Machines for sheet metal
Faspar-Simic: intelligent revamping of a coil-to-coil line for Arvedi AST
Faspar-Simic, in collaboration with Castellini Spa, has designed and built a coil-to-coil line for Arvedi AST for welding carbon steel tail ends onto stainless steel coils, combining cutting-edge technologies, industrial sustainability, and maximum production flexibility.
The project is based on the concept of intelligent revamping — that is, enhancing and renewing existing machinery by integrating it with high-performance new technologies. Through a comprehensive mechanical reconditioning process, hydraulic system upgrades, and the complete redesign of the electrical and automation systems, the line achieves technological and quality standards comparable to those of a brand-new installation, with significant benefits in terms of sustainability and investment optimization.
Production features and advanced automation
The line is designed to process coils weighing up to 30 tons, widths up to 1,540 mm, and speeds up to 200 m/min, with an estimated output of approximately 4 coils/hour. The entire process is managed by advanced automation systems that ensure:
- Continuous monitoring of process parameters
- Automatic strip guide
- High-precision centering and alignment
- Intuitive HMI interfaces for the operator
- Advanced monitoring of welding operations
CCW laser welder
The welding unit at the core of the line is the CCW coil-to-coil laser welder supplied by Castellini Spa.
The welder employs high-precision laser cutting technology with a Cold Wire Laser Welding (CCW) process — using filler material — along with automatic gap and edge alignment control, and an 8 kW high-efficiency fiber laser source.
This configuration delivers extremely robust welds, high mechanical performance, and excellent strip rollability, even in the most demanding applications.
Revamping: sustainability and industrial value
One of the most distinctive aspects of the project is the recovery and refurbishment of a significant portion of the existing machinery.
The stations subject to revamping include the opposed-mandrel uncoiler — for which the cones, drive system, and pressure arm were renewed while the base and machine body were preserved — the crop shear (existing module, integrated with a new scrap box), the strip centering unit, the extraction pull roll with deflector roller, the paper rewinder, the tension bridle, the exit-side deflector roller, and the paper unwinder. The remaining units — including storage cars, loading and unloading cradles, pinch rolls, straighteners, the entry gantry, the second uncoiler, the recoiler with strip alignment system, and coil storage saddles — were instead designed and built from scratch, ensuring maximum performance at the most critical stages of the process.
Through this approach, Faspar-Simic has successfully integrated components of different origins — reconditioned machinery and newly built units — into a line that operates as a single, optimized system, delivering:
- Reduced environmental impact compared to full new-build construction
- Optimized investment costs
- Recovery of the industrial value of existing equipment
- Reliability and performance on par with modern production standards
- Integration of a cutting-edge laser welder for maximum quality
In this way, Faspar-Simic brings circular economy principles to life on the steelworks floor.
Designed for the future
The line has also been designed with a modular structure and prepared for future expansions. Key upgrade possibilities include the installation of a side trimming unit, the integration of scrap chopper systems, and the conversion of the line from a tail-end welding setup to a full coil preparation line. A solution built not just for today's production needs, but engineered to scale with the customer's evolving process developments.
Do you have an existing system to recondition? The Faspar-Simic team is available to analyze your needs and identify the most effective solution for your coil processing lines.
