Automatic punching without the hassle
An international manufacturing company from Finland found Van Dulst Techniek via our website and asked: how can we punch aluminium extrusion profiles faster, more consistently and with fewer errors, so that the profiles fit perfectly with shopfront roller shutters?
The solution was a bespoke automatic punching line from MPS (Modular Production Systems), Van Dulst Techniek’s specialist division for machine building, automation and service.
The challenge
After giving the customer our full attention, we discovered that there was more to this request than met the eye. With this type of production, everything revolves around repeatability. Sometimes a highly complex machine seems necessary, but our experience is that the simpler, the better for the customer. The hole pattern determines whether profiles fit together properly during assembly, so precision in the form of identical repetition is of the utmost importance. But at the same time, the market also demands speed and flexibility. Rapid, fully automatic changeovers are desirable, especially in this specific case, as every shop window is different.
The customer was mainly facing three bottlenecks:
1. Long lead times due to manual changeovers and a high level of manual work during production
2. Increased risk of deviations and errors due to human-dependent production
3. Unnecessary scrap and downtime, particularly with profiles where partial hole patterns are required at the start and end
Our solution
MPS Techniek designed and built a shielded punching machine with enclosed feed and discharge conveyors on plastic rollers, combined with a standard MPS Powerstop. This push-on system positions each profile length fully automatically, quickly and precisely at any desired position.
The application in this case
Aluminium lengths up to 3 metres, punching with a variable pitch. The standard punch hole is 60 millimetres, rectangular or oval, but of course various other shapes can also be used via an interchangeable punch die. The starting position of the hole pattern is adjustable, ensuring the pattern aligns precisely with the end product.
How the process works on the shop floor
1. Preparation at the feed end
On the feed side, there are additional swivelling support brackets. The operator uses these to prepare the next batch of base material in advance. The line processes profiles one by one, but preparation runs in parallel with production, ensuring the pace remains high.
2. Positioning with the MPS push-on system
The operator places a new profile on the roller conveyor and positions it against a gripper-less push-on finger of the carriage. The operator then starts the pre-programmed cycle at the touch of a button.
Why this makes a difference
The MPS push-up system increases speed and precision and reduces the risk of errors by reducing reliance on manual operations.
The Trespa rear guide supports the profile, ensuring both scratch-free and stable operation. The rear guide also easily guides the profile against the gripper and into the machine’s punch die.
Hardened steel shafts and guide rollers ensure a long service life and reduced maintenance.
3. Punching with fixed control and quick changeover
The line uses a 10-tonne hydraulic press manufactured by Wisent. The punching unit operates with a changeable punch at the front, allowing punching patterns and dies to be adapted for different product variants.
4. Output and scrap removal
Punching scrap falls through the cast-iron punch table into a removable scrap bin. On the discharge side, the material is decelerated and finally positioned neatly on the discharge conveyor via the extended push finger. The result is a stable output flow without damage to the profile.
Click here to see the machine in operation on YouTube or watch the video at the bottom of this case study
Safety and the CE Machinery Directive
This line is designed with mechanical guards and fitted with safety contacts. As soon as the guard is opened, the punching cycle stops immediately. The system remains in a safe and controlled state, ensuring the operator cannot find themselves in an unsafe situation. This type of safety logic, featuring dual and redundant safety contacts, aligns seamlessly with the CE requirements for machine safety in the manufacturing industry.
From enquiry to delivery: how the process unfolded
Step 1: Online enquiry and quick intake
The customer found Van Dulst Techniek via the website and got in touch. This was followed by an intake session focusing on profile data, desired patterns, output rate and quality criteria.
Step 2: Translation into a working line
MPS Techniek translated the application into a concrete line design incorporating feeding, positioning, punching, discharge and waste removal. The focus was on consistent pitch dimensions, simple programming and an adjustable starting position. Furthermore, the entire feed length had to be produced fully automatically, without operator intervention.
Step 3: Construction, testing and commissioning
Following the engineering and construction of the system, testing was carried out to correctly validate the punching pattern, stroke length of the punching cycle, carriage positioning and the necessary safety measures for a hydraulic system. Van Dulst Techniek then delivered the system on site, including a comprehensive briefing for the operators and a service and maintenance schedule, as a guarantee of continuity and the desired quality.
This approach aligns with how MPS Techniek carries out projects, from engineering to installation and support. The customer therefore received a complete package under one roof with short lines of communication between all parties.
The outcome for the customer
The customer achieved three key improvements:
1. Increased automation and shorter lead times by reducing manual changeovers and manual tasks during the production process.
About the client
An international Finnish manufacturing company specialising in aluminium profiles for roller shutters and retail applications. With over 40 years’ experience in the design, manufacture and installation of their products, the company offers bespoke solutions and a comprehensive service.
