WIRE BULLETINIndia’s Quarterly Bulletin Dedicated to the Wire and Cable Industry

VOLUME II | ISSUE I | JANUARY 2011 Rs. 125

A D V E R T I S M E N T

IN THIS ISSUE:Editorial .............................. 2Calendar & Event Review ..... 3Industry News ..................... 4Business Innovation ............ 6Corporate Focus.................. 8Featured Concepts ............ 10Global News...................... 12Products, Media, & Technology .................... 13Production Tips ................. 16Ask the Expert ................... 17Technical Article................ 18Economic News ................. 21People on the Move........... 22Ad Showcase..................... 24

Global wire and cablemarket to cross USD113.9 Bn

According to a new report by Global Industry Analysts, Inc., a market researchpublishing company, the global market forinsulated wire and cable is forecast to exceed USD 113.9 billion by the year 2015.The factors influencing the market in amajor way include a resurgence of theglobal construction industry and the robustexpansion of the energy sector. Further, therise of smart grids in matured economiesand increased investments in high-speedrail networks are poised to drive marketgrowth in the next few years. The insulatedwire and cable market suffered a severeblow during 2008 and 2009 mainly becauseof the global economic recession.

Slowdown in construction activity, espe-cially in matured markets such as NorthAmerica and Europe, and decline in world-wide automotive sector impacted the wireand cable revenues to a noticeable extent.Likewise, the weak demand for wire andcable products in other end-use sectors suchas telecommunications and electronic equip-ment also discouraged market growth. How-ever, the wire and cable market is expectedto witness significant demand growth in thecoming years driven by robust expansion inthe wind energy, nuclear energy, and othergreen energy sectors. Information process-ing and communications—two of the largestmarkets— are expected to prop up growth inthe global insulated wire and cable market.

In wireless communications, applicationssuch as base station transmission units andantenna towers are expected to drive the demand for wire and cable.

Asia-Pacific represents the largest as wellas the fastest growing regional market for insulated wire and cable worldwide, as statedby the new market research report. Prior tothe onset of global economic recession in2008, the Asia-Pacific insulated wire andcable market grew by leaps and boundsdriven by huge growth in telecommunica-tions, energy, and construction/infrastructuresectors. The insulated wire and cable marketwitnessed a decline in 2009 in the region andis likely to recover by 2011 driven by grow-ing demand for telecommunications, datawire, and cable products, especially in Chinaand India.

The telecommunications, data wire, andcable category constitutes the largest aswell as the fastest growing segment in theglobal insulated wire and cable market.

continued on p. 5

Prysmian, a global player in the energyand telecommunications cables industry,and Ravin Cables Ltd., its Indian jointventure subsidiary, recently presentedtheir development strategies and growthobjectives for the Indian market.

“Our commitment is to establish a cred-ible and sustainable full range cables sup-

plier in the Indian market, targeting a 10per cent market share, said Fabio Romeo,COO, Prysmian Group, at a meeting withIndian journalists in Mumbai.

“Furthermore, by leveraging on Prysmian’sstate-of-the-art technology, expertise, andcapabilities, we believe that Ravin Cablescan become one of the top three cable systems suppliers in India. To deliver these ambitious objectives, we are committed toimplementing a long-term investment pro-gramme involving resources, training, tech-nologies, and manufacturing facilities.

“The group’s initial plan is to invest ina new high voltage cable manufacturingunit of up to 220 kV as well as to improveRavin’s product offer in the industrial cables market in sectors that include auto-motive, mining, and renewable energies.”

continued on p. 5

Vijay Karia and Fabio Romeo.

Prysmian-Ravin targets 10% market share for cables

QUOTABLEQUOTES

“I have been a great believer in theIndia growth story.” ~ Wilfried Aulbur,MD & CEO, Mercedes Benz India

“India seems to be one of the only few bright beacons in the otherwisedark and confused global economic scenario.” ~ Prashanth Narayan, VP & Head (PMS Investments), ING Investment Management India

NEWS BITES• Tata Steel plans to invest Rs 4,500crore this fiscal for various projects,followed by Rs 7,000 crore in 2011-12.The company is also in the process ofplacing orders for the six-million tonneOrissa project and should start production in three to four years.

• Steel Authority of India Ltd’s Ranchi-based R&D Centre for Iron and Steel(RDCIS) proposes to develop 18 newproducts in 2010-11, in collaborationwith SAIL’s manufacturing units.

ASK THE EXPERTQ: I am a mechanical engineering student and a member of a group project for a Manufacturing Processes course. Our student group was instructed to design aprocess for the manufacture of 2024 Aluminium wire. We must focus on defining the complete process parameters. Can you help provide your expertise?

See answer on p. 17

See page 7.

&

Sterlite Technologies, provider of trans-mission solutions for the power and tele-com industries, and CTC Cable Corp.have announced a strategic relationshipwherein the former would manufacturespecialty ACCC power conductors for theIndian market, using CTC’s patentedACCC conductor technology.

“Sterlite has been engaged in actively ex-ploring the latest technologies to make iteasier, faster and more cost-effective forutility companies to build power infrastruc-tures. India needs to rapidly increase thecurrent-carrying capacity on its grid to keeppace with its economic development.ACCC conductors would offer India aunique ability to increase the current-carry-

ing capacity of the existing lines and to significantly improve the overall econom-ics on new lines,” said Rajendra Mishra,COO (Power), Sterlite Technologies.

US-based Composite Technology Cor-poration (CTC) develops, produces, andmarkets innovative energy efficient prod-ucts and renewable energy projects for theelectrical utility industry. CTC’s productsincorporate advanced composite materialsand innovative design solutions that pro-vide solutions to efficiently modernise theelectrical grid systems.

CTC’s principal subsidiary is CTCCable Corp. and its primary product is thepatented ACCC® conductor for transmis-sion and distribution power lines. TheACCC® product line is designed aroundadvanced composite materials which en-able the highly efficient transmission ofelectricity.|WB

Sterlite signs deal with CTC Cable

Electrical and power equipment majorHavells India has doubled its cable andwire manufacturing capability at an invest-ment of Rs 120 crore. The company, whichhas a 10 per cent share of India’s Rs 12,000crore cable and wire industry (includingelectricals), expanded its manufacturingplant at Alwar in Rajasthan to make Rs2,400 crore worth of electrical goods.

“The expansion is in line with the demand the market is witnessing in both thedomestic and international markets,” saidSunil Sikka, President, Havells India. According to Sikka, the capacity expansionwill also help the company in meeting thegrowing domestic demand and also to targetnew emerging markets such as the MiddleEast and Africa regions. The company expectsthe demand of its cable and wire productsto hit Rs 1,800 crore by 2012 from the

organised construction sector and independ-ent home builders.

“We now have the capacity and it is upto the marketing division to do its job,which they would be able to achieve asthere is a 10-15 per cent growth in the mar-ket,” Sikka said. He added that the invest-ment of Rs 120 crore was a part of the Rs200 crore expansion plan which the com-pany had earmarked. “We regularly investin capital expenditure for the company’sexpansion,” he said. The state-of-the-artwire and cable plant in Alwar was first acquired by the company in 1996. Theplant manufactures various ranges of lowtension, high tension, and electrical highvoltage cables.

Currently, the USD 1.2 billion companyis present in 50 countries with 11 domesticand four international manufacturing plantswhich churn out products like switchgears,motors, geysers, fans, CFL lamps, and luminaires.|WB

Havells doubles its capacity

EDITORIAL

WIRE BULLETINPublisher | Steven J. Fetteroll

Editor | Huned Contractor

Contributing Writer | Mark Marselli

Director of Marketing & Corporate Communications | Janice E. Swindells

Graphic Artist | Adrienne E. Simpson

Advertising Sales | Robert J. Xeller & Anna Bzowski

WIRE BULLETIN is published quarterly by WAI Wire and Cable Services Pvt Ltd, a wholly owned

subsidiary of the Wire Association International, (WAI) Inc.

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The best of any achievement is that it gets you into soaringspirits. That is what we can say after enjoying three

productive days at the Wire & Cable India show at Mumbai in November. The buzz at the exhibition prompted dozens of introductions, enquiries, and new WIRE BULLETIN subscribers.We received more than enough content to include in this issue.More importantly, we were pleasantly surprised by the strongcontingent of the foreign companies, a clear indicator that Indiais being taken very seriously by manufacturers from Germany,France, Austria, USA, U.K., and China.

The foreign exhibitors we spoke to shared the unanimous opinion that India is certainly themost ‘happening’ place; its growth ensured by the government’s proactive policies of strength-ening the country’s infrastructure and power domains. Meanwhile, the boost in the automobilesegment has added another feather to this upward spiral of the economy. Yet, this outlook istempered by the recent spate of scams and corruption deals that reveal one inescapable fact: a rising economy breeds greed. As such, not all foreign manufacturers are rushing to establishproduction plants in India. Many—remaining focused on the sale and service of their products—have adopted a wait and watch stance.

On the news front, the feedback we have received from subscribers over the past 12 monthsindicates that WIRE BULLETIN is on the right path. After a superb first year, we too, are in an expansion mode, increasing the publication from 16 to 24 pages to accommodate more industry and technology-related articles and to provide continued value to our readers. New content debuts in this issue and includes Company Profiles on pp. 8 and 9 and an EconomicNews column on p. 21.

As the activities of the Wire Association International in India are also set to increase, it is inyour interest to become a member and obtain the benefits of networking. See membership

information on p. 15.

We invite your suggestions to help us continually improve the publication. Keep writing in.

JAN

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Huned Contractor

Editorhcontractor@wirenet.org

CALENDAR & EVENT REVIEW

WORLD CALENDAR

February 11-14, 2011: Energy Power India – 2011Bangalore, India. This international level mega electrical convention and trade showwill be held at the Bangalore International Exhibition Centre (BIEC). The event, organised by ELCA and conducted by AdsStation, will enable manufacturers, suppliers,distributors, agents, electrical consultants, and those in the electricity industry to pro-mote brand image, establish contacts, expand markets, and initiate business deals. Theevent will also promote electrical safety, energy conservation, and green energy. Contact: AdsStation | 1365, 2nd Floor, Sarakki Gate, Kanakapura Main Road, Bangalore - 560 078, Tel.: 080-65707899, www.adsstation.biz.

March 15-17, 2011: Cables 2011Cologne, Germany. This international conference and exhibition for the plastic cables industry will be held at the Maritim Hotel, Cologne. It will be the 11th international con-ference of its kind organised by AMI for companies involved in the cable industry. Thiswell-established event regularly attracts more than 250 delegates from across the globalsupply chain, bringing together cable producers, raw materials suppliers, and equipmentmanufacturers. The two-day programme will cover key technical, material, and regula-tory trends and developments in the context of a challenging business environment.Contact: www.amiplastics.com.

March 15-18, 2011: CABEX-2011Moscow, Russia. Organized by MVK International Exhibition Company, this event forcables, wires, fastening hardware and accessories and installation technologies(CABEX). will be held at the EcoCentre.Contact: Natalia Medvedeva | Tel./Fax: 7-495-925-34-82 or 995-05-95, ext. 260,mns@mvk.ru, www.cabex.ru.

April 4-8, 2011: Hannover MesseHannover, Germany. Deutsche Messe, organiser of the world’s largest technologyevent (Hannover Fairs), has announced Hannover Messe 2011, a leading industrialtechnology event that will showcase 13 leading international trade fairs at a singlevenue in Hannover, Germany. More than 130 firms—many of them from India—areslated to participate. The spotlight will be on industrial automation, energy technology,power transmission, industrial sub-contracting, and services.Contact: Deutsche Messe | Messegelände, 30521 Hannover, Germany, Tel.: +49-511890,Fax: +49-5118932626, www.hannovermesse.de.

May 2-5, 2011: Interwire 2011Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the tradeshow (May 3-5) and the Wire Association’s 81st Annual Convention (May 2-5). Interwireis an international trade event that draws participation from more than 50 countries aroundthe world. It is the largest and longest running wire and cable marketplace in the Americas.The exhibits feature technology and information from the more than 500 companies thatare represented. More than 90 distinct elements comprise the technical conference, whichis the most robust offering ever, featuring technical paper and operational presentations,courses, production solutions, a productivity workshop, panel discussions, guest speakers,and a keynote address from astronaut Mike Mullane.Contact: WAI | Tel.: (001) 203-453-2777, www.wirenet.org.

May 2-5, 2011: Global Continuous Casting ForumAtlanta, Georgia, USA. WAI offers the Global Continuous Casting Forum for copperpractitioners from around the world. The program runs concurrently with Interwire 2011.Contact: WAI | Tel.: (001) 203-453-2777, www.wirenet.org.

May 18-19, 2011: National Electrical Wire Processing Technology ExpoMilwaukee, Wisconsin, USA. The National Electrical Wire Processing TechnologyExpo is one of the exclusive showcases of the latest technology for the electrical wireharness, wire and cable processing, and related industries.Contact: www.electricalwireshow.com.

May 23-26, 2011: wire RussiaMoscow, Russia. Organized by Messe Düsseldorf, the International Wire and CableTrade Fair (wire Russia) will be held along Tube Russia at the ZAO Expo CentreKrasnaya Presnya.Contact: Messe Düsseldorf North America | Tel.: 312-781-5180, erowe@mdna.com.

June 15-17, 2011: Wire & Cable Expo ChinaTianjin, China. To be held at the Tianjin International Exhibition Center, the 15thstaging of this event will include a conference, exhibition andfeatured events.Contact: AIT Events Co., Ltd. | Tel.: 86-10-85868930, www.bvents.com/event/389490-wire-cable-expo.

Event ReviewsIndia economic summit focuseson manufacturing

India’s development trajectory has seen agreen revolution for agriculture, a white revo-lution for the diary industry, a technology revolution in the IT sector, and now Indianeeds a revolution for manufacturing. Thiswas the view expressed by JyotiradtiyaScindia, Minister of State, Commerce and Industry at the India Economic Summit organ-ised by the World Economic Forum (WEF) inpartnership with the Confederation of IndianIndustry (CII) from November 14 to 16, 2010,at New Delhi. The minister was addressing theplenary session on ‘India’s Role In GlobalCompetitiveness’ on the second day of thesummit and was categorical in stating that development initiatives and financing modelscan create global competitiveness for Indianmanufacturing by leveraging India’s strengthin skilled manpower.

The minister defined the contours of anew manufacturing strategy focusing on ra-tional exit mechanisms, technology zones,training programmes, and infrastructure de-velopment that is expected to be announcedby the Ministry of Commerce and Industryvery soon. Scindia added, “The main dividein India was that between those who hadopportunities and those who did not. Therole of the Indian government is to reach

out and provide equal opportunities. Alongwith information technology and engineer-ing growth, we will be able to do that.”

Pawan Munjal, Managing Director andChief Executive Officer, Hero Group, em-phasized some of the fundamental constraintsthat need to be addressed in achieving a decent and sustainable manufacturing growthpath. He listed poor infrastructure, redundantlabour laws, and the lack of capacity of theIndian capital goods sector as the some of theobstacles that need to be overcome for the Indian manufacturing sector to move ahead.

Mining sector focusAn exclusive show highlighting the mining

sector of India will be presented with bC India2011 scheduled to take place at Mumbai fromFebruary 8-11, 2011. Under the emergingeconomic upswing, effective and environ-mentally-friendly mining technology is nowin greater demand in India and worldwide.bC India, a Bauma Conexpo show, will offera platform for machines, processes, and so-lutions for the construction, building, andmining industries. According to figures fromthe India Brand Equity Foundation (IBEF),prospecting for ores such as iron, bauxite,chrome and titanium was carried out in almost 3,000 Indian mines in 2008-09.

A press release from the show organizersaid, “The Indian mining groups must de-velop their capacity over the next few yearsto meet the domestic energy demand. Thecountry’s coal production must rise annuallyby 8-10 per cent to satisfy the growing energydemand of India’s processing industry alone.Currently, around 90 per cent of Indian coal isproduced by two state-owned mining groups:Coal India Ltd. (CIL) and Singareni CollieriesCompany Ltd. (SCCL). India is the seventh-largest country in the world in terms of itsarea, and its infrastructure development willrequire huge quantities of raw materials.”|WB

Scindia

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INDUSTRY NEWSBedmutha to set up new facility

Bedmutha Industries, one of the leadingsteel wire manufacturers in western India,initiated an IPO of Rs 92 crore to set up a36,000 tonnes per annum (tpa) manufactur-ing facility for low relaxation pre-stressedconcrete (LRPC) wire and spring steel wirewith installed capacity of 18,000 tpa on 12acres at Nashik in Maharashtra. LRPCwires, which are in high demand, are usedin pre-stressed concrete girders for roads,railway sleepers, and flyovers. It also plansto set up a high-tech galvanising plant of48,000 tpa and manufacturing of alu-minium rods and conductors with capacityof about 42,000 tpa. Its expansion planshave received a ‘mega project’ status underthe package scheme of the incentives of-fered by the Government of Maharashtra.

K.R. Bedmutha, Chairman, Bedmutha Industries, said that the company has alreadyplaced orders for all the critical machineriesrequired for the new project. Currently thecompany has four manufacturing units atNashik with a galvanised wire capacity of25,300 tpa. It also produces high carbon PCwire, spring steel, and binding wires. It of-fers a wide range of wire and wire productssuch as cable armour wires, stray wires,spring steel wires, and barbed wires. “With

all the four manufacturing units at Nashikstrategically located in proximity to thesource of raw materials and markets, thiswill ensure cost savings and logistic bene-fits,” Bedmutha said. The company hasrecorded a turnover of Rs 150 crore and netprofit of Rs 10 crore for the year endedMarch 31, 2010.

Shilpi Cables to expand its product portfolio

Delhi-based Shilpi Cable Technologies,a radio frequency (RF) cables manufac-turer, is planning to set up a wire and cableassembly shop, expand its product portfo-lio, and manufacture low voltage power ca-bles and cable accessories. The funds willbe channeled out of an IPO of over Rs 50crore. A family-owned venture in operationfor more than three decades, the companybought out its joint venture partner, Rosen-berger Hochfrequenztechnik GmBH & CoKG, for Rs 22 crore in 2008. “The JV wasset up to manufacture RF cables but ourpartner wanted a majority stake which wewere not willing to concede,” the com-pany’s director, Manish Goel, said in amedia interview. The company caters pri-marily to the telecom sector and its prod-ucts are used in telecom towers.

“This segment is poised for exponentialgrowth over the next few years and henceour growth prospects are immense,” Goelsaid. In FY10, the company clocked aturnover of Rs 170 crore and profit beforetax of Rs 14.9 crore. According to the stockmarket buzz, given the growth prospects ofthe industry, the company could double itsturnover and profit after tax in the next twoyears. Recently, the company started a newdivision to cater to the passive telecom infraspace. “This division will look after the op-erations and maintenance of networks andalso be active in the in-building wireless so-

Nashik is known as a pilgrimage city.

lutions space,” Goel said. The companywould also get engaged in the cell-site roll-out across India for independent power in-frastructure companies, he added. ShilpiCables is also eyeing overseas markets inAfrica and the Middle East where there istremendous scope for its services.

Also, Shilpi Cable Technologies has en-tered into an agreement with CrossbowTelecom Projects to undertake turnkey tele-com service provider (TSP) business that isin relation to undertake civil and electricalworks required for the setup and establish-ment of the telecom infrastructure. Throughthis pact, the company will establish a sep-arate TSP division within its managementcontrol. Crossbow will be responsible toprovide project management and consul-tancy for all the locations where TSP proj-ects are implemented. Further, Crossbowwill also identify the clients, liaison, and se-cure projects on behalf of Shilpi Cable aftertaking due approvals from its board of di-rectors. As per the agreement, Crossbowwill be entitled to 33.33 per cent share ofgross profit generated from all the projects.

Bajaj Electricals receives orderof Rs 408 crore

Under the aegis of the Rajiv GandhiGramin Vidhyutikaran Yojana (RGGVY),Pune-based Bajaj Electricals Ltd. (BEL)has received orders worth Rs 408 crore forthe construction of 312 kms of 400 kV dou-ble-circuit transmission lines, village elec-trification, and high mast and streetlightening segments. With these new or-ders, the company’s order book has crossedRs 1,150 crore, to date. BEL, a 72-year-oldcompany with a turnover of over Rs 2,252crore, is a part of the USD 6 billion (Rs29,000 crore) Bajaj Group. It has six strate-gic business units i.e., C. Engineering andProjects, Appliances, Fans, Luminaires,Lighting, and Morphy Richards. Its towermanufacturing facility has been approvedand appreciated by Powergrid and severalelectricity boards across the country.

BEL’s plant manufactures a range of tow-ers of 110/132/220/400/765 kV single/dou-ble circuit power transmission lines. Thepresent capacity for manufacturing trans-

mission line structures is more than 30,000tonnes per annum. It is the first company inIndia to have designed, type-tested, andsupplied monopoles of 400 kV double cir-cuit line with a height of 42 metres for thePower Grid Corp. of India Ltd.’s projectline from Dadri to Ballabhgarh. There aremany advantages vis-a-vis the lattice towers,the biggest being that monopoles provideease of erection in areas where space is aconstraint. For a lattice tower four founda-tions are required for the tower legs thatconsume land of up to 100 sq. meterswhereas a monopole can be erected in a 5 sq.meter area.

Wire rod demand favours steel giants

The increasing intake by the constructionand manufacturing sectors has helped majorsteel companies like the state-run Steel Au-thority of India Ltd. (SAIL) and Vizag Steelpost excellent sales figures for wire rod asreflected in the financial results of 2010. Infact, SAIL achieved its best-ever July-Sep-tember quarter sales of 3.17 million tonnes(MT) due to this demand. “In comparisonto sales in the previous quarter (Q-1), theSteel Authority of India Ltd. achieved agrowth of 30.8 per cent,” the company reported in a statement. The steelmaker saidthe sale of wire rod during the period increased by 60 per cent compared to thecorresponding period last year; and that thesales of other products like bar, sheet, andcoil was also higher.

“During the July-September quarter of2010-11, SAIL sold 8.5 lakh tonnes of special and value-added steel products,showing a growth of 10.1 per cent over thecorresponding period last year,” the state-ment said. SAIL has an annual steel production capacity of about 14 milliontonnes. Meanwhile, the cumulative produc-tion of saleable steel comprising wire rod,rebar, rounds, re-rollables, and structuralsat Vizag Steel’s Visakhapatnam rose to 1.5million tonnes during the first half of 2010.The company sold 1.33 million tonnes ofsaleable steel in the first six months of thelast financial year. This was mainly on theback of record sales in September that stoodat 3,50,000 tonnes, 70 per cent higher ascompared with the same period last year.

Kalpatru wins transmission linecontract in Africa

The Indian firm, Kalpataru, has beenawarded a contract to construct a high-ca-pacity electricity transmission line fromMombasa to Nairobi. The 400 kilovolt (kV)line with a price tag of Sh 7.4 billion (USD91 million) will be used to transfer electric-ity from thermal power stations in thecoastal area to Nairobi. The plants includethe 90 MW Rabai diesel plant that is already operational, the 120 MW diesel facility being erected by KenGen, and theproposed 300 MW coal power plants ex-pected by 2014.

“This line will improve the power systemstability, reliability, and reduce technicallosses besides playing a major role in regional power trade,” said Joel Kiilu, managing director, Kenya Electricity Trans-mission Co. The project, which is being implemented in a turnkey basis, will in-volve the construction of 393 km of 400 kVand 81 km of 220 kV transmission linesand should be completed within 27 months.A recent news report stated that the com-pany has also received two other ordersworth Rs 3.84 billion. The first order is tosupply and construct a transmission line in

One of BEL’s transmission towers.

BEL’s Pune plant.

A view of the plant.

4 | WIRE BULLETIN

INDUSTRY NEWSUS, Japan, and Western Europe will con-tinue to lead the world in production ofmore advanced, highly-engineered fasten-ers. However, Chinese firms are narrowingthe technological gap as their access to capital grows and they acquire more manu-facturing experience.|WB

Prysmian-Ravin continued from p. 1

As part of its worldwide expansion strategyin high growth countries and in the high-tech cables and systems sector, Prysmianacquired a 51 per cent stake in Ravin Ca-bles early in 2010, thus entering into a jointventure agreement with the Karia familythat now controls 49 per cent of the com-pany. Ravin Cables’ Board of Directors appointed Luigi Sarogni as chief executiveofficer and Vijay Karia as chairman andmanaging director of the Board of Directors.“Thanks to the integration with Prysmian,we will be able to bring to India state-of-the-art cable technologies that werescarcely available before,” Karia said.

The integration has started yielding itsfirst business results. Reliance Infrastruc-ture has awarded Ravin Cables contracts fordeveloping 220 kV systems for varioussites. For the first time, cables and networkaccessories produced by Prysmian will beprovided to the Indian market. In particu-lar, Ravin Cables will supply some 52 kmsof 220 kV high voltage cables, includingjoints and terminations, in Mumbai. The ca-bles will be manufactured at Prysmian’smost advanced plant, capable of producingcables of up to 500 kV. The Indian highvoltage cables and systems market is ex-pected to grow strongly, doubling in sizeover the next three years, thanks to thecountry’s dynamic economy and the needto rapidly develop the power grids. The

group is considering starting local produc-tion of high voltage cables at Ravin Cables’facility in Pune.|WB

Global wire and cablecontinued from p. 1

The growing adoption of the Internet andthe emergence of wavelength division multiplexing (WDM) technology are fu-elling the market for telecommunications,data wire, and cable across the world.Power wire and cable represents the othermajor product segment in the global insu-lated wire and cable market. The report pro-vides annual sales estimates and projectionsfor the insulated wire and cable market forthe following geographic markets: USA,Canada, Japan, Europe, Asia-Pacific, theMiddle East, and Latin America.

The major players profiled in the reportinclude ABL Electronic Supplies Inc., AEICables Ltd., AFC Cable Systems Inc.,Alcan Cable, Alcatel-Lucent SA, AlcoaInc., Amphenol Corp., Asia-Pacific Wire &Cable Corp. Ltd., Brand-Rex Ltd., CableUSA Inc., Carlisle Interconnect Technolo-gies, Cerro Wire LLC, Copper Cable Co.,Delphi Corp., Draka Holding NV, DrakaLtd., Electrical Components International,Finolex Cables Ltd., Fujikura Ltd., Furukawa Electric Co. Ltd., General CableTechnologies Corp., Hitachi Cable Ltd., LSCable Ltd., Nexans, NKT Cables GroupGmbH, Olex Cables Ltd., Permanoid Ltd.,Prysmian Cables & Systems Ltd., ReaMagnet Wire Co. Inc., Southwire Co., Sumitomo Electric Industries Ltd., andTele-Fonika Kable Handel SA, among others.|WB

Maharashtra worth Rs 2.86 billion; the sec-ond is to set up a transmission line in thePhilippines for Rs 980 million.

GPIL selects CableBuilder©

Gupta Power Infrastructure Ltd. (GPIL),a leading cable brand in India with aturnover of USD 170 million, has chosenCableBuilder© to further enhance its designand quoting processes. CableBuilder is apopular and powerful cable design softwaredeveloped by Cimteq Ltd., the industrypartner of InnoVites.

According to M.K. Gupta, Managing Director, GPIL, “The investment in thissoftware is a part of the company’s strategyto further enhance the R&D infrastructurein GPIL. It makes the company more re-sponsive and effective when it comes tomatching customer requirements with tech-nological innovations.”

InnoVites is the exclusive reseller of CableBuilder in India and sells and supportsthis solution from its Cable CompetenceCenter at Hyderabad. InnoVites also devel-ops and sells ERP software specific forcable manufacturers: InnoVites for Cable©.This innovative and complete business solu-tion is based on Microsoft Dynamics® AX.

Tata Steel to invest Rs 1,000crore in plants

Tata Steel proposes to invest Rs 1,000crore to establish two units in the GopalpurIndustrial Park being developed by it in theGanjam district of Orissa. About Rs 250crore will be spent on a 50,000 tonnes perannum (tpa) ferro-chrome plant. The com-pany will also erect a 4,00,000 tpa rebarsteel mill. These units are expected to go onstream by the end of 2012. The foundationstone for the industrial park was laid by theOrissa chief minister Naveen Patnaik. Thepark is coming up on 3,200 acres taken overby the company more than a decade ago forthe mega steel plant near Gopalpur that thecompany had then proposed.

According to a media report, Tata Steelwill use the strength of companies in theTata Group to develop the internal and ex-ternal infrastructure with a view to attract-ing maximum investment to the industrialpark. Speaking during the stone-laying cer-emony, H.M. Nerurkar, Managing Director,Tata Steel, said, “This industrial park is ex-pected to attract investments worth Rs10,000 crore to Rs 15,000 crore through es-tablishment of ancillary and downstreamindustrial units in the area.” The new proj-ect would depend on rain water harvesting,100 per cent recycling of used water, anddesalination of sea water.

Sify Technologies to lay globalundersea cable

Chennai-based Sify Technologies, providerof enterprise and consumer Internet serv-

ices, has proposed to lay an internationalundersea cable connection between Delhiand Singapore, Sify Technologies’ chair-man and managing director, Raju Vegesna,is reported to have told the EconomicTimes. The discussions in this regard are innascent stages. He didn’t divulge furtherdetails about the project. This will be in ad-dition to the project the company has onhand. According to the report, it has alreadyentered into an agreement with the MiddleEast-based submarine cable operator, GulfBridge International, to lay an internationalundersea cable to India, which will enabletelecom operators and other communicationcompanies to connect in the region.

India to lay optical cablethrough Bangladesh

Bharat Sanchar Nigam Ltd. (BSNL), thestate-run telecom operator in India, will lay optical fiber cable (OFC) throughBangladesh to connect northeast India withthe rest of the world. Speaking on the side-lines of launching Worldwide Interoperabil-ity for Microwave Access (WiMax) servicesin Tripura, BSNL General Manager Debkumar Chakraborty said, “BSNL willlay optical fiber from Agartala to Dhaka.Around 12 km optical fiber is needed toconnect Agartala and Akhuwra (nearesttown in Bangladesh to capital Agartala) tele-phone exchange. We will also be extendingour network from Sabroom to Chittagong(in southeast Bangladesh) sea port and thento Ashugang (in eastern Bangladesh) port.”He added that apart from overcoming thegeographical isolation of the northeast region, the new project will give relief to thepresent OFC network passing through thehills that often gets disconnected.

Global fastener demand to reach new heights

The global demand for industrial fasten-ers is forecast to expand 8.5 per cent peryear to USD 80.5 billion in 2014. Accord-ing to a media report, the global motor vehicle output will make a strong recoveryfrom the declines registered during the2004-2009 period, bolstering associatedfastener demand. The Asia/Pacific region isexpected to register the strongest sales increase through 2014, paced by healthy12.8 per cent annual demand gains inChina. China surpassed Japan to becomethe world’s largest manufacturer of motorvehicles in 2009, providing industrial fas-tener producers with important new salesopportunities as output continues to climb.Producers in developed areas such as the

A street in Mombasa.

A street in Dhaka.

JANUARY 2011 | 5

BUSINESS INNOVATION

Sikora, headquartered in Bremen, Germany,has developed a reputation over three decadesas a global leader in the supply and support ofexcellent measuring, controlling, and testingequipment for the wire, cable, plastics, andrubber industries. In 1972, Harald Sikora presented the first non-contact measuringsystems for energy cables. This technology enabled the sensor to detect the position ofthe cable inside the CV tube where power cables are cured on a non-contact basis. Theinnovative product gained immediate successand became the standard system for CV lines.

Today the sensor is known as ‘the Sikora’around the world. On September 12, 2002, thecompany evolved into Sikora AG stock company.Since then the company has expanded rapidlyand has set up regional offices in China,France, India, Italy, Japan, Korea, Russia,Turkey, Ukraine, and the USA.

WB interviewed Harry Prunk, CEO, SikoraAG, about the company, its plans, and itsfocus on India. The following are excerptsfrom the Interview:

Q: What has been Sikora’s pioneeringcontribution to the control of various parameters in the production of data cables?

A: Sikora offers a great variety of meas-uring and control devices that are suitablefor the production of data cables. One ofthese devices is the Centerview 8000. Ithelps the operator of an extrusion line

to center the conductor in the insulation,monitor the concentricity and moreoverprovide measuring results that allow for acontrol of the outer diameter or wall thick-ness to the nominal size. A unique feature is the patented cloud diagram. This is an additional way of visualizing the measuredvalues of the ongoing measurement at theprocessor system EcoControl.

Another technology which plays an important role during the production of datacables is capacitance measurement withhigh resolution. For this application Sikoraoffers the Capacitance 2000, which includesa multi-zone electrode to measure the capacitance including FFT analysis andSRL prediction.

Q: When did Sikora establish a presencein India and what was the market scenariothen?

A: Sikora has been active in the Indianmarket for more than 20 years. Originallywe started our business with sales repre-sentatives in India who sold our devices tothe customers on site. In 2004 we estab-lished an office in New Delhi, ensuring re-liable and flexible customer support.

Q: How well have Sikora’s products beenaccepted in India?

A: On the one hand, our products, whichare made in Germany, have a very goodreputation in India. On the other hand, theproduct on its own is not sufficient to con-vince customers. An important aspect isservice. Our customers should feel allaround satisfied. If they need help we arethere to support them. That’s the reasonwhy we have service employees in NewDelhi and Mumbai today who care for allcustomer needs.

Q: Does the production of data cables inIndia require any specific customisation inSikora’s products?

A: There are no customisations necessaryto run the devices. This applies [to] all theother devices that we offer. The productionrequirements for high-quality data cablesare the same in India as somewhere else inthe world.

Q: Has Sikora set up a manufacturingbase in India? Or is there any plan to do so?

A: We think our strength results from thecapability to control the quality of the man-ufacture of our products. This can be bestachieved at our headquarters in Bremen. Inparticular, with regard to the quality man-agement norm ISO 9001, our intention is tokeep our production in Germany.

Q: What is the company’s current marketshare in India?

A: We are one of the leading suppliers ofmeasuring and control technology in India.This is confirmed by the excellent turnoverdevelopment in the last few years. Due to ourinnovative technology and the service net-work we have a very good market position.

Q: What are your future plans for theIndian market?

A: We aim at further extending our cur-rent market share in India. We still see somepotential in that area. That means we aim atentering new markets other than wire andcable. We believe that our products are alsosuitable for other industries to serve qualityneed on the highest level.

Q: Do you see the Indian growth story,especially in infrastructure and automo-biles, as an integral part to your operationsin India?

A: For years we have pursued the devel-opment in India and notice that there isgreat potential in the automotive, commu-nication, installation, and energy industry.This has also been confirmed at the Wire2010 show in Mumbai where we got manydevice inquiries for these application fields.

Q: Have there been any particular demands from the Indian wire and cablesector regarding your Centerview 8000 orany of the other products?

A: There is a significant demand for ourCenterview 8000 regarding online qualitycontrol of communication, installation orautomotive cables of up to 25 mm. More-over, there is the need for measuring tech-nology in insulating and jacketing lines thatoffers more than conventional diametermeasuring devices. In this respect the X-Ray 6000 for eccentricity, wall thickness,diameter, and ovality measurement plays animportant role in the Indian market.

Q: How important is R & D in your com-pany’s portfolio of various activities?

A: Research and development is our secret of success. It is only with innovativeproducts that you remain competitive andassert your position in the market. Tostrengthen our position we invest a greatpart of our turnover into research and development. Moreover, in February 2011we will dedicate our new Technology Center at our headquarters in Bremen.

Q: What is the next generation of meas-uring systems that will be offered by Sikorafor the global market?

A: Sikora has many new as well as further developed products in the pipeline.There is for example the new online lengthmeasuring system Length 6000. This device is pioneering as the technology defines the length of cables through thecomparison of image patterns. It is reliablefor all kinds of products, even for thosewith reflective surfaces. Apart from that, wework on several projects that generate ideasfrom customers and machine manufacturers.Our ultimate ambition is to provide cus-tomers with equipment that improves thequality and productivity of their productionlines.|WB

6 | WIRE BULLETIN

Harold Prunk, CEO | Sikora AG

JANUARY 2011 | 7

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CORPORATE FOCUS-INDIA

Shankar CableIndustries: Gearing up for expansionWith the Indian Railways amongits primary clients, the companyis currently increasing its capacity in view of the government’s emphasis on infrastructure development.

For more than 30 years, the Gorakhpur-based Shankar Cable Industries has retainedits niche position in manufacturing cables,specifically for use by the Indian Railways.That, indeed, has been a creditable journeyand one that the company’s CEO AshishJaiswal would like to continue. However,this domain expertise has been a long timein the making. It began when O.P. Jaiswal,the founder of the company and Jaiswal’sfather, first ventured into entrepreneurshipin 1975 with the production of house wires.

“My father, a 1972 batch graduate inelectrical engineering from the MadanMohan Malviya Engineering College ofGorakhpur, started this business on a verysmall scale. Having found success withhouse wires, he then focused his attention

on making cables for the railways. Later,what really gave us a good holding in thissector was the fact that we were the first tostart sequential length marking on railwaycables when such specifications were re-leased by the Research Designs & Stan-dards Organisation of the Ministry ofRailways,” said Jaiswal, a graduate in me-chanical engineering from the Tever Tech-nical University in Russia.

Equipped with ISO 9001:2000 certifica-tion for the implementation of quality man-agement systems by BSI ManagementSystems India, Shankar Cables provides awide range of products that include PVCwire cables, control cables, armoured andunarmoured cables, railway signalling ca-bles, railway signalling power cables, jelly-filled axcel counter quad cables, and superenamelled copper wires.

“Apart from railway cables, our con-trolled cables have an excellent marketshare. These are suitable for measuring cir-cuits in generating stations, sub-stations, in-dustrial installations, etc. On account of thearmouring, the cables can withstand roughinstallation and operation conditions, andtensile stresses. These can be laid in wateror buried directly into the ground, even on

steep slopes. They can also be installed in-doors or outdoors, in the air or in cableducts,” Jaiswal said.

With a turnover of Rs 129 crore for thefinancial year 2009-10 and in view of theimpressive orders for different kinds of cables from Indian Railways, ShankarCable has set up a state-of-the-art plant formanufacturing high density polyethylene(HDPE) double wall corrugated (DWC)pipes of different sizes using the latest Ital-ian technology. “By the end of this finan-cial year (2010-2011) we are planning tostart another plant for the manufacturing ofbigger sizes of DWC pipes which will beused for sewerage disposal,” Jaiswal said.

The company’s current order book, exclud-ing supplies to be made to Indian Railways,is worth Rs 75 crore which, as Jaiswal putsit, may increase after enacting a plan tobegin the export of cables and DWC pipesto the Middle East countries.

“The vision of our company is to createcomplete coordination through forward andbackward integration by developing orsourcing products and their main substitutesto add value for our customers. We are verykeen on adapting the latest technologies inthe most cost-effective manner. Moreover,as suppliers to Indian Railways, we also seeourselves as fulfilling a social obligation byproviding it the best of cables. Continuousresearch and development is also an integralpart of our operations and all our cables gothrough very strict quality control checks.Flaws found during production are imme-diately referred to our R&D team memberswho work on finding the right solutions,”Jaiswal said.|WB

Contact: Shankar Cable Industries

Industrial Area, Lucchipur, GorakhpurUttar Pradesh – 273 015Tel: 0551-2260767/9415260222E-mail: shankarcable@gmail.comWebsite: www.shankarcable.com

An internal view of the Shankar CableIndustries plant.

An external view of the Shankar CableIndustries plant.

Ashish Jaiswal

8 | WIRE BULLETIN

“The vision of ourcompany is to create

complete coordinationthrough forward and

backward integrationby developing or

sourcing products andtheir main substitutes

to add value for ourcustomers...”

– Ashish Jaiswal –

CORPORATE FOCUS-INTERNATIONAL

InnoVites: Perfectingperformance parametersBuilding a bridge between information technology andcable manufacturing, InnoVitesdeveloped a solution to helpcable companies improve business performance.

In an intensely competitive global busi-ness environment, cable manufacturers consistently seek solutions to improve per-formance and profit margins. At the sametime, highly cyclical markets, power shiftsin key supply chains, and price volatility ofraw materials are all contributing factorsthat force cable manufacturers to cut costsand increase business agility.

“There are certain questions that cablemanufacturers have to always answer suchas: Can the working capital be driven belowthe industry average? Can the response timebe faster than the competition to changingcustomer demands? Can one reach out inthe supply chain and create value for thecustomers? For answers to these and suchquestions, the requirement is for an ERPsystem that understands the unique natureof the cable business,” said Albert Groothedde,CEO, InnoVites.

InnoVites is a company with offices inIndia and The Netherlands that providesEnterprise Resource Planning (ERP) soft-ware to help cable manufacturers improvebusiness performance. It combines thepowerful and user-friendly functionality ofMicrosoft Dynamics® AX ERP softwarewith its domain experience in the cable sector to deliver ERP solutions for cablecompanies. To help understand how thisconnection works, Groothedde offers a cou-ple of case studies. Universal Cables Limitedat Satna in India, a company belonging tothe M.P. Birla Group, uses the CableBuilder©

package to integrate its design, cost, andquoting processes; improve quality; and reduce costs. Gupta Power InfrastructureLimited (GPIL) of India has selected CableBuilder to innovate its product datamanagement, while improving the qualityand responsiveness of customer interactionin quotation operations.

One reason InnoVites is focused on thecable sector is Groothedde’s experience inthis domain. He began his career as a cableindustry consultant for Proloq in 1997 aftergraduating as a mechanical engineer fromthe University of Delft, The Netherlands.

[He also holds an M.B.A. degree from theRotterdam School of Management.] Later,as an industry director for the cable sector atBaan Co., he acquired a deep understand-ing of the business needs of cable compa-nies. He was responsible for the definitionand the launch of the Baan Industry Solution for Cable in 2002, and expandedhis international leadership experience asdirector of global customer support atCordys, a global BPMS software supplier.As a founding co-owner of InnoVites, he returned to the cable industry which he describes as his “first love.”

Given his background, Groothedde natu-rally wanted to find solutions for the cable industry. “The precise management of mate-rials, the tracking of materials’ market price,the effective management of information relating to cable lengths, and customer ordersare unique characteristics of the cable indus-try. The effective management of these char-acteristics requires a specialised softwaresolution that understands the unique natureof the cable industry and is designed to address the issues today’s cable manufactur-ing companies’ face,” he said.

Groothedde outlined specific factors thatmake cable manufacturing companies unique.Length management, for example, is a criticalelement throughout the cable manufacturingprocess and must be managed at multiple levels of production. “Today’s cable manu-facturers must be able to control and transferlength-related information across the wholeproduction process to be sure that the rightlengths are produced and eventually purchased,” he said. The second factor is thatthe cable manufacturing industry involves processing numerous, expensive raw materi-als—such as copper and aluminium—intohighly specialised finished goods at dimin-ishing margins.

“This makes the industry particularlyhungry for capital and makes the manage-ment and control of working capital integralto success. Today’s cable manufacturersneed to have complete visibility and controlover inventory levels and work in progressand must borrow from LEAN manufactur-ing principles so that the working capitalcan be optimally managed,” Grootheddesaid. Further, the price volatility of metals,combined with the fact that they represent80 per cent of the value of the finishedgoods, requires specific and tight controls tominimise risk and exposure. Cable manu-facturers, therefore, need systems to trackprocesses and enable changes to be reflectedin the final order value, depending on thenature of the agreement with the customer.

Due to the high cost of raw materials,manufacturers must avoid waste and pro-duce the exact length of cable required bythe customer.

“Cable manufacturers must also be surethat the reels on which the raw materials arestored are optimally used to reduce waste.They must be able to manage the reels sothat the right lengths of strands are avail-able and are positioned in front of the rightmachines” he said. And finally, cable man-

InnoVites’ office at Hyderabad.

CableBuilder software from InnoVites.

Groothedde

ufacturers must be able to record and trackdetailed data relating to the specificationsof the raw materials used in any manufac-tured cable.

InnoVites developed software called “InnoVites For Cable” that addresses all suchspecific business issues in the industry. Thesoftware uses Microsoft Dynamics AX as itsplatform. “We don’t want to reinvent thewheel for functions that are generic across industries. Instead we want to leverage theenormous innovation power of Microsoft andcomplement the popular AX software withthe features that are relevant for the cableindustry,” Groothedde said.

InnoVites, a Certified Microsoft Partner,received Microsoft’s endorsement for thequality of the “InnoVites For Cable” solution.

A long-term industry partner is Cimteq,who developed CableBuilder. “CableBuilderis a powerful cable design solution fromCimteq, for which InnoVites is the exclu-sive reseller in India. This solution helpsour customers to enhance the processes ofengineering, product data management, andquotation management,” Groothedde said.InnoVites has integrated the two products

into one solution to bring its customers themaximum benefit. Meanwhile, even as In-noVites continues to reach out with a globalfootprint, India is one of its priority regions.That explains why it has set up a CableCompetence Center in Hyderabad. “We arenow developing here a solution to addressmanufacturers’ planning and scheduling operations,” he said.

Explaining the vital role of IT in the cableindustry, Groothedde says: “The cable in-dustry, as a conversion industry, employs alot of capital to generate moderate margins.Moreover, this capital is largely captured incommodities with highly volatile prices,like copper. Cable manufacturers must useIT to manage the risks of price changes—the right IT solutions for cable manufactur-ers give insight into the risks and providetools to manage these risks. Here, an ERPsystem works like the nervous system of ahuman body. It collects and processes in-formation from all parts of the business andprovides managers with the tools to controlthe organisation, and the information tomake decisions and to respond to changingbusiness environments.”|WB

Contact: InnoVites The Netherlands

Galileilaan 23 F, 6716 BP EdeThe NetherlandsTel.: +31-0-88-5000-150InnoVites India

Plot No. 564/A39, Phase III, Road No. 92,Jubilee Hills, HyderabadTel.: 040-64636345/09701230284Email: agroothedde@innovites.comWebsite: www.innovites.com

JANUARY 2011 | 9

“Cable manufacturers must use IT to manage

the risks of pricechanges...”

– Albert Groothedde –

FEATURED CONCEPTS

The traffic was dense, bumper to fender.The weather was hot and balmy with notrace of the approaching winter. And hoursbefore the opening there was no sign thatthe show would be in perfect order. Yet, onthe morning of November 18 when the exhibitors entered the imposing hall of thethird international exhibition for the wireand cable industry held at Goregaon (East)in Mumbai, it was apparent that the nextthree days would pass without chaos or irritation. That is precisely what happened.Business was the order of the day andeveryone spoke it, mostly in English, evenif that wasn’t their native language.

For the 281 exhibiting companies theshow proved to be a perfect meeting groundfor existing and potential clients. But whatwas most surprising was that the number offoreign companies (172) easily overshad-owed those from India (109). The signalwas clear: India is now a ‘happening’ coun-try when it comes to the wire and cable sector and as one of the participants put it,“The scenario is going to get stronger overthe next five years.”

When we analysed the show data, surprisingly China had the most booths (37)followed by Germany (33). “It shows theaggressive marketing strategy being adoptedby China to sell their products in India,”one exhibitor said.

Upward spiralThe primary factor for this attraction to-

ward India is the country’s consistent eco-nomic growth despite the two years ofeconomic recession that hindered most ofthe developed countries. According to estimates by the Ministry of Statistics andProgramme Implementation, the Indianeconomy registered growth of 7.4 per centin 2009-10, with 8.6 per cent year-on-yeargrowth in its fourth quarter. The growth isdriven by robust performance of the manu-facturing sector combined with governmentand consumer spending. The GDP growthrate of 7.4 per cent in 2009-10 exceeded thegovernment forecast of 7.2 per cent for thefull year. According to government data, themanufacturing sector witnessed a growth of16.3 per cent in January-March 2010, froma year earlier.

Economic activities that showed signifi-cant growth rates in 2009-10 over the cor-responding period last year were miningand quarrying (10.6 per cent), manufactur-ing (10.8 per cent), electricity, gas andwater supply (6.5 per cent), construction

(6.5 per cent), trade, hotels, transport andcommunications (9.3 per cent), and financ-ing, insurance, real estate, and businessservices (9.7 per cent). The Gross NationalIncome was estimated to rise by 7.3 percent in 2009-10 as compared to 6.8 per centin 2008-09. The per capita income was es-timated to grow at 5.6 per cent in 2009-10.India’s industrial output grew by 17.6 percent in April 2010. The manufacturing sec-tor, which accounts for 80 per cent of theindex of industrial production (IIP), grew19.4 per cent in April 2010, compared with0.4 per cent a year ago.

Not surprisingly foreign players are mak-ing a beeline to India.

As providers of value-creating plasticssolutions to the wire and cable industryacross the world, Borouge and Borealis displayed advanced insulation, semi-conductive, and jacketing materials whilepromoting their Visico solutions for low- andmedium-voltage cables offering reducedcomplexity versus other silane cross-linking technologies.

“In recent times the Indian government’semphasis on improving the infrastructureand allocating a huge budget for it is goodnews for all the wire and cable players.Also, because of the growth in India’s tele-com sector, the need for power cables willbe on the rise. As such, India is definitelyan important country for us as of now,” saidFrank Waets, Senior Technical Manager,Borouge.

What everyone is eyeing right now isIndia’s construction industry that has beengrowing at more than 20 per cent CAGRover the past five years. Taking a cue fromthe government’s ambitious forthcomingprojects for the Eleventh Plan period, thedemand for construction is expected togrow by at least 8-9 per cent. During thisperiod private sector investment in the in-frastructure sector is expected to total Rs1,323.85 billion, constituting 42.46 per centof the total investments. According to astudy conducted by ASSOCHAM, the In-dian real estate industry was expected toreach USD 60 billion by the end of 2010.The increasing number of special economiczones (SEZs) should also contribute to thisrobust growth.

Further, it is estimated that the power sec-tor will grow at least 1.8 to 2 times of theGDP, translating to an addition of genera-tion capacity by nearly 18,000 to 20,000MW each year. It is estimated that nearly 3

to 3.5 per cent of investment per MW goestoward power cables. Therefore, with anapproximate investment of Rs 40 millionper MW, the demand for cables will be inthe range of Rs 1.2 to Rs 1.4 million.

“The steel wire sector has an annualturnover of Rs 8,000 crore with the pro-duction of approximately 2.5 million tonnesof steel wire per annum. The growth of thisindustry is directly linked to the growth ofthe infrastructure, automobile, and powersectors,” said Tirthankar Banerjee, Secre-tary, Steel Wire Manufacturers Association.

Adding fuel to this growth engine is theautomobile sector. In a report by the Auto-motive Component Manufacturers Associ-ation of India (ACMA), the turnover of theauto component industry was estimated atmore than USD 19.2 billion in 2010. Thiswill positively impact the wire and cable industry, especially players supplying wireharnesses, cables, and other components to OEMs.

The Indian telecommunications networkwith 621 million connections (as of March2010) is the world’s third largest and a sector that has grown at a speed of 45 percent recently. The Indian Telecom Analysis(2008-2012) report by RNCOS IndustryResearch Solutions shows that the mobiletelecom segment has surpassed all the othersegments in the Indian telecom sector dueto the advance of services such as InternetProtocol Television (IPTV) and 3G.

The foreign handInterestingly, even as the foreign compa-

nies set up sales offices on Indian turf, thereis also a scramble by Indian companies toform associations with leading foreignplayers to gain both branding mileage andenhancements to their production processesand technologies.

Scouting at the exhibition for quality ven-dors, Zoeb Chitalwala, Director, ZarhakSteels Ltd., said, “The entry of the foreigncompanies has changed the perception ofquality. It has now become very importantto have quality control benchmarks of in-ternational standards because anything thatis sub-standard will no longer find a mar-ket. As such, this is indeed a good thing tohappen to India. Also, the space has ex-panded. Our company, for example, is nowlooking at the growing auto sector with in-terest.”

The best example of this shift of focus toIndia is that of InnoVites from The Nether-lands that was perhaps one of the first fewcompanies to have realised the vast poten-tial that exists here. (See related article onpage 9.)

Zumbach Electronics AG, a Switzerland-based company that provides online moni-toring and control equipment, also has foundthe Indian soil fertile for its operations.

“We started as an agency outfit in India al-most three decades ago and then set up ourown office eight years back. However, sincethe last four years Zumbach Electronics isnow an independent Indian company. Thereason for this development is obviously the increasing demand for our products and theneed to provide a professional level of service

support. We have already started assemblingthe products here and may even start full-scalemanufacturing with localisation of vendors,”said Silvio Piller, Area Sales Manager,Zumbach Electronics AG.

Given this situation, collaborations be-tween Indian and foreign players are in fullswing. While Walson Woodburn Wire Dieexemplifies a perfect understanding betweenan Indian and an American company to pro-duce natural diamond wire dies, Enkotec ofDenmark is another. Enkotec makes rotarynail machines with a modernised tooling system and touch screen for data display,machine adjustments, and trouble-shooting.“We have tied up with an Indian partner tolaunch this machine in February,” said BentJust Petersen, Enkotec’s managing director.

Dr. Kurt Eder, President, Eder Engineer-ing, Austria, attributed the rapid growth inIndia to two factors: “the growth of Indianeconomy and the huge investments in theinfrastructure, telecom, automotive, powerand other sectors; and, the change in themindset of the Indians. Earlier quality wasnot such an important factor but now it is and therefore Indian companies are increasingly joining hands with establishedforeign companies to avail of the best prod-ucts and technology,” he said.

The challengesThe entire picture of India isn’t rosy. For

one thing, India is still being looked upon as a good place to sell but not to produce.“Yes, it is true that not many of the foreigncompanies have started to manufacturetheir products here for the wire and cableindustry unlike what is happening in the automotive sector where giants like Mercedez-Benz, Volkswagen, General Motors, and others have already investedhuge amounts in the local manufacturing oftheir vehicles. That may be because everyoneis still studying the scenario with caution.Manufacturing operations can be startedonly when there is a guarantee that the wireand cable sector will witness long-termgrowth,” Dr. Eder said.

Another obstacle is that the Indian bu-reaucracy continues to be a nightmare formost of the foreign companies. “What ismost annoying is that the policies changewith any change in the government which isnot the case in most of the other countries.As of now the policy is in favour of FDIsand industrialisation but this could shift ifanother political party with a differentagenda takes over,” Dr. Eder said.

Also, it is not as if every player is enam-oured of this foreign influence and impacton the Indian wire and cable industry. NewDelhi-based Sarvasv Machinery & Equip-ments, for example, has avoided any foreign partnership. “Getting into one forthe sake of it is meaningless. We are able toprovide wire and cable machines of top-notch quality without the need to obtaintechnology from abroad,” said VarunKapoor, the company’s director. Clearlyenough, there is scope for more.|WB

G. Abraham and Silvio Piller, ZumbachElectronics AG, were among the exhibitors at Wire & Cable India 2010.

Banerjee Eder

From l to r: Mahesh Poddar, StevenFetteroll, Huned Contractor, and Nirmal Singh met at the WAI booth.

A view of the wire and cable exhibitionat Mumbai.

10 | WIRE BULLETIN

Destination: India

Wire & Cable 2010, the third international

exhibition and conference for the wire and

cable industry hosted by Messe Düsseldorf at

Mumbai in November, was a clear indicator of India’s

allure to foreign companies. WIRE BULLETIN queried

participants to learn the details.

FEATURED CONCEPTS

JANUARY 2011 | 11

The economic gloom of 2009 in China isin the past. That became apparent at the WireChina 2010 event held at the Shanghai NewInternational Expo Center from September21-24, 2010, where 4,30,550 sq. ft. of exhi-bition space was booked to capacity by 1,098participants, 746 of them from across China.

The buzz at that time, according to mediareports, was that the Chinese economy hadpicked up speed again and its GDP growthrate for 2010 was estimated at 10 per centby the Chinese Academy of Sciences.

China’s wire market has become one ofthe world’s fastest growing markets; its out-put leads the world in turnover. Related statistics show that the total value of pro-duction in China’s wire industry increasedby 6.3 per cent in 2009, while the total out-put rose by about 10 per cent.

A Messe Düsseldorf media release priorto the Wire China event, anticipated a brightfuture for the wire and cable market in 2010because the government’s RMB* 4 trillionstimulus package which was expected tocontinue to play a role in promoting growth.Many other factors are expected to drive thedemand for wire in the domestic marketsuch as high-speed railway, 3G communi-cations networks, and the construction ofintelligent power networks, nuclear powerplants, major infrastructure projects, andurban property development.

At the same time, other themes will alsoeffectively stimulate demand for cable and

wire in China such as green energy networksinvolving wind and solar energy. China hasalso become the world’s largest producer ofsteel tube, contributing one-third of theworld’s overall tubular steel products.

China’s output of crude steel in 2009 was568 million tonnes while processed steelmaterial amounted to 692 million tonnes.The domestic steel consumption structureis as follows: 51.9 per cent for construction,33.8 per cent for industry, 6.3 per cent fortransportation, and 8.0 per cent for the remaining sectors. The predicted consump-tion of steel tubes by the major domesticsteel consuming industry in 2010 stated thatfrom among the major users, real estate willincrease by 12.6 per cent, railways by 15.8per cent, and cars by 16.5 per cent comparedto last year.

Offshore oil—another area that is sched-uled to enter into a rapid development phaseover the next five years with an investmentof more than RMB 120 billion—is slated todrive the demand for submarine cables forpower transmission between platforms aswell as for the flow of communication andtechnical data. In fact, it is estimated that thedemand and supply gap for submarine cableswill reach 3,000 kms. Some of the companiesproducing submarine cables include Quing-dao Han Cable, Ningbo Orient, ZhongtianTechnology, Shanghai Cable, and HubeiHongqi Cable, with an average annual capacity of 3,500-4,000 kms.

For 15 years at a stretch China’s wire andcable industry has had an annual increaseof more than 15 per cent. It has become thelargest industry, second only to the auto-mobile sector. By 2008, the total outputvalue of this industry had exceeded RMB400 billion, higher than that of the USA.For many foreign companies it is a matterof life or death to be present in China.Among other things, the activities therehelp to secure jobs at the company head-quarters, which is a view shared by Dr. Ing.Hans-Jochem Steim, managing director ofthe Kern-Liebers Group headquartered inSchramberg, Germany.

The company’s production programme in-cludes various types of springs and bentcomponents, as well as stampings and nee-dles for textile machines. In May 2007, thecompany, together with C.D. Wärzholz, asemi-finished goods producer from Hagen,Germany, opened two inter-connected facto-ries on a 70,000 sq metre lot in Taicang. Inone of the buildings, a subsidiary managedby a joint venture entity of both the compa-nies produces steel strips, which are eithersent directly to Asian customers or are fur-ther processed in the other building. Accord-ing to a Kern-Liebers’ spokesperson, this and

other foreign investments help secure thesustained growth of the Kern-Liebers Groupand the jobs at the German locations.

According to a study reported by the International Cablemakers Federation,China will continue to hold its position asthe world’s top wire and cable supplier. Thegrowth of China’s wire and cable industryhas been achieved as part of the country’stransition from a centralised economy to amarket economy, as well as its transitionfrom a rural agrarian economy to an urbanindustrialised economy. No other country islikely to duplicate this feat, considering thefollowing factors:

• the size of China’s labour force;• the role of the strong central government; and • governmental policies to promote domestic business investments by offering subsidies in facility and energycosts, structuring tax breaks and otherincentives; and making strategic use ofvalue-added taxes to promote domesticmanufacturing.Other advantages include progressive

government measures to encourage foreign investment and to support key industries inelectronics manufacturing, transportation,electric power, and information and communications technology. Providing aglimpse of what is to come, the reportstates, “As the standard of living improvesfor the entire population, China’s contribu-tion to worldwide GDP will increase. And ifpast performance is any indicator, China’swire and cable industry also will continueto grow with the economy. In recent years,this growth has been partially fuelled by thecost advantages of manufacturing in China,but in the future, the extent of domestic demand also will contribute to wire andcable industry growth.”|WB

China has a growing economy. Photocourtesy: www.freeimages.co.uk

China: Taking giant strides

Once a mere work station, now an exporter in its

own right, China’s wire and cable industry has

travelled far.

* The official currency in China is the Renminbi (RMB) orthe Yuan (CNY); 1 RMB equals Rs 6.81.

GLOBAL NEWS

12 | WIRE BULLETIN

CANADA—ArcelorMittal has agreedto an acquisition deal with Canadian

mining company Baffinland Iron Mines Corp.worth USD 433 million which is focused on itsMary River iron ore mine located on Baffin Is-land in the east Arctic. The mine has beenproven to hold reserves of at least 365 milliontonnes, averaging more than 66 per cent ironcontent.

CHINA—Hu An Cable started the constructionof its new USD 67 million plant to strengthenits cable production capabilities. The group has already placed orders for two world-class production lines for ultra-high voltage powercables from Finland and Germany.

CHINA—Taiyuan Mining Machinery GroupCo., a Chinese state-owned manufacturer ofheavy-duty machinery products and coal miningmachinery equipment, has signed a contract tobuild a two-strand high-speed wire rod pro-duction line with an annual output of 1 millionMT for Chinese steel maker Zhengfeng Ironand Steel Co. The contract is worth USD 30.77million.

DENMARK—NKT Cables has signed a contractwith RWE Innogy, Germany, for the manufac-ture and delivery of high voltage submarinecable to the Welsh offshore wind farm GwyntY Môr, one of the world’s largest wind farmswith a capacity of 576 MW. NKT Cables willproduce 85 kms of 132 kV high voltage sub-marine cables and accessories for the transmis-sion system, the contract value of which isaround 260 mDKK. The cables are to be pro-duced in Germany.

FRANCE—Nexans has been awarded a contractto supply 5,000 km of specialized low-voltage(LV) power, control, and instrumentation cables for Mochovce 3&4, currently under con-struction in Slovakia. The contract is valued inexcess of Euro 20 million. The cables for theMochovce nuclear power plant are being man-ufactured in the Nexans Mehun-sur-Yevre plantin France and they will be installed onsite overa 12-month period beginning in January 2011.

FRANCE—France Telecom-Orange and theother members of the LION2 consortium havesigned an agreement to build a submarine cablein the Indian Ocean. The 3,000-km LION2cable will extend the LION cable to Kenya viathe island of Mayotte. The project is being con-ducted by a consortium of France Telecom-Orange and its subsidiaries Mauritius Telecom,Orange Madagascar, and Telkom Kenya, alongwith carrier companies Emtel, Societe Reunionnaise du Radiotelephone and STOIInternet. The construction of the LION2 cablerepresents a total investment of around Euro56.5 million.

FRANCE—Nexans has been awarded contractsworth Euro 7.5 million to supply its specializedFLAMEX rail cable solutions for installationon the new and modernised rolling stock on theSão Paulo City Metropolitan Transportationnetwork, as Brazil’s largest city upgrades itssubway system for the FIFA World Cup in2014 and the Olympics in 2016.

GERMANY—Leoni has been awarded a projectto equip a new two-litre MultiJet turbo dieselengine from Fiat Powertrain with cable har-nesses. It is to be used in several upcoming carsof both Fiat and Chrysler, starting with the newDodge Journey. The engine cable harness com-prises 57 wires with a total length of around110 meters and more than half a kg of coppercontent. It resists temperatures of 150°C.

GERMANY—ArcelorMittal Hochfeld GmbHhas reinstated its order with SMS Meer for thesupply of a complete high-capacity wire rodmill for quality steel. It will commence pro-duction in spring 2012. Additionally, the wirerod blocks will be equipped with a new indi-vidual drive technology (MEERdrive) developed by SMS Meer. The mill has been designed to roll technically demanding gradesto the closest of tolerances with an annual capacity of 6,90,000 tonnes.

ITALY—Specialty steel wire rope manufac-turer Redaelli Tecna has claimed a place in theGuinness Book of Records after loading out the

world’s heaviest steel wire rope from its newdockside facility in Trieste Harbour. Therecord-breaking 361 tonne Flexpack rope, acompacted non-rotating steel wire rope forultra-deepwater applications, had a nominallength of 3,000 m and a nominal diameter of160 mm.

OMAN—General Cable Corp. has formed ajoint venture with International Cable IndustriesLLC (ICI), a limited liability company inOman. The joint venture company, in whichGeneral Cable will have a majority interest, willdistribute a wide variety of wire and cable prod-ucts for the energy, electrical infrastructure, andconstruction markets in Oman and other GulfCooperation Council (GCC) countries.

THE PHILIPPINES—Filipino-owned HarbourIndustrial Development Corp. is investingP1.948 billion for the establishment of a steelmanufacturing facility in Panabo, Davao delNorte to serve the Mindanao market and exportas much as 20 per cent of its production toManado, Indonesia. The firm has applied for apioneer status saying it would be the first toemploy such new technologies as twin 4-standtungsten carbide monoblock high-speed deliv-ery and twin tempcore quenching system. Itsstate-of-the-art equipment will make it the firstcompany in the Philippines to manufacturePNS 211 and small sizes of PNS 49 from billetsrather than from wire rods.

SOUTH KOREA—A South Korean consortiumhas won a USD 1 billion deal to lay fiber opticcables in Saudi Arabia. Korean Middle EastEngineering, a joint venture of four South Korean businesses, was named the main projectcontractor by Saudi Arabia’s Integrated TelecomCo. The project will establish a national net-work in Saudi Arabia and also connect thecountry with Sudan, Yemen, Oman, and theUAE by undersea cable by December 2013.

SOUTH KOREA—LS Cable has signed a con-tract to buy 3,000 kms of superconductingpower wire from American SuperconductorCorp., the world’s first commercial-scale deal

for the next-generation product. The firm saidit would use some of the new cables in SouthKorea. The rest will be exported to the UnitedStates for the Tres Amigas project in New Mex-ico aimed at connecting the country’s threemain power networks.

SOUTH KOREA—Taihan Electric Wire Co.has won a USD 81 million deal with Australia’sEnergy Australia Co. to build a 132 KV turnkeypower cable.

UK—UK telecom operator Cable & Wirelesshas signed a memorandum of understanding tobuy 51 per cent in Bahamas Telecommunica-tions Co. for USD 210 million from the localgovernment. The move will bolster the com-pany’s operations in the Caribbean region.

USA—Teknor Apex Co. has agreed to pur-chase the worldwide Sarlink® thermoplasticvulcanizate (TPV) elastomer business fromRoyal DSM NV. Sarlink operates compound-ing facilities in Leominster, MA, USA andGenk, Belgium and has extensive engineeringand laboratory resources for application devel-opment. The addition of the Sarlink TPV busi-ness will strengthen the position of TeknorApex as the world’s most diversified inde-pendent compounder of TPEs and expand itsportfolio at the high-performance end, particu-larly for automotive applications.

USA—General Cable Corp., a North America-based wire and cable supplier, has received aUSD 270 million order to supply underwaterand underground transmission cables for anoffshore wind farm in the Baltic Sea starting in2012. The company’s subsidiary, NorddeutscheSeekabelwerke GmbH, will design, manufac-ture, supply and install two 60 kilometer sec-tions of 150 kV high-voltage export submarinecables as well as three single cores measuring12 kilometers each of terrestrial undergroundtransmission cable.|WB

PRODUCTS, MEDIA, & TECHNOLOGY

ProductsPWM presents manual coldpressure welders

British company PWM, which has beendesigning and manufacturing cold pressurewelders and dies for more than 30 years, exhibited its range of high-performancemanual welders at Wire & Cable India 2010at Mumbai. PWM’s hand-held welders, theM10, M25, and M30 models, are ideal forjoining wire in confined spaces. Suitable fornonferrous wire and strip 0.10 mm to 1.80mm diameter, the machines are comfortableto hold and easy to use. The larger BM10and BM30 bench-mounted models aredurable, low maintenance machines withsimilar capacities. The versatile M101, oneof PWM’s best-selling models, can bebench-mounted or supplied with a trolley,enabling the machine to be wheeled directlyto the work area. The M101 has a capacityof 1.00 mm to 3.60 mm diameter copperand 1.00 mm to 5.00 mm EC aluminium.

For further details contact: Kris Lancaster, E-mail: kris.lancaster@btinternet.com.

Lapp Kabel offers PV cable lineLapp Kabel has launched its product

range for photovoltaic (PV) cabling underthe name Ölflex Solar. All of the cables areUV-resistant with a high resistance toweather and temperature extremes. The latest addition to the product range is theelectron beam cross-linked Ölflex SolarXLR. The TÜV-approved cable offers ther-mal resistance from -40°C to +120°C,thereby guaranteeing long-lasting function-ality under any weather conditions.

The standard cross-linked Ölflex SolarXLS solar cables are increasingly beingused in temperature ranges from -40°C to+100°C. Both types of cable are normallymounted on flat and pitched roofs and fieldsystems for wiring solar modules togetherand connecting the individual rows of mod-ules and the power inverter. Due to its largeconductor cross-section, the hard-wearingXLS is used in large PV systems as a col-lective line to carry high electric loads be-tween the individual rows of modules andas a connector to the power inverter. It isalso suitable for underground installation.In contrast, Ölflex Solar V4A is recom-mended for use on stables, barn roofs, andother agricultural buildings.

It’s sheath is rust-free stainless steel, thusoffering effective protection against rodentsand termites. To supplement the cable, LappKabel also offers extruded, pre-assembledor freely configurable Epic Solar connec-tors and built-in connectors to connect thesolar modules. Robust and weather-resis-tant connector boxes also form part of thecompany’s solar range. The so-called EpicSolar module box (supplied with or withoutcable) is attached to the rear side of thesolar module. Solar modules can be con-nected in parallel using Y-splitters.

For futher details contact: Grant Joyce,Lapp Kabel, Tel.: +27 (0)11 201 3200, E-mail: grant.joyce@lappkabel.co.za,www.lappcable.co.za.

Rigid strander from AEIRajasthan-based Associated Engineers &

Industrials (AEI), introduces a latest-in-the-series rigid stranding machine with the following features:

• motorised bobbin pintles requiringminimal maintenance; • auto regulated pneumatic brakingmechanism settable at control desk; • instant detection of wire breaks, displayed at control desk;• rapid row loading hydraulic systemdedicated for each cage; • latest AC drives and PLC/touch panelcontrol systems using Profibus andProfinet communication for completeline synchronisation in case of powerfailure; and• remote diagnostic assistance over atelecom network. AEI has manufactured high technology

stranding machines for the production ofmedium, high and extra-high voltage powercables for 40 years.

For further details contact: Ajmer, Rajasthan, Associated Engineers & Industrials Ltd., Tel.: 0145-2440125,2440126, Fax: 91-145-2440126, E-mail: info@aeimachines.com.

Eland copper cablesUK-headquartered Eland Cables has an-

nounced that its national rail-approved railtelecom cable portfolio now includes a fullrange of Low Smoke Zero Halogen (LSZH)and armoured LSZH trackside cables. Thenetwork rail approval (NR/PR/TEL/00015)covers 32 variants of 0.63 mm and 0.9 mmLSZH and armoured LSZH copper track-side cables. Earlier this year, as part ofEland’s product acceptance strategy, 32variants of PE and armoured PE coppertrackside cables were also approved.

For further details contact: Eland Cables, E-mail: sales@eland.co.uk.

OFS launches PowerGuideShortSpan DT cable

OFS, a designer and manufacturer offiber optic network products, announcedthe launch of its totally gel-free Power-Guide® ShortSpan DT All-Dielectric Self-Supporting (ADSS) cable. According to apublished report, the product enables fasterdeployment and helps lower installationcosts through reduced cable preparationtime, increased span length capability, andflexible buffer tubes for ease of routing andmanagement within closures than similargel-filled products. The 100 per cent gel-free construction allows for light-duty at-tachment hardware costing on an average40 per cent less per pole than comparablegel-filled cables on a typical 250 foot spandue to lower loaded tension. Additionally,compared to similar gel-filled cables, up to60 per cent less labour per dead-end loca-tion can be realised by using hardware thatdoes not require reinforcing rods.

“Totally dry cables have been field-proven in both aerial and underground in-stallations for nearly a decade, so this is anatural extension to an existing technol-ogy,” said Timothy Pillow, Senior VicePresident (Global Marketing & Sales),OFS. “The introduction of a totally gel-freeADSS cable is a significant milestone in theindustry with OFS leading the way to helpour customers continue to speed FTTH deployments and improve deployment economics. The PowerGuide ShortSpan DT cable enables our customers to extendtheir service reach and to cost-effectivelyserve remote rural locations,” he said.

This cable meets the IEEE 1222™ Stan-dard for ADSS cable, which addresses the

needs of those using all-dielectric, self-supporting fiber optic cable on overhead orin underground facilities.

For further details contact: Sherry Salyer,E-mail: shsalyer@ofsoptics.com.

Cerro Wire introduces True Sequential Footage™

Cerro Wire LLC, a leading manufacturerof copper electrical building wire and cable,has introduced True Sequential Footage™,a sequentially printed cable reel that pro-vides accurate wire length with each cut.True Sequential Footage prevents the needto carry excess cable inventory, providingprecision length, accurate footage, and costcontrol. It uses a footage mark to documentremaining wire, beginning with zero at thebottom of the reel and ending with the fin-ished length at the top. The accurate footagemark allows for quick identification of there-order point, guaranteeing the full pur-chased wire length and reducing randomlengths. This better controls end-of-reelscrap and reduces the need to carry excessinventory.

For further details contact: Cerro WireLLC, Consumer Markets Div., 1002 Industrial Way, Crothersville, IN 47229,USA, Tel.: (001) 866-572-3776.

Paige Electric introduces newpackaging design

USA-based Paige Electric introduces anew packaging design for the wire andcable industry that is intended to replace thenon-recyclable, chemically infused ply-wood reels which had been used fordecades with a more environmentallyfriendly alternative. The 1 Pac2 is a 100 percent recyclable box cable dispensing sys-tem that meets sustainability goals whilesaving customers time and money.

“The challenge was to develop a productthat was environmentally responsible, able to handle the weight of the product,provide multiple dispensing options, andnot add costs,” said Paige Electric PresidentLou Grotta.

The 1 Pac2 can handle weight of up to100 pounds. The new design prevents cabletangles and stops spinning when the installer stops pulling. It includes dual rein-forced handles. The 1 Pac2 can be usedwith or without a rack and also saves ware-house costs, stacks easier, and eliminatesspecial handling charges during shipping.

“We get a lot of positive feedback fromthe guys on the job and they always men-tion there are no more splinters,” said FrankConaty, Vice President, Paige Electric.

For further details contact: FrankConaty, Tel.: (001) 908-687-7810, E-mail: fconaty@paigeelectric.com.

Sterlite Technologies launchesEnd-To-End OPGW solution

Pune-based Sterlite Technologies Ltd., aglobal provider of transmission solutionsfor the power and telecom industries, an-nounced the launch of its new opticalground wire (OPGW) solution at Africa-Com 2010 held at the Cape Town Conven-tion Centre. This solution, according to acompany media release, is a one-stop win-dow for application engineering, hardwaresupply, and installation. The solution com-prises a comprehensive suite of OPGW ca-bles and related accessories. The company’sscope of services also includes route survey,application engineering, live line/new lineinstallation and commissioning, supply ofactive equipment, and integration support.

The OPGW cables have been certified bythe South African Bureau of Standards and

continued on p. 14

JANUARY 2011 | 13

PRODUCTS, MEDIA, & TECHNOLOGYthe OPGW solution would be immediatelyavailable to power transmission utilities, large ultra mega power plants, and telecomservice providers planning to merge exist-ing power line infrastructure with longhaul/access communication networks. Thecompany plans to launch this solution im-minently for all its global clients. SirajBhattacharya, Solution Manager (OPGW),Sterlite Technologies, said “Through ourOPGW solution offering we have opera-tionalised an extremely versatile set-up,considering all the design options mappedto geo-technical conditions applicable globally.”

For further details visit: www.sterlitetechnologies.com.

MediaSpecification guide for extrudedpower cables

The Association of Edison IlluminatingCompanies (AEIC) Cable EngineeringCommittee, an authority on undergroundelectrical cable, has released its second edition of Guide for Developing Specifica-tions for Extruded Power Cables Rated 5 kV Through 46 kV. AEIC CG10-10 is designed to provide guidance for electricutility engineers who must develop cablespecifications for medium voltage cables (5 kV to 46 kV). The electric utility indus-try has relied on AEIC specifications forunderground cables to ensure that qualityand reliability issues are met.

“It is often necessary, however, for an indi-vidual utility to augment its purchasing spec-ification to include items that are specific toits needs. This updated guide should be of sig-nificant help to electric utility personnel, de-scribing the choices that must be consideredand outlining the criteria necessary to ensure

the cable will perform as intended,” saidMichael Smalley, AEIC’s Cable EngineeringCommittee Chairman, in a media report.

AEIC Cable Engineering Committeespecifications and guides are used by utili-ties, municipalities, large industrial installa-tions, and consultants throughout the world.AEIC’s Cable Engineering Committee pub-lishes seven underground cable specifica-tions and 11 underground cable guides.Guides and specifications undergo regularreviews and updates by the committee.

A listing of specifications and guides, aswell as information on becoming an AEICmember, may be found at AEIC’s website.

For further details contact: the AEICsecretary, E-mail: secretaryaeic@bellsouth.net., www.aeic.org.

New guide reports on global cables industry

The Cables: Global Industry Guide pro-vides data and analysis related to the globalcables industry including market size andsegmentation, textual analysis of the keytrends and competitive landscape, and pro-files of the leading companies. This reportprovides analysis on a global, regional, andcountry basis. Other highlights include:

• in-depth five forces competitive envi-ronment analysis and scorecards, • individual chapters on the five majormarkets of France, Germany, Japan, theUK, and the US; and• a five-year forecast of the industry.The report is published by www.compa-

niesandmarkets.com, an online business information aggregator with more than5,00,000 market reports and company pro-files. In terms of company profiles, thecompany’s online database allows clientsaccess to market and corporate informationto more than 1,00,000 different companies.

It provides clients with a fully indexed data-base of information wherein they can findspecific market reports on their niche industry sectors of interest.

For further details contact: Mike King,Tel.: +44 (0) 2030868600, E-mail:info@companiesandmarkets.com.

Study covers transmissionpower cable costs

The UK-based Institution of Engineeringand Technology (IET) announced thelaunch of a comprehensive study into thecosts of building new high-voltage cables.The IET, in partnership with the energyconsultancy KEMA, will produce an independent report to compare the costs oflaying power transmission cables under-ground, in tunnels, or under the sea againstthe costs of building new overhead lines.The report, which is due for release thisyear, is intended to provide an objective andindependent basis for assessing the overallcosts of these different methods of powertransfer through Britain’s electricity trans-mission system. It will also provide an in-dication of the environmental impacts ofthe different technologies.

The study will examine technical andcost issues around the different methods,looking at case studies from both the UKand abroad, as well as drawing on informa-tion from a wide range of organisations,companies and academicians. It will pro-vide cost implications from a variety of fac-tors such as terrain, geology, length ofcable, power carrying capacity of cables,voltage, and network operating characteris-tics. KEMA will provide the technical con-tent and analysis, while the IET willprovide quality assurance and engineeringoversight for the study. As part of the infor-mation gathering process, the IET will host

a seminar at which organisations will havethe opportunity to contribute facts and costinformation about the various technologies.

For further details visit: http://electrical.theiet.org/.

TechnologyWhat Does BS 8519 Mean?

Terry Journeaux, Prysmian’s technicalmarketing manager, discusses exactly whatthe new BS 8519 standard means and howbest to comply.

The BS 8519 is a new code of practice forselecting and installing fire resistant powerand control cables, applying only to cableused in life safety and fire fighting systems,specifically in large and complex buildings.Although it is not a legal requirement to com-ply with its recommendations (because it is,after all, a code of practice), it is still importantto be aware of what BS 8519 recommends.As buildings become larger, taller and evermore complex, the electrical systems that sup-port them must follow suit. This is especiallypertinent when specifying cable and compo-nents for systems designed to protect life inthe event of fire in such buildings.

Should these systems fail, the emergencystaff trying to manage the fire is at greaterrisk of death and injury themselves. Somesay that the publication of BS 8519 has resulted in confusion within the industry—especially with regard to the interpretationof the different test methods needed forcontrol and power cables. Confusion suchas this is not a good situation for anyone responsible for specifying or installing anytype of life safety or fire fighting electricalsystem. Therefore, common sense dictatesthat one fully understands the implicationsof the BS 8519 code.

continued on p. 15

14 | WIRE BULLETIN

PRODUCTS, MEDIA, & TECHNOLOGY

JANUARY 2011 | 15

BS 8519, introduced in February 2010, isnow effective. The standard acknowledgesthat fire engineered solutions for high riseand complex buildings require a higherlevel of performance than other buildingtypes. BS 8519 offers recommendations forthe selection of fire resistant power andcontrol cables in systems such as:

• wet riser pumps;• sprinkler pumps, water mist, powder,water spray, and automatic foam extin-guishing systems;• fire fighting and evacuation lift supplies;• supply and control to pressurisationsystems;• supply and control of smoke and heatexhaust ventilation systems;• supply and control of fire barriers; and• supply and control of smoke barriers,smoke control dampers, smoke curtains,and smoke fans.The guidance and recommendations of

BS 8519 would be sufficient to ensure bestpractice for any of these key applicationsand also provide a secure route to compli-ance with Approved Document B, whichrefers to BS 7346-6 and has now been with-drawn and replaced by BS 8519. It is im-portant to note that BS 8519 does not coverthe wiring of fire detection and fire alarmsystems which are still covered by BS 5839.A particularly important part of BS 8519 isthe introduction of three fire survival times.Life safety systems must remain operationalfor 60 minutes in large and complex build-ings and 30 minutes in other types of build-ings. Fire fighting systems should be fullyfunctioning for 60 or 120 minutes depend-ing on the system being used.

This means that in life endangering situ-ations, the appropriate survival time can bechosen from BS 8519 in order to be certainthat the cables operating the fire fightingpower and control systems will perform as

intended. This gives assurances to any firefighters and emergency staff that need tooccupy or enter a building following anevacuation, that systems protecting themshould work as expected. The three-timecategory cable requirements are split be-tween control and power cables.

BS 8519 also gives recommendations forcomponent use in a cable system such as fix-ings, containment systems, glands and joints,so that they do not compromise the circuitintegrity in the event of fire. It suggests thatjoints should be avoided unless absolutelyessential and that cable fixings and fixingcentres should always be according to thecable manufacturer’s recommendations. Ro-bust armoured cables should be fixed eitherdirectly to the building structure or to a cablemanagement system. If additional mechani-cal protection is needed for cables, a cablemanagement or containment system is ad-visable. This must be able to maintain its fullfunction in adverse conditions such as fire,direct mechanical impact and under pressurefrom water jets, and for the same period oftime as that set out for cables.

Specific tests for cable management sys-tems under BS 8519 are still in the processof development so manufacturers should beconsulted before installation. BS 8519 rec-ommends that HV supply cables servinglife safety and fire fighting systems shoulddirectly enter fire-rated switch rooms fromtwo diverse routes and not pass throughother parts of the building structure. This isto ensure security of power supply. If suchcables have to be routed through the build-ing, they should be fire protected by a suit-able protective system.

A full colour detailed guide on BS 8519is available free from Prysmian. To receivea copy, e-mail cables.marketing.uk@prysmian.com.|WB

WAI MEMBERSHIP

Positively Engaged. Absorbed. Informed.

Align yourself with WAI members and be recognized in the companyof the industry’s most dynamic leaders

The Wire Association International (WAI) is teeming with vibrant, like-minded

people who are accomplished in the wire and cable industry and are bound for

CONTINUED ACHIEVEMENT.

Whether you already lead an organization or you are in line for a role that suits

you, we think you will identify with the thousands of world-wise professionals

who value WAI membership for its career-sustaining resources. Membership

offers a daily means to unite with colleagues and streamline even your most

ambitious agenda.

Find contacts, vendors, and customers through WAI’s extensive website. Chat

online or catch a free educational webinar. Take print or online delivery of the

industry’s leading publication—Wire Journal International. Get a year’s worthof networking at Interwire and Wire Expo trade shows and receive discounts

at the same time. Technical workshops, mentorship, committee work; all

are business-building groups in WAI’s global community. And all help

WAI MEMBERS MAINTAIN THEIR COMPETITIVE EDGE.

Whatever your pursuit—WAI will help you develop a following. So join

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16 | WIRE BULLETIN

PRODUCTION TIPS

Silver- and nickel-plated copper conduc-tors are widely used in the cable industryfor high-technology electronics, aerospace,defense, and medical applications becausethe reliability of the cable is paramount insuch mission critical industries.

Special requirements exist for high-qual-ity silver-plated copper conductors. One ofthe key requirements for reliability of bareconductor is a uniform coating of silver, forwhich relevant standards are used in the industry. Research findings suggest theneed to use a continuous 1-micron silvercoating over copper; however since the costof such use has become a concern, stan-dards have been overlooked recently re-sulting in thinner silver coatings on theseconductors.

Why plate copper wire?Copper has excellent electrical and me-

chanical properties, which make it useful inelectrical conductors. Other than silver it isthe next best conductor of electricity. Barecopper tends to react with atmospheric oxy-

gen forming cupric oxide on its outer layer.That’s why copper and its alloys are platedwith other metals to avoid corrosion.

Typically metals like silver, nickel, andtin are used as coating elements dependingon the application. Nickel can be used toprovide good protection against corrosionand high temperature; however it degradesresistance and solder-ability. Tin, due to itslow melting point, should not be used forhigh-temperature cables.

Silver plating on copper andcopper alloys

Silver is the best conductor of electricityand is resistant to corrosion; therefore it isused for plating on copper for most elec-tronic applications. It provides good resist-ance to high temperatures of up to 200°C.

In Radio Frequency (RF) applications,silver plating provides excellent conductiv-ity due to the ‘‘Skin effect’’ (in which thecurrent density near the surface of the con-ductor is greater than at its core).

Silver plating provides improved solder-ability for hook-up wires. The electroplat-ing process is used for silver plating as it provides good control over the thicknessof the coating. Multiple ends of SilverPlated Conductors (SPC) are typicallystranded together and subsequently insu-lated with fluorocarbon plastics like PTFE,ETFE, FEP, etc.

When copper is coated with silver—under humid conditions in presence of air—corrosion can occur in copper. This happensdue to the formation of galvanic cells be-tween the copper and silver, where, in thepresence of moisture at pinholes or breaksin silver, cuprous oxide tends to form.

The oxides, visible as brown-red depositson exposed copper, is a well-researchedproblem commonly known as “red plague.”

In one study, red-plague corrosion in in-sulated cables affected the electrical con-ductive path. The primary causes wereidentified as pinholes in the silver platingand the presence of moisture and air duringuse, even inside the insulation.

To ensure a continuous coating of silver,that is free of pinholes, a minimum thick-ness (1 micron or 40 microinches) of silvercoating is required. Various internationalstandards have been defined to ensure reliability and quality of SPC conductors.

While cables that use sub-standard con-ductors may not have immediate negativeimpact, they do impose serious risk on the long-term reliability and functionalityof the end application. So, it is imperative

that high-quality cables complying with relevant standards are used in mission critical industries.

This section presents findings reported byMr. Sunand Mittal in his article entitled:“Silver coating on copper conductor: do weneed 1-micron coating?”

To purchase a copy of his article, contactWAI’s Director of Education & MemberServices at: mmurray@wirenet.org.|WB

Biographical Information

Sunand Mittal is associated with SukritiVidyot Udyog Pvt. Ltd., INDIA, a manu-facturer of silver- and nickel-plated copperconductors. He holds two US patents andhas four patents pending in the field ofsemiconductors and software.

Mittal

Silver coating on copper conductors: The silver lining for mission critical industry applications

Rod-breakdown line. Schematic courtesy of SAMPSISTEMI.

JANUARY 2011 | 17

ASK THE EXPERT

ASK THE EXPERTcontinued from p. 1

Q: I am a mechanical engineering student and a member of a group project for a Manufacturing Processescourse. Our student group was instructedto design a process for the manufacture of2024 Aluminium wire. Our starting point is a hot rolled rod of 9.0 mm in diameter,which we must reduce to a final wire size of0.72 mm by using a multi die commercialpractice without intermediate annealing.We must focus on defining the completeprocess parameters including semi angles,lengths, reduction pass schedule, lubricant, drawing velocities, etc.

We have started the design process, but find ourselves making rather slowheadway as no hints or relative information have been given to us. We are in need of assistance. Can you help provide your expertise?

A: You will find yourself, throughout yourprofessional career, in manufacturingprocesses you never studied at university so it is good to get such a project now. I’msure you will enjoy this challenge and although we don’t think we should solve your problem, we can certainly send you in the right directions.

The standard electrical conductor grade ofaluminium used is 1350 which is mostly forhigh-voltage Aluminium Conductor Steel Reinforced (ACSR) non-insulated overheadcable feeding cities and low/medium voltageinsulated distribution cable. There are a number of aluminium alloys used in the electrical industry but 2024 is not usually used.

1. Rod Drawing Machine SystemsFor the 2024 aluminium drawing machinecomprising a payoff, the drawing machine itself and a take-up or spooler (single reel for stop and go or dual reel for continuousoperation) contact:• Maschinenfabrik Niehoff GmbH & Co. KG(Germany, India, Dubai, Singapore, China,Brazil, USA) | www.niehoff.de• SAMPSISTEMI division of SAMP S.p.A.(Italy, China, USA) | www.sampsistemi.com• Sangamesa Wire Technologies (India) |www.wiremach.in

These companies can provide you with theprocessing speeds and drawing die progres-sions (likely referred to as “Taper Drafting”)as well as an up-to-date machine brochure including the size of the payoff coil, take-updrawing reel and recommended drawing oil(lubricant). Also ask them for a pointer andstringer so you can string up the drawing machine the first time and every time thereafter you change finish wire diameter or if the wire breaks inside the drawing machine. If for some reason, you need a final in-line induction annealer, talk withthem about this.

2. Multiple Upset Rod WeldersFor the aluminium multiple upset rod welder(for continuous payoff), contact: • T. Fukase & Co., Ltd. (Japan) |www.fukase.co.jp• August Strecker GmbH & Co. KG(Germany and worldwide) | www.strecker-limburg.de

3. Drawing LubricantFor the drawing lubricant information contact:• RichardsApex (USA, China, India, Europe,AustralAsia) | www.richardsapex.com You may also be able to get their recommen-dations about the drawing die cone anglesand drawing die materials.

4. Drawing Lubricant SystemsFor the drawing lubricant system (storagetanks, aluminium fines filtration, temperaturecontrol, pumping and return) contact:• Filtertech (USA) | www.filtertech.comThey also have a featured system entitled,“Aluminum Wire Production & FiltrationSystem Concepts.”

5. Drawing DiesFor the drawing die information, contact:• Fort Wayne Wire Die, Inc. (USA) |www.fwwd.com• Paramount Die (USA) | www.paradie.com• Ajex & Turner Wire Dies Co. (India) |www.ajexturner.com

You should inquire with each of them abouttheir recommendations for die angles and diematerials. Be sure to tell them the drawing lubricant, the finish line speed, and calculatethe rod entry speed for them.

6. Take-up ReelsFor the wiredrawing take-up reels contact: • The Pentre Group (England) | www.pentregroup.comCheck out the steel “SF” drawing reel.• Cabrol Group – MSP Division (India) |www.cabrolindia.com

Try to get pdf copies of technical brochuresfrom all of the companies you contact. Makesure all know that you are doing an assignedmechanical engineering project at universityand that you need their help.

After all this, you will be an expert in com-mercially drawing 2024 aluminium alloy wire and you should get high marks on your project provided, of course, that you put some reasonable effort into it.|WB

Excerpted and edited from theWAI Forums | Nonferrous Section – November 2010

Content updated December 2010.Post your question or join the discussions at:

www.wirenet.org/forum/index.cfm

TECHNICAL ARTICLE

18 | WIRE BULLETIN

We have all seen how a car’s tyre getsslightly flattened when it rests on the roadunder the weight of the vehicle. If we markthe flattened portion with chalk and pushthe car a little, we would notice that themarked portion is no more flattened but hasbecome perfectly round. On the other hand,that part of the tyre which is now in contactwith the road has become flat. This flatteningis temporary, not permanent. In technicallanguage, the flattening is known as elasticdeformation which recovers the moment theload is removed. The degree of flatteningincreases with an increase of the grossweight of the car and a decrease in the airpressure in the tyre.

The same elastic flattening of rolls inrolling mills occurs when roll wire, or any-thing else, is rolled. The portion of the rollin contact with the wire being rolled getstemporarily flattened as long as the contactis there. As soon as that particular sectionof the roll that was flattened goes up be-cause of rotation, it becomes round in thesame manner as in the case of the car tyre.The flattening of the tyre is quite visibleowing to its low elasticity and relativelyhigh load. On the other hand, the flatteningof a rolling mill roll is not noticeable because of the very high elasticity of therolls and relatively low load. Moreover, therolls are not easily observed in roll flatten-ing. They are somewhat hidden inside theframe of the rolling mill.

In order to explain this phenomenon intechnical terms, consider the load-extensioncurve that refers to the properties of any engineering material (see Fig. 1).

The above figure shows a load extensioncurve which has been plotted for a wiresample. The ‘Y’ axis represents load andthe ‘X’ axis represents the extension of thewire under that load. The figure shows threecurves, one of which is for steel wire beingrolled. Steel wires are like patented mediumcarbon wire for flat healed wires, annealedhigh carbon wires for card clothing, drawnmild steel wires for reed, and flat cable armour or bush wires for industrial chains.

The second curve is for hardened and tempered steel rolls and the third is for carbide rolls.

The initial portions of the curves for thesteel roll as well as for the steel wire over-lap onto each other up to a point which isthe end of their elastic limit, generallycalled yield point for wire. The yield pointis directly related to the hardness of the ma-terial. Up to the yield point of steel wire, thecurve for the steel roll is the same as thatfor steel wire. After the yield point of steelwire Y1, the curve for steel roll goesstraight up to point Y2, which is the yieldpoint for steel rolls, whereas the curve forsteel wire takes a curvature and becomesless steep than before.

The curve up to the yield point is astraight line and it follows Hook’s Law,whereby the increase in the length or theextension is directly proportional to theload with a straight line relationship. Up tothe yield point, the extension increases asthe load increases. As soon as the load is removed, the extension becomes zero. If theload increases beyond the yield point Y1 toY1’ in the case of steel wire, it does not re-trace the load extension curve backwardswhen the load is reduced or removed. How-ever, it comes back to point ‘P’ on the ‘X’axis along the dotted line parallel to OY1. Itcan be seen that the yield point of the steelwire has increased to ‘Y1.’ In other words itgets a permanent deformation as much as‘OP’ because the load on it exceeds the ear-lier yield point Y1.

Under the same load, the steel roll is stillbelow its yield point Y2, which is higherthan the highest point on the curve for steelwire. Therefore, the roll does not perma-nently deform while rolling. However, itgets temporarily (elastically) deformed asmuch as the component of its curve on the‘X’ axis corresponding to the rolling load,as long as it is in contact with steel wire. Thethird curve is for carbide rolls. Note howhigh the yield point (hardness), Y3, is ascompared with Y2 of steel rolls and Y1 ofsteel wire and the steepness of the straightline up to Y3 as compared with the steep-ness of the straight line up to Y2 or Y1.

The curves in the above figure are forelongating or stretching, i.e., for tensileloads, whereas the loads in rolling and mostof the other metal-working operations arecompressive or opposite to tensile. It can beseen that when the wire is under a com-pressive load up to the highest point on itscurve, the steel roll gets only elastically deformed and does not have permanent(plastic) deformation. The straight line por-tion up to the elastic limit or yield point expresses the tendency of the material toundergo elastic deformation under a givenload. The slope of the straight line up to theyield point is called the modulus of elastic-ity. It represents the rigidity of any material.In the case of tensile loads it is calledYoung’s Modulus.

The higher the Young’s Modulus, thelower is the tendency to deform elasticallyunder a given load. All steel products gen-erally have the same value for Young’sModulus, which is in the region of 20,000kg/sq mm. With cold working, the value of

Young’s Modulus goes down to 18,000kg/sq mm. On the other hand, for heat-treated steels such as hardened temperedrolls as well as soft annealed steel wire, it isaround 22,000 kg/sq mm. It means that theelastic deformation in both the cases is thesame for the given load below the yieldpoint. Therefore, when the wire is beingrolled it deforms elastically as well as plas-tically. As soon as it emerges from the rolls,this elastic deformation recovers and theplastic deformation remains.

On the other hand, steel rolls are contin-uously under temporary elastic deformationon section after section of their circumfer-ence, which is recovered as soon as the sec-tions go away from the wire being rolled.This deformation or localized flatteningmeans increasing diameter of that part ofthe roll temporarily in contact with the wirebeing rolled. It causes inaccuracy in rolledprofiles. Any such deformation of the rollis more in the larger rolls than in the smallerones. This is the reason why working rollsin cluster mills used for cold rolling of thinsheets or foils are of barely 30 mm diame-ter. These rolls are backed by a cluster oflarger rolls.

It can be seen that the yield point of hard-ened and tempered steel rolls is higher thanthe highest point on the curve for steel wire.However, the difference is quite low andtherefore the wire soon inflicts wear onsteel rolls. Consider the third curve for car-bide rolls. The important features are:

• Yield point (hardness) is significantlyhigher than that of wire as well as that ofsteel rolls.• The steepness of the curve is signifi-cantly higher than that of steel wire aswell as that of steel rolls.

The steepness, i.e., the slope of the curveup to the yield point is:

For steel wire or rolls:y2 - y1 on Y axisx2’ - x1’ on X axis

Whereas for carbide rolls it is:y2 - y1x2 - x1

x2’ - x1’ = 3 × (x2 - x1)

Therefore:y2 - y1 = 3 x y2 - y1x2 - x1 x2’ - x1’

Young’s Modulus (carbide) = 3 x Young’sModulus (steel)

Then, the following becomes clear:• The yield point (hardness) of carbide is significantly higher than that of steel. • The Young’s Modulus (steepness of thecurve) for carbide is three times that of steel.Young’s Modulus of tungsten carbide is

as high as 72,000 kg/sq mm. This is thehighest-known value of the modulus ofelasticity for any known material in theworld. This value comes down because ofmaterials like cobalt and other carbidesmixed in industrial carbides. For the above

illustration, I have considered an averagevalue for Young’s Modulus of carbide rollsas three times that of steel. Because of highYoung’s Modulus, the elastic deformationof the carbide rolls is three times that ofsteel rolls and, therefore, the accuracy of theprofiles rolled by carbide rolls is very highcompared with those rolled by steel rolls.

This is an important but somewhat neg-lected aspect of carbides than their highhardness, which gives rise to wear resistancebecause of the significant difference be-tween the yield point of carbide and thehighest point on the curve for the steel wiresbeing rolled. With a little stretch of theimagination it can be easily appreciated thateverything produced using carbide tools inplace of steel tools is more accurate andthere is less power consumption using car-bide tooling compared with steel tooling.

CamberCamber or bow means the bending of the

strip in the plane of its width. The camber isobjectionable in further processing or useof the strip and should be minimised if notcompletely eliminated.

Cause and calculation of camber

Fig. 2 shows the cross section of a pro-filed wire having the following dimensions.

The wire can be rolled with four rolls outof which the bottom and the two side rollsare without any profile or groove and thetop roll is with a profile containing ‘step’and ‘blade’. Alternatively, the top roll canbe a split roll i.e., made of two rolls. Thewire can also be rolled with only two rollswhere the bottom roll is a roll without pro-file or groove in it and rolls the flat bottomof the wire. The top roll is with a steppedgroove that contains the entire cross-sectioni.e., blade as well as step, above the bottomof the wire.

The figure shows that for the bottom rollof 100 mm diameter, the blade rolling rolldiameter would be 100- 2 x T = 97 mm andthe step rolling roll diameter would be 100 - 2 x H = 94 mm for S No 1 in Table 1below. Both the blade rolling and step rollingrolls rotate together on the same shaft withthe same RPM. Therefore, their peripheralspeeds would be in the ratio (Л x 97 x RPM)/(Л x 94 x RPM) or 97/94 = 1.032.

continued on p. 20

Fig. 2. A profiled wire.

Fig. 1. Load extension curve.

Part 2: Cold rolling profile wiresIn continuation of the first part of this article as published in our issue of October 2010, the author examines the various factors associated with cold rolling profile wires such as the flattening process, Young Modulus, camber, and gauge control.By Abhay D. Hajare, BTech (Hons)-IIT (Bom), MSc (UK), DSM, CMM, FIE

JANUARY 2011 | 19

TECHNICAL ARTICLE

20 | WIRE BULLETIN

In other words, the blade of thickness ‘T’would come out of the rolling roll assemblyat a speed 3.2 per cent higher than the step.This means the profiled wire would be bentin the plane of its width or it will have cam-ber of 313.13 mm radius (S No 1) as seen in Table 1 below. If the profiled wire appearsas in Fig. 2 while looking from the inlet sideof the rolling stand, the wire will bend towardthe left after its exit. This is true for rolling of the wire, not roll-drawing of the wire.

If we increase the bottom roll diameterfrom 100 mm to 175 mm as in S No 3, theblade rolling roll diameter would be 175 - 2x T = 172 mm and step width (SW) rollingroll diameter would be 100 - 2 x H = 169mm. Their peripheral speeds would be inthe ratio 172/169 = 1.018. In other words,the blade of thickness ‘T’ would come outof the rolling roll assembly at a speed 1.8per cent higher than the step. Thus, the cam-ber would be of radius 563.33 mm (S No 3)as seen in Table 1.

Any higher radius of bending meanslower bending or lower camber. Thus, thecamber decreases as roll diameter increasesas can be seen in S Nos 1, 2, and 3 in thetable. Similarly, it can be seen from thetable that the camber decreases as width Wincreases - compare S Nos 3 and 4, and thecamber increases as wire height H increases- compare S Nos 4 and 5. When the bladethickness T decreases, the camber increases- compare S Nos 5 and 6. Since cambermeans the curvature in the wire, the lowerradius of curvature implies higher camber.When the wire is straight or without anycamber the radius of curvature or camberradius would be infinite.

The formula for calculating camber radius is:

Camber radius = (step width rolling roll diameter) x (wire width W)/(blade rolling rolldiameter - step width rolling roll diameter).

From the above formula it is apparentthat the phenomenon of camber is associ-ated with height disparity between twoparts of the wire cross section being rolledby rolls of different peripheral speeds. A flatwire or strip won’t have camber. From Fig.2, Table 1, and the above formula it be-comes clear that asymmetry is the maincause for camber. In Fig. 2, there is a steponly at the left side of the profile, therebybringing in asymmetry. If there is a similarstep of the same dimensions on the rightside of the profile as well, the asymmetrywill get converted into symmetry and thecamber will vanish.

All wire profiles are not so straightfor-ward to feed into the formula to quantita-tively determine camber. Nevertheless, theformula can provide at least a comparativeidea of camber in two similar profiles.Camber is undesirable and troublesome forsubsequent processing or use. It may alsodeprive the product of that excellencewhich is possible without camber. If theprofile of the wire is rolled in more than onepass then the wire with camber from thefirst profiling pass is difficult to feed intothe second profiling pass and it is evenmore difficult for the third pass. Therefore,the endeavour should be to produce profiledwire devoid of camber.

Control of camber As discussed above, the camber is in-

evitable wherever a profile with asymme-try is rolled. Its magnitude depends on thefactors illustrated in Table 1. However, thecamber can be at least partially eliminated.

Depending upon the profile of the wire andwhether the rolling stand is driven or is roll-drawing, the direction bending will be dif-ferent. Therefore, to remove camber, rotatethe rolling stand in either a clockwise oranti-clockwise direction and see if the cam-ber increases or decreases. If it decreases,rotate further in the same direction until thecamber is almost eliminated, or rotate in theopposite direction.

In case there are high demands on theprecision of the wire we can device guide-lines from whatever discussed above. In thelast pass the yield strength of the strip isquite high. Therefore, there is hardly anyplastic deformation of the profiled wire butrelatively high elastic deformation or flat-tening of the rolls. Thus:

1. Finishing rolls may be of lower diam-eter to reduce magnitude of their elasticflattening. 2. Bright anneal the profiled wire beforethe last pass to reduce its hardness andimprove its ductility. 3. Reduce the coefficient of friction by a)using highly polished rolls, and b) usingsuperior lubricants.4. Use carbide rolls to reduce their elas-tic deformation or flattening. 5. Apply front and back tensions as applicable to reduce the rolling load andelastic flattening of the rolls.6. Use overall low total reduction in areaso that the profiled wire has the highestpossible ductility in the final pass.

Gauge control From the discussions so far we can in-

stinctively write down ‘what to’ and ‘whatnot to’ do for gauge control also.1. Be in constant dialogue with the suppli-ers of round wire (raw material) for:

• Minimisation of surface contaminants, surface finish variation, and tensile vari-ation within a coils;• Minimisation of diameter variation be-tween coils assuming no measurablevariation within a coil; and• Prevention of any welding within a coil.

2. Prefer annealed and pinch-drawn wire to finish annealed wire to avoid kinks in thewire.3. Minimise the inter-stand tension variation.4. Ensure precise concentricity of rolls withtheir bearings to avoid cyclic variation.5. Avoid speed variation.6. Avoid variation in the coefficient of friction or in lubrication.7. Maintain the temperature of the rolls byproper cooling.

8. Avoid rolling speeds that are too high.9. Avoid too much height and/or area re-duction in a pass to eliminate the possibil-ity of skidding.10. Select a rigid mill for the expectedrolling loads and speeds.11. Rely more on tension control thanscrew-down mechanism in the last pass. Asthe strip becomes thin and hard, its yieldstrength moves very close to that of therolling rolls.

ConclusionKnowing the whys and hows of any sub-

ject and understanding the reasoning behindthe axioms thereof rather than taking themas given provides an insight that helpschoosing the most suitable raw material, de-signing the best optimum process, solvingproblems, and adding excellence to theproduct. A sofa bed is functional as a sofa aswell as bed but it is neither a good sofa nora good bed. Similarly, a multi-purposerolling mill can be utilised for a number ofproducts but it cannot be the most appro-priate choice for all of them. Therefore,knowing everything there is to know aboutcold rolling profiled wires can help workout the best equations to achieve the high-est benchmarks of quality, productivity, andprofitability.

Further reading 1. “Steel Wire: Whys And Hows,” A.D. Hajare, Wire Journal International, No-vember 1991.2. “Work Hardening of Austenitic StainlessSteel Wires,” A.D. Hajare, Wire Industry, U.K., November 1993.3. “Bright Annealing of Steel Wire,” A.D.Hajare, Wire Industry, U.K., October 1998.4. “Elasticity and its Effects on Dies andTooling in Wire Production and Process-ing,” A.D. Hajare, Wire Industry, U.K.,April 1997.5. “Elasticity and Steel Wire,” A.D. Hajare,Wire Industry, U.K., May 1995.|WB

Copies of these articles can be obtained by writing to ahajare@rediffmail.com or hajare.abhay24@gmail.com

Biographical Information

Pune-based Abhay D. Hajare is an indus-trial metallurgist and chartered engineer as well as a steel wire and card clothingtechnologist. He was graduated from the In-dian Institute of Technology (Bombay) and has also been a member of the United Nations Industrial Development Organisa-tion (UNIDO) roster of experts. He has authored numerous articles related to thewire industry.

Hajare

Camber Calculations For Wire Rolling

S No H (mm) W (mm) T (mm)Blade RollingRoll Diameter

(mm)

Step Width RollDiameter (mm)

Camber Radius(mm)

For Bottom RollDiameter (mm)

1 3 10 1.5 97.00 94.00 313.33 100

2 3 10 1.5 147.00 144.00 480.00 150

3 3 10 1.5 172.00 169.00 563.33 175

4 3 12 1.5 172.00 169.00 676.00 175

5 4 12 1.5 172.00 167.00 400.80 175

6 4 12 1.0 173.00 167.00 334.00 175

Note: Lower the camber radius, the higher is the camber.1. Camber increases as roll diameter decreases - compare S Nos 1, 2, 3. 2. Camber decreases as width W increases - compare S Nos 3, 4. 3. Camber increases as wire height H increases - compare S Nos 4, 5. 4. Camber increases as blade thickness T decreases - compare S Nos 5, 6.

Table 1. Camber calculations for wire rolling.

JANUARY 2011 | 21

Business Confidence Index for SMEs on the rise

The second quarterly survey of CII, meas-uring the Business Confidence Index (BCI)of small- and medium-size enterprises(SMEs), showed a bullish outlook of thesector for the Oct-Dec 2010 quarter. TheBCI for the current quarter is estimated at67.0 on an outlook scale of 0-100, movingfrom a most unfavourable to favourable sit-uation. A value of 50 is the dividing line between a favourable and unfavourablechange in the outlook. What is even moresignificant is that the outlook of this criticalsector has improved over the last quarter bya significant 1.4 points. “This is a positivesign of a sector emerging from the shock of the global economic meltdown, and hav-ing a huge employment potential,” saidChandrajit Banerjee, Director General, CII.

According to the survey, much of thebuoyancy in the SMEs’ performance is dueto domestic demand rather than exports.The export prospects for the SMEs havecome down significantly from the last quar-ter, which is not surprising given the slowand uncertain economic recovery in a largepart of the western globe. The appreciatingIndian rupee against the US dollar is furtheradding to the woes of the SME exporters,

the survey said. The CII survey—that aimsat gauging the mood of the SMEs a quarterin advance—reveals that the services sec-tor, on an average, is expecting to performbetter than the industrial sector.

The estimated BCI value of servicesSMEs stood at 67.5 compared to 66.5 for industrial SMEs. The exuberance of theservices sector in the previous quarter hadsurpassed the industrial sector. Based on alist of 14 exhaustive outlook indicators, theCII Survey has highlighted four variables—gross sales, new orders/contracts, capacityutilisation, and capacity expansion—thathave done exceptionally well to cross themark of 75 on the BCI scale to indicate sig-nificantly better outlook (more than 10 percent) from the previous quarter. This, in turn,is also keeping the prospects of employmentbright with its BCI standing at 73.6

Indian energy sector needsstructural reforms

According to India’s finance minister,Pranab Mukherjee, various structural re-forms are needed to make the energy sectorvibrant and investor-friendly. “While thegovernment is adopting a number of fiscalincentives to attract investments, includingin the vital energy sector, there are struc-tural reforms required in the energy indus-try to utilise those incentives,” he said.Expressing confidence that India wouldsoon turn to double-digit growth path,Mukherjee said that the contribution of theenergy sector was vital for achieving higheconomic growth. “If we can put into effectsome important structural policy measures,there is no reason why India cannot achievedouble-digit gross domestic productgrowth,” he said.

Secondary steel makers to formumbrella body

Several thousand secondary steel pro-ducers across the country, covering spongeiron units, mini steel plants and rollingmills, are trying to regroup themselves toform an umbrella organisation at the na-tional level to effectively address the issueof rationalisation of iron ore prices with theUnion Government. Anil Nachrani, Presi-dent, Chhattisgarh Sponge Iron Manufac-turers Association said, “Unless there issome correlation between the steel pricesand iron ore prices, many of these units willnot survive. Since 2006-07, the prices ofiron ore increased nearly 400 per cent, fromRs 1,200 to Rs 6,000 a tonne, while duringthe same period the steel prices increasedby 17.63 per cent, from Rs 22,953 to Rs27,000 a tonne.” The secondary steel pro-ducers said they had been hit hard by whatthey called the frequent and arbitrary up-ward revision of iron ore prices.

India-Japan CEPA pact can helpIndian steel makers

India’s integrated steel makers, lookingto move up the value chain in the autospace, will have to gear up to become morecompetitive once the Comprehensive Eco-nomic Partnership Agreement (CEPA) be-tween India and Japan kicks in. UnderCEPA, duties on some 90 per cent of thecommodities traded between India andJapan will get eliminated in the next sevenyears or so. At present, steel that is hotrolled, cold rolled, or galvanised attracts du-ties of around 5 per cent, which is likely tobe zero by 2017. With the automobile sec-tor in India clocking in sales of 35 to 40 per

cent, steel producers are moving up the lad-der and creating capacity of higher autograde steel.

Infrastructure key to India’scompetitiveness

High transaction costs that diminishIndia’s competitiveness are directly relatedto the country’s infrastructure deficit. Suchhigh transaction cost means that Indianfirms do not have a level playing field tocompete globally. This was the view pre-sented by Kamal Nath, Minister of RoadTransport and Highways at a conferenceentitled “India-US: An Agenda For Co-Cre-ation” jointly organised by the Confedera-tion of Indian Industry (CII) and the USIndia Business Council (USIBC) on No-vember 8, 2010, at Mumbai. According tothe minister, the key to sustaining India’shigh economic growth would be to bridgethe current infrastructure deficit.

Nath explained that India has embarkedon a huge infrastructure development pro-gramme across the country that is aimed atconstructing 70,000 kilometres of highwaysevery year. He said that the focus of the cur-rent infrastructure development programmeis public private partnership (PPP) which isaimed at engaging with the private sector;and that more than 90 per cent of current infrastructure is being built on a Build Op-erate Transfer Model. Nath acknowledgedthe lack of institutional capacity as thebiggest challenge toward infrastructure development and that to develop 70,000kilometres of highways in a year, there is aneed to have 20,000 kilometres of highwaydevelopment work in progress, which inturn requires bidding out several projects tothe private sector. |WB

A shop-floor view of a small-scale unit.

ECONOMIC NEWS

PEOPLE ON THE MOVE

SPC appoints three key market managers

Singapore Polymer Corp. (SPC), a unitof Teknor Apex Co., has appointed threenew managers in its vinyl and thermoplas-tic elastomer (TPE) compound businesses,as announced by Stanly Tan, SPC’s manag-ing director. One of Asia’s largest customcompounders, SPC serves customers in the Asia-Pacific, Oceania, the Indian sub-continent, the Middle East, and Africa,noted Tan, who became head of SPC onAugust 1, 2010.

“Our new managers are charged withhelping SPC to intensify its outreach to cus-tomers across a vast and diversified part ofthe world,” he said. “Many plastics proces-sors, medical manufacturers, and wire andcable producers in the region will discoverthe breadth of SPC’s product offerings, in-cluding literally thousands of compoundsdeveloped in the USA by Teknor Apex.”

New SPC team members are listed below:• Serene Cheng Sook Ee, TPE marketingmanager, has 10 years of experience in thepolymer industry. Previously she workedfor 3M Singapore Pte. Ltd. and GE Plastics(now Sabic Innovative Plastics). • Raymond Chua Boon Lin, marketingmanager in charge of vinyl medical prod-ucts, has 12 years of experience in theAsia-Pacific region as a sales and mar-

keting manager for medical device prod-uct ranges. Most recently, he worked forPall Filtration Pte. Ltd. as a businessmanager responsible for bioscience, med-ical, and OEM business portfolios. • T.S. Wu, PVC sales manager for allvinyl products in Africa and Europe, andwire and cable compounds in Saudi Ara-bia, Southern Malaysia, and Singapore,previously worked for Witco (laterCrompton) Corp. and GE Silicones. Wuhas experience in sales of commoditypolymers and in technical support forsilane-related applications.

Tata Steel appoints new CTOUday Chaturvedi has been appointed

Tata Steel Europe’s chief technical officereffective October 1, 2010. He joined thecompany’s executive committee and reportsdirectly to the Tata Steel Europe ManagingDirector and CEO. The responsibilities ofthe new role include Tata Steel Europe’sproposed new manufacturing hubs. A re-placement as head of strip products in theUK will be announced in due course.Chaturvedi has held a number of high-leveloperational positions during his career withthe Tata Steel Group. Before becomingManaging Director, Corus Strip ProductsUK in 2008, he was Vice-President Coke,Sinter and Iron and TQM in Jamshedpur.

WorldSteel honours Lakshmi Mittal

Lakshmi Mittal, Chairman and CEO,ArcelorMittal, received the WorldSteelMedal at the company’s annual dinner inTokyo. The medal was presented by PaoloRocca, chairman of WorldSteel and theCEO of the Techint Group. The WorldSteelMedal is awarded to retiring chairmen asthey step down from being an officer of theexecutive committee (chairman, vice-chair-man or treasurer). It is an honour in recog-

nition of distinguished service to the steelindustry and WorldSteel. After four years asan officer of the executive committee, Lak-shmi Mittal has now stepped down, thoughhe remains a member of the committee. TheWorldSteel Medal was first awarded in 1992and has been presented to 16 recipients todate. Sir Robert Scholey of British Steel was the first to receive it. The last three recipients have been Kirby Adams (2007,BlueScope), Akio Mimura (2008, NipponSteel) and Ku-Taek Lee (2009, Posco).|WB

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Chua Boon LinCheng Sook Ee Wu Mittal

IN REMEMBRANCE: SCOTT HIGGINS

Former president of The Wire AssociationInternational (WAI), Inc., Scott S. Higgins,died on October 30 at a hospital in NewJersey, USA, days after suffering a heart attack. He was 50 years old. A New Hampshire resident, Higgins entered the industry in 1983, and worked at, among others, General Cable Corp., Capital Wire &Cable, Hendrix Wire & Cable, IGC Advanced Superconductors and Autac, Inc.In recent years, he continued to work as anindustry consultant, but also pursued his life-long passion for boating and scuba diving,

working as a boat captain and a scuba instructor, while remaining an active mem-ber in WAI, which he joined in 1989.

Higgins, who attended Indiana StateUniversity, served on just about everyWAI volunteer body, and was presidentin 2002. He was a founding member ofthe New England Chapter, where he wasboth a director and president, and repre-sented WAI at events from Germany toAustralia. He served as a moderator onnumerous occasions for WAI technicalprograms, and was honored with WAI’sDonnellan Memorial Award in 2004. Inaddition to serving as president of theNew England Chapter in 1996, he servedas a member of its Board of Directors. Hehelped rewrite the chapter formationmanual, revise the WAI bylaws and workprocedures, and update the interviewprocess for prospective WAI employees,as well as provide substantial input forWAI’s technical programs.|WB

Higgins

JANUARY 2011 | 23

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