EuroWire May 2023

Featuring: Interwire 2023

The new X-RAY 6000 PURE • 360° measurement of the total wall thickness, inside and outside diameter, eccentricity and ovality of single-layer cables • “One Button Operation” – no calibration, no material parameters • Clear visualization of product parameters and data logging • Automatic control of wall thickness to the minimum value

Visit us at Interwire Atlanta, GA, USA Booth 1241

www.sikora.net/xray6000

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The new X-RAY 6000 PURE • 360° measurement of the total wall thickness, inside and outside diameter, eccentricity and ovality of single-layer cables • “One Button Operation” – no calibration, no material parameters • Clear visualization of product parameters and data logging • Automatic control of wall thickness to the minimum value

Visit us at Interwire Atlanta, GA, USA Booth 1241

www.sikora.net/xray6000

RAYEX® D Dynamic X-Ray Measuring System

Benefits: Latest generation of measurement algorithm provides measurement readiness within one second

Micro-focused X-ray beam ensures highest measurement accuracy New generation of X-ray sources with extended lifetime

Direct access to the sensors via the web server

Simultaneous acquisition of all measured values from both measurement axes

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

VISIT US AT INTERWIRE 2023 May 9-11, Atlanta, Georgia

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

Golden celebrations at testing and measuring specialist Celebrations are in order for measuring technology specialist Sikora. The company, based in Bremen, Germany, is celebrating its 50 th anniversary this year, and our main story on page 8 highlights significant timelines through the company’s history. Harald Sikora formed the company in November 1973 and since then there has been a pattern of continued growth, moving from the cables industry to the hose, pipe and tube market, the glass fibre market and the plastics industry. In 2000, the company launched its first subsidiary, in the USA, and this was followed by China and Italy. The company’s growth continued and led, in 2019, to the opening of a new four-storey building for production, R&D and other employees to have spacious and creative working environments. Anticipation is also building for the staging of Interwire 2023, from 9 to 11 May, at the Georgia World Congress Center, Atlanta, Georgia, USA. Turning to page 54 will provide a brief highlight of the keynote speeches, Industry 4.0 sessions, workforce sessions, extrusion/polymer sessions, industry outlook, technical sessions, Mordica lecture, and production solution demonstrations, including a speech by Dr Mary Ellen Weber, astronaut, executive, aviator and scientist. Dr Weber will talk about the experience of space flight, and will then give a second presentation: A new era of space travel: Commercial space, NASA, tourism, the Moon and Mars.

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

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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.

The exhibition is also highlighted, with some of the exhibiting companies detailing their products, right through to page 72. Our popular ‘Focus On’ feature turns its attention to Italy, starting on page 46. This covers industry highlights from several Italian companies promoting their production methods and technological advantages.

David Bell Editor

Front cover courtesy of Sikora AG showing their X-RAY 6000 PURE For more details please call:

Tel: +49 421 48900 0 Fax: +49 42148900 90

sales@sikora.net www.sikora.net

The new X-RAY 6000 PURE • 360° measurement of the total wall thickness, inside and outside diameter, eccentricity and ovality of single-layer cables • “One Button Operation” – no calibration, no material parameters • Clear visualization of product parameters and data logging • Automatic control of wall thickness to the minimum value

All rights reserved © 2023 Intras Ltd ISSN 1463-2438

Visit us at Interwire Atlanta, GA, USA Booth 1241

www.sikora.net/xray6000

www.read-eurowire.com

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May 2023

Contents May 2023

Corporate News 8

73

EuroFasteners

ISSN: 2633-9706 print ISSN: 2633-9714 online Photo by Gioia M, Unsplash

EF 3/75 Corporate News EF 6/78 Products

32 Technology News

www.read-eurofasteners.com

Focus on Italy 46

Technical Article 81

Lightfastness and weather resistance: key steps for avoiding the degradation of polymers and the discolouration of cables By Manel Miret, product developer, Delta Tecnic

Editorial Index 84

Photo by Mathew Schwartz, Unsplash

Advertising Index 84

Interwire 2023 54

35

9 – 11 May, Atlanta, Georgia, USA

Photo: Marianna-Smiley • www.unsplash.com

Diary dates

■ Focus on UK ■ Interwire 2023 review ■ Cable production machinery ■ Getting technical Breakthrough XLPE insulation for power cables Next issue

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

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

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24-27 May 2023 Wiretech Istanbul Trade exhibition Istanbul, Turkey Organisers: Tüyap Fairs www.wiretechistanbulfair.com

Subscribe today!

4-7 September 2023 wire China Trade exhibition Shanghai, China Organisers: Shanghai Electric Cable Research Institute Co Ltd Messe Düsseldorf Shanghai Co Ltd www.wirechina.net

The new X-RAY 6000 PURE • 360° measurement of the total wall thickness, inside and outside diameter, eccentricity and ovality of single-layer cables • “One Button Operation” – no calibration, no material parameters • Clear visualization of product parameters and data logging • Automatic control of wall thickness to the minimum value

Visit us at Interwire Atlanta, GA, USA Booth 1241

www.sikora.net/xray6000

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

Shows correct at time of publication, please check to ensure the event is going ahead

Corporate News

The first Sikora company building

The headquarters of Sikora AG in Bremen

Measuring technology specialist celebrates 50 th anniversary

plastic pellets, marking its entry into the plastics industry. In the tube, pipe and hose market, a millimetre wave-based measuring system for plastic pipes was introduced. The company continued to grow, and in 2019 opened a new four-storey building in Bremen, Germany, for production, R&D and other employees to have spacious and creative working environments. Within 50 years, the one-man operation has grown into a globally active manu facturer and supplier of measurement, control and inspection technologies. With the help of its measuring systems, manufacturers can save plastic material, making production more economical and simultaneously protecting the environ ment. The company states that by using its measuring devices, up to five million fewer tons of carbon dioxide are released annually, because less plastic material is produced. “I am very proud and humbled by how the company has developed over the 50 years,” said Harald Sikora. “Then, as now, the secret of Sikora’s success is characterised by innovations that always keep the customer one step ahead in the market; our passion for the products and the consistent focus of all activities are on the customers.” Sikora AG www.sikora.net

The success of the X-ray measuring system for CV lines was the basis for the development of an advanced new series of X-ray devices for the measurement of wall thicknesses in core and sheathing lines. With the next generation of X-ray measuring systems for high-voltage cable production, Sikora gained a market share of approximately 90 per cent worldwide in the power cable segment. In 2000, the company’s first subsidiary opened in the USA, followed by China and Italy. In the following years, numerous other international locations opened. In 2002, the decision was made to trans- form Sikora Industrieelektronik GmbH into the stock corporation Sikora AG. Since 2004, Sikora has applied the experience gained in the cable industry to the hose, pipe and tube market, where X-ray and laser technologies also became standard. In 2009, the company entered the glass fibre market with measuring devices for quality control in the drawing tower. The extended product portfolio and an increase in employees were influential in the 2011 decision to construct a new building for R&D and service at the headquarters. At the same time, in line with the succession plan, the company was divided into two business segments: Sikora Holding GmbH & Co KG and Sikora AG. For the first time, Sikora launched a system for the inspection and sorting of

Sikora is looking back on its company history as it celebrates its 50 th anniver- sary this year. Since 1973, it has been developing and producing measuring and control technology to increase customers’ productivity. In 1972, Harald Sikora invented a non contact measuring device for the continu ous measurement of cable insulation, wall thickness and concentricity during manu facturing. This technology became the basis for a start-up. On 1 November 1973, Mr Sikora founded his one-man business. An inductive measuring method for power cables that measures the position of the cable, the so-called sag, made the company well known in the high voltage cable industry. Laser technology, using line sensors to enable non-contact diameter measurement of wires and cables in the production process, also gained popularity. The company grew, and in 1979 changed its name to Sikora Industrieelektronik GmbH. In the 1990s, Sikora added many more products to its portfolio, including X-ray devices for measuring the wall thickness of three-layer medium, high and extra high voltage cables during production. These devices display the measuring results in fractions of a second and enable the operator to immediately make any needed adjustments. Worldwide, approximately 1,800 devices are installed to ensure reliable quality control.

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May 2023

Corporate News

Major industrial decarbonisation project gets under way

already signalled substantial financial support for the project. As part of the tkH2Steel transformation concept, the replacement of CO 2 -intensive steel production by climate-friendly technologies is now beginning. Previously, coal-based hot iron produc- tion in the blast furnace always involved emitting large amounts of CO 2 , amounting to around 20mn metric tons per year from the Duisburg location alone. Hydrogen-based processes in direct reduction plants offer a significant basis for manufacturing carbon-neutral steel in the future. thyssenkrupp Steel is already planning to avoid as much as 6mn metric tons of CO 2 by 2030, representing in excess of 30 per cent of its emissions. The transformation to carbon-neutral production is expected to be completed by 2045 at the latest. SMS group GmbH www.sms-group.com

thyssenkrupp Steel has placed an order with SMS group, Germany, for the engineering, delivery and construction of the first hydrogen-powered direct reduction plant at its location in Duisburg, thyssenkrupp Steel CEO Bernhard Osburg (left) and Burkhard Dahmen, CEO of SMS group

Germany. The order marks the start of one of the largest industrial decarbonisation projects worldwide, which will avoid more than 3.5mn metric tons of CO 2 per year in the future. The order volume for SMS amounts to more than €1.8bn, making it the largest single order in the company’s history. Significant structural building services will be required in addition to infrastructure and media connections. The preliminary tasks can be started immediately, under the scope for an earlier start to work that has been approved. The plant will have a capacity of 2.5mn metric tons of directly reduced iron (DRI), and is scheduled for completion by the end of 2026. The overall project remains subject to European Union approval under state aid provisions, as well as the final funding decision. Both are expected in the coming months. The state of North Rhine-Westphalia and the German government have

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May 2023

Innovative • Reliable • Smart The new generation of NIEHOFF multiwire drawing lines

You manufacture copper and aluminium wires of the highest quality. When choosing equipment, top production speed and reliability are a must. Your new machines must run at maximum output to make your investment pay off. Fast. What we offer: the new generation of NIEHOFF multiwire drawing lines. MMH 112 Multiwire Drawing Machine with Continuous Resistance Annealer RM 202 and Dynamic Single Spooler S 632 : fast, precise, efficient. Created for your success. How you benefit: You will save time and effort during installation. Your production output will increase while energy consumption decreases. You will experience great ease of operation and maintenance. The quality of your products will improve.

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Corporate News

Condat takes platinum medal again

product self-assessment system, the Lubriscore®. Reducing the carbon impact of its production sites is also a priority. In 2022, significant efforts were made, for example, on the French site in terms of reducing water consumption (-15 per cent) and electricity consumption (-18 per cent); and on transport, the company was able to reduce its CO 2 emissions by 8 per cent compared to 2019. In February 2023, Condat integrated the Climate Enterprise Convention (CEC). The aim of this programme is to support, for ten months, companies and their managers to move towards being a “regenerative company” – to go beyond the ambition of a responsible company by shifting towards a business model that contributes to the environment. With the climate challenges, Condat’s objective is to encourage social and

Condat, a specialist in industrial lubri- cants, has announced the renewal of its Platinum medal awarded by corporate social responsibility (CSR) platform EcoVadis. The company demonstrated its com- mitment through concrete actions and its efforts to evolve its business model over the long term. This proactive approach allows the company to keep the medal it obtained in 2021, and places Condat in the top one per cent of companies rated by EcoVadis. Condat’s commitment to responsibility, initiated decades ago, is based on one of the group’s core values: build to last. It claims to be one of the precursors in the development of industrial lubri- cants with a reduced environmental impact, launching its first biodegradable lubricants more than 20 years ago. The company also integrates sustaina- bility goals at each stage of product life, as evidenced by its eco-designed

Condat has again been certified platinum by EcoVadis

environmental commitment by offering a safe, efficient and least impactful product range. Condat SA www.condat.fr

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Intelligence that transforms the world.

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May 2023

Corporate News

Exhibitors already looking ahead to wire Düsseldorf 2024 Following the successful restart of wire and Tube in June 2022, preparations for the 2024 events are already under way. Three weeks after publication of the “early bird” offer, more than 500 exhibitors had already registered for the trade fairs, to be held in Düsseldorf, Germany, from 15 to 19 April 2024. The registrations received came from Germany, Europe and overseas, emphasising that the industries are committed to Düsseldorf as a location. Many regular exhibitors and a large number of new ones have already secured their positions in the Düsseldorf exhibition halls.

Beneke appoints VP/GM

Shannon King has been named vice president and general manager of Beneke Wire Company in Louisville, Kentucky, USA. Mr King joined Beneke in 2012 as plant manager in charge of the production of round drawn aluminium wire for the cold heading market.

He has 28 years’ experience in the aluminium wire industry and earned his Bachelor of Science degree in metallurgical engineering from the University of Alabama and an MBA from the University of North Alabama. Beneke manufactures and globally supplies wire, rod, bar and redraw rod in both heat treatable and non-heat treatable aluminium alloys. Shannon King

The early-bird offer runs until 1 June 2023.

“The two Düsseldorf trade fairs are absolute front-place for the wire and tube sectors when it comes to presenting innovations from the relevant industries to a broad, international audience,” said Daniel Ryfisch, director wire/Tube and Flow Technologies at Messe Düsseldorf.

Messe Düsseldorf GmbH www.messe-duesseldorf.de www.wire.de

Beneke Wire Company www.benekewire.com

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May 2023

Supermac – Global Solution Provider in Extrusion and Process Technology along with IIOT applications

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 Supermac 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

Benefits of BASEC certification and accreditation Product and management system third party approvals in relation to cable products are established in the market, and their credibility is underpinned by an international system of governance. The International Accreditation Forum (IAF) is at the forefront of this system through its work as a worldwide association of accreditation bodies (ABs) whose primary function is to develop a single worldwide programme of conformity assessment. Certificates issued by non-accredited organisations are dependent solely on the standing and credibility of the issuer and might not be accepted by the end user. Manufacturers require system approval as part of their product approvals, and the starting point is a management system conforming to ISO 9001:15. If this system has been certified by a non-accredited CB, BASEC cannot issue its product approval certificates.

ISO is not part of the governance process: it writes the standards but does not govern how they are utilised. Users of certification services are advised to choose a certification body (CB) accredited by an IAF member. When selecting a CB, consideration should be given to its recognition in particular sectors; the knowledge and experience of its staff; and its overall level of service. For organisations operating in the cable sector, BASEC (British Approvals Service for Cables) not only has the expertise to test, audit and certify cables, but also has the credibility and accreditations to provide a one-stop solution for accessing international markets. The initial and ongoing assessments to gaining BASEC certification are stringent, providing assurance to end users that the cable products and quality manage- ment processes maintain compliance.

Kieran O’Brien, certification and com- pliance director at BASEC, commented, “In the case where a non-accredited CB has been used to gain ISO 9001:15, BASEC would treat the system as not certified. A full management system audit would be required from scratch, adding to the costs of product approvals.” As an expert in the cable testing and certification sector, BASEC provides certification to ISO 9001, continuously auditing cable manufacturers and stockists, and can undertake this in parallel with its PCR audits. Certification to ISO 14001 and 45001 with additional benefits for those who have implemented integrated management systems are also available.

This system ensures the consistency of approach, reducing risk for businesses and their customers by assuring them that accredited certificates and validation and verification statements may be relied upon.

BASEC Group Ltd www.basec.org.uk

The international accreditation conformity system

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Corporate News

Metal powder for additive manufacturing – new atomisation plant opens

that use technologies such as additive manufacturing (AM), metal injection moulding (MIM), binder jetting (BJ) and hot isostatic pressing (HIP) to produce parts for demanding applications. With metal powders, manufacturers can produce parts with higher complexity, less weight and decreased lead times, avoiding disruptions in the supply chain. “In the near future, the estimated total production capacity will be approximately 330 tons annually,” added Mr Anstots. “Our longer-term target is to utilise the learnings and to build up our R&D know how to support the customer journey with expertise, new material development, flexibility and customisation for various powder metallurgy technologies. In our future vision, we could be able to serve our customers in such a way that they could come to us with a problem and leave with a solution.”

Outokumpu, a specialist in sustainable stainless steel, is entering a new business by starting to produce metal powder at the company’s mill in Krefeld, Germany. The metal powder production strengthens the company’s sustainability strategy and circular economy efforts by using steel scrap from local production to create new market solutions. “The global demand for metal powder is on the rise and we see great potential for the business in the near future,” said Thomas Anstots, president of BL advanced materials at Outokumpu. “We have seen the growth of additive manufacturing industries and the potential to strengthen the position and use of stainless steel for metal powder products, and therefore decided to start the construction of a new designed atomisation plant.” Outokumpu’s primary focus is on pro- ducing metal powders that are not yet on the market, suited to companies

The atomisation plant in Krefeld, Germany

circular economy. In 2022, it achieved a record-high recycled material content rate of 94 per cent. The new metal powders, including stainless steel and nickel alloys, have been specially formulated to meet the demands of modern manufacturing in terms of quality, sustainability and flexibility. Outokumpu is partnering with SMS group as the technology supplier. The equipment as a service (EaaS) contract ensures continuous line optimisation and close collaboration in the powder business between the supplier and the producer. Outokumpu www.outokumpu.com

Outokumpu’s business is based on a

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Corporate News

Rebar minimill ordered Highbar LLC has placed an order with SMS group for a new rebar minimill, which will be built on a site near Osceola, Arkansas, USA. The minimill will enable Highbar to produce rebar at a sustain- able scale and with environmental sustainability results. Highbar also agreed to continue its cooperation with SMS for a further two minimills in the future. Dave Stickler, Highbar’s CEO, said, “SMS has been and continues to be at the forefront of advancing the world’s steel industry in terms of operating efficiency, ever-increasing quality capabilities and environmental sustainability. I fully expect the SMS-supplied rebar minimill to build on the tremendous success my partners and I have had developing many of the finest scrap metal recycling and steel production facilities in the world while using SMS technology.” SMS group’s relationship with the founders of Highbar dates back almost three decades, with a number of successful projects being completed between the two partners. The new minimill will feature SMS group’s CMT® (continuous minimill technology), a low-emission and energy-efficient steelmaking system that supplies liquid steel to a high-speed caster to directly feed the rolling mill in a single, reliable process. Efficiency is increased by the SMS group’s Aura DC (advanced unit rectifier assembly) powered electric-arc furnace with all-charge continuous feeding system, and robotic solutions that improve labour efficiency.

SMS Concast will supply a high-speed single-strand caster, and the link to the rolling mill will be through an induction equalisation furnace provided by SMS Elotherm. The rebar mill will be equipped with fourteen housing-less stands and an eight-pass MEERdrive® high-speed finishing block. SMS group’s quenching and soft cooling TMbaR® thermo-processing systems will be incorporated into the rebar mill. The minimill will have industry 4.0 digital solutions and AI controlled processes to be future-ready to take advantage of digitalisation from start-up. It is designed so that natural gas is not required during the production process, achieving a low carbon footprint and up to 50 per cent reduction in emissions. Groundbreaking for the project is expected to take place in Q2 2023, with start-up planned for 22 months later. SMS group GmbH www.sms-group.com Highbar will produce rebar on the new minimill with up to 50 per cent lower carbon footprint

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May 2023

VERSATILITY FOR TOP QUALITY

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Corporate News

Individual cable carrier system for hydropower plant

with the new cable carrier system as part of maintenance work. “It guides the power, communication and sensor cables to the valve,” explained Pascal Berg, industry manager cranes and long travel at Tsubaki Kabelschlepp. For the movement of the valve across the large distance of 120m, the customer ordered a cable carrier system from Tsubaki Kabelschlepp to replace the old conductor rails. The carrier can transport more cables of different types than the conductor rail, including telephone and sensor cables. The system is also more reliable than the rail, as there is no risk of bad contacts.

An international team at Kabelschlepp France has implemented a robust cable carrier system for the safety valve at the Châteauneuf du Rhône hydroelectric power plant in the South of France. The purpose of the valve, which moves across the entire power plant, is to prevent over-speed of the turbines. In an emergency, a heavy barrier is used to block the ingress of water. The project, for hydroelectric power plant company CNR, included the largest travel length that Kabelschlepp France has ever implemented. The hydroelectric power plant was to be equipped

The extreme conditions at the site required a robust design. Installed on the retaining dam, the cable carrier system is exposed to high winds, and optimum functioning has to be ensured even at temperatures below freezing in winter. In addition to the RSC MC0950 cable carrier, the solution included all required cables, the guide channel, floating TKFMD drivers including driver arm, the substructure/wall brackets and the roof system.

The cable carrier runs on a guide channel over a total distance of 120m

Maintenance work at the hydroelectric power plant included the installation of a new cable carrier system

Tsubaki Kabelschlepp GmbH www.tsubaki-kabelschlepp.com

Photo credit: Tsubaki Kabelschlepp

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May 2023

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Corporate News

Steel mill modernisation with digital solutions SteelAsia Manufacturing Corp, the Philippines, is equipping its steel mill in the City of Calaca, Batangas, with SMS group-developed digital solutions that will provide a more efficient way to boost output without increasing its carbon footprint. condition monitoring and expert systems delivers real-time recommendations and notifications. Finally, the alarm manager will act as an intelligent alarm and main tenance management system to simplify fault analysis using intelligent prioritisa tion, multiple analysis options, linkage of resolution advice and automated notifications.

SteelAsia signed a performance improve ment agreement with SMS group to equip its Calaca steel plant with process automa tion and digitalisation based on artificial intelligence to produce green steel. The EPICA project (EAF performance improve ment partnership for Calaca) uses the lat est combustion technology and will be employed in the electric arc furnace (EAF). The pollution control system will also be upgraded to support the project. The digital components of the package include solutions based on artificial intel ligence and machine learning. The SMS Data Factory Suite functions as the central data platform. It collects all plant data, evaluates it and forwards this informa tion to the appropriate systems, for exam ple, to optimise real-time dashboards for KPI and plant monitoring. The complete platform for developing and managing

By using machine learning algorithms to provide real-time insights into the plant’s condition and process deficiencies, and by predicting machine failures, mainte nance measures can be taken proactively, production can be rescheduled and pro ductivity can be increased. SteelAsia’s Calaca steel plant will have higher energy efficiency, allowing it to in crease output by 20 per cent and cut emis sions because of the new digital solutions. Engineers and technicians at the SteelAsia plant will be given extensive training on the use of all digital technologies. “Advanced integrated solutions is the day’s buzzword, and we are proud to have Calaca as the Philippines’ first steel plant to be equipped with our leading technol

ogy,” said Prof Pino Tesè, chief sales officer, India and Asia Pacific region of SMS group. SteelAsia operates five other manufac turing plants in Bulacan, Cebu, Davao and Misamis Oriental. It plans to open a seventh plant this year in Compostela in Cebu, and to increase output from two million metric tons of steel rebar annually to three million metric tons. SMS group GmbH www.sms-group.com SteelAsia Manufacturing Corp www.steelasia.com Benjamin Yao, chairman and CEO of SteelAsia (left), and Prof Pino Tesè, chief sales officer India and Asia-Pacific region of SMS group

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Corporate News

Three-roll RSB approved

The RSB is located as a finishing unit after 20 stands in H/V rolling mill arrangement

The Chinese steel producer Shaoguan Iron & Steel has issued the final acceptance certificate (FAC) for its new Kocks RSB® 370++/4 in 5.0 design – the 115 th Kocks reducing and sizing block worldwide. Despite adversities due to the pandemic and the current world situation, the order was completed on time, on target and on budget. Shaoguan Iron & Steel (SGIS) is located in Guangdong province. The company is a joint venture of the government of Guangdong and the central government-owned iron and steel conglomerate China Baowu Steel Group, one of the largest steel producers in the world. SGIS produces premium steel products with high added value. Using the performance of the Kocks three-roll technol ogy, the company intends to expand and strengthen its share in the SBQ sector for high-quality engineering steels, primarily for the automotive industry. The Kocks RSB 370++/4 in the existing 490,000 t/a bar mill line will produce seamless straight bars in a range from Ø 17 to 80mm, with a tight tolerance level, onto the cooling bed. The RSB 5.0 is located as a finishing unit after 20 stands in H/V rolling mill arrangement. Further scope of supply for the order included a roll shop for off-line three-roll stand and guide preparation, as well as supervision for the installation and commissioning. The new block at Shaoguan follows previous installations, such as those at Baosteel Shanghai #5 in 2002 and at Shaoguan Iron & Steel wire rod and BIC line in 2018.

It is the fifth Kocks RSB within the China Baowu Steel Group.

Friedrich Kocks GmbH & Co KG www.kocks.de

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Corporate News

E-marine commissions MakaiLay software across installation and repair fleet

being added to the Cable Ship Niwa , with other ships to follow. “It is a great honour and achievement to get a vote of confidence from an experienced operator like E-marine,” said Dr Venkata Jasti, director of engineering software at Makai. “With their team coming on board, MakaiLay is now being used by over 90 per cent of the global fibre-optic cable laying fleet.” In addition to MakaiLay, E-marine PJSC will be using MakaiPlan Pro for pre installation planning in its offices. The E-marine team has completed training on both software products and plans to conduct more training as the software becomes fully adopted and integrated into the workflow. Omar Jassim Bin Kalban, CEO of E-marine, commented, “We’re looking forward to leveraging the advanced modelling and real-time control functionality of MakaiLay to tackle deep-water cable lays and repairs.” E-marine plans to use the software products on all future cable installation and repair projects. MakaiLay will allow for more precise control throughout the cable installation, with specific improvements in the deep-water areas. MakaiLay subsea cable installation software enables users to lay submarine cables with accuracy, speed, safety and reliability, reducing the risk of cable failures. The software has been rigorously tested and validated, and has been used on commercial lays and military installations to install more than 600,000km of cable worldwide. MakaiPlan Pro enables powerful and precise 3D dynamic simulations of submarine cable installations. Cable operators can quickly simulate an entire cable lay in advance at up to 50 times faster than real time. An entire trans oceanic lay simulation can be completed in one day. MakaiPlan Pro is an extension of the MakaiPlan cable route planning software, and includes all of the planning features of MakaiPlan. Makai Ocean Engineering, Inc www.makai.com E-marine PJSC www.emarine.ae

In the last year, Makai Ocean Engineering, Inc, has started commissioning its MakaiLay submarine cable installation software on E-marine PJSC’s cable installation and repair vessels. MakaiLay was recently added to the Cable Ship Maram and Cable Ship Umm Al Anber , and is also

Cable Ship Maram

Copyright E-marine

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Corporate News

Recognition of commitment to sustainability

integrated the principles of sustainability/ CSR into its business and management systems based on seven principles: assessment by international experts; tailored to industry sector, country and company size; source diversification to ensure rich stakeholder input for reliable scoring; utilising technology to ensure a secure and confidential process and accelerated cycle time; traceability and transparency of documentation; evidence-based; and excellence through continuous improvement. The methodology is built on international sustainability standards, including the Global Reporting Initiative, the United Nations Global Compact and ISO26000, with performance measures across 21 indicators in four themes: environment, labour and human rights, ethics, and sustainable procurement. Inductotherm Group offers technology for the engineering, manufacturing and service of thermal processing equipment used in the melting, heating, heat treating, forging, galvanising, coating, cutting and welding of metals.

Inductotherm Heating & Welding has been awarded the Silver EcoVadis sustainability rating. This new accolade follows the company’s triple BSI – ISO accreditation awarded in 2022, which included ISO9001 for quality, ISO45001 for occupational health and safety and ISO14001 for the environment. The company is undertaking a process of developing and improving its environ- mental and sustainability practices to ensure they are sensitive and responsible to the local and wider environment. This includes implementing a wide range of changes in all areas of the business, from adopting renewable energy to changing to eco-friendly supplies and engaging with suppliers as an ongoing commitment by the company. In addition to the commitment to social and environmental responsibility, the accolades provide customers with reassurance that they are engaging with a forward-thinking, ethical company committed to providing environmentally sound service. Achieving the Silver rating has already allowed Inductotherm Heating and Welding to attain “preferred supplier status” with existing Tier 1 customers who value sustainability across all areas of their business. The EcoVadis sustainability methodol- ogy evaluates how well a company has Chinese special steel producer Xinyu Iron & Steel Co Ltd (XISCO) has signed a contract with Friedrich Kocks GmbH & Co KG for the supply of an RSB® 370++/4 in 5.0 design. The reducing and sizing block will be part of the company’s new rolling mill complex in Xinyu City, China. XISCO is a subsidiary of Baosteel group, a steel producer with annual production of around 120mn tons. Through further acquisitions, this output will be increased to around 200mn tons by 2025. With more than 32,000 employees, XISCO accounts for 10mn tons of speciality steels per year.

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The group comprises 40 companies with 38 manufacturing facilities located in 23 countries. Inductotherm Heating & Welding Ltd www.inductothermhw.com XISCO chooses core technology for new SBQ bar mill line

Cold-Rolling Wire Drawing Wire Stretching

In XISCO’s new rolling mill, a Kocks three roll RSB will balance quality with economic results. The new RSB 370++/4, designed according to the individual requirements of XISCO, will be located as a finishing block after 22 stands in H/V arrangement in a 560,000 t/a SBQ mill. It will produce straight bars onto the cooling bed within a finished size range of Ø 20 to 90mm with high dimensional tolerance. The scope of supply includes remote control for stand and guide adjustments, equipment for the roll shop and proprietary Kocks software solutions. Commissioning of the RSB is scheduled for the end of 2023. Friedrich Kocks GmbH & Co KG www.kocks.de

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