Copper wire manufacturer Aerumtec has been relying on lubricants from Zeller+Gmelin for several years to optimize its wire drawing production. The introduction of the Multidraw CU SY series in particular has significantly improved production processes.
Aerumtec – Copper Products and Solutions is an international manufacturer of high-quality wire products with roots dating back to 1569. Originating from the production of gold and silver wire, the company has specialized in copper wire solutions since the 1920s. Following the spin-off from LEONI AG in 2023, Aerumtec operates as an independent company and offers a wide range of copper wires, strands, ropes and special alloys. With five production facilities in Germany, the UK and China and a headquarters in Weissenburg, Bavaria, Aerumtec employs over 500 people worldwide. The company serves customers from dynamic sectors such as the automotive industry, e-mobility and renewable energies. Thanks to centuries of experience and modern technology, Aerumtec supplies innovative, customized wire solutions for the highest technical demands.
Product diversity at the Weißenburg site
Aerumtec in Weissenburg manufactures single and round copper wires as well as multiple wires and wire bundles. The diameter of the single and round wires ranges from 0.04 to 1.8 mm. These copper wires are offered in different versions: bare, tin-plated, nickel-plated, silver-plated or gold-plated, and they are available in both hard-annealed and soft-annealed form. Coil sizes vary from 80 mm (1 kg) to 630 mm (400 kg), depending on the dimension.
Challenges in production
Before switching to Zeller+Gmelin lubricants, Aerumtec had serious problems with deposits of copper soaps in the multi-wire drawing systems. These deposits led to significant contamination of the machines and caused wire breaks. The complex piping system, which supplies several machines from a central supply station, places special demands on the lubricant to prevent contamination and incrustation.
Cooperation and test phase
As part of a close collaboration between Aerumtec and Zeller+Gmelin, a test system was initially equipped with lubricants from the Multidraw CU SY series. This product line comprises lubricants that have been specially developed for the wire drawing process and are characterized by good lubricating properties and long-term stability. Another advantage of the CU SY series is its ability to minimize deposits, which is of key importance in the wire industry.
The positive results of the test phase led to the gradual conversion of other systems within the production line. Today, Aerumtec relies almost entirely on Zeller+Gmelin lubricant solutions in the multi-wire drawing area. This decision has not only improved production processes, but also increased machine availability and reduced maintenance costs.
Dr. Maximilian Daniels, Head of Electrochemical Process Engineering at Aerumtec, emphasizes: “Since the introduction of CU SY lubricants, our systems are much cleaner. The problem of deposits is a thing of the past and we have been able to significantly increase machine availability.” And Markus Mühleisen, the responsible product manager at Zeller+Gmelin, adds: “The partnership with Aerumtec shows how targeted product development and close cooperation between manufacturer and supplier can lead to significant progress in production.”
Sustainable lubricant solutions for the wire industry
The Multidraw CU SY products from Zeller+Gmelin demonstrate high stability and good cleaning performance under the demanding conditions of wire production. This is particularly relevant for Aerumtec’s complex multi-wire drawing systems, where deposits and impurities can lead to production problems.
Markus Mühleisen explains: “With our long-lasting Multidraw products, we cover the entire range of lubricants for wire drawing. Users can achieve maximum drawing speeds while their machines remain clean and consistent for a long time. Our research and development department is constantly working on innovative formulations that are both environmentally friendly and improve our customers’ processes.”
One example of Zeller+Gmelin’s continuous product development is the new Multidraw CU SY T. This fully synthetic drawing agent has been specially designed for drawing bare and tinned copper wire. It offers a high pH buffer capacity and ensures high machine cleanliness, which further improves the quality of the end products.
Working together to achieve the maximum
The use of Multidraw CU SY products at Aerumtec led to a noticeable reduction in machine downtimes and a long-term improvement in product quality. In particular, the cleanliness of the wires and the drawing systems was optimized thanks to the improved lubricating properties of the products. Dr. Maximilian Daniels notes: “The regular on-site support was crucial for us. Lubricants are a complex subject and we benefited greatly from the direct exchange with the experts from Zeller+Gmelin”
The support provided by Holger Birle, Zeller+Gmelin’s sales representative, deserves special mention. He accompanied Aerumtec throughout the entire changeover process and helped to find solutions that met the company’s specific requirements.
With the CU SY lubricant solutions, Aerumtec has created the prerequisites for maintaining its own quality standards and making production more efficient. In addition, the employees appreciate the easy handling of the Zeller+Gmelin wire drawing lubricants.
The advantages of Multidraw CU SY T at a glance
+ Long-term stability
The new copper wire agent is characterized by excellent long-term stability. The solution remains stable even under demanding conditions, which enables robust production processes without interruptions.
+ High pH buffer capacity
The high pH buffer capacity ensures that the pH value of the solution remains constant over the long term. This extends the life of the solution and increases the efficiency of the wire drawing process, while reducing the need for pH adjusters.
+ Excellent lubrication performance
The fully synthetic concentrate provides excellent lubrication performance that minimizes wear on drawing machines while maximizing the quality of the drawn wires.
+ Excellent cleanliness
Another key feature is the excellent cleanliness that is guaranteed for both the wires and the drawing machines. This ensures the quality of the end product.
