BWE Ltd.

Beaver Industrial Estate, TN23 7SH Ashford, Kent
United Kingdom of Great Britain and Northern Ireland
Telephone +44 1233 627-736
Fax +44 1233 630-670

Hall map

wire 2020 hall map (Hall 11): stand G26

Fairground map

wire 2020 fairground map: Hall 11


Kevin Bennett

Sales Director

+44 1233 627736


Our range of products

Product categories

  • 01  Machinery for the manufacture of rods, wires and strips
  • 01.03  Extrusion
  • 01.03.01  Extrusion lines (for metals)
  • 02  Machinery for the processing of rods, wires and strips
  • 02.02  Machinery for the processing of rods
  • 02.02.09  Welding machines
  •  Cold pressure welding machines

Cold pressure welding machines

  • 02  Machinery for the processing of rods, wires and strips
  • 02.06  Machinery for the manufacture of cables
  • 02.06.11  Extrusion lines
  • 02  Machinery for the processing of rods, wires and strips
  • 02.06  Machinery for the manufacture of cables
  • 02.06.12  Sheathing lines

Our products

Product category: Extrusion lines (for metals), Extrusion lines

The Conform™ Process

The use of a single revolving wheel as the driving force in an extrusion process enables the manufacture of products of unlimited length. In its simplest form the wheel has a single groove in its periphery which accepts the feedstock and transfers the material to the extrusion zone and die.

The diagram shows the configuration used for the production of most solid and hollow sections. A die chamber, carrying the appropriate die, is supported in a shoe. The die chamber incorporates an abutment that protrudes into the wheel groove. The force applied by the rotating wheel causes the feed material near the abutment to flow plastically into the die chamber and extrude through the die. Whilst the feedstock is usually in the form of rod, the process can also operate with material of any morphology provided that it can be fed into a suitably sized groove.

An Induction Heated Tooling System is available for applications which require a constant and direct heat source to the extrusion zone. The ability to rapidly pre-heat the chamber to the precise extrusion temperature prior to start-up reduces the stresses on tooling and allows more difficult products to be extruded.

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Product category: Extrusion lines (for metals), Extrusion lines, Sheathing lines

The Conklad™ Process

In the 1980’s BWE pioneered the development of cladding and sheathing using the Conform continuous extrusion method. This work led to the introduction of Conklad, which has become the industry standard for many applications.

The geometry of the Conklad process is arranged so that a central core can be introduced inside the extrusion. Twin or Single feedstock rods are used
to produce two flows of metal on either side of the chamber so that the pressure around the central core is balanced.

The Conklad process has two formats –  direct cladding on hard cores and indirect sheathing of soft cores.

The greatest advance in Conform technology has been achieved by BWE in the application of the process for the sheathing or cladding of temperature sensitive (soft) or hard cores as they pass through the extrusion tooling.

There are three basic variants of the Conklad Process:

High Pressure Direct Cladding –  where the core material is directly exposed to the extrusion pressure. This method is used where a measurable bond (diffusion bond) is required between the core and the cladding material. Usually the core material is heated in an inert atmosphere immediately before it enters the Conklad machine. An example of High Pressure Direct Cladding is A.S. Wire.

Low Pressure Direct Cladding –  where the core material comes into contact with the cladding material but is protected from the full extrusion pressure. This method is used where the core material is not strong enough to withstand the extrusion pressure, e.g. cladding copper wire with aluminium.

Indirect Cladding or Sheathing –  where the core material is temperature sensitive or it is not desirable that it comes into contact with the cladding material. In this case the tube is extruded oversize and subsequently drawn down in line to be a close or loose fit on the core as required.

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Product category: Extrusion lines (for metals), Extrusion lines, Sheathing lines

The SheathEx™ Process

The most recent innovation in continuous extrusion is BWE’s new, patented, SheathEx process.

A Metallic Sheath is utilised in cables to prevent the ingress of moisture without diminishing the flexibility of the cable. Water penetration is detrimental to the integrity of insulation. The combination of moisture and high electrical
stresses leads to the initiation of water tree growth, resulting in the premature failure of the cable.

SheathEx™ Extrusion Technology

A ‘Seamless’ Aluminium Sheath is very reliable, economical and its mechanical properties make it both lighter and stronger than Lead Sheath.
After forming, the Aluminium Sheath is normally corrugated inline to improve flexibility of the cable. In some applications a smooth type sheath is preferred.

A high efficiency induction heater ensures an even temperature distribution around the extrusion die, which gives accurate control of wall thickness and concentricity.

Caterpillar haulers are used to transport the cable through the line and the extruded sheath is corrugated to size before being wound onto large diameter drums.

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Product category: Cold pressure welding machines

The Coldweld™ Process

Cold welding is a method for joining non- ferrous metals and their alloys without using heat, fillers or fluxes. Round wire sections, dissimilar materials and materials of different sizes can all be welded with BWE’s proven cold welding technology. A cold weld is generally stronger than the parent material and has the same electrical characteristics.

In order to obtain a true weld, all contaminants (oxides, oils, chemicals etc) must be removed so that clean surfaces can be brought together. BWE’s cold welding machines achieve this by using a multiple upset technique which ejects the contaminated material from the weld zone eliminating the need for any special preparation.

A wide range of cold welding machines are available covering applications from rod to fine wire. BWE offers a facility for test welding customers material to confirm its suitability for cold welding.

BWE Ltd is the world’s longest established manufacturer of Cold Pressure Welding equipment, having manufactured Cold Pressure Welding Machines at its Ashford factory since 1969.

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About us

Company details

BWE Ltd (formerly Babcock Wire Equipment) was established in 1969 and has four principal product ranges:

  • Conform™ –  extrusion machinery for aluminium, copper and other non- ferrous metals.
  • Conklad™ –  machinery for cladding or sheathing wires and cables with aluminium.
  • SheathEx™ –  machinery for sheathing high voltage power cables with aluminium.
  • Coldweld™ –  machines for joining non- ferrous metals without heat, fillers or fluxes.
Extrusion Technology

BWE Ltd is a British engineering company specialising in Continuous Extrusion Machines for many different applications and Cold Pressure Welders for the cable and wire industry.

The Company has manufactured Cold Pressure Welding Machines at its Ashford factory since 1969. BWE Ltd and its American associated company, Koldweld LLC, are the world’s longest established manufacturers of this equipment and have supplied more than 25,000 machines to the Wire & Cable Industry.

In 1976 the Company was awarded the first licence to develop, manufacture and supply Conform™ Continuous Extrusion Machines by the inventors, the United Kingdom Atomic Energy Authority. BWE has continued to invest in developing the process and has pioneered many new applications including thin-walled aluminium round and multi-port tube, aluminium clad steel wire and sheathing fibre-optic, CATV and power cables with aluminium.

BWE has a strong management team committed to providing a comprehensive service to customers from application development through pilot production, training, installation, commissioning and after-sales service.

BWE Ltd owns the registered names Conform, Conklad and SheathEx together with a number of critically important patents associated with the processes and their development.

Over the years it has been the policy of BWE Ltd to invest in the business. The range of applications and patents demonstrates its success in development of the technology.

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