High-quality wire rod packing through automated solutions

Adopting new technologies in material packing has become top priority for the steel industry. The main drivers are operational costs, safety, and customer demands.

Shifting focus towards automated packing

Pesmel’s fully automatic solution is actively shifting the focus towards automated packing to achieve the best possible process efficiency and accuracy, as well as to ensure the highest possible safety standards. The solution is based on proven designs and technologies using a modular concept approach to create the layout. The key to efficiency is not in the individual machines themselves but in the expertise creating a complete layout that works and pairing it with the automation intelligence, both provided by Pesmel. The introduction of automation improves everything from packing accuracy and speed to true traceability and predictability. The reduction of manual processes also decreases the potential for human error.

Packings minimizing mechanical damage

The most important aspect when improving the quality of packing in wire rod applications is protection from potential mechanical damage that happens during shipping and transportation. Considering the precision required in many of the final applications for wire rod, ranging from riveted bolts and the wire mesh used to strengthen car tires, dents and scratches in the coil can be critical and costly. Depending on the grade of steel and end use, Pesmel’s packing can also create an efficient moisture barrier that minimizes rust during storage and transportation, help reduce the need for pickling, and have a positive environmental effect with less use of acid.

End-to-end packing solution

The solution delivered includes the full packing line, which starts from the in-feeding stands and coil carriages. The first stage involves the unique coil profile measuring and eye checking functions used to measure the width and diameter of coils, and ensure an unobstructed path for the through-eye wrapping (TEW) machine down the line. These accurate measurements help optimize the use of wrapping materials, eliminating material waste and delivering considerable savings. Ensuring that the eye is clear also minimizes the risk of bottlenecks and expensive downtime in the process. The packing phase itself consists of a wrapping machine that provides extra protection for coil ends and the TEW machine that provides all-around protection from both moisture and mechanical damage. The through-eye wrapping process consists of two layers. The first is a layer of polyethylene cloth followed by stretch film wrapping. Before out-feeding, the packed coils pass through the automated labelling equipment.

The quality of wrapping materials will be carefully selected each time based on packing requirements. Together, the machines and materials create the high-quality packing Pesmel is committed to delivering to its customers. The high-quality wrapping materials used in this application are provided by Pesmel’s partner in Japan, Horitomi Commercial & Industrial Inc.

Enjoying the benefits of automation and customer care

The high degree of automation means that the only manual functions left in the packing process are related to re-stocking the labelling machine and the wrapping machines a few times per shift. Overall safety has improved, as the delivered system is divided into different safety areas and the automatic functions ensure that operators are able to stay a safe distance away from any potential danger. The Pesmel solution helps customers to reduce the number of operators involved with the packing process, whilst at the same time improving the productivity, efficiency, accuracy, and quality of packing. Pesmel offers service support across the solution life cycle, which includes the fast online 24/7 Help Desk that enables service in the local language, and when necessary grants Pesmel remote access over a secure connection to address any potential issues. The customer knows that Pesmel is committed to delivering on its promises, and that the partnership does not end when the system is up and running.