Brütsch/Rüegger Metals AG, a Swiss metal distributor rich in tradition, has upgraded its operations by replacing a semi-automatic honeycomb storage system with the fully automatic UNITOP and UNITOWER long goods storage systems from KASTO. To enhance the process chain, the company has also integrated two modified bandsaws from the KASTOwin series. In light of growing demands, this combination has become a vital factor for success.

The data speaks for itself: Brütsch/Rüegger Metals AG, located in Regensdorf in the canton of Zurich, boasts a portfolio of over 8,000 products and maintains a warehouse stock of 5,500 tonnes. Since its establishment in 1877, this full-range distributor of metal products has experienced steady growth. Today, with a team of 30 employees, it stands as one of the leading suppliers of tubes, bars, and sections in Switzerland. However, with growth came new challenges: The semi-automatic honeycomb storage system from the 1980s in Hall 5 was increasingly reaching its limits. Issues such as inefficient use of space, high search times, and safety risks associated with manual operations have hindered operational processes.

The manual setup process using a rail crane became a significant bottleneck, making it impossible to meet efficiency requirements. “The continual expansion of our product range, along with the takeover of Walter Looser AG—the leading provider of semi-finished and finished bronze products in Switzerland—prompted us to look for a high-performance solution,” explains Patrick Epp, Managing Director of Brütsch/Rüegger Metals AG. “Our warehouse stock continued to increase, and we eventually reached our maximum storage capacity.” Expanding the warehouses was not feasible due to existing infrastructure constraints, leaving only one option: consolidation. This led to the initiation of “Project Core.” The objective was to increase storage capacity, modernise the warehouse with state-of-the-art technology, and enhance process efficiency.

The key advantage: a complete system from a single source

The metal specialist had complex requirements for the new system. It needed to have twice the storage capacity, fit within the 26-meter-wide Hall 5, and accommodate both 6-meter and 12-meter long goods. Additionally, the system had to be reliable and easy to operate. The project included a request for the capability to implement seven different storage and retrieval stations, allowing for simultaneous storage and processing of materials with multiple saws. The capacity requirements presented a particular challenge, as the design had to consider not only the limited floor space but also the height restrictions due to a photovoltaic system installed on the roof of the hall, which generates green electricity.

“We conducted extensive market research,” reports Patrick Epp. “Since 2018, we have been using the KASTOwin A 3.3 bandsaw from KASTO, and we are very satisfied with its performance.” This high-performance bandsaw is designed for efficient series cutting, providing fast and reliable operation. It includes automatic functions, minimises non-productive times, and features comprehensive monitoring systems, all of which contribute to high efficiency and safety while reducing tool wear, whether for single cuts or large series. “This efficiency was one of the primary reasons we chose to meet with KASTO in person at LogiMAT in Stuttgart in 2022 to discuss our planned warehouse.”

There it became evident: KASTO, a specialist in sawing and storage solutions, offers exactly what Brütsch/Rüegger Metals AG was looking for with its two systems, UNITOP and UNITOWER. The managing director emphasises, "A significant advantage of KASTO over its competitors is that we receive both storage systems from a single source. All other suppliers could only deliver one or the other." This expertise in system solutions comes as no coincidence. KASTO is the global leader in both market and technology for metal sawing machines, as well as long goods and sheet metal storage systems and material handling. The company, based in Achern, positions itself not just as a manufacturer of machines, but also as a comprehensive solution provider for the entire process chain—from storage and transport to prefabrication.

Tailor-made system for complex requirements

The new installation at Brütsch/Rüegger features two KASTO storage systems: the UNITOP overhead storage system, which has a storage length of six meters, and the UNITOWER tower storage system, with a storage length of twelve meters. Additionally, the installation includes two sawing centres from the KASTOwin series (models F 3.3 and A 3.6).
This configuration allows the company to efficiently store and process long goods within a single hall, optimising the use of space. The overhead storage system is equipped with an operating gantry crane that moves above the cassettes containing the metals, enabling quick storage and retrieval. Special feature: to achieve the required capacity given the limited height of the hall, both systems were installed four meters into the floor.

The UNITOP overhead storage system optimally utilises available space and provides a clear overview of inventory through its computer-controlled features. This system efficiently transfers long materials to three double output stations in short cycles, seamlessly integrating into the material flow. By incorporating automatic bar separation and connecting to KASTOwin saws, Brütsch/Rüegger Metals AG has developed a flexible production system that operates largely without human intervention. The metal specialist stores specialised products, such as twelve-meter-long cylinder tubes for the hydraulics industry, in the UNITOWER. This tower storage system enhances material flow and saves significant space thanks to its compact design. It can handle loads of up to five tonnes per cassette, which can be provided quickly and easily.

From an outdated storage system to an integrated comprehensive solution

The conversion process occurred in several phases: In the first stage, technicians removed the right half of the old honeycomb storage system and the operating gantry crane (OGC), creating space for the new structure. During this time, Brütsch/Rüegger Metals AG temporarily stored its goods in other halls. The left half of the storage system remained operational, with employees managing it manually. Next, a four-meter-deep channel was created, into which KASTO installed two new storage systems: UNITOP and UNITOWER. Following this, the KASTOflow align front storage station was integrated into the overhead storage system. This installation enabled Brütsch/Rüegger Metals AG to efficiently transfer long goods from both the temporary storage systems and the remaining old storage half to the new UNITOP.
In the final phase, specialised personnel completely dismantled the remaining half of the old system and installed three double retrieval stations in the newly available space. These stations automatically supply four sawing centres with materials. "It was a challenge to coordinate the conversion while managing day-to-day business," recalls Patrick Epp, Managing Director. "However, the KASTO systems—both the storage solutions and the saws—have significantly improved our efficiency," he praises.

More than just speed: the advantages in action

The changes are evident at all levels. “The organisation and access to the material are much simpler since the conversion.” says Patrick Epp happily. “This improvement is not only seen in the speed of the current honeycomb storage system but also when comparing it to the overhead storage system from another manufacturer that we use”. Thanks to the shorter storage and, particularly, retrieval times, the metal specialist operates much more efficiently. Additionally, the new storage system has increased workplace safety, since goods are now transferred automatically via retrieval stations to the saws. This represents a significant improvement over the previous manual solution. The reduction in error rates during the setup process directly impacts customer satisfaction. Faster access to materials leads to shorter delivery times, giving us a decisive advantage over competitors in the Just-in-Time production landscape of modern industrial companies. Furthermore, the KASTO subsidiary in Switzerland ensures quick assistance in the event of malfunctions, thereby minimising downtime.

"Our expectations regarding performance and quality were fully met," concludes Managing Director Epp with satisfaction. The company successfully completed 'Project Core' with the commissioning of the final saw, a KASTOwin A 3.6, at the end of the year. He summarises his assessment: “The key competitive factors are the compact storage and efficient processing of our products. KASTO provides complete systems and solutions from a single source that we can depend on.”