Our custom engineered Tech-Mesh™ products lean on innovation and quality materials to provide excellent performance in mass transfer and filtration applications. However, before these products are used in Oil and Gas refineries, Renewable Energy applications or Brewery and Distillation columns, they go through a meticulous manufacturing process.
The precision engineering behind our Tech-Mesh™ line redefines industry standards and sets us apart from the competition. Continue reading to learn about the 7-step process that goes into creating our efficient Mist Eliminators and consistent Knitted Wire Mesh.
Tech-Mesh™ Manufacturing Process
From raw materials to versatile machines to size customization options before purchase, the process behind these products is complex but efficient. Learn more about how our materials are processed below:
Rod Processing: The Foundation of Quality
Every great product starts with top-quality raw materials, and Fil central Tech-Mesh™ is no exception. The manufacturing process begins with wire rods, typically made of materials like stainless steel, Monel®, Inconel or other specialized alloys. Incoming raw wire rods are typically hot rolled,solution annealed, et acid pickled. Le wire rod is then pre-coated in preparation for the breakdown stage.
Rod Breakdown: Creating Precision
Once the wire rods are prepared, they move to the rod breakdown stage. Here, the larger diameter wire mill rod coils are reduced to sizes suitable for further processing. Central Wire stocks a variety of redraw sizes that can be processed to the finished wire diameter. Precision is key during this step to ensure that the wire maintains its intended diameter and tensile strength.
Drawing Process: Getting the Right Diameter
The drawing process is where the wire is further sized to achieve the desired diameter and tensile strength. There are different methods employed for this purpose:
- Dry Drawing: This method involves coating the wire with a dry lubricant and is typically used for larger diameters where surface area reductions are low. It results in a matte appearance on the wire, which may be preferred for certain applications.
- Wet Drawing: Smaller diameters benefit from wet drawing, where the wire is processed in a liquid lubricant, such as water or petroleum-based grease. This method produces a bright, smooth surface finish and is suitable for diameters under .040″.
Annealing Process: Enhancing Mechanical Qualities
Recuit is a critical step in the manufacturing process of Tech-Mesh™. After the wire has been drawn to its desired thickness, it undergoes controlled heating and cooling. This process improves the wire’s mechanical qualities and ensures maximum performance. It also reduces internal stresses that may have built up during the drawing process, increasing ductility and flexibility—essential properties for Tech-Mesh™ to perform under challenging environments. This step is critical because the material must be softened to be knitted and must have the right mechanical properties for its eventual application.
Knitting Process: Precision in Design
The heart of Tech-Mesh ™ lies in its knitting process. Each individual wire is meticulously knitted together in a precise and complex design. Specialized technology is used to connect the wires, ensuring uniformity and accuracy in the mesh pattern. The knitting process directly impacts the final properties of Tech-Mesh™, including rigidity, flexibility, and strength. Different knitting patterns, whether open or tight, are chosen to meet the specific requirements of various applications.
What sets our quality control apart from the competition is that our knitting machines were made internally, at our Loos Pomfret location in Connecticut!
Crimping Process: Enhancing Structural Integrity
In many variations of Tech-Mesh™ manufacturing, crimping is employed to achieve the final mechanical properties and specifications for its application, dictating its performance. Properties such as wire diameter and mesh density impact parameters of performance like removal efficiency and pressure drop. Crimping creates pleats in individual layers of mesh, depending on the requirements of a project. The pleats ensure the captured liquid droplets agglomerate and drain properly, thereby ensuring a dry vapor exiting the mesh.
Support Frame Construction & Attachment: Maintaining Shape and Stability
In most applications, Tech-Mesh™ will require a support frame to maintain its correct shape, structure, and stability. These support frames are constructed from robust materials, which usually match the alloy of the mesh, complementing the Tech-Mesh™ and providing essential structural support. However, if needed we can incorporate different alloys into the frame to meet a customer’s requirements.
Without this support, the mesh does not have enough structural strength to maintain its required size when installed and in operation/ During fabrication, various methods such as welding, clamping, or mechanical fastening are used to create a strong and long-lasting connection between the Tech-Mesh™ and the support frame.
Customization Options: CWI Tailors Tech-Mesh™ to Your Needs
One of the unique strengths of our Tech-Mesh™ is its ability to be customized to meet the specific requirements of diverse projects and industries. Whether it involves modifying wire composition, adjusting mesh density, fine-tuning measurements, or addressing other unique characteristics, our customization capabilities ensure that our Tech-Mesh™ performs optimally in a variety of applications.
The journey from raw materials to customized Tech-Mesh™ is a testament to the precision engineering and dedication to quality that CWI brings to every product. Tech-Mesh™ stands as a reliable, long-lasting, and high-performing knitted wire mesh solution, ready to meet the demands of diverse industries by offering customized solutions backed by technical expertise and manufacturing excellence.
At CWI, our commitment to excellence and innovation ensures that Tech-Mesh™ continues to be a driving force in redefining industry standards. Our meticulous manufacturing process reflects our dedication to delivering adaptable, premium-quality products that empower our customers and industries for generations to come.
To invest in our durable and precision manufactured Tech-Mesh™ products, fit to your exact needs, Request a Quote with us today!
