1700mm Continuous Galvanizing Line (CGL) – Tension Leveler Application

Project Case Study: 1700mm Continuous Galvanizing Line (CGL) – Tension Leveler Application

1. Project Overview

Project Name: 1750mm Continuous Hot-Dip Galvanizing Line (CGL) Expansion Project

Location: Binzhou City, Shandong Province, China

Application: Continuous Galvanizing of Hot/Cold Rolled Strip (GI/GA)

Line Capacity: 350,000 Tons/Year

Commissioning Date: Q3 2025

Key Equipment: 1700mm 6-High Tension Leveler supplied by Xiangyan Jiade Machinery

Line speed: 250m/min

2. Background & Challenges

The client aimed to penetrate the high-end home appliance and construction markets with their new 1750mm CGL. In galvanizing, "furnace breaks" and "poor zinc adhesion" are critical production bottlenecks. The client required a tension leveler capable of handling ultra-wide strips while ensuring zero defects before the annealing furnace. Their primary concerns were eliminating residual stress to prevent snapping inside the furnace and achieving superior surface roughness for optimal coating adherence.

3. Our Solution

To meet the stringent requirements of the galvanizing process (high temperature entry, zero breakage, high surface quality), we engineered and delivered a customized 1750mm High-Performance Tension Leveler. Key technical features included:

· Precision Elongation Control: Advanced hydraulic servo system maintaining elongation stability within ±0.05%.

· Advanced Flatness Correction: Optimized roll gap geometry to eliminate edge waves and center buckles on wide strips.

· Robust Sealing System: Enhanced sealing technology to prevent lubricant leakage into the process sections, protecting water quality and preventing strip staining.

4. Performance Results & Technical Advantages

4.1 Eliminated Furnace Breaks & Increased Uptime

By applying controlled plastic deformation, our machine eliminated the yield point elongation, stabilizing the strip before it entered the high-temperature furnace.

· Result: Achieved Zero Furnace Breaks for 6 consecutive months post-commissioning.

· Data: Line operational efficiency increased from the industry average of 85% to 96%.

4.2 Enhanced Zinc Adhesion & Surface Quality

The powerful bending action removed stubborn iron oxide scales and optimized the strip's surface topography (roughness).

· Result: Pass rate for zinc adhesion tests (bending/cupping) reached 99.8%.

· Data: Consistent surface roughness (Ra) maintained between 0.8–1.6μm, meeting strict OEM standards for home appliance panels.

4.3 Improved Coating Uniformity

Superior flatness control ensured the strip remained perfectly centered and stable at the air knife position.

· Result: Eliminated "zinc feathering" and "edge buildup."

· Data: Galvanized coating thickness tolerance controlled within ±5μm. Strip flatness improved to < 5 I-Units.

4.4 Cost Reduction & Yield Improvement

· Energy Saving: Optimized roll configuration reduced drive power consumption by 10%.

· Yield Rate: Reduced scrap caused by shape defects and coating issues, increasing overall yield by 1.5%.

5. Problems Solved for the Client

6. Client Comment

"In a 1750mm Galvanizing Line, the Jiade Tension Leveler is the heart of the operation. Jiade's equipment has exceeded our expectations. Particularly when processing high-strength galvanized sheets, the stable elongation control and excellent scale-breaking performance allowed us to pass certifications from major clients like Haier and Hisense. It is not just a machine; it is the guardian of our product quality."

— Plant Manager Mr.Yang, Galvanizing Division

7. Project Significance

This project stands as a benchmark for wide-format, high-end galvanizing lines in North China. The successful deployment of our tension leveler enabled the client's transition from commodity building materials to premium appliance-grade steel. It demonstrates the competitiveness of domestic heavy-duty Metallurgical Equipment in the continuous galvanizing sector and provides valuable process data for future high-strength steel applications.

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