HALCOR is the copper tubes division of ElvalHalcor S.A. and a leading industrial player in the production of copper and copper-alloy semi-finished products. With a strong international presence, HALCOR is the No.1 copper tube supplier in the EMEA region, delivering high-performance solutions to demanding industrial value chains worldwide.
The company serves a wide range of markets, including HVAC and heat transfer applications, energy systems, construction, industrial applications, and mobility-related value chains. Its core production focuses on copper tubes and tube systems for energy-efficient and heat-transfer applications, as well as copper and copper-alloy products manufactured to strict industrial and customer specifications.
Operating in highly competitive and quality-sensitive markets, HALCOR continuously invests in advanced manufacturing technologies to enhance flexibility, efficiency, and product quality.
HALCOR Pilot Use Case within the R3GROUP project
The primary goal of the R3GROUP pilot at HALCOR is to enhance flexibility, quality, and efficiency in copper tube manufacturing through data-driven reconfigurability and predictive quality control.Key objectives of the pilot include:
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Enabling predictive quality control and full traceability across production stages
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Supporting smart routing and allocation of semi-finished copper tubes to customer orders
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Reducing operator dependency through adaptive digital work instructions
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Improving early detection of process and equipment deviations
These objectives directly support HALCOR’s strategic transition toward zero-defect manufacturing and increased responsiveness to market volatility and material variability.
Manufacturing Challenges Addressed
HALCOR operates in a high-mix, multi-stage copper tube production environment, which presents several challenges:
Production Reconfiguration
Frequent product changes and tight customer specifications increase the complexity and cost of production reconfiguration.
Material Availability and Allocation
Variability in material quality and availability makes optimal coil-to-order assignment challenging, particularly when balancing quality requirements and delivery timelines.
Introduction of New and Recycled Materials
The growing use of new and recycled materials introduces additional variability in material behaviour, increasing the risk of quality deviations during forming and finishing processes.
R3GROUP Solutions Implemented at HALCOR
To address these challenges, R3GROUP introduces an integrated digital ecosystem that connects production data, quality insights, and operator decision-making:
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Product Digital Twin
Enables predictive defect detection, end-to-end traceability, and informed routing decisions for semi-finished products. -
Material Rerouting Module
Optimises the allocation of copper coils to customer orders based on quality predictions, production constraints, and material availability. -
Adaptive Digital Work Instructions
Provide real-time, context-aware guidance to operators, reducing errors during cutting, setup, and reconfiguration activities. -
Indirect Machine Monitoring
Uses sensor-based data to detect early process deviations and recurring defect patterns, enabling proactive intervention.
Together, these solutions significantly reduce reconfiguration time, scrap generation, and variable production costs during copper forming and finishing operations.
Expected Impact and Benefits
The implementation of R3GROUP solutions at HALCOR is expected to deliver measurable improvements across key performance indicators:
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~20% reduction in reconfiguration time
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~8% reduction in production lead time
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~20% reduction in scrap rate
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~7% improvement in Overall Equipment Effectiveness (OEE) on spoolers
Beyond quantitative KPIs, the pilot strengthens HALCOR’s ability to:
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Respond rapidly to changing market demand
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Manage material variability, including recycled inputs
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Build a scalable foundation for advanced traceability and future Digital Product Passport requirements
Towards a More Resilient Copper Manufacturing Process
Through its participation in R3GROUP, HALCOR demonstrates how data-driven reconfigurability and predictive quality control can transform complex metallic manufacturing environments. The pilot showcases how digital tools can enhance resilience, support sustainability goals, and enable high-quality production in the face of increasing product and material variability.