Correspondent Evan Ludwig, Global Marketing Manager for Long Rolling at Primetals Technologies, traveled to Switzerland to meet with Christiane Hess, Technical Project Manager, and Gerhard Dyrdek, Technical Project Director, at AFV Stahl Gerlafingen to discuss, among other things, the 200th anniversary of the Swiss steel producer and its recent wire rod mill upgrade.
AFV Stahl Gerlafingen recently celebrated its 200th anniversary. What does this significant milestone mean to you, and how do you believe it demonstrates your company’s commitment to Switzerland?
Gerhard Dyrdek: 200 years is a long time. Not many companies celebrate this kind of milestone. A lot has changed in the past two centuries, but the core of our business has not. Times were different back then—we are here today due to the proximity of the river running behind us. With the forest around, they cut down trees and fired the furnaces with that to make steel. Of course, we no longer do this today. Throughout the past two centuries, our company has prioritized the environment and significantly limited our carbon footprint to become one of the lowest carbon-emitting steel mills in Europe. We have witnessed numerous world-changing events over the past 200 years, many of which have tested our resolve. Perseverance, along with a strong dedication to what we do across two centuries, shows our commitment to Switzerland.
You mentioned the company has one of the lowest carbon footprints in Europe. How was this achieved?
Christiane Hess: We use 100% recycled steel.
Dyrdek: This is a big difference compared to mills utilizing a blast furnace. We prioritize utilizing local scrap, brought in via rail, and then processed by the machines we use here. Every piece of equipment we add to the mill is vetted to ensure we’re getting the highest energy efficiency rate. Additionally, we utilize solar panels across the entire facility. There are so many practices—both small and large—which add up to enhance energy efficiency to minimize overall carbon footprint.
How did you begin your journey within the steel industry?
Hess: I started over 15 years ago in 2009 as a shift electrician working in a 4-shift model at Stahl Gerlafingen. Afterward, I began studying to become a certified automation technician (HF).
Dyrdek: After my time in the army, I went to university because the military isn’t good for your back. After university, my first role within the industry was at thyssenkrupp, learning how to roll wire in a wire rod mill. After moving through various German steel companies, I ended up where I am now: Stahl Gerlafingen.
What intrigues you most about the industry?
Hess: What fascinates me most about the steel industry is the perfect interconnected nature between electrical engineering, mechanical systems, and metallurgy. From recycled steel scrap, we create high-quality end products that form the foundation for structures such as houses, bridges, schools, and/or hospitals—essential elements for our modern infrastructure. What particularly impresses me is the immense power behind these processes. For example, a single PLC output controls 5-megawatt motors to roll massive steel blocks, or when precision control technology is used to create a controlled short circuit to melt 80 tons of steel, it’s this combination of natural force and technical precision that genuinely excites me most.
Dyrdek: Big machines. I started my career in steel and have developed a passion for the industry. You either like it or you don’t. It isn’t an “easy” industry since it isn’t predictable, but at the end of the day, for me, it is a passion.
What does your current role entail, and how does it contribute to AFV Stahl Gerlafingen’s overall mission?
Hess: As a Technical Project Manager for AFV Stahl Gerlafingen, I’m responsible for planning and implementing projects that simultaneously increase our productivity and reduce CO2 emissions. These initiatives are crucial for strengthening and expanding our position as a leader in green steel production. By optimizing our production processes and implementing innovative technologies, we not only improve efficiency but also make a valuable contribution to environmental protection. My work supports AFV Stahl Gerlafingen’s overarching mission to develop sustainable solutions to help lead the industry into a more environmentally friendly future.
How long have you been working with the company, and what do you enjoy most?
Hess: I have been with the company for 10 years. What I enjoy most about my role is its versatility. I can contribute across all areas of production and bring my ideas, which makes my job exciting and varied. I also appreciate the flexibility AFV Stahl Gerlafingen provides. Thanks to my part-time schedule, I can balance my career with family life to care for my eight-year-old daughter. Over the years, I’ve been able to adjust my working schedule to match her daily routine. This worklife balance is invaluable to me and reflects my company’s modern approach to employee-focused scheduling.
Dyrdek: I have been here for over 13 years now. I started my career as an apprentice in a rolling mill, and now I’m responsible for everything that’s rotating. I appreciate that in a family-driven business like ours, trust plays a significant factor, allowing for more direct communication.
What advice or recommendations do you have for aspiring engineers looking to join the steel industry?
Hess: My most important advice to aspiring engineers is to gain hands-on experience as much as possible—ideally through several years of training in your chosen field before starting your educational studies. This practical foundation is still incredibly valuable to me today. It helps me plan projects more realistically and implement them more effectively because I know firsthand the demands and challenges of maintenance and production. Understanding how things work on the mill floor enables engineers to work more efficiently, bridging the gap between theory and practice.
Overhead view of 8 millimeter wire rod exiting upgraded Morgan Laying Head
Do you / did you have a particular role model whose advice helped you along the way or whose input contributed to your success?
Hess: Yes, definitely. My father and grandfather both worked in the water and shipping authority, sparking my interest in technology from an early age. As a child, I welded and used the drill press with my grandfather, encountering steel for the first time at 5 years old. I still love the smell of welding. For me, it’s a childhood memory that served as a calling for the industry. A pivotal moment in my development happened during my time at my technical high school. A senior teacher told me he didn’t believe I was suited for electrical engineering—perhaps because I was a young woman. That experience stuck with me and sparked something inside. When someone underestimates me, that’s when I push myself even harder.
Primetals Technologies recently upgraded your wire rod outlet. Has this upgrade resolved issues associated with the previous equipment?
Hess: Yes, the upgrade successfully addressed several existing challenges. Thanks to the new screw technology, both the start and end of the coil are now placed significantly more precisely and stably in the coil formation area. Additionally, the latest equipment allows for higher production speeds and a more powerful drive mechanism, improving overall process stability and product quality.
How was the installation process overall?
Hess: The agreed-upon timeline was reliably met by all parties involved. We had access to multiple competent points of contact throughout the installation process, making the collaboration with Primetals Technologies smooth and efficient. We would particularly like to highlight the startup team, whose professional and dedicated approach ensured a smooth project launch. The consistently professional execution of the entire project is particularly noteworthy, from planning through implementation to commissioning. All phases of the project were well-structured, with smooth communication, and everyone involved adopted a solution-oriented mindset.
How was the ramp-up curve?
Hess: The ramp-up curve was completely smooth. From our perspective, it was perfect. The system was operational immediately with a high degree of reliability and stability, marking a successful project completion.
How is the new Pinch Roll/Laying Head performing?
Hess: The new Pinch Roll and Laying Head have proven highly effective in practice. A key advantage is the simplified maintenance, where driver rollers can now be replaced much more quickly and easily. Furthermore, the Laying Head operates with high precision, which is especially evident in the accurate positioning of the start and end of the coil. Overall, this new solution stands out for its accuracy and maintainability.
How about automating the existing system?
Hess: Once the relevant interfaces were defined and aligned, the new automation system was seamlessly integrated into our existing rolling mill. Custom requirements and special requests were also promptly and efficiently implemented by Primetals Technologies. The automation works flawlessly, and the laser speed is optimally tuned to the overall process.
What results have you seen since commissioning?
Hess: Since commissioning at the beginning of 2024, the system has operated continuously without errors. From the very beginning, it has proven to be highly reliable and has fully met all expectations in terms of performance and stability.
How do you believe this upgrade will support Stahl Gerlafingen’s long-term goals?
Hess: The upgrade plays a key role in achieving our long-term goals. With significantly reduced disruptions in the coil formation area, system availability is at an all-time high. We also expect lower energy consumption, which is both ecologically and economically advantageous. Thanks to the standardized motor design, spare parts management is also simplified, saving resources and reducing maintenance.
Close-up view of 8 millimeter wire rod exiting upgraded Morgan Laying Head
How happy are you with this upgrade? Has it met your expectations?
Hess: Yes, we are extremely satisfied with the upgrade. It met our expectations in every respect, both technically and in terms of collaboration and implementation. The results confirm that working with Primetals Technologies was the right decision.
Dyrdek: In my position, I must decide what solution is best for the company. When evaluating suppliers, we decided to go with Primetals Technologies because, to me, your Laying Head system was the best solution presented to us.
How was your experience working with our team through the entire process?
Hess: The collaboration with the Long Rolling team at Primetals Technologies was consistently effective and competent. Communication was always constructive, concerns were promptly addressed, and the overall project execution went smoothly. This professional cooperation was a key factor in the project’s success.
How would you describe Primetals Technologies as a supplier?
Hess: Primetals Technologies stands out for its professionalism, reliability, and solution-oriented approach. We would gladly work together again.
Where do you see the future of the steel industry?
Dyrdek: There’s a great deal of uncertainty with the future of the steel industry, particularly the immediate future. The steel industry typically works in cycles with highs and lows, though lately, this cycle seems to move at a faster rate due to a variety of global influences. For me, there are three main areas shaping the future of the steel industry. These include climate change, labor costs, and maintenance costs. I believe we will see suppliers prioritizing innovation in response to the growing demand for energy-saving equipment with minimized maintenance requirements.
Morgan High-Speed Laying Head
Achive the Highest Operating Speeds with Consistency and Reliability
Designed for sustained high-speed operation, the Morgan High-Speed Laying Head plays a crucial role in high-quality bar and wire rod production. Typically located at the finished end of a bar-in-coil or wire rod outlet, the Laying Head ensures smooth operation by efficiently controlling the tension and laying the coiled bar or wire rod in a uniform pattern.
The updated 6th-generation Laying Head system includes the innovative, patented self-regeneration SR Series® pipes from Primetals Technologies. These pipes deliver consistent coil patterns and well-formed head and tail rings, while boasting a significantly extended lifespan for reduced maintenance. Upgrading to the SR Series Laying Head reduces downtime, ensuring consistent high performance and throughput.
