The numbers speak a clear language: More than 8,000 products and 5,500 tons of storage material make up the portfolio of Brütsch/Rüegger Metals AG in Regensdorf in the canton of Zurich. The full-range supplier of metal products has continuously expanded since its founding in 1877. Today, with 30 employees, it is one of the leading providers of pipes, bars, and profiles in Switzerland. However, with growth came new challenges: The semi-automatic honeycomb storage from the 1980s in Hall 5 increasingly reached its limits. In addition to poor space utilization, the high search effort and safety risks from manual operation also hindered the processes.
The manual setup process using a rail crane increasingly became a bottleneck, and the efficiency requirements could no longer be met. 'Continuous expansion of the product range and the acquisition of Walter Looser AG, the leading Swiss provider of semi-finished and finished products made of bronze, led us to look for a powerful successor solution,' explains Patrick Epp, managing director at Brütsch/Rüegger Metals AG.
'The storage volume steadily increased, and our storage capacities were exhausted at a certain point.' Expanding the halls was not possible due to the existing infrastructure. This left only the option of densification. The company initiated the 'Project Core'. The goal was to increase capacities, bring storage management up to current technical standards, and significantly improve processes.
The decisive advantage: complete system from a single source
The requirements of the metal specialist were complex: The new system had to offer double the storage capacity, fit into the 26-meter-wide Hall 5, and be able to store both 6-meter and 12-meter long goods. It needed to operate reliably and be easy to use. Additionally, the wish list included the possibility of realizing seven different input and output stations to store material simultaneously and process it with several saws. A particular challenge was the necessary capacity – as both the area and height were limited, since a photovoltaic system for green electricity is installed on the hall roof.
'We conducted extensive market research,' reports Patrick Epp. 'We have been using the KASTOwin A 3.3 band saw from KASTO since 2018, which we are very satisfied with.'
The high-performance band saw automation for series cuts operates quickly and reliably. Automatic functions, short auxiliary times, and extensive monitoring systems ensure high efficiency, safety, and tool-friendly operation – from single cuts to large series. 'This was one of the main reasons why we personally exchanged ideas with KASTO at LogiMAT in Stuttgart in 2022 about the planned storage.'
It quickly became clear there: The specialist for sawing and storage solutions offers exactly what Brütsch/Rüegger Metals AG was looking for with the two systems UNITOP and UNITOWER. 'A clear advantage of KASTO over the competition is that we receive both storage systems from a single source,' emphasizes the managing director. 'All other providers could only deliver one or the other.' This system competence is no coincidence. KASTO is a global market and technology leader for metal sawing machines, long goods and sheet storage systems, as well as material handling. The company from Achern sees itself not only as a machine builder but as a solution provider for the entire process chain – from storage to transport to processing.
Customized system for complex requirements
The new system consists of two storage systems from KASTO: the UNITOP overhead storage with a storage length of six meters and the UNITOWER tower storage system with a storage length of twelve meters, as well as two sawing centers from the KASTOwin series (F 3.3 and A 3.6). This configuration allows Brütsch/Rüegger to store and process long goods space-saving in one hall. In the overhead storage, a storage and retrieval machine moves over the metals stored in cassettes and quickly stores them in and out.
The special feature: To achieve the required capacity despite limited hall height, the company had both systems installed four meters deep into the ground.
The UNITOP overhead storage optimally utilizes the available space and, thanks to computer control, provides transparency in inventory. The system reliably hands over long goods in short cycles to the three double dispensing stations, thus seamlessly integrating into the material flow. With automatic bar separation and connection to the KASTOwin saws, Brütsch/Rüegger Metals AG utilizes a flexible manufacturing system that largely operates without personnel. In the UNITOWER, the metal specialist stores special products such as twelve-meter-long cylinder pipes for the hydraulic industry. The tower storage facilitates material flow and also saves a lot of space due to its compact design. Loads of up to five tons per cassette can be quickly and easily prepared.
From the old storage to the integrated overall solution
The conversion took place step by step: First, the installers removed the right half of the old honeycomb storage and the storage and retrieval machine (RBG) to make room for the new construction. During this time, Brütsch/Rüegger Metals AG temporarily stored the goods in other halls. The left part initially remained and was manually operated by the employees. A four-meter-deep pit was created, into which KASTO installed the two storage systems UNITOP and UNITOWER.
Next, the KASTOflow align front-side storage station was added to the overhead storage, allowing Brütsch/Rüegger Metals AG to efficiently transfer the long goods from the temporary solutions and the still-standing old storage half into the new UNITOP. Finally, the specialists completely dismantled the remaining half and established three double unloading stations on the now free space, which automatically supply four sawing centers with material. 'It was a challenge to balance the conversion and daily business,' reflects Patrick Epp. 'But the KASTO systems, both the storage solutions and the saws, have significantly advanced us in terms of efficiency since then,' praises the managing director.
More than just speed: the advantages in practice
The changes are noticeable at all levels. "The organization and access to the material have become much easier since the renovation," says Patrick Epp happily. "And this applies not only to the speed of the previous honeycomb storage but also in comparison to the overflow storage of another manufacturer that we have in use." Thanks to the short storage and especially retrieval times, the metal specialist works significantly more efficiently. The new storage system has also improved workplace safety, as goods are now automatically handed over to the saws via retrieval stations – a noticeable advancement compared to the previous manual solution. The reduced error susceptibility in the setup process directly impacts customer satisfaction. Faster access means shorter delivery times – a crucial competitive factor in the just-in-time production of modern industrial companies. The KASTO branch in Switzerland ensures quick assistance in case of disruptions and minimizes downtime.
"Our expectations for performance and quality were met 100 percent," summarizes Managing Director Epp with satisfaction. The company successfully completed the "Project Core" with the commissioning of the last saw, a KASTOwin A 3.6, by the end of the year. His conclusion sums it up: "Decisive competitive factors are the compact storage and the efficient processing of our products. KASTO provides complete systems and solutions from a single source that we can rely on."
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