Bare Copper Wire | Bare Tin Coated Copper Wire | Braided Flexible Copper Wire – Round/Flat | Braided Flexible Tin Coated Copper Wire – Round/Flat | Tinsel Copper/Silver/Tin/Cadmium Wire | Earthing Copper/Tin/PVC Wire - CRT Assembly | Glass Wire | Stranded/Braided – Copper/Tin/Silver Wire – Connector/Jumpers | Laminated Flexible Copper/Tin/Silver - Connectors/Jumpers/Leads | Stranded Hi-Flexible Copper/Tin/Silver Wire Rope – Round | Aluminium Wire / Rod | Submersible Winding Wire | Braided Copper Flexible Wire Connectors/Jumpers/Leads | Braided Tin Coated Copper Flexible Wire Connectors/Jumpers/Leads | Bare Silver Plated Copper Wire | Bare Nickel Plated Copper Wire | Copper Pipes | Copper Sheets | Copper Strips | Copper Tape

Jun 8

5 Steps Involved in Contemporary Production Lines of Copper Wires

Posted on Jun 8, 2020

In 200 years of its existence, the copper wires have been invented more than a dozen times. Each era has brought its own set of demands and technical specifications that pushed the boundaries of designing, architecture and manufacturing to a new height. The copper wires that we see today in the industries and houses are a result of years of manufacturing excellence and engineering brilliance that make them so handy in the ready to use layouts.

The braided copper wires together with the stranded copper wires are designed exclusively for industrial purposes. We tell you how the copper wires are decked up for the said applications.


Cabling and Jacketing of the copper wires are done to make the loops strong and more flexible than the traditional bare copper wires. The primary jacketing process is done to ensure total insulation from the physical interventions present in the environment. Moreover, the Copper Braided Wire are looped into multiple groups during the process of cabling and stranding process.

How is cabling done?

The process of stranding is often followed by cabling of copper wires. The stranded wires are grouped into different classes of cables depending on their diameter, wire density and insulation covering. This is how cabling is normally done in the factories.

Step 1:

The braids are grouped together for stranding. It is stranded into a multiple strands of copper wires.

Step 2:

The stranded copper wires and the bunched copper wires coated with tin metal are introduced in to the faceplate. The wires are twisted in the apparatus to achieve an ordered sequence.


The twisting is continued over a rotating bob. The rotating bob circulates with a variable speed. It is controlled by the operator assigned by the wire manufacturing company at the assembly line. The move over the rotating bob removes all signs of impurity form the wire and concentrates the lighter properties towards the surface. Once rotation is complete, the outer surface can be scrapped out with convenience.

Step 4:

The second step is rotation over a non-magnetic bob to ensure that the stranded copper wire is completely isolated from the effect of electrical and magnetic intervention.

Step 5:

The rotation and the stranding process is the basic difference between the manufacturing of bare copper wires and the stranded ones. The bare copper wires are susceptible to the electrical interference owing to the fact that these set of wires are not mounted over a rotating bob during production.


The production method ensures highest degree of flexibility and ductility. The stranded copper wires packaged into smaller bundles are usually used in the micro-gadgets that we see around us. From Smart Phones to laptops, the stranded copper wires connect every bit of electrical unit we know or understand.

Removal of Moisture before Jacketing

For wires that are not produced by twisting, they are normally used in the smaller gadgets as single units. The braided copper wires manufactured without twisting are directly jacketed following the stranding process. It is done to minimize the effect of atmospheric moisture.

Leave a Reply

    Copyright ©2013 Ganpati Wires, All Rights Reserved