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How to Reduce the Operating Cost of Rolling Mills

 

India has been growing rapidly when it comes to the steel industry. In comparison to other countries, India rightfully caters to the world’s needs with its high-quality steel solutions. Nowadays, manufacturers have only one goal in mind, which is to provide only superior quality products to their customers.

But how can one achieve that level of quality? It is simply to install state-of-the-art machinery to give attention to detail and produce better quality products. However, what often stops multiple companies from doing so is the cost of operation. Let us find out how we can reduce the operating cost of rolling mills.

What is the main purpose of a rolling mill? It is to form metal. Depending on the client’s demands and the goal they want to achieve, the thickness will vary. Now there are various categories of rolling mills, and they are differentiated based on the temperature. For instance, if the temperature is above the level of recrystallisation, i.e., hot, then it will be considered hot rolling but if it remains below the recrystallisation temperature, then it shall be regarded as cold rolling. 

One of the biggest concerns of manufacturers worldwide is the operating cost. Luckily, with a few alterations to the operating process, the manufacturers can drastically decrease the cost without altering the end product. 

Here are a few steps with which you can reduce rolling mill costs-

1. Energy Consumption 

The first thing that needs to be done is the reduction of energy consumption. On a daily basis, there is a lot of energy waste during operation, and there is no track of it. Our priority is to reduce the energy cost of the unit. How should we do that?

  • There is a dire need for high-quality machinery in daily operation. The main reason is that advanced machinery and its mechanism will reduce rejects. If there is a reduction of rejects from 1.5% to 2%, this small shift can decrease fuel use up to 9%. 
  • The electricity used during the rolling process can also be decreased significantly if motors are used in conjunction. This process is highly efficient and reduces nearly 1%-2% energy consumption. 
  • A decrease in oxygen levels by even 1.5% in the heating furnace effectively reduces the cost. Energy consumption reduces down to 2.4% once the oxygen reduction is implemented. 

2. Process Optimization

Process optimisation is a key way to control and reduce the operating costs of rolling mills. Multiple components work in sync to utilise state of the art rolling mill. There needs to be constant analysis, evaluation, and improvisation for the best output. The most essential is to reduce downtime and accurate interconnection of the production stages. 

This method effectively increases the productivity of the operation. One can also accurately measure the energy used per unit. In general, optimisation reduces the risk of scale loss and heightens efficiency. This is a practice that can be adopted by steel plant consultants and multiple different metal manufacturers.

3. The Right Equipment 

High-quality rolling mill equipment plays a major role in the operating cost and impacts the overall value in many ways. Good quality equipment reduces maintenance costs as you will omit the need for regular maintenance as these are much more reliable.

It also reduces system downtime significantly and improves operation costs. High-quality equipment also has replacement parts readily available, making replacing much smoother. 

4. Leverage Automation

When it comes to reducing the cost of the rolling mill, leveraging automation can be incredibly useful. Making any production process efficient requires advanced mechanical equipment, process technology, and automation functions. These three together can transform the overall cost of operation.

The more suitable software and electrical equipment used will allow more accurate information to be received by mill operators to automate and unify mill setup. This process improves overall operating practices and reduces costs. 

Find The Most Reliable Partner in Steel Forming

The Steefo Group is your reliable partner in steel forming when it comes to steel forming. They provide the most high-quality products and turnkey solutions from concept to commissioning. Advanced machinery, highly skilled engineers, state-of-the-art manufacturing facilities, and undisputed quality make the Steefo Group an eminent steel rolling mill manufacturing company in India. 

To learn how you can reduce your operating costs and improve profits with the products and solutions of The Steefo Group, contact +91 98240 76873 or drop a mail at marketing@thesteefogroup.com.  

 

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The Steefo Group: Innovating Rolling Mill Solutions Around the World

 

When we talk about reliable experts in steel forming, the only name that comes to the forefront is The Steefo Group. Our reputation stems from the word steel forming. Our origins are rooted in excellence and superior production, both in national and international export markets. 

The Origins of The Steefo Group 

The Steefo Group has humble beginnings; we started our journey four decades ago in 1976.  With Mr K.K Agarwal laying the foundation of the  Steefo Industries in 1976, starting our first order in 1979 to achieving our first export order in 1991, we have always had an upwards trajectory. The only goal that we had in mind was to provide precision in design and manufacturing and produce superior quality products and turnkey solutions that fit our clients’ expectations and standards. 

We aimed to become the one-stop shop for all steel rolling and melting industries. We have expanded our services and products since 1976, and now we have a group of expert engineers catering to numerous sections of this ever-demanding industry.

The Steefo Group Quality

One thing that we have pledged to maintain and have never compromised on is quality. The name of The Steefo Group is recognised worldwide today because we are consistent in provisioning high-quality products. We hold ourselves to the strictest standard and norms possible to ensure that only products of the highest grade products to our clients. 

We have a dedicated quality assurance team that performs quality checks and rigorous testing from raw materials to the finished products. This is done to ensure that we stay true to the promise of being your reliable steel forming partners. We take a quality-based approach to quality commitment.  

Our Commitment To Innovation 

From its very inception, Steefo has been dedicated to growth and innovation.  We believe that innovation can transform change into new beginnings and fruitful opportunities. Innovation is more than just developing new products but rather producing cohesive design and technology that comply with the constant evolution. Our team of dedicated and experienced design engineers have the vision and talent to delve into undiscovered and uncertain aspects of the world of steel forming to discover and develop new processes, systems, and management methods to positively impact the growth, productivity, and profitability of our clients. 

When you partner with us, you invest in premium grade products and are consistently provided with a workforce that offers the skill to produce the best output in the competitive steel forming market. 

Research and Development

The Steefo Group is known worldwide because of our drive toward developing and improving our R&D and design capabilities. We invest our resources in technical improvements because we know that only development in the field of technology guarantees consistent improvement in our manufacturing speed and product quality. Only the most advanced technology can cater to and match the demands of our varied clients. We utilise software such as CAD and Kissoft and more to procure future-ready equipment that complies with industry 4.0. 

How Has The Steefo Group Solutions Transformed the Steel Rolling Industry?

The Steefo Industry has become synonymous with innovative and unique turnkey solutions that transform rolling mill solutions worldwide. From concept to commissioning of rolling mills and integrated steel plant, we have complete expertise in all aspects of the field. Multiple turnkey projects are supplied with plant equipment and execution, including erection and commissioning to obtain the maximum desired production value. 

1. TMT Bar Rolling Mill 

Steefo Group - TMT bar rolling mill

For The Steefo Group, TMT bar rolling mills have been ingrained in our DNA. Being your one-stop-shop for all your rolling mill solutions, we ensure that we provide our clients with innovative and modern designs in our turnkey solutions. Our expert engineers can handle these projects from concept to commissioning. We constantly customize our products according to the demands and needs of our clients and have production capabilities ranging from 80 TPH to 100 TPH. We ensure that productivity is boosted and ensure faster ROI.

2. Structural Rolling Mill 

The production process in the rolling mill

The Steefo Group is a front runner amongst companies known to produce end-to-end solutions for structural rolling mills. We guarantee that our structural rolling mills have the most incredible performance capacity and shortest downtimes.

3. Wire Rod Mill

Wire rod mill solutions

We have mastered wire rod mills over four decades and have become a trusted name in this industry when it comes to the production of wire rod mills. From cost-effectiveness to flexibility, the growing demand for wire rods is being matched by our support in creating impeccable wire rod mills to allow large production capacities. The Steefo Group creates wire rod mills that are not only high speed but are also capable of rolling themselves into the smaller dimension to increase production rates. 

The Services of The Steefo Group That Sets Them Apart

For anything related to steel, you can trust The Steefo Group. From process analysis to optimization and up-gradation, our skilled engineers are here to help you from start to finish. Our end goal is to drive our clients towards success and profitability. 

1. Product Design and Engineering

As your reliable steel-forming partner, you can trust us as we are equipped with worldwide experience in implementing turnkey solutions. Our technical departments come together to customise the project to your exact requirements. From individual to products to complete solutions, we provide it with all to ensure that our clients do not face any disadvantage in any step of the process. 

2. Spares and Consumables 

We have provided superior customer support and client satisfaction throughout the project lifecycle. We understand how demanding the process is, and that is why we are there every step of the way. We are not only involved in turnkey projects; we also offer spare parts and consumable products to our customers to ensure prolonged service and consistent performance and endurance. 

3. Technical Support and Repairs

The Steefo Group always ensures that the steel plants are always equipped with advanced technology to maintain and raise the bar in terms of quality and production. Our team of engineers works closely to keep an eye on the project until the output production stage to prevent downtime and cost overruns. 

4. Service Agreement Program

Surviving the rapidly evolving steel market is not an easy task. We meet the demands of the evolving market and rapidly proceed to optimise and improve the efficiency and quality of the plant. It includes adopting the best practices and maintaining equipment and machinery pristine and well maintained. Our company provides a complete service program to ensure that your products reach peak performance levels. The entire process involves evaluating equipment and improving them whenever deemed necessary. 

Why Work With The Steefo Group?

Today, The Steefo Group has reached this level of success due to its relentless drive toward excellence and an uncompromising attitude towards quality. We are constantly evolving and trying to improve our current products and solutions, and therefore, we have transformed into the leading innovation in the world of rolling mills. 

When you work with us, you get high-quality products and receive constant support from our team of professionals. Join the world of success. To learn more, call us at +91 98240 76873 or drop us a mail at marketing@thesteefogroup.com

 

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5 Crucial Things When Buying a Steel Rolling Mill Machine

 

Although the steel industries of India have witnessed their share of ups and downs in the last few decades, lately they have picked up their pace and are flourishing greatly. Certain factors play a crucial role in your purchase of a steel rolling mill machine. If you happen to be a part of this industry and are looking for a steel rolling mill, here are a few unsaid rules of buying one that you ought to know before you invest in any company across India.

5 Things to Think about When Buying a Rolling Mill Machinery

1. Production facilities in the manufacturing unit

Production facilities play a crucial role in the quality of the products manufactured, especially in producing high-quality rolling mill equipment. It is a known fact that steel is a dense metal, which is why it might be difficult to assess the true capability of various machines shown. You can check the quality of rolling mill machinery using its source. In addition to this, the kind of material used in the machinery, the quality, durability, and resistance, all come into play. Doing so will help you understand whether the company can justifiably deliver trustworthy machinery that meets your needs.

2. The range of the products offered

A steel manufacturer typically provides several products to cater to the varied needs of customers across industries. Ask about the types of rolling mills the manufacturer offers, before deciding to buy from them. This will help you understand how diverse they are and ensure you get a superior quality product. A reliable rolling mill manufacturing company caters to all the requirements by promising to offer high-quality products for various industries.

3. Check the quality

When buying steel rolling mills, ensure the manufacturer offers value for money. Ask about the production methods and quality checks, how their quality control department operates, and they manage the overall operation. This way, you can rest assured about working with a reliable rolling mill manufacturer and receiving high-grade products that suit your specifications.

4. Scope of development

Several rolling mill manufacturers in India have invested dedicatedly in the research and development of the mills. When buying any machinery for your industry, always make sure it fulfils the latest updates in the market and is designed in a manner that leaves space for evolution in the future. It helps to remember that any technological advancements can help improve your performance.

5. Shipping procedure of the company

Last but not the least, it is the smooth and hassle-free delivery that all customers look forward to. Ensure the manufacturer you want to purchase offers flawless machine installation services, and has expertise in concept-to-commissioning. This way, you will get your delivery on time without any issues.

Get High-Quality Steel Rolling Mills with Installation

Steefo Industries is now a part of the Steefo Group. With over 45 of experience in the industry, we are one of the leading rolling mill manufacturers in India. We never negotiate with the quality we deliver and strive for excellence in all our activities. We hold ISO 9001:2015 certification, reflecting the high manufacturing standards we comply with. Our products and services extend to various industrial applications such as reheating furnaces, quenching systems, loopers, DC motors, mill stands, shears, pinch rollers, and more.

You can reach out to us at marketing@thesteefogroup.com or call and schedule a meeting at +919824076873 for more details about our steel rolling mills. It would be our pleasure to serve you!