Products

Innovations that push boundaries. With us, complex profiles can be produced faster, more flexibly and with an optimal price-performance ratio.

Roll forming with XELLAR

The roll forming line made of modular production cells

Modular design and integrated processes enable roll forming, punching, welding, toxing, riveting and much more – on one roll forming line. Xellar production cells set standards in productivity, safety, noise protection, energy consumption, operation and ease of service. Xellar is an extremely flexible production system. With its modular design, it is just as suitable for individual adaptation to frequently changing profiles as it is for process-reliable large-scale production. The Xellar profiling systems combine the advantages of a series product with customisability.

Profiling machine Xellar

1. Belt system

2. Stamping module

3. In-feed module

4. Drive system

5. Profiling module

6. Extraction

7. Minimal lubrication

8. Tool system

9. Digital process and quality control

10. Integrated cooling system

11. Crosscut module

Flexible

Flexible

Smart

Thanks to its patented design, the combination of individual production cells, the Xellar Roll Forming Line is outstandingly flexible and adaptable. Intelligent details such as intuitive positioning of the tools and quick-change systems accelerate set-up processes and make adjustments easier. We are proud to call the result „smart profiling“.

Functional

Functional

Extendable

Xellar designs the roll forming process to be highly functional. On the basis of the manufacturing cells, individually controllable drives, intelligent sensor systems and simple control functions can be perfectly implemented. If new process steps need to be added, different roll-formed profiles have to be produced or manufacturing technologies are changed on short notice, the true strength of the concept comes into play.

Efficient

Efficient

Profitable

Xellar pays off from the very first day. The standardised design and robust technology guarantee high uptime. Optionally controllable transmission units lower tool wear, while a clever (intelligent) drive concept allows for rapid tool setup. Based on a comparable initial investment, these advantages make Xellar Roll Forming Lines clearly more economical than other systems in the long run.

Reliable

Reliable

High-performance

Millions of metres of roll formed profiles have been created on our lines. That’s why we know that uptime and productivity are paramount. Xellar Roll Forming Lines are robust by conception. The protected work area, the separation of electric supply and mechanical elements, the intelligent drive concept and low-maintenance design enable the system to achieve the highest level of performance.

Profiling machines

Forming technology in perfection

Customised profiling machines have been our expertise for more than four decades. You benefit from our combined know-how in mechanical engineering and contract profiling. Depending on the material properties and requirements, we advise, develop and build machines and systems exactly for your needs. The criteria for machine design include:

  • Shape accuracy and tolerance ranges of the products or product series
  • Surface quality, from uncoated sheet metal to pre-painted materials
  • High production speed and short cycle times for subsequent processes
  • Uncomplicated changeover concepts and intuitive operation
  • Optimum price/performance ratio

The result: innovative machine technology for every profile!

Production systems

The process-integrated solution

Holistic turnkey projects are a comfortable way to increased productivity. With more than 40 years of experience in contract profiling and plant engineering, we understand your needs in terms of speed, quality and cost efficiency.

From project management to general contractor, we realise complete production plants including networking, process chaining and the combination of several sequential process steps in one coherent production plant. We will be happy to provide you with references from the electrical industry, aviation, construction industry and air-conditioning technology, among others, on request.

We provide you with process-integrated production processes from the semi-finished product to the packaged finished product – for direct delivery to your customers.

Punching systems

for individual functional features

From complex punching patterns for the assembly of electrical components or for simple rows of holes to bind other sheet metal parts – we realise the full spectrum of pre-, intermediate and post-punching processes. Our punching tools and system control enable any geometries as well as combined processes at the highest speed. Standard geometries with metric and inch dimensions can also be realised.

  • Intelligent feed and tool technology
  • Automatic set-up of pre-programmed hole patterns
  • Highest production output and precision
  • Minimum changeover times with test run and verification
  • Automated punch waste transport
  • Cost-effective standard or integration in XELLAR production cells
  • Noise- and emission-reduced

With our expertise in cutting and punching, we turn every requirement into functional solutions!

Cutting machines

Each piece has character

Roll-formed profiles are cut to the appropriate length with a cutting machine or with process-integrated cutting concepts. We use the appropriate technical operating principles and clamping devices for your requirements on a product-specific basis:

  • Saws
  • Shears
  • Punching
  • Laser cutting

Depending on the requirements, cutting of the metal profiles is possible in “stop and go” operation or as “flying cutting” in continuous operation.

Welding systems

The reliable connection

Welded profiles are the supreme discipline, combining precision in roll forming with the reliability of the welding process. Relevant factors are the precision of the strip edge, the required production speed and, of course, the resilience of the weld seam including proof of tightness.

Our proven delivery spectrum ranges from transverse welding systems for joining the strip ends of a new sheet coil to automated and process-integrated welding systems:

  • Transverse welding systems
  • Laser welding
  • TIG welding
  • Up to complete XELLAR laser welding cells including safety-related acceptance. Here, optics with high welding performance can be accommodated in the smallest space!

Special systems

For individual production processes

Do you want to implement an individual production process for your product or your product range? Even better performing, more precise and more economical than before? Talk to us.

From bending systems, e.g. for Airbus cabin bulkheads, space-saving belt systems for belt preparation, rounding off or on the subject of “ContiLoop”, we offer versatile process know-how for the development of functional production solutions. All the way to so-called double-head profiling systems in which the adjustable roller stands are infinitely variable in their distance from each other in order to meet special requirements for flexibility or component diversity.

System Control

As simple as a smartphone

The decisive interface for the interaction between man and machine is the human-machine interface (HMI). As experienced rollformers, we also think of our control concepts consistently from the user’s point of view. Modern sensor technology and process support are fundamental principles of this way of thinking. To this end, we have mastered the interfaces with both Siemens-based and Bosch-Rexroth control solutions.

With our intuitive human-machine interface (HMI), you get the benefits of modern digitality for ease of use and maximum functionality. The customer-specific applications and processes can be optionally added – just like apps.

The software coordinates all relevant production parameters. It provides real-time information on all plant parameters clearly displayed on a monitor for the

  • evaluation of production processes and process parameters
  • management of product variants such as hole patterns and length variants
  • integrated quality inspection

Because in the end, profiles are as good as the perfect synergy of man and machine. That is smart profiling!

Tools

A tool for every task

The product can only be as good as the tool used to produce it. As a machine manufacturer and user of the most diverse technologies, we see our tools from different perspectives and can perfectly analyse and understand the needs. That is why we place the highest value on the quality of our tool systems and components.

In the Technology section you can see the variety of processes for which we offer tools. The systems can be seamlessly integrated into our plants as well as the control system and offer all users the best possible comfort.

  • Design and manufacture of tools and tooling systems according to your requirements
  • Commissioning and testing of the tools
  • Tool development for special processes possible