How Dulasta powers its XXL sheet metal processing with KOHLER technology

When High-End Leveling Becomes the Foundation of Modern Manufacturing

 

The Challenge at Dulasta: High-Strength Steels and Hidden Costs

 

As a market leader in XXL sheet metal processing, Dulasta handles components with lengths of up to 16 meters. Whether in shipbuilding, wind energy, or crane construction – the company primarily works with high-strength steels. The problem: the raw material is often burdened with internal residual stresses.

 

These stresses previously led to significant issues throughout the entire process chain at Dulasta:

• Scrap after Laser Cutting: Deformed parts could not be reused.

• Inefficient Bending: Multiple attempts were needed to achieve the required angular accuracy.

• Hurdles in Robotic Welding: A welding robot requires perfectly flat components. "Automation doesn't work with crooked sheets," explain managing directors Harm and Bennie Dunnink of Dulasta.

 

The Insight: To eliminate "hidden costs" and reduce lead times, leveling parts became an absolute necessity for Dulasta, rather than just an option.

 

The Solution: Dulasta Invests in Peak Performance

 

To uphold their quality promises to customers, Dulasta invested in a Peak Performer 60P.1600 part leveling machine from KOHLER. This decision was made after intensive leveling trials where the technology proved its superiority.

 

Why the Peak Performer Makes the Difference for Dulasta

 

Unlike conventional systems, the Peak Performer operates electromechanically instead of hydraulically. Dulasta benefits from these advantages every day:

• Precise Leveling Gap Control: Thanks to high-speed servo motors, the gap between the leveling rollers remains constant – even with complex cross-sections.

• Stress-Free Results: The sheet is not only flattened but its internal stresses are neutralized. This is the prerequisite for subsequent milling and welding at Dulasta.

• Sustainability: The servo-electronic concept eliminates the need for hydraulic oil, reducing maintenance costs for Dulasta and protecting the environment.

 

The Result: 300% More Output in Assembly

 

The integration of the leveling machine has sustainably changed the way Dulasta works. An impressive example is stair stringers for exclusive designer stairs:

• Before: Time-consuming, manual leveling using a three-roll bending machine.

• Now: Automated throughput via the Peak Performer.

• Efficiency Jump: The team now handles three times the workload in the same amount of time.

Furthermore, welding robots benefit from the perfect flatness of the parts. Assembly work runs smoothly, and the final product exactly matches the specifications – without expensive rework.

 

Technical Highlights in Use at Dulasta: Peak Performer 60P.1600

 

Here are the facts of the system that sets the new standard at Dulasta:

 

Feature	Specification
Material Thickness	0.6 mm to 17 mm
Maximum Width	1,600 mm
Drive System	Servo-electronic (Hydraulic-free)
Control System	Intuitive user guidance & intelligent overload protection
Unique Feature	Patented electromechanical leveling gap control

 

Conclusion: Quality at Dulasta Starts Before Processing

 

The success story of Dulasta clearly shows: investing in modern leveling technology saves process costs in the long run. In an era where 3D drawings and digital workflows are the standard, the material must provide the corresponding precision.

Would you like to find out how a part leveling machine can reduce your production costs? Contact us for a personal consultation or a test leveling of your components!

 

Image Source: Dulasta