Annealing & Patenting
Natural gas or LPG-fired open-fire and premix furnace systems designed around wire metallurgy, speed and product quality.
Surface Treatment & Coating
Continuous Galvanizing Lines
High-capacity multi-wire galvanizing and patenting lines for low, medium and high carbon steel wire, integrating thermal treatment, HCl pickling, fluxing, zinc or Zn-Al coating, wiping, cooling and synchronized take-up.
System Scope
Complete continuous coating technology
Wironex can supply the core galvanizing equipment or a complete turnkey plant including utilities and environmental systems.
HCl Pickling
Integrated hydrochloric-acid cleaning sections with rinsing and process-control provisions for consistent surface preparation.
Fluxing
ZnCl₂ / NH₄Cl-based flux preparation and conditioning ahead of coating.
Zinc & Zn-Al Coating
Ceramic or steel bath concepts for conventional galvanizing and zinc-aluminium alloy coating applications.
Wiping & Coating Control
Nitrogen, air and pad wiping alternatives with online coating measurement available as an option.
Turnkey Utilities
Cooling towers, compressors, nitrogen generation, process tanks, automation and auxiliary systems can all be included.
Technical Range
Designed for multi-wire industrial production
Line architecture is sized from wire diameter, carbon level, number of wires, coating class, thermal route and required production capacity.
| Wire materials | Low carbon / medium carbon / high carbon steel |
|---|---|
| Wire diameter range | 0.80 – 14.00 mm |
| Number of wires | Typically 10 – 40 wires |
| Maximum line capacity | Up to 6,000 kg/h, product and process dependent |
| Maximum operating index | Up to DV 160, product and thermal-route dependent |
| Coating quality | Commercial-quality coating through high-coating classes including AA-class requirements, according to applicable product standard |
| Coating materials | Zinc and Zn-Al alloy systems |
| Final package | Spool or rosette coil |
Typical Process Route
From incoming wire to finished galvanized package
The exact sequence is configured according to whether the line includes annealing, patenting, direct galvanizing or alloy coating.
01Multi-wire pay-off
02Open-fire / premix furnace
03Annealing or patenting
04Cooling / conditioning
05HCl pickling
06Rinsing
07ZnCl₂ / NH₄Cl fluxing
08Drying / preheating
09Zinc or Zn-Al bath
10N₂ / air / pad wiping
11Water quench + air cooling
12Spool / rosette coil take-up
Thermal Section
Natural gas / LPG furnaces engineered around metallurgy
Wire temperature, residence time, combustion architecture and atmosphere are selected from the required metallurgical route and production speed.
Open-Fire Furnace
Direct-heating furnace concept for robust continuous wire processing where the product and surface route permit open-flame operation.
Premix Furnace
Premixed combustion architecture for improved combustion uniformity, controllability and zone-by-zone thermal management.
Annealing
Continuous thermal treatment for required ductility and downstream forming performance.
Patenting
Thermal treatment route for high-carbon wire applications requiring controlled microstructure before subsequent drawing.
Heat Recovery
Recuperator and exhaust-heat recovery options can be integrated to preheat combustion air or selected process streams.
Combustion Automation
Zone control, burner safety, gas-train monitoring, flame supervision and recipe-based temperature control.
Chemical Preparation
Stable coating starts with a clean and controlled surface
Pickling, rinsing, flux concentration and drying are treated as coating-quality variables rather than independent utility tanks.
| Pickling chemistry | HCl |
|---|---|
| Rinsing | Multi-stage configuration according to process and water-quality target |
| Flux chemistry | ZnCl₂ / NH₄Cl |
| Flux control | Concentration / density / temperature monitoring can be integrated |
| Drying | Hot-air or project-specific preheating / drying arrangement |
| Chemical storage | Fresh / spent acid, flux and process tanks can be included in turnkey scope |
Zinc Bath & Coating Control
Bath design selected around coating target and operating philosophy
Ceramic Zinc Pot
Ceramic bath architecture for applications requiring dedicated refractory containment and project-specific heating arrangement.
Steel Zinc Pot
Steel bath option for selected operating and maintenance strategies.
Immersion Burner Heating
High-efficiency immersion-burner concepts can be used where suitable for the bath and alloy system.
Side-Burner Heating
External / side-heating arrangements available according to pot design and process preference.
Zn-Al Alloy Coating
Bath and process concept can be adapted for zinc-aluminium alloy coatings in addition to conventional zinc.
Online Coating Measurement
Online coating-weight measurement can be integrated for continuous quality monitoring and process adjustment.
Wiping & Cooling
Coating mass and surface finish are controlled after immersion
Wiping technology is selected according to wire diameter, target coating class, surface quality and line speed.
| Wiping systems | Nitrogen / air / pad wiping |
|---|---|
| Coating range | Commercial quality through heavy-coating / AA-class applications |
| Primary cooling | Water quench |
| Final cooling | Air cooling / drying as required |
| Measurement | Online coating-weight measurement option |
| Take-up | Spool or rosette coil |
Environmental Systems
Plant-level environmental equipment available within the project scope
Environmental systems can be supplied as optional integrated packages according to local regulations and customer responsibility matrix.
HCl Scrubber
Acid-fume capture and scrubbing system for pickling sections.
Fume Extraction
Localized extraction for furnace, flux and zinc-bath process areas as required.
Waste-Water Treatment
Rinse-water and process-water treatment can be integrated into the turnkey plant scope.
Chemical Storage
Fresh / spent acid and flux tanks, transfer pumps and associated piping systems.
Heat Recovery
Recuperation options for furnace exhaust and selected thermal process streams.
Process Containment
Hoods, covers, drainage and containment provisions designed around the process layout.
Turnkey Plant Scope
Core line plus utilities — under one engineering responsibility
Wironex can extend the supply from the galvanizing line itself to plant-level auxiliary systems.
Process Tanks
Fresh / spent acid, rinsing, flux, cooling and auxiliary chemical tanks.
Cooling Towers
Process-water cooling circuits sized from the total plant heat load.
Compressed Air
Air compressor and distribution package for pneumatic and process-air consumers.
Nitrogen Generation
N₂ generator package for wiping and other selected process requirements.
Water Treatment
Process-water preparation, filtration and waste-water treatment packages.
Automation & Utilities
PLC/HMI, MCC, field instrumentation and integration of gas, air, water and process utilities.
Configure a Galvanizing Line
Start Engineering →
Send us the wire range, carbon level, coating class and target capacity.
We will define the furnace route, number of wires, bath concept, wiping method, utility load and complete process layout.