The increasing complexity of requirements in metal processing and international cost pressure pose particular challenges for manufacturing companies in high-wage countries. The Austrian PENN GmbH has established itself as an internationally operating metal processor through high manufacturing depth and consistent automation. A key role in the production chain is played by the vertical lathes of the VL series from EMAG, which have been in use at PENN for over a decade and have now grown to 43 spindles.
From forging part production to complete machining
Founded in 1965, PENN GmbH has evolved from a small forging company to a high-tech supplier with over 700 employees. A milestone in the company's history was the investment in a Hatebur forging plant at the Stratzdorf site in 2007, which produces rotationally symmetric forged parts at a rate of up to 70 parts per minute. This corresponds to an annual volume of up to 10 million forged parts.
The high production volume requires equally powerful machining technology. This is where EMAG machines come into play, as Managing Director Gernot Penn explains: 'A large part of our forged parts is subsequently machined in-house. For this, we use our interconnected EMAG VL manufacturing systems, which practically run around the clock.'
Customized machine concepts for large-scale production
The collaboration between PENN and EMAG began in 2010. The first systems - two interconnected VL 5i machines - were commissioned in 2011 and used for the machining of rotationally symmetric forged parts for the automotive industry. In 2014, the first VL 2 machines for gear blanks, also for the automotive industry, followed.
Over the years, the machine portfolio has been systematically expanded and now includes over 30 EMAG VL 2 machines for machining small to medium-sized rotationally symmetric parts, VL 2 DUO line machines with TrackMotion system for automated interlinking, VL 3 DUO machines for larger workpieces, and VL 5i systems for machining complex geometries.
Technical features of the EMAG VL series at PENN
The VL series from EMAG is characterized by its vertical design, which allows for a particularly compact footprint. The vertical lathes offer several technical advantages that are crucial for PENN's production requirements. First and foremost is the vertical pick-up spindle, where the workpieces are picked up directly from the work spindle by integrated transport belts, making additional handling systems unnecessary and minimizing non-productive times.
With the TrackMotion system, multiple machines can be interconnected to form a flexible production line, ensuring an automated workpiece flow.
The powerful EMAG turret with turning and driven tools also enables complete machining of complex parts in a single setup. Last but not least, the machine body made of mineral casting and the vertical concept provide high thermal stability, which is particularly important in 20-shift operations.
Maximum machine availability - the decisive economic factor!
For a company like PENN, which must compete against international competitors in the high-wage country of Austria, machine availability is a crucial economic factor. 'We operate the majority of the year in 20-shift operation. At this production volume, the availability and reliability of the machines are absolutely critical,' emphasizes Gernot Penn.
The EMAG systems achieve an exceptionally high availability at PENN. This is made possible by several factors:
The robust machine construction with high stiffness forms the basis. In addition, preventive maintenance concepts minimize failures, as well as the quick service support from EMAG. Last but not least, the well-trained maintenance personnel at PENN also contribute to the high availability.
'When it comes to service: cheaper is always possible, cheaper machines can be found everywhere. But service makes the decisive difference. One must consider the machines in terms of life cycle costs,' explains Penn. The close collaboration between the EMAG service team and PENN maintenance technicians is a key success factor.
Automation as a competitive factor
To remain competitive despite higher wage and ancillary wage costs in Austria, PENN also consistently relies on automation. 'To compete in the international market, especially against low-wage countries, we must implement smart automation solutions,' explains Gernot Penn. 'In Europe, there are countries with only 30 percent of the wage costs of Austria or Germany. We must compensate for this difference through intelligent automation and high machine availability.'
The EMAG machines support this approach through their sophisticated automation concepts. The integrated workpiece feeding and removal significantly reduces manual effort. At the same time, the automated measurement technology ensures continuous process monitoring. The interlinking possibilities through the TrackMotion system allow for a continuous material flow without manual intervention.
These automation solutions enable PENN to primarily deploy employees for quality monitoring: 'We expect our employees to have a high awareness of quality. The actual work should be done by the machine. The employee must be able to focus on monitoring the produced quality.'
Complete process chain under one roof
A particular advantage of PENN GmbH lies in its comprehensive manufacturing depth. From forging part production to machining to assembly and final inspection, all process steps are carried out in-house. The EMAG machines are a central element in the value chain.
Future perspectives and further development
PENN GmbH plans to consolidate all three Austrian locations at the Stratzdorf site by 2028, which will mean a significant rationalization boost. The EMAG machines will play an important role in this, as their compact design allows for high area productivity.
Regarding market development, PENN positions itself broadly.
'We do not focus exclusively on the combustion engine or electric mobility, but keep our eyes open in all directions,' emphasizes Gernot Penn. This flexibility is also reflected in the versatility of the EMAG machines, which can be used for a wide variety of workpieces and materials.
Economic production through optimized machine systems
The long-standing collaboration between PENN and EMAG demonstrates how modern machining technology can help maintain competitiveness even in high-wage countries. By combining powerful forging systems, highly automated vertical lathes, and comprehensive manufacturing depth, PENN has created a production system that combines maximum efficiency with maximum flexibility.
The 43 EMAG spindles of the VL series, which are partially in operation around the clock, form the backbone of the machining technology at PENN and underscore the importance of reliable machine systems for economic success in metal processing.
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