Metal industry

Solution design

We design layout concepts for internal logistics and material flow through the mill. Our solutions have been expertly designed and engineered to serve the needs of each individual customer. Tailoring is essential due to variations in production parameters and mill site preconditions as well as end customer needs and requirements. We work in close cooperation with our customers and plan functional, highly automated solutions for both brownfield and greenfield projects. All systems are designed according to the latest safety regulations.

Feasibility study

Real-life situations and conditions at the site are simulated using 3D models of planned or existing production. This is done to understand and analyze operations and identify potential bottlenecks. At the end it will help us optimize the mill layout and our customers to make the correct investment.

Process simulation, part of the feasibility study, allows us to anticipate situations that we could not otherwise prepare for. The adaptive model can be manipulated to simulate exceptional situations or possible future needs. Logistics and buffering functions as well as guidelines for the control system can also be defined.

Project implementation

Pesmel has more than 40 years of experience in delivering material handling projects. With deep knowledge and insights into the mill processes, material flows and end customer requirements we excel in delivering solutions in mechanics, electric, PLC and ICT. Our in-house experts in engineering and manufacturing fulfill the highest international standards and country-specific quality criteria.

As a total system supplier Pesmel takes overall responsibility for the project from pre-engineering to hand-over. Project implementation includes full equipment and system engineering, manufacturing, assembly, testing and commissioning, and work safety is of prime importance throughout the project. We also offer comprehensive training for operators upon commissioning and throughout the lifecycle of our solution.

Automated internal logistics integrate the production processes and material handling functions into one efficient system. Automated handling ensures fast and accurate material transfers between processes and provide full control of all the material flows on site. This in turn means no damages, no lost products and no errors in deliveries.

Pesmel provides a fully automated yard management system (YMS) specifically designed to oversee and control the entire mill logistics in an efficient manner. It has built-in automatic re-routing and recalculating capability of material flows giving production full redundancy. The YMS with yard mapping becomes essential when the number of coils to be handled, tracked, processed per hour increases beyond the value which can be handled manually. It is often used in conjunction with warehouse management systems (WMS) and transportation management systems (TMS). It may also have bar code or radio-frequency identification (RFID) technology built in for faster and more accurate tracking.

Automated logistics for coils is done with modern coil cars and 4-way cars, which bring the needed flexibility to product transfers. Coil cars work independently, enabling efficient buffering and restocking after rush hours.

Pesmel’s packing lines are designed to provide leading protection for your valuable end products, while at the same time optimizing the usage of packaging materials. A high degree of automation increases employee safety and reduces the risk of human error.

Our packaging lines are modular in design, making them easy to adjust to meet prevailing requirements. Each customer’s specific needs, such as space considerations, capacity and packing code requirements are taken into consideration.

Our packing systems all have fully automated functions with high capacity. One line can effectively serve several slitters or production lines simultaneously. Pesmel’s through-the-eye TEW packing technology provides excellent protection against moisture. Furthermore, various packing materials are automatically applied to protect against mechanical impact. This modern method is highly competitive in terms of total cost of ownership.

Pesmel packing systems are designed with environmental aspects such as material usage, recycling as well as energy savings in mind. Packing can be carried out with 100% recycled materials and completely without VCI chemicals. Packing quality is never compromised, but rather improved in comparison to conventional methods.

Pesmel’s unique high bay storage solution is at the heart of the Material Flow How® Concept delivering unparalleled capacity, accuracy, safety and reliability through advanced automation. A well-planned solution helps reduce the footprint of the storage facilities in both greenfield and brownfield projects. The system keeps track of inventory and reduces risks related to manual storage and handling. The storage is integrated to the mill process providing high performance and availability without bottlenecks.

The WMS (Warehouse Management System) controls material flow between different processes, optimizing storage and logistics functions, increasing the total system capacity and decreasing operational costs. The system buffers products and transfers them between various phases of the manufacturing process. A smart, unmanned solution is not just safer, it also allows for flexibility, adaptability to changing circumstances, shorter shipment times and better customer service.

The Pesmel Material Flow How® concept does not only cover our automated solutions but support and services across the process lifecycle. A comprehensive service agreement ensures availability through regular maintenance operations as well as fast troubleshooting in unforeseen circumstances. Minimizing the risk of unplanned and expensive downtime is a part of our service ethos.

Maintenance

Regular maintenance guarantees high availability and extends the lifetime of the system. Preventive maintenance minimizes unexpected repairs and helps to keep total investment and operational costs in balance. Regular checks and adjustments ensure reliable operation. Maintenance breaks can also be used for optimizing the processes.

HelpDesk

Our HelpDesk service is there for our customers 24/7 ensuring reliable performance of the process and equipment. A HelpDesk service contract will provide constant access to expert assistance whenever needed. Our specialist will help the customers over the phone or set up remote access to the control system to directly assist in troubleshooting.

Spare parts

We provide comprehensive spare part services for material handling systems. Spare and wear part recommendations are made for every delivery project. Pesmel’s spare part services guarantee the latest, best quality spare parts available.

Upgrades

Frequent upgrades can help extend the lifetime of a process and the profitability of the original investment. Our research and development, focused on material flow how, not only generates innovative process solutions but a variety of cost-effective upgrade packages. The packages include solutions that increase system throughput and capacity or improve operational safety, or they can be software upgrades to the control system.

FlowCare

FlowCare is a remote supervisory and preventive maintenance solution for production facilities. The solution monitors the performance of all Pesmel equipment. Important data is visualized in a web portal that can be easily viewed on a computer or any personal mobile device. The custom-built portal allows creation of various types of reports, including periodical reports, which can be sent out via email. This online service product is built with security and user-friendliness in mind. FlowCare will provide valuable insight into the performance of the Pesmel solution, helping identify risks and avoid expensive unexpected repairs. The FlowCare solution puts the entire customer support in our customer’s pocket, 24/7.