Complete grinding of rolling rings – Saarstahl relies on JUNKER

Saarstahl is one of the world’s leading manufacturers of long steel products and, as a reliable partner, supplies customers from a wide range of industries with tailor-made products that meet the highest quality standards.

The product portfolio of Saarstahl AG comprises a broad spectrum of long products, with wire rod accounting for the largest share, followed by bar steel and rail products. These diverse products are used in key industries such as the automotive industry, mechanical engineering, rail transport, as well as construction and infrastructure. The company’s success story is based on a combination of technological expertise, consistent customer focus, and a strong international positioning. A key element of the corporate strategy is the sustainable transformation of steel production: Saarstahl is consistently investing in modern, climate-friendly technologies with the aim of producing steel with reduced CO₂ emissions in the future. From a technological standpoint, Saarstahl sets benchmarks – for example, with wire rod from the Burbach plant starting at diameters of 4.5 mm, the thinnest of its kind in Europe.

At the Burbach plant, every minute, every component, and every process step counts. And it is precisely there, at the heart of production, that the rolling rings take center stage: highly stressed components that significantly influence the quality of the entire rolling process. This is how the collaboration between Saarstahl and JUNKER began in 2019, with initial grinding trials, when Saarstahl was searching for a new, more efficient, and more precise solution for grinding rolling rings. Where previously two separate machines were required to grind the outer diameter and the profile, the JUNKER Lean Selection shaft grinding machine enables complete grinding in a single setup. In addition, the grinding wheel can be dressed directly on the machine – another decisive advantage over the previous solution. Complete grinding in one setup not only increases process reliability, but also noticeably improves the quality of the rolling rings. The results are impressive, with perfect concentricity, high dimensional accuracy, and consistently excellent surface and profile precision. At the same time, significantly reduced non-productive and setup times streamline the production process. Another key benefit is the fast changeover of calibers without additional conversion measures, ensuring a high degree of flexibility in day-to-day operations.

Overall, the JUNKER grinding machine offers a modern, economical, and technologically superior solution that clearly outperforms the previous systems. 

The rolling rings produced on the Lean Selection shaft are used in the 10-stand finishing block. There, the rolling stock is rolled into wire in four individual roughing and finishing blocks, reaching production speeds of up to 100 m/s. The high performance of the line requires rolling rings that are both extremely precise and durable – requirements that are met through the precise machining on the JUNKER grinding machine. In ongoing operation, up to 500 rolling rings are machined per week on the Lean Selection shaft in an 18-shift model. This performance figure highlights the machine’s central role within the production chain and ensures a continuous supply of rolling rings for the four finishing blocks. “Since integrating the JUNKER grinding machine into our production process in 2023, the results speak for themselves: the Lean Selection shaft has taken our rolling ring production to a new level, both technically and economically,” reports Stefan Hellbrück, Head of the Rolling Mill at the Burbach plant. Today, only a few grinding wheels are required – compared to more than one hundred in the past.

But technology alone does not create success. It is also the collaboration that makes the difference. The very good relationship between the teams is particularly valued – one that is characterized by open and reliable communication. Both sides were able to contribute to the project, exchange ideas, and jointly develop solutions – a partnership-based collaboration in which both Saarstahl and JUNKER were able to actively realize their strengths. “Since the first grinding trials in 2019, our cooperation with JUNKER has continuously evolved – and we greatly value the open, constructive, and technically strong collaboration. Communication was always transparent, solution-oriented, and conducted on an equal footing,” says Stefan Hellbrück.

Thomas Bender, foreman in the production-related workshops at the Burbach plant, adds: “The trusted contacts we have worked with for many years formed the foundation for fast solutions, short communication paths, and reliable service and after-sales quality.“