Thirty years apart, the son of a former Mordica Memorial Award winner follows in his father’s footsteps. Here, he traces some of the challenges and successes that came with leading the family business through periods of great change.

By Giulio Properzi.

[ Reprinted with Permission from Wire Association International ]

Editor’s note: this presentation is included in the 12 minute History Video with rare historic footage. An edited version of the narration is presented here.

When I was informed about this recognition, I started to muse over what I was supposed to write. I knew theoretically I should tell you something about “a contribution to the wire industry’s base through research, development, innovation or other technical contributions” but no special topic rose in my mind. There was only that sentence knocking and knocking again: “Already thirty years have passed.”
I would not have been here today if exactly 30 years ago the same Mordica Award had not been awarded to my father, Ilario Properzi, during the WAI Convention in Toronto in 1973. The path that led him there was accomplished at no small price.
So I said to myself, “Why not?” Why not try to make a ride with those years, a ride that is my life and has been lasting for more than thirty years?”
At that time, in 1973, I had already been following my father’s work for more than 10 years on a part-time basis. I used to go to call on factories and visit customers with him. I had, therefore, the chance to live through his golden age from the ‘50s, when I went with him to see the first copper casting Properzi machine in Germany, to the ‘70s, a period already considered ancient history but the basis of my future.
I did not mean to bother you with a flood of words on these old times so we have prepared a video with images that may better explain the role of the Properzi’s in terms of the invention and subsequent developments of the continuous casting and direct rolling of aluminum and copper rod, a process that shaped an entire industry.

-HISTORY VIDEO-
Now, as you have seen, this video is dedicated to the glorious part, to the inspiration, but let me say a few words also on those aspects often hardly highlighted, on those worries and concerns, if not the blood and tears that are behind all stories of success.
When Isaac Newton was asked how he had been able to reach his tremendous achievements in the knowledge of the laws of Nature and God, he answered “I climbed on the shoulders of giants” meaning Tycho Brahe and Keplero, the two great astronomers before him.
I have climbed no giant shoulders but the past did climb on my shoulders as a road roller. What was my situation like in 1973 as general manager and continuer of Continuus company’s activity at the age of 31?
My father’s renown started to clash with his physical decay (he was born in 1897) and, moreover, an American “giant” and a European one had gotten active in our activity niche. They were not only suppliers of machines and equipment but users as well, and therefore owners of profound day by day operative know-how.
If, in addition to this, you think of the ordinary toil in a family company of a generation passing, it is evident that only a lofty deal of stubbornness and youthful recklessness allowed me to take the road that has brought me here among you.
While my father was still, though nominally, chairman of our company for few years (1973-1976), with the only help of my younger brother, Lucio, I made a general survey that froze my blood. To survive, I was obliged to sell lines for copper rod in addition to the aluminum rod lines, although I was threatened worldwide by a huge suit for infringing patents that could bankrupt us.
I had to prepare our lines to make a technological leap, to reconstruct a technical team and a commercial one, to readjust the company organization on an up-to-date basis, to form and communicate an image of the Continuus company, which up to that time had never paid for an ad or printed a brochure and had attended one single fair as exhibitor in Moscow. All that with only additional in-house resources (actually mine!) for I had no means to pay professionals.
It was a question of carrying out a deep company shake-up in every single department. Since I had to start from somewhere, I decided to begin from what I was more familiar with and congenial to me, for attitude or for imprinting: design.
I had to go the drawing board, but first of all it was essential that I dispel the many lingering tales and go deep into the core of the true problems.
The incredible Properzi rolling mill, with its bicycle chain-like transmission moving 13 or 15 rolling stands with one motor in the early years, developed step-by-step into a sturdy and efficient machine many of which, as you have seen, is still operating after 40 years. Yet at that time it was criticized for the uniqueness of its rolling technique, which employed three rolling rolls inside the stand instead of the two cantilevered rolls that were commonly used by manufacturers then and continue to be used by some today. See Fig. 9.
Since everybody made or used the two-roll system, the criticism and mistrust towards the Properzi Mill were indeed strong, to such an extent that they almost succeeded in convincing me I was on the wrong track.
And just to increase my doubts then as a young engineer, there were other lingering tales about the Properzi wheel itself, often based on beliefs of the time. For instance: a bar solidified in a ring could not afford to be straightened; and that a bar leaving the wheel could not even afford the minimal deviation to skip the belt. These claims, which were both repeated and printed, drew the attention of people not paying enough attention to the actual facts.
I thought deeply about these topics and I convinced myself that the remarks about the Properzi wheel were only propaganda. Further, that the three-roll configuration, perhaps preceded by two 2-roll passages (just as we did back in 1964 for the first copper line), was the most economic solution besides controlling the metal flow or the metal spreading under the rolls. This was a tricky factor in a mill where a number of in-line rolling stands were driven by one motor, and therefore having fixed speeds. It was a difficult task for any expert in rolling sequences as the goal was to design all roll profiles to maintain exactly the same metal flow in each pass.
Another advantage is that the three rolls lay on six bearings located in an optimal position that is contrary to the geometry of the two rolls mills where the separating rolling force is not distributed and, in practice, increased and concentrated on a single bearing. See Fig. 9.
The 3H system, at the same level of sturdiness of the machine, allows a much smaller and lighter construction.
Yes, the Properzi Mill of the ‘70s was a good machine; there were, nevertheless, two points that had to be improved: the roll change and stand maintenance, and the design of roll profiles, meaning the entire rolling sequence.
At that time, the roll change was a very difficult operation although it was counterbalanced by the fact that replacement of an entire stand only took about 10 seconds, and that it was possible to perform maintenance outside the rolling line. This solution had been only recently adopted in the steel rod mills of three roll and the two-roll kind, confirming that this was not a foolish idea.
What I initially faced, though, was the rolling sequences problem. At that time, there were doubts about either too much tension or too much compression between stands or poor metal deformation under the rolls due to a lack of a solid theoretical knowledge.
Therefore I had to find a scientific formula to calculate the rolling sequences: that is to say, a formula which, according to the needed reductions, established the right speed and roll profiles for each stand.
I started a series of calculations with one of the first portable computers, trying to verify the numbers with practical tests. After years of effort, the magic formula was found. It proved to be a good, precise tool to control the metal deformation in a series of rounds and triangles dimensioning as well as the tension between stands “ad libitum.”
Eventually I was able to set up a rolling sequence for any kind of metal or alloy, whether the inlet size was down to 1.6 mm or 1/16 of an inch. Such a level of precision was reached that in the last few years it has been possible to produce dimensional tolerances close to or even equal to those ones obtained by a drawing die. For instance, plus or minus 1% on a 3.2 mm cast-and-rolled wire that is coiled on stems at 20 m/sec exit speed.
Meanwhile, I started to face the second issue. I designed a completely new stand that required little maintenance and made it easy to change rolls in a short time period.
The Model 9, as we call it, is produced in two sizes. One has rolls of 180 mm theoretical diameter, the other a 270 mm diameter. Both are very compact. Each one of the three work rolls is mounted on a single support located in the monobloc housing. It is simple to disassemble, with only four screws to be unscrewed to change the roll support.
The work roll gauging and alignment is done with the stand completely mounted, thanks to the help of an optical projector. Gauging is obtained by means of spacers and the alignment by eccentrics.
The use of a profile projector makes human error practically impossible. A sophisticated mechanism, which is three time lighter than a two-roll stand with the same performance, it offers good savings in space requirements and spare parts cost.
Having developed both a firm control of the metal flow and practical rolling sequences, I could dare to try and design a cold rolling mill for ferrous and nonferrous rod reduction from 10-8 mm down to 2-1.6 mm.
Said and done! A new type of a smaller but sturdy rolling stand, stronger and easier to be handled was devised. In just one year, it was designed, produced and exhibited in Basel.
This first Micromill would be followed by “brothers” that work with material that had proven difficult to draw. The larger-sized Model 9 (see Fig. 10) was one such system. The Micro design eventually developed into the Model 10 (see Fig. 11), replacing the Model 7s and 8s in old continuous casting lines that could not fit a Model 9. This stand, an enlarged Micro Model, is even more compact than the others. The monobloc is built in two halves. The main shaft below distributes power and speed to the secondary rolls (simple rings) that are mounted on a hub containing the bearings, oil lubricated. In this case continuous gauging and alignment by eccentrics are possible from the outside with the help of a projector.
These stands are giving a new youth to the rolling mills of the ‘60s, aged more than 40 years old. Better than any cosmetic surgery!
Changing the subject...
In the same year I had another target to reach, that is to say the setup of a new complete line for copper rod.
It was a small line for a “small” price, done and thought for manufacturers that could not justify huge equipment with a production close to or bigger than 100,000 metric tons per year.
It was common, in those days, to say that it was impossible to produce good quality rod with small equipment. Once more I was just facing a good mixture of myth and advertisement.
I had to restudy and redesign the whole line, from the shaft furnace to the coiler and all the ancillaries’ equipment. Further, I had to hope to sell one or two lines a year on the basis of affordability.
It is noteworthy that all this technical development had to be done under stormy clouds, because long before we had been subjected to negative propaganda and even sued for infringement of 20 patents, a deadly accusation for us as sellers of copper rod lines. Needless to say, we had not infringed upon any patent, as five verdicts eventually recognized, although they were delivered with incredible slowness. Further, three subsequent court decisions found that we were the ones that were copied and slandered.
We persevered, and in the last 20 years, during a period of heavy demand for giant copper lines, I succeeded in starting up more than 30 small or medium size lines all over the world for customers that, in general terms, could be called absolute beginners in molten copper operation. Most of them today are still competing in the world market.
It was not an easy task, but it was something to be proud of. One of these lines was especially unique: everything started from copper scrap and not from the cathodes. This was a very difficult task, which was not a rare occurrence in my life.
Today, we can do so using modified shaft furnaces and reverberatory furnaces, but in this adventure I was lucky enough to meet and work with a first-class man, the general manager of a Spanish company who started from scratch and step-by-step established an exceptional facility that was able to accomplish this most difficult task. Refining bad copper scrap, casting it, rolling rod and then producing the multiwires is incomparable in difficulty and requires profound know-how, ability and scientific study with a standard operation starting from cathodes.
Recycling of copper scrap via wirebars and hot rolling had been in use for a long time for rod to be marketed as second quality. Today it might seem easy but you can be sure that in this factory in the last 16 years, R&D had not been only an expression.
As Properzi continued to evolve, so did our focus. We concentrated on new applications, new machines and new methods for the wire industry, but we also served the strip industry. Thus it was that we were able to develop machine lines to produce thin lead strip to produce automotive batteries. One of our systems produced a coil of such strip 75 mm (3 in.) wide and 0.8 mm (.003 in.) thick.
We also created a giant wheel caster (see Fig. 3) with a diameter of 4.2 m (14 ft) designed for a new system for producing foundry aluminum alloys at very high production rate, nearly 15 ton/hr.
The traditional ingot produced in open top molds often had cracks and oxides on the surface and variable height. The new ingot is sound, clean and of stable dimensions. It is easy to stack and the bundles are compact, which is a great advantage for storage and transportation.
Now, going back to the wire industry, a few years later we used the experience of the giant caster for a super wire rod line produced for a new Canadian smelter, an astonishing best-of-the-best realization. A continuous cast bar is cut into short lengths called ingots that to this day continue to range between 8 and 10 kg. See Figs 5 and 7.
As not all my work has been in the wire field, so today not all the efforts are in the nonferrous field.
In 1999 I decided to take a big jump in the ferrous industry, taking over three famous brand names: France’s O.T.T, Italy’s R.T.M. and Germany’s J.A. Kraft. Their traditions, old files, drawings and collective know-how became our base in the ferrous world.
I realized that these operations needed a quick and profound revamping. For instance, O.T.T. had been a leader in high carbon drawing machines during the ‘80s, but a perfect drawing machine for the third millennium had to be thought and designed almost from zero. Well, in 12 months, we had the Megalogos, a high carbon drawing machine. It was ready for the market and the first sale was in December 2000. We started with the biggest machine, with 50-inch capstans, but 35 and 30 inch sizes are available. See Fig. 8.
I wanted a human friendly machine in operation and for maintenance, so it has capstans with a horizontal axis. As regards to the cooling system, it was a pleasure to use our 50 years’ experience in casting wheels. It is not easy to make something innovative and advanced in this field but we have taken steps forward.
We also have modernized RTM’s PC wire lines and several J.A. Kraft’s stranders (see Figs. 4 and 6) for rounds or flat wires, as well as transposing lines for transformer cables up to 64 flat wires. Those are a few of our winning products.
To make this long story short, I was lucky enough to inherit a “craft shop” from a genius father. I could have done no better than to turn it into an advanced engineering company, one able to develop in many fields, producing new ideas, including many pieces of equipment that work at high speed. They may not all have been revolutionary ideas, but they were good ones. Now, looking back at what I have done, step by step, together with you, I feel proud about what has been accomplished by two different people named Properzi, one a 1973 Mordica Award winner, the other a 2003 winner.
Much has changed in the wire industry. Thirty, forty years ago, the industrial configuration and the market allowed that most technological advances often came with a first and last name, such as the Properzi Process, and that they often were revolutionary ideas. Later, working groups were established, and their targets and behaviors are different.
In my field, research has concentrated more on the details and economics; it is more a filing job than a real break of a tradition. It looks to me that because of the present hard times we have lost the will to risk something in the present for a success in the future.
Well, good times will come back soon; the world does not stop!
I once was asked what I would say to a young person who wants to embark on this career. My answer was this: “Think, ponder always at any time, even when you are drinking a cup a coffee; never give up thinking, producing ideas.”
I say to you, never aim to the great ideas, but pursue the little advances. Today, it is easy to say that it is difficult to be original, but consider this: At the time of Michelangelo there were already unbelievable sculptures and paintings and still, he sculptured and painted masterpieces.
There is always something to do better, even though, just a little bit better!
Thanks again to everybody.
Giulio Properzi, the president of Continuus S.p.A., Milan, Italy, and an industry veteran with more than 40 years of experience, is one of the two winners of the 2003 Mordica Memorial Award. He follows the steps of his father, Ilario Properzi, who won the Mordica Award in 1973. The award recognizes an individual’s contributions to the knowledge base of the wire and cable industry.
Starting early in his youth, working for his father, Properzi became head of his family owned business in 1971 and in 1979 co-founded Properzi International, Inc., Davenport, Iowa, USA, which has been under ownership by Continuus since 1988.
Properzi holds a master’s degree in mechanical engineering from the Politecnico of Milan. His achievements over the last four decades include the design and development of numerous processes. He holds about 100 worldwide patents in different fields, mostly related to continuous casting and rolling of nonferrous rod. He has also authored several WAI technical papers.
Properzi, who joined the association in 1976 and became the first person outside North America to serve as an officer, will serve as president in 2004. He organized the WAI’s first Italian Technical Conference in Como in 1981 and was chairman of the 1997 European Technical Conference in Stresa, Italy. He was chairman of the organizing committee for the multi-association technical conference that was held October 2003 in Stresa, Italy.
This presentation, which comes in a package that includes two video discs (PAL format), can be ordered through the WAI’s Technical Information Department.