Compact storage and sawing from a single source

To meet growing demand, stockholder, processor and distributor Brütsch/Rüegger Metals AG, located in Regensdorf, near Zurich, has upgraded its operations by replacing a semi-automatic honeycomb storage system for housing long stock with fully-automatic Unitop and Unitower storage systems from Kasto. The Swiss metals distributor has also integrated two additional bandsaws from the KASTOwin series. Similar storage and sawing products and services are available in the UK and Ireland through the group’s subsidiary in Kibworth Harcourt, Leicester.

Brütsch/Rüegger stocks 5,500 tonnes of metals of 8,000 different types and sizes. Since its establishment in 1877, the distributor has experienced steady growth and today, with a team of 30 employees, it is one of the leading suppliers of metal tubes, bars and sections in Switzerland.

With the higher level of business came challenges. The honeycomb storage system from the 1980s was reaching the limit of its capability. Inefficient use of space, protracted material retrieval times and safety issues associated with manual operations were hindering operational efficiency. Problems came to a head with the takeover in 2023 of Walter Looser AG, a provider of semi-finished and finished bronze products in Switzerland.

Patrick Epp, Managing Director of Brütsch/Rüegger, explains: “Our warehouse stock continued to increase and we eventually reached our maximum storage capacity. Expanding the existing warehouse was not feasible due to infrastructure constraints, leaving only one option – consolidation. This led to the initiation of a new project to increase storage capacity, modernise the warehouse and enhance process efficiency.”

The metals specialist had complex requirements for the new installation, which needed  twice the storage capacity and fit within the 26 m wide hall. Additionally, the system had to be reliable, easy to operate, and able to employ seven different storage and retrieval stations, allowing simultaneous processing of materials with multiple saws. The capacity requirements presented a particular challenge, as the design had to consider not only the limited floor space but also height restrictions due to an array of solar panels installed on the roof of the hall.

“We’ve been using a KASTOwin A 3.3 bandsaw from Kasto since 2018 and we’re very satisfied with its performance,” says Patrick. “It’s designed for series cutting and is fast and reliable in operation. The saw includes automatic functions, minimises non-productive times and features comprehensive monitoring systems, all of which contribute to efficiency and safety while reducing blade wear, whether for single cuts or large series. This level of ongoing efficiency was one of the primary reasons we chose to meet with Kasto at a LogiMAT trade fair in Stuttgart to talk about our requirements.”

During discussions there, it became evident that Kasto could offer exactly what Brütsch/Rüegger sought. The supplier recommended its Unitop 3.0 overhead, horizontally-moving gantry crane system with 521 storage positions for storing material up to 6.5 m long, and its Unitower 3.0 cassette storage system, with vertically-moving stacker crane, able to accommodate 12-m long material.

Says Patrick: “A significant advantage of Kasto over its competitors is that we would receive both storage systems from a single source. All other suppliers could only deliver one or the other.”

The new installation in Regensdorf comprises a Unitop with three double-output stations that automatically supply four sawing centres with material, plus a 12-m long Unitower. Both systems are computer controlled by the KASTOlogic warehouse management system.

To achieve the required capacity, given the limited height of the hall, the systems were sunk 4 m into the floor in recesses measuring 35 x 9 m and 14 x 4 m respectively. Additionally, the installation includes two new bandsawing centres from the KASTOwin series, models F 3.3 and A 3.6. The new warehousing arrangement, which was completed at the end of 2024 with the commissioning of the final saw, allows the company to store and process its long goods in a single hall, optimising the use of space.

Special products, such as 12 m tubes for the hydraulics industry, are stored in the Unitower. This tower storage system enhances material flow, saves significant space due to its compact design and can handle loads of up to five tonnes per cassette.

The revised storage system has increased workplace safety, since goods are now transferred automatically via a retrieval station to the saws. It represents a significant improvement over the previous solution. Moreover, the reduction in error rates has enhanced customer satisfaction. Faster access to materials leads to shorter delivery times, giving Brütsch/Rüegger a decisive advantage over its competitors in today’s just-in-time production landscape.