WiTechs Wire Rod In-Line Pre-Treatment Machinery

Engineering catalog of WiTechs equipment: Ecoclean high-speed brushing machines, PCM automated coating systems, SEZ belt sanding descalers, and DZH payoff tooling.

WiTechs: Netherlands leader in wire rod in-line pre-treatment equipment

WiTechs B.V. located in Hengelo designs modular equipment for in-line mechanical pre-treatment of wire rod prior to drawing. The proprietary technologies eliminate chemical acid pickling baths through highly efficient mechanical descaling and coating methods.

Company established in 2007 in Hengelo with active memberships in IWMA and AWPA
Comprehensive processing lines handling hot-rolled wire rod from 5.5 mm up to 34 mm
Drastic reduction of total cost of ownership for wire drawing and processing plants
Engineered modular equipment meeting modern international metallurgical standards

High-speed WiTechs Ecoclean brushing machines for wire rod descaling

The Ecoclean brushing unit performs mechanical final descaling of wire rod with diameters between 5.5 and 10 mm. Operating at line speeds up to 10 m/s, the machine achieves a run time of up to 1500 tons of wire without process downtime or maintenance interruptions.

Working diameter range from 5.5 to 10 mm with line speeds up to 10 meters per second
Reduction of drawing lubricant residues on wire surface by up to 80 percent
Reliable operation across volume runs reaching 1500 metric tons without downtime
Surface activation improving lubricant carrier retention during high-speed drawing

Automated WiTechs PCM pre-coating units for wire drawing lubrication

The compact PCM pre-coating unit installs inline to apply borax or borax-free carrier coatings onto wire rod measuring 5.5 to 34 mm in diameter. With a footprint of 2100 mm, internal sensors monitor fluid concentration and regulate dosing automatically.

Compact inline footprint of 2100 mm allowing integration into existing drawing lines
Processing diameter range from 5.5 to 34 mm operating at line speeds up to 4 m/s
Automated concentration monitoring and continuous chemical solution dosing control
Automated line stop triggering whenever solution concentrations deviate from targets

WiTechs SEZ belt sanding machines for fine wire surface finishing

The SEZ sanding unit employs abrasive belts for final mechanical descaling of wire rod measuring 5.5 to 34 mm at line speeds up to 6 m/s. Integrated monitoring systems halt line operation prior to belt fatigue, ensuring prime quality for cold heading CHQ grades.

Precision wire surface conditioning for 5.5 to 34 mm diameters at speeds up to 6 m/s
Integrated belt break safety and quality system preventing unground rod progression
Engineered for cold heading quality CHQ wire and coil to bar manufacturing setups
Completely sustainable mechanical processing without hazardous chemical acid baths

Autonomous WiTechs WBE wire brushing modules for scale removal

The WBE brushing unit cleans scale from medium and high carbon wire rod sized 5.5 to 8.5 mm and up to 18 mm. With wire speeds up to 5.5 m/s, the machine achieves 3000 tons of throughput without line downtime through automated motorized brush positioning via HMI.

Rod processing range covering 5.5 to 8.5 mm with heavy-duty capacity up to 18 mm
Extended continuous run time of up to 3000 metric tons without scheduled downtime
Motorized brush gap regulation controlled via operator digital HMI interface
Scale removal operating costs over ten times lower than shotblasting installations

WiTechs scale breakers, payoff towers and OEM spare parts

WiTechs provides multi-plane bending scale breakers DZH-1s, DZH-2s, DEG-5/2, payoff towers TZ-3, and drawing accessories HDS and DSK. The company supplies replacement parts for proprietary machinery and Koch drawing lines delivered up to and including 2019.

Multi-plane roll bending descaling assemblies of series DZH-1s, DZH-2s, and DEG-5/2
Heavy-duty vertical and horizontal wire rod payoff towers of modification TZ-3
Pneumatic and motorized haul-off and drying auxiliary units of HDS and DSK series
Spare parts support for GSG Machines and Koch drawing equipment built through 2019

Mechanical wire rod descaling engineering by WiTechs

Mechanical descaling systems engineered by WiTechs combine multi-plane bending, radial wire brushing, and precision belt sanding to eliminate mill scale without hazardous chemical baths.

Scale breakers bend the incoming rod across hardened grooved rollers, causing the brittle oxide crust to crack and dislodge from ductile steel. Following primary bending, Ecoclean and WBE brushing machines remove residual flakes and activate surface roughness to optimize lubricant retention.

This eco-friendly process completely avoids acid waste handling and toxic chemical sludge disposal.

Ecoclean and WBE wire brushing modules specification

High-velocity Ecoclean and WBE modules feature specialized rotating wire brush drums crafted from high-tensile spring steel wire.

Integrated servomotor actuators regulate radial brush gaps and contact pressure via a digital operator HMI terminal, compensating for normal brush wear over extended operational runs. Each brush assembly achieves uninterrupted production runs up to 3000 metric tons of processed rod.

Selection criteria depend on rod tensile grade, drawing line velocity, and targeted micro-finish ahead of primary reduction dies.

Integration of WiTechs PCM inline pre-coating units

The WiTechs PCM station applies borax and borax-free lubricant carrier coatings onto wire rod ranging from 5.5 to 34 mm in diameter directly ahead of continuous drawing machines.

Featuring a compact inline footprint of 2100 mm, the system integrates smoothly into existing straight-line drawing setups. Automated monitoring sensors and dosing pumps continuously verify solution density and temperature, introducing chemical concentrates automatically.

If bath concentration drifts beyond tolerance limits, the controller transmits an interlock signal to protect wire quality.

Precision SEZ belt sanding units for CHQ wire production

SEZ abrasive belt sanding machines deliver thorough surface conditioning for wire rods intended for cold heading CHQ fasteners, automotive components, and bright bar applications.

Unlike shotblasting units, abrasive belt grinding leaves no embedded grit on the steel surface, prolonging the operational lifespan of tungsten carbide heading dies.

An integrated belt break safety and quality monitor continuously checks belt tension and tracking, halting drawing line motion immediately if belt degradation occurs to prevent unprocessed rod from proceeding downstream.

Payoff towers TZ-3 and multi-roll scale breakers DZH

Heavy-duty WiTechs TZ-3 payoff towers and DZH series bending scale breakers provide continuous, knot-free entry of wire rod coils into high-speed processing machinery.

The TZ-3 tower layout prevents wire twisting and tangling at payout speeds up to 10 m/s, dampening dynamic tension spikes on capstan drives. Roll bending modules utilize heavy-duty sealed bearing housings with iron scale exclusion seals and adjustable roller guides.

Engineered replacement components are also manufactured to original drawings for Koch drawing lines and GSG equipment built prior to 2019.

Maintenance guidelines and wear part replacement

Maintaining peak productivity across WiTechs installations requires periodic inspection of high-wear tooling.

Critical replacement components include high-tensile wire brush drums for Ecoclean and WBE modules, abrasive belts for SEZ sanders, hardened guide rolls for DZH scale breakers, and dosing pump diaphragms for PCM coating units.

Technical specialists at SpareX assist wire drawing facilities in identifying reliable replacement assemblies based on equipment serial plates, wire diameter schedules, and metallurgical steel classifications.

WiTechs and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of WiTechs and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.