Hussey Copper F31 Upgrade

About

Founded in 1848, Hussey Copper has been a cornerstone of American manufacturing for nearly 170 years. As the world’s largest and most experienced producer of electrical copper bar, Hussey Copper’s expertise spans a wide range of capabilities. From melting and casting primary metal to delivering precision-finished copper components, Hussey Copper serves a wide variety of industries.

Hussey Copper’s Leetsdale, PA facility is the heart of its operations, producing high-volume, high-quality copper sheet, strip, and plate products that meet extremely tight tolerances, tailored to meet customer needs. The company is ISO certified, adheres to ASTM standards, follows lean manufacturing principles, and continues to invest in technology and process optimization to maintain its reputation for quality, reliability, and innovation.

As part of its ongoing commitment to excellence, Hussey Copper continually seeks opportunities to modernize its production equipment with process efficiency and reliability in mind. When an aging control system – the F31 Continuous Copper Annealing and Pickling Line – no longer met modern performance or reliability standards, Hussey Copper partnered with Premier Automation to upgrade this decades-old system.

The Problem

The F31 Continuous Copper Annealing and Pickling Line was originally controlled by a 1990-era automation system consisting of two Automax PLCs and five operator stations. Over time, the system became increasingly unreliable:

  • Frequent communication failures: across I/O drops disrupted operations.
  • Limited flexibility: made it difficult to modify code or improve system logic.
  • Obsolete hardware: meant spare parts were nearly impossible to find.
  • Unpredicted shutdowns: resulted in costly production downtime, sometimes requiring up to 8 hours of repairs.

    • This outdated system was a growing risk to production reliability, maintenance efficiency, and overall operational visibility. To address these challenges and improve the F31 line for long-term performance, Hussey Copper turned to Premier Automation, a long-term trusted partner, to modernize and enhance their manufacturing systems.

The Solution

Premier Automation designed and executed a comprehensive retrofit of the F31 control system. The upgrade included:

  • Replacement of the two legacy Automax PLCs with a Siemens S7-1500 PLC.
  • Installation of six new remote I/O panels for distributed control.
  • Five upgraded operator stations, including two modern Siemens Unified HMI interfaces.
  • A new Siemens DC drive for the exit recoiler.
  • Replacement of entry and exit accumulator resolvers with Profinet absolute encoders for improved accuracy and reliability.

Despite the complexity of the project, the entire demolition, installation, and commissioning were completed in just 17 days, minimizing production interruption. The completed retrofit gave Hussey Copper a modern, reliable, and serviceable automation system designed for long-term performance.

The Results

Since commissioning in January 2025, the upgraded F31 line has operated without any issues, callbacks, or modifications. Key improvements include:

  • Zero unplanned downtime: related to control failures since installation.
  • Enhanced visibility: so that operators can now view defect issues in real time – even remotely – eliminating the need to dig through code or manually inspect equipment.
  • Easier maintenance and support: thanks to standardized Siemens hardware and open architecture.
  • Improved production reliability: enabling Hussey Copper to maintain its commitment to quality and on-time delivery.

This modernization project has not only improved day-to-day operational reliability but also strengthened the long-standing resilience of Hussey Copper. The new system enables their team to focus on continuous improvement and production excellence, aligning with the company’s commitment to quality and innovation.