SYSPAL Ltd, a leading manufacturer of stainless steel and aluminium equipment have invested in one of the most technologically advanced laser cutting machines in the UK. With a desire to continuously improve equipment and processing capability, the Shropshire based company installed a flat-bed fibre laser cutting machine from Bystronic UK to expand the range of materials it can process.
SYSPAL specialise in providing hygienic, durable solutions to the medical, pharmaceutical, food and beverage industries as well as sectors where reliable and accurate equipment is required.
The laser cutting system extends the range of antimicrobial materials and coatings able to be used in the manufacturing processing, offering SYSPAL a great competitive advantage.
Copper touch surfaces have intrinsic properties to combat a wide range of microorganisms and viruses. Benefits of antimicrobial surfaces in the healthcare and food industries are:
Early adopters of CO2 laser cutting and CAD modelling systems for more than 25 years, SYSPAL are always looking for ways of expanding their capabilities. As machining technology advances and the number of new material finishes is increasing, SYSPAL has the ability to respond to market demand.
Managing Director at SYSPAL, Chris Truman explains: “We have operated a number of CO2 laser profiling machines for many years and continue to do so, but that type of machine is not able to cut copper, as reflections can damage the optics and beam delivery system.
Fibre laser machines, on the other hand, are able to cut copper and its alloys such as brass up to 8 mm thick, which will allow SYSPAL to produce components and complete assemblies from the latest antimicrobial material like KME Plus copper sheet (www.kme.com).
Due to its high reflectivity, even aluminium sheet, which is one of our main materials, is problematic to cut with a CO2 laser, while processing stainless steel tends to be slow. We regularly cut both metals up to 10 mm thick, which are tackled efficiently by the fibre laser, while up to 15 mm can be processed if needed. The CO2 machine is now mainly used for profiling thicker materials.”
Software is Key
Analysing ways to reduce waste, energy and abrasive consumption, SYSPAL focus on manufacturing better quality parts and maximising productivity in all aspects of the business.
Operating with the latest CNC system, containing advanced nesting software, the Bystronic BySprint 4020 increases efficiency in SYSPAL’s production lines, saves costs and reduces cutting times when utilising the 4 x 1.5 metre sheets, which is the manufacturers standard size.
To achieve longer periods of operated running and maximise production outputs, SYSPAL has automated the fibre laser machine with a ByTrans 2040 Extended sheet handling system which receives the instructions from the program running, delivering raw material to the shuttle table and unloading processed sheets.
Chris Truman adds: “Another advantage of a fibre laser is its speed. When cutting aluminium and stainless steel sheets, it is generally twice as fast as the CO2 laser machine, while the gauges in some other materials can be profiled three to four times faster.”
By using nesting software, SYSPAL’s manufacturing cycles are consistently programmed, showing an increase of up to 20% more products, which not only reduce the amount of wasted material, but also delivers orders promptly.
When dealing with larger, heavier stainless steel sheets, the risk of injury and accident occurrences increases. SYSPAL protects its employees by making sure that all health and safety practices are followed. For the stainless steel manufacturing company, eliminating manual handling to minimise risks of accidents is a priority.
SYSPAL’s latest automation equipment comprises of two cassettes of three tones capacity each, one above the other, providing a range of possibilities for material handling. Each cassette can be loaded by fork lift truck with a different type of palletised sheet material. Pallets are prepared at one of the output stations serving the 100 location Stopa automated sheet metal storage and retrieval system at the Broseley factory.
Alternatively, the second cassette can hold cut parts or protective separators that are interspersed with cut sheets to prevent damage to sensitive material. The space beneath the bottom cassette can be utilised for temporarily holding a processed sheet or placing skeletons ready for recycling.
Convinced by the efficiency in automation, Chris Truman comments:
“With the BySprint Fibre, cutting parameters are more consistent over the different grades of material we process. It leads to more repeatable cut quality, helped by automatic nozzle change and alignment after a pre-determined number of piercings.”
Subcontract services account for around 10% of SYSPAL’s turnover. Work carried out includes laser cutting on the flat bed fibre and CO2 laser cutting machines as well as the tube laser cutting centre, a four metre automated press brake and other machine tools at SYSPAL Ltd.
Whether it is a bespoke design or the customer wants to choose from a high quality product range, SYSPAL provides the highest level of customer service. The technical and production team at SYSPAL have enormous experience in the fabrication of stainless steel and aluminium components and assemblies. With the in-house extended capabilities, the leading manufacturer delivers consistent quality and prompt delivery to a widening market, both in the UK and internationally.
For further information or enquiries, please contact us.