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Heavy industry and metallurgy

Modernization system of monitoring and control of the slitting machine in the aluminum plant

In 2014, PRO-CONTROL Sp. z o.o. modernized the control system and control of the slitting line of the LW2 machine for the largest Polish manufacturer of aluminum products. 

The production plant, apart from rolled products in the form of sheets and strips, is also the only Polish producer of primary metallurgical aluminum. 

Purpose of the investment 

The Wickeltechnik slitting line is designed for cutting cold-rolled coils of aluminum and its alloys into strips of the required dimensions. The cutting line control so far was carried out with the help of an old SIEMENS control system, based on the S5-135 controller. The modernization of the line consisted of the complete replacement of the existing controller with a modern DCS class PCS7 by SIEMENS.

In order to adapt the machine to the current requirements of safety standards and regulations, and in particular to comply with the EU Machinery and Tool Directives, a safety audit was carried out and recommendations were included in the investment. 

Due to the change of the system architecture to a modern distributed one, the control wiring in the facility was completely replaced.

System description

Scope of work

  • Replacement of the control system from old (no longer supported) SIMATIC S5 to PCS7;
  • Exchange of visualization from Coros to WinCC;
  • Replacement of control cabinets in the machine switchboard;
  • Replacement of the existing drives with new Sinamics DC types with controls;
  • Replacement of the operator panel with a new touch panel from the Simatic Comfort

Panel series..

The mechanical part of the machine has also been modernized. For this purpose, PRO-CONTROL has made and launched two new arms with pressure rollers for the internal and external reels. The new pressure arms based on a pneumatic system made it possible to adjust the pressure force independently for each of their two sides with additional joint compensation of this force.


The investment raised the reliability and safety of the machine, but also thanks to the new interface allowed us to improve the work of operators and improve the quality parameters and performance.


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