Cost-efficient welding wire production begins long before the actual drawing process. Even minor deviations during wire preparation or poorly matched equipment can lead to quality variations, increased scrap rates and unplanned downtime. This is particularly true for production lines consisting of machines supplied by multiple vendors, where interface issues frequently arise.

Lämneå Bruk therefore follows a fully integrated approach. The Swedish company designs complete production lines for welding wire manufacturing – from wire pre-treatment and drawing to copper coating, winding technology and packaging. Since all major components, including the automation system, are engineered to work together, customers benefit from a technically optimized production line as well as a single point of contact for engineering, project management, commissioning and after-sales service.

Surface preparation is the first critical process step. Mechanical reverse bending descalers efficiently remove mill scale without the use of chemicals. Combined with cleaning and washing units, they provide a uniform wire surface that forms the basis for a stable drawing process and a high-quality copper coating.

For the drawing process, Lämneå Bruk utilizes multi-block dry drawing machines in loop line configuration. These systems achieve drawing speeds of up to 50 m/s while efficiently processing a wide range of wire diameters. Precisely controlled drives, optimized cooling and wear-resistant drawing blocks ensure stable operating conditions. Double-cooled drawing blocks, specially designed V-grooves and automatic drawing lubricant level control further contribute to stable drawing conditions and high process reliability, even at elevated production speeds.

Copper coating represents another key factor in achieving consistent welding wire quality. A uniform coating thickness improves electrical conductivity during welding, reduces wear on contact tips and ensures consistent wire feeding. Precisely synchronized line control provides repeatable process conditions and consistently high coating quality throughout production.

Winding technology also plays an important role in downstream processing. Lämneå Bruk's fully automatic precision layer winders achieve traverse accuracy of up to 0.01mm. Uniform layer winding prevents wire crossovers and ensures smooth wire payoff, even at high processing speeds. Automatic spool change further enables virtually uninterrupted production while increasing overall line availability.

For large wire packages, Lämneå Bruk has continuously refined its “No Twist Coiler” technology since its introduction in 1992. The wire is laid into pattern-laid coils without introducing torsional stress, enabling continuous, twist-free payoff. Depending on the application, coil weights of up to 4.5t can be achieved. This reduces package changes, improves material flow in downstream operations and simplifies the integration of packaging and logistics solutions.

In addition to the mechanical equipment, Lämneå Bruk develops the complete electrical system in-house. PLC control systems, electrical cabinets, frequency inverters and HMI systems are fully integrated into the production line. This simplifies commissioning, minimizes interface issues and facilitates maintenance as well as future upgrades. Customers benefit from shorter project lead times, clearly defined responsibilities and faster start-up.

Today, approximately 60% of all projects delivered by Lämneå Bruk are dedicated to welding wire applications. This specialization reflects the company’s extensive process expertise and its commitment to complete production solutions rather than individual machines. The objective is a fully integrated production line in which every process step works seamlessly together to deliver consistent wire quality, maximum line availability and long-term operational reliability. For customers, this means a cost-effective, future-proof solution from a single supplier – from initial engineering through commissioning to long-term service and support.

The author is Ann Kathrin Hassenburs, Lämneå Bruk.

Lämneå Bruk AB

61273 Ljusfallshammar/Sweden

Tel.: +46 122 23200

info@lamnea.se

www.lamnea.com