Sutton, Massachusetts: Where Innovation Keeps on Rolling

The Sutton, Massachusetts, U.S.A., location of Primetals Technologies serves as the company’s long-rolling powerhouse. Here, a skilled team of engineers, programmers, manufacturing experts, and sales and services specialists supports metals producers worldwide. Dr. Tom Widter explores how the Sutton facility continues to drive innovation for long-rolling producers and its impact on the steel and non-ferrous metals sectors in production and services.

On a December afternoon, I meet Michael Hagauer in the cafeteria at the Linz, Austria, location of Primetals Technologies. He serves as Vice President of the long-rolling business from the company’s U.S.A. location. Born and raised in Upper Austria, he relocated in 2008 when Primetals Technologies acquired Morgan Construction. He told me about the location in Sutton, Massachusetts, where he works in the Northeast region of the U.S.A., known as New England. Boasting a rich history in steel production, Primetals Technologies U.S.A. continues to innovate by supporting steel producers worldwide with best-in-class long-rolling equipment and services.

From Worcester to Sutton

“Tom, you really need to see what we’re doing in Sutton,” Michael says enthusiastically over coffee. Sutton became home to the company’s long-rolling operations in 2020. For decades, Morgan Construction was based in Worcester, Massachusetts, but when the time came to upgrade its facilities and workshop, the team found the nearby town of Sutton to be an ideal fit. Its location and infrastructure were perfectly aligned with the company’s needs, and the new premises could be customized to suit the team’s requirements.

Michael’s description of the facility ideally aligns with our series “Company Locations,” and a few months later, I catch a plane to Boston, Massachusetts. Upon arrival, I rent a car and make the hour-long drive to Sutton. The company location is situated in the southern part of the town, and the workshop spans over an impressive 143,000 square feet (13,300 square meters).

Evan Ludwig, the location’s marketing manager, greets me in the lobby. “Welcome to Sutton,” he says, inviting me on a tour. One detail catches my attention immediately: a large “always-open” gate connecting the lobby to the main workshop. Evan explains that the design was intentional, symbolizing the close collaboration between engineering and manufacturing. “It’s like a restaurant,” he says, “where the kitchen is visible from the dining area. We want visitors to see our ‘kitchen’ here in Sutton.”

Just as Evan and I discuss this direct connection between the two sections of the company building, Todd Cournoyer, the head of manufacturing, comes around the corner. “Hey Todd,” Evan says, “would you have time to give Tom a quick workshop tour?” “Sure,” he answers, “I’d be happy to. Tom, have you been to another company workshop before?” As I told Todd about my visits to the company’s locations in Mexico, Brazil, Japan, and India, he gave me safety gear and guided me through the gate. On the other side is a fascinating space where engineering drawings come to life as massive pieces of long-rolling equipment.

“Our workshop is organized into five bays,” Todd explains. “We arranged them based on the size of the components we handle. Smaller parts are manufactured near the entry area, while the larger ones are produced in the back, where they’re easier to load and ship.”

Todd goes on to describe how each bay’s team meets every Monday to plan the schedule for their machines, which are often quite large. During these meetings, they also review progress and address any challenges from the previous week. “Safety is always our top priority,” he emphasizes. “Even when our workload is at its peak, we focus on setting clear priorities rather than rushing. There’s always time to do the job safely.”

Touring the Workshop

As we begin our tour of the workshop, Todd leads me to one of the facility’s 5-axis CNC machines. These machines revolutionized manufacturing by dramatically improving speed, capabilities, and overall efficiency. “With these machines, what used to take five separate manufacturing steps can now be done in two,” Todd says.

While I have seen CNC equipment many times before, it is clear these machines are among the most advanced. The core concept remains familiar: a forged base component is secured to a table behind glass doors, where motors and drives control a precision tool to cut, shape, or drill the part into its final form.

I ask how 5-axis machines differ from the more traditional setups. “Have you found a way to break into a higher dimension of space?” I say jokingly. Todd chuckles. “Not yet, but we’re working on it,” he replies. “For now, the fourth and fifth axes come from the magnetic table that holds the part. In a 5-axis configuration, the table can rotate clockwise or counterclockwise and tilt left or right. This allows the cutting tool to reach angles and positions that wouldn’t be possible in a standard setup, all within a single manufacturing step.”

He gestures toward the DMC MORI 5-axis machine in front of us, which is currently crafting a part for a Morgoil bearing. “These are typically produced in our Ohio workshop,” Todd notes, “but we’re lending a hand this time.” CNC manufacturing demands a skilled machinist, along with the expertise of an experienced engineer and a programmer, to manage the entire workflow. The Sutton location has all three roles covered. “We have six programmers on our team. They work closely with our engineers to understand the purpose of each part and to develop the most efficient, streamlined way to make it.”

As we approach another CNC machine, Todd introduces me to Lillian Berry, a young operator who quickly earned a reputation for consistently delivering exceptional quality parts. Lillian tells me she genuinely enjoys her work. “You might think making part after part all day would get repetitive, but I find it calming. It allows me to focus on what really matters in this role and continually improve my skills,” she says. Todd adds that many workers in Sutton spend several years honing their expertise on the shop floor before advancing to senior roles with greater responsibilities. “We like to promote from within,” he says. “It’s part of the U.S.A. spirit.”

Where Past Meets Future

As we continue through the workshop, we see components at various stages of completion. Among them are laying heads, a key element in long-rolling production, which have been manufactured here for over a century. This legacy means steel producers still request models from older product generations. They also rely on Sutton’s expertise to meet diverse requirements, such as supporting different coil sizes. Despite the variety of setups, Todd notes a growing trend: “Pipe support is important these days,” he says, explaining that many producers are shifting their portfolios toward high-end steel grades.

Smaller gearbox components, each destined to become part of a 50-ton machine, are stored throughout the workshop. At the time of my visit, Michael Marengo is assembling one such gearbox. “It takes about six to eight weeks to complete,” he explains. The process is complex but rewarding. Once finished, these gearboxes can achieve up to a massive 198 different ratio combinations.

Nevertheless, the industry is evolving. Traditional long-rolling mills powered by a single motor and gearbox are giving way to more advanced designs with individually driven stands for the finishing mill. This innovation provides finer process control and allows operators to “switch off” stands not in use, depending on the steel grade being processed. The result is increased energy efficiency and extended equipment lifespan, thanks to reduced wear and tear. Yet, the transition to individually driven stands will take time, and Marengo and his colleagues will have made many more gearboxes before it is completed.

Employees of Primetals Technologies share a passion for developing innovative solutions for their customers. Yet, each location has its own distinct character. In this section, we explore the unique spirit that defines the Sutton team.

The self-critical nature integral to U.S. society leads to
continuous improvement. Americans put their work out in the open, focus on what could be better, and improve together.

Gabrial Royo
Head of Metallurgical Services U.S.

I am originally from Greece. And in my view, Americans tend to be more direct, practical, and open to change. This mindset often makes the U.S. a launchpad for new advancements.

Effrosyni Tampali
Commercial Project Manager

We have a diverse community, and everyone is free to choose their own path in life. I recently felt this freedom firsthand while discussing future options with my kids.

Amanda Schiltz
Inside Sales Manager

America embodies openness and freedom, offering to build a life full of unique opportunities. This spirit has driven countless technological breakthroughs.

Mike Baldarelli
Commercial Project Manager

America is a huge melting pot. It gives everyone a chance to experience different cultures. It offers a deeper understanding of the world. I find living here incredibly fulfilling.

Casey Kross
Systems Engineer

At the back of the workshop, Todd shows me a reconditioning area where producers send equipment for scheduled inspections or urgent check-ups. We pass several mill stands and pipe-bending stations used to make cooling equipment. “For maximum lifetime, a pipe-in-pipe design is best,” he explains, describing a waterproof, heat-resistant double-layer pipe that lasts five to ten times longer than standard designs. He explains to the mill stands that many customers will send components for reconditioning for mills several years after installation. “As long as our customers factor maintenance into their mill’s lifecycle, their long rolling mills can remain in operation for decades.”

Non-Ferrous Metals

Not all manufacturing in Sutton focuses on components for steel production. The Massachusetts location also supplies aluminum and copper mills. “You know what,” says Todd, “let me take you to four of our engineers. They’ll be able to give you more details about the non-ferrous side of things.”

I meet Justin Scott, Chris Rogalski, Dylan Stimson, and James Trapp in a conference room in the adjacent office area. The engineers speak enthusiastically about the broad range of equipment they design. “Engineers enjoy variety,” says Dylan, “and that’s something we have in spades here in Sutton. Plus, having in-house manufacturing gives us valuable hands-on experience.”

For copper mills, the company collaborates with its long-standing partner, Southwire. This relationship has proven remarkably fruitful: no less than half of the U.S.A. households rely on electrical wiring from Southwire. While Southwire supplies casters directly to copper producers, Primetals Technologies provides practically all downstream production equipment—from the caster to the finished rod. “Arguably, the electrification of America, including the push for electric vehicles and the voltage loads they require, is supported by products made on our mills,” Dylan explains. He adds that Sutton supplies both copper and high-transmission aluminum wire mills, contributing in a significant but often invisible way to the U.S.A.’s green transformation.

Designing a Mill From Scratch

Speaking with the engineers sparked my curiosity about how rolling mills are designed from start to finish. I am introduced to Neil Gow, one of the engineers. Neil walks me through how his team determines the layout and specifications for new facilities.

The process begins with in-depth discussions with the customer about their goals and ambitions. This fundamental information is then handed off to specialists like Neil, who draft the initial basic
layout of the rolling mill. “When a steel producer communicates their requirements, we build a model of the ‘roll pass’. Essentially, the rolling area of the plant,” Neil explains. “The model helps us determine the number of mill stands needed, motor sizes, the amount of water cooling between stations, gearbox configurations, including ratios and torque capacity, and much more.”

Interview with
Vishnu ‘Rick’ Narain

Vishnu Narain, also known as Rick, develops new technologies and services for metals producers in the U.S.A. and beyond.

What innovations are you working on?

Vishnu ‘Rick’ Narain: One of our key innovations is an “advanced guiding development.” This design became the foundation for a range of guide models, including four-roller, twist, slitter, and roller-entry options. We developed every detail in-house and even brought on two programmers to perfect the product. Another standout is our advanced water cooling header. These are just a few examples of how we’re constantly pushing the boundaries of what’s possible.

Are there any “tricks” to be more creative?

Rick: As a team leader, I promote out-of-the-box thinking and make sure everyone has the flexibility they need for a healthy work-life balance. A welcoming and fun workplace culture plays a big role in our success.

How do you conceptualize new ideas?

Rick: The crucial first step is to listen to your customer. We often learn what’s needed from detailed conversations with metals producers. Safety has become absolutely paramount. One customer has very clearly communicated to us their “red lines,” i.e., ­scenarios that must be prevented, and we use these “lines” as reference points to instruct and inspire our own R&D work.

Is there an innovator who inspires you?

Rick: I would say, Elon Musk. He may be a bit of a character, but he is also a free thinker and a leader whom people want to follow.

Once Neil’s team provides their initial recommendations, the conversation with the customer continues. Some producers arrive with clear ideas about the technologies they want to incorporate, but surprises can emerge, especially when venturing into new products. After several iterations and refinements, the project’s scope takes shape, culminating in a tailor-made offer.

Neil also works extensively on upgrades to existing mills, a challenge he particularly enjoys. “It’s like solving a puzzle,” he says. “We analyze the potential and limitations of a customer’s current setup. Sometimes, we discover unique production line configurations that haven’t been fully optimized, and it’s our job to figure out why.” Many producers adopt an incremental approach, upgrading step by step, but Neil notes that he admires those who “leapfrog future projects” by making early strategic investments that pave the way for rapid progress.

The journey of delivering a long-rolling mill does not end with the installation or the first run of new products. The Sutton team remains closely involved, offering expert guidance and long-term support. According to Gabriel Royo, who oversees the U.S. Metallurgical Services organization at Primetals Technologies, the goal is to maximize mill utilization. “Some producers have faced challenges maintaining their workforce,” Gabriel explains. “We bring continuity and can fill knowledge gaps that may arise.”

Looking ahead, Gabriel sees services evolving further, with additive manufacturing playing a key role in spare parts production. He also anticipates innovative service models, such as charging based on “dollars per ton” of steel produced. “This way, everyone’s interests align, ensuring that both we and our customers are focused on maximizing plant output,” he says.

A Seamless Operation

As my visit to Sutton wraps up, I sit down for one final meeting. I speak with Michael Hagauer, the person who invited me here, and Paul Riches, who leads the company’s global long rolling business.

Their shared mission is perfectly ambitious: helping long-rolling producers worldwide elevate their operations, often by upgrading mills to produce high-margin, high-end steels.

Paul Riches, an industry veteran who started in the early 1980s, explains what still inspires him about his work. “The scale of these projects is truly remarkable, especially when constructing a plant from the ground up,” he says. “Few industries can operate at such a high level while ensuring everything runs smoothly through effective maintenance.”

Then Paul asks me: “But Tom, what impressed you the most during your time here?”

I could mention the advanced technology, the impressive workshop, or the company’s century-long legacy. But what truly stands out is how seamlessly the team operates as a “one-stop shop” for steel producers across the globe. From the initial inquiry to long-term support, the Sutton team delivers everything required for the entire lifecycle of the plant.

It is this winning approach that impressed me the most—along with their uniquely dry and unmistakably Massachusetts sense of humor.

Experiencing the location and the New England Countryside