Baden-Baden, Germany – Cut-to-length

lines represent the first step in sheet

metal processing by cutting steel strips

into panels. Yet because they are also

taken for granted, little attention is

given to cut-to-length line technology.

Nevertheless, the spectrum runs from

high-tech facilities to robust everyday

systems for less demanding tasks.

Combining to create the right system

The challenge with cut-to-length

lines consists of assembling the

right system for the specific appli-

cation, market and service provi-

der and then optimizing it through

the right technology. Steel service

centers in particular are confronted

with strongly varying requirements

from country to country and market

to market. „For example, in Germa-

ny and Western Europe there is an

increasing trend toward processing

high-tensile steel. Other countries

are now demanding higher quality

due to greater levels of automation“,

says Franck Hirschmann, ARKU’s

Business Segment Manager for cut-

to-length lines. ARKU can draw on

a comprehensive range of proven

components to address these ex-

act requirements, creating cut-to-

length lines and leveling technology

tailored to meet the customers‘ indi-

vidual needs. Three cut-to-length li-

nes which are currently either being

installed or manufactured in Baden-

Baden are perfect examples.

Flexible production and high-er quality are essential

For the last six months BITO, a ma-

nufacturer of storage systems, has

been working with a cut-to-length line

which includes integrated stations for

the first processing steps. The order-

based production is extensively auto-

mated and manufactures and compiles

all of the components belonging to one

shelving order. Although this elimina-

tes intermediate storage, the systems

themselves must be highly flexible.

ARKU also integrated a punching ma-

chine into the cut-to-length line. As a

result, the panels leave the system the

right size, leveled, and with the right

hole patterns.

In December last year, the Polish steel

service center RBB-Stal SA modernized

its central cut-to-length line with a

rotary shear and a HiCap® high capacity

leveler in order to offer customers high-

er quality panels. This was necessary

because the increasing level of auto-

mation among Polish sheet metal pro-

cessors has created a rising demand for

cleanly-cut and level panels. Further-

more, the customer also welcomes the

fact that the rotary shear increases the

system‘s output by 80 % in comparison

to the previous start-stop shear.

Coil material is the starting point for

all sheet metal cuts. The coils are

often processed by service centers

and delivered to sheet metal manu-

facturers as panels. In the next step

of the value chain, the panels are

punched, embossed and notched

or shaped into folded or bent parts.

When your sheet metal processing

has reached a critical size it is often

worthwhile to manufacture these

panels or shaped parts directly from

the coil. This simplifies the logistics,

saves material, and shortens the

delivery times. Flexible cutting sys-

tems such as these are one of our

company‘s core competencies. We

are the specialist for cut-to-length

lines with shears, in-line punches,

or laser cutters. With our equipment

you can manufacture batch sizes

starting at single units directly from

the coil. Send us your requirements.

We will work with you to find the

right concept.

ARKU CEO Albert Reiss

Finished shaped

panels from coil

High-tech modular systems for cut-to-length lines Specific cut-to-length lines assembled using tried and tested modules

ARKU Maschinenbau GmbH Siemensstraße 11 76532 Baden-Baden Germany T: + 49 72 21 / 50 09-0 E-Mail: info@arku.de www.arku.de

No. 41 / 2013

InfoMAXThe experts for sheet metal and coil leveling

HiCap® high-performance leveler and rotary shear at RBB-Stal

Robert Pospieszny (Head of Mechanical Cutting, RBB-Stal), Włodzimierz Borusiak (Managing Di-rector RBB-Stal) and Franck Hirschmann (Business Segment Manager cut-to-length lines, ARKU)

ARKU Maschinenbau GmbH · Siemensstrasse 11 · 76532 Baden-Baden · Germany · Phone: + 49 72 21 / 50 09-0 · Fax: + 49 72 21 / 50 09-11 · E-Mail: info@arku.com · www.arku.com

ARKU gewinnt Außenwirtschaftspreis

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ARKU‘s production department is

currently manufacturing a cut-to-length

line for Liebherr. In this case, the focus

is on processing thin sheet metal and

ensuring high productivity. This system

will also be equipped with a rotary she-

ar. The challenge here lays in the need

to ensure perfectly square cuts when

processing the thin material.

Modular system consisting of proven components

ARKU assembles its cut-to-length li-

nes from a modular range of proven

components capable of fulfilling al-

most every customer requirement.

Loading stations, decoilers, start-stop

shears or rotary shears, precision or

high capacity levelers with the Eco-

Plan® system: All of the components

are compatible and combined by

ARKU‘s specialists to create a comple-

te solution. The modular equipment

can even provide flexible systems ca-

pable of handling single-unit batches

and large-scale production. All of the

systems feature optimized costs, pro-

ductivity, flexibility automation and

most importantly cutting quality.

Baden-Baden, Germany – On the week-

end ARKU trainee Sven Certan swaps

his work clothes for a helmet and

racing gear. He races his BMX around

obstacle courses and generally leaves

most competitors behind. BMX is the

abbreviation for bicycle motocross and

even became an Olympic discipline in

2008. The X stands both for the word

“cross” and also for the verb „to cross“.

What began as a children‘s hobby in

the USA has since gone on to become a

demanding, high-performance sport.

15 meter long rampsat 60 km/h

The BMX race takes place on 400-500 m

long courses consisting of obstacles,

corners, and hills. The starting ramp is

up to 15 m long and allows the cyclists

to accelerate up to 60 km/h before they

hit the track. Six to eight riders com-

pete against each other - one of whom

will be the first to cross the finish line

after roughly 40 seconds. „Excellent

technique and above all physical fit-

ness are essential to compete against

the best,“ emphasizes Sven Certan.

„That is why two to three training ses-

sions per week are a must.“ ARKU‘s

management also knows that training

and racing at Certan‘s level demand

a lot of time. That is why the machi-

ne manufacturer supports its reigning

European champion with his semi-

professional hobby.

From a trial training to the national team

The trainee mechanic began his hobby

with a trial training session at a nearby

club in 2009 when he was 14 years old.

„I was always enthusiastic about cyc-

ling and BMX‘s“, explains Sven Certan

while his eyes light up. „And after the

training session I knew: BMX racing is

my sport.“ During the very first season

of his exemplary career, Certan beca-

me the Baden-Württemberg Champi-

on in his class. A year later he went on

to become the German champion, and

has been competing in the German

national league since 2010. In 2011 he

was nominated for the national team

and now trains under professional ri-

ders in Stuttgart. In 2012 he success-

fully won first place in the junior class

at the European Championships. Since

his European Championship victory,

Certan has begun competing in the

most difficult category: the Elite class.

He is already beginning to prepare to

compete at the 2016 Olympic Games

in Rio de Janeiro. „Representing Ger-

many at the Olympics would be an ab-

solute dream for me“, says the young

mechanic. He has already been nomi-

nated for the national team. Now he

only needs to score the points and win

victories in the coming races.

Baden-Baden, Germany – Row upon

row of FlatMaster® machines stand in

the new production hall. With a single

glance you can see the various pro-

duction stages of the parts levelers –

from the mechanical assembly onward

to the machines in operation at the

leveling center.

Simplified assembly process

The new hall enables the machines to

be assembled more easily than previ-

ously. The elements of the assembled

machine as well as the necessary tools

are placed nearby. This enables the en-

gineering workers to quickly access all

of the tools and equipment which they

require to assemble the FlatMaster®

levelers. As a result, the 1,600 m² hall

has an optimal material flow – The

goal is to achieve shorter lead times

and faster delivery times.

Capacity for larger machines

While planning the hall, ARKU kept an

eye on the future and built in the capa-

city for assembling larger machines.

Cranes able to lift up to 50 tons and

the appropriate logistics measures

provide the necessary capabilities. Up

to ten parts levelers can be assembled

simultaneously.

Edge trimming shear in the cut-to-length line at the manufacturer for storage systems, BITO

In February, the new ARKU website went online in eight languages. The home page

provides a clear overview of the company‘s two business areas, „Parts Leveling“

and „Coil Lines.“ The intuitive layout allows visitors to view news, exhibition dates,

and specialist articles at a single glance. Additional features include a direct con-

tact option to the ARKU service team and an overview of all of ARKU’s worldwide

locations and branches. Take a look now and see for yourself: www.arku.com.

Leveling technology online in eight languages

ARKU trainee is the European BMX ChampionSven Certan climbs to the top of BMX racing

New assembly production hall in operationLeveling center and production up and running in the new building since February

InfoMAX

ARKU-Ticker

Sven Certan makes the jump

Continuation of page 1

Ostwald, France – Quality has always

played a critical role for the French

supplier company, Viwametal. That is

why the sheet metal company cons-

tantly strives to improve its processes

and its machinery. This focus on qua-

lity also serves to increase productivi-

ty, greatly benefiting the company. An

ARKU FlatMaster® 50 precision leve-

ler plays a central role.

Outstandingly organized fa-mily company

Viwametal has been in business as a

sheet metal supplier since 1975 and

thanks to its experience the company has

established itself as a leading expert in

sheet metal processing within the most

demanding industrial sectors. The fami-

ly-owned company has 50 employees.

„Thanks to outstanding organization we

have the same structures as a company

three or four times our size“, explains

the Managing Director, Christian Walter.

„We are investing in state-of-the-art ma-

chinery in order to maintain this level.“

Leveling as solution

Viwametal cuts sheet metal parts using

both mechanical and thermal proces-

ses. This often results in uneven sur-

faces and stresses within the workpie-

ce. This can have a negative influence

on subsequent processing such as ben-

ding and welding, increasing the time

required. Deformations can also impair

the functionality and aesthetics of the

components. Leveling is the solution to

this problem. At Viwametal, level sheet

metal parts with minimal internal stress

have long served to ensure reliable pro-

cesses and perfectly functioning parts.

In addition, this also saves time for the

subsequent processing steps. Costs de-

crease, productivity increases.

The ARKU FlatMaster®

At Viwametal, ARKU‘s servo-hydrau-

lic leveler is positioned between the

cutting and bending stations. As a

result, the machine is ideally integra-

ted into the overall process. „With the

FlatMaster® from ARKU we increase

the quality of our sheet metal parts“,

explains Mr. Walter. „As such, we ac-

tively promote value creation.“ As a

supplier, Viwametal needs to be able

to react quickly and flexibly to a broad

range of varying requirements. The

FlatMaster® 50 is easily capable of

handling this challenge. The leveler

processes sheet metal parts with a

thickness ranging from 0.5 to 12 mm

and a width of up to 1,250 mm. Further-

more, the intuitive control system also

makes the FlatMaster® easy to opera-

te and user-friendly. The staff rapidly

has become familiar with the machine,

quickly making uneven sheets a thing

of the past.

Energy-saving part and strip leveling ARKU is a partner of the VDMA Blue Competence® initiative

Leveling cut sheet metal parts with the FlatMaster® 50

Process Reliability from levelingViwametal relies on the FlatMaster® 50 parts leveler

InfoMAX

A FlatMaster® 120 has been carrying out its reliable work at FAM Förderanlagen Magdeburg since

January. The servo-hydraulic precision leveler processes sheet metal parts up to a thickness of

35 mm and a width of 2,000 mm. The FlatMaster‘s easy and flexible operation enables it to rapidly

and efficiently level a large range of unique parts - often with a batch size of one single part. FAM

manufactures systems for surface extraction, bulk goods handling along with crushing and mate-

rials preparation technology.

FlatMaster® 120 for manufacturer of material handling systems

From 05 - 08.11.2013, international visitors will meet in Stutt-

gart for the 11th Blechexpo sheet metal working trade fair.

ARKU will once again be represented with its own exhibition

booth. We look forward to your visit. This year, ARKU will be

attending nine trade fairs worldwide. Visit our website and

find out where.

Blechexpo upcoming

Baden-Baden, Germany – More than

10 years ago ARKU set the standard for

the production of energy-saving leve-

lers with the patented EcoPlan® drive

system. Since then, ARKU has continu-

ed developing its machines and facili-

ties to achieve greater performance and

energy efficiency. As an official partner

of the Blue Competence® initiative from

the VDMA, clearly defined standards

need to be met and complied with. That

is why Blue Competence® serves as a

good and reliable source of orientation

when selecting companies which offer

sustainable solutions and products.

Performance-controlled hy-draulic pumps save energy

Performance-controlled hydraulic

pumps in the FlatMaster® series of

parts levelers save real money every

day during production. The pumps only

require full power when under load du-

ring leveling. During downtime, perfor-

mance is reduced and thus less energy

consumed. In comparison to levelers

with uncontrolled hydraulic pumps, the

FlatMaster® saves up to 60,000 kW/h

of energy per year. This corresponds to

CO2 savings of up to 36 t.

Protects the environment and saves resources

Additional energy-saving concepts

have also qualified ARKU as a Blue

Competence® partner. Controlled drive

components further reduce the

amount of unnecessary heat gene-

ration. Design measures reduce the

hydraulics to the bare necessities,

which also decreases the amount of

oil required. Energy recuperation mo-

dules have been integrated into indivi-

dual system components on coil lines.

For example, energy is recuperated

and stored when braking. When nee-

ded, the system draws on this excess

energy and returns it to the system.

Jarocin, Poland – The Polish steel ser-

vice center, RBB-Stal SA, modernized

a cut-to-length line with a HiCap® high

capacity leveler and a rotary shear.

„The market demands better quality

blanks“ says Włodzimierz Borusiak, Ma-

naging director of RBB-Stal in Jarocin.

To deliver the desired quality, the com-

pany modernized an existing cut-to-

length line with ARKU‘s HiCap® 55 high

capacity leveler for 2,000 mm strips

and a rotary shear. These machines

have improved the leveling results and

cutting quality while also increasing the

output by approximately 80 % in compa-

rison to the previous equipment.

Automation demands higher quality

Because of the increasing levels of au-

tomation, sheet metal processors in

Poland have begun to demand high-

er quality blanks. “Those steel service

centers which cannot deliver this qua-

lity will not survive in the Polish mar-

ket,“ states RBB-Stal with certainty.

The company has approximately 200

employees and generates an annu-

al turnover of 50 million euros. Three

cut-to-length lines and three slitting

lines process approximately 80,000

tons of steel per year. The modernized

facility now processes roughly 60 % of

this material. Which explains why it

had to be rapidly converted during the

company holiday between Christmas

and New Year 2012.

From start-stop to continuous operation

The mechanical leveling unit and the

old start-stop shear were replaced, the

control system was modified, and the

machines rearranged as the loop had

been eliminated. The HiCap® 55 high

capacity leveler is specially designed

to work with both wide and thin strips.

These are leveled in the six-high version

without any imprints and surface mar-

kings, delivering flat results with low

internal stress. The intermediate rollers

mounted between the leveling rollers

and the supporting rollers consistently

ensure high surface quality. The adjus-

table back-up serves to counteract any

eventual leveling defects resulting from

the leveling rollers bending. The leveled

strip can thus be reliably and consistent-

ly cut to length by the continuously run-

ning rotary shear. The control system

automatically monitors the cutting gap

during the adjustment process of the

panel length, working together with the

guided cutting beam to constantly ensu-

re perfectly square and clean cuts.

RBB-Stal cuts from the smallest sizes

beginning at 500 x 500 mm, producing

a broad variety of standard and custo-

mized formats. Both hot-rolled strips

and cold-rolled strips along with stain-

less steel and galvanized materials are

processed. The company‘s product range

even includes high-tensile sheet metal

with yield strengths of up to 700 N/mm2.

RBB-Stal‘s own customers’ initial feed-

back already confirms their decision to

modernize the facility: Customers have

noticed and value the higher quality.

RBB-Stal J. Borusiak SP.K.Ul. Wojska Polskiego 83

63-200 Jarocin, Poland

www.sk.rbb-stal.com.pl

Quality campaign at the steel service center

Larger, lighter, more friendly and

more ergonomic - That sums up

ARKU‘s new workshop for apprenti-

ces. The 12 trainees obviously feel at

home in the 400 m² workshop, which

is now twice the size of the former

location and has been in operation

since February. Following the con-

version of the old leveling center, all

of the trainees now have their own

workplace – including tools. This

provides the perfect conditions for

the automation technicians, indus-

trial mechanics and mechatronics

technicians to get the very best out of

their 3.5 year apprenticeship. „With

the new apprentice workshop we can

definitely hold our own with larger

companies“, says the Training Mana-

ger, Sascha Hutzler, proudly. He and

his colleague, Michael Müller, pre-

pare the young men and women for

their professional future.

The new workshop also establishes

an organized and logical division into

individual work areas. As a result, the

measurement benches, workplaces

for electro-technology, assembly and

milling are all arranged separately.

The new apprentice workshop has

also laid the foundation for expan-

ding the range of training offered,

because „the best specialists always

come from the company‘s own trai-

ning“, says Sascha Hutzler with ab-

solute conviction.

His melodious American accent is

easy to recognize even amid the

sound of colleagues talking on the te-

lephone. The man behind the voice is

Nicholas Miller – born in Indiana,

USA. The ever-cheerful American joi-

ned the ARKU team as a design engi-

neer at the beginning of 2011. He has

since gone on to additionally become

a project manager for coil lines. In

this role he serves as the interface

between production and the custo-

mer and thus, can react directly to

every need.

Nicholas studied mechanical engi-

neering and economics simultane-

ously at two universities in Indiana-

polis, Indiana until 2006. In his first

job he designed forklifts at Toyota.

His desire to travel took him on a tour

through Europe in 2008. Nicholas’s

journeys inspired him to learn Ger-

man, which led him to work for as

an English teacher for one academic

year at a boarding school in Thuringia.

While there, he taught himself Ger-

man, primarily through speaking with

colleagues. After a short time working

at the German-American Chamber of

Commerce in Chicago, Nicholas had

the opportunity to realize his dream:

Working as a design engineer for a

German engineering company.

Nicholas loves cooking and enjoys

playing basketball. A passionate fan

of American football, satellite tele-

vision allows him follow the season

from Germany. He provides ARKU

with an important connection bet-

ween America and Germany. Do

you have any questions about coil

lines or tips for a German baseball

or basketball team? Nicholas looks

forward to hearing from you:

nicholas.miller@arku.de.

Larger apprentice workshop

Personality Nicholas Miller

Masthead / Publisher: ARKU Maschinenbau GmbH Responsible: Albert Reiss, CEO Coordination: Tobias Christoph Layout: Marschner+Kühn GmbH & Co. KG, Rommel & Company Print: Naberdruck

InfoMAX

ARKU rotary shear

HiCap® 55 high capacity leveler