Product catalogue

Elmas Machine

Rolling Mill Machinery

Jahan Foulad Almas

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About

Elmas Machinery

Elmas Machine Company started working in Iran in 2019 as the first company producing rolling machines on a scale of over 300,000 tons. Setting up rolling lines had been one of the biggest challenges of Iranian investors and engineers in the past, but now we are proud that we were able to complete all design stages as well as manufacture and operation in Iran with the help of one of the strongest design teams in the country in this industry. Elmas Machine Company is the only company with a systematic design team in the field of rolling machinery design, which has been able to use young and experienced Iranian engineers along with foreign, expert engineers and manufacturers.

Global iron and steel production is a growing industry that readily benefits from any technological advancement. We are committed to work with ever-increasing enthusiasm and constantly update ourselves to provide our customers with high-quality machinery innovation and excellent engineering services. Since our inception, we have steadily grown into a renowned provider of high-quality, cost-effective business solutions. Our ability to continuously evolve and flexible approach to the dynamic business world have helped us to achieve success in a short period of time. The design and manufacture of the first housingless stands with the world's latest technology can be considered the winning card of the company.

About

Research & Development

Innovation behind every machine

At Jahan Foulad Almas, we continuously invest in research and development. Behind the innovative products lies a lot of expertise and courage to leave the conventional paths in order to exploit the new potential. We provide our customers with comprehensive knowledge ranging from conceptual design, manufacturing, assembly and service to automated data analysis. Thanks to our R&D department, it's no surprise to see the positive results of our hard work to minimize energy consumption while maintaining production at optimal levels for our customers. We are proud to present our products which are technologically advanced and optimized with our experience. We strive to provide you with our best to support your competitiveness in this intensive global iron and steel industry.

2019Started working in Iran

300,000+tons — scale of rolling machinery

340,000tons/year — Amin Sim Gostar line

94 mlargest cooling bed set up

About

Services

Our services at Elmas Machine Co.

Planning, manufacture and operation of rolling mills
Re-manufacture of existing facilities
Providing a wide range of reliable and trustworthy knowledge, experience and expertise
Providing complete solutions for the production of rebar and other steel products
Providing new solutions
Fast, flexible and efficient comprehensive support by combining technology and innovation in the manufacture of rolling lines
Creating synergy for innovative solutions
Supporting your investment with the help of a set of expertise to build production lines with high productivity

About

History

Company History

Kaveh Zanjan steel complex rolling line project

11classic top-open stands

150,000tons per year

With eleven classic top-open stands
With a production capacity of 150,000 tons per year

Amin Sim Gostar Meybod steel rolling line project

340,000tons per year (nominal)

94 mcooling bed length

The largest production line of rolling rebar and coil
With a nominal capacity of 340,000 tons per year
Turnkey contract
Having the responsibility of the entire line from the beginning to the time of operation
Setting up the largest cooling bed with a length of 94 meters

About

Policy

Company Focus

The policy of Elmas Machine Company focuses on designing production lines with the most up-to-date technology in the world, low production costs, flexibility, increasing productivity considering improving energy efficiency, improving the quality of the final product and providing environmental requirements with minimum cost.

Development

Our research and development department strives to provide the most up-to-date services according to the needs of our customers. We strive to be ready for a future that heralds fierce competition by building the most advanced machinery in the industry with the help of new technology.

Elmas Machine — Rolling Mill Machinery

Hot Rolling Mill

Products

Hot Rolling Mill

Steel plays a vital role in the modern world. In addition to being one of the most important construction and infrastructure materials, steel is also an enabler of a wide range of production activities. It also creates opportunities for innovative solutions in other sectors and is essential in research and development projects around the world. Industrial steel products play an important role in the development of a sustainable society and also in a society that creates health and vitality and human nature. In this regard, the establishment of steel companies creates employment, domestic and export revenues, and ultimately accelerates innovation.

The main purpose of the hot rolling mill is to produce various steel products. The main elements of the rolling mill Group system are stands and gearboxes, all of which are designed and manufactured in Elmas Machine. This company is able to make housingless rolling stands that have a high production capacity and are more compatible with today's technology. It should be noted that by implementing the horizontal and vertical combination of housingless stands, its efficiency can be increased. Besides this type of stand, classic rolling stands with two or three rollers are also produced. The company also offers a complete and high-quality range of product manufacturing services, including roller conveyors, crop shears, error shears, cold shears, sizing shears, cooling bed platforms, packaging units, and loopers.

Complete range

Housingless rolling standsClassic 2- and 3-roller standsGearboxesRoller conveyorsCrop shearsError shearsCold shearsSizing shearsCooling bed platformsPackaging unitsLoopers

Stands & Gearboxes

Rolling Stands

The design and manufacture of Elmas Machine Company's stands are done according to the needs of its customers for three groups of rolling lines:

1Roughing group

2Intermediate group

3Finishing group

Housingless roughing type stands for continuous rolling lines
Intermediate and final groups, for continuous rolling lines with classic rolling stands (top-open) or housingless type with the capability to design and manufacture horizontally or a combination of horizontal and vertical

Types of Rolling Stands

Three-roller roughing stand
Two-roller stand for the intermediate and the final group
Housingless type rolling stand
Universal rolling stand

Stands & Gearboxes

Features

Guarantee the quality of rolling line stands with the highest technology by precise engineering calculations
Production of housingless type stands according to modern technology with precise CNC machines
The capability of applying the hydraulic clamping system optionally on the connection of the classic rolling stand chassis
The capability of removing the slip of the horizontal and vertical stand by adding a hydraulic lock to fix the axis of the rolling stand during the passage of rolling materials
Supply of stand rollers from the best companies in the region with warranty, certificate and necessary chemical analysis
Calibrating rolling rollers with the most accurate CNC lathes

Stands & Gearboxes

Gearboxes

An industrial gearbox is a system in which mechanical energy is transferred from one device to another and is used to increase torque and decrease speed. Transmissions can vary their speed and torque to convert energy into a compatible format. They are useful for facilitating mechanical operation in industries. Elmas Machine gearboxes are made with different strength and with a wide gear ratio for use in different groups of driving axles. Also, the produced gearboxes can be used in various industries besides iron and steel.

Manufacture of all gearbox parts in Jahan Foulad Almas collection
Accuracy in inspection, testing and quality control of output parts at every stage of production
Gear cutting is checked according to power, output load capacity, durability, vibration, etc.
Necessary optimization with the help of up-to-date technology

Function	Increase torque, decrease speed
Gear ratio	Wide range, for different groups of driving axles
Manufacture	All parts made in-house
Gear cutting checks	Power, output load capacity, durability, vibration

Gearboxes

Shears

Cold Shears

Cold Shears are suitable for cutting metals with different shapes and sections at the end of the cooling bed and at the beginning of the packaging unit immediately after cooling. The design and production of cold shears with different features is done for each specific project. The produced shears have high strength, and the capacity of the cutting force and the length of the blade are determined according to the annual production capacity of the factory.

Position	End of cooling bed / start of packaging unit
Cutting force & blade length	Set by the plant's annual production capacity
Automation	Pneumatic brake-clutch system

The capability of automating the Cold Shears using a pneumatic brake clutch system, mechanically with a high capacity
The capability to equip the shield mechanism with the ability to adjust the length to input-output rollers

Shears

Fly Shears

Fly Shears are the right size for cutting rebars and steel profiles at the end of the rolling process, each shear is designed specifically for its purpose and to meet the needs of customers.

Position	End of the rolling process
Drive	Electric motors with clutch-brake (pneumatic)
Options	Thermal sensors, more automation

The capability of automating the size of Fly Shears with electric motors with a clutch-brake (pneumatic) system
The capability to integrate thermal sensors and more automation systems depending on the needs of the project
The capability to use U and I brackets and profiles (iron beam, studs) to cut larger sections such as metal sheets
The capability to cut more vertical products due to the new design to protect the blades

Shears

Crop Shears

Crop Shears are suitable for cutting steel bars and profiles during the rolling process, which can be used for both end cutting and cross-sectional cutting depending on the location. The design of each scissor is done specifically according to the location and to meet the needs of the customers.

Position	During the rolling process
Cuts	End cutting and cross-sectional cutting
Drive	Electric motors with clutch-brake (pneumatic)

The capability of automating Crop Shears with electric motors with a clutch-brake (pneumatic) system
The capability to integrate thermal sensors and more automation systems depending on the needs of the project
The capability to use U and I brackets and profiles (iron beam, studs) to cut larger sections such as metal sheets
The capability to cut more vertical products due to the new design to protect the blades

Thermex

Thermo mechanical operation (Thermex)

Thermo mechanical operation (Thermex) is done to pass the steel rebar produced in the hot rolling process from water. Quench systems are used to apply water under pressure through a special nozzle system to increase the strength and hardness of the rebar. Thermex is designed and built in one to four lines with different lengths depending on the speed of the line. But the Thermex system can be designed according to the need and type of hot rolling, depending on the length and number of nozzles (for example, two lines, three lines, and more).

Lines	1 to 4 (or more, as required)
Linear speed	Up to 16 m/s
QST yield stress target	500 N/m (as stated in source)

Resistant to pressure up to a linear speed of 16 m/s in sudden cooling of hot rebars using water (thermo-mechanical treatment of rebars will greatly improve their quality)
The ability to design and produce high-quality and appropriate steels based on international standards with high resistance and strength against erosion and corrosion using the Thermex system

Thermex

QST

QST Technology in Thermex

QST technology means quenching and self-tempering, which is done to increase the strength of ribbed rebar. The main goal of this system is to bring the yield stress of the rebar to 500 N/m in an in-line process in the rebar hot rolling unit, which results in the ease of constructing large buildings.

No need to change the chemical composition of the produced steel
Reducing alloying costs with less manpower to produce rebar used as reinforcement (alloying is needed to produce earthquake-resistant rebars)

Line equipment

Roller Conveyor

The roller conveyor is a series of rollers that are placed in a special body. Roller conveyors are known as the most widely used transfer systems due to their ease of use and low manufacturing cost. These systems are designed and manufactured according to the needs of customers and the capacity of the factory. The design of the excitation system can be done in different forms of gears, chains, or belts and pulleys according to the user's needs.

Drive options	Gears, chains, or belts and pulleys

Remarkable strength
Simple operation
High reliability factor

Fast Roll Changing Robot

Fast roll changing robot is used to prepare housingless stands. It is used to increase the speed of changing rollers and preparing them. One of the biggest advantages of these robots is to reduce the need for device users. Robots are designed and manufactured fully automatically or semi-automatically in different capacities according to the needs of customers.

Operation	Fully automatic or semi-automatic
Capacity	Different capacities to customer needs

Line equipment

Tying Machine

The Tying Machine of Elmas Machine Company is used to pack the products that are finished and come off the line in different sizes and lengths. Customer satisfaction has increased due to simple operation and fast packing time. Robots are designed and manufactured fully automatically or semi-automatically in different capacities according to the needs of customers.

Operation	Fully automatic or semi-automatic
Products	Different sizes and lengths

Tilting Machine

This device is used to tilt housing-less stands from horizontal to vertical and vice versa, which can be designed and manufactured in two types, semi-automatic and fully automatic, hydraulically or mechanically.

Types	Semi-automatic, fully automatic
Actuation	Hydraulic or mechanical

Cooling, Loopers & Guides

Cooling Beds

Cooling beds are used at the end of the rolling process to cool the newly produced hot rolling. The main purpose of the bed is to lower the temperature of the entire product at the same time to prevent tension in the rebars.

Cooling Bed Parts

Set of input rolls
Apron mechanism (cassette)
Fixed shoulders
Movable shoulders
Vimlayer part (chain, step)
Set of bed output rollers
Cold cutting scissors
The main gearbox of the bed (bed stimulation system)
Apron stimulation system set (mechanical or hydraulic systems)

Cooling, Loopers & Guides

Cooling Beds

Cooling Bed Operation

Equipped with rakes with parallel movement of the ribs, which includes a two-way stimulation system to change the place of rolling contact with the substrate to prevent continuous contact of a part of the rolling with cold metals and substrate parts.
Continuously changing the contact point of the rebars by lifting and moving towards the outlet and lowering in order to reduce the temperature evenly and transfer them to the end of the line on a set of roller tables.
Billet Cooling Bed: lowering the temperature of the billets by continuously rotating the billet in order to change the contact surface of the billet with the cooling bed and also to avoid distorting the shape of the billet.

Advantages

The most common type of cooling
Design with standard elements according to customer needs in product size and material grade
Using the best quality materials in manufacture
The possibility of using chain transfer as a traverse method
Cooling of the product in the specific cycle thanks to the appropriate size of the cooling beds

Cooling, Loopers & Guides

Loopers

A looper is used to create the expected tension between the stands. Under load input and output is used with pneumatic piston. Loopers are placed in the final group of stands. The height of the looper is always level, which is obtained by using the signals of the scanner installed in the place of passage inside the loopers. The input command of the loopers is by scanners that are installed behind it to check the height of the looper. Loopers change the speed of the stands according to the flow and input signals of the scanners for the purposes of proper steel shaping.

Position	Final group of stands
Actuation	Pneumatic piston
Control	Scanner signals (loop height)

Cooling, Loopers & Guides

Guides

Guides are mechanical systems used to provide a smooth and controlled path for rolling materials. Another purpose of these systems is to help the rolling materials (ingots) to pass and to adapt to the calibration of the rollers. Guides can be designed and produced according to material properties and available calibration.

Guides Types

Static conductors
Converter boxes
Two-roller input boxes
Four-roller entry box guides
Double slate boxes
Triple cutting boxes
Quadruple cutting boxes

Ethics & Certificates

Values

Ethics

Due to our business ethics and striving for perfectionism, our team always strives to create the best possible products and provide unparalleled service. We make sure that we prioritize efficiency and never compromise on quality.

The guarantee of success and sustainability of production is honesty and quality. Our respect for our work never compromises our principle which has certainly made us a pioneer in the industry since our establishment.

Engineering, manufacturing, assembly, training, technical assistance, we do all of them with the same excitement and enthusiasm as on the first day.

Ethics & Certificates

Certificates

Management system certificates issued by EIQM Certification Services to Jahan Foulad Elmas Co. — scope: construction of steel processing production line.