The core of the line is the high-performance continuous rotary extrusion machine. High-purity copper rod (typically Ø12.5 mm oxygen-free or ETP grade) is fed into a precision-grooved rotating extrusion wheel. Intense frictional contact in the solid-state process generates the heat and pressure required to plasticize the copper (typically 400–500 °C in the deformation zone) without melting. The material is forced against a stationary abutment and extruded radially through a precisely engineered die chamber, forming continuous high-quality profiles in one seamless operation.
Key process advantages include:
- True single-step forming from rod to finished profile with theoretically unlimited product length (no welds or joints)
- Dynamic recrystallization producing a dense, fine-grained microstructure with excellent electrical conductivity and mechanical properties
- Superior surface finish with minimal oxidation and no defects such as bubbles or scratches
- Extremely low scrap rates — typically 95–99% material yield in stable production
- Precise dimensional control and outstanding batch-to-batch consistency
- Fully annealed/soft-state product ready for downstream drawing, stranding or insulation
The TLJ300H high-speed series incorporates optimized wheel speed, advanced cooling systems, mechanical shoe locking and intelligent process control, delivering significantly higher output while maintaining premium quality and extended tooling life.
Key Features & Competitive Advantages
- High Production Efficiency — Up to 800 kg/h output on TLJ300H models (higher on TLJ350H). Continuous operation and high line speeds dramatically increase daily capacity versus traditional multi-stage routes.
- Excellent Energy Efficiency — Friction-generated heat plus optimized design delivers 20–30% or greater reduction in specific energy consumption compared with conventional billet heating + multi-pass processes.
- Superior Product Quality — Dense, uniform microstructure; smooth, defect-free surfaces; excellent formability and consistent electrical performance (100–101% IACS achievable with quality feedstock).
- Wide Product Range — Copper flat wire (various widths/thicknesses), round wire, small busbars, commutator segments and specialized profiles.
- Intelligent & Reliable Operation — PLC + touch-screen HMI, real-time monitoring, remote diagnostics, industrial cloud/Industry 4.0 integration for full traceability and predictive maintenance.
- Compact & Cost-Effective — Significantly smaller footprint and lower operating/labor costs. One or two operators can manage multiple lines.
- Strong Process Stability — Mechanical shoe locking system and robust tooling design ensure consistent extrusion conditions and extended tooling life with minimal maintenance.
- Environmental & Operational Benefits — Low noise (<82 dB), no oil or water leakage, clean production environment.
Technical Specifications (TLJ300H / TLJ350H Series)
| Parameter | TLJ300H | TLJ350H |
|---|
| Extrusion Wheel Diameter | 300 mm (nominal) | 350 mm (nominal) |
| Main Motor Power | 110 kW | 160 kW |
| Copper Rod Diameter | Ø12.5 mm | Ø16 mm |
| Maximum Flat Wire Width | Up to 30–40 mm | Up to 100 mm |
| Product Cross Section (Flat Wire) | 5 – 150 mm² | 15 – 1000 mm² |
| Maximum Production Output | Up to 800 kg/h | Up to 950+ kg/h |
| Conductivity of Finished Product | Close to or exceeding 100% IACS | Close to or exceeding 100% IACS |
| Control System | PLC + Industrial Cloud + Remote Module | PLC + Industrial Cloud + Remote Module |
| Energy Saving Advantage | Significant (20–30%+ vs traditional) | Significant (20–30%+ vs traditional) |
Exact specifications can be tailored to your target product dimensions and required production capacity.
Product Range & Typical Applications
Our lines produce high-quality copper conductors for:
- Power cable and overhead line conductors
- Transformer windings and electrical equipment
- Automotive (including EV busbars and high-current components)
- Infrastructure, data centers and renewable energy power distribution
- Commutator segments for motors and generators
- Custom profiles and shaped conductors
The resulting products feature excellent electrical performance, superior surface quality and consistent mechanical properties, ready for further processing or direct use in demanding applications.
Why Choose Our Continuous Rotary Extrusion Solutions?
With deep expertise in cable and conductor equipment manufacturing, we deliver not only advanced machinery but complete technical solutions tailored to your production goals and market requirements. Our lines are built for long-term reliability, consistent quality and efficient operation in real-world industrial environments.
We support customers with:
- Customized machine configurations, die/tooling design and full line layouts matched to your exact product mix and capacity targets
- Process optimization, product development assistance and metallurgical guidance
- Comprehensive operator training and responsive global after-sales service
- Remote monitoring, diagnostics and technical support for installations worldwide
- Full production line integration (pay-off, pretreatment, extrusion, cooling, take-up and control systems)
Whether you are scaling high-volume standard copper flat wire production or developing specialized profiles for next-generation applications, our continuous extrusion technology provides the performance, dependability and total cost efficiency required for sustainable business growth and long-term partnership.
Inquiry Now — Contact our engineering team to discuss your copper wire production requirements. We will provide a detailed technical proposal, capacity analysis and customized configuration recommendations tailored to your needs.
Frequently Asked Questions (FAQ)
What is the main advantage of Conform continuous rotary extrusion over traditional copper extrusion and rolling methods?
It enables true single-step, continuous production from rod to finished profile with near-scrap-free operation (95–99% yield), superior metallurgical quality through dynamic recrystallization, significantly lower energy consumption, and unlimited product lengths without welds or joints.
What conductivity can be achieved with copper products from this line?
Finished products typically achieve excellent conductivity close to or exceeding 100% IACS (subject to input material quality), thanks to the fully recrystallized, dense microstructure produced by the friction-driven solid-state process.
What are the typical production rates for the TLJ300H series?
High-speed models such as the TLJ300H are capable of outputs up to approximately 800 kg/h for copper flat wire, depending on specific product cross-section and process parameters.
Is the equipment suitable for oxygen-free copper (OFC) production?
Yes. With appropriate cooling and process control configurations, the line can produce high-quality OFC-grade profiles suitable for demanding applications such as high-end transformers and EV components.
What after-sales and technical support do you provide for global installations?
We provide comprehensive operator training, on-site commissioning, 24/7 remote diagnostics, spare parts support and a global network of experienced engineers. Our industrial cloud platform enables real-time monitoring and predictive maintenance for maximum uptime.
How does the line integrate with existing production?
We supply complete turnkey lines including horizontal pay-off for rod coils, extrusion machine, cooling system, constant-tension take-up and coiling/spooling equipment, all synchronized via PLC for seamless operation.
Continuous Rotary Extrusion Line for Copper Wire / Bus Bar - Reliable Doing Cable
High-performance Continuous Rotary Extrusion Line for Copper Wire using proven Conform technology. Produce premium copper flat wire, small busbars, commutator segments & custom profiles with up to 800 kg/h output, 95–99% material yield, and conductivity close to or exceeding 100% IACS. Energy-efficient, reliable single-step solution. Inquiry Now for technical proposal.
Product SKU:
Continuous Extrusion Line
Product Brand:
RLB Machinery
Product Currency:
USD
Product Price:
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