Processinghttp://www.internationalmetaltube.comSat, 21 Apr 2018 09:48:16 +0200Joomla! - Open Source Content Managementen-gbSun Chemical and DIC Corporation to Increase Production Capacity of DAILUBE® Extreme Pressure Additives at Kashima Plant

Beginning in April 2018, Sun Chemical and its parent company, DIC Corporation, will increase the production capacity of its DAILUBE® extreme pressure additives by 6,000 tons per annum at its eco-friendly plant in Kashima, Japan.  

The move will better serve customers around the globe as well as promote and deliver its trusted and market leading sulfurized extreme pressure additives into new and existing markets.

Sun Chemical, DIC Kashima PlantSun Chemical, DIC Kashima Plant

Optimised for metalworking fluids used in cutting, forming and rolling, DAILUBE extreme pressure additives are light in colour, low odour and available in a range of chemistries, including olefin, lard, vegetable, ester and fatty acid.

Opened in 1972, the 600,000-square meter Kashima plant is the ideal location for capacity expansion due to its dedication to eco-friendly production processes, award-winning achievements and technological legacy. Along with extreme pressure sulfur additives, the facility produces organic pigments, bases for inks, metal carboxylates and polyphenylene sulfide (PPS) resins.

To reduce environmental impact, the Kashima plant utilises steam generation facilities, biomass boilers, solar panels and windmills to power the majority of its production processes. The facility has received various certifications and honours related to quality management, hygiene and safety and serves as a keystone to Sun Chemical and DIC Corporation's commitment to quality, innovation and environmental responsibility.

About Sun Chemical
Sun Chemical, a member of the DIC group, is a leading producer of printing inks, coatings and supplies, pigments, polymers, liquid compounds, solid compounds, and application materials. Together with DIC, Sun Chemical has annual sales of more than $7.5 billion and over 20,000 employees supporting customers around the world.
Sun Chemical Corporation is a subsidiary of Sun Chemical Group Coöperatief U.A., the Netherlands, and is headquartered in Parsippany, New Jersey, U.S.A. For more information, please visit our website at


]]> (Ian Melin-Jones)ProcessingTue, 17 Apr 2018 09:42:16 +0200
ArcelorMittal India Private Limited submits offer for Essar Steel India Limited

ArcelorMittal announces that its subsidiary ArcelorMittal India Private Limited (AMIPL) has just submitted an offer for Essar Steel India Limited (‘Essar’), the Indian steel company, in-line with the corporate insolvency resolution process for Essar.

arcelormittal logoIn its offer, AMIPL set out a detailed industrial plan for Essar aimed at improving its performance and profitability and ensuring it can participate in the anticipated growth of steel demand in India. It also highlights the extensive experience and track record of the group in the successful acquisition and integration of under-performing assets, which AMIPL believes would be of considerable value to Essar. Essar would also have access to the deep bench of technical expertise and knowledge from across the group which is unparalleled in the steel industry.

Commenting, Mr. Lakshmi Mittal, Chairman and CEO, ArcelorMittal, said:

“Essar provides a compelling opportunity for ArcelorMittal to enter the high growth Indian steel market. The offer submitted today by AMIPL includes a detailed investment plan to address operational issues in Essar’s existing asset base. With our industry expertise and renowned operating prowess, we believe we are uniquely equipped to implement a successful turnaround which would be beneficial to Essar’s stakeholders.”

Aditya Mittal, Group CFO and CEO ArcelorMittal Europe, said:

“This opportunity aligns with the group’s strategy of selectively investing in attractive projects to maximize long-term shareholder value. India is expected to be the world’s fastest growing economy over the next decade and as the economy grows its steel intensity will also increase. We believe our technical experience and management know-how, gained from many successful acquisitions and integrations, will ensure success for the various steel and pelletizing operations at Essar.”

Essar Steel is an integrated flat steel producer. Its main production facility is in Gujarat. It has a nameplate crude steel capacity of 9.6 million tonnes per annum, although the current maximum achievable crude steel production level is 6.1 million tonnes per annum, due to a bottleneck in the steelmaking and casting process.

About ArcelorMittal

ArcelorMittal is the world's leading steel and mining company, with a presence in 60 countries and an industrial footprint in 18 countries. Guided by a philosophy to produce safe, sustainable steel, we are the leading supplier of quality steel in the major global steel markets including automotive, construction, household appliances and packaging, with world-class research and development and outstanding distribution networks.

Through our core values of sustainability, quality and leadership, we operate responsibly with respect to the health, safety and wellbeing of our employees, contractors and the communities in which we operate.

For us, steel is the fabric of life, as it is at the heart of the modern world from railways to cars and washing machines. We are actively researching and producing steel-based technologies and solutions that make many of the products and components people use in their everyday lives more energy efficient.

We are one of the world’s five largest producers of iron ore and metallurgical coal. With a geographically diversified portfolio of iron ore and coal assets, we are strategically positioned to serve our network of steel plants and the external global market. While our steel operations are important customers, our supply to the external market is increasing as we grow.

In 2017, ArcelorMittal had revenues of $68.7 billion and crude steel production of 93.1 million metric tonnes, while own iron ore production reached 57.4 million metric tonnes.

ArcelorMittal is listed on the stock exchanges of New York (MT), Amsterdam (MT), Paris (MT), Luxembourg (MT) and on the Spanish stock exchanges of Barcelona, Bilbao, Madrid and Valencia (MTS).

For more information about ArcelorMittal please visit:

]]> (Ian Melin-Jones)ProcessingThu, 01 Mar 2018 11:57:04 +0100
SigmaNEST Product and Industry Update 2.5.18

montySigmaTEK Systems, LLC has recently named Monty Brown the Sales Director, heading up the Midwest Territory. Brown started with SigmaTEK in 2012 in the Services Group, where he focused on selling integration and consulting services. In 2016, Brown transitioned to selling SigmaMRP, where he expanded his territory nationwide and gained valuable experiences that will translate to his new role.

As a result of his unmatched technical knowledge and sales accumen, he was named the Director of Sales in the Central Territory, where he plans to leverage his past experiences to expand the partnership between SigmaTEK and SigmaNEST users. In his new role, he desires to use a mix of lean and business consulting tools to plan, sell and support integration projects and grow existing business while developing new business with prospects. Working closely with the Central Sales Team and the SigmaTEK Services Group will be key to his plan.

Monty says, “The most exciting thing about stepping into this new role is my chance to engage in true team selling projects with the regional representatives of the central territory. I have always enjoyed collaborative projects where team members work towards a common goal, much like the members of a music group who combine their unique skills to bring a song to life.”

“Monty is a great addition to the Central Sales Team. His background with the company has given him a unique advantage and his knowledgeable insight will carry through this new position”, explains Jandre, Vice President of Sales and Operations.

Product Update: Load Manager X1

Load Manager X1, which was released on January 22, 2018, is 64-bit capable and offers faster response times, greater stability and a modern, intuitive user experience. Load Manager X1 allows users to set shifts and breaks across all machines using a global schedule making it easy to view assigned and unassigned programs with a single click and quickly preview and move scheduled programs using a streamlined process. Get help instantly using the all-new Load Manager Help Center.

Load Manager X1 was optimized for slower networks, allowing more companies to utilize this newly rewritten technology. With this new version comes increased speed in processing, a new interface, and optimization for slower networks. Load Manager X1 is included for existing Load Manager customers with a current maintenance subscription. To upgrade to Load Manager X1, use the SigmaNEST X1.4 installer or contact our SigmaTEK Support for assistance at (513)595-2002.

About SigmaTEK

Founded in 1993, SigmaTEK Systems, LLC is headquartered in Cincinnati, OH (USA) and has an extensive global support network with branches in North America, South America, Europe, Asia, Australia and Africa. This year, SigmaTEK is celebrating 25 years of business and looks forward to celebrating with your continued business. For more information visit or call 513-674-0005.

SigmaTEK develops and sells SigmaNEST®, a comprehensive software solution for nesting, NC programming and cutting of steel sheet, plate, tube/pipe, and wood.  SigmaNEST is the leading CAD/CAM nesting system for plasma, laser, punch, oxyfuel, waterjet, router, knife, tube/pipe and combination cutting machines. SigmaNEST ensures superior material utilization, machine motion optimization, and maximum part quality balanced with cutting speed, work flow integration, material handling, accurate estimates and information management.

]]> (Ian Melin-Jones)ProcessingThu, 01 Mar 2018 11:48:22 +0100
New Nesting - To stay competitive, fabricators look for more from their nesting software

2018 02 13 093826

From lasers to plasma, punch, warterjet and beyond, metal processing equipment represents a significant investment for any size job shop, fab shop, steel service center or manufacturer. Maximizing and accelerating the return on investment is, therefore, critical, and it only makes sense to drive such advanced equipment with sophisticated software designed to fully leverage the machine’s capabilities.

To this end, more fabricators are replacing basic software with more advanced applications provided by the specialists. To learn more, SigmaTEK Vice President of Engineering, Glenn Durham, explains what the industry can expect to see from CAM software providers moving forward.

Farrell: Scrap reduction and accelerated cutting cycles are a few of the obvious benefits of nesting programs. Where else do nesting programs make a difference?

Durham: Nesting isn’t only about scrap reduction. It’s also about part placement for manufacturability. A main goal for fabricators – beyond simply cutting and processing materials, is to efficiently manage inventory. While companies like SigmaTEK want to help manufacturers reduce scrap, we also provide tools that make it easier and more efficient to track and reuse drops.

To elaborate, there are many situations in which the location of a part on the material must be optimized before we can even consider material utilization. For example, vacuum table routers have the strongest suction in the center of a sheet. Therefore, nesting must prioritize placement of the largest parts, which need less suction to remain stable during cutting, around the outside of the sheet – and furthest from the center of the table. Smaller parts must be nested toward the center of the sheet where the table suction is greater.

Another example is nesting for machines that drag the sheet. In these nests, we must lay the largest parts down closest to the clamps and then cut parts furthest from the clamps. Design for manufacturability must understand machine specifics to make the best nest and apply a proper toolpath.

Cutting machines generally come with a pre-installed nesting program. At what point should a fabricator consider upgrading to more advanced software?

The basic software package delivered with a new cutting machine can help most smaller shops get up and running quickly. At SigmaTEK, we partner with machine manufactures to provide a basic version of SigmaNEST, called Companion. What makes Companion useful is that it’s quick and easy to get parts imported and then cut. However, when professional fabricators want to move beyond cutting a few parts and into managing business in the most profitable and efficient way, then it’s time to move to an advanced package.

What should one look for in a more sophisticated nesting program?

The answer really depends on the needs of the fabricator. We find that as newer and smaller shops grow, they first need to add the capability to import parts from a wide variety of CAD systems, nest those parts in a very efficient way and then machine them with an optimized tool-pathing algorithm. Advanced importing, nesting and NC are usually the basic requirements. Beyond that, most shops quickly want to manage inventory and work orders, controlling remnants and reducing waste; then managing the quote to delivery process in a robust and comprehensive solution. We find that at each step in this process, the ROI is such that advanced CAD/CAM solutions like SigmaNEST pay for themselves very quickly.

Can you cite examples of the ROI that SigmaNEST is delivering?

For some industries and companies, the material cost drives the ROI. We recently completed a project where our nesting improvements saved an entire sheet over a production run. That was due to about a three percent better nesting efficiency compared to what the company was previously able to get. Three percent may not sound like a lot, but since they had runs of more than 25 sheets, they got to the end of the job using one less sheet. This is a great example of saving material. But think of the savings in handling time, in machine on-time, in worker hours, and in machine wear and tear.

ROI can also be seen in situations where material utilization wasn’t the main goal. As an example, a fabricator working with plywood had more orders than they could cut and no room to add another machine. Therefore, they needed to reduce the time to cut a nest. Through a combination of nesting and motion optimization, the SigmaNEST software helped them reduce machine on-time by more than 10 percent. Since they were running seven machines, 24 hours per day, they suddenly fulfilled production demand without purchasing additional machines, adding head count or hours to the workweek.

A 10 percent run-time improvement is significant. Can those running metal fabrication equipment expect similar results?

No, I wouldn’t suggest that 10 percent run-time improvement can be expected. That was a very specific case where ROI was based solely on machine on-time rather than material utilization. Certainly, we want to cut more material faster, but the advantage that SigmaNEST brings to the professional fabricator is a comprehensive solution that allows the business to maximize the ROI based on a variety of factors.

For example, we worked with a company that cuts three-six-inch-thick stainless with their waterjet. Processing a sheet typically takes 4 to 10 hours. So, they wanted to set up a run at the end of each day and let the machine process it overnight. To minimize the chance of tip-up for these types of lights-out tasks, the company uses SigmaNEST’s Part Avoidance feature. By setting Part Avoidance to a very conservative value, an extra safety factor is injected into the operation. This gives the company the confidence to run the machine all night without direct supervision. Although the “safety factor” adds a few minutes to a multi-hour run, it allows a plate to be cut every night, ramping up ROI beyond nesting efficiency.

What are the biggest nesting challenges fabricators face today?

Fabricators are challenged by both the high cost of machines and the difficulty of finding skilled employees qualified to program and run increasingly complex machines and shop process. But we can help address those challenges through a two-fold process. We are making software that helps keep machines running continuously and, at the same time, we are placing better tools in the hands of programmers and SigmaNEST users. We are increasing and improving automation control through sheet loading, part picking and scrap processing while also making it easier to run these advanced features from a software “command central.”

One approach for dealing with these complex challenges is by importing assemblies and creating multi-machine process plans. Fabricators are increasingly concerned with more than simply drawing and cutting parts. They need a solution that also deals with the assembly of parts that may be cut on a variety of machines. The newest version of SigmaNEST recognizes which parts need to go to the tube laser, the press brake and the plasma cutter. It can then unfold sheet metal parts, task and nest for each different type of machine – all while managing the flow of different kinds of parts through the shop floor.

How does SigmaNEST support Just-In-Time nesting and similar initiatives?

Nesting and posting machine tool-path code is great, but fabricators often face challenges that require even more. This is what I mean by the importance of a software “command center” and why we offer solutions like SigmaNEST Console, which allows automatic nesting at the machine based on the work needs of the day.

This type of tool works because it can integrate SigmaNEST parts, orders and inventory with a company’s ERP/MRP system. Furthermore, with our SimTrans integration tool, the SigmaTEK services group informs the SigmaNEST user within minutes of a new order or a changed order or even a new shipment of material – whether in a centralized programming office or at the particular machine that needs to nest and cut the part.

Bevel cutting can be challenging. How can software like SigmaNEST address this?

Bevel cutting involves complicated processes and careful thought, which is why it’s essential to understand the cutting machine first and then the bevel pathing before parts are nested. Bevel nesting has to consider bevel pathing, which is a new layer of complexity. To address that complexity, we introduced a new way of applying toolpath to bevel edges that should be available in the coming months.

How does SigmaTEK capture and translate customer requirements into software features and how are enhancements prioritized?

We use a methodology for software development called Agile. One of the principles of Agile is that we receive input and ideas from stakeholders – the people who actually use the software. That means we have a constant flow of incredible ideas from our global customer base. We are constantly amazed by the creative and innovative ways that customers use our products.

Some of the best examples of customer input are related to cutting on lasers, especially on new fiber lasers. For example, when a part has a small hole in it, the laser can cut out the material and drop it through the slats. However, we started receiving calls to our support desk and messages through our sales teams that customers wanted a way to automatically cut a larger drop (one too big to fall through the slats) into small pieces that would fall through.

In response, we added the Laser Destruct feature to do precisely that. It was a big success, but then customers called our support lines and began to register enhancement requests to the feature. Our initial design worked, but customers thought of ways to make the cuts in a more elegant way, which also made the cuts faster. After listening to those suggestions, we improved the feature and debuted it at Fabtech 2017 in Chicago.

Another example relates to tabbing parts into a sheet. Customers told us that they needed an automatic method for tabbing in parts that are small enough to fall through the slats of their machines while leaving tabs off parts that would not fall through. So, we created Center of Gravity Tabbing to provide this functionality.

When the SigmaNEST user activates the feature, we automatically tab parts that don’t have a slat on both sides of the center of gravity of that part. Not only does this improve the manufacturing process, but it also makes the user experience more efficient and more enjoyable. And that’s all because a customer brought us a great idea.
What are some recent software enhancements of note?

We introduced the X1 platform in the last two years, and with that system, we added many features and improvements designed to advance the work of professional fabricators. Of course, the center of every shop is the machines that cut. Whether it’s a laser, punch or waterjet machine processing every metal imaginable, we continue to add new capabilities.

X1 also continues our history of innovation in nesting with new mathematical algorithms for automatic nesting and improved controls for those who prefer manual nesting. We also continue to roll out new tool-pathing features that optimize machine motion and tool placement and control.

Ease of use, ability to run the most machine types from the most machine manufacturers, and feature rich software that handles all aspects of the workflow for fabrication are just a few of the things that make X1 unique. These features and advancements are each significant for different people in a fabrication business.

Where do you see the industry as a whole five years down the road?

Industry 4.0 and the Internet of Things get a lot of press. However, I think it’s unlikely that these will be brought into the fabrication industry as a complete package. Instead, components of these new technologies will be incorporated into our workflows to improve processes, efficiencies and quality.

So, I think we will see more companies taking advantage of process monitoring and machine utilization studies. Automation, just-in-time nesting and tool-pathing will be seen as powerful ways to get more return from investments already made.

On an almost daily basis, manufacturing processes are being revolutionized by more complete and more accurate knowledge of what is really happening on the shop floor.Therefore, when fabricators invest significant time and money into their machines, it’s critical that they use the very best nesting solution available to manage and extract the best quality parts.

About SigmaTEK
Founded in 1993, SigmaTEK Systems, LLC is headquartered in Cincinnati, OH (USA) and has an extensive global support network with branches in North America, South America, Europe, Asia, Australia and Africa. For more information visit or call 513-674-0005.

SigmaTEK develops and sells SigmaNEST®, a comprehensive software solution for nesting, NC programming and cutting of steel sheet, plate, tube/pipe, and wood. SigmaNEST is the leading CAD/CAM nesting system for plasma, laser, punch, oxyfuel, waterjet, router, knife, tube/pipe and combination cutting machines. SigmaNEST ensures superior material utilization, machine motion optimization, and maximum part quality balanced with cutting speed, work flow integration, material handling, accurate estimates and information management.

]]> (Ian Melin-Jones)ProcessingTue, 13 Feb 2018 09:44:11 +0100
Bright, shiny, oxide-free welds with PurgExtra®

Tubes and pipes made from titanium, stainless steel, chrome/nickel steels are mostly required to be welded in a non-oxidised environment in order to achieve a metallurgically correct, zero colour weld. Best results are obtained by reducing the volume to be purged, with an inflatable Weld Purging System.

Leading the way in Weld Purging Technology, Huntingdon Fusion Techniques HFT® have developed PurgExtra®, for purging tube and pipe joints from 1 – 24” diameter that provide an extra gas purge hose to speed up the purging process even further.

Additional advantages of this design improvement are that the operator can use the extra purge gas supply for welding reactive metal joints in particular, such as those made from titanium and zirconium. In addition, the extra gas can be used for cooling welded joints faster than normal, where permissible.

PurgExtra APBM PHO 3C PurgExtra with Helmet Torch

Luke Keane, Technical Support for HFT® said: “The PurgExtra® Range complements the PurgElite® Series that has a single purging inlet and is more appropriate for stainless steel only. PurgExtra® however, allows the operator to purge at the recommended rates initially and then, when conditions are correct, to introduce the additional gas at high flow rates. This system is especially valuable for achieving the lower oxygen levels required for welding materials around 20 parts per million.”

When welding joints where interpass temperature control is necessary, PurgExtra® allows extra argon gas into the welding zone, helping to cool the weld zone dramatically.  The extra gas also helps to remove the gases that are expelled by the outgassing, which occurs as the metal is being heated. The extra gas flow will prevent these expelled gases from combining with the hot metal and oxidising, which would otherwise cause the metal to discolour and lose its corrosion resistance and possibly introduce defects that would cause loss of joint integrity.

PurgExtra® comprises two inflatable dams connected by a heat resistant, highly flexible gas hose that has the unique IntaCal® gas release system. IntaCal® allows the dams to be inflated correctly and then releases the inert gas to safely purge the space between the dams. The low profile IntaCal® Valve replaces the old fashioned, bulky complicated valves and eliminates the need to make adjustments to flow rates.

The highly flexible spinal hose between the inflatable dams allows the PurgExtra® Systems to be pulled or pushed easily around bends and elbows. In the centre of the spinal hose a strip of RootGlo® material is adhered, allowing the welder to see clearly through the root gap, when the system has reached the correct position in the pipe. RootGlo® can be charged by exposing it to daylight for 10 minutes, after which it will provide up to 24 hours of bright illumination inside the pipe.

The innovative PurgeGate® Valve may be fitted to the PurgExtra® Systems as an accessory, to protect the inflatable dams from bursting due to accidental over pressurisation.

Heat Resistant Covers are also available for PurgExtra®, which fit onto the inflatable dams and allow operation with pre-heated and post-weld heat-treated pipe joints where the temperatures might reach 760°C.

The HFT® Weld Purge Monitors® are used to give precise oxygen values throughout the purging process.

Huntingdon Fusion Techniques HFT® are Weld Purging Innovators, Designers and Manufacturers with offices located globally.

Huntingdon Fusion Techniques HFT® invented the ‘Weld Purge Monitor®’ in 1975 and own all international intellectual property rights and registered trademarks.  

Weld purging is the act of removing, from the vicinity of the joint, oxygen, water vapour and any other gases or vapours that might be harmful to a welding joint. Such gases may combine with the metal to form undesirable compounds that may reduce corrosion resistance or may be instrumental in creating cracks or other structural defects in metals.

]]> (Ian Melin-Jones)ProcessingWed, 24 Jan 2018 07:35:37 +0100
A new dimension of efficiency

The MSP series from Schuler allows efficient production of formed parts for a low acquisition cost

Schuler has expanded its MSP series with the addition of a newly developed servo press. In addition to its 100 and 200 ton stamping presses, the technology and market leader in the field of forming technology now also offers a machine that features 400 tons of press force and the innovative drive concept. The first type MSP 400 press will go to a customer in the automotive supplier industry.

"With the MSP 400, we're proving that the efficient production of blanked and formed parts is also possible for a low acquisition cost," says Executive Director Markus Bieg from Schuler. "This new generation of presses is aimed at customers who are seeking a more balanced cost/benefit ratio without having to sacrifice the versatile ServoDirect technology or the convenience of simple operation."

The new generation of presses is aimed at customers seeking a more balanced cost/benefit ratio.The new generation of presses is aimed at customers seeking a more balanced cost/benefit ratio. image source - Schuler

Mechanically decoupled drive train
Similar to Schuler's TwinServo technology, the MSP 400 utilizes an opposing pair of drive trains that feature exclusive electronic synchronization. These drive trains consist of a highly dynamic servomotor, a brake module, and an eccentric shaft. The shaft itself is made up of a connecting rod, a hinged joint for quiet and rigid operation, and a slide. The resulting benefits are similar to those delivered by the TwinServo technology: The pressure points are positioned well to the outside and improve the tilting rigidity, which allows greater eccentric loads.

Compared with presses that use conventional drive technology, the oscillating stroke mode makes it possible to increase output with a customizable stroke height setting between 60 and 300 millimeters. The clamping surface for the bed and slide measures 2,500 by 1,200 millimeters. The slide – along with the monolithic press frame – consists of a welded steel structure that has undergone stress-relief annealing.

Frequently used movement sequences are already included
With the help of an easy-to-use touchscreen, operators can select from five preprogrammed slide movement curves for forming, blanking, embossing, bending, and drawing. The movement sequences can be customized to fit specific process parameters, which improves both the precision of the processed parts and the service life of the dies. The optionally available OptimizerPRO also allows full-range free programmability of the slide kinematics. Last but not least, the setup and try-out functions reduce the time required to run-in the dies.

The MSP 400 can also be equipped with Smart Assist from Schuler, in order to assist the press operator during setup. The operator is guided step-by-step through the process by an electronic wizard which uses videos and graphics for illustration, provides fully-automated optimization of the slide and transfer movement curves, and transfers the data to the entire system. Smart Assist is part of the Smart Press Shop, a collection of Schuler solutions for the digitization and networking of forming technology.

Electronic overload protection device prevents damage
In the unlikely event of an operating error, the electronic overload protection device keeps problems under control. It registers excessive press force immediately and, within the span of a few milliseconds, reverses the main drive torque in the opposite direction to prevent the press from becoming damaged. The electronic overload protection device thus helps to reduce downtime. The press can only be started up again after an acknowledgment from the operator console.

What's more, the direct and low-maintenance drive via torque motors – without any gear transmission – also translates into high availability and excellent process reliability. Combined with a reduced moment of inertia, this also improves energy efficiency. Maintenance work is focused on the condition of the machine, which can be monitored around the clock on a smartphone or tablet from anywhere in the world.

About the Schuler Group –

Schuler is the technology and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and lightweight automobile construction. Its customers include automobile manufacturers and automotive suppliers, as well as companies from the forging, household appliance, packaging, energy and electronics industries. Schuler is a leader in coin minting presses and implements system solutions for the aerospace, rail transport and large-dimension pipe manufacturing sectors. In the 2016 fiscal year, Schuler generated sales of 1.174 billion euros. After acquiring toolmaker AWEBA and a majority stake in Chinese press manufacturer Yadon, Schuler has a presence in 40 countries with roughly 6.600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group.

]]> (Ian Melin-Jones)ProcessingThu, 30 Nov 2017 09:47:53 +0100
Steel company installs high density storage system

At its distribution centre in Perth, Western Australia, steel producer and wholesaler OneSteel Metalcentre, part of Arrium Mining & Materials Group, stocks approximately 8,000 tonnes of different types of material for supply to its branches and customers, including construction companies, shipyards and plant manufacturers. To streamline the handling and management of its extensive range of bar and tube, the company has invested in a Unicompact honeycomb storage system from German manufacturer Kasto.

From its distribution centre in Perth, Western Australia, OneSteel Metalcentre holds approximately 8,000 tonnes of different types of steel.From its distribution centre in Perth, Western Australia, OneSteel Metalcentre holds approximately 8,000 tonnes of different types of steel.

Andrew Cosgrove, National Operations Manager at OneSteel explained, “We deliver a wide range of types and quantities of material, often just-in-time. The automated warehouse provides rapid access and continuous traceability of our stock, giving us the transparent, efficient storage that is crucial to our operation.”

The Unicompact at OneSteel has 2,272 cassette locations, each of which can accommodate five tonnes of material up to nine metres long. In total, almost half of the steel on-site, subdivided into some 700 different line items, is currently stored in the system.

Mr Cosgrove added, “Compared to conventional storage methods, the small footprint of the Unicompact provides very high storage density, which for us means shorter distances to move the material and more space for additional stock or process steps.

Nearly half of the stock is held in a Kasto Unicompact honeycomb storage system with 2,272 cassette locations.Nearly half of the stock is held in a Kasto Unicompact honeycomb storage system with 2,272 cassette locations.

“The goods-to-man storage system has greatly reduced our access times. At the press of a button, material is loaded and unloaded from the store and sent automatically to the picking area. It guarantees productivity and efficiency in our business.”

He went on to explain that working in the warehouse has become considerably easier and the process more reliable. While the store carries out the laborious loading and unloading of material virtually by itself, employees have more time for other tasks.

KASTOlvr warehouse management software controls the processes and gives OneSteel a detailed overview of orders and stock levels. Every delivery and individual cassette can be identified and tracked, helping to avoid delivery errors and provide customers with a consistently high quality service. The software has also simplified the task of consolidating items required for each order.

The KASTOlvr warehouse management software ensures efficient material flowThe KASTOlvr warehouse management software ensures efficient material flow

Mr Cosgrove concluded, “Everyone at OneSteel is very impressed by the Unicompact storage system. It enables us to work more quickly, safely, reliably and efficiently than before.

“Ultimately, this is all to the benefit of our customers, as they get exactly the material they require from us, flexibly and in the shortest possible time.

“If additional capacity should be necessary in the future, the modular Unicompact system can be easily modified and extended to meet our new requirements.”

]]> (Ian Melin-Jones)ProcessingWed, 22 Nov 2017 07:26:39 +0100

Will direct North American sales and marketing efforts for tube & bar processing machine builder

Jon Hisey, Director of Business DevelopmentJon Hisey, Director of Business DevelopmentManufacturer of tube and bar processing machinery Rattunde Corporation today announces the appointment of Jon Hisey as Director of Business Development for North American operations.  The announcement was made at company headquarters in Caledonia, Michigan (Grand Rapids) by the company President, Rick Stadler. 

Mr. Hisey comes to Rattunde, a builder of metal tube & bar processing machines for high-production component manufacturing in the automotive, off-highway, consumer durable and other markets, from one of the leading industrial saw blade manufacturers, where he was the National Sales Manager and General Manager.   Hisey had occasion to work with Rattunde during that time and became familiar with the company.  He replaces Alec Banish, the former Director of Business Development, who left the company recently to pursue another career outside the industry.

For Rattunde, according to Rick Stadler, “Jon brings us a wealth of knowledge and experience from the cold sawing industry, plus he already had a good working knowledge of our machines.  We have some very aggressive plans to grow the business and expand our market presence in North America.  I know Jon will be a real asset in that process.”  

Hisey assumed the position on October 23, 2017.  He will operate from the company headquarters in Michigan.  Jon is 53 and attended Michigan State University.

]]> (Ian Melin-Jones)ProcessingTue, 21 Nov 2017 11:00:49 +0100
Conex Bänninger industrial valves keep water flowing and the Dubai landscape green

Conex Bänninger industrial and specification valves are helping keep water flowing and the landscape green at some of Dubai’s most prestigious infrastructure projects.

2017 11 21 071745The resilient seated Gate Valves, Butterfly and Air Release Valves, were custom designed by Conex Bänninger of the IBP Group to cope with the arid desert conditions in the UAE.

The valves, manufactured in IBP’s purpose-built factories, are a key element in the irrigation networks for major attractions including the Dubai Parks and Resorts integrated theme parks and the world class Dubai Opera in the Downtown Dubai opera district.

The valves were supplied by Delta Power Electrical, which specialises in providing support services across the Middle East and is a distributor for Conex Bänninger’s range of valves. The valves help to maintain and manage the flow of treated water to pump stations and on into local pipelines.

Delta Power Electrical is also using Conex Bänninger industrial valves for the irrigation network that will supply water for landscaping around entrances, pathways and accommodation for Expo 2020, the world fair site being developed in four phases.

It will be the first time the World Expo, with the theme ‘Connecting Minds, Creating the Future’, will have been held in the MENA & SA (Middle East and North Africa & South Asia) region.

Nitin Sinha, Business Head for Delta Power Electrical, said: “These are hugely significant projects and it is really important that the right surroundings are created and maintained around them, particularly when we are talking about parks and resorts.

“These areas are in what would otherwise be desert but they need to be kept green, which is achieved by using treated water from the sewage and drainage network.”

The harsh environment required a bespoke solution, said Nitin.

“Conex Bänninger worked with us for six to eight months, offering lots of technical advice and have developed a custom range of products for the Dubai market because conditions are a lot harder here than in Europe,” he said.

“Higher grades of metal were used to manufacture the valves; they are not something normally run off the production line. And they come with a five-year warranty.”

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Delta Power’s expertise, coupled with Conex Bänninger’s technical capabilities, helped meet the exacting requirements of the Dubai Municipality, which set the specifications.

“Obtaining approval from the utility and overcoming this first barrier to entry is a big step. Being able to work with a great company such as Conex Bänninger, which is recognised for excellent quality, is hugely important to the process,” said Nitin.

Conex Bänninger’s industrial products are manufactured using high performance ductile iron, which is resistant to corrosion, and are specifically designed to withstand heavy use whilst meeting all appropriate industry standards and requirements.

The resilient seated Gate Valve is a full-bore valve, which ensures low friction losses and full flow throughout the system, while Air Release Valves operate continuously to maintain system efficiency and prevent pipeline surges.

Richard Franks, Business Unit Director for the Gulf region for Conex Bänninger, said: “Dubai is home to some of the most awe inspiring and prestigious development projects in the world. It also has one of the most challenging environments.

“Working closely with Delta Power and its team of highly skilled project engineers and managers, it’s a challenge we’re delighted to meet as we play our part in delivering infrastructure that operates effectively and efficiently in such tough conditions.”

For more information on Conex Bänninger’s complete range of valves and fittings solutions, visit

]]> (Ian Melin-Jones)ProcessingTue, 21 Nov 2017 07:18:58 +0100
Local business receives coveted F4N status

Devoran Metals, located near Truro in Cornwall, has become the first reinforcing steel company in the UK to achieve Fit for Nuclear status after 2 years of hard work and continuous improvement.

Devoran Metals are the county’s leading suppliers of reinforcing steel and concrete reinforcement products. The Fit for Nuclear programme (F4N) is a unique service to help UK manufacturing companies get ready to bid for work in the civil nuclear supply chain – in new build, operations and decommissioning.

(L-R) Georgina Cooper (General Manager), Carina Martin (Sales), Richard Orsman (Managing Director), Sarah Hickling (Sales)(L-R) Georgina Cooper (General Manager), Carina Martin (Sales), Richard Orsman (Managing Director), Sarah Hickling (Sales)

In order to achieve the status, companies must measure their operations against the rigorous standards required within the nuclear industry. Achieving it means not only has Devoran Metals’ hard work and commitment been recognised, but it opens up a range of new opportunities for the company - as industry leaders are using F4N to identify potential companies for their own supply chains.

Richard Orsman, Managing Director of Devoran Metals, is delighted to have achieved the status, saying:
“Having F4N status means we have benchmarked our performance against the standards demanded by the civil nuclear industry’s top tiers. We are one of only two companies in the whole of Cornwall to receive F4N recognition, which is a fantastic achievement for us as we are committed to driving continuous improvement in all areas.”

Mark Knowlton, Fit For Nuclear industrial advisor, commented:
“It was obvious from the start that the Devoran team were fully committed to the Fit For Nuclear program, during each of my visits there was clear evidence of progress as they completed the necessary improvements identified using the F4N Business Excellence tool.”

Alongside the F4N status, Devoran Metals are the only Certification Authority for Reinforcing Steels (CARES) certified company in the county, and are dedicated to producing high quality concrete reinforcement products with a focus on safety and reliability.

Richard continued:
“Safety and quality are extremely important to us at Devoran Metals, which is why we are so committed to achieving the highest standards and the latest qualifications and certifications. The team’s hard work has seen vast improvements in areas of quality management, lean manufacturing techniques and health and safety. We have introduced 5S workplace organisation onto the factory floor which is proving very beneficial. We hope to continue these improvements as the company progresses into the nuclear supply chain.”

For more information about Devoran Metals, visit their website

Devoran Metals is the leading specialist supplier of CARES approved cut & bent reinforcing bar or rebar and mesh for concrete reinforcement in Cornwall. 

Holding an extensive range of construction accessories, chemicals and formwork products in stock, Devoran Metals is the one stop shop for concrete reinforcement.
A well-established company with over 50 years’ experience of supplying the construction industry, offering customers fully automated production for the fast and efficient processing of orders from initial enquiry right through to on site delivery.

F4N has been developed by the Nuclear AMRC with the support of its top tier partners, including nuclear new build developers and the Nuclear Decommissioning Authority. These industry leaders are using F4N to identify potential companies for their own supply chains.

Devoran Metals are one of the South West’s leading specialist suppliers of steel reinforcement and associated products for concrete reinforcement. The company provide a complete package of products for reinforced concrete. Devoran Metals have comprehensive stocks of all reinforcement steel rebar and steel mesh fabrics and associated products and are able to respond quickly to the needs of customers not just in the South West but across the UK.
]]> (Ian Melin-Jones)ProcessingTue, 31 Oct 2017 18:18:02 +0100