Large workpieces sawn with precision

Structural steel and tool steel stockholder and processor, JKZ Bučovice, uses KASTObbs automated block bandsaws from Kasto to cut large, heavy billets and plates of various geometries, grades and dimensions.

The components are delivered to domestic customers in the Czech Republic and others in Slovakia, Poland, Austria, Germany, Slovenia, Hungary, Romania and the Baltic States.

Founded in the year 2000, employing 125 staff and with an annual turnover of €20 million, the company holds approximately 10,000 tonnes of steel in its 15,000m² warehouse. The oldest Kasto vertical block bandsaws have been in use for nearly 20 years and are still operating reliably today. More recently, a pair of KASTObbs A 3x20 bandsaws were installed for cutting material up to 420mm high by 7m long and weighing up to 56 tonnes.

In addition to 35 automated bandsaws, processing equipment includes flame cutting, plasma cutting, grinding and deep-hole drilling as well as 20 3- and 5-axis machining centres. Workpiece dimensions are up to 2.5 x 4.5m to suit customer requirements.

Marek Hermann, sales and production director at JKZ explains: "We already had extremely positive experience with the two older Kasto block bandsaws we acquired in 2006 and 2007, which still perform well today.

"As we only have a few competitors that are equipped for processing such large parts, we decided to expand our capacity further to meet the high demand more efficiently. The new KASTObbs saws are very robust and reliable and provide the high degree of quality and precision that our customers demand, especially those in the toolmaking sector."

Characteristic of this bandsaw series is the longitudinal cutting method using a vertically orientated blade. The saw head moves on rails having side mounted, hardened and ground rollers, while the workpiece remains static on the saw table. The configuration results in a small footprint, while the torsion-resistant, welded construction provides smooth running and vibration-free operation, leading to shorter cutting times and longer blade life.

JKZ employees are able to adjust the cutting infeed to optimise productivity, consistent with the required workpiece quality and the cross section of the material being processed. Band speed is also infinitely variable from the integrated control panel.

Mr Hermann continues: "Due to the zero to 90° rotation of the KASTObbs A saw band, we can cut workpieces both lengthwise and crosswise, enabling unmanned operation from the raw block to the finished cut workpiece."

In 2015, the stockholder bought a compact, automated Kasto Unitop 5.0 storage system to handle bar stock weighing up to 5,000 tonnes. The 3D storage facility operates seamlessly with the saws, with which it is interfaced, and it is also linked to the stockholder's ERP system, enabling efficient material flow.

Mr Hermann concludes: "The store not only allows us to optimise our material flow from goods-in to shipping, shortening delivery times, but also reduces error rate and has freed up space for additional processing machines.

"We are very satisfied with the collaboration with Kasto, from the joint planning exercises through commissioning to maintenance. The service from the company is prompt and the supplier is always there to answer any queries we may have.

"We are delighted to have such a reliable partner that is familiar with the challenges of the steel trade and supports us in mastering them by providing innovative, functional, future-proof solutions."

Kasto
www.kasto.com