Over the past nearly 20 years, EMG eMASS® has developed into the industry-leading solution for electromagnetic strip stabilisation in continuous galvanising lines (CGLs).
Originally introduced to minimise strip vibration in the coating zone and to enable narrower nozzle gaps, EMG eMASS® has since evolved into a mature, modular system that sets the global standard for non-contact strip stabilisation. With more than 90 systems ordered and successfully implemented in production lines worldwide, EMG eMASS® plays a central role in improving coating quality, reducing zinc consumption, and increasing overall process reliability in galvanising operations.
The development path of EMG eMASS®
The early development of EMG eMASS® was driven by the need to stabilise the steel strip in the high-temperature, high-turbulence environment above the zinc pot, where air knives are used to control coating thickness. The original system architecture relied on fixed magnet boxes that generated a stabilising electromagnetic field across the strip. Since then, the system has undergone continuous development: the introduction of modular configurations tailored to specific plant layouts and strip dimensions; the downsizing and thermal optimisation of magnet boxes for improved integration near the nozzle lips; and most recently, the incorporation of movable magnet actuators for dynamic stabilisation across the entire strip width. These advances have transformed EMG eMASS® into a versatile platform capable of adapting to a wide range of CGL designs, including integrated solutions in combination with the advanced air knife system DUMA-BANDZINK JetPro.
The major effects of applying EMG eMASS® in CGLs
In current industrial practice, EMG eMASS® systems typically achieve a damping effect of more than 50 %, significantly reducing strip vibration and a 60 % crossbow reduction. This enables closer nozzle-to-strip distances — down to less than 7 mm in specific cases — while maintaining coating uniformity and minimising overcoating. As a result, customers benefit from improved material yield and lower zinc consumption, directly impacting the return on investment.
New perspectives with EMG iCASS®
To further support process optimisation and open new opportunities for lines not yet equipped with EMG eMASS®, EMG has developed the EMG iCASS® platform (intelligent Control and Analytical Software Solutions). EMG iCASS® enables in-depth analysis of production data from existing galvanising lines, using machine learning models and statistical evaluation to simulate the potential performance gains of EMG eMASS®. For example, EMG iCASS® can identify and quantify coating inhomogeneities, strip shape deviations (cross bow), air knife misalignments and currently applied safety margins in actual process situations. This allows plant operators to make informed investment decisions regarding the implementation of EMG eMASS® in their lines ahead of investing. EMG offers this as a consultancy service for line operators who are not absolutely sure about the current optimisation potential for their galvanising line with and without EMG eMASS®.
Additionally, EMG iCASS® supports performance monitoring and automated or semi-automated process adjustment, as well as optimisation of coil transitions and target coating changes, in lines already equipped with EMG eMASS® or without. This further enhances the benefits of the EMG system family.
Conclusion
After almost two decades of industrial application, EMG eMASS® represents a mature and well-established solution for electromagnetic strip stabilisation in continuous galvanising lines. Its measurable effects on strip stability, coating uniformity and zinc consumption have been demonstrated in a wide range of plant configurations worldwide. Complementing this hardware-based approach, EMG iCASS® extends the system portfolio with data-driven analysis, simulation and control capabilities, enabling both prospective evaluation of optimisation potential and systematic performance improvement in the air knife operation.
Prepared for next steps?
Operators seeking to quantify stabilisation potential, validate investment decisions or further optimise existing EMG eMASS® installations are encouraged to engage with EMG. Detailed assessments and solution concepts can be discussed with EMG Product Management (steffen.dombrowski@emg-automation.com), EMGs Sales and Service organisation (How to contact EMG), or directly with the EMG iCASS® team (icass@emg-automation.com), based on the specific technical and operational objectives of the galvanising line.
Originally introduced to minimise strip vibration in the coating zone and to enable narrower nozzle gaps, EMG eMASS® has since evolved into a mature, modular system that sets the global standard for non-contact strip stabilisation. With more than 90 systems ordered and successfully implemented in production lines worldwide, EMG eMASS® plays a central role in improving coating quality, reducing zinc consumption, and increasing overall process reliability in galvanising operations.
The development path of EMG eMASS®
The early development of EMG eMASS® was driven by the need to stabilise the steel strip in the high-temperature, high-turbulence environment above the zinc pot, where air knives are used to control coating thickness. The original system architecture relied on fixed magnet boxes that generated a stabilising electromagnetic field across the strip. Since then, the system has undergone continuous development: the introduction of modular configurations tailored to specific plant layouts and strip dimensions; the downsizing and thermal optimisation of magnet boxes for improved integration near the nozzle lips; and most recently, the incorporation of movable magnet actuators for dynamic stabilisation across the entire strip width. These advances have transformed EMG eMASS® into a versatile platform capable of adapting to a wide range of CGL designs, including integrated solutions in combination with the advanced air knife system DUMA-BANDZINK JetPro.
The major effects of applying EMG eMASS® in CGLs
In current industrial practice, EMG eMASS® systems typically achieve a damping effect of more than 50 %, significantly reducing strip vibration and a 60 % crossbow reduction. This enables closer nozzle-to-strip distances — down to less than 7 mm in specific cases — while maintaining coating uniformity and minimising overcoating. As a result, customers benefit from improved material yield and lower zinc consumption, directly impacting the return on investment.
New perspectives with EMG iCASS®
To further support process optimisation and open new opportunities for lines not yet equipped with EMG eMASS®, EMG has developed the EMG iCASS® platform (intelligent Control and Analytical Software Solutions). EMG iCASS® enables in-depth analysis of production data from existing galvanising lines, using machine learning models and statistical evaluation to simulate the potential performance gains of EMG eMASS®. For example, EMG iCASS® can identify and quantify coating inhomogeneities, strip shape deviations (cross bow), air knife misalignments and currently applied safety margins in actual process situations. This allows plant operators to make informed investment decisions regarding the implementation of EMG eMASS® in their lines ahead of investing. EMG offers this as a consultancy service for line operators who are not absolutely sure about the current optimisation potential for their galvanising line with and without EMG eMASS®.
Additionally, EMG iCASS® supports performance monitoring and automated or semi-automated process adjustment, as well as optimisation of coil transitions and target coating changes, in lines already equipped with EMG eMASS® or without. This further enhances the benefits of the EMG system family.
Conclusion
After almost two decades of industrial application, EMG eMASS® represents a mature and well-established solution for electromagnetic strip stabilisation in continuous galvanising lines. Its measurable effects on strip stability, coating uniformity and zinc consumption have been demonstrated in a wide range of plant configurations worldwide. Complementing this hardware-based approach, EMG iCASS® extends the system portfolio with data-driven analysis, simulation and control capabilities, enabling both prospective evaluation of optimisation potential and systematic performance improvement in the air knife operation.
Prepared for next steps?
Operators seeking to quantify stabilisation potential, validate investment decisions or further optimise existing EMG eMASS® installations are encouraged to engage with EMG. Detailed assessments and solution concepts can be discussed with EMG Product Management (steffen.dombrowski@emg-automation.com), EMGs Sales and Service organisation (How to contact EMG), or directly with the EMG iCASS® team (icass@emg-automation.com), based on the specific technical and operational objectives of the galvanising line.
