The new drive system delivers 20% higher torque than the original design, significantly enhancing the mill’s aluminum processing capabilities. (Image source: SMS Group)
SMS group has successfully completed a major modernisation project at Gulf Aluminium Rolling Mill B.S.C. (GARMCO), a leading aluminum producer based in Manama, Kingdom of Bahrain, upgrading the motors and drives in the one-stand reversing hot rolling mill
Originally built by a third-party supplier, the mill has now been restored to full operational capacity and equipped to meet future demands in aluminum processing.
The upgrade replaced outdated DC motors with three-phase AC motors and advanced drive technology, including variable frequency drive systems powered by active front ends and new transformers. The new drive system delivers 20% higher torque than the original design, significantly enhancing the mill’s aluminum processing capabilities.
“The completion of this modernisation project is a testament to our commitment to maintaining world-class operational standards. SMS group’s expertise and advanced technological solutions have provided us with greater reliability and efficiency in our hot mill operations,” said Ebrahim Khalil, executive manager Operations at GARMCO.
The project scope was comprehensive, covering plant engineering, electrics and automation, equipment procurement and manufacturing, as well as installation and commissioning supervision. At the heart of the modernisation was SMS’s innovative twin-motor drive train equipment, featuring a custom gearbox to combine two electric motors with a rated power of 2150 KWs each, paired with two SMS giant torque spindles. The design offers high power capability, reduces space requirements, lowers investment costs, and provides some operational redundancy.
Additional equipment included the X-Pact Drive low-voltage frequency converter for the entry and exit coilers, a medium-voltage converter operated in load share mode, and transformers to supply the new systems. The equipment was tailored to GARMCO’s demanding operations, which include producing aluminum coils, tread plates, slit coils, and foils for industrial applications such as packaging and heat exchange systems.
The modernisation strengthens the collaboration between GARMCO and SMS group. This is the first joint project of this scale, reflecting SMS’s reputation for high-performance, reliable solutions with optimised technical features and superior power efficiency. The new drive system provides enhanced torque across the full speed range, a critical factor for rolling operations requiring high torque at elevated speeds.
“The project highlights the strong partnership between both companies and demonstrates how innovative solutions can elevate operational efficiency,” the SMS team noted.
Having previously supported GARMCO with technical services for its scalper machine, SMS group has built a foundation of trust and collaboration. With the hot rolling mill now modernized, GARMCO is well-positioned to deliver sustained operational excellence and produce high-quality aluminum products for its global customers.
