Metals production is an expensive and highly demanding process where getting things right first time can make the crucial difference to yield and profitability.

Equally important is minimizing unplanned downtime. The harsh operating conditions in cold rolling mills impose extreme demands on equipment. With temperatures reaching several hundred degrees Celsius and exposure to vibrations, aggressive chemicals, and continuous 24/7 operation, measurement and control systems must be kept in peak condition to ensure accurate and reliable performance. The risk of performance degradation over time means that proactive maintenance is crucial to preventing breakdowns and ensuring consistent measurement accuracy.

However, with the metals industry facing a growing shortage of skills and labour, it is becoming harder for many companies to dedicate the resources needed to maintain their equipment effectively. 

To address these challenges, ABB offers a comprehensive suite of lifecycle services designed to optimize metal production processes, minimize risks and tackle engineering gaps. These services help customers shift from a reactive maintenance approach to a proactive  one, ensuring consistent quality and operational efficiency.

By identifying potential risks, such as wear and tear, non-optimum performance and signs of impending failures, they provide proactive solutions to prevent unexpected mill stoppages. Health checks and surface inspections are key components of this service, giving producers access to detailed reports and actionable insights for maintaining equipment performance. In many cases, these checks and inspections can also reveal wider issues with production processes themselves, adding extra value.

Additionally, ABB enables on-site servicing, reducing the need to send equipment away for repairs and minimizing production disruptions. By working as both a supplier and partner, ABB can provide assistance with conducting thorough process surveys, recommending improvements, and providing fine-tuning of processes and control systems to enhance performance.

One of the most crucial aspects of ensuring product quality in metal rolling is maintaining consistent flatness. Variations in flatness and thickness can lead to defects that affect the overall performance and appearance of the metal. ABB’s Stressometer services play a vital role in detecting process performance changes and retuning control loops to maintain optimal flatness control.

Flatness control is essential in cold rolling mills, where the conditions are extreme, including high temperatures, humidity, vibrations, and exposure to aggressive chemicals like kerosene and industrial detergents. ABB’s advanced measurement solutions help mitigate these challenges, ensuring precise control over the rolling process. By detecting even minor deviations in flatness performance, they enable manufacturers to make necessary adjustments in real time, improving overall efficiency and quality.

Boosting sustainability

ABB’s Lifecycle Services provide the tools and expertise needed to stay both competitive and sustainable in an increasingly demanding market. Through predictive maintenance, on-site support, flatness control optimization, and spare part solutions, they can help minimize production risks, enhance product quality, and maximize uptime.

As quality becomes an increasingly important differentiator, companies that look to providers such as ABB to help optimize their production processes will be best equipped to outrun their production challenges to surpass customer expectations, increase uptime, and achieve the all-important competitive edge.