INDUSTRIAL Production Products of the year 2024
1st place, category handling, assembly and production logistics: KASTO Maschinenbau
The KASTOsort tower is a space-saving, highly productive solution for pre-processing including sorting, which automates the sawing and storage process in 24/7 operation. The system was awarded 1st place in the competition for Product of the Year 2024 in the Handling, Assembly and Production Logistics category.
Space miracle: A new approach to smart material flow Automating sawing and storage processes even though the hall is already full? This has hardly been possible for metal processors until now. KASTO has tackled the problem. The solution: a space-saving, fully automated system for pre-processing, including sorting, that works 24/7. Sawing, storage - and much more: KASTO is topping its own motto with the idea of enabling its customers to automate in the smallest of spaces. "This concept is a world first for unmanned processing," explains Sönke Krebber, member of the management team at the sawing and storage specialist from Achern.
The new KASTOsort tower is of interest to metal processing companies that already use a KASTOvariospeed or KASTOtec high-performance saw with or without a KASTOsort robot. For an efficient process, the parts must be sorted as quickly as possible after sawing and handling and placed in appropriate boxes.
Cleverly combined, area increased, space saved
With the integrated KASTOsort tower storage solution, significantly more storage space is available in a smaller area. The space requirement is just over eleven square meters for a KASTOecostore storage system in medium format. To realize the idea, the developers combined reliable technologies from the KASTO range to create a highly productive concept consisting of a chain magazine on the infeed side, a KASTOvariospeed circular saw, a KASTOsort robot and a KASTOecostore storage system. However, it is also possible to connect other KASTO saws.
The tower storage system scores points for its optimum use of space at the top, its storage density, flexibility in picking up materials and short access times. The KASTOsort tower offers the user even more advantages: The saw works regardless of whether the operator has time to pick up the filled boxes and resupply empty ones. The machine can saw much more material without having to pick up a pallet in between. The pallets are retrieved via the drive-through station at the rear of the warehouse.
Fast processes, smooth cooperation
The KASTOsort tower is not only space-saving, but also smart: the ProControl control system ensures fast, error-free workflows and smooth cooperation between the components. Warehouse management is possible via the KASTOlogic mobile app. This allows the user to seamlessly record the goods and track the location of the material at all times.
The advantages at a glance
With the help of the KASTOsort towers, the removal and buffering of sawn parts is fully automated and seamlessly integrated into an automatic production process. The system works in unmanned 24/7 operation and thus supports companies in coping with the shortage of skilled workers. Utilizing the room height by storing many system pallets on top of each other in the storage system results in a significantly larger storage area with minimal use of space. The space saved enables an increase in the production area and therefore in productivity. Storage movements are reduced to a minimum and conserve resources.
For fast and error-free sorting, finished part containers are stored on standardized system pallets in the storage system and the required finished part pallets are provided fully automatically in the robot's sorting area. The good parts can be removed from the storage system on the removal side parallel to production time. The user has digital access to the warehouse management software at all times via the KASTOlogic mobile app with tracking of the material/sawing sections.
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