After nearly two years of preparation, the time has come: Schoeller has launched series production on one of the largest and most advanced large-diameter laser welding lines in the industry. This successful commissioning represents not only a unique project in the sector but also a showcase for knowledge transfer across the value chain, with Schoeller, the equipment manufacturer, and suppliers all contributing their expertise and problem-solving capabilities.
The new XL+ category laser welding machine is the centerpiece of the Laser Competence Center in Hellenthal. The facility is designed for the production of longitudinally welded stainless steel tubes with diameters ranging from 65 mm to 127 mm and wall thicknesses from 0.7 mm to 3.5 mm. With a welding speed of at least 7.5 meters per minute, the Laser XL+ quadruples the welding speed compared to existing TIG systems, significantly shortening the production process.
When Schoeller's technical project management team began planning the system about two years ago, the specification sheet kept growing. The goal was to achieve a significantly higher degree of automation and to reduce previously required manual operations, such as loading the decoiler, deburring the pipes, and welding the strip ends. Additionally, the Laser XL+ was to feature a new pipe-cleaning technology, improved pipe-end finishing, fully automated quality control, and packaging of the finished pipes. It also needed to be capable of processing austenitic, ferritic, and duplex steels.
Although these requirements provided a clear foundation for project planning and implementation, finding a suitable partner with the necessary expertise and a shared understanding of the project goals proved to be the first major challenge. Schoeller selected Olimpia 80 as its cooperation partner—an equipment manufacturer with more than 40 years of leadership in the production of high-quality stainless steel tube machinery. Olimpia is known for customized solutions that stand out for their technology, quality, and user-friendliness, helping to reduce manufacturing costs and lead times while increasing productivity.
The next challenge was managing complexity. During the installation phase, up to seven companies with over 30 individuals and a wide range of competencies had to be coordinated—not only to assemble the core system, which measures 96 by 11.5 meters, but also to install, set up, and configure 33 subsystems. This ensures that the system will offer maximum flexibility and allow for rapid changes in tube dimensions.
“The fact that we successfully managed this complex project is mainly due to the empathy and sensitivity of our project management team,” says Michael Gottschalk, CTO at Schoeller. “Solving technical problems requires the transfer of knowledge from all involved. Managing this within an interdisciplinary team of various cultures and nationalities was the key success factor. In the end, everyone involved—Schoeller, the machine builders, and the suppliers—learned a great deal from this project that can now be incorporated into future processes and product development.”
Achieving flawless pipe surfaces without discoloration posed a significant technical challenge for the team. Mastering the annealing process and surface structure alone took six weeks and several tons of material. “Despite our 40 years of experience in planning and implementing tube production systems—and our deep knowledge of the tube manufacturing market and all its challenges—this project was truly special and a milestone for us as a plant manufacturer,” says Gianluca Tarana, CEO of Olimpia 80. “Never before have we developed and implemented a system of this scale in such a customized way together with a customer. The insights gained from this pilot project will help expand our consulting and product offerings.”
With the Laser XL+ now handed over to production, Schoeller has further strengthened its expertise and competitive edge. The high-performance induction system ensures consistent and material-appropriate strength values. The laser cut-off delivers low-burr, reproducible, and flawless pipe-end quality. The fully automated quality control operates reliably, and in combination with the automated packaging, the targeted efficiency gains are being achieved.
With the new system, Schoeller will unlock additional revenue potential in the area of larger pipe dimensions—both in existing customer business and in applications such as heating technology, heat exchangers, hydrogen applications, and solar technology. Further opportunities are emerging in customer segments such as the chemical, pharmaceutical, food, and automotive industries.
