Automated cutting line for aluminium shutters
We implemented a fully automated sawing solution for a manufacturer of high-quality patio canopies with adjustable aluminium slats. This client supplies bespoke products, with each canopy being unique in terms of dimensions and design. This places high demands on flexibility, accuracy and lead times in the production process.
The challenge was clear: how do you transform a largely manual process into an efficient, low-error and scalable production line?
The challenge
The initial situation was characterised by a number of typical bottlenecks:
- Many manual operations when positioning and cutting profiles
- High risk of errors due to variable lengths and angles
- Limited production speed
- Inefficient material utilisation and relatively high levels of scrap
- No direct link to subsequent steps in transport and welding
The aluminium slats (up to approx. 250 mm wide and 6.7 metres long) are custom-made to each customer’s order. Furthermore, some of these slats must be cut at a specific angle (90° ± 7.5°, with the option to extend this to ± 20°). This made standard solutions unsuitable.
The customer’s objective was ambitious yet concrete:
a fully automated sawing line as the starting point of an integrated production line, with higher output, fewer errors and reduced staffing pressure.
Solution and approach
Our MPS engineering department, comprising specialists in mechanical engineering, control engineering and electrical engineering, began with a thorough analysis of the existing process and the desired output.
This led to a bespoke concept: an automated sawing cell that functions as a ‘slave’ within a larger production line, controlled by a welding robot (‘master’). The sawing line delivers precisely cut slats, fully tailored to the requirements of the welding robot.
The solution comprised:
- Automatic feeding via a side magazine for profiles up to 6,500–6,700 mm
- A sawing module with both straight and adjustable angled cuts
- Fully automatic discharge and sorting of products and offcuts
- Integration with a brushing machine and welding robot
- Buffering options to prevent line downtime
The starting point: continuous flow without manual intervention after loading.
Technology and innovation
The completed sawing line combines multiple technologies into a single integrated system:
CNC-controlled sawing technology
The sawing unit is CNC-controlled and processes both straight and mitre cuts with an accuracy of ± 0.35 mm. The cutting angle is easily adjustable, allowing both standard (90°) and non-standard angles to be produced quickly.
Smart material handling
A rack-and-pinion-driven feed system with a gripper positions the profiles accurately. The machine can automatically process up to 10 feed lengths.
A unique feature is that the cross-cut is already performed whilst the previous product is being discharged. This results in immediate time savings.
Advanced discharge systems
The discharge system is designed with three separate streams:
- Standard product → automatic transfer to brushing machine and welding robot
- Long offcuts (250–1500 mm) → cross-conveyor to operator for reuse
- Short offcuts → automatic discharge via conveyor to waste bin
This ensures optimal use of material and keeps the workplace tidy.
Integration into production line
The sawing line communicates bidirectionally with the welding robot. Based on production requirements, the robot calls up the correct slats. The sawing cell produces just-in-time and prevents overproduction or waiting times.
- 1
Dispatch of finished products
- 2
Disposal of long offcuts for reuse
- 3
Sawing centre (straight or angled)
- 4
Disposal of short offcuts
- 5
Supply
- 1
Challenges and solutions
During the project, a number of technical challenges arose:
Variation in cutting angles
Although only ~5% of the products are cut at an angle, the machine had to be able to perform this quickly and accurately.
→ Solution: an easily adjustable sawing system with fixed reference points and fast changeover times.
Synchronisation with welding robot
The cutting line had to align precisely with the welding robot’s cycle time.
→ Solution: smart software integration and buffer zones to accommodate peaks and troughs in production.
Minimising waste
In customised production, material loss is a significant cost factor.
→ Solution: ‘clean cutting’ at gripper position (0 mm) and separate removal of reusable offcuts.
Result
De nieuwe zaaglijn vormt nu het begin van een volledig geautomatiseerde productielijn. De verbeteringen zijn significant:
- B Up to 30–40% higher productivity
- Cycle time of approx. 40–45 seconds per product
- Accuracy of ± 0.35 mm
- Significantly fewer manual operations
- Significantly reduced risk of error
- Optimal material utilisation through smart off-cut management
- Reduced staffing pressure and increased process reliability
In addition, the customer benefits from a scalable solution that can be easily adapted to future product variants.
Conclusion
This bespoke solution demonstrates what is possible when process knowledge, engineering and technology come together. Where standard machines fall short, bespoke solutions begin.
With our own engineering department and extensive expertise in mechanical engineering and automation, we develop solutions that fit seamlessly with our customers’ operational needs. From standalone machines to fully integrated production lines.
Would you like to optimise or automate your production process?
We’d be happy to work with you every step of the way; from analysis to implementation.
Please do get in touch for a consultation. Together, we’ll look at your challenges, areas for improvement in automation and your desired output, and translate that into a suitable MPS solution.
0180 510 455
verkoop@vandulst.nl
Find out more about MPS Techniek at Van Dulst Techniek
See more examples of bespoke MPS Techniek solutions on our website and YouTube channel
The results
Up to 30–40% higher productivity
Cycle time of approx. 40–45 seconds per product
Accuracy of ± 0.35 mm
Reduced staffing requirements and improved process reliability
About the client
For many years, Renson has been developing products and systems designed to improve quality of life and promote better health. They help create an ideal indoor climate in the home and a comfortable outdoor experience. This ambitious mission is built on four solid pillars. Renson combines ventilation, sun protection, façade cladding and outdoor solutions into a personalised all-in-one package.
