SMS group modernizes process automation in hot strip mill at Steel Dynamics (SDI) hot strip mill in Butler, USA

• The new X-Pact^® level 2 system is designed to enhance long-term maintainability, reliability, and operational flexibility at the Butler hot strip mill
• Advanced process models, modern ProconTEL-based communication, and an X-Pact^® Vision webHMI support precise rolling and consistent product quality
• X-Pact^® PSC^® and PCFC improve the rolling schedules as well as profile, contour, and flatness control in the finishing mill
• The CSC cooling model ensures reproducible material properties and appropriate strip temperatures, with commissioning planned for the end of 2026

Steel Dynamics, Inc. (SDI) has commissioned SMS group to complete a comprehensive upgrade of the process automation system at its hot strip mill in Butler, Indiana, marking an important step toward long‑term maintainability and increased operational flexibility of one of its core production assets. By replacing aging hardware and legacy models with state‑of‑the‑art technologies, SDI continues to ensure that the hot strip mill, originally supplied by SMS group in 1993, remains highly productive, easy to maintain, and reliable for years to come.

The new X‑Pact^® level 2 system integrates advanced process models developed by SMS group, modern ProconTEL‑based communication architecture, and the intuitive X‑Pact^® Vision webHMI to support high‑precision rolling, improved strip geometry control, and consistent product quality.

The X-Pact^® PSC^® model provides the physical foundation for precise pass schedules. It helps to secure maximum production output and superior strip quality while automatically adjusting parameters based on real process results—enhancing responsiveness to new product requirements and increasing production flexibility.

In the finishing mill, the X-Pact^® PCFC model calculates the ideal set points for the CVC^® plus (continuous variable crown) and work roll bending systems, ensuring excellent profile, contour, and flatness control across SDI’s full product range. Its high flexibility is particularly advantageous for mills that run long rolling campaigns with wear-optimized roll barrel profiles, where traditional CVC^® strategies are limited. By applying shifting methods such as cyclic work roll shifting, the PCFC system combines outstanding strip quality with efficient roll wear management—an important contributor to operational stability.

Accurate cooling is achieved through the X-Pact^® Cooling Section Control (CSC). With highly precise cooling strategies for a wide range of hot rolled products, CSC ensures consistent, repeatable material properties. It enables variable coiling temperatures along the strip and provides in bar temperature control from head to tail, ensuring that mechanical properties meet SDI’s target specifications.

Randy Patterson, Hot Mill Manager at SDI Butler, commented: “SMS is a trusted partner whose technologies continue to deliver the performance and reliability we expect. With this upgrade, we are strengthening the long term capability of our Butler operations and ensuring that our customers receive consistently high quality products.”

André Merten, Project Manager at SMS group, added: “The modernization builds on a decades long partnership between SDI and SMS. Our level 2 systems ensure stable production at other SDI facilities, including Columbus and Sinton. With this project, SDI Butler will benefit from future ready automation designed for sustained operational excellence.”

First coil production with the modernized system is scheduled for late 2026, with the Final Acceptance Certificate (FAC) targeted for early 2027.