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Manufacturing Processes

Walro Flex’s manufacturing facility consists of four major processes:

1. Rod Breaking & Wire Drawing

This process starts with the drawing down of 7,90mm diameter copper rod. Then four high speed, multi-end fine wire drawing machines draw annealed copper wire down to various sizes and combinations of wires.

2. Bunching and Stranding

The double twist bunching machines produce strands ranging from 0.22mm² to 8.00mm² at speeds of up to 5 600 twists per minute. A single twist buncher and cable stranders produce conductors ranging from 10mm² to 95mm².

3. Extrusion

The extrusion department has four fully automated extrusion lines producing auto cable from 0.22mm² up to 6mm². This process has undergone a major capital investment. The new equipment works on the principle of skinning, this enables Walro Flex to be highly flexible in terms of product range and therefore improve delivery and turnaround times. The battery cable extrusion line has also undergone major refurbishment, thereby increasing production capacity of 800 000 metres per month.

4. Highly flexible, super-fine conductor (pigtail)

This department has two super fine multi-end wire drawers which are capable of drawing wire down to 0,05mm. Four specialized bunchers and a tubular strander produce these special, highly flexible strands.