Automated sawing and processing line increases efficiency and quality
Innovation
DURALU, based in Wevelgem, recently invested in a state-of-the-art production line at Soenen Hendrik. This strategic move underlines the company's commitment to remain at the forefront of the aluminium processing industry using high-tech solutions.
Efficiency and return
The evolution in the construction sector presented Duralu with a challenge: how to increase production capacity and efficiency without sacrificing the quality and flexibility the company is known for. The solution came in the form of a fully automatic sawing and machining centre from Soenen Hendrik, a machine builder known for its high-tech and innovative solutions.
"For us, it was crucial to find a system that could not only increase our production capacity, but would also allow us to machine a wider range of profiles," Duralu's business managers explains. "With Soenen Hendrik's DEM/ALU, we found exactly that."
The fastest in the market
The installed production line performs all operations in one pass: milling, drilling, tapping, transfer milling (also with angles), glass on glass, sharp corners, labelling, .... are done fully automatically. Thanks to, among other things, the 2 independent tool holders, each on 3 CNC axes, the system can perform synchronous operations, which significantly reduces throughput time. Comparative tests have proven that Soenen is up to 45% faster than other solutions.
The sawn and complete finished profiles arrive ready-to-use on the output tables and without an operator. Ready for further processing directly on the Soenen CNC 4-head press.
Unmanned production - lower costs
The large input and output table, combined with roll detection and automatic labelling, enables unmanned operation. "Operators can now be deployed elsewhere in the production process, which significantly increases our overall efficiency," said the Duralu business manager All knowledge remains in the company but it is applied in an even much more performant way than before. The same number of operators but more production, larger orders, larger yards are now possible without any problem and all at very competitive prices.
The system is also equipped with advanced monitoring tools that prevent errors. Automatic toolbreak detection ensures that machining of a defective tool is automatically taken over by other available tools, minimising production interruptions.
Soenen makes a difference
Soenen distinguishes itself in the market by constantly innovating, listening to customers' needs and developing further. "What makes Soenen Hendrik unique is their ability to think beyond standard solutions," say managing directors Kjell and his wife Delphine.'' We thoroughly examined, weighed up and compared the different solutions on the market. If you pay attention to all the technical details, the completeness of the SOENEN system, approach and possibilities, you immediately see the numerous advantages. Soenen stands out as a highly professional machine builder with a clear vision of the future and in-depth technical expertise - this at both the machine construction and software level. In addition, the positive feedback from many colleagues in the sector was a decisive argument that further strengthened our choice for Soenen.
While this step was big for us, it was necessary. The guidance of the Soenen team ensured that the process went smoothly and our expectations were far exceeded.''
Direct line to the machine designer - without unnecessary links
Our exclusive cooperation with Soenen is without intermediaries, which ensures direct and efficient communication. This means that wishes and requirements are discussed directly with the machine developer and builder. The result? Faster decisions, tailor-made solutions and smooth implementation. No unnecessary delays, but seamless alignment with needs - that is the power of direct cooperation.
''We develop and produce everything in-house across our 3 production sites, R&D to very thorough testing of the machine with the customer at the Soenen site," Pepijn Carlier stresses. "We also create the accompanying software modules with a team of our own software engineers and are therefore fully tailored to the customer's specific needs. Our engineers are constantly working on new solutions that push the boundaries of what is technically possible."
Revolutionary innovations
During the talks with Soenen Hendrik, Duralu was also informed about the many pioneering innovations Soenen is currently working on, this on different types of machines and solutions. ''At Soenen, years of experience and constant innovation come together. The dynamics and constant developments within the company make it particularly valuable for customers to work with a partner that not only offers a solid base of expertise and reliability, but also continues to invest in cutting-edge technologies. This ensures that machines not only perform optimally today, but are also ready for the challenges of the future. Being part of that as a customer offers the security of always being one step ahead and prepared for future market developments.
Digital twins and industry 4.0
One of the innovations of the Soenen Hendrik solution is the current development and implementation of 'digital twin' technology. This Industrie 4.0 approach will provide unprecedented insights into their production processes in the future, increasing yield and efficiency and reducing costs.
Direct support with mixed reality
A decisive argument for Duralu to choose Soenen Hendrik was its proximity and high-tech support. "We can always contact the manufacturer directly with questions.
"Cameras and Mixed Reality allow us to watch along with the customer inside the machine and to do so within a minimum of time," adds Pepijn Carlier. "Our MR technology enables our technicians to be virtually present with the customer, see exactly what is happening and provide direct support as if they were physically on site." This direct line to the manufacturer provides Duralu with the assurance that if assistance needs to be offered it will be given very quickly and efficiently.
‘Citius, Altius, Fortius’
Faster, higher and stronger is Duralu's motto. That is why this was not the last investment. Duralu has now also bought from Soenen Hendrik a horizontal 4-head press, fully equipped with feed table, over 38 Fanuc-controlled axes and a tipping table. Duralu will be able to prepare, press and output on 1 machine. So no waiting times, easier work for the operators and together with the Dem Alu all in 1 flow. Kjell reported: Soenen and Duralu have together set up a very nice project, ready for today, ready for the future and all with 1 partner, the one-stop shop. More on the installation of these high-tech alupers in a subsequent article.
