How a central warehouse is reorganising production and dispatch
3,500 tonnes of aluminium profiles per year, material lengths of up to 7.5 metres and limited storage space: TIR Technologies needed a logistics system that could keep pace with its growing production. Two UNIGRIP automatic honeycomb storage systems, the intelligent KASTOlogic warehouse management system and a KASTOfenestra station now bring structure to the material flow. The profiles are stored safely, stock levels remain transparent and the right materials are reliably available for the manufacture of awnings and pergolas.
SCHMOBI
Around 100 employees at SCHMOLZ + BICKENBACH Stahlcenter AG – SCHMOBI for short – supply the Swiss manufacturing industry with bright steel, stainless steel, high-grade structural steel and other product groups. The sawing department produces more than three million cut-to-size pieces annually, with dimensions of up to 530 millimetres.
The challenge: increasing storage capacity within a limited space
The large volumes of material and profile lengths of up to 7.5 metres placed significant demands on TIR Technologies’ internal logistics. Manual handling and checklists created additional work and increased the risk of errors. At the same time, the profiles needed to be stored in a dry and protected environment and be available for production at any time, allowing for reliable planning.
Awning production was particularly challenging: within the specified space, cassettes for 6-metre and 7.5-metre-long profiles had to be accommodated within a single system. This called for a solution that made efficient use of the available space and handled both types of cassette safely.
The solution: automated honeycomb storage systems and intelligent profile handling
KASTO has developed an automated storage and material flow concept in collaboration with TIR Technologies. An initial UNIGRIP-type honeycomb storage system with 1,200 storage locations supplies the pergola assembly line. A second system, situated at a height of 13 metres, provides 2,000 storage locations for awning production.
Storage and retrieval operations are controlled by the KASTOlogic warehouse management software. In addition, KASTOfenestra align ensures the precise, ergonomic and continuous transfer of the profile racks.
Project highlight: Two types of bin, one storage and retrieval machine
The second UNIGRIP honeycomb storage system performs a technically demanding dual task within a minimal footprint: a single storage and retrieval machine handles cassettes for 6-metre and 7.5-metre-long profiles on opposite sides. A dual sensor system detects the cassette type and position and provides the data required for precise braking manoeuvres and a safe handover.
The KASTOfenestra align recirculation station complements the concept with a centring aid, hydraulic lowering and two cassette stations, ensuring a material flow without unnecessary waiting times.
Fully automated technology, handling everything from cutting to sorting
The Swiss steel service provider, SCHMOBI, tackles the challenge of balancing speed and product variety using consistent automation. At their facility in Wil, located in the canton of St. Gallen, the KASTOsort robot handling system efficiently handles key processes around the high-performance KASTOgripspeed C 10 automatic circular sawing machine. This system not only increases throughput but also alleviates the workload for employees, showcasing how efficiency and flexibility can be effectively combined.
The Bronschhofen industrial district in Wil West is home to rows of industrial halls, including the facility of SCHMOLZ + BICKENBACH Stahlcenter AG, commonly known as SCHMOBI. Since its establishment in 1959, SCHMOBI has been supplying the Swiss manufacturing industry with a diverse range of products, such as bright steel, stainless steel, and premium structural steel. Each day, approximately 100 employees handle a significant volume of bar stock. Annually, the steel centre produces over three million cut parts, with widths ranging from 5 to 530 millimetres.
Upon entering the plant, one can immediately sense the company’s pulse, perfectly synchronised with the machines. Bar stock is transported from the warehouse, to where it is cut, cleaned, marked, and packaged. Many job orders consist of fixed-length cuts. The batch sizes can vary significantly: sometimes they are individual parts and other times entire series. For over 20 years, SCHMOBI has put its trust in solutions from KASTO. The partnership began with the KASTOtec AC 4, a fully hydraulic and automatic high-performance bandsaw that features a depositing table but does not include automatic sorting. Today, it continues to reliably process all orders.
Intelligent robotics applied in practical applications
The KASTOtec FC 4 was introduced later and in combination the KASTOsort robot handling system, which not only cleans but also pick the cut pieces. Philipp Harter, Technical Sales Manager at KASTO, describes it as "plug-and-produce in its purest form." He further states, “The robot operates based on a decentralised, self-organising programming logic, eliminating the need for any programming or teach-in by the user. The entire automation process for the robot occurs without any operator intervention. The intelligent workflow effectively replaces cumbersome setup procedures.”
A decisive factor in SCHMOBI's decision to purchase the system was the principle of having "everything from a single source." By procuring the saw, robotics, and gripping technology developed by one source, SCHMOBI was able to avoid complex interfaces and clearly define responsibilities in the event of service needs.
Peter Breitenmoser, Managing Director and Chairman of the Board of Directors at SCHMOLZ + BICKENBACH Stahlcenter AG, explained, "We are making sustainable investments in the automation of our machinery pool. Our goal is to minimise tasks that do not add value and reduce the physical strain on our employees. Thanks to the integration of modern sawing machines and robots, we can offer our staff attractive and ergonomic workplaces."
Based on the excellent results, proven service, and established relationships, KASTO was the logical choice for the next project. Consequently, the second automated system began operations in 2025: a KASTOgripspeed C 10, which was also equipped with the KASTOsort robot handling system. Its compact design, along with the overall package, met all our requirements. Armin Thalmann, Operations Director at SCHMOBI, emphasises, "After our initial successes, continuing with the same partner was the right path for us."
Increased added value and reduced manual work
Although many ancillary tasks in the steel industry are essential, they do not directly enhance the product's value. Tasks such as manually removing cut pieces, cleaning away chips, and marking and stacking the cut pieces consume valuable time and place considerable physical strain on employees. This is where the automation provided by the KASTOsort robot handling system becomes beneficial.
The industrial robot is designed to handle repetitive tasks and autonomously determines the optimal stacking pattern for each job order, maximising the packing density within the container. This efficiency, along with the required process stability, is achieved through specially developed grippers and corresponding gripping concepts. "This was a key feature of the project," recalls Marcel Bösiger, Regional Sales Manager for Switzerland. "SCHMOBI picks a wide variety of saw cuts for orders and needed a solution that could handle each part as safely as possible." As a result, KASTO developed a total of 24 grippers for this system, most of which are vacuum-operated.
The project presented everyone involved with a significant challenge: the available space was limited and had an awkward layout. The new system needed to fit between existing machines and an unloading station. "We had to revise the original installation plan shortly before the deadline because a service shaft required a completely new design for the layout,” recalls Philipp Harter. Despite the resulting delay, KASTO used this time constructively by focusing on further optimisation of the gripper technology. Armin Thalmann adds, "Finding a solution was a major undertaking for all of us. But in the end, we have a system that meets our requirements perfectly."
Technology details
The KASTOgripspeed C 10 is a high-performance circular saw designed for mid-range diameters between 15 and 102 millimetres. It operates at high cutting speeds while maintaining precise feed control, resulting in short cycle times and consistent cutting quality. A standout feature of this saw is its advanced control system, which manages cutting data, stores parameters, and facilitates quick adjustments for different job orders. Operators can easily input these orders directly at the machine.
The material is loaded into the saw through a universal chain magazine that has six buffer shelves. The magazine is loaded manually using lifting aids. This allows SCHMOBI to remain flexible, even when working with varying bar stock. After cuts are made, the robot takes over: KASTOsort removes the cut pieces and loads them onto prepared load carriers based on optimised calculated stacking patterns. This facilitates further processing and shipping.
One of the key advantages of the system becomes evident during operation. The combination of the saw and the robot allows for longer production run times. Additionally, the system can operate during what are known as "ghost shifts", which means it functions without constant supervision by an operator. The duration of autonomous operation varies depending on the job order.
For short cut lengths and consistent bar stock, the machine can process multiple parts from a single bar. The operator only needs to intervene when containers require changing or when new material is necessary.
The KASTOapp is a platform-independent tool that allows for seamless real-time monitoring of sawing machines. Users can access performance data and operating statuses from any device, providing location-independent transparency. This feature enables early detection of errors and significantly reduces downtime by allowing for quick, targeted responses. "This means there is no longer a need for someone to stand by the machine all the time," states Armin Thalmann. "The operator can easily see whether everything is running smoothly or if there’s a problem." If an issue does arise, production can be stabilised quickly without lengthy delays.
Partnership with a future
The use of the robot has significantly improved throughput and reliability, stabilising work processes at SCHMOBI. As a result, the operator’s tasks on the shop floor have evolved. Operators no longer engage in physically demanding tasks; instead, they focus on monitoring and controlling the automated system. Managing Director Peter Breitenmoser states, “With KASTO’s solution, we have created sustainable, ergonomic workstations that provide real added value for our employees.”
The project in Wil illustrates the implementation of automation in the steel industry. Both the machine and the interaction between the saw, handling systems, and process knowledge are essential. KASTO supplies the necessary building blocks for this purpose, while SCHMOBI uses them to enhance its own operations. In doing so, SCHMOBI continuously adapts to changing market demands and optimises the value chain in collaboration with trusted partners.