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Achieving Cost Reductions With Faccin-Boldrini Combo Line

Achieving Cost Reductions With Faccin-Boldrini Combo Line

Due to the high transportation costs of the supplies, long delivery times and geographic distance from the dished-head supplier, Industrias Metalúrgicas Serrano was forced to increase its products’ final price, decreasing consequently its competitiveness in the market. The company decided to establish a new long-term business strategy: the acquisition of a high-quality metal dished-head manufacturing combo line that would allow it to excel in the region offering products at competitive prices and with the quality standards required by the most prominent manufacturers of tanks nationwide.

When Industrias Metalúrgicas Serrano discussed the project with the Faccin Group, they were offered a very interesting solution that perfectly suited their long-term strategy, budget, and future benefits.

They knew about Boldrini for a very long time from word-of-mouth by other companies, and when they approached Faccin Group, the company was offered a very interesting solution that perfectly suited its long-term strategy.

During the decision process Industrias Metalúrgicas Serrano was supported by a very professional team from Faccin Group who gave them the confidence to continue with the project with excellent results.

The products proposed by the group were the Boldrini Hydraulic Press paired with a manipulator and a Faccin flanging machine, a line that gives them excellent results, so much so that its new customers highly value the quality of the final product.

Thanks to the advanced numerical control system installed on both machines, the company is seeing constant improvement in terms of the time of dished-head forming, which translates into cost reduction and, consequently, providing a product with superior quality at a more competitive value.

Industrias Metalurgicas Serrano soon hopes to make the acquisition of an even more powerful flanging machine and they do not doubt that they will trust Faccin Group again for future investments.

The Company

Faccin S.p.A. is a very powerful group which combines the best brands – Faccin, Boldrini and Roundo – in plate rolling, profile bending and dished-heads manufacturing, all united under one roof and offering the widest range of high-quality options available in the metal forming market.

For further information visit Faccin and Boldrini’s websites.

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Faccin Metal Forming Taking The Middle East By Storm

Faccin Metal Forming Taking the Middle East By Storm

Saudi Arabia, spearheaded by its national oil company Saudi Aramco, has taken the ambitious strategic decision to involve more domestic companies in the development of the country’s infrastructure and as consequence, and important flow of investment in machinery and equipment is taking place. Aramco’s goal is to purchase 75 percent of all their material needs locally by 2021. Currently at 35 percent means they are going to slightly double their purchases from Saudi businesses in the next two years.

Following suit, a large Saudi organisation, one of the first companies Saudi Aramco has worked with, has decided to appoint Faccin to supply them with three 4-rolls plate rolling machines with capacities ranging from 75mm to 125mm plate thickness for their Storage Tank and Process Equipment business sectors. These three new rolling machines have been added to a medium sized plate rolling machine they acquired some time ago.

Furthermore, a Dubai state-owned company, primarily focused on the upstream oil and gas industry has approached Faccin with another order for a new plate rolling machine for its new manufacturing facility in Saudi Arabia. The investment was driven by the need to enhance the company’s IKTVA (in-Kingdom Total Value Added) and thus ordering a 4-rolls plate rolling machine, a solution that combines power, reliability and precision in an exclusive package.

A UAE based company specialising in oil and gas, petrochemical, power and water, marine and mining industries has also selected the 4-rolls plate rolling machine during expansion of their factory.

The company has successfully hundreds of plate rolling machines installed in the region from medium thick plates to over 300mm plate thickness, covering the needs of each manufacturer and demonstrating demonstrate a prompt service support.

 

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CNC Control For Rolling Machines

CNC Control for Rolling Machines

Today, CNC controlled machines can be found in almost all industries, from small-scale metalwork shops to big manufacturing companies. There is barely any phase of the manufacturing process that is not affected by automated CNC machines. Faccin SPA, a manufacturer of plate rolling equipment, foresaw back in the early 1980’s the need of the metal forming industry to have CNC-controlled rolling machines. Article by Faccin SPA.

After a continuous research and development, the first generation of Faccin-CNC bending rolls reached the metal forming manufacturers and for more than 30 years Faccin has been offering them all the benefits of the most advanced and powerful numerical control developed for bending rolls: the PGS-ULTRA.

The first benefit offered by Faccin’s CNC PGS-Ultra is improved automation for its plate rolls. The operator involvement linked to producing workpieces can be greatly reduced or eliminated. Therefore a CNC-controlled plate roll can run unattended during most of its rolling cycle, freeing the operator to do other tasks. This gives the CNC-controlled machine user other benefits like reduced operator fatigue, less mistakes triggered by human error and a steady and foreseeable rolling time and quality for each piece.

Since the rolling machine will be running under program control, the skill level required of the operator will also be reduced, decreasing the dependability risk of the manufacturing company on a single highly skilled operator.

The CNC PGS-Ultra, built with industrial SIEMENS hardware and a perfected user-friendly graphic interface, is so simple to use that even an inexperienced operator can program the rolling machine to produce simple circular shapes of different diameters and lengths or more complex pieces like polycentric tanks, spirals for ventilators, plates of variable lengths, and many more.

Accurate Rolled Pieces

The second major benefit of the CNC-controlled plate-rolling technology is consistent and accurate rolled pieces. Today’s CNC-controlled machines manufactured by Faccin can claim unbelievable precision and repeatability of rolled pieces. This means that once a program is verified, no matter the quantity, identical rolled pieces can be effortlessly produced with precision and consistency.

A third benefit offered by the CNC-controlled plate rolling machines is flexibility. Since these machines are run from a very “easy-to-use” program, running a different workpiece is as easy as selecting it from a different shape option on the screen. Special and unique options are available in the standard configuration like the possibility to build programs for rolling variable thickness programs, calculation of the plate developed length, cycle time, etc. Once a program has been verified and executed for a production run, it can be easily recalled the next time the workpiece is to be run. This leads to yet another benefit, fast change-over.

Motion Control Feature

Finally yet importantly, a wide range of machine accessories like feeding table, plate centering, lateral and top supports, clamping devices, can be controlled with the CNC PGS-Ultra through an easy-to-use motion control feature that manages 15 programmable directions (axes) allowing the operator to configure all the accessories required in the manufacturing process of high quality rolled plates.

Since programs can be easily loaded on the CNC PGS-Ultra, a very short setup time is required and therefore plate-rolling machines become very easy to set up and run which is imperative with today’s just-in-time production requirements.

Manufacturing companies face today huge challenges, intensified pressure and the need to reduce production time, improve flexibility and increase quality with energy reduction. Faccin is ready for Industry 4.0 thanks to its Smart Package 4.0 that offers features like Systems Diagnosis, Teleservice, Management Control, Drawing Imports, Rolling and Production Lot Statistics and Flexible Network Solutions between others, helping the manufacturers of today, face the challenges of tomorrow.

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Interview With Andrea Ceretti, CEO At Faccin S.p.A

Interview With Andrea Ceretti, CEO at Faccin S.p.A

Asia Pacific Metalworking Equipment News is pleased to conduct an interview with Mr. Andrea Ceretti, CEO at Faccin S.p.A regarding current trends and outlook of the manufacturing and metal forming industry.

  1. Could you provide us with an overview of the current trends regarding the manufacturing industry?

There will be an increase in the demand of metal formed products in the market, but due to the current geopolitical situation, the high volatility will push metal fabricators to be as flexible and as reactive as possible. The metal industry will attempt to standardise as much as possible with measures like industry 4.0 in order to maximise the production capacity of each equipment, to apply energy saving measures and lobby/demand the governments for more tax reforms and incentives to stay competitive and improve the workforce development.

 

  1. With increasing digitalisation, how has Faccin kept up with these trends to remain competitive.

It is our core business to develop top technology to help manufacturers maximise from our machines and we realise industry 4.0 is one of the ways to capitalise on the technology we already provide. Our machines are ready for industry 4.0 thanks to SMART packages that offer features like systems diagnosis, teleservice, management control, drawing imports, rolling and production lot statistics and flexible network solutions between others, helping the manufacturers of today, face the challenges of tomorrow. Indeed, we have started thinking about industry 5.0 as our company attitude.

 

  1. What are the main challenges faced by this industry in Asia

The fluctuations in the market and the struggle to find skilled workers are driving fabricators to replace their old equipment with high quality gear, principally looking for accuracy and automation to increase their production output, which is precisely what our group proposes. We focus in providing metal forming companies with equipment that is of the maximum quality, powerful, cutting-edge and most importantly, accurate.

 

  1. How can they be overcome?

As steel prices increases and the margins grow smaller, accuracy is the answer. We design our machines to offer a return of investment centered on the accuracy of the forming process and avoidance of metal waste, always integrating powerful forefront technology that increases the output cycle and return of investment.

 

  1. Moving forward, where do you think the industry is headed in the next 5 to 10 years?

The metal forming industry in general is subject to the cycles of the market economy like any other industry. In today’s world, these cycles are much shorter than in the past and companies that do not adapt and do not prepare beforehand with the latest technology will struggle when the markets fluctuate. Today, it is emerging regions and their rising demand in energy like Asia that are backing the global growth in the demand for the metal forming industry.

 

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