Space-saving storage systems and high-performance saws are essential for metal-working companies to store and cut sheet metal and bar stock. When seamless, operator-free processes are required, robots take over handling and prefabrication tasks.
Intralogistics today demands speed, flexibility, and digitalisation to stay competitive. KASTO, based in Achern, is a leader in storage, sawing, and handling technology, covering all process steps before and after cutting. Many companies use KASTOtec bandsaws or KASTOvariospeed circular saws, as cutting is now a critical, integrated step in production chains.
Automated palletising and order picking
Modern needs go beyond the saw itself — small batches, integrated downstream processes, and controlled personnel costs are key. KASTO supports fully automated discharging, reworking, and palletising via its KASTOsort robotic handling system. This ABB-based system automates loading, unloading, deburring, chamfering, weighing, measuring, marking, labelling, and chip removal. It requires no programming, communicates with ERP and connected machines, and can handle anything from coin-sized parts to heavy bars.
Individual concepts
KASTOsort calculates optimal stacking patterns for high packing density and adjusts stacks automatically. Custom-designed grippers — vacuum, mechanical, or magnetic — match each application, with KASTO providing the software, electrical design, and selection of stations, pallet receivers, and chip removal systems. The benefits include higher efficiency, better machine utilisation, extended tool life, and flexible adaptation to machining changes. In three-shift operation, payback can be under nine months compared to manual handling.
Successful in operation
Over 100 users already operate KASTOsort. One site automated two saws using a robot on a linear axis with magnetic grippers lifting up to 350 kg. Eighteen pallet and container storage locations along the axis allow precise placement, with forklifts transporting cut parts onward. Another site integrated a robot with a saw to remove, deburr, and sort parts into various containers supplied automatically via roller conveyors. A carousel with eight pallet spaces enables continuous operation, while shipping labels are printed and applied automatically.
Everything from a single source
Both users report higher efficiency and improved working conditions, with employees welcoming robotic support. The integrated KASTOsort tower solution also increases storage capacity in a smaller footprint, enabling 24/7, operator-free operation. KASTO’s modular products can be combined into complete systems, covering the entire process from raw bar to cut piece, ready for collection.