At the packing bed of W Steel Mill in Saudi Arabia, glowing rebar bundles roll off the line continuously under intense desert heat. But unlike in the past, no operators are standing near the scalding steel to manually count bars or split bundles. Taking over this high-risk zone is DBM’s newly commissioned Automated Bar Counting and Separation System.
In high-speed bar rolling mills, precision bundle counting and smooth separation have long been a bottleneck for packing bed efficiency. Under the Middle East’s harsh climate—extreme ambient temperatures, heavy dust, and dense scale—manual counting routinely suffers from operator fatigue. Over-giving bars causes unseen yield loss for the mill, while short-counting leads to customer claims and commercial disputes.
DBM’s custom automated solution has fundamentally transformed the packing line operations for W Steel Mill:
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Sub-Second Optical Intelligence: High-speed industrial vision AI sensors scan bar cross-sections in real time, executing millisecond-level optical counting with near-100% accuracy.
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Automated Mechanical Precision: Interlocked directly with downstream mechanical separators, the system automatically isolates the exact rebar count on the fly—completely removing personnel from the cooling bed.
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Built for the Saudi Desert: Equipped with heavy-duty thermal shielding, positive-pressure dust protection, and self-circulating cooling, the system is engineered to thrive through 24/7 continuous operation under extreme ambient heat.
From manual estimation to millisecond AI scanning, and from hazardous manual separation to automated mechanical isolation, DBM’s system not only safeguards plant workers from extreme heat hazards but also protects the mill’s bottom line by eliminating counting errors and yield giveaway.
The smooth commissioning and site acceptance at Saudi W Steel Mill mark another successful landmark for DBM in the Middle Eastern metallurgical automation market. DBM remains committed to empowering global steelmakers with reliable, intelligent equipment and process control solutions.