US-based Steel Dynamics, Inc. (SDI) has awarded SMS group a contract to modernize the process automation system at its hot strip mill in Butler, Indiana, as part of efforts to improve long-term maintainability, operational flexibility, and production performance.
The project will replace aging hardware and legacy automation models with SMS’s latest X-Pact level 2 automation system. The upgrade includes advanced process models, a modern ProconTEL-based communication architecture, and the X-Pact Vision webHMI interface to support high-precision rolling, improved strip geometry control, and consistent product quality. The Butler hot strip mill was originally supplied by SMS in 1993.
Among the key technologies to be installed is the X-Pact PSC model, which optimizes pass schedules and automatically adjusts rolling parameters based on actual process results, helping to maximize productivity and product quality. The finishing mill will also be equipped with the X-Pact PCFC model for enhanced profile, contour, and flatness control through optimized operation of the CVC plus and work roll bending systems. The system is designed to improve roll wear management and operational stability, particularly during long rolling campaigns.
In addition, the X-Pact Cooling Section Control (CSC) system will provide precise cooling strategies and temperature control to ensure consistent mechanical properties across a broad range of hot-rolled products.
First coil production using the upgraded automation system is scheduled for late 2026, while final project acceptance is expected in early 2027.
Steel Dynamics is a leading industrial metals solutions provider with operations across the United States and Mexico. The company is among the largest steel producers and metal recyclers in North America and also operates a significant downstream steel fabrication platform. It has recently expanded into aluminum, further diversifying its portfolio with flat rolled aluminum products.