EMPOWER :2014-15

Displaying the process of our solutions capability in a true blue steel plant

The processes and challenges

BMM Ispat’s plant is spread over a vast area of 50 acres (approx. 200,000sq.m.) and the entire manufacturing process is divided into four stages.

Steel melting shop

The first area is called the steel melting shop, which handles all the operations from the melting of raw material to forming of billets of desired shape and size.Here the metal is processed in the molten form and handled by ladles. The formed billets are to be rotated in 90° and are to be transferred on the idle rollers to take them to two different storage locations.

Furnace and rolling mills

The second phase of the entire process consists of a furnace and rolling mills and includes handling of long metal billets of an average length of 12m each. The process is initiated by passing the billets on to idle rollers installed besides the furnace. The rolling facility is spread over 200m length and the preheated billets are passed through various horizontal and vertical rolling mills to give them the desired shape. The dies of the presses are required to be changed frequently to suit the particular product to be rolled, which includes rolled angles, TMT bars, metal rods and I-beams.

Quenching and cooling

The third phase is the quenching and cooling process. This is a well-equipped and technologically advanced process cycle performed using a plant manufactured by siemens, Italy. The products are rapidly cooled, which produces a harder material and prevents low temperature processes such as phase transformations in the material. Further cooling is then done and the product is then prepared to undergo the final finishing process.


The fourth and final phase includes the despatch of the finished products. The despatch yard is spread over 380m long and 50m wide area. This consists of parking bays for trucks and a railway track for loading on railway carriages. The despatch area has to store and handle long rods and beams. Rotating crabs are used to control the angle of long metal bars and other similar components in the despatch bay. BMM Ispat was looking for a competent partner who could understand the challenges and design a complete material handling system to integrate the various processes. The objective was to ensure safe, quick and precise handling and appropriate manoeuvring during loading at the despatch bay.