Fiskdale,  MA 
United States
  • Booth: 1635

Stop by our booth to talk with out rolling mill specialists.


Russula is a global engineering company serving the largest steel producers in more than 35 countries. With its headquarters and workshop located in A Coruña, Spain, the company has major offices in Brazil, India, Italy, Mexico, Russia, Sturbridge, MA and Dublin, OH. Russula has implemented over 200 electrical and mechanical upgrades and greenfield water treatment plants in the United States and Canada.

Russula collaborates with steel producers to help them become high-performance businesses by developing innovative technology for meltshops, bar, wire rod and section mills, flat mills and water treatment plants. Our strategy builds on our technical expertise to develop engineering solutions to help steel producers around the world increase productivity and improve operational efficiencies.

Brands: COMPUTER VISION: Russula has developed computer vision solutions for rolling mills. MILL PULSE®: A user-friendly, mobile, flexible, goal-oriented, integrated and customizable Manufacturing Execution System.


Finish first with Mill Pulse®

 Press Releases

  • In February 2021, Nucor Steel awarded Russula a contract to supply a water treatment expansion to roll bar-in-coil at the mill in Plymouth, Utah. With the addition of a new spooler line, water boxes and a fast speed finishing block, extra water capacity was required. 4560 GPM of contact water will be added to treat the new quenching area and external cooling.

    Within the water treatment plant expansion scope, Russula will supply the civil, mechanical, and piping design cooling towers, pumps, sand filtration system and all the necessary sensors and transmitters. An independent power control room, which houses the AC drives, MCCS, remote I/O and PLC, has the plug and place advantage to speed up the electrical integration. A new HMI application will be developed for the operations and maintenance functionality of the water plant. Russula will also provide erection supervision, hot and cold commissioning support. The startup is scheduled for March 2022.

  • The fully digitalized mill will produce wire rod for the France and Belux markets. Russula supplied the entire plant technology setting a new benchmark in sophisticated mechanical equipment, advanced automation, and ecological design.

    Russula was responsible for the design and the complete execution of the project under a turn-key contract. Within the Russula scope of supply were the general design of the plant, warehouses, main and auxiliary technological equipment, civil construction, assembly, and commissioning support.

    The new train has involved an investment of 65 million euros and will generate around 140 new direct jobs and 420 indirect jobs, between France and Spain.

  • SIMEC Group selected Russula to modernize the light structural rolling mill located in Cariacica, Espirito Santo state, Brazil. Russula will deliver the complete mechanical, electrical and engineering package for the state-of-the-art modernization. Part of a $50 million USD investment to expand the melt shop and modernize the rolling mill, this modernization will increase the production capacity of the plant to 1.3 Mtpy of crude steel and 1,05 Mtpy of hot rolled products. This mill produces 360,000 tpy of light structural rods and profiles for the Brazilian market.

    The Russula supply includes engineering, mechanical and electrical systems from the reheating furnace through the bundling area. A total of fourteen new stands will be supplied for the roughing and intermediate mills, perfectly assembled in both vertical or horizontal configuration for quicker maintenance and spare parts reduction. New crank, rotary and flying shears will help the mill meet cut tolerances and maximize throughput. The mill automation will also be modernized to a single, operating platform based on Siemens S7-1500 PLCs and WinCC.

    Productivity and product quality will significantly increase after the mechanical and electrical modernization, bringing the plant up to the demanding standards of steel production today.

    Equipment is expected to begin arriving on-site starting from October 2021. The commissioning is planned for the summer of 2022.

  • Nucor Corporation awarded Russula a contract to supply the water treatment plant engineering and electrical equipment for the new 1.2 MTpy plate mill under construction in Brandenburg, KY, USA. This is the single, largest capital investment undertaken in the history of Nucor and ranks as one of the largest-ever for the state of Kentucky.

    Water will be treated and cooled in the non-contact, contact and laminar circuits for the plate mill. Russula will supply the civil, mechanical and electrical engineering package, electrical and control equipment and on-site services for the water treatment plant.

    Russula’s engineering solutions save time and lower costs. Engineering development of the piping and support structures using 3D software reduce construction interferences between engineering disciplines. Independent, power control rooms with pre-mounted MCCs inside, dramatically reduce the assembly and installation time in the field. Leveraging decades of expertise and comprehensive process know-how, Russula will provide a robust automation and drive solution that lowers energy consumption.

    Plate production is expected to start in late 2022. Nucor Brandenburg marks the 26th water treatment solution Russula has sold worldwide. Russula was very pleased to be awarded this contract and participate in making history with Nucor.

  • Votorantim Paz del Rio, the second largest steel producer in Colombia, has contracted Russula to upgrade the block drives of line 2 of the wire rod mill. Existing ABB DCS 500 drives will be replaced with two ABB DCS800 model. Russula will supply the electrical equipment, hardware engineering, software engineering, integration into the existing HMI system, installation supervision and commissioning support. The plant is in located in the Hacienda Belencito, Boyaca, Colombia.

    The collaboration between Russula and the Paz del Rio plant began with the audacious project to streamline the performance and quality of the 2-strand wire rod mill, originally built in the 1950s. In 2014, the Paz del Rio and Russula team performed a mechanical, electrical and control upgrade. Russula supplied a new table for two horizontal loopers. After the upgrade the plant recorded sustained improvements in mill utilization rate and metallic yield.


  • Optical Alignment System
    Russula has designed a novel guide alignment system based on computer vision....

  • Traditionally, optical alignment systems (OAS) for finishing block roller guides are adjusted by eye using shadow projection systems on a bench optic. Shadow adjustment methods are subject to human error and require regular calibration of the optical components. Russula has designed a novel guide alignment system based on computer vision. Employing telecentric lenses, high resolution cameras and Russula’s own computer vision algorithms, operators can now adjust the block guides and its mounting bases to perfection, with full digital feedback.

    The Russula OAS system includes both tools required to set and align block guides: a bench optic for the setting the roller guides, and a portable optic for aligning the guide saddles to the mill rolls. Guide alignment is simple; first mount the guide on the bench, select the desired profile then turn the adjusting screws according to the instructions on the screen. The portable OAS follows a similar procedure to align the RE guide bases to the roll grooves. Both models are rugged, designed and tested to withstand the harsh working conditions of rolling mills.

    The Russula OAS is easy to use. The operator can easily update the profile target database according to any changes in the roll pass design or setup. Navigation can be done from the OAS screens, a laptop or smartphone. Guide and mounting base adjustments take only a matter of minutes. Both the bench and portable models have battery backup, rechargeable batteries that can operate for hours unplugged.

    Russula engineers on both sides of the Atlantic have designed, prototyped, manufactured, and commissioned several of the new OAS systems in Europe and the USA. The use of the OAS in steel mills helps reduce downtime and improve the final product quality.

  • Computer Vision for Rolling mills
    The all in one mill sensor...

  • Across many different industries and agencies, from autonomous vehicles like the NASA Mars Exploration Rover to medical processing imaging in early diagnosis of tumors, Computer Vision is making great strides. Russula has made eye-breaking advancements in the development of Computer Vision applications for rolling mills.

    Now, seven long product rolling mills scattered throughout the globe are implementing Russula Computer Vision solutions. Some of the projects are in the initial phases of trials, while others have established CV-Sensors as part of the rolling mill process. Loop position, HMD, material speed, shear cut size, event triggers, and cobbles can all be detected and measured by a CV-Sensor, creating an all-in-one mill sensor.

  • Mill Pulse®
    The Mill Pulse® Suite is a new, fully integrated manufacturing execution system designed specifically for continuous, hot rolling processes....

  • Mill Pulse®, a sophisticated MES, is designed exclusively for the rolling process to manage, harmonize, and control all production activities. Mill Pulse® optimizes operations while responding to customer requirements immediately.

    This centralized tool for Rolling Mill Production Management effectively integrates the rolling process with the ERP business level, synchronizing all the production processes together. Divided into various scalable and configurable modules, Mill Pulse® is made for the steel process of the future.

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