Quality copper-silver product is continually cast

With product quality critical, Rautomead processed several tonnes of copper-silver at their R and D facility; this material was then fully examined, tested and processed into the finished products.

With over 280 customer installations across 45 countries, specialist continuous casting machine manufacturers, Rautomead, of Dundee, Scotland, aims to provide the highest standards of service and support - as well as uncompromising product excellence - to its customers all over the world.

When Swedish firm, Elektrokoppar of Helsingborg, selected a new Rautomead RS model upwards vertical casting machine to produce silver-bearing oxygen-free copper wire rod for use as feedstock material in 2001, the company was as impressed by Rautomead's commitment to delivering best practice in terms of customer service as it was by their upwards vertical casting technology.

In Elektrokoppar's case, the final product to be manufactured was small copper-silver profiles, to be used as commutator sections for electric motors, principally in the automotive industry.

With product quality critical, Rautomead processed several tonnes of copper-silver at their R and D facility in Dundee; this material was then fully examined, tested and processed into the required finished products by Elektrokoppar to ensure its quality and suitability.

* Graphite-based furnace technology - Rautomead's upwards vertical casting equipment is designed around the company's unique graphite furnace technology.

The company has specialised in this technology for over 25 years.

When applied to copper wire production the graphite furnace technology facilitates the production of the highest and most consistent quality oxygen-free wire rod in a range of diameters - as well as the production of other conductor alloys.

* Major advantages - commenting on the choice of the Rautomead RS model, Elektrokoppar company spokesperson, Bengt Jonasson, said: "The introduction of Rautomead's wire rod casting technology into our manufacturing process has provided significant advantages.

By producing our own silver-bearing copper rod, we can precisely control product quality from cathode to finished wire.

We have the flexibility to change the diameter and alloy composition of rod manufacture depending on production requirements." * Comprehensive service programme - whilst the Rautomead equipment is both simple to operate and maintain, customers need to be fully trained and knowledgeable to manage the process efficiently and minimise production costs.

To meet this need, Rautomead offers the most comprehensive pre and post-sale customer service programme.

In Elektrokoppar's case, this included: the manufacture of samples for assessment and evaluation, pre-shipment testing of the casting equipment, training of Elektrokoppar engineers at Rautomead in Dundee, installation and commissioning of the casting equipment at their Helsingborg factory and regular aftersales support visits.

* Forging good relationships - "As well as providing a vital training opportunity, sending our engineers to Rautomead's Dundee HQ, also enabled them to become involved in the hands-on pre-shipment testing of our RS machine," commented Jonasson.

"Most importantly, they were also able to meet - and forge good relationships with - the Rautomead engineering and service teams whom they have been working with since the equipment has been in production." * Seamless commissioning - after delivery, Rautomead sends engineers to the customer's works to check the installation, supervise commissioning and to continue the training process.

The result is a smooth commissioning programme with customer service staff taking responsibility for the equipment following hand-over.

A customer service engineer also visits a new installation approximately six weeks following hand-over to review the status of the plant, answer customer queries, establish clear lines of communication with the production management team, advise on consumable materials, quality control, component identification and stocking and usage of spares.

Repeat visits are then normally programmed on a six-monthly basis.

* Thorough back-up - as with the Elektrokoppar contract, Rautomead operates a next-day delivery service for standard spares and consumables.

Using air-courier service, components can generally reach customers anywhere in the world within three or four days.

Where Customs procedures entail inevitable delays, local stock-holding is normally arranged.

* Long-term partnerships - Rautomead views its relationship with every customer as a long-term partnership.

This view stems from the genuine belief that the customer's success is no less important to the company concerned than to Rautomead itself.

Similarly, the quality of service and support provided by Rautomead are considered no less important than the delivery of good technology.

Second Rautomead continuous casting machine further increases Elektrokoppar's OFC wire rod capacity As a further demonstration of their appreciation of the high standards of customer service and technical expertise that are to be gained by selecting Rautomead's continuous casting technology, Elektrokoppar subsequently purchased a second Rautomead machine.

Installed and commissioned in 2004, this latest RS3000/5/25 upwards-vertical copper rod casting machine will be used to further increase production of silver-bearing copper feedstock rod for the company's well-established Conform continuous extrusion process to 12,000 tonnes per year.

* Close process control - when asked about this latest Elektrokoppar contract, Rautomead chairman, Sir Michael Nairn, said: "It is very gratifying that Elektrokoppar have selected Rautomead for their second copper rod casting machine.

The combination of the Rautomead process, with Conform's expertise to make high quality wrought profiles, represents a very neat and elegant solution for the production of small copper-silver sections.

It also gives the manufacturer close control of the whole process sequence, from the refined cathode to the end product.".

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