Roll Forming Lines Case Study : Tata Ryerson)

Client Background :

Tata Ryerson Limited is a joint venture of Tata Steel Ltd and Ryerson Tull Inc USA.  With the vision of providing toll processing services to TISCO CR division, an MMC was set up inside TISCO works. TRYL had planned to install a Roll Forming line which may also be operated as a GPCut-to-Length. Targeted productivity of  export quality corrugated sheets was 1,50,000 tpa, to be met by using three high speed Roll Forming Lines @50,000 tpa per line.

The Challenge

Tata Steel will introduce full hard GP sheets (Coil form) into the market with the brand name "Tata Shaktee" which shall be a unique brand in terms of quality. TRYL as the service provider, will be processing the same to satisfy global customer necessities of corrugated sheets for roofing purposes. The company's aim is to achieve high productivity of 50,000 Mt @line maintaining superior quality at par with international coil processors.

The Solution

To meet the annual productivity of 50,000 Mt, the estimated speed was 60 MPM, which is high to be achieved especially in large panel full hard corrugated sheets. Dassnagar offered continuous roll forming lines with a top operating speed of 70 mpm. It can produce both sinusoidal & trapezoidal roofing sections depending on the tooling profile. Spring back is negligible (pitch tolerance  < 1.5 mm), with no edge bending. The entry cut-to-length ensures continuous supply of cut sheets to the roll forming section. The line can also be operated as a roll feed GP Cut-to-Length line with provisions for automatic stacking and piling discharge.