Automation Upgrades Lead to Financial Savings for Steel Industry Leader

A steel company came to E Tech Group for help with their cold mill line automation. Improvements to the client’s cold mill yielded measurable financial savings by reducing defects and improving the safety of their automated processes.

The Project: Utilize Automation to Increase Production & Decrease Downtime

E Tech Group was hired for a large project by a leading steel company to increase throughput and safety on the customer’s six-stand cold mill line. Additional project goals were to reduce head and tail off gage, reduce inner stand strip breaks, reduce electrical downtime, and improve safety.

The solution to the client’s goals would require creativity on the part of the system integrator and open communication with the steel company. E Tech Group worked closely with the client from start to finish on this targeted control system update.

Solution: Design & Implement an Automated System with End-to-End Coverage

E Tech Group conducted a mill drafting study to determine HP and speed limitations, reviewed the mill model, and set up proper procedures. E Tech Group control system engineers also conducted an equipment audit to determine the failure rate and root causes, and then began implementing the audit’s recommendations.

E Tech Group’s automation professionals implemented monitoring and tuning of the inner stand tension, MG set stand one custom 12 pulse drive to fit on existing gen base, screw down clutchless control, and regulated the voltage to the speed reg.

Additionally, a safety study was performed and the recommendations implemented. Installation, startup and commissioning were then performed.

Results: Improved Processes & Increased Production Capacity

This control system integration resulted in the client experiencing tangible results immediately upon implementation. This successful project proved the value of custom automation system upgrades:

  • Reduced head and tail off-gage
  • Reduced strip breaks, WR and BU roll wraps by 50%
  • Improved strip shape
  • Increased annual tonnage
  • Reduced electrical downtime by 50%

This resulted in a quick ROI for the client, who now has an integrated control system that allows them to closely monitor processes on the cold mill to improve and ensure the quality of their products. E Tech Group’s automation solutions for metals clients employ strategic design and the best in automation technology today to keep manufacturers ahead of the competition curve, facilitating future growth and success.