12/02/2025 HBK - Hottinger, Bruel & Kjaer
Peter-Stefan Tampsi, Segment Manager at ABB IEC Low Voltage Motors, breaks down how reliable and robust Roller table motors stand to give a competitive edge back to the European metals industry. bipolar stepper motor
The European steel industry has reached a critical juncture. As of 2023, European steel production has fallen by 18% compared to its peak in 2007, according to the World Steel Association. High energy costs, regulatory hurdles, and the ever-growing pressure of global competition have intensified the struggles. The continent has seen several mills forced to scale back operations or shut down entirely, leaving the metals industry in need of innovative solutions to enhance productivity and reduce costs.
In this context, ABB's premium Roller table motors present a path forward. By enabling greater reliability, robustness, and operational savings, these motors promise the technological edge that European steel producers need to reclaim lost ground and outrun the competition, while levelling the playing field in the global metals market.
The European steel industry's recent struggles stem from a perfect storm of challenges. Energy, one of the industry’s largest cost factors, is nearly 50% more expensive in Europe compared to global averages, particularly in nations like Germany, which has some of the highest electricity prices in the world.
Additionally, despite being welcomed and necessary to achieve Net Zero, European Union emissions regulations have pushed production costs even higher. This makes it difficult for mills to compete with regions benefiting from looser environmental rules and subsidies.
In a landscape dominated by cost pressures, robust roller table motors that are resistant to unplanned stoppages and downtime could play a decisive role in bridging gaps in productivity. ABB’s Roller table motors are perfectly matched with ABB drives at the outset and are designed not just to keep mills running but to optimise their output – saving energy, time, and money, all while staying compliant with strict emissions standards.
ABB’s Roller table motors are particularly well-suited to meet the European steel industry's demands for increased efficiency and reliability. Several innovative features set them apart and hold the potential to reinvigorate struggling mills.
For example, the motors’ vertical fins provide natural cooling, eliminating the need for a fan and reducing heat buildup, enhancing durability even in the harshest operating conditions. Liquid or dust build-ups — common in steel mills — won’t cling to these fins, lowering the risk of overheating and substantially reducing cleaning and maintenance frequency.
Additionally, ABB’s motors are designed to operate seamlessly with Variable Frequency Drives (VFDs). In a continent where industrial electricity costs are high, using VFDs to control multiple motors allows for coordinated and cost-effective operation. Synchronised movement ensures a smooth steel rolling processes, minimising mechanical strain and energy consumption.
ABB's motors also utilise an optimised pole design tailored to each application. Customising a motor’s design to maintain stability in different load conditions and run cooler can extend motor lifespans up to 20 years. Optimisation is key to avoid overheating — even a 10°C temperature reduction has an outsize effect on insulation lifetime.
One of the persistent operational bottlenecks in the steel industry is bearing failure, which often results in costly motor servicing and downtime. The hot and corrosive environment of the mill puts immense stress on bearings, and this compounds with the harsh mechanics of steel production, such as sudden braking, rapid acceleration, and turbulent mechanical loads.
ABB mitigates this issue by combining smoothness of operation with robustness at the component level in both motors and drives. Accredited test labs provide specific performance data about components to customers.
Moreover, ABB provides motors that meet IEC (International Electrotechnical Commission) standards, allowing for seamless retrofitting into existing setups. This combines with an easy process of installation and the potential for customised specifications. This flexibility means that even older steel mills in Europe — some of which haven’t undergone a complete infrastructure overhaul in decades — can be upgraded with minimal disruption.
While challenges persist, European policy shifts are creating fertile ground for improving the metals sector’s future. The EU’s Green Deal Industrial Plan, launched in 2023, emphasises cleaner, more energy-efficient processes. By 2030, the European Commission aims to achieve a 55% reduction in greenhouse gas emissions compared to 1990 levels, and ABB’s Roller table motors align perfectly with this vision by offering lower energy consumption and fewer environmental impacts thanks to their seamlessly integration with drives.
Retrofitting a single steel mill with ABB’s motors and perfectly matched drive systems could significantly cut costs by reducing energy demands and minimising unplanned downtime – two key barriers to European competitiveness. Coupled with the ability to remotely monitor motor health using ABB Ability™ smart sensors, plant managers can optimise maintenance schedules and avoid costly failures.
While global steel players like China and India continue to dominate in raw output, Europe’s future lies in becoming a hub for high-quality, eco-friendly steel production. This means adopting innovations that not only reduce operational costs but elevate sustainability standards. ABB's Roller table motors and drives are particularly well-suited to usher in this transformation, enabling European mills to remain viable in an intensely competitive global market.
In unexpected locations like Eastern Europe, where industrial manufacturing is undergoing new investment, and established markets like Germany, where energy efficiency is a top priority, ABB’s robust motor systems have already begun to make inroads. The ability of these motors to perform under the most demanding conditions makes them a game-changer for the industry.
Now more than ever, Europe’s steel industry must prioritise efficiency and innovation to remain competitive. ABB’s Roller table motors offer a pathway out of stagnation by increasing productivity, saving energy, and easing maintenance burdens. By investing in premium technologies that address real-world industry pain points, European steel producers have the opportunity to reclaim their role as global leaders.
Innovation, flexibility, and reliability remain core to ABB’s mission — and with its comprehensive motor solutions, the company is positioned to support the European metals industry in navigating its most difficult challenges and emerging stronger on the other side. Smarter, efficient roller table motors could help shift the balance.
For more information, please contact: ABB Limited (Zurich) ABB Industrial Automation Affolternstrasse 44 Zurich 8050 Switzerland Tel: +65 (0) 6773 5857 Web: https://www.abb.com
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