As part of the long-term collaboration between Salzgitter Flachstahl and SMS group, the latest upgrade ensures reliable operations and prepares the mill for future interfaces and digital tools. The project resolved challenges caused by obsolete spare parts, high CPU loads, and unsupported operating environments. Although the customer plans to replace the current HMI system in the coming years, the upgraded automation already supports the upcoming interface through an OPC-UA driver - a standardized, platform-independent protocol enabling secure and reliable data exchange across industrial systems. The modernization focused on the X-Pact® level 1 automation of three downcoilers and the entire coil transport area, strengthening process stability and consistency.
Since its commissioning in 1963, the hot strip mill has been continuously enhanced to maintain a high level of performance. The latest modernization integrates high-speed control and precise communication structures through an EtherCAT real-time network, while the existing PROFIBUS remote I/O system ensures continued compatibility with established sensor setups. This combination allows the plant to adopt modern automation capabilities without disrupting its operational backbone.
Ongoing improvement has been a defining feature of the cooperation between Salzgitter Flachstahl and SMS group. Mechanical and automation enhancements - such as the latest upgrades of finishing stands F5 to F7 and the complete revamp of the level 2 process automation - support sustainable and more self-optimizing mill operations. A long-standing service X-Pact® Service contract further ensures that maintenance, modernization, and process optimization are aligned with the plant’s long-term performance goals.
This customer project is a clear example of our lifecycle service approach. By upgrading the automation systems, we have not only solved immediate challenges but also created a platform for future developments. Our goal is to ensure that Salzgitter’s hot strip mill remains competitive and efficient for decades to come. This modernization reflects the strength of our partnership and our shared commitment to long-term operational excellence.
