Indian job shop opts for part leveling machine from KOHLER
For upstream and downstream work processes
Optimizing sheets with minimum stress
Precision and Efficiency in Sheet Metal Processing
Whether it’s laser cutting, deburring, edge trimming, welding, or assembly, the levelness and stress state of sheet metal play a crucial role in every step of the process. Professionally leveled sheets are low in stress and maintain the required flatness, ensuring seamless further processing. To meet the stringent quality and flatness standards of global customers like SIEMENS, POWER SYSTEMS, General Electric, and Alstom, Gorasia Industries Pvt. Ltd. has integrated a KOHLER Peak Performer 30P.1300 part leveling machine into its production.
The Indian job shop, with a team of 45 employees, processes between 70 and 300+ tons of material per month. Founded in 1985 by Gorashiya Murji Harji, the company was established to deliver high-precision sheet metal components quickly and at competitive prices. Operating from a 2,500 m² facility, Gorasia boasts a state-of-the-art machine park featuring a Salvagnini laser cutting system, three press brakes (Bystronic, Amada, Accurpress), a Timesavers deburring machine, and various manual welding stations. To enhance quality and reduce production times, the company recently expanded its capabilities with the KOHLER Peak Performer 30P.1300 part leveling machine.
Based in Gujarat, western India, Gorasia operates with a flexible shift model (one to three shifts), depending on customer demands. Their core focus lies on steel (70%), stainless steel (20%), and aluminum (10%), with products ranging from cut parts to fully assembled machine housings.
Optimizing Processes with Stress-Free Sheet Metal
Gorasia understands the importance of leveling stamped and laser-cut parts before further processing. Flatter, stress-free sheets simplify bending, welding, and assembly, leading to higher precision and fewer rejects. Previously, skilled workers had to manually level parts using hammers—a labor-intensive, time-consuming, and inconsistent process. Additionally, if an experienced worker was unavailable, production efficiency was severely impacted.
“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: A Commitment to Quality
Leveled parts ensure greater repeatability in bending angles and improved fit during welding, as internal stresses are reduced, and distortion is minimized. This results in more stable and efficient downstream processes, eliminating costly rework.
Gorasia was also impressed by the intuitive operation and advanced cleaning system of the KOHLER leveling machine. Regular cleaning of leveling and support rollers is essential, especially when processing a mix of steel and stainless steel, to prevent contamination and potential surface defects. The fully extendable leveling cassette allows one operator to quickly and easily clean the rollers between jobs—ensuring consistent leveling quality and reducing material waste.
A Future Built on Precision
This success story highlights how KOHLER's cutting-edge leveling technology helps manufacturers optimize production and prepare for future challenges. Gorasia Industries is already planning for growth, having secured a large plot of land for future expansion. While construction has not yet begun, the company has the flexibility to launch within six months. With plans to produce larger and thicker components, Gorasia will eventually require a more powerful KOHLER part leveling machine to meet its evolving needs.
By investing in state-of-the-art leveling solutions, Gorasia is strengthening its position in the industry and ensuring a stress-free, high-precision future.
Part leveling machine at Gorasia:
- Peak Performer 30P.1300
- Levels sheets made of steel, stainless steel, and aluminum
- Width of the sheets: up to 1,300 mm
- Material thickness of the sheets: up to 6.5 mm
- Advanced cleaning system
- Intuitive user interface
