Combined mechanical and electrolytic in-line pre-treatment systems

WiTechs’ combined mechanical and electrolytic in-line pre-treatment system integrates mechanical scale removal with inline electro-phosphating in a continuous process. Designed as an alternative to conventional pickling, it achieves comparable drawing quality while improving process stability and reducing handling steps.

Integrated process concept

The system combines multiple WiTechs and partner technologies within a compact, continuous line.

A horizontal pay-off system ensures controlled coil feeding, followed by the pull-in, bending, and straightening unit, which breaks the scale layer and prepares the wire for further treatment.

The double-head sanding descaler (SEZ-6-302S) performs mechanical cleaning through two sanding belts, achieving a minimum of 100% cleanliness.

The final stage is the Ephos® inline electro-phosphating system from STAKU, providing surface conditioning suitable for high-performance drawing processes.

This configuration enables mechanical descaling and electrolytic phosphating to operate at wire drawing speeds of up to 10.0 m/s, matching the performance of conventionally pickled wire without compromising quality.

Technical specifications

• Wire inlet diameter: 8.0–15.0 mm
• Wire inlet speed: up to 1.5 m/s
• Wire outlet drawing speed: up to 10.0 m/s

Advantages of the electrolytic phosphating process

Compared to traditional chemical phosphating, the inline electrolytic process reduces operating temperatures, eliminates sludge formation, and lowers chemical and wastewater consumption. Coating times are significantly shorter, and the resulting fine-crystalline layer provides excellent adhesion for subsequent drawing operations.

By integrating several pre-treatment stages into a single automated line, WiTechs offers a stable, efficient, and high-performance alternative to conventional pickling, ensuring consistent wire quality and reliable productivity in modern manufacturing environments.

For more information about WiTechs’ in-line wire pre-treatment systems, readers are invited to contact the company directly.