Large-capacity, gantry-type Zayer milling machine delivers improved productivity and increased processing capacity and capabilities for leading digital printing machinery OEM.
KERAjet, a leading, international digital printing machinery manufacturer has recently invested in a new, large-capacity gantry-type milling machine from Zayer.
The machine, an ALTEA 8000, with its large X-, Y-and Z-axis travels (8,000mm, 4350mm and 1500mm, respectively), and an 8000mm x 3000mm fixed table, is being used by the company to machine high-precision, complex components (i.e., machine frames, engine bridges and other performance critical parts) that go into its digital printing machines.
These machines, with their advanced electronics and innovative and intuitive software, are aimed at customers in the ceramics, textiles, glass, tableware sectors etc., and are renowned for their accuracy, flexibility, speed and reliability. There is high demand for the company’s digital printing solutions and to date, KERAjet has sold over 4000 machines in 44 countries throughout the world.
The investment in the large ALTEA 8000, with its gantry configuration, has helped KERAjet’s business objective to achieve self-sufficiency, bring machining/manufacturing operations in-house and control methods of production.
The new machine enables the company to produce, more quickly and efficiently, production components, as well as wear and replacement parts.
“Our digital printing machines are accurate, but such precision can only be realised as long as the components that go into them are machined to the tight tolerances and exacting surface finishes, we and our customers expect and demand.
“It is worth bearing in mind that when it comes to our print head unit technology, our machines are working day-in, day-out for customers achieving accuracies in the hundredths of a millimetre, and even the nanometre, range.”
Jose Luis Granell, head of the machining workshop at KERAjet
The ALTEA 8000, since being installed, is working an eight-hour shift but, if repeat components are being machined and the process used is secure and repeatable, it can be left to run unattended and operate through the night – significantly improving KERAjet’s productivity and its ability to hit customers’ stringent delivery schedules.
In addition to its rigid design and build, and large working envelope, the ALTEA 8000 has also increased KERAjet’s machining flexibility.
“We can use the machine in pendulum mode machining workpieces up to 4000mm in length in both work zones as well as machining longer parts using the full stroke of the machine.
“In addition, the machine is equipped with a number of heads (30- and 45-degree).
“When machining aluminium, for example, we use the 30-degree head with electro-spindle at 18,000rpm. We use the 45-degree head when machining steel and select the electro-spindle, if and when superior surface finishes are required.”
Jose Luis Granell, head of the machining workshop at KERAjet
The ALTEA 8000 was supplied to KERAjet with a number of onboard software apps that have help improve the machine’s performance and process reliability.
These include the iCAL App which, via automatic calibration, ensures the machining of highly-accurate geometries, and the FAST MACHINE PROTECTION App that eliminates spindle/tool collisions.
Of particular benefit are a) the remote, real time diagnostic and support that Zayer provides to KERAjet, and b) the HORUS NX facility that provides KERAjet with access to important machining and process data for future decision making.
“We have developed strong relationships with Zayer, and they pulled out all the stops to get us the ALTEA 8000 in double-quick time.”
Jose Luis Granell, head of the machining workshop at KERAjet