WCA March 2021

RAYEX S XT • Easy and quick set up for new products • Fast eccentricity and diameter measurement • Added longevity due to high-quality xray source Precision Wall Thickness Measurement

Family owned since 1957, Zumbach is a global leader in the industry. Driven by innovation and experience. We are here for you and ready to build the future together. www.zumbach.com • sales@zumbach.ch

Bringing cable packaging into the stratosphere.

Innovative design We removed everything that wasn’t needed from the payout tube, and improved everything else.

Smaller boxes Less shelf space, easier to carry. Reduce box width by more than 20%.

or

Backward compatible Swap out REELEX II tubes with REELEX AIR and drop into your exsiting boxes. Or, take it a step further and reduce box sizes for maximumbenefit.

Shipping efficiency Up to 40%more boxes per pallet means huge improvements to shipping efficiency andmuch less cost per box.

Lessmaterial, lower cost 40% less material. Less plastic means less cost, while being better for the environment. 40% less material

(Even) better payout Rounded entry provides

smoother pulls, while I-beam design promotes even better payout performance.

A new package from the leaders in packaging innovation.

REELEX P A C K A G I N G S O L U T I O N S I N C.

www.REELEX.com

Patterson, NY USA

Effective flame retardant for HFFR/PVC cable compounds

EcoPiren ® is a natural magnesium hydroxide obtained by XRF separation and innovative milling of brucite mineral. EcoPiren ® is used as an effective flame retardant and smoke suppressant in halogen free and PVC cable compounds. It can be applied in compounds of cable sheathing, bedding or insulation as a single flame retardant or in mixture with synthetic aluminum hydroxide (HFFR) or with antimony trioxide and zinc borate (PVC).

Application of EcoPiren ® achieves the highest grades of fireproof classifications in polymer systems. ⸰ Prevention of burning droplet formation ⸰ Reduction of smoke toxicity ⸰ Effective smoke suppression ⸰ High productivity due to high decomposition temperature (330 °C) ⸰ Good processability ⸰ Improvement of the CPR category of the cable ⸰ Optimization of the cost of compound ⸰ Naturally occurring and environmentally friendly

www.brucite.plus info@brucite.plus +7 (495) 789 65 30

Contents

8 Industry News 26 Technology News 40 India Insight 56 Editorial Index 56 Advertisers Index Regulars

45 Industry News 48 Products 51 Manufacturing Technology

Technical Article 54 Inspection and sorting of plastic pellets as a guarantee for visually and functionally perfect products

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March 2021

Getting Technical Research on cold-resistant optical cable in alpine regions Featuring Testing and measuring of wires and cables Dry and wet lubricants Next Issue

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bigstockphoto.com Artist Ivan Zhukevych

Editor ( 编辑 ) ................................................. David Bell Editorial Assistant ( 助理文字编辑 ) ................................. Christian Bradley Design & Production ( 设计/制作 ) ............................................... Lisa Wright Advertising/Marketing ( 广告/营销 ) ............................................... Jason Smith UK, Italy, ROW, USA & Canada Linda Li 中国 Advertisement Coordinator ( 广告联络人 ) ............................................... Liz Hughes Accounts Manager ( 财务经理 ) . ........ Louise Jennings Subscriptions ( 订阅) . ................... Louise Jennings Publisher ( 发行人 ) ............................. Caroline Sullens Founder ( 创办人 ) .................................... John C Hogg Europe ( 欧洲 ) Advertising/Marketing & Editorial ( 广告, 营销及编辑部 ) 46 Holly Walk, Leamington Spa Warwickshire CV32 4HY, UK Tel ( 电话 ): .................... +44 1926 334137 Fax ( 传真 ): .................. +44 1926 314755 Email ( 电子邮址 ): ........ wca@intras.co.uk Website ( 网站 ): ........... www.read-wca.com 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. Wire & Cable ASIA reserves the right to edit, reword and subedit all editorial submissions in accordance with editorial policy. Wire & Cable ASIA 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. 《亚洲线缆》杂志所有图文受版权保护。未经书面授权 不得全部或部分以任何方式转载。出版商、编写者、代 理商、印刷商及投稿者对在本期、以前、以及将来刊登 的稿件或广告的准确性和提出的索赔不承担责任。英国 Intras Ltd 公司拥有《亚洲线缆》 ( Wire & Cable ASIA ) 图像和文字注册商标。 Wire & Cable ASIA is published three times a year. It is distributed throughout North and Southeast Asia to registered readers in wire, cable and wire component producer and consumer industries. Annual subscriptions are available from just US$80. 《亚洲线缆》每年出版 3 期,面向整个北亚、东南亚地区 的电线、电缆和线材制品的生产商和用户发行。订阅年 费最低 80 美元。 USA ( 美国 ) Editorial ( 广告/营销 ) Intras USA – Doug Zirkle Danbury Corporate Center, 107 Mill Plain Road, Danbury, CT 06811, USA Tel ( 电话 ): .................... +1 203 794 0444 Email ( 电子邮址 ): ........ doug@intras.co.uk

All rights reserved © 2021 Intras Ltd ISSN 0218-3277

Photo by siyuan on Unsplash

Speeding up foreign investment

Forward thinking and investment are high on the list of priorities for Turkey’s Cokyasar Holding. The company, which operates from three modern facilities, manufactured 180,000 tons of steel wire products in 2020. And these encouraging figures have led to the company expanding its international operations with a new site in Albania, operating as CWI Albania. The company exports 70 per cent of its products to more than 80 countries worldwide and has seized on the opportunity to expand further. “CWI – Cokyasar Wire Industries – is an investment needed for European and Balkan countries,” said Erman Korkusuz, CEO, as the company plans to accelerate its other foreign investments as a result of this success. Full story on page 8. Also looking ahead are Messe Düsseldorf and SECRI, with the announcement of their continued cooperation with the launching of the WireShow – being staged from 31 August to 2 September this year at the Shanghai New International Expo Centre, China. The show will run in odd years – alternating with wire China. More details on page 14. Ducab has appointed its first Emirati as CEO. Mohammed Abdul Rahman Al Mutawa has been with the company, one of the UAE’s largest manufacturing businesses, since 2015, and most recently served as CEO of Ducab Cable Business. The appointment is the result of a carefully planned succession strategy in line with the company’s UAE national development programme. Turn to page 16 for the full details. Making a foray into a new market is ABZ (Shanghai) Smart Tech. The wire and cable machine making supplier took the move to cover the small strand market by

making the high-level double twister bunching machine, designed in conjunction with a European engineering team. The new machine, for 630mm flange bobbins, is available in two versions and the first one has been successfully made and tested at the customer’s plant. Full story on page 39.

David Bell Editor

Dates for your diary 8-10

wire Russia – trade exhibition – Moscow, Russia

June

www.wire-russia.com

WireShow – trade exhibition – Shanghai, China

31 August – 2 September

www.wireshow.com

wire India – trade exhibition – Mumbai, India

8-10

September

www.wire-india.com

AMI Cables – trade exhibition – Cologne, Germany

14-16

September

www.ami.ltd/event-cables

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Wire & Cable ASIA – March 2021

Industry news

❍ Cokyasar has started production of steel wire in Albania

Taking experience further afield Cokyasar Holding was founded by Ahmet Cokyasar in 1973. Despite the pandemic in 2020, it manufactured 180,000 tons of steel wire products in three modern facilities. 70 per cent of its products are exported to more than 80 countries.

CWI will supply steel wires to sectors including energy, automotive, construction, agriculture, gabion manufacture and security. Erman Korkusuz, CEO of Cokyasar Holding, said, “We are going on our investments despite the global pandemic problem. CWI – Cokyasar Wire Industries is an investment needed for European and Balkan countries. We are proud of supplying this need with our Turkish based company.” The company plans to accelerate its other foreign investments with the success of CWI. Cokyasar Holding www.cokyasarholding.com.tr

The company is now taking its experience in the sector abroad, with a new factory in Albania – CWI Albania – which has already started to manufacture steel wire. Cokyasar Holding is aiming for a manufacturing capacity of 45,000 tons of steel wire at its Albania facility. It will manufacture zinc alu steel wires and standard galvanised steel wires in a 1 to 5.5mm diameter range, to international standards.

Graphics bigstockphoto.com Artist Eky Studio

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Wire & Cable ASIA – March 2021

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.

IIOT screen

Supermac has expertise providing on line commissioning from remote. Post commissioning customer service support is provided

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 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.

High speed building wire line

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

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

www.supermacindia.com

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

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

Industry news Condat acquires Kemno Condat SA has taken possession of the Italy-based company Kemno. The acquisition will give Kemno new means to expand, backed by an international group. It will also allow Condat Group to strengthen its diversification strategy in Italy, particularly in the fastener and machining industry. Established in 1854 and headquartered near Lyon, France, Condat formulates and produces a wide range of lubricants. As a multi-specialist, the group has earned recognition for

its lubricants dedicated to a wide range of applications such as wire drawing, tunnel boring, forging, glass, machining, heat treatment and industrial maintenance. With responsible performance as a main objective, Condat develops lubricants with a reduced environmental impact, without compromising either their performance or the safety of users. Like Condat, Kemno is a family-owned company. Created in 2004, the Italian firm specialises in the production of neat and soluble coolants. Mainly active in the cold heading business, Kemno also offers metal working fluids, maintenance oils and greases, and quenching oils. With continued partnership with OEM and tooling providers, its lubricants range is described as a reference on the Italian market for its ability to increase tool life and decrease oil consumption. Showing its commitment to the new deal, Condat has decided to formalise the venture with the creation of a 100 per cent subsidiary, named Condat Italia. The company will ensure continuity and quality of service locally. With the two ranges being complementary, Italian customers will benefit from a larger choice of lubricants dedicated to specific needs in many fields of application. Condat SA www.condat-lubricants.com

❍ Condat’s headquarters near Lyon, France

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Wire & Cable ASIA – March 2021

Industry news

Commissioning of rolling mill in Chicago Automazioni Industriali Capitanio (AIC) successfully supplied and com- missioned the process automation solution for the rolling mill of CHS Chicago Heights Steel in Chicago Heights, Illinois, USA. revamping of the rolling mill, starting rougher group and going through the takeout of the bar on the cooling beds. The scope of supply covered new main and auxiliary drives; automation and control desks; HMI control system based on Stratus Server and ThinManager; safety system; sensors; engineering; spare parts; The project included the automation system and equipment for the

New warehouse for Rosendahl Nextrom Rosendahl Nextrom’s new extension in Pischelsdorf, Austria, has been completed. The new space will allow the company to process orders faster and more efficiently. Production processes have also been automated and improved. An area of around 3,000m 2 , distributed over two levels, is now available to the mechanical assembly, steel construction and warehouse depart- ments. The facility was also partially built with a basement, resulting in a storage height of 16m. During the planning phase, care was taken to ensure that work processes could be made more efficient and to facilitate the daily work routine. As an example, automated parallel vertical storage systems were installed. Rosendahl Nextrom www.rosendahlnextrom.com AIC was also involved in the installa- tion supervision and commissioning phases within the project schedule, which took place in October 2020. Throughout the project, AIC and CHS Chicago Heights Steel teams worked closely to develop the best solution and ensure a smooth system start-up. Automazioni Industriali Capitanio Srl www.aicnet.it remote support services, after sales and certification; and packing and shipping.

FORM+TEST Seidner & Co. GmbH Zwiefalter Str. 20 88499 Riedlingen Germany

 +49 7371 9302-0  +49 7371 9302-99  www.formtest.de

Improve Safety & Reliability For wires, ropes and chains

❍ The new building in Pischelsdorf

WITH US

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Wire & Cable ASIA – March 2021

EXCELLENCE ISA CONTINUOUS PROCESS

Upward casting since 1968

®

UPCAST OY FINLAND www.upcast.com

Industry news

CMS invests in new premises

premises will extend to 2,000m 2 . All system construction activities (pro- duction, handling and assembly) will be able to take place in a single location, allowing the design of benches and control lines up to 70m long. In this project, the company also wanted to emphasise its ecological commitment. A 60m-long water storage and retention basin will allow the preservation of the local ecosystem. In addition, an area at the rear of the building will be developed to meet environmental standards and preserve the wildlife present on-site. ContrôleMesureSystèmeshas invested nearly €3mn in the project. The director of the company commented, “CMS is a family business; I am delighted to see this project evolve and I am impatient to discover all the possibilities that this new space will bring us.” Contrôle Mesure Systèmes www.cmseddyscan.com

❍ The design of CMS’s new premises

For more than 30 years, Contrôle Mesure Systèmes (CMS) has been de- signing and manufacturing products and equipment for non-destructive test- ing by eddy current and ultrasound, and also combining these two methods of control in complete inspection benches. After more than twenty years in its current premises, and following the growth of its activity, the company decided to invest for the future with the construction of new premises.

Located in Burgundy, France, the new site will allow CMS to expand its teams and to hire new talent. A developer will join the venture in order to enhance the IT team; a designer will join the mechanical design office; and a marketing department will allow the brand to reinforce its communication and digital strategy. The production capacity will also be increased, since the company will double its working space – the new

Messe Düsseldorf Shanghai and SECRI expand cooperation In addition to the wire China trade fair held in Shanghai every two years, Messe Düsseldorf Shanghai and its regional partner SECRI (Shanghai Electric Cable Research Institute Co, Ltd) have expanded their cooperation to organise the WireShow – China International Wire & Cable Industry Exhibition – taking place on odd-numbered years, and alternating with wire China. The 12 th staging of theWireShowwill be held from 31 August to 2 September 2021 at the Shanghai New International Expo Centre (SNIEC). With this addition, Messe Düsseldorf Shanghai and SECRI will offer trade fairs for the global wire and cable industry every year in Shanghai. As well as live exhibits at the fairgrounds, the WireShow 2021 will feature interactive online showrooms for companies unable to travel to Shanghai. At the last staging of the WireShow in 2019, 419 Chinese and foreign exhibitors showcased their products, on 25,000m 2 of exhibit space, to 14,360 visitors from 41 countries. Messe Düsseldorf North America www.wireshow.com

Full range wire rope and strands Material: carbon steel and stainless steel Surface: galvanized / plastic coated / un-coated

ANBAO CORP.

Tel: +86-335-3893600 Fax: +86-335-3870760 Email: anbao@anbao.com Website: www.anbao.com Add: 1302/1312, Building A, Jinming International Fortune Center, No.3 Liupanshan Road, ETDZ ， Qinhuangdao , P.R. China 066004

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Wire & Cable ASIA – March 2021

As good as new again – or even better. NIEHOFF modernization.

During the design and manufacturing of its equipment, NIEHOFF focuses on advanced technology, quality, reliability, robustness and durability. That is the reason why NIEHOFF machines that have been in operation for decades are also worth a modernization performed by NIEHOFF specialists. These professionals have access to well-maintained and original documentation, and thus to all pertinent data. Because of their experience and expertise, NIEHOFF specialists can handle all customer-specific particularities. This applies practically to all NIEHOFF machines including any modifications made to them by customers. The spare parts needed for reconditioning are produced in house on cutting-edge machining centers to OEM quality, and thus meet the same high requirements as parts for new machines. Our technicians inspect the machine or line in question on site and analyze the specific increase in efficiency, which can be achieved by a modernization . The measures will then be done at either the customer’s site, on the shop floor at NIEHOFF facility or at a NIEHOFF subsidiary with its own manufacturing. After completion of the modernization measures, the machines or lines are not only “in mint condition”, but often show higher productivity than before. In most cases, modernizing NIEHOFF machines even after decades of use is therefore worthwhile. Allow us the opportunity to evaluate your modernization needs.

NIEHOFF Original +

Convincing Quality

Top Performance

Expertise, Customer Driven, Service – in Good Hands with NIEHOFF

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

www.niehoff.de

Industry news

“The magic world of metalworking” at fieramilano

A press conference for the South Korean public was held in February to present EMO Milano 2021, an exhibition for the metalworking and machine tool manufacturing industry, scheduled to take place at fieramilano, near Milan, Italy, in October 2021. Speakers at the web-streamed meeting were Luigi Galdabini, general commissioner of EMO Milano 2021; So-Ahn Kang, director general at Komma, the Korea Machine Tool Manufacturers’ Association; and Vincenzo Calì, Italian trade commissioner – Italian Trade Agency Seoul – Korea. The conference involved more than 40 participants, including machine tool manufacturers, representatives of local organisations and journalists.

Promoted by CECIMO, the European Association of Machine Tool Industries, EMO Milano 2021 will take place at fieramilano Rho from 4 to 9 October. According to forecasts processed by Oxford Economics, after a 23.4 per cent fall registered in 2020, 2021 should bring about a recovery in machine tool consumption worldwide – expected to grow by 18.4 per cent to €61bn (Asia €33bn, +15.6 per cent; Europe €17bn, +23.5 per cent; and the Americas €12bn, +19.7 per cent). Mr Galdabini stated, “We are very confident of the success of EMO Milano 2021, which represents the leading exhibition dedicated to the world manufacturing industry. Availability of vaccines, forecasts of demand growth in all the main areas

and Dubai, and a champion of UAE industry. During this period, Ducab has raised the bar globally for quality products manufactured in the UAE. As the new group CEO, I look forward to Mohammed A Al Mutawa continuing to work with all our stakeholders to grow Ducab, taking more ‘Made in UAE’ products to the world, and developing local talent within the sector.” In recent years, Ducab group has both diversified and expanded its geo- graphical footprint. Export markets have grown from just under 15 countries to over 30 countries in the last decade, with ventures such as Ducab Aluminium Company (DAC) and Ducab Metals Business (DMB) both contributing to growth. During the last year in particular, the company’s factories remained fully op- erational, with health and safety proto- cols put in place and office employees adopting a work-from-home approach. The company cited resilience and business continuity as being corner- stones of its strategy, supported by strong supply chain partners and prudent financial management. Ducab Group www.ducab.com of the world and important incentive measures for investment in new production technologies in Italy: these are all elements that make up a really favourable context.” The Italian government has set up special fiscal incentives, which consist of tax credit of up to 50 per cent, for Italian companies investing in 2021 and 2022 in new machine tools, robots, automation systems, 4.0 and digital technologies. This is an important business opportunity for the exhibitors, in particular for Korean machine tools builders, as South Korea is third in Italian machine tool import ranking. CECIMO www.emo-milano.com

Ducab appoints new group CEO Mohammed Abdul Rahman Al Mutawa has been appointed as CEO of Ducab Group, becoming the first Emirati to hold the position. He has been with Ducab, one of the UAE’s largest manufacturing businesses, since

2015 and most recently served as CEO of Ducab Cable Business, where he focused on strengthening market leadership in the UAE while growing the wire and cables export business that now generates around 25 per cent of revenues and sells to over 20 countries. As group CEO, he takes over from Andrew Shaw, who led Ducab Group for the past 13 years and will now take the role of board advisor for the company. Ducab’s first Emirati group CEO appointment is the result of a carefully planned succession strategy in line with the company’s UAE national development programme. UAE nationals currently hold approxi- mately two thirds of the senior management positions within group. Dr Ahmad Bin Hassan Al Shaikh, chairman of Ducab Group, said, “Since Mohammed joined Ducab, he has demonstrated great leadership qualities and a passion for developing

❍ Mohammed Al Mutawa, CEO of Ducab group

the company as a world-class UAE manufacturing enterprise. “This transition is evidence of Ducab’s commitment to the sustainable growth of the business and the UAE economy, paving the way towards a bright future upon the strong foundation of successes established under Andrew’s leadership. On behalf of the company, I would like to thank Andrew for his years of dedication to Ducab and congratulate Mohammed on his new role.” Engineer Jamal Salem Al Dhaheri, vice- chairman of Ducab Group, said, “Over the past four decades, Ducab has been a shining example of a successful partnership between Abu Dhabi

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Industry news

A positive outlook for 2021

Swedish wire machinery manufacturer Lämneå Bruk started the year with an overall positive outlook. After a drop in sales in May and June last year, the company is back on its feet with a stable amount of orders during the last months of 2020. “We are currently in a comfortable position despite the pandemic, and everyone in the company is working hard to keep it like that,” said company president Jonas Hagstedt. “It was definitely a very tough year, but we have adapted our work processes quickly, offered increased online customer support, [and] could improve our production and delivery times; that is why I am confident that we can get out of this crisis even stronger.” The company says that its versatile No Twist Coiler (NTC) was a particular success factor in the second half of 2020. The NTC combines high wire coiling qualities with speeds up to

40m/second. The machine is suitable for different solid and flux core wire types and can be used in the production of spring wire. Depending on the requirements, the NTC can be used with a range of differ - ently sized and shaped drums, adding to the flexibility and customisability of the machine. Lämneå Bruk AB www.lamnea.se

❍ Jonas Hagstedt, president of Lämneå Bruk

❍ No Twist Coiler for spring wire

Micro surface defects become visible !

Fine wire/tube analysis

Full surface coverage

High speed measurement

Designed for fine wire/tube manufacturers, SQM detects, localises and characterizes surface defects during manufacturing.

FEATURES :

200 000 lines/sec 360° measure Ø : 20µm to 2.0mm

An innovative and patented technology to enhance fine wires quality

SQM is now available ! Please contact your local agent for more information

www.cersa-mci.com sale@cersa-mci.com

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Wire & Cable ASIA – March 2021

Industry news

Sikora ranks in top 100 Sikora AG has again ranked among Germany’s 100 fastest growing medi- um-sized companies, and improved from place 61 to 18. This is the result of a study carried out by the management consultancy Munich Strategy Group. Dr Christian Frank, CEO of Sikora, com- mented, “I am delighted that we are among the ‘Top 100’ again this year. The award once again shows that we belong to the elite of the German medium- sized companies. We set significant trends and play a leading role in the field of innovative measuring, control, inspection and sorting technologies. I am particularly proud that we worked our way up from rank 61 to rank 18. My special thanks go to our colleagues in Bremen as well as in our subsidiaries around the world. Their achievement made this result possible.

“By focusing on technical innovations as well as expanding our global sales and service network and the simultaneous concentration of research, development and production at our location in Bremen, we create the conditions for future, constant growth.” More than 4,000 companies, from all industries, with an annual turnover

between tenmillion andonebillion euros were evaluated by the Munich Strategy Group. The Top 100 companies were determined on the basis of their long- term growth and profitability. The basis for selection is the performance of the companies during the last five years. Sikora AG www.sikora.net

You’ll like our power cuts

Expanding the team

Windak, a manufacturer of packaging systems for the cable industry, last year invested in a new factory and a new service organisation for the EMEA market. To further improve customer satisfaction, the company has added Dieter Gerger to its team in the role of EMEA sales manager, with a focus on supporting customers and expanding Windak’s presence in the market. Mr Gerger was international sales manager for ten years at Rosendahl Nextrom, a manufacturer of extrusion systems for energy cables and fibre optic. He is based at Windak’s new sales and service centre, Windak EMEA GmbH, in Fehring, Austria. Windak OÜ www.windakgroup.com

More energy efficient than electrical welders, our rod welding machines rely on advanced hydraulic and pneumatic systems to produce reliable welds stronger than the parent material. So you save on operating costs, improve productivity and reduce waste, too. Find out more at www.pwmltd.co.uk

World leader in cold weld technology

❍ Dieter Gerger

Pressure Welding Machines Ltd Tel: +44 (0) 1233 820847 Email: pwm@btinternet.com

New PWM welders and dies available only from PWM or its authorised distributors.

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Industry news

Continuous customer service Upcast ® customer service provides technical service, spare parts and consumables to maintain the smooth operation of Upcast lines.

market growth in the region, and serves customers through its office and team in Mumbai. The latest investment strengthens this support and presence. Maillefer will introduce local manu- facturing and local supply of Maillefer India technology for the low voltage market, combining its expertise with local Indian manufacturing and resources. This local supply, testing As the exclusive source of original Upcast parts, Upcast Oy ensures reliable operation of casting lines, and keeps a stock of spare parts and consumables available for dispatch within 24 hours – or within the same working day for urgent cases. The modular construction of Upcast lines allows them to be expanded and updated. With continuous product development, many components can be replaced with the most recent technology, and solutions are available

The team’s understanding of produc- tion- and maintenance-related chal- lenges makes it available for assistance in any technical issues, via phone, email, remote access or site visit. The new Upcast ® UPtime maintenance software provides clarity in the maintaining of casting lines.

for increasing capacity or using copper scrap as raw material. Upcast Oy www.upcast.com ❍ Upcast Oy is the source of original Upcast parts and consumables

Maillefer expanding in India Maillefer is strengthening its support and presence in India by introducing local manufacturing and supply of brand-name technology destined for low voltage wire and cable manufacturers within the region.

capability and service/support will bring the Maillefer brand and technology closer to building wire, low voltage cable and automotive wire producers in India and the region. Herlin Products and Services Pvt Ltd will be the key contact in the region for low voltage solutions. Maillefer Extrusion Oy www.maillefer.net

The Indian subcontinent in the long- term is seen as one of the fastest growing wire and cable markets. Maillefer has a history of supporting

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Industry news

Kocks RSB commissioned at Xiangtan SBQ mill Chinese special steel producer Hunan Valin Xiangtan Iron & Steel Co Ltd has started up its new SBQ mill #3. The core piece of the rolling mill is a three-roll reducing and sizing block (RSB ® ) in 5.0 design supplied by Friedrich Kocks GmbH & Co KG, Germany.

The RSB 5.0 is designed for thermomechanical rolling, and finishes most flexible/all straight bar sizes of Ø 16 to 100mm onto the cooling bed. In addition to the RSB 5.0, Kocks’s responsibility includes the roll shop for the preparation of three-roll stands and three-roller guides, as well as the supervision services. This is the second successful installation of a three-roll Kocks RSB at Xiangtan since 2005. Friedrich Kocks GmbH & Co KG www.kocks.de

❍ The three-roll RSB operating in Xiangtan

Merger of Inhol and Melos completed In January 2018, Inhol BV, based in Soest, the Netherlands, was taken over by Melos GmbH. With the acquisition, Melos expanded its product offering of special compounds for the cable industry, strengthening its activities and portfolio. Since then, Inhol has functioned as part of and on behalf of Melos. One specialism of the company is the production of resistant compound solutions for use in extreme conditions, particularly in the fields of heat-shrink tubing and heat- and moisture- resistant compound solutions for the cable industry.

“Workforce safety is paramount, and we consistently work towards the highest safety standards. “These awards provide us with the checks and balances to make sure we are always striving for better for our business and our employees.” Metalube is part of the Bishopdale Group of industrial lubricants brands – Metalube, Molyslip and UOP. The company exports 95 per cent of its production to more than 90 countries worldwide. Metalube Ltd www.metalube.co.uk “The two business fields complement each other perfectly. In addition to existing products, we can now offer our customers an expanded portfolio of special compounds for the cable industry. “In particular, we will be able to expand our activities abroad, which will help us achieve a stronger and more competitive position on the global market for cable compounds.” Compound solutions from Inhol will continue to be available in the same quality from Melos. Melos GmbH www.melos-gmbh.com

Melos is a manufacturer of compounds for the cable industry and granules for the sports and leisure sector. Through themerger, Melos expanded its portfolio in the field of cable compounds and gained relevance as a manufacturer for the cable industry. “We are very pleased with the success- ful merger,” said Marcus Hohlweck, head of cable compounds at Melos.

In December 2020, Inhol was merged with Melos. As a result, years of cooperation in the project business and product development will move forward to the next stage. Inhol was founded in the Netherlands by Ron Goethals and Jacob Steendam in 1989.

Metalube awarded ISO 45001 Lubricant manufacturer Metalube has been granted the seal of approval, securing its latest international standard accreditation in occupational health and safety (OH&S) management systems ISO 45001.

to have achieved these certifications. In times like these, it is important for us to be fully committed to health and safety, worker wellness and wellbeing. ❍ Metalube has gained accreditation for its health and safety systems

This complements the company’s existing ISO 9001 and 14001 accreditations, and was achieved due to greater OH&S performance, which involved integrating additional aspects of health and safety into the business, such as injury prevention, ill-health and worker wellness and wellbeing. Managing director Robert Brown commented, “We’re extremely proud

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Industry news

First virtual “Sikora Connect” live event In November, Sikora presented its first virtual live event – Sikora Connect – for the wire and cable, optical fibre and plastics industries. The company reported that the high number of participants and the positive feedback of the audience met its expectations, allowing it to achieve an important step in the virtual exchange with customers. During the three live days Sikora Connect registered nearly 1,000 partici- pations, with visitors coming from 68 countries. The presenter Weihua Wang guided the event, which was characterised by short and diversified topics with technical product and service presentations as well as insights into research and development. desired and works excellently in customer communication.” While the virtual format will continue to influence communication at Sikora, the company states that it is also clear that digital solutions cannot completely replace personal contact, and it will pursue a combination of a presence

at trade fairs and virtual events. Those who could not join in live at Sikora Connect still have the opportunity to visit the event pages at www.connect. sikora.net, and view the contributions under “Session Replay”. Sikora AG www.sikora.net

Among the highlights were expert discussions on future trends in the cable industry with well-knownmachine manufacturers. Live connections to the 14 worldwide Sikora subsidiaries generated great interest and were well attended throughout the event. On average, the audience stayed for one hour and 20 minutes. “With Sikora Connect we have succeeded in giving an insight into our products as well as current projects, and to focus on the contacts to our customers also in virtual format,” said Katja Giersch, head of corporate communications at Sikora. “Through the Q&A sessions and chat function in the livestream we received more than 100 customer questions to our presentations. The great interest shows that a virtual exchange is definitely

❍ (from left) Sikora Connect presenter

Weihua Wang, executive board member Dr Jörg Wissdorf, CEO Dr Christian Frank and Harry Prunk, member of the executive board

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Technology news

❍ Niehoff has already delivered thirteen D 1252 double-twist stranders

❍ Detail of the D 1252 model

Manufacturing larger dimensioned strands for power cables

Maschinenfabrik Niehoff’s latest de- velopments in stranding technology include three types of double-twist stranding machines for spool sizes up to 2,000mm. The new models – D 1252, D 1602 and D 2002 – are designed for the manufacture of conductors with a uniform lay direction (“unilay”) and a strand cross-section of 6 to 500mm 2 . However, cable producers also have the option to manufacture other products such as flexible control, connection and motor cables on the new double- twist stranders. The D 1252 model is a further development of Niehoff’s D 1251, and is fully equipped with a new Siemens control and HMI. Niehoff has already delivered thirteen D 1252 type stranders to the wire and cable industry. The D 1602 strander is designed for 19- wire Class 2 conductors and Class 5 conductors of up to 150mm 2 , while the D 2002, being combined with a PTD 1000 external rotating capstan, can be used for larger constructions, such as

those with up to 61 wires and a maxi - mum cross-section of 500mm 2 when manufacturing aluminium conductors, and 400mm 2 for copper conductors. The new stranders enable the conductors to be compacted by means of a compacting die with interval lubrication, making a compacting degree of up to 13 per cent possible. To ensure proper laying, all three models are equipped with a laser-controlled flange detection system (NBAT). In designing the machines, Niehoff put emphasis on optimising the conductor path: all rollers and capstans have large diameters, while a straight path from the second pulley to the capstan contributes to conductor quality. Ergonomic criteria also played an important role in the design, making the operator’s work easier, since the machines’ working height is 1,300mm. In common with the other machines of the Niehoff D series, the new models feature an energy-saving one-bow design. The double-twist stranders also include an energy efficiency class

IE3 rotor drive and a controllable fan drive in the soundproof cabin. Niehoff has increased production safety and simplified maintenance for the D series by using wireless telemetry for all signals. The machines are operated via a network-compatible interface with a colour touchscreen monitor – the NMI (Niehoff Machine Interface). Information, instructions, maintenance advice, stored recipes and system status messages are displayed on the screen in the operator’s language. Sensors monitor quality throughout the stranding process, such as the temperature of the rotor bearings and the vibration of the rotor. The sensors enable production parameters to be recorded, documented and evaluated in accordance with Industry 4.0, allowing continuous proof of quality. Maschinenfabrik Niehoff GmbH & Co KG www.niehoff.de Niehoff Endex North America Inc www.niehoffendex.com

Graphics bigstockphoto.com Artist Olechowski

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Technology news

Lowering the minimum diameter of metal wire drawing dies

Geili is a die manufacturer dedicated to R&D and production of ultra-fine wire drawing dies. Its die products, which have obtained 16 patents, include polycrystalline diamond dies, natural diamond dies, enamelling dies, shaped profile dies, and bunching, compacting and stranding dies. By 2020, the company had more than 120 employees, realising annual production and sales of 400,000 die products. Geili has added to its range of micro stainless steel wire drawing dies with a natural diamond wire drawing die with a minimum diameter of 0.005 ±0.00002mm.

and sells a full line of wire drawing tooling, including large cased dies with cases up to 300mm (12") in diameter. It is also a major supplier of shaped dies to the global wire drawing industry, and makes other carbide tools used in the wire drawing process, such as shaving dies for high carbon valve spring wire, stainless and non-ferrous applications. Paramount has incorporated the scientific approach used in the The new PCD-TD product series, in the application field of stainless steel wire, has a lifetime claimed to be three to five times that of conventional PCD material. At present, the minimum pore size for mass production is 0.02mm. In the field of micro enamelled wire production, Geili’s enamelling die has been successfully applied to the coating of polyurethane, polyesterimide, polyimide, nylon and other insulating or self-adhesive materials with a size of 0.04 to 0.008mm. Compared with the microfilament coating method, mould coating can make the coating more uniform and

❍ Super-fine enamelling dies

development of the ParaLoc holders and its wire drawing dies into the development of large dies, shape dies and shaving dies, aiming to provide improved productivity, higher quality and scrap avoidance. This approach is followed through the design, production, inspection and application of Paramount dies. Paramount Die Company www.paradie.com Geili is equipped with stable laser drilling equipment, precision testing equipment (SEM, CU10, DM300, etc) and an all-round wire drawing experimental centre that can provide customers with many kinds of metal material drawing solutions. Yichang Geili Diamond Industrial Co, Ltd www.geilivable.com.cn effectively reduce the use and emission of solvents, which can better protect the environment.

Large round and shaped wire drawing dies In the late 1990s, Paramount Die Company incorporated pressure

dies and draw dies in a single holder – the ParaLoc pressure system. The company says that this technology has enabled wire producers to increase productivity, improve finished wire quality and grow their businesses. In addition to dies for fine wire drawing in the size range of 5.5 to 0.5mm (0.218" to 0.02"), Paramount produces

Invented in 1952.

Fit for the future.

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Technology news

Smart buffering brings production to new levels The productivity of optical cable manufacturing can increase with higher line speeds. However, these higher speeds call for more precise process control. The manufacturing process contains several parameters that the line operator controls during production. The state of the process is both controlled and estimated by process parameter adjustments and observations. and is able to optimise the process automatically during production. The Smart Buffering process assistant processes the raw sensor data into information that it uses, together with process state models and quality prediction models, to control the clinching and the buffering process. The process assistant has been successfully applied to a secondary coating line’s buffering process running at 800m/min with dry PP product. adjusts the process parameters until the sensor values correspond to those expected by the internal process models. Automated feedback-based process adjustment leads to more predictable operation of the line, which eventually leads to a more stable process and better product quality.

Expertise from humans remains essential, and their knowledge is invaluable when operating the AI system and handling the abnormal situations, such as wear and tear of machinery or material abnormalities. The system signals the need to perform line maintenance when detecting a process that cannot be fully optimised, and generates a list of items to check before further line operation. Maillefer Extrusion Oy www.maillefer.net

Interpreting sensor data is difficult due to complex interactions throughout the manufacturing process, and the wear and tear of equipment causes drift in absolute sensor values. The ideal process state window, originally defined by process sensor values, shifts over time. Maillefer has developed an artificial- intelligence-based automated process assistant (patent pending) that analyses the buffering process in real-time

Abnormal process conditions, such as coupling and slipping, can easily lead to inferior quality products. Smart Buffering detects such situations and optimises the process back to a quality production state. The automated process assistant removes the “gut feeling” of knowing good process parameter values. Instead, the system automatically

Tooling for wire and cable industries Ajex & Turner (A&T), engaged in manufacturing since 1962, has a wide range of products for wire, cable and fastener industries. The company is technically assisted by Turner & Stott, UK. The company’s VNT Nano dies are a third- generation development to save electricity, manpower and metal when producing high-quality bright wire, particularly with stainless steel and low-carbon welding wire. The carbide/PCD/extrusion tools are accepted by crosshead and extrusion machine manufacturers and users for any make of machine in single, double or triple hole sizes. A&T says that its most advanced products are TW and sector dies in VNT Nano, for smooth production, correct geometry and high brightness of the conductor. The company’s PCD/ND/carbide wire drawing dies, in round and other shapes, are used in Europe and the USA with multi-wire/rod breakdown machines of any make. A&T’s ceramic project, started in 2010, manufactures different types of shape tooling for buncher bows, guides, pulleys and coated pulleys. For re-sizing and re-polishing of dies and extrusion tools, the company has developed many types of in-house die polishing machines and accessories. It has also developed PCD groove/trolley wire dies for railways. Ajex & Turner www.ajexturner.com

Jiangsu Qunye Electrical Co., Ltd. is a specialized spools manufacturer. We have highlevel workshops and offices, first class equipment lines and complete inspection facilities, advanced management and quality control systems to fulfill all customers’

requirements. We manufacture all kinds of metal and plastic spools and gain a good market share both at home and abroad.

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