Metal bar storage

Bar & Sheet Storage

Metal bar storage

KASTO is a world leader in the manufacture of automated storage systems for long stock and sheet. Our storage solutions can be supplied in isolation or linked to sawing machines, or indeed to other machine tools such as lathes and sheet metal profilers. An extensive variety of systems is offered, allowing each solution to be tailored accurately to the customer's needs and budget.

The rationale is to use the height of a building to maximise the amount of material that may be stocked within a given footprint, resulting in efficient material storage and optimal space utilisation. Standardised modules form the basis of the systems, allowing a high degree of customisation at economic prices.

KASTO acts, depending on application and requirement, either as a supplier of components and sub-systems or as a turnkey contractor responsible for an entire process, from analysis through design and installation to service back-up.

STORAGE AND HANDLING OF LONG STOCK

KASTOlift

KASTOlift is a new, compact storage system designed for workshops, trade and small to medium-sized industrial enterprises. The universal storage system can be configured to a maximum height of 4 metres. It is easy to integrate, no matter in which field you use it. Operation is manual via a flexible hanging pedant control, only one operator being needed.

KASTOlift stores bars, plates, tools and boxes, as well as work-in-progress and finished goods. Individual racks or single bars can be moved in four directions. The result is a simplified material handling system with optimal material flow, allowing quick access to the stored material, pallets and cassettes (with a capacity of 3 tons), leading to high production efficiency. Standard crane equipment guarantees easy and safe operation and a fast supply of the goods.

UNIBLOC

Ideally suited to bar stock, sheet metal and other bulky material, the Stacking Cradle System, UNIBLOC, is the sensible solution where automatic bar storage systems are not economically feasible. Often, small storage volumes and small to medium turnover dictate a transport device where easy access, small footprint and uncomplicated operation are most important. For conventional restacking, twin-hoist, possibly sway-free cranes are needed. Material lengths best suited to the system are between 3 and 24 m.

With UNIBLOC E, KASTO offers a manual single-lift spreader beam with safety chains for the KASTO transport cradle UNIVERSAL. The manual, multiple-lift spreader beam UNIBLOC U allows multiple restacking of up to three layers simultaneously and can be easily automated. Up to three layers of stacking cradles, with a usable height of 40 mm each, can be transported together via the mechanical gripper function. Only the crane's up/down movement is required to lock/unlock the spreader beam with the cradles.

With the KASTO Magnet Spreader Beam UNIBLOC F, an electro magnet, integrated into the spreader beam allows direct access to individual bars without changing the spreader beam. This UNIBLOC variety also has a device for multiple restacking. Retractable grippers are offered for material removal from the side with cradles next to each other.

The Stacking Cradle System UNIBLOC A, together with a floor mounted KASTO Gantry Crane or an automatic sway-free crane, further speeds the replenishment process. Up to three cradles stacked on top of each other can be transported simultaneously. The KASTO Inventory Control Computer manages material and location and controls storage, restacking and retrieval orders.

UNITOWER

Applications for a UNITOWER Storage System include buffer storage in steel and other service centres, as well as storing small quantities of raw material and parts in job shops and all types of manufacturing operation. The compact cassette storage system optimises material flow - and not only for bar stock.

Pretensioned, virtually maintenance-free precision roller chains are used. They are not only more reliable than steel cables, but also help lower maintenance costs. The UNITOWER uses power more effectively because, unlike paternoster systems, only the required cassette is moved and not the entire storage volume. The design also saves space and rental. If the steel structure is cladded with sheet metal or concrete, it may be installed externally.

Featuring easy operation and fast cassette deliveries for loads up to 1.5 t per cassette, the standard UNITOWER E 1.5 offers storage control with location preselection. It can be extended to control inventory with up to 12 different materials per cassette. Up to 59 cassettes can be stored in a double tower.

For loads up to 3 t per cassette and a total capacity up to 300 t: by installing several in/output stations, simultaneous and independent working is possible with a double tower UNITOWER F 3.0. The PLC control allows inventory management by length, weight or by number of pieces with material identification numbers. Connection to the KASTO Inventory Control Computer is available.

UNIPORTAL

The UNIPORTAL is of gantry-type, cassette design, allowing fast access to stored material. Due to its modular design, the system can be easily extended at a later date. Only additional shelf blocks are needed plus extension of the crane rails, permitting the gantry crane to be used as is.

UNIPORTAL an ideal solution for individual material flow in small to medium-sized businesses; or as a fast and economical buffer system near a manufacturing area, for example to supply lathes or an automatic saw.

UNITOP

A unique feature of the UNITOP automatic bar storage system is that the operating crane travels on top of the shelf block. The enclosed, compact design of the system ensures fast access to cassettes. Computer controlled, the UNITOP allows a perfect overview of the inventory at any time and is able to deliver the requested bar stock every 120 seconds - depending on system height - to the unloading station. Individually tailored input/output stations ensure easy adaptation to a company's material flow requirements. With (optional) integration of an automatic bar separator and connection to a KASTO CNC saw, a flexible, profitable manufacturing system is created.

UNITOP is a highly efficient and extremely reliable, fully automated system requiring a minimum of personnel. The virtually wear-free hoists are equipped with precision roller chains to guarantee an absolute minimum of service.

A roof and walls can be mounted onto the steel rack construction, giving additional storage space without costly new construction. The height of the UNITOP does not depend on the height of the connecting building - and therefore can tower above it. Storage and removal can take place directly at the interface to an existing production building.

UNIGRIP

For system heights from 4 to 15 m with loads of up to 3 t, the UNIGRIP system is the perfect choice, as it offers everything that an efficient storage system needs - and with low investment costs. The compact dimensions of the operating gantry crane allow for good space utilisation and short cycle times. The cassettes can be modified to individual requirements by adding dividers, lining of the material supports or floor plates.

The semi-automatic version UNIGRIP U works according to the principle "Operator to Material" - ideal for commissioning tasks of small to medium storage volumes with slow to medium cycle requirement.

The fully automatic version UNIGRIP A brings "Material to Operator". The loading traverse can be equipped with one or two cassette storage locations. The KASTO random cassette access principle ensures optimised travel, short distances and a minimum of non-productive movements.

UNICOMPACT

The Honeycomb Storage System, UNICOMPACT, features excellent space utilisation for new as well as for existing buildings, especially stockholding and service centres. The compact dimensions of the gantry crane ensure that as much space as possible is used for material storage. Utilising the principle "Material to Operator", the UNICOMPACT bar storage system delivers the requested material rapidly to the outfeed stations. An extensive variety of different station designs increases efficiency of cutting and commissioning of bar, tube, profile and other long stock, be it of steel, aluminium, plastic or non-ferrous materials.

The KASTO random-access cassette principle lowers the number of travel movements and, together with fast drives, allows cycle times of approx. 75 seconds: and this in a system with 2.000 cassettes! The most important components of the random-access principle are two simultaneously working, cassette-pulling devices on the mechanical side, and on the control side, a well-thought-out program to minimise travel distances and optimise cycle times.

KASTOcenter

In a KASTO Sawing Centre, computer-controlled operating cranes (moving on top of the shelf block or in gantry design) feed a single bar, fully automatically, to an integrated CNC saw and automatically return the remnants. A storage computer keeps inventory up-to-date. KASTO offers this flexible manufacturing system for the sawing department, complete with storage system, saw, control and service as a single-source supplier. Result: highest reliability and minimum idle times. Such a sawing centre can service up to 7 individual saws!

These systems combine the advantages of cantilever and cassette storage for a universal solution and can be used for a large variety of applications. Individual bars are picked and returned rapidly and fully automatically from the cantilever store. The search from the cassette supply is done automatically. Main advantages are high storage density and high material turnover.