The Pesmel approach to aluminium intralogistics

The global aluminium industry is characterized by continued growth in demand and supply. As a cornerstone of modern manufacturing – vital to automotive industry, construction, packaging, and electronics – its efficiency is dependant on the flawless execution of every step in the production and supply chain process. However, the very properties that make aluminium so valuable, its softness and malleability, also present significant logistical challenges within the rolling mill.

Aluminium coils are highly susceptible to surface damage. Scratches, dents, and deformations can easily occur during transport, compromising the value of the final product. Furthermore, coils emerging from hot rolling at temperatures of 300 to 400 °C require precise, controlled cooling before they can be processed further. Traditional handling methods, which often rely on manual crane and forklift operations, struggle to meet these demands, leading to potential product damage, production bottlenecks, inefficient use of space, and even safety hazards on site.

Pesmel’s offering is particularly well suited for aluminium processing following hot rolling. The mid-stream processes can benefit from efficient and uninterrupted material flows between the functions, where the high-bay warehouse acts more like an internal logistics hub or buffer for materials in different phases of production.

A new paradigm – more than just storage

We offer customers a comprehensive, automated material handling and storage solution engineered to be the intelligent heart of the aluminium rolling mill. By positioning a high-bay warehouse as a central work-in-progress (WIP) storage buffer, the system seamlessly integrates the cold rolling mill’s subsequent processes, such as annealing, degreasing/tension levelling, brushing, polishing, slitting, cutting, and packaging.

The one-stop-shop concept is built on 50 years of material handling expertise and is designed to solve the core challenges of aluminium production. Our solution both respects the material and ensures the accurate continuity of operations.

Gentle handling ensures quality

Preserving the integrity and surface quality of every coil is a priority. Pesmel’s system eliminates the risks associated with conventional handling. Coils are managed by automated cars and stacker cranes that provide gentle, damage-free transport and support from underneath. This automated approach is crucial for maintaining perfect coil shape and preventing costly surface defects, scratches, and edge damage.

Optimized space, safety and throughput

Floor space is a premium asset in any production facility. The vertical design of the high-bay warehouse optimizes the facility footprint by taking storage skyward. This is valuable for confined mill environments in both brown and greenfield projects where space is limited.

Engineered for high throughput, the system ensures all process lines are fed in a timely and accurate fashion for uninterrupted production. The automated environment drastically improves personnel safety by removing the need for staff to work in close proximity to moving coils and heavy machinery.

Controlled and individualized cooling

A key innovation in Pesmel’s solution is the advanced coil cooling system integrated into the warehouse. It offers an improved alternative to traditional forced-air systems where the cooling of individual coils cannot be adjusted. With targeted cooling provided for each individual storage position, the system manages and affects the temperature of individual coils to a higher degree of accuracy.

Targeted cooling allows the system to avoid significant energy wastage and the risk of condensation forming on coil surfaces – both issues associated with indiscriminate aggressive cooling. This controlled cooling process ultimately results in a more consistent, predictable, and higher-quality final product.

The intelligence behind the muscle

The entire system is orchestrated by Pesmel’s proprietary Warehouse Management System (WMS), the brains behind the operation. It is linked to the customer’s ERP, MES and other mill control and information systems. This software platform provides full traceability in real time. It knows the exact location, status and cooling data for each individual coil from first contact to final dispatch. In addition, the solution supports advanced production optimization. The WMS manages storage and cooling times, directs all material flow, and intelligently feeds coils to the correct process lines in the requested order.

System simulation using WMS Digital Twin

The design and construction of a high-bay warehouse is in the core of the customer solution. However, before a single piece of warehouse shelving goes up, the entire system’s logic, material flow, and performance are simulated and verified using our Digital Twin. This guarantees a smooth, predictable ramp-up and allows foconfident lifecycle management and predictive maintenance planning that maximizes process uptime.

Delivery based on understanding of the customer process As a comprehensive partner, Pesmel delivers a complete, turnkey solution – from initial design and engineering to the physical warehouse, automation equipment, intelligent software, and full lifecycle services. By understanding the demands of the aluminium industry, Pesmel provides an integrated solution that not only protects the product but also boosts safety, efficiency, and throughput, future-proofing the heart of the modern rolling mill.