In a significant advancement for Europe's steel processing sector, German plantmaker SMS Group has successfully completed a key modernization project at Thyssenkrupp Steel Europe's facility in Duisburg, Germany. The upgrade targets the automation systems of the downcoilers in hot strip mill No. 1, a critical component of the plant's flat steel production network. This hot strip mill, originally supplied by SMS Group, produces high-quality carbon steel flat products across various grades and dimensions, serving as a cornerstone of Thyssenkrupp's production portfolio.

The project specifically renewed Level 1 automation and human-machine interface (HMI) systems for the mill's three downcoilers. Aging control platforms and discontinued spare parts had posed operational risks, limiting performance and hindering digitalization efforts. By implementing an updated technological control system (TCS) and revised HMI environment, SMS Group has enhanced operational consistency in the coiler area, ensuring seamless high-speed control and robust communication.

Central to this upgrade is SMS Group's proven **X-Pact® ProBAS** software platform, paired with **X-Pact® Embedded controllers**. These technologies deliver the high-speed control performance essential for modern steel processing. An **EtherCAT real-time Ethernet network** facilitates robust communication between high-speed sensors, while a **PROFIBUS remote I/O system** supports standard sensors. The HMI enhancements introduce modern visualization with ergonomic faceplates, improving user interaction, diagnostic capabilities, and overall plant availability.

This initiative resolves longstanding issues caused by outdated spare parts and legacy operating systems, paving the way for future digitalization. It forms part of a long-term cooperation framework between SMS Group and Thyssenkrupp Steel Europe, under which individual units of the Duisburg hot strip mill have undergone staged modernizations in recent years. Previous upgrades include Level 2 process automation adaptations in 2024 for varied setting values, integration of run-out roller tables involving 90 drives in 2019, extensive side guide control enhancements in 2017, and coil transport system conversions in 2013.

Michael Wirtz, Service Manager for Solutions Flat Products at SMS Group, emphasized the lifecycle service approach: "Our X-Pact® Service contract, in place since 2009, underscores our partnership with Thyssenkrupp Steel Europe and enables us to sustainably optimize the plant." This ongoing collaboration ensures continuous plant operations, reliability, and preparation for Industry 4.0 technologies.

For steel industry professionals, this upgrade exemplifies strategic investments in **automation and control systems**, a key category for maintaining competitiveness amid decarbonization pressures. Enhanced TCS and HMI systems reduce downtime, optimize energy use, and support quality improvements in strip processing. As European steelmakers navigate CBAM enforcement and trade safeguards in 2026, such targeted modernizations provide essential operational resilience.

The Duisburg facility's role in producing carbon steel flats positions it ideally for downstream applications in automotive, construction, and engineering sectors. By addressing spare parts obsolescence, the project mitigates risks associated with **preventative maintenance** and extends equipment lifecycle, aligning with sustainability strategies. SMS Group's integration of real-time networks like EtherCAT sets a benchmark for **non-contact measurement** and process analytics in rolling mills.

Looking ahead, this upgrade creates a strong foundation for advanced digital twins, AI-driven predictive maintenance, and integration with IT/software solutions. It supports Thyssenkrupp's broader transition goals, including potential hydrogen-based processes, while bolstering efficiency in **forming and finishing** operations. Industry stakeholders, including mill operators and system integrators, can draw insights on partnering for phased upgrades to balance capex with immediate ROI.

In the context of Europe's steel landscape, where financial strains from ETS costs and imports persist, automation enhancements like this deliver tangible business value. They enable higher throughput, better product consistency, and reduced operational costs—critical for strategic positioning. SMS Group's 150 years of expertise in metals technologies continues to drive innovation, ensuring clients like Thyssenkrupp remain leaders in flat steel production.

This development underscores the importance of **automation and control systems** in sustaining Europe's steelmaking prowess, offering a model for similar investments across rolling, strip processing, and heat treatment applications. With enhanced diagnostics and communication, the mill is primed for next-gen analytics, reinforcing long-term competitiveness.