Page 19 - ITAtube Journal 3 2025

Interview
ITA: SMS supplied Zekelman Industries
with the world’s largest continuous ERW
tube welding line in 2022. What technical
factors make it the industry benchmark for
large-diameter ERW production?
M. Braggiotti: Over many years, SMS has
developed a coherent, market-aligned
concept for highly efficient, high-perfor-
mance and flexible ERW pipe welding lines.
Now we have applied this concept to a
28-inch pipe welding line. For the first time,
this line can produce wall thicknesses of up
to 1 inch (25.4 mm) using an ERW process.
This sets a new benchmark and demon-
strates SMS’s ability to maintain a consist-
ent portfolio of market-driven solutions
and innovative concepts to meet current
industry requirements.
ITA: Are there any targeted retrofit meas-
ures to bring brownfield ERW tube welding
lines close to RD 710 performance? What
outcomes can plant operators expect?
M. Braggiotti: We deliver the full range of
capabilities necessary to modernize exist-
ing plants in line with market dynamics and
customer requirements. The scope and
potential benefits of modernization are
defined by our customers’ objectives, and
our team works closely with them to define
and tailor a wide range of options. We view
this as the start or continuation of a close,
value-driven partnership aimed at achiev-
ing the best possible result together.
ITA: During a brownfield retrofit, which
technical levers deliver the largest perfor-
mance improvements and why?
M. Braggiotti: There are numerous ways
to enhance a plant’s performance: mod-
ernizing or replacing equipment, increasing
capacity, refining component geometry,
upgrading control systems, and optimizing
process flows, among others. One effec-
tive option is converting to quick-change
equipment with X‑Pact® Quicksetting con-
trols, which enable rapid, automatic and
reproducible changeover and positioning
of pipe-welding lines. Many such improve-
ments have already been implemented
successfully on existing plants of various
sizes.
ITA: What role do rapid automatic roll-set-
ting systems, such as X-Pact® Quicksetting,
play within a targeted upgrade program?
M. Braggiotti: The SMS quick-change
concept, coordinated by the X-Pact®
Quicksetting system, is a proven solution
deployed across all SMS ERW pipe welding
lines. It allows dimensional adjustments
to be performed rapidly, simply, accu-
rately, and reliably, fulfilling current market
demands for powerful, flexible and precise
ERW welding equipment. These solutions
can be supplied as full systems or modular
upgrades for existing installations, offering
a cost-effective way to enhance efficiency
and competitiveness.
ITA: From a commercial and operational
perspective, what advantages do targeted
upgrades offer compared with building a
new ERW line?
M. Braggiotti: Pipe production operates in
a highly competitive, price-driven market.
Each pipe manufacturer must sustain its
market position through ongoing adjust-
ments and improvements. Requirements
are shaped by a multitude of local cost
factors. New plants entering the market set
a higher bar and frequently achieve sub-
stantially greater efficiency than existing
facilities. As a result, operators of existing
plants will, sooner or later, need to adjust
to remain competitive. The impact of
these adjustments varies with their scope
and can include expanded dimensions or
product ranges, quality improvements, cost
savings or higher production efficiency.
ITA: Which customer segments and specific
applications should prioritize upgrades,
and what product mix or margins can they
expect after modernization?
M. Braggiotti: Global trends show that
manufacturers are pursuing greater
independence, and customers are seeking
increased flexibility in product offerings.
Priority customers are those facing fre-
quent size changes, high scrap costs or
capacity constraints. After modernization,
they can expect a broader product mix,
reduced changeover times, higher margins
through lower scrap rates and greater
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