As part of the modernization, a new generation of rolling heads powered by smart compression cylinders, electric motors, and drives, along with an advanced automation system, were put into operation. This enables the factory to produce 600,000 tons per year of water-cooled construction steel in the 6-20 mm range and low-carbon wire rods in the 5.5-20 mm range.
Permanent solution to vibration problem
Problems experienced with the old rolling head, such as excessive vibration, irregular coiling, and unplanned downtime, have been eliminated with the 6th generation rolling head. The new system has almost completely removed vibrations, reducing unplanned downtime while increasing production speed.
Christiane Hess, Technical Project Manager at Stahl Gerlafingen, described the improvements provided by the new system: “Thanks to the new technology, both the start and end of the product are positioned much more precisely. Process stability and product quality have also increased significantly with a more powerful drive mechanism and higher production speeds.”
Real-time monitoring and control
The new winding head is equipped with a tension control system that monitors product movement in real time using laser speed indicators. Integrated with the plant's existing human-machine interface (HMI), the system enables operators to make more informed decisions about the process.
Producing over 700,000 tons of low-CO₂ steel per year, Stahl Gerlafingen is Switzerland's largest recycled steel producer. Founded in 1823, the company now supplies steel bars and beams under the AFV Beltrame Group umbrella.
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