Advanced automation modernizes tube manufacturing

Orrcon Steel manufactures steel tube and pipe products for construction, infrastructure, and industrial applications. Operating high-throughput tube mills requires precise coordination of forming, welding, sizing, and cutting processes. Variability in line speed, manual adjustments, and limited production data can affect dimensional accuracy, surface quality, and overall equipment effectiveness.

To address these constraints, the company sought to modernize its automation architecture. The objectives were to improve process stability, reduce unplanned downtime, enhance product consistency, and gain real-time visibility into production performance across its tube manufacturing lines.

Integrated automation and digital control
Orrcon Steel selected an advanced automation and control system supplied by Fives Group. The project focused on upgrading legacy control platforms with a unified automation environment integrating programmable logic controllers, human-machine interfaces, and production data management tools.

The system centralizes control of forming stands, welding parameters, and downstream finishing equipment. By synchronizing line speed with welding and cutting operations, the solution reduces process fluctuations and improves dimensional repeatability. Real-time monitoring enables operators to detect deviations earlier and adjust parameters before defects propagate along the line.




The choice was driven by the supplier’s experience in tube and pipe automation, its ability to integrate with existing mill equipment, and the scalability of the control architecture for future upgrades. The digital layer also supports production reporting and performance analysis, facilitating data-driven decision-making at both operational and supervisory levels.

Deployment and operational support
Implementation was carried out in phases to limit disruption to ongoing production. The supplier provided engineering, commissioning, and operator training services, ensuring that the upgraded system was aligned with site-specific process requirements. Integration with existing drives and mechanical equipment was maintained, avoiding major structural modifications to the mills.

During commissioning, process parameters were optimized to take advantage of the improved control precision. Operators were trained to use the new interfaces and diagnostic tools, enabling faster troubleshooting and more consistent setup between product changes.




Measured and operational benefits
Following deployment, Orrcon Steel reported improved line stability and more consistent product quality. Enhanced synchronization between forming and welding stages reduced variability and scrap generation. The centralized automation platform also simplified maintenance by standardizing components and improving access to diagnostic data.

Although specific performance figures were not disclosed, the operational impact can be explained technically. Tighter control loops and real-time data acquisition typically reduce setup times, improve yield, and increase effective production rates in continuous tube manufacturing. In addition, digital production records support traceability and continuous improvement initiatives.

www.fivesgroup.com