High-Performance Metallurgical Cored Wire Manufacturing Line - Precision Engineering | High-Throughout Production | Advanced Process
Our Metallurgical Cored Wire Machine is a heavy-duty, fully integrated production system engineered to manufacture premium-grade cored wires (9mm to 20mm diameter) for advanced steelmaking and metallurgical applications. Combining robust structural fabrication with precise electronic synchronization, this manufacturing line guarantees consistent powder filling, tight dimensional tolerances, and high-speed operational reliability.
EXECUTIVE OVERVIEW
| Production Output | Nominal production capacity of 250 Metric Tons per month, benchmarked on 13 mm wire. |
| High-Speed Operation | Linear line speeds up to 120 meters per minute, with specialized synchronization parameters for various core materials. |
| Workforce Requirement | 3 operators per shift, excluding final coil packing. |
| Compact Footprint | 6 m (W) × 25 m (L) × 3.2 m (H) per line. |
TECHNICAL & MATERIAL FLEXIBILITY
The system supports both powder-filled and solid-core configurations through rapid-change setup arrangements. It processes high-ductility CRCA EDD Grade steel strips conforming to IS 513 standards for the outer sheath.
| 9 mm Diameter | 0.4 mm | 40 mm | Powder / Granules |
| 13 mm Diameter | 0.4 mm | 56 mm | Powder / Granules |
| 16 mm Diameter | 0.4 mm | 68 mm | Powder / Granules |
| Solid Calcium Core (Seam Type) | 0.7 mm | 36 mm | Solid wire Calcium |
CORE ENGINEERING COMPONENTS
| Heavy-Duty Vertical De-Coiler | 3 Metric Ton capacity; manually and hydraulically expandable/collapsible core from 475 mm to 525 mm; pneumatic braking system for precise tension control. |
| Advanced Forming Mill | High-torque mill drive powered by 3 synchronized geared motors with VFD; 120 mm × 120 mm MS roller block housings; 67 mm EN-24 induction-hardened shafts; heavy-duty oil seals; structural I-beam chassis with 16 mm MS plates. |
| Synchronized Conveyor System ( 3 Unit Aarry) | 3-unit array with 16 mm MS plate frames, 200 mm wide heavy-duty belt and 40 mm EN-31 hardened steel shafts. Mechanically synchronized with the pinch roller. |
| Smart Overhead Hopper & Weighing Station | Two 1.5-ton hoppers and one 600 kg hopper with electronic weighing scales and high-accuracy load cells. |
| Semi-Automatic Intelligent Winder | 170 mm main shaft, 20 mm MS spool flanges, 12 mm collapsible core plate, hydraulic coil removal system powered by a 3 HP motor and 80 L fluid tank power pack. |
| Traverse Layering | 800 W servo motor with zero-backlash ball screw assembly for controlled and uniform wire layering. |
MODULAR OPTIONAL UPGRADES
| Automated Strip Feeder | 3 HP gear motor with dedicated VFD and proximity switches for synchronization with the accumulator loop. |
| Continuous Strip Accumulator | 2.2 m diameter steel accumulator wheel with 1-ton holding capacity, driven by a 5 HP gear motor and VFD. It allows continous working strip butt-welding instead of stopping completely. |
| Solid Calcium De-Coiler | Vertically oriented 600 mm diameter expandable core with 300 kg capacity and manual friction brake. |
| Solid Calcium Straightening Unit | Multi-axis heavy-duty horizontal and vertical guiding rollers to ensure flowless strengthening of wires during feeding. |
| Internal Powder Mixer | 5 HP gear motor-driven granule and powder mixing mechanism installed inside the 1.5-ton hopper for core mixture homogeneity. |
ELECTRICAL ARCHITECTURE & TIER - 1 COMPONENTS
| Geared Motors & Gearboxes | Bauer — Premium industrial grade |
| Automation (PLC, VFD, HMI) | L&T — Advanced programmable control and intuitive interface |
| Switchgear & Contactors | Siemens — Heavy-duty safety & switching |
| Power & Control Cabling | Polycab — High-conductivity, fire-retardant cabling |
CONNECTED POWER ALLOCATION
| Forming Mill Drive | 39 kW |
| Winding System | 20 kW |
| Overhead Hopper System | 8 kW |
| Strip Accumulator Module | 4 kW |
| Strip Feeder Module | 4 kW |
| Control System Hub | 2 local machine-mounted operating panels and 2 remote control panels housed inside a clean electrical control room. |
OPTIMIZED VELOCITY CONTROL PROFILES
| Maximum Mechanical Speed | 120 meters / minute | Maximum line operating capability. |
| Powder Wire Profiles | 70% of maximum speed | Optimizes powder filling density and helps prevent core voiding. |
| Solid Calcium Profiles | 90% of maximum speed | Balances extreme mechanical pulling force with precise straightening. |
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