By introducing combined roll forming and double twist stranding into a single high-speed continuous manufacturing process, this system significantly enhances productivity while reducing material waste and operational costs.

The “roll form strander system” optimizes manufacturing efficiency by allowing continuous operation with large payoff packages, handling up to 1,000kg of aluminum or 3,000kg of copper per load. This system reduces downtime and eliminates frequent machine stops, ensuring a seamless and highly productive workflow. The automatic changeover feature enables operators to replace wire coils and perform welds without stopping the machine, further increasing output efficiency.

Additionally, the “Single Input Wire“ (SIW) method incorporated into the “roll form strander” reduces conversion costs by eliminating the need for multiple wire diameters. Traditional stranding processes require separate drawn wire diameters for each finished conductor, resulting in higher setup times and material waste. In contrast, the SIW method enables manufacturers to use a single wire diameter across multiple strand configurations, reducing wire drawing costs by 15% to 20%.

The system’s external roll forming section reshapes round wire into optimized profiles, enhancing conductor compactness and stability. It supports a range of strand constructions, from simple two-layer (1+6) designs to complex four-layer (1+6+12+18) configurations, enabling manufacturers to produce high-quality stranded conductors for various applications, including:

– Copper and aluminum stranded conductors (8 AWG - 600 kcmil)

– Stranded conductors with fill factors up to 97%

– Aluminum Conductor Steel Reinforced Conductors (ACSR)

– All-Aluminum (AAC) and Aluminum Alloy Conductors (AAAC)

– Cabling of insulated conductors

The precision of the roll-forming process ensures tighter, more stable strands, reducing the risk of birdcaging and material scrap during insulation and extrusion. This translates to

higher quality final products and lower overall manufacturing costs.

With speed ranging 1,000-1,200 twists per minute (TPM), the “roll form strander” outperforms traditional rigid stranders, which max out at 300TPM. This dramatic speed increase allows manufacturers to increase their output while requiring only a single operator to oversee the process. Additionally, the system minimizes downtime during reel changes, reducing labor-intensive stops and increasing overall equipment effectiveness.

By combining roll forming with high-speed stranding, Bartell has created a system that provides manufacturers with a cost-efficient, high-productivity solution that can help improve both performance and profitability. Bartell Machinery’s commitment to innovation ensures that wire and cable manufacturers can stay ahead in an increasingly competitive market. With reduced material waste, lower energy consumption, and streamlined production, the “roll form strander system” is poised to redefine industry standards.

Interwire 2025, Booth 739

Bartell Machinery Systems L.L.C.
6321 Elmer Hill Road
Rome, NY 13440, USA
Contact person is Mike Hovey
Tel.: +1 315 356-4000
mhovey@bartellmachinery.com
www.bartellmachinery.com