Wire Rod Pickling and Phosphating Line

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.