Fasteners ASIA May/July 2020

Industry & technology news from the world of fasteners

www.read-eurowire.com www.read-eurofasteners.com

www.read-wca.com www.read-fastenersasia.com

To advertise call UK, ROW, USA, CANADA & S. AMERICA, GERMANY, AUSTRIA, SWITZERLAND Jason Smith | Email: jason@intras.co.uk | Tel: +44 1926 834684 ITALY

CHINA, TAIWAN, HONG KONG Linda Li | Email: linda@intras.co.uk Tel: +44 1926 834685

Giuliana Benedetto | Email: giuliana@intras.co.uk Tel: +39 342 397 7383 | Tel: +44 1926 834686

for the wire and cable industries...and now fasteners! Leading magazines

Contents FA 2/36 Industry News FA 5/39 Products FA 9/43 Manufacturing Technology

May/July 2020

Diary of Events

2020

23–26 September: wire China – trade exhibition – Shanghai, China Organisers : SECRI and Messe Düsseldorf (Shanghai) Co Ltd Fax : +86 216 169 8301 Email : shanghai@mdc.com.cn Website : www.wirechina.net 11–14 October: IWCS – virtual symposium and trade exhibition Organisers : IWCS Tel : +1 717 993 9500 Website : www.iwcs.org 7–11 December: wire 2020 – trade exhibition – Düsseldorf, Germany Organisers : Messe Düsseldorf GmbH Email : wire@messe-duesseldorf.de Website : www.wire.de 25–28 January: MACH – trade exhibition – Birmingham, UK Organisers : MTA (Manufacturing Technologies Association) Email : mach@mta.org.uk Website : www.machexhibition.com 25–27 March: wire India – trade exhibition – Mumbai, India Organisers : Messe Düsseldorf India Pvt Ltd Fax : +91 112 697 1746 Email : info@wire-india.com Website : www.wire-india.com As with all shows, and with the continuing coronavirus pandemic, please check to ensure the event is going ahead. 2021

bigstockphoto.com/PIXbank

New dates for wire 2020 The coronavirus pandemic has led to a number of postponements in the exhibition calendar – the largest being wire 2020 in Düsseldorf, Germany, which has been rescheduled for 7 to 11 December this year. Turn to page 14 of Wire & Cable ASIA for the latest details. Hafren Security Fasteners steals the limelight in this issue of Fasteners ASIA with the opening of a new purpose-built storage facility adjacent to its head office in Newtown, Wales, UK. See page FA 2/36 for the full details. Another exhibition in the headlines is SpringWorld, which takes place from 7 to 9 October in Rosemont, Illinois, USA. Presented by the Chicago Association of Spring Manufacturers Inc (CASMI), the exhibition brings together spring manufacturers, wire formers and OEMs. In 2018, nearly 2,200 attendees and exhibitors took part. Turn to page FA 3/37 for more information. Bulten has also expanded – inaugurating its new factory in Tianjin, China, for the production of high-quality fasteners for the automotive industry. Read the full story on page FA 4/38.

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

FA 1/35

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Industry news

Expanding to meet growing demand for security fasteners ❍ (from left) Matthew Lynes, MD; Russell George, Assembly Member for Montgomeryshire; and warehouse manager Mike Williams

add more bespoke solutions. Mr Lynes added that “2020 is our 25 th year in this market … it has already seen the launch of one new range and we’re putting a lot of time and investment into R&D and innovation. We are the first globally to stock a range of A4 stainless steel security screws, which will no doubt be popular with customers looking for a security fastener that can withstand the harshest environments. “Sustainability is key to our business. In line with our ISO 14001 certification we have launched our new range of 100 per cent recycled cardboard packaging and have just added our first fully electric vehicle to our fleet.”

that this growing company is securing well-paid jobs in the Newtown area. Hafren Fasteners is committed to Mid Wales, and this investment further secures the company’s future to the local area which supports the local economy.” Having more storage space will allow for increased capacity and flexibility to offer distributor customers better service in terms of stock availability and delivery speed. It will also help to future-proof the business ahead of supply chain threats and transportation issues that could occur due to external unforeseen incidents such as the coronavirus epidemic. The extra space will allow an expansion of the range of specialist security fasteners and the ability to

The team at Hafren Security Fasteners has cut the ribbon on a new purpose-built storage facility adjacent to its head office in Newtown, Wales. MD Matthew Lynes said, “It is a great day for Hafren as the global home of security fasteners expands again. This new building is more than three times larger than our current warehouse facility; we have built it to meet and exceed the growing demands of our clients, to safeguard jobs, create more jobs and to keep us one step ahead in everything we do.” To help celebrate the completion of the storage facility, Hafren was visited by Russell George, the Assembly Member for Montgomeryshire, who cut the ribbon for the official opening. Mr George commented, “I’m delighted

Hafren Security Fasteners www.hafrenfasteners.com

Graphics bigstockphoto.com/Artist Kumruen Pakom

FA 2/36

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Industry news

SpringWorld trade show

Refinery is back for more

SpringWorld will take place from 7 to 9 October 2020, in Rosemont, Illinois, USA. Presented by the Chicago Association of Spring Manufacturers, Inc (CASMI), SpringWorld provides an opportunity to network with other spring manufacturers, wire formers and OEMs, including one-on-one discussions with colleagues who share challenges and are ready to discuss solutions, providing new insights for business. On the trade show floor, attendees will see the latest technology available to improve company productivity, quality and service. More than 90 suppliers will be demonstrating their products and services in nearly 30,000 square feet of exhibit space. Products and services on the show floor will include compression springs, constant force, extension springs, fasteners, flat springs, hot wound springs, spiral torsion and power springs, spring washers, stampings, torsion springs and wire forms. In 2018, nearly 2,200 attendees and exhibitors from around the world participated in SpringWorld. The event is located at the Donald E Stephens Convention Center in Rosemont, Illinois, only five minutes from O’Hare International Airport. Attendance is free, but is limited to spring, stamping, fastener and wire form manufacturers. The pre-registration deadline is 14 September. CASMI was founded in 1944 as a not-for-profit trade association dedicated to the development of good business practices and sharing of technical information through ongoing communications among the job-shop spring manufacturers in the Greater Chicago area. Membership now includes spring companies and industry suppliers from the mid-west and throughout the USA. Details correct at the time of going to press. Owing to the situation regarding the coronavirus epidemic and its impact on industry events, please check the website below for the latest information. CASMI-SpringWorld www.casmi-springworld.org CAM joins Stanley Black & Decker

about the prospect of welcoming CAM to the Stanley Black & Decker family to further diversify our industrial business segment. With its well-recognised brands, proven business model and experienced management team, CAM will play a significant role in the growth of our industrial business and company overall.” Stanley Black & Decker is a $14bn revenue industrial organisation. With employees in more than 60 countries, it operates an engineered fastening business, a tools and storage business, a commercial electronic security company and oil and gas and infrastructure businesses. Stanley Black and Decker, Inc www.stanleyblackanddecker.com Consolidated Aerospace Manufacturing, LLC www.camaerospace.com Based in Pacific Palisades in California, NASCO has worked with Ellis since 2016 and has secured a number of high-profile specifications, including a major order for its Centaur cable saddles from the US Army Corps of Engineers (USACE) for the Fort Randall dam in South Dakota. Ellis Patents Ltd www.ellispatents.co.uk Ellis Patents has secured a repeat specification from a major Gulf Coast refinery, ten years after its cleats were used on the refinery’s first substation. Ellis’s Vulcan+ cable cleats have been specified by Dashiell Corporation to secure two 68 kV armoured cable circuits, both of which stretch for over two miles and carry power across the refinery to a new process unit. Manufactured in 316L stainless steel, Vulcan+ cleats are designed to provide corrosion protection, even in harsh environments, while also ensuring cables remain secure and operational after a short circuit incident. They are quick to install, and feature integral LSF zero-halogen polymeric liners and base pads that protect and cushion cables during short circuit conditions. Dashiell Corp ordered the cable cleats through Ellis’s North American distributor, NASCO.

specific needs,” said Peter George, CEO of CAM. “We have enjoyed tremendous support under the ownership of Tinicum, during which we invested heavily in upgrading the equipment and facilities of the businesses we integrated, in addition to strengthening our engineering and management resources. The CAM management team is grateful for the Tinicum partnership that was a central part of the company’s growth. We are extremely pleased to be taking this next step of joining Stanley Black & Decker. Being part of such a capable industrial company will enable us to further expand our company’s resources globally, including accelerating the development of new products and pursuing acquisitions, allowing us to better serve the needs of our customers.” Stanley industrial president John Wyatt commented, “Our team is excited

Consolidated Manu- facturing, LLC (CAM) has entered into an agreement to be acquired by Stanley Black & Decker, Inc, subject to regulatory approvals and other customary closing conditions. CAM designs and manufactures hardware and fastener solutions for demanding aerospace applications worldwide, and is controlled by Tinicum Inc. CAM’s products include fasteners, fittings, couplings, latches, quick- release pins, tubing sub-assemblies and other complex components and assembled products. The company was founded in 2012 and has consolidated eight businesses pro- viding service and solutions to commercial aerospace and defence customers. “We specialise in collaborating with our customers to develop application- based solutions that satisfy their Aerospace

FA 3/37

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Industry news

Bulten inaugurates factory and strengthens platform in China

Kadimi’s global expansion continues Kadimi has completed the acquisition of Precision Castparts Corporation USA’s 50 per cent share in its subsidiary, Kadimi Tool. Kadimi Tool is a manufacturer of flat thread rolling dies, and holds licences for making Taptite, MAThread and Ejot PT dies. It manufactures a full range of flat thread rolling dies including all standards and specials. The dies are now being sold using Kadimi’s global sales network. This is Kadimi’s second acquisition, after the purchase of JFE Steel & Nakagawa Steel’s shares in Kadimi Special Steels in early 2019.

Bulten has inaugurated its new factory in Tianjin, China, for the production of high-quality fasteners for the automotive industry. With the establishment of the new business, Bulten has strengthened its position as an international supplier of fastener solutions and created conditions for managing future growth in China. “Bulten is gradually growing as an international supplier of fasteners,” said

❍ The exterior of Bulten’s new facility

Anders Nyström, president and CEO of Bulten. “Having well‐functioning and modern factories with room for further growth is necessary. The inauguration of the new factory in Tianjin is an important milestone for us and strengthens our platform in China, which is the world’s largest car market.” Bulten has manufacturing units for fasteners in six countries, and established its operation in Beijing, China, in 1996. In October 2018, a decision was made to move the Chinese operation to newly built premises in Tianjin, around 150 km from Beijing, in order to create better conditions for expansion, and to meet Bulten’s sustainability goals. The move has meant investments of approximately SEK 25mn, and the costs are estimated to be approximately SEK 16‐20mn. The modern and fully integrated plant features cold forming, heat treatment and surface treatment. Bulten is one of the few fastener suppliers in China that controls all of these steps in the manufacturing process in‐house. Bulten supplies fasteners to the international automotive industry. Its products range from customer‐specific standard products to customised special fasteners. The company also provides technical development, line‐feeding, logistics, material and production expertise. Bulten AB www.bulten.com

❍ Team members outside the Kadimi Special Steels plant

Kadimi Special Steels manufactures cold heading quality and bearing steel wires for the fastener and cold forging industry. Kadimi has been supplying its products to the fastener industry globally for 43 years. The acquisitions allow the company not only to expand its reach to its worldwide customer base but also to strengthen its supply chain. Kadimi Tool Manufacturing Company www.kadimitool.com Fastener Taiwan show rescheduled

at the show will include one-on-one procurement meetings, and seminars and forums. Details correct at the time of going to press. Owing to the situation regarding the coronavirus epidemic and its impact on industry events, please check the website below for the latest information. TAITRA www.fastenertaiwan.com.tw

that serves as a trading platform for sourcing and procurement, featuring a complete range of fastener products. The show also presents the highly integrated supply chain of Taiwan’s fastener industry. 430 exhibitors will display products including nuts, bolts and screws; fastener manufacturing equipment; fastener tools; meters and instru- ments; and wire and raw materials. In addition to a welcome dinner, events

Following comprehensive considera- tion of the coronavirus epidemic, the organisers of the 2020 Taiwan International Fastener Show have decided to change the exhibition dates to 14-16 October. The sixth edition of the show, to be held at the Kaohsiung Exhibition Center, was originally scheduled to be held in April. Fastener Taiwan is an international business-to-business fastener show

FA 4/38

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Products

Bumax supplies `CERN-rated`screws for cancer therapy equipment ❍ Low magnetic permeability Bumax 109 screws with silver coating

applications, not merely medical equipment. We anticipate supplying our premium high-strength fasteners to many more customers in the future.” Bumax is a specialist manufacturer of stainless steel fasteners in a variety of steel grades that provide safety and reliability in demanding applications. Customers include CERN, ABB, Alfa Laval, Alstom, Vestas and Rolls Royce, and other companies in industries such as marine, automotive, oil and gas, chemical processing, energy, defence, pulp and paper, construction and general engineering. The company is headquartered in Åshammar in Sweden’s steel district, and has offices or distributors in more than 30 countries on four continents. It is fully owned by the listed Swedish Bufab Group. Bumax AB www.bumax-fasteners.com

The customer required a high-strength stainless steel screw with low magnetic permeability that met the CERN 507 standard to fasten all vacuum parts on its new model proton machine, to avoid vacuum leakages and machine failure. Low magnetic permeability is essential for proton machines to not interfere with the movement of protons. “Our customer found that Bumax was the only fastener supplier in the world that was able to manufacture screws to CERN 507 standard,” said Camille Feuillet, business development manager at Bumax. “Bumax was able to fully meet the customer’s requirements by offering high-strength, low magnetic permeability Bumax 109 screws with silver coating.” Bumax managing director Patrik Lundström Törnquist commented, “CERN 507 has huge potential to benefit various advanced manufacturing and high-tech industry

Swedish manufacturer of premium stainless steel fasteners Bumax has won an initial order from a medical equipment customer for 17,000 ultra premium screws for the manufacturing of a new model of proton cancer therapy machine. Bumax was the only supplier able to provide screws that meet the CERN 507 standard, which is required for fastening the vacuum parts of this new type of proton cancer therapy machine. CERN 507 is a new standard for ultra-high vacuum applications for magnetic field strength stainless steel. Bumax developed the standard together with CERN (the European Organization for Nuclear Research). Proton therapy machines are a major advancement in the fight against increasing cancer rates around the world, as they accurately deliver proton beams to precisely where they are required.

Graphics bigstockphoto.com/Artist Wladimir

FA 5/39

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Products

Sealing fasteners to meet surge in ventilator manufacturing As manufacturers across industry sectors pitch in to accelerate production of life-saving ventilator equipment, Zago Manufacturing is ready to meet heightened global demand for its high-tech sealing fasteners. Manufacturers can use Zago’s clean, sustainable sealing solutions to protect and optimise the functionality and performance of their ventilator equipment. In addition to medical ventilators, Zago sealing screws, nuts, bolts and washers are used in the production of extracorporeal membrane oxygenation systems (ECMO), which are similar to external blood pumps and are in dwindling supply, and can be used by frontline healthcare workers when treating COVID-19 patients. While applications vary, ventilator manufacturers often integrate Zago sealing fasteners in the suctioning mechanism of the compressor, in order to prevent airflow leakage while ensuring that contaminants are sealed out. Zago’s high-tech sealing fasteners are engineered with a rubber O-ring that, when tightened, permanently seals out hazards while withstanding extreme pressure, temperature and weather. The sealing fasteners are corrosion-resistant and made in the USA with FDA-approved O-rings. According to Harvey Rottenstrich, lead engineer, president and co-founder of Zago Manufacturing, “Medical devices that contain either a suction mechanism or a pumping mechanism benefit from integrating Zago high-tech sealing fasteners with O-ring technology as they are essential for optimal air flow, reliability and peace of mind.” Gail Friedberg, the company’s CEO and co-founder, stated, “Zago is open and operating smoothly, without any disruption to its supply chain. It’s important that manufacturers who are stepping in to produce ventilators and may be unfamiliar with the supply chain know that Zago is here and capable of meeting heightened demand.” Time is of the essence when producing medical ventilators for COVID-19 patients. “If we can save manufacturers, engineers, purchase managers and distributors precious time by letting them know that we are here for them, hopefully we can play our part in the expeditious production of ventilators and in saving lives,” said Ms Friedberg. Zago Manufacturing www.zago.com

Fasteners get smart

Hilti, a manufacturer of products for the construction industry, has launched Internet-of-Things-enabled ’smart’ fasteners using its Tracefast technology. The connected fasteners each have a unique identifying code to simplify the digital documentation of anchors, screws and bolts installed on a job site. The technology uses a data matrix code that can be scanned by construction workers using the Hilti Connect app, in order to view installed fastener details. The company believes that bringing the Internet of Things (IoT) to job sites will provide control and digital access to setting instructions, training, and inspection documents and certifications. ”As IoT transforms the construction industry, our product portfolio will continue to expand and shape possibilities for broader applications and services,” said Muthu Manohar, senior director of fastening and protection at Hilti North America. Hilti www.hilti.com

❍ ‘Smart’ fasteners from Hilti

FA 6/40

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Products

Compression springs made of tool steel for high-temperature applications

Lightweight tool-free clamps TE Connectivity has introduced its new P-Clamps, with lock and mounting features that offer engineers the flexibility to rethink the way electrical and fluid systems are configured. Engineered with separate mounting and locking features, the clamps can be installed earlier in the assembly process compared to standard AS21919 P-clamps. The clamps simplify and speed up installation by eliminating the need for tools and hardware when installing cable assemblies. The risk of foreign object debris also decreases when tools are not required for installation. The P-Clamp’s design incorporates a quick-lock feature that allows users to quickly open and close the clamp without unmounting it. Made of lightweight, aerospace- grade PEEK (polyether ether ketone) polymer, TE P-Clamps are available in ten sizes that cover the same range as 21 standard AS21919 P-clamps. Using PEEK helps reduce weight by up to 25 per cent while maintaining comparable physical strength as metal P-clamps. “Our new P-Clamps are helping enable next generation harness assembly by removing the design roadblocks of standard metal P-clamps and replacing them with features that give engineers and operators more flexibility,” said Tyler Weber, product manager for TE’s aerospace, defence and marine division. “Combined with easier installation and reduced weight, that flexibility makes [the clamps] ideally suited for customers who need versatility and simplicity without sacrificing ruggedness.” TE P-Clamps are designed for mounting cable harnesses in a wide range of applications includ- ing commercial aviation, military aerospace, military vehicles, mar- ine vehicles, industrial vehicles, rail and automotive. TE Connectivity Ltd www.te.com

❍ Compression springs made from tool steel Spring specialists in Sweden have made and tested prototypes of springs in a new material that can withstand high temperatures. One of the requests for firm compression springs for high- temperature applications originated in the Lesjöfors sales office in the Netherlands, where the customer wanted to replace disc springs with compression springs in an actuator application for large valves. The compression springs would have to work in an environment of around 200-250°C with high demands on strength and relaxation resistance. To discuss these challenges and possible solutions, sales manager André Boskemper contacted Stefan Musslinder, the group’s technical manager, and Per Davidsson, technical manager at the factory in Lesjöfors, specialised in the manufacture of large industrial springs. They came up with the idea of producing springs in tool steel, which had never been done before. The traditional materials used for springs working in high-temperature applications are either stainless steel or super alloys such as Inconel or Nimonic. The disadvantage is that these materials are costly compared to tool steel, and the strength is fairly low in larger dimensions.

The advantages the team anticipated with tool steel led to the decision to start prototype manufacturing and testing. Mr Musslinder, commenting on the development process, said, “We manufactured ten springs in tool steel and did setting tests at temperatures between 200 and 300°C. By doing so, we can measure how well the springs’ characteristics withstand high temperatures. The test results are very positive and we look forward to extended tests in longer time-series to investigate long-time relaxation resistance.” Lesjöfors in Åminnefors, Finland, has received similar requests for tool steel springs from companies in Asia. “Regularly, we get requests from customers who need springs working close to a furnace or in flow valve for steam, for example. Compression springs in tool steel could be a great cost-effective alternative in many high-temperature applications,” said Mr Davidsson. Lesjöfors springs, stampings and pressings are used in diverse industries. The large selection of standard springs is combined with high-tech, customised solutions. The company has both manufacturing and sales offices in several European countries, Asia, the USA and Mexico. Lesjöfors AB www.lesjoforsab.com

FA 7/41

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Products

Sparks Innovation Center releases new Nail Guard

screws, and prevents damage to electrical power cables that could short the conductors and start a fire. Mr Turner had the idea for Smart Shield when he was working on a job: “I was remodelling a home and I realised I can’t drywall if my life depended on it, and the traditional nail plates I was using created unsightly bulges. Smart Shield is easier to install, but it also made the job safer because it stops you from striking wires from either side of the wall.” Inventors are invited to share their product ideas with the Sparks Innovation Center and apply for the chance to develop a contract, allowing their product to be made and sold with support from Madison Electric. “We have marketing; we have the sales channel; we have the distribution channel; we have the manufacturing capability,” said Rob Fisher, vice president of marketing for Madison Electric Products. “What we need are the innovative and relevant ideas that help electricians and contractors work smarter, more safely and efficiently.” The Sparks Innovation Center has also produced inventions such as the Smart Box™ Shark Tooth™ fixture box; the MEIBB intersystem bonding bridge that connects directly to the meter socket and provides protection for the main ground wire; and the Stingray, used to run help pull cable through a drop ceiling without damaging the grid.

Madison Electric Products has launched the new Smart Shield™ Nail Guard, the latest product from its Sparks Innovation Center, a crowd-sourced approach to new product development. The innovative steel nail guard has a cylindrical shape that protects wires and cables in wood framing from stray nails or screws. The concept was submitted by inventor Bruce Turner of San Jose, California, USA.

The Smart Shield protects wires and cables on both sides of a stud, eliminating the need for multiple standard nail plates. It is also easier to install than standard nail plates and eliminates drywall bulge caused by using surface-mounted nail plates. The design also prevents hand injuries from the sharp edges commonly found on traditional nail plates. Smart Shield is resistant to direct strikes from nail guns and ❍ The Smart Shield Nail Guard protects wires and cables in wood framing

Madison Electric Products https://www.meproducts.net

Automotive safety parts

Watching the load

Maxbolt load-indicating fasteners from Valley Forge and Bolt can reduce downtime, premature wear and catastrophic joint failure by using a load-monitoring device inserted into each fastener. Observation of the monitor allows technicians to see if the clamp load falls out of specification on an individual bolt and so correct the issue immediately.

Canatex Industrial Co Ltd, established in 1998, is located in the southern part of Taiwan, close to Kaohsiung – a city where fastener manufacturers gather alongside Taiwan’s main material supplier, China Steel Corp. Canatex is not only familiar with standard parts but also specialises in automotive safety parts – both external and internal thread special parts. The product line involves various production methods, such as cold forging, CNC machining, stamping, deep drawing, sintering, and metal and plastic injection. 100 per cent of the company’s suppliers are from Taiwan, and 70 per cent of its products are used in the automotive industry. Beside the company’s head office, a sorting and logistics centre keeps stocks for customers and improves lead time. Canatex Industrial Co Ltd www.canatex.com.tw

❍ Maxbolt load-indicating fasteners

Maxbolt offers clamp loads within 5 per cent of design specification. Measurements are based on tension, eliminating inaccurate torque control. Custom labels can show the optimum operating range, using a green zone, or pinpoint precise clamp load values. Valley Forge & Bolt Mfg Co www.vfbolts.com

FA 8/42

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Manufacturing Technology

❍ The Bumax facility in Åshammar, Sweden

Bumax halves energy use and streamlines production

energy use by more than 150 MWh. The work on energy efficiency continues in 2020 with the replacement of the facility’s gas heating system with an electric heating system powered by renewable electricity. The switch to renewable electricity is the first phase of a project to replace the entire heating system with a more sus- tainable solution. The various energy- efficiency measures were identified following two assessments in recent years that identified how energy is used at the facility in Åshammar. Bumax also participated in the Energig project together with the University of Gävle and Linköping University, which helped companies to become more energy efficient. Following its success in promoting energy efficiency, Bumax has been highlighted as a good example by the Swedish Energy Agency. Bumax AB www.bumax-fasteners.com

also provide a more equal indoor temperature at the facility and a better working environment. Other measures taken include better controls for the boiler heating system, optimisation of the ventilation system, reducing the temperature in the warehouse from 15°C to 10°C, and installation of a heat recovery ventilation unit that optimises heating in the offices and canteen. Bumax sources 100 per cent of its electricity from renewable hydroelectric power plants. In 2019, the company used approximately 1,249 MWh of renewable electricity. At the same time, electricity use has been reduced by around 55 per cent, following investments in low-energy lights and lighting motion sensors. In addition, the facility’s wastewater treatment plant has been closed, as it was not economical for the small amounts of wastewater the company produces; this move reduced annual

Bumax, a Swedish manufacturer of high-strength stainless steel fasteners, has reduced the energy it uses for heating and electricity at its Åshammar facility by over 50 per cent since 2011, to significantly lower its carbon emissions and further streamline the production of products. “This is an impressive feat for a manufacturing company operating in a large facility in the Nordics,” said Patrik Lundström Törnquist, managing director of Bumax. “We commenced our sustainability programme already in 2011 and have seen fantastic results. By using less energy for heating and electricity, we are not only reducing our carbon footprint; we also realised financial savings that increase our competitiveness.” Key investments to reduce heating demand included upgrading roof insulation, fitting energy-efficient triple-glazed windows and insulated skylights, and installing better-insulated large industrial doors. These measures

Graphics bigstockphoto.com Artist Koloj

43 FA 9/43

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Manufacturing Technology

“FUL” speed ahead in spring production The FUL series of spring coiling machines from Wafios are designed for maximum productivity and quality. The range previously consisted of seven models covering spring wires ranging from 0.12 to 8mm. With the addition of the FUL 166 for wires from 6.1 to 16mm, Wafios is expanding the upper end of the range. The features are mostly identical to those of the smaller models.

The feed rollers are fixed to their shaft in two ways: via positive locking with three driving pins and via force locking with a preloaded central nut. In the event of wear or if the spring wire thickness is changed, it is easy to carry out the necessary modifications. Keeping the (dis)assembly work to a minimum is a design principle that runs through the entire machine. This also applies to the slip control, for example, which only needs to be moved out of the work area rather than being dismantled. In addition to the new FUL 166, other Wafios models for the production of suspension springs are the FUL 175 (up to 17mm), the FUL 183 (up to 18mm), and the FUL 203 – the largest suspension spring machine for up to 20mm oil hardened and tempered wire. Wafios AG www.wafios.com

possible to achieve feed speeds of up to 220m/min. The lack of hydraulic systems offers an advantage, as pneumatic components require less maintenance. As a result, the cutting and coiling unit has also been designed without hydraulics. The FUL 166 is the first Wafios spring coiling machine with six pairs of feed rollers. However, all six pairs are only required for wires with a thickness greater than 14mm. For thinner wires, the machine fitter equips the machine with fewer rollers. “There are two possibilities as far as the number and design of the feed rollers are concerned,” explained Andreas Sigg from the design department at Wafios. “Either fewer pairs with a large diameter, or more with a smaller diameter. Large rollers are heavy. In order to make handling as easy as possible, we decided on six pairs of rollers that were smaller in diameter.”

Wire is transported via feed rollers with pneumatic clamping for all machines; the FUL 16 is the only model where the operator carries out clamping manually using spring assemblies. The larger the machine or wire diameter, the more feed rollers are used – FUL 16 to FUL 46 use two pairs, while FUL 56 to FUL 86 use four pairs. The pneumatic contact pressure can be adjusted on-screen for each pair of rollers. This concept makes it

The turning of the screw in metal pre-treatment for cold forming operations

reduced CO 2 impact and less water usage. Bonderite L-FM FL is a non-reactive, water-based polymeric coating that adheres to the surface physically without any reaction, so the only evaporates produced in the subsequent drying step prior to cold deformation are aqueous. As a one-step process, it eliminates all rinsing steps, which saves water, and also has a reduced energy demand with appropriately lower CO 2 emissions. When the cold formed screws are dephosphatised for final heat treatment, the polymeric coating is easier to remove, which permits the use of a dephosphating cleaner in lower concentration, which means less consumption. In addition to the environmental benefits, the Bonderite L-FM FL technology is characterised by its reduced complexity over zinc phosphating. As a single-bath process, it minimises equipment footprint and maintenance. Raw material surface properties require initial sand blasting or pickling and neutralising, but the conversion cycle is simplified to a single step and operates at a temperature between 40°C and 50°C, providing time and energy savings. Overall productivity is enhanced by the lubricity and pressure resistance, in comparison with traditional zinc phosphating processes, which results in longer extrusion die life, and has been confirmed in industrial-scale applications.

Henkel Adhesive Technologies has enhanced the market fit of its Bonderite L-FM FL portfolio of polymeric coatings for the surface conversion of metals used in cold forming operations. The optimised Bonderite L-FM FL process reduces the number of treatment steps, from as many as ten, to one or two, and is an alternative in the production of high-performance automotive bolts and screws. Medium carbon or alloy steel grades designed for cold formed threaded fasteners in property classes such as 8.8, 9.8, 10.9 and 12.9 require a prior surface conversion process to create a thin, adherent coating that will facilitate deformation and ensure the quality of the final product. In the automotive industry, these cold formed screws and bolts are used in a wide range of engine, powertrain, suspension, wells and other demanding applications. Traditional zinc phosphating and reactive soap processes, although well established in metal pre-treatment for cold deformation, are associated with a number of potential drawbacks, including high acidity, high energy consumption and phosphate sludge. They can also involve up to ten individual steps, from initial degreasing and pickling to activation, phosphating and soaping, with frequent intermediate rinsing. With Bonderite L-FM FL, Henkel has developed a solution to these issues that provides a flexible one-step process,

Henkel Italia Srl www.henkel.com

FA 10/44

Fasteners ASIA – May/July 2020

www.read-fastenersasia.com

Manufacturing Technology

Cold heading oil launched

Concerns about PAHs and BaP (polycyclic aromatic hydrocarbons and benzo[a]pyrene) have been present in the metalworking industry since 2015. Some petroleum-based products, such as process lubricants, can release PAHs and BaP under severe operating conditions. For greater vigilance, the French Health Insurance authority issued a recommendation, reference R.451, concerning the “Prevention of chemical risks caused by cutting fluids”. It uses the data provided by the INRS on the risks and thresholds related to BaP contained in new and in-service neat cutting oils. While this issue is regularly raised when using machining neat oils, there are no recommendations for cold heading operations. Guided by its HSE (health, safety and the environment) and CSR (corporate social responsibility) principles, Condat decided to go further by taking into account this question and by anticipating the regulation. The company’s in-depth knowledge of how to reduce PAHs/BaP in in-service machining oils led to the development of Neat Green oils, which do not show an increase in BaP content after 1,500 hours of machining. In early 2018, Condat requested its R&D laboratory to work on new formulas for cold heading oils with neutral impact in terms of BaP. Beyond its CSR commitment, the company also wants to address the concerns of automotive suppliers and provide customers with the safest possible products. The objective was to co-develop with major automotive groups a high-performance product for very difficult forming operations. After six months of research, Extrugliss HT 268 VP was created. In partnership with an automotive supplier, the product was tested for nearly 12 months on cold heading operations for the manufacture of seat pinions and hubs, and reportedly showed good results. Available for sale since June 2019, Extrugliss HT 268 VP is positioned as a premium product specially formulated for extreme operations that generate excessive heat (stainless steel, alloy steel with high elastic limit, etc).

Developed to solve BaP emissions problems, the neat cold heading oil is formulated from high-quality, highly refined base oils, and contains fewer residual compounds that may degrade to PAHs. It resists oxidation, increases the life of the baths and facilitates degreasing by preventing the formation of sticky residues on the parts. It is less volatile, and limits oil evaporation and mist generation, improving the atmosphere in workshops. The dual-purpose cold heading oil provides lubrication characteristics to the mechanical components of cold heading machinery as well as lubrication for the deformation operations, and has a viscosity of 68 cst. Condat SA www.condat.fr ❍ Extrugliss HT 268 VP cold heading oil from Condat

BB Price selects Radyne Flexitune bar end heating units Inductotherm Heating & Welding has announced the successful factory acceptance of six new Radyne Flexitune induction heaters to BB Price Ltd in Halesowen, UK. The units will heat bar ends up to hot forging temperatures and

will cover diameters from 16 to 22mm across a range of heated lengths. BB Price Ltd has traditionally used oil-fired furnaces for its hot forging systems. The Radyne Flexitune induction heaters will provide improved energy efficiency, minimal start-up times and an improved working environment for the operators. Inductotherm Group offers advanced 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. Bringing together 40 companies with 38 manufacturing facilities located in 23 countries, Inductotherm Group delivers products throughout the world. Brands within the group include Inductotherm, Banyard, Inductoheat, Thermatool, Radyne and Consarc. Inductotherm Heating & Welding www.inductothermhw.com

❍ Radyne Flexitune bar end induction heaters

FA 11/45

www.read-fastenersasia.com

Fasteners ASIA – May/July 2020

Manufacturing Technology

Water-resistant eco box challenges plastic packs on building sites

Arvid Nilsson and BillerudKorsnäs have joined forces to reduce plastic waste on construction sites with a new water-resistant box made of strong cartonboard. The box packs and dispenses nuts, bolts and screws and is a sustainable alternative to plastic boxes. “We are constantly reminded of the threats to the environment posed by plastic trash, not least to the oceans and ocean life,” said Josefin Nordlöw, marketing manager at Arvid Nilsson, a supplier of fastening elements to the construction industry. “We decided not to be part of that problem. Conventional packs of screws, bolts and nuts on construction sites are made of plastic and we set out to do something different: to introduce a durable and environmentally friendly box.” The material used instead of plastic is CrownBoard Craft™, a stiff and strong cartonboard made of 100 per cent primary Nordic wood fibre, with a multiple-layer structure. The board is made by BillerudKorsnäs, sourced from responsibly managed forests and produced in energy-efficient processes. BillerudKorsnäs is ranked by Dow Jones Sustainability Index as the world’s most sustainable packaging company. ❍ The waterproof cartonboard box replaces plastic packs for screws and bolts

To replace plastic boxes, a priority for Arvid Nilsson was water resistance. The box made of CrownBoard Craft can be left outside in the rain for several weeks without collapsing or letting in water. This is due to the strength of the board, the laminated surface, and the packaging design without gaps at the bottom corners of the box. Tests for water resistance, compression strength and converting properties were carried out by the carton solutions team at BillerudKorsnäs. “CrownBoard Craft is one of our new products, engineered especially to offer exceptional strength in demanding applications,” said BillerudKorsnäs packaging engineer Clas Dahlin. “This is a fine example of how quality cartonboard can be a sustainable alternative to conventional plastic packaging.” BillerudKorsnäs has eight production units in Sweden,

Finland and the UK. BillerudKorsnäs AB www.billerudkorsnas.com Arvid Nilsson www.arvidnilsson.se

FA 12/46

Fasteners ASIA – May/July 2020

www.read-fastenersasia.com

Industry & technology news from the world of fasteners

www.read-eurowire.com www.read-eurofasteners.com

www.read-wca.com www.read-fastenersasia.com

To advertise call UK, ROW, USA, CANADA & S. AMERICA, GERMANY, AUSTRIA, SWITZERLAND Jason Smith | Email: jason@intras.co.uk | Tel: +44 1926 834684 ITALY

CHINA, TAIWAN, HONG KONG Linda Li | Email: linda@intras.co.uk Tel: +44 1926 834685

Giuliana Benedetto | Email: giuliana@intras.co.uk Tel: +39 342 397 7383 | Tel: +44 1926 834686

for the wire and cable industries...and now fasteners! Leading magazines