European Outlook

WIRE JOURNAL JUNE 2009

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I N T E R N A T I O N A L w w w. w i r e n e t . o r g

European Outlook

INTERWIRE/IFE WRAPUP OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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WIRE JOURNAL

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I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . 6

CONTENTS

Volume 42 | Number 6 | June 2009

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 20 People . . . . . . . . . . . . . . . . 22 Fiber Watch . . . . . . . . . . . . . 24

European Outlook

. . . . . . . . . . . .34

Fastener Update . . . . . . . . . 26

Perspectives on the European markets from two industry specialists as well as thoughts from three suppliers and a previously published interview of a key European banking official.

WAI News . . . . . . . . . . . . . . 28

Interwire 2009/IFE 2009 wrapups .38

Chapter Corner . . . . . . . . . . 32

The Interwire and IFE trade shows reflected the trying times before the wire and cable industry. While attendance was low, attendees who did come had specific reasons and plans for doing so.

Technical Papers . . . . . . . 58-76

T ECHNICAL P APERS Products/Media . . . . . . . . . . 78 Classified . . . . . . . . . . . . . . 83

Estimation of thermal diffusivity of crosslinkable cable insulations Sergio A. Montes and Carlos A. Alejo . . . . . . . . . . . . . 58

Career Opportunities . . . . . . 83

Overview of fluoropolymer foam technology Robert T. Young . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Advertisers’ Index . . . . . . . . 86

Screw selection and extruder considerations for wire and cable coating Edward L. Steward . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Cover: Pictured are flags for France, Germany, Italy, The Netherlands, Portugal, Spain and U.K. See p. 34.

JUNE 2009 | 3

INSIDE THIS ISSUE WAI 5K I NDUSTRY R UN . . . . . . .56

Gregory J. Lampert, General Cable North America, and Hugo Alberto GĂłmez Sierra, Condumex, were two of the four participants at the Executive Panel at Interwire 2009, attended by more than a hundred people. Representatives from four leading cable companies commented on topics from the impact of lower operating capacities to what would make them consider new suppliers.

It was a pleasure indeed for Neville Crabbe, president of Leoni Wire, Inc., which has sponsored the last three WAI 5K Industry Runs, to congratulate the winner of the race at Interwire 2009 as it was a Leoni staffer, Alex Boekholt.

Leoni Wire’s Albin Dickert came in third out of the field of 20, making it a very good showing for Leoni as well as the American Cancer Society, the recipient of the charity event.

CONTENTS

I NTERWIRE E XECUTIVE P ANEL . . . .38

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EDITORIAL WIRE JOURNAL

®

EDITORIAL

I N T E R N A T I O N A L

Times call for a forward-looking approach

Publisher | Steven J. Fetteroll Editor-in-Chief | Mark Marselli

We are all going through difficult times in our industry, and I believe that we need to look forward and see where we want to be rather than dwell on today’s negatives. The economic downturn was reflected in attendance at Interwire 2009, and even though many of us had hoped for better, it was what it was. So what can we do? Many companies are using this time to re-evaluate themselves, to position and change so that they will ready for the recovery. It makes sense for the WAI to do the same.

Beyond the numbers, Interwire did have many positives. Staff did everything possible to promote the show in Cleveland, and there was more pre-show promotion than at any previous show. The education program was strong and the Executive Panel discussion was excellent.

The two social events, opening reception and ball game, were well attended and received.

That said, the WAI is very aware of the need to make sure that Interwire 2011 is a success. At the Board of Directors meeting held during Interwire 2009 there was a lively discussion about where we are and where we are headed. Rest assured that the WAI is not sitting still. A task force was formed to develop ideas and a plan to present to the board before Reconvene—the WAI’s second business meeting of the year—to improve participation at Interwire, increase membership and better meet the needs of our industry. This task force is not focused on restructuring, but rather will look at where we need to focus our efforts and resources as we move forward. Every company and organization can get better, and that is what we are going to work toward. The task force members include Mark Spencer, W. Gillies Technologies; Don Schollin, QED Wire Lines, Inc.; Dominique Perroud, SAMP USA; Nick Nickoletopoulos, Ivaco Rolling Mills; and myself, Henkel Corporation.

We have our ideas, but we want to hear yours. It is our goal to solicit new ideas from you and determine if we can implement them. We all want the same thing—to see our industry return to a successful level.

Please e-mail your ideas to us at darmendariz@wirenet.org. You have my word your submissions will be read, discussed and seriously considered. So don’t be shy! I will keep you up to date on our progress.

Dane G. Armendariz WAI First Vice President

Editor | Barbara Douglas Senior Graphic Designer | Bill Branch Director of Sales | Robert Xeller Advertising Sales | Anna Bzowski Director of Marketing Services | Janice E. Swindells Graphic Artist | Adrienne E. Simpson Proofreader | Livia Jacobs Circulation Manager | Jan Valois Publications Advisory Board Antonio Ayala | J.J. Lowe, Mexico Ferruccio Bellina | TKT Group/President ACIMAF, Italy Anand Bhagwat | Wire and Cable Services, India Malcom Michael | AWAI, Australia Don Schollin | Q-S Technologies, USA Ken Scott | UK Ralph Skalleberg | Skaltek USA Dave Stackpole | Nutmeg Wire, USA Giulio Properzi | Continuus Properzi, Italy Robert Wild | Niehoff Endex North America, USA WAI Executive Committee Liaison Dane Armendariz | Henkel Corporation Technical Advisors John Drummond | Scotia Group R. M. Shemenski | RMS Consulting, Inc.

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel.

203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices.

Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2009 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700.

POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR June 22-26, 2009: NPE 2009 Chicago, Illinois, USA. NPE 2009, organized by The Society of the Plastics Industry, Inc. (SPI), NPE 2009 will take place at Chicago’s McCormick Place.

Contact: NPE 2009, www.npe.org.

September 30-October 1, 2009: Electrical Manufacturing Coil Winding & Coating Expo Nashville, Tennessee, USA. This event is to be held at the Opryland Convention Center. Contact: Jo Thurman, tel.

619-435-3629; fax 619-435-3639; jothurman@emcw.org.

October 13-15, 2009: Wire Southeast Asia Bangkok, Thailand. To be held at the BITEC Exhibition Centre in Bangkok, this event, formerly known as wire Singapore, is organized by Messe Düsseldorf Asia Pte Ltd., Singapore. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312-781-5188; info@mdna.com; www.mdna.com.

8 | WIRE JOURNAL INTERNATIONAL

October 24-27, 2009: Exhibition & Conference for Wire & Cable New Delhi, India. The 9th International Exhibition & Conference for Wire & Cable will present wire and cable, fasteners and springs and more at the Pragati Maidan.

Contact: www.intechtradefairs.com.

Nov. 2-3, 2009: New Technology for Global Markets Istanbul, Turkey. This biennial conference is jointly organized by the IWMA, CET, ACIMAF and the WAI. Prior conferences have been held in Bologna, Italy (2007), Prague, The Czech Republic (2005), and Stresa, Italy (2003). Contact: WAI, tel. 203-453-2777, www.wirenet.org.

Nov. 8-11, 2009: 58th IWCS Conference™ Charlotte, North Carolina, USA. The 58th Annual IWCS Conference will be held at the Charlotte Convention Center. Contact: IWCS, www.iwcs.org.; phudak@iwcs.org; tel. 732-389-0990.

CALENDAR

April 12-16, 2010: wire Düsseldorf Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180; info@mdna.com.

May 11-12, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show and technical program.

It will be co-located with The National Electrical Wire Processing Technology Expo. Contact: WAI, tel. 203453-2777, www.wirenet.org.

September 2010: wire China 2010 Shanghai, China. The All China International Wire and Cable Industry Trade Fair (wire China) is organized by Messe Düsseldorf China Ltd. and SECRI Shanghai Electric Cable Research Institute. Contact: Messe Düsseldorf North America, tel. 312-781-5180; fax 312-781-5188; e-mail info@mdna.com; www.mdna.com. ■

W IRE ASSOCIATION INT ’L EVENTS For more information, contact the WAI, USA. Tel. 001-203453-2777; fax 001-203-453-8384; Internet www.wirenet.org.

June 15, 2009: 7th Annual WAI Midwest Chapter Golf Tournament West Chicago, Illinois, USA. The WAI Midwest Chapter returns to the St. Andrews Golf & Country Club for its annual golf outing. For more information, contact WAI’s Chip Marsh or call him at tel. 203-453-1748.

Nov. 2-3, 2009: New Technology for Global Markets Istanbul, Turkey. This biennial conference is jointly organized by the IWMA, CET, ACIMAF and the WAI. Prior conferences have been held in Bologna, Italy (2007), Prague, The Czech Republic (2005), and Stresa, Italy (2003). Contact: WAI, tel. 203-453-2777, www.wirenet.org..

May 11-12, 2010: Wire Expo 2010 Milwaukee, Wisconsin, USA. To be held at the Midwest Airlines Center, this event includes the WAI’s 80th Annual Convention, trade show and technical program.

It will be co-located with The National Electrical Wire Processing Technology Expo.

JUNE 2009 | 9

INDUSTRY NEWS

INDUSTRY NEWS Drumet up for sale, June 1 was date for potential buyers to make a bid Drumet Sp. z o.o., one of Poland’s largest steel wire rope companies, filed for bankruptcy in January, halted production in February and was subsequently put up for sale with a minimum asking price of approximately US$38 million. Bid submissions were due by June 1.

The company, founded in 1895, was converted to a single-person State Treasury company in 1991 and into a private stock company in 1994. Until recently, the company’s outlook had been on an upswing. The Drumet website notes that in 1998, it added two new product groups: staple band for production of stitches and wire ropes for passenger lifts. In 2000, it added production of non-rotating ropes and in the following years “new machines were bought, and (the company had planned) to impel new productions lines, including an electrolytic galvanization wire line.”

The company’s product lines include wire rope, wire for nail production, wire rope slings, general purpose carbon wire and cut wire. Drumet notes that production was halted because it had a limited supply of electricity, and that the operations are “in operational technical condition and ready to resume production within a short time.” It states that the business, which was founded in 1895 and has annual production of more than 156,000 metric tons, has total fixed assets that include land, equipment and buildings/infrastructure.

The company reports its operations had some 850 employees, including 515 in production, 137 white collar employees, 115 in maintenance and 81 in supporting departments.

“The official receiver is currently trying to arrange a tender to sell the whole enterprise,” a press release said, adding that the sale will include perpetual rights to 238,000 sq m of state-owned real estate as well as rights, permissions and other owned licenses. “The purchase of the enterprise is connected with taking over the employees …,” it said.

CommScope technology to star in showplace for Dallas Cowboys The Dallas Cowboys’ new football stadium in Arlington, Texas, designed to be the nation’s largest and most spectacular domed venue when it opens this summer, will operate the most sophisticated, high-performance and world-class communications infrastructure of any sporting facility in the world, reports CommScope.

The new stadium’s infrastructure, the release said,

An artist’s likeness of the new Dallas Cowboy football stadium, which will feature a 600-ton, four-sided scoreboard and more than five million feet of cable. required more than five million feet of CommScope SYSTIMAX copper and fiber cabling, including approximately 2.7 million feet of SYSTIMAX GigaSPEED X10D® cabling. The cornerstone will be the 600-ton, four-sided scoreboard, while the stadium will also house 3,000 monitors throughout the facility, which will be the world’s largest IPTV installation. CommScope’s Enterprise Solutions™ and Andrew Solutions™ technology will support the new stadium’s core operations and communications requirements for fans, staff and public safety officials, the release said.

The stadium will feature an extensive in-building wireless communications network from Andrew that will provide complete cellular coverage in the stadium and its surrounding property for all spectators and team officials, coaching staff, employees and public safety agencies. The stadium will also deploy CommScope’s SYSTIMAX iPatch System technology, a first for NFL stadiums that will help Dallas Cowboys IT staff document and manage activity from more than 40,000 copper and fiber ports, it said.

CommScope’s installation work, which started in September 2008, was scheduled to be completed this month.

“CommScope helped us craft one of the finest high-performance networks on the planet,” said Jerry Jones, owner and general manager, Dallas Cowboys Football Club. “We have a vision for a place that reflects the emotion and competition encapsulated by the stadium, and CommScope has helped bring that to life.”

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

Citing poor market conditions, American Spring Wire Corp. (ASW), a manufacturer of valve-quality and commercial wire in carbon and alloy steel grades, announced that it plans to idle its facility in Kankakee, Illinois, as soon as possible.

“This action is a necessary response to the unprecedented weakness in our tempered spring wire order book, said ASW Executive Vice President William Snyder. He said in a press release that ASW’s Kankakee spring wire customers that use tempered wires in sizes greater than .120 in. will be serviced from the company’s plant in Bedford Heights, Ohio. The Bedford Heights plant, he noted, has undergone recent capital expenditures in its tempering department, and it has “ample capacity to service the Kankakee order book.”

The ASW release said that the company opened the Kankakee factory in 1980 with an interest in serving fine music wire and oil-tempered spring wire needs used primarily in automotive markets. Over the years, the company evolved its product offering to include fine shaped wires and flat wires used for housing related spring applications. In previous years, the factory employed about 120 people, but recently has been operating at substantially reduced hours, it said.

“We’re very sorry to have to make this decision,” said ASW President and CEO Timothy Selhorst. “The Kankakee employees have done a superb job of making wire over the years and adapting to new and difficult market requirements. I look forward to a set of economic circumstances and market opportunities to give this operation the chance to serve wire markets again in the future.”

Nexans wins cable FPSO contract Nexans reports that it has won a US$10 million contract from Hyundai Heavy Industries (HHI) to manufacture and supply the topside power, control, instrumentation and telecommunications cables for the FPSO (floating production storage and offloading) vessel currently under construction for the Usan deepwater oilfield, off the coast of Nigeria.

The contract calls for Nexans to supply more than 1,700 km of cable that will be manufactured at the Nexans Kukdong factory in South Korea. Nexans will also provide cables with different insulation types (ERP or XLPE) and armor protections (galvanized steel wire braid or copper wire braid), it said, adding that the cables are scheduled to be delivered and installed between October 2009 and March 2010.

Per Nexans, the 114,000-metric-ton Usan FPSO will measure 320 m in length and 61 m in width, with a depth of 32 m. It will have the capacity to produce 160,000 barrels of oil and 5 million cubic meters of gas per day, and will be able to store 2 million barrels of oil. The Usan field development will be operated by Elf

Petroleum, and is located around 100 km offshore southeast of Bonny Island in Nigeria at depths of 750-900 meters. The development plan involves 23 subsea production wells and 19 water and gas injector wells tied back to the FPSO vessel, and it is expected to come online early in 2012.

“The Usan FPSO contract demonstrates Nexans total capability to handle both the topside and subsea cable needs of the oil and gas industry, especially in meeting demanding delivery schedules” declared Salvatore Di Giorgio, Nexans Global Segment Manager for offshore topside activities. “In fact, we are already working on a contract for Saipem to supply the subsea umbilicals for Usan.”

Georgetown steel mill closed again ArcelorMittal has laid off 242 workers and closed its steel mill in Georgetown, South Carolina, as part of its efforts to temporarily cut its global steel production by 45 percent.

Company spokesman Adam Warrington said the steel company is working with the local United Steelworkers to help the workers and their families make it through the shutdown, and hopes to bring many of the employees back whenever the mill reopens, AP reported.

The mill has been shut down before, including for more than a month at the end of 2008, then again in March because of a steep decline in orders. The plant has two electric furnaces that can annually produce 1 million tons of liquid steel and 750,000 tons of wire rod.

ArcelorMittal, which operates in more than 60 countries, has seen harsh reaction elsewhere to its cuts. These include angry employees storming an annual general meeting at the its Luxembourg headquarters to protest proposed job cuts. Published reports say police fired rubber bullets after a number of people broke down the building's doors and smashed ground floor windows, then threw smoke flares and boards from inside. The workers, mainly from France and Belgium, have been angered by the company's decision to shut down 25 furnaces in Europe.

Tele-Fonika cables for power upgrade are commissioned at Gdansk refinery Poland’s Tele-Fonika reports that its 110 kV cables have been commissioned in a new power system at the Gdansk Refinery, which belongs to the LOTOS Group.

The single-core cables, made from cross-linked polyethylene insulation, type XRUHKXS, have an overall length of nearly 12 km, and are valued at about US$1.35 million, a press release said. It will update a refinery power system from the 1970s, permitting “the connection of another 40 MW for the new refinery plants,” it said.

In other news, the company also announced the commissioning of a new testing station for overhead conductors at the Akademia Górniczo-Hutnicza (University of

JUNE 2009 | 11

INDUSTRY NEWS

American Spring Wire to idle plant in Kankakee, hopes to reopen someday

INDUSTRY NEWS

Science and Technology) in Cracow. The station, which will test dynamic and stress-cycle curves of bare overhead conductors, including resistance to vibrations caused by weather conditions (colian vibrations), represents “a remarkable achievement” for researchers from the university and Tele-Fonika specialists, the release said.

phosphorous bronze, all grades of stainless steel, highnickel specialty alloys including Inconel™, Elgiloy™ and Hastalloy™ and other age-hardened wire for unique customer designs. The company notes that its user-friendly website, www.katyspring.com, makes it easy for customers to browse for springs, via the online catalog.

Spring manufacturer celebrates anniversary, third move in 10 years

Superior Essex to reduce distribution centers, expand Fort Wayne operation

Katy Spring & Mfg., Inc., this year celebrates its 10th anniversary, noting that since it was founded by original partners, James West, Scott Pitney and Mark West, the manufacturer has literally not stood still. The company reports that it has moved three times since it was founded in 1999, each time to a larger facility, to keep up with the growth and demand for the company’s compression, torsion, extension and flat springs.

Superior Essex announced that it plans to consolidate its distribution centers in Louisville, Kentucky and Columbia City, Indiana, into its center in Fort Wayne, Indiana.

The facility is expected to be operational by June 2009, an article in Inside Indiana Business reports. The expansion, which calls for a company investment of about $485,000, will create 15 new jobs in the area by 2010, the report said. Superior Essex is a subsidiary of LS Cable.

Belden to lay off employees in Europe

Katy Spring & Mfg., Inc., founders James West, Scott Pitney and Mark West, whose company recently completed its third move since it started 10 years ago.

“The move into our new headquarters is complete,” said co-owner Scott Pitney. “We have the capability to run at full capacity with several new coiling machines on-line.”

He added that the company has added new clients such as Weatherford, Fastenal, 3M, NASA and Waistquip.

Pitney said that the company is not afraid of the economy. “Because of our production knowledge, CNC capabilities and frugal business philosophy, Katy Spring’s rates are very competitive to industry standards,” he said.

“We too have been effected by the downturn, but we posted record quoting activity in March and April. As soon as customers’ inventory levels are reduced to reorder points (which has been the trend since January), we should see order activity and order quantities follow suit.”

In addition to compression, torsion, extension, and flat springs, Katy Springs provides formed metal components, stampings and wire forms and heat-treating services for industrial metal. Production is offered in high-carbon spring steel, brass and spring brass, beryllium-copper,

12 | WIRE JOURNAL INTERNATIONAL

Belden Inc., which last December announced plans to lay off 1,800 employees, about 20 percent of its work force, plans to lay off 110 employees in Europe.

Published reports say that the company plans to close manufacturing facilities in Germany, transferring production to Eastern Europe.

The reports also noted that Wolfgang Babel, former president of Belden Europe, Middle East and Africa, has left the company, and that Belden President and CEO John Stroup will oversee that segment until the position is filled. The reports cited Stroup say saying, “The environment in Europe has proven to be more demanding than initially expected. We are taking additional actions to size our business for what we expect to be a longer period of economic weakness.”

LS Cable reports plans to deploy record superconductor cable South Korea’s LS Cables reports that it plans to deploy the world’s longest distribution voltage superconductor cable, a 22.9 kV 50MVA cable system that will be deployed in one of the Korea Electric Power Corporation (KEPCO)’s commercial power network near Seoul, the capital of South Korea.

“With a minimum of five times capacity to carry electricity with minimized construction cost, superconductor power cables will play an important role An LS Cable superconductor cable.

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INDUSTRY NEWS

in Korean power network and worldwide in the 21st Century,” LS Cable Technology Development Group Executive Vice President Joon-Hyung Cho said in a press release. The cable system, he said, will be nearly 500 m in length, making it the world’s longest distribution-voltage superconductor cable system. It is scheduled to be

manufactured by the end of 2009 using HTS 2G wire, installed by June 2010, and commissioned and energized in one of Seoul’s largest satellite cities by the end of 2010, he said.

“As with the cases in many countries around the world, Korea has been experiencing rapid increases in electricity demand and is relying increasingly on renewable energy sources to meet that demand,” said KEPCO CEO Sang-Su Kim. The project, the release said, is an extension of Korea’s DAPAS (Development of Advanced Power System by Applied Superconductivity Technologies) program, which has provided funding for the development and commercialization of superconductor systems. In 2006, it said, LS Cable and the Korea Electrotechnology Research Institute (KERI) successfully tested a 30-meter and 100-m long 22.9kV superconductor cable in 2004 and 2007, respectively.

T&T Marketing adds resin/compound client U.S.-based T&T Marketing announced that it has reached an agreement with Dandong Decheng Plastic & Rubber Science & Technology Company to distribute Decheng Chlorinated Polyethylene (CPE) resins and compounds in the U.S. and Canada.

T&T CPE Product Manager John Accorsi said in a press release that Decheng, which is based in Dandong, China, has an annual capacity of 15,000 mt/yr of CPE. That is important because there has been a disruption in the CPE market in North America with Dow closing its TYRIN resin plant in Louisiana, which has forced companies to look for alternatives. “That’s why we see an opportunity for T&T to offer our wire and cable customers additional CPE product choices,” he said.

For more details, Accorsi can be contacted by e-mail at jaccorsi@ttmarketinginc.com.

14 | WIRE JOURNAL INTERNATIONAL

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INDUSTRY NEWS

TMS to represent Inosym reels/drums U.S.-based Technical Marketing Services reports that it has been chosen by New Zealand’s Inosym Reels and Drums to serve as its sales and marketing representative for New England, the mid-Atlantic states and Eastern Canada.

A press release noted that Inosym provides precision, high-quality wiredrawing, metal process, plastic process and dispatch reels and drums and supplies to the global wire and cable market. For more details, contact Patrick Carney, TMS, at tel. 860-844-8646, tmspat@cox.net.

Dumping case over for Atlantic Wire, but possibly not for former officials Atlantic Wire, which pleaded guilty last year to two counts of violating the federal Clean Water Act and one count of submitting false statements to the state Department of Environmental Protection, was fined $1.5 million by a federal judge, although in published reports he and the prosecutor termed the outcome “moot and ineffective” as the company is bankrupt and dissolved.

While the case against the Branford, Connecticut, wire manufacturer is considered closed, Prosecutor

16 | WIRE JOURNAL INTERNATIONAL

Christopher Schmeisser said the U.S. attorney’s office is “assessing whether there are particular actors” responsible for dumping contaminated wastewater into the river during the summer of 2007, causing the death of hundreds of blue crabs.

Schmeisser told Droney that a $740,000 surface cleanup

by Atlantic Wire, including the removal of tanks, chemical drums, cleaning houses and a waste-treatment system, was nearly complete. The cleanup plan was part of the company’s liquidation plan approved by the bankruptcy court in February.

Connecticut Attorney General Richard Blumenthal said that his office is also investigating individuals who used to work for the company.

OneSteel cuts 19 jobs in Geelong Onesteel Wire has cut 19 positions at its plant in Geelong, Australia, the Geelong Advertiser reports.

The plant, which has 92 employees, has seen a work slowdown from the weak global economy. The article cited Tony Hynds, an Australian Manufacturing Workers Union representative, as saying that the losses would affect both blue and white collar workers at the plant.

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AFL to acquire Draka OPGW unit

the reports said.

“These changes will help to reduce our overall cost structure and better allow us to control manufacturing costs in these challenging economic times. We understand and regret the impact this will have on the employees and families of the East Longmeadow facility, but have determined that this action is necessary due to the decline in sales volume associated with the weak economic conditions,” the reports said.

U.S.-based AFL Telecommunications reports that it has agreed to acquire Draka’s Optical Ground Wire (OPGW) business, which is based in Monchengladbach, Germany.

This acquisition, it said, further positions AFL Telecommunications as a leading worldwide OPGW manufacturer, increasing its reach in additional countries of Europe, Africa and the Middle East.

“The combined business synergies will enhance our technologies, increase manufacturing efficiencies and leverage the value of what we offer our customers,” said AFL Telecommunications' President Model and CEO Jody Gallagher. The company CJS 1000 notes that the OPGW cables, manufactured in the U.S. and U.K., are a dual functioning product that serves as ground wire for power lines while providing a path for the transmission of voice, video or data signals by incorporating optical fibers into the design of the cable. AFL Model BJS 1000* Telecommunications, which also has *Model BJS 1000 is bench-mounted. operations in Mexico, is a subsidiary of All other models are free-standing.

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Coleman Cable to close East Longmeadow plant Coleman Cable announced that it plans to close its plant in East Longmeadow, Massachusetts, which employs some 70 people, as part of a company realignment.

Published reports noted that the East Longmeadow plant, which has been around since 1985 under another name, Spectrum Wire, was bought by Coleman Cable in 2001. An announcement to employees said that the manufacturing and distribution facility will be closed on May 15, 2009.

“We find it necessary to take this unfortunate action in order to align our manufacturing capacity and cost structure with the reduced volume levels resulting from the current economic environment.

Between now and May 15, the East Longmeadow production will be transitioned to our East facility in Bremen, IN, with our Waukegan, IL and Texarkana, AR facilities providing backup capacity,”

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INDUSTRY NEWS

now,” Hynds said. "All these redundancies are disappointing ... it's getting so difficult to find a job." He said workers had seen the announcement coming, with shifts cut back and some workers forced to take leave in recent weeks.

INDUSTRY NEWS

Furukawa to consolidate its magnet wire unit with 2 other companies The Furkuawa Electric Co., Ltd., announced that it will consolidate its magnet wire operations with those of Totoku Electric Co., Ltd., and Riken Electric Wire Company Limited, with the new business to called Furukawa Magnet Wire Co., Ltd. The new subsidiary, established April 22, will market magnet wires on behalf of Furukawa Magnet Wire, an announcement at Furukawa’s website site noted. The business is scheduled to launch production on April 1, 2010.

“Furukawa Magnet Wire expects synergy from the consolidation of the three companies' operations and aims to generate customer value as a comprehensive magnet wire manufacturer equipped with world-leading technology,” the announcement said. It noted that domestic demand for magnet wires plunged the second half of 2008.

“In this environment, (we seek) to develop the ability to make comprehensive proposals based on a full lineup ranging from thick wires to extremely fine and special wires,” the announcement said.

Nexans wins airport cable contract Nexans reports that it has been awarded a contract worth approximately US$2.7 million from Tepe AkfenVentures (TAV), an airports operator in Turkey, to supply the power cables for the terminal building at Tunisia’s new Enfidha Airport.

A press release said that TAV, the global contractor responsible for the construction of Enfidha airport, has ordered both low- and medium-voltage power cables for the terminal building from Nexans in Turkey. The cables, it said, will be supplied by different production units of Nexans Group.

“The key to winning this important contract was strong collaboration and coordination between the sales management teams and manufacturing units across all the countries within Nexans,” said Paolo Pieri, Nexans’ airport infrastructure business segment manager.

For airport infrastructure, Nexans provides a range of cables from energy and communication networks to multiple terminals and hangars, control tower and runways.

In order to optimize safety, security, and efficiency within the airport, Nexans supplies high- and medium-voltage underground power cables to feed all vital airport applications, low-voltage power cables for weather beacons, fiber optic cable for radar control networks, and flexible halogen-free control and power cables for baggage handling systems.

Alcoa to sell wire harness business U.S.-based Alcoa Inc., announced that it has agreed to sell its wire harness and electrical distribution business to Platinum Equity, a Los Angeles-based private-equity firm.

The aluminum giant has previously announced plans to

18 | WIRE JOURNAL INTERNATIONAL

sell four business units, including its electrical and electronic solutions business, as part of a cost-cutting drive that called for cutting 13 percent of its work force, a press release said, adding that the wire harness and electrical distribution business is the biggest part of that unit.

The deal, expected to close by the end of the second quarter, includes operations in 13 countries that employ about 17,500 workers.

Minnesota Wire wins defense contact U.S.-based Minnesota Wire has been chosen to be the exclusive provider of cables for the Ekeel backplane assemblies on the first of the U.S. Army's M-ATV vehicles (Mine Resistant Ambush Protected All Terrain Vehicle).

A report in the Leader-Telegram said that the vehicles, a follow-up design to the original MRAP, will play a key role for combat forces in Afghanistan. Minnesota Wire’s pre-production cable sets already have gone to test vehicles in use by the U.S. Army in Iraq, the article said. It added that the company is now bidding on a Pentagon order for cable assemblies that may eventually reach 2,000 of the vehicles, a contract worth about $10 million.

The Ekeel system for the M-ATV, built by Synexxus, was described as a “plug and play” information backplane that can operate on vehicles with any weapon system, sensor device, and communication module within the same network. This type of backplane system can be found on modern fighter aircraft, and is increasingly found on next generation vehicles like M-ATV. Minnesota Wire’s cables enable the backplanes to handle a vast amount of electronic signal transfer for communications and data with robust shielding, signal purity, and combatready ruggedization.

“This order reflects the confidence that defense agencies have in our ability to provide electrical signal integrity for complex electronic systems, with speed and quality,” said Defense Sales Manager Tom Ashenbrenner. He noted that Minnesota Wire has a reputation for providing such complex defense application cable solutions, with past successes including cables for the Army’s Land Warrior and Future Force Warrior systems, the MRAP program and even for communications systems on the presidential aircraft, Air Force One.

Phygen Coatings adds U.S. facility Phygen Coatings, Inc., announced that it has added a new facility in Springfield, Ohio, that will be upgraded and ready for use in six to nine months. The company supplies coatings that are used for products such as dies, which require high abrasive wear resistance. ■

ASIAN FOCUS

ASIAN FOCUS China, India and South Korea to play large role in world economic recovery A half-dozen large emerging economies, including China, India and South Korea, will have a great impact on the global recovery, declares Dr. Thomas Duesterberg, president and CEO of the Manufacturers Alliance/MAPI, an executive education and business research organization in Arlington, Virginia.

In a statement from his organization, Duesterberg cited The Peterson Institute for International Economics (IIE), which he noted “has taken to calling six large emerging economies of China, Russia, India, Brazil, Mexico and South Korea the ‘Trillion-Dollar Club,’ as all have, at least before the current recession, passed this threshold in national output. Duesterberg said that this half dozen nations, along with the those that are part of the Association of Southeast Asian Nations (ASEAN) are “crucial to near-term global economic recovery, to the long-term health of the global economy, and especially to U.S. manufacturing.”

The six emerging countries and the 10 These countries ASEAN nations Brunei, Burma, are “crucial to Cambodia, near-term global Indonesia, Laos, Malaysia, Myanmar economic recovery...”

(Burma), The Philippines, Singapore, Thailand and Vietnam account for about 20% of world GDP, Duesterberg notes. He points out that emerging markets grew at an 8.3% rate in 2007, compared with 2.7% for the advanced economies. “In contrast to the financial crisis of 1997 when many emerging markets were at the epicenter of the crisis, most of these countries have shown relative stability in the current recession, in large part due to the lessons they learned in 1997,” he wrote. “Indeed, they could well help lead the world out of the 2008-2009 downturn.”

China has a significant stimulus plan that should lead to a return to as much as 9% growth in the second half of 2009, Duesterberg said. “India, Korea, and Brazil all have withstood the worst of the downturn and, together with ASEAN, could recover quickly if the massive stimulus in the United States and China manages to turn these economies around,” he said.

“As we look beyond the debilitating recession still plaguing us, the six-plus ASEAN will be a prime pillar of growth,” Duesterberg said. The collective GDP of this somewhat artificial grouping is large enough to be an engine of

The focus for efforts to revive the ailing global economy may depend more on large emerging countries such as China, India and South Korea, and some of the ASEAN nations rather than the U.S. and European countries. growth as it has a higher potential growth rate than the debtridden and consumption-saturated industrial countries, and so is likely to be the primary focus of increased demand for manufactured goods once global recovery begins, he said.

To take advantage of the growth opportunities, however, U.S. manufacturers will have to regain lost market shares both domestically and, especially, in Asia, Duesterberg said.

He noted that about 30% of U.S. exports went to this grouping in 2008, but only 18% if free-trade partner Mexico is excluded.

“Moreover, we have lost market share in the vital Asian region, primarily to China,” Duesterberg said. “Between 2000 and 2008, China increased its exports to other Asian destinations by 400%, while we saw an increase of only 19%. China now has more than twice the U.S. market share in Asia, the fastest-growing and most populous region in the world.”

China, Korea, Japan and ASEAN have been aggressive in recent years in building a web of free-trade agreements (FTAs) spanning most of Asia, said Duesterberg, adding that “India is now negotiating entry” into this network. “At a minimum, the United States will have to find a way to join this free-trade network, or risk losing even more market share. A vital first step is ratifying the U.S-Korea FTA. Our trade with FTA partners is largely in balance.”

Beyond those measures, there is a need to find a global path to rebalance the undervalued Asian currencies, an action which also will contribute to global economic stability in the coming decades and, hopefully, accelerate consumption growth in Asia, Duesterberg said.

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

20 | WIRE JOURNAL INTERNATIONAL

NEC Corp. to provide submarine system that will link Indonesia and Hong Kong NEC Corp. reports that it has signed a multimillion-dollar full turn-key contract with PT. Fangbian Iskan Corporindo (FIC) and Telemedia Pacific Inc. (TPI) to supply the new intra-Asian Submarine Cable Asia Network (SCAN) system.

The cable system, it said, will provide the first direct cable link that connects the Indonesian capital of Jakarta and the second largest city of Surabaya to Hong Kong, where it will be further connected to other cable systems reaching around the globe. Per the report, the SCAN system will span 4,300 km, with three branching units to support potential future expansion to key ASEAN countries such as Singapore, Vietnam and the Philippines. This cable will use the most advanced Dense WDM systems, with an initial capacity of 40Gbit/s transmission speed, upgradeable to 1.92Tbit/s. The new cable is scheduled to be completed by the end of 2011.

Andrew Solutions expands Suzhou plant Andrew Solutions, a CommScope business, announced that it is completing the expansion of its plant in Suzhou, China, an investment that was needed to meet increased demand for 3G technology.

E-mail: fukaseco@ja2.so-net.ne.jp http://www.fukase.co.jp

3G, the third generation of telecommunication hardware standards and general technology for mobile networking, superseding 2.5G. A press release said that the Suzhou plant, in operation since 1998, has more than 2,000 employees and a production area of more than 20,000 sq m. The expansion, it said, will increase the workforce by approximately 400 people and the production space for base station antenna manufacturing by 50 percent. The Suzhou plant also manufactures HELIAX® 2.0 coaxial RF cable, RADIAX® radiating cable, and cable components and accessories, it said.

Bhart Airtel joins group of telecom companies that plan cable system to link U.K. and India India’s Bharti Airtel announced that it has joined 15 global telecommunications majors, which include South Africa’s MTN, British Telecom and U.S.-based AT&T and Verizon, to build a high-bandwidth, sub-sea cable system that will link the U.K. and India.

The 15,000 km cable system, known as the Europe India Gateway (EIG), will connect 13 countries across three continents, a press release said. The EIG will cost about $700 million, it said, noting other participants include Cable & Wireless, Djibouti Telecom, Du, Gibtelecom, IAM, Libyan Telecom, Omantel, PT Comunicações-S.A, Saudi Telecom Company, Telecom Egypt and Telkom SA Ltd. ■

Sk Bldg #1 2- 6 -1 Hamada Mihama -Ku Chiba Bhiba-Ken 261-0025, Japan FAX 81-43-276-0463 TEL 81-43-276-0630

JUNE 2009 | 21

ASIAN FOCUS

ASIAN NEWS BRIEFS

Zane Daggett has joined RSCC Aerospace & Defense as vice president of sales and marketing for aerospace and defense products. He heads the sales and marketing team for the New Hampshire, USA facility, as well as the miltary/shipboard products in East Granby, Connecticut, USA. He will assume responsibility for the RSCC Zane Daggett Aerospace & Defense sales team and will develop new business, further client relationships and introduce industry partnerships. Based in Manchester, New Hampshire, USA, RSCC is a Marmon Wire & Cable/Berkshire Hathaway company, which comprises more than 25 business units that manufacture electrical and electronic wire and cable.

Allied Wire and Cable announced the hiring of four new sales representatives. Mike Autry has been in the wire and cable industry for over eight years, working for SEA Wire and Cable. Chuck Crane has been in the connectors and accessories side of the electrical and electronics industry for 21 years, all with Molex. David Smith has worked in sales for several years, most recently in the food service and apparel industries. Ben Ficken has over five years of sales experience in the IT industry, selling business-to-business software and hardware. Based in Collegeville, Pennsylvania, USA, Allied Wire & Cable is a privately owned, value-added manufacturer and distributor of electrical wire and cable products and accessories.

Chicago Hardware & Fixture Company announced the addition of Michael Stamm to its sales staff. Stamm assumes territory responsibilities for selected USA areas in Chicago Metropolitan, Iowa and Wisconsin. He is in line to become regional sales manager for part of the East Coast and New England, directing several manufacturing

JULY 2009

PEOPLE

PEOPLE

22 | WIRE JOURNAL INTERNATIONAL

representative agencies. He worked in wholesale distribution and business management prior to joining Chicago Hardware & Fixture Company. Based in Franklin Park, Illinois, USA, Chicago Hardware & Fixture Company is a manufacturer of forgings and wire forms including eyebolts, u-bolts, shackles, turnbuckles, wire rope clips, threaded rod, shapes and angles.

Alcoa Fastening Systems (AFS) announced the promotion of Craig Brown to the position of vice president, global aerospace customers and marketing. Brown has been with AFS since 1983 and in his new position is responsible for worldwide customer relationships, sales and marketing, customer service and technical support. Based in Torrance, California, USA, AFS, a business unit of Alcoa, designs and manufactures specialty fasteners, nut and frangible collar systems, fluid fittings, assembly components Craig Brown and installation tools for aerospace and commercial applications. â–

OBITUARIES James E. Ghio, the founder of Westport Metlas, Inc., died March 5, 2009, at age 88. He founded the Missouri producer of high-carbon steel wire in the 1960s, and was president until his retirement in 2002. Prior to that, he was employed

by Bekaert, selling drawn steel wire products at the company’s headquarters in Belgium. A WAI Life Member, he was educated at the University of Notre Dame and Washington University, and was an Army Air Force veteran, serving in World War II from 1942 to 1946. He is survived by his wife, Jean McGregor Ghio, two children, two stepchildren and five grandchildren.

RE :

W IRE & F A STENER M ACHINERY - PART 1

James J. Anastasi, who attained legendary status for his extensive knowledge and contributions to the wire and cable industry, died April 28, 2009, at age 66, following a battle with pulmonary fibrosis.

A 1964 graduate of Lowell Technical Institute, Lowell, Massachusetts, he received the Charles D. Scott Distinguished Career Award from WCMA in 2006 for his service to the industry.

Anastasi, who helped develop the original IBM LAN Cable, used widely in computer networks, began his industry career in 1964 as a project engineer with the former Brand-Rex Co. in Willimantic, Connecticut, and remained there for 30 years. In 1966, he joined the new Siloam Springs Telecom plant as process engineering supervisor. He returned to Willimantic in 1967, continuing various engineering capacities through his position as vice president of engineering before becoming director of tape and cable marketing. During the BICC ownership, he helped site its facility in Jackson, Tennessee, and was instrumental in converting over all extrusion manufacturing equipment to PLC technology.

James J. Anastasi The author of two U.S. patents,Anastasi served on UL, CSA, TIA and IEC committees and code-making panels with the National Fire Protection Association. He chaired the original (NEMA) Electronic Technical Committee and the current Premise Technical Committee. In 1994 he joined C&M Corporation as vice president of engineering. In 1996, he joined Helix/HiTemp Wire and Cable, Draka USA, where he served as director of engineering for five years. In 2001, he served as technical manager for the wire and cable group with Intertek Testing Company (ETL). “I nicknamed him ‘The Godfather’ of the cabling industry. Many times while walking trade shows or industry events with Jim, people would come up to him for conversation and eventually they would tell me, ‘I use to work for Jim,’ ” said Intertek Vice President Don Nicholson. “It seemed to me that every engineer in our industry worked for him at one point or another.”

As the former chairman of the NEMA Premise Wiring Committee (high performance wire and cable section), Anastasi was implemental in publishing the industry's first standards for Cat 6 and Cat 7 cable, said Dan Strachan, NEMA program manager. “Jim kept my feet to the fire and had no hesitation in speaking his mind,” he recalled. “(Jim) was quite extraordinary in every respect. By the time I came to work with (NEMA) in 2001, he no longer worked for a wire and cable manufacturer, the main requirement for membership in the National Electrical Manufacturers Association,” said Andrei Moldoveanu, NEMA technical director. “Nevertheless, the association made a rare if not unique exception of inviting him not only to stay on the committee but also to continue to chair it, which he did very successfully until retirement. There’s no doubt about it: He was one of the fathers of the high performance communication cable industry, foreseeing the need to move farther ahead than the telecommunication industry capabilities of that time and creating the standards to support its progress.”

“Jim was one of those unique individuals who loved to spend the time to teach and coach everyone who came in contact with him,” said Dave Kiddoo, global business manager, AlphaGary Corporation. “He used his career to build meaningful and lifelong friendships. His hard work, contagious smile and New England charm reflected the leadership he brought to our wire and cable industry. We will miss him dearly.”

Anastasi is survived by his wife of almost 44 years, Sharon (Moore) Anastasi; three daughters; and nine grandchildren.

He was predeceased by a daughter, Jill Anastasi.

WIRE JOURNAL

®

INTERNATIONAL

MARKETING EXPOSURE. It’s one way equipment suppliers stay viable despite cloudy business conditions.

The July WJI will showcase wire, cable, and fastener equipment. And for an added twist on a traditional feature, editors will investigate what other tactics keep these companies radiant.

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Contact WJI’s Sales Team: Tel.: 001-203-453-2777 Bob Xeller E-mail: bxeller@wirenet.org Anna Bzowski E-mail: abzowski@wirenet.org

JUNE 2009 | 23

PEOPLE

James J. Anastasi: industry loses expert, leader and a good friend to many

FIBER WATCH

FIBERWATCH FTTH Council reports climb in North American subscribers

Sumitomo’s fiber at work at National Library of Medicine

The number of North American fiber-to-the-home (FTTH) subscribers continues to grow at an annual pace of approximately 1.5 million and now stands at more than 4.4 million, according to a RVA Market Research study released by the Fiber-to-the-Home Council.

The report also showed healthy growth in the number of homes linked into fiber networks—from 13.8 to 15.2 million—and showed that FTTH networks are now available to more than 13 percent of North American households, with end-to-end fiber connections now being used by nearly 4% of the residential telecommunications market.

Four years after FTTH deployment took off in earnest in North America, the study pegs the annual growth rate for FTTH in North America at 52 percent, down from the initial phases of deployment, but still among the highest rates of any country or region in the world.

“The strong annual growth rate of this new technology is unsurprising, even with a subscriber base now numbering in the millions,” said Joe Savage, president of the FTTH Council. “At a time when some communications providers are treating bandwidth as a scarce commodity, our industry is moving forward to a future of almost unlimited bandwidth delivered over end-to-end fiber networks.” The study also noted that the number of homes receiving video services over FTTH is up 62 percent over the past year, from 1.6 million in March 2008 to nearly 2.7 million.

Meanwhile, the overall “take rate”—the percentage of those offered FTTH service who decide to subscribe— rose for the sixth straight six-month period, and now stands at nearly 32 percent.

Led by Verizon's investment in FTTH technology in the deployment of its FiOS service, the FTTH industry in North America also includes hundreds of smaller telephone companies and other network providers, municipalities, planned residential communities and cable television companies that are making the move to end-to-end fiber to deliver next-generation video, internet and voice services.

Sumitomo Electric Lightwave announced the deployment of its FutureFLEX® Air-Blown Fiber® system at the National Library of Medicine (NLM), the world’s largest medical library and the information and research arm of the National Institutes of Health (NIH) in all areas of biomedicine and health care.

A growing collection of articles and other resources accessed through the web by approximately 900 million searches a year has required NLM to expand its two data centers and storage capacity. The data centers also support research and development of the National Center for Biomedical Communications and the National Center for Biotechnology Information, both of which use highbandwidth video and virtual reality for projects including telemedicine, The Visible Human Project and others.

The expansion of the data centers and support of the growing bandwidth needs of researchers require a reliable, immediately scalable, non-obtrusive, and cost effective fiber optic backbone infrastructure, according to published reports. Unlike conventional fiber optic infrastructures where fiber optic cables are pulled to provide sufficient bandwidth and capacity for network moves, adds and changes, Sumitomo’s fiber allows NLM to blow any type and amount of fiber in and out of the IT network between and within buildings on an as-needed basis.

This eliminates the need and expense of dark fiber and allows NLM to respond to bandwidth requirements and any network changes in real-time, Sumitomo noted.

24 | WIRE JOURNAL INTERNATIONAL

Asia to invest in undersea cable Several Asian countries plan to jointly build a third AsiaPacific undersea cable to bring faster Internet service to the region, Taiwan media reported.

The countries plan to jointly invest $500 million to lay the Asia-Pacific Cable Network 3 (APCN3), according to the Economic Daily News and the Commercial Times, which cited unnamed Chunghwa Telecom Co. sources.

The APCN3 would link Singapore, Hong Kong, Taiwan, Japan, Thailand, the Philippines and Vietnam.

The main companies involved in the venture—including Taiwan's Chunghwa Telecom, China's China Unicom Ltd and China Telecom Corp, Singapore's Starhub Ltd and Japan's KDDI Corp—were expected to sign a contract by June and the APCN3 was to be completed by 2013, the reports said. The undersea cable would be 11,000 km long.

It would provide 40 gb transmission capacity, compared with the 10 gb capacity offered by the APCN2, which is 10 years old and frequently breaks down. ■

FASTENER UPDATE

FASTENER UPDATE Astronauts face off with fasteners Space shuttle Atlantis astronauts on a servicing mission to repair a failed instrument on the Hubble Space Telescope found themselves grappling with more than 100 irksome fasteners on the circuit board cover plate of the Hubble’s Space Telescope Imaging Spectrograph (STIS).

STS-125 Mission Specialist John Grunsfeld displays the power tool that was used to remove the fasteners. Photo courtesy NASA. According to a Reuters report, astronauts Michael Massimino and Michael Good had expected problems unscrewing 111 fasteners on the STIS cover plate, which had to be removed to access its faulty circuit board during a servicing mission last month. But what frustrated the astronauts was a stripped bolt on a handrail that needed to be removed before they could reach STIS. Massimino reportedly ended up tearing off the handle with brute force. The spacewalkers then installed a custom-made device to catch the 111 screws, but when Massimino attempted to use his battery-operated screw-driver, it would not work. Per the report, the fasteners and other equipment glitches turned a routine servicing mission into a tedious spacewalk.

Justin Cassidy, lead systems engineer for Crew Aids and Tools at NASA’s Goddard Space Flight Center, said tools had been developed for such instances. It took four to five years to design the tool used to remove the fasteners and the fastener capture plate, he said, noting that the tool had to be able to withstand temperature swings of 500 degrees from the heat of direct sunlight to frigid shade, either extreme which can make the metal innards of a power tool seize up instantly. He added that the astronauts work “while wearing thick gloves on their hands and a fishbowl on their heads.”

Engineers wanted at least 10 times the speed, but didn’t need the torque the pistol-grip tool generated,” he said, not-

26 | WIRE JOURNAL INTERNATIONAL

ing that the fasteners could not be allowed to float away. It took four to five years to develop the mini power tool and the fastener capture plate, Cassidy said. The power tool spins at 210 revolutions per minute.

Ingersoll Fasteners to close doors The Ingersoll Times reports that Ontario, Canada-based Ingersoll Fasteners is slated to close before the end of this year, a victim of the economic downturn.

A press release from parent company Ifastgroupe said that Ingersoll Fasteners will wind down operations over the next few months and be completely closed before the end of 2009, affecting almost 120 employees. Sales, distribution services and some production will be moved to other divisions of Ifastgroupe. Ingersoll Fasteners represents about 10% of Ifastgroupe's fastener-making capacity.

“Although in recent months our team at Ingersoll had made tremendous strides in improving its cost structure and productivity, the economic forces at play in the market proved overwhelming in regards to our efforts toward ensuring Ingersoll's long-term financial viability,” said Ifastgroupe President Darren Dalgleish.

Ingersoll Fasteners has been producing fastener products for over 100 years. It was founded in 1887 as Morrow Screw and Nut Company. In the late 1960s, it was purchased by Ivaco Corporation. Various expansion projects have seen the facility grow to 235,000 square feet of production space.

“The combined impact of the faltering economy, collapse of the North American automotive sector, and the increasingly aggressive presence of foreign competitors have delivered a fatal blow to our collective aspirations of making Ingersoll profitable again,” said Dalgleish.

Sealtight completes first phase of Lockheed fasteners contract Sealtight® Technology announced it has completed Phase I of a contract with aeronautics company Lockheed Martin to supply hi-tech patented self-sealing fasteners, a deal that Lockheed Martin calls, “a critical part in America’s next generation anti-missile system.” The contract, after Phase II testing, could result in a considerable ramp-up in production at Sealtight, requiring the hiring of additional employees, the company said.

The recently completed prototypes were described by Sealtight’s patented American Fastener Journal self-sealing fasteners.

organizer Yang Junfeng. The day will be topped off with a dinner yacht cruise on the Zhujiang River.

An application form for global buyers can be found at www.chinafastener.com.

Purchasing meeting slated for June

Sencorp, the Cincinnati, Ohio, USA-based parent of Senco Products, a worldwide marketer of air-powered nail guns, nails, staples, screws and fasteners, will be sold to a Chicago-based private equity firm through a Chapter 11 bankruptcy reorganization.

Sencorp and most of its operating units, including Senco, will be acquired by Rosemont, Illinois, USA-based Wynnchurch Capital Ltd. Wynnchurch, which provides equity to middle-market companies, will pay US$43 million in cash for Sencorp’s assets and assume certain liabilities, according to the filing, Business Courier online reported.

The bankruptcy reorganization culminates more than a year of efforts by Sencorp, owned by the George Juilfs family, the Cincinnati Enquirer wrote. ■

ChinaFastener Purchasing Meeting 2009 Guangzhou, an event co-organized by ChinaFastener.com and Julang Exhibition Co., Ltd., will be held on June 24, 2009 in the China Import and Export Fair Pazhou Complex, Guangzhou, China. The 10th annual China International Fasteners Spring & Equipment Exhibition will be held simultaneously at the same venue, from June 23-26, 2009.

More than 50 professional global fastener buyers are expected to attend the purchasing meeting, organizers said.

While specified competitive suppliers will be selected for the purchasing meeting according to the purchasing items of the invited global suppliers, “the characteristics of ChinaFastener Purchasing Meeting are cost-efficiency, time-efficiency with a stronger goal and high probability of real deals,” said

Sencorp acquired by Chicago equity firm for $US43 million

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FASTENER UPDATE

Publisher/Editor Mike McGuire as “a work of technological art.”

Sealtight® Technology, based in Goleta, California, USA, designs, manufactures and distributes patented selfsealing fasteners, screws, nuts, bolts and washers. It has fulfilled similar contracts for Medtronic, Boeing, GE, I Robot, L-3 Comm., Raytheon, NASA and Cal Tech.

WAI NEWS

WAI

NEWS

Ferruccio Bellina receives Wire Association’s President’s Award Ferruccio Bellina was honored in April with the WAI’s President’s Award at Interwire 2009, the second time the award has been issued.

Bellina is owner of TKT Group and president of the Italian Wire Machinery Manufacturer’s Association (ACIMAF). He has served on the WAI Board of Directors for the past six years, but his contributions began well before his board service. He has guided WAI on several matters and was instrumental in building and rebuilding relationships on an international level. Bellina was the driving force in WAI’s collaboration with ACIMAF and IWMA in producing four international technical programs, was influential in the Italy chapter formation and has been an advocate for WAI products and services in his large network of industry contacts.

“You won’t find a person that has dedicated more time and energy into his business and yet takes the time to help others make the wire industry grow, so it is no surprise that he gives so much to WAI,” said Jim Marr, a WAI past president.

28 | WIRE JOURNAL INTERNATIONAL

Ferruccio Bellina, center, recipient of the WAI’s President’s Award with, left, WAI Executive Director Steve Fetteroll and WAI Past President Jim Marr.

SAVE

© 1898 by The Gugler Lithographic Co., Milwaukee, Wis.

panoramic view of

MILWAUKEE

Wis.

taken from city hall tower

co-located with the National Electrical Wire Processing Technology Expo

MAY 11-12, 2010 | MILWAUKEE, WISCONSIN, USA The Home of Harley-Davidson

After more than 100 years, we’re getting closer to our neighborS.

A

cross town or across the country wire making and wire processing are two manufacturing sectors that have been linked by industrial proximity for years.

Neighbors. One may be downtown, one downstream, but these groups share mutual interest.

Join us as two industry events—Wire Expo and the National Electric Wire Processing Technology Expo—share residence in Milwaukee, Wisconsin, for exhibitions that will run side by side making cross-over admission open to all who register.

History shows many ways to assemble groups. Sometimes into regions, neighborhoods, or sales territories and—from a finished wire perspective—many times into cable assemblies, cord sets, and wiring harnesses.

It takes a village. So if you want to develop your career in a community of like-minded industry professionals visit us at Wisconsin’s Midwest Airlines Center, May 11-12, 2010 where we’ll be celebrating the 20th anniversary of Wire Expo with new friends and great neighbors. Make it a point to drop in.

For 2010 we’ve planned a new group to show a panoramic view of the industry and provide the most current solutions available from exhibitors and educators.

For exhibiting information e-mail WAI sales at bxeller@wirenet.org or abzowski@wirenet.org. Find upcoming show details online at: www.wirenet.org.

The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

Organizers of Istanbul Cable & Wire ’09, to be held at the WOW Hotels & Convention Center, Istanbul Dunya Ticaret, Merkezi Yesilkoy, Istanbul, Turkey, announced the availability of tabletop exhibition space for the November 2-3, 2009, event.

One tabletop includes a drape, company name board plus one full delegate registration. A laptop electrical connection will also be provided, and tabletops will be situated near the two main conference rooms where most foot traffic is anticipated.

The International Wire & Machinery Association expects approximately 200 attendees, with special interest

from Turkish, Ukrainian and Russian industries (the conferences will be held in English plus these three languages).

Organizers of the biennial conference note that there are prospects for local sponsorship and support, in particular from Ihlas Group with its extensive media resources, including the trade magazine BORU. Its daughter company, Ihlas Fuar, is organizer of the BORU tube exhibition and has offered its support for the conference.

Tabletop costs for WAI, IWMA and ACIMAF members and speakers are $940 per tabletop with electrical connection, and $915 without electrical connection. The fee per tabletop with electrical connection for non-members is $985; and $960 without electricity. Both members and speakers and non-members can take advantage of a $70 discount for registering early (before June 30, 2009).

Payment may be made by credit card, check or invoice.

Credit card transactions will be made in Pounds Sterling at the current Euro exchange rates. To reserve a tabletop for Istanbul Cable & Wire ’09, contact WAI Director of Sales Bob Xeller at tel. 203-453-2777, ext. 119, bxeller@wirenet.org; or the IWMA at tel. 44-1926834680, info@iwma.org, www.iwma.org. ■

JUNE 2009 | 31

WAI NEWS

Tabletop space available for Istanbul Cable & Wire ‘09 conference

CHAPTER CORNER

CHAPTER CORNER Ohio Valley Chapter sets Aug. 5 date for its 7th Annual Golf Tournament The Ohio Valley Chapter cordially invites golfers, be they WAI members or not, to take part in its 7th Annual Golf Tournament, to be held on Wednesday, August 5, 2009, at the Grantwood Golf Course in Solon, Ohio, USA near Cleveland. The scramble format event is a great way to network with industry colleagues, entertain clients and reward employees at a player-friendly course.

Prizes will be awarded for the best team scores as well as for a variety of individual skills contests. The day’s top prize of $10,000 will be awarded to the golfer who can ace the designated hole. That prize may well prove elusive, but prizes will definitely be awarded for the “closest-to-the-pin” challenge (three winners), the most accurate drive and the longest drive (two winners).

“We’re pleased to return to the Grantwood course and expect that everyone will have a great time,” said tournament chair Mike Caranna of American Spring Wire Corp. “This event really gives you the opportunity to connect with people in the industry in a relaxed setting, and the prizes help add a little challenge to the mix.”

32 | WIRE JOURNAL INTERNATIONAL

WAI Ohio Valley Chapter Open Chairman Mike Caranna (far right) presents prize to the 2008 tourney’s first place team from Charter Steel (l-r): George Dowidchuk, Dave Light, Scott Fravel and Mark Zak.

Southeast Chapter sets October date for its 8th Annual Golf Tournament The Southeast Chapter has scheduled its 8th Annual Golf Tournament for Thursday, October 15, at the Rock Barn Golf and Spa, Conover, North Carolina, USA. The event, which will have a scramble format, will be played at a challenging course, designed by Robert Treat Jones, Jr., that was used for the PGA’s Champions Team Greater Hickory Classic. Prizes will be awarded for skill contests that include most accurate drive, longest drive and “closest to the pin.” Each player also gets a shot at acing a designated hole for a $10,000 prize. A range of sponsorships are available, including the hole-in-one ($300), beverage cart ($300), awards dinner ($300), pre-tournament lunch ($250), and the long drive, closest-to-the-pin and accurate drive ($150 each) as well as corporate hole sponsorships ($100).

More details will follow in future issues. Raffle prizes are also sought, with proceeds going to the chapter’s scholarship fund.

For more details, contact co-chairs Tim McElhany at tel. 864-223-6146, tmcelhany@process-control.com; Steve Vannais at tel.704-799-2258, svannais@ davis-standard.com; or WAI’s Chip Marsh at tel.

203-453-1748, cmarsh@wirenet.org. ■

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JUNE 2009 | 33

CHAPTER CORNER

Sponsorships are available, ranging from the hole-in-one ($300) and skills contests ($150 each) to the corporate hole sponsors ($100 each). All companies who take advantage of this opportunity get signage and acknowledgment at the course as well as recognition in the tournament wrap-up article.

“The companies who sponsor the various activities of the tournament make this event not just possible, but more fun for everyone,” said Ohio Valley Chapter President Dane Armendariz, Henkel Corporation. “We really appreciate their support and are pleased to recognize them for it.”

Check-in and warm-up begin at 8:30 am with the first tee time set for 9:30 am. The awards reception and dinner will take place at 4 pm.

Tournament fees are $120 per golfer and include greens fees, cart, lunch at the turn and the awards dinner. Deadline to register is July 29, 2009, and the registration form is available at the chapter webpage at www.wirenet.org/members/ chapters/ohioval.htm.

Non-golfers who want to attend and network with industry colleagues can join the reception and awards dinner for only $35.

For more information, contact Mike Caranna, tel. 216-2924620, ext. 257, mcaranna@amspringwire.com; or WAI’s Chip Marsh at tel. 203-453-1748, cmarsh@wirenet.org.

FEATURE

European Outlook n many ways, the European outlook is tied to the global outlook, as world trade has a

I

strong direct and indirect impact in terms of how available capital funds are, what

actions different nations are taking and how effective stimulus plans can be. The shortterm outlook does not appear good, nor should it given the economics, but these are conditions that eventually will change. This feature presents comments from two industry observers, three industry suppliers and a key European banking official.

Ferrous view The below information is from Murat Eryilmaz, CEO of SteelOrbis, www.steelorbis.com, which provides steel news, sector analysis, trade statistics on steel, market pricing and more as well as a secure e-trade platform for steel buyers and sellers.

The progression of the U.S. financial crisis into a global economic crisis brought about a massive and regionally synchronized global decline of steel demand in late 2008 as confirmed

by Daniel Novegil, the chairman of the world steel Economics Committee, in London in late April 2009. Significant reduction in credit availability and confidence falling off a cliff in all important economic regions of the world, have put the global demand for investment and intermediate goods on a downward trend for almost the last three quarters.

The trend during first quarter of 2009 was not much different than late 2008 for most of the world.

Europe, for sure, is the most affected region after North America. According to worldsteel’s most recent estimate, the apparent steel use in Europe is expected to decline by almost 29% in 2009.

Perhaps this estimate could be found a little on the optimistic side given the trend so far. GDP for the European Union (EU) decreased by 1.5% during the last quarter of 2008 compared to the previous quarter of the year.

This was the worst quarter-on-quarter GDP decline in the last 50

34 | WIRE JOURNAL INTERNATIONAL

Monthly steel production for the 27 EU countries. Chart courtesy SteelOrbis. years.

As a matter of fact, things have gotten worse in the EU since the beginning of the year. Exports have been going down drastically for the EU countries and the trade balance started to show a deficit by the end of the year. Many companies have been reducing inventories since the end of third quarter of last year but still complain of high stocks as there is almost no demand for the goods. As demand continues to shrink, the industrial production in the EU also continues to go down. January figures show a year-on-year decline of 16.3%. There is no doubt that

the manufacturing sector in the EU is in trouble and not going to get out in the short run.

Looking at the individuals does not help much either. The consumer confidence is almost at all-time lows.

Unemployment rises across Europe with equity and housing prices going down. As a result, household income levels have Murat Eryilmaz shrunk, having a further negative impact on demand.

Inflation is expected to be probably under 1% this year, hence the European Central Bank has been lowering the interest rates in an effort to help the economy. Unfortunately this is far from being enough to revive the economy. The so-called “toxic assets” have to be cleaned up from the banking sector, and the banks should start lending to private companies again.

There is no doubt that the European governments should Without real signs also support economthat the worst of the ic revival by some measures to boost current global finandemand and tackle cial crisis has been unemployment.

However, the EU left behind, confidence governments have cannot be restored, been relatively slower and the risks will still in taking actions in terms of stimulus be pretty high. packages whatsoever.

The EU also carries the burden of the Central and Eastern European economies. Those economies are in terrible shape today as a result of the collapse of their banking systems and the European automotive industry in general.

The re-emerging protectionism poses another huge threat for the European economy. As mentioned above, the EU trade balance is showing a deficit more or less one year after the last meaningful surplus figure was seen there. The EU needs to export but increasing trade barriers around the world are having a big adverse effect on its open market economy. In short, almost everybody can sell their goods to the EU but many do

It is hard to say if the economic situation has bottomed out yet. It depends on the sector. Banking has probably bottomed out and is on the way to recovery. This will have an impact in the medium term on the recovery of the property market, hence an impact on cable manufacturers that supply building and office communication products. Automotive is still in decline, causing a great deal of pain to all of its suppliers.

Power and communication infrastructure projects seem not to be affected as much as other sectors.

The Euro zone countries in general have not suffered the losses that other countries have had to endure due to two factors: the common currency that provided stability, and the strict banking regulations that prevented bankers from listening to their wallets rather than their Ali Shehab heads.

Recovery is about the regain of trust: the trust in your bank to keep your money safe, the trust in your supplier to deliver, the trust in your customer to pay. My dealing with U.S. firms suggests that they are much less conservative when it comes to taking calculated risks.

Such risks lead to the return of trust, therefore the return to economic recovery. The world’s economies are highly linked, and a recovery in one country will lead to global recovery.

In my opinion the global recovery will be led by the U.S. as it is the largest economy in the world and the reasons mentioned above. I am in favor of securing manufacturing industries because they are the heart of the economy. If we lose them, then countries with manufacturing traditions will not be in a confident position to trade with the rest of the world, and that would significantly slow down recovery. Governments’ stimulus efforts around the world may vary, but they need to provide good value for taxpayers.

Industry hopes for a return to “normalcy,” but what will that mean? Is that when we are all feeling good and the economy is booming, or when we are feeling hopeful and the economy is recovering, or when we are feeling down when the economy is recessing? To me there is no normal state. The economy is a system, and like any other system in the universe has a natural frequency of expansion and recession. That frequency is determined by many factors, some we are in control of, others we are not. The short answer is what is happening is normal. We soon will be hopeful when recovery starts, and happy when it booms, and anxious when we are back here again.

Cimteq Ltd. Principal Ali Shehab

JUNE 2009 | 35

FEATURE

U.K. view: Cimteq Ltd.

FEATURE

Danish view: Enkotec A/S The regional economies have always evolved in cycles, often not visibly, but this time the recession is visible in most countries and regions, which aggravates the situation. In the Scandinavian countries, and especially in Denmark, we have been better prepared to meet the challenges of the economic crisis than the bigger European economies such as Italy, France and Germany, not least because of our significantly lower unemployment rate.

Enkotec operates in a B2B niche market that is governed by other “rules” than the general consumer market. Thus, we have throughout the Brent Just Peterson present economic crisis witnessed a certain activity in the nail manufacturing business, but of clearly strategic character.

Our customers, and as a consequence Enkotec, strongly depend on the activities and economic trends within the building sector. In view of the current state of this market, I expect that, within nail manufacturing, we will reach 2010 I believe that the U.S. before we see will recover more investments that are based on quickly than Europe, requirements for especially because the increased capacity.

I believe that the EU countries have U.S. will recover difficulties in agreeing more quickly than Europe, especially on common action. because the EU countries have difficulties in agreeing on common action in order to overcome the financial and economic crisis, contrary to the U.S. This is clearly rooted in the bigger cultural differences to be found within the European Union compared with the U.S. However, in my opinion, after a couple of turbulent years with recession, decrease in GDPs, etc., we will gradually see a new economic world order with a reduction in the present dominant position of the U.S and the U.S. dollar, so that instead of having one world economic super power, we will see a more balanced world economy with three or four power centers.

Enkotec A/S Managing Director Brent Just Peterson

36 | WIRE JOURNAL INTERNATIONAL

not want to buy from them. It is certainly not the ideal condition for an export dependent economy!

Without real signs that the worst of the current global financial crisis has been left behind, confidence cannot be restored, and the risks will still be pretty high.

Under these circumstances most observers share the same opinion: the recovery of the EU economy will be slow, painful and is actually dependent on the recovery of other major economies in the world as well as emerging markets. We shall be ready for more investment cuts until the banking system starts functioning again, which is probably going to take many more months. We shall also be ready for more inventory reductions due to low demand level throughout the rest of the year. The EU GDP is expected to contract by more than 3% this year.

According to worldsteel’s short range outlook, apparent steel use will decline this year by 28.8% in the EU and 25.7% elsewhere in Europe, compared to 2008. These figures follow respective decline figures of 8.4% and 8.3% observed last year.

Getting new orders is so difficult nowadays that companies are literally implementing survival strategies. Order books are very light, stocks are down, investments have either been cancelled or postponed.

The automotive industry in the EU is probably the hardest hit.

New registrations are down dramatically overall and the situation is even worse for commercial vehicles. It can be described as a disaster for the EU’s new member states, which have The automotive indusseen heavy truck sales drop by 68% try in the EU is probyear-on-year. ably the hardest hit.

The mechanical New registrations are engineering sector is also very badly down dramatically hit. Weak housing overall and the situamarket and credit restrictions have cut tion is even worse for demand for domescommercial vehicles. tic appliances.

Subsequently, output in these sectors are expected to fall drastically this year. The 2009 outlook is that the first half year’s sharp reduction of output will see some slowdown in decline the second half of this year.

The construction industry had already weakened throughout the EU countries in 2008. The housing market corrections had caused the construction activity to decline significantly in the U.K., Ireland and Spain since 2007. Further financing problems on top of rising stocks of unsold homes and the overall decline in consumer confidence have all had their share of adverse impact on the construction activity during the course of last year.

The industry is still not in good shape. The EU countries are

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FEATURE

Spanish perspective: Gotex S.A. Even though much of Europe is suffering, including Spain, we at Gotex feel confident about the next three to five years. Our company is in a good position because much of our focus is in the fiber-optic market. The field is still growing because wider and more powerful networks are still required in many countries, especially in Eastern Europe where infrastructures are not yet well-develDaniel Diego and David Ferre oped. The opposite is the case for the Scandinavian area, as they have better cable installations.

The European market has decreased in the last quarter, and an excess of cable production due to the last good times (2007 to mid-2008), followed by the unexpected fiscal crisis, has caused many headaches for production and sales people.

We expect to continue getting orders from Mid Europe (France, Germany, Italy and Spain), likely not as many as there might have been without the financial crisis, but how much less will never be known. We do believe that it is important for us to have a solid network, with a local presence in many areas, including local sales offices in more than 40 countries.

The first regions We expect to continue to recover will be those with more getting orders from financial strength, and from our point Mid Europe (France, Germany, Italy and of view, the U.S. is a unique nation, Spain) ... with a unique government and a unique language. In Europe, everything is much more complicated and slow. We assume the U.S. will recover before Europe, but really this is just a guess. We are pushing the U.S. market hard for that reason, and first results have been obtained already.

We need to believe that this difficult period will pass, otherwise it is the end of an era. The question, of course, is, “When?”

Gotex Commercial Manager Daniel Diego Gotex Product Engineer David Ferre

38 | WIRE JOURNAL INTERNATIONAL

now trying to find ways to increase public investment in infrastructure, but as mentioned above, progress is rather slow.

There is not much hope for a revival in the residential and non-residential construction activity either. Overall, the EU outlook for steel consumption in is not bright at all for 2009. Real steel consumption is expected to decline by more than 16 % thanks to the optimistic expectations for the second half the year.

If such optimism fails to prove right, then we shall be prepared to see an even worse decline this year.

Looking at the apparent steel consumption, the situation gets even more dramatic. The apparent consumption is projected to decline by 45.1% in the first quarter, 40.5% in the second quarter and by 22% year-on-year in the third quarter. The overall forecast is for apparent steel consumption for 2009 to drop 28.8% if one uses the optimistic expectations for the second half of the year.

Market demand for wire rod is also at a very low level. Steel mills have cut production significantly, around 50% on average, trying to survive the crisis. There are certain price increases in the market but those have to be taken into consideration as normal and temporary given the abnormal circumstances of short supply and super low inventory levels in the market.

European mills are now trying to fill While the above their order books for early summer presents a bleak months trying to safely reach the hol- picture, we all idays in August. We know that the steel expect the market to industry has operated show some volatiliin down periods ty until then but supply and demand before and survived to remain low. Only them ... after the holidays may we see some slight inventory rebuilding, provided that consumer confidence is restored up to a certain extent by then, and that the banking sector starts showing signs of support in terms of letting private credit. Overall, 2009 is going to be a year to forget for the EU steel industry.

While the above presents a bleak picture, we all know that the steel industry has operated in down periods before and survived them, in particular the ‘80s and the ‘90s. Even though it seems that 2009 is going to be a year to forget, probably from 2010 onwards the steel industry will revive, with the most cost-effective and best-run companies emerging as the big-time winners out of these difficult couple of years.”

SteelOrbis CEO Murat Eryilmaz

FEATURE

Nonferrous view The below information is from Philip Radbourne, principal, Integer Research (www.integer-research.com), a U.K. research and consulting company that covers wire and cable as well as other sectors.

As can be seen by the below chart of cable production, this has not been a good period for wire and cable production in Europe. Actually, I’m afraid you can say that this has been a horrendous period for much of Europe, and while that goes for most of the world, parts of Europe have truly suffered in ways that exceed what we projected as the global fiscal woes began last year.

European cable production has mirrored the economy. Chart courtesy of Integer Research.

Two countries that have been especially hard hit are Ireland and U.K., the former which has seen cable production down anywhere from 50 to 60 percent, partially because it had been doing so well, with its economy growing 7 to 8 percent a year for close to a decade. Year-onyear, the U.K. is down about 35 percent, but it’s just started to turn in rate of decline. As you know, the cable industry lags behind the economy, so the depths that we have seen have further to go and will take longer to recover once the economy takes an upswing and some semblance of business Philip Radbourne normalcy returns.

Year-on-year cable production figures show that Spain is down about 20 percent; France is down only about 12 percent, bolstered by infrastructure efforts and the presence of world leader Nexans; and Germany is down about 11-12 percent, hit harder than most by the decline in the auto industry as auto exports account for about 20 percent of the country’s exports, and that effect feeds back elsewhere.

40 | WIRE JOURNAL INTERNATIONAL

I was shocked by the results for Eastern Europe, where the Ukraine and Baltic states are down 50 percent year-on-year for cable production. This is year-on-year, and last year was good, so it’s very much off the peak. To put that in perspective, North American cable production is only down about 10 percent, but that’s 10 percent from what had been relatively weak numbers.

The decline is similar to that for the telecom/fiber optics market earlier this decade. Poland, whose cable makers had not long ago turned to exporting to the U.K., is now finding that difficult because of the weak pound. U.K. manufacturing is just starting to turn, but the problem is that demand isn’t good.

This is a period of uncertainty for many companies, both large and small. We’ve seen lots of closures, such as Nexans closing its building wire operations in Germany and an operation last year in Ireland. That kind of thing is going on for many companies as they adjust to declining demand. While larger companies have to be good at adjusting their fixed overhead costs, cutting but not cutting out their ability to meet demand when times get better, smaller- and medium-sized companies have to be really nimble. Some companies are especially challenged because they are so large in a given area, such as Leoni, which is a major player in automotive wire.

Companies need to look to adjacent sectors, and that’s hard to do because you’re then competing with companies that are already focused there. Utilization rates has always been a key factor, and those rates have fallen very quickly in Germany although there are signs that the bottom has been reached. It’s down 20 percent so far, and the rate of decline is slowing, but “The above sounds you have to remember that you’re comparing gloomy, but we that figure to a shrink- believe that the ing pie.

European cable indusWe expect conditions to get a bit worse try will grow next in the U.S., and even year, not necessarily for China to see its manufacturing growth in revenues but in rate slow down. What volume. we see is that companies are focused on trying to absorb their situation, where to make cuts. You get to the point where you can’t cut any more shifts, and then your utilization rates get too low and you have to cut more staff, and once the temporary workers are gone it becomes very tough.

The above sounds gloomy, but we believe that the European cable industry will grow next year, not necessarily in revenues but in volume. It will recover, but it will be a slow recovery.

Integer Research Director Philip Radbourne

The following interview with European Central Bank President Jean-Claude Trichet, by Süddeutsche Zeitung’s Helga Einecke and Martin Hesse, has been edited to fit.

SZ: When will the end of the crisis finally be in sight?

Trichet: It’s an ongoing phenomenon. That is why we have to remain constantly alert. In the summer of 2007 we experienced unusual events in the money market and were the first central bank to respond. Since mid-September 2008 we have been in a very serious crisis. The new, globalized financial world that has been created over the last 10 to 15 years is for the first time being put to the test. It is proving to be much more fragile and less resilient than it should be.

SZ: Can this world ever be brought back to health?

Trichet: Yes, certainly. It calls for bold decisions today as well as credible exit strategies to improve confidence of our fellow citizens and of the corporate sector on our capacity to go back to medium-long term sustainable path. This is true for fiscal policies as well as for monetary policies. And we have to implement effectively, efficiently and as rapidly as possible the decisions the decisions taken in the G-20 meetings.

SZ: Who must accept responsibility for this crisis?

Trichet: I don’t see any value in looking for scapegoats. For instance, some may make banks or rating agencies the whipping boys. But to me the entire financial system has proved unsatisfactory. It must be reformed from the bottom up. All parts I don’t see any value and parcels of globin looking for scapeal finance together goats. … to me the have not delivered the stability that citi- entire financial system zens rightly has proved unsatisfacdemand. Thus, significant improvetory. It must be ments must be reformed from the introduced everywhere. We owe this bottom up. to the citizens and to the whole world.

SZ: How great is the political pressure?

Trichet: We are not subject to political interference or shortterm thinking. The EU Treaty is crystal clear on this point and guarantees fully our independence.

e-mail Dave.Evans@george-evans.com

JUNE 2009 | 41

FEATURE

Interview: European Central Bank

FEATURE

SZ: Why did central banks not see the crisis coming?

Trichet: In 2006 and 2007 I said—on behalf of the Governors of Central Banks meeting in Basel—that the quantity of risk and the price of risks were underestimated in global finance. Spreads were very low, risk premia were abnormally meagre and volatility was very modest. This called for a market correction and we asked market participants to prepare for that market correction.

SZ: You forecast the crisis?

Trichet: Not the extent and the depth of this global crisis. But if anyone saw warning signs and voiced them, it was the central banks.

SZ: Have central banks not been able to prevent this crisis?

Trichet: In the past we have made no compromises on our objective of price stability.

From 2003 to 2004 we were publicly urged by the heads of the governments of three large countries to cut rates. We said no. In December 2005, 10 out of 12 governments in the euro area called on us not to raise rates.

We still did it and we have delivered what our democracies and our fellow citizens had asked us to deliver, namely stable prices.

SZ: How can the central banks now help to find a way out of the crisis? Can you do any more than print money?

Trichet: The present circumstances are extraordinary. Central banks and governments must therefore resort to extraordinary measures. To prevent the collapse of the financial system, we have provided the banks with an exceptional framework of liquidity. But citizens can have full confidence that we will guarantee stable prices over the medium and long term. The 329 million citizens of the euro area are very clever. They would not improve their level of confidence and help restart the economy if they had the sentiment that we were forgetting our primary medium term goal.

SZ: Do you think that governments will be able to quickly pay off the debts they are now accumulating?

Trichet: We call upon the governments to do that. We support strongly the European Commission in its task of ensuring the respect of the stability and growth pact in such exceptional circumstances.

SZ: Are fears justified that there will be either a massive reduction in the value of money or tax increases—or both?

Trichet: We are here to preserve the value of the money of our fellow citizens. They can count on us. As regards governments’ fiscal policies they must be designed to incorporate the exit strategies to reassure people that these policies are on a medium term sustainable path.

SZ: Many experts, however, are worried about deflation, i.e., a lasting fall in prices. Are there grounds for such fears?

42 | WIRE JOURNAL INTERNATIONAL

Trichet: We should not confuse disinflation and deflation. At the moment I am speaking, we are experiencing very low inflation and in the months to come negative inflation due to the decrease of the prices of oil, energy and commodities, before it increases again at the end of the year. This is good for the purchasing power of households and is a correction of the high prices of the past. Deflation means steady decrease of all prices and negative inflation expectations. This is not the case today. As you know our definition of price stability is below 2% but close to 2%. And today’s medium term inflation expectations, at 1.9%, are in line with this definition.

SZ: German companies are complaining of a credit crunch. Are they right?

Trichet: Everything that we have done since the beginning of the crisis has been aimed at putting banks in the position to lend money. In the euro area 70% of all financing is via banks. We are doing everything we can so that banks can do their job. In addition, the governments have provided assistance for banks. It is the core function of banks to lend money and we strongly encourage them to do their job.

SZ: Have the banks given you any sign that they are satisfied with your liquidity provision?

Trichet: The banks are in different situations. Some are better off, others are worse off. But they are receiving an enormous amount of support. All the risks and credit that have been taken over by the state amount to almost The banks are in one-quarter of GDP in the euro area. I different situations. would not call for Some are better off, even more aid. The measures launched by others are worse off. governments now But they are receiving have to be implemented as profession- an enormous amount ally and expeditiously of support. as possible.

SZ: Does the euro ensure stability in the financial crisis or are weak countries such as Ireland and Greece proving to be a burden?

Trichet: The euro ensures a very high level of stability. The years 1992/93 demonstrate what would happen in a crisis situation if the euro did not exist. At that time, there was dramatic turbulence in the European exchange rate system. Every member of this community must of course make its own contribution, in particular by keeping government finances in order.

SZ: Wouldn’t it then be a good idea to bring the euro more quickly to the struggling countries in eastern Europe?

Trichet: Participating in the euro area means joining a community and deciding to share a common destiny. No one can

SZ: Wouldn’t it be better to introduce the euro in Eastern Europe than to let those countries go bankrupt?

Trichet: This is not about short-term thinking or to avoid temporarily major difficulties. It is about a commitment for life.

SZ: Can Eastern Europe survive the crisis on its own?

Trichet: Yes, of course, even if the situation is difficult.

Eastern Europe isn’t alone and countries in this region are not all in the same situation. The euro area economy is Eastern Europe’s main customer. Those which need it are receiving help from the European Union, from the IMF and other institutions.

SZ: The crisis will change the world. What role should Europe play in this changed world?

Trichet: “Europe, which as Europe, which as regards trade, regards trade, is sigis significantly nificantly more open more open to the rest of the to the rest of the world than the world than U.S. and U.S. and Japan, Japan, will continue to will continue to play a major play a major role in role in the globthe global economy. al economy. It will participate as actively as possible in making the global economy and global finance as resilient as possible in the future. And it will continue to bring at the global level its own sense of stability and medium term perspective.

The European Central Bank (ECB) is the central bank for Europe's single currency, the euro. Its main task is to maintain the euro's purchasing power and thus price stability in the euro area, which includes 16 European Union countries. For more information on its activities, go to www.ecb.europa.eu. ■

JUNE 2009 | 43

FEATURE

simply adopt the euro because they are having a period of major difficulties. It is an alliance forever. We are open, we started with 11 countries and are now at 16. There are rules and criteria in the Treaty. Our position is “all the criteria of the Treaty, nothing but the criteria of the Treaty.” These rules guarantee that the euro is good for new members and good for old members.

INTERWIRE WRAPUP Sjogren Industries’s Jim Jolda explains two-plane roll straightening as part of the Production Solutions presentations on the show floor.

Print Safe’s James Lienhard discusses system features with Colonial Wire’s Harrish Dalal and Jake Saladino, Jr.

Interwire 2009 reflects harsh times, the industry need to be proactive

By Mark Marselli editor-in-chief If the industry had hoped to find signs of a turnaround at Interwire, it was not to be. While some exhibitors at WAI’s biennial event, co-located with IFE at the I-X Center in Cleveland, reported good activity, for most it proved to be a trying period.

Overall attendance for the trade shows, at 3379, was down 43

percent from 2007. The decline was disappointing but not a surprise as other industry trade shows had reported similar results.

Many companies that usually sent multiple attendees cut those numbers back, but travel bans also dimmed attendance. The sight of wide aisles with relatively few attendees was hard to

From l-r, Executive Panel participants included:Gregory J. Lampert, General Cable North America; Hugo Alberto Gómez Sierra, Grupo Condumex; Jack Carlson, Southwire Company; Richard Carr, Coleman Cable, Inc.; and moderator Philip Radbourne, Integer Research.

44 | WIRE JOURNAL INTERNATIONAL

INTERWIRE WRAPUP The Awards Breakfast included an on-stage gathering of WAI Past Presidents with WAI President Antonio Ayala.

dismiss. At the same time, 930 unique companies—not exhibitors—sent employees to the event, and a short sampling of those attendees shows that many came with specific goals, as reflected in brief interviews presented in this wrapup.

“The level of activity was off, but the industry showed its resilience as suppliers made the most of the opportunity and

As part of the International Buyer Program, government representatives held 50 meetings with exhibitors.

positioned their companies for the recovery,” said WAI President Antonio Ayala. “The amount of business that occurs during the show and as a result of the show, even in a down cycle, would surprise many people. I had the unique opportunity of visiting a cross section of the floor and saw equipment sold, quality visitors getting the royal treatment, and new ideas being explored,

Donnellan Memorial Award winner Anand Bhagwat and Mordical Memorial Award winner Etienne Aernoudt.

JUNE 2009 | 45

INTERWIRE WRAPUP

Attendee view: Southwire Company Ben Paschal, engineering manager for Southwire Company’s Carrollton Utility Products Plant, was a first-time attendee. “I got a huge value out of being at this show,” he said. “I’ve been in the business now for a year and a half, and I’m soaking this up like a sponge. It’s been a great opportunity for me.”

Paschal explained that while his background is in the metals field, he appreciated the ability to meet with the company’s wire and cable industry suppliers and to discuss their products and see what new ideas they had. His division sent fewer representatives but they had done their homework and knew who they

Attendees had questions at the Micro Products booth.

Southwire Company’s Ben Paschal was a first-time Interwire attendee. wanted to contact. He noted that it is quite helpful to speak to people who have decades of industry experience. “I asked a lot of ‘why’ questions,” he said. “I came here with no preconceived ideas. I enjoyed building on existing relationships, as well as investigating new opportunities that I did not have in my original schedule."

such as manufacturing partnerships to reach new markets.”

Attendance numbers were also lower for the technical programs, but the event featured bright spots. One was Tuesday’s executive panel session, which was moderated by Philip Radbourne, Integer Research Inc., and featured four panelists: Greg Lampert, President & CEO, General Cable North America; Hugo Alberto Gómez Sierra, Director del Sector Cables, Grupo Condumex; Richard Carr, Executive Vice President, Coleman Cable Inc.; and Jack Carlson, President Electrical Division, Southwire Company. Fielding questions from moderator Philip Radbourne, Integer Research, the panelists collectively spoke on topics ranging from their outlook for the industry to how they are reacting to the woeful business climate.

“One concern we have is this ‘buy American’ policy, which has started to affect our business in the U.S.,” Gomez said. “This kind of idea is increasing all over, and that includes Mexico too. It’s driven us to take decisions where to produce or what products to make for certain countries.”

“As a company, we have to look at our balance sheet. It’s all about how you manage your inventory, balance sheets and strate-

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Numalliance equipment drew an audience.

Ideal Welding Systems’s Kevin Davis explains welding technique.

Ron Coffey, senior process engineer for the Energy Team at General Cable Corporation, notes that he has been in the industry for over 30 years, and that he looks forward to attending Interwire. The company sent fewer people this year, mostly senior management, engineers and people running large projects, but it sent them with a plan, each going their own direction.

“We split up and go our own ways and later on we share our findings.” Coffey said that it’s always good to rekindle relationships, and that it was a plus to have the time to do so at length.

“When you get together with suppliers and have technical discussions, there’s value, if for no other reason than you can pick their brain in terms of what they will be looking at down the road or talk to them about problems you’re having with equipment. It’s a centralized location that makes it easier to get information.

Occasionally, you’ll find something new, something General Cable’s Ron Coffey. that might fit into your own area of interest or need.”

Asked if he had made any discoveries at Interwire, Coffey said that he did find some technology that was of special interest, a topic that he will report on back to headquarters. “I haven’t really even had a chance to walk the entire show yet,” he said, explaining that he had he visited five booths the previous day, had done two more in the morning and planned to do three more that afternoon.

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INTERWIRE WRAPUP

Attendee view: General Cable

INTERWIRE WRAPUP

Attendee view: Astro Industries Kailash Mehta, president and CEO of Astro Industries, came to Interwire with Cabling Department Supervisor Chris Anshutz, to look at new braiding and cabling equipment as well as auxiliary equipment and new conductor materials.

“We’re a growing company,” Mehta said, noting that his Dayton, Ohio, business, founded in 1967, focuses on the aerospace sector but also does service work, such as cut and strip, cable assembly and distributes other cable products. He said that his company, which has about 40 employees, specializes in small orders with fast deliveries, and that the company’s equip-

Attendees get a hands-on experience with equipment at the Morgan-Koch booth.

Astro Industries’President and CEO Kailash Mehta, and Cabling Department Supervisor Chris Anshutz came to Interwire with a specific shopping list. ment, while dependable, needs to be upgraded to better serve its customer base.

“We met with 20 suppliers and we knew where we were going,” Mehta said. He used the Show Program as a guide but was already familiar with most of the potential suppliers he saw.

Anshutz, he said, has years of experience in the field and was able to spend time with exhibitors to pinpoint the technology they were looking for.

“We wanted to talk about braiding and taping machinery and we asked people what they could do to reduce our production costs,” Mehta said.

Mehta explained that one reason Interwire was practical is that he was open to different directions in terms of technology.

“We are open to new and used machinery. We also visited FSPONE, Leoni Wire and AEB International to discuss the availability of new generation conductors. We found quite a few things of interest to us and while we haven't made any purchases yet, there is a good chance we will. I learned a lot about the availability of the equipment and the materials to expand our business. I also got a few new ideas as to the areas we should expand into as a result of the show. We will attend Interwire in 2011.”

48 | WIRE JOURNAL INTERNATIONAL

gy,” Lampert said. “We hope the U.S. stimulus package will have an impact, but we have not seen the impact yet. 2010-11 is more likely. It takes time for things to work through. We hope that spending is in the right places, such as infrastructure and energy.”

“It wasn’t too many months ago that there wasn’t enough capacity,” Carr said. “Now, we have plenty of equipment and

Representing P/A Industries, first-time Interwire exhibitors, were l-r, Edward Morris, Tim Qualls, Don Frank and Tim Malarky.

INTERWIRE WRAPUP

Attendee view: BD Medical BD Medical GPDS Project Engineer Thomas Griffith attended Interwire with a colleague from division headquarters to explore new cleaning and lube technologies for the BD facility located in Nebraska, which employs about 900 people.

The New Jersey-based company, a leading global medical technology company, develops, manufactures and sells medical devices, instrument systems and reagents together with needles

not enough demand. In times like these, companies tend to get conservative, and that’s both good and bad. When times are good, we don’t pay attention to details as much as we should. …

I see a lot of equipment guys here today. Most of us do not need additional capacity but we do need equipment, parts and methods that reduces our material and operating costs while improving efficiencies. With our high fixed costs these low demands put a great deal of pressure on our bottom line. Those who survive these very difficult times will be well positioned as the economy, and demand, improves.”

“Someone once put it this way, and I have to agree, technology will change and companies will need to become a broader systems provider as customers will want value beyond quality and service,” Carlson said. “There are three things you can offer. The first is time, which I see as a clock. How can you make your customers more efficient? The second is save them costs, which I see as dollars. The third thing is to give them a happy face, and the way you give them that is by giving them the first two things so they want to do (business) with you all over again.”

Adjusting to the needs for current business and preparing for the future was also the focus of keynote speaker Cheryl Jones, vice president, Toyota Manufacturing Kentucky, Inc. Jones said that while times are tough for the auto industry,

BD Medical’s Thomas Griffith, another first-time attendee. from stainless steel strip for customers that include major hospitals. A first-time visitor, Griffith said that he decided to attend Interwire after he learned about it from a colleague who forwarded him an e-mail about it. “We wanted to learn about new technology and reinforce what we’re doing right,” he explained, noting that they were interested in lubricants and cleaning fluids.

He said that he and his co-worker had a list of approximately 20 vendors to visit, and that they ran across some suppliers at the show that they had not known about.

As a result of those visits, Griffith said that his company is “more than likely” to make some purchases. He said that they also discovered a few ideas at the show that might be useful for other applications in their facility. The Show Program was quite helpful in pinpointing the booths to stop by, he said, citing a Huestis air wipe they saw as one item he found that was of special interest. “It may be well known to you in the wire industry, but not to us,” he said. He also saw some induction annealing technology that was of interest and found time to sit it on several technical paper presentations.

“There was value in our trip,” Griffith said. “I'm not sure if we will attend the next Interwire, but I will recommend that we do, and if we’re given the okay, we will definitely be more aware of what to expect.”

50 | WIRE JOURNAL INTERNATIONAL

WAI President Antonio Ayala and keynote speaker Cheryl Jones, vice president, Toyota Manufacturing Kentucky, Inc. there are reasons to believe it will get better. She pointed out that more cars are being scrapped than sold, and that many new car purchases have been deferred. What Toyota has done is focus on being up front with its employees in terms of letting them understand the situation, and finding ways to save jobs. The goal is to make efforts to find ways to improve operations by working with employees to create “a workforce that remains involved.”

Applying a Kaizen approach is important, but finding practical ways to make a difference is also highly encouraged, Jones said.

She cited the value of even small, simple changes, such as adapting an electrode with a threaded end so it can be replaced cheaper and quicker or using a simple “grabber” tool from

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INTERWIRE WRAPUP

Attendee view: W.L. Gore & Associates Ed Kozlowski, a senior design engineer at W.L. Gore & Associates, came to Interwire with co-workers Steve Gibson, mechanical design engineer and Steve Brinkley, electrical/controls engineer, with specific goals. He had been to Interwire, but not in awhile, and he was looking for technology that could help one of the company’s products, miniature coax cable, 24-50 gauge.

Anand Bhagwat, r, discusses the status of WAI’s India subsidiary during the WAI Board of Directors meeting.

Lowe’s to make it easier for employees to install an antenna on a car roof. “Ideas like that add up,” she said. Beyond those measures, Toyota, which has continued to focus on new technology, is taking advantage of the slower times to bolster training efforts so that it will emerge from this period as a stronger company, she said. Her conclusion, which applies across industry lines, was simple: listen to what customers want and provide them a quality product.

Making the U.S. government your partner W.L. Gore’s Ed Kozlowski, Steve Gibson and Steve Brinkley.

Kozlowski said that he and his colleagues from the Pennsylvania company visited specific suppliers. They found interesting technology at the Wardwell and Kinrei booths, enough that the company may be interested in making purchases. “We’re still looking at what else is here,” he said on the show’s second day.

Beyond the opportunity to see new technology, Kozlowski said he appreciated the chance to have a closer relationship with suppliers. “Even though the show was sparsely attended, we found some value.” he said. “As always, having all or most of the vendors in one location for a face-to-face has always had unmeasured value and still does, especially when times are tougher for travel and the like. I knew before going in that this was going to be the case, which made it much easier to justify.

Our company believes in the future of the business and that means get out there and find out what is going to take us into the new future markets. I’ve already recommended that we return in 2011.”

At its website, W.L. Gore, notes that the company, one of the 200 largest privately held U.S. companies, has been granted more than 2,000 patents worldwide in a wide range of fields, including electronics, medical devices and polymer processing.

52 | WIRE JOURNAL INTERNATIONAL

Interwire 2009 saw WAI’s first-ever participation in the U.S. Commerce Department’s International Buyer Program (IBP).

Ideally, the program was meant to bring qualified international buyers to Interwire, but that element waned with the global economy. Where the program excelled was at the face-to-face meetings that were held during Interwire, both at the IBP Business Center and at the booths of U.S. exhibitors who had signed up for one-on-one meetings where they could find out how the government could help them export or export better.

Some 50 such meetings took place, reports Graylin Presbury, who headed the Commerce Department’s efforts for Interwire.

One participating company, Fushi Copperweld, found the meeting of value to its business development planning. Anthony Hale, senior account manager, and Lawrence Webb, global marketing director, explained that Copperweld’s acquisition last year

by Fushi International (China) led to capital developments, an expanded product line and a platform from which to broaden the company’s global reach. Webb said that the DOC does provide useful intelligence and research as well as introduce companies to potential agents and partners in targeted countries. Hale noted that while Fushi Copperweld has shipped to Russia and India in the past, they found the process to be very challenging. “It can be a nightmare,” he said, adding that the IBP reps said they have specialists in these locations to assist with practical solutions. He added that it was good to see tax dollars being used to support U.S. businesses.

Another exhibitor also described the meetings as being worthwhile. “I met with three groups: small business, Commerce and the import-export bank,” said Richard Medoff, Ace Metal, Inc.

AlcoTec Wire Corporation, a producer of aluminum welding wire with about 120 employees, sent three employees: Doug Fink, associate plant engineer for AlcoTec Wire Corporation, who was making his second trip to the I-X Center for Interwire, and Maintenance Supervisor Mike Garvon and Quality Manager Chuck Carter, both there for the first time.

Fushi Copperweld’s Anthony Hale, l, and Ace Metal’s Richard Medoff both reported good experiences with the IBP. “Each came by my booth and gave me information on their resources. They may even be able to help me save money if I exhibit at wire Dusseldorf and possibly even provide me a translator there,” he said. “That’s absolutely of value.” He said the export bank discussion “opened up a new business platform for me” and that he plans to continue the discussions after the show.

One other program element that continues to be especially well received is the Production Solutions presentations that are held at booths on the show floor. The presentations are designed to be basic, but in several cases discussions continued long afterwards, a good sign for any program. Participating companies included Horace Pops Consulting, Inc., Ideal Welding Systems, From l-r, AlcoTec Wire’Corporation’s Mike Garvon, Chuck Carter and Doug Fink.. The men were there to meet with existing suppliers and look into other items, such as in-line laser inspection technology and wire straighteners.

Wire Lab’s Rob Fulop explains the finer points of mechanical descaling during his Production Solutions presentation.

Sjogren Industries, Wire Lab Company, Aztech Lubricants LLC and Paramount Die Co., Inc. During his comments at the Awards Breakfast, Ayala stressed the need to remain resilient in harsh times and to focus on the future. “This morning is our chance to celebrate the strength of our industry, and while the global economics has certainly impacted the wire and cable business, I can assure you that better times are ahead. The banking industry is getting their house in order, and as credit returns, business will also. We hope that the price of the gallon of gas, a pound of copper and a ton of

“The show was a good experience, and this time I knew what to expect and was better prepared,” Fink said. “There were a lot of suppliers there we use from other countries, such as Italy and the U.K., that we had a chance to talk to. Some of these were people we had just dealt with by e-mails, so it was good to have a face to associate the names with.”

Fink said that he and his colleagues met with four primary suppliers and that he returned alone the next day to go into even more detail. In addition to the equipment, they looked at in-line laser inspection technology and wire straighteners. The company may make further purchases based on the results, he said. He added that he especially liked the two show floor presentations for die technology at the Paramount Die booth and the one on wire straightening at the Sjogren Industries booth.

“Our company is monitoring expenditures closely, but when I came the first time two years ago I came back with a lot of ideas, and we made some purchases that helped us. We felt that it was worth being here again, and I plan to recommend we return for the next show,” Fink said.

JUNE 2009 | 53

INTERWIRE WRAPUP

Attendee view: AlcoTec Wire

INTERWIRE WRAPUP

Attendee view: American Wire & Cable American Wire & Cable, which had the home field advantage for Interwire as it is a short drive from the I-X Center, sent a total of eight of its 50 employees. Mark McClain, one of six McClains to attend from the family cable business, said that the company would have gone even if the show had been elsewhere, although likely with fewer people.

Attendees from Mexico’s Viakable included Jose Zamudio and Patricio Murga.

American Wire & Cable’s Mark McClain, one of six McClains who attended Interwire, said that the venue provided a good meeting place.

“We attended Interwire for several reasons,” McClain said.

“The first was to follow up with several companies on their trial equipment we had been testing throughout the past year. The second was to keep our eyes open for any new equipment and processes that would help us operate more efficiently. Lastly, we used the event as a unique opportunity to associate with such a large spectrum of people involved in the industry. This helped us to gain greater knowledge of what others are seeing within the industry as well as picking up tips on how to shore up our operation.”

McClain said that AWC met some exhibitors at their company while other meetings were held at the show floor. They also visited a few other exhibitors. “There are always a few suppliers we don’t know who will catch our eye. They might be new that year, have a new product we haven’t seen, or we’ve just managed to overlook them at past shows.”

From those meetings, McClain said that “we are going to take a closer look at a few things we saw. Due to the economic climate we aren’t in as much of a hurry to buy new equipment.

However, if we find that we can justify the investment on some items, there is a good possibility that we will purchase something.” He noted that the company came across one item of interest “that was something that we had never seen before but are now interested in.”

Overall, McClain said that AWC “definitely found value in attending the show. We walked away with some ideas that we will be trying to implement into our manufacturing process, as well as some equipment to consider in the future.”

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steel come to the normal price soon. The truth is that the global nature of business, combined with the mature stature of the wire and cable sector, has created a constant state of stress on our industry, regardless of the overall economy. Thanks to our doctors, stress has a negative meaning. But, on a business level, I can see stress as a motivator for innovation. Good and sometimes great accomplishments are born during the most challenging of periods.”

The theme of the need for innovation was central at the behind-the-scenes meeting of WAI’s Board of Directors. The times are extraordinary and so was the discussion, which centered on how the WAI can better work with both manufacturers and suppliers to find ways to make Interwire, which will once again be held in Atlanta, a success in 2011. The message at the meeting was clear: every effort must be made to ensure that companies see value in sending representatives. See the editorial on p. 4 for more details.

Awards, networking and the American pastime The exhibits and technical programs are the key draws for Interwire, but the WAI also held its 79th Annual Convention during the awards ceremony. This year’s meeting saw the presentation of a special President’s Award by Ayala to ACIMAF President Ferruccio Bellina, a longtime WAI supporter (see WAI News, p. 28).

At the Awards breakfast, the WAI bestowed its highest honors on Etienne Aernoudt, Catholic University of Lueuven, Belgium, and Anand Bhagwat, WAI Wire and Cable Services, Pvt. Ltd., Pune, India, winners of WAI’s Mordica Memorial Award and Donnellan Memorial Award, respectively. At his presentation later that morning, Aernoudt quipped that his Mordica Lecture “Drawing induced structural and mechanical anistrophy,” should have been entitled, “Memories of a wire freak.” It will be presented later this year in WJI. Winners for the best technical papers in 2008 presented at

INTERWIRE WRAPUP Etienne Aernoudt presents his Mordica Lecture.

The focus of Michael Zelin’s workshop was Innovation in Wire.

WAI’s ITC in Monterrey, Mexico, and at Wire Expo 2008 in Pittsburgh, included the following: Ferrous Division: The Allan B. Dove Memorial Medal Award went to José M. Atienza Riera, Jesús Ruiz Hervías and Manuel Elices Calafat, Madrid Polytechnic University, Spain. The Silver Certificate Award in the Ferrous Division went toYea-Yang Su, Amorphous Oxide Technologies, Inc., USA, Robert M. Shemenski, RMS Consulting, Inc., USA, and Rosario A. Gerhardt, Georgia Institute of Technology, USA.

Nonferrous Division: The Marshall V.Yokelson Memorial Medal Award went to Horace Pops, Horace Pops Consulting, Inc., USA, and Gil Baker, Confident Instruments, USA. The Silver Certificate Award in the Nonferrous Division went to Jesus O. González and José L. Cavazos, Universidad Autónoma de Nuevo León, Mexico, and Sergio A. Montes and J. Angelica Ramos, Viakable-Conductores Monterrey, SA, Mexico.

Electrical Division: The Urbain J.H. Malo Memorial Medal Award went to Sergio Castañeda and Octavio Parra, Centro de

Call Cemanco for

Drawing Cones and Capstans (by Ceramtec)

Parts available for all OEM equipment SYNCRO parts in stock 951 N.W. 31st Avenue • Pompano Beach, FL 33069 Phone: 954/970-3099 • Fax: 954/970-3056 e-mail: sales@cemanco.com Web page: cemanco.com

JUNE 2009 | 55

INTERWIRE WRAPUP Among the award winners honored at Interwire were, l-r, Kazunari Yoshida, José M. Atienza Riera, Robert Shemenski, Horace Pops and Gil Baker.

Year-in, year-out, the WAI’s Opening Reception proves to be a wonderful meeting place for the industry.

Investigación y Desarrollo Condumex, Mexico; and Eduardo Ramírez and Saúl Sánchez, Centro de Investigación en Química Aplicada, Condumex, Mexico. The Silver Certificate Award in the Electrical Division went to Sergio A. Montes, ViakableConductores Monterrey, SA, Mexico, and Carlos Alejo, Universidad Autónoma de Nuevo León, Mexico.

In the General Division, the Horace Pops Medal Award went to Kazunari Yoshida and Tsuyoshi Sugiyama, Tokai University, Japan. No Silver Certificate Award was given in the General Division.

Also honored at the Awards Ceremony were WAI’s new Life and 25-Year Members. A different program element was Ayala’s gathering on stage of all the past WAI presidents who were at the ceremony.

The WAI’s Opening Reception continued to be a good social event, with some 950 attendees enjoying the industry gathering.

The WAI’s baseball outing on Wednesday night drew some 300 participants, who saw Cleveland fall to the Boston Red Sox, an

outcome much appreciated by the many Red Sox fans in attendance. A more moving event was the fifth holding of WAI’s Industry Run, which was won by Alex Boekholt, Leoni Wire, who ran the 5K course in very respectable time of 19 minutes and 13 seconds. A total of 20 runners took part in the charity event, which was sponsored for the third year in a row by Leoni Wire, with all proceeds going to the American Cancer Society.

Co-located for the second time with IFE, organized by The International Fastener Machinery & Suppliers Association (IFMSA), Interwire was supported by the American Wire Producers Association (AWPA), The Society of Plastics Engineers (SPE) and the Steel Wire Manufacturers Association of India (SWMAI).

In 2010, WAI will stage Wire Expo on May 11-12 in Milwaukee, Wisconsin, co-located with The National Electrical Processing Technology Expo. In 2011, Interwire returns to the Georgia World Congress Center in Atlanta, Georgia.

Many Interwire attendees, also Boston Red Sox fans, got to smile later when the Sox rallied to beat the Cleveland Indians.

Runners line up for WAI’s 5th Annual 5K Industry Run, which was won by Leoni Wire’s Alex Boekholt, sixth from the left.

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Despite low attendance, some IFE exhibitors report leaving with high-quality sales leads Yes, you could safely roll a bowling ball down the aisles of the recently concluded IFE show in Cleveland, without significant risk of injury to the relatively few hardy souls who took time away from the worries of the current economic slump to attend the four-day event.

Attendance was off dramatically from IFE 07, which was also held at the I-X Center in Cleveland, co-located with Interwire. There were 57 exhibitors, down from the more than a hundred exhibitors in 2007.

“We’re not going to sugar coat this,” said Ray Zirkle, executive director of the International Fastener Machinery & Suppliers’ Association (IFMSA), which organizes and sponsors the event. “Quite frankly, we were completely surprised if not dumbfounded by the poor turnout. We knew we were operating within a tough economy, and in spite of exhibit sales being off substantially, we did more...and spent more...on our attendance promotion efforts this year than we did for our successful event in 2007. We finalized our attendee push with a first-class mailing to more than 3,500 key fastener manufacturing titles...all within driving distance of the show.”

“Considering the nature of our equipment, we need to present and demonstrate our machinery to the customer in a face-to-face setting,” IFMSA Chairman Ray Sullivan said. “This show was in many respects a reflection of the current state of affairs in the automotive industry—the largest segment of the fastener market. It’s dead out there and the show reflected the reality of current market conditions.” He noted that his company, Cinco Industries, did sell a large machine to a company in the aerospace sector.

Observed Jim Flanagan, Reed Machinery Company, Inc., “Sometimes you exhibit at a show brimming with attendees, yet when you review your leads, you may only have a handful with real potential. Sure attendance at IFE was disappointing, but, in reality, we came away with a number of quality leads, which, if they work out, will make our exhibit experience more than worthwhile.”

Jim Kasper, Plan-E-Tech, Inc., agreed. “We did end up with a handful of very good leads. If one or two pan out, the show will have been a success. I think that the show was a microcosm of the economy in general. Some business was taking place, but at a much scaled down state.”

Bob Munn and Susan Williams, B.M. Rebuilders, Inc., said they met some 50 customers. “We could never have met with all those people if traveling in a 3-5 day period.

So, in effect, we believe the show was definitely worthwhile. We made a couple of new contacts, and we will see what happens with those in the near future. We will be ready for the next show in two years, and by then we

Discussions go on at the Cinco Industries booth at IFE 2009.

anticipate that things will be on the mend.”

Several exhibitors sold equipment off the show floor, including Taiwan’s Jern Yao Enterprises Co., Ltd. It sold a five-station nut former to Airfasco Industries, whose president, Dennis Dent used a bottle of champagne to christen the system. “Sure, these are tough times,” said Dent, “but it’s times like these that companies need to make the necessary investment to make themselves more competitive when the recovery kicks in.”

Other exhibitors were clearly frustrated. Riccardo D’Ambrosio, ORT Italia SpA, attributed the “very disappointing” turnout to the global recession, while John Walters, Scientific Forming Technologies, simply dismissed the show as “a disaster.” Craig Benjamin, president of Intera Systems, Inc., was also disappointed, but added, “In this economy, we’re lucky that anyone came to the show.” Added Kasper, “Trade shows are considered by many to be a luxury item and many of those who wanted to attend were simply told...not this year.”

The IFE Conference Program, which featured a keynote address on steel pricing, and seminars on fastener testing, ultrasonic cleaning, fastener manufacturing software, aerospace fasteners and the worldwide fastener market, was also poorly attended in spite of no-cost admission and extensive pre-event publicity. “The conference sessions offered a great deal of information,” said IFE Sales Director Doug Zirkle. “It’s a shame more fastener professionals did not take advantage of this program.”

IFE is the only industry event with an exclusive focus on the manufacture of fasteners, fastening systems and precision formed parts. The date and venue for IFE 2011 will be announced shortly. For more details, contact Ray Zirkle at tel. 203-794-0444, rzirkle@bzsales.com.

This report was provided by IFE/IFMSA.

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IFE 2009: bowling balls and sales

D

Estimation of thermal diffusivity of crosslinkable cable insulations

LV E R ATE C I F I T CER AWA R

SI

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This study focuses on why crosslinkable wire and cable insulations based on the same polymer system can have substanially different thermal diffusivity values.

By Sergio A. Montes and Carlos A. Alejo

In the wire and cable industry there is a need to determine thermal transport properties of cable materials to accurately calculate heat flows in insulated cables. One such calculation involves transient heat dissipation when the cable is in operation, while other applications involve heat transfer processes during the manufacturing stages. Of particular importance are continuous vulcanization numerical simulations, which require reliable material data to accurately calculate heating and cooling phenomena when

an insulated cable travels within a vulcanizing tube and undergoes heating, curing and cooling. For transient simulations, it is preferable to experimentally determine thermal diffusivity as opposed to calculate it based on heat capacity, density and thermal conductivity data. While thermal transport properties depend on temperature, heat flow calculations of cables during manufacturing or insulated conductors already installed and operating, they usually involve a single thermal conductivity or diffusivity value.

Fig. 2. Effect of platten temperature on transient response of sample C. Fig. 1. Midplane temperatures for CPE compounds.

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TECHNICAL PAPERS Table 1. Characteristics of test materials.

The thermal diffusivity data of cable insulating materials available in the literature is incomplete and generic in character. For medium voltage EPR and XLPE insulations, thermal diffusivity as a function of temperature can be calculated from heat capacity, density and thermal conductivity data1. However, in a typical cable factory today there are many compounds based on the same polymer. For instance, insulations and jackets can be unfilled, lightly filled or heavily filled using various types of mineral or organic fillers and the same polymer. Recalling that fillers increase the thermal diffusivity of polymers, one would expect to find substantial differences in heat transfer behavior among materials having such a wide range of particulate content. Therefore, there is a need to determine accurate thermal diffusivity data of similar compounds in order to explain their differences in heat transfer properties observed in practice. Although it would be desirable to determine the temperature dependence of thermal diffusivity, an accurate temperature-averaged value would be quite useful for heat flow calculations provided that it is determined from a specific compound, as opposed to a generic insulation, and that the testing temperature range is the same as the one observed in use.

Various methods exist in the literature to measure ther-

mal transport properties of solid materials. These include laser-based techniques, guarded hot plate and comparative methods, among others. Some of these procedures are based on steady state measurements while others use transient temperature data. Depending upon the experimental method involved, in some cases thermal conductivity and diffusivity can be determined simultaneously. There is abundant literature on this topic2-8. Many of these techniques involve the use of time-consuming, sophisticated or expensive pieces of equipment. Beatty et. al.4 developed a very simple experimental technique to determine thermal diffusivity of solid materials involving heating a slab containing thermocouples located at the midplane of a rubber slab heated by a laboratory press. This work was followed by other researchers9-15.

The objective of this work is to describe a simple procedure to determine a temperature-averaged thermal diffusivity of crosslinkable cable insulations. Data of typical vulcanizable compounds used in the cable industry are provided for a number of polymer systems. Elastomeric, semicrystalline and crystalline insulating materials are treated accordingly.

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Experiments Materials. Table 1 shows 11 uncured compounds that were used in this study. They are typical crosslinkable compounds used in the wire and cable industry in various types of insulated conductors, from low- to medium-voltage, either as insulations or jackets. Some materials are commercially available, whereas the rest are proprietary. The range of materials investigated covers crosslinkable polyethylene (XLPE), various polyethylene copolymers (XLPO), ethylene-propylene rubber (EPR), chlorosulphonated polyethylene (CSM) and chlorinated polyethylene (CPE). Except for Sample XLPE K, which is semicrystalline, the rest of the samples are amorphous or have low levels of crystallinity, as indicated by their heats of fusion. All materials contain organic peroxides as crosslinking agents that decompose above 130°C. For some materials the heat of curing was determined finding that it is rather small in comparison with latent or fusion heats. For instance, for XLPE K the heat of curing is about 7.6 J/g, an order of magnitude lower that its heat of fusion.

Crosslinking properties, such as scorch time and time-to90% cure, were determined using standard curometer procedures.

Measurements. Square slabs (100 mm wide, 6 mm thick) were prepared in a hot press by molding at 100°C for 15 minutes, except for sample K, for which the temperature was set at 120°C. Previous trials with these materials had indicated that negligible crosslinking occurred under these conditions. In a second step, two of these slabs were stacked and molded together at the same time at the previously cited temperatures. A thermocouple wire was carefully placed between the slabs at the geometrical center. In this manner, the thermocouple was located at half the thickness of the final slab and located well away from the slab edges.

The heat conduction experiments were carried out by

measuring the slab center temperature profile after a step change in temperature is suddenly applied. The thermocouple wire was connected to a high-precision digital thermometer and the initial temperature (To) was recorded.

Both platens of the laboratory hot press were set to the test temperature (Tp) and positioned 25 mm apart. The slab was then positioned in the center of the hot press and the platens were very quickly closed until a preset thickness was reached. This process only took a few seconds. Midplane temperatures T(0,t) were then recorded every 15-30 seconds until a steady state was reached, typically within 10-20 minutes. Reproducibility of the test runs was considered satisfactory since the standard deviation of triplicate runs was about 5 % of the mean. All the materials considered in this study have a curing time of about 6-12 minutes, as shown in Table 1, which means that under these test conditions the thermal response is the result of heat conduction and complete curing. The effect of temperature was studied by repeating these experiments at various platen temperatures.

Results Amorphous materials. Fig. 1 exhibits the midplane temperature T(0,t) profiles obtained from the CPE compounds, which according to Table 1, differ among themselves primarily in filler content, as indicated by the density values.

The curve shapes are similar. It is apparent that at equal times the compounds reach substantially different temperatures, an indication of thermal diffusivity differences.

Curing in these samples occurs from about 130°C until a steady state is reached. However there is no indication that the shape of the curve is affected by the exothermic nature of peroxide crosslinking. The effect of varying the platen temperature is shown in Fig. 2, where it can be observed that the curve shape remains about the same when the platen temperature is varied. Also, the steady state is reached

Table 3. Reported values of thermal diffussivity of selected compounds at 100°C.

Table 2. Thermal diffusivity results.

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Fig. 3. Midplane temperatures for semicrystalline compounds.

crystalline material with a melting point around 115°C, its behavior suggests that there is a heat of melting effect in this portion of the curve. This will be discussed in more detail further on.

Discussion Analytical treatment. Heat conduction in solids is determined by Fourier’s law, which in one-dimensional form in Cartesian coordinates can be written as: Eq. (1) where α is the thermal diffusivity, defined as k/ρCp, k is the thermal conductivity, ρ the density and Cp the heat capacity. It is assumed that α is independent of temperature.

Consider the case of a solid plate of thickness 2H and infinite lengths in the other two directions and initially having a constant temperature To. At time zero, both surfaces of the plate are placed at a constant temperature Tp. Due to symmetry considerations, the origin of the coordinate system can be located at the plate axis, giving the following boundary conditions: t < 0 T(x,t) = To

Eq. (2)

t > 0 T(H,t) =T(-H,t) = Tp

Eq. (3)

An analytical solution for the temperature at the plate axis as a function of time T(0,t) is well known and can be found in the literature and can be written as:

Fig. 4. Transient responses of amorphous, semicrystalline and crystalline compounds.

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roughly at about the same time.

Semi-crystalline materials. Samples E through J are compounds based on copolymers of ethylene and therefore contain some degree of crystallinity as indicated by the data shown in Table 1. The midplane temperature profiles are shown in Fig. 3, where for the sake of clarity some sample curves have been omitted. As it was observed in the case of amorphous materials, the temperature response is the characteristic sigmoidal shape. No measureable differences can be observed resulting from the obvious variations in crystallinity among the samples. This is probably a result of the low level of crystallinity of these materials, and perhaps due to the low melting points, which should be below 100°C. Also, there is no indication that the effects of the exothermic behavior of peroxide crosslinking affect these temperature profiles. The steady state of all samples is reached in about the same time. The same observations can be made on the semi-crystalline samples G, H and I, not shown in Fig. 3.

Crystalline materials. Sample K is a crosslinkable unfilled low-density polyethylene which, according to Table 1, has a high crystallinity level as indicated by its relatively high value of heat of fusion. Its thermal response to the step change is shown in Fig. 4, where for comparison an amorphous material (Sample C) and a semi-crystalline material (Sample E) are also shown. It is observed that Sample K shows a markedly different behavior, with its temperature growing almost linearly in the range of 100°C to 140°C, instead of the s-shaped response exhibited by the other two samples. It would appear that at this temperature range, its response is slower than that suggested by the initial and final portion of the curve, indicating a delay in temperature response. Recalling that this sample is a semi-

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Eq. (4)

where Fo = αt/H2 is the Fourier number.

Eq. (4) indicates that in this case the temperature response depends only on time and α. In this treatment the effects of melting or crosslinking are not considered.

A fit of T(0,t) data using a constant value of α was carried out by taking five terms of the series. The results are shown in Fig. 5, where an excellent agreement is observed for sample C (amorphous) and Sample E (semi-crystalline) but not for Sample K. Clearly, for amorphous or low-crystallinity materials, a constant diffusivity value satisfactorily describes the heat conduction response over this temperature range, except for the XLPE Sample K, which shows a marked deviation in the middle of the temperature range.

This behavior will be studied in more detail later in this work.

This procedure was repeated for the rest of materials considered in this study, obtaining very good fits in all cases.

The α values thus obtained are shown in Table 2 and vary from 0.91 to 2.28 x 107 m2/s, a factor of 2.5. These values are comparable with those reported in the literature for similar rubber compounds, as shown in Table 3. The agreement is particularly satisfactory in the case of the medium-volt-

Fig. 5. Comparison between experimental data and fit from Eq. 4 for amorphous, semi-crystalline and crystalline materials.

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age EPR insulation (Sample E), whose diffusivity value, calculated from reported data1, 1.23 x 107 m2/s , is almost identical to the 1.21 x 107 m2/s obtained in this work.

Although the cable materials used in this work have different formulations, it was found that thermal diffusivity correlates reasonably well with density for materials based on the same polymer or similar copolymers. This is the case of CPE samples A, B and C and the group of olefin copolymers (samples E through H), as shown in Fig. 6. Thermal diffusivity increases nearly in a linear fashion with density.

However, sample J shows a much higher thermal diffusivity, probably due to its very high filler content. Therefore, it is confirmed that for wire and cable insulations in crosslinking conditions the effect of fillers is to increase α, as reported previously in the literature8.

The effect of melting This section studies the case of crystalline materials, in particular the temperature response of XLPE K (Figs. 4 and 5). It is clear from Fig. 5 that, unlike amorphous or semicristalline cable insulation materials, a single temperatureaverage thermal diffusivity value cannot explain the observed response. The authors here attempt to explain this behavior. The aim is to separate the melting and diffusivity effects to eventually extract meaningful data from the midplane temperature profiles of crystalline materials of the XLPE K type, as was the case for the rest of the cable materials.

DSC runs show that this material has an average melting point (Tm) of about 115°C, an enthalpy of fusion (ΔH) of 82.9 J/g and a heat of vulcanization of 7.6 J/g. Compared to

Fig. 6. Thermal diffusivity-density relationship for CPE and PE copolymer samples.

or solidification problems. Kamal and Lafleur18 performed one-dimensional cooling experiments on a molten, highdensity polyethylene plate containing a thermocouple at the center of the midplane position. At the beginning of the experiment the melt temperature falls rapidly and then reaches a plateau around Tm to continue decreasing in a monotonic fashion. This is to be compared with the behavior shown in Fig. 4 for XLPE K where there is a nearly double sigmoidal curve, showing that around Tm the rate of increase decreases substantially to eventually increase again.

Heat conduction in solids that show a phase change leads to moving boundary problems that are more difficult to solve by analytical methods. Following various authors16,19, this problem was tackled using two approaches: Model 1. Finite difference scheme. This model uses an explicit finite difference numerical formulation where, in addition to heat conduction, the effect of melting is considered. Initially, the temperature of a solid element is computed until it reaches Tm. Then, for a given time lapse, the net heat input into that element is calculated by using a temperature-dependent thermal conductivity1, which melts a fraction of the element while the temperature of the molten element fraction remains at Tm. This process continues until the entire element is molten. When this happens the temperature of the node is allowed to increase, as in traditional finite difference methods. The melting front then advances inwards to the next available element. At appropriate time intervals, the temperature profile and the

Fig. 7(a). Comparison of experimental data from XLPE K and calculated responses from Eq. 4 and Model 1. Thick line represents the position of interfase.

Fig. 7(b). Comparison of experimental data from XLPE K and calculated responses from Eq. 4 and Model 2.

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the rest of the materials studied, it is highly crystalline.

Values of its thermal conductivity, heat capacity and thermal expansion as functions of temperature have been reported1.

In developing a model for crystalline materials, the authors consider the case of a heated slab made of a solid having a melting temperature Tm and enthalpy of fusion Î&#x201D;H. Since Tp > Tm when the experiment begins, the solidmelt interface is initially located at the slab edge and then progressively moves inward. Since both platens are maintained at Tp, there would be two interfaces moving in opposite directions until the material contained between them reaches the melting temperature. Once all the material is molten, there is only one phase and heat flow proceeds as described earlier for elastomeric or semi-crystalline materials.

The behavior of moving interfaces as a result of heat transfer within solids having a heat of fusion is known as the Stefan-Neumann problem, and has been well documented in the literature16. Therefore it is assumed that sample K would behave like a crystalline solid such that, once the effect of melting is accounted for, the entire temperature profile can be used to obtain an estimate of the temperature-averaged thermal diffusivity in the simplest possible manner, requiring the minimum amount of additional material property data.

Inward and outward heat flows in crystalline solids having a one dimensional rectangular geometry have been studied by various authors17,18 in connection with melting

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interface position are recorded.

The rate of melting is given by:

Eq. (5)

where Xs is the interface position. The density ρ, the melt thermal conductivity kl, and the solid thermal conductivity ks are functions of temperature, taken from reference 1.

Both temperature gradients are evaluated at the interfase.

Model 2. Temperature-dependent heat capacity. In this formulation, a conventional finite difference scheme is used except that thermal diffusivity is expressed as β/Cp(T) where β is a curve-fitting parameter equivalent to temperature independent k/r and Cp(T) is the temperaturedependent heat capacity whose temperature range includes melting, as reported1.

Results are shown in Fig. 7, where T(0,t) data for XLPE K is compared to theoretical predictions from models 1 and 2. It can be noted that in both cases the model correctly describes a temperature response with a rate of change that decreases when the temperature approaches Tm , showing a nearly double sigmoidal behavior, while at the same time provides a temperature-average thermal diffusivity value.

The inflection point appears to be located near Tm. At about 130-140°C the effect of melting disappears and the temperature increases monotonically again as observed previously in this work. The temperature profile obtained by assuming a constant value of α and neglecting melting effects is shown as reference as a dotted line. This is the finite difference equivalent of the Eq. 4 prediction, previously shown in Fig. 5. It is apparent that there is a temperature delay in which the material temperature does not increase as expected for an amorphous material due to melting effects, as indicated by the nearly double sigmoidal curvature. The model correctly describes this behavior.

The thick solid line of Fig. 7(a) shows the interface position, expressed as percent of half width as a function of time, which grows exponentially with time as temperature approaches Tm. This is probably due to the fact that heat enters the slab from both sides. At the same time, T(0,t) increases at a rate that decreases as Tm is approached.

Once Tm is reached, T(0,t) shows a sigmoidal behavior, as shown before for amorphous materials. Obviously, when the slab is completely molten the midplane temperature is exactly Tm. Model 1 results indicate that for XLPE K, a thermal diffusivity value of 1 x 10-7 m2/s provides the best fit when

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melting effects are taken into consideration, whereas for model 2 a value of 9.5 x 10-8 m2/s is obtained. This value compares reasonably well with published results1, where a range of 1 x 10-7 - 7 x 10-8 m2/s is reported. For crystalline materials such as XLPE K, the temperature dependence of α is certainly an area or further refinement of the model provided that melting effects are not neglected.

The effects presented above suggest that when XLPE K insulated cables are heated or cooled, melting effects must be considered and that these effects may be dependent upon the relative contributions of the heat sources, such as the conductor itself and the surroundings. As described above, melting effects can be quantified following a Stefan-Neumann approach or a temperature dependent heat capacity function.

With regard to curing effects, the melting enthalpy for XLPE J is more than an order of magnitude larger than its heat of vulcanization. For amorphous and semi-crystalline materials, no curing effects were observed since the agreement between experimental data and theory is quite satisfactory. Therefore it is reasonable to assume that curing effects can be neglected from these models for all materials in the temperature ranges considered in this work.

Conclusions Temperature-averaged thermal diffusivity of crosslinkable materials used as cable insulations can be determined in a simple manner by means of heating experiments on slabs. A single value of thermal diffusivity explains the thermal response of amorphous and semi-crystalline materials. However, crystalline materials such as unfilled crosslinkable polyethylene used in power cables, show a thermal response which is affected by melting effects. Two mathematical treatments were used in this case to be able to extract an average diffusivity value, which agreed with previously reported values. For common wire and cable insulation materials thermal diffusivity values can vary by a factor of 2.5. As previously reported, particulates raise thermal diffusivity that help to explain why wire and cable compounds based on the same polymer system can have substantially different thermal diffusivity values. The influence of the heat of curing appears to be rather small compared to heat conduction or melting effects.

References 1. R.M. Einhorn, IEEE Trans on Electr. Insul. EI-16, 469, 1981.

2. H.K. Frensdorff, Rubb. Chem. Technol. 47, 849, 1974.

3. D. Hands and S. Horsfall, Rubb. Chem. Technol. 50, 253, 1977.

4. K.O. Beatty, A.A. Armstron and E.M. Shoenborn, Ind. Eng. Chem. 42, 1527, 1950.

5. H. Lobo, SPE ANTEC Proceed. 37, 1281, 1991.

6. ASTM E1225-99, “Standard Test Method for Thermal Conductivity of Solids by Means of the Guarded-

Dr. Sergio A. Montes graduated from the University of Akron, Ohio Polymer Engineering Department.

Previous academic experience includes graduate studies at the University of Tennessee at Knoxville and at the Coahuila Autonomous University at Saltillo, Mexico. He has been Montes author or co-author of more than 17 publications in the polymer research area, especially in the field of rheology and processing of polymeric materials. He is currently manager of the R&D Materials Laboratory of Viakable, a group of wire and cable companies that includes Conductores Monterrey. At the time this work was carried Alejo out, Carlos A. Alejo was a mechanical engineering student of the Facultad of Ingeniería Mecánica y Eléctrica (FIME) of the Nuevo León Autonomous University (UANL) in Monterrey, México. He now works for Kellogg Brown & Root, an engineering design firm in Monterrey, Mexico, as a mechanical designer specialized in piping projects. This paper, which was presented at WAI's International Technical Conference in Monterrey, Mexico, October, 2008, won the Silver Certificate Award in the General Division.

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Comparative-Longitudinal Heat Flow Technique,” Vol. 14.02, ASTM International.

7. ASTM E1461-01, “Standard Test Method for Thermal Diffusivity of Solids by the Flash Method,” Vol. 14.02, ASTM International.

8. D. C. Kong, J.L. White, F.C. Weissert and N. Nakajima, Rubber Chem. Technol., 60, 140, 1987.

9. Michaud, D.J. “Simulation-Based Design Optimization and Control of Thick Composite Laminates Manufactured by Resin Transfer Molding,” Univ. of Delaware PhD Dissertation, Spring 2000.

10. M. Juma and M. Bafrnec, Chem. Pap. 58(1), 29-32, 2004.

11. M. Bafrnec, M. Juma, J. Toman, J. Jurciová, A. Kucma, Plastics, Rubber and Composites, 28 (10), 482, 1999.

12. M. Juma, J. Reinforced Plastics and Composites, 19, (13)1024, 2000.

13. M. Juma, M. Bafrnec, J. Brezani, Proc.

Thermophysics Sixth Meeting of the Thermophysical Society—Slovak Physical Society—Kocovce, West Slovakia, p. 95, 2000.

14. E. Camaño, N. Martire, S. Goyanes, A.J. Marzocca, G.H. Rubiolo, J. Appl Polym. Sci., 63, 157, 1997.

15. M. Bafrnec, J. Haydary, J. Toman, And A. Karva, Chem. Listy, 101, S33, 2007, Proc. Slovak Rubber Conference, Bratislava May 15, 2007.

16. Z. Tadmor and C. Gogos, “Principles of Polymer Processing,” Wiley, NY, pp-288-291, 1979.

17. C. Gutfinger, E. Broyer and Z. Tadmor, Polym. Eng. Sci. 15, 515, 1975, 18. M.R. Kamal and P.G. Lafleur, Polym. Eng. Sci. 24, 692, 1984, 19. R.L. Boysen, IEEE Summer Power Meeting and EHV Conference, pp. 926–933, 1970. ■

TECHNICAL PAPERS

TECHNICAL PAPER Overview of fluoropolymer foam technology Proper use of current technology can enable cable producers to use resins such as FEP and PFA via gas injection extrusion to produce plenum-rated cables with optimum size, weight and electrical performance.

By Robert T. Young

Introduction Patented technology for the compounding and processing of fluoropolymer foam resins has been developed and commercialized over the last 20 years. The foam process involves the continuous injection of a gas such as nitrogen directly into an extruder filled with molten resin. A specially designed extruder screw is typically utilized to create the polymer gas mixture with an inert nucleating package contained in the resin to help promote cell growth. Foams of up to 60% voids have been demonstrated through the use of this process.

Applications for melt processable perfluorinated resins FEP and PFA perfluorinated resins possess melt viscosities low enough for processing in melt extruders. Additionally, FEP and PFA are well suited for extrusion foaming while maintaining their low dielectric constant and low dissipation factors, both necessary for twisted pair and coaxial cable insulations.

Data cables are used in the transmission of electronic signals

Fig. 1. Effect of void content on Properties of FEP and PFA.

Table 1. Typical physical characteristics of PTFE, PFA, FEP and ETFE. 66 | WIRE JOURNAL INTERNATIONAL

TECHNICAL PAPERS

in a variety of settings and applications. The key electrical properties required for these cables include a low dielectric constant and a low dissipation factor. These properties can be further enhanced by foaming the insulation. Depending on the resin utilized, constructions having a foamed insulation allow cable miniaturization, weight reduction of the end product, and the transmission of clear high-quality electrical signals at high signal speeds.

Foamed cables fabricated from fluoropolymer resins have become extremely popular in computer manufacturing and installation of network systems. Cables made with FEP or PFA have low-flame and low-smoke attributes. These cables can be routed through plenums and other air handling ducts, reducing the need for the costly installation of electrical conduit.

Fig. 2. Typical foam extruder configuration.

Structure and properties of fluoropolymers The discovery of PTFE occurred in the 1930â&#x20AC;&#x2122;s, but at that time, the new perfluorinated resin could not be melt extruded.

Further research by DuPont into the modification of the polymer architecture led to the development of a series of melt processable fluoropolymers such as FEP, PFA, and ETFE. The ability to melt extrude these polymers, combined with such characteristics as low dielectric constant and low flammability, made FEP and PFA well suited for wire and cable applications.

Table 1 shows typical physical characteristics of PTFE, PFA, FEP, and ETFE.

General aspects of foamed insulation The dielectric properties of polymeric insulation on wire can be improved by the inclusion of gaseous bubbles. However, this must be done in a way that results in small and evenly distributed voids throughout the insulation. Large bubbles can lead to failures within the insulation and uneven void distribution can cause mismatched performance around a conductor.

Technology has been developed by resin producers such as DuPont which allow the controlled nucleation of gas in the fluoropolymer melt as it is extruded and drawn onto wire.

Foaming provides a collection of distinct advantages that are not achievable with conventional melt extrusion techniques.

For FEP and PFA, when foaming technology is utilized, the dielectric constant drops as the void content increases. The reduced dielectric constant achieved through foaming increases the relative velocity of propagation while lowering capacitance (Fig. 1). Because of these improved attributes over conventional melt extrusion, foaming also allows for reduced wall thickness, leading to a corresponding drop in overall weight of the required insulation.

injection. Proper sizing of the extruder and appropriate screw design are key factors in the foaming process. Improper sizing can result in poor mixing and melting (slow rpm) or excessive shear and heat (high rpm).

Fig. 2 shows a typical extruder configuration for foam processes.

As the polymer is melted and fed through the extruder barrel, pressurized gas is injected at or about sonic velocity by a high pressure pump. Proper sizing of the injector via the metering orifice is required to deliver a controlled gas injection into the polymer at the desired levels.

Fig. 3 depicts an example of an extruder injector and high pressure pump. Fig. 4 shows an example of the estimated gas flow into the extruder versus the pressure (in psig) provided by the high-pressure injector.

The amount of gas metered into the extruder is controlled by varying the injection pressure as well as the size of the metering orifice within the injector. For a stable process, it is desir-

Equipment requirements for foaming Conventional extruder screws for melt extrusion have two key zones, a feed and a shallow metering zone. In foam extrusion applications, a three- or four-stage screw is used with feed, compression, metering, and mixing stages. A reduced diameter ring is typically machined at the middle of the first mixing section to reduce the pressure in that region, facilitating gas

Fig. 3. Key components to an extrusion process.

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Fig. 5. Melt draw extrusion and foaming drawing.

Fig. 4. Flow versus pressure for gas injector.

able to operate the injector at pressures greater than 1.8X the barrel pressure in that region.

Gentle but thorough mixing is recommended to properly distribute the gas. The gas dissolves into the melt, forming a polymer/gas solution. Using low shear mixing elements, the continual division and recombination of the melt helps ensures the proper and even distribution of gas. This serves to provide consistency in the size and quantity of voids in the end product.

As the polymer/gas mixture exits the crosshead under pressure, the gas nucleates, forming “bubbles” in the insulation.

Nucleating agents which are contained in the polymer assist in the formation of these voids. The polymer cools as it exits and “freezes“ onto the wire structure. The optimal situation is to have the foaming occur once the extrudate is on the wire (Fig. 5). Crosshead temperatures and tooling selection can be varied to keep the head pressure high enough so gas bubbles do not form until the melt is drawn down onto the wire.

The Draw Ratio Balance (DRB) must also be within a limited range to prevent tearing or fold-over of the polymer. Draw Ratio Balance is defined as the rate the outside of the draw

Fig. 6. Die geometry and shear relationships.

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down cone comes down, divided by the rate the inside of the cone comes down. Draw Ratio Balance is calculated by the equation DRB = R1/R2 where R1 equals the die diameter divided by the coated wire diameter and R2 equals the tip diameter divided by the bare wire diameter. A perfect balance equals 1.00, and a DRB of 1.02 to 1.10 is typical for FEP and PFA foam extrusion. Incorrect DRB is the most common source of process problems with fluoropolymer melt extrusion. Excess flow on the outside or the inside can be attributed to problems in profile dimension control.

The Draw Down Ratio (DDR) is defined as the ratio of the cross-sectional area of the tooling gap to the cross-sectional area of the finished profile. FEP and PFA can be processed over a wide range of Draw Down Ratios, depending upon melt temperature, the profile precision needed and required throughput rates. A DDR of 5:1 to 30:1 is typical for FEP and PFA foam extrusion.

Fig. 7. Die and shear rate mathematical relationships (*at recommended processing temperatures).

TECHNICAL PAPERS Fig. 8. Example of FEP/PFA rheological behavior

Since foaming typically occurs once the material is on the wire, tooling factors such as DRB and DDR should be calculated utilizing the solid equivalent “pre-foamed” OD. The process contact metals for the tooling, such as the tip and die, must be high-nickel, low-iron alloys suitable for fluoropolymer processing.

Figs. 6 and 7 show the relationship between shear rate, shear stress, output and die geometry. For a given profile tooling geometry, the shear rate increases directly as the melt output is increased.

Safety considerations The major safety consideration for the extrusion of fluoropolymers and other organic polymers is the removal of offgases released from hot polymers into work areas. This can be accomplished by the installation of exhaust hoods at the die and the hopper heaters, if utilized. Extruding into water – either a

Fig. 10. Effects of different nucleant packages (same wall thickness and void content for each extrusion).

Fig. 9. Effect of nucleant packages.

quench tank or a partially filled container – for purging, is also recommended.

For additional safety information, refer to the following: Guide to the Safe Handling of Fluoropolymer Resins, published

by The Society of the Plastics Industry, Inc.; safety articles published by PlasticsEurope, available through their website library; and Material Safety Data Sheets provided by the resin producers.

Rheology Fig. 8 represents a map of possible flow conditions typically seen in the processing of FEP and PFA fluoropolymer resins.

The figure is a plot of shear stress versus shear rate and illustrates how shear stress increases with increasing shear rate. For a given profile tooling geometry, the shear rate increases directly as the melt output is increased. The shear stress also increases as the pressure is increased.

Fig. 11. Example of miniature foam/skin construction.

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The map also defines four possible regions of extrusion behavior. The first region is the wide area of normal operation where almost all extrusion is typically performed. The second region represents going from a smooth extrudate to a rough “melt fractured” extrudate by increasing the resin flow through the tooling. During this transition the polymer melt goes through its “critical shear rate.” A smooth extrudate is obtained again in the third region, normally referred to as the “super shear” region. Super shear occurs when the flow of the polymer melt has lost its adhesion to the surfaces of the tooling.

This phenomenon is accompanied by a drop in extrudate head pressure, allowing greater extrudate output. Foaming resins typically are processed in this region. Processing at higher shear rates facilitates lower draw down ratios and produces higher head pressures, helping to minimize premature foaming within the crosshead. In the fourth region, the extrudate becomes excessively rough again.

Resin, construction and processing considerations Final wire construction is dictated by a balance of processing methods, consistency in operations, and the choice of resins used. Foaming of thicker-walled constructions such as RG6 cable (>20 mil wall) allow for higher void contents (>45%) and the use of lower melt flow rate resins, typically <15 MFR. Lower drawn-down tooling is also required for these thickwalled constructions. Thinner-walled constructions, such as Cat. 5e, Cat 6, 10Gig and twisted pair applications (<20 mil wall) with lower void contents (<45%), are accomplished using higher melt flow rate resins (>15 MFR) and higher drawdown tooling.

One critical end-product property is the rate of return loss, or the amount of signal that is lost due to reflections along the length of a cable. Excellent return loss properties and good adhesion of the resin to the wire can be achieved through small and uniform cell structure, uniform material along the conductor, and consistent and good bonding between the wire conductor and the foamed insulation. The polymer, nucleant formulation, and processing are all contributing factors to producing uniform cells and better adhesion to the conductor. Figs. 10 and 11 are excellent examples of small and uniform void distribution desirable for a foamed construction.

Nucleant type and loading can also have an effect on processing and cell structure, which in turn can impact the diameter, capacitance, and other electrical properties of the final wire/insulation product. Fig. 9 shows how variations in the nucleant package can affect the ultimate foaming behavior as measured by finished product diameter and capacitance stability.

Fig. 10 shows the void morphology achieved when two different nucleant packages are utilized to make constructions of the same dimensions and measured capacitance. Nucleant A has uniform voids while Nucleant B has a variation in voids Additionally, process variables such as cone length, wire preheat temperature and quench point can influence factors such as return loss and measured capacitance.

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Alternative methods of processing Variations on the foaming process have been developed to help enhance the performance characteristics of the insulation.

Process variants such as the inclusion of an outer skin material provide a smooth surface for improved contact for shielding and braiding, a protective layer to minimize blow-through issues, and facilitate better processing control. Fig. 11 shows an example of a miniature foam/skin construction with a typical wall thickness between 30 and 50 mils.

Additional variants include the addition of a solid film layer placed in contact with the wire conductor, providing a voidfree uniform material and serving to improve return loss and adhesion properties.

Summary and Conclusions The foaming of fluoropolymer resins such as FEP and PFA, through the use of gas injection extrusion, provides a safe and economical way to produce plenum rated cables with reduced size, reduced weight, and improved electrical performance. ■

Robert T. Young is a technical service consultant working in the Wire and Cable group within DuPont Fluoroproducts, Wilmington, Delaware, USA. His responsibilities include product/process development along with customer support for DuPont’s melt processable fluoropolymers for the wire and Young cable industry with a specialization in foaming technology.

During his 12 year career with DuPont he has served in a number of research positions working in the area of polymer processing and applied rheology supporting a number of areas and products. He holds B.S. degrees in chemical engineering and chemistry from North Carolina State University and holds a Ph.D. degree in chemical engineering from Virginia Tech. This paper was presented at WAI’s 78th Annual Convention, Pittsburgh, Pennsylvania, USA, June 2008.

WAI ACKNOWLEDGES THE FOLLOWING CONTRIBUTORS TO THE INTERWIRE 2009 TECHNICAL PROGRAM

The educational program at Interwire 2009 was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission.

Authors/Presenters Etienne A.D. Aernoudt Rick Amaral Jonathan Anderson Motoo Asakawa Ban Deok-Young Eric Bieberich James Brocklehurst Ryszard Budzik Nick Buschur Cho Kil-Won Michael Colvin Lindsey Cook Kevin Davis Primoz Eiselt Leonid I. Frayman Rob Fulop Ron Garceau Wayne Gardella Bogdan Golis Jack Hall Willy Hauer Patrick Hayes Ron E. Higgins Tom Horn James Jolda Satoshi Kajino H. Kanaeda Shunichi Kikuchi

Marcin Knapiński Ryosuke Komami Al Kozlowski Jan Krnac Robert Kruzel Stanisław Księżarek Paul Kulongowski Jorge Lopez Kiran Manchiraju Dieter Mangold Thomas H. Maxwell Jr. Thomas H. Maxwell Sr. Bill Murphy Motohiro Nakano Aaron Nolan Denis F. Pasay Jan W. Pilarczyk Horace Pops JoAnn Foster Queen Igor Rogelj Victor Rundquist Danielle Rust Takanori Sato Sonomi Shirasaki Zbigniew Smolarczyk Song Seong-Hun Gary L. Spence Mark Spencer Yuichi Tanaka

Carl Teitelbaum Ike Tripp Jeffrey T. Tyl Thomas W. Tyl Motohiko Urabe Hiroshi Utsunomiya Kevin Weaver Rafał Włudzik Kazunari Yoshida Masahiro Yoshida Peter Ziger Moderators Dane Armendariz Mark Garretson Tom Horn Erik Macs Thomas H. Maxwell Jr. Donnie Norton Philip Radbourne Jose Ranc Briggs Whitefield Bhaskar Yalamanchili Course Instructors Joseph Bahadrian Ron Beeckman Anand Bhagwat Rick Gordon

Tony Irujo Dale Olp Horace Pops Douglas B. Relyea Michael Zelin Guest Speakers Jack Carlson Richard Carr Hugo Alberto Gómez Sierra Cheryl Jones Gregory J. Lampert Supporting Sponsors American Wire Producers Association (AWPA) Society of Plastics Engineers (SPE) Steel Wire Manufacturers Association of India (SWMAI) Educational Alliances Asociación Nacional de Transformadores de Acero, AC (ANTAAC) Australasian Wire Industry Association (AWIA)

Interwire 2009 is organized by The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | Web site: www.wirenet.org

TECHNICAL PAPERS

TECHNICAL PAPER Screw selection and extruder considerations for wire and cable coating One size or approach does not fit all when it comes to choosing the optimum method and set-up for the different non-metallic materials that are used to manufacture cable.

By Edward L. Steward

Wire-coating extruders are often asked to handle several polymers and/or a wide range of operating conditions in production. Selecting the proper screw to optimally handle the requirements set forth is important to maximizing performance and profitability. Screws over the years have evolved and barrier screws are still widely used, but the simpler screws of the past still fit well in some applications.

This paper will discuss screw and extruder performance features for many of todayâ&#x20AC;&#x2122;s wire and cable applications.

Screw designs started with simple metering screws, which ran some polymers reasonably well, although at lower than todayâ&#x20AC;&#x2122;s output rate levels for the majority of polymers. See Fig. 1, top. As time progressed, the metering

screws were altered to attempt to achieve higher output rates. This was basically a trial-and-error approach, where screws with deeper channel depths and differing section lengths were tested and compared. Some highly filled materials ran well on deep metering screws and are still used with that type of screw today. Semi-conductive cross linkable PE (XLPE) was also found to process well on the low-shear metering screws and still is typically processed on the metering screws. The non-conductive XLPE materials and materials that are not highly filled reached processing limits on the metering screws that were improved by first adding mixing sections. See Fig. 1, middle. These mixing sections were first tried as rows of pins, which blocked about 50% of the channel area. The mixer choice

Fig. 1. Three basic extrusion screw designs.

Fig. 2. Schematic showing interior view of mixing element of single screw extruder.

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view. See Fig. 1, bottom. These designs provide improved pumping stability and further deepening of channels, especially when supplied with a mixing section. At elevated screw speeds, the pumping stability (product tolerance variations) typically worsens with a metering screw and the barrier design avoids the melting inefficiencies of solids bed breakup and improves the pumping stability. If the barrier screw is properly designed for a polymer and a processing situation, the solids bed can be held together in the solids channel and the melt can be held in its own channel, away from the solids bed, and will avoid the destabilizing affects seen on metering screws. See Fig. 2. Most of today’s high output screws for those desiring optimum product tolerance control are barrier screws. The high output barrier screws typically include a mixing section. Only for applications where lower output is required and the screw can have fairly shallow channels can the mixer be removed with no negative results. The barrier section is designed to control the pumping stability of the extrudate, and the mixer does not noticeably impact the pressure stability at the end of the extruder barrel. There have been many mixer designs marketed over the years with some great claims, but the optimum screw choice is usually a good barrier design coupled with a streamlined and compact mixing section. A mixer that takes up 2D of the screw length is typically sufficient. Further, it should be designed to be as low in shear level as is necessary to ensure good melt quality and mixing.

Probably the easiest way to handle a discussion on performance is to look at several polymers that are encountered in the wire coating applications and briefly discuss screw and extruder performance highlights of each, as follows.

Fig. 4. Three extrusion screw designs for rubber.

Fig. 3. Typical extrusion screw.

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employs the Maddock mixing design, which forces all the material over dams that were given fairly tight clearances.

The pin mixing sections were found to be not as streamlined for good flow as the Maddock mixer design, which has been improved further over the years from the mixer shown with the axial groove orientation. Today’s mixers are often given a helical orientation and the groove depth contours are made to improve the flow at the ends of the groves versus the older deep grooves. Streamlined mixers are especially important for processing XLPE, PVC and any other degradable polymer. Color changes are aided by streamlined flow through mixing sections. See Fig. 3.

Adding mixing sections allowed the metering screws to be made with deeper channels and therefore allow higher output rates at a given screw speed. Adding the resistance and shear of a mixing section on the screw would increase melt temperature compared to an identical screw without a mixer. If the screw channels were allowed to be deepened without losing melt quality due to the mixer’s additional energy, the mixing screw would provide higher output/RPM and thereby deliver a given output rate at a lower screw speed. Screw speed is the parameter with the largest influence on the melt temperature, so comparing output rate at a given melt temperature usually favors a mixing screw selection since that screw allows deeper channels and slower screw RPM. Processes that allow higher screw speed operation (FPVC, PE, etc.) are especially good candidates for mixing screws. Higher screw speed presents more of a challenge to maintaining melt quality, especially as the screw channels are deepened for maximized output rate results.

After the performance limits of metering/mixing screws were reached, the barrier screw designs had come into

TECHNICAL PAPERS

Polyvinyl Chloride (PVC) PVC in wire applications can range from soft to semirigid. The softer the PVC (lower durometer), the shallower the screw channels need to be and the higher shear a mixer or barrier section would need to ensure fully melted material exiting the extruder. Basic screw design started with metering screws that had core holes along the entire screw length. Screw cooling (circulating water inside the screw) was used to allow the metering screws to fully melt the polymer at moderate screw speeds. Without the water cooling, the old FPVC metering screw designs would not fully melt the PVC and the extrudate would be lumpy and/or poorly mixed. Mixing sections and altered screw designs allowed the removal of water cooling and resulted in higher output rates. The water cooling inside the screw was a maintenance concern and also reduced the screwâ&#x20AC;&#x2122;s pumping ability by up to 50% compared to a non-cooled screw.

Water-cooled screws are rare these days, with mixing screws or barrier/mixing screws predominant. The higher rate applications almost always have barrier/mixing screw designs.

Extruder barrels are typically air cooled up through 3.5 in. or 4.5 in., with 6 in. and larger machines usually watercooled. The mass of the large machines makes the efficiency of water justifiable. Wherever possible, air cooling is used, due to its simplicity and maintenance advantages.

Screws are typically made from a good grade of steel (AISI 4140, for example) and the flight tops are usually hardened by welding on a compatible material with the selected barrel lining material. These barrel and screw materials often contain tungsten carbide to provide greater life with the filled PVC materials of the wire coating applications. A 4.5 in., 24:1 extruder would typically have a 150 or 200 HP motor set in at 100 RPM maximum screw speed for most PVC installations.

Polyethylene (PE) PE includes a large family of products including LDPE, MDPE, HDPE, LLDPE and MPEs (family of metallocene PE). These materials have evolved from the metering screw to the mixing screw and now the barrier/mixing screw. The metering screw used was not internally water cooled as PE does not offer the same positive results on a water-cooled screw as does PVC. For years the successful screw selection was a meter/mixing screw, but that has been outperformed in most cases by todayâ&#x20AC;&#x2122;s barrier/mixing screws (when they are properly designed). The higher viscosity PE materials (MD, HD, LLD, many mPEs) would use a lower shear screw design (deeper channels), no matter what the basic design is. A 4.5 in., 24:1 extruder for processing LDPE might be supplied with a 150 hp motor set in at 100 rpm maximum screw speed, while the higher viscosity PEs would have a 200 or even 250 hp motor set in at 100 rpm maximum screw speed. As with PVC, the extruder would be air cooled up through 4.5 in. and typically water cooled at 6 in. and larger. The screw would be a good grade of

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steel with material welded to the flight tops for abrasion resistance. HDPE was the material that led away from flame hardening screws to the various welded abrasion resistant materials available today. LLDPE and MDPE run similarly to HDPE and have similar processing scenarios.

The mPE family includes a wide range of viscosities to deal with in-screw design selection. Some use fairly high torque and exhibit melting instabilities from solids bed breakup early along the screw. These mPE choices require barrier screws with barrier section placement that can alleviate the early melting instabilities.

Polypropylene (PP) PP does not process as efficiently as PE with regard to output rate. The feeding and melting efficiencies are both reduced and the result is that the output rate for PP is up to 40% lower than PE rates on a given screw. Homopolymers are a bit lower in performance versus copolymers, but both PP types are noticeably lower in extrusion efficiency versus PE. Extruders for PP extrusion are often longer than 24:1, since output rate increases almost linearly with barrel length. A 30:1 extruder would offer up to 20-25% higher output rates versus a 24:1 extruder. A 34:1 extruder would offer even more of an increase. The optimum screw design would be a properly designed barrier/mixing screw and would be altered in the areas of barrier starting point and melt channel volume versus PE or PVC screw designs.

Earlier screw selection was metering screws and then mixing screws, as was seen for PE applications.

Nylon The most common nylon materials are nylon-6 and nylon-6/6. For maximized output rates on a given extruder, both of these choices are best extruded on a barrier/mixing screw. Lower rates can be handled on a metering screw or barrier screw with no mixing section. There is a bit of difference in the extrusion performance between these common nylon choices, but one screw could be designed to handle both regardless of the screw type selected. Nylon extruders are usually air-cooled, even on larger extruders, due to the higher extrusion temperature settings and the ability of air cooling to control even a large extruder at these levels. The metallurgy on the screw and barrel are similar to that for PE or PVC. Heated clamps or flange heaters at the end of the extruder are favorable, due to the higher melting points involved with nylons. Supplying the screw with a short core hole makes sense (through the first three flights), in case bridging ever occurs due to feed section cooling deficiencies on a given extruder. This is especially important if the extruder does any slowdowns or stoppages during the operation of the wire line. Cooling the first few flights of the screw (those in the feed section) will not affect output rate, as seen in full screw cooling, but can avoid prematurely melted nylon that can stick to the screw root and cause the output rate to decrease or stop completely.

This family of materials has high-temperature requirements and requires corrosion resistant metallurgy for the screw and barrel. The screw is typically Hastelloy or Inconel, which is high in nickel and has proven to have good resistance to the fluorines being given off during extrusion. The die and barrel lining also must be high in nickel content. Air cooling is a standard at the temperatures needed along the barrel and alternate heater material is typical. Normal extruders have cast aluminum heaters that do not stand up well to the setpoints required for most fluoropolymers. Either cast-bronze heaters or ceramic-band heaters are the choice in fluoropolymer extrusion. Screw design has remained either metering screws or meter/mixing screws. The output rates required on a given extruder are typically modest, due to the limits of melt fracture at the die exit. At modest output rates and screw speeds, the metering screw has proven to run with decent pumping stability. Fluoropolymer screws are not strong and need to be checked for torque-carrying capacity, to ensure the ability to break the screw is minimized.

Rubber Rubber includes EPR, EPDM, natural rubber and many custom blends of components. It can come in pellet form but is commonly in strip form. The strip form usually requires a special feed section on the extruder with a powered roller to assist the strips into the screwâ&#x20AC;&#x2122;s feed flights, which are usually long lead and double flighted. Screws are either double-flighted metering screws with deep channels or deep barrier screws with no mixer included. See Fig. 4, first and second. The barrier section does not serve the same melt/solid separation function as in plastics extrusion, since rubber does not really melt. Rubber softens with heat and shear energy and the barrier section aids in the process of getting the material to a uniform temperature state (it acts like a long gradual mixing area). The barrier screw also tends to dampen out any feed instability and offers improved pumping consistency as it does in the plastics extrusion arena. Pelletized rubber would not necessarily require the power feed roller, but would benefit from the same types of deep, low-shear screw designs as the strip feed versions. Rubber materials are often highly filled and the screwsâ&#x20AC;&#x2122; flight tops are hard-surfaced, perhaps with the tungsten carbide option. Most rubber extruders are watercooled, since the barrel settings are quite low (150-200oF), where air cooling efficiency is low. Rubber is typically high in viscosity, so high extruder torque is required, for example a 4.5 in. extruder with a 150 hp motor set in at 4550 maximum screw rpm. Since rubber does not actually melt and the high viscosity nature causes high energy buildup along the machine, most rubber machines have short barrel lengths compared to plastics. A typical rubber machine would be 15:1 or 20:1 L/D barrel length, where plastics extruders are 24:1 and sometimes 30:1. The screw is fully cored and hot water or warm oil is used to control

screw temperature. In rubber extrusion, screw temperature control offers a parameter to help control extrudate quality and stock temperature.

Silicone is in the rubber family and has even lower temperature requirements (barrel settings of 50-60oF). Screw water is used at similar temperatures to the barrel settings mentioned. Screw selection is typically metering designs, either similar to the double-flighted rubber screws or single-flighted screws with diminishing flight lead, where higher die pressure is anticipated. See Fig. 1, first and third.

The length of silicone extruders are even short for typical rubber extrusion, with L/D in the 8-12:1 range. Silicone is usually strip feed, so powered feed rolls are standard. Older machines were supplied with tangential feed opening shapes and no feed rolls, but the powered roll offers improved feeding control and improved pumping stability control.

Polyurethane Urethanes come in a range of hardnesses, which impact the shear that the screw needs to impart to fully melt the extrudate and achieve a smooth surface. Some urethanes are a blend of durometers to yield a final durometer, which makes the screwâ&#x20AC;&#x2122;s job difficult since it has to melt and mix the two differing viscosity components. It is often difficult to achieve good pumping stability with urethane. The early melting inefficiencies related to solids bed breakup are common with many urethanes and the best way to attain good pumping stability is with a well-designed barrier screw. Metering screws need to have long metering sections. This will give the best chance for good pumping stability by dampening out some of the early pressure variations, although this does not eliminate the basic instability problem where a barrier screw can. Urethanes have medium- to high-torque requirements, sometimes like HDPE or LLDPE.

Thermoplastic elastomers (TPE or TPR) When these materials are based on PP, the screw design considerations follow the PP notes mentioned earlier.

When the TPE is PE-based, the considerations are more like those for PE materials. This is a wide family of materials with ranging viscosities and therefore will alter the screw shear levels necessary to handle specific TPE choices.

Flame retardant compounds The additives for flame retardancy and the fillers typically present require screw design and screw/barrel hardening considerations. Typically, the screws need low shear barrier/mixing designs. Earlier screws had deep metering or meter/mixer designs that operated decently at low screw speeds, which are often the only rpm range possible with the heat sensitivity of these materials. When many flameretardant materials reach 400oF or higher, a thermal reaction causes volatiles (gases) to be released and bubbles are

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Fluoropolymers

TECHNICAL PAPERS

quality is the best screw design choice. A typical choice, due to the abrasiveness of the fillers present, is the use of hardening screws and barrels with tungsten carbide materials.

Cross Linkable Polyethlene (XLPE) This family of materials also requires different screwselection considerations. The semi-conductive XLPE materials are typically processed on metering screws or meter/mixing screws, which do a decent job with respect to melt quality and pumping consistency. The carbon black additives, which give the semiconductive function, aid in the melting process by improving the heat transfer into the polymer passing along the extruder. Melting occurs stably and at an enhanced rate versus the virgin PE polymer.

The semi-con XLPE materials are usually extruded on short-barrel machines, typically 20:1 and sometimes even 15:1 L/D barrels. The non-conductive XLPE materials perform best on barrier/mixing screws of medium or low shear design, typically on 24:1 L/D barrel lengths. This includes the silane-based crosslinking materials. Hardening materials are typically welded to the flight OD, typical for HDPE or LLDPE extrusion.

A general consideration for wire-coating extruders is the desire to process several polymers in one screw. This can be best accomplished with today’s barrier screws, but there are still limitations as the range of desired polymers gets wider. Metering screw designs can also handle several polymers on one design, but the resulting performance is typically lower than with the barrier-screw approach.

When deciding on an optimum screw design, the polymer choices to be processed, the output range required, the pumping consistency desired and the pressures anticipated at the end of the screw should be included in the decisions.

Conclusions While there is no one right choice for all applications, past experience processing a given polymer has led to screw designs that handle given output and pumping stability requirements.

When multiple polymers need to be processed on one screw, the processing sacrifices need to be determined, to ensure that one screw design is the best approach. When deciding on an optimum screw design the polymers to be processed, the output range required, the pumping consistency desired and the pressures anticipated at the end of the barrel should be included in the decisions. ■

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Edward L. Steward is director of process technology.at American Kuhne Corp., Ashaway, Rhode Island, USA. His responsibilities include screw design and application along with processing related tasks that ensure extrusion systems will meet designated performance goals. Prior to Steward joining American Kuhne in 1997, he was employed at the Davis Standard Corporation for 24 years as its chief process consultant. He holds a B.S. degree in mechanical engineering from the University of Connecticut. He is a fellow of the Society of Plastics Engineers and has written numerous papers for various extrusion societies and publications on screw design and related topics. This paper was presented at WAI’s International Technical Conference, Monterrey, Mexico, October 2008.

PRODUCTS & MEDIA

PRODUCTS & MEDIA PRODUCTS CL-3 audiophile loudspeaker cables feature rope-laid central conductors U.S.-based Lenbrook America, importer of British specialist cable brand QED, announced the introduction by QED Cables of its Professional Silverline Five loudspeaker cable for installation as speaker cable in walls and between floors.

Silverline Five is QED’s first audiophile speaker cable to be fully rated by Underwriter Laboratories (UL), a press release said. It meets the UL-CL3 standard for in-wall use, the UL13 standard for power limited cables, and the UL-CL3R standard for use as a certified riser cable that can safely be used between floors in both residential and commercial locations, it said.

The cable features four rope-laid central conductors with optimized geometrical spacing to provide the best impedance for audio signal handling, the release explained. Each conductor consists of four 99.999 percent oxygen-free, silver-plated central conductors, the cable is sheathed in a flexible white PVC outer jacket, and has an outer diameter of 3.4 mm, it said. Its capacitance is rated at 42.9 pF/m, its loop Inductance at 0.51 uH/m, and its loop resistance at 14.9 mV, and it comes in a resistive pull pro box that ensures accurate issuing and measurement of cable on site, it said.

Contact: Lenbrook America, www.lenbrookamerica.com.

Stainless steel, flux-cored wires offer superior weld performance U.S.-based Lincoln Electric announced that it has expanded its UltraCore® line of flux-cored wires to include six stainless wires that provide superior weld performance with a variety of stainless steels.

The new wires, FC and FCP 308L, 309L and 316L, are designed to provide high deposition rates in flat and horizontal positions and offer allposition welding capability, a press release said. Wires with a 308L designation are ideal for welding 18/8 stainless steels or other common 78 | WIRE JOURNAL INTERNATIONAL

austenitic grades; wires with a 309L designation are designed for joining stainless steel to mild or low alloy steel; and the 316L designation offers high resistance to corrosion and pitting on molybdenum-bearing austenitic stainless steels, it added.

Contact: The Lincoln Electric Company, tel. 888-3553213, www.lincolnelectric.com.

Temperature measuring system precisely tracks XLPE melts U.S.-based SIKORA International Corporation announced the development of ULTRATEMP 6000, a temperature measuring system based on ultrasonic technology that is specifically designed for the measurement of XLPE melts.

The ULTRATEMP 6000 is a non-contact melt temperature measurement system based on noninvasive ultrasonic technology, a press release said.

It precisely measures the melt temperature during production and does not influence the melt flow properties, and melt shear heating errors are eliminated, it said. Its design helps to avoid premature cross-linking after screens, which may lead to ambers and scorches in the polyethylene material, and the system optimizes the running time and the productivity of the extrusion line, it added.

Contact: SIKORA International Corporation, tel.

770-486-1233, sales@sikora-usa.com, www.sikora.net.

Harness tool kit can take on a variety of wire applications U.S.-based Xuron Corporation announced the release of a wire harness tool kit that includes three specialty tools for handling many wiring tasks.

The Xuron® TK2300 Wire Harness Tool Kit features three ergonomic hand tools: Model 2175 Maxi-Shear™ Flush Cutter for soft wire up to 12 AWG; the Model 501 Adjustable Wire Stripper for wires from 10 to 26 AWG; and Model 440 High Precision Shear for slitting coaxial cable jacketing, a press release said.

They are stored in a handy tri-

Energy-efficient ultrasonic splicer accommodates tinned, oxidized wires U.S.-based Sonobond Ultrasonics announced the release of its SpliceRite™ Ultrasonic Wire Splicer.

According to a press release, the unit offers significant advantages over other ultrasonic wire splicers: It can easily accommodate tinned or heavily oxidized wires; splices wire bundles quickly while creating a true metallurgical bond; consumes minimal energy while creating solid-state metallurgical bonds; and splices wire bundles quickly—without melting wires and without producing arcs, sparks, or fumes.

Another plus of the new unit is that it eliminates the need for clipping, soldering, crimping, or dipping, the release said.

Its microprocessor controller is able to store and recall up to 250 jobs, while producing welds by height, energy, or time, and the patented Wedge-Reed system is available with either 1500 or 2500 watts power capacity, it said. It can also be operated easily with only minimal training, it added.

Contact: Sonobond Ultrasonics, tel. 800-323-1269, www.sonobondultrasonics.com.

Sjogren Wedge Grips and Replacement Parts

Call today for a free quote (706) 376-6584 x227 or visit our website www.fabritex.com

Morgan-style

Sleeper & Hartley-style

Vaughn-style

Sleeper & Hartley-style with Thumb Release

Whether you require a standard wedge grip assembly or a customized unit, Sjogren Industries has the flexibility to manufacture an assembly to your requirements.

Sjogren Industries, Inc. Tel: 1-508-987-3206 Fax: 1-508-987-1965 Email: sales@sjogren.com www.sjogren.com

JUNE 2009 | 79

PRODUCTS & MEDIA

fold canvas pouch with separate pockets and a Velcro® closure, it added. Designed to fit into a shirt pocket, brief case or field service kit, the kit features tools including Xuro-Rubber™ soft rubber grips, Light-Touch™ flat return springs and a glare-eliminating black finish, it said.

Literature is available upon request.

Contact: Xuron Corporation, tel. 207-283-1401, arobey@xuron.com, www.xuron.com.

PRODUCTS & MEDIA

Narrow automotive wires lighten load on cars’ electrical systems Germany-based Delphi Deutschland announced it has developed notably thin wires for automotive wiring harnesses, a technology that could help reduce the weight of a sometimes problematic part of a car’s electrical system.

According to a press release, cabling harnesses have grown from an insignificant part of a vehicle’s electrical interior to the third heaviest part in modern cars, after motor and transmission. Since today a significant part of design efforts aim at reducing the weight—and hence fuel consumption—of the vehicle, cable harnesses have attracted increased notice from designers, it said.

The wires have a diameter of only 0.03 mm for automotive use, the press release explained, smaller than the previously smallest diameter of 0.67 mm.

Contact: Delphi Deutschland, tel. 49-0202-2-91-0, www.delphiauto.com.

LAN cables are now verified beyond TIA and ISO/IEC industry benchmarks U.S.-based Berk-Tek, a Nexans Company, announced that it now provides customers independent ETL verification of cable performance to Berk-Tek specified cable requirements, which significantly exceed the TIA/EIA568-B.2 and ISO/IEC 11801 standards that have traditionally served as the industry benchmarks.

Berk-Tek believes it is the first manufacturer to develop this program at the component level, which focuses on the LANmark™ family of Category 5e, 6 and 6a cables.

According to a press release, Berk-Tek is the first manufacturer to utilize third-party verification to certify that the claimed cable performance is being met. Testing is performed by Intertek, the world’s largest independent testing, inspection and certification provider and proprietor of the ETL Verification Mark, it said.

Berk-Tek has secured a position in the “Intertek Directory of ETL Verified and ETL Listed Cabling Products,” with a dedicated page to the LANmark family of UTP cables, it said, adding that official ETL test reports for each electrical characteristic on each cable are available on the Berk-Tek web site at www.berktek.com.

Contact: Berk-Tek, tel. 717-354-6200, berktek.info@nexans.com, www.berktek.com.

TPE compounds offer durability in extreme temperatures U.S.-based Teknor Apex’s thermoplastic elastomer (TPE) division announced the release of its new, Telcar® TL-1934 Series TPE compounds that are fully RoHS-compliant and meet stringent UL criteria for flame retardance while providing flexibility and toughness over a broad temperature range.

80 | WIRE JOURNAL INTERNATIONAL

According to a press release, the four Telcar® TL-1934 compounds are styrenic formulations available with Shore A hardnesses from 56 to 88. Teknor Apex recommends them for insulation, jackets, and molded parts for flexible cords, coil cords, and cables in power tools, appliances, industrial robots, welding equipment and audio and lighting systems, it said.

Telcar TL-1934 compounds contain no polybrominated diphenyl ether (PBDE) flame retardant, are oil-resistant and available in a broad range of hardnesses.

Contact: Teknor Apex (U.S.), tel. 866-438-8737, tpe@teknorapex.com.

Heavy-duty dispensing system averts large wire feed problems U.S.-based ELCo Enterprises, Inc., announced that it now offers Wire Pilot™ Feed Assist, part of the only product line in the world that it says is dedicated to largediameter weld wire dispensing.

The system includes low-friction conduit for large wire, drum turn tables, heavy duty wood reel dispensing equipment and wire straighteners built for handling wire as large as 5/32 in., both solid and cored, a press release said.

The unit also allows for longer conduit runs when using wire of any size, it said, adding that it is designed to solve feeding problems that occur when dispensing large wire in MIG and SAW applications, such as wire flip, excessive shaving and inconsistent wire feed.

Contact: ELCo Enterprises, Inc., tel. 866-584-7281, shall@wire-wizard.com, www.wire-wizard.com.

Replaceable teflon insert offers improved friction reduction U.K.-based RG Attachments, Ltd., reports that it has added a low-friction design replaceable Teflon insert to its Tapeformer Range.

The Replaceable Teflon insert offers improved friction reduction when used with the RG Tape Former, a press release said. The RG Tape Former is used by cable manufacturers to fold a variety of insulating material around cable cores before entering the final jacketing stage. The

said.

Contact: RG Attachments, Ltd., tel. 0044-1162611038, www.tapeformers.com.

Cables permit HDTV/SDI format U.S.-based Belden announced the development of installable performance and extending sweep testing of Brilliance® Precision Video Cables to 4.5 GHz, paving the way for 1080P HDTV/SDI format.

Belden’s Brilliance® broadcast video cable is designed for maximum bandwidth, minimum return loss and minimum attenuation loss, a press release said. The cables meet specifications for electrical properties and are suited for analog and digital video in broadcast, post-production and other critical video applications, the release noted.

The specifications for these cables have increased from 3 GHz to 4.5 GHz, and every reel is sweep tested for return loss and certified to the new higher frequency, the release explained. This extension will assist broadcasters and broadcast manufacturers as they begin to move from the existing 1080i (interlaced) HD format to the emerging 1080p (progressive) format, it said.

Contact: Belden, www.belden.com.

Extrusion temperature control system expands to do full machine checks U.S-based OEM Design Services, Inc., announced the release of its new, low-cost, high-feature PLC extrusion temperature control system designed to replace unreliable discrete controllers.

According to a press release, the system features Siemens, Allen Bradley, or Gefran PLC and touch screen, Gefran GFX4 Controller/Power unit, zone current display, cooling relay

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MULTI-WIRE STARTUPS,

WOODBURN IS THE PERFECT MATCH!

JUNE 2009 | 81

PRODUCTS & MEDIA

tape former can be used with many insulating tapes including LAN, power, telephone, and communication, coaxial and automotive cable, it

PRODUCTS & MEDIA

output, melt PSI and melt temperature, recipe storage, and Ethernet for data collection or remote service. The entire system is expandable to do full machine control.

An optional full color 10-in. screen is available (standard comes in 6-in. color with a separate PLC), and the minimum system has one four-channel Geflex unit that supports four single-phase or three-phase zones, it said.

Contact: OEM Design Services, Inc., tel. 203-3149159, sales@oemdesignservices.com.

Precious metal-clad medical wire outpaces single-alloy systems U.S.-based Anomet Products, Inc., reports that it has developed a custom engineered precious metal-clad wire for fabricating connectors and bioconductors used in pacemakers, stents, and neurostimulation devices.

According to a press release, the medical wire combines materials like platinum for biocompatibility, oxidation and corrosion-resistance, silver for conductivity, and gold for contact resistance.

Designed to achieve properties not available in a single alloy, each precious metal and core component of the wire is metallurgically bonded together, the release explained.

Available in sizes from 0.002 to 0.125 in., the wire can incorporate 2% or more cladding thickness, depending upon the desired properties, and provides greater ductility and formability than filled or plated wire products, the release said.

Contact: Anomet Products, Inc., tel. 508-8423069, dlambert@anometproducts.com, www.anometproducts.com.

MEDIA Online catalog adds newest cable merchandise to offerings U.S.-based CableOrganizer.com announced that it has added a dozen new Platinum Tools® solutions to its online catalog.

The Platinum Tools products recently added to CableOrganizer.com are the E Series Coaxial Cable Strippers, Cyclops 2 Twisted Pair Cable Jacket Stripper, 18 Piece Belt Clip Set,

82 | WIRE JOURNAL INTERNATIONAL

SealSmart Compression Crimp Tool and Shielded EZRJ45 Connectors, a press release said. They are designed for the preparation, installation and hand termination of wire and cable to its inventory, it said.

Contact: CableOrganizer.com, www.cableorganizer.com.

New global website makes products search fast and easy Belgium-based Bekaert, a leader in advanced metal transformation and advanced materials and coatings, announced the launch of its new corporate global website.

The website presents a product portfolio available in 120 countries, a press release said, adding that it replaces more than 30 former websites worldwide. The site structures Bekaert’s product range by means of an industry selection tool, combined with an auto-complete search that helps users find what they are looking for, the release said.

Contact: Bekaert, www.bekaert.com.

116-page product catalog provides numerous time-saving solutions U.S. based Brady Corporation announced its most recent catalog release, a 116-page, S-27 index that focuses on issues such as visual workplace, compliance, lockout/tagout and slips, trips, and falls, all focused on essential MRO products that companies require.

According to a press release, customers seeking a “one-stop shop” experience can source and order stock/custom products online instead of searching through catalog pages for what they need. Brady's website, www.bradyid.com, will be the repository for Brady's complete product offering, it said.

Contact: Brady Corporation, tel. 888-250-3082, www.bradyid.com.

Fastener supplier’s new websites offer downloads, service contacts U.S.-based Lindstrom Metric, LLC announced the launch of its new website, www.lindfastgrp.com, and the new website for Mega Metric, Division of Lindstrom Metric, LLC, http://megametric.com.

According to a press release, website visitors will be able to download the new Lindstrom Technical Manual, view the services and product range offered by either company and connect via e-mail to sales and management personnel. From the contact link, visitors can also connect via e-mail to the outside sales representative responsible by state for Lindstrom and/or Mega.

Contact: Lindstrom Fastener Group, tel. 763-7804200, 800-328-2430, www.lindfastgrp.com or www.megametric.com. ■

WIRE ASSOCIATION INTERNATIONAL MEMBERS seeking employment positions are entitled to FREE “Position Wanted” classified ads. Limit: one ad per issue, maximum three ads per year. This WAI membership benefit is not transferable to nonmembers or to companies.

CLASSIFIED AD RATES: • $1.30 per word for Wire Journal International and on-line classifieds at wirenet.org (20 word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.

BLIND BOX INFO: Blind box numbers assure the confidentiality of the advertiser in both the WJI and the on-line publication. Responses are mailed out within two business

CAREER OPPORTUNITIES SALES REPRESENTATIVE. Traxit North America is looking for a sales representative to become part of the TRAXIT sales team in the following areas: Illinois, Wisconsin and Indiana.

Sales will include dry and wet drawing lubricants, precoats and other wire products. Compensation is negotiable.

Also, looking for straight commission sales in all areas of the USA. Please send resume to: Traxit North America, P.O. Box 381465, Memphis, TN 38138 or e-mail to tnamanf@bellsouth.net.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence.

Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler at jcutler@wireresources.com, w w w. w i r e r e s o u r c e s . c o m . Wi re Resources, Inc., 522 E. Putnam Ave,

days after receipt. Responses to Blind Box ads should be addressed to: Wire Journal International, Box number (as it appears in print or on-line), P.O. Box 578, Guilford, CT 06437-0578 USA. PAYMENT POLICY: All ads must be pre-paid.

DEADLINES: Copy is due a full month in advance, i.e., it must be received by March 1 for publication in the April issue. Classifieds booked on-line, run for at least one-month on-line, from the date of booking. Wire Journal International “Print classifieds” booked on-line as an “add-on” to an “online classified” booking will run in the next available issue of the WJI.

Greenwich, CT 06830, 203-622-3000 or 800-394-WIRE. DIES APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural & PCD DIAMOND DIES. Fair prices & excellent lead times. Contact Paulette, Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@wmconnect.com.

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904-388-3654.

MACHINERY FOR SALE. Complete Niko Decking Line, capacity 120 pcs/hr. Includes: Niko Mesh Welder: Max Width: 68” X 96” long with automatic cross wire loader, 6 X 125 KVA welding Transformers.

Niko Edge Wire Welder: 2 Automatic Wire Loaders, 2 X 125 KVA welding Transformers.

Niko Bending Station: Model: 1152, serial 0999-1152, volts 575, hz 60.

Niko Channel Welder: Model: 1153, serial: 0999-1153, 4 X 200 KVA welding Transformers, volts 575, hz 60.

Line is complete with transfer stations.

Price: $450,000.00 USD. Call: Marc #450-653-6333 Ext: 222 or e-mail ma@premierwire.com.

Serving the non-ferrous and ferrous industries since 1983

JUNE 2009 | 83

CLASSIFIEDS

CLASSIFIEDS

CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment. Tel. 727-863-4700 or by e-mail: urbassoc@ verizon.net.

84 | WIRE JOURNAL INTERNATIONAL

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org.

For more details, you can call her at 203-453-2777, ext. 116.

WIRE FOR SALE

MEDIA

FOR SALE. Titanium wire for sale. .125,” .144,” .160,” .187.” Grade 2, 4, 5. In coil and 12” length. Contact info@filochrome.com.

ELECTRICAL WIRE HANDBOOK. This three soft-cover book set examines materials, equipment and products. They include sections on electrical conductors, insulating materials, extrusion equipment, power transmission, building wire, flexible cords and cables, control and signal cables,

CLASSIFIEDS

communication cables, magnet wire, heater wire and more. Part 1 is Wire and Cable Production Materials, Part 2 is Wire and Cable Production Processes and Part 3 is Types of Cables. The new format allows for more frequent future updates when necessary. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. The handbooks, produced by the WAI’s Electrical Management Committee, are a valuable reference tool for members of the industry to help keep up with today’s rapidly changing technology.

List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore. ■

By order of the U.S. Bankruptcy Court for the Southern District of Mississippi, assets of Tal-Port Industries, LLC

Wire Harness/Cordset Manufacturing, Assembly, Test Equipment & Huge Offering of Copper Wire (Approx. 220-Tons) & Parts Inventory Online Auction Sale Closing Dates: Mexico Assets – Wednesday, June 17th, 2009 at 4:00 PM CDT (local time) USA Assets – Thursday, June 18 th, 2009 at 4:00 PM CDT (local time) Locations:

Saltillo & Fresnillo, Mexico; Mission, Texas & Yazoo City, Mississippi

Inspection:

By appointment only

Highlights Include: • (20) KOMAX Wire Processor Machines m/n’s 40T; 43ST; Alpha’s 355, 411, 433, and 433S; Gamma 333

• (10) MELLO Twisting Machines m/n’s MHT-1700D & MHT-II-2250 • ARTOS Wire Cut & Hot Stamp Machines • Large Quantity of Braiders (16C & 24C carriers), Crimpers, Presses, Applicators and Applicator Dies • HUGE Offering of Insulated Copper Wire (Approx. 220-Tons), 4-22 Gauge Wire on Spools and Other Parts Inventory, Including: Connectors, Clips, Shrink Tubes, Conduit, Brackets, Ty-Raps, Plugs, Terminals, Spacers, Pins, Retainers & MUCH MORE • Large Quantity of Plant Support Equipment, Including: Forklifts, Floor Scrubbers, Air Compressors, Pallet Racking & More

For more information, please contact: LOUIS GOLDBERG Tel: +1 914 235 4905 Email: louis.goldberg@go-dove.com Auctioneers & Licenses: TX - David S. Fox #7775 MS - Go Industry #1131F, David Fox #1130

For more information and terms of sale, please visit www.Go-Dove.com and Search: Tal-Port Industries

JUNE 2009 | 85

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

Amacoil Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Gem Gravure Co Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Amaral Automation Associates . . . . . . . . . . . . . . . . . . . . .46

Henkel Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .81

Howar Equipment Inc/Unitek . . . . . . . . . . . . . . . . . . . . . . .32

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .41

IDEAL Welding Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Cable Consultants Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Kamatics Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

KCS Enterprise Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Cemanco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .80

Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

DoveBid/GoIndustry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Koster Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Eurolls Group/Vitari . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Lamnea Bruk USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Lesmo Machinery America Inc/Cometo . . . . . . . . . . . . . .28

Gita Group of Industries . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Lesmo Machinery America Inc/Appiani . . . . . . . . . . . . . .28

Gimax SRL . . . . . . . . . . . . . . . . . . . . .insert, between 16-17

Madem SA/Madem Reels USA Inc . . . . . . . . . . . . . . . . . . .19

Fabritex Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Manner Plastics LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

FMS USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Mathiasen Machinery Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83

Mario Frigerio SpA/Cabmach . . . . . . . . . . . . . . . . . . . . . . . .2

Micro Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Mario Frigerio SpA/Frigeco . . . . . . . . . . . . . . . . . . . . . . . . .5

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .14

WIRE JOURNAL I N T E R N A T I O N A L

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/fax: 44-1223-360472 franksco@btopenworld.com

86 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

Anand Bhagwat Wire & Cable Services Pvt. Ltd. (WCS) Mobile 91-98-508-38467 abhagwat@wirenet.org

ADVERTISER . . . . . . . . . . . . . .PAGE

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

WIRE ASSOCIATION INTERNATIONAL ADS

Sanxin Wire Die, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Wire Expo 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Sikora International Corp . . . . . . . . . . . . . . . . . . . . . . . . . . .7

WAI ITC: Turkey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Talladega Machinery & Supply . . . . . . . . . . . . . . . . . . . . . .8 Teknor Apex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2 Unitek/Howar Equipment Inc . . . . . . . . . . . . . . . . . . . . . . .32 U.S. Synthetic Wire Die . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .81 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

PLEASE VISIT US AT WIRE RUSSIA BOOTH #FOB39 RECENT PURCHASES — INVENTORY HIGHLIGHTS CBR1030 24” TEC D.T. Twinner, BTTW-600 w/backtwist payoffs.

BPK055 (2) Bongard 14” TW470-KT Barrel Packers, (1999).

CBR984 22” Watson 6+12 Planetary Line with taper, 72” Take up. Still Installed).

WRD831 Samp 8 Wire Drawing Line, MT8.2.4.21 w/annealer, static spooler Still Installed).

MSC1461 Steuler Electroplating Line 400 amps w/(2) GBC rod dwg, Endex 30” drop coiler. Still Installed CBR983 Watson/BEB 61 Wire 22” rigid strander w/72” dual capstan. (still installed).

TBR159/160 (2) Watson & NEB 12 wire 22” tubular stranders. (still installed).

CBR1007 Edmands 1+3 36” Bow twister w/taper, 60” S/L take up. (still installed).

(4) Davis Standard CV Lines: EXRL36: 6”, EXRL33 4 1/2”, EXRL32 3 1/2”, EXRL37 2 1/2”. Still Installed.

CBR985 WMCA 50” Cord twister w/rot. cat, payoffs. (still installed).

RWD477 (6) 72”/60” D.Elect rewind lines. (still installed).

EXR173 Farrel llD Banbury 1000 HP DC w/15” x 12” strainer extruder and 2 roll 84” mill. Still Installed.

CBR957 48” Cook S.T. Buncher, BH-48, Conc. Taper, Still Installed.

CBR953 1.0m Setic D.T Buncher, Model T1085. Still Installed.

EXPL347 2 1/2” Davis Standard/Samp Tandem Wire Drawing Insulating Line with 2 1/2” and 1 1/4” Extruders. Yr. Mfg. 2005.

EXPL319 (2) DeAngeli/Samp 45mm Hi Temp Lines with Zumbach Preheater, SS multipass Capstan, 560mm Dual Parallel Axis Take ups.

EXPL310 1 1/2” 24:1 D.Std. Extruding Line w/24” B.W. Capstan, PA-16 Clipper Dual Take-up, Beta MCS 120 Preheater, Yr. Mfg. 1996.

EXPL252 3 1/2” D.Std. 24:1 Therm II Jktng Line w/2 Skaltek 50” Payoffs, (2) 40” Take-ups, 60” MGS Caterpuller, Accumulator EXPL325 4 1/2” Luigi Jktng Line w/2) 60” Belt Caterpullers, 96” Portal P/O, T/U, 30” multipass capstan.

CBR998 (8) Setic 630mm PA630i D.T. Twinners, (1998).

CBR986 (2) 30” Entwistle SC-30 S.T. Cablers.

CBR995/CBR989 630mm MGS & TEC D.T. Twinners, NMC 800mm D.T. CBR923 1.25m Pourtier Drum Twisting Line, w/12 630mm Neutralizers, tapers, cat, 1.25m rot. Payoff, (1993) CBR948 48” TEC Drum Twister w/(2) Conc. Tapers.

CBR712 (7) 36” Cook S.T. Buncher, BH-36.

CBR927 (10) 560mm Watson/Kinrei D.T. Twinners, NB-560, 1998.

TKU1021 30” D.StD Clipper Dual Parallel Axis Shaft Type, PA-30.

TKU1106 50” Clipper Dual Parallel Axis Take up, PS-50.

TKU1057 96” Bartell S/L Take-up. Rebuilt.

TKU943.2 84” Bartell S/L Take up, SLTU-84. Rebuilt.

WRD837 (4) Niehoff M30 Int Wire Drawers w/VG_30 annealer, 75 kw DC motor, controls.

WRD835 16” Endex Drop Coiler.

JUNE 2009 | 87

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE

Wind up with an Amacoil/Uhing assembly for perfect pitch every time Pitch is adjustable (10:1) without requiring gear changes or adjusting motor speed. A single Amacoil/Uhing assembly may be used for winding many different diameter materials. Automatic reversal of the traverse is mechanically controlled – without clutches, cams or gears. No electronics or programming needed.

FEATURES • Zero backlash.

• Automatically synchronizes pitch with take-up reel rotational speed.

• Traverse drives with up to 800 lbs. axial thrust.

• Smooth, unthreaded shaft won't clog or jam – no bellows assembly needed.

• One inexpensive, unidirectional motor drives both the traverse and take-up reel.

• Free movement lever – no need to "jog" system on and off to position linear drive.

• Options and accessories for every winding situation.

• Light, medium and heavy-duty systems.

For Brochure or CD-ROM Call toll free 800-252-2645

email: amacoil@amacoil.com

www.amacoil.com AMACOIL, INC. PO Box 2228 • Aston, PA 19014 • Phone: 610-485-8300 • Fax: 610-485-2357

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