How Premier Automation Helped Modernize Critical Mill Operations at Gary Works
At Premier Automation, we pride ourselves on being more than a vendor—we’re a hands-on engineering partner committed to solving complex industrial challenges. That’s why stories like Louis Covelli’s stand out. As an electrical lead at U. S. Steel’s Gary Works—one of the largest steel-producing facilities in North America—Louis has seen firsthand how trusted support and technical excellence can keep production running, even under the toughest conditions.
A Problematic Drive in a High-Pressure Mill
Louis recalls his first experience with Premier Automation back in 2016. His team had installed a DC drive from a local supplier on one of the finishing mill motors in their hot strip mill—a high-output, high-pressure environment.
“We tried getting it running, but it just wasn’t working. Time and time again, we ran into issues. This is a critical part of the mill, and we couldn’t afford extended downtime.”
After repeated setbacks, someone suggested calling Premier Automation. Premier engineer, Pete Krahe, came on-site to assess the situation. After observing the setup and reviewing how the drive had been tuned, he identified the root cause—but offered something more valuable than just advice.
“They didn’t just point out the issue—they offered to take full ownership. That was when it was a no brainer to us— we wanted Premier and Premier only to handle this. They came in, tuned the drive, and got it running perfectly. That was extremely impressive.”
Expanding the Partnership
That success led to new projects. U. S. Steel purchased additional drive lineups for Finishing Stands 6 and 7, and Premier commissioned both systems with precision.
“Those drives have been running flawlessly since 2022. Even during COVID, when so many things were uncertain, the Premier team came on-site and got the job done. That level of commitment really stood out.”
Our support didn’t stop at commissioning. From remote troubleshooting and tuning to redesigning faulty breaker systems, Premier became a go-to resource.
“Whenever we had a problem, Drew Weihrauch and the team were quick to respond. They’d either walk us through the fix or log in remotely to take care of it. It’s been an outstanding level of support.”
Leading a Major Mill Modernization Effort
With a proven track record in place, Louis knew exactly who to trust for an even bigger challenge: a multi-year electrical upgrade at the 84-inch hot strip mill, aimed at replacing decades-old equipment.
“I told the integrator I wanted all drives to be handled by Premier. That was non-negotiable. The quality, responsiveness, and results spoke for themselves.”
Premier Automation is now a key player in this long-term modernization, supplying and supporting countless drive systems—each tailored to the mill’s specific needs and production demands.
Consistent, Safe, and Professional
In steel production, technical knowledge isn’t enough. The pace is fast, the stakes are high, and the environment is demanding. According to Louis, Premier’s team consistently rises to the challenge.
“Your team is professional, responsive, and safe. We’ve never had any incidents during startup or commissioning. You understand how to work in a mill environment—and that makes a huge difference.”
A Strong Partnership Moving Forward
As U. S. Steel continues its modernization journey with their new ownership by Nippon Steel, Premier Automation remains a trusted partner—offering the drive systems, automation expertise, and ongoing support needed to succeed.
“Premier Automation is more than a solution provider. They’re an asset to anyone in the steel industry.”