The steel cutting capability allows Electroalfa to get the optimal layouts for each order. To minimize the scrap Electroalfa uses dedicated software solutions.
The following machines are used within the in house steel center:
- Decoiler line with strengthening mechanism capable of processing steel coils up to 1250 mm in width, 3 mm in thickness and 5 tones in weight
- Steel shear type FGH 420 for steel up to 3 mm thick
Electroalfa SFPBU uses: 2 hydraulic presses for tubes, 9 eccentric presses in the range 20 and 63 tones force and 1 hydraulic press of 500 tones force.
The LT Combo Fiber 3000W machine is able to cut various types of steel sheets (structural steel up to 20 mm thick; stainless steel up to 10 mm thick; aluminium up to 10 mm thick; cooper up to 6 mm thick) and specific profiles up to 6000 mm length and 200 kg in weight.
Punch laser combi
The TC6000 machine from Trumpf provides high precision and manufacturing flexibility, optimizing the types of tools needed in production.
Various machines are available:1 PrimaPower punching and shearing machine, 3 Trumatic punchers and 2 Euromac.
CNC press bending
The 5 CNC abkant presses provide precise and reliable bending: Ermaksan Power Bend Pro 135 -30, Gasparini PBS45/1600, Gasparini PBS45/2100, Gasparini PBS85/3000, Trumpf Turmabend V85S.
CNC automated bending centers
For large series with complex bents there are 2 automated centers available: PrimaPower FBe4 and Weinbrenner B12.
CNC tube bending
The BLM E-Turn 52 machine provides tube bend in various shapes.
The Carl Cloos welding robot may be fitted with various types of welding sources while its working table is capable of movements on 6 axis for high productivity.
Several welding booths prepared for MIG/MAG, WIG/WAG manual welding are available.
Electroalfa uses machines from reputable manufacturers Tecna, Fronius, Telwin.
The surface preparation prior to painting is performed on a line fitted with automated process control and variable speed conveyor. The nanoceramic pretreatment applied before painting in an automated mode allows the powder painting of various material types (standard steel, galvanized steel, electrochemical steel, stainless steel, aluminized steel, aluminum) with high corrosion resistance. Electroalfa developed and tested a solution for corrosion resistance up to C4 according ISO12944-2.
On the same line providing the pretreatment process there are fitted an automated painting booth of type cyclotron and a manual booth for small series.
The ManzGalvanotech line is fitted with partially automated process control and own water treatment line for Zn plating in drums or frames. Large parts may be plated due to the size of the baths installed on the line, i.e. 2100x400x1100 mm.
The CNC Rampf gasketing machine pours PU gaskets on 2 axis with high precision and productivity.
Specialized teams are working on the assembly lines using lean production processes as Kamban and supermarket.