Digitized and Networked Sawing Processes are Indispensable
Manual processes and isolated operations are becoming outdated in the metal processing industry. Thanks to innovative concepts from KASTO, machines and systems can now communicate autonomously. This shift leads to more efficient processes and a more connected workflow.
According to Sönke Krebber, member of the management board at KASTO, “When it comes to sawing, we no longer focus solely on the individual machine; we consider the entire material flow. Our experts develop solutions that optimise cutting strategies, automate processes, and intelligently network machines. Interfaces play a vital role in this aspect – we have been offering OPC UA and various other standards for over a decade. This integration turns every saw cut into a component of a well-designed digital process chain, ensuring maximum efficiency, safety, and transparency for our customers.”
Seamless System Connection
KASTOlink enables seamless networking of KASTO saws with processing machines, storage systems, warehouse management programs, and ERP platforms.
The interface supports a continuous and fully digitalized process chain from order intake through production. It also offers flexible integration with machines from other manufacturers.
Using interfaces such as OPC UA, MQTT, REST API, DSTV+, CSV, or the proprietary HOST link, users can efficiently network their KASTO technology with the entire IT and machine environment.
Optimum Cutting Plans at the Touch of a Button
During sawing operations, maximizing material usage is essential for reducing waste and minimizing costs. KASTOoptisaw addresses this challenge by assigning stored bar stock to sawing orders based on machine parameters such as kerf width and minimum kerf length.
Fully integrated into KASTOlogic WHM software, it handles bars, tubes, and profiles of varying dimensions and mitre angles. The system automatically determines optimized cutting plans by evaluating multiple section arrangements.
Users may also create manual plans through a graphic wizard that selects stock based on geometric criteria. This reduces waste, lowers storage needs, and improves resource efficiency.
Mobile Control and Monitoring
KASTOapp provides real-time visibility into the status of all networked KASTO sawing machines. When a machine operates in automatic mode, the app retrieves data directly from machine control systems.
It displays relevant information such as cut-off lengths, article data, target and actual quantities, feed rates, and cutting speeds. If an error occurs, the app issues an immediate alert so users can respond quickly and limit downtime.
Encrypted HTTPS connections and KASTO’s servers in Achern ensure secure transmission of all data.
Automatic Saw Optimization
KASTOrespond automatically optimizes saw settings while processing solid materials, tubes, or profiles individually or in bundles. The system continuously measures forces acting on the tool without requiring additional sensors.
Based on this information, it calculates the appropriate digital feed rate. It reacts to changes in wall thickness, contact length, or harder material sections, adjusting automatically.
Operators only input essential parameters such as cutting lengths, material types, and quantities. This reduces operating time and extends tool life significantly.
New Control Generation – Smarter, More Intuitive and Efficient
KASTO will introduce its new control generation early next year as part of its suite of intelligent solutions.
Developed from the ground up, the technology simplifies daily operations with a modern interface, smart functions, and a role-based user guide. Simple Mode allows sawing orders to be processed quickly with fewer clicks, and browser access enables flexible machine control from a PC or tablet. Multiple lengths of the same material can be combined into one cutting plan, allowing consecutive orders to run automatically. A clear dashboard shows important statistics, and context-related help offers support directly where it is needed.
About KASTO
The KASTO Group, headquartered in Achern, Baden, specialises in sawing, storage, and automation technology for bar stock and sheet metal. The company is a global leader in metal sawing machines and semi-automatic and automatic storage systems. KASTO also provides automated handling equipment for metal bars, sheets, and cut pieces, supported by intelligent software. With more than 180 years of experience, KASTO is one of Europe’s oldest family-owned businesses. Their achievements include 170 patents, over 140,000 delivered sawing machines, and more than 2,400 installed automatic storage systems. In addition to its branch in Schalkau, Thuringia, KASTO maintains subsidiaries in England, France, Singapore, China, Switzerland, and the USA, supported by an international network of sales and service partners.
