Season 9 Challenges

OPENED ON: 21 FEB 2020  |  CLOSING ON: 22 MAY 2020  |  REWARD: INR 2,00,000
Reward money is paid in exchange of legally acquiring the solution, implementing it to solve the problem and meeting the success criteria. Milestones for paying the reward money would depend upon the complexity of challenge and maturity of the proposed solution, which would be discussed with the solver as soon as the proposed solution is selected by us.

Short Description:

We are looking for low-cost solutions to prevent early rusting of barbed wire tips.

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Challenge Details

Barbed Wires are extensively used for fencing of farm, houses, ground, garden etc.  The wire forming or barbing operation involves the manufacturing of single wire and then Zinc coating it through galvanization. The zinc coating is done to enhance life through sacrificial protection (Zinc corrodes preferentially to steel), thereby protecting the steel wire.

While making Barbed wire, 2 GI wires are formed into a strand and at every 3 - 4 inch, another two wires are tightly twisted and cut into sharp barb as depicted in this video. These barbs prevent intrusion of animals or humans through the fence. The diameter of the barb wires varies from 2 mm to 2.5 mm. The barbing operation takes place at line speed varying from 12 to 25 metres/min. The outer diameter of the barbed wire coils varies from 380 to 400 mm and weigh approx. 26 kg.

In the process of barbing, the barbed wire is severely twisted and cut, which exposes the steel surface. Therefore, these Barb are found to be the initiation point or source of the rust, which gradually spreads over line wire and thereby reduces the overall life of the barbed wire. Normally, the barb tips start appearing rusty within 1-3 months, depending on the season. After installation of a fence, the spread of corrosion across the barbed wire fence is observed from these barb points. As a result of this, there is internal rejection, diversion and customer complaints causing customer dissatisfaction.

This is a universal issue due to the way the barbed wire is designed and manufactured, which cannot be changed or altered. Globally, this issue is addressed with heavy zinc coating or painting, but that is a costly process. Customers seek bright shiny barbed wire bundles with higher service life.  Thus, we are looking for an economical method of enhancing the corrosion life of barbed wires.

Options Tried:

  • During manufacturing of the GI wires, the secondary coating was tried in addition to zinc coating. However, this coating gets damaged during the barbing operation and thereby could not stop rusting of barb tips.
  • Organic colour coatings were not feasible.
  • Barbed wire bundles are packed and stored inside the factory premises to protect from corrosion, but this only gives temporary corrosion protection.



  • The solution should eliminate the issue of rusty barb tips, thereby enhancing the life of barb wires.
  • The solution should not degrade the appearance of the barb wires and should be acceptable to customers.
  • The solution should be possible to implement and operate with ease as all the barbed wire plants are operated by unskilled works. 
  • The solution should enhance the shelf life of the barbed wires and reduce the packaging costs incurred during storage and transportation.
  • The cost of the solution should be less than INR 1000/MT of Barbed wire produced.



  • The process of barb wire manufacturing cannot be altered.
  • The barbed wire is complex in shape. So, the technology for getting uniform post-corrosion coating on barbed wire is not easily available at a lower cost.
  • The cost of implementing any solution on each barbing machines is very high and also not possible due to the overall complexity

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