Advanced Guiding in Long Rolling Mills

With growing demands for safer operations, higher mill utilization, and higher-quality products, long rolling mills are increasingly adopting ­automated systems to modernize key processes. One such innovation is the Advanced Roller Guide by Primetals Technologies. It combines real-time measurement, predictive diagnostics, and remote operation into a durable, user-friendly design. We spoke with Matthew Anderson, Development Manager for Metallurgical Services – Downstream Long Rolling, and lead developer of the Advanced Roller Guide, to discuss the challenges this technology addresses, the results from early deployments, and how it fits into the industry’s move toward smarter, hands-free rolling.

What prompted the development of the Advanced Roller Guide?

Matthew Anderson: Several factors came together: the need for improved safety, the desire to enhance product quality with fewer defects, and the goal of reducing downtime caused by guide failures. Historically, operators have used calipers or wood burning to check section height. Such methods can yield inconsistent or inaccurate results and also pose safety risks. We saw an opportunity to bring modern sensing and control technology into this critical part of the mill and deliver a solution that addresses all of these challenges. That’s what led to the creation of Advanced Roller Guides.

This has not been the first time the industry has investigated “smart” guide technology. How does ­this solution differ?

Anderson: That’s true. Similar ideas have been introduced before, but have struggled to gain traction. Past attempts faced reliability issues, and early users did not see the expected return on investment. One main challenge was the use of wired data transmission, which was problematic in harsh mill environments. At Primetals Technologies, we took a different approach. Instead of simply adding sensors to a traditional guide, we built the system from the ground up to withstand demanding mill conditions and fit into existing guide shop workflows. As a result, Advanced Roller Guides include the following characteristics: the electronics are fully enclosed in a sturdy stainless-steel shell; ­measurements are continuous and automated; and we focused on integrating predictive analytics that provide operators with actionable insights. Moreover, wireless operation resolved reliability concerns seen in other systems and allows operators to remotely ­monitor and adjust guide settings from a safe distance, reducing exposure to hazardous areas and streamlining setup.

What kind of data does the system provide, and how does it benefit mill operations?

Anderson: The guide constantly measures section height and roller speed, while also tracking impact severity and trends in size and speed. This data feeds into predictive algorithms that can identify emerging problems, such as a bearing beginning to seize or upstream process issues. The system has successfully flagged several degrading roller bearings minutes before they failed, causing cobbles. Early warnings like this enable operators to safely stop the line, replace the part, and prevent downstream damage or material defects. Furthermore, the data helps improve quality control, guide alignment, and optimize maintenance schedules.

Safety is a significant concern in rolling operations. How does this technology address that?

Anderson: Safety was a primary focus from the beginning. With this guide, operators no longer need to make manual adjustments next to a running mill stand. Remote, symmetrical roller adjustments can be made from a safe location via wireless communication. Visual inspections are replaced by real-time condition monitoring, and manual section height measurement using calipers is replaced by continuous measurement. Every feature we added is designed to reduce operator exposure or eliminate hands-on checks. The more we can remove people from dangerous environments without sacrificing performance, the better.

How has the system performed in real-world trials?

Anderson: We’ve already installed the Advanced Roller Guide in several North American mills, including both bar and rod producers, and initial feedback has been positive. Operators appreciate the advanced features and the system’s ease of use, especially during setup. Some customers have already ordered additional guides based on their early experiences. These aren’t just test runs; these are demanding production environments with high throughput and uptime expectations. The system has shown reliable performance in challenging operating conditions.

Is this solution difficult to implement in existing mills?

Anderson: Not at all. The guide fits standard mounting saddles, and no rest bar modifications are required. We also offer a “smart ready” version that includes a mechanical guide body with a dummy plate where the control module mounts, allowing customers to install the hardware now and easily upgrade to the full advanced version later. This provides mills with the flexibility to incorporate the technology into their upgrade plans gradually. We designed it to be as simple to install as possible without sacrificing durability or performance.

What’s next for the Advanced Roller Guide? Are there additional features being developed?

Anderson: We’re continually improving our data analysis models and expanding the size range to accommodate different mill setups. We’re also exploring ways to integrate this data with broader plant systems to offer a more comprehensive view of mill health. The more interconnected these systems become, the more valuable the insights. This is part of a broader shift toward advanced, automated, and safer rolling operations. The Advanced Roller Guide is a key step toward that future, and we see it as a foundation for the evolution of long product rolling.