For high product quality, protection against corrosion during coil storage & transport is the guarantor for the further processing of cold strips . Efficient oiling during cold rolling is elementary for this in various areas of the rolling or slitting lines. technotrans developed customized and sustainable concepts for spray oiling for several production lines of the BILSTEIN GROUP. This not only enables production that is gentle on resources and health, but also greater flexibility and significant cost savings.
High product availability requires intelligent stock management in steel processing. To ensure the quality of the products, their protection is a top priority. In particular, counteracting corrosion of materials by external influences even when stored in halls plays an important role. Even in the cold rolling processes, manufacturers therefore rely on the application of effective corrosion protection by means of special oils. To make them as efficient as possible, oiling equipment in cold rolling mills needs to be precisely designed for the specific conditions.
New oiling concept for zero-defect principle
Due to the increasing demands on product quality and sustainability by its customers, particularly in the automotive industry, the Hagen-based company also recognized a growing need for effective oiling of its cold strip to prevent corrosion. This is because in the mile-by-mile manufacture of its products, the company follows a strict zero-defect principle along the entire process chain in production. For years, the steel processor had already relied on well-known oiling solutions from a long-standing supplier. But the group wanted to take the processes to a new level.
Up to now, technically comparatively simple systems had provided the oiling. In its search for a new solution provider, the group came across technotrans’ fluid expertise. Previously active in particular in the printing industry and in stamping and forming technology, the Sassenberg-based manufacturer transferred its know-how and established technology for airless spray lubrication to the requirements of cold rolling processes. Following a successful test phase, technotrans was awarded the contract for equipping two plants at the site in the US state of Kentucky – and later at other plants in Germany.
Increased cost and process efficiency and flexibility at the same time
“Thanks to technotrans technology, we have raised the oiling processes for high-quality corrosion protection of our cold-rolled strip to a new level of quality. We save costs, reduce maintenance measures on the periphery and continue to be extremely flexible in processing oiled and non-oiled cold-rolled strip on just one line.”
– Eugen Schitz, responsible for plant and process engineering
The technotrans oiling system is used at various locations for both re-rolling and slitting, as well as on the packaging line. For the different areas of application, technotrans designed the tailor-made solution based on its spray.xact technology. The focus was particularly on achieving the highest possible level of efficiency and sustainability.
The compressed air-free spray lubrication of the lubrication system turned out to be advantageous for the requirements. “In contrast to conventional solutions, the technotrans valves open and close in a predefined cycle using electrical pulses,” explains Schitz. “Because there are no compressed air currents, we achieve uniform and at the same time low-mist oiling” – and this despite the high processing speeds of up to 16 m/s during cold rolling. The group thus not only achieves a homogeneous result for corrosion protection, but also saves costs thanks to the high efficiency of the technotrans solution.
Laterally movable for dry running
The spray bars in the re-rolling lines can be moved laterally electrically or pneumatically and are thus not rigidly integrated in the plant as was previously the case. This results in the following advantage for the BILSTEIN GROUP: The steel processor can process the cold-rolled strips both with and without spray lubrication, depending on customer requirements. Because the technotrans components are not located above the conveyor belts in the case of unlubricated products, there is no risk of oil droplets getting onto the belts during dry running. “Such impurities on our belts would be an absolute disadvantage for further processing – for example, during painting,” says Schitz. “Thanks to the technotrans idea, we assure our customers of high product quality.”
In the case of re-rolling, the positioning of the spray bars on both sides also provides additional flexibility. The group is able to adapt their processes according to the respective requirements. This is because different required plate thicknesses entail different rolling intervals. “In the end, it doesn’t matter whether the line rolls in an even or odd number,” explains Hary Kosciesza, Business Development Manager at technotrans.
“As needed, spray nozzles located behind or in front of the rolling stand apply the corrosion inhibitor.” In order for the spray bars to be able to deliver the required amount at all during the high speeds of the cold rolling processes, technotrans in some cases integrated double spray rows with spray nozzles located one behind the other per system. This enables the group to apply oil in quantities ranging from 0.5 to 2.5 g/m². The fact that machine operators can very easily set and precisely regulate the desired oil quantity also makes work easier.
From first order to close partnership
The cooperation, which now extends over eight joint projects, started with the establishment of a new site in Kentucky in the USA. At the newly established BILSTEIN Cold Rolled Steel LP, technotrans developed a spray system along the slitting line, which went into operation at the end of 2017. In addition, the oiling unit within the connected packaging line sprays the end faces of the coils with corrosion protection agent.
The group was so convinced by the solution for the two processes that it also made use of technotrans’ expertise for other processes. Already at several locations, including the headquarters in Hagen and the subsidiary Hugo Vogelsang, technotrans spray systems ensure optimum oiling results in the final pass directly at the rolling mill within the re-rolling process in various spray widths from 500 mm. Most recently, a new re-rolling, slitting line and the associated packaging line at the main plant in Hagen went into operation in September with a 1,350 mm wide spray oiling system.
BILSTEIN intends to continue relying on technotrans
“Depending on the requirements of the specific cold rolling line and the needs of BILSTEIN customers in terms of order volumes, we design our solutions into the machines,” Kosciesza emphasizes. For the BILSTEIN GROUP, technotrans developed precisely fitting spray systems for existing plants or for completely new plants in close coordination with the OEM partners. The retrofitting was carried out during the scheduled downtimes of the systems as part of the regular maintenance intervals.
The company intends to continue its modernization course in the future not only because of the technical implementation with technotrans technology. The harmonious and targeted project handling from the development of the custom-fit solution through to commissioning also speaks in favor of the Sassenberg company, says Schitz: “For us, one thing is certain: if we need new solutions for cold strip oiling, technotrans is our first port of call.”
During a demonstration run as part of the DGUV “Aerial Work Platforms” trainer training course, Matthias Müller forgot to test the emergency stop function, got stuck with the scissor lift on several cones and hit his head on a roof beam of the training hall. The academy director did a lot of things wrong during the demonstration – and thus everything right. After all, his goal was to train the participants to evaluate test rides in every detail. This will be part of their daily routine after receiving their certificate.
Comprehensive starter package
After several days of theoretical and practical training at the modern “Campus M – Home of Safety.” at the company’s headquarters in Blaustein, they are allowed to instruct and train operators of aerial work platforms and issue certificates of competence in accordance with DGUV Principle 308-008 – for telescopic and truck-mounted platforms and vertical lifts, among other things. The newly qualified trainers can also carry out annual follow-up training, and the company also provided them with a start-up package containing presentations and documentation aids for their own training.
Designing driving courses
The training also included information on legal requirements for aerial work platforms, on liability and responsibility, instruction in technical basics and the various types of construction and drive, traffic regulations and traffic routes, and the design of driving courses. For Matthias Müller, whose academy also conducts the trainer training in accordance with the IPAF Handbook and in coordination with IPAF Germany, it is clear: “The need to train qualified trainers for MEWP operators arises both from the high risk potential during use and from a large number of relevant regulations.”
Guidance on moderation
For Miriam Winter of “Hessen Mobil,” this was a wealth of information. By taking on new tasks, the employee of Hesse’s road and traffic management department is entering completely new territory for her with the certificate – and immediately felt comfortable at the training as the only participant: “The exchange with colleagues was very good for me. I was able to take away some concrete tips.” In addition to the practical practice runs, it was also important for her to learn how to moderate instruction: “At AST, I learned how to lead a group, teach it, and get it excited about a topic.” Siggi Kern, on the other hand, is already an “old hand” in the broad field of aerial work platforms. But for him, too, there is always something to learn: “For me, it was important to get into the depths of the legislation in addition to the practical instruction. This allowed me to learn more about the high responsibility of employers and their concern for the physical integrity of employees.”
But one thing is clear: MEWP operators must also always be mindful and prudent, and learn that even at heights, you should always stay grounded.
Occupational safety rethought
The company is one of the leading engineering firms for occupational health and safety in Germany and operates Campus M “Home of Safety.”, one of the most innovative training centers for occupational safety in Germany. The company offers an extensive seminar and training program, including virtual reality simulators. The focus is on practical training and further education and trainer certification in the field of safety management and technology – also available as an e-learning offering on request.
Fire protection management and company certifications round off the range of services. The training program, as well as the company itself, are ISO 9001 certified. Founded in 2003 by Angelika and Matthias Müller, the company now employs around 15 people who rethink the area of occupational safety on a daily basis and thus help to make the working lives of many people safer every day.
Measurement, Instrumentation, Control & Automation Mechanical & Thermal Processes News Processing Technologies
Inauguration of the modern corporate campus in the greater Houston area
Endress+Hauser has invested $34 million in a modern corporate campus near Pearland, Texas, in the greater Houston area. A large new training center, office space for 110 employees, a calibration laboratory and a repair shop have been built on 112,000 square meters. The new building strengthens the Group’s presence in the Gulf region.
Located in Pearland, Texas, the building is in the heart of the economically strong Gulf of Mexico region. “The expansion reflects our strong roots in the USA. It demonstrates our proximity to our customers and helps us to serve them even better in the future,” said Matthias Altendorf, Group CEO during the dedication ceremony on October 26, 2021.
Training facility for customer training
The new campus features the largest process training unit in the U.S., with 200 pieces of equipment and seven tanks, as well as a laboratory for metrology and process analytics. Local customers and partners can learn how to use modern measurement and automation technology here in customized training courses.
In addition, the campus is equipped for the accredited calibration of instruments for flow, temperature and pressure measurement. These can be carried out both in the laboratory and with a mobile calibration system at the customer’s site. A service workshop completes the range of services.
Sustainable construction in regional style
When planning the campus, the company placed great emphasis on sustainability. The building is already the fifth in the U.S. to be certified according to LEED (Leadership in Energy and Environmental Design) standards for environmentally friendly construction. In addition, regional materials were used in the interior and exterior to reflect Texas architecture.
The campus provides space for 110 employees. In addition to Endress+Hauser teams, the new building also houses the gas analysis business unit, the laboratory analysis specialists of subsidiary Analytik Jena, and regional sales and service partner Vector Controls & Automation Group.
Ingredients & Auxiliary Materials Measurement, Instrumentation, Control & Automation News Processing Technologies
Decanter for leading paper and packaging manufacturer in South Asia
Two CF 8000 decanters have now been supplied by GEA to ITC Paperboards and Specialty Papers Division in Bhadrachalam, India. The decanters support the modernization and new construction project.
The Paperboards and Specialty Papers Division is a company in the paper and board industry in South Asia. Modern recovery boilers will be installed at the site to improve the ash handling process. The two new CF 8000 decanters are important components of the ash leaching stage of a modern Chemical Recovery Boiler.
The advanced chemical recovery boilers are not only an integral part of the pulp recovery process, but also generate electricity and steam for the entire mill. This project is being carried out by Valmet, the world’s leading developer and supplier of process technologies, automation and services for the pulp, paper and energy industries. Valmet, in turn, had contracted GEA to supply the CF 8000 decabnters as part of this overall project.
Serves as immediate and later as long-term solution
The company has already delivered the two decanters. As a first step, they were initially installed to support the three existing, old recovery boilers. When the new boiler is ready, the ash leaching system, including the two decanters, will be connected to it. The installation of the decanters so far is therefore initially an interim solution, but one that will allow ITC to continue production without interruption and without interruption.