At Wheels Polymers, our manufacturing process is built to deliver consistent quality, precision, and performance at every stage—from raw material selection to final inspection.

We specialize in the production of Oxygen-Free Copper (OFC) and Electrolytic Tough Pitch (ETP) copper, catering to a wide range of industrial and electrical applications. Our facility is equipped to handle both high-volume requirements and customized specifications with equal efficiency.

Our integrated manufacturing setup combines advanced machinery, controlled processes, and rigorous quality checks, ensuring that every product meets stringent standards for conductivity, durability, and dimensional accuracy.

At every step, our focus remains the same: to deliver copper solutions that are not only engineered to specification, but built to perform reliably in real-world applications.

Our manufacturing process is a carefully integrated sequence of operations designed to ensure material integrity, dimensional precision, and consistent performance. Each stage is optimized and monitored to maintain the highest standards across both OFC and ETP copper production.

  • Raw Material Analysis & Preparation 

Every batch begins with rigorous testing of incoming material using spectro analysis, ensuring the correct chemical composition and purity levels. This step is critical in maintaining the conductivity and performance characteristics required for different applications.

  • Upcast

Copper is processed through controlled melting and up-casting systems, forming rods with a uniform internal structure. Temperature and cooling are carefully regulated at 1,082°C using cooling towers and treated water systems, ensuring metallurgical consistency and minimizing defects.

  • Extrusion & Primary Shaping

Using a high-capacity konform machine, copper is shaped into rods, flats, and strips. Out of 350+ dies, the appropriate size and shape is chosen. This stage ensures uniform cross-sections, structural strength, and flexibility in meeting different size and application requirements. A density calculator is also employed at this stage. Based on the output from the konform machine, the product goes either to the rolling machine, draw bench, or for wire drawing.

  • Rolling Machine

Copper is further processed through multiple rolling stages to achieve precise thickness and flatness. This step is essential for producing flats and strips with tight tolerances and smooth surface finishes, critical for electrical and industrial use.

  • Wire Drawing

For applications requiring finer dimensions, copper is drawn through specialized systems to produce wires and precision components. This process ensures uniform diameter, improved surface quality, and enhanced mechanical properties.

  • Draw Bench

Copper flats are processed through a draw bench to form precise sections with defined profiles. By pulling the material through specialized dies, this step enables accurate shaping, consistent dimensions, and improved surface finish—ensuring suitability for structural and industrial applications.

  • Straightening

Processed copper is passed through straightening systems to eliminate bends and ensure linear accuracy. This step delivers uniform alignment, improved dimensional consistency, and readiness for final finishing or application—especially critical for rods, sections, and flats.

  • Heat Treatment & Annealing

Based on product requirements, controlled annealing improves the ductility and conductivity of copper by relieving internal stresses. This allows the material to perform reliably in applications requiring flexibility, formability, and consistent electrical performance.

  • Cutting & Forming

Products are cut, aligned, and shaped to required specifications. This ensures that all products are delivered with accurate dimensions and ready-to-use form.

  • Surface Finishing & Cleaning

Final surface treatment processes remove impurities and enhance finish quality. Clean, smooth surfaces improve both conductivity and product lifespan, especially in high-performance electrical applications.

Integrated Process Control

Each stage is interconnected and continuously monitored to maintain:

  • Consistent quality across batches
  • Uniform material properties
  • Reliable performance under application conditions

This integrated approach ensures that every product leaving our facility meets the expectations of precision-driven industries. From controlled processes to verified performance—our focus on precision continues through rigorous quality control and testing.

Quality Testing

At Wheels Polymers, quality isn’t just a standard—it’s a commitment. Our state-of-the-art Quality Lab is equipped with cutting-edge testing technologies—including Vickers Hardness and Verniers Machine—that ensure mechanical strength, conductivity, and precision in every copper product we manufacture.

To ensure that our copper rods meet industry standards, we conduct tensile strength testing, a crucial step in determining their resistance to force and elongation, where our state of the art machine records breaking point data, ensuring that our rods possess the required elasticity and structural integrity.

Next, the rod undergoes compression testing, where it is subjected to immense force to analyze its ability to withstand pressure without deformation. This test ensures that our copper products maintain their dimensional stability and load-bearing capacity, making them ideal for applications in power transmission and industrial engineering.

For superior electrical performance, conductivity is critical. Our conductivity test verifies that our copper products meet an impressive 98% purity standard, ensuring minimal resistance and maximum efficiency.

Using advanced eddy current and four-probe measurement techniques, we analyze the electrical conductivity of our copper rods and strips. This test guarantees that our materials offer optimal energy transfer, making them the preferred choice for high-performance electrical applications such as switchgear, transformers, and solar power systems.

Technology and Infrastructure

Our manufacturing strength is supported by a robust infrastructure that combines modern machinery, process integration, and skilled expertise.

At Wheels Polymers, we operate a fully equipped facility with advanced systems across casting, extrusion, rolling, drawing, and finishing. These machines are selected to ensure precision, repeatability, and efficiency at every stage of production.

We incorporate automation elements and process controls to enhance consistency, reduce variability, and maintain uniform quality across batches. This allows us to deliver products that meet exact specifications, even at scale.

Equally important is our team—our operations are driven by a skilled and experienced workforce that understands both the technical and practical aspects of copper manufacturing. Their expertise ensures that every process is executed with accuracy and care.

With an annual production capacity of 4500 MT, our facility is designed to handle both high-volume orders and specialized requirements, without compromising on quality or turnaround time.

Customisation Capabilities

We understand that different industries and applications require copper products with specific dimensions, properties, and performance characteristics.

Our manufacturing setup is designed to offer flexibility across:

Custom Sizes & Dimensions

Ability to produce rods, wires, flats, strips, and sections in a wide range of sizes and profiles

Specific Grades (OFC & ETP)

Manufacturing based on required conductivity, purity, and application standards

Application-Based Modifications

Tailored solutions based on end-use requirements such as electrical performance, mechanical strength, or surface finish

By combining process control with production flexibility, we ensure that our products are not just standardized—but aligned to the exact needs of our clients.

Safety and Sustainability

Workplace Safety

Handling copper—especially in molten form—requires strict safety measures. We follow well-defined protocols to ensure:

  • Safe handling of high-temperature materials
  • Use of appropriate protective equipment
  • Continuous monitoring of critical processes

Our focus is on creating a safe and controlled working environment for our workforce.

Operational Responsibility

We actively work toward improving energy efficiency and resource optimization across our processes. This includes:

  • Efficient use of power and utilities
  • Process optimization to reduce waste
  • Controlled use of water and cooling systems
  • Recycling & Waste Reduction

Copper is inherently recyclable, and we incorporate practices that support:

  • Reuse of process materials where possible
  • Minimization of production waste
  • Responsible handling of by-products

By integrating safety and sustainability into our operations, we ensure that our manufacturing processes are not only efficient—but also responsible and future-ready.