Stahl Gerlafingen boosts output and reliability with wire rod mill upgrade

Stahl Gerlafingen has completed a successful upgrade of its wire rod mill, significantly improving production performance and plant stability. The modernisation, supplied by Primetals Technologies, focused on the installation of a new laying head system and advanced automation components.

The upgraded mill now benefits from reduced vibration, fewer unplanned shutdowns, and improved coil formation. These enhancements are already translating into higher yield, better product consistency, and improved process stability.

The retrofit included Primetals' sixth-generation laying head with an integrated tension monitoring system, as well as a new pinch roll and drive system. The new design features a segmented deflector plate, roller bearing gearbox, and enhanced mechanical stability, all contributing to smoother operation and lower wear. Laser-based tension controls help maintain optimal front-end orientation and improve coil uniformity.

“Thanks to the new screw technology, both the start and end of the coil are now placed much more precisely and stably,” said Christiane Hess, Technical Project Manager at Stahl Gerlafingen. “The system also enables higher rolling speeds and enhances product quality.”

The wire rod mill now produces up to 600,000 tonnes per year, ranging from 6 to 20 mm quenched rebar and 5.5 to 20 mm low-carbon wire rod. Operators also benefit from real-time process insights via integration into the plant’s HMI system.

Stahl Gerlafingen, part of the AFV Beltrame Group, is Switzerland’s largest recycler of steel scrap and produces over 700,000 tonnes of low-CO₂ steel annually. The site, located in the canton of Solothurn, has been in operation since 1823.

Source and Photo: Primetals