KatsoPick bar for handling long stock
Materials Handling World delves into the background behind German sawing machine and storage system manufacturer Kasto, who recently launched an innovative system, KatsoPick bar for handling long stock.
Since its founding in 1844, Kasto has been a pioneer in materials handling and cutting technology.
The company’s journey began in 1884 when Karl Stolzer, a skilled carpenter, established a mechanical workshop in Achern, Germany.
Stolzer's vision and technical expertise laid the groundwork for what would become a leading global player in the machine tool industry.
Industrial heritage
In its early years, Kasto focused on manufacturing machines with wooden frames and iron-plated parts.
This approach allowed the company to produce a range of essential industrial machinery, including water wheels, weaving looms, paper machines, and milling machines.
These products were critical to various industries, helping to power the industrial revolution. The subsequent construction of sawmills and sawmill plants further cemented Kasto’s reputation as a reliable and innovative company, setting the stage for its long-term success.
A significant breakthrough for Kasto came in 1947 with the invention of the hacksaw machine. This development revolutionised the cutting industry by introducing a new level of precision and efficiency.
The hacksaw machine marked Kasto's transition from a traditional workshop to a modern machine tool manufacturer.
This innovation demonstrated Kasto’s ability to stay ahead of market demands and set new standards in the industry.
In the 1960s, Kasto expanded its product line to include circular saws, building on its established expertise in cutting technology.
Circular saws offered different cutting capabilities compared to hacksaws, allowing Kasto to meet a broader range of customer needs across various industries.
This diversification not only reinforced Kasto’s position as a leader in cutting technology but also opened new avenues for growth and innovation.
Diversification into automated storage
The 1970s saw Kasto diversify further by introducing the first fully automated bar stock storage system.
This system featured a portal operating gantry crane designed for handling and transporting self-supporting cassettes.
The automation of bar stock storage addressed a critical need in the manufacturing sector for more efficient materials handling solutions.
By automating the storage and retrieval process, Kasto’s system enhanced operational efficiency and reduced the physical strain on workers, improving workplace safety and productivity.
Kasto has consistently pushed the boundaries of innovation in materials handling, driven by a commitment to research and development.
This dedication is encapsulated by Sönke Krebber, Kasto’s research and engineering manager, who notes, “Strong products are the result of innovation, strategy, clear processes as well as a customer-oriented and reliable team.”
This philosophy has guided Kasto’s development of cutting-edge solutions for over a century, ensuring the company remains at the forefront of the industry.
Long stock handling innovation- extension to KASTOpick handling solutions range
Today, Kasto’s extensive product portfolio includes fifty-two types of saws and eleven state-of-the-art storage systems, with a twelfth recently launched: the KASTOpick bar.
The compact system joins existing KASTOpick handling solutions. This innovative system addresses one of the most challenging aspects of materials handling—the automatic handling of long stock that has been randomly placed inside a cassette.
Traditionally, the unpredictable positioning of items within a storage cassette made automation difficult, but the KASTOpick bar is designed to overcome this challenge.
The KASTOpick bar system incorporates advanced robotics capable of autonomously picking magnetic bright drawn or black steel material of various cross-sections, including flat, square, and round shapes.
These robots can handle both bar and tube materials in any orientation, offering unparalleled flexibility and precision.
A key feature of the KASTOpick bar is its user-friendly design; the robots are operational out of the box, requiring no extensive programming or user intervention.
The process begins with an optical sensor scanning the storage cassette, which can be up to six meters long.
The system’s algorithm then processes the 3D point cloud generated by the scan, accurately determining the position and orientation of each item.
Once the scan is complete, the KASTOpick system selects the appropriate gripper for each material, ensuring safe and efficient transport across the warehouse.
The use of magnetic grippers tailored to the specific shape and size of the materials allows for the handling of high-mix, low-volume requirements just as effectively as large-volume operations.
This advanced system not only enhances the efficiency of materials handling but also significantly reduces the risk of injury to the workforce by automating the handling of heavy, cumbersome, and potentially hazardous materials.
By automating these tasks, companies can reduce the physical demands on their employees, lowering the risk of workplace injuries and improving overall productivity.
The efficiency gains offered by the KASTOpick system also allow companies to optimise labour utilisation, reduce operating costs, and accelerate processing and delivery times.
Kasto’s impact on the industry is reflected in numerous customer testimonials. In Europe, Debrunner Acifer in Switzerland has benefited from Kasto’s materials handling expertise.
The Birsfelden site, originally built in 1953, had grown to include two high-bay storage facilities. However, maintaining these two facilities, each with 1,100 cassettes operating across two shifts, became increasingly cost-intensive. As a result, Debrunner sought to revitalise its materials handling process with a more efficient system.
After evaluating multiple vendors, Debrunner chose Kasto due to its cost-effective solution, seamless integration with central processing, and efficient material flow that includes fast truck loading.
“The ability to expand the storage facility with minimal effort was crucial for us,” says Roger Durand, site manager.
Kasto also integrated the storage control system with Debrunner’s existing ERP, a significant advantage in the company’s ongoing digital transformation.
“It’s vital that our processes work harmoniously both in hardware and software,” Durand emphasizes. The unified control system ensures smooth operations, transparency, and ease of use, with a single point of contact for all storage technology needs—another key factor in Debrunner’s decision to partner with Kasto.
Since June 2018, the new high-bay storage facility has replaced the two older systems at Debrunner, helping the company achieve its optimization goals.
“With the UNICOMPACT system, we’re ready for future challenges in efficiently storing long goods,” Durand explains.
“Our downtimes are minimal, ensuring reliable, smooth operations, and the fast, well-coordinated processes allow us to respond quickly to customer demands, even with smaller batches and more orders.”
Kasto’s journey from a small mechanical workshop to a global leader in cutting and materials handling technology is a testament to its commitment to innovation, quality, and customer satisfaction.
The company’s ability to anticipate industry trends and develop cutting-edge solutions has ensured its continued success in a competitive global market.
As Kasto continues to expand its product offerings and explore new technologies, it remains well-positioned to shape the future of the machine tool and materials handling industries for years to come.
Closer to home, Kasto recently moved into more centrally located premise in Kibworth Harcourt, Leicester.
They have thirteen employees ready and wating to revolutionise your experience of materials handling.