UK’s first ‘Fully-Auto’ structural Saw/Drill
line starts production at ParkerSteel, with
dramatic gains in processing efficiency.

“An initial production run for example,
using a 305x305x198 Universal column,
reduced our overall sawing processing
time from 4 minutes to a staggering
90 seconds” says Guy Parker, ParkerSteel
Managing Director.

First UK Fully-Auto Saw/Drill line is at ParkerSteel, Canterbury; with AS1051 Auto-Sorter, KDXS1051 3-axis drilling & much more!

This UK first installation comprises:

KBS 1051 mitre-cutting band saw, with AFC (Auto-Feed-Control); World’s fastest

AS1051 Auto-Sorter; unique auto-removal of trim-cuts and remnants; a World first

KDXS1015, 3-axis, 5-tools per axis, carbide drilling system, 5 x faster than HSS

Contour-Marking on 4-axis

Automated Hard-Stamping

Automatic input/output material crossway and conveyor handling systems

KPLC (Kaltenbach Logical Processing and Control) software suite




ParkerSteel, Canterbury, Fully-Auto KBS1051/KDXS1015 saw/drill line		Kaltenbach's unique AS1051 Auto-Sorter is seen on the left



AS1051 Auto-Sorter in foreground, achieves first fully-auto system		ParkerSteel saw/drill line viewed from KDXS1015 drill input side

Kaltenbach have completed the installation of the UK’s first fully-auto structural saw/drill line at ParkerSteel’s Canterbury
site. As one of the UK’s leading steel suppliers the new ParkerSteel system gives them a very marked gain in structural
steel processing efficiency. “An initial production run for example, using a 305x305x198 Universal column, reduced our
overall sawing processing time from 4 minutes to a staggering 90 seconds” says Guy Parker, ParkerSteel Managing Director.

The new installation, completed in Feb 2011 comprises; Kaltenbach’s revolutionary new KBS 1051 mitre-cutting band saw,
which as the World’s fastest structural saw, uses Kaltenbach’s unique AFC (Auto-Feed-Control), which cuts up to 100% faster
than industry norms. The saw is inter-linked with another unique first, Kaltenbach’s AS1051 Auto-Sorter, to achieve the first
‘fully-automated structural sawing system’, including auto-removal of trim-cuts and remnants, which eliminates the need for
time-consuming operator intervention and the use of a crane for heavier sections. The saw is close-coupled to the latest
Kaltenbach, heavy-duty drilling system, a KDXS1015, which is a 3-axis, 5-tools per axis, high-performance ‘carbide drilling’
machine (or optional HSS). Kaltenbach have perfected the heavy-duty, ultra-fast carbide drilling and processing of
steel columns and beams, with carbide drills cutting 500% faster than HSS bits and their impressive process speeds being
almost likened to those associated with the drilling of timber.

Other features of the Kaltenbach, ParkerSteel installation include; high-performance, 4-axis Contour-Marking, automated
Hard-Stamping and automatic input/output material crossway and conveyor handling systems, together with Kaltenbach’s
latest Logical Processing and Control (KLPC) software suite, which utilises common DSTV + data file format and can provide
complete integrated logistical processing control of an entire processing line, from order intake to shipped structural material.

The KBS 1051 AFC system is CNC controlled and achieves dynamic, auto-sensing & adjustment of the band-cutting angle
‘during’ the cutting cycle, throughout a changing cross-section, to optimise cutting performance and minimise the cutting edge
contact area. AFC dramatically improves cutting performance and in particular fully exploits the full potential of carbide bands
(bi-metal bands are optional), with up to 100% faster cutting speeds achieved and even greater gains through associated
overall process and handling. The KBS1051 AFC has a high-speed positioning mitre range of -30°/ 90°/+45°, with maximum
material capacity of 1030 x 500mm down to 20 x 10mmminimum. Another structural band saw first from Kaltenbach, is the
use of a ball-screw spindle for the saw band feed, a technology Kaltenbach have pioneered and proven over many decades
through installations globally, as used in their heavy-duty circular sawing systems. The ball-screw ensures continuous smooth
operation and reproducible feed rates under very high-performance cutting conditions throughout the long-term life of the
machine.

The integrated NC driven, KHS fast-marking, hard-stamping system, sits between the saw and drill and can apply up to 22
alpha- numeric characters to the steel, without the need for material movement, with imprints remaining clearly visible after
galvanizing or painting. Extensive Kaltenbach automated material crossways and conveyor system feed steel directly into the
drilling machine, which after final processing auto-exits from the saw via a motorised conveyor and traverses onto a holding
area, ready for collection. The system can be overseen by a single operator, or left unmanned. Operator interface is via
coloured touch-screen console, with cutting instructions fed down the line from the ParkerSteel Production Control Department.
Remote machine interrogation via the internet is included, to enable quick, cost-efficient, system assessment by Kaltenbach
service engineers.

Close-coupled sawing/drilling systems are increasingly popular with structural stockholders and fabricators, with the attendant
advantages of faster process cycle times and now with full-automation, uninterrupted material management being possible
with the Auto-Sorter. Greater software integration and a reduced overall installation footprint are additional benefits.

“More than ever in to days market, operating efficiency is key to being competitive on cost and service levels, says
Guy Parker, “Our new Kaltenbach steel processing and logistics capability, along with other technology investment at our
Canterbury site, helps ensure we meet our key objectives of cost-effective, ultra-low operating costs and high customer
service ”.

This policy has just been perfectly demonstrated by the opening of ParkerSteel's purpose-built 12 acre, ultimately £20 million
dockside investment in a steel stockholding, processing and distribution centre at Shoreham Docks on the Sussex coast.
Bundles of 25 tonne structural steel are lifted directly from 5000 tonne ships and into the ParkerSteel dockside distribution
yards and processing plant. Their vision of efficient ‘direct-from-dock’ structural steel distribution has taken six years to build
and will achieve ultra-low operating costs, with savings being passed onto customers. The company also boast the only UK web
based, fully on-line steel purchasing site. An extensive very modern fleet of over 60 vehicles satisfy ParkerSteel’s nationwide
delivery service.With steel supply competition ever present, particularly for the construction sector, it is predicted that this new
Kaltenbach technology and the ParkerSteel approach to ultra-high efficiency, low-cost supply, is the likely trend and the way
forward for structural steel suppliers to remain competitive.

View a video tour of a fully-automated structural line.

For further information visit: Kaltenbach Group web site or for ParkerSteel visit their directfromdock site.