BlueScope steel elevates workplace safety and efficiency with TRUMPF Power Tools

In the steel manufacturing industry, precision, safety, and reliability are non-negotiable. For BlueScope Steel, one of the world’s leading steel producers, ensuring smooth operations in challenging environments is critical. At their Cold Rolling operations in Port Kembla, NSW, outdated tools posed risks to employee safety and efficiency. With the support of Headland Technology and TRUMPF’s advanced power tools, BlueScope has transformed its operations, setting a new benchmark for safe and effective steel cutting.

About BlueScope Steel: BlueScope is a global steel company with operations across Australia, New Zealand, the United States, and other regions. In Australia, the Port Kembla Steelworks is a major centre for steelmaking and flat steel product manufacturing. The company also operates metallic coating and painting facilities nationwide and plays a vital role in downstream manufacturing and distribution.

With over 16,500 employees across 15 countries, BlueScope is dedicated to delivering innovative and sustainable steel solutions for a broad range of industries. More about Bluescope Steel

The Challenge

At BlueScope’s Cold Rolling operations, Giovanni D’Alessio, Principal Technologist for Cold Rolling at the CPCM rolling mill, faced critical challenges with existing tools.

Working in a harsh, dirty environment, the previous electrical tools frequently failed and posed serious electrical hazards. Requiring 110V and 240V power, these tools not only endangered personnel but also caused downtime during critical operations. Additionally, the unishears previously in use demanded significant manual effort, increasing the risk of fatigue and manual handling injuries.

The team needed a solution that prioritised safety, reliability, and ease of use in an environment that pushes equipment to its limits.

The Solution

To address these challenges, BlueScope Steel – Springhill Works partnered with Headland Technology to integrate TRUMPF power tools into its operations.

The TRUMPF TruTool N500 and 18V C250 with chip clipper provided the ideal combination of performance and safety. The 18V C250, designed for cutting steel strips between 0.3mm and 2.5mm, eliminated the need for 240V electrical power, reducing electrical hazards. For thicker materials (2.5mm to 5mm), the robust 240V TRUMPF TruTool N500 nibbler delivered exceptional reliability even under continuous use.

Key benefits of TRUMPF Power Tools

• Safety first: Eliminated electrical incidents and reduced manual handling risks.
• Durability: Operates for hours in environments coated in coolant sludge without failure.
• Ease of use: Lightweight design reduces fatigue and makes cutting effortless.

The decision to move forward with TRUMPF Power Tools was reinforced by excellent online resources, including instructional videos that made the transition seamless.

Implementation

The adoption of TRUMPF Power Tools was smooth and well-received. Employees with over 40 years of experience using unishears quickly embraced the new technology. Positive feedback encouraged Giovanni to fully replace the old tools, with no requests from the team to return to the previous unishears.

Headland Technology provided responsive support throughout the process, ensuring the supply of spare parts and additional units when required.

The results

• Enhanced workplace safety: The TRUMPF tools significantly reduced workplace risks. The TruTool N500 nibbler, weighing only 4kg, replaced much heavier legacy tools, improving ergonomics and reducing strain on employees.
• Operational efficiency: Downtime for scrap removal has been reduced, leading to smoother and more productive operations.
• Employee satisfaction: The team praised the improved ease of use and reliability, enabling them to work more confidently and comfortably.
• Long-term benefits: Giovanni highlights that no price can be placed on the health and wellbeing of personnel. The tools are now an essential part of BlueScope’s CPCM strategy to maintain safe and efficient operations.

Looking ahead

BlueScope plans to continue equipping the CPCM rolling mill with TRUMPF TruTool, acquiring two TRUMPF TruTool C250 and two TruTool N500 units annually to maintain performance in the challenging environment.

With Headland Technology’s expertise and TRUMPF’s innovation, BlueScope is confident in its ability to lead the way in safe, efficient, and sustainable steel manufacturing for years to come.

Client testimonial

“I hope that these tools will be used long after I retire at the CPCM because they were considered the safest, and TRUMPF and Headland have proven to be long-term suppliers. I am proud of implementing the use of these tools at the CPCM.” – Giovanni D’Alessio, Principal Technologist for Cold Rolling at Bluescope

Ready to improve your operations?

If you’re looking for safer, more reliable solutions for cutting and processing steel, our TRUMPF Power Tool experts are here to help. Contact Headland Technology to find out how we can support your business with innovative tools that deliver measurable results.