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 the production processes.
Aerumtec – Copper Products and Solutions is an international manufacturer of high-quality wire products with roots dating back to 1569. Evolving from the production of gold and silver wire, the company has specialized in copper wire solutions since the 1920s. After its spin-off from LEONI AG in 2023, Aerumtec operates as an independent company and offers a wide range of copper wires, strands, cables, and special alloys. With five production facilities in Germany, the United Kingdom, and China, as well as a headquarters in Weißenburg, Bavaria, Aerumtec employs over 500 people worldwide.
The company serves customers from dynamic industries such as the automotive industry, e-mobility, and renewable energies. With centuries of experience and modern technology, Aerumtec delivers innovative, customized wire solutions for the highest technical demands.
Product variety at the Weißenburg location
Aerumtec in Weißenburg manufactures, among other things, single and round wires made of copper, as well as multi-wire 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 various finishes: bare, tinned, nickel-plated, silver-plated, or gold-plated, and they are available in both hard and soft annealed forms. The spool sizes vary from 80 mm (1 kg) to 630 mm (400 kg), depending on the respective dimensions.
Challenges in Production
Before switching to the lubricants from Zeller+Gmelin, Aerumtec faced serious issues 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 avoid contamination and crusting.
Collaboration and Testing Phase
As part of a close collaboration between Aerumtec and Zeller+Gmelin, a test facility was initially equipped with the lubricants from the Multidraw CU SY series. This product line includes lubricants specifically designed for the wire drawing process, characterized by good lubrication properties and long-term stability. Another advantage of the CU SY series is its ability to minimize deposits, which is of central importance in the wire industry.
The positive results of the testing phase led to a gradual transition of additional systems within the production line. Today, Aerumtec relies almost entirely on the lubricant solutions from Zeller+Gmelin in the multi-wire drawing area. This decision has not only improved production processes but also increased machine availability and reduced maintenance effort.
Dr. Maximilian Daniels, head of electrochemical process engineering at Aerumtec, emphasizes: "Since the introduction of the CU SY lubricants, our systems have become significantly cleaner. The issue 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 collaborative partnership with Aerumtec demonstrates how targeted product development and close cooperation between manufacturer and supplier can lead to significant advancements 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 the complex multi-wire drawing systems from Aerumtec, where deposits and contaminants can lead to production issues.
Markus Mühleisen explains: "With our durable Multidraw products, we cover the entire range of lubricants for wire drawing."
Users achieve maximum drawing speeds while their machines remain clean and consistent for a long time. Our research and development department continuously works on innovative formulations that are both environmentally friendly and improve our customers' processes.
An example of the continuous product development by Zeller+Gmelin is the new Multidraw CU SY T. This fully synthetic drawing lubricant has been specifically designed for the drawing of bare and tinned copper wire. It offers a high pH buffering capacity and ensures high cleanliness of the machines, thereby further improving the quality of the end products.
Working together at maximum capacity
The use of the Multidraw CU SY products led to a noticeable reduction in machine downtime and a long-term improvement in product quality at Aerumtec. In particular, the cleanliness of the wires and drawing systems was optimized through the improved lubrication properties of the products. Dr. Maximilian Daniels notes: "The regular on-site support was crucial for us. Lubricants are a complex topic, and we greatly benefited from direct exchanges with the experts from Zeller+Gmelin."
Particularly noteworthy is the support from Holger Birle, sales representative from Zeller+Gmelin. He accompanied Aerumtec throughout the entire transition process and helped find solutions that met the specific requirements of the company.
With the CU SY lubricant solutions, Aerumtec has created the conditions to maintain its own quality standards and make production more efficient. In addition, employees appreciate the easy handling of the Zeller+Gmelin wire drawing agents.
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