream from brown coal power generation. In terms of environmental sustainability, the project converts nearly 100 per cent of the resource into valuable commodities. The released CO 2 emissions are claimed to be approximately 50 per cent less than comparable magnesium production plants. “Demand for magnesium worldwide is strong,” said David Paterson, chief executive officer at LMG. “It has the best strength-to-weight ratio of all common structural metals and is increasingly used in the manufacture of car parts, laptop computers, mobile phones and power tools. Currently, the Latrobe Valley contains 25mn tons inventory of fly ash; that is why it so important for us to have a reliable partner in this project.”

Tenova, a developer and provider of sustainable solutions for the green transition of the metals industry, has been awarded a contract by Latrobe Magnesium Limited (LMG), a company based in Australia. The scope of work is the engineering, supply and supervision of a magnesium oxide (MgO) production plant in Latrobe Valley, Victoria, Australia – a demonstration plant using a world-first process of combined hydromet/thermal reduction. As part of the first phase of the project, Tenova will supply a magnesium oxide plant with spray roaster technology, with a production capacity of 300kg/h. The demonstration plant will initially have capacity of 1,000 tons of magnesium metal per year; in the second stage, LMG intends to develop a commercial-scale operation with an envisaged annual production capacity in the range of 10,000 to 40,000 tons.

The contract signing by Tenova executive vice president Antonio Catalano (left) and David Paterson, CEO at LMG

Gregor Kappacher, branch manager at Tenova Austria, the competence cen tre for spray roaster technology, added, “Through many years of experience and continuous improvement of pyro hydroly sis process, Tenova is able to meet specific customer requirements. The positive and constructive cooperation with Latrobe during the development phase of the magnesium production facility was a de cisive factor to now deepen this work in the course of realisation.” The first magnesium is forecast to be produced in 2023. Tenova www.tenova.com

39 apprentices join British Steel British Steel has recruited 29 new starters at its location in Scunthorpe, UK – 12 each on mechanical and electrical apprenticeships, and a further five on structural programmes. the transformation of our business. We’ll give them first-class training and support, and they now have the chance to build an excellent career with British Steel.”

www.candorsweden.com • Electrolytic plating • Candojet hot water cleaning • Electrolytic & Ultrasonic degreasing • Welding wire cleaning and copper coating • Pickling & phosphating

The apprentices will study towards a National Apprenticeship that will directly relate to the work they are undertaking, and they will be rewarded with a progressive salary and benefits package. Mr Scott added, “All our apprentices were appointed after a rigorous selection process, so they should be proud they’ve been chosen. They are the next generation of steelmakers and I’ve every confidence they’ll be huge assets to British Steel.” British Steel www.britishsteel.co.uk

In addition, six apprentices have joined the company at Teesside Beam Mill, while a further four people have started their training with the Special Profiles business at Skinningrove. British Steel HR director Derek Scott said, “We’re delighted to welcome our new apprentices to British Steel. Given the huge levels of investment across the company and the major changes we’re undertaking on the road to net zero, they have a fantastic opportunity to support

Welding wire copper coating

Multi wire cleaning plant

Ultrasonic & Electrolytic

CANDOR Sweden AB Tel: +46 11 21 75 00 Fax: +46 11 12 63 12 Email: info@candorsweden.com Tel: +46 11 21 75 00 Fax: +46 11 12 63 12 Email: info@candorsweden.com CANDOR Sweden AB

New apprentices at British Steel in Scunthorpe

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Technology News

The ASCON range can process starting material up to 26mm in diameter

Innovation in extrusion The engineers at mechanical engineering firm ASMAG have been dealing with the continuous extrusion of copper and aluminium products for almost 30 years.

increased, and the tools’ service life is extended. Fast tool set-up times of less than five minutes from good material to good material offer a high degree of flexibility, which is of particular benefit in small batch production. One ASMAG customer who already oper ates a complete line is enthusiastic about the ASCON products: “We got involved with energy- and resource-efficient production at an early stage. However, our expectations were far exceeded. With the recently acquired second ASCON, we will cover a rapidly growing market.” ASMAG GmbH www.asmag-group.com

“The three main criteria for the new development of the ASCON machine series were to construct a very robust system that enables the flash to be adjusted under load and at the same time enables the shortest possible tool setup times,” said a spokesperson for the ASMAG development team. “This has resulted from close cooperation with our customers.” The design of the ASCON machines enables high forming forces. Very wide and thin strips, which are currently produced by conventional methods, can be produced economically. A special system allows adjustment of the flash under load. As a result, the productivity of the entire system is

Owing to high customer demand for environmentally friendly and flexible product manufacture, a separate range of machines was designed. Standard round wire, as the starting material, is fed to the system via a straightening section. Depending on the size of the system, this can have a diameter of up to 26mm (1"). Using high force in the main machine body, the raw material is brought into any desired final shape, such as flat material, round material or profiles.

New conical crosshead for MV and HV cable production

Maillefer’s new addition to its conical crosshead range – THC 50/90 – is a solution for medium- and high-voltage cable production. It features optimised bi-flow distributors to enable accurate wall thickness, centricity and roundness of the cable. Short residence times, streamlined flow channels and efficient water tempering allow long production lengths and smooth layer surfaces. The centring of all layers can be adjusted independently. Conical flow pieces are made of nitrided steel to ensure continuity in production. The crosshead is suitable for three-layer extrusion for MV and HV insulations up to 132kV. It enables a wide production range, with fast set up, and easy handling with low damage risk. Maillefer Extrusion Oy www.maillefer.net

The new conical crosshead

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Technology News

Loose tube production: repeatable precision at high speed

The line length of only around 30m is made possible by a short cooling trough design and a new linear guiding. The line provides the option to monitor excess fibre length (EFL) online, enabling fast feedback during production and givingmanufacturers the ability to react immediately during the process. An offline EFL measuring system is also available. The Rosendahl Nextrom crosshead with linear guiding has been further optimised, and works for dry as well as for jelly-filled applications. An improved clenching capstan helps to minimise excess length of the fibre and post shrinkage of the PP/PBT tube during the production process, helping to produce a storable, temperature-insensitive product at a high yield.

Rosendahl Nextrom has created a com- pletely new design for a loose tube manufacturing line, allowing PBT micro- tubes to be processed at line speeds of up to 1,200m/min while meeting product requirements with precision.

The line includes an option for EFL monitoring

The line is also equipped with a fibre cutter, a rewinding mode and dual take up for automatic reel changes. The company has a demonstration loose tube line at its technology centre in Pischelsdorf, Austria. Visitors can observe the line during production, and interested parties can bring materials and recipes for tests on the laboratory line.

RL-R loose tube production line for fibre optical cables

Rosendahl Nextrom GmbH https://rosendahlnextrom.com

Electrolytic pickling Descalinox P22 is a new product devel oped by Condoroil for the electrolytic pickling of stainless steel bars, profiles and wire rods.

Descalinox P22 has been developed to substitute sulphuric-acid-based electro- lytic pickling products in electrolytic pickling tunnels installed directly in line. The pickling solution can be continu ously regenerated using the acid retarda tion technology of Condoroil’s Resibed unit. Condoroil Chemical Srl https://condoroil.com

The formula is based on organic acids and the product is labelled only as irritating. This is of particular benefit when electrolytic pickling is performed directly in the production line, where the possibility of accidental contact with the operator is greater.

Condoroil’s new formulation replaces sulphuric-acid based electrolytic pickling products

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