In 2005, R&D activities focused on standardization and optimization of controls, especially for rolling mills and HCl (Hydrochloric acid) recovery plants, as well as on process improvements for levelling technologies and corrosion-resistant strip coatings for the automotive industry.

Fulfilling the demand of the automotive industry to improve laser weldability of corrosion-protected steel sheet, the research work for coatings focused on zinc alloys using electro-galvanizing, and PVD (Physical Vapor Deposition) or CVD (Chemical Vapor Deposition) technologies.

IDEAS simulation software is now in use for acid recovery plants in the steel industry. The development of a dynamic model allows operator training, control loop optimization, and equipment optimization.

A new, more accurate rolling pass schedule using Advanced Process Control (APC) has been developed ensuring precise calculation of the cold rolling process to optimize motor power and rolling speed. Combined with other improved design features, Andritz Sundwig rolling mills underscore their leading technology position in this field.

One other important step to improve strip quality during cold rolling was the redesign of the flatness control system. The new flatness roll with closed surface and improved sensor application assures the highest surface quality also for sensitive strip surfaces avoiding imprints. Using predictive control technologies, Andritz contributes state-of-the-art technology to the market, resulting in superior tolerances and quality.

A further development area focused on leveling technologies. The newest, high-precision leveler for automotive sheets was put into operation at Renault to full customer satisfaction. The newly developed leveler for very thick, high-strength steel strip is now in operation with excellent results. This has resulted in a new cost-efficient, multi-functional leveler to cover a wide range of strip thickness with only one machine.