West Manufacturing News • March 2025 • Efficient Storing and Sawing Solution

Companies in the metalworking industries, such as machine and window construction, sheet metal processing and steel distribution, store and process large volumes of metals. The range of application is vast, and the warehouse goods can vary greatly. Not only do these companies handle bar stock such as bars, tubing and profiles, they also process sheet metal. The rule always applies: storage space is a valuable resource and should be used efficiently. The same efficiency is required when processing and compiling individual orders. The industry uses high-powered, fully automated saws to perform straight or miter cuts. Some companies still depend on sorting solutions for palletizing and picking, which can be either cumbersome or rough on materials. Robot handling systems from KASTO are designed to gently remove cut sections directly from the sawing machine. KASTO provides various other solutions that enable end-to-end optimization of the entire process chain. Users can optimize their process for sawing and storing bar stock and sheet metal in seven steps.

To maintain efficient operations in the warehouse, a high-performance system is essential. KASTOlogic manages all processes. The software optimizes movement sequences, assists the operator with a graphical interface and visualizes the system. An ERP system and WMS exchange data automatically through standard interfaces. As a result, efficiency and performance increase throughout the entire system while operational and categorization errors are virtually eliminated.

Users can access different modules to customize the software to meet their specific requirements. These requirements include, for instance, the control of automated storage systems, integration of machines and generation of comprehensive statistics for system analytics.

Standardized storage systems are suitable for many applications and materials. However, greater efficiency, space-saving, faster placement of goods and versatility are sometimes needed. KASTO’s modular systems allow precise customization to individual material flow. Storage and retrieval stations can be tailored to user needs, for instance, by using automated bar separation. The customized design with selectable storage lengths and heights makes it possible to accommodate all formats used, maximizing space efficiency.

KASTOrail is an intelligent material distribution system that transports picking bundles efficiently and ergonomically for shipping. At the same time, individual materials can be transported between the different processing steps. The system operates with a combination of manipulator and material buffer chain conveyors. The installation on raised rails ensures maximum space utilization.

KASTO bandsaws and circular saws cut bar materials, sheet metals and profiles with straight or miter cuts. In addition to high cutting efficiency, users require low idle periods. In response to these demands, parameters such as material qualities and the sawband tailored to them can be stored permanently on the KASTO saws. The control system automatically selects the cutting technology appropriate to the specific job. Not only does this reduce tool costs, it also reduces cutting times.

CNC-controlled, fully automated production circular saws like KASTOvariospeed can cut any bar stock to size, regardless of material quality. Where required, the sawing solution can also work in conjunction with the KASTOsort robot handling system.

In the KASTOcenter, automated computer-controlled operating gantry cranes transport individual bar stock to an integrated CNC saw and automatically return remnants to storage. The software updates the inventories and can trigger new orders if needed. The flexible system consists of a storage system, saw and control system. KASTO coordinates the components seamlessly, enabling the sawing center to output as much as three to seven individual saws.

KASTO created the KASTOsort robot handling system specifically for the automation of palletizing and order picking. The system is ready for operation directly behind the saw: it can transfer workpieces to downstream processes such as deburring, length measurement or marking directly to packaging. The robot automatically calculates the stacking pattern with the highest packaging density. It gathers the required information directly from the ERP system. The decentralized, self-organized program logic makes teach-in or programming by the user obsolete.

The KASTOapp provides users a complete status overview of all KASTO sawing machines in the network. All-important parameters, such as article, cut length, target and actual number units and cutting speed, are accessible at any time. KASTOlogic mobile assists personnel in the storage system. By scanning QR and barcodes, for example, operators can easily trigger a repeat order when removing items from the magazine. The apps notify users in the event of an operational error, enabling a rapid response.

Due to augmented reality, KASTO VisualAssistance offers an option to easily service machines and systems remotely. Service technicians assist users with operation and fault diagnostics using a direct remote connection. The core component is an interactive app for tablets, smartphones or smart glasses.