Roll Pass Design

The perfect fusion of art and technology that ensures flexibility, stability and quality in your rolling mill.

Roll Pass Design is a complex problem due to the large number of processing conditions involved. Our purpose is to ensure the correct production of roll profiles within the constraints of the mill complying with quality standards, minimum cost and maximum output.

Teksmithe's approach combines the application of sophisticated process models and computer aided simulations to achieve the optimum number of passes with the desired geometry, avoiding roll defects while maximizing the reduction in the cross section area per pass. This is normally achieved by considering the geometrical, mechanical, thermal, thermomechanical and metallurgical behaviours of the entire rolling system.

Our team of experts can deliver exactly what you need:

• Flow charts
• Detailed pass design and groove details
• Power calculation through simulation (motor sizes, gear ratios, and rolling)
• Set-up sheets
• Pass schedules

What do we look for?

• Rolling “flexibility”
• Increase in overall life of rolls
• Process stability
• Reduced tolerances
• No surface defects
• Micro structure optimization
• Minimum consumption of energy
• Minimum internal stresses in finished product

Process Consulting

Unparalleled experience and steel process know-how.

Our process consulting service team helps producers achieve and maintain high standards in production excellence. Based on decades of experience in steel rolling mills worldwide, our specialists are skilled in proposing how to improve mill efficiency.

Teksmithe's process consulting services include:

• On-site operations consulting for Small & Medium Section & merchant bar Mill.
• Production assistance
• Commissioning assistance
• Full training packages
• Custom design projects
• Engineering consulting
• Metallurgical support
• Retainer packages for real time troubleshooting

By collaborating with Teksmithe steel solutions, steel producers can be assured of continual production excellence at their plants.

Operational Support and Improvements

Our technical team has a 100% focus on delivering operational support and improvements to long product rolling mills. Different from other suppliers, which fold customer service into other areas, this team is solely dedicated to making mills run better.

Our multi-disciplinary service team consisting of operations, mechanical and electrical experts offer:

• Process optimization
• Modern methods of process analysis
• Custom equipment design
• Small and medium sized upgrades
• Customized solutions

Customer satisfaction requires having continual close customer contact. Our process consulting team has purposefully been structured as a small team to provide a more personalized service.

Automation & Drives

Fine-tuned rolling mill control solutions to improve process stability, minimize downtime and maintain a consistently high quality product.

The Teksmithe automation team has a unique combination of long product process knowledge and electrical system knowledge to ensure our technology solutions increase mill productivity, provide consistent production and premium product quality. Our high customer retention rate is our best indication of superior technology performance.

Why choose a single brand when you can benefit from the latest technologies offered by the top brands in control and automation?
Depending on your current equipment configuration and preferences we propose the best combination of equipment to upgrade your rolling mill.

• Deep knowledge of the most widely used OEM automation platform
• Flexibility to work simultaneously with different brands
• Standard hardware
• Easy integration with existing systems
• Same know-how applied to all platforms
• Open standard programming

We use standard, non-proprietary hardware in all our system designs to ensure multi-sourced, long-term service, and enhancement capabilities, which protect your investment.

Multi-Phase Revamping

We understand how difficult it is to obtain the financial resources for a whole rolling mill revamping. Multi-phase revamping shifts your CAPEX to OPEX, helping you maintain a lean balance sheet. We propose the best approach for your specific scenario, reusing your existing control equipment to optimize project expenditures.

Our Control An Industry Reference

Our system makes sure our customers roll their products with ease, taking advantage of today's latest advancements in rolling process technology. Decades of experience an dozens of mills working with our control is the best of the guarantees that we can offer.
Long product rolling automation is a challenge due to its high speeds and different parametrization to produce a wide range of steel grades, shapes and dimensions. As a result our engineers have developed and algorithms that minimize manual operator inputs to ensure reliable rolling.

Cascade Control

Cascade Control uses the reduction concept (R-Factor) to calculate the mill cascade speed reference. This parameter, directly related to rolling fundamentals, simplifies the setup and operator control. During production the loop and tension control automatically adjust the R- Factor, ensuring minimum material stress between the stands. No matter if you have one strand or two we have the solution for controlling your mill.

Impact Speed Drop Compensation

The system speeds up the stand during the head threading, reducing the speed drop when the material impacts the rolls. Once the bar is inside the stand, the control changes back to the mill cascade speed reference.

Tension / Loop Control

Tension and loop control reduces the material stress along the mill,to diminish dimensional and metallurgical defects. Teksmithehas developed and improved this control module over the years, ensuring the right response in all situations.

Shear Cut Control

The performance and accuracy of the shears in a mill is critical to increase the yield and avoid problems when the bar enters the stand. Over the years,Teksmithehas implemented our control configurations on a gamut of different platforms. Today our shear control is a reference in the steel industry.

Automatic Cobble Detection

Our automatic cobble detection is designed to help operators react faster to unexpected events and continuously track the bar. If a cobble occurs, the system automatically reacts to minimize the effects; commanding the upstream shears to chop the existing bars block the furnace from sending another billet.

Laying Head Control

Correct positioning of the laying head synchronized with the bar front end ensures that it always leaves at the correct position and eliminate snagging in the cooling conveyor.