Customer Magazine 1 | 2013
MAGAZINE
UPCAST & ASMAG - A perfect match Next User Meeting coming up! 11-13 September Vienna
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AST C P U D I HYBR ETAwLoLrk M T N AT fBsyUstematic Re &aDnd tube
esult o st both wir uipment As a r e eq o ca sible t ith the sam s o p w it is
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Persistent work with reliable partners pays off
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R&D resources beefed up
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High quality products from an innovative supplier
Strong growth with reliable partners
4 UPCAST®-SGTube coming of age 5
UPCAST & ASMAG -
“Brothers in Tubes”
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A word from the Board of Directors
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The Pilot Plant – Versatile capabilities
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Presenting UPCAST OY personnel
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Introducing ASMAG Group
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Case Buntmetall: Green, greener,
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When 1 + 1 equals more than 2
In order to serve you better
hybrid 11
UPCAST OY around the world
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Two in one with hybrid
Strong growth with reliable partners The year 2012 was the best year in UPCAST OY’s entire history. We have worked ambitiously to meet the demands from the market and the needs of our customers. Our engineers have travelled around the world commissioning casting lines and supporting our customers’ production. Our design and R&D teams have done excellent work manifested by the rapid acceptance of the UPCAST®-SGTube technology on the market. The same is true for the “Cast&Draw” concept developed jointly with our Austrian partner ASMAG GmbH. UPCAST’s after sales team has exceeded its goals, too. I am very proud of our extremely motivated and committed personnel. One of our fundamental strengths has been efficient networking. In a situation with such a heavy workload, we have been able to find extra resources through our partners and thus support our customers without the need to compromise our service standards. Our long-term subcontractors and suppliers both in Finland and Europe have also been able to step up their production according to our requirements. Our entering into the field of copper tube casting has introduced new partners into our global network. During many casting campaigns in our Pilot Plant we have produced dozens of tons of copper tube as part of our R&D work. These tubes have then been further processed at several tube mills. Without the valuable contribution of these partners we would not have been able to introduce the SGTube technology to the market as fast as we have done.
“One of our fundamental strengths has been efficient networking”.
Although we seem to be living in the midst of persistent economic uncertainty we at UPCAST feel confident of the future. Hard work, close cooperation with our partners and listening with a sensitive ear to our valued customers will form the basis for success also tomorrow. JUKKA LÄHTEENMÄKI Managing Director
UPCAST®-SGTube coming of age Copper tube has been cast with the UPCAST® system already in the 70’s and we even delivered two such lines back in the 80’s. However, these customers use their cast tube in the manufacture of fittings, not for actual tubing. The rather coarse grain structure inherent in these cast tubes prevent them to be successfully drawn. Some years ago requests to look into the possibility of reaching a much finer grain structure emerged from the market. “Why not” we thought and started a R&D program which then eventually led to the development of the UPCAST®-SGTube technology, tells Markku Koivisto, UPCAST’s Engineering and R&D Manager. The route to success was a combination of well-organized casting tests at UPCAST’s Pilot Plant, further processing of the cast tube first at Cupori Oy’s tube mill in Pori followed later by more comprehensive drawing tests within the Wieland
Group. As proof of the development program’s success there is today a hybrid - casting both rod and tube - UPCAST® line running at Buntmetall’s (part of Wieland Group) Enzesfeld plant in Austria.
The on role per
the first production line in South-America helped us make rapid progress. What then are the crucial factors in reaching a thin-walled cast tube with good drawability? They are the tooling - in particular the cooler/die combination - in the casting machine, the casting program as well as the correct handling of the cast tube. It’s a combination of all these factors, tells Markku Koivisto.
development and testing were based existing metallurgical knowledge on the of grain structure in the drawing of coptubes. It was clear that smaller grains
The main advantage of producing copper tubes
are an essential feature for successfully drawing the cast tube into small diameters and thin wall-thicknesses. Our partnership with the Austrian company ASMAG GmbH making tube-processing machinery led the way to verifying the drawing performance of the cast tube within the Wieland Group. Additional testing at some other tube mills as well as feedback from
along the “Cast&Draw” route - with UPCAST®SGTube as the first step - are the marked savings in your overall costs. This is due to the SGTube being already close in size to the end products. In the more traditional methods you need several costly steps to get to the same point. As the footprint of a “Cast&Draw” line is much less than needed in conventional tube producti-
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“The perfect match where 1 + 1 equals more than 2”.
Mr. Johann Vielhaber
UPCAST & ASMAG -
“Brothers in Tubes” on you can get additional savings also this way. At the moment SGTube is being used for the production of sanitary and certain ACR (Air Conditioning and Refrigeration) tubes. SGTube production is ongoing at three different sites and judging from a growing interest on the market these will soon be followed by new ones.
SGTube will definitely be also adapted to copper alloys. One potential candidate being coppernickel that is used in seawater applications due to its good corrosion resistance especially in salt-water environments and desalination applications. Although we have already made remarkable progress, the development of SGTube is far from finished but will continue in the foreseeable future, says Markku and seems very inspired by his work.
Combining forces The cooperation between UPCAST OY and ASMAG GmbH began in 2009 and has been further strengthened and deepened with time. The two companies although separated geographically - were brought together by customers wanting end-to-end deliveries for their copper tube production lines. UPCAST’s knowhow in upward continuous casting fits well with ASMAG’s expertise in machinery for processing tubes. Together the two companies can offer complete production lines.
“Cast&Draw” concept By combining their respective expertise UPCAST and ASMAG came up with a new, cost-efficient concept for the pro-
duction of seamless copper tube called “Cast&Draw”. UPCAST fills in the “Cast” portion with its UPCAST®-SGTube technology and ASMAG provides the straight drawing machinery and annealing equipment needed in the “Draw” portion. The technologies provided by the two companies fit together seamlessly.
Common aspirations Cooperation between UPCAST and ASMAG has been very smooth and easy. A common way of working and talking was easy to find. The driving force behind the partnership is a common passion to find new ways of adding value to our customers’ production chains. Seeing new innovations and applications in real life use inspires our technical people, says
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Mr. Johann Vielhaber, the Managing Director of ASMAG. Naturally, the success of our cooperation motivates people in both companies to push further on with our common R&D efforts. UPCAST and ASMAG see a huge potential in working together as well as a great opportunity to enter global markets with totally new technologies.
Successful partnership Even though the partnership doesn’t yet have a long history, the interest it has raised on the market has exceeded all expectations. Encouraged by this new innovations are under development. One of the latest being the hybrid UPCAST® sys-
tem which enables casting of both rod and tube from the same casting line. This offers smaller companies with lower production volumes the possibility of a feasible in-house casting operation. Further improvements toward greener and more efficient processes are the decisive aims behind our R&D work. Mr. Vielhaber reveals that there are a lot of new ideas on the table, which are under discussion with UPCAST.
zesfeld plant in Austria. ASMAG’s role as a trusted machinery supplier to Buntmetall has forged a close relationship with the two companies. ASMAG’s confidence in UPCAST’s technology was naturally an important factor when Buntmetall considered their investment in the UPCAST-SGTube process. This together with the progress-oriented thinking characteristic of Buntmetall’s top management made the acquisition finally a logical choice.
Case Buntmetall A key milestone in the UPCAST – ASMAG cooperation was reached with the start-up of the hybrid UPCAST® line at Buntmetall’s En-
A word from the Board of Directors All-inclusive service to the customers UPCAST OY and ASMAG GmbH share partly the same target group. The two companies which were brought together through common customers quickly discovered that their processes compliment each other perfectly. By combining their individual expertise, the companies can better fulfil the needs of their customers through the supply of complete tube production processes. Together UPCAST and ASMAG posses a huge amount of knowhow all the way from upward tube casting to drawing, annealing and finishing. Through this partnership we both are stronger and able to offer end-to-end production lines, complete process knowhow as well as comprehensive after sales services to our common customers. Our first joint project based on the “Cast&Draw” concept is already in its realization stage and we are sure that this represents just the beginning of a long line of similar cases in the future. Close-knit cooperation will also improve our understanding of the markets and customer requirements. Working together with ASMAG has fallen in place quite naturally. We seem to share the same kind of pragmatic company culture.
Long-term cooperation with key partners has always played an important role in UPCAST’s business thinking.
Success through innovation and productization In addition to their combined work UPCAST and ASMAG will naturally continue to develop independently their respective products and services. In order to boost its own R&D work UPCAST has embarked on a major investment project concerning the pilot plant in the form of a second casting line. When fully operational in the beginning of 2014 the new test installation will enhance our R&D capabilities remarkably. An interesting example of new innovations is the hybrid UPCAST® system for casting both rod and tube from the same line. It is an offspring of our baseline SGTube technology offering high flexibility and cost-efficiency. Thank’s to its diverse product mix the installation and operation of such a line becomes feasible even with rather small product-specific quantities. Two such lines are already running proving the successfulness of the concept tells Mr. Timo Ellilä, UPCAST’s Chairman of the Board.
Mr. Timo Ellilä
Mr. Markku Koivisto
The Pilot Plant – Versatile capabilities UPCAST OY’s aim is to remain as the market leader in upward continuous casting technology. UPCAST® lines are manufactured by long-time, mainly local subcontractors. This close partnership has continued in some cases for several decades. However, for us to stay in the forerunner position, it is essential that we test all new designs in order to ensure their proper functioning and durability as well as the quality of the cast product. For this purpose we have our custom-made Pilot Plant.
UPCAST’s Pilot Plant is situated close to our office, which is advantageous for smooth R&D work. Furthermore, since our facilities are located within a so-called Copper Industrial Park having a big concentration of non-ferrous production companies, laboratory services important to our work are readily available, says Markku Koivisto, UPCAST’s Manager of Engineering and R&D.
More capabilities for R&D work Our Pilot Plant was moved into its current premises in 2010 and R&D activities were initiated there in the beginning of 2011. The new premises are much roomier and more modern than in the old place. However, as development
of our SGTube technology has reserved practically the complete capacity of our existing testcasting line there was a clear need to remove this bottleneck. Accordingly a decision was made to install a second casting line into the Pilot Plant. The new equipment will include a furnace with associated electrics, a casting machine and an additional coiler as well. Engineering work started already in 2012 and the necessary procurements will take place this year so that the new casting line will become operational early 2014. This expansion will enable us to separate the casting of copper and copper alloys to different lines which will speed up testing remarkably as we can reduce the need to empty the furnace in order to
go from one type of melt to another. Moreover, the new equipment will facilitate longer casting campaigns as well as higher coil weights.
Diverse usage We have also built a meeting room and certain training facilities into the Pilot Plant to create an environment convenient for training of customers’ personnel. The utilization of the Pilot Plant will definitely grow in the future. UPCAST is investing increasingly in R&D, which means higher demands on our human resources. As a response a new R&D engineer has already joined our team and we hope to hire one more later this year, Markku Koivisto summarizes.
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Presenting UPCAST OY personnel Sami Ollila Project Manager
HannaLeena Mäkitalo Marketing Manager, Sales
Sami joined UPCAST at the end of 2010 to work as a project manager. Previously he was employed in offshore industry as a project engineer. In UPCAST Sami is in charge of project implementation which includes e.g. scheduling, cooperation with our engineering side, coordination of procurement activities, following equipment manufacture at subcontractors, supervising commissioning people and keeping customers informed about the progress of their projects. Sami tells that the diversity of his work is a source of motivation; no two
days are the same. The many different cultures within UPCAST´s customer base just underscore this matter. All in all it’s our customers together with our own staff that make things worthwhile, Sami summarises. Regular visits to a local gym and meeting with friends are important parts of his free time. Furthermore, Sami enjoys playing the guitar and spends often time in the kitchen preparing tasty food. Sami feels that we should not be discouraged by problems but take them as things calling for a solution.
Susanna joined our spare parts team in the summer of 2011. Before being hired by UPCAST she performed similar activities at Metso Group but had earlier worked also as a mechanical designer in various companies which forms a good basis for doing spare parts sales. What’s new for her in UPCAST is the handling of exporting procedures. When the same person who takes in an order sees the case all the way through including procurement and dispatch, a smooth ser-
vice is ensured as well as making our work more satisfying, she says. Furthermore, active communication with the customers is essential in providing a high quality service. Susanna enjoys the hectic and global atmosphere in spare parts sales. I have always wanted to work with people in an international environment, she says. In her free hours Susanna enjoys various sports and spends time with her friends. Susanna thinks that if you can dream it you can do it.
Hanna-Leena started with UPCAST in March 2013 as Marketing Manager. She has a long experience in the metals and manufacturing industries. Before joining UPCAST Hanna-Leena
ing, which will take place in Vienna in September. She promises a rewarding event and hopes for a large participation. Hanna-Leena devotes a big part of her spare time to her family but likes also
worked with a company producing radio frequency shielded rooms for testing purposes and radio frequency protection. On her first working day Hanna-Leena started organizing our participation at exhibitions in Moscow and in Sao Paolo as well as arranging our 2013 User Meet-
to sing and play the piano when on her own and to do outdoor activities every now and then. She is really excited about learning the new business and hopes to be able to contribute her experience to the benefit of UPCAST and its customers.
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Introducing ASMAG Group
per In cop oduction pr bH tu b e G Gm ASMA the total s cover ream st n w o d ss e p ro c
UPCAST OY’s close partner ASMAG GmbH has served both steel and non-ferrous metal industry for decades. Manufacturers of tubes, bars or profiles from both steel and non-ferrous metal industry find the right partner for improving and extending their production facilities in the ASMAG Group. The group consists of two highly specialized companies: ASMAG GmbH, based in Scharnstein, Austria, plans, produces and installs machinery for the production of tubes, bars and profiles in steel, copper and copper alloys. SEUTHE GmbH, based in Hemer, Germany supplies longitudinal seam wel-
ming through to stacking and bundling of the finished tubes.
sizes on smooth material flow, high automation and cost-effective operation.
In the area of copper tube production ASMAG GmbH covers the total downstream process starting from straight drawing down to finishing of tubes in level wound coils, pancake coils, jumbo coils and straight lengths.
Contrary to the general trend, ASMAG GmbH manufactures its machines and installations in its own workshop in Scharnstein, Austria. Engineering, automation, production and assembly are under a single roof. This results in high manufacturing standards, extraordinary level of flexibility and excellent customer service and support. Moreover, continuous and consequent technical development and the
For the production of bus bars and profiles ASMAG GmbH also offers equipment for the entire process from continuous rotary extrusion of the rod to the
ded tube and profile welding plants.
ready-to-sale products.
With altogether more than 200 employees the ASMAG Group can thus provide solutions covering the entire steel tube production process: from tube for-
Whether it’s about the planning of complete plants, design and manufacturing of individual machinery or modernisation of existing plants, ASMAG GmbH empha-
openness for new technologies make ASMAG GmbH one of the most innovative suppliers in the industry. With an export ratio of almost 95% this has been proven several times in their projects worldwide.
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Case Buntmetall:
Green, greener, hybrid UPCAST OY is well known for its unbeatable know-how in wire and tube casting. Now as a result of systematic R&D work it is possible to cast both wire and tube with the same equipment. The first of such “hybrid” lines has been installed and commissioned at Buntmetall Amstetten GmbH, Austria.
Recipe for keeping project schedule The installation and commissioning of the new UPCAST® hybrid line went well and on time. This was a result of the professional and well-coordinated work on both sides, says Eugen Wegmayr, Director Technical Service of Buntmetall. UPCAST’s expertise in the machinery and Buntmetall’s know-how in the necessary construction and installation work complemented each other very well, he continues. Since the fall of 2012 the line has been casting rod and in the course of 2013 we have started to introduce also the tube to our production program. Being the first of its kind we - with support from UPCAST - are still working our way up along the learning curve in exploiting the line’s full potential as a versatile part of our pro-
duction process, Mr. Wegmayr summarizes. We want to thank all who have contributed to this successful project, adds Anton Zierhut, Managing Director of Buntmetall. He also wants to state that it is a pleasure to work together with UPCAST. The correct and controlled performance of scheduled tasks has been paired with a trustworthy and friendly atmosphere between both parties right from the beginning of the project. This atmosphere even gave room for some harder discussions over controversial point of views, which were always handled and solved in a swift and cooperative manner.
To Buntmetall it was important to build up a self-sufficient rod supply for our rotary extrusion machines. The concurrent decision by the Wieland Group to develop another production
path for tubes supported Buntmetall to invest into a hybrid process. The UPCAST® hybrid plant gives Buntmetall and Wieland Group the capability of ensuring the supply of rod as well as the opportunity to establish a new competitive way for tube production in Europe, says Mr. Zierhut with satisfaction. From a production point of view it is quite beneficial to be able to change a worn out die with no interruption of the overall casting process. Not to forget the reduced safety risk in the UPCAST® process with no way for any cooling water / copper melt blowing or splashing during die changes. Besides these advantages the plant operates very clean with low emission levels meeting todays environmental standards, which may even make you forget that you are looking at a casting process when walking in the plant, he concludes.
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SGTube casting process at Buntmetall
UPCAST OY Around the world Wire Russia 25-28 June 2013 UPCAST OY is exhibiting in wire Russia, Moscow 25-28 June 2013. Mr. Anton Zierhut
Meet us at our stand 7-6 D 10! The exhibition is held in conjunction with tube Russia.
Wire South America 1-3 October 2013 UPCAST OY is exhibiting at wire South America, Sao Paulo 1-3 October 2013.
Meet us at our stand No. 636!
The exhibition is held in conjunction with Tubotech. Mr. Eugen Wegmayr
User Meeting in Austria, Vienna 11-13 September 2013 The 7th UPCAST® User Meeting in Vienna 11-13 September 2013.
Meet other UPCAST® family members and hear what’s new!
UPCAST OY | Kuparitie 10 P.O. Box 60, FI-28101 PORI, Finland Tel: +358 (0)207 577 400 Fax: +358 (0)207 577 401