POLYCAB INDIA LIMITED Successfully Implements Fully Automated Copper Wire Rice Centralized Spiral Hopper Briquette Press Solution!

Project Overview

POLYCAB INDIA LIMITED, a leader in India's wire and cable manufacturing industry, generates a large amount of copper wire granules as a byproduct annually. To improve resource recycling efficiency and reduce operating costs, the company introduced our fully automated copper wire granulator centralized spiral hopper press in 2023, achieving a comprehensive upgrade to its copper wire granulation process.

Challenges and Needs

Before introducing the equipment, POLYCAB faced the following core challenges:

- Low efficiency and high manual operation costs of traditional copper granule processing

- Significant copper granule loss due to spillage during storage and transportation

- The need for a waste disposal solution that meets international environmental standards

- Frequent equipment malfunctions affecting continuous production

Solution

Our company customized a fully automatic copper granule pressing system with a capacity of 1500kg per hour for POLYCAB, including the following core configurations:

Core Advantages

- High Capacity: Processing capacity of up to 1500 kg per hour, 300% faster than traditional methods

- Intelligent Control System: Fully automated operation, reducing manual intervention and decreasing the number of operators by 60%

- Spiral Hopper Design: Unique centralized feeding system ensures continuous and uniform feeding, avoiding blockages

- Safety Protection: Multiple safety features Fully interlocked system, compliant with international safety standards

Implementation Results

Increased Production Efficiency

- Copper granule compression density increased to 7.2 g/cm³, facilitating storage and transportation

- Processing time reduced from 12 hours per day to 5 hours

- Compressed copper cake volume reduced by 70%, significantly reducing storage space requirements

Significant Economic Benefits

- Raw material loss reduced by 45%, saving approximately 12 million rupees annually

- Labor costs reduced by approximately 40%

- Equipment investment payback period expected to be only 14 months

Reliability and Maintenance

- 99.2% uptime achieved in 6 months of operation

- Modular design reduces average maintenance time to less than 2 hours

- Remote monitoring system enables preventative maintenance, avoiding unexpected downtime

Customer Feedback

Rajesh, Production Director, POLYCAB Mr. Kumar stated, “The stable performance of this granulator exceeded our expectations. It not only solved our copper granule processing challenges, but its low failure rate and high safety also ensured the smooth operation of our production line. The 1500 kg/hour capacity perfectly matches our production pace.”

Technical Highlights

1. Adaptive Pressure Control System: Automatically adjusts compression parameters based on copper granule characteristics.

2. Energy-Saving Design: Reduces energy consumption by 25% compared to similar equipment.

3. Environmental Compliance: Fully enclosed process with near-zero dust emissions.

4. Intelligent Monitoring: Real-time data acquisition and analysis, supporting cloud management.

Looking to the Future

Based on this successful collaboration, POLYCAB plans to introduce the same equipment system at its two other production sites to further expand its resource recycling capabilities. We will continue to provide technical support to ensure the long-term efficient operation of the equipment.

Make Efficiency and Reliability the Standard Configuration of Your Production Line

For more information about the fully automatic copper granule granulator, please contact our professional team to customize the most suitable metal recycling solution for you.