Production Line

01. Non-stop H-shaped Wheel Pay-off

The process kicks off with a non-stop H-shaped wheel pay-off system equipped with dual spools. With AC motors, automatic tension control, and carbon-coated surfaces, it allows uninterrupted wire feeding. The design includes a tension-adjustable nylon pulley, a signal light alarm, and a user interface for spool switching without halting production.

02. Annealing

Using a counterflow gas-fired furnace with multiple heating zones, the annealing stage ensures even heat treatment. Pre-heating and up to four heating zones allow precise temperature and gas control, preserving wire integrity. The structure includes steel wire brackets, oxygen treatment ports, and pressure stabilization for consistent annealing outcomes.

03. Air Cooling

After annealing, the steel wire passes through an air cooling stage designed to stabilize its mechanical strength. This step uses ambient air in a designated section, ensuring consistent temperature drop while preventing internal stress buildup before water quenching.

04. Water Cooling

Equipped with stainless steel troughs, overflow trays, and a circulation system, the water cooling section rapidly reduces wire temperature. The setup includes overflow pumps, fans, and a splash-proof air knife system to ensure surface cleanliness and cooling consistency while minimizing wastewater discharge.

05. Smoke-free Acid Pickling

The pickling tank adopts an enclosed overflow design using PP material. With acid-resistant pumps, multi-path sealed channels, and circulation heating, it ensures effective oxide removal. Additional mist control and liquid heating systems enhance wire surface treatment while preventing acid mist emissions.

06. Acid Mist Purification

To prevent environmental contamination, acid mist from pickling is captured by a dual-tower scrubber. The unit uses seven water spray stages and a corrosion-resistant fan to absorb HCL emissions and discharge neutralized gas, maintaining safe workshop air quality.

07. Water Washing

Fabricated from enhanced PP panels, the water washing tank removes residual acid from the wire surface. Equipped with six acid-resistant pumps and a back-blowing air knife system, it prevents acidic overflow into downstream processes and ensures thorough cleaning.

08. Fluxing

The overflow fluxing tank, made from reinforced PP, includes a circulation heating system and chemical balancing module. Operating around 75°C, it prepares wire surfaces for galvanizing by applying flux solution evenly, assisted by filtration and back-blow drying equipment.

09. Drying

After fluxing, wire is dried in an electric-heated oven to remove residual flux or water. The drying chamber maintains temperatures between 150–250°C, preventing coating defects during galvanizing.

10. Hot-dip Galvanizing

Wire enters a ceramic zinc pot heated by electric ceramic heaters. Molten zinc uniformly coats the wire, with temperature controlled by a dual-zone system to ensure optimal adhesion and surface finish.

11. Vertical Support Frame

The vertical wire support structure ensures consistent alignment and minimal vibration during galvanizing. Its steel frame and damping elements allow smooth wire travel and easy maintenance access.

12. Ceramic Guide Rollers

Made from sintered SiC+SiN, these rollers resist high wear, corrosion, and temperature. With large diameters (≥300mm), they maintain precise wire routing and surface protection under extreme conditions.

13. Nitrogen Wiping

A precision-controlled nitrogen wiping system adjusts the zinc coating thickness. Each gas knife operates independently with adjustable flow, pressure, and temperature for uniform, high-quality coating.

14. Post-Coating Cooling

After wiping, the galvanized wire is cooled using dual water spray lines and one air duct. Water volume is individually controlled per pipe for efficient temperature drop, enhancing surface smoothness and coating adhesion.

15. Inverted Take-up

The take-up unit uses an inverter-controlled pneumatic accumulator and motorized trolley to wind wire without stopping. It includes tension control, alignment system, and alarms for stable operation and precise coil formation.

16. Packaging

A semi-automatic hydraulic baler wraps finished wire coils with minimal manual labor. It operates via control panel and solenoid valve, and includes safety interlocks to protect operators from accidental activation.

Production Line

Production Line

01. Non-stop H-shaped Wheel Pay-off

02. Annealing

03. Air Cooling

04. Water Cooling

05. Smoke-free Acid Pickling

06. Acid Mist Purification

07. Water Washing

08. Fluxing

09. Drying

10. Hot-dip Galvanizing

11. Vertical Support Frame

12. Ceramic Guide Rollers

13. Nitrogen Wiping

14. Post-Coating Cooling

15. Inverted Take-up

16. Packaging

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