Machining in record time

GELO Holzwerke’s existing premises in Weißenstadt/DE did not allow any expansion for a machining plant. “For several years, we have been trying to buy the neighboring property – a former foundry”, remembers Wolf-Christian Küspert, managing director of GELO Holzwerke. At the beginning of 2019, there was an opportunity to buy the 30,000 m² property.

At the end of February, the contracts were signed and already on March 1st, GELO’s employees rolled up their sleeves. The old production hall had to be freed of more than 150 tons of waste and needed to be completely revitalized. After only a few months, GELO started up the new machining plant in early October. According to Küspert, a total of 1.3 million € was invested, which includes all construction measures.

A successful collaboration

“The demand for machined elements is increasing and the trade sector is looking to the industry for solutions. If we, as a manufacturer of solid structural timber, offer the machining, our customers, i.e. the trade sector, can get the entire added value from us”, says Küspert with regard to the reasons for the investment. “Now, the trade sector has only one contact person”, adds sales manager Tommy Häneke. “We deliver complete kits for roof and frame constructions.” When it comes to the machining center, GELO trusts in the technology offered by Hundegger of Hawangen/DE. “Hundegger is the global market leader”, is Küspert’s simple explanation. “Their expertise convinced us. In retrospect, we did everything right. We’d like to thank the team in Hawangen who always supported us. It was a successful collaboration”, says GELO’s managing director, who is clearly satisfied and also delighted with the quick start-up. Within just eight days, the machining center was installed. “We were able to produce what has been ordered right from day one – and do order picking as well.”

In Weißenstadt, the company opted for a Robot-Drive 1250. “This system is highly flexible considering the space that is required. Our Robot-Drive also includes the speed package, which makes it even faster”, says Küspert.

During the renovation of the production hall, attention was paid to making sure that there was room for the Robot-Drive. “With the help of Hundegger’s project manager Robert Lejeune we were able to place the entire system along the hall wall so that enough space is left in front of the machine for the handling of the elements”, explains Häneke. The disposal of the waste chips is located outside the hall.

All sizes are possible

Thanks to the Robot-Drive 1250, GELO is extremely flexible: The system machines elements of almost all sizes – from small parts of 20 x 60 mm to large formats of up to 30 cm in thickness, 1.3 m in width and 15.3 m in length. Not only can one machine solid structural timber (KVH), but in the future CLT elements can be processed as well. Another advantage of the Robot-Drive is the six-axis machining unit: All the necessary work can be done in just one cycle and without having to turn the workpieces. A variety of tools are available for this process. During the tour, Matthias Jahreiß, who is responsible for machining at GELO, lists the slot drill, the large circular saw blade and the many drills and milling cutters as examples. In the processing area, the waste chips fall down onto a conveyor belt, which transports them outside where they are collected.

At GELO, the preparatory work is done with the Sema machining program. Then, the data are transferred directly to Hundegger’s Cambium software. This program is characterized by a simple, timber construction-friendly input and high user-friendliness. When things have to be done quickly, the machining data can be entered directly into the Cambium software. At the control panel, where Jahreiß can do the final settings, there is also a label printer: “Every finished element is labeled with the customer’s name and address as well as with the element’s dimensions and number. This makes assembly easier for the craftsmen.”

Currently, GELO operates the machining plant in a one-shift operation. Depending on demand and order situation, Küspert aims for one and a half to two shifts in 2020. The annual machining volume is estimated at 2,500 to 3,000 m³ per shift. For the most part, of course, this concerns the company’s own KVH. GELO also offers glulam which can be machined as well. “With the new Robot-Drive, we are definitely well prepared for the future”, says Küspert.