Traxit FAQ: Technical Solutions for better Performance, Process Stability and Efficiency in Wire Drawing

Dry drawing lubricants are filled into the drawing box as “powdered drawing lubricants” so that the wire is almost completely covered. The wire is guided through the drawing box and picks up the dry drawing lubricant on its surface. After leaving the drawing box, the wire is fed into the die. In the front section of the die, the lubricant is transformed by heat into an adherent lubricating film. This supports the wire as it passes through the die and undergoes reduction. The adherent lubricating film reduces friction, temperature and wear.

The selection depends primarily on the steel grade being processed, the steel’s carbon content, the starting diameter, the reduction stages (drawing sequence), the planned final diameter, the pre-treatment (for example pickled or phosphated) and the end application (for example welding wire, spring wire or rope wire). If we have this data, we can provide a targeted product recommendation and avoid unnecessary trials.

Dry drawing lubricants are often calcium soaps, sodium soaps or blends of both. Depending on the process stage (i.e. which pass of the drawing machine) and the target outcome (e.g. film stability vs. cleanliness/further processing), the appropriate product or product combination is selected. The main difference lies in their lubricating properties at different speeds and temperatures.

Calcium soaps are characterized by the following properties:

• Less water-soluble, with higher lubricant adhesion
• Usually a lower melting point
• Ideal for low drawing speeds and high deformation rates in the die

Sodium soaps are characterized by the following properties:

• More water-soluble, more heat-stable
• Tends to have a higher melting point
• Ideal for higher/high drawing speeds and for thinner wires or when using pressure dies

Because the drawing lubricant forms a lubricating film in the die that influences friction, temperature and wear, and therefore affects the wire surface, process stability, drawing speed and die service life.

Wet drawing lubricants are liquid lubricants used in wire drawing within a closed system. The wire continuously passes through a bath or emulsion, creating a stable lubricating film on the wire surface.

This film reduces friction, temperature and wear in the die and enables higher drawing speeds as well as fine final diameters. Wet drawing lubricants are used primarily for fine and ultra-fine wires, as well as for continuous high-speed processes.

The selection of the appropriate wet drawing lubricant depends on factors such as:

• Wire material and alloy
• Drawing speed and machine concept
• Cooling capacity and filtration system
• Requirements for the wire surface and subsequent processing

An optimally matched wet drawing lubricant makes a decisive contribution to process stability, wire quality and energy efficiency.

Coating agents are pre-treatments of the wire surface that act as adhesion promoters between the wire and the drawing lubricant. They create the basis for uniform lubricant pick-up and enable a stable lubricating film during the drawing process.

Typical coating agents include phosphating systems or alternative coating systems that are specifically matched to the drawing lubricant.

Their main functions in the process are:

• Improving the adhesion of the drawing lubricant to the wire surface
• Stabilizing the lubricating film in the die for higher drawing speeds
• Reducing friction and wear
• Supporting a uniform wire surface

The right combination of coating agent and drawing lubricant is essential for a stable and economical drawing process. Both systems must be matched to one another in order to achieve optimal results in terms of surface quality, service life and process reliability.

Oil- and Volatile Organic Compounds (VOC)-free corrosion protection is an innovative system for temporary wire preservation that completely eliminates the need for traditional oil-based protective media and volatile organic compounds (VOCs). Instead, a stable protective film is generated directly within the production process.

Modern systems are applied inline, directly after the drawing process, and form a uniform, homogeneous protective layer on the wire surface. This eliminates the need for additional process steps such as external oiling or elaborate packaging.

The key advantages are:

• High process stability through clean and controlled application
• Reduction of additional process steps and handling effort
• Consistent and reproducible wire surface quality
• Energy and cost efficiency through integration into the production process
• Meeting increasing environmental and occupational safety requirements by eliminating oil and VOCs

This concept sets new standards in the wire industry and supports manufacturers in making their production more sustainable, efficient and future-proof.

The goal is a stable process with lower consumption, more consistent drawing quality, longer die service life and energy savings. The greatest optimization potential lies in aligning the customer-specific drawing process, the products used and the drawing lubricants. Only a best-possible overall system delivers both ecological and economic benefits.

Yes. In dry drawing lubricant optimization projects, savings of up to 2% can be achieved, and in some cases even more. The overall result and the achievable level of optimization depend on the customer-specific drawing process and the equipment. What matters most is matching the drawing lubricant to the machine, dies, speeds and wire quality.

A stable lubricating film reduces tribological stress in the die and can therefore lower wear and unplanned downtime. The objective is a consistent process and longer die service life while maintaining a good surface finish.

The drawing lubricant directly affects surface quality because it controls friction and temperature in the die. Especially in sensitive applications, such as welding wire or stainless steel wire, surface stability is a key factor for reproducible quality.

The TOTAL USE concept is based on customer consulting aligned with the customer-specific drawing process. Looking at the entire process, the aim is to use the drawing lubricant longer in production without losing lubrication performance or quality. In customer projects, we have achieved drawing lubricant savings of up to 20%.

The wet drawing lubricant plays a central role in the drawing process because it is responsible for both lubrication and cooling. Both factors have a direct impact on drawing performance.

An optimally adjusted wet drawing lubricant offers the following advantages:

• Reduction of friction and drawing forces
• Stabilization of process temperature at high speeds
• Extension of die and tool service life
• Improved wire surface quality
• Enabling higher drawing speeds and finer final diameters

By contrast, an emulsion that is not optimally matched can lead to unstable processes, increased wear or quality problems. The right balance of concentration, cooling, filtration and adaptation to the process parameters is crucial.

Coating agents are a key factor in drawing performance because they form the basis for lubricant uptake and stability on the wire surface.

An optimally matched coating agent improves drawing performance in several areas:

• Uniform lubricating film formation in the die
• Reduction of friction and drawing forces
• Improved process stability across multiple drawing stages
• Minimization of wire surface defects
• Extension of tool service life
• Higher drawing speeds

If the coating agent is not optimally adjusted or is not compatible with the drawing lubricant, this can lead to unstable lubrication, increased wear and quality fluctuations.

That is why the holistic coordination of pre-treatment, coating agent and drawing lubricant as an integrated system is essential to achieve maximum and stable drawing performance.

Various technical challenges can arise in the wire drawing process that affect product quality, process stability and profitability. Common issues include:

• Wire breaks or microcracks in the material
• Build-up or lumps in the drawing box
• Dust generation and increased strain on people and equipment
• Unsteady or unstable drawing process
• Scratches, scoring or uneven wire surfaces
• High tool wear or short die service life
• Excessive temperatures in the drawing process
• Insufficient lubricating film formation
• Fluctuating wire quality or problems in downstream processing

These challenges can have a range of causes, for example in the interaction between drawing lubricant, coating agent, material, process parameters and equipment technology.

We know these issues from practice and are happy to support you in analyzing the causes and developing a tailored solution.

Lump formation is often linked to temperature windows and the thermal stability of the drawing lubricant. It makes sense to review process data such as temperatures, reductions, drawing stages and lubricant parameters together and then carry out targeted testing.

Dust occurs in the process as fine particles, including from the drawing lubricant and wear in the drawing line. Two levers are important for reducing dust exposure:

• Drawing lubricant optimization
• Suitable extraction and filtration technology

This is because emissions such as metal dust, scale and drawing lubricant abrasion must be reliably extracted.

The drawing lubricant is one influencing factor because it affects friction, heat and therefore process stability. However, a reliable assessment requires an overall view of the material, pre-treatment, dies, reductions and speeds.

In wet drawing, the drawing lubricant is responsible for both lubrication and cooling. Problems often arise when the emulsion is not optimally adjusted or maintained.

Typical influencing factors are:

• Incorrect emulsion concentration
• Insufficient filtration or contamination in the system
• Temperature rise due to insufficient cooling capacity
• Unstable emulsion or incorrect water quality
• Unsuitable matching to wire material and drawing parameters

It is advisable to consider emulsion parameters, process conditions and equipment concept together and optimize them in a targeted way.

If the coating agent does not fulfill its function, this directly affects lubricating film formation and process stability.

Possible causes may include:

• Insufficient or uneven coating quality
• Poor coordination between coating agent and drawing lubricant
• Fluctuations in pre-treatment (e.g. pickling or descaling)
• Incorrect coating thickness or poor adhesion to the wire surface
• Process fluctuations in temperature or dwell time

What matters is the coordinated consideration of pre-treatment, coating and drawing lubricant as an overall system.

Corrosion can occur at various points in the process. During production as well as during interim storage or transport.

Common causes include:

• Insufficient or uneven corrosion protection film
• Moisture ingress or unfavorable storage conditions
• Residues from the drawing process
• Too much time between production and downstream processing
• Unsuitable packaging or missing protection during transport

Modern approaches rely on integrated, process-safe solutions in which corrosion protection is applied directly within the production process, reducing additional handling and sources of error. We are happy to help you identify the causes and develop a suitable process-integrated solution.

We are also happy to advise you on how the drawing lubricant influences this.

Borax-free products are actively being developed and offered in the industry. The background includes requirements relating to occupational safety, product safety, environmental protection and regulation. For a recommendation, it is important to understand where borax is used in the process (for example as part of pre-coatings and/or carriers, or in specific drawing lubricant formulations) and what performance targets you have.

Typical measures include energy efficiency, reduced consumption (the Traxit TOTAL USE concept with reduced drawing lubricant consumption) and, as a result, CO₂ reduction. In practical examples, we have implemented optimizations for various customers and achieved measurable savings in drawing lubricant consumption and energy use.

Yes, we offer vegan drawing lubricants (without ingredients of animal origin) in our portfolio. Our products were the first in the world to receive the Vegan Trademark from The Vegan Society. Selecting the right product depends on your process: we review your application and requirements and recommend the appropriate vegan drawing lubricant.