Tenova Modernizes Marcegaglia’s 20-Hi Cold Rolling Mill: Paving the Way for Future Manufacturing Excellence
Tenova, a global leader in developing sustainable solutions for the green transition of the metals industry, has secured a significant contract with Marcegaglia Gazoldo Inox to modernize and restart its 20-Hi Cold Rolling Mill located at the Gazoldo degli Ippoliti plant in Mantua, Italy. This exciting collaboration signals a leap forward in automated manufacturing technology for the steel and metal industry.
The modernization of the 20-Hi Cold Rolling Mill will include the implementation of cutting-edge automation and digital tools that aim to optimize production efficiency, improve rolling accuracy, and increase the overall reliability of the mill’s operations.
Scope of the Modernization Project
The revamping of the mill will involve a number of advanced technological upgrades designed to meet the evolving needs of the steel industry. Key features of the modernization include:
• Advanced Level 1 and Level 2 Automation: These systems will enhance the mill’s ability to control and monitor its operations at all stages of production, allowing for real-time adjustments to improve rolling efficiency and product quality.
• Next-Generation Human-Machine Interface: The introduction of a more intuitive HMI will allow operators to control and monitor processes more easily, providing better control over the mill's operations.
• Machine Learning Applications: These tools will optimize the rolling pass schedule, ensuring the most efficient rolling configurations and improving the overall speed and quality of production.
• Advanced Roll Cluster Configurator: This smart system automatically selects the optimal roll sizes required for different rolling configurations, ensuring that each batch of metal is processed with the correct setup for maximum efficiency.
• Vibration Monitoring: The integration of vibration monitoring will enhance process stability, ensuring that the mill operates without disturbances that could affect production quality or equipment longevity.
Expected Outcomes of the Modernization
The integration of these sophisticated systems and tools is expected to result in a variety of performance improvements for Marcegaglia's 20-Hi Cold Rolling Mill, including:
• Higher Rolling Accuracy: With better automation and digital monitoring, the mill will be able to produce more accurate rolled products, ensuring consistent quality across batches.
• Improved Process Stability: The use of machine learning and vibration monitoring will lead to more stable operations, reducing the likelihood of breakdowns or production slowdowns.
• Enhanced Operational Reliability: With automation taking over some of the manual processes, the mill’s operations will become more consistent and reliable, with fewer errors and interruptions.
• Increased Production Volumes: The mill will be able to handle higher production volumes thanks to the optimized rolling schedules and increased machine reliability, allowing Marcegaglia to meet growing market demands.
• Expanded Product Portfolio: With the revamped mill’s increased capabilities, Marcegaglia will be able to offer a broader range of products, catering to diverse customer needs in the cold-rolling industry.
• Flexibility in Production: The digital tools and AI applications will allow Marcegaglia to quickly adjust to different product specifications, offering greater flexibility in responding to customer demands.
Leadership and Strategic Vision
The modernization project is a strategic milestone for both Marcegaglia and Tenova, with Paolo Tenca, Project Leader and Chief Technical Officer at Marcegaglia, expressing his confidence in Tenova's ability to help them restart the mill with the most advanced automation and rolling models available. Tenca noted, This modernization marks a key step in reactivating one of the most modern 20-Hi cold rolling mills, integrating state-of-the-art automation and digital solutions to enhance performance and efficiency.
Leonardo Frascino, Head of Cold Rolling Product Line at Tenova, shared his excitement about partnering with Marcegaglia on this critical project. The integration of advanced automation systems and artificial intelligence will optimize Marcegaglia’s mill performance, ensuring production efficiency and operational flexibility, Frascino said. This collaboration exemplifies Tenova's commitment to driving the future of digital and automated manufacturing in the steel and metals industry.
The Road Ahead
The revamped 20-Hi Cold Rolling Mill is expected to be fully operational by early 2026, with the goal of achieving significant improvements in rolling accuracy, production efficiency, and product portfolio expansion. With the strategic integration of advanced digital tools, AI, and automation, the mill will not only meet the increasing demands of the cold rolling industry but also set new benchmarks for the industry as a whole.
Marcegaglia’s investment in technology and digital transformation aligns with their long-term goals to maintain leadership in the steel industry, while simultaneously pursuing more sustainable and efficient production methods to reduce their environmental footprint.
Key Takeaways
• Contract Awarded: Tenova has been awarded the contract to modernize and restart Marcegaglia's 20-Hi Cold Rolling Mill at the Gazoldo degli Ippoliti plant in Mantua, Italy.
• Advanced Automation: The project includes the installation of Level 1 and Level 2 automation, next-generation HMI, and Machine Learning Applications to optimize rolling pass scheduling.
• Enhanced Roll Management: The implementation of the Advanced Roll Cluster Configurator will allow for automatic selection of optimal roll sizes for different rolling configurations.
• Vibration Monitoring: Integration of vibration monitoring systems will improve process stability and overall production efficiency.
• Expected Benefits: The modernization will lead to higher rolling accuracy, increased production volumes, expanded product portfolio, and improved operational reliability.
• Digital and AI Integration: The incorporation of digital tools and artificial intelligence will ensure Marcegaglia's mill achieves better production flexibility and enhanced operational efficiency.
• Operational by 2026: The revamped mill is expected to be fully operational by early 2026, setting new industry benchmarks for cold rolling performance and flexibility.
• Sustainability and Efficiency: Marcegaglia’s investment in state-of-the-art automation reflects its commitment to improving operational efficiency while supporting green transition efforts in the steel industry.
This modernization marks a significant step for Marcegaglia and Tenova as they pave the way toward a more automated, efficient, and digitally advanced future for cold rolling mills globally.
