A Cut Above: Take a Peek Inside an Excellent Tube Sawing and Storing Operation

Rohr-Mertl has used KASTO sawing and storage solutions for roughly 55 years. The specialist for steel tubes values the high-quality products they've purchased from the German saw manufacturer. Even the first saw, constructed in 1970, still operates just as it did on its first day.

Tubes as far as the eye can see -- Rohr-Mertl cuts, picks and stores 8,000 tons of steel tubes in more than 5,000 dimensions and qualities.

Karl Mertl Handelsges.m.b.H. has always specialized in steel tubes in various forms. Since its establishment in 1949, the company has consistently increased its product range, services and staff, which currently totals 90 employees.

Rohr-Mertl is located near Vienna, Austria and supplies various customers throughout Europe, including industrial corporations as well as workshops. The distributor acquired a 90,000 square meter former brewery site from the City of Vienna in 1968. "One of our warehouses is located in the historic vaulted cellar," explained Marie Gruscher-Mertl, CEO. The family-owned company is currently managed by the fourth generation, with both daughters active in management.

For cutting the steel and stainless-steel tubes, Rohr-Mertl currently operates ten bandsaw machines and two KASTO hacksaws, the oldest of which dates back to 1970. "We've been using the EBS 400 U hacksaw for well over 50 years, and it is still performing superbly," says a satisfied Marie Gruscher.

Continuous Growth

Since 1970, Rohr-Mertl has continuously expanded its machinery pool with new KASTO sawing machines.

For instance, the company purchased two heavy-duty, fully hydraulic, high-performance bandsaw machines, model KASTOhba AU, in 1994. The parallel horizontally moving sawband is ideal for cutting profiles, tubes and solid material in any quality. Even difficult- to-cut materials such as Hastelloy can still be cut reliably and quickly to this day. "The system has been running like clockwork for 30 years," Christan Wunderlich emphasizes.

Because the old SNLS 3000 S overhead storage system with 1,012 cassettes was bursting at the seams, Rohr-Mertl built a new hall in 2012.

The new UNICOMPACT 2.0 honeycomb storage system, equipped with 2,633 honeycombs and fully automatic bandsaws, has since provided increased capacity and efficient processes. "It was not a difficult decision to opt for KASTO," recalls Marie Gruscher-Mertl. "We were already familiar with the quality of the products and the great service. KASTO's recommended solution was also the best fit for our requirements. We were also able to seamlessly connect it to our packaging machine."

Safe Processes

The name UNICOMPACT for these storage systems is well-suited: since the overhead gantry crane (OGC) has a small footprint. Rohr-Mertl can then utilize a large amount of space for storage purposes. "The new hall was a significant milestone for us," says Marie Gruscher-Mertl. "Not only have we significantly increased our storage space, but also our level of safety." The goods now come to the person and no longer the other way round. "Reduced manual handling and movement in the warehouse leads to a lower risk of accidents. That is very important to us," adds the CEO.

Rohr-Mertl utilizes a variety of KASTO bandsaws at the UNICOMPACT stations to process mostly seven-meter standard length bar stock: KASTOtwin LE 4, KASTOssb A 2, and KASTOtec A 4.

KASTOtec demonstrates impressive performance, particularly for large series production and extremely hard materials. Innovative technologies such as the intelligent control system achieve maximum throughput. For example, this includes the automatic assignment and permanent storage of the cutting technology. This can be adjusted to the respective material qualities and the bi-metal or carbide sawband used.

KASTOtwin is an all-rounder. The machine can be used flexibly with various sawband models and is suitable for a wide range of applications, thanks to its tried-and-tested technology.

The KASTOssb cuts bars precisely and quickly -- particularly in series production. Thanks to the vertically moving sawband, the machine is extremely compact and delivers high performance within a small space. Special feature: The KASTOssb A 2 has a sturdy feed roller conveyor with fixed yet adjustable sides. This makes the saw an excellent choice for bundle and large-scale cutting jobs.

The UNICOMPACT has enabled Rohr-Mertl to automate the storage and picking of goods since 2012. In conjunction with the sawing machines, the system processes orders without human intervention. The orders are prepared for shipping by a packaging machine at the end of the line.

"We use a proprietary ERP system that is tailored specifically to our needs," explains Christian Wunderlich. In collaboration with KASTO, Rohr-Mertl's IT department connected the high-rack storage system to the ERP system. "This allows us to maximize the use of the automated system," adds Gruscher-Mertl.

Trustful Collaboration

When new investments are in the pipeline, Rohr-Mertl gladly accepts KASTO's offer to inspect systems at reference customers and speak with users directly on site about their respective experiences.

"Three of our employees are experts on our high-rack storage system and our saws. Over the years, they have gathered a lot of experience," says Marie Gruscher-Mertl. This is hugely helpful when issues arise. "They can speak to the KASTO service technicians at eye level," explains Christian Wunderlich. Which means that each problem can be solved quickly.

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