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  • Offer Profile
  • Metzner Maschinenbau GmbH is an internationally active, medium- sized enterprise and a leading manufacturer of cutting and converting machinery for cable, rubber and plastics processing and solutions in automation for the carbide industry and for the diagnostic and life sciences sector.

    Metzner also offers a complete product range in the area of cable processing for cutting round and ribbon cables. From the standard series to the customized production line – machines from Metzner will convince you with their outstanding cutting force, wide range of cutting methods, such as the rotary cut, and the robust, durable construction. With convincing, patented solutions, Metzner is also a leading manufacturer in the area of corrugated pipe processing.  
Product Portfolio
  • Machines for Cable and Corrugated Tube Processing

  • For over thirty years we develop and manufacture machines and assembly lines for the processing of cables, wires, wires and conduits. We are focused on accurate, patented cutting processes, high cutting and stripping force and robust and durable construction. In addition to standard machines, we also offer customized solutions that go far beyond the standard. All machines are in use worldwide.
      • Cut & Strip

      • Metzner cable processing machines for cutting, stripping and pull-off of multi-layer cables, coaxial cables and shielded cables with multi-conductors are powerful, efficient and precise. The various series perform precise cutting and stripping of a broad spectrum of standard cables and special cables.
          • Metzner AM 2000

          • The »Metzner AM 2000« automatic cut-to-length and stripping machine processes cable up to 6mm² and wire up to 1.5mm² with high precision and repeatability. For all industry sectors, in which secure processing, flexibility and rapid production in cable converting is demanded, the »Metzner AM 2000« offers a standard of equipment which is unique in its price class.

            Processing of cable and wire is done with speed and precision. The operator carries out all the cut-to-length and stripping operations via the machine control system with just a few settings. Numerous pre-set functions make for easy set-up and provide many processing possibilities. Further special features are the standard automatic end-of-material stop and a standard RS-232 interface, with which the »Metzner AM 2000« is equipped for PC-supported working as well as printing.

            Before the cut-to-length stripping process, a standard high-spec wire straightener arranges all the braids and wires, which often come from tightly wound spools, to ensure that they are guided into the machine in an orderly fashion. Also, after processing, the cut-and-strip machine standard specification offers the convenience of a moveable storage tray to provide orderly storage of the finished wires.
          • Metzner AM 3000 Series without Rotary Cutting Module

          • The cable processing machines of the »Metzner AM 3000 series« are distinguished by their outstanding cutting and pull-off power and robust, long-life design for continuous industrial use.

            Developed and equipped with a performance potential to deal with complete processing of cables and wires up to 70mm², these machines offer comprehensive processing possibilities: from standard stripping processes up to multi-stage stripping, even of very short shielded coaxial cables. Metzner offers seven base models for this, all with different cutting powers and equipment levels. In addition, their blade technologies vary with different blade contours to suit the requirements of different applications. The patented »Double-blade cutting system«, for example, with two knives operating together in one process step to perform different cutting processes and the additional rotary cut, providing precise circumferential cutting for wires with very thin or tough insulation and for coaxial cables.

            All models in the »Metzner AM 3000 series« are prepared – as standard – for a full set of interfaces for peripheral equipment and to facilitate IT
            integration. In this way, these cut and strip machines are converted easily and without the need for further design work into complete production lines to further increase production automation.
          • Metzner AM 3000 Series with Rotary Cutting Module

          • The cable processing machines of the »Metzner AM 3000 series« are distinguished by their outstanding cutting and pull-off power and robust, long-life design for continuous industrial use.

            Developed and equipped with a performance potential to deal with complete processing of cables and wires up to 70mm², these machines offer comprehensive processing possibilities: from standard stripping processes up to multi-stage stripping, even of very short shielded coaxial cables. Metzner offers seven base models for this, all with different cutting powers and equipment levels. In addition, their blade technologies vary with different blade contours to suit the requirements of different applications. The patented »Double-blade cutting system«, for example, with two knives operating together in one process step to perform different cutting processes and the additional rotary cut, providing precise circumferential cutting for wires with very thin or tough insulation and for coaxial cables.

            All models in the »Metzner AM 3000 series« are prepared – as standard – for a full set of interfaces for peripheral equipment and to facilitate IT
            integration. In this way, these cut and strip machines are converted easily and without the need for further design work into complete production lines to further increase production automation.
          • Metzner AM 5000 Series

          • For production where large diameter cables are processed reliably and with precision, the Metzner AM 5000 series is available, giving a solution with the highest level of cutting and pull-off power, ease of operation and long service life.

            The Metzner AM 5000 series was specially developed for cables up to 30mm diameter and sections up to 240mm². The particularly high-torque and powerful 3-phase stepper motors are guaranteed to give the necessary power for the pull-off and cutting operations. Their precise finger-tip way of working also makes the Metzner AM 5000 series suitable for processing thinner cables from 1,5mm².

            All models are equipped with an electronically controlled »Vario-Press«. This innovative system ensures that the belt closing pressure of the feeders is matched with the necessary applied pulling force in fractions of a second. This ensures optimum gripping pressure of the cables both for stripping and forward feeding of the cables.

            To ensure unbroken, automatic production, the material feed is monitored by several sensors. If a material blockage occurs, the production is stopped automatically and the operator is informed about the cause of the stoppage.
        • Cable Shield Processing

        • Machines for cable shield processing are patented solution for quick and extremely precise processing of cable shields and cable braids. All machines use an unique process to provide complete cable shield processing.
              • Metzner CS-Series

              • The semi-automatic cable shield processing machines »Metzner CS-10« and »Metzner CS-20« are patented solutions for quick and extremely precise processing of cable shields and cable braids.

                Developed for cable shield processing in hybrid and electric vehicles, this machine uses a unique process to provide complete cable shield processing: Opening the cable shield, cutting, folding down and stripping the outer sheath or inner conductor.

                With the »CS-10« and »CS-20« Metzner offers two processing concepts that define itself by the outer diameter of the cable. For all cables up to 20 mm in diameter the shielding braid is opened by a patented procedure before it is cut and everted. Cables with an inner conductor can then be stripped easily. This process is reversed for smaller cables up to 8 mm in diameter: Stripping of the outer sheath first, then opening, everting and cutting of the cable shield. Additionally, a precise cut-to-length is possible for cables up to 8 mm in diameter.

                All processes are designed to eliminate damaging the sheath, the inner insulation or the shielding braid. The user-friendly control panel can be used to programme many parameters including pull-off length and insertion path.
          • Cutting to Length

          • When length precision and cutting quality are important for cutting in the cable assembly, Metzner automatic cutting machines are the right equipment for the job.They allow round and flat materials to be perfectly cut. Whether it's cables, cords, wires, flat cables, tubes, profiles, paper or labels – Metzner cutting machines can handle these requirements.
              • Metzner Variocut Series

              • The Metzner Variocut universal cutting machines are designed for automatic cut-to-length and cutting of a wide spectrum of materials. Wires, cords, flat and round cables can be cut as precisely as soft and hard tubes, foils, labels, and many other materials.

                To ensure the best cutting quality and, at the same time, meet a wide range of material-related requirements, you can choose among three different cutting types: die cut, shear cut and tube cut. All Variocut machines offer tool changing times of less than three minutes and is thus the optimal solution for varying and multi-faceted applications. And also with just a single cutting tool, the Variocut embodies the convincing product concept: pneumatic raising and lowering of the upper belt with adjustable closing pressure and cutting width of 100mm.

                Whichever Variocut version you choose, PLC controls and stepper motors for exact positioning and variable speeds are always standard equipment.
              • Metzner ST-OB Series

              • The universal cutting machines of the Metzner ST-OB Series are distinguish by their precision, their compact design and the wide spectrum of applications, such as profiles, textile-covered tubes, film, textiles, labels, cables, wires and many other materials.

                For cut quality that is always optimal with different materials, the ST-OB machines offer you the choice of three alternative cutting tools (die cut, shear cut or tube cut) and two versions with different equipment possibilities.

                The Metzner ST-OB Red is similarly convincing due to its attractive price and modern specification. An electronic PLC control system offers the possibility to specify and save all processing parameters such as feed-in conveyor speed, cut length and cutting time. A modern stepper motor ensures highly exact positioning and stepless adjustable feed conveyor speeds. The result is a modern machine with superior application characteristics compared to machines with DC-drive and clutch.

                The big »plus« of the Metzner ST-OB Green is the additional cutting and drive power as well as its interface connectivity. A special high-performance pneumatic cylinder with adjustable cutting depth offers up to 30 percent more cutting capacity when cutting short lengths. A stepper motor with higher material transport speeds and increased torque guarantees superior pulling power when feeding the material to be cut and increased cutting capacity of longer lengths. With its comprehensive interface equipment, ST-OB Green is ideally prepared to work with peripheral equipment such as feeding units, speed controllers, material throw-offs and other devices to make up a complete production line.
            • Solutions for Panel Building

            • With the Triathlon system Metzner offers a unique and complete system solution for the reduction of your costs in the control cabinet manufacturing. According to your requests, different solutions are available, that differ in the construction, achievement and automation degree.
                • Metzner Triathlon System

                • Automation in control cabinet manufacture is not only a worthwhile proposition for long production runs. Particularly for single component and small series production, considerable economies and improvements in efficiency can be achieved by the adoption of automatic converting processes.

                  With the Triathlon System, Metzner offers a unique and complete system solution for reducing your costs in the manufacture of control cabinets. Dependent on the actual requirements, different solutions are available to you, solutions which differ in their construction, performance and their degree of automation. Either with the budget-level »Triathlon 2000«, or the flexible and fast »Triathlon 3000«, we can offer you the right solution to match your needs.

                  All Triathlon model cut cables to the correct length, strip the wires at the precise positions and crimp the cable end terminals. At the same time, they add freely-programmable text and logos and take away the processed material according to pre-arranged sorting programs. Not only in the cutting and preparation of the cables but also in the subsequent wiring of the control cabinets, you save valuable time and costs: Because all the cables are printed and pre-sorted into their component groups, the cabinet wiring can be carried out considerably faster than previously. In addition, the number of wiring faults is reduced to virtually zero.
                • Metzner Triathlon Soft

                • Triathlon Soft® starts with the control cabinet layout and automatically calculates the lengths for all the wires, cable trays and cable ducts. At the same time, Triathlon Soft® produces all the data for the printing of the cables and the machining of the assembly baseplates.

                  Via an interface to its CAE system, the software collects all the necessary data in the form of wiring lists, sub-assembly lists or terminal lists and processes them on this basis into a production-orientated layout for the control cabinet.

                  Triathlon Soft® is compatible with all commonly-used drilling centres and automatically creates all the data for the mechanical processing of the assembly baseplates. All the NC-data for automatic machining are produced by working from the construction plan and an optimised interface transfers the data to a drilling and milling machine.

                  The use of Triathlon Soft® in combination with the Triathlon cable centre results in time and cost savings. For single work steps, such as cable assembly, labelling or mechanical machining, time savings of up to 70% can be reached. By labelling all cables, the circuit diagram is usually not needed for wiring, and time savings of up to 50% can be reached. The use of exactly pre-assembled conductors with labels drastically reduces the number of wiring errors.
                • Metzner Triathlon Cutting Center

                • The Metzner Triathlon Cutting Centre offers you the option of cutting cable channels and DIN rails precisely with time savings. Thanks to our many years of experience and development in automation for control cabinet building, all requirements for the cutting centre were implemented practically and user-friendly.

                  The separate cutting devices for cable channels and DIN rails are conveniently put into position via a rotary disc. A program-controlled length stop then moves to the desired length so that the material only has to be inserted and cut. The Metzner cutting centre allows data to either be imported automatically with Triathlon-Soft® or manually via the control.

                  In connection with the software Triathlon-Soft®, the lengths of all cable channels and DIN rails are calculated automatically, the waste-optimised values are transferred to the Metzner cutting centre and are displayed there graphically. Besides the exact length, the corresponding data for the material type, height and width also appears on the display. The program-controlled length stop moves exactly to the calculated position, thus allowing quick and exact cutting to the desired length.

                  Several sensors installed on the cutting devices detect the completion of a cutting operation and automatically switch to the next data block. All cut articles are referenced via a part number in a Triathlon-Soft® layout and in a Triathlon-Soft® parts list, so that even after cutting, clear allocation is guaranteed.
              • Corrugated Tube Cutting

              • Standard, split or corrugated tubes with muffles and flexible conduits are used for protecting cables and wiring harnesses. Cutting these protective coverings to length depends on cutting accurately on the crest of the ridge. Otherwise sharp cut edges are formed which results in damage to the drawn in cables.
                  • Metzner CT 4000 Series

                  • Corrugated tubes are used for protecting cables and wiring harnesses. Cutting these protective coverings to length depends on cutting accurately on the crest of the ridge. Otherwise sharp cut edges are formed which results in damage to the cables.

                    Metzner corrugated tube cutting machines of the CT 4000 series offer absolute precision with the cut on the crest of the corrugation. All types of unslit corrugated tube are cut reliably and precisely. The machines offer processing for corrugated tubes from 4.5mm up to 35mm outer diameter. This wide spectrum is unique and makes these models a future-proof investment.

                    High-performance sensors guarantee reliable reading of the tube profile and place the cut precisely on the top or in the valley – providing just the processing result you expect.
                  • Metzner SM 4000

                  • Corrugated tubes are used for protecting cables and wiring harnesses. Cutting these protective coverings to length depends on cutting accurately on the crest of the ridge. Otherwise sharp cut edges are formed which results in damage to the cables.

                    The Metzner SM 4000 has revolutionised the process of cutting split corrugated tubes. As the only machine in the world the SM 4000 guarantees with its unique and patented cutting technology an unattainable cutting result and very high cutting rates.

                    The patented Metzner SM 4000 with »Laser toothed wheel« system is the only solution available in the market to process pre-slit corrugated tube. The material specific feed wheels guarantee a form-fit and twist proof feed of the pre-slit material. The laser sensor controls the position of the feed wheels and releases the blade precisely on the crest of the ridge - with precise repeatability and up to 8000 cuts per hour.

                    All machine parameters are fully programmable and all models are prepared for both front panel or PC control.
                • Customer-Specific Solutions

                • For applications that demand functions over and above those of the standard machines, we plan, develop and manufacture customer-specific solutions. In this way, complete individual solutions are created, based on our long years of experience as a machine-builder for cable processing and matched to each application to work under highly demanding conditions.
                    • Cutting machine for mineral mnsulated thermocouples

                    • With the »MTE-8« special machine, Metzner offers a fully automatic solution for cut-to-length and orbital cutting of mineral insulated thermocouples of up to 8mm diameter. Time-consuming preparations, like manual pre-cutting and straightening are eliminated by this converting unit.

                      To ensure optimal processing, mineral insulated thermocouples have to be arranged straight and twist-free. An individually adjustable straightening station, developed specially for wound mineral insulated thermocouples, deals with this process automatically on the run and with no lost time.

                      For up to 30mm total insulation stripping length – at both ends – the cutting machine guarantees a tolerance range of ± 0.15 mm. As well as the cutting-to-length, all the orbital cuts into the material are program-controlled and carried out with high precision. This minimises overheating, reduces burrs and thus provides a very good cut quality. Any dust that is created during the cutting can be removed from the machine by a powerful extraction system.

                      All the machine parameters such as depth of cut, penetration speed, material advance and straightening speeds are freely programmable.
                    • Fully automatic cutting of steel ropes

                    • Metzner has developed a production line for the fully automatic processesing of wound steel ropes with outstanding cutting quality and length accuracy. In addition to the cutting process, the equipment also marks all the rope positions that will be required for later processing.

                      The steel rope is fed in using a motorised feeder connected to a loop control system. The speed of the feeding process is controlled by the position signals of the loop control system. Thus, the material is fed in a way that it is protected without the machine coming into contact with the floor.

                      In order to avoid drilling on the cut rope ends, the production equipment fastens marking bands to the section points that will be cut at a later time. In this process, all the marking bands are programme-controlled to be glued to the steel rope - with a cycle time of less than 2 seconds. In addition, a wax printer marks all the fastening and processing points that will be required for subsequent processing. This marking method is carried out in the throughput. This is followed by the cutting process. Precise length accuracy is ensured here by a special laser measurement system.

                      For the orderly storage of the steel rope, Metzer has integrated a material stacker with a storage space of up to 12 metres. All cut steel rope can be stored and sorted according to length so that it can be removed at a later point.
                    • Automatic processing of high-frequency coaxial cables

                    • Problem-free processing of high-frequency coaxial cables with corrugated sheaths is not possible with a commercially available series machine. For this reason, Metzner developed a groundbreaking method for the fully automatic processing of these cables for a well-known company.

                      Metzner developed a new groundbreaking method for processing rigid high-frequency coaxial cables with corrugated sheaths, which can't be managed using only a standard machine. The starting point for the fully automatic machining process is a material-specific aligning station for aligning the unusually stiff cables. This alignment is an important precondition, both for the following processing steps as well as for later further processing.

                      Metzner uses a newly developed stripping head at the heart of this machining method, which combines a rotary cut with powerful clamping and simultaneous turning of the material. In this way, the highly precise and multi-layer rotary cut is able to apply precise multilevel cutting and stripping.

                      The quality check under the microscope confirms the perfect processing without any scratches, pressure or scrape marks. In addition to the high processing quality, the system also provides special precision: both the total length as well as the stripping lengths are kept with a precision of 0.2mm.

                      The machine is able to process cables with a diameter of up to 28mm. The cycle time for this lies for a cable of 2000mm length at 35 seconds. Processing steps included here are longitudinal slits, cutting to length by saw cut, rotary cutting, stripping, brushing and depositing. Automatic ink-jet printing is also done during the process.
                    • Fully automatic processing of ESP sensor cables

                    • Modern ABS and ESP systems decisively contribute to driving becoming increasingly safer. To guarantee problem-free functionality, the highest safety standards are already applied in the production of these systems – also in the processing of PUR cables.

                      A worldwide leading supplier in the cable industry, was looking for a fully automatic assembly system for processing PUR cables and found what it was looking for at Metzner. The system should be completely PC-controlled so human error can be avoided during the production sequence. All processing steps (printing, roughing, stripping, depositing or winding) had to be taken care of in one run-through and be designed for PUR cables having a diameter ranging from 2 – 14.5 mm and a length up to 25 meters. In addition, set-up times should be reduced and the processing speed increased with the new system.

                      The cables to be processed are clamped in a Metzner DR 1000 dereeler. A cable reservoir ensures that material is continuously dispensed to the feed device and sag control. A thermotransfer printer labels the cable afterwards. Due to the PC control, the stamp doesn't have to be changed during labelling. The printer receives all data via the software and stamps the required information on the cable. This eliminates expensive set-up times.

                      All cables are provided with contact plugs after processing on the Metzner system. The beginning and end of the cable are roughened to ensure problem-free fastening. The Metzner roughing station grinds the circulating cable in line with two pivoted diamond grinding wheels to the exact roughing depth.

                      The outer sheath of PUR cables can expand up to 700 percent. This only serves as a safety factor, however. When processing cable, it is therefore attempted to avoid expansion. In order to guarantee this during cutting as well, Metzner developed a customized variant of the Metzner AM 150/200 SVA. This machine has the property of clamping the PUR cable directly behind the matrix form knife at the right and left due to the offset feed. This way, the outer sheath is minimally expanded during stripping, thus optimising the stripping result. After the processing operation, the PUR cables are placed in a material stacker, or, for cables longer than six meters, wound up to form cable coils with an automatic winding machine.
                    • Fully automatic processing of flat solid conductors

                    • Assembly halls require light in large amounts fluorescent lamps are often used for this. A company form the Netherlands which is specializes in the production of light lines, works now more effectively than ever, thanks to Metzner.

                      Today, fluorescent lights are connected to the mains using solid ribbon cables. The advantage: Once the line is fastened, the lamps can be simply and quickly connected using clips. The individual wiring of lamps is then no longer necessary. Ribbon cables usually have 5 or 7 poles and are produced with a diameter between 1.5mm² and 2.5mm² as continuous material, but without cut-outs for attaching the tubes.

                      The company required a machine which strips the solid ribbon cables at those places where the lamps are later attached and approached Metzner with this requirement. In addition, a high processing speed and length precision in combination with exact alignment of the coiled solid cables were the central requirements of the customer.

                      For the company, it is important to individually process the respective ribbon cable. In order to handle this in simple and efficient way, all processing parameters can be called up at the push of a button via a PC program which is connected to the IT-network online. Based on this, the cables are then processed at any length and with cut-outs at every desired position.

                      The ribbon cable is dereeled from a roller, safely transported with a project-specific feeding device and is exactly aligned at the same time. Afterwards, three tools ensure exact processing. A matrix-like knife cuts the cable sheath. Then a punch exactly punches out the later connection points. Finally, the cable is cut to the desired length and is stacked. Since Veko Lightsystems usually cuts fixed lengths between two and six meters long, the material stacker also measures six meters. By working this way, it is possible to deliver completely pre-assembled lighting systems to the building site, which considerably reduces the installation effort on site.
                    • Stripping of semi-rigid coaxial cables

                    • The AM 3550 Semi-Rigid from Metzner is a precision machine, with characteristics that are unique in the world. Its decisive benefit? This machine, designed for cutting to length and stripping of semi-rigid coaxial cables up to 6mm in diameter, is also capable of working with cables with extremely short lengths.

                      Compared to other models in the AM 3000 series the advance conveyor belt is positioned before the rotating head. In this way, the length precision of short cables can be optimised and a tolerance of ± 0.2mm is made possible.

                      Rotating cut
                      When cutting into the cable, the patented Metzner rotating cut delivers the precision demanded by this function. Depending on the requirement, up to three different cutting depths can be freely pre-programmed. The material is then positioned exactly by the integral handling system, which and provides trouble-free insulation stripping and deposits the produced parts in a cable tray. Any waste or scrap parts are sorted out and separated. Depending on the part length and the properties of the material, the processing cycle takes between 8 and 10 seconds per piece.

                      Simple to operate
                      As with all the models in the AM 3000 series, the control system is simple to understand and easy to operate. Just entering a few parameters is sufficient to get the AM3550 Semi-Rigid producing exactly and error-free. All the working parameters are freely programmable, ensuring that the machine is well prepared for the demanding process. All the process steps, as well as the current production status are shown on the easy-to-read touch screen display.
                    • Fully automatic cable processing up to 240mm²

                    • At the start of a large project for high-speed trains, an Chinese manufacutrer was looking for a solution for automatic cable processing. As well as high length accuracy, the company needed a machine that could withstand the demands of processing particularly hard copper cables of up to 240mm² in continuous industrial production.

                      To increase production and processing quality, the automatic infeed of the cable to the processing machine is a significant element. The cable drums, weighing up to 1000 kg, had to be unwound at high speed but at the same time subjected to low tension to avoid damage to the material. This requirement is handled by the electrically driven „Metzner DR 12.1000“. All the functions, such as for example, the unwinding of the cable, the tensioning of the cable rolls or the raising of the cable rolls are motorised. Most of all, the electrical handling of the heavy cable drums make the whole process more easy.

                      Precise cut-to-length and processing
                      The best results in processing the particularly hard copper cables of up to 240mm² were produced by the „Metzner 5300 HD“. With the „Heavy Duty“ version and its related hardened knives, even the thickest copper cables could be cut to length and multi-staged stripped. The required production controls were provided, thanks to the standard system supervision by the machine. Using a series of sensors, the machine monitors the material infeed, stops the production when there is a material blockage and informs the operator about locating the fault.

                      Winding
                      For the onward transport of the processed cables, Metzner integrated an automatic cable winder for rapid and effective winding of the cables. With a weight of up to 80 kg per wound spool and an internal diameter of 250-600 mm, the „Metzner CRC 750“ was the right solution.

                      Marking
                      For identification of the cables, Metzner integrated a thermal transfer labeller, capable of producing all types of print ( texts, graphics, barcodes) in very high print quality ( 300dpi). The label with all the relevant production data is attached to each cable ring at the end of the winding process, allowing the cable ring to be easily identified during subsequent processing.
                    • Automatic cable processing with robot handling

                    • Metzner many machines are prepared for a complete set of interfaces. Thus, if necessary, numerous peripherals are integrated into the process - to increase productivity.

                      Even with the use of standard machines modifications and additions are possible. Based on our years of experience as a mechanical engineer for cable processing arise Sun sophisticated, application-engineered custom solutions that are in use under demanding conditions. Metzner takes over the entire development process from analysis and consulting to design to successful delivery.

                      For the processing of cables up to 50 mm² so a customized, fully automatic processing line has been realized. Here, the following peripherals to increase automation, scroll through reels, label the cables and multi stripping. Following is a robotic handling is used, which after the winding process takes the cable, a bundle, and then fed to the packaging station stores.
                  • Peripherals & Accessories

                  • As well as high-quality processing machinery, Metzner also offers quick, product-friendly and economical peripheral equipment to extend your cut and strip machine into an automatic processing line.
                      • Dereeling and Feeding

                      • To achieve optimal results in cable processing, the tension-free cable feeding to the machine is an important pre-requisite. Metzner offers a wide range of solutions for dereeling and feeding, irrespective of whether your material comes in a drum or on a spool and weighs ten, a hundred or a thousand kilos.
                      • Printing and Marking

                      • For product identification and to determine assembly positioning, cables, wires and other products often have to be printed or marked. In response to a variety of requirements, Metzner offers several different printing systems from leading manufacturers, which can be combined with all Metzner machines.
                      • Stacking and Coiling

                      • After the cable, wire or corrugated tube processing, precise take-off, sorting or coiling of the products is a logical step in the quality assurance of the total process. For this, Metzner offers well thought-out and practically proven peripheral solutions.
                      • Software Solutions

                      • For effective cable and corrugated tube processing, Metzner offers powerful software solutions that have been proved in practice. All our software packages provide comprehensive functionality such as processing of complex parts lists and individual printing and marking.
                    • Machines for Rubber and Plastics Processing

                    • For cutting and processing of profiles, tubes, hoses, foils and gaskets made of rubber or platics, we offer a comprehensive range of machines – from low-priced universal cutting machines to fully automatic production systems.The competent and reliable implementation of your requirements thereby also includes planning, development and construction of all the necessary tools, the software design and programming.
                        • Profile Processing

                        • For processing of rubber and plastic profiles Metzner offers a comprehensive range of machines. Whether you cut flexible, rigid or steel-reinforced profiles or require special contours - we offer the right solution - from the affordable universal cutting machines to fully automatic production systems.
                            • Metzner Modular Cutting Machines

                            • Metzner cutting machines of the »MBS series« represents outstanding flexibility in the processing of flexible and semi-rigid profiles of rubber and plastic. Different cutting processes and machine components provide cutting machines that fit flexibly and individually with customers’ requirements and are available in the shortest time with practically no development being necessary.

                              Many processing and cutting tasks are as varied as the materials themselves. With the MBS-System it is possible for you to combine more than 130 standard components together to fit your requirements. Just like building blocks, the appropriate elements are selected and applied. Elements like the type and number of cutting tools, length of the transport conveyor (from 200mm up to 800mm) and width (from 100mm up to 400mm), control system, feed-in device, working direction, nature of the transport conveyor surface covering and the support framework: all these are tailored to the needs and demands of the customer and the materials. Thanks to this flexibility, there are virtually no limits to meeting and satisfying your requirements.

                              The use of standard components makes it possible to create the MBS machines very quickly with very little further development. Modular cutting machines are thus not only matched to processing requirements but are also extremely economical and efficient. In addition, all MBS machines are equipped as standard to be fully integrated with peripheral systems such as take-off and feed mechanisms, throw-off devices and winders, printers and marking units.
                            • Metzner Circular Knife Cutting Machines

                            • Circular knife cutting machines of the »Metzner CCM series« have been developed to ensure reliable processing of flexible, steel-reinforced and rigid materials.

                              The rotating circular knife is perfectly suited to cutting rubber, plastic and metal and gives extremely good cutting quality by the combination with other parameters such as optimum material guide, knife rotation speed, knife rotation direction, knife feed and knife lubrication, ensuring both, »in-line« and »off-line«.

                              Central to all »CCM machines« is that they are fitted with a linear servo-drive for the circular knife arm movement. This feature allows various feed speeds for working on different materials, e.g. inserting material gently for the best possible cutting result or a slow feed for removing the blade to reduce the formation of sprags and burrs. All circular knife cutting machines of the »CCM series« can be supplied with a knife speed range from 1.000 – 6.000 rpm or 4.000 – 10.000 rpm. This means that, as well as circular knives, abrasive discs can also be used in combination with a profile clamping system to optimize the end cut surface quality by a grinding action.

                              The PLC control can be programmed freely, allowing for all the processing parameters to be set to meet the demands of various profile contours and mixtures of materials. These parameters can be saved and then used again at the press of a button.
                            • Metzner Single-Pass Cutting Machines

                            • With an automatic single-pass cutting machine, tooling and machine blend into one high-performance system with high output rates and impressive flexibility.

                              Sealing profiles for the automobile industry, but also for applications in furniture, thermal insulation for buildings or in household goods often require complex cutting processes, as these illustrations show. Process such as drilling and milling can also be integrated in these one-pass machines.

                              For tasks of this nature, Metzner’s convincing capabilities provide a range of automatic single-pass guillotines. The common feature of all these machines is the storing of all the processing parameters and associated machine settings in a single processing recipe. At the start of production, an in-built barcode scanner reads the data from the production paperwork, activates the saved parameters and shows the required tooling and material on the operator panel display. The barcode also contains the required quantities and lengths to be produced. Thanks to well thought-out quick-change systems, the necessary tooling and material changeover is performed rapidly – generally within 30 seconds – to minimise downtime. The integral tool coding system then independently checks to ensure that the correct tooling is in place.

                              With a further step in automation, material and tool changing are carried out completely automatically: the machine reads the barcode and the operator presses the start button. Everything else happens dully automatically and without human intervention.
                              Fully automated one-pass guillotines are often equipped with intelligent length-measuring systems and quality monitoring functions to achieve outstanding precision – depending on material – of approx 0.1% (min. 0.5 mm). Parts which are out of specification are automatically identified and separated.

                              Closely matched to the tasks in hand, tools with several contour forms are often employed for complete processing. Metzner automatic one-pass guillotines are used off-line in converting as well as in-line at the end of a production line. In summary, these machines offer two decisive advantages: they deliver high performance at a surprisingly low investment cost and a constant quality standard independent of the operator personnel.
                            • Metzner Eccentric Drive Cutting Machines

                            • If a die cut at very high speed is required and the pneumatic drive has reached its limit, the eccentric-drive cut opens new possibilities in terms of cutting performance.

                              With the Metzner ST 25, instead of a pneumatically driven cutting tool, we use an electrically-driven eccentric mechanism bearing the cutting tool. In this way, we can achieve ground-breaking guillotine cutting performance of up to 800 cuts/minute. A beneficial side effect: the electric drive enables the ST 25 to work very quietly, making this model the choice for customers in low-noise environments.

                              Metzner offers for eccentric drive cutting machines two cutting modes: With the intermittent Stop-and-Go cut, the belt feeder transports the material to the exact position and stops briefly while the knife cuts through the material. Due to the brief stop, high length accuracy and a precise right-angled cut are achieved. The feeder does not stop for the continuous cutting method. The material is continuously transported and cut simultaneously. In this way, the production output can be increased. The cutting quality here is still good, but not as perfect as the intermittent Stop-and-Go cut.
                            • Metzner Universal Cutting Machines

                            • The basic idea: Robust and reliable base models, equipped with the correct cutting technology (die cut, shear cut, tube cut) and a choice of »Red – Green – Blue« equipment levels.

                              Metzner universal cutting machines are designed for automatic cut-to-length and cutting of a wide spectrum of materials. For flexible profiles, tubes, plastic pipe, lace, seals, film, labels, cables, braids and wires, our universal cutting machines deliver precise results with good cut quality and high working speeds. The KL-BV has a place on its own in the universal machine category: it is designed for precise cut-to-length of elastic and pressure-sensitive tubing.

                              The three equipment levels Red – Green – Blue are differentiated by the following features:
                              Red: Dependable basic functionality, very attractive price, reduced conveyor speed and compatibility with peripheral equipment as a stand-alone unit.
                              Green: Easy-to-use controls, higher working speed, integral connections for peripheral units, PC-operation and printing.
                              Blue: Touch-screen operation and Metzner PLC (with CoDeSys programming), highest working speed, integral connections for peripheral units, PC-operation and printing.
                            • Metzner Traveling Head Cutting Machines

                            • Traveling-head machines for in-line processing of rigid profiles are often regarded as the »King Discipline« of cutting machine technology. Intensive dialogue with leading end-users and the many years’ experience of our designers have produced a ground-breaking product concept.

                              Thanks to a servo-linear drive as standard for the working tool carrier, the traveling-head machines achieve a very long processing time of several seconds for outstanding end-cut quality. At the same time, a very short cycle time is achieved for the processing of short part lengths at high line speeds. In addition, there is a servo-linear drive for the circular knife penetration with varying penetration speeds for different parts of the material section, for example a careful knife entry speed or a knife exit at lower speed to reduce the formation of sprags.

                              We also offer a great choice of knife rotation speed range alternatives, from 2,000 - 6,000 rpm or 4,000 -12,000 rpm. In this way, there are no limits to the use of different types of circular knife types, including clamp/cut in traveling head operation. For complete in-line processing of rigid plastic profiles, our traveling-head machines offer a powerful platform that can be adapted to many tasks by the employment of rapid-change tooling or drilling and milling modules.
                            • Metzner Drilling Devices

                            • Sealing systems often require ventilation drillings or location holes. For this purpose, Metzner drilling units are employed. We deliver the following solutions to match your requirements:

                              In-line eccentric-drive drilling station for regular drillings at constant pitch
                              In-line traveling-head drilling station for constant or variable pitch drillings
                              In-line »Drilling Beam« to drill all the holes for a complete profile at different pitches in one action
                              Off-line for drilling in combination with end cutting
                              Metzner drilling units are distinguished by drill spindles with very high speeds up to 60,000 rpm. This gives precision drillings with short cycle times. The drill geometry ensures that the waste generally falls to the outside. Pneumatically driven drilling spindles have the advantage of lower investment cost but have higher running costs. Electrically driven drilling spindles cost less to run but are a more expensive investment.

                              In addition, Metzner supply laser drilling systems for in-line operation. Lasers are more expensive but offer the advantage of processing variable hole pitches during automatic running and can be employed in changeover to different profiles.
                            • Metzner Notching Stations

                            • The basic idea: For all work processes that cannot be carried out in the extrusion line or in an automatic pass, off-line notching stations are employed.

                              For these applications, Metzner combines its own tool-making capability with its experience in machine building to create economical and functional notching stations for precision end-cutting with matrix tools and saw units for rigid and flexible profiles.

                              Depending on the task in hand, single, multiple or interchangeable tools are used. With a special tooling arrangement, Metzner also offers the flexibility to change from manual operations to automatic cycle machinery. In this way, our customers are able flexibly to accommodate changing quantity demands and choose the most economical method of production.

                              As well as the development and manufacture of tooling, Metzner also undertakes sample production for customers and machinery capability proving tests, as well as process start-up and integration into production in the customer’s factory.
                            • Metzner Transfer Type Machines

                            • The basic idea: Highest productivity combined with highest precision is the outstanding characteristic offered by automatic Metzner Transfer Type Machines.

                              Metzner develops and builds automatic transfer type machines for the complex finishing of automotive seals for example at the Glass Run Channel or the Door Weather Strip. In the process, mounted within a special clamping, the profile is transported automatically to individual cutting stations by a transfer system. Phase-controlled by a programmable system, the particular cutting is then performed at the tooling station. After all individual steps are completed, the processed part is dispensed.

                              The processing within a fixed clamping combined with the precision of a servo-system and additional positioning sensors guarantees the compliance with continuously tighter manufacturing tolerances and high repetition precision.

                              Metzner transfer type machines offer an especially high cost-effectiveness for vehicles produced between 50.000 and 250.00 units per year.

                              Automatic component feeding and component take-off with a robot or other handling systems put unmanned manufacturing within reach.
                          • Hoses and Tube Processing

                          • Metzner developed and designed since more than 30 years production machines for tube and hose processing. Through these years of experience we now offer solutions that are tailored to the variety of different tube diameters and material properties. No matter whether you want to edit hydraulic hoses, brake hoses or medical tubes - we have the right solution.
                              • Metzner Modular Cutting Machines

                              • The basic idea: Cutting machines that fit flexibly and individually with customers’ requirements and are available in the shortest time with practically no development being necessary.

                                Many processing and cutting tasks are as varied as the materials themselves. With the MBS-System it is possible for you to combine more than 130 standard components together to fit your requirements. Just like building blocks, the appropriate elements are selected and applied. Elements like the type and number of cutting tools, length of the transport conveyor (from 200mm up to 800mm) and width (from 200mm up to 400mm), control system, feed-in device, working direction, nature of the transport conveyor surface covering and the support framework: all these are tailored to the needs and demands of the customer and the materials. Thanks to this flexibility, there are virtually no limits to meeting and satisfying your requirements.

                                The use of standard components makes it possible to create the MBS machines very quickly with very little further development. Modular cutting machines are thus not only matched to processing requirements but are also extremely economical and efficient. In addition, all MBS machines are equipped as standard to be fully integrated with peripheral systems such as take-off and feed mechanisms, throw-off devices and winders, printers and marking units
                              • Metzner Fly-Knife Cutting Machines

                              • The basic idea: Highest cutting rates of up to 4000 cuts per minute with one knife and, if required, even higher speeds with multiple knives, a choice of »Stop & Go« or continuous cutting, different machine sizes for materials up to 120mm diameter, knife lubrication and peripherals interfacing as standard.

                                The Dynamat machines process elastic materials with precision and high repeatability – from silicone tubing for medical applications, textile-reinforced hoses to profiles. It makes no difference whether the material comes from a single extruder or is unwound from a reel.
                                The customer-orientated »Red – Green – Blue« equipment levels are also offered for the Dynamat range with the following features:

                                Red: Only continuous cut, simple controls, very attractive price and combination with peripherals as stand-alone units.
                                Green: Choice of »Stop & Go« cut (up to 400 cuts/min) or continuous cut, easy-to-use PLC controls with many menu functions.
                                Blue: Unique cutting performance of up to 800 cuts/min in »Stop & Go« cut mode in combination with a particularly high-speed control system. Also continuous cut mode.
                              • Metzner Universal Cutting Machines

                              • The basic idea: Robust and reliable base models, equipped with the correct cutting technology (die cut, shear cut, tube cut) and a choice of »Red – Green – Blue« equipment levels.

                                Metzner universal cutting machines are designed for automatic cut-to-length and cutting of a wide spectrum of materials. For flexible profiles, tubes, plastic pipe, lace, seals, film, labels, cables, braids and wires, our universal cutting machines deliver precise results with good cut quality and high working speeds. The KL-BV has a place on its own in the universal machine category: it is designed for precise cut-to-length of elastic and pressure-sensitive tubing.

                                The three equipment levels Red – Green – Blue are differentiated by the following features:
                                Red: Dependable basic functionality, very attractive price, reduced conveyor speed and compatibility with peripheral equipment as a stand-alone unit.
                                Green: Easy-to-use controls, higher working speed, integral connections for peripheral units, PC-operation and printing.
                                Blue: Touch-screen operation and Metzner PLC (with CoDeSys programming), highest working speed, integral connections for peripheral units, PC-operation and printing.
                              • Metzner Nylon Tube Processing

                              • Working with leading manufacturers in the truck and commercial vehicle sector, Metzner have developed automatic converting lines to process truck brake pipes which provide enormous benefits to the users.

                                The tubes, with diameters of between 4mm and 16mm, are drawn by the Metzner machine from a coil, cut to exactly the right length and printed to the customer’s specification (ink jet or laser printing, thermal transfer printing or with adhesive labels) and then stacked, bundled or wound. At the end of a material roll, the machine gives an optical signal and a message on the display. The operator can then load another material roll to continue the automatic production without interruption.

                                Depending on the number of pipes per vehicle, a Metzner converting line of this type produces brake pipes for 50 to 100 vehicles per shift and the machinery is fully integrated into the customer’s computer-aided manufacturing system. The data sets for the production are transferred from a central computer to the converting line, which then sends back the necessary status information.
                              • Metzner Circular Knife Cutting Machines

                              • The CCM machines are designed specifically to meet the material requirements of metal-reinforced sealing profiles and tubes as well as sponge rubber seals. The circular circular knife provides the correct conditions for penetration and cutting of rubber and metal and gives extremely good cutting quality by the combination with other parameters such as optimized material in-feed, knife rotation speed and direction, knife penetration rate and lubrication.

                                The freely-programmable controls enable the varying demands of different profile contours and compounds to be exactly matched, saved in a single working program and called up by the press of a button. Thanks to the intuitive logical operator guide, a new processing program can be created in a few minutes. We offer the three equipment levels »Red – Green – Blue« for the CCM machines with the following features:

                                Red: Metzner PLC-controls with colour touch-screen and CoDeSys programming and circular knife penetration with pneumatic linear drive; max. belt conveyor speed 60m/min.
                                Green: Metzner PLC-controls with colour touch-screen and CoDeSys programming und servo-linear drive for the circular knife penetration; max. belt conveyor speed 120m/min.
                                Blue: Siemens S7 PLC-controls with colour touch-screen and servo-linear drive for the circular knife penetration; max. belt conveyor speed 120m/min.
                              • Metzner CT 4000 Series

                              • Corrugated tubes are used for protecting cables and wiring harnesses. Cutting these protective coverings to length depends on cutting accurately on the crest of the ridge. Otherwise sharp cut edges are formed which results in damage to the cables.

                                Metzner corrugated tube cutting machines of the CT 4000 series offer absolute precision with the cut on the crest of the corrugation. All types of unslit corrugated tube are cut reliably and precisely. The machines offer processing for corrugated tubes from 4.5mm up to 35mm outer diameter. This wide spectrum is unique and makes these models a future-proof investment.

                                High-performance sensors guarantee reliable reading of the tube profile and place the cut precisely on the top or in the valley – providing just the processing result you expect.
                            • Plain Section Gaskets

                            • Plain section gaskets are frequently to be found in many objects of daily use. For these reasons, they must be produced on high-performance machines with high output capacity. Virtually all plain section gaskets have a diameter that is considerably larger than the length, so that specialised cutting procedures are necessary for defect-free production.
                                • Metzner SR Series

                                • The basic idea: Metzner mandrel cutting machines of the SR range are precision machines for cutting gaskets and O-rings from moulded or extruded tubes. The distinguishing features are the unique cutting method and the high cut quality.

                                  To produce the plain section gaskets, rubber tubes – already cut to length – are stretched onto mandrels. Loading and unloading of the tubes onto the mandrels is done quickly by a special unit and without any particular skill being required. Then the mandrels are automatically clamped between rotating centres and the production is started. A knife carriage travels along the tubes, cutting the rings to the required length, either with stiletto-type tools or circular knives.

                                  This process fully brings together high output and the highest cut quality. The use of the most modern servo-technologies makes the SR machines even more versatile: knife penetration speed and carriage advance are fully free-programmable – for optimal processing of materials with different characteristics. The SR range includes two and seven-spindle machines, so that Metzner can offer you the most economical solution for different capacity requirements.
                                • Metzner CCM 4 Gasket

                                • For tubes with suitable material properties, the »CCM 4 Gasket« offers an excellent possibility to produce gaskets with a circular knife. Depending on requirements, with each cut a plurality of seals can be cut, so that the production is increased significantly.

                                  As opposed to the mandrel cutting machine the circular knives cutting machine requires no supporting mandrels. It handles continuous material and is flexible for different diameters. By special tube guides the feeding mechanisms of the circular cutting machine "CCM 4 Gasket" is flexible for different diameters. At the same time, several tubes can be cut next to each other. The circular blade feed is with a servo linear actuator and with material specific feeding programs. Thus it makes for a perfect cut quality.

                                  The Metzner »CCM 4 Gasket" is equipped with a cooling and lubrication system can operate with water as well as coolants. The coolant is to regularly prepared in a closed circuit and also filters out chips and solids.
                                • Metzner KL-BV Gasket

                                • With its very thin blades and precise knife advance, the »KL-BV Gasket« is ideally suited for the cutting of plain section gaskets with diameters of up to 12mm (18mm optional). The attraction of this machine is its very attractive price for this application and its notable cutting capacity of up to 400 cuts/minute.

                                  Thanks to the long belt feed and the centrically adjustable contact pressure of the feed belts, the material is transported without any slipping and stretch is reduced to a minimum. Due to the standard "draw and cut technique“ and the use of extremely thin blades, the Metzner »KL-BV Gasket« achieves an outstanding cutting quality – even for very soft and elastic hoses.

                                  With peripheral devices, every Metzner »KL-BV Gasket« can be converted to an automatic production line without any difficulties. Whether you are looking for automatic and fully tension-free material supply, automatic marking or controlled and sorted depositing – the »KL-BV Gasket« can tackle all these tasks efficiently.
                              • Foil Processing

                              • For the foil processing Metzner offers solutions that go far beyond cutting precision. As automation partner, we also include upstream and downstream processes in our solutions: From unwinding and feeding to positioned stacking and sorting to handling applications. Also for quality control (weigh, measure, camera systems), we integrate the right solution.
                                  • Metzner Modular Cutting Machines

                                  • The basic idea: Cutting machines that fit flexibly and individually with customers’ requirements and are available in the shortest time with practically no development being necessary.

                                    Many processing and cutting tasks are as varied as the materials themselves. With the MBS-System it is possible for you to combine more than 130 standard components together to fit your requirements. Just like building blocks, the appropriate elements are selected and applied. Elements like the type and number of cutting tools, length of the transport conveyor (from 200mm up to 800mm) and width (from 200mm up to 400mm), control system, feed-in device, working direction, nature of the transport conveyor surface covering and the support framework: all these are tailored to the needs and demands of the customer and the materials. Thanks to this flexibility, there are virtually no limits to meeting and satisfying your requirements.

                                    The use of standard components makes it possible to create the MBS machines very quickly with very little further development. Modular cutting machines are thus not only matched to processing requirements but are also extremely economical and efficient. In addition, all MBS machines are equipped as standard to be fully integrated with peripheral systems such as take-off and feed mechanisms, throw-off devices and winders, printers and marking units.
                                  • Metzner Universal Cutting Machines

                                  • The basic idea: Robust and reliable base models, equipped with the correct cutting technology (die cut, shear cut, tube cut) and a choice of »Red – Green – Blue« equipment levels.

                                    Metzner universal cutting machines are designed for automatic cut-to-length and cutting of a wide spectrum of materials. For flexible profiles, tubes, plastic pipe, lace, seals, film, labels, cables, braids and wires, our universal cutting machines deliver precise results with good cut quality and high working speeds. The KL-BV has a place on its own in the universal machine category: it is designed for precise cut-to-length of elastic and pressure-sensitive tubing.

                                    The three equipment levels Red – Green – Blue are differentiated by the following features:
                                    Red: Dependable basic functionality, very attractive price, reduced conveyor speed and compatibility with peripheral equipment as a stand-alone unit.
                                    Green: Easy-to-use controls, higher working speed, integral connections for peripheral units, PC-operation and printing.
                                    Blue: Touch-screen operation and Metzner PLC (with CoDeSys programming), highest working speed, integral connections for peripheral units, PC-operation and printing.
                                  • Customer-specific machine for cutting ski foils

                                  • Longitudinal cutting of films and foils presents particular demands with regard to the arrangement of the tool and the guiding of the material. Our designers have provided convincing solutions to these challenges, for example for films used in the manufacture of skis and snowboards.

                                    To ensure the precise positioning of the feeding material, the sheets of glass fiber and carbon fiber are mounted on a driven material dereeler and fed to a dancer arm, which feedsthe material to the system exactly positioned and tension-free.

                                    After loading the production program, the machine works on its own and cuts the material to the desired length. When cutting the fibre glass and carbon foils, special attention was given to precision, since the thinner the material to be cut is, the more difficult it is to cut. In order to guarantee constant cutting quality, Metzner integrated a cutting module with precision guides. All parameters like cutting length, piece number, stack offset, material thickness, piece number per stack and production speed are freely programmable.

                                    Finally, the machine stacks the cut material onto a dolly. The machine automatically recognizes the number of stacked foils and stops cutting at a pre-defined number until the material has been removed.
                                  • Customer-specific machines for processing of GPR foils

                                  • Weight saving for energy conservation is one of the main themes in vehicle design. Metzner is playing its part in this by the development and supply of converting machinery for pre-preg material used in the manufacture of vehicle components.

                                    The machines designed by Metzner first monitor the quality of the pre-preg material at a speed of 1 metre/second using a camera system. Defective material is cut out and separated. The defect-free material is cut into the required lengths and arranged according to pre-set plans in numerous layers and in different positions.

                                    Certain vehicle components (e.g. leaf springs) also require cut-outs and shaping of the pre-preg materials and subsequently the exact positioning of the cut relative to a material feature. The machine then performs further quality control functions with automatic documentation and back-traceability.
                                • Customer-Specific Solutions

                                • For applications that demand functions over and above those of the standard machines, we plan, develop and manufacture customer-specific solutions. In this way, complete individual solutions are created, based on our long years of experience as a machine-builder for rubber and plastics processing and matched to each application to work under highly demanding conditions.
                                    • Customer-specific machine for the processing of silicone hoses

                                    • With a customiser-specific special machine for the processing of silicone hoses, Metzner offers a fully automated solution: ranging from the safe and material-saving prefeed of the elastic hoses and cutting to length through to spooling, labelling and stacking.

                                      All hoses are cut to a total length of 2000 mm. A special laser knife procedure allows the machine to guarantee high length accuracy - even at high feed rates.

                                      For further processing in production, the cut tubes are coiled into a bundle. This is done directly in the machine. A barcode label which contains all relevant production information is then applied to all the silicone hoses for the purpose of identification and quality control. This is automatically scanned and stored in the IT system after application to the coil of hoses. This permits continuous production monitoring and allocation.

                                      Metzner gripper systems then remove the coiled and labelled bundle of hoses and place it on a conveyor belt which automatically transports the hoses away for further processing.
                                    • Customer-specific machines for processing of GPR foils

                                    • Weight saving for energy conservation is one of the main themes in vehicle design. Metzner is playing its part in this by the development and supply of converting machinery for pre-preg material used in the manufacture of vehicle components.

                                      The machines designed by Metzner first monitor the quality of the pre-preg material at a speed of 1 metre/second using a camera system. Defective material is cut out and separated. The defect-free material is cut into the required lengths and arranged according to pre-set plans in numerous layers and in different positions.

                                      Certain vehicle components (e.g. leaf springs) also require cut-outs and shaping of the pre-preg materials and subsequently the exact positioning of the cut relative to a material feature. The machine then performs further quality control functions with automatic documentation and back-traceability.
                                    • Customer-specific machine for cutting ski foils

                                    • Longitudinal cutting of films and foils presents particular demands with regard to the arrangement of the tool and the guiding of the material. Our designers have provided convincing solutions to these challenges, for example for films used in the manufacture of skis and snowboards.

                                      To ensure the precise positioning of the feeding material, the sheets of glass fiber and carbon fiber are mounted on a driven material dereeler and fed to a dancer arm, which feedsthe material to the system exactly positioned and tension-free.

                                      After loading the production program, the machine works on its own and cuts the material to the desired length. When cutting the fibre glass and carbon foils, special attention was given to precision, since the thinner the material to be cut is, the more difficult it is to cut. In order to guarantee constant cutting quality, Metzner integrated a cutting module with precision guides. All parameters like cutting length, piece number, stack offset, material thickness, piece number per stack and production speed are freely programmable.

                                      Finally, the machine stacks the cut material onto a dolly. The machine automatically recognizes the number of stacked foils and stops cutting at a pre-defined number until the material has been removed.
                                    • Customer-specific machine for processing of brake pipes

                                    • For technical reasons, brake pipes can be only be made in fixed lengths of for example 6 metres. For assembly into vehicles, however, lengths of between 70mm and 800mm are required. With a machinery installation from Metzner, the pipes are cut into the required tube lengths at lightning speed (1.2 seconds per pipe) and with high precision (± 0.25mm).

                                      But the demands go further: Because the woven reinforcement can contain defects, the machine has to recognise faults in the material layers that lie below the surface, reliably cut them out and automatically separate them.
                                      As the defects can appear in random locations, Metzner is presented with the additional task of evaluating the remaining good product after the defect location and to cut a selection of different set lengths, in order to minimise the number of reject parts. Subsequently, parts of the same length are sorted into different storage containers.

                                      Another new feature is the integral energy-saving concept: If there is a pause in the automatic feeding of the brake pipes of more than 60 seconds, then the machine switches to an energy-saving standby mode and is immediately ready to produce on receipt of the next part.
                                    • Customer-specific take-off unit

                                    • For all applications which demand more than the functionality of standard machines, we plan, develop and manufacture customer-specific solutions. Based on our many years’ experience in the processing of profiles, tubes and plain-section gaskets, these result in the creation of fully-fledged special machinery, closely tailored to each precise application. For each individual task, our specialists select the best method to achieve your targets.

                                      Beside complex machine solutions also unusual challenges in profile processing are handled successfully by Metzner. This material take-off unit has the task of handling freshly-extruded profiles reliably and evenly at a temperature of 90° C, a weight of 400 kg and a length of 20m.
                                  • Peripherals & Accessories

                                  • As well as high-quality processing machinery, Metzner also offers quick, product-friendly and economical peripheral equipment to extend your processing machine into an automatic processing line.
                                      • Unwinding and Feeding

                                      • Irrespective of how your material is presented, on a roll or a coil, as a ring, bundle or spirally wound, we provide an effective means of receiving and unrolling it.
                                      • Printing and Marking

                                      • For product identification and to determine assembly positioning, tubes, profiles and other products often have to be printed or marked. In response to a variety of requirements, Metzner offers several different printing systems from leading manufacturers, which can be combined with all Metzner machines.
                                      • Take-Off and Winding

                                      • After the profile, tube or foil processing, precise take-off, sorting or coiling of the products is a logical step in the quality assurance of the total process. For this, Metzner offers well thought-out and practically proven peripheral solutions.
                                      • Tools

                                      • As well as a powerful cutting machine, cutting tools are the second essential success factor for optimum cutting results. As a system provider, Metzner provides a wide range of tool making services.
                                      • Software Solutions

                                      • For effective rubber and plastics processing, Metzner offers powerful software solutions that have been proved in practice. All our software packages provide comprehensive functionality such as, the supervision and processing of complex parts lists as well as individual printing and marking.
                                    • Automation Solutions for Carbide Industry

                                    • Highest quality standards and an efficient, economical production of precision parts, require a high degree of automation. With their automation systems for manufacturing of indexable inserts and other precision parts made of cemented carbides, metal powders and technical ceramics Metzner offers perfect solutions for individual handling tasks in preparation of subsequent production processes, and process linking.
                                        • Automation Solutions for Presses

                                        • Robot press automation for fast, economic, and quality securing unloading of green parts from powder-presses.
                                            • Metzner RPA 3-SC Series

                                            • Metzner powder press automation of the »RPA 3-SC series« automatically unload blanks from a powder press and place it quickly and gently into a definable pattern.

                                              The transfer of each sintered plates and loading the blanks occur in the »RPA 3-SC1« by a 4-axis SCARA robot. The empty sintered plates are manually inserted into a sintering plate magazine, taken as required using a sintered plate gripper and the loading position fed. Subsequently, the robot moves to a gripper station places the sintered plate gripper picks up a part gripper and begins loading the sintered plate. This process is fully automated and in the shortest time.

                                              In the »RPA 3-SC2« sintered plates are placed manually on a double conveyor belt. In each case a sinter plate is automatically conveyed by the conveyor belt in the loading position. The robot will immediately start loading the blanks. Loaded sintered plates are removed from the loading position and manually removed from the belt. Through this process, the plate changing time compared to the »RPA 3-SC1« is significantly reduced.

                                              All robot-automated press are equipped with its own control (hardware and software) and a separate operating unit. All production processes can be controlled so easily, also the teach-in of new laying patterns.
                                            • Metzner RPA 10-SL

                                            • The »Metzner RPA 10-SL« is a powerful and flexible powder press automation to handle indexable carbide inserts, small ceramic parts and similar products.

                                              The »Metzner RPA 10-SL« features an integrated magazine system for up to ten sintered plates. Empty sintered plates are automatically removed from the magazine, and then returned charged ligands. This press automation works independently for a longer period without loading and unloading lead to press stop. Also additional tasks such as weighing or deburring of the pressed parts is fully automatic.

                                              With the integrated 4-axis SCARA robot, the machine achieves high system speeds of up to 30 strokes / min. Thus, the "RPA 10-SL" is suitable for the integration of electric presses ideal high cycle.

                                              The operation of the "RPA 10-SL" is simple using the integrated controller or via the mobile operator terminal. By pressing a button loaded sintered plates are taken out and new accepted. Defined operating data are transferred via an interface to the controller of the press.
                                            • Metzner RPA 60-LT

                                            • The »Metzner RPA 60-LT« is a powerful robot press automation with an excellent storage system for high performance in the handling of press parts of carbide.

                                              With a storage capacity of up to 60 sintered plates offers the "Metzner RPA 60-LI" outstanding opportunities for continuous industrial use in the manufacture of cutting inserts and other stampings. All sintered plates are fed by four trolleys à 15 plates of the machine.

                                              The intelligent system handling of the "RPA 60-LT" provides an uninterrupted loading of pressed parts: During the first sintered plate is filled with a linear robot with multi-function hook, put the handling system, a second blank plate. As soon as the first plate is filled, starts the loading of the second. Meanwhile, the handling system performs the sintered plate loaded back into the trolley. The automated system thus operates according to the Kanban principle, which ensures that the press can be operated continuously during the pallet change.

                                              Optionally, the "RPA 60-LT" and all popular choices for quality control, such as deburring or weighing. Here for example is weight control for a user-definable number of parts. Parts that do not meet the specified weight tolerance will be rejected automatically by means of a conveyor belt.
                                          • Automation System for Part Reloading

                                          • Flexible system for swift and secured pick-up of inserts from sinter trays and for depositing them into pallets.
                                                • Automation System for Part Reloading

                                                • The automatic unloading of blanks is an important process in the production of inserts and other precision parts.

                                                  The automated system is used for reloading of parts of different workpiece carriers such as sintered plates, flat or pin pallets and coating carriers. Reloading of parts is done by a four-axis SCARA robot. To achieve a high reload performance, the robot with a multiple gripper is fitted, which can simultaneously handle several pieces. To ensure an accurate pick and place parts of vision systems are used for robot guidance.
                                            • Automation of Grinding & Lapping Processes

                                            • Automation of grinding processes for safe and quality securing handling of inserts during loading and unloading of the machines.
                                                  • Automation of Grinding and Lapping Processes

                                                  • Automation of grinding and lapping processes are used in all applications where inserts removed from a sintered plates and grinding machines are supplied. By including the sintered plates in magazines autonomous operation of press and automation for a long time is possible.

                                                    The pallets are supplied to the stack by a pallet truck with the magazine. After the feeding of the stack is raised by a lifting unit to the appropriate working height. Thereafter, the pallet is lifted off the stack. The feed unit is controlled by a servo motor.

                                                    In the workspace of the robot, a camera is installed. With the camera, the parts are identified in the relevant range of the nest. The camera works here in transmitted light. The lighting unit is designed as a light strip. In order to recognize the different parts of the palette, the palette is gradually driven by the drive unit on the light strip.

                                                    After the grinding process, the parts of the linear slide is transported back into the working area of the robot. After removing the parts of the robot initially moves to a cleaning station, in which the parts are cleaned by means of a compressed air stream. Thereafter, the machined parts are put back into a flat panel.

                                                    When all the parts of a pallet have been processed, this range is supplied from the feed unit to a second staple magazine. The stack of pallets with the finished parts are from the second magazine again manually removed using the pallet trolley.
                                              • Automation of Coating Processes

                                              • Automatic loading and unloading of part-carrier-systems for CVD-, or PVD-coating.
                                                    • Automation of Handling Tasks in Preparation of Coating Processes

                                                    • For automatic loading and unloading of coating substrates for CVD and PVD coatings Metzner offers several proven automation solutions. The abbreviations PVD (Physical Vapor Deposition) and CVD (chemical vapor deposition) represent different coating processes.

                                                      When loading the PVD spears distinguishes between "single-loading" and "back-to-back-loading." Next to the loading of the parts in addition to the parts of the spacer, so-called spacer, loaded onto the spears. In the single-loading is behind every single insert a spacer, when back-to-back-loading, however, two inserts are "back to back" and only after that comes a spacer.

                                                      To realize the "back-to-back-loading" in the system a turning station is built. About this the appropriate insert is turned 180 degrees and loaded directly onto the respective spear.
                                                • Peripherals & Accessories

                                                • Besides high-end Automation Systems, Metzner offers effective and economically worthwhile accessories and peripheral equipment, designed to enhance and improve the production process.
                                                    • Gripping Systems

                                                    • With our different, changeable gripper systems for powder press automation We offer a wide range of tasks: vacuum grippers, balloon grippers and mechanical grippers. For applications that require special solutions, we offer special grippers.

                                                      Vacuum Grippers: The part is picked up by means of suction force. Grippers of various designs are utilized, depending e.g. on the geometry of the part. The application for these grippers are carbide inserts and other small parts with a plain surface on their pick up side.

                                                      Balloon grippers: Balloon grippers are using the form-lock principle, whereby the balloon is expanded (inflated) inside a bore, or another cavity of the part. Very suitable for small carbide inserts and other parts with bores ≤ approx. 3mm.

                                                      Mechanical Finger Grippers: The grippers are pneumatically activated, or motor driven. The parts are grabbed at their outer-, or inner contour. As a consequence grippers are distinguished in outside- and inside grippers. The clamping force is adjustable. Suitable for larger carbide inserts and other parts, featuring a complex outer geometry, and parts with larger bores or cavities.

                                                      Customized Grippers: Metzner develops customized grippers for specific handling applications. This includes gripper solutions, allowing the orientation of the part to be changed between pick up and deposition. This functionality secures an optimized arrangement of the parts on the sinter tray, and allows parts to be turned for placing them on a side, none-compromising to the product quality.
                                                    • Flat Pallets

                                                    • The Metzner Flat Pallet System has especially been developed for the storage and transportation of carbide cutting inserts.

                                                      Applications in other areas in which sensitive small parts in big quantities and various types are treated are possible as well. The system forms the basis for a continuous automation in the production. It becomes particularly efficient combined with standardized stacker systems for a automatic handling of the pallets.

                                                      Powerful vision systems enable the handling of different workpieces without any need of specific pallet modifications. The position of the workpieces within the pallet is automatically recognized and transferred to the robot control system. With the Metzner Flat Pallet the best solution for an efficient and reliable automation is found. Only five different pallet sizes are needed to handle nearly all available types of carbide cutting inserts.
                                                    • Cleaning Tools

                                                    • With their automation systems offers Metzner perfect solutions for the production of precision parts made of cemented carbides, metal powders and technical ceramics. This includes individual handling tasks in preparation of manufacturing processes, and process linking tasks. As provider of entire automation systems for complex applications we support our customers, starting with project engineering and planning, through commissioning and service of the systems.

                                                      Cleaning systems are the automated cleaning of press tools. Depending on the application needs cleaning grippers is used in regular cycles. The change between material grippers and grippers cleaning is done automatically and in a short time. Depending on the compression tool, different types of the cleaning systems to choose..
                                                    • Part Measuring

                                                    • With their automation systems offers Metzner perfect solutions for the production of precision parts made of cemented carbides, metal powders and technical ceramics. This includes individual handling tasks in preparation of manufacturing processes, and process linking tasks. As provider of entire automation systems for complex applications we support our customers, starting with project engineering and planning, through commissioning and service of the systems.
                                                    • Vision-Control

                                                    • With their automation systems offers Metzner perfect solutions for the production of precision parts made of cemented carbides, metal powders and technical ceramics. This includes individual handling tasks in preparation of manufacturing processes, and process linking tasks.

                                                      Image processing systems are used for high-precision robotic positioning. The camera installed in the workspace of the robot, the camera detects the precise location of the sintered parts position on the pallet. The camera works here in transmitted light.
                                                    • Scale Enabling

                                                    • With their automation systems offers Metzner perfect solutions for the production of precision parts made of cemented carbides, metal powders and technical ceramics. This includes individual handling tasks in preparation of manufacturing processes, and process linking tasks.

                                                      To ensure quality, the pressing member is frequently before dropping on the sintered plate initially supplied by the robot an optional weigh station. For highly accurate weighing of the compacts are different scales are available. The weighing result is evaluated. pressed parts, not within a definable weight tolerance, the robot automatically fed the bad part storage. Simultaneously, the weight can be transferred to the control of the press, so that an automatic correction of the pressing operation is possible.
                                                    • Deburring Systemes

                                                    • With their automation systems offers Metzner perfect solutions for the production of precision parts made of cemented carbides, metal powders and technical ceramics. This includes individual handling tasks in preparation of manufacturing processes, and process linking tasks. As provider of entire automation systems for complex applications we support our customers, starting with project engineering and planning, through commissioning and service of the systems.