Complete Manufacturing process Pure Copper wires From Scrap material Recycling

A-to-Z FACTORY TOUR: How Copper Wires Are Made From Recycled Scrap! ♻️
Discover the complete lifecycle of copper in this comprehensive guide! This exclusive factory tour takes you through the entire copper wire manufacturing process, starting from piles of discarded copper scrap and ending with pristine, high-quality copper wire spools.
Ever wondered how old electronics and discarded cables are given a second life? We show you the sustainable recycling methods used to recover pure copper and transform it into the essential wiring that powers our world.
Watch the entire A-to-Z process, including the intense smelting and refining stages, the specialized continuous casting techniques, and the high-speed wire drawing that creates the perfect gauge copper wire. This is a must-see for anyone interested in metal recycling, industrial automation, electrical engineering, or sustainable production!
The A-to-Z Manufacturing Process Timeline:
Stage 1: Preparation & Recovery (The 'A' Stages)
Scrap Collection & Sorting: Copper waste (cables, pipes, old electronics) is collected and mechanically sorted to remove non-copper materials.
Chopping & Stripping: Insulated wires are put through machinery to shred the insulation, isolating the raw copper strands.
Smelting: The cleaned copper scrap is fed into a furnace and melted at high temperatures (\sim 1100^\circ C) to create a molten copper bath.
Stage 2: Refining & Casting (The 'B' Stages)
Refining/Electrolysis: Impurities are removed. Often, a crucial step involves electrolytic refining to achieve extremely high-purity (99.99%) copper, known as "Cathodes." - Continuous Casting: The molten, refined copper is poured into a specialized continuous casting machine to form thick copper rods, often referred to as "Copper Rod Stock."
Stage 3: Drawing & Final Product (The 'C' Stages)
Rod Breakdown: The thick copper rod is passed through a series of rollers and dies, progressively reducing its diameter in the first major drawing step.
Fine Wire Drawing: Further drawing processes use specialized diamond or carbide dies to achieve the final, precise wire gauge (thickness).
Annealing: The wire is heated and slowly cooled (annealed) to soften it, making it flexible for use in cables and electronics. - Spooling & Packaging: The finished, clean copper wire is spooled onto reels, ready for insulation or distribution.
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