In today’s fast-growing cable and wire industry across Saudi Arabia and the GCC, reliable access to high-quality copper rod is fundamental to supporting massive infrastructure development, renewable energy targets (58.7 GW by 2030), giga-projects and grid modernization under Vision 2030. Local copper rod demand stands at approximately 318,000 tons per year, with only around 48% currently produced domestically — creating a clear strategic opportunity for manufacturers who invest in modern, efficient production technology.
Our Copper Rod Continuous Casting and Rolling Line provides a complete, modern solution that integrates the best engineering principles from Southwire SCR (USA), Continuus-Properzi (Italy) and SMS (Germany) with our own proprietary innovations. The system converts cathode copper or high-grade copper scrap into bright, high-conductivity low-oxygen copper rod (Φ8–30 mm), tubes, flat billets and profiles in a single continuous melting-casting-rolling process.
Compared with traditional wirebar or semi-continuous routes, this integrated CCR technology delivers 20–30% higher operational efficiency, significantly lower capital investment, reduced energy consumption (typically 320–360 kWh per ton), simpler operation, superior and consistent product quality, and minimal environmental impact. These advantages translate directly into faster ROI (typically 12–18 months on automation upgrades) and strong alignment with Saudi Arabia’s localization and sustainability goals.
Key Benefits for Saudi and GCC Cable Manufacturers
- Lower total cost of ownership and accelerated return on investment through high efficiency and reduced energy & maintenance costs
- Strong fit with Vision 2030 — supports local manufacturing, job creation, technology transfer and circular economy (100% scrap route available)
- Flexible multi-strand design (4–28 strands) with annual capacities from 2,000 to 15,000+ tons
- Full customization for local raw material mix (cathode or scrap), factory layout, ambient conditions and desired automation level
- Excellent rod quality — bright surface, uniform microstructure, outstanding drawability with minimal breakage during subsequent wire drawing
- Proven Middle East project experience with fast-response technical support and training programs
Detailed Process Flow
Cathode Copper Route Cathode copper is charged into the vertical melting furnace → transferred via launder to holding furnace → precise temperature and chemistry control → 5-wheel (or upward) continuous casting machine → front traction unit → automatic shear → straightening & chamfering → feeding into the two-roller continuous rolling mill (typically 12 stands) → in-line cooling and reduction → back traction → automatic coiler with traverse system → hydraulic packing.
High-Grade Copper Scrap Route Scrap is melted and refined in a reverberatory furnace (oxidation + reduction steps for quality control) → launder transfer → same high-precision casting and rolling downstream process. This route supports sustainability targets and reduces reliance on imported cathode.
Our patented innovations — including the SouthW separated-tension crystallization wheel design and high-precision electromagnetic flowmeter water-cooling system — deliver approximately 30% higher casting stability and significantly longer steel belt service life compared with conventional systems. The process produces rods with minimal surface oxide, excellent ductility and consistent electrical performance.
Advanced Features & Operational Benefits
Power Frequency Induction Furnace & Intelligent Feeding System Stable, precisely controlled melting ensures consistent high-purity melt chemistry and temperature. This is critical for achieving uniform grain structure and predictable drawing performance downstream.
Continuous Casting Machine (Wheel or Upward Configuration) Available in 4–28 strand configurations with servo-driven precision. Supports rod diameters from 8–20 mm or 16–30 mm. Multi-strand flexibility allows producers to scale output efficiently while maintaining tight dimensional tolerances.
Siemens PLC + Advanced HMI Control System Full-line integration, real-time process monitoring, automatic data logging, recipe management and remote diagnostics. Touch-screen interface enables quick parameter adjustment and supports Industry 4.0 connectivity for predictive maintenance.
Flexible Take-up, Crystallizer & Product Range Automatic tracing take-up with traverse system. Custom crystallizers available for pure copper rod, copper alloy rod (Cu-Mg, Cu-Ag, Cu-Sn), copper strip and copper tube production.
Comprehensive Auxiliary Systems Advanced closed-loop water cooling, precise temperature measurement, automatic lubrication and robust electrical controls ensure stable 24/7 operation with low maintenance requirements.
Resulting Rod Quality Bright surface finish, uniform internal structure, high ductility and excellent electrical conductivity (≥98% IACS, with higher values achievable on oxygen-free configurations). These characteristics enable high-speed wire drawing with low breakage rates — essential for competitive magnet wire, enameled wire and fine wire production.
Technical Specifications
| Model | Strands | Up-Cast Size (mm) | Frame of Furnace | Yearly Output (Ton) | Take-up Form | Coil Weight (kg) | Installed Power (kW) | Actual Power (kW) | Electricity per Ton (kWh/T) |
|---|
| SL04-Q2-S-B-8/20 | 4 | 8–20 | Two compounding furnaces | 2000 | Automatic tracing + traverse | ≤3000 | 330 | 160 | ≤360 |
| SL06-Q2-S-B-8/20 | 6 | 8–20 | Two compounding furnaces | 3000 | Automatic tracing + traverse | ≤3000 | 330 | 180 | ≤350 |
| SL06-Q2-S-A-16/30 | 6 | 16–30 | Two compounding furnaces | 3000 | Automatic tracing + traverse | ≤2500 | 330 | 180 | ≤350 |
| SL08-QL-S-B-8/20 | 8 | 8–20 | Three compounding furnaces | 4000 | Automatic tracing + traverse | ≤3000 | 480 | 230 | ≤340 |
| SL10-QL-S-A-16/30 | 10 | 16–30 | Three compounding furnaces | 6000 | Automatic tracing + traverse | ≤2500 | 480 | 270 | ≤340 |
| SL12-QL-S-B-8/20 | 12 | 8–20 | Three compounding furnaces | 6000 | Automatic tracing + traverse | ≤3000 | 480 | 270 | ≤340 |
| SL16-QR-S-A-16/30 | 16 | 16–30 | Three compounding furnaces | 10000 | Automatic tracing + traverse | ≤2500 | 950 | 540 | ≤330 |
| SL20-QW-S-B-8/20 | 20 | 8–20 | Three compounding furnaces | 10000 | Automatic tracing + traverse | ≤3000 | 950 | 500 | ≤320 |
| SL24-QW2-S-B-8/20 | 24 | 8–20 | Three compounding furnaces | 12000 | Automatic tracing + traverse | ≤3000 | 1000 | 540 | ≤320 |
Higher-capacity models (up to 28 strands and 15,000+ tons/year) and custom configurations for alloy rod, strip, or pipe production are available upon request.
Main Parts & Standard Configuration
- Copper Melting Furnace + Holding Furnace (1 set)
- Five-Wheel / Upward Continuous Casting Machine (1 set)
- Front Traction + Automatic Shear (1 set)
- Straightening & Chamfering Machine (1 set)
- Double-Roller Continuous Rolling Mill with Feeding Device (1 set)
- Copper Rod Cooling System (1 set)
- Automatic Rod Coiler + Hydraulic Packing System (1 set)
- Siemens PLC + HMI Full-Line Control & Monitoring System (1 set)
Primary Applications in the Cable & Wire Industry
- Power cables, building wires, low-voltage and medium-voltage cables — Φ8 mm high-conductivity low-oxygen rod
- Enameled wire, magnet wire, telephone & data cables — high-purity bright rod with excellent surface quality
- High-speed rail contact wires, welding wire, bearing sleeves — copper alloy rods
- Busbars, copper foil, electrical components — copper strip and flat billets
- Air-conditioning tubes and industrial piping — copper tube via specialized crystallizers
Why Choose Us – Reliable Quality, Customized Service, Long-Term Partnership
As a technology-driven supplier with extensive experience in the global cable industry, we deliver more than equipment — we deliver complete production solutions tailored to your market and operational realities.
- Proven Reliability — Every line is tested under full load for 72 hours. We guarantee compliance with conductivity, oxygen content, dimensional tolerance and surface quality specifications.
- Tailored Solutions — Complete customization of capacity, raw material handling (cathode or 100% scrap), factory layout and automation level to match your Saudi or GCC facility conditions.
- Full Lifecycle Support — Professional installation, commissioning, operator and maintenance training, genuine spare parts supply, remote diagnostics and annual service contracts.
- Local Market Expertise — Fast-response technical team with proven experience in Middle East projects. We understand the importance of Vision 2030 localization, energy efficiency and sustainable manufacturing.
- Customer-Centric Partnership — Over 85% repeat purchase rate from cable manufacturers worldwide — clear evidence of long-term satisfaction and trust.
Frequently Asked Questions (FAQ)
What is the typical ROI period for a new copper rod CCR line or automation revamp?
Most clients achieve full return on investment within 12–18 months through energy savings, higher yield, lower maintenance and increased production capacity.
Can the line process 100% copper scrap?
Yes. Our reverberatory furnace + refining route is specifically designed for high-grade scrap while maintaining consistent rod quality.
What oxygen content and conductivity can be achieved?
Standard low-oxygen configuration delivers excellent drawability suitable for most cable applications. Optional upward casting configurations can achieve oxygen content below 10–20 ppm for premium oxygen-free copper rod requirements.
How does energy consumption compare with traditional methods?
Our modern CCR lines typically consume 320–360 kWh per ton — representing significant savings versus the traditional wirebar reheating route.
Do you provide support for Vision 2030 localization projects?
Absolutely. We offer technology transfer packages, operator training programs, spare parts localization planning and documentation support aligned with Saudi industrial development goals.
Ready to strengthen your competitive position in the Saudi and GCC cable market?
Contact our technical sales team today. Within 48 hours we will provide a customized configuration proposal, detailed ROI calculation, energy consumption analysis and relevant reference cases from similar regional projects.
Inquiry Now — Partner with a reliable, experienced technology supplier committed to your long-term success in copper rod production.
Copper Rod Continuous Casting and Rolling Line
Advanced Copper Rod CCR Line integrating SCR, Properzi and SMS technology. Produce bright low-oxygen copper rod (Φ8–30 mm) with 320–360 kWh/ton energy consumption and superior conductivity. Custom capacities 2,000–15,000+ tons/year. Ideal for Saudi Vision 2030 localization. Inquiry Now for detailed ROI proposal.
Product SKU: CCR-8MM-TR-12
Product Brand: Reliable Cable
Product Currency: USD
Product Price: Contact for Quote
Product In-Stock: InStock
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