Engineering and metallurgy solutions company SMS group has successfully upgraded the motors and drives in the one-stand reversing hot rolling mill – originally built by a third-party rolling mill supplier – for leading Bahrain-based aluminium producer Gulf Aluminium Rolling Mill B.S.C. (GARMCO), according to a press release published last month.

The project marks a significant milestone for both companies and seeks to enhance the mill’s operational efficiency and reliability, while equipping it to meet future demands in the aluminium processing sector.

Additionally, the scope of the project included the replacement of outdated direct current (DC) motors with three-phase alternating current (AC) motors and “state-of-the-art drive technology”, including variable-frequency drive systems powered by active front ends and new transformers.

The drive system, built to deliver 20% higher torque compared to the mill’s original design capacity, restored GARMCO’s hot rolling mill to full operational capacity and positioned it as a “future-ready” facility capable of advancing research and development in aluminium hot rolling, SMS group stated.

Central to the modernisation was SMS’s “cutting-edge” twin-motor drivetrain equipment, which includes key components such as a tailored gearbox for combining two electric motors with a rated power of 2 150 kW each and two SMS giant torque spindles.

Combined with SMS’s “highly advanced” gear design, this drivetrain concept provides unique power capabilities and significantly reduces both investment costs and space requirements, while allowing for some degree of redundancy.

In addition to the two main motors for the mill, SMS also supplied the X-PactDrive low-voltage frequency converter for the entry and exit coilers, a medium-voltage converter operated in load share mode, as well as transformers to feed the new systems.

The equipment is tailored to meet the rigorous demands of GARMCO’s operations, which include the production of aluminium coils, tread plates, slit coils and foils for diverse industrial applications such as packaging and heat exchange systems.

This drive-related collaboration was the first of its kind between the companies, with GARMCO choosing SMS group for its reputation for “reliable, high-performance solutions boasting superior technical features and an optimised power factor”.

The new drive system guarantees enhanced torque capability over the entire speed range – a critical advantage for rolling operations requiring high torques at elevated speeds.

“The completion of this modernisation project is a testament to our commitment to maintaining world-class operational standards. SMS group’s expertise and advanced technological solutions have [afforded] us greater reliability and efficiency in our hot mill operations,” said GARMCO executive operations manager Ebrahim Khalil.

The successful completion of this project underscores the strong ties between GARMCO and SMS, he added, noting that SMS has supported GARMCO with technical services for its scalper machine, building a foundation of trust and collaboration.