Kaltenbach customers magazine 1/2012 english

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KALTENBACH If Steel is Your Deal!

Steel Fabrication/Steel TradingSteel Construction and Plate Processing Steel/Aluminum

Sawing / Drilling / Flame Cutting / Coping / Punching / Shearing / ShotblastingPainting / Software / Service / Engineering / Complete Solutions

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125 Years of KALTENBACH 1887 - 2012

What our customers sayModern solutions for the use of band and circular saws

Goldbeck Automatic sheet metal machining

Beautiful architecture Major saw order for the company Vorndran

www.kaltenbach.comIssue 1 – 2012

KALTENBACHFrom Lörrach into the World

1887 - 2012 125 Years of KALTENBACH

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EditorialValentin Kaltenbach

CEO of the KALTENBACH-Group

ContentsPage 3 125 Years of KALTENBACH

Page 4 and 5 KKS 463 at AtotechMSK 471 at Schickling Visbek

Page 6 and 7 KBS 761/1051Interview with Jörg Tetling

Page 8 and 9 Shotblasting at Bresser Metaal in the Netherlands

Page 10 and 11Goldbeck: Automatic sheet metal machining

Page 12 and 13 KSB 1051 band saw - highly efficient, even for large profiles

Page 14 and 15 Steel construction made up of 1144 individual parts

Page 16 - International Trade Fairs 2012- Address table - Imprint

Insert: 125 Year of KALTENBACH.From Lörrach into the World

www.kaltenbach.com

Dear Business Friends,

when my great-grandfather, Julius Kaltenbach, opened his small locksmiths in Haagen in 1887, he could not have dreamed that it would develop into a company that supplies products all over the world.

Looking back at 125 years of KALTENBACH gives us the opportunityto place the current situation with the on-going euro and sovereign debt crisis in a bigger setting and to specifically realign the company in a period of social change. The traditional industrialised countries are in the process of losing their long-established economic dominance. More and more emerging countries are experiencing a barely imaginable economic development and are increasingly catching up with the global market. These changes are also having an effect on Kaltenbach. We are thus, for instance, experiencing the economic upturn in South America, Russia and India at first hand. These regions now account for a third of our turnover.

However, the company‘s 125th anniversary is also an occasion to look back at the past. Over all four generations, the family-run business has experienced many changes. In the process, there were abrupt changes – such as that from the glassblowing factory to the mechanical engineering company – and there were gradual adaptations such as that over the last 20 years, from a purely mechanical engineering company to a system supplier.

We want to actively help to shape economic structural change in the future too. Our experience and our strengths that have grown over 125 years give me the confidence that we will continue to work successfully with our business friends all over the world in the years ahead.

Kind regardsKALTENBACH GmbH + Co. KG

Yours sincerelyValentin Kaltenbach

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KALTENBACHFrom Lörrach into the World

1887 - 2012 125 years of KALTENBACH

In the anniversary year, the so-called „Kaltenbach Trolley“ is the symbol of the company‘s development from a locksmithery to the current Kaltenbach Group. It became the most important means of transport in the region in the hard years of the post-war period and also symbolises a new beginning: From Lörrach into the world.

In 1887, Julius Kaltenbach opened a small locksmiths. How he and his descendants turned it into a company of global repute will be highlighted in our 2012 anniversary year.

„KALTENBACH. From Lörrach into the world“

is the title of a book to be published in April and also of a major exhibition in the Lörrach „Museum am Burghof“ – we will be presenting a virtual tour through the exhibition from April onwards at www.kaltenbach.com.

Tour of the company

From the beginning of April to mid-July, KALTENBACH will be opening its production halls every Friday for interested guests from near and far.

We will shortly be publishing dates and registration options for the tours through our production facilities on our homepage.

The book from the series „Lörracher Hefte“

(„Lörrach booklets“) presents the company‘s

development on 76 pages in volume 15.

The book can be ordered at [email protected] for a

processing fee of 10 euros.

The town of Lörrach – the headquarters of the KALTENBACH Group – is putting considerable focus on the KALTENBACH anniversary. KALTEN-BACH is an important employer; 280 people work here at the headquarters. Lörrach also appreciates KALTENBACH for its exceptional commitment. This is where entrepreneurs have demonstrated over four generations how it is possible to shape the life of a town‘s society and assist people in times of need. That is why in the anniversary year 2012 there will be stories of tool-making machines and expansion but also of the Dieter Kaltenbach Foundation and the „Zentrum für Spielen und Gestalten“ („Centre for Play and Creativity“). And also of a simple hand-pulled cart that in the hard years of the post-war period became the most important means of transport in the region: the KALTENBACH „Rolli“ or trolley, which can be seen on the attached fold-out card on the 125-year anniversary.

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Fully automatic, fast and economical - these are the qualities that distinguish the KKS 463 NA universal mitre cut circular saw that was launched by KALTENBACH in 2011. The first of these new saw systems was purchased by Atotech for its factory located in Feucht in the Franconia region of Germany. Atotech is part of the mineral oil company Total and specialises in clean room technology and electroplating equipment.

“Until almost a year ago, we were running an old KKS 401 NA 600. However, this had come to the end of its useful life after 20 years. We wanted to replace it with a modern saw, one that is fast and powerful and above all fully automatic,” explains Armin Paulus, mechanical systems and vertical machining technology production manager. “With the KKS 463 NA, we have found the perfect machine capable of sawing the large number of different individual pieces made of stainless steel or titanium which we require for our production,

A high degree of automation

The first KKS 463 NA in practical trials

effortlessly and at great speed.” High speed is ensured by the optimized automatic feeder and flexible feed rate of the saw blade.

The new saw has been in use at Atotech since May 2011, mostly in two-shift operations, 16 hours per day. Depending on the required number of pieces, it is used in fully or semi-automatic mode. “This works beautifully. We have achieved an automation rate of over 70 percent on the machine,” says Armin Paulus. Two colleagues have attended a

short training course on how to use the machine and the software at KAL-TENBACH in Lörrach. “It was easy to put the acquired knowledge into practice afterwards. The input screen for the PC control is clearly arranged and intuitive to use.

The KKS 463 NA is programmed directly in the cutting shop. Staff refill the automatic bar magazine of the machine several times a day. The saw will then cut the different jobs automatically. Afterwards, the finished pieces only have to be removed and taken away.

After entering the section lengths, the software of the mitre cut circular saw automatically calculates the bar optimization. Since the gripper jaws of the automatic feeder and the output grippers are separately controlled via their own ballscrew spindle, the length of the remnant pieces is reduced to a minimum. Apart from automation level and speed, this represents a clear advan-tage in favour of the KKS 463 NA for Armin Paulus: “Given the high cost of our raw materials, we are of course pleased that we were able to reduce waste in this way.” Another benefit is that the machine can carry out up to three multiple cuts at the same time at the start and end of the bar - this is unique in the market. The resulting offcuts are automatically removed.

The KKS 463 NA

Technical Data:• Fully automatic universal circular saw for materials up to Ø 153 mm

• Standard saw blade: Ø 460 mm

• Automatic mitre cuts +/- 60 Degrees

• Automatic processing of flat, angle and solid materials, tubes and special profiles

• Multiple front and back cuts

• High cutting quality through workpiece clamping on both sides of the saw blade and infinitely variable adjustment of the saw-blade feed, as well as contactless saw blade return stroke

• Short cutting and cycle times through electronic cutting-height adjustment and rapid reverse motion of the saw blade

• Minimal end-piece lengths through special gripper design and measuring cut-off gripper

• Automatic cut-off sorting

• Simple operation and programming via touch screen

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From up-market BBQ grills to fully automated animal feed systems, from medical techno-logy to recycling containers - Schickling Ma-schinenbau manufactures components and assemblies for a wide variety of industries. The family business based in Visbek in Lower Saxony processes more than 40 tons of steel

For large quantities in a short time:

MSK 471 NA at Schickling

Fast, accurate

and flexible

every day. In order to fulfil the require-ments of the various applications to the highest standards, the latest production technology and a versatile range of machi-nery is employed. One of the latest acquisi-tions is the MSK 471 NA high-performance circular saw from KALTENBACH.

The main reason for acquiring the new machine just over six months ago was the growing number of or-ders. The high cutting speed was the decisive factor for purchasing the MSK 471 NA. “Cycle times are very much faster,” explains production ma-nager Werner Themann. “Previously it would have taken us three days to complete an order with the band saw but now we are finished in six hours.” The new fully automated circular saw is designed for large quantities and that is exactly what it has to deal with on a daily basis at Schickling. “Our aim was to tackle series production quickly and economically, and that’s what we have achieved.” The accuracy of the cut pieces has also improved significantly. This is ensured by linear guides and ball-screw spindles with servo drive. Although precision was not the over-riding reason for the decision, Werner Themann is obviously delighted with the improvement. The production manager lists the fully automated operation and the bundle magazine

for pre-storing materials as further benefits. “This saves us a lot of time and allows us to use our employees more efficiently.”

“At Schickling, we have always fo-cused on innovation and the latest technologies,” stresses Werner The-mann. “Opting for the MSK 471 NA has once again proved the point. The machine delivers what it promises and has significantly increased our production capacity.”

Schickling uses the MSK 471 NA to cut solid metal, mainly pipes and shafts with a diameter range of 15 to 150 mm and a maximum section length of 1000 mm. The pieces are used, for example, in vehicle con-struction, in the furniture industry and in the manufacture of agricultural machinery. In order to achieve the highest possible cutting speed, car-bide saw blades are predominantly used. Yet, short set-up times allow for a quick changeover to HSS saw blades which makes the MSK 471 NA extremely flexible. Possible cutting speeds range from 8 to 15 m/min, the frequency-controlled motor output is 19 kW.

H. Schickling Maschinen-bau was founded as a family business in Visbek in 1989 and today employs over 200 staff. Innovation, state-of-the-art production techniques and efficiency are the trademarks of the sheet metal fabrication and machining specialist. In 2009, Herrmann Schickling was ho-noured as businessman of the year in the Oldenburg Münster-land region.

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The KBS 1051 band saw has revolutionised the cutting of structural profiles by using a servo-controlled feed system with ballscrew spindle and increasing the cutting speed in conjunction with the auto feed control system (AFC). Among the strong points of the machine are its excep-tionally smooth operation and reliable, repeatable feed rates as well as its record speed. The unique machine now has a baby sister, the KBS 761. At the same time, another innovative highlight will help both high-performance saws to perform even better: The new V-tract rising table feature virtually eliminates the saw band jamming during cutting. We talked to sales director Jörg Tetling about the addition to the family and the new technologies.

V-Tract ... If steel is your Deal!

Innovation and a new addition for the fastest band saw in the world

KBS 761The optimum solution when a capacity range of up to 750 mm is required: The KBS 761 has all the strong points of the KBS 1051. It is the customized top model for medium-sized steel fabricators and steel traders.

Technical Data• Capacity Range (w x h): 750 × 500 mm• Vertical saw in robust twin-column construction• AFC (Auto Feed Control) – Adjustment of the saw band incline angle to suit changing profile cross-sections• Mechanical feed with ballscrew spindle and servomotor• Self-adjusting profile clamping including cross-section measure- ment• Machine operation via modern PROFICUT steel-construction software package

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How did the market react to the launch of the KBS 1051?The response was overwhelming. We had a hugely enthusiastic reaction from many of our customers. They have experienced a previously unheard of increase in efficiency. The machine became one of our best sellers right from the start. The only reason preventing some customers from buying was the oversized working area. The KBS 1051 is designed for beams up to 1030 mm but not all customers require these dimensions.

Jörg Tetling, sales director Is that why you have introduced the baby sister, the KBS 761?Exactly! It has the same technology as the KBS 1051, but it is one step smaller and consequently more reasonable. It is capable of machining profiles up to 750 mm which is sufficient for many medium-sized steel fabricators and steel traders. It can also be combined with the KDM 615 drilling machine for structural profiles. We now have a suitable solution for an important market segment. With V-tract, we can also offer another very interesting innovation for both machines.

What does V-tract” mean?It refers to the hydraulic raising of the saw table by a few millimetres above the level of the roller conveyor. As the table rises, the cutting channel opens slightly during the cutting cycle; it becomes virtually V-shaped. Jamming of the saw band is almost impossible.

Why does the cutting channel have to open?The hot rolling process often causes residual stress in large I-beams. This can lead to deformation of the material at the cutting site during the cutting cycle which then jams the saw band inside the cutting channel. This in turn can lead to production shutdown and high tooling costs.

Thank you very much!

KBS 1051 unveiled at an exhibition in the Czech RepublicIn October 2011, visitors were on the lookout for the most innovative exhibits at the International Mechanical Engineering Exhibition in Brno in the Czech Republic. 1600 companies from 23 companies were presenting their wares at this exhibition with a total of 6000 exhibits. Eight exhibits, including the KBS 1051, the world’s fastest band saw, were ceremonially unveiled in the presence of president Vaclav Klaus and prime minister Petr Nečas. The prize-giving met with a great deal of interest in national newspapers and specialist journals alike.

New for KBS 1051 and KBS 761

Petr Kužela, CEO of Czech Kaltenbach subsidiary on the way to receive the award.

V-Tractsaw table lifting systemDuring the cutting cycle, the saw table is hydraulically raised by a few millimetres above the level of the roller conveyor. The cutting channel opens when the table is being raised.

Unbeatable arguments in favour of the new “V-tract” innovation from KALTENBACH:• More room for the saw band• Prevents jamming• Reduces tooling costs• Increases the availability of the sawing system

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What production step was involved in this project?The system aims to manufacture the parts from sheet material that are then welded on to the steel components. It is also about the flame cutting and drilling of foot and head plates, reinforcement sheets and ribs etc. Previously, we had used acetylene gas cutting machines and HSS drills or purchased parts.

Fully integrated

Plate flame drilling system with robot handling developed for Goldbeck

Systematic construction, fast, cost-effective, ready-to-use – these words summarise the benchmark that the Bielefeld-based corporate group Goldbeck sets itself. The basis for their success and the dynamic growth of the past years are last but not least the systemised components from the company‘s own production. Here, supreme standards of quality, speed and cost-efficiency apply. With the new fully automated plate flame drilling system with robot handling, Goldbeck has acquired further production depth and efficiency. The system was developed and assembled by KALTENBACH. Plant manager Fabian Metz explains in an interview how the collaboration came about and its results.

What do you want to achieve with the new system?Initially, the machining was to become faster, which is what plasma cutters and carbide metal drills in the new system fundamentally helped to achieve. The higher-level goal, however, was to intelligently integrate the production step in the overall process and achieve full machining with a modern production approach.

What do you understand by complete machining?We call the „assembly“ of the steel components at our plant „compilation“. We wanted to achieve a status in which no more time is spent on sorting parts at a compilation workplace. All parts that are put together should already be picked when they arrive there so that the compiler can focus entirely on his actual task.

In other words, machining technology and production logistics were also important for you?Exactly. We wanted to minimise the effort required in the handling of the parts and improve the flow of values. We therefore considered which engineering technology steps could help us to achieve greater efficiency and a higher share of value creation here.

In the process, it soon became clear to us that we need a fully automated system with robot connection here.

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There were already systems for thin sheet meet on the market, but not yet for strengths of up to 30 millimetres. We were therefore looking for a partner that would take over this technology transfer. There were not many who wanted to tackle it.

Why did you opt for KALTENBACH?There were a number of reasons for it. For a start, the chemistry was right – a medium-sized, owner-run, technology-driven family-run business is a partner that is a good match for our company. We were then able to systematically clarify and coordinate the marginal conditions and requirements for the system in a joint process.

As the project was so large, Valentin Kaltenbach got involved personally, which was a clear signal to us of the importance that KALTENBACH attached to this project.

The system has been in operation since last September; the final acceptance was carried out in December. What is your conclusion?Our expectations were met in full. In January, the piece counter showed more than 65,000 parts produced; we can therefore expect an output of at least 200,000 parts a year.

We have achieved a large increase in efficiency because the compilation department receives the pallet for the individual workplaces with the parts

already picked and no manual interim step is required any more. The various items are sorted separately on the pallet; parts numbers are face up and are recognised immediately. The skilled workers can make more intensive use of their know-how because less searching is required. At the same time, the machinery operators can use the system without having to become software specialists.

So you are satisfied with the ease of operation?Yes. It was one of the important requirements from the outset. We wanted a robust system with stable software, and we got both. The availability is also very good, just as we requested.

For all eventualities, the system is also designed in such a way that it can also be run without the robot. If a robot fails, the parts are automatically tipped into the collecting vessel. We were able to continue with fewer personnel and remain more flexible.

How has the robot separation proven its worth?It is the requirement for lightly manned operation. In the course of the project, we have developed the approach further and can now not only pallet the finished parts but also compile consignments for the welding workplaces across several orders with different sheet metal strengths. This improves nesting, which helps to minimise waste.

How time-consuming is the programming of the system? It is very simple as the robot and machine levels are separate and the two of them can be accessed parallel to operations at all times.

The data are provided as DSTV-NC data from our system and are processed automatically. This is the standard case; the programming time is therefore very low. For the concluding cost-efficiency check which is soon to be done, I am assuming very good results for the new system

Goldbeck GmbH was established in Bielefeld in 1969 as a classical steel construction company. As a medium-sized, owner-managed corporate group, it is today one of the driving forces in industrial and communal structural engineering in Europe. The focus of its range of services is the conceptual planning, construction and servicing of office buildings, halls and multi-storey car parks. In the 2010/11 financial year, it generated annual turnover of some EUR 1.1 billion. It employs 3,000 staff at four plants (Bielefeld, Hamm, Plauen, Kutna Hora/Czech Republic), two system centres (Bielefeld, Mannheim) and 38 branches in Germany and other countries in Europe.

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Last year the existing painting system was declared obsolete and had to be replaced. Although the upstream Gietart shotblasting sys-tem, built in 1994, was still in perfect working order, managing director Daan Bressers, who runs the compa-ny with his cousin Valentijn Bressers, opted for a complete upgrade: Both systems were exchanged in one single operation. The foundation and roller conveyors for loading and un-loading were retained; the new ma-chines were perfectly compatible with each other. The Marathon A 2506 shotblasting system and KPC 2504 preservation system from KALTEN-BACH SPS (formerly Gietart) have been in operation since mid-2011. A new band saw, the KALTENBACH KBS 1051, provided the finishing touch to the process chain and en-sures a particularly swift throughput.

Extensive portfolio, high efficiency

A Marathon A 2506 shotblasting system enhances the service process offered by Bressers MetaalProduction and service process under one roof, combined with flawless logistics and fast delivery – Bressers Metaal B.V. has exploited these strengths to reinforce its strong market position. A wide product range, consisting of steel profiles, sheets, pipes and wire products, is stocked and processed on a production site covering some 70,000 square metres in the Dutch city of Tilburg. Fully automated transport systems support the fast and accurate manufacturing process. In addition to cutting and bending, the services provided include the shotblasting, finishing and galvanising of parts. Bressers Metaal uses state-of-the-art systems for this purpose, such as, for instance, a new shotblasting and preservation line from KALTENBACH.

“Thanks to careful planning by the supplier, the installation of the new systems went completely to plan,” reports Daan Bressers. “Production continued right up to the day before and started again immediately after the installation had finished.” The company also took the opportu-nity to modernise the electrical sys-tems for operation of the extensive transport systems. In order to reduce energy costs, a switch was made from normal to frequency control. Managing director Daan Bressers sets great store by state-of-the-art technology to ensure that the service the company provides to its custo-mers is fast and of the very highest quality: “With the new shotblasting system we have achieved signifi-cantly higher throughput rates and are able to process a wider range of materials. The old machine struggled

with thin sheet metal, but the new one doesn’t have any problems in this area either,” he says. A further significant advantage of the Marathon A 2506 is its economical use of blasting abrasive. The almost complete recovery of the abrasive saves resources and protects the environment. Thanks to multi-level cascading air cleaning, dust and scale are largely removed, and the high level of shotblasting efficiency is maintained over a long period of time. Daan Bressers is also happy that the abrasive can be more pre-cisely dosed than before. With its triple housing, the system is extremely wear-resistant. Moreover, the use of structural steel ensures high rigidity; the manganese lining is bolted to the outer hull and can as required be quickly and easily repla-ced. Three access points are provi-

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ded for the service and maintenance of the shotblasting system. “Smaller parts can now also be replaced more easily,” the managing director reports, “and the machine is significantly more economical overall. With its six strong turbines, the machine offers a lot more capacity without any reduction in the quality of the end product.” Daan Bressers goes on to explain that, thanks to the new KPC 2504 preservation system, the overall process has gained in speed and ef-ficiency. Whilst the level of automation has increased at all points, materials consumption and processing time have both been noticeably reduced. The individually adjustable positioning of the eight spray guns, automatic adaptation of the spraying stroke to the feed rate and optimised air flow management save paint and reduce emissions.

Thanks to the chain conveyor system the material has only minimal contact with the machine, and all-round pain-ting can be carried out in one single operation. In line with the reduced processing times, significantly less labour and expense are involved in cleaning and maintenance. The walls and ceiling of the dry filter spray booth are equipped with non-stick film for ease of cleaning; the floor is protected from pollution by a dispo-sable film. Energy consumption in the drying process has also fallen, as the end dryer is connected by pipes to the preheating furnace and uses the hot air generated by it. So it is that the new preservation line is fully consistent with one of the most important elements of the Bressers Metaal philosophy: “Shotblasting and preservation – flawless in execution and environmental awareness.”

The family-run Bressers Metaal B.V. company from the Dutch city of Tilburg can look back at a history spanning some 120 ye-ars. Its strengths have always in-cluded the use of state-of-the-art processing technology.

In 1966, Holland‘s very first fully automated preservation system was installed here; computer-controlled machines have been in use since 1995. Bressers Me-taal is now one of the largest in-dependent companies of its kind in the Benelux countries

Daan Bressers, CEO

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The old circular saw was getting on a bit. It wasn’t worth giving it another complete overhaul, a new machine was needed. The cutting technique was not really an issue - based on past experience only a circular saw would be worth considering for the new acquisition. Up to now, this was the only saw capable of delivering a stable cutting performance even for large profiles. However, a detailed comparison of the machines had shown that nowadays there is definitely an alternative. Not only can the “fastest band saw in the world” keep up easily when it comes to speed, it also offers a number of advantages compared to the heavy circular saw. After some initial scepticism, the metal workers at SIAG Stahlbau Ruhland were soon con-vinced. Today, they are more than satisfied with their decision regarding the KBS 1051.

The flexible alternative

KSB 1051 band saw – highly efficient, even for large profiles

SIAG Ruhland is a traditional steel manufacturing company, whose ran-ge of services covers everything from pipe bridges to power plant const-ruction. The wide variety of projects meant that a constantly changing range of profiles from 50 to 1000 mm needed to be machined on a daily basis.

The existing circular saw worked well for large sections but it was not ne-cessarily the best machine for small ones. Depending on the workpiece dimensions, saw blades with a variety of tooth pitches were required. Two men and a crane were needed to replace them and it could take up to 20 minutes. If a job required the machining of many different profiles, this resulted in downtime which is a

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significant cost factor. Since extreme-ly heavy beams are almost always part of the job, the circular saw was the best available universal machine up to now.

A demonstration at KALTENBACH was the reason for considering an alternative. “There were fears that the cuts of a band saw would not be an-gular enough but these were well and truly dispelled during the demonst-ration of the KBS 1051,” remembers Winfried Jenke. He is in charge of project development and investments at SIAG Stahlbau Ruhland. The de-monstration in Lörrach was followed by a detailed performance compa-rison of the band saws and circular saws in question. “The purpose of the new machine was to optimise the material flow and primarily to speed up production.”

When it came to cutting speed, the band saw was clearly in the lead which has also been confirmed in everyday operation: “Our old circular saw took 20 minutes for a 600 mm steel beam. The KBS 1051 cuts it

with a carbide band in one and a half minutes,” says a delighted Winfried Jenke. “On average, we save 40 to 50 percent of processing time. We are now under pressure to speed up the follow-up processes.”

The band saw provides another significant time advantage. On the one hand, it can be used to saw small to large profiles with a single tooth pitch, consequently the blade does not require changing as often. On the other hand, if the change does become necessary, it is much easier. It can be carried out by one person without a crane and only takes about ten minutes.

SIAG Stahlbau Ruhland normally uses HSS saw bands. “We use carbi-de bands for profiles over 500 mm in larger quantities,” explains Winfried Jenke. “Compared with the circular saw, we have saved at least 50 per-cent on material and related costs.”After one and a half years of operati-on, he is extremely pleased with the new acquisition. Apart from an adjust-ment to the chip removal system, no

Until the introduction of the KBS 1051 band saw, the HDM circular saw was the fastest saw for steel construction. It is the perfect machine for this area. When handling large profiles and large quantities at the same time, it stands out with its extreme robustness and short cutting times. It is still unbeatable when it comes to profiles over 600 mm.

However, since its launch, the KBS 1051/761 - the fastest band saw in the world - has been competing with the HDM. With a carbide blade, it manages equally short cutting times even for large profiles. It has clear advantages when it co-mes to flexibility and investment and incidental costs. For the first time, a band saw can be used as a standard machi-ne even in heavy steel construction. Now it’s a question of

Circular or band saw?

HDM and KBS 1051/761 in comparison

HDM 1432KBS 1051

weighing up whether a circular saw or a band saw offers the best solution where quantities and profile sizes play an important role.

The strengths of the KBS 1051/761

• Higher cutting capacity even with HSS band• Optimum cutting capacity with carbide band• Lower incidental costs and downtime• Lower acquisition costs• Lower tooling costs• Greater flexibility for varying profile sizes• Wider range of materials

repairs have been carried out during that time. The cost benefit analysis of the machine has even exceeded the already high expectations. “In addi-tion, we have an excellent working relationship - KALTENBACH’s field engineers are always there when you need them. We get competent tech-nical support and if spare parts are needed they arrive in no time at all.

SIAG Stahlbau Ruhland GmbH & Co. KG looks back on a 90-year tradition in steel construc-tion. The company was founded in Ruhland/Lower Lusatia in 1921 under the name of “Eisenbau Manig”. It became a “nationally-owned enterprise” in 1949 which was subsequently privatised in 1996. It was part of a steel construction group for a time but since last year, it is once again an independent company. It has specialized in structural steel-work at its traditional location in Ruhland and manufactures light to medium-heavy steel construc-tions

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On the outskirts of Heilbronn, the construction of an exceptional new office building has caught the eye of passing motorist over the past few months. Here you can find a gigantic cube with a glass facade which is framed by an irregular grid of steel profiles painted bright white which is also cube-shaped - 37 metres long, 32 metres wide and 21 metres high.

Impressive facade

Steel construction made up of 1144 individual parts

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The impressive and elaborate construction has been installed by Vorndran Metallbau based in Kleinwenkheim/Franconia. A total of 1144 individual steel pieces were cut on a KALTENBACH band saw, the KBS 750 DG NA.

“This job certainly presented us with an unusual challenge,” explains chartered engineer and junior manager Tiemo Vorndran. “We had never done anything like this before but we tackled the work with enthusiasm. The design of the steel grid is the work of Riemer Planung architects based in Heilbronn who have designed the entire office building. Vorndran Metallbau was responsible for the construction.

Cutting the individual pieces of the steel grid was the biggest order the KBS 750 DG NA at Vorndran had to cope with since its acquisition in 2006. Between May and July 2011, 1144 pieces of hollow section steel measuring 400 x 200 x 6 mm were cut in varying angles from acute to obtuse. This is equivalent to 2.7 linear kilometres of rectangular tube with a total weight of some 150 tons.

“The KBS 750 DG NA was the ideal machine for this job, especially with

regard to the straightforward set-up of the cutting-angle,” explains Tiemo Vorndran.

In order to ensure easy and safe transport of the rectangular tubes to the building site after cutting, the individual pieces were not allowed to exceed a maximum element size of 15 x 3 m. Therefore, the longest individual pieces cut were 15 metres long - the shortest had a length of just 10 centimetres.

The individual elements were welded together at the junction point of members and bolted together through

a hand-hole on the rear, so that the seams are not visible from the outside. To ensure that everything fits together perfectly during installation on site, the Vorndran team pre-assembled the individual sections of the steel grid in a kind of “dress rehearsal” in the factory in Kleinwenkheim.

The first offices in the building should be occupied in April. Until then, there is still some residual work to be done. But even without these finishing touches, a new landmark has been created on the outskirts of Heilbronn.

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Trade Fairs 2011

ImpressumPublisher: KALTENBACH GmbH + Co. KG, P.O. Box 1740 • 79507 Lörrach, GermanyEditor/Layout: Ursel Kiefer, Klartext PekkerPrinted by: Uehlin Print und Medien GmbH, GermanyCirculation: 32.000

Germany

Sales-Centers Germany

KALTENBACH GmbH + Co. KGP.O. Box 1740D-79507 Lörrach, GermanyPhone: +49 (0) 7621 175-0Fax: +49 (0) 7621 [email protected]

www.kaltenbach.com

Heilbronn: Franz N. StreitPhone: +49 (0) 71 32-1 82 89Freiburg: Jürgen StehlinPhone: +49 (0) 76 43-3 33 97 33München: Gregor SchwarzhuberPhone: +49 (0) 84 31-50 77 41Hildesheim: Jan MöschlerPhone: +49 (0) 50 69-80 69 90Gera: Volker GühnePhone: +49 (0) 365-7 10 67 55Bochum: Franz-Josef GiesPhone: +49 (0) 234-43 49 01Sprockhövel: Hansgeorg WodauschPhone: +49 (0) 23 39-30 73

SubsidiariesGROSSBRITANNIEN / IRLANDKaltenbach Ltd. [email protected] EAST Kaltenbach Middle East FZC [email protected]ÖSTERREICH, UNGARN, KROATIEN, BOSNIEN-HERZEGOVINA, KOSOVO, MONTENEGRO, MAZEDONIEN, ALBANIEN, SERBIEN, SLOWENIENKaltenbach Ges.m.b.H. [email protected], MAGHREBKaltenbach [email protected] / BALTIC STATESKaltenbach GmbH & Co. KG / Olli [email protected], BELGIEN, LUXEMBURG Kaltenbach Tools B.V. [email protected] / LIECHTENSTEINKaltenbach Schweiz [email protected] REPUBLIK, SLOWAKISCHE REPUBLIK Kaltenbach s.r.o. [email protected] Kaltenbach Asia PTE Ltd. [email protected]

Production FacilitiesKALTENBACH GmbH + Co. KG, [email protected] Shotblast and Painting Systems B.V., Niederlande (vormals Gietart)[email protected] S.A.R.L., [email protected]

Sales agenciesSPANIEN, PORTUGAL, MITTEL-/SÜDAMERIKA I.P. Ingenieria de Produccion, S.L. [email protected], Zypern G. & I. Pangakis [email protected] Servizi Lame di A. Marchesini [email protected] IRLAND Gillen Machine Tools [email protected] Meidell A/S [email protected] Intercut Sverige AB [email protected]ÄNEMARK V. Loewener A/S [email protected]ÄNIEN, BULGARIEN Straaltechniek Minex Int. S.R.L. [email protected] PHU Effect [email protected] Ben Adiri & Cohen Machinery Ltd. [email protected] TÜRKEI Memak Makina Sanayi ve Dis Tic. Ltd. Sti. [email protected]ÜD AFRIKA First Cut (Pty) Ltd. [email protected] Daido Kogyo Kaisha Ltd. [email protected], NEUSEELAND ProTUBE Asia Pty Ltd. [email protected] Ionization Engineers Pvt. Ltd. [email protected], KANADAStructural Machinery Solutions [email protected]@gmail.com CHINA, MALAySIA, SINGAPUR• Kuteck Ltd. [email protected]• Melaju Jaya Corporation Sdn. Bhd. [email protected]

Exhibition Country City DateINDUSTRIE France Paris 26.-30.03.2012Expomin Chile Santiago 09.-13.04.2012MACH England Birmingham 16.-20.04.2012BIAM Croatia Zagreb 17.-21.04.2012Nistra SK Tschechien 05.2012Fabtec/Expoweld Mexico Mexiko DF 02.-04.05.2012Industriautomation Hungary Budapest 15.-18.05.2012Mecànica Brazil Sao Paulo 22.-26.05.2012BIEHM Spain Bilbao 28.05.-02.06.12Metallooobrabotka Russia Moskau 28.05.-01.06.12MACH-TOOL Poland Posen 29.05.-01.06.12Construmetal Brazil Sao Paulo 14.-16.08.2012MSV Czech Rep. Brünn 17.-21.09.2012AMB Germany Stuttgart 18.-22.09.2012Den Tekniska Messen Norway Oslo 25.-28.09.2012Expomin Peru Lima 12.-14.09.2012Expo Metallica Colombia Bogota 01.-05.10.2012Stahlbautag Bouwen Netherlands 10.2012Intertool-VIENNATEC Austria Wien 09.-12.10.2012Tekniska Mässan Sweden Stockholm 23.-26.10.2012Euro-Blech Germany Hannover 23.-27.10.2012Metavak Netherlands Gorinchem 08.-10.11.2012Prodex Switzerland Basel 20.-24.11.2012