Shorter Throughput Times and Increased Productivity Relieving the Stress in Modern Sheet Metal Processing

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Flatness and low tension in sheet metal are crucial factors for further machining in the metalworking sector, including cutting, bending, punching, edge trimming, welding, and assembly. ALCOLOR GmbH is using the Peak Performer 60P.1600 part leveling machine from KOHLER Maschinenbau GmbH to great effect to meet the high demands of international customers and the construction industry in particular.

ALCOLOR GmbH is a leading powder coating and sheet metal processing company based in Nenzing, Austria. The company employs around35 people and generates an annual turnover of approximately €6.5 million (approx. $7.0M). ALCOLOR produces anything and everything made of sheet metal—be it window sills, coverings, facades, electronic housings, or ventilation grilles. Over 50 tons of steel and around150 tons of aluminum are processed by the sheet metal specialist every year.

ALCOLOR's production site covers 5,300 m²  (approx. 57,000 sq ft) and boasts modern machinery: 1 laser cutting machine, 1 plate shear, 1 stamping machine, 2 press brakes from Amada, and 1 folding machine from Schröder.To improve quality, comply with strict standards, and reliably shorten throughput times, the production line has recently been expanded with the addition of a Peak Performer 60P.1600 part leveling machine from KOHLER Maschinenbau GmbH.

The sheet metal specialists in Nenzing know only too well that punched and laser-cut sheets have to be leveled before they can be further processed. The lower the stress and the more level the parts are, the easier it is to edge, weld, and assemble them. Advantages include a higher repeatability of the bending angle during edge trimming and the accuracy of fit of the parts during welding thanks to tensions 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.

Precisely Meeting Tight Tolerances

The Peak Performer 60P.1600 part leveling machine has been in operation at ALCOLOR since the end of January 2025 and is responsible for the entire leveling process in production. Regardless of whether parts are made of steel or aluminum, a flatness tolerance of up to 0.1 mm/m can be continuously achieved with professional leveling.

Before we purchased the 60P.1600 part leveling machine, we had to outsource leveling to an external partner, which led to additional costs and delays. We needed a solution that would not only ensure the quality of the sheet metal parts, but also shorten production times and increase flexibility. We opted for the KOHLER 60P.1600 part leveling machine because of its ease of maintenance, energy efficiency, and optimal leveling quality

Sandro Vonier, Head of Sheet Metal Technology at ALCOLOR GmbH

The sheet metal specialist was impressed at how easy and intuitive the machine is to operate as well as the advanced cleaning system. 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 aluminum. This prevents abrasive particles from being deposited on the leveling material and dirt or even scratches impairing the material being leveled. The rollers can be cleaned effortlessly thanks to the fully extendable leveling cassette. This additional feature not only improves leveling results by preventing contamination, but also reduces unwanted scrap.

Leveling The Way Forward

The KOHLER part leveling machine has proven to be a valuable addition to ALCOLOR's machine fleet. ALCOLOR is now optimally equipped for future requirements and can deliver high-quality results at all times, even with deteriorating sheet qualities and tight tolerances. Using the KOHLER machine has not only allowed the sheet metal professionals to increase production quality and optimize processes, but also successfully open up new business areas such as contract leveling.