Lines for continuous oxygen-free casting of copper wire

Business concept

Wire is a metal thread or cord. Usually the products have a round cross-section, but on sale you can find different options - square, rectangular, etc. The main materials used in the manufacture of wire are copper, steel, aluminum, zinc, and titanium alloys.

The scope of application of wire is very diverse. It is used for the manufacture of electrical wires, springs, drills, and various electronic devices.

The business idea is related to the opening of an enterprise for the production of galvanized wire. The main buyers of finished products will be individuals, agricultural, industrial enterprises, companies engaged in the manufacture of electronic equipment, etc.

The wire manufacturing process may involve a number of repetitive sequential operations. The number of repetitions is affected by the diameter of the finished product.

At the first stage of production, the metal is heat treated, after which the surface of the material is prepared for drawing. Next, the wire is drawn to the specified dimensions.

The process itself is quite complex and requires a large number of different equipment, the main element of which is furnaces with low-oxidation heating. Scale is removed by keeping the material in acid-base solutions.

Another type of equipment is refrigeration machines, rapidly cooling drums and dies. These are precisely what are used for wire drawing.

Thanks to the use of modern lubricants in the production process, the final products are resistant to corrosion and oxidation.

The required thickness is obtained by applying a zinc coating to the metal surface. To do this, the wire is kept in special solutions.

Modern equipment makes it possible to bypass the classical technology of chemical etching, removing scale using mechanical action, thereby making all stages of work safe for human life and health, and the environment.

hood

3.Drawing mechanism: Consists of a frame, lifting/lowering motor, servo motor, drawing roller reducer, holding rollers, pneumatic cylinders, valves, water cooling pipes, cooling water flow sensor. The frame is welded from profile steel, the raising/lowering gearbox uses a four-way screw spindle gearbox driven by a motor. The servomotor for drawing out the workpiece (made in Japan) is combined with a planetary gearbox. The drawing rollers are made of heat-treated 40CrMo, high hardness, wear-resistant, and the driven rollers use a toothed belt with large drive torque for drawing. The clamping rollers are driven by pneumatic valves and pneumatic cylinders made of heat-treated steel. The flow sensor allows you to clearly control the intensity of water supply, making the technological process simple. Main technical characteristics:

• Diameter of exhaust rollers: 115 mm
• Pneumatic cylinder: 12 pcs Cylinder diameter: 63 mm
• Working pressure: 0.3-0.5 MPa
• Motor power raising/lowering: 1.5 kW
• Servo motor power: 3KW
• Number of streams: 6 pcs

4. Receiving line speed control device: Consists of a cabinet with a synchronized controller.

What will be required for implementation?

The main tasks that need to be solved before launching an enterprise are the search and rental of premises, the purchase of equipment, raw materials, and the selection of qualified personnel.

The production of galvanized wire uses powerful equipment, including 4 main units:

• machines for pre-processing scrap or other raw materials containing metal, melting furnaces, dryers, that is, everything that is needed to prepare the raw materials for the manufacturing process;
• drawing mill, winder;
• device for galvanizing products. This includes an unwinder, a drying machine, instrumentation for control and computing measurements;
• main winder with reels of the required sizes, designed to prepare the wire for sale.

The Chinese line will cost less than analogues from Russia and Ukraine. The price of the equipment will be affected by its power and performance. A production line designed for the production of several types of wire in large volumes will cost at least 20,000,000 rubles. You can purchase a supported version. Its price will be almost half that.

It is also necessary to purchase office equipment and furniture for the administrative staff premises. Before opening an enterprise, you will need to register with the tax authorities and obtain the status of a business entity. You can register as an individual entrepreneur by selecting code from classifier 25.93 “Production of products from wire, chains and springs.”

But, if you plan to sell products among legal entities, then you need to register an LLC.

It is also necessary to obtain permits from Pozhnadzor and Rospotrebnadzor.

To open a small workshop, you can look for and rent an abandoned factory, or a production area in an industrial zone on the outskirts of the city. The amount of rent will be influenced by the condition of the premises, the presence or absence of the need for repairs, transport links and other factors.

For a workshop, it is necessary to rent a minimum of 300 m², and the rented area is divided into separate zones: workshops, warehouses for materials, finished products, premises for administrative personnel.

The total cost of raw materials and equipment to launch the enterprise will be about 15,800,000 rubles. Of them:

• production line – RUB 15,000,000;
• furniture, equipment for administration - 300,000 rubles;
• raw materials – 500,000 rub.

The number of personnel that will need to be hired for the job depends on the number of types of products produced. First of all, it will not be possible to start production without a professional technologist. To ensure stable and timely sales of finished products, it is necessary to form a staff of experienced marketers. Also, the workshop will not be able to work without a manager, foreman, auxiliary workers, production line operators, a storekeeper, and loaders. A company definitely needs an accountant.

You can sell your products wholesale or retail. A high-quality source of information and additional profit is your own website.

You can distribute business cards to hardware stores. Other printed information (flyers, booklets), advertisements in the media will be irrelevant. The most important thing is to gain regular customers and establish stable sales channels for products. To do this, you need to take care of promoting the enterprise with the help of employees. The marketing department will have to try to attract customers (conduct presentation demonstrations of products, develop a system of discounts for loyal, regular customers, etc.).

Advertising expenses will be at least 50,000 rubles.

Financial calculations

Start-up capital

Monthly expenses

How much can you earn?

The price of the wire varies depending on the thickness of the product and its shape. For example, a wire with a diameter of 0.8 mm in a 110 m reel will cost the buyer approximately 250 rubles. Using the equipment, the enterprise can produce up to 8 tons of products every month.

As for the specific amount of net profit, in the first few months it will barely cover operating expenses. However, after six months, the initial investments will gradually begin to pay off, and the net profit minus monthly costs will range from 450,000 - 500,000 rubles. The most important thing is to find regular customers and eliminate the presence of finished products for a long time in the warehouses of the production workshop, ensuring the fastest possible sale of products.

Payback period

The payback period for the investment will be approximately 24-36 months.

The cored wire production line is a combination of several machines designed to produce cored wires of various diameters and designs. The manufactured product, flux-cored wire, serves as a filler metal and electrode in welding pressure vessels, shipbuilding, and the production of military equipment and heavy equipment. WANYI cored wire making machines are characterized by high automation, simple and stable operation. Their annual production capacity is 2000-10000 tons of products.

Steel Coil Cutting Unit The steel coil cutting unit is composed of 3 parts: unwinding machine, slitting machine and winding machine with speed tracking unit. The machine automatically slows down to the allowable range when the cutting speed exceeds the limit.

Specification 1. Maximum cutting width: Bmax = 16mm 2. Cutting thickness: δ = 0.6-1.0mm (different tools for different thickness) 3. Maximum number of cuts: Nmax = 15 strips 4. Maximum cutting speed: Vmax = 60m/ min 5. Cutter outer diameter: φ200mm 6. Reel maximum weight: 1000kg 7. Reel inner diameter: φ500mm 8. Receiving plate outer diameter: φ1000mm

Steel Tape Winding Unit The steel strip winding unit consists of an unwinding machine, a tensioning system and a winding machine. The unwinding machine is equipped with a double-sided screw to ensure the tape width is 3-5mm. The winding unit slows down before the end of the tape and then places it between the unwinding machine and the tension frame.

A. Parameters of the unwinding machine Characteristics: 5.5 kW inverter motor; balanced tension frame; sequential winding and unwinding; double pneumatic brake Maximum belt diameter: ∮1600 Band tension: pneumatic; range: φ380-φ420mm

b. Winding machine parameters Bobbin size: φ800×φ450×500mm/according to customers' drawings Maximum linear speed: 8m/s Tightening: pneumatic double cylinder Belt arrangement: double-sided screw Braking: double pneumatic lever brake Motor: 15KW inverter motor

Black Wire Drawing Unit The black wire drawing unit includes unwinding machine (automatic/manual mode), tensioning system, roller bending machine, servo driven powder feeding system, longitudinal drawing machine and electric control system.

Main Features 1. The unwinding process is carried out automatically using an inverter motor. The speed of the unwinding machine matches the speed of the roller bending machine, which ensures stable wire tension. 2. The lubricating device lubricates the back side of the steel strips to ensure a burr-free surface. The lubrication rate is controlled using a peristaltic pump. 3. Strip feeding system: The steel strip moves along an S-shaped path, it does not slip due to the large contact area between the strip and the guide roller. This system has a speed measuring device. 4. Speed ​​measurement system: The moving speed of the steel strip can be accurately counted by the high-precision encoder. The signal from the encoder is transmitted to the powder feeder for more accurate production. 5. Forming roller: The steel strips are rolled in a U shape onto 3 vertical drive rolls and 3 horizontal drive rolls, and then filled with powder. 6. Powder feeding device: 3-stage loading hopper; drive with servomotor; radial channel with positioning rollers at 2 ends to prevent belt vibration; an emergency signal device in case the powder runs out. The hopper is made of stainless steel, which does not have magnetic properties. 7. After adding powder, the steel strip is closed in an O shape using 3 horizontal and 3 vertical rolls. 8. Reducing the diameter of steel wires rolled into an O-shape is carried out by 2 pairs of vertical and horizontal rolls. To avoid burrs or any damage, horizontal and vertical rollers are located at a certain distance from each other. The process of reducing the wire diameter is repeated several times until the required value is reached. 9. The rollers are adjusted according to the scale. 10. The drawing machine is equipped with 1/2 narrow V-belt to ensure stable transmission and low noise.

Longitudinal Drawing Unit This unit adopts advanced design, convenient operation, high degree of automation and good product quality.
Main parameters

High Precision Layer Winding Unit The high precision layer winding unit with wire positioning function can be customized to meet customers' specific requirements.

Power supply: 37KW AC motor for unwinding machine, 5.5KW AC motor for winding machine