For metal producers, challenges around maintenance, quality, and unplanned downtime are persistent sources of concern. The production of metals comes with significant costs – over $600 per ton for steel, $2,500 per ton for aluminum and stainless steel, and $4,000 per ton for copper.  These high costs, coupled with the reputational repercussions of a defect or delay, make it imperative to ensure every ton produced meets exacting standards.

Today’s metals producers are under increasing pressure to deliver impeccable quality within strict tolerances, as customers demand pristine surfaces free from imperfections.

Meeting these demands requires precise measurement and control of strip quality parameters throughout the production process, from hot rolling to finishing.

With hot and cold  rolling mills operating under harsh conditions, keeping everything in good working order can be challenging. The environment is  often hot and humid, with process temperatures reaching several hundred degrees Celsius, and with machinery subjected to intense vibrations and forces. Bearings, rolls, and other critical components are at constant risk of damage, and without regular upkeep, equipment failure becomes a real threat. When machinery falters, it not only halts production but also increases the risk of quality issues, introducing extra complexity for producers.

In a competitive landscape where time equals money, the impact of any stoppages can quickly be felt, delaying production, disrupting schedules, reducing output, and eating into profitability. To stay ahead, producers must ensure their machinery and equipment are always operating at peak performance. However, with many companies facing a growing shortage of in-house technical expertise, maintaining complex machinery and developing and improving metal production processes can be a struggle . Consequently, more producers are turning to external suppliers to bridge the engineering gap. 

For those with limited in-house resources, turning to suppliers with specialized expertise is becoming an increasingly attractive solution. Companies like ABB are well-positioned to provide comprehensive support, helping producers secure uptime, maintain quality, and shift from reactive to proactive maintenance strategies.

ABB’s Lifecycle Services are particularly valuable, allowing producers to identify risks early. In cold  rolling applications, for example, our assessments can highlight the need for measures such as recoating or repolishing measuring rolls, ensuring that production runs smoothly without interruptions. We can also provide spare rolls, enabling continuous operations even during maintenance.

To minimize downtime and the logistical problems of sending equipment for offsite repairs, producers are increasingly turning to on-site and remote services. We can meet this need by providing tools and expertise that enable production schedules to be maintained with minimal disruption.

Flatness control is another crucial area of support. Through regular condition monitoring and optimization of our Stressometers, we can ensure consistent, long-term performance in measuring and controlling flatness. By analyzing Stressometer data, we can also detect and manage undesirable actuator performance changes to maintain continued production quality.

ABB also supports customers with expertise that extends beyond equipment. Acting as both a supplier and partner, we provide highly experienced engineers to conduct thorough process surveys, offer tailored recommendations, and implement improvements. These engineers are equipped to assist with tasks including commissioning and fine-tuning processes. They can also provide guidance on specialized tasks like roll grinding, including finding partners to carry out the work and helping make informed decisions about practical steps to maintain and enhance performance.

The combination of superior measurement technologies and deep application expertise makes ABB a trusted ally for metal producers. By partnering with ABB, companies can navigate the challenges of shrinking engineering teams, rising customer expectations, and the relentless demands of production  process improvements. With ABB’s support, producers can focus on delivering high-quality products, maximizing uptime and staying competitive in an increasingly demanding market.

When every ton counts, having the right expertise on your side can make all the difference.