The Schelling cut-to-size plant in action at MDF/HDF wood fiber board producer Homanit in the Karlino factory in Poland.

Special infeed solution
Schelling has developed a special thin board infeed that has already been used with excellent results in numerous plants. This solution uses two vacuum infeed carriages and a nip roller. Here boards are lifted one at a time by the vacuum carriage and transferred to the nip roller. Due to the two alternately operating vacuum carriages, very high cycle times of more than 25 cycles per minute can be achieved. The technical availability of this infeed system is more than 99%. Ernst Keider, General Manager of Homanit GmbH, describes the advantages of this type of feed:

"While one infeed cycle is running, the other is already being prepared – the systems are interleaved without hindering each other. As a result we were able to double the speed during infeed. The infeed concept on the new plants impressed us so much that we have even had older saws upgraded."

Schelling has developed several infeed options depending on the required weighting between capacity and protection of the surface finish: a combination of "nip roller system & pusher" or "nip roller system & vacuum feeding rails", as well as the "dual vacuum system" in case of the need for maximum protection of the surface finish.

Minimum trim waste
A crucial stage in the thin board cut-to-size process is the alignment system. If the cutting books are precisely aligned, unnecessary trim waste can be avoided. The alignment tables on the cut-to-size plants in Homanit's Losheim and Karlino factories have electronically positioned, adjustable aligning devices that make it possible to align even the thinnest boards without damage within the necessary cycle time. To ensure the small trim waste does not fall through the saw gap on the sawing machine and cause soiling or malfunctions there, Schelling Anlagenbau developed a special saw gap closing device that only opens briefly in the area of the saw blade and then closes again. The waste that is produced during trimming or "dust cuts" is ejected through automatic waste flaps to a conveyor system below. The waste is transferred via a central outlet to the guillotines where it is chopped up and transported away.  
Using a turntable in front of the rip saw, it is also possible to cut complex cutting patterns with head cuts in the Karlino factory.

Cutting to size on a cushion of air
Another aspect that impressed the wood fiber board manufacturer Homanit is the method used to protect the material during the cutting to size phase. For this purpose the steel saw machine tables have a hard chromium-plated work surface that, at Schelling Anlagenbau, is also equipped with air nozzles to provide "floating" transport. The saw carriage is based on a concept developed and patented by Schelling. In this case the saw motor remains stationary, only the saw blade is raised for the cutting process. As a consequence it is possible to use more powerful saw motors, resulting in turn in higher cutting speeds.

Flexible sorting and stacking solutions
The stacking solution has a major impact on the overall capacity of the plant. If, after cutting to size, the boards are not removed at the same speed as during the infeed and cutting to size phase, a typical "bottleneck situation" is produced that slows down the whole process. Schelling can offer a very diverse range of solutions for this task, starting with simple, manually assisted material stacking to fully automatic sorting and stacking. Homanit decided for a combination of automatic stacking devices and manually operated stacking places. A software program developed by Schelling is used to indicate precisely to the operators at the manual stacking places which format is to be placed in which stacking place using color coding on a monitor.

Due to two alternately operating vacuum carriages, very high cycle times can be achieved in the infeed.

Easy to operate
"So that we can manufacture flexibly and efficiently, with both large and also small batch sizes, we need plants that are as uncomplicated as possible", explains the General Manager of Homanit. "As Homanit produces seven days a week around the clock, we need cut-to-size plants with user interfaces that are easy to use", he reports, "even if no programmers or software specialists are available." This requirement was rigorously implemented during development at Schelling.

Furthermore, quick, un-bureaucratic decisions, short communication channels and a quick response are also important criteria for him. "Even on the best plants there are sometimes technical defects. If need be, companies with a flat hierarchy can help quicker than those in which it is necessary to first fight your way through several layers. Here we have had a very positive experience with Schelling."


Schelling Anlagenbau GmbH is a specialist in custom solutions for cut-to-size plants for the board and furniture industry as well as for the circuit board industry, metal industry and plastics industry. The 90-year-old company now trades worldwide – with subsidiaries or representatives in almost all parts of the world.


Fact box

Information on Schelling cut-to-size plants

• Cut length: 3300 mm - 7800 mm
• Width: 1300 mm - 3300 mm
• Height: 120 mm - 210 mm
• Saw motor power: 27-75 Kw/50 Hz
• Infeed, cutting to size and stacking solution to suit customer requirements

For many years, non-ferrous metal plates were cut with the circular sawing technology. This method produces a so called “finished cut” which can not be achieved with traditional cutting methods. Five years ago, Schelling, the industry leader in manufacturing non-ferrous metal plate saws, set the goal to implement the circular cutting technology for steel, stainless and titanium plate cutting.

The result of several years of research and development processes is the new Precision Plate saw, type fs 10. The working principle of this machine is similar to the proven and well established Schelling non ferrous metal plate saw.

After a two year development process this past March, Schelling represented the new Precision Plate Saw fs 10 to a circle of industry experts. The feedback was overwhelmingly positive and mainly due to the convincing fs 10 operational data.

• Saw carriage cutting speeds: 1.1730 tool steel, 80 mm thickness > 400 cm2/min; 1.2312 tool steel, 50 mm thickness > 300 cm2/min; 1.4301 tool steel, 35 mm thickness > 60 cm2/min
• Dimensional accuracy     +/- 0.1 mm
• Highest production redundancy for a three shift operation
• The cutting surface and the dimensional accuracy are of such quality that subsequent machining can be minimized or eliminated
• The high productivity of the fs 10, combined with the factor of reduced or eliminated subsequent machining time, results in extraordinary escalation of efficiency and shorter machine cycle times.

ThyssenKrupp Material, located in Wil Switzerland, had significant input on the fs 10 development process. For many years ThyssenKrupp has placed trust in the Schelling know-how and is using Schelling Plate Saws in their non ferrous cut-to-size operation. ThyssenKrupp tested the fs 10 prototype in house over a two year production period. During that time, they contributed important technical data for the continuous developing/design process of the new fs 10.

Operation Manager Walter Pfaefflie of ThyssenKrupp Wil, explains this close cooperation:

"The new fs 10 contains the Schelling machine building know-how and the ThyssenKrupp expertise in cutting tool steel. The goal was to bundle this synergistic expertise and implement all factors in the fs 10 development and design process. The new fs 10 offers exceptional operational characteristics. The tool set-up, the plate handling and operation of the machine is so much simpler, faster and more comfortable compared to traditional steel cutting methods."

Remarks from Claudio Roth,Tool Steel Department Manager ThyssenKrupp Wil, on the fs 10: 

"Order processing, particularly short term orders with large quantities, is not an issue anymore. Since the new fs 10 customer satisfaction is up, we can expand our customer base and achieve a higher customer loyalty. "

Schelling readies the path toward a new area in cut-to-size of steel, stainless and
titanium Plates.

Schelling Manufacturing, a worldwide operating company group, is the market leader for the highest technically challenging and custom tailored cut-to-size plate saws and systems used for all panel based material in the Wood, Plastic, Printed Circuit Board and Metal Industry.Starting with the product development and design process, manufacturing, installation and commissioning up to a dedicated after sales service, everything comes from one source. This guarantees 100 % responsibility for the project, combined with the highest expertise.Individual and professional solutions combined with the newest technology, enable Schelling to further strengthen their position in the world market. The main benefits for the customer are top quality durable machines and plants with short start-up times. A highly qualified and motivated staff, working out of sales & service centers around the world, guarantee optimum and professional support service.

Functional description

The 3rd phase cut-router is used in connection with a conventional cut-to-size angular plant. Single boards are cut into strips on the rip-cut saw and then moved to the cross-cut area. Before the 3rd phase cut application, the strips are clamped and moved towards the cross-cut saw by the programmed feeder carriage. Now the trim cut on the cross-cut saw is made and the part aligned against the cross-cut-fence. The programmed feeder carriage then pushes the strips through the stationary router for 3rd phase cuts. During the milling the specially designed strip aligner with press-roller constantly pushes against the material and guarantees absolute accurate sizing.The required 3rd phase cut width is achievable with the moveable frequency controlled drive router. The router is raised to the working area by a servo motor.A separate extraction system for the router provides a perfect, dust free surface. The extraction hood is lowered on to the material during the milling progress. The integrated rollers in the extraction hood hold the material down against the roller table underneath.

Once the required 3rd phase cut depth has been milled, the router lowers and the feeder positions the strip for the cut-to-size process. For a board thickness of up to 25 mm the router tool has a diameter of 10 mm.The saw blade of the cross-cut saw is 5.4 mm and therefore we can guarantee that with only one cut cycle, the parts are produced with a perfectly cut edge.

The trim waste is removed via an adjustable waste flap into a waste bin. This waste bin tilts and turns 90° so that trim waste is disposed into the waste conveyor of the cross-cut saw.

With this system, Schelling offers a complete system that is logisticaly supported by Schelling's Optimisation Software HPO. Maximum output, perfect tecnical solution in highest quality, all out of one hand. This is what this new innovation from Schelling stands for.

Often labels are applied to positively identify cut parts. Typically the label printer is located after the cut line at the cross cut fence of the saw. Labels are printed in real time and are dispensed by the printer for manual pickup. The operator removes the label and applies it to the appropriate part. Consistent innovations and improvements of panel saws have dramatically improved the output of panel saws. Especially saws with two feeders that can cut two different sizes at one time increase output dramatically. If it is required to place a label on each part, the operator will be overwhelmed by the complexity and volume of labels that need to be placed onto parts; hence he has to stop the machine frequently to keep up. Therefore, the theoretical output of the highly efficient saw cannot be reached.

Optimized work method

Schelling has developed an automatic label printing system for automatic loading panel and angular saws. Labels will be applied to the panel in the infeed area, while the previous pattern is being processed in the saw. The location of the label on the part can be programmed. If a part is turned 90 degrees in the pattern, the label will be turned accordingly. Additionally, every label placed will be checked via a control scan.

Therefore, all parts are already labeled as they come off the saw. Handling two different parts that come off the saw at the same time is absolutely no problem; therefore, no capacity reduction is experienced due to labeling.The functional description of a single beam saw with automatic push infeedand with automatic label applicator is as follows:

Functional description

The printer is stationary mounted on the side of the infeed station and dispenses labels according to the cut pattern. An applicator with rotating head picks up the label and places it onto the panel. The applicator has its own X-axis and the push off carriage provides the Y-axis. Therefore, labels can be applied anywhere on the panel and in the appropriate orientation. Once the label is applied, the applicator moves up into its home position and simultaneously, the label is scanned and checked for proper information. Once the information is confirmed, the next label is printed and the process repeats itself until all labels are applied.

Once the label process is finished, the infeed pusher pushes the panel into the saw to start the cutting process.

Single beam and angular saws with vacuum infeed

Saws with vacuum infeed or an inventory system with vacuum carriage can process books where each individual board is labeled. This process requires the vacuum to place the panel onto the roller table behind the saw and then the label applicator applies the labels. In this configuration the applicator is mounted onto its own X/Y carriage. Once finished the vacuum places another board on top of the previous one and the process repeats itself.

Conventional work procedure

Until now, the operator of a cut-to-size saw had manually handle the boards or strips for every different directional cut. For a cutting pattern – as shown below – the operator first has to load the full board into the machine. This enables him to produce the two rip-cut strips and thereafter he will have to turn these for cross-cutting to get the parts required. For the top left part, the third phase cut part, the operator has to load the part back into the machine to make this third cut to achieve the required finished part size.

Time optimized work procedure

3rd phase cuts are parallel to the cuts on the rip-cut level and therefore can be processed in the same cycle. A small strip of waste between the parts allows the completion of the 3rd phase cut part, without damaging the neighbouring part. The consequence of this is that during cross cutting, the 3rd phase cut part is produced with its final measurements. This, in turn, results in reduced handling and decreased production time and eliminates any mistakes made by the operator. The required waste strip is not truely wasted, it is simply taken from the required front and end trim.