The Rewinding Concept


(Published on wire industry, November 1999, page 637-638)

In recent years copper manufacturers have become increasingly aware of the advantages that can be gained from using Rewinding in the manufacture of single, bunched and multi wire.

This technique used to be thought of as expensive and unnecessary: a process which serves no purpose and, in fact, which could result in considerable delay, such that “what can I get from spooling my wire again?” was a common question.
Looking at the production results: most of the material is supplied to the clients, but always some of it can not be supplied because of technical reasons or considered as scrap.

In the past few years, however, due to the increasing demands efficiency and the need to cut unnecessary expenses, there has been a reluctance to accept scrap or faulty spools.

All the spools produced must instead be full and contain the quality of wire required, so that the advantages of the rewinding concept, or the process of transferring wire from one spool to another, have begun to rise to the surface.

These demands surfaced the advantages of the REWINDING CONCEPT, which means to transfer wire from one spool to another.

Rewinding line is a separated stand alone system which includes two synchronize parts:

  1. Payoff unit.
  2. Takeup unit.

A third part of quality control / measuring / labeling - can be installed as a middle part according to the manufacturer needs and would performed while transferring the wire from the Payoff to the Takeup.

Rewinding can be combined in the beginning, middle and the end of the manufacturing process and serves three major purposes:

a) Saving wire from fault spools: 1. Fixing bad traversing.
2. Replacing damaged spools.
3. Filling up semi filled spools.

b) Quality control - catch high wire.

c) Replacing working spools to shipping ones.


A. Saving wire from fault spools

There are three major situations where a spool declared as fault and the wire on it, even if good, could not be supplied.

  1. A full bunched spool which it’s traversing is not homogenous can not be submitted because of the fear for bad quality at low layers. However, due to the Rewinding process it can be fixed and saved by Rewinding in the correct parameters (tension, traverse’s pitch).

While transporting the spools from one place to another, even within the factory area, spool’s flance might be damaged. A filled up spool with a