Manufacturing Capabilities of ETO | Copper Alloy Conductor Production

Manufacturing

Manufacturing

Our manufacturing facilities span 32,800㎡ and are capable of producing more than 400 types of copper and copper alloy wires, and other metal conductors, with a monthly production capacity exceeding 800 tons. The production process is organized into specialized workshops, including wire drawing (medium, small, and micro drawing), copper-clad steel processing, coating, and stranding workshops, annealing as well as inspection, and storage areas. The facilities are equipped with over 500 advanced machines, including wire drawing equipment, annealing units, stranding machines, coating systems, and cladding devices.

To ensure optimal production conditions, the workshop environment is maintained at temperatures between 5°C and 35°C with humidity levels below 70%, while raw material and finished product warehouses are kept at 5°C to 30°C with the same humidity controls. These stringent measures have enabled the company to achieve a 95% yield rate for ultra-fine alloy wires with a diameter of 0.127mm.

ETO is certified under the IATF16949 and ISO9001 quality management systems, demonstrating its commitment to maintaining the highest standards of quality and reliability. Its products are widely utilized in industries such as automotive, robotics, medical, railways, telecommunications, and aerospace, ensuring broad applicability and exceptional performance. We have also established strong partnerships with internationally renowned companies, including Leoni, Hitachi, Sumitomo, and Coficab, reflecting its reputation as a trusted supplier of high-quality copper alloy-based conductors and solutions.

Medium Wire Drawing Workshop

The medium wire drawing workshop focuses on reducing the diameter of wires by forcing the material through dies under external pressure. The process compresses the metal’s cross-sectional area to achieve the desired shape and dimensions, such as reducing a 2.4mm wire to 0.25mm. The workshop is equipped with five advanced processing machines and staffed by two skilled technicians. The wire drawing machines used include extrusion, rotary, traction, controlled, and powder metallurgy wire drawing machines, which are designed for precision and performance. Wires processed by the medium drawing machines are vibration-free, highly stable, and resistant to deformation. These wire drawing machines incorporate a dual-frequency tension automatic correction control system for precise control. The drawing wheel surfaces are treated with high-durability tungsten carbide coating, providing excellent hardness, wear resistance, and low noise operation.

The medium drawing machines can be integrated with continuous annealing machines, shaftless single-bobbin take-up machines, and meandering take-up machines to enhance efficiency. For smaller wire diameters, products are sent to the small wire drawing workshop or micro wire drawing workshop for further refinement. Each batch undergoes rigorous inspection, with conforming products advancing to the next stage, while defective products are discarded.

Fine Wire Drawing Workshop

The fine wire drawing workshop processes wire diameters from 0.7mm down to 0.16mm. This workshop is equipped with 50 small wire drawing units and operated by 5 skilled technicians. Fine wire drawing machines in this workshop are built with a cast iron integrated structure to ensure vibration-free performance and high operational stability. Dual-frequency drive systems and minimal slippage allow the production of smooth, high-quality wires. The vertical layout of the drawing zones optimizes space utilization. Drawing wheels are coated with high-durability tungsten carbide, offering superior hardness, wear resistance, and noise reduction. Flat belt transmission systems are incorporated for ease of maintenance and low operational noise, contributing to consistent production efficiency and reliability in wire processing.

Ultra Fine Wire Drawing Workshop

The ultra-fine wire drawing workshop is responsible for processing wire diameters from 0.08mm down to 0.016mm. This area is equipped with 20 ultra-fine wire drawing units and operated by 5 skilled technicians. Ultra-fine wire drawing machines feature dual-frequency drive systems, ensuring minimal slippage and producing wires with superior quality and a smooth, visually appealing finish. The vertical configuration of the drawing zones maximizes space efficiency and supports precise and reliable wire processing.

Copper-Clad Steel Processing Workshop

The copper-clad steel processing workshop handles the production and processing of copper-clad steel products with a conductivity range of 14-40% IACS. Equipped with 10 specialized processing units, this area can produce copper-clad steel wires based on various diameters, including thick wires above 1.6mm, large wires between 0.6mm and 1.6mm, medium wires between 0.2mm and 0.6mm, and fine wires below 0.2mm.

Copper-clad steel wires can also be categorized based on strength and elongation properties into soft (A), half-hard (M), hard (HS), and extra-hard (EHS) conditions. This processing workshop produces copper-clad steel in various forms, including deep-drawing parent wires, finished wires, and stranded wire blanks. Further processing options are available, such as tinning, silver plating, enameling, wire bundling, cabling, nail manufacturing, bright annealing, and braiding, meeting a wide range of functional requirements.

Tinning Workshop

The tinning workshop is dedicated to coating copper wires with a thin layer of tin. Tinned copper wires are softer, exhibit excellent electrical conductivity, and offer superior resistance to corrosion and oxidation compared to bare copper wires, significantly extending the service life of low-voltage cables.

The production process for fine tinned copper wires involves eight key steps:
Pay-off → annealing → acid pickling → tinning furnace → cooling → traction → application of guide axle oil (to reduce tin ash) → spooling.

Stranding Workshop

The stranding workshop specializes in twisting single wires into multi-strand conductors based on specific requirements. The production process includes the following steps: loading single-wire spools, threading wires, connecting wires to the stranding machine, setting production parameters, and initiating production. The stranding workshop can produce multi-strand wires, such as 7-strand, 48-strand, 60-strand conductors or 1330-strand conductors, with customization options available to meet client specifications. The stranding workshop is staffed by 20 skilled technicians and equipped with 200 stranding machines, ensuring high-capacity and efficient production tailored to diverse customer needs.

Inspection Workshop

The inspection workshop conducts a 100% full inspection of both raw copper materials and finished copper alloy conductors, ensuring thorough quality control and interception of defective items. Each wire conductor is meticulously tested for appearance, workmanship, functionality, safety, and specific customer requirements. This rigorous inspection process significantly reduces the risk of product defects.

The inspection workshop is equipped with 10 types of testing equipment and operated by 12 qualified technicians. While the industry standard for wire diameter accuracy is typically ±5%, we have implemented strict controls to achieve an accuracy of ±2%, ensuring superior precision and quality in every product.

Comprehensive Inspection from Raw Materials to Finished Conductors

Appearance Inspection
Wire Diameter Tolerance Inspection
Conductor Tensile Strength Inspection
Resistance Inspection
Elongation Rate Inspection

Packaging Workshop

The packaging process varies slightly depending on the product or customer requirements, ensuring tailored packaging solutions for each order.

Conductor Surface + Anti-Rust Paper + Stretch Film
Bubble Wrap
Corrugated Paper + Stretch Film

Wooden crate packaging ensures product quality is unaffected during long-term shipping

Warehouse

The warehouse or storage area is equipped with 5 pieces of relevant equipment, including mobile forklifts, used for storing raw materials and finished products after packaging. All raw materials and finished products are logged by professional warehouse personnel to ensure accuracy and prevent errors. Additionally, all finished copper alloy conductors undergo a final inspection before shipment, with a shipment report provided to guarantee quality and compliance.

Looking for High-Performance Copper & Copper Alloy Conductors?

Whether you need copper and copper alloy wire products or custom conductor solutions, our team is ready to assist to satisfy your specific needs.

Copper and Copper Alloy Conductors