Kasto at EMO 2025

Explaining how metal stockholders and manufacturers can optimise material flow and raise productivity using intelligent material handling, automated sawing and 3D storage solutions will be the theme of the Kasto stand, C54 in Hall 17, at EMO 2025 (22-26 September, Hanover). The company is set to present numerous product innovations.

As far as sheet metal is concerned, from the moment material arrives at a plant, KASTOflow unpack assists the job of manually removing the packaging. Its drum-shaped rotating device can turn packages weighing up to 5 tonnes through 180 degrees, making it easy to remove straps, film and wooden pallets. Vertical and horizontal guides then ensure that the sheets are aligned precisely, which is a significant advantage for downstream automated storage.

A double-roller conveyor, KASTOload, enhances feeding of long stock into sawing machines to reduce non-productive time. While sawing is in progress on one side, on the other side the next job can be set up simultaneously. A system on the outfeed side of the saw automates part handling after a cut has been made. In addition, a carousel sorting system accommodates Euro pallets and material containers, while a lifting system positions pallets accurately for transfer.

KASTOsort robot systems offer automation solutions. They can pick and palletise orders, without requiring any programming or teach-in by the user. The robot control automatically calculates the optimum stacking pattern to achieve maximum packing density.

A KASTOsort tower automates an entire sawing and storage process within a small footprint and can run around the clock with minimal operator attendance. The space-saving system incorporates storage, sawing and sorting in a compact design. It provides high-density storage and users can access material flexibly, without the need for personnel to be present, due to a drive-through station at the back. It allows a collection vehicle, such as a forklift, to pick up pallets as needed, without interrupting the sawing and sorting processes.

On show will be advanced sawing technology, featuring machines such as the KASTOwin, KASTOmicut and the KASTOtec power package, which are bandsaws designed for cutting a large range of material sizes. Additionally, Kasto offers innovative software, including the KASTOlogic WMS (warehouse management system) that, in conjunction with its KASTOoptisaw module, automatically optimises both straight and mitre cutting plans using iterative algorithms. The aim is to obtain the maximum number of parts from a given bar, reducing rest piece length.

Without the need for sensors, the saw blade infeed rate is adjusted based on the type of material being cut and its cross section. Furthermore, saws can be integrated seamlessly into existing systems through open interfaces, for instance OPC UA or MQTT.

At the beginning of 2026, the first sawing machine models will be introduced featuring the new, easier-to-use, higher-performance generation of Kasto control systems, ProControl and ExpertControl. One of the novel features is ‘Simple Mode’ for streamlining operation, particularly during straightforward cutting tasks, to reduce complexity and allow quick, easy job entry. The solution will be shown for the first time at EMO 2025.

Kasto’s overall message at the show will be that storage, sawing and handling involve more than just cutting and transporting material; they are all parts of a digitally interconnected process. The integrated system solutions can streamline operations, reduce downtime and are compatible with Industry 4.0 concepts. Businesses also benefit by having a single partner manufacturing and supplying products for the entire material flow.