Cutting-edge technology, new dimensions, and cross-industry know-how transfer: With the Laser XL+, Schoeller takes the next step
Schoeller has commenced series production on one of the largest and most advanced large-diameter laser welding systems in the industry following nearly two years of preparation and ramp-up. The successful commissioning of the system is not only a unique achievement within the sector but also a prime example of knowledge transfer along the value chain, with Schoeller, the plant manufacturer, and various suppliers contributing their expertise and solution competencies.
The new XL+ category laser welding system is the centerpiece of Schoeller’s Laser Competence Center in Hellenthal. The system is designed for the production of longitudinally welded stainless steel tubes with diameters ranging from 65 mm to 127 mm and wall thicknesses between 0.7 mm and 3.5 mm. With a tube welding speed of at least 7.5 meters per minute, the Laser XL+ quadruples the welding speed compared to existing TIG systems, significantly reducing production time.
When Schoeller’s technical project management team began planning the system about two years ago, the list of requirements continued to grow. The machine was to feature a significantly higher degree of automation, reducing previously necessary manual tasks such as loading the decoiler, deburring the tubes, and welding strip ends. Additionally, the Laser XL+ was designed to include a new tube cleaning system, improved tube end machining, fully automated quality control, and packaging. Furthermore, it had to be capable of processing austenitic, ferritic, and duplex steels.
While these specifications provided a clear foundation for project planning and execution, identifying the right partner—one with both the necessary expertise and a shared understanding of the project objectives—was the first major challenge. Schoeller selected Olimpia 80, a leading machine manufacturer specializing in high-quality stainless steel tube production for over 40 years. Olimpia is renowned for its customized systems, which stand out for their advanced technology, quality, and user-friendliness while helping to reduce manufacturing costs and processing times and increasing productivity.
Another challenge was managing the project’s complexity. During the installation phase, up to seven companies with more than 30 experts from different disciplines had to be coordinated to not only assemble the core system—measuring 96 x 11.5 meters—but also install, set up, and configure 33 subsystems to ensure maximum flexibility of the system in the future, enabling quick adjustments to tube dimensions.
“Successfully managing this complex project was primarily made possible due to the empathy and sensitivity of our project management team. Solving technical challenges requires knowledge transfer from all involved parties. Managing this process within an interdisciplinary team with different cultures and nationalities was a key success factor. In the end, all stakeholders—clients, system manufacturers, and suppliers—gained valuable insights that will influence future workflows and product development,” says Michael Gottschalk, CTO at Schoeller, reflecting on the two-year preparation phase.
Producing tubes with flawless surfaces and without tempering colors was one of the most significant technical challenges. Mastering the annealing process and surface structure alone took six weeks and required several tons of material. “Despite our 40 years of experience in designing and building tube production systems and our in-depth knowledge of the tube manufacturing market, this project was unique and a milestone for us as a plant manufacturer. Never before have we collaborated with a customer to custom-develop a system of this scale and successfully integrate it into the production process,” says Gianluca Tarana, CEO of Olimpia 80. “The insights gained from this pilot project will help us expand our consulting services and product offerings.”
With the handover of the Laser XL+ to production, Schoeller has further expanded its technological leadership and quality advantage. The in-line bright annealing machine ensures material-appropriate and consistent strength properties, while the Laser Cut-Off enables low-chip, reproducible, and flawless tube-end quality. The fully automated quality control system is functioning seamlessly, and together with the automated packaging system, the targeted efficiency gains are being realized.
With this new system, Schoeller will generate additional revenue potential in the market for larger tube dimensions, both with existing customers and in key industries such as heating technology, heat exchangers, hydrogen applications, and solar technology. Further opportunities arise in customer segments such as chemicals, pharmaceuticals, food processing, and the automotive industry.