PIM Metal April/May 2022 by ASTAC

PIM METALS INCORPORATING IMT

NEWS

VOLUME 1 c ISSUE 2 c APRIL/MAY 2022

STEEL

PRODUCTS

SMELTING

NEWS

December 2021

Measures Rebar like Never Before Even at highest rolling speeds

High Tech light section measurement

Family owned since 1957, Zumbach is a global leader in the industry. Driven by innovation and experience. We are here for you and ready to build the future together.

PIMM Metals April/May 2022

www.zumbach.com • sales@zumbach.ch

COMMENT/IN THIS NEWS ISSUE

COMMENT

IN THIS ISSUE

elcome to the April issue of PIM metals. With the turmoil in Ukraine still on going we are seeing the pressure on production costs ever increasing. Energy prices continue to soar and the producers of metal tube, pipe, strip and sheet products face an ever-increasing fight to maintain profit margins, in addition some producers also face the possibility of insecurity of energy supply. Energy efficiency is not just limited to the production process but also extends to those producing processing machinery and equipment, whether it is bending, forming, cutting and so on energy efficiency now comes high on the buyers check list.

Welding equipment- technology and consumables, Tube & Wire Düsseldorf preview (20-24 June) Mill energy options and reducing environmental impact, Issue published June 16th

It’s Time: Pick Up Speed In The Digitisation Process

Leicester laser cutting firm cut costs by going green with GoodWe

STEEL

ABB technology to help optimise production for major steelmaker thyssenkrupp

Publisher and Editorial Director

PIM Metals

VOLUME 1, NUMBER 2 – APRIL/MAY 2022 Contact information

KVJ Enterprises, Tralee, Hillcrest Road, Edenbridge, Kent, TN8 6JS, UK

PRODUCTION Anthony Wiffen ASTAC Business Publishing Tel: +44 (0) 1460 261011 Mobile: 0785 161 2799 Email: anton_print_1@mac.com

PRINTING

Tel: +44 (0) 1732 505724

Brown Knight and Truscott

Mobile: +44 (0) 7747 002286

Tunbridge Wells, Kent,

Email: processindustrymatch@virginmedia.com

PRODUCTS

Pipe sizing technology for the perfect inner pipe contour

Cover picture: Laser Cutting - page 13

Vince Maynard

LASER CUTTING

INTERVIEW

Vince Maynard

PUBLISHER & EDITORIAL DIRECTOR

NEWS

Magnetic Analysis Corp. acquires TacTic Ultrasonic NDT Systems

Looking forwards we will see the long-awaited return of Tube & Wire Dusseldorf (June 20-24th). Visitors can register to attend via the website Overview (tube-tradefair.com) For our next issue (June) we will be looking at the following topics and press releases should be received no later than June 3rd.

SMELTING

Plibrico supports ELYSIS in launch of World’s first zerocarbon aluminum smelter technology

EVENTS

Getting fit for future production: Exigo-UK invests in Nukon Fibre Laser display machine at MACH ‘22 PIMM Metals April/May 2022

NEWS

Magnetic Analysis Corp. acquires TacTic Ultrasonic NDT Systems

agnetic Analysis Corporation, a designer and producer of nondestructive

test instruments and systems since 1928, is pleased to announce the asset acquisition of TacTic, a Division of Laboratory Testing Inc. (LTI), effective February 28, 2022. Originally founded as TAC Technical Instrument Corp. in 1962, the company became part of LTI’s operations in 2018. The acquisition will broaden MAC’s range of NDT systems to include automated and specialized immersion, ‘spin the tube’ ultrasonic test systems to detect surface and subsurface

of TacTic’s customers are also

in this new venture. It brings

and years of experience

defects in round tube, pipe,

customers of MAC. Support will

with it many opportunities

during future sale activities.

and bar. These systems are

be handled through our existing

as both companies have

TacTic operations in Trevose,

especially applicable to metal

field network of Engineers and

developed established products

PA will be moved to MAC’s

producers who are looking for

experienced Representatives

that complement each other

Elmsford, NY headquarters

a cost-effective system to test

around the world. With MAC’s

with little overlap. MAC’s

and manufacturing plant.

small batches of material or

wider sales and support and

instruments provide a much-

In addition to expanding

frequent diameter size changes.

the synergies with our existing

needed source for ultrasonic

enhanced sales opportunities

customer base, we expect to

instrumentation designed for

for TacTic systems, customers

MAC President and CEO Dudley

be able to build this into a

production testing of tubular

will gain the advantage of local

Boden noted that “This is a

substantial product line for

and bar products. Moreover,

support, service and calibration

natural fit for us as we have

MAC, bringing this technology

their domestic and international

capabilities provided by MAC’s

partnered with TacTic for a

to customers around the world.”

sales and service teams will

global network of sales and

allow TacTic customers to be

technical staff. For many

In making the announcement,

number of years supplying our

Commenting on the

Echomac Ultrasonic Electronics

acquisition, Fred Beck, who has

served more efficiently. I am

markets, MAC will also be able

for integration with TacTic’s

been serving as VP Sales for

also pleased that our companies

to offer the option of leasing,

systems. Both companies have

TacTic at LTI in recent years and

share a history of family

a choice that has not been

a long history of helping metal

is a son of TacTic’s co-founder,

ownership.”

available to TacTic customers

producers achieve reliable, high-

Kenneth H. Beck, said “I am very

Beck will be assisting MAC

quality inspection that meets

excited about the future and will

during the transition as well as

www.mac-ndt.com

their specific needs and many

continue to play an active role

sharing his technical knowledge

www.tactictest.com

PIMM Metals April/May 2022

previously.

NEWS

World first for Lesjöfors and Wafios

reaking all records, the Lesjofors Heavy Springs group recently installed the largest model

ever made of Wafios wire coiling machinery. In a first for Wafios, the globally recognised leader of wire working manufacturing technology, their massive FUL 226 model has made its debut in the groups Lesjöfors Fjadrar AB site. The €1.75m investment is part of an ongoing future focused growth plan in the groups expanding heavy springs market. Michael Gibbs, Managing Director of the UK factories and Chair of the Heavy Springs group says: “This exciting

(L-R) Jan Carlson, Managing Director & Project Lead David Stolpe, Lesjöfors Fjadrar

new investment cements the

coiling pre-tempered wire up to

Director of Lesjöfors Fjadrar

only enables us to expand our

Lesjöfors group expansion

22mm diameter, with a tensile

says: “As leaders in heavy

product range, it also creates a

intentions in the heavy springs

strength of 2000 MPa.

springs we strive to lead from

new flexibility in material grade

the front, securing the very

opportunities, increasing quality

sector and fuels our teams to

Capabilities have been further

continue to thrive being leaders

enhanced with a new motorised

latest technology to ensure

options, which in turn enables

in spring manufacture.”

wire pay-off, specifically

we stay ahead of the game

us to pass on cost efficiencies to

developed by Wafios to manage

to deliver competitively to

our customers.

10m long, the substantial FUL

the safety requirements of large

our customer base across the

226 can cold coil wire up to

wire dimension coiling.

multiple sectors we serve.

At 40 tonnes and just shy of

30mm diameter in addition to

Jan Carlson, Managing

This latest investment not

Securing this significant investment through our parent company further supports the recognition of growth in the heavy springs sector and we’re delighted to be able to expand our level of delivery to existing and new customers.” David Stople, Project Lead at Lesjofors said: “It was certainly challenging, for us and Wafios, installing such a large and heavy piece of machinery but world firsts are meant to be difficult, aren’t they? Our engineers ensured the installation went smoothly and after a period of intense training, we are now eager to optimise the potential of this new equipment.” More information call Tamsin Loveless Tel: 07855 798536 TAG Communications PIMM Metals April/May 2022

NEWS

Danfoss Power Solutions renames Walterscheid tube-fitting series to Waltech

anfoss Power Solutions has rebranded its Walterscheid series of tube fittings.

Following its acquisition of Eaton’s hydraulics business, Danfoss plans to continue investing in the product line under the new name Waltech. The Waltech name better aligns with the three connection systems that are part of the series: Walpro, Walring and Walform. Danfoss’ Waltech tubefitting series features a leakfree design, high bending and impulse resistance, and a variety of manual and machine assembly options. OEMs and end users rely on the system’s quick, simple assembly and dependable performance, as well as an array of services that help deliver successful project outcomes. The Waltech system is used in

Waltech-tube-fitting-series from Danfoss Power Solutions

hydraulic and fluid conveyance applications across agriculture,

brought in line with the familiar

simple, safe and repeatable

represents a complete system

construction, manufacturing,

red-and-white Danfoss branding.

assembly by hand or by machine.

solution for all tube-fitting

transportation and other industries.

“The Waltech series is known

“Our brand refresh marks

needs. Available for tube

for outstanding performance,

a new beginning. We’ll be

diameters of 6 millimeters to

robust design and leak-free

applying the global expertise of

42 mm, the fittings provide

technical advances and product

operation,” said Christian

Danfoss to build on Waltech’s

exceptional durability and

line additions, the rebrand

Kuenstel, product management

fantastic heritage, engineering

stability as well as a 4-to-1 safety

from Walterscheid to Waltech

leader, Connectors, Fluid

new advances that ensure it

factor.

marks a new era of engineering

Conveyance, Danfoss Power

remains the clear choice for

innovation under Danfoss

Solutions. “It offers a complete

high-performance tube-fitting

Waltech tube-fitting series, visit

ownership. The appearance of

solution for any application

systems.”

the Waltech webpage.

the Waltech series will also be

requirement, while enabling

Following several decades of

PIMM Metals April/May 2022

Danfoss’ Waltech line

To learn more about Danfoss’

www.danfoss.com

NEWS

Corinth Pipeworks awarded contract by Subsea 7

ubsea 7 has

Hasselmus will be manufactured

awarded to Corinth

and coated in ultra-long lengths

Pipeworks (CPW),

at Thisvi facility, Greece and

steel pipe segment

delivered directly to Subsea

of Cenergy Holdings,

7’s spoolbase in Vigra, Norway,

a contract to provide High

where fabrication will take place

Frequency Welding (HFW) steel

for subsequent offshore reel-lay

pipes for the tie- back of OKEA

installation. Offshore operations

Hasselmus gas discovery to the

will be executed

Draugen production platform

Corinth Pipeworks has

in the Norwegian North Sea via

worked closely with Subsea 7

one subsea well. This will be

over the years to develop the

the first subsea tie-back to the

optimised longer length solution

facility executed by OKEA with

allowing early decision making

start-up targeted for Q4/2023.

and accelerated delivery time,

The Hasselmus project is located

ultimately cutting project costs

7km north-west of the Draugen

and improving schedule.

platform. This award to CPW is the

Hasselmus is yet another milestone in Corinth Pipework’s

latest coming from Subsea 7 and

growing offshore presence with

builds on the success of a string

end- users and lay-contractors

of earlier pipeline developments.

recognising the value in the

successful execution of offshore

introduced, advance upstream

latest welded pipe technology for

linepipe projects in global

tie-back project developments

product supplied by Corinth

critical offshore applications.

markets. We strongly believe

like Hasselmus to remain an

Pipeworks for tie-backs, the

Corinth Pipeworks has

technology driven cost reduction

important part of the future

10km of 12” HFW linepipe for

built a strong track-record in

measures, that CPW has

energy mix.

As per the previous successful

PIMM Metals April/May 2022

NEWS

Final acceptance for the world’s highest yielding electric arc furnace

eading metals industry suppliers ABB and Tenova have now obtained final acceptance from their

customer Acciaieria Arvedi, after partnering to deliver an innovative technology package, enabling optimal charging, melting and electromagnetic stirring for the world’s highestyielding EAF. The powerful solution combines a Tenova Consteel EAF continuous scrap charging system with Consteerrer, a model of the well-established ABB ArcSave electromagnetic stirrer designed specifically continuous charging EAF systems. sustainable, efficient and modern

improved continuous casting and

is a unique, patented, non-

arc furnace has a 300-ton

steel operations,” said Zaeim

rolling line, takes into account

contact electromagnetic

tapping size and utilises a

Mehraban, Global Sales Manager,

the requirement for increased

stirring technology that has

charge mix which include Hot

Metallurgy Products at ABB.

productivity and operational

repeatedly been shown to deliver

The record-breaking electric

“We are already working with

flexibility, particularly in relation

a wide range of metallurgical

installed to meet the demand for

a modern plant based on Arvedi

to the metallic charge mix that

improvements. Site results

increased output following the

patented technologies, fulfilling

is of strategic importance in the

confirm that the Consteerrer

recent revamp of the continuous

productivity, technological,

EAF process.

electromagnetic stirring

Endless Strip Production (Arvedi-

environmental, and safety

The careful design of the

system has delivered a range of

ESP) casting and rolling mill line

objectives. An important

equipment and the operational

process improvements, thereby

at the plant.

achievement has now been

results achieved demonstrate

increasing EAF productivity,

“We’re really thankful for the

reached on the melting side

the reliability of the technology

energy and resource efficiency at

seamless collaboration between

thanks to the work with our

involved and the validity of

Acciaieria Arvedi. These include

Tenova, ABB and the Arvedi

partners Tenova and ABB,” said

this approach for the safe

an 18 degrees Celcius lower

technicians and site personnel,

Andrea Bianchi, R&D Director

production of steel with

tapping temperature and a 3.6

and for the great efforts our

at Acciaieria Arvedi. “We are

minimal environmental impact.

percent reduction in electrical

teams have made during this

showing that it is possible to

The new electric arc furnace

energy consumption resulting in

world-class project. We’re very

produce high-quality steel for

has a diameter of 9.1 meters

a 38,000-tonne annual reduction

proud of the contribution our

our customers with the highest

and is continuously fed by a

in CO₂ emissions at the plant.

technologies are making to

output from a single EAF,

Consteel conveyor and the latest

EAF productivity has increased

Acciaieria Arvedi’s ambitions as

reducing the resources and the

generation of Tenova injection

by 5 percent and final oxygen

a steel industry trailblazer,” said

energy we need to use, and

system. A plant of advanced

content in the EAF steel has

Silvio Reali, Tenova Senior Vice

minimising CO2 emissions.”

and innovative technology, as

decreased by 17 percent. Other

demonstrated by the integration,

benefits can be seen in increased

Briquetted Iron (HBI). It was

President.

Acciaieria Arvedi chose

“The metals industry is

Tenova Consteel EAF for

since the beginning of the

scrap yield, reduced electrode

essential for the transition

the second time in 2018,

project, of the Consteerrer

use, lowered refractory wearing,

to a net zero world. Working

strengthening the plant supplied

system designed in collaboration

reduced carry-over slag while

together on this milestone

in 2008. The new installation,

between ABB, Arvedi and

processing is more stable and

project will support Acciaieria

built to comply with the higher

Tenova.

final tapping conditions more

Arvedi to have one of the most

productivity of the recently

PIMM Metals April/May 2022

At the core of Consteerrer

easily controlled.

Fronius Open House

Wed 18 - Thurs 19th May - Milton Keynes Technology Centre We have recently received intelligence that Fronius UK will once again open its doors to unveil the latest cutting-edge technology as it hosts its fifth Open House at its Milton Keynes Technology Centre.

n Access all areas with the NEW Flex-Drive. Never have problems welding those hard to reach areas again. n Find out about our commercial green hydrogen solution: Solhub. The system for local generation, storage and usage of hydrogen from solar energy.

We invite you to take up your Licence to Try - An opportunity to explore the world of Fronius, visit our facility and try our products including the most recent advances in welding technology. And if The

n See how the TPS/i can be easily integrated into various robotic welding systems. n Find out how our unique, intelligent battery chargers can reduce

Weld is Not Enough, we can show you our latest hybrid solar inverter

the energy costs and CO2 emissions of your E-forklifts/warehouse

that recently won first place for efficiency (5 kWp category) in the

trucks – Did you know our range has been extended to include 96V

Energy Storage Inspection 2021. You can also see our new powerful

and 120V models to charge powerful traction batteries for heavy

yet robust, project inverter for high yields, the Tauro, and With a View

duty forklifts? PLUS solutions also now available for LITHIUM-ION

to Kill those energy prices, you can find out about our Fronius Solar Lease scheme where it’s our absolute mission to save you money

batteries. n With Charge & Connect, you can go beyond the limits of

on your bills from the word go. Or perhaps you are interested in our

conventional charging. Increase the performance and efficiency

guarantee to reduce your energy costs across your materials and

of your intralogistics operation with this cloud-based software

handling fleet using intelligent battery charging technology?

solution that provides real-time data on your charging

For Your Eyes Only, we have put together a wide range of demonstrations across our range of products, solutions and applications – including some specially selected guest speakers and industry partners.

infrastructure. n PV installer refresher workshops on Fronius software and web based applications n Hear from an expert on the development and possibilities of Wire+Arc Additive Manufacturing (WAAM).

Due to the success of our previous Open Houses, we have spread this year’s event across two days to allow everyone the time and space to observe demonstrations safely, provide time to speak to our experts and try out products were possible.

n We have a View to Kill those energy prices. We’ll show you how to protect your business with no upfront investment. n See our EV charger, the Fronius WattPilot in action and charge your EV whilst you look around. n Industry leading speakers and exhibitors will be in attendance –

Time: 9:30am – 3:30pm on both days

keep an eye on our social media channels and registration page for

Location: Fronius UK, Maidstone Road, Milton Keynes, MK10 0BD

these as they are announced.

Just a snippet of what you can you expect to see… n Designed to perform: The Tauro, our robust project inverter that

We are serving a hot lunch, with refreshments available throughout

makes commercial large-scale photovoltaic systems even more

the day.

cost-effective.

If you are intending to join us don’t keep it secret! To ensure we can

n Now you have the full freedom to unleash your welding potential: The New iWave Multiprocess Pro. In addition to all the TIG

provide refreshments for everyone please register at: http://www. froniusopenhouse.co.uk and let us know you intend to join us.

functions, you can weld all MIG/MAG process variants with a single system as well as expanding your high-tech welding system

Email or call us to find out more information on 01908 512300.

platform to suit your own specific needs with the Welding Packages

We have so much in store for you to experience throughout the

Standard, Pulse, PMC, LSC, or CMT.

event, including talented performers, plus a vintage classic you may

n Want to weld faster, with less rework? Check out the Fronius

have seen on an assignment or two.

TransSteel Pulse. n See if you can Spy the New MagicCleaner 150/300. This innovative

We look forward to seeing you at our Open House on either the 18th

technology allows optimum reworking of TIG weld seams and

or 19th May. If you register for one day, but need to come on the

stainless steel surfaces in a single step, with minimal impact on the

other don’t worry - we would appreciate you amending online where

material surface.

possible.

NEWS

Quick Fitting rebrands its extremely reliable push-to-connect fittings

uick Fitting,

connections, and get the job

unlike many other connections

technology. Quick Fitting Copper

a leading

done 75% faster than traditional

and seals, greatly simplifying

offers a sharp, professional look,

manufacturer of

methods, including soldering.

installation in wet conditions

a patented dual seal, chloramine-

“The rebranding positions

and in emergency conditions.

resistant design that surrounds

Quick Fitting for the future

Plumbers can work more safely

the connected tubing with a

plumbing, electrical, industrial,

as we roll out our evolving

and efficiently without having to

larger sealing surface, creating

municipal, and OEM applications,

catalog of innovative and

use chemicals or open flames.

a stronger, more rigid, instant

announces that its extremely

reliable connections solutions

reliable push-to-connect

for plumbing, electrical and

ProBite+) delivers superior

fittings with the industry’s best

HVAC professionals and DIYers.”

technology, premium quality,

one of the first push-to-connect

warranty has been rebranded

says Matthew Boucher, Chief

value pricing, and the widest

pipe connection product line

as Quick Fitting Brass, Quick

Executive Officer.

selection of any push fit brand.

available in stainless steel.

The lead-free brass push fit

Plumbers and DIYers can now

innovative and proven pipe

includes patented designed

take advantage of both the ease-

connection technology is

enhancements that deliver

of-installation and reliability of

of high-quality plumbing fittings

warranted to last 75 years,

increased sealing performance,

the Quick Fitting design and the

and valves for Copper, CPVC,

longer than any other

as well as lower insertion forces.

corrosion resistance, food-safety

and PEX plumbing, heating,

conventional method and

compressed air, inert gas and

covering product replacement,

Quick Fitting Copper (formerly

steel.

fluid applications. The fittings

labor and damage. The fittings

CopperHead) raises the bar

For more information visit www.

are reusable, durable plumbing

can be installed wet or dry,

for push to connect plumbing

quickfitting.com/

quick connection technology for

Fitting Copper, and Quick Fitting Stainless Steel. Quick Fitting offers a full range

With 54 U.S. patents, the

Quick Fitting Brass (formerly

Easy, durable, reliable.

connection. Quick Fitting Stainless Steel

and premium look of stainless

SMS group to supply new melt shop to Nucor Steel West Virginia Nucor Steel has awarded SMS group, Inc. the contract to supply a complete melt shop for the new facility to be built in Mason County, West Virginia. The scope includes two 190 metric ton direct current electric arc furnaces (DC EAF), two twin ladle furnaces, and two vacuum tank car degasser facilities. The mechanical supply includes several safetyrelated auxiliaries, the proprietary SMS bottom anode system, two mechanical vacuum pumping systems, and a unique equipment layout designed to minimise

supplied “digital ready”, for

portfolio in the automotive

selection of SMS group. Project

crane movements. The

incorporation into a data

market. The vast experience

completion is anticipated by

electrics & automation supply

driven system.

in supplying liquid steel

2024 with hot commissioning

intended for such grades was

beginning in the second half of

a determining factor in the

2024.

includes an advanced Level 2 system. All equipment is 8

PIMM Metals April/May 2022

The facility is intended to enable Nucor to expand their

NEWS

TRUMPF invests a further 3.2 million euros in Optimate start-up

Optimate optimises the design of sheet-metal parts at the touch of a button / AI and machine learning reduce manufacturing costs / Start-up aims to use investment to expand its activities in the sheet-metal fabrication market

TRUMPF is investing

Optimise part design, reduce manufacturing costs

a further 3.2 million

Optimate’s online platform

euros in Optimate, a

provides an AI-based software

igh-tech company

solution that enables sheet-

solution to help customers

metal fabricators and design

cut costs by optimizing

engineers to optimize parts and

sheet-metal part design.

avoid design errors, thereby

The investment will enable

reducing their manufacturing

Optimate to further expand

costs. The wholly owned

its activities in the sheet-

TRUMPF subsidiary uses its

metal fabrication market.

own in-house algorithm and

“Optimate has already inspired

machine learning system to

real enthusiasm among our

identify how customers can

customers and our design

improve their part design,

the manufacturing steps that

TRUMPF’s in-house incubator

engineers. We’re seeing a

for example by minimizing

drive costs the most.

initiative “Internehmertum”.

growing need for digital

material usage. Optimate’s

assistance systems and cloud-

software can also correct

based services in the industry,

design errors at the touch

and this additional investment

Photo: TRUMPF

start-up that offers a software

“It’s a scheme designed to promote intrapreneurship –

of a button. Users can then

TRUMPF incubator programme paved the way for Optimate

in Optimate will help accelerate

download the optimized CAD

The start-up company was

validate our idea. We hit the

that transformation,” says

file and immediately put it

spun off from TRUMPF in the

ground running from the

Tom Schneider, managing

to use. Optimate is currently

summer of 2020. The founders

moment we were spun off,”

director for research and

working on the next version of

were originally employed by

says Optimate founder Jonas

development at TRUMPF

its software which will identify

TRUMPF and were able to

Steiling. The start-up already

Werkzeugmaschinen SE + Co.

optimisation potential for

successfully develop their idea

employs seven people and aims

KG.

complex components and tackle

into a business model as part of

to grow further.

and that made it the perfect environment to develop and

Corinth Pipeworks wins contract in Australia for hydrogen certified linepipe This award highlights

Corinth Pipeworks, steel pipe

Welded (HFW) line pipe,

future Port Kembla Energy

segment of Cenergy Holdings,

certified to transport up to

Terminal to the existing

the significance of our

announces that Jemena Asset

100% hydrogen, which will

797km Eastern Gas Pipeline.

technologically advanced

Management Pty Ltd has

include FBE coating, internal

At the same time, Jemena is

solution for hydrogen

awarded a contract for their

epoxy lining, and the supply

exploring the role of hydrogen

certified pipes and the

Port Kembla Lateral Pipeline

of induction bends. The HFW

in domestic, transport, and

utilisation of our state-of-

project to CPW America Co,

pipes will be manufactured

commercial settings. As

the-art hydrogen testing

a wholly owned subsidiary of

in Corinth’s facility in Greece

such, Jemena has selected to

laboratory. The pipes

Corinth Pipeworks.

and delivered directly to

utilise Corinth’s solution of

will be tested in-house in

Australia within 2022.

high-grade steel pipes for the

full compliance with the

future transmission of up to

requirements of the ASME

100% hydrogen.

B31.12 code.

The contract covers approximately 13km of 18” diameter High Frequency

The construction of the gas pipeline will connect the

PIMM Metals April/May 2022

NEWS

MACH 2022 ‘A huge success for Unison and Nukon Laser’

Integration, we had an awful lot to catch the attention of visitors. Talking to prospective customers during the show, we gained the clear impression that confidence

ACH 2022 was an

is back in manufacturing and that

unprecedented

companies of all sizes are ready

success for Unison

to invest in the machine tools and

Ltd – the inventors

technologies that will help them

of all-electric tube

achieve their goals.”

manipulation, and for its sister

Such was the success of

company Ingenium Integration

Unison’s attendance at MACH

Ltd – the exclusive UK and

2022, the company has already

Ireland distributors of European-

booked its space at MACH 2024.

built Nukon fibre laser cutting machines. During the event, Unison sold

The Unison and Ingenium Integration/Nukon team members at MACH 2022.

“Rather than having two stands - one for Unison and one for Ingenium Integration with Nukon

one of its newly launched Synergy

laser machine, a 6kW model, has

again,” comments Unison

- as we did this year, we will be

hybrid multi-stack tube bending

been purchased by a specialist in

joint managing director, Alan

bringing all our technologies

machines, while Ingenium

architectural metalwork. Between

Pickering. “With significant

together on one much larger

Integration sold two Nukon fibre

them, Unison and Ingenium

performance enhancements to

stand in two years’ time,” adds

laser machines. One Nukon

Integration secured just short of

our Breeze range of all-electric

Alan Pickering. “As for now,

machine, the Eco 315 2D 4kW

200 serious enquiries at MACH

tube manipulation machines,

we’ve a very healthy order book

model on display at MACH, is now

2022.

our brand-new Synergy range

to fulfil and a lot of MACH-based

to showcase, and the highly

enquiries to pursue.”

on its way to leading commercial

“It was wonderful to be

gym equipment manufacturer,

able to exhibit our world-class

accessible range of Nukon fibre

www.unisonltd.com

Exigo-UK. The other Nukon fibre

technologies at MACH once

laser machines from Ingenium

www.ingeniumintegration.com

Gain the cutting edge. • • • •

2D, 3D and tube fibre laser cutting machines from Europe Accessible high power and high performance – up to 20kW American-made nLIGHT fibre lasers, with adaptive beam optimisation Advanced Lantek CAD/CAM nesting software

• Only from Ingenium Integration in the UK and Ireland

ingeniumintegration.com 10 PIMM Metals April/May 2022

INTERVIEW

It’s Time: pick up speed in the digitisation process The metalworking industry has not yet arrived at digitisation and Industry 4.0. It is high time to remain competitive.

ecarbonisation, electrification, energy transition and sustainability are the future topics for the metalworking industry. Bas Sanders van Well, Business Unit Manager Benelux at Messer Cutting Systems, believes that much more flexibility and agility in the processes in the

industry are needed to be able to cope with these challenges. In his opinion digitisation of production is an absolute prerequisite. We spoke to him about his experiences and asked him about possible strategies. As Business Unit Manager Benelux, you have been in constant contact with your customers since 2017, and you have known the industry since 2013. Where do you currently see the greatest need for action for companies in the metalworking industry? In my view, digitisation is a very important development for the industry. It is currently the key issue for making companies lean. In

Bas Sanders van Well, Business Unit Manager Benelux at Messer Cutting Systems

particular, the shortage of skilled workers plays a decisive role. For some time now, it has been very difficult for many flame cutting

without losing control, personal aspects and contacts to existing

companies to find good technically trained personnel for some

customers. Of course, costs and workload should be reduced. Often

time now. In addition, some of the jobs are not very attractive. The

it is also about integrating existing ERP systems in order to create

topic of digitisation comes at exactly the right time to solve these

a digital workflow without floods of paperwork in production. For all

problems.

these tasks, we see ourselves as equal partners to solve them.

Why should flame cutting companies digitize their processes?

How do you find the right solution and the right implementation

The biggest advantage is that they can do their production more

partner?

smoothly and accurately with fewer resources. An increasingly

Good preparation makes sense for a company that wants to

important aspect are legal regulations and standards that must be

digitise production and processes. In addition, it should be clear

complied with. Steel production and cutting suffer more and more

that digitisation is a process and is usually implemented step by

from the effort and the requirements for documentation, registration

step. When selecting the right partner, one should ask a number of

and traceability. With the help of digitisation, these things have

questions and research offers on the market accordingly. The most

become very easy for digitized production and can be done with little

important questions are:

administrative effort. Software solutions provide great support and ensure the necessary automation of the production processes. How should a company start the digitisation process? There is now a large selection of providers of digitisation solutions. This means that there are enough options on the market to cover most needs for digitizing processes. But finding the right overall solution of machines, software and automation is quite difficult. The key here are the open interfaces. Because often several providers

c Is it possible to connect this solution to existing software systems? c Can this solution also be implemented on my other third-party machines? c How good is the local/international support? c How are the updates and further development of the solution regulated after my purchase? c Do I always enjoy the latest developments? c Do I have any influence on the development?

have to come together to connect the systems and create bridges of

It is also important that all project partners involved pull together.

digitized communication.

You always need third-party software, mostly that of the ERP

We are most frequently asked about digitisation projects when

systems. There are many effective packages for ERP solutions that

companies want to expand their production and need additional

have been launched on the market and that are already in use in most

Messer machines to do so. This is often combined with the desire to

companies. Open interfaces then give the customer the opportunity

digitize production as well. The task is usually to digitize the company

to choose the best from different worlds. We work together with PIMM Metals April/May 2022

INTERVIEW various providers. This means that our customer can enjoy a practical basis as a reference for a deal or comparison. What are the particular challenges of a digitisation project? Well, you always need a proactive approach on the customer side. This means that there must be someone in the company who is responsible for managing and driving the project. In addition, some knowledge of IT and software in the company is necessary. Because a 100% outsourcing to the project partner is extremely difficult. It’s no longer just about machines, but about the digitisation of processes. This has far-reaching consequences for the entire company. You should be clear about that. The challenge for the external partner, like us, then lies in finding a solution to cover all of this together and thus help the customer. Messer Cutting Systems is straightforward and, in my view, currently number one, offering both worlds, i.e. machines and software, from a single source. This allows us to get the best out of the machines. Once the decision to go digital has been made, what happens next?

Production is automated to the greatest possible extent and exclusively controlled from a control room. In fact, one of the biggest benefits we see from our customers is the

The first step is to understand the existing processes and their

tracking, monitoring and traceability of products and cut components.

connections in your company. The next step is to define the best

But also fast reaction times in the preparation of offers and

options where you can optimize your production and shorten and

production planning mean that our customers are really enthusiastic.

digitize workflows. Once this evaluation has been completed, the new

We have customers who have permanently won back lost customers

workflows are displayed and the ideas discussed with the project

because they can provide them with precise data, prices and dates on

partners. Of course, the implementation can take place step by step

an ad hoc basis. Customers appreciate that.

and in clearly defined phases. Sometimes the digitisation project can

Of course, digitisation solutions also ensure efficiency and cost-

get to such a scale that the impact on the business is too big, and we

effectiveness. You save time when receiving orders, in planning,

recommend our clients to split the project into several parts. For a

production and business process analysis. Everything is faster,

successful implementation, you should always bring your production

without media breaks and ensures reliable planning. You save

management, IT, work preparation, nesting and the board together to

resources, make better use of your machines and gain time for

move the project forward.

additional processes. You can reduce personnel costs and minimize

Here are the most important project steps again: 1. Analyze and evaluate your current situation internally. 2. Define your desired situation.

downtime costs. Are there also advantages for the employees?

3. Work out a solution with your project partner and define the details.

Yes of course. Every single employee has the opportunity to work

4. Have the project partner create a test environment on site.

paperless and digitally. Digitisation solutions enable everyone

5. Implement the defined solution, step by step if necessary.

involved to track the entire production flow. Due to automation,

6. Follow up with your project partners after a few months.

work becomes easier and faster. It’s more fun and well-motivated

How long does a digitisation project take? Of course, this always depends on the complexity. In general, it takes between three and nine months from ordering the solution

employees stay with the company longer. Which future trends are important and how will digitisation solutions develop?

to implementation, quality assurance and acceptance. The better

I see the focus on the complete digitisation of the workflow in

and closer the cooperation between those involved, the more open

combination with the automation of loading and unloading the

the communication, the better things will progress. We have found

machines. The future is the unmanned production factory.

that a continuous contact process combined with a well thought out

Digitisation will change existing jobs extensively. Work will change.

plan with written requirements for both parties is the best recipe for

The entire production will change in the future. Everything will be

success.

done much faster and will save resources. First of all, you have to

Messer Cutting Systems offers itself as a partner for complete solutions. We listen to our customers and meet them where they are.

understand this and adapt to it. However, many companies are far from having arrived there.

If you use our solutions, you have the opportunity to continuously

Although they know that digitisation is inevitably coming their way,

develop and improve them with us. We use your information to

they have not yet done too much in this direction. Here I see an acute

include them in new solutions.

need for action in many areas so that the development is not missed

You have already implemented numerous digitisation projects for your customers. So, what did it actually do for customers?

PIMM Metals April/May 2022

and the competitiveness of European companies lags behind the aggressive Asians. Mr. Bas Sanders van Well, thank you for the interview.

LASER CUTTING

Leicester laser cutting firm cut costs by going green with GoodWe GoodWe inverters power ADS Laser Cutting’s site in Leicester helping them slash energy costs and carbon emissions.

oodWe, a

generated by solar panels on

world leader

ADS Laser Cutting’s East-West

in photovoltaic

roof.

(PV) solutions, partnered with

Eugene Lucarelli, marketing manager at GoodWe UK, said:

Environmental Roofing Services

“We are very happy with ADS

(ERS) and ADS Laser Cutting

Laser Cutting’s decision to make

to provide a green supply of

the switch to solar power. We

energy and protection from

designed the HT inverter to save

rising energy costs.

users money on installation

Once the site of Fox’s Glacier

and energy bills, and they have

Mints, the factory now bears an

taken great steps with GoodWe

array of iceberg-saving solar

to futureproof themselves

panels and GoodWe inverters.

against further energy price

In January 2022, four GoodWe

increases.”

100kW HT inverters were installed to convert PV energy

Following the successful installation, another 400kW of GoodWe solar inverters have

come a long way in the past

been authorised, bringing the

several years, and we are glad

total capacity to 800kW once

to be using it to power our site,

the project is completed. ADS

knowing the good we’re doing

Laser Cutting’s solar setup will

for the environment.”

save an estimated 414,000KG of

Solar energy is a crucial

carbon emissions, similar to the

element for many businesses

annual carbon produced by 90

facing skyrocketing energy

cars driven for one year.

costs. According to the Office

ADS Laser Cutting chose

for National Statistics in

GoodWe’s HT inverters for their

February 2022, 12-month

high efficiency and small size.

inflation rates for gas and

Exceeding 100kW, they are

electricity are at their highest

designed to reduce the LCOE

level since early 2009, with

(Levelized Cost of Energy) and

gas at 28.1% and electricity at

maximise wattage in a small

18.8%.

footprint, making them the

Mark Powell, sales director

natural fit for commercial sites

at ERS, said: “It’s great to see

in the UK.

ADS Laser Cutting deciding to

The carbon savings of ADS

go solar. The technology is more

Laser Cutting’s installation will

affordable than ever and, with

equal just under 1,000 barrels

energy prices increasing, it’s

of oil. Duncan Keates, managing

not surprising companies like

director at ADS Laser Cutting,

ADS Laser Cutting are making

said: “We are proud to double-

the smart choice to have solar

down on our commitment to

panels and inverters installed.”

renewable energy. Solar has

goodwe.com. PIMM Metals April/May 2022

STEEL

ABB technology to help optimise production for major steelmaker thyssenkrupp as part of plant revamp and new build

BB has been awarded a major contract by Primetals Technologies to

help optimise production at thyssenkrupp Steel Europe’s (tkSE) Duisburg-Bruckhausen plant in Germany, using the unique and proprietary ABB Flow Control Mold electromagnetic stirring and braking technology for higher quality steel produced faster and at lower cost. The construction of a casting rolling mill and the upgrade of an existing continuous casting plant is part of a wider project awarded to Primetals Technologies, a global leader in plant engineering for the metals industry. It is part of tkSE’s Strategy 20-30 which aims to optimize operations for

Mold uses electromagnetic fields

goals, while contributing to

quality products for demanding,

the requirements of automotive

to control meniscus flow speed

the company’s Strategy 20-30

state-of-the-art applications.

customers seeking improved

and fluctuations. It enables

ambitions to meet customer

It has set itself the goal of

surfaces, thinner and high-

improved process control and

requirements for higher

producing three million tons

performance steels to meet

increased resource efficiency,

performance steel grades,”

of CO₂-neutral steel a year by

crash safety standards in the

requires very little maintenance

said Zaeim Mehraban, Global

2030 as the industry moves

growing e-mobility market.

and typically has a long lifespan.

Sales Manager, Metallurgy

towards climate-neutral steel

Products at ABB. “Backed

production by 2050 in line

sites worldwide, performance

by decades of experience

with the UN Paris Agreement.

can prevent gas bubbles and

improvements delivered by FC

working with plant builders, like

Primetals Technologies is a

impurities from becoming

Mold technology are well-proven.

Primetals, and knowledge of

pioneer and world leader in

trapped in the solidifying steel

Typically, these include 50%

metallurgical processes such

the fields of engineering, plant

as the technology will offer

reduction in defects and up to

as slab casting from numerous

building, and the provision of

simultaneous stirring and

80% reduction in rejected or

installations worldwide, ABB

lifecycle services for the metals

braking from one fixed position

downgraded product. In addition,

continues to devise solutions

industry.

on the caster. In continuous

FC Mold can allow for a higher

to solve bottlenecks in steel

slab casting, conditions in the

casting speed.

and aluminium manufacturing

to: https://new.abb.com/

processes and repeatedly prove

metals/abb-in-metals/

they are effective.”

offering/products/metallurgy-

By using FC Mold G3 (generation 3), thyssenkrupp

With an installed base at 40

For more information go

meniscus area of the solidifying

“By significantly reducing

steel are crucial to determining

defects, rejects and downgrades

end-product quality and have

the FC Mold will improve cost

a major impact on productivity

and resource-efficiency at

world’s leading producers of

stirrers-and-brakes-for-steel/

and overall operating costs.

tkSE, thereby supporting both

carbon flat steel and drives

electromagnetic-devices-for-

Integrated with the caster, FC

sustainability and profitability

innovation in steel and high-

slab-casting

PIMM Metals April/May 2022

thyssenkrupp is one of the

products/electromagnetic-

PRODUCTS NEWS

Pipe sizing technology for the perfect inner pipe contour

in a short amount of time.

t TUBE, Dango &

The first PST-PE-EX machine,

Dienenthal (D&D) will present laser-

currently being manufactured by

assisted calibration

D&D for a German manufacturer

of large-diameter

of large-diameter pipes, will

pipes for the first time. The

straighten and expand the

machines of the PST series

ends of pipes with diameters

achieve unprecedented levels

between 270 and 1,016 mm with

of precision. At the same time,

wall thicknesses of up to 60

they drastically reduce the time

mm. Here, too, the circular laser

required for straightening and

provides the inner contour of the

allow complete documentation of

pipe end, which is used to control

the inner contour.

the pressure cylinder. Denis Albayrak, Senior Sales

The basic new feature of Pipe Sizing Technology (PST)

Engineer at D&D, places great

is that a 360° circular laser

importance on precise laser

measures the inner contour of

measurement: “The demands on

the pipe during the straightening

the quality of pipes – especially when it comes to optimal

process, with the results being circumference.

roundness – have grown steadily

immediately incorporated into

measuring points over the entire

the process. The machines of the

circumference of the pipe. In

PST series are generally used

this way, the complete image of

measuring and forming, the

manufacturers with enormous

for straightening. The PST-PE-

the inner contour of the pipe is

systems drastically reduce

challenges. With Pipe Sizing

EX version is also capable of

created in real time. This data

the time required for handling

Technology, we replace “trial

expanding the pipe ends, while

is the basis for controlling the

the pipes. This means that

and error” with exact measured

the PST-FB version (full body

straightening tools.

considerably more pipes can

values. After sizing, the finished

be straightened per shift than

pipes have a perfect circular

machines are equipped with

with conventional systems.

shape, while the specified

The laser mounted in the

six expanding jaws, which are

For example, laser contour

nominal diameter remains

measuring head projects a line

precisely controlled according

measurement makes it possible

unchanged.”

onto the inner wall of the pipe.

to the results of the laser

for the first time to measure

A camera, also located in the

measurement. The result:

each individual pipe and

be exhibiting at TUBE 2022,

measuring head, captures the

the pipe is not expanded, but

document its geometry – such as

Düsseldorf, June 20–24, at Hall 5,

circular line with up to 3,200

instead retains its original inner

inner circumference and ovality –

Booth 5F08

sizing) straightens the pipes over their entire length.

For sizing, the PST-PE

Since the Pipe Sizer combines

in recent years, presenting pipe

Dango & Dienenthal will

PIMM Metals April/May 2022

PRODUCTS

New Oseon software from TRUMPF boosts productivity in connected manufacturing Oseon software allows users to fully automate the flow of materials on the production floor without linking it to a large-scale storage system. Production staff can see all relevant data on the manufacturing process and on upstream and downstream activities in one intuitive display – no paper, no switching between different media, and no need to leave the shopfloor. Oseon can boost productivity by up to 20%

igh-tech company

market-leading position as a

need to invest in a large-scale

parts that are required on the

TRUMPF will be

solution provider for digitally

storage system. “Oseon lets

shop floor.

presenting a new

connected manufacturing. As

users synchronize material flow

software package

well as reducing downtime

with their production schedule.

for production

and non-productive time, the

So they can respond even faster

Constantly keep track of orders

scheduling and control at its

software also makes a better use

and more flexibly to unexpected

The TRUMPF developers rely

Digital Summit in-house trade

of machine capacity and makes

events such as rush orders, as

on a combination of barcodes

fair on April 6, 2022. Companies

life easier for employees. And

well as processing more orders in

and smart docking stations

can use the new “Oseon”

the resulting productivity gains

less time,” says Liertz. Once the

to efficiently manage the

software to create significantly

can be as high as 20 percent,”

user has loaded their production

flow of materials. Each pallet

leaner production processes and

says TRUMPF product manager

schedule into Oseon, the

transported by cart or trolley

make major gains in productivity.

Wolfgang Liertz. The software

software takes over the task of

has a barcode. After placing the

The software includes a range

is easy to deploy in any sector

managing many of the factory’s

machined parts on the pallet,

of new options for managing

thanks to its open interfaces.

logistics processes. Oseon

the worker scans this barcode

receives continuous process data

with a hand-held scanner,

updates from all the production

thereby “wedding” the pallet

machinery. As well as the data

to that particular batch. Next,

production workers a clear

Smooth flow of materials even without large-scale storage

from the production schedule

the worker pushes the cart

display of all relevant production

The software allows users to

and machines, the software also

into a special docking station

data directly within their work

fully automate the flow of

holds information on batches,

developed by TRUMPF that

environment. “Oseon once

materials on the shop floor,

material stocks, the locations

includes various built-in sensors.

again demonstrates TRUMPF’s

potentially eliminating the

of each cart and trolley, and the

Alternatively, this journey can

the transportation of materials in a flexible and automated fashion. Oseon also offers

be made autonomously by an automated guided vehicle (AGV) controlled by Oseon. As soon as the cart or AGV has successfully docked, the docking station sends all the information to Oseon. Now the software has all the data it needs to efficiently organize the transportation of the materials.

Smart software As well as automatically selecting the right sequence for transporting materials, Oseon also automatically sends transportation orders to free AGVs and to workers with carts. Photo: TRUMPF

In this way, it ensures that the materials are always in the right place at the right time. If the company receives an urgent

PIMM Metals April/May 2022

MACH PRODUCTS 2022 order, Oseon can easily adapt to