EuroWire November 2014

Trafco’s purchase of Cortinovis Sictra is our main story in this issue, with the new company being based in northern Italy. With both companies operating in the copper sector, the deal enhances the advantages in terms of technology, and the design and construction of machines for producing wire, cable and rope. The full story can be found on page 10. Mittal Corp’s expansion plans go unhindered as it has set up a new technology plant at Pithampur, India, with the entire plant and machinery being provided by Danieli Morgardshammar in Italy. Read all about this on page 15. And there has been a change in the Spectris family of companies with NDC Infrared Engineering and Beta LaserMike merging to create NDC Technologies. The move, described as “the best strategic move for both NDC Integrated Engineering and Beta LaserMike”, will see the new company headquartered in Irwindale, California, USA. See page 22 for the full details. November also brings with it the IWCS technical symposium. Our coverage of this three-day event, in Providence, Rhode Island, USA, including its conference and table-top exhibition, starts on page 46. This year there will also be a welcome extended to the new yet-to-be-named chief executive and a farewell to the current post-holder, John Barteld. Mr Barteld’s rst conference was in 2005 and since then IWCS has gone from strength to strength. Everyone at EuroWire would like to wish him health and happiness on his retirement from the role and industry on 31 st December. Buy out, expansion, merger and farewell

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Diary of events

9

Corporate News

30

Transatlantic Cable

10

34

Technology N ews

46

IWCS Conference

76

Editorial Index

76

Advertisers’ Index

Copyright © - Mike DeLucia

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Market News

Deutsch Inhalt 51

Neuigkeiten

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Inserentenverzeichnis

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Technical Articles

Features On

48 Developments in green technologies for power cables – using clean materials in the production process By Sikora AG

• Wire & Cable Arabia 2015

Entwicklungen in Umwelttechnologien für Stromkabel – mit Einsatz sauberer Werksto e im Produktionsverfahren von Sikora AG

53

• Straightening and cutting for wires and wire products • Welding techniques and applications – equipment, tools and machinery

58

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«Sikora AG»

GettingTechnical

63 Développements des

écotechnologies pour les câbles de puissance en utilisant des matériaux propres durant le processus de production Par Sikora AG

Water lubricating application in wire and coaxial cable drawing process with nano-dies Subscribe Now! Visit us online at: www.read-eurowire.com

68 Sviluppi delle ecotecnologie per cavi di potenza mediante l’utilizzo di materiali puliti

durante il processo di produzione A cura di Sikora AG

73 Avances de las tecnologías verdes para cables de suministro eléctrico

mediante el uso de materiales limpios durante el proceso de producción Por Sikora AG

Indice Español

Sommaire Français 61

Indice Italiano 66

71 76

Nouvelles du Marché Index des Annonceurs

Notizie del Mercato

Noticias de Mercado Indice de Anunciadores

76

76

Indice degli Inserzionisti

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November 2014

dates for your diary . . .

2014

Wire & Cable Arabia 10-13 January: Wire & Cable Arabia – trade exhibition – Dubai, UaE

November

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

Organisers : al fajer Fax : +971 4340 3608 Email : jeen@alfajer.net Website : www.wirecablearabia.com

2015 April

28-30 april: Interwire – trade exhibition – atlanta, Ga, USa Organisers : Wire association International Fax : +1 203 453 8384 Email : sales@wirenet.org Website : www.wirenet.org May 12-15 May: wire Russia – trade exhibition – Moscow, russia Organisers : Messe Düsseldorf and VNIIKP Fax : +7 499 246 9277 Email : info@wire-russia.com Website : www.wire-russia.com

September

16-18 September: wire Southeast Asia – trade exhibition – Bangkok, Thailand Organisers : Messe Düsseldorf asia Pte Ltd Fax : +65 6337 4633 Email : wire@mda.com.sg Website : www.wire-southeastasia.com 6-8 october: wire South America – trade exhibition – Sao Paulo, Brazil Organisers : Messe Düsseldorf GmbH Fax : +49 211 45 60 668 Email : info@wire-south-america.com Website : www.wire-south-america.com October

November

TBa November: IWCS – technical symposium – rhode Island, USa Organisers : IWCS Tel : +1 717 993 9500 Email : phudak@iwcs.org Website : www.iwcs.org

8

November 2014

Imagecourtesyofwww.bigstockphoto.com“BurjAlArabHotel,Dubai”bybloodua

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November 2014

Corporatenews

Trafco buys Cortinovis Sictra ▲ ▲ A Trafco drum twister line

monotorsion/conotorsion wire armouring, screening and laying up machine, mono-bitorsion strander • Cable production range for ferrous/ non-ferrous materials: Bow type laying up and stranding machine, tubular strander, planetary machine • Extrusion lines: Double and triple coextrusion, triple coextrusion for medium tension, vertical and horizontal extruders • Accessories: Automatic coiling lines, rewinding lines, drawing dies laboratory, and a complete range of spare parts, drawing dies and accessories. Trafco Srl – Italy Website : www.trafcomachinery.com Cortinovis Sictra – Italy Website : www.cortinovismachinery.com

for the production of wire, cable and rope. The range of products will include: • Wire drawing lines: Complete twin rod breakdown line, controlled slip rod breakdown line, evolutionary multi-wire drawing line for plain and tinned copper wires, twin intermediate wire drawing line, intermediate single wire drawing line, drawing line for trolley wire • Accessories: Spoolers, down coilers • Cable production range for ferrous materials: Double twist strander for the steel industry, PC wire line, PC strand line, steel ropes machinery • Cable production range for non-ferrous materials: Central tube strander, double twist bunching, stranding and laying up machines, drum twister, rigid stranding machine, rigid cage screening machine,

Trafco has recently completed the purchase of Cortinovis Sictra. The new company’s head office, as well as cable machine production workshop and assembly hall, will be based in northern Italy. long experience in refurbishment of used machines and its trade activities, as well as the review and improvement of clients’ machinery. With both companies being in the copper sector and with experience in rolling processes, drawing of non-ferrous materials and processes for cable production, the merger will allow the new company an advantage in terms of technology, the design and construction of all types of machines and installations The deal maintains Trafco’s

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November 2014

News Corporate

WESCO’s UK distributor role for CommScope

“Partners such as WESCO are a valuable resource for CommScope in providing local support and outstanding service to our network customers.” “CommScope is a pioneer and proven leader in providing innovative enterprise and wireless solutions that are sought after by customers across many important end markets. We are very pleased to be offering CommScope’s highly regarded infrastructure solutions and expanding our global relationship with CommScope,” said Les Kebler, vice president and international general manager, WESCO International. New face at Siebe Siebe Engineering GmbH, which makes plastic processing machines, has appointed Henning Tepe as international sales manager. Mr Tepe takes responsibility for all sales and marketing functions and tasks. He previously worked as sales engineer and project manager for a large industrial cable manufacturing group, and brings a wealth of knowledge and experience in the fields of sales coordination, project management and development as well as customer service, especially in the cable industry. Siebe Engineering GmbH – Germany Website : www.siebe.com WESCO International – USA Website : www.wesco.com

WESCO International Inc, a provider of electrical, industrial and communications MRO and OEM products, construction materials, and advanced supply chain management and logistics services, has been appointed a distributor for CommScope in the United Kingdom. Under the agreement, WESCO will offer CommScope’s Systimax® and Uniprise enterprise solutions in supporting end users, contractors, and value-added resellers with technical, marketing and implementation capabilities to help drive joint business opportunities in the UK. It offers a complete portfolio of network infrastructure solutions that enable business enterprises, regardless of size, industry or IT budget, to take advantage of business and technology opportunities. Through its Systimax® and Uniprise® brands, CommScope offers voice, data, video, and converged solutions that meet the demands of all types of networks across the globe. This is backed by its commitment to ongoing innovation, represented through a portfolio of approximately 2,600 patents and pending patents, and an average annual investment of more than $100 million in research and development activities. “WESCO’s local market presence, industry-leading Global Accounts programme, and focus on customer supply chain solutions will extend our reach to customers and strengthen our overall presence in this market,” said Koen ter Linde, vice president of enterprise sales Europe, CommScope.

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News Corporate

Being precise at IWCS

A true yarn from Artofil

than three minutes. The system includes easy-to-use testing software with complete test management and reporting capabilities. application specialists will also be available to discuss the following measurement and control solutions for wire and cable: LaserSpeed length and speed gauge CenterScan eccentricity gauge High-frequency spark tester and pre-heater systems cut sample measurement system DataPro process controller and data management system SRL Pro on-line structural return loss (SRL) prediction and analysis system and fully integrated, for LAN/ data, telecom, coaxial, and aerospace/defence cables and Hitachi Cable USA will give a joint technical paper on the topic “8 Cable Transmission Measurements: A Comparative Study between 4-Port and 2-Port Vector Network Analyzer Methods.” The paper will be co-presented by Rafael Herrera and Nadim Kafati of NDC Technologies (DCM Cable Testing Product Line) and Stefan Estevanovich of Hitachi Cable USA, on Wednesday, 12 th November between 8am and 11.25am. Beta LaserMike • • • • BenchMike table-top • • • DCM cable testing systems, bench-top NDC Technologies

NDC Technologies, a provider of precision measurement and control solutions, will showcase several offerings from its line of Beta LaserMike products at this year’s 63 rd IWCS Conference in Providence, Rhode Island, USA, from 9 th to 12 th November at booth 106. The innovations on display include the latest LayScan® length measurement system and DCM ES-2G LAN/data cable testing system. The Beta LaserMike product team will also be available to discuss the new DCM SCS-700 cable testing system with dual low-frequency and high-frequency testing capabilities. The latest version of the LayScan lay length measurement system solves scrap, costly rework, and productivity loss problems due to manual, time-consuming lay length measurement methods and crosstalk performance issues from lay variations during datacom cable production. LayScan enables manufacturers to simultaneously measure four pairs at the cabler and twinner to confirm the accuracy of twisted-pair cable construction during production. A data acquisition and control system effectively collects and processes each lay length and enables the use of off-line analysis tools such as trend charts, statistical analysis or FFT analysis to readily observe, measure, and report systematic lay variations. LayScan measures lay lengths up to 25.4mm at speeds up to 152.4m/min with 0.025mm accuracy. LayScan can also be used in conjunction with the Beta LaserMike SRL Pro structural return loss measurement system for a total on-line cable performance quality solution. SRL Pro can be used before and/ or after the extruder to identify potential causes of structural return loss problems on Datacom cable. ES-2G testing platform extends the high-frequency measurement range to test Cat 5e/6/6a/7/7a cables up to 2.2GHz. This The latest DCM

bench-top also optimised to test next-generation 40 Gb/s Cat 8 cables. The base unit includes automatic four-pair switching and the baluns needed to interface the cable under test to an external vector network analyser for fast cable testing. Testing can be performed in less than three minutes. The DCM ES-2G cable testing system is also equipped with innovative technology that eliminates the effect of jacket removal on reflection measurements, such as input impedance and return loss. The heart of the system is the Windows-based software engine that includes a simple, easy-to-use test program with automatic comparison to the test specification, full test reporting, and data management. The new DCM SCS-700 LAN/data cable testing system efficiently tests Cat 5e/6/6a cables to 700 MHz and offers a low-frequency option to test cables down to 100Hz. Dual-frequency testing can be performed with a single connection to significantly reduce set-up and testing time. The DCM SCS-700 is engineered with an automated four-pair switching platform, enabling operators to perform cable testing in less ▲ ▲ The SCS-700 LAN/data cable testing system system is

Since 1951 Artofil, a manufacturer of high performance yarns, has used its knowledge and ▲ ▲ Artofil has used its knowledge and skills to create a range of yarns The company, which is on booth 110 at IWCS, has a dedicated team of experts from the cable and textile industry, and by listening to partners in this niches market, has developed a complete range of waterblocking The latest development of waterblocking hydrocoat™ has enhanced Arotfil’s position in the market. With this range of products the company is able to cater for tomorrow’s needs in the industry in cable designs, including microduct and nanocables. skills to create waterblocking spun yarn. fine, filler and binder yarns.

NDC Technologies – USA Website : www.ndc.com

New director role

Jackson T Edwards has been promoted to the position of director of technical services and sales for the Mount Joy Wire Corporation. At Mount Joy Wire, he has worked in production, in the lab performing physical and chemical tests and as the quality manager. He was named manager of process engineering in 2007 with additional responsibility for managing the company’s environmental services and safety programmes. He is a graduate of the University of Maryland, Baltimore County. Mount JoyWire Corporation – USA Website : www.mjwire.com

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November 2014

News Corporate

Foerster takeover of NDT Systems

Foerster has expanded into new business sectors after completing the takeover of NDT Systems GmbH. The company completed the deal and the continuation of all business operations after both companies signed the agreement at the end of August. Foerster, based in Reutlingen, Germany, is a medium-sized company in the field of non-destructive testing of materials. It has been active in the development, production and sale of equipment for testing bars, tubes and wires for more than 60 years. With the takeover of NDT Systems, it now has a product range that fits well into the current organisation with regards to sales, project planning and service, and technologically complementing the existing range of products. Counting ten international sales and service subsidiaries as well as representatives in over 60 countries, the group can continue to offer optimum customer support.

▲ ▲ The management of NDT Systems GmbH and Institut Dr Foerster after signing of the agreement. Photograph courtesy of Foerster

to testing applications. With its 330 employees in Reutlingen and 560 employees worldwide, Forester generates €110 million per year in group revenue. Institut Dr Foerster GmbH & Co KG – Germany Website : www.foerstergroup.de customers in different

NDT Systems‘ ultrasonics and Foerster’s eddy current – for quality testing in railroad track production, has been successfully applied in many testing lines around the world. President Felix Förster is convinced that the two companies will complement and therefore give additional value

The combination of the two methods –

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News Corporate

Hayakawa wires used to help save lives

new technology, Sure Chill manufactured wire harnesses in-house on an ad-hoc basis, which resulted in inconsistencies in production. Hayakawa was approached to redesign the wire harness and create a better solution for the company’s mains powered refrigerator. reverse engineered the original sample and implemented a number of value engineered concepts to improve the overall performance whilst achieving a cost effective solution. The project delivered a number of significant improvements in assembly for The Sure Chill Company. managing director Phill Harry said: “We are proud to be associated with such revolutionary technology produced by a very forward-thinking and dynamic company. “It has been great to work with such a successful and driven Welsh organisation that is helping to save both lives and the planet.” Hayakawa – UK Website : www.hayakawa.co.uk Technicians at Hayakawa Commenting collaboration, on the successful Hayakawa organic absorber gives a significant boost in terms of efficiency.” The Sheffield team found that by spray-painting the perovskite they could make prototype solar cells with efficiency of up to 11 per cent. Professor Lidzey said: “This study advances existing work where the perovskite layer has been deposited from solution using laboratory scale techniques. It’s a significant step towards efficient, low-cost solar cell devices made using high volume roll-to-roll processing methods.” Solar power is becoming an increasingly important component of the worldwide renewables energy market and continues to grow at a remarkable rate despite the difficult economic environment. Professor Lidzey said: “I believe that new thin-film photovoltaic technologies are going to have an important role to play in driving the uptake of solar-energy, and that perovskite based cells are emerging as likely thin-film candidates.”

Wrexham, UK-based Hayakawa UK has manufactured and supplied wire harnesses for use in a revolutionary refrigeration system that ensures the safe storage of vaccines throughout the world. The company has supplied a redesigned wire harness solution for a cooling system developed by Snowdonia, Wales, UK-based The Sure Chill Company. The highly advanced technology is set to transform the refrigeration, food and beverage, and healthcare industries by bringing reliable cooling to countries without adequate power. The new refrigerators are currently being used to store vaccines in developing nations to help combat life-threatening illnesses such as polio, as well as maintaining the freshness and preventing the damage of food. Inventor Ian Tansley, of Sure Chill, with investment from UK Business Angel Of The Year 2012 Peter Saunders OBE, has identified a robust, reliable and cost-effective way to store vaccines, foods and drinks in optimum condition. He has developed an entirely new solution and, unlike traditional fridges A team of scientists at the University of Sheffield, UK, are the first to fabricate perovskite solar cells using a spray-painting process – a discovery that could help cut the cost of solar electricity. Experts from the University’s Department of Physics and Astronomy and Department of Chemical and Biological Engineering have previously used the spray-painting method to produce solar cells using organic semiconductors – but using perovskite is a major step forward. Efficient organometal halide perovskite-based photovoltaics were first demonstrated in 2012. They are now a very promising new material for solar cells as they combine high efficiency with low materials costs. The spray-painting process wastes very little of the perovskite material and can be scaled to high volume manufacturing – similar to applying paint to cars and graphic printing. Lead researcher Professor David Lidzey said: “There is a lot of excitement around perovskite-based photovoltaics.

▲ ▲ Ian Tansley, of Sure Chill, with Peter Saunders OBE

that require a continual power source, Sure Chill’s technology needs very little power. It can actively cool without power for over 12 days in an ambient temperature of 32°C. The technology also achieves an even temperature throughout the fridge compartment with no stratification.

During the development of this radically

Discovery could help cut the cost of solar energy

offers the potential to combine the high performance of mature solar cell technologies with the low embedded energy costs of production of organic photovoltaics.” While most solar cells are manufactured using energy intensive materials like silicon, perovskite, by comparison, requires much less energy to make. By spray-painting the perovskite layer in air the team hopes the overall energy used to make a solar cell can be reduced further. Professor Lidzey said: “The best certified efficiencies from organic solar cells are around 10 per cent. “Perovskite cells now have efficiencies of up to 19 per cent. This is not so far behind that of silicon at 25 per cent – the material that dominates the world-wide solar market.” He added: “The perovskite devices we have created still use similar structures to organic cells. What we have done is replace the key light absorbing layer – the organic layer – with a spray-painted perovskite.

University of Sheffield – UK Website : www.sheffield.ac.uk

“Using a perovskite absorber instead of an

“Remarkably, this class of material

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News Corporate

New technology plant for Mittal

Dr Jeremy Hodge, chief executive of the British Approvals Service for Cables (BASEC), anticipates a strong demand for the soon-to-open cable fire testing facility, as the cable industry moves to implement the Construction Products Regulation 2011 (CPR). BASEC’s headquarters in Milton Keynes, UK, are into the commissioning phase and will go fully live by the end of this year. new re-configurable fire test labs and a ladder rack rig, joining BASEC’s existing smoke and halogen testing facilities, represent a considerable investment for the approvals and testing body and further expand the capability of the largest dedicated testing facility in Europe. He says BASEC expects there will be increased demand from its current clients for the fire testing of cables in accordance with the CPR and the test labs will also be open to other cable manufacturers and traders seeking to conform to the regulations as they become applicable to cables. “In anticipation of this, BASEC has made a substantial investment in laboratories, The test laboratories at Dr Hodge says the three • Reheating furnace with moving hearth for uniform heating and low scale formation, with input size of 160 x 160mm billet • Descaler before roughing stands to remove scale formed during reheating • Intermediate rolling on horizontal-vertical roll configuration to give better control during rolling due to no-twist arrangement • Delta-type ten-stand wire rod block with post-rolling arrangement of forced cooling, retarded cooling and water quenching to achieve Mittal Corp Limited (MCL), an ISO 9001 & ISO 14000 certified company that manufactures stainless steel flats (200 series) in India, has set up a new technology plant at Pithampur to manufacture stainless steel, alloy steel and special steel rods in coils, rounds, stainless steel reinforcement bars and QTR rebars. The entire plant and machinery has come from Danieli Morgardshammar, Italy, a manufacturer of rolling mill and steel plant equipment. Key features include:

▲ ▲ A new technology plant for Mittal Corp at Pithampur, India

A new steel melt shop is being set up to produce niche grades for specialised applications like nuclear, aerospace, air craft industry and defence hardware.

grain size/structure and mechanical properties for different grades • Level II automation to ensure dimensional tolerances better than international designated standards in accordance with requirement of customers

Mittal Corp Ltd – India Website : www.mittalcorp.net

New BASEC lab facilities to meet demand for CPR fire tests

equipment and a dedicated team of staff and we have expanded the range of our services to meet the demands of the industry,”said Dr Hodge. “At Milton Keynes we have combined the expertise and experience of our staff with state-of-the-art equipment within first-class facilities to serve our clients from around the world who hold BASEC approvals. “And with the implementation of the CPR for cables we also expect there will now be a demand from other manufacturers who do not have access to the kind of facilities we can offer, such as production/ certification and development testing of their products. We will also be able to turn test samples around quickly and competitively.” BASEC laboratories can carry out a number of cable fire tests: BS EN 50200; BS EN 50200 Annex E; BS 8434-2; BS 6387 CWZ; and others based on IEC standards, and will shortly also encompass a BS EN 50399 3.5-metre-tall ladder rack rig for vertical fire tests on cables. The Milton Keynes headquarters also has a 3m 3 smoke chamber for smoke emission tests (EN 61034-2). BASEC – UK Website : www.basec.org.uk

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News Corporate

High interest and quality counts

“I can see great potential for the optical fibre market, especially in India and China. In 2012, Sikora successfully launched a series for measuring and control technologies for the use in the drawing tower. “Visitors were especially interested in the detection of airlines in the optical fibre, as well as in our new devices for measuring the temperature of the optical fibre and for lump detection. We always develop new technologies in close cooperation with our customers in order to realise performance standards optimally. “Furthermore, we are noticing a positive trend in the optical fibre market in Europe and the USA. Copper cables are being exchanged more and more for optical fibre in order to meet the increasing demand for data transfer. A long distance data transfer without losses requires optical fibre of the highest quality, which must be ensured already during production.”

In April this year the biggest international trade fair for the wire and cable industry was staged in Düsseldorf, Germany. As in previous years, Sikora was an exhibitor at the event and we spoke with Holger Lieder, sales director at Sikora, following the exhibition. What was your impression of wire 2014 and could you give us your conclusion? “The fair went well for us. We are especially happy about the increase of visitors at our booth, an eight per cent increase from 2012. “The high interest shows us that customers worldwide are looking for innovative solutions and that they want to stand out from their competitors due to the quality of their products. Especially popular were our technologies for the automotive and energy cable market. The purity scanner was a highlight in technology for the high voltage and subsea cable area. The system is the outcome of a co-development with the company Maillefer and is used for the inspection and sorting of XLPE pellets.

▲ ▲ Holger Lieder, sales director, Sikora

“Many visitors were also interested in our latest conductor preheater, the Preheater 6000 TC, which was developed specifically for quality control of automotive and data cables. Although wire 2014 did not specifically aim at optical fibre cable, we had many interesting conversations about the online quality control in the drawing tower. Overall, the trade fair completely fulfilled our expectations for this year.” You have just mentioned the optical fibre market. What potential can you see with regards for manufacturers of optical fibre and Sikora?

Sikora AG – Germany Website : www.sikora.net

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News Corporate

Pride at third award

The company is well equipped for the future, having had continuous growth in recent years. It has used this positive development to invest heavily at its headquarters. continuously premises expanded and extended and personnel development actively encouraged. During the last five years the company has expanded production capacities at its headquarters three times, and in the most recent development, work has started in one hall of around 1,100m 2 . “Our growth ensures our future viability at Meschede. We have a powerful and motivated team here, our long-standing and experienced staff ensure a high process know-how. “By using modern CNC-based systems they create products which meet the highest quality standards,“ added Mr Grans. Theleico Schleiftechnik GmbH & Co KG – Germany Website : www.theleico.de modernised, Plant and machinery have been

Theleico, a manufacturer of grinding wheels and abrasive products for industrial use, with headquarters in Meschede, South Westphalia, has been granted the award ‘best supplier 2013’ by the German Spring Federation (VDFi). Out of a total of 193 suppliers the Sauerland-based family-owned company managed to secure first place in the competition for the best supplier in the category of ‘process materials.’ Theleico is the only company having obtained this award for the third time. “We are proud of this award. It demonstrates the consistently high quality of our products and the outstanding service,” said managing director Frank Grans. The award is only granted every three years, since analysis and assessment are carried out over this long period. The jury assessed criteria such as rate of complaints and handling of complaints, meeting delivery deadlines and delivery schedules, quality of service and technical service.

Theleico manufactures high quality precision grinding tools which are used in many different areas of industrial applications, for example in the processing of springs, in gear and motor construction, in processing of rolls, or in rail and track construction. The midmarket company puts the focus on good service by giving technical support and expert advice to its customers. Federation (VDFi). Pictured, from left, are Wolfgang Hermann, managing director VDFi; Frank Grans, managing director Theleico; and Paul-Bernd Vogtland, deputy chairman VDFi ▲ ▲ For the third time Theleico has been granted the ‘best supplier’ award by the German Spring

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News Corporate

Wire for tomorrow’s world

Markets demand new technologies that are as fast and flexible as possible. Ernst Koch will provide solutions today for the challenges of tomorrow. Wire plays an important role in industry. It is present in the reliable production of mobility, in strong connections for architecture, and in highly sensitive medical applications. Ernst Koch manufactures wire drawing and cold rolling systems for the iron and steel wire industry, which is able to build its own machinery. As a system supplier, it can plan, supply and install complete machine lines for the production of wire – lines that are designed for particular tasks and implemented with all the components needed. The company’s consultancy, products and services have been of a high standard for more than 90 years. Customers in more than 60 countries value this long experience and its pioneering technological capabilities. Ernst Koch GmbH & Co KG – Germany Website : www.koch-ihmert.de

▲ ▲ Ernst Koch – providing solutions today

Fast growing Ajex

Ajex & Turner is a fast growing technology driven company engaged in the manufacture of wire drawing dies, die polishing machineries and consumables. The company has joined forces with Turner & Stott Ltd, Manchester, UK, and specialises in making compact PCD and carbide dies from 16mm 2 to 1,000mm 2 ; ND dies from 50 micron to 1.5mm; PCD and carbide dies for MIG, SS and high/low carbon/brass, made for any size and shape. The company also sells die polishing and re-grinding machines with all accessories. Ajex & Turner Wire Dies – India Website : www.ajexturner.com

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News Corporate

The IWMA moves to a new home The International Wire & Machinery Association (IWMA) – the world’s largest corporate trade association for the wire and cable industry – is moving to new offices. The IWMA will be taking up residence at an office complex ideally situated near Birmingham International Airport, in the UK. The move comes as part of the association’s long-term expansion plans to develop its membership and grow internationally, and was passed at an executive board meeting in September. The IWMA is currently based in the same building as Intras Ltd, publishers of EuroWire , Wire & Cable ASIA and wiredInUSA , in Leamington Spa, Warwickshire, UK, and will make the move over the next two months. Steven Rika, chairman of the association, said: “This is both an exciting and challenging time for the IWMA, but one which we are very much looking forward to. It is an ideal opportunity for us to grow and we are relishing the challenge.

“I would like to take this opportunity of thanking Intras for the help and assistance we have had over four decades in building the IWMA into what it is today. “We have, and continue to maintain, an excellent relationship with everyone at Intras and I expect to see us working closely together for the foreseeable future.” Caroline Sullens, managing director of Intras, added: “Over the last two years the IWMA has developed exponentially under the direction of the current executive committee and new management team. “Following on from a corporate re-branding and new website in 2013 I am delighted to see the IWMA take up residence in its own premises which has come about at precisely the right time with the association in such good hands.”

New role for John Conneaut Industries Inc has named John Mancinelli as its new national sales manager. A global supplier of speciality fibres used in applications for wire and cable, magnet wire, composites and industrial markets, Conneaut processes high performance industrial yarns, binder yarns, ripcords, braiding yarns and serving yarns. Its product line includes E-glass, S2 glass, polyglass, PTFE-coated fibreglass, KlassCore®, DynaCore®, ConnCore® and others. Mr Mancinelli, an industrial engineer, comes from 15 years at AGY, where he was engaged as a product engineer and regional sales manager. Before AGY he worked for 11 years at Owens-Corning as production supervisor. assignment, he brings excellent engineering skills, yarn processing expertise and customer support experience to Conneaut, where he will work closely with John Santos, president. In addition to his new sales

International Wire & Machinery Association – UK Website : www.iwma.org

Tailor-made fromTecnofil

The plant is composed of:

Tecnofil manufactures low to medium carbon steel wires and machines for steel wires and wire bands. A strong point of the company is its overall control of production and the possibility to deliver tailor-made solutions, starting from the specific needs of its clients. and test every single part of the machines, from high precision mechanics to electrical equipment and software. Among the key products offered by Tecnofil are its reliable and efficient spoolers, cooling systems and decoilers. It specialises in the realisation of horizontal and vertical spoolers, designed to spool wire on different reels, with an electronic stratification system. This guarantees the correct winding, full adjustability of pace and the possibility to realise traditional as well as special spooling (eg conical, bi-conical). The line is equipped with a wire straightener unit and pulleys that can be personalised in order to meet customer requirements. The machinery division’s engineers produce

• Welded metal carpentry • Pulling wheel (depending on type of material) • Motorised coiling system with lateral rollers • Dancer for inlet speed adjustment (servo-assisted 4-way dancer with ceramic covered pulley) • Switchboard Its static payoff with motorised rotating platform for winding balancing is designed for coil/ spool decoiling and to avoid jams during the steel wire payoff process. The line is suitable to take up wire at the entrance of steel wire cutting/straightening machines or other wire-working machines. Payoff pedestal with transfer pulleys Rotating platform that can be synchronised with the machine used No-jam unit with pulleys Electrical equipment, and control sensors for wire breakage and jam • • • The system is composed of: •

▲ ▲ The company places high importance on reliability and efficiency

Moreover, a switchboard with inverter, PLC and a touch screen panel to set working parameters and display alarms. As far as the cooling systems are concerned, Tecnofil designs static winding machines for single or multiple winding, for wire working lines. it features

Tecnofil SpA – Italy Website : www.tecnofil.net

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News Corporate

Joining forces after merger

New coating service from Applied A new service for used fuse welding and tipping mandrels that strips worn Parylene® and Teflon® coatings and applies PTFE Natural™ coatings is being introduced by Applied Plastics Co Inc, of Norwood, Massaschusetts, USA. Featuring a smooth, anti-stick surface that withstands heat simplify catheter removal in fuse welding and tipping operations. Suitable for larger diameter mandrels 0.02" and up, the service lets users recondition rather than discard worn mandrels, which saves delivery time and eliminates grinding, especially with complex configurations. PTFE Natural™ mandrels are coated using a proprietary process that enhances the bonding surface and prevents flaking and cracking. up to 300°C continuous, with excursions to 371°C, PTFE Natural™ coated forming mandrels provide a 0.05 coefficient of friction per ASTM-1894 to

NDC Infrared Engineering and Beta LaserMike, both part of the Spectris family of companies and recognised worldwide in non-contacting measurement and control solutions, have merged to create NDC Technologies. The combination strengthens the new company’s position in the marketplace by offering a more comprehensive portfolio of gauging solutions with enhanced cross-selling opportunities. In addition, the new operating model expands the company’s reach to better serve its growing global base of customers. The corporate headquarters of NDC Technologies will be based in Irwindale, California, USA. NDC Technologies is part of Spectris PLC, a supplier of productivity enhancing instrumentation and controls, based in the UK. Drew Cheshire, president of NDC Technologies, said: “This merger supports our overall strategy to deliver the most comprehensive and highest quality measurement and control solutions on the market. companies, each with strong offerings directed to meet the unique needs of our target markets. By combining these rich offerings into a single complete portfolio, we can provide customers with a broad range of gauging systems that meet a diverse scope of application requirements. This combination will yield many synergies and benefits in the years ahead and pave the foundation for future growth.” “This merger represents the best strategic move for both NDC Infrared Engineering and Beta LaserMike, and it is the strategy that is most likely to deliver increased value to our respective stakeholders,” said Ken Wright, former president of Beta LaserMike and now president of global engineering and marketing for NDC Technologies. “We are confident that the combined company, NDC “It brings together two best-in-class

▲ ▲ The headquarters of NDC Technologies at Irwindale, California, USA

• Web the converting, extrusion, calen- dering, and non-wovens industries, delivering real-time measurement and control of key product parameters such as product thickness, coating thickness, and basis weight gauges and at-line analysers for the measurement of moisture and other key product constituents in the food, chemical, pharmaceutical, mineral, bulk materials and tobacco industries Metals: X-ray gauges for the on-line measurement of thickness, coat weight, width and optical flatness measurement for the ferrous and non-ferrous metals industries for the on-line and off-line measurement of diameter and ovality, wall thickness and eccentricity, length and speed, and other dimensional monitoring of products in the wire and cable, fibre optics, pipe and tube, building, non-wovens, paper, plastic and metals industries As part of the merger, NDC Technologies has launched its new brand identity, inclusive of its corporate logo. Solutions: For • Sensors: On-line • • Laser and ultrasonics: Non-contact gauges

Technologies, increase our competitive advantage in products, sales distribution, and technical support, while enhancing our relationships with customers and partners.” Other key strategic benefits of the merger include: Commitment to innovation: The combined company shares a commitment to delivering innovative, cost-effective solutions to address the unique needs of industry and customers Commitment to customer excellence: The new company has proven teams of talented, experienced employees and sales representatives with strong customer relationships and a commitment to customer excellence Commitment to operational ease: Integration of business intelligence systems will streamline business processes, enhance the customer experience, and make it easier for customers to work with NDC Technologies and flexibility: NDC Technologies is part of Spectris PLC, a technology-based company with over $2 billion in revenue and listed on the London Stock Exchange will • • • • Financial strength

NDC Technologies – USA Website : www.ndc.com

NDC Technologies will offer four key product groups:

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News Corporate

Multi-wire induction heating

ATE recently developed two induction heating systems for treating wires in parallel, with the names IMW (independent control wire) and CMW (common control wire). Through the use of advanced technologies in the field of power electronics, these systems represent a sophisticated and efficient solution for the simultaneous heating of multiple wires with the same or even with different diameters. The main characteristics of the two systems are: • for the IMW system the possibility of heating multiple wires of different diameter separately, wire by wire, with the same or different temperatures and speeds (upon request) • for the CMW system the possibility of heating wires of the same diameter to the same temperature or wires of slightly different diameter to almost the same temperature, taking account of a suitable‘velocity x diameter’ (DV) Compared to other types of furnaces, such as resistance, gas, fluid bed or lead bath heaters, the IMW and CMW multi-wire induction heating systems have the following advantages: • no environmental pollution • more compact • higher efficiency • optional closed loop process control Besides wires, the systems are also able to treat metal strips or bands. In these cases the systems are identified with the codes IMS or CMS, instead of IMWor CMW. In addition to ferrous materials, the systems can heat aluminium, copper, brass, etc, with efficiency values proportional to the type of material.

▲ ▲ Induction heating the ATE way

• stress relieving (max temperature of around 400°C) • diffusion/brass coating of wires for steel cord (max temperature 550-600°C) • preheating for galvanising (around 500°C) • preheating for painting or coating (max 200-250°C) • preheating before an existing gas furnace in the case of increased productivity of the system The IMW/IMS and CMW/CMS systems are completely modular and can heat a variable number of wires. ATE Srl – Italy Website : www.ate.it

The compactness of the heating units allows them to be easily installed in limited spaces and, above all, in existing lines in which overall dimensions are binding. The frequency converter, the heat exchanger and the control panel which complete the system can be positioned remotely in available spaces, even at a certain distance from the heating unit. The IMW and CMW multi-wire induction heating systems can be used in various industrial processes, some of which are: • annealing (max temperature of around 720°C)

Merger leads to broader portfolio From January this year, Sandvik Hard Materials joined forces with Diamond Innovations, by combining the previously independently operated businesses into a new business, Sandvik Hyperion. Sandvik Hyperion is a full-line provider of cemented tungsten carbide, tungsten carbide powders, diamond and cubic boron nitride materials used in wide range of material-removal and wear-protection applications. In addition to innovative materials, the company offers product solutions, unique services and application development capabilities to support its customers’ needs. Sandvik Hyperion – Spain Website : www.hyperion.sandvik.com

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News Corporate

THE Machines has received an order for a plant to produce submarine cables with optical fibres with sleeveless continuous length of up to 120km formed and welded tubes. The future target is to provide a single length of some 240km. The production lines are designed to meet these challenges and are composed of the following main core components: • One fibre optic steel tube production line for up to 48 fibres. The lines are being designed for a production speed up to 30m/min and a dial-in adjustable and controlled fibre excess length of 0.1 to 0.5%. (1 to 5% – per mille) • One production line for the sheath over the steel loose tube Submarine cable order for THE Machines 40 th anniversary for DeWAL

(which is available at the customer’s plant) • One armouring and welding line to apply a layer of reinforcement elements and to form and butt weld a copper screen over the cable Since the armouring line is equipped with 630mm diameter spools it is necessary to stop the production line to re-load the machine. A unique in-line system has been developed allowing the welding process to be stopped and restarted without losing any welding seam quality or weld seam integrity. THE Machines Yvonand SA – Switzerland Website : www.the-machines.ch

thickness. DeWAL Industries’ stringent process and design capabilities ensure DeWAL’s place as a supplier in all segments of the wire and cable industry. DeWAL Industries has recently introduced its newest packaging put-up for the PTFE film used in wire wrap. Solid Pack® allows for the largest amount of material to be wound onto a single spool. Solid Pack spools payout more smoothly compared to traditional packaging, eliminating breakage. These long lengths promote extended production runs, increasing manufacturing efficiencies which are demanded in current economic conditions. These spool configurations are requested most often in aerospace wire manufacturing where narrow widths and extended runs are the norm. weld copper/aluminium wire 0.0039" to 0.071" (0.1mm to 1.8mm). Comfortable to hold and quick and easy to use, they are suitable for welding wire breaks in confined spaces. PWM’s range also includes air/hydraulic, electro/hydraulic, pneumatic and electro/ pneumatic powered cold welders, for wire and rod up to 25mm (0.984") copper and 30mm (1.181") aluminium. PWM’s cold welding equipment is designed and made to high standards in PWM’s British workshops. Dies are individually hand-made in matched sets, in standard or custom sizes, to suit round or profile wire. DeWAL Industries – USA Website : www.dewal.com

Celebrating 40 years, DeWAL Industries designs and manufactures PTFE and UHMW-PE films and pressure sensitive tapes. Materials are produced using proprietary skiving equipment and tight quality control in the engineering and production facility in Narragansett, Rhode Island, USA. With knowledge and experience in polymer chemistry and compounding, DeWAL has developed a family of high quality PTFE custom thin films used for abrasion resistance, low friction and insulation. DeWAL films may be filled, bonded, sintered or porous. Typical applications include EMI shielding, medical device construction, wire and cable, and automotive assemblies. DeWAL’s design teams have the ability to work with engineers to customise taping solutions including colour clarity, specific run lengths and narrow widths.

▲ ▲ PTFE custom thin films for abrasion resistance, low friction and insulation

In addition to extruded unsintered PTFE, low-density PTFE and sintered skived PTFE, DeWAL can provide fluoropolymer laminates with dissimilar materials to custom specifications.

Proprietary technology enables the manufacture of these films to a precise

Best-selling manual cold welder at IWCS 2014

used to weld profiles and strips for armouring lines. Low maintenance and simple to operate, the M101 can be used either on a workbench or supplied

PWM’s best-selling M101 cold welder and other manually operated models from its comprehensive range will be in action at Booth 104 at this year’s IWCS in Rhode Island, from 9 th to 12 th November.

with a trolley, enabling the operator to wheel it quickly to the work area, saving effort and reducing downtime. PWM’s smaller BM10 and BM30 manual welders are robust, reliable machines, designed for non-ferrous wire and strip 0.0039" to 0.071" (0.1mm to 1.8mm). They can also be used on a workbench or supplied with a trolley. The M10, M25 and M30 hand-held models will

Represented by Joe Snee Associates, exclusive dist- ributor for PWM’s machines, spares and dies in the USA and Canada, visitors are invited to watch demonstrations of the cold welding technique and try out the machines for themselves. The versatile M101 cold welder for bonding copper wire 0.04" to 0.141" (1mm to 3.6mm) and aluminium 0.04" to 0.197" (1mm to 5mm) is also commonly

PWM Ltd – UK Website : www.pwmltd.co.uk

▲ ▲ The M101 will be on display at this year’s IWCS

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