Metal industry

Individual solutions engineered to improve customers’ material flows is one of Pesmel’s strengths. As a total system supplier, we take overall responsibility for the project from pre-engineering to handover. Planning starts with defining the needs of a functional layout, material flows between processes, requirements for the finishing area, and alternative routings for exceptional situations.

We build a simulation model to design, develop, optimize, and validate our logistics systems. The model acts as a guidance for implementing a fully functional and optimized system. It enables pre-construction testing and verification of large and complex systems.

The simulation process creates a digital twin, which is a virtual representation that serves as the digital counterpart of a physical process. Our digital twin is proven to be usable tool in commissioning and development of customers’ material flow solution.

A digital twin is also used in daily operations such as continuous optimization of automated storage, estimation of near future occurrences, and support for operator decision-making. It also plays an important role in planning and executing aftersales operations including data collection of equipment usage, preventive maintenance, and virtual testing of software updates.

Logistic system
Efficient and well-organized in-mill logistics ensure smooth throughput without bottlenecks. Automated logistics reduce cycle times and boost utilization of main process lines. They enable full control over material flows between raw material, semi-finished, and finished production processes including shipping.

Logistics solutions need to be both agile and robust when dealing with continuously growing production volumes and heavy products,. Our logistics solutions are designed for heavy coils and plates. High availability is provided with full redundancy, as the system has a re-routing capability in case of a sudden disturbance or equipment maintenance. Our logistics solutions are based on coil car technology to ensure gentle product handling from underneath the product.

Logistics systems combined with Pesmel’s high-bay warehouse provide an integrated in-mill logistic solution – the Pesmel Material Flow How® concept.

Packing protects the product against damages in handling and during transportation. Customer drivers for automating their packing systems include comprehensive protection against mechanical damage and rust during storage and transportation, efficient capacity utilization, increased overall safety, and elimination of packing material waste.

With years of research work, we at Pesmel provide our customers an automated packing system that enables complete rust protection, including in the most challenging environments. Our modern packing equipment enables savings in packing material consumption and packing material storage, as the materials are automatically cut on-site according to product dimensions.

Automating packing operations enables the no-man-on-the-floor concept, which improves operator safety considerably by eliminating hard and dangerous work phases. Pesmel’s packing systems require only one to two operators for supervising and material replenishment. Operator safety is also increased in the packing area by using environmentally friendly packing materials, and all the materials are fully recyclable.

Sizeable capacity and efficiency in one simple, space-saving layout is what Pesmel’s high-bay storage is all about. In a smart mill layout, production processes and storage operations are seamlessly connected without any unnecessary steps in between.

Integrated storage handles all the buffering needs of the mill working as a WIP (work in process) storage as well as a shipment storage, if needed. Storage capacity can be flexibly adjusted for various product types and products that are at different stages of the production process. This removes the need for many separate storage units located around the mill complex, and optimal material flow can be maintained with even a smaller buffer.

Pesmel’s high-bay storage can store products to a height of over 30 meters. This means that greater storage capacity can be achieved with a much smaller footprint than with traditional storage solutions or in a typical storage yard. Automated stacker cranes enable high handling and sorting capacity, raising efficiency to a new level. Streamlined material flow and real-time product control help eliminate delivery errors and shorten lead times considerably.

The storage solution uses no cranes that could damage the products. Instead, they are always lifted from below, which ensures flawless condition of the final product. The lack of overhead cranes also means a safer working environment for staff.

Improving the in-mill material flow’s speed, accuracy, and efficiency with automated high-bay storage and logistics systems has allowed many steel manufacturers to enhance several areas of mill performance, resulting in a positive impact on the mill’s entire logistics chain.

Road or rail transport times often account for less than 50% of the total time from mill to customer. This means that there is little forward progress the rest of the time. This is the point where improved efficiency of in-mill logistics and shipping functions can have a positive influence on the entire logistics chain. Reducing waiting and turnaround times through proactive and predictive operations and smart sharing of information has the potential to genuinely impact business performance.

Pesmel’s solutions can pre-sort outgoing orders for easy pickup well in advance, which reduces turnaround times for trucks and trains. A fast and accurate loading process increases efficiency and improves customer service. In some cases, improved throughput times have helped boost annual sales by up to 15%. In a world where competition is tough, these types of improvements in efficiency are extremely valuable. Automated solutions also regularly report zero errors in deliveries due to eliminating   the component of human error.

Pesmel’s Material Flow How® concept includes equipment integration, material flow management throughout the entire mill, and information flow management. A full control system enables integration of the various functions contained within the mill into one logistical entity.

Full material handling control means zero damage and no lost products or delivery errors. The entire system – logistics, storage, and packaging – is managed by a centralized control system which tracks and tasks the products from arrival to departure. The real-time inventory feature significantly supports production planning, a critical area in terms of cost savings.

A state-of-the-art mill needs a modern control structure. Our system integrates all levels of production and logistics control, from electrification to automation, monitoring, material flow planning and management, and logistics into one full chain using a comprehensive and user-friendly platform.