Two-Bend One-Straightening Scale Breaker

Project Case Study: Two-Bend One-Straightening Scale breaker

Client: Leading Stainless Steel Processor

Location: India

End User: Stainless Steel Continuous Annealing & Pickling Line (APL)

Equipment Supplier: Xiangyang Jiade Machinery Co., Ltd.

1. Project Overview

Xiangyang Jiade Machinery supplied a high-performance Two-Bend One-Straightening Scale Breaker for a stainless steel continuous annealing and pickling line located in India. The equipment was engineered to process hot-rolled stainless steel strips under demanding production conditions, ensuring optimal surface preparation prior to acid pickling.

Key Technical Parameters:

· Material: Stainless Steel (300 & 400 Series)

· Strip Width: 450 mm – 750 mm

· Strip Thickness: 1.5 mm – 5.0 mm

· Line Speed: Up to 250 m/min

2. How It Works

The scale breaker is designed to remove brittle oxide scale formed during annealing while simultaneously correcting strip shape defects. As the steel strip travels through the machine:

1. Controlled Bending & Straightening

The strip passes through heavy-duty rollers arranged in a precise “two-bend, one-straightening” configuration. The rollers apply calibrated mechanical stress to fracture the tightly adhered oxide layer without compromising the base metal.

2. Shape Correction

The bending cycles eliminate common flatness defects such as edge waves, center buckles, and camber, delivering a geometrically stable strip.

3. Integrated Tension-Leveling Effect

In this system, a tension-Leveler mechanism is synergized with the scale breaker to increase elongation and improve surface-to-roller contact—critical for consistent scale removal across the full strip width.

4. Downstream Compatibility

While the scale breaker performs primary descaling, optional skin-pass mills positioned later in the line can further refine flatness and surface finish when required by final product specifications.

3. Problems Solved for the Client

Prior to installing Jiade’s scale breaker, the customer faced several operational challenges:

· Incomplete Descaling: Residual scale reduced pickling efficiency and caused surface defects.

· Poor Strip Flatness: Shape irregularities led to off-center tracking, wrinkles, and frequent line stoppages.

· High Maintenance Costs: Hard oxide particles accelerated wear on pickling tank rolls and downstream equipment.

· Bottlenecks in Throughput: Inconsistent strip quality limited line speed and overall productivity.

Our solution directly addressed these pain points by delivering reliable, high-speed descaling and flattening in a single inline process.

4. Key Benefits Delivered

✅ Enhanced Surface Quality

By effectively fracturing and loosening the oxide scale, the strip enters the pickling section with optimal surface exposure. This significantly improves acid penetration, reduces pickling time, and ensures a cleaner, more uniform final surface—ideal for subsequent coating, polishing, or painting.

✅ Improved Flatness & Shape Control

The two-bend one-straightening design eliminates wave formations and camber issues common in stainless steel strips. The result is excellent flatness and straightness, which enhances downstream processing accuracy and reduces rejection rates.

✅ Higher Production Efficiency

With scale removal efficiency exceeding expectations, the pickling stage operates at peak performance. Combined with superior strip shape, the line now consistently runs at its full design speed of 250 m/min, maximizing output and reducing per-ton processing costs.

✅ Reduced Maintenance & Equipment Wear

By removing abrasive scale upstream, our scale breaker protects critical components such as bridle rolls, deflector rolls, and tension reels. This has notably decreased unplanned downtime and extended the service life of downstream machinery.

5. Customer Feedback

“Jiade’s scale breaker has become a vital part of our APL line. The improvement in surface quality and flatness is immediately visible, and we’ve seen a measurable reduction in pickling acid consumption and roll maintenance. Running at 250 meters per minute with stable strip shape—this machine delivers exactly what our production demands.”

— Plant Manager, Indian Stainless Steel Processing workshop

6. Conclusion

The successful deployment of Xiangyang Jiade Machinery’s Two-Bend One-Straightening Scale Breaker in India demonstrates our capability to deliver robust, high-precision solutions for stainless steel continuous processing lines. By combining efficient descaling with advanced shape correction, we help global customers achieve higher product quality, lower operating costs, and greater competitiveness in demanding markets.

Xiangyang Jiade Machinery Co., Ltd.

Specializing in High-Performance Metal Processing Machinery

www.xfjdmc.com

www.jiademachinery.com

robinc2007@126.com