What Is a Ring-Making and Butt-Welding Machine—and How Can It Mass-Produce 2–6mm Wire Storage Racks Efficiently?

From commercial kitchens to supermarket aisles, stainless steel storage racks are essential due to their strength, corrosion resistance, and ease of cleaning. But when monthly orders reach tens of thousands of units, traditional production methods simply can’t keep up.

 

That’s where Jinchun Mechanical, one of the leading small 2D CNC iron wire bending machine manufacturers, steps in. With a fully automated production line featuring ring making, butt welding, hydraulic forming, and auto welding, Jinchun offers a complete solution to transform 2–6mm wire into high-precision, structurally sound storage racks—at scale.

 

Why Choose an Integrated Wire Bending & Welding Line for Storage Rack Production?

⚙️ Step-by-Step Breakdown of the Three Core Production Processes

1. Ring Making + Butt Welding in One Machine

The process starts with the Jinchun 2–6mm CNC ring-making and butt-welding machine, combining forming and welding into a single unit.

Flexible Ring Forming:

Handles 2–6mm low-carbon steel wire

Ring diameter range: 25–550mm

±0.2mm circumference tolerance, flatness under 0.5mm

Ensures uniform arcs and smooth connections

 

Smart Butt Welding:

Equipped with 2.3kW servo wire feeder and 1.0kW cutting motor

Wire feed speed up to 35m/min

Deburring, alignment, and welding completed in one pass

Weld strength ≥ 90% of base material—eliminates weak joints, false welds

 

2. Hydraulic Forming Machine for Custom Rack Features

J-hooks, tiers, and structural bends are handled by a 2T hydraulic press:

Precision Control:

140mm upper cylinder diameter, 350mm stroke

7.5kW oil pump with 0.6MPa air pressure output

One-step forming of 90° bends, arc stretches, or punched hooks

 

Quick Tool Change:

850mm wide table supports most rack sizes

Total machine weight ~1.5T

Tool change time reduced by 40% vs traditional presses

 

3. Single-Point Auto Welding for Reinforcement

After forming, the frame is reinforced via automatic spot welding at 10–20 pieces/min (e.g., 80mm diameter frames):

Precise Spot Welding:

Servo-controlled weld point placement

<1mm deviation for consistent strength, no deformation

 

Strengthened Joints:

Optional multi-layer weld stacking for stress points

Weight capacity up to 20kg per rack section

 

How Does Jinchun's Wire Bending System Deliver Both Speed and Accuracy?

For high-volume production—100,000+ units/month—manual processes aren't sustainable. Jinchun solves this with three core innovations:

⚙️ Full Servo Drive System: Traceable Quality

The integrated ring bender and welder features Xinje-brand servo motors. Every parameter—wire speed, weld current, etc.—is monitored via PLC. Batch consistency: 99.7%, far exceeding manual production at ~85%.

 

⚙️ Compact, Scalable, Modular Design

The full production line (2400×1450×1500mm) takes up minimal space but delivers closed-loop manufacturing from wire input to finished product. Field tests in Linyi, Shandong show:

12,000 units/day in single-shift (8 hours)

OEE (Overall Equipment Effectiveness): ≥85%, over 2× that of semi-automated setups

 

⚙️ Cost-Efficient by Design

Wire Usage Efficiency: Less than 3% waste (vs. 8% for traditional methods)

Labor Efficiency: Only 2 operators required (loading + QC), cutting workforce needs by 60%

Ideal for labor-intensive wire product factories aiming to scale with less overhead

 

Case Study: How a Shandong Manufacturer Tripled Output with Jinchun

A kitchen hardware company in Linyi was struggling with:

Order spikes: Monthly demand surged from 50,000 to 150,000 units during peak seasons

Quality issues: Manual welding caused 15% rework due to poor joint consistency

After deploying Jinchun’s full wire bending and welding line:

Response time improved by 70%

Order to first finished product: 2 hours

Format switching time cut from 4 hours to 1

Product quality improved:

Weld pass rate: 99.2%

Dimensional tolerance: within ±0.3mm

Became certified supplier for Walmart and Carrefour

 

“Jinchun’s automation completely changed how we work. We deliver faster, with fewer defects—and now export racks to Southeast Asia.”

— Production Manager, Linyi

 

Conclusion: Redefining the Formula for Efficient Wire Rack Manufacturing

When 2–6mm wire meets automated bending, forming, and welding, the result is no longer “fabrication”—it’s smart manufacturing. From ±0.2mm ring-making precision to 0.6MPa hydraulic forming control and 20 pieces/min automated welding, Jinchun Mechanical creates a proven formula:

Capacity × Quality ÷ Cost = Competitive Advantage

 

Already trusted by over 300+ wire product factories nationwide, Jinchun’s integrated line is the go-to solution for high-volume, high-consistency rack production.

 

Need a tailored solution or live factory demo?

➤ Contact Jinchun Mechanical today to schedule a consultation.

Let every bend become the start of higher efficiency.