KOCKS NEWS and SERVICE

IT’ S
MO RE
TH AN

WE KEEP OUR PROMISES
An investment decision for a KOCKS block brings the highest
ratio of profit to total investment costs as well as the
best long-term investment security.
A customer who makes a strategic investment decision for KOCKS will
secure his competitive leadership for the lifetime of the KOCKS equipment.
Our vision „Know-how for tomorrow“ underlines this claim.
1
KOCKS 3-roll technology blocks have been successfully operating for more than 40 years
and still (!) surpass today’s market requirements. Thus, an investment in KOCKS is an
intergenerational long-term investment.
2
... just a machine
With KOCKS our customers will realize the highest ROI. It is not the investment price which
determines ROI in the long term. KOCKS customers will maximize their ROI in the long run by:
+
+
A more valuable
product mix with
a higher average
selling price.
price
+
A reliable, best
in class process
leading to the
highest mill availability
and utilization
in combination
with the lowest
operating costs.
+
The shortest
ramp up curves
leading to immediate
production
and immediate
profit after start up.
Investment projects
that are – in the
KOCKS world –
always realized on
target, on budget
and on time.
costs
- rolled
2
3

TABLE OF CONTENTS
Editorial
Reliable Partner for
the Steel Industry
03
01
Advancements beyond
our rolling blocks
in the field of industrial
automation & digitization.
Towards the digital roll shop
36
38
Optimum cooling processes
40
Green steel and the shift
towards a BANI world are
among the key trends shaping
the future of the steel industry.
Navigating in a “BANI WORLD”
10
12
From science to industry
42
05
Ready Steady Green
16
02
The latest developments and
exciting updates from KOCKS,
showcasing our commitment
to innovation and progress.
18
04
Step into the world of steel and
explore installations of KOCKS
blocks all over the world.
Sizing blocks for Europe
and beyond
iRSB ® for Nucor Steel
Nebraska in the U.S.
44
46
48
Insights and motivations
why the people at KOCKS do
what they do, highlighting
the importance of people
in our business.
Interview: Jessica
Interview: Thomas
Interview: Andrea
Interview: Shi Tao
62
64
66
68
70
We make your product gold
20
KOCKS rolled ® steel in China
50
Upgrade for proven
sizing blocks
24
Special bar quality
made in India
52
Meet the advanced KOCKS
intermediate RSB ®
26
Japan`s steel industry
and KOCKS
54
Metallurgical Consulting
for long products
27
KOCKS 3-roll technology
in South Korea
56
Stands are the heart
of a rolling mill
28
Walsin Lihwa`s decades-long
relationship with KOCKS
58
A decisive factor for the quality
of the rolled product
30
Partner for seamless
tube production
60
Made in Germany
32
4
5

EDITORIAL
RELIABLE PARTNER
FOR THE STEEL INDUSTRY
Ali Bindernagel, Chairman of KOCKS and the Managing Directors Rötger Teyke (Finance) and Günther Schnell (Sales &
Marketing) share their perspectives on where the industry is heading and give an overview of recent developments at
KOCKS. A conversation about mastered and forthcoming challenges, but foremost about the major trends and new
opportunities in the steel sector.
A pandemic outbreak in 2020, radical
changes in the global supply chains,
geopolitical changes… The past three
years have been everything but easy.
How did KOCKS navigate through the
complex market conditions?
Ali: We are a family business in the third
generation, and throughout our history
we have encountered a few turbulences.
However, thanks to our strong
foundation, KOCKS has always been
able to adapt and evolve. This applies to
the Covid-19 pandemic, too, where we
have been able to effectively manage the
challenges of recent years. In particular,
our emphasis on unparalleled reliability
and our great team, who is committed to
close relationships with our customers
and delivering superior products, helped
us to maintain a competitive advantage.
Nevertheless, often crises are
accompanied by financial challenges…
Rötger: Operating in the international
steel industry has always been
challenging. In some ways, we’re used
to dealing with big changes in the
business world. Personally, I remember
the “Asian crisis” in the late 90ties and
especially the financial crisis in 2008,
as both had a big impact on KOCKS. I
think the reason why we can manage
these major upheavals so well is indeed
our focus on economic sustainability
and reliability. Within the framework
of a very conservative, long-term
financial management, we have already
established measures to be resilient
when this word was not as popular as it
is today. Even when the sea gets rough,
this resilience allows us to react very
flexible to changes and insecurities in
global markets.
Nonetheless, 2020 must have been a
tough year, as all active projects were put
on hold and revenue from machine sales
broke in?
Günther: It was really a challenging
period which confronted everybody
with quite some unique and unknown
situations, both in our personal lives
and in our professional lives. All of a
sudden, travelling was impossible for
an unexpected long period. However,
we adapted quickly and continued to
be in close contact with our customers
and partners throughout the pandemic.
Numerous projects were concluded
successfully by meeting virtually, which
was a surprising experience for us but
also for our customers. There have
been disruptions in the supply chains
worldwide and shipping of products was
not easy at all. Carrying out supervision
services was almost impossible because
the plants are installed in places
worldwide. But it was not possible to do
everything online and thus, especially
our field engineers experienced
increased stress and uncertainty due
to various health and safety protocols
as a result of the unprecedented
situation. A special “thank you” to all field
supervisors who spent weeks and weeks
in quarantine before being allowed to
go to site. Today, we can say that KOCKS
has been capable to draw on its strengths
and resources, handling challenging
situations, and continuing to provide
value to its customers. Fortunately, the
conditions calmed down, although some
hurdles remain.
6
Managing Directors: Günther, Ali and Rötger
7

EDITORIAL
Speaking of the current business
situation, what do you perceive as
the most pressing challenges facing
companies of the “old economy”?
Rötger: Progressing digitalization
has rendered the term “old economy”
obsolete. Nevertheless, the challenges
in traditional industries like the steel
sector vary greatly in different regions
and countries. In a broader global
context, one of the key challenges is the
substantial investment to realize the
vision of “green steel”, which is hindered
by an increase in trade barriers. Another
challenge is the major task to implement
digitalized processes and drive targeted
product innovations. Additionally, aging
societies, including several European
countries and China, are confronted
with a growing shortage of skilled
employees in the industry.
What is KOCKS’ strategic approach
to innovative solutions in this
environment?
Ali: KOCKS is a niche player. In our
niche, we are mindful to the specific
needs of every customer. Focusing on
quality, performance, and customer
satisfaction, we have been a trusted
partner for steel producers for decades. In
the world of today, characterized by the
green and digital transformation of our
industry and ever new circumstances,
our customers can rely on the fact that
we deliver what we promise, regardless
of the efforts we need to invest. By living
this approach, KOCKS has become the
most recognized expert worldwide in
the particular field of 3-roll technology
for rolling tubes as well as bars or wire
rods, and we, as a team, are committed
to stay ahead and maintain our leading
position.
Staying tuned and ahead on a global
scale undoubtedly requires considerable
investments – How does KOCKS
master this?
provide new solutions to the market.
However, the most valuable factor
we aim to cultivate is the creative
and solution-oriented thinking of
all members of our team and their
understanding of “engineering” as a way
of making things even better.
In recent years, KOCKS has started
to actively integrate Industry 4.0
technologies in its portfolio… What’s the
main idea behind it?
Ali: The steel industry is increasingly
incorporating Industry 4.0 technologies.
In times of a growing globalization,
these technologies help steel producers
to tap various potentials and stay
ahead. With the rise of Industry 4.0
a few years ago, we have started to
enhance our products with digital
tools and automation solutions. Thus,
we can further improve the efficiency,
performance, and quality of the rolling
process. Our latest developments
include the BAMICON Octopus that
assists operators in the stand and guide
preparation, as well as our advanced
cooling solution “The Blue Box ® ”.
Digital innovations are one thing, but
what has happened regarding KOCKS’
unique 3-roll technology?
Günther: KOCKS’ Reducing & Sizing
Blocks (RSB ® ) are widely recognized in
the steel industry for their outstanding
overall performance and reliability. To
better meet the constantly evolving
demands of the steel industry, we have
further advanced our RSB ® generation.
Another result of our efforts is the highly
flexible iRSB ® , which was successfully
commissioned at Nucor Steel Nebraska
in USA. Here, the KOCKS iRSB ®
replaces traditional 2-High stands in
the intermediate section, which brings
numerous benefits and will attract more
steel producers facing limited space,
restricted flexibility and short process
length in their rolling mill.
steelmaking. At KOCKS we are fully
committed to embrace sustainability
throughout our operations. We have
made substantial investments in solar
energy at our manufacturing facilities
in Bremen. Averaged over the year,
forty percent of our electrical power
consumption is already generated by
our own photovoltaic system. This will
help us to align our operations with
environmental goals and contribute to
a more sustainable future for the steel
industry.
Rötger: The urgency to address climate
change and our responsibility to act
are evident in our daily lives. At KOCKS,
we recognize the importance of
investing in and further reducing our
CO 2 footprint. However, it is essential
to recognize that today’s business
environment presents multilateral
challenges, including dysfunctional
supply chains, increased competition,
and the emergence of new technologies
in an Industry 4.0 era. In the light of
these complexities, it is crucial for me
to adopt a holistic approach. Our future
success is not solely determined by the
green transition, but by how well we can
integrate ecological, economic, social
and technological aspects. All these
dimensions are interwoven, and I believe
that only by embracing a comprehensive
approach we can drive success and
contribute to a more sustainable future.
What’s your strategy to tackle the
challenges ahead?
Günther: We are confident that we
can overcome any of the current
hurdles facing our industry and
continue to thrive in the years ahead.
We are committed to keeping pace
with technological advancements,
responding to ever-changing market
demands. We are working hard to
maintain our leading position in the field
of 3-roll sizing technology, continuing
with highest-quality engineering and
trusted reliability.
Thus, KOCKS has a bright future ahead?
Ali: This is what KOCKS stands for. At
the same time, we are convinced that
our success is not limited just to our
machines. We say: “It’s more than just
a machine”. The machine comes along
with the unique KOCKS family and
culture, with the perspective to deliver
what we promise, on time and on budget
and an exemplary service covering
the whole lifecycle of our products.
The latest issue of our KOCKS News
Corporate Magazine will provide you
with further insights into our KOCKS
world and our proactive approach to
shape the future.
Enjoy the content and stay connected
with our journey!
Rötger: We continue our conservative
financial policy, which enables us to
invest in our innovation-driven strategy.
Furthermore, we are implementing
very professional, modern project
management and development tools,
which help us to complete our projects
on target, on time and on budget, and
You have already mentioned the
industry’s significant shift towards green
steel production. What are your thoughts
on this transition?
Ali: We do recognize a significant
focus on green innovation in the
steel industry, especially in primary
8
9

MEGATRENDS
cis s a
tE wo l
R
is n e cu
of n e .
E
Industries across the globe are grappling with the simultaneous challenges
of digital transformation and sustainability. But these challenges provide
new opportunities, too. However, to release potentials we must rethink our
approach to business, innovation. By embracing new principles, we can
develop the resilience and adaptability, and agility needed to manage this
transition and build a better future for ourselves and the planet.
10
11

MEGATRENDS
NAVIGATING IN A “BANI“ WORLD
Current conditions in business and society as well as social, political and economic aspects are changing very quickly and
dynamically. These changes unfold their force in a variety of ways and are characterized by factors which are summarized in
the acronym BANI. The concept behind this term was developed by the US-American futurologist Jamais Cascio and is intended
to make the multi-layered developments and tendencies in the world tangible, thereby helping to realign one’s own actions
if necessary. Cascio describes the interaction of Brittleness, Anxiety, Non-linearity, and Incompleteness – resulting in BANI.
Brils
Ani
Non-ar
Inopne
In the BANI world, brittleness refers to the fragility
and instability of our systems and structures.
We are experiencing an entirely new frequency
and intensity of change. New situations arise
within seconds. The world is characterized by
changes that occur ever faster and with increasing
momentum, potentially causing more and more
consequences. The result is a world that “feels” like
it is spinning ever faster. Countermeasures can be
taken by increasing the resilience of a system from
within and acting with flexibility and courage.
In a business context, this may involve building
more flexible and adaptable systems, or developing
backup plans and redundancies to ensure that
critical functions can continue in the event of
unexpected disruptions.
BBRITTLE
Anxiety in the BANI concept is driven by a range
of factors, including rapid technological change,
economic volatility, and political instability. At the
same time, anxiety is probably one of the feelings
that humans are the least able to cope with. And
yet, the world we wake up to in the morning is often
very different from the world we woke up to the day
before. Old patterns and rules are becoming less
and less valid. We will all have to take this fact into
consideration. Meaning that we will increasingly
have to question ourselves, consciously rethink and
adapt our behavior. Using this approach can help
individuals and organizations adjust to a constantly
changing new normal.
AANXIOUS
Non-linearity describes the phenomenon where a
small change in one area can lead to unexpected
and disproportionate effects in another area. The
multitude of influencing factors can no longer
be evaluated. This makes it almost impossible to
predict the outcome of any particular action or
decision, as even minor changes can have far-
reaching and unpredictable consequences. This
non-linearity can be seen in a variety of contexts,
from global finance markets or value chains. The
reality of the BANI world is diffuse, and less and less
plannable and predictable. The view into the future
seems blurred, and the consequences of one‘s own
actions are characterized by a rising degree of
uncertainty. It is therefore important to be aware
of potential non-linear effects and to take a holistic
and adaptive approach to decision-making.
N
NONLINEAR
Incompleteness refers to the lack of reliable
information that individuals and organizations
must handle. It can manifest itself in a variety of
ways, including conflicting data, limited access to
information, and the rapid pace of change that can
make it difficult to keep up with new knowledge.
An example of incompleteness in decisionmaking
is the challenge of dealing with emerging
technologies that are rapidly changing and
evolving, and the question of how to integrate these
technologies into processes. Developing the skills
and tools to manage such incomplete information is
essential. It is also essential to cultivate a culture of
continuous learning and adaptation to keep up with
the fast pace of change and to remain agile in the
face of uncertainty.
i
INCOMPLETENESS
12
13

MEGATRENDS
CHANGE:
THE ACRONYM BANI
CHARACTERIZES
THE WORLD WE
CHANCE:
HOW KOCKS
FACES THIS
CHANGING WORLD.
LIVE IN TODAY.
We live in a time where the global
economy seems to be facing ever new
challenges: multiple threats, disrupted
supply chains, financial perils, and
continued uncertainty about the
outcome of numerous crises. Situations
arise in which proven systems,
strategies and established thought
patterns reach their limits.
In this environment, companies
face the task of making the right
forward-looking decisions. Future
competencies, i.e. acting flexibly,
proactively and anticipatively are
more important than ever.
Values, commitment and resonant
relationships form important points
of orientation in a complex, volatile
BANI world. Companies that create
this environment will be able to
successfully shape their future
and the path of change.
The greatest danger in
times of turbulence
is not the turbulence,
it is to act with
yesterday‘s logic.
Peter Drucker,
Management author and
consultant – described as ‘the
founder of modern management’.
KOCKS – as a pioneer and for decades
leader in 3-roll sizing technology –
draws its strength from a proven
formula: FUTURE SKILLS EMBEDDED
IN ABSOLUTE RELIABILITY!
At KOCKS, we create an atmosphere
in which we combine people, abilities
and uniqueness in an inspirational
way. This is how we enable and support
change processes. Ingenuity and astute
thinking ahead are always combined
with strong KOCKS values as well as
proven, sophisticated engineering.
It’s our KOCKS vision to
go with great ideas far
beyond the existing while
focusing on absolute
reliability and partnership
towards our customers
Ali Bindernagel,
Chairman of KOCKS
C G
14
15

MEGATRENDS
READY
STEADY GREEN
One of the major challenges the steel industry is facing today is the shift towards green steel production.
Green steel refers to steel that is produced using environmentally friendly methods and processes focusing on
reducing carbon dioxide emissions and other pollutants. This shift is necessary in order to meet the growing
demand for sustainable materials on one hand and mitigate the negative impacts of traditional steel production
on the environment on the other.
Traditional steel production
considerably contributes to global
carbon dioxide emissions. The
furnaces and processes used in steel
production release a significant
amount of CO2 into the atmosphere,
contributing to climate change
and other environmental issues. In
addition, the mining and processing
of raw materials for steel production
can have negative impacts on local
ecosystems and communities.
To address these issues, the steel
industry is turning to so-called green
steel production methods. These
methods use renewable energy
sources and innovative technologies
to reduce carbon dioxide emissions
and other pollutants.
Popular approaches to green steel production, include:
• Electric arc furnaces: These furnaces use electricity
from sustainable sources to melt scrap steel and
produce new steel or go by DRI rather than using
high-temperature traditional BOF-routes.
• Hydrogen-based processes: Some innovative steel
production methods use hydrogen to reduce iron
ore and produce steel, rather than using coke.
• Carbon capture and storage: Some steel producers
are experimenting with capturing carbon dioxide
emissions from traditional steel production processes
and storing them rather than releasing them into the
atmosphere.
• Recycling loops: Recycling steel reduces the need
for raw materials and energy, leading to lower carbon
dioxide emissions.
Although, many leading steel producers already foster the integration of new technologies, challenges remain to be
overcome. Traditional steel producers are hesitant to make the switch due to the upfront costs or uncertain return
on investment. In addition, there is still a lack of consistent regulations and standards for defining green steel
production, which makes it challenging on many levels.
However, this does not change the fundamental direction and dynamics of the green transition and will not derail
it. Instead, the industry will likely overcome those challenges in the years to come, moving increasingly towards
green production. There is a lot to gain, too.
From a market-oriented view, by adopting sustainable production methods, steel producers can not only reduce
their environmental impact and meet the increasing demand for “green steel“. Additionally, it comes with positive
side effects as this shift often leads to increased efficiency, cost savings, and also results in strong reputational
gains for companies that honestly work on the transition.
DRIVERS:
Climate Change: The most significant driver of the transition
towards green steel is the urgent need to reduce greenhouse gas
emissions and mitigate the effects of climate change. The steel
industry is one of the largest industrial emitters of greenhouse
gases accounting for approximately 7-9 % of global emissions.
Corporate Social Responsibility: Companies are recognizing
the importance of reducing their environmental footprint and
are adopting sustainability goals that include reducing carbon
emissions.
Government Regulations: Governments around the world
are introducing policies and regulations aimed at reducing
greenhouse gas emissions, and incentivizing the transition
towards low-carbon and carbon-free steel production.
CHALLENGES:
Cost: One of the main transition challenges towards green steel
are the high costs to implement new technologies and processes.
This includes the cost of investing in new equipment, research and
development, and the cost of raw materials.
Limited Availability: Another challenge is the limited
availability of low-carbon and carbon-free raw materials.
For example, carbon-free hydrogen is not yet produced at a scale
large enough to support widespread use in steel production.
Scalability: New technologies are still at an early stage and must
be scaled up to meet the demands of the global steel market.
All in all, the shift towards
green steel production may be
challenging in the short run, but
it is necessary for the long-term
sustainability of the industry and
the preservation of our ecosystems.
At KOCKS, we believe that the
future of the steel industry depends
on the successful adoption of green
steel production methods. From
our perspective, it is not only up
to industry leaders, but we all have
to contribute that this transition
becomes reality.
Pursuing our sustainability
initiative, we will continue to
invest in future-oriented green
innovation. As a team of specialists,
we work on the integration of
ecological aspects into every part
of our business. With this ambition,
we are blazing our trail to act as
a sustainable company. We have
worked out three major pillars;
Reducing our company carbon
footprint, continuous optimization
of KOCKS technologies and their
environmental impact as well as
long product lifecycles.
Reducing the carbon footprint with
solar power: KOCKS MANUFACTURING
in Bremen utilizes 2296 solar modules,
generating 750kw(p) and covering up to
80 % of the energy need.
16 17

02
»KOCKS IS THE PIONEER
OF 3-ROLL TECHNOLOGY
AND HAS BEEN
DOMINATING THE
MARKET FOR DECADES.«
- rolled
Steel producers trust in KOCKS‘ high-level
market orientation and reliability in a
rapidly changing world.
18
19

SPOTLIGHT
WE
MAKE YOUR
PRODUCT GOLD
PARTNER OF STEEL PRODUCERS WORLDWIDE
KOCKS is a global player in the rolling mill industry with a proven track record of worldwide references. The unique
products are intergenerational investments, as the equipment operates highly reliable over decades. Technologists with
in-depth expertise focus on providing customers with advanced solutions for the rolling of long products.
The company’s history dates back to
1946, with customer orientation being
a tradition since that time. Today,
customers rely on KOCKS for highest
market-orientation as well as for mindful
dedication to people and teams in an
increasingly changing world. Based on
the requirements of the steel industry,
a team of engineers continuously
develops new solutions. Consulting,
planning, development, design, supply,
assembly and commissioning of
rolling mill equipment as well as taking
mindfulness responsibility have become
core competencies.
One of the most significant innovations
took form early in the company history –
the idea of applying the 3-roll technology
from forming tubes also to forming
bars and wire rod. The KOCKS 3-roll
technology allows for the precise control
of the material being formed, resulting
in a high-quality finished product. Until
today, the motivated team continues
to innovate and improve its advanced
3-roll blocks. Key technologies such as
the SRB ® for the production of seamless
tubes and the RSB ® for reducing &
sizing of bar and wire rod are installed
worldwide and produce millions of
tonnes of quality steel every year.
With a KOCKS block in the heart of their rolling
mills, customers define the quality of the end product
utilizing the unique 3-roll technology.
REDUCING & SIZING BLOCKS
FOR SPECIAL BAR QUALITY
The KOCKS RSB ® technology is the
leading sizing application for steel
producers of long products worldwide.
Addressing the market needs, the
RSB ® allows SBQ producers to roll large
amounts of special steel in the highest
qualities, including straight bars, bar
in coil and wire rod. Those are used
in demanding industries such as
automotive and aerospace applications
around the world.
The highly precise blocks allow
the significant improvement of
productivity, availability and yield.
The absolute reliability has made the
RSB ® the most versatile solution for
SBQ sizing applications. Its free-size
rolling capability in combination with
fastest size changes is a big plus, as it
allows tight tolerances to be met while
maintaining maximum mill availability.
“The RSB ® product range provides
customers the ideal foundation for the
perfect production of SBQ products”,
says Günther, Managing Director Sales &
Marketing. “We are the preferred supplier
of producers for the automotive, machine
building and engineering industries as
these branches ask for highly reliable
rolled products with an excellent quality
and close tolerances.” In consequence,
KOCKS is present worldwide wherever
those sectors are a significant part of the
respective economy and counts various
references not only in regions such as
China, Japan and India, but also North
and South America and of course in
Europe. “Based on our know-how from
over 75 years in the industry and more
than 4500 cumulated operating years
of the installed base, we aim to actively
shape the future of SBQ-production”,
explains Günther.
20
21

SPOTLIGHT
STRETCH & REDUCING BLOCKS
FOR SEAMLESS TUBES
The latest generation of Stretch Reducing
Blocks (SRB ® ) has been designed to be
extremely compact, making it a highly
efficient and cost-effective solution
for producing seamless steel tubes of
the highest quality. The SRB ® StarDrive
System is a key feature of this generation
of blocks, and it is designed to ensure
individual drive of the rolls in the 3-roll
stands on all stand positions of the
SRB ® . Major advantages of the SRB ® is
its ability to provide the shortest stand
spacing, a highly precise mill setup and
the possibility of adjusting roll gaps in
the finishing passes. Furthermore, the
highly dynamic drive system is capable
of producing seamless tubes with no
distortion and maximum precision.
The SRB ® comes with standardized
components that are designed for
maximum reliability and ease of
maintenance. “The SRB ® is a result of
years of research and development, and it
has been designed to meet the demands
of the most modern steel industry”,
states Günther. Customers like Benteler,
Vallourec Mannesman or Voestalpine,
have decided trust the combination of the
strong and precise rolling stands with a
highly dynamic drive system to produce
seamless steel tubes of excellent quality
highly reliable.
Günther, Managing Director Sales & Marketing at KOCKS
IT’S MORE THAN JUST A MACHINE
Embedded in a profound quality strategy,
KOCKS is investing in the further
development of its rolling mill equipment
and digital solutions for the steel
industry. The engineers have developed
in-depth expertise in the specific area
of rolling mill technology and can focus
resources on improving the products
and solutions in that area. “This niche
position allows KOCKS to differentiate
from larger full scale suppliers which are
recognized as generalists and provides
a unique added value proposition as
the highly reliable specialist to our
customers”, explains Günther. The result
is superior performance and quality
compared to more generalized large
plant builders. In this regard, the slogan
#itsmorethanjustamachine is meant
to show, that the company is not just
supplying rolling blocks or equipment,
but acts with a tangible attitude of loyalty
and mindfulness and as a fully reliable
and highly flexible partner in the process.
„Our goal as a team of specialists is to
create holistic solutions according to the
specific needs of our individual customers,
not just products“, says Günther. With
its team of around 180 specialists with
an unique focus, KOCKS is flexible and
responsive to changing market conditions
and demands of customers.
It’s more than a machine” implies a spirit of
dedication and great attention of the team to individual
givenness and realities of every steel producer as well
as a direct line of communication to relevant experts.
“With great dedication we address our
honest commitment to contribute to
the success of our customers”, tells
Günther. For KOCKS this means working
closely with steel producers to further
improve the performance of the installed
equipment – even decades after the
block has rolled its first bar. This leads
to creative and advanced solutions for
example the new 3-roll intermediate
block (iRSB ® ) for Nucor Steel Nebraska
in the United States but also to further
improved technological software which
is undergoing a constant fine tuning to
solve specific challenges and to optimize
the customer’s production process.
With this focus on specialization,
flexibility, customer service, loyalty,
and reliability, KOCKS has established a
reputation as a leading supplier of rolling
mill technology worldwide. Through
its commitment to ongoing innovation
and long-term relationships, KOCKS acts
as a trusted partner for its customers,
supporting them in achieving their
production goals.
“All this is the story behind our slogan,
“WE MAKE YOUR PRODUCT GOLD.”,
Günther sums up.
22
23

SPOTLIGHT
UPGRADE
FOR PROVEN
SIZING BLOCKS
ADVANCED DESIGN FOR RSB ®
In the steel industry, KOCKS unique Reducing & Sizing Blocks (RSB ® ) stand for
maximum overall performance and reliability. After the successful completion of
the project, “Performance. Reborn“, the finishing blocks now come with a new
appearance featuring a redesigned safety cover and casings and with the futureoriented
BAMICON Octopus Software.
Thus, the RSB ® is now even better
equipped to meet the ever-changing
demands of the steel industry.
The advanced design features a more
compact block casing that improves
the accessibility and ease of use for
operators. The new safety design
minimizes the risk of accidents and
injuries, making the RSB ® not only
more efficient but also safer.
Customers can rely on the same great
overall performance and reliability wellknown
from the previous generations.
Moreover, the new design allows
for easier integration of peripheral
equipment, such as measuring systems.
The use of profile gauges has
become the standard in the steel
industry over the past years, as they
assure the product quality supervision
and a competitive advantage.
Chinese steel producer Jiyuan was
among the first to receive the updated
design, which boasts the mentioned
improvements. The new RSB ® 500 ++ /4 for
the production of medium and large size
SBQ products also incorporates the latest
digital and automation technologies,
allowing for improved process control
and quality assurance.
EXPERIENCE · RELIABILITY · PRECISION
24
25

SPOTLIGHT
MEET THE
ADVANCED KOCKS
INTERMEDIATE RSB ®
MAXIMUM REDUCTION ON SHORTEST SPACE
Commonly, the proven KOCKS RSB ® technology finds its application as a finishing unit in highperformance
SBQ-mills for rolling straight bar or bar in coil, as well as a pre-finisher in high-speed
sizing applications for wire rod. Now, KOCKS has made its proven 3-roll technology ready for
an integration as an intermediate mill. The new iRSB ® has been developed to replace traditional
2-High stands. This comes with several advantages.
The 3-roll intermediate block, gives
rolling mill operators more options in
terms of flexibility and safety. Especially
in rolling mills where space is limited,
still being able to add additional
reduction capacities grants some
very crucial advantages. For example,
bigger billet sizes can be used, or a
different, more flexible distribution of
the reduction in the stands is feasible –
which allows it to further optimize the
quality of the finished product.
With an iRSB ® , steel producers benefit
from a tailor-made rolling mill with a
minimum footprint and less foundation
and piping efforts. Foremost, the iRSB ®
not only helps optimize the overall
project costs but also the operating costs
with the lowest possible media and
energy consumption per ton of rolled
material and efficiency gains over the
entire mill line, e.g. through a reduction
of needed stand changes. Furthermore,
the whole mill operation is simplified
due to a fully automatic stand change.
No overhead crane manipulation or
manual, operator-requiring adjustments
in the rolling mill are needed.
Various benefits in day-to-day
business:
Simplification of whole rolling
mill operation
Flexibility of the rolling mill
Increase in productivity
Higher safety for rolling
mill operators
Shortest downtime for revamping
Minimized foundation work
and field piping
The new concept simplifies operation
and flexibility of an existing rolling mill
and increases productivity and safety at
the same time.
METALLURGICAL
CONSULTING FOR
LONG PRODUCTS
QUALIFIED PARTNER FOR
STEEL PRODUCERS
As a qualified partner for producers of special steel and sophisticated materials,
KOCKS expanded its service portfolio to include consulting – from the billet to the
finished product. Customers benefit from leading expertise and in-depth know-how
for their projects in the field of process design and comprehensive production system
optimization. Special emphasis is placed on conducting research projects and hot
rolling trials on behalf of customers, in addition to material and process consulting
and technology webinars.
For the long product rolling process,
KOCKS provides customized consulting
services to help customers achieve higher
quality, better productivity, and costeffectiveness.
The company’s experts
offer process optimization services
that include an analysis of the entire
production process, finding ways to
improve it, and coming up with solutions
that meet the customers’ needs. KOCKS
also assists customers in selecting and
integrating the appropriate rolling mill
equipment and technology to maximize
the efficiency of their operations.
Research and development capabilities
allow KOCKS to conduct hot rolling
trials and material testing in Bremen,
Germany to determine the most efficient
and effective process parameters for
customers’ materials. KOCKS also offers
regular technology webinars to keep
customers updated on its products and
the latest trends, innovations, and best
practices in the industry. With a focus
on quality, performance, and customer
satisfaction, KOCKS’ consulting team is
committed to being a trusted partner for
steel producers looking to improve their
long product rolling processes.
The leading American steel producer
Nucor Steel Nebraska was among the
first to order the intermediate block from
KOCKS. Their RSB ® 370 ++ /8 works
hand in hand with the existing
RSB ® 370/5, allowing for improved
flexibility and efficiency.
26
27

SPOTLIGHT
STANDS ARE
THE HEART
OF A ROLLING MILL
THE BACKBONE OF RELIABLE PRODUCTION
At KOCKS, our philosophy is
straightforward: we believe in German
engineering and manufacturing
standards. Why? Because at the heart,
quite literally, of the steelworks are the
core components in the rolling process –
the 3-roll stands. KOCKS rolling mills are
essential for the production of SBQ steel
bars and high quality tubes. They define
the quality of the finished product. These
parts that have to withstand extraordinary
forces during operation are at the same
time part of a finely tuned process.
28
29

SPOTLIGHT
A DECISIVE FACTOR
FOR THE QUALITY
OF THE ROLLED PRODUCT
Our customers can rely on more
than 75 years of experience in our
niche; accumulated by KOCKS in 254
block installations and more than
4500 operation years of our reliable
3-roll technology. KOCKS supplies
proven, sophisticated engineering and
equipment, developed with ingenuity and
inventiveness to meet customer needs
of tomorrow. This forward thinking is
embedded in a well-rooted philosophy:
KOCKS reliability in partnerships, in
processes and as an attitude.
DECADES OF EXPERTISE
30 31

SPOTLIGHT
MADE IN
GERMANY.
WE ARE THE MANUFACTURING TEAM OF KOCKS
WE DO!
Flexible. Precise. Solution-oriented.
In a rapidly developing world with
constantly new challenges for markets,
technologies, and customer needs, we,
KOCKS MANUFACTURING, believe in
our team and encourage them to the
distinctly open mindset: “WE DO“
is more than a claim, “WE DO“ is a
solution-oriented attitude.
For our customers, precision is the be-all
and end-all for machine durability, plant
availability and – last but not least – their
productivity.
At KOCKS MANUFACTURING, we
have a particularly keen instinct for the
details of a wide variety of machining
operations.
We as a team talk about how to
solve an issue – not who caused it! Our
attitude: WE DO! All this is supported
by our open and creative KOCKS
MANUFACTURING team spirit”.
Thanks to our decades of expertise
and our quality philosophy “Made
in Germany“, we can call ourselves
as a recognized manufacturer and
established KOCKS workshop for
sophisticated mechanical engineering,
large gear manufacturing and gear
technology. Our projects move in an
exciting mix of classic mechanical
engineering, the highest definition of
precision, technical craftsmanship as
well as a lot of innovative Smart Factory
according to Industry 4.0.
Manufacturing standards.
According to Industry 4.0 standards.
Our service – whether as a contract
manufacturer or as a KOCKS
manufacturer – is characterized by
the latest standards of Industry 4.0:
From engineering, manufacturing,
and assembly of complete blocks to
extensive test and inspection runs.
Robotics workpiece handling, modern
pallet changing and setup concepts
complement our flexible manufacturing
strategy. We use advanced CNC
machines, which we program exactly
to the desired component to be
manufactured.
Thus, we can react flexible to customer’s
needs, we can shorten delivery times
and lead the manufacturing order to
sustainable success.
Our close link to the market in
combination with our consistently
high standards in engineering the
KOCKS Technology for SBQ, stainless
und seamless tube processes enhance
vice versa the profound knowledge of
precision.
Our in-depth expertise in
sophisticated gear technology allows us to
offer a special SERVICE to our customers:
Previously installed C-discs and
components are overhauled and repaired
to a high standard in our workshop”.
Moreover, we dedicate ourselves
continuously with passion to achieve
optimum process performance. Thanks to
our Quality Management according to ISO
9001 – our internationally provable quality
capability – we benefit from a learning
and continuously improving organization.
PRECISION MINDSET
32
33

Next Generation team spirit.
We grow with the competence
of every individual.
We exchange views on strategic,
technological, and operational issues in
close cooperation between our teams of
KOCKS and KOCKS MANUFACTURING. In
manufacturing we look back on more than
50 years of experience and distinctive skills
in the field of mechanical engineering.
In addition to this, we believe in involving
the expertise of our employees for
getting the best results. An internalized
mentality of customer orientation, an open
communication within our teams and at
interfaces, transparent information as well
as focused trainings stand for a holistic
agile management and process approach.
Lean management is part of our KOCKS
MANUFACTURING philosophy, which
includes effective and efficient design of the
value chain. Always focusing on customer
orientation and avoiding waste”
And all this pays off on our quality
philosophy “Made in Germany” and
sustainable sourcing standards
“Sourced in EU”.
Assuming social responsibility.
We qualify young professionals.
Industrial value creation also means
investing in young people, offering
high quality trainings in a smart factory
environment. Within our KOCKS
MANUFACTURING team young people
find exciting career prospects with unique
later job prospects – being located at the
pulse of industrial value creation.
Qualifying young professionals also
means getting fresh ideas and the impetus
of a new generation to our KOCKS
MANUFACTURING approach.
Last but not least.
We use the power of the sun.
In our corporate responsibility, we owe
future generations and our climate
sustainable energy production. This is
our conviction and attitude. So, with
our investment in a solar plant, we have
made the decision to make our ecological
footprint significantly more sustainable.
KOCKS Manufacturing supplies itself
to a large extent independently and
ecologically sensible with regenerative
energy from the power of the sun.
SMART FACTORY
LEAN MANAGEMENT
34 35

03
»FOCUS MEANS
BEING A PROVEN
EXPERT AND STAYING
AT THE PULSE OF TIME.«
- rolled
Companies who ignore the growing influence of industry 4.0 related topics,
risk their competitive advantage and fall behind. Industry 4.0, also known
as the fourth industrial revolution, refers to the integration of advanced
technologies such as automation, data exchange, and the Internet of
Things in manufacturing and other industries. These technologies are
transforming the way businesses operate and compete.
As a leading manufacturer of rolling mill technology, KOCKS recognizes
the importance of embracing Industry 4.0 and related topics to remain
competitive in today's rapidly changing business environment. KOCKS
acts as a partner of steel producers to tackle the challenges of industrial
digitization and automation by providing cutting-edge technology
solutions that enable clients to optimize their production processes,
increase efficiency, and reduce costs.
Further advanced process, automation and digitization solutions, enable
steel producers to maximize the benefits of Industry 4.0 technology. With
a focus on innovation and reliable relationships with customers, KOCKS is
committed to helping steel producers thrive in the digital age and beyond.
36
37

DIGITIZATION & AUTOMATION
TOWARDS
THE DIGITAL
ROLL SHOP
A NEW WAY OF ORGANIZING
SET-UP PROCESSES
THE SYSTEM SUPPORTS
ROLLING MILL OPERATORS:
Visual, paperless guidance to help
operators perform routine tasks and
complex processes more efficiently
Automatic product planning and
synchronization with the RSB ®
Identifying and managing correct
set-up of stands and guides in the
roll shop
Simplifying roll inventory
management
Transparent overview of rolls,
stands and their condition
Easy to operate – intuitive
dashboards
Embedded in a profound solution-oriented process strategy, KOCKS as 3-roll pioneer is investing in the continuous
development of its rolling mill equipment and digital solutions, as well as modern automation technology. The roll shop is
equipped with a tailor-made solution that supports the entire tooling process from start to finish. The BAMICON Octopus
software assists operators in the preparation of stands and guides in the roll shop and supports all verification steps before,
during and after rolling – including assistance for setup corrections as needed. Furthermore, it calculates the perfect rolling
program and the optimum rolling set-up automatically.
Arne,
General Manager AIT Division
The steel industry is constantly evolving
and producers are always looking for
ways to improve their efficiency and
productivity. KOCKS has further developed
their Bar Mill Configuration System
(BAMICON) that does just that. Arne,
General Manager at KOCKS’ Automation
& IT Division puts it concisely “The recent
BAMICON generation covers setup
calculation, production planning, 3-roll
management and assists operators during
their work in the roll shop”. The tool is
intended for steel producers utilizing a
KOCKS RSB ® for sizing applications.
Since decades, KOCKS’ BAMICON, an
acronym for the company’s Bar Mill
Configurator, acts as an integral digital
tool for the set-up of the Reducing &
Sizing blocks (RSB ® ). The most advanced
generation, named BAMICON “Octopus”,
is a workflow-oriented application that
streamlines the production process and
improves overall efficiency in the roll shop.
“Offering a range of features and a userfriendly
interface, the advanced BAMICON
Octopus comes as a valuable software
solution for every steel producer aiming to
digitize roll shop operations”, states Arne.
By introducing the BAMICON
Octopus, KOCKS is demonstrating its
commitment to provide innovative
solutions which address the needs of the
steel industry. “Production planning and
tool handling for finishing rolling mills
can be complicated, time-consuming
and fault-prone – BAMICON Octopus
cleans up with this”, says Arne. The
system will reduce planning work for the
RSB ® to a minimum and make shop floor
tasks easy, safe and hassle-free.
Visual and paperless workflow
management
One of the key features of the BAMICON
Octopus is its ability to automate the
workflow management in the roll shop.
The work steps at each station are
visualized, and the operator is guided
through the entire process, minimizing
potential errors and increasing overall
process safety. “The software allows
operators to access the necessary
information and instructions directly on
their screens, eliminating the need for
paper-based documentation and reduces
the chances of problems caused by
incorrect interpretation of handwritten
instructions to zero”, explains Adrien as
Lead Developer.
Digitizing the tooling processes in
the roll shop, the BAMICON Octopus
will also lead to more efficient
communication between different
shifts and employees, as it facilitates
the sharing of information and updates
in real-time. Even individual notes
and hints for each working step of the
standard processes can simply be added
in the BAMICON Octopus. This ensures
that the tailor-made suite fits even better
to the individual customer needs over
time.
Interfaces to higher level systems
As connectivity becomes increasingly
important inside rolling mills, the
BAMICON Octopus has interfaces to
higher level process control systems,
allowing for automatic product planning
and synchronization with the RSB ® .
According to Adrien, on this basis, the
set-up calculation automatically finds
the best stand arrangement for each
product. The product queue feature will
furthermore plan the best sequence of
tools to be used with the RSB ® , taking
into account factors such as stand
preparation status, rolled material,
product dimensions, mill capabilities
and roll stand times.
“Together, the set-up calculation
and product queue synchronization
features of the BAMICON Octopus
provide valuable insights and help steel
producers to optimize their production
process and improve their bottom
line”, summarizes Andreas as product
manager.
Set-up and inventory management
for stands and guides
As another important aspect of the
BAMICON Octopus, Andreas highlights
the software’s ability to manage the
stands, rolls and guides in the rolling
mill and their preparation for production
use. “The system prevents potentially
incorrect set-ups as RFID tags at every
stand and guide identify accidental
misplacements”, he says. For every
prepared set of stands, it is ensured that
Arne, General Manager,
Adrien, Lead Developer,
Andreas, Product Manager
the final set-up complies with the given
specifications. Furthermore, BAMICON
Octopus provides tools to track the entire
life cycle of rolls and helps to organize all
rolls in the workshop and their condition.
“We want to help customers manage
their entire KOCKS inventory and provide
them with a transparent overview of all
rolls, guides and their condition”, Andreas
explains the strategic approach.
This will also bring steel producers
in the position to make data-based
decisions about maintenance,
necessary replacements, and inventory
management, throwing the light on
customer’s benefits.
From “just” machines to holistic
solutions
KOCKS has a long history of closely
working with its customers to understand
their unique pain points and develop
solutions that are tailored to those needs.
This approach has helped KOCKS to
establish itself as a trusted partner for steel
producers around the world, and also led
through the development of BAMICON
Octopus.
Instead of just providing a product,
KOCKS came up with a complete solution
that addresses the digitization of manual
processes in today’s KOCKS sizing mills.
38
39

DIGITIZATION & AUTOMATION
OPTIMUM
COOLING PROCESSES
ADVANCED COOLING FOR
LONG PRODUCTS
Rolling temperatures have a decisive impact on the microstructure of the finished product and the
respective mechanical properties. The highest quality can be achieved when rolling at low temperatures
is possible. Based on extensive experience with the rolling process, KOCKS has developed an advanced
cooling solution. The Blue Box ® comprises a set of innovative features. Highlights are KOCKS’ advanced
cooling nozzles. In addition, the cooling system works with the KOCKS Microstructure Simulator (KMS),
a digital twinning software enabling operators to simulate and control the whole cooling process.
Michael,
General Manager DPC Division
For decades, thermomechanical rolling
processes have been crucial when it
comes to achieving the highest quality
in most modern wire rod and special bar
quality mills, since controlling rolling
temperatures can significantly affect the
microstructure of the finished product.“
I am convinced that although, numerous
developments and improvements have
taken place over the years, The Blue Box ®
is a milestone in the thermomechanical
processing of long products”, says Michael,
General Manager Development, Process &
Consulting at KOCKS. KOCKS developed it
to be a perfect supplement to the Reducing
and Sizing Block (RSB ® ), but it also works
as highly efficient stand-alone equipment
within a perfect process control.
The advanced water box allows optimum
cooling of bars and wires, which is a big
plus for steel producers. Combined with
the fastest reaction times of the individual
process valves, cooling strategies can
be very dynamic. The Blue Box ® always
perfectly centers the rolled product
independent from the nozzle diameter or
the individual geometry to be cooled. All
this takes place at the lowest operating
costs and leads to other economic benefits,
which are related to thermomechanical
rolling processes.
Three cooling strands can be chosen
to cool small, medium and large sizes.
Furthermore, a bypass roller strand can be
inserted for traditional rolling operations
within the shortest time. The height of this
bypass roller table can be adjusted to ensure
that the bars are always guided properly.
Advanced cooling Nozzles
for optimum results
The Blue Box ® allows to achieve a
precise bar temperature of +/- 10 °C and
very homogeneous cooling along the
rolled stock. “This results directly in a
homogeneous microstructure across
the bar and over the length”, explains
Michael. As a core component of the
water boxes, he also refers to the special
cooling nozzles. “The further advanced
nozzles allow for a modern and efficient
optimization of both the process and
the resulting material properties of long
products”, the technologist states.
A smoothly working automation system
supports the properly temperaturecontrolled
rolling process. Since the
cooling nozzles can be set individually,
the control concept of The Blue Box ® is
very powerful. It allows for the separate
adjustment of each process-relevant
water flow setting resulting in highly
flexible cooling of the rolled material.
Standard valves are placed close to
the nozzles achieving the fastest
reaction times. “Together, these tools
provide rolling mill operators with the
best possible solution to pursue the
objective of obtaining specified product
microstructures and mechanicaltechnological
properties”, Michael
assures.
Process simulation with KOCKS’
Microstructure Simulator
Besides automation technology,
advanced software solutions are
crucial to get the best out of the water
boxes. Here, the KOCKS Microstructure
Simulator (KMS) comes into play. It
creates a digital twin of the forming
and cooling process that operators can
oversee. In advance, different cooling
programs can be simulated to predict
how temperatures and microstructures
change under controlled conditions.
According to Michael, the water flows
can be controlled in a very precise way to
achieve the best possible cooling for the
rolled product. “The water volumes are
automatically adapted to each position
of the rolled product based on in- and
outgoing temperature profiles”, he
explains. During rolling, the system also
reacts to temperature differences and
maintains the entire cooling level within
the tightest tolerances.
Holistic thermomechanical
processing
Demanding SBQ products require
precise temperature control and highly
dynamic cooling strategies. An example
for this are challenging preliminary
products for automotive parts.
“At KOCKS, we have conducted many
years of research and development
and have continuously improved our
cooling solutions. The Blue Box ® is a
big step forward to improve the thermomechanical
process of long products”,
Michael recalls. The advanced water
boxes come as an essential tool for
steel producers who strive to deliver
the highest quality and best materials
properties to their customers – while
at the same time optimizing their
production. The first integrations of the
advanced system are currently in the
project planning stage.
40 41

DIGITIZATION & AUTOMATION
FROM
SCIENCE
TO INDUSTRY
BERLIN-BASED ENGINEERING SERVICE
PROVIDER GMT IS NOW PART OF KOCKS
With effect from April 29, 2021, the Berlin-based engineering service provider GMT became part of KOCKS. The products,
including the materials database MatILDa ® , the HDQT ® technology and the support for the FEM software QForm UK as well as
the services in the fields of simulation, technology, plant development and material consulting remain in the portfolio and will
be further advanced. As an agile company, GMT operates independently within the KOCKS group.
FEM simulation of forming processes
GMT supports the FEM software QForm
UK since 2011. Thus, GMT manages about
20 customers and several universities
located in Germany, Switzerland and
Austria. QForm UK allows the simulation
of an entire technological chain at
high-speed and excellent reliability and
provides a wide range of possibilities for
process analysis as well as the calculation
of the resulting microstructure and the
phase transformation. At GMT, extensive
expertise in forming simulation has been
built up over many years for diverse warm
and cold metal forming processes. Thus,
FEM simulation is also offered by GMT as
a service. Furthermore, the FEM experts
are actively involved in optimizing
QForm UK: If any inconsistencies occur
in a simulation, they can be reported
directly to the developers and appropriate
adjustments can be made.
Combination of material
and forming simulation
Since GMT has the expertise and
software for both material and FEM
simulation, the team achieves realistic
simulation results. For example,
temperature-dependent properties, flow
curves and grain size models can be
provided from the materials‘ database
MatILDa ® via a standard interface to the
FEM software QForm UK. An extension
of the interface to provide neuronal
networks for the calculation of phase
is in progress.
42
KOCKS and GMT share a common
history of working together on different
metallurgical projects. For example,
the KOCKS Microstructure Simulator
is significantly extended through the
MatILDa ® databases open interface for
data exchange, which supports the
software with material data and models.
Since GMT is a member of the KOCKS
group, there are now even
greater synergies.
GMT can draw on the decades of practical
experience of KOCKS for the further
development of its products. On the other
hand, KOCKS leverages the profound
knowledge from GMTs experience in the
application of scientific knowledge into
industrial solutions. With the takeover, Ali
Bindernagel, Chairman of KOCKS, along
with Frank Padur, general manager at
KOCKS, moved into GMTs management
and will lead GMT into a successful
future. The positions and functions at
KOCKS remain unaffected.
MatILDa ® – Material
Simulation, but realistic
MatILDa ® , the company’s Material
Information Link and Database, contains
an extensive collection of material data
and models that has been continuously
developed by GMT for over twenty-five
years. The materials database offers an
extensive material archive with a wide
range of visualization functionalities,
for example flow curves and CCT
diagrams. Using neuronal networks for
the simulation of phase transformation,
MatILDa ® calculates properties of steels
even with deviating chemical composition
and austenitizing temperatures.
The data sets are based on practical
material investigations and are therefore
highly accurate. This knowledge is also
accessible to FEM simulation programs
via special interfaces. The open nature
of the database is unique. Users can
integrate, create and manage their own
material data sets. If required, GMT
experts are available to provide individual
consultation. Efficient program libraries
further allow the material data and
models to be integrated into user-specific
software. Thus, MatILDa ® can be used as
a stand-alone program or together with
simulation systems.
Kristin is responsible for research & development at the engineering service provider GMT.
She shares some insights in the company’s data-driven and scientific approach towards
innovation and draws a conclusion about the last two years and the developments that have
been driven by the teams at KOCKS and GMT.
How would you describe GMT’s
approach to business?
Kristin: I particularly like GMT‘s
interaction between science and
industry: for the transfer of scientific
knowledge into industrial applications.
It starts with the first idea: where can a
development from science be applied
in industry? Then it needs appropriate
partners and funding for its realization.
If the idea can be implemented in
industry, the first prototype must be
turned into a product, which can
also be a labor-intensive and
expensive process.
So, what are the main challenges here
for the GMT?
Kristin: The first challenge is to
maintain the network with scientific
institutions, partners from different
sectors and interested parties from the
steel industry. On the other hand, it is
the generation of ideas. In this case,
we present existing technologies from
other fields, such as image processing
or an acoustic camera, to demonstrate
the existing technical possibilities. This
generates numerous ideas about possible
areas of application.
How does this mentioned research transfer
actually take place?
Kristin: We regularly apply for research
projects together with universities or
other scientific institutions and select
the most promising ideas. Within 2 to
3 years, they are developed to market
maturity; in the case of very complex
projects, we also need a follow-up
project. All of this is only realized with
the explicit interest of an industrial
company; otherwise, approval is not
possible in most cases.
Now, as part of the KOCKS group, how
does GMT navigate into the future?
Kristin: We have a lot in common
in our activities and work on several
future-oriented topics. Presently, we
are involved in a cooperative research
project, together. Here, GMT can benefit
from the enormous expertise and
world-wide presence of KOCKS in the
steel industry. And as a small and highly
specialized team, we bring our in-depth
knowledge of material and forming
simulation to the table. This is how
KOCKS and GMT use their synergies
to implement new processes and
technologies for the metal industry.
43

04
»STEEL PRODUCERS
WORLDWIDE
TRUST IN KOCKS
3-ROLL TECHNOLOGY.«
- rolled
44
45

AT HOME IN THE WORLD OF STEEL
46
SIZING BLOCKS
FOR EUROPE
AND BEYOND
MEETING THE NEEDS
OF LEADING STEEL PRODUCERS
Steel producers value KOCKS for its most profound process know-how in 3-roll technology based on the experience
of more than 4,500 years of cumulated 3-roll operation in SBQ production. KOCKS applies this knowledge in the plants
of its customers to simulate and design rolling processes for the production of high-quality long products. By focusing
on technology and customer service, KOCKS sets benchmarks in innovation, long-lasting quality, and proficiencybased
services. While it all started with the idea to apply the 3-roll technology to the production of seamless tubes, the
technology was also quickly adapted to roll bar and wire rod of highest qualities. Today’s RSB ® (Reducing & Sizing Block)
technology is installed in more than 130 plants around the globe.
Born in Germany in 1979
A significant milestone for KOCKS was
the installation of the world's first PSB ®
at Krupp Edelstahlprofile (KEP) in Siegen
Geisweid in Germany in 1979. It was the
first time, KOCKS provided a Precision
Sizing Block for the industrial production
of highest quality SBQ products. The
installation, consisting of a 7 + 10 stand
Reduction Block upstream of the 3 stand
PSB ® , was a great success and set the
stage for many more blocks to come.
The advantages of KOCKS’ unique 3-roll
technology in reliability, efficiency, and
overall productivity – combined with
easy handling – set new standards in the
industry. Further installations followed
immediately in Europe, Japan, the U.S.
and South Korea.
Since then, the technology has
continued to evolve by always meeting
the requirements of customers and
markets. Today, leading steel producers
in Europe and around the globe rely on
KOCKS for highest market orientation
in a rapidly changing world. When
discussing 3-roll technology for the
sizing of bar and wire rod, the Reducing
& Sizing Block (RSB ® ) has become
the industrial standard.
Made for serving the steel
industry (forever)
Many of the first generation blocks,
which were installed early in KOCKS
history, still run smoothly.
For example, 3-roll sizing blocks of
the first generation have been installed
over 40 years ago and many of them
still stand the test of time. Apart from
some minor maintenance activities, the
blocks still deliver excellent results and
KOCKS rolled ® steel meets the quality
requirements of today's markets.
More than four decades later, the RSB ®
as 5.0 design is the most advanced
rolling block available to steel producers.
Moreover, just as it was before, it is part
of KOCKS’ corporate strategy to focus on
long-term partnerships with customers.
Specialized engineers work closely with
steel producers on the rolling process
and have in-depth experience to deliver
the highest product quality combined
with excellent after-sales services.
Italian’s special steel producer Acciaierie
Valbruna and KOCKS have such a
long-standing relationship. It is based
on the common goal of making the
best possible rolling mill equipment.
Acciaierie Valbruna is a leading producer
of specialty steel products and known
for its commitment to highest quality.
At its rolling mill in Bozen/Bolzano, the
capital of South Tyrol, Italy, the steel
producer relies on KOCKS blocks of the
first generation to roll SBQ products
achieving the best quality. Here, the
blocks have proven to be a very reliable
solution, too, that works well day in and
day out, even under heavy production
conditions.
Like Valbruna, several leading steel
producers in Europe have been
relying on KOCKS 3-roll technology
for generations. Most recently, Sidenor
Aceros Especiales S.L. in Spain, which
have already been operating a KOCKS
3-roll block at their Azkoitia works since
1998, installed a RSB ® 435 ++ /5 in 5.0
design in its highly modern rolling mill
in Basauri. Sidenor is the leading special
steel producer in the country and one
of the largest in Europe. In 2019, they
have significantly modernized their
straight bar SBQ mill to strengthen their
competitiveness in the market.
The goal was to further develop addedvalue
products based on a commitment
to the highest standards concerning
tolerances and surface quality.
One of the highlights of this
modernization project was the
implementation of the KOCKS RSB ®
435++ with 5 stand positions as new
finishing sizing mill. This RSB ® is
able to produce all finished sizes from
Ø 20 – 120 mm. Each stand position
has an individual drive train, allowing
fully flexible adjustments in terms of
reduction and motor speed respectively
rpm (i.e. tension). This advanced drive
concept of the latest RSB ® 5.0 is designed
for the smallest possible footprint, while
still being able to transmit the highest
possible 3-roll reduction & sizing
technology.
By commissioning the 3-roll RSB ® as
new Reducing & Sizing Block together
with the new cooling bed and finishing
area, Sidenor successfully completed
their substantial modernization project.
On the whole, productivity increased up
to 50 % by taking advantage of a higher
furnace capacity, an extended size range,
faster rolling speeds and an optimized
highly flexible rolling setup.
The relative operation costs were lowered
by optimizing the mill availability, the
furnace utilization, and by reducing
the required stand-by equipment in the
rolling mill – the RSB ® has played a vital
role in achieving this. It helped Sidenor
to further improve the rolling process
and make it more flexible, but also
enhanced product quality significantly.
The block is positioned behind
traditional stands in H/V arrangement
and also equipped with the KOCKS
Remote Control and the Size Control
System (SCS ® ). In combination with
the measuring gauge 4D EAGLE ® , it
adjusts the setup parameters of the
RSB ® fully automatically and in realtime.
Thus, maximum reduction can
be implemented on shortest rolling mill
length while simultaneously simplifying
the operation process and improving
the product quality.
47

AT HOME IN THE WORLD OF STEEL
iRSB ® FOR
NUCOR STEEL NEBRASKA
IN THE U.S.
RSB ® AS INTERMEDIATE MILL
Nucor Steel Nebraska trusts in the advanced iRSB ® . It is a subsidiary of Nucor Steel, the largest steel producer in the U.S.
The plant was established in 1979 and produces quality steel in straight bars and BIC products, as well as wire rod. Since
2005 Nucor is successfully operating a RSB ® 370/5. In May 2021, Nucor announced its plan to replace its intermediate mill
– and has chosen KOCKS as supplier again.
Nucor’s initial idea was to replace its
2-High intermediate rolling mill train by
new conventional 2-High stands in H/V
arrangement. After defining the exact
scope of work and technical requirements,
experts of KOCKS presented a concept,
where the flexible 3-roll technology is
positioned as a combined intermediate
mill train and finishing block. Nucor and
KOCKS further investigated the benefits
and finally Nucor selected the iRSB ® .
With eight stand positions, the 3-roll
intermediate block has been tailored to the
exact requirements of Nucor and recently
rolled the first bar. With two more stands
than in the previous arrangement with six
2-High stands, a greater reduction of the
products can be achieved and increases
Nucor’s flexibility in rolling long products
of different diameters.
The multi-talented KOCKS iRSB ® 370 ++ /8
not only provides pre-sections for the
existing RSB ® 370/5 sizing block, but can
also finish sizes up to 100 mm.
A simple foundation, a small footprint,
quick installation time, no shears or
loopers between stands and a safe
operation concept are the key benefits of
the solution. The iRSB ® comes with KOCKS
proven StarDrive system, where the rolls in
the stands are driven by individual motors.
48
49

AT HOME IN THE WORLD OF STEEL
KOCKS rolled ®
STEEL IN
CHINA
KOCKS BLOCKS SHAPE CHINESE
STEEL PRODUCTION
For over 20 years, KOCKS has been a trusted partner to Chinese special steel producers, providing innovative solutions for
the production of bar, bar in coil and wire rod. Over 40 Reducing & Sizing blocks have been installed across the country,
helping to drive the growth of the steel industry in China and meet the demands of a rapidly developing market. With
KOCKS Beijing Metallurgical Equipment Co. Ltd., located in the heart of the country’s capital, KOCKS has a strong presence
in China, providing local sales and service support to its Chinese customers. Recently, highly modern Reducing & Sizing
Blocks (RSB ® ) have been installed in China or are scheduled to be commissioned soon. All of them will contribute to further
shaping the Chinese steel industry.
XINYU IRON & STEEL CO.
LTD. CHOOSES KOCKS RSB ®
Chinese special steel producer Xinyu
Iron & Steel Co. Ltd. known as XISCO, has
signed a contract with Friedrich KOCKS
GmbH & Co. KG for the supply of a RSB ®
370 ++ /4 in 5.0 design. The Reducing &
Sizing Block will be part of the company’s
new rolling mill complex in Xinyu City,
China.
In XISCO’s new rolling mill, a KOCKS
3-roll RSB ® will master the balancing
act between the highest possible quality
and best economic results. The new
RSB ® 370 ++ /4 will be located as finishing
block after 22 stands in H/V arrangement
in a 560.000t/a SBQ mill and has
been designed according the individual
requirements of XISCO. It will produce
straight bars within a finished size range
of Ø 20.00 to 90.00 mm with the highest
dimensional tolerance onto the cooling
bed. The scope of supply further includes
the remote control for stand and guide
adjustments, the equipment for the rollshop
and KOCKS software solutions.
BAOSHAN IRON & STEEL CO.,
LTD. ORDERS RSB ® 300 ++ /4
The Chinese special steel producer
Baoshan Iron & Steel Co., Ltd. as
subsidiary of the Baosteel group,
decided on a RSB ® 300 ++ /4 in 5.0 design
for equipping its new combined bar
in coil/wire rod mill in Shanghai,
China. Baosteel group is a state-owned
enterprise of the People’s Republic of
China. With a cumulated production of
120 million tons per year, it is the world’s
leading steel producer.
With the decision to equip the new
rolling mill with a KOCKS Reducing &
Sizing Block of the latest generation,
Baoshan Iron & Steel is continuing the
successful cooperation between the two
companies, which began in 2003 with
the key investment into a RSB ® 370/4 for
the combined high-capacity SBQ rolling
mill “Shanghai No. 5”.
The new RSB ® 300 ++ /4 will be located
as finishing unit after 14 stands in H/V
arrangement in a 600.000 t/a combined
SBQ bar in coil and wire rod mill. It will
produce bars in coil within a dimension
of Ø 18.00 to 50.00 mm and feeders for
the wire rod line to finish dimensions of
Ø 7.5 to 28.0 mm. The RSB ® comes with
a remote control for stand and guide
adjustments, equipment for the roll-shop
and KOCKS software solutions.
FIRST BAR ROLLED AT
HUAIGANG ON RSB ® 500 ++ /4
AND RSB ® 370 ++ /4
The steel producer Huaigang Special
Steel Co. Ltd., a subsidiary of the Shagang
Group – the world‘s 6th largest steel
producer and one of China‘s largest
privately owned industrial enterprises –
has rolled the first bar on its new KOCKS
RSB ® 500 ++ /4 in 5.0 design and its RSB ®
370 ++ /4. The two companies look back on
a successful partnership – with previous
projects in 2010 and 2019 Huaigang now
operates four KOCKS Reducing & Sizing
blocks.
With the installation of the biggest
KOCKS RSB ® 500 ++ /4 in Huaigang existing
bar mill line, the Chinese SBQ producer
is increasing its capacity to make
high-quality special steel for various
industries. In addition, Huaigang‘s RSB ®
370 ++ /4 plays a crucial role in achieving
the best tolerances for long products
in smaller dimensions. The advanced
KOCKS 3-roll technology of the RSB ® will
greatly benefit Huaigang Special Steel‘s
production capabilities and improve the
overall efficiency of its operations.
In addition to providing the RSB ® technology,
KOCKS also supplied equipment
for the roll shop and proprietary software
solutions. Even though the pandemic
was still going on, the project team was
able to install the two KOCKS blocks in a
timely and efficient manner.
NEXT KOCKS 3-ROLL RSB ®
FOR FUJIAN SANGANG MIN-
GUANG GROUP CO., LTD.
Fujian Sangang Minguang Group Co.,
Ltd. (Sanming) has placed an order with
KOCKS for another Reducing & Sizing
block. The RSB ® 500 ++ /4 will be part of the
company’s new rolling mill complex in
Fujian province. The government-owned
enterprise was founded in 1958. It is part
of the Sangang group with over 17,000
employees and one of the most important
steel producers in the Fujian province
on the southeastern coast of China.
Sanming is dedicated to providing its
customers with the highest quality steel
products and in this course chose to
build a new medium bar rolling mill
featuring state-of-the-art equipment and
highly reliable and automated processes.
The integration of KOCKS’ 3-roll technology
into the new rolling mill complex
is expected to bring significant benefits
to the production process. Sanming is
familiar with the KOCKS 3-roll technology
from a previous project comprising a
RSB ® 370 ++ /4 and is confident in its high
precision, efficiency, and reliability.
The RSB ® 500 ++ /4 is equipped with advanced
technology that allows the precise
control of the rolling process, resulting
in consistent and high-quality. It comes
with KOCKS software solutions and will
be located as finishing unit after a 2-High
Reversing Roughing Mill and 10 stands in
H/V rolling mill arrangement to produce
straight bars within a dimension of Ø 50
to 130 mm in a 800.000t/a mill line.
50
51

AT HOME IN THE WORLD OF STEEL
SPECIAL BAR QUALITY
MADE IN
INDIA
KOCKS BLOCK FOR ARJAS SPECIAL STEEL
Arjas Special Steel is an integrated steel plant located in Tadipatri, Andhra Pradesh in India. Arjas Steel offers products to
a wide range of industries, including the automotive, railway and construction sectors. The Tadipatri plant, former under
management of Gerdau Steel India, was established in 2012 and transformed into a fully integrated special steel producer.
The initial idea for production of rebars and construction steel products was modified in favor of SBQ production. The
plant covers an area of over 846 acres with a sinter plant, coke oven, blast furnace and steel melt shop with full refining
facilities. Since 2018 the Tadipatri plant is under new ownership and was re-named to Arjas Steel Ltd.
52
TATA STEEL LONG PRODUCTS
CHOOSES KOCKS
The Indian Tata Steel Group is among the top 10 global steel companies. It is one of the world’s most geographically
diversified steel producers, with operations and commercial presence across the world. Its subsidiary Tata Steel Long
Products (TSLP) is in the business of manufacturing high-alloy, value-added steel. Currently, they are working on a green
field project at the Jamshedpur site to meet the expected increase in demand for SBQ products.
The large-scale green field project of
Tata Steel Long Products is one answer
to the fast-growing demand for special
steel products in India. The long products
segment is poised to witness significant
growth as India builds its infrastructure
and industrialization through the
Atmanirbhar Bharat Program of the
Government. With its booming economy,
India aims to expand its infrastructure and
create new jobs, which means the country
is investing heavily in steel production.
Ready for today’s and tomorrow’s
demand
KOCKS was invited to develop a concept
for a Greenfield project of Tata Steel Long
Products in Jamshedpur, India. Among
different options for the sizing of long
products, TSLP has chosen the reliable
KOCKS 3-roll technology. The new RSB ®
370 ++ /4(5) will be located as finishing unit
after a reversing mill and 12 stands in H/V
arrangement in Tata’s new 500.000t/a
combined SBQ and wire rod mill.
The RSB ® at Tata’s new rolling mill will
produce straight bars within a dimension
of Ø 20.00 to 90.00 mm onto the cooling
bed and the feeders for the wire rod line
to finish dimensions of Ø 5.0 to 27.0 mm.
The scope of supply further includes the
equipment for the roll-shop. A special
feature is the option to upgrade the block
with a 5th stand position in the future. This
gives TSLP the flexibility to add further
reduction capabilities – whenever needed.
The option to upgrade the RSB ® with an
additional 3-roll stand in the future gives
TSLP the possibility to further simplify
the upstream processes, extend the TMR
production range and tap even more
potentials. The traditional H/V-stands
usually require time-consuming, manual
adjustments by human operators. The
additional reduction capabilities of the 5th
stand inside the RSB ® and its automatic
stand change directly result in less required
changes in upstream processes.
With the decision for a modern KOCKS
RSB ® , Tata Steel Long Products sets the
stage for its future success in the SBQ
market:
Best tolerances
Absolute reliability
Increase in productivity
Optimum overall efficiency
Shortest ramp-up curves
The proven RSB ® stands for absolute
reliability and highest overall quality of the
rolled products.
Arjas Steel runs a modern rolling mill
and state-of-the-art finishing and
inspection facilities. Facilities for Heat
Treatment and Cold Finishing have also
been installed to meet the meticulous
precision requirements of the processing
industry. Important part of the product
portfolio are diverse long products,
which are processed in automotive,
railways and other related industries.
The respective mill at Tadipatri plant
has a yearly capacity of 300,000 tons
of special steel.
Investing in the future
With the goal of integrating a reliable and
highly productive finishing block into
the existing mill, Arjas invited KOCKS to
develop a machine concept and involved
the engineering team in the project at an
early stage. The RSB ® showed as a perfect
fit, as it is a sizing block that can be used
to roll a wide range of steel products in
different sizes, highly efficient. Inside
the block, the proven KOCKS 3-roll
technology comes to play. Production
processes are improved through unique
free-size ranges and fast automatic stand
changes.
Arjas’ special focus on the domestic
automotive industry was decisive for
the specification of the new KOCKS
Reducing and Sizing Block. The RSB ®
300 ++ /4 produces straight round bars
within a size range of Ø 16.0 to 65.0
mm, as well as hexagonal bars from Ø
18.5 to 40.5 mm onto the cooling bed.
Furthermore, the KOCKS block can size
round sections down to Ø 13.0 mm for
the bar in coil line, which will be installed
following the Kocks RSB ® .
With the upgrade of its rolling mill, Arjas
Steel aims to create the basis for future
success. The block has been tailored
to the exact requirements of Arjas.
Engineers on both sides worked hard
to ensure the highest quality of rolled
products without neglecting economic
aspects. The RSB ® 300 ++ /4 for Arjas
rolling mill is the result of those efforts.
53

AT HOME IN THE WORLD OF STEEL
JAPAN‘S STEEL
INDUSTRY
AND KOCKS
MORE THAN 40 YEARS OF
SUCCESSFUL ROLLING
The Japanese steel industry is one of the largest and most technologically advanced in the world. It has a
long history and has been important for the country’s economic growth. Today, Japan is a major producer
of SBQ products used in a wide range of industries, including automotive, aerospace, and manufacturing.
The steel industry stands out for its commitment to achieve superior quality – and trusts in KOCKS 3-roll
blocks for achieving the best results. Especially, its depth and longevity make the relationships between
Japanese steel producers and KOCKS unique.
It all began in 1981, when Proterial Ltd.
(former Hitachi Metals) invested in the
first KOCKS 3-roll block for Japan for
their combination wire rod and bar
mill. This 1st generation block consists
of 10 stands type 370 and is used as
pre-finishing block. Features like a
fast stand changing system, as well
as individual drives for the last two
stand positions were already part of
the design. It is noteworthy to point
out that this machine is still operating
after more than 40 years of continuous
rolling. Numerous further 3-roll block
installations were made in the upcoming
years in Japan resulting in a perfect
display of different 3-roll block types and
possible applications.
Tailor-Made Revamping Projects
While these first block generations of
KOCKS have proven to be designed to
last forever, numerous developments and
advanced features allowed a potential
increase in flexibility and productivity
of the rolling mills. After detailed
studies together with the Japanese steel
producers, tailor-made solutions were
worked out and several blocks of the first
generations were replaced by replaced
by more modern RSB ® generations.
Examples of such modernization
projects are NSC Kokura, Kobe Steel and
Sanyo Special Steel where new state
of-the-art KOCKS’ Reducing & Sizing
Blocks were installed as finishing blocks.
The Heavy-duty stands (++) can transmit
higher higher rolling forces and torques
allowing to optimize the pass schedule
with higher reductions, as well as
thermomechanical rolling. New features
like the Remote Control and the Size
Control System increase the flexibility
and mill availability of the rolling mill.
Mutual Success with sharing
similar Values
In the last 40 years, we from KOCKS and
Japan’s steel producers have worked
together on numerous projects. We share
similar values and principles which
build trust and common goals. Having
professional and respectful business
relationships while at the same time
striving to always perform the best, are
only a few of the traits that we seem to
have in common. We are proud and
honored to be a part of the long lasting
success of Japan’s steel industry.
Year Company Name Kocks Block
1981 Proterial
(former Hitachi Metals)
370/10
1983 Nippon Koshuha Steel 200/10
1985 NSC Kokura
(former Sumitomo
Metals)
370/7
1987 Aichi Steel 500/7
370/7
500/3
1987 Sanyo Special Steel 500/3
1988 Kobe Steel 500/5
1997 NSC Muroran 370/4
2000 JFE Sendai 370/4
2002 NSC Hikari 370/4
2007 NSC Kimitsu 4 x 215/2
2010 NSC Kokura 435 ++ /4
2018 Kobe Steel 370 ++ /5
2019 Sanyo Special Steel 370 ++ /5
54
54
55

AT HOME IN THE WORLD OF STEEL
KOCKS 3-ROLL
TECHNOLOGY
IN SOUTH KOREA
POWERFUL PARTNERSHIPS WITH
LEADING STEEL PRODUCERS
The rapid development of South Korea into one of the leading industrial and technological nations in the world, with the
world’s sixth-largest steel output at more than 70 million metric tons per year, also set the stage for the KOCKS 3-roll
technology. A high industrial standard, driven by the microelectronic equipment, semiconductor, ship and car industry,
requires corresponding SBQ material grades with outstanding properties. The leading steel producers in South Korea,
POSCO, Hyundai Steel and the SeAH Group have relied on KOCKS’ 3-roll technology over the past decades to cement
and enhance their competitiveness.
A SUCCESSFUL PARTNER-
SHIP WITH SEAH BESTEEL
The two examples of POSCO and SeAH
Changwon Special Steel impressively show
how continuous further developments of
KOCKS 3-roll blocks are accompanied by
close alliances with customers in a spirit of
trust, even beyond machine generations.
The third successful partnership in South
Korea was entered into with SeAH Besteel
in 2004. The strong SBQ producer opted
in its 900.000t/a high performance SBQ
mill for an RSB ® 370 ++ with five stand
positions in heavy-duty design, the first
RSB ® of this type in Asia, which made it
possible to cover an even larger range of
finished diameters while allowing higher
rolling forces by maintaining the roll ring
diameter of 370 mm.
GLOBAL PLAYER HYUNDAI
STEEL RELIES ON KOCKS
When Korea’s longest established steel
producer and global player Hyundai
Steel decided to install an ultra-modern
combined wire rod and bar mill in their
new steel complex in Dangjin, there
was no way around KOCKS from a
technological point of view in 2013. For
almost 10 years, a 5-stand RSB ® 370 ++
with the size control system SCS ® has
been the guarantor for consistently
reliable excellent quality of the BIC and
straight bar finished products for Korea’s
automotive industry.
WRITING HISTORY WITH
SEAH CHANGWON
SPECIAL STEEL
The first company in South Korea to
invest in KOCKS 3-roll technology was
Sammy Steel – today’s SeAH Changwon
Special Steel, one of the world’s leading
companies for specialty steel and super
alloys – in 1987, with a mill configuration
that was state-of-the-art and widely used
at the time. A 7-stand 500 mm reducing
block, a 10-stand 370 intermediate block
and a 3-stand precision sizing block
(PSB ® )
However, in order to make the mill more
flexible and even more productive, it was
decided in 2014 to replace the PSB ® and
the intermediate block, after almost 27
years of reliable service, with a 6-stand
RSB ® of the latest generation. This installation
in Changwon was also a milestone
in the history of KOCKS. It was the first
time that the KOCKS 4D EAGLE ® profile
gauge went into industrial operation with
a closed loop automation package with
the real-time Size Control System (SCS ® ).
RSB ® 300/4 AND RSB ®
370 ++ /5 FOR POSCO
The reputation of successful and reliable
technology is spreading fast. A few
years later, after successful results of
the Sammy Steel plant, the steel giant
POSCO decided in 1994 to finish rolling
its quality steels in the combined wire
and BIC mill line with a 4-stand RSB ®
300, one of the first KOCKS blocks
worldwide that unified reducing and
sizing stand positions in one machine.
Thus granting a flexible and high
availability operation of the entire mill
line by reducing the number of entry
sections of the RSB ® to a minimum.
When POSCO decided to modernize
the rolling mill in order to expand the
dimensional range of the bar in coil line
and to further increase the productivity
of the mill, the partnership with POSCO
and KOCKS was continued in 2018
with a 5-stand RSB ® 370 ++ of the latest
generation (including SCS ® and the
KOCKS profile gauge 4D EAGLE ® ).
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57

AT HOME IN THE WORLD OF STEEL
WALSIN LIHWA‘S
DECADES-LONG
RELATIONSHIP WITH KOCKS
CONTINUED TRUST IN RSB ® TECHNOLOGY
Walsin Lihwa was founded in 1966. Today, the Taiwanese company has over 10,000 employees and is
not only the leading manufacturer of wire & cable, stainless steel, and resources business in the Greater
China region, but also a leading real estate developer across the Taiwan Strait. The stainless steel
business produces billets and slabs, wire rods, straight bars, seamless pipes and tubes, and is a specialized
manufacturer of stainless steel long products in Asia.
Walsin Lihwa has a long history with
KOCKS, having installed the very first
KOCKS Reducing & Sizing Block with
one input drive shaft, a RSB ® 370/10,
already in 1991 at the company’s rolling
mill in Tainan, Taiwan. In the same
course, Walsin Lihwa also equipped
a KOCKS Intermediate Mill 500/7. A
KOCKS RB ® 500 ++ /4 followed in 2017.
Since the installation of the first blocks,
the steel producer has continued to rely
on KOCKS’ expertise and innovative
technology solutions.
A trustful relationship
The trustful relationship between KOCKS
and Walsin Lihwa spans more than three
decades, with a shared commitment
to excellence and a focus on overall
highest quality. In 2019, on the back of
the successful previous projects, Walsin
Lihwa placed the order for another
KOCKS 3-roll block for its greenfield
rolling mill for SBQ products in Yantai,
Shandong province in China.
This new RSB ® 370 ++ /4 for the subsidiary
Yantai Walsin features four 3-roll stand
positions for optimal deformation
behavior and yield strength. The RSB ®
has been designed to deliver superior
surface quality and dimensional
accuracy at lowest operating costs over
the entire mill line.
Succesful teamwork
All of a sudden, COVID delayed the
original schedule. It was a challenging
time for steel producers and the entire
industry. Due to travel restrictions the
project – as most others in the industry
– had to be put on hold as site visits and
commissioning were not possible. But
despite the challenges brought on by the
2020 pandemic outbreak, Walsin Lihwa
and KOCKS remained committed to their
collaboration on the RSB ® for the entirely
new rolling mill in China.
After the situation had eased, the two
companies immediately resumed
working closely together on this project.
As the world continues to recover from
the pandemic, in 2023 the first bar
was rolled with the RSB ® , marking a
crucial milestone for the project. The
new Reducing & Sizing Block acts a key
component of the greenfield rolling
mill, as it allows precise control over the
size and shape of the final product. The
block is positioned behind 20 stands in
H/V arrangement and finishes round
dimensions from 18.00 – 100.00 mm,
hexagonal dimensions from 18.00 – 80.00
mm and feeders for the wire rod line.
In addition to the sizing block, KOCKS
supplied the roll-shop equipment and
its proprietary software solutions. The
advanced block enables a highly efficient
production at Walsin Yantai. The RSB ® is
equipped with a KOCKS measuring gauge
and connected to the Size Control System
(SCS ® ) which allows real-time adjustments
of the operating parameters of the rolling
block. This ensures transparent process
monitoring and the quickest possible
adjustments whenever necessary.
As Walsin Lihwa continues to grow and
expand its operations, KOCKS remains a
trusted partner, supporting their success
and driving innovation in the stainless
steel industry.
58 59

AT HOME IN THE WORLD OF STEEL
PARTNER FOR
SEAMLESS TUBE
PRODUCTION
KOCKS SRB ® – FIRST CHOICE FOR
INNOVATION AND RELIABILITY
For generations, KOCKS has been taking the challenge to be a pioneer and a driver of innovations in the field of sizing and
Stretch Reducing mills for the seamless tube industry. In more than seven decades, it has always been the vision to go
ahead with great ideas and find creative solutions for the needs of customers.
Not only for the recent generation of
Stretch Reducing Blocks (SRB ® 3.0) KOCKS’
engineers have received tremendous
trust from customers and partners from
all over the world. They always liked the
progressive approach, and many of the
ideas and inventions were born in close
cooperation with valuable customers.
Jointly with them, KOCKS made ingenious
solutions an integral part of this industry.
A number of unique SRB ® features
In particular, the fully flexible quick change
of the rolling stands and the individual
redressing of the rolls outside the stands
on a conventional CNC lathe have been
a revolution. Rolling stand inventory can
be reduced by up to 70 % in comparison to
conventional designs, which also require a
special lathe. The overall investment as well
as the operating cost of an SRB ® 3.0 can be
reduced significantly. This technology has
been implemented successfully since 2006
in all the KOCKS SRB ® .
The combination of strong and precise
rolling stands with an accurate remote
control enables rolling mills to make
adjustments from the pulpit and produce
seamless tubes of the highest quality and
best tolerances.
Along with those mechanical features,
the smart TUMICON software package
ensures a highly consistent production
process. Key parameters can be further
analyzed and optimized. The Heavy End
Control (HEC) in combination with the
Automatic Wall Thickness control (AWC)
actively optimize the SRB ® rolling process
and substantially increase the final yield.
Close relationships and steady
optimization
KOCKS is committed to being a trusted
partner for customers to improve
production processes for seamless tubes,
reduce costs, and increase profitability.
This commitment goes beyond the
installation of a new SRB ® . In the current
tough market environment, KOCKS’
team of specialists supports producers of
seamless tubes with individual support for
achieving optimum results of the installed
rolling mills. The engineers provide
holistic after-sales and consulting services,
ensuring that rolling operators receive the
support they need. A range of after-sales
packages and individual optimization
projects ensure the efficient and reliable
operation of the SRB ® throughout its
lifespan.
Technologists regularly visit sites to discuss
the overall performance of the SRB ®
with the operating team. Those visits are
very valuable because they provide an
overview of how different customers run
their processes and what their priorities
are when it comes to rolling seamless
tubes for different applications. The close
relationships also allow for receiving
feedback from the field about changing
market requirements and how the KOCKS
SRB ® can contribute to further optimize
products.
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05
»WE AT KOCKS ARE
PEOPLE WITH A GREAT
SPIRIT OF FOCUS,
CANDOR & RELIABILITY«
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We are an international team of colleagues characterized by a wide range
of expertise, cultures and countries. We are united by a strong belief in
engineering as a way of making things even better. Ingenuity and astute
thinking ahead – beyond what already exist – is a strong part of our futureoriented
KOCKS spirit.
We foster short routes. That gives us a competitive edge which cannot be
overstated in today’s fast-moving world. Our goal: To enhance the market
position of our customers by an extraordinary quality of the finished
KOCKS rolled ® product.
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RELIABILITY & OUR BELIEF IN PEOPLE BUSINESS
Jessica
Working with KOCKS since 2015.
General Manager Human Resources.
Focus: Organizational development.
My personal motivation.
Feeling inspired by freedom
and a creative scope.
I enjoy living and working in
a responsible and challenging
environment. This is as true in my job as
it is in my personal life, where I love to
go on adventurous holiday trips around
the globe. My personal drive to work
with KOCKS is characterized by a strong
bond with the people in combination
with a great degree of freedom as well as
exciting topics. This environment allows
me to create a noticeable corporate
impact. Personal growth and the feeling
of progress are ‘must haves’ in my life.
That’s what makes KOCKS
special for me.
Our unwavering loyalty towards
our employees and customers.
As a manager in Human Resources,
I enjoy a great deal of trust, respect and
fairness within our KOCKS team.
If I had to choose three characteristics
to describe KOCKS, it would be
our unique ingenious spirit, our
consistently perceivable sense of family
and our high standard of reliability.
The goal of my Human Resources
commitment at KOCKS is to enable
people and to strengthen people’s
self-esteem, professional and personal
skills as well as their motivation – the
motivation to shape KOCKS’ future, our
products and our customers as a team.
What PEOPLE BUSINESS at KOCKS means
to me.
Together we are unstoppable.
We employees don’t let tense times
get us down and we stick together. I
believe our customers feel this, too.
We are a German mid-sized company
with around 180 employees worldwide
who design, install and commission
comparatively huge rolling blocks
including equipment worldwide.
Together we are unstoppable as a team
characterized by strong cooperation and
enormous inventiveness.
Customers are often positively surprised
when they personally meet our entire
team in person at our headquarters
in Germany. They can hardly believe
that comparatively few people can
handle such big projects together. This
makes us proud because we know how
important cooperation and respect is
in order to deliver excellent results and
to be accepted as a hidden champion in
this industry.
Last but not least – enjoying work as
part of everyone’s life is indispensable.
Therefore, we never miss an opportunity
to celebrate successes and special
moments together.
This special ‘something’
can be felt everywhere
and is, in my point
of view, essential
for staying resilient
in a brittle and
incomprehensible
world.
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RELIABILITY & OUR BELIEF IN PEOPLE BUSINESS
My personal motivation.
The on-site work and interacting
with people.
Thomas
Working with KOCKS since 2015, for 2 years in the United States now.
Mechanical and Design Engineer.
Focus: Development of blocks and special solutions. Commissioning on site.
I enjoy to accompany a machine from
the first line we drew on a whiteboard
to production start. Thanks to this
approach, I always get valuable technical
insight and I grow personally, too. I
internalized the need to act in an openminded
and solution-oriented manner
to get extraordinary quality. I wouldn’t
want to miss out on the interaction
with the customer and the on-site work.
The mix of classic office work and the
“action” on-site is very appealing.
That’s what makes KOCKS
special for me.
We are highly appreciated for
our results.
We make products FOR the customer.
Means: We take time for their
requests, look at the conditions onsite,
and interact with the people –
always pursuing the goal to deliver
customized design that meets the
needs of every single customer.
As a result, our RSB ® that was tailormade
achieves the results that were
guaranteed. Our customers are truly
thrilled when the first products come
out of the RSB ® . Especially in our
Greenfield projects, when the line has
not been aligned yet, our customers
are amazed when a non-optimum
pre-round is sent through the RSB ® and
a nearly perfect product comes out;
no matter of the configuration of the
block.
What PEOPLE BUSINESS at
KOCKS means to me.
KOCKS cares.
During my time at KOCKS, I have
never experienced a customer being
let down in any way. It doesn’t matter
where in the world the plant is located.
We are ready to help either by phone
calls, video meetings or even personal
on-site. Sometimes a problem arises
and a day later I get on a plane and I
am on the way to the customer. This
“KOCKS cares” is the certain something
our customers highly value in us and
emphasize.
I enjoy to stay
agile and to
understand the
customer at
every step of
the project. No
way is too far for
me to help the
customer.
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RELIABILITY & OUR BELIEF IN PEOPLE BUSINESS
Andrea
Working with KOCKS since 2008.
Manager Engineering.
Focus: Expanding service engineering.
My personal motivation.
Broadening horizons.
One year ago, I made the decision to go
as a KOCKS service engineer to Taiwan
for 18 months. I am highly motivated
by the thought to expand our KOCKS
service business in close proximity
to the market and to enhance thereby
the satisfaction of our East Asian
customers. Moreover, this step into
another culture means for me to benefit
from enormous personal growth. I am
personally fascinated by exciting daily
challenges and all this in a sophisticated
mechanical engineering environment.
That’s what makes KOCKS
special for me.
“Family cohesion” and a distinctive
international attitude.
Our customers benefit from a unique
KOCKS will to achieve ideal solutions.
In our KOCKS world and in our
daily projects I feel a strong spirit of
cooperation, a high degree of flexibility,
fast reaction and decision-making
times, very low bureaucratic hurdles.
All of us feel very committed to
quality and reliability. I appreciate
the international high reputation of
KOCKS.
What PEOPLE BUSINESS at
KOCKS means to me.
The willingness to help.
People business means, in my
perception, dealing respectfully with
cultural and linguistic diversity as
well as shaping trust and good will in
customer relationships.
People business also means paying
special attention and dedication when
the going gets rough i.e. exuding a
willingness to help, being approachable
for quick and competent support.
KOCKS – for me – is more than just a
high-precision block. KOCKS are my
mindful colleagues and the special
“family spirit” – complementary
to excellent rolling mills, decades
of expertise and sophisticated
mechanical engineering!
Loyalty, mindfulness
and deep appreciation
of other cultures guide
me as values in my
work with our KOCKS
customers worldwide.
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RELIABILITY & OUR BELIEF IN PEOPLE BUSINESS
My personal motivation.
Taking responsibility.
Taking responsibility is a fundamental
inner drive for me – whether in a
private or professional context. Taking
responsibility means committing myself
to make sure that – within my own
capabilities – everything goes as well
as possible by doing what is right and
necessary. Responsibility, on the other
hand, gives everybody the freedom of
shaping the future.
That’s what makes KOCKS
special for me.
Attitude decides everything.
The people at KOCKS are humble
and we give our best to act wise. If I
had to name three terms with which
I characterize KOCKS, it would be:
reliability, reliability and reliability.
Reliability at KOCKS covers every
aspect along our value-added chain.
It means: We feel committed towards
our customers and keep our promises!
This commitment becomes tangible
by helping our customers to achieve a
high ROI and productivity. WIN/WIN
is not just a saying in our company, it
is an intrinsic KOCKS attitude: shaping
the market in solidarity, acting in
transparency and honesty, assuming
corporate social responsibility to
maintain the “German Master Art
philosophy” and “Made in Germany”
reputation.
This attitude
includes a willingness
to look at
the big picture –
responsibility for
oneself, for others,
for society and for
us as a company.
What PEOPLE BUSINESS
at KOCKS means to me.
Flat hierarchies and effective
communication.
At KOCKS we are not driven by
unmanageable hierarchies! We
have a strong link to the market
and our customers. We benefit from
“family business” circumstances,
characterized by a flat organization,
with lots of experts and focused
competences. In our “KOCKS world”,
we talk to each other, live a transparent
communication and we are able to
avoid frictional losses. I appreciate very
much that we focus on the resources
of every colleague, within every team
and project by following the Maxim
“Doing the right things”. As a result,
we focus all of our attention, expertise
and efforts on every single customer
and their individual manufacturing
processes.
Shi Tao
Working with KOCKS since 2008.
General Manager of KOCKS Beijing Metallurgical Equipment Co., Ltd.,
100 percent subsidiary of KOCKS in the Chinese market.
Focus: Business development and strategic sales in China.
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»IT’S OUR VISION
TO GO WITH GREAT
IDEAS FAR BEYOND
THE EXISTING IN
ORDER TO CREATE
A MORE RELIABLE
AND A MORE HONEST
WORLD OF STEEL
OF TOMORROW.«
#INGENIOUS
Engineering as a way of making things even
better: Reliability pushed forward by Industry 4.0.
This is the reason why our customers say: “KOCKS
is an intergenerational long-term investment”.
#UNIQUE
It’s more than proven technology that makes
us unique: We keep our promises! Customers
can count on realizing their investment
projects on target, on time and on budget.
#FOCUSED
Focus means being mindful of the customer
and creating tailor-made solutions. We are proud
of our customers’ strong references and their
belief that: “This is where we make the quality”.
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IMPRINT
Editor
FRIEDRICH KOCKS
GmbH & Co KG
Neustrasse 69
40721 Hilden, Germany
Fon: +49-2103-79 00
www.kocks.de
Concept & Editorial team
Robin Schiffler
Marketing Manager
all’n you – Strategien
für Menschen & Marken
Sybille Teyke
www.all-n-you.de
KOCKS experts
Design
Kreativ Konzept
Agentur für Werbung, Bonn
www.kreativ-konzept.com
Image verification
Katja Velmans Fotografie
Rüdiger Knobloch
Oliver Pracht
Karsten Filipan
Printing
Warlich Druck Meckenheim GmbH
www.warlich.de
RSB ® , SRB ® , BAMICON Octopus ® ,
The Blue Box ® are trademarks
registered by KOCKS
INGENUITY AND
ASTUTE THINKING AHEAD –
BEYOND WHAT ALREADY EXISTS
– IS A STRONG PART OF
OUR FUTURE-ORIENTED
KOCKS SPIRIT.
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