(141) Start a Electric Wires & Cables Making Plant
Electric wires and cables have become such an important part of everyday life that without them the world as we know it would simply not exist. For without wires and cables the existence and operation of conveniences such as electric lights, telephones, computers and a host of other household appliances would not have been possible. Moreover, as the standard of living rises, so does the demand for those types of products. Consequently, there has been an incredible increase in the demand for electric wire and cable. As developing nations around the world continue to develop, this demand will undoubtedly continue to rise.
For example, Taiwan, the Republic of China, a country with a population of only 19 million, has more than one hundred factories successfully producing electric wire and cable to satisfy the needs of the domestic market. According to an estimate made in 1984,the total production of electric wire and cable had reached a level of 200,000 tons per year. Furthermore, the vast majority of this cable was purchased domestically by retailers, manufacturers, construction contractors, and the government owned power and telephone companies. Clearly, the establishment of an electric wire and cable making plant is a project worthy of investment.
The wire and cable making plant described in this particular proposal is designed for the production of wire and low voltage (below 600V) power cable. It is not intended to be used for the production of telecommunication or high voltage power cable, as the plants capable of producing these types of cable are considerably more expensive and require a higher level of technical knowledge to set up. The types of wire and cable which can be produced by the machinery outlined in this proposal are classified as follows:
I. Single wire: PVC insulated single copper conductors.
II. Multiple wires: PVC insulated copper conductors consisting of 7-61 stranded wires.
III. Flexible wire: single or twin core, PVC insulated cords consisting of 20-100 fine copper wires.
IV. Flat twin-cord wire: twin core, PVC insulated single or multiple copper conductors, sheathed with PVC layers.
V. Power cables: three of four cores of PVC insulated multiple copper conductors assembled together.
VI. Armour cable: power cables consisting of three or four round and shaped cores armored with steel wires and sheathed with PVC layers.
For example, Taiwan, the Republic of China, a country with a population of only 19 million, has more than one hundred factories successfully producing electric wire and cable to satisfy the needs of the domestic market. According to an estimate made in 1984,the total production of electric wire and cable had reached a level of 200,000 tons per year. Furthermore, the vast majority of this cable was purchased domestically by retailers, manufacturers, construction contractors, and the government owned power and telephone companies. Clearly, the establishment of an electric wire and cable making plant is a project worthy of investment.
The wire and cable making plant described in this particular proposal is designed for the production of wire and low voltage (below 600V) power cable. It is not intended to be used for the production of telecommunication or high voltage power cable, as the plants capable of producing these types of cable are considerably more expensive and require a higher level of technical knowledge to set up. The types of wire and cable which can be produced by the machinery outlined in this proposal are classified as follows:
I. Single wire: PVC insulated single copper conductors.
II. Multiple wires: PVC insulated copper conductors consisting of 7-61 stranded wires.
III. Flexible wire: single or twin core, PVC insulated cords consisting of 20-100 fine copper wires.
IV. Flat twin-cord wire: twin core, PVC insulated single or multiple copper conductors, sheathed with PVC layers.
V. Power cables: three of four cores of PVC insulated multiple copper conductors assembled together.
VI. Armour cable: power cables consisting of three or four round and shaped cores armored with steel wires and sheathed with PVC layers.
2. General Process Information
2.1. Process Description(1) Drawing
Bulk copper is formed into wire of varying diameters by drawing it through a series of dies.
Bulk copper is formed into wire of varying diameters by drawing it through a series of dies.
(2) Annealing
Since the drawing process causes the copper to become hard and brittle, it should be annealed.
Since the drawing process causes the copper to become hard and brittle, it should be annealed.
(3) Stranding
Anywhere from 20-100 (very fine copper conductor wires) are twisted into cords which will be used in making flexible wire and cable.
Anywhere from 20-100 (very fine copper conductor wires) are twisted into cords which will be used in making flexible wire and cable.
(4) Twisting
Layers of wires (1+6+12+18+24 etc.) are stranded together to make copper conductors. The maximum nominal cross-section area of a power cable core is 500m㎡.
Layers of wires (1+6+12+18+24 etc.) are stranded together to make copper conductors. The maximum nominal cross-section area of a power cable core is 500m㎡.
(5) Insulating
The copper conductors, whether they are single wire or multiple stranded wire, are covered by PVC for current insulation.
The copper conductors, whether they are single wire or multiple stranded wire, are covered by PVC for current insulation.
(6) Lay-up
Three or four of these PVC insulated copper conductors are assembled into power cables.
Three or four of these PVC insulated copper conductors are assembled into power cables.
(7) Sheathing
Complete cables are formed by sheathing twin-core or multiple-core PVC insulated copper conductors with PVC.
Complete cables are formed by sheathing twin-core or multiple-core PVC insulated copper conductors with PVC.
(8) Armoring
Special purpose power cables must be surrounded with steel wires in order to increase the cable structure strength.
Special purpose power cables must be surrounded with steel wires in order to increase the cable structure strength.
*For Special Purpose Power Cable Only.
2.2. Flow Chart
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3. Plant Description
3.1. Production capacityAccording to investor’s different situations, we classify the plant within three sizes.
Plant scale | Copper consumption | Production capacity |
Mini plant | 30 Tons/month | 45 Tons/month |
Small plant | 60 Tons/month | 90 Tons/month |
Medium plant | 120 Tons/month | 180 Tons/month |
3.2. Raw materials- - PVC grain (30% of the product weight)
- - 8.0mm or 2.6mm diameter copper rod (70% of the product weight)
- - 8.0mm or 2.6mm diameter copper rod (70% of the product weight)
In order to save money for the beginning investors, it is more economical to purchase 8mm (or 2.6mm) diameter copper rod and PVC grains as raw materials. These raw materials can be supplied by Taiwan. For the detail information, please contact the supplier in Taiwan.
3.3. Manpower
Job Classification | Manpower Required | ||
Mini plant | Small plant | Medium plant | |
| Staff | 2 | 4 | 6 |
| Technician | 2 | 3 | 4 |
| Skilled operator | 8 | 10 | 16 |
| Unskilled labor | 8 | 13 | 24 |
| Total | 20 | 30 | 50 |
3.4. Machinery and equipment(1) Machinery
Name of Machinery | Plant scale | ||
| Mini | Small | Medium | |
| 8mmØ copper rod breakdown machine Medium Wire drawing machine Fine Wire drawing machine Annealing machine Flexible wire twisting machine 7-Wire stranding machine 19-Wire stranding machine 37 wire stranding machine 3-4 core cable lay-up machine 70mm PVC insulation machine 90mm PVC insulation and sheathing machine 120mm PVC sheathing machine | 0 1 2 1 1 1 1 0 0 1 1 0 | 1 1 4 1 2 2 0 1 1 2 1 0 | 1 2 8 2 4 2 1 1 1 2 2 1 |
(2) Accessory equipment
- Copper wire drawing dies
- Copper wire welding devices
- Fork Lift
- Air Compressor
- Cooling systems for drawing lubrication oil
- Drums and bobbins
- Copper wire drawing dies
- Copper wire welding devices
- Fork Lift
- Air Compressor
- Cooling systems for drawing lubrication oil
- Drums and bobbins
(3) Accessory equipment
- Lathe
- Milling machine
- Drilling machine
- Grinding machine
- Grinding machine
- Welding machine
- Lathe
- Milling machine
- Drilling machine
- Grinding machine
- Grinding machine
- Welding machine
3.5. Inspection and testing equipment(1) Mega meter
(2) Tensile tester
(3) Heat deformation tester
(4) Dielectric withstanding tester
(5) Spark tester
(6) Aging tester
(7) Drawing dies polishing machine
(2) Tensile tester
(3) Heat deformation tester
(4) Dielectric withstanding tester
(5) Spark tester
(6) Aging tester
(7) Drawing dies polishing machine
3.6. Utilities(1) Requirement of water (KL/month)
| Mini plant | Small plant | Medium plant |
| 1,500 | 2,200 | 3,000 |
(2) Power requirement capacity (KW)
| Mini plant | Small plant | Medium plant |
| 1,000 | 1,500 | 2,500 |
3.7. Plant site planning(1) Abundant electric power supply and water supply
(2) Abundant labor
(3) Convenient transportation
(4) Lower humidity and far from the seashore
(2) Abundant labor
(3) Convenient transportation
(4) Lower humidity and far from the seashore
3.8. Area of land and plant building (square meter)
| Item | Mini plant | Small plant | Medium plant |
| Land Plant building | 2,500 1,500 | 3,200 2,000 | 5,000 3,000 |
3.9. Plant layout(1) Mini size plant layout Legend:
1. QC room
2. Conference room
3. Lobby
4. Office
5. Manager room
6. Raw material storage
7. Product storage
8. Packing area
9. Annealing machine
10. Medium drawing machine
11. 19B stranding machine
12. Fine drawing machine
13. Twisting machine
14. 7B stranding
15. Maintenance room
16. 70mm PVC insulation machine
17. 90mm PVC insulation and sheathing machine
(2) Small size plant layout Legend:
1. QC room
2. Conference room
3. Lobby
4. Office
5. Manager room
6. Raw material storage
7. Products storage
8. Packing area
9. Breakdown machine
10. Annealing machine
11. Medium drawing machine
12. Twisting machine
13. Fine drawing machine
14. 7B stranding machine
15. 37B stranding machine
16. Cable lay-up machine
17. 70mm PVC insulation machine
18. 90mm PVC sheathing machine
19. Maintenance room
1. QC room
2. Conference room
3. Lobby
4. Office
5. Manager room
6. Raw material storage
7. Products storage
8. Packing area
9. Breakdown machine
10. Annealing machine
11. Medium drawing machine
12. Twisting machine
13. Fine drawing machine
14. 7B stranding machine
15. 37B stranding machine
16. Cable lay-up machine
17. 70mm PVC insulation machine
18. 90mm PVC sheathing machine
19. Maintenance room
(3) Medium size plant layout Legend:
1. QC room
2. Conference room
3. Lobby
4. Office
5. Manager rooms
6. Raw materials storage
7. Products storage
8. Packing are
9. Break down machine
10. Annealing machine
11. Medium drawing machine
12. Fine drawing machine
13. Twisting machine
14. 7B stranding machine
15. 19B stranding machine
16. 37B stranding machine
17. 120mm PVC insulation machine
18. Cable lay-up machine
19. 70mm PVC insulation machine
20. 90mm PVC insulation & sheathing machine
21. Maintenance room
1. QC room
2. Conference room
3. Lobby
4. Office
5. Manager rooms
6. Raw materials storage
7. Products storage
8. Packing are
9. Break down machine
10. Annealing machine
11. Medium drawing machine
12. Fine drawing machine
13. Twisting machine
14. 7B stranding machine
15. 19B stranding machine
16. 37B stranding machine
17. 120mm PVC insulation machine
18. Cable lay-up machine
19. 70mm PVC insulation machine
20. 90mm PVC insulation & sheathing machine
21. Maintenance room
4. Suppliers InformationU Gear Automatic Machinery Co.,LTD .
5F,No,10,Lane315,chungshan Rd.,Sec.2, Chungho, Taipei Hsien, Taiwan,R. O. C.
TEL: FAX:886-2-2240-5083
URL: http://www.A1A1A.com
E-mail: ugten@ms19.hinet.net
5F,No,10,Lane315,chungshan Rd.,Sec.2, Chungho, Taipei Hsien, Taiwan,R. O. C.
TEL: FAX:886-2-2240-5083
URL: http://www.A1A1A.com
E-mail: ugten@ms19.hinet.net
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