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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - SURFWIRE (Innovative machine for surface finishing of wire-drawn products)

Teaser

Summary

The rising demand of hard wire rod for high-tech applications requires higher mechanical strength, perfect straightening and improved surface finishing quality. Wire rods are employed in applications in the automotive, furniture, aerospace and electronic sectors, among others. In order to increase competitivity, manufacturers need to produce higher quality rods, improving and automating processes to minimize costs. Delta aims to launch a new process for the continuous production of steel and nickel alloy rods from wire obtaining high quality product with prefect surface finishing and superior strength. The SurfWire solution includes a fully automated set of machines for the transformation of wires using external cylindrical grinding.
The overall objective is to this technology to build a complete production line able to operate in continuous mode with automatic control, and featuring superior performance while at the same time reducing water requirement, oil and energy consumption.

Work performed

During the SME Instrument Phase 1, we have analysed the technical and economic viability and steps required for the final validation, with a dis-continuous prototype already operating and a first batch of product already validated by a customer. We defined the requirements to take this prototype to a continuous production line and designed the technical roadmap to achievement including hardware, software and control system. The technical requirements were also defined for the products in agreement with clients for different final applications.
For the product commercialization, we have contacted key partners for a successful project implementation including technical suppliers, clients and external consultants. Finally, we have carried out a deep market study and the set the final product applications for penetration: furniture, domestic appliances and relays in aeronautics applications. We analysed our main competitors and we have carried out a freedom to operate analysis in target countries. The report also includes a financial viability assessment including forecasts for the 5 years after market launch and a cost/benefit assessment.

Final results

During the last few months, a first batch of rods manufactured with the SurfWire project have been tested and validated by a final client for door hinges in high-end furniture applications: a 100% inspection on the rods from the SurfWire process, resulted in no defects found, 100% of parts were in conformity, while our rival results were 20% defects (minor and major). This proves the potential impact of SurfWire and how it will benefit customers.
Besides the existing previous client, the dissemination activities and approach to new customers in this period has resulted in the positive response of 2 new clients in new sectors: domestic appliances (refrigerators) and relays for the aeronautics sector. These new customers have already confirmed interest and have placed the first orders to carry out tests and validate the products for their application.
During the feasibility study, we have estimated that the implementation of the SurfWire project will create 6 new qualified jobs in the first 3 years after market launch and this number would be increased by indirect jobs created across the value chain. With the investment planned for the execution we expect a payback time of 2 years and a positive ROI from year 1. SurfWire will help Delta to differentiate from competitors by offering higher quality products and reducing water consumption and energy requirements. Our estimations show how the implementation of SurfWire will significantly improve the economic forecasts of the whole company.