Technical requirements and challenges

In AAC manufacturing, cutting wires are used to process "green" cakes after they have achieved a specified strength. These wires are typically made from spring steel coil with a tensile strength between 2000–2500 N/mm². Fixation components such as pressed-on nipples allow the wires to be clamped and pneumatically tensioned within the cutting machinery.

Several factors influence the technical specification of the cutting wires, including:

·       Type of production technology

·       Oscillation methods (if any)

·       Hardness of the green cake

·       Production recipe

·       Velocity of the cutting process

These variables result in unique wire specifications for each plant. However, the fundamental requirements remain consistent: cutting wires must be geometrically precise, durable, and maintain consistent quality.

In-house wire production is often perceived as beneficial for stock control, immediate quality adjustments, or labor cost reduction. However, in practice, achieving consistent quality is difficult due to fluctuating raw materials, variable operator expertise, differences in nipple quality, and rising labor costs. These inconsistencies often result in wire breakages, increased waste, and unplanned downtime.

The role of specialized suppliers

Wandwire was established in response to recurring issues experienced by AAC plants worldwide, such as reduced product dimensional accuracy, increased downtime due to wire failures, and the high cost of manufacturing varied wire types internally.

The production of high-quality cutting wires requires stringent control over raw materials and manufacturing processes. Consistent outcomes are best achieved through standardized procedures: using the same raw materials, trained personnel, precise cutting techniques, controlled pressure application, regular maintenance of equipment, and internal quality testing.

Cutting wires, like other consumables such as mould oil or bearings, benefits from specialized production. Given the evolving requirements for wire types, lengths, and surface finishes, relying on in-house production with limited equipment may not offer the flexibility or quality assurance that specialized suppliers can provide.

Product specifications

Since 2018, Wandwire has utilized only high-quality, EU-sourced high-tensile spring steel coils. Cutting wires are fully customizable and can be supplied according to the following specifications:

·       Any length between nipples

·       Wire diameter: 0.6 – 1.5 mm

·       Nipple dimensions: Length = 8 – 20 mm, External Ø = 5 mm

·       Surface finishes: phosphated, polished, or stranded

·       Options available with or without beads

Outsourcing the production of AAC cutting wires to a dedicated, experienced supplier can ensure consistent quality, reduced downtime, and better adaptability to changing technical requirements. Standardized manufacturing and experienced personnel contribute to a more efficient, reliable production process – key factors in maintaining long-term operational stability.