Large precision sawn pieces
Shareholder and processor of structural and tool steel, JKZ BuÄ ovice, uses Kasto’s KASTObbs automated band saws to cut large billets and heavy plates of various geometries, grades and sizes.
The components are delivered to domestic customers in the Czech Republic and to others in Slovakia, Poland, Austria, Germany, Slovenia, Hungary, Romania and the Baltic States.
Created in 2000, employing 125 people and achieving an annual turnover of 20 million euros, the company holds approximately 10,000 tonnes of steel in its 15,000 m² warehouse. The oldest Kasto vertical bandsaws have been in use for almost 20 years and still work reliably today. Most recently, a pair of KASTObbs A 3×20 band saws were installed to cut materials up to 420mm high by 7m long and weighing up to 56 tonnes.
In addition to the 35 automated band saws, the processing equipment includes oxy-fuel cutting, plasma cutting, grinding and deep drilling as well as 20 3- and 5-axis machining centers. The dimensions of the room can reach 2.5 x 4.5 m to meet customer requirements.
Marek Hermann, Sales and Production Manager at JKZ, explains: “We have already had an extremely positive experience with the two old Kasto band saws that we acquired in 2006 and 2007, which are still working well today.
“As we only have a few competitors equipped to machine such large parts, we decided to increase our capacity even further in order to meet the high demand more efficiently. The new KASTObbs saws are very robust and reliable and offer the high degree of quality and precision that our customers demand, especially those in the tooling industry.”
Characteristic of this series of bandsaws is the longitudinal cutting method using a vertically oriented blade. The saw head moves on rails with 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, vibration-free operation, reducing cutting times and extending blade life.
JKZ employees are able to adjust the cutting feed to optimize productivity, depending on the required quality of the part and the cross section of the material being processed. The tape speed is also infinitely variable from the integrated control panel.
Mr. Hermann continues: “Thanks to the zero to 90° rotation of the KASTObbs A saw band, we can cut pieces lengthwise and crosswise, which enables unmanned operation from rough block to the finished cut piece.”
In 2015, the shareholder purchased a compact, automated Kasto Unitop 5.0 storage system to handle bars weighing up to 5,000 tons. The 3D storage works seamlessly with the saws, with which it is interfaced, and it is also linked to the stockist’s ERP system, allowing efficient material flow.
Mr. Hermann concludes: “The warehouse not only enables us to optimize our material flow from receipt of goods to dispatch, shortening delivery times, but also reduces the error rate and frees up space for additional processing machines.
“We are very satisfied with the collaboration with Kasto, from joint planning exercises to commissioning and maintenance. The company’s service is fast and the supplier is always there to answer all our questions.
“We are delighted to have such a reliable partner, knowing the challenges of the steel industry and helping us to master them by providing innovative, functional and scalable solutions.”