Copper Tube Manufacturing: Complete Guide
(Process, Types, Applications & Business Scope in India)
Introduction
Copper tube manufacturing plays a crucial role in modern industrial and infrastructure development. Copper tubes are widely used in air conditioners, refrigerators, plumbing systems, medical gas pipelines, and heat exchangers due to their excellent performance and reliability.
Copper is known for its high thermal conductivity, corrosion resistance, flexibility, and long service life, making it the most preferred material for tubing applications. As India’s HVAC, construction, and healthcare sectors continue to grow rapidly, the demand for copper tubes is increasing steadily.
This blog explains the complete copper tube manufacturing process, types, standards, applications, quality control measures, and business opportunities in India in a simple and structured manner.
What is a Copper Tube?
A copper tube is a hollow cylindrical pipe made from high-purity copper (typically 99.9% pure). It is manufactured in various outer diameters, inner diameters, and wall thicknesses depending on the application.
Copper tubes can withstand high pressure and temperature. Their smooth internal surface improves fluid flow efficiency and reduces energy loss, making them ideal for refrigeration and air-conditioning systems.
Copper Tube Manufacturing Process (Step-by-Step)
Copper tube manufacturing is a multi-stage process that requires precise temperature control, advanced machinery, and strict quality standards.
1. Raw Material Selection
The manufacturing process starts with selecting high-quality copper cathodes. The most commonly used raw materials are:
- Electrolytic Tough Pitch (ETP) Copper – Used for general industrial, HVAC, and plumbing applications
- Oxygen-Free Copper (OFC) – Used for medical and high-purity applications
High-purity copper ensures better mechanical strength, thermal conductivity, and corrosion resistance in the final product.
2. Melting and Casting
Copper cathodes are melted in a high-temperature furnace. The molten copper is cast into billets or rods using controlled casting methods.
- Uniform grain structure
- Reduced material wastage
- Consistent chemical composition
3. Hot Extrusion Process
The cast copper billets are reheated and passed through an extrusion press, where they are forced through a die to form a hollow tube.
- Formation of the basic tube shape
- Improved grain structure
- Enhanced mechanical strength
4. Cold Drawing Process
After hot extrusion, the tube undergoes cold drawing through multiple stages using draw benches.
- Achieving precise outer diameter
- Maintaining uniform wall thickness
- Improving surface finish
5. Annealing (Heat Treatment)
Cold drawing makes the copper tube hard and less flexible. To restore ductility, the tube undergoes annealing, a controlled heat treatment process.
- Soft (Annealed) – Highly flexible, supplied in coils
- Half-Hard – Balanced strength and flexibility
- Hard Drawn – High strength, supplied in straight lengths
6. Straightening, Cutting, and Coiling
- Small-diameter tubes are supplied in coil form
- Large-diameter tubes are cut into straight lengths
Plastic end caps are applied to prevent contamination during transportation and storage.
7. Testing and Quality Control
- Eddy current testing
- Leakage and pressure testing
- Dimensional accuracy checks
- Chemical composition analysis
Types of Copper Tubes
Based on Application
- Air Conditioning and Refrigeration Copper Tubes
- Plumbing Copper Tubes
- Medical Gas Copper Tubes
- Industrial Heat Exchanger Tubes
Based on Standards
- ASTM B280 – Air conditioning and refrigeration
- ASTM B88 – Plumbing systems
- EN 12735 – European standard
- IS 1545 – Indian standard
Common Copper Tube Sizes
- Outer Diameter: 1/4”, 3/8”, 1/2”, 5/8”, 3/4”
- Wall Thickness: 0.6 mm to 1.2 mm
Applications of Copper Tubes
- Air conditioners and refrigeration systems
- Drinking water pipelines
- Medical gas systems
- Solar water heaters
- Heat exchangers and condensers
Copper Tube Manufacturing Business Scope in India
The Indian copper tube market is growing rapidly due to infrastructure, HVAC, and healthcare expansion.
Machinery Required
- Melting furnace
- Continuous casting machine
- Extrusion press
- Draw bench
- Annealing furnace
- Testing equipment
Despite high initial investment, copper tube manufacturing offers strong long-term profitability.
Advantages of Copper Tubes
- Excellent thermal conductivity
- High corrosion resistance
- Easy installation
- Long service life
- Fully recyclable
Conclusion
Copper tube manufacturing is a high-value industrial process with strong demand across multiple sectors. With modern technology and quality standards, it offers a sustainable business opportunity in India.
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