Wire Mill

OUR PRODUCTS

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WIRE MILL

Westral Wire Mill manufacturing processes begin by using the highest quality “ELECTROLYTIC TOUGH PITCH” ETP Copper Rod made from Cathode meeting 99.9% purity specifications.

The Copper rod is supplied in from 8mm and 14mm diameter sizes allowing Westral to produce a wide range of cross sections.

WIRE MILL PRODUCTS

Westral produce insulated round & rectangle copper to order, offering a large range of product options such as ENAMEL (HPAM), KAPTON POLYIMIDE FILM, IFC POLYESTER GLASS, HIGH VOLTAGE MICA, NOMEX 410, COMPOSITE MICA & FILM TAPES, MYLAR, FIBER GLASS AND POLYESTER GLASS.

Westral manufacture rectangular and round copper wire to order and customer's specifications, exact spool weights, cut to length bars and specific insulation builds. Emergency delivery options mean customers no longer have to wait for weeks on wire delivery to meet urgent repair deadlines and project completion targets.
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Products

WIRE MILL

ENAMEL HPAM 200C

ENAMEL HPAM 200C

ENAMEL & SINGLE POLYESTER GLASS

ENAMEL & SINGLE POLYESTER GLASS

ENAMEL & DOUBLE POLYESTER GLASS

ENAMEL & DOUBLE POLYESTER GLASS

ENAMEL & MICA

ENAMEL & MICA

KAPTON TAPE 220C

KAPTON TAPE 220C

KAPTON & POLYSTER GLASS

KAPTON & POLYSTER GLASS

NOMEX PAPER

NOMEX PAPER

DOUBLE POLYSTER GLASS

DOUBLE POLYSTER GLASS

PROCESS FLOW

Drawing Process

Drawing Process

Westral uses a combination of Heavy, Medium and Fine Rod drawdown machines to produce blemish free round wire free of inclusions. The round wire can then be further processed through our Rolling Mills to produce a range of standard and non-standard rectangular wire sizes. Westral Rectangular wire exceeds minimum requirements for ASNZ and NEMA specifications for Radius and Size tolerances.

Rolling Process

Rolling Process

The correct round wire size is then rolled to customer specific rectangular size using a combination of Flattenning Rolls and Edge Rolls.The Edge Rolls are ground to specific profiles meeting ASNZ and NEMA radius specifications.This allows for superior voltage endurance once the wire is insulated.Westral has Edge Roll tooling that covers a huge range of rectangular sizes so non-standard wire sizes can be manufactured to order.

Annealing Process

Annealing Process

After the Rolling process is complete the wire must be softened so it can be easily formed by our customers.This softening process is achieved using Vacuum Canisters that prevent any tarnishing of the copper.Once cool, the copper wire comes out of the canister will be very soft, clean & shiny with no remaining lubricant residue. The wire can then be insulated to provide our customers with the highest quality insulated copper products.

Enamel Insulation System

Enamel Insulation System

Westral trademark HPAM "Heavy Polyester Amide Imide" Enamel leads the industry in performance with superior Breakdown Voltage, excellent Abrasion Resistance, soft Copper with low Springback Levels all developed for superior performance.The two coat system of Enamel utilises the latest Enamel Resin system with a Polyester base coat supported by a hard and flexible Amide Imide top coat.This system provides excellent cut through resistance and very high Breakdown Voltage (BDV) performance.

Insulation Options

Insulation Options

Westral has developed a range of insulations suited to specific electrical repair requirements. Nomex tape for Dry Type Transformers, Kapton and Polyimide Film for DC Field Coils, IFC Polyester Glass for High Voltage (HV) Stator Coils and Generator Bars, Round Enamel with IFC for High Frequency applications and many other specialty insulation combinations. Westral Round and Rectangular wire is used for all high quality repairs from Refrigeration and Pump Motors to High Voltage Generator Sets, Transformer Repairs and Inverter Motor applications. If you need guaranteed performance and reliability then Westral is the name to trust.

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Get In Touch With Us

To gain a better understanding of our products and services , please contact us via email or phone.
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