Wire Rod Pickling and Phosphating Line
1. Fully Automated End-to-End Operation
6 RGV units synchronized with rail transfer cart enable unmanned, precise handling of wire rods between process tanks.
Only 1 operator needed for auxiliary loading/unloading, reducing labor dependency significantly.
Enhances operational safety and production continuity.
2. Intelligent Process Parameter Control
Central control system allows real-time adjustment of critical parameters (acid concentration, phosphating temperature, dwell time).
Supports recipe-based process management and comprehensive data logging.
Ensures consistent batch quality and meets strict traceability requirements.
3. Environmentally Sustainable Design
Integrated environmental protection systems: online phosphating solution filtration, elevated settling tank, two-stage acid mist scrubber, spent acid recovery tank, fresh acid supply system.
Reduces consumption of acids, water, and energy by 20–30%.
Minimizes waste gas and liquid emissions, complying with national clean production standards and global carbon-reduction goals.
4. Compact Layout with High Flexibility
Centralized utility equipment with optimized piping/cabling, minimizing plant footprint.
Flexible loading/unloading orientation to adapt to different factory layouts and future expansion.
5. High Reliability and Intrinsic Safety
Process tanks made of corrosion-resistant materials.
Equipped with real-time monitoring (liquid level, temperature), fault alarms, and multi-level safety interlocks.
Ensures stable, safe, and uninterrupted 24/7 industrial operation.
6. Additional Operational Benefits
Labor costs reduced by over 70%.
Thorough scale removal and uniform, dense phosphate coatings improve downstream processes (drawing, cold heading, coating).
Seamless integration with MES/ERP systems for digitalized, transparent production management.
Intelligent Automation · Green Manufacturing · High Efficiency & Reliability
Developed and engineered in-house by RITMAN, the fully automatic wire rod pickling and phosphating production line integrates advanced automation, digital process management, eco-friendly technologies, and intrinsic safety principles. Designed specifically for surface treatment of coiled wire rods (also known as wire coils or rod-in-coil), this turnkey solution delivers end-to-end processing—from loading to unloading—with minimal human intervention, full process control, and complete traceability. It significantly enhances product consistency, operational efficiency, and overall economic performance.
1. Typical Process Flow
Loading → Water Seal → Low-Acid Pickling → Scattering & Flipping → High-Acid Pickling → First Immersion Rinse → High-Pressure Spray Rinse → Second Immersion Rinse → Surface Conditioning → Phosphating → First Water Rinse → Second Water Rinse → Saponification → Drying → Unloading
2. Key Advantages
1) Fully Automated End-to-End Operation
The system employs six RGV (Rail-Guided Vehicles) units synchronized with a floor-mounted rail transfer cart to enable precise, unmanned handling and transportation of wire rods between process tanks. Only one operator is required for auxiliary loading/unloading tasks, substantially reducing labor dependency while improving safety and production continuity.
2) Intelligent Process Parameter Control
Critical parameters—including acid concentration, phosphating temperature, and dwell time—can be adjusted in real time via the central control system. The line supports recipe-based process management and comprehensive data logging, ensuring consistent product quality across batches and meeting stringent traceability requirements.
3) Environmentally Sustainable Design
Integrated environmental protection systems include an online phosphating solution filtration unit, elevated settling tank, two-stage acid mist scrubber tower, spent acid recovery tank, and fresh acid supply system. These features significantly reduce consumption of acids, water, and energy while minimizing emissions of waste gas and liquid, aligning with national clean production standards and global carbon-reduction initiatives.
4) Compact Layout with High Flexibility
All utility equipment is centrally arranged with optimized piping and cabling, minimizing the plant footprint. The loading/unloading orientation can be configured flexibly to accommodate various factory layouts and future expansion needs.
5) High Reliability and Intrinsic Safety
Process tanks are constructed from corrosion-resistant materials and equipped with real-time monitoring of liquid levels and temperature, fault alarms, and multi-level safety interlocks. This ensures stable, safe, and uninterrupted 24/7 operation under industrial conditions.
3. Operational Benefits
Labor costs reduced by over 70%
Acid, water, and electricity consumption lowered by 20–30%
Thorough scale removal and uniform, dense phosphate coatings enhance downstream processes such as drawing, cold heading, or coating
Seamless integration capability with MES/ERP systems for digitalized, transparent production management
RITMAN is committed to advancing the metal wire rod surface treatment industry through intelligent equipment and sustainable manufacturing practices. We provide customized, high-reliability smart manufacturing solutions to global customers in sectors including fasteners, spring steel wire, tire cord, welding wire, and standard components.
