The U.S.-based cable manufacturer Encore Wire has gradually equipped its production lines with industrial inkjet printers of the JET RAPID WIRE type from LEIBINGER. The goal is the reliable marking of cables at high throughput rates – a legally required measure that also places high demands on print quality and system availability. The decision in favor of LEIBINGER was made following a multi-year evaluation process and was initiated by positive experiences in an initial practical test in 2016.
Encore Wire produces large volumes of copper and aluminum cables for residential, industrial, and commercial construction. When marking fine conductor wires with diameters between 16 and 8 AWG, speeds of up to 1,000 meters per minute are reached. Conventional systems quickly reach their limits here. The JET RAPID WIRE was specially designed for this application and uses a modified print head that positions the nozzle closer to the product. This reduces ink spray dispersion and improves print quality even at maximum line speed.
A key aspect of the integration was operational stability under challenging environmental conditions. In Encore Wire’s Texas production facility, temperatures above 40°C are not uncommon. The JET RAPID WIRE meets the IP54 protection rating and proved itself in continuous operation thanks to its robust design and low maintenance requirements. The automatic nozzle sealing technology prevents ink from drying during production breaks, further increasing system availability.
Tom Fisher, Sales Engineer at LEIBINGER partner Rusco Packaging, explains:
“LEIBINGER printers do exactly what they promise. Maintenance is minimal, operating costs are low, and the system is easy to use. The overall build quality is superior to many others.”
The ability to apply fast-drying specialty inks directly onto various plastic materials such as PVC or XLPE also contributed to the decision. According to the company, maintenance efforts were reduced while consistently high marking quality was achieved. Integration into the existing control system was carried out via standardized interfaces without significant adjustments.
The seamless integration of the LEIBINGER printers at Encore Wire came as no surprise to Tom Fisher: “We didn’t have to do anything special to integrate the LEIBINGER printers at Encore. It just worked, because we knew it would.”
“We maintain very close relationships with our suppliers. For us to switch to a new product, it has to be significantly better – and LEIBINGER clearly was,” says Encore’s management. Encore Wire’s advice to other companies is equally clear:
“I would recommend LEIBINGER printers without hesitation for any industry and any business.”
Encore Wire sees its collaboration with LEIBINGER as a sustainable solution to increase production efficiency. The partnership is expected to expand further, especially in light of new product lines and increasing demands for traceability and quality assurance in cable manufacturing.
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