Metals industry
Metals industry automation.
A metals plant is unforgiving. Dust, heat, vibration and non-stop operation. We supply control, instrumentation, drives and manipulators that survive in that environment, and we install them during refurbishments without unnecessarily long shutdowns.
Heavy industry, precise control.
Metals industry automation almost always happens while the plant is running. New equipment goes in next to the old, refurbishments are planned around shutdowns and every day of downtime costs a great deal of money. Metals producers in Slovakia and the Czech Republic therefore need a supplier that can handle electrical design, installation and programming and is not afraid to work on an existing control system. Often equipment from different decades and different manufacturers has to be brought together into one working whole.
Our engineering team has worked in heavy industry since 1993. For new builds and refurbishments of process units we supply electrical design and installation, instrumentation and control, control systems, variable speed drives and RFID-based warehouse management. For example, we built an automatic machine for unlocking and locking rodded anode blocks on transport pallets in aluminium production, connected to the existing PLC via Profinet. The delivery covered mechanical design, electrics and the programming of the manipulator, control system and visualisation.
Our designs reflect how the plant really operates. Drives can be moved in an emergency even without power, laser sensors reliably detect the state of the material, HMI operation is simple and signalling is visible even in a noisy hall. We hand over documentation your maintenance team can actually work with. For critical equipment we agree contract service with 24/7 standby, preventive maintenance and a stock of spare parts, so the failure of one drive does not stop the whole line.
Typical tasks in a metals plant.
Control systems
New or extended PLCs, operator workstations and control loops for lines and auxiliary processes, connected to the existing control system.
Drives and variable speed drives
Design, supply and set-up of drives and servo drives, including repair and refurbishment of servo drives and their position feedback.
RFID automation for metals warehouses
RFID on the lifting gear identifies each piece being moved, the system tracks the crane position in three axes and updates the warehouse map online.
Manipulators for heavy parts
Special-purpose manipulators and robotic cells for pallets, blocks and semi-finished products, with controls and safety designed for heavy-duty operation.
Sensors for harsh environments
Laser and radar position and presence sensors, process variable measurement and connection to instrumentation and the control system.
Environment and flue gas cleaning
Electrical scope, instrumentation and control and visualisation for combustion and filtration plants, so operations meet emission limits.
What we deliver to metals producers.
Individual contracts as well as complete process units for new builds and refurbishments.
- HV and LV electrical design and electrical installation
- Instrumentation and control, control systems
- Control panel manufacture, cabling and fibre optic process networks
- Variable speed drives, servo drives and their refurbishment
- Mechanical design and manufacture of manipulators and special-purpose machines
- RFID warehouse tracking and connection to production planning
- PLC, HMI and visualisation programming
- 24/7 service and spare parts for critical components
Technologies in our metals projects
How the cooperation works.
Consultation
We come to you, look at the operation or the brief and tell you what makes sense. Without obligation.
Concept and quote
Technical design, scope, schedule and price. Always with a reserve for what practice reveals.
Implementation
Engineering, manufacturing, installation, programming and commissioning. One team, one responsibility.
Operation
Operator training, documentation and a service contract according to how critical the technology is for your production.
Related services.
Electrical design and control panels
HV and LV electrical design, bespoke control panels, installation, commissioning, inspection and multilingual documentation.
Instrumentation and control
Turnkey I&C and process control systems: sensors, actuators, control loops, panels and the control system.
Line retrofit
Modernisation of machines and lines: new controls, drives, sensors and safety with minimal downtime.
Frequently asked questions.
Did not find your answer? Write to us and we will reply within 24 hours.
What does metals industry automation involve?
Most often control systems for process units, instrumentation and control, drives, manipulators and material tracking in warehouses. For new builds and refurbishments we add electrical design and installation. We can deliver the whole package or a single part.
Can control be modernised without a long shutdown?
Yes, if it is planned well. We prepare and test the new control in advance, make the connection to the plant during a planned shutdown and introduce changes in stages. Where possible, we simply extend the existing PLC.
How does an RFID warehouse for metals work?
An RFID reader on the crane recognises every piece being moved, the system continuously measures the crane position and, when the piece is set down, assigns it an exact location. Receipts, issues and transfers are recorded automatically and the warehouse is linked to production planning.
Which standards do you follow for electrics and machine safety?
We design the electrical equipment of machines to EN 60204-1 and safety functions to EN ISO 13849. The delivery includes documentation, inspections and supporting documents for the conformity assessment.
Do you also repair servo drives and variable speed drives?
Yes. We maintain, repair and refurbish servo drives, including the electronics, limit and torque switches and position feedback. We service Danfoss, Rockwell, Siemens and Vonsch drives.
How much does automating a metals process cost?
The range is wide, from modifying a single control loop to controlling an entire line. The price is determined by the scope of instrumentation and control, the number of drives, the work needed on the power side and the shutdown requirements. We give a fixed price after a site survey and technical concept.
Planning a refurbishment or shutdown?
Tell us which process you want to modernise and when. We will get back to you within 24 hours, arrange a site survey and propose an approach with the shortest possible downtime.