For upstream and downstream work processes Indian job shop opts for part leveling machine from KOHLER

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Optimizing sheets with minimum stress: Whether laser cutting, deburring, edge trimming, welding, or assembling—the levelness and stress of the sheet metal play a decisive role in all areas of sheet metal processing.  

Professionally leveled sheets are low in stress and have the required degree of levelness to be optimally processed further. In order to meet the stringent quality and levelness requirements of international customers such as SIEMENS, POWER SYSTEMS, General Electric and Alstom, a Peak Performer 30P.1300 part leveling machine from KOHLER Maschinenbau GmbH is now successfully being used at Gorasia Industries Pvt. Ltd.

The 45 employees at the Indian job shop now process 70 to over 300 tons of material each month. Gorasia Industries was founded in 1985 by Gorashiya Murji Harji with the aim of delivering high-precision sheet metal products quickly and at attractive prices. Its factory covers 2,500 m² (approx. 2990 sq yd) and boasts state-of-the-art machinery: one laser cutting machine from Salvagnini; three press brakes from Bystronic, Amada, and Accurpress; one deburring machine from Timesavers; and various manual welding systems. To improve quality and reliably shorten throughput times, the production line has recently been expanded with the addition of a Peak Performer 30P.1300 part leveling machine from KOHLER Maschinenbau GmbH.

Depending on the order volume and customer requirements, the company, which is headquartered in the state of Gujarat in western India, offers a flexible shift system with one to three shifts. Its main products range from cut parts to complete machine housings, with the focus being on steel (70%), stainless steel (20%), and aluminum (10%).

Level sheets optimize processes with minimum stress

The Indian job shop knows only too well that stamped and laser-cut sheets have to be leveled before they can be further processed. The more level the parts are and the less stress they exhibit, the easier it is to edge, bend, weld, and finally assemble them. Before acquiring the part leveling machine, experienced employees had to painstakingly level sheets manually using hammers to meet the customers' high levelness requirements. This process was time-consuming and not always precise. It was also a big problem if an experienced employee was off work.

“Manual leveling didn't allow us to achieve the optimal results we needed in the long run. Since our customers are increasingly demanding tight levelness tolerances – in some cases of just 0.1 mm/m on the end product – the decision to invest in a part leveling machine was not a difficult one. We discovered the KOHLER part leveling machine thanks to GVK METALFORMS. GVK is a close sales partner of KOHLER and was able to show us the perfect machine. The KOHLER part leveling machine has proven to offer a huge number of benefits, as it enables faster and more flexible production with less reworking and fewer complaints.The machine's ease of use and maintenance as well as the advanced cleaning system which assists us when changing from structural steel to stainless steel or aluminum play their part in ensuring the machine is efficient and durable. As soon as we had commissioned the machine and produced the first leveled parts, we realized that this machine would save us a huge amount of time and we would be able to meet customer requirements faster and with a greater degree of precision. We were also able to perfectly level perforated components such as speaker grills or perforated and facade components which are intended as high-quality design elements on the KOHLER Peak Performer,” explains Rupesh Gorashiya, Managing Director at Gorasia.

Leveling: Quality right from the get-go

Advantages of leveled components include a higher repeatability of the bending angle during edge trimming and the accuracy of fit of the parts during welding thanks to stress in the sheet metal being reduced to a minimum and the parts exhibiting less distortion.As a result, downstream work becomes more reliable and more efficient,as time-consuming reworking is eliminated.

The ease of use of the machine as well as of the advanced cleaning system impressed Gorasia right away. It is important not to forget to regularly clean the leveling rollers and supporting rollers to remove dirt particles, especially when processing a mix of steel and stainless steel. This prevents abrasive particles from being deposited on the leveling material and dirt or even scratches impairing the material being leveled.Thanks to the fully extendable leveling cassette, the leveling rollers and supporting rollers can be easily cleaned by only one person between two leveling jobs. This additional feature not only improves leveling results by preventing contamination, but also reduces unwanted scrap.

Looking to the future with minimum stress

This success story shows how investing in state-of-the-art leveling technology from KOHLER optimizes production processes and prepares companies for future challenges. Gorasia Industries Pvt. Ltd. is also planning on expanding and has already purchased a large plot of land. Although no construction work is currently planned, they do have the flexibility to start construction within the next six months. In the new facility, Gorasia intends to produce larger and thicker components and will, therefore, need a larger part leveling machine when that time comes.

Peak Performer Part Leveling Machines | Flattening and de-stressing Sheets and Parts | Metal Part Straightening Machines | Straighteners |