{"id":582,"date":"2025-04-14T09:00:00","date_gmt":"2025-04-14T07:00:00","guid":{"rendered":"https:\/\/mrbeta.dkonto.pl\/blog\/turnkey-gutter-line-for-a-polish-manufacturer-18-week-delivery\/"},"modified":"2025-04-14T09:00:00","modified_gmt":"2025-04-14T07:00:00","slug":"turnkey-gutter-line-for-a-polish-manufacturer-18-week-delivery","status":"publish","type":"blog","link":"https:\/\/mrbeta.dkonto.pl\/pl\/blog\/case-study\/turnkey-gutter-line-for-a-polish-manufacturer-18-week-delivery\/","title":{"rendered":"Turnkey Gutter Line for a Polish Manufacturer \u2014 18-Week Delivery"},"content":{"rendered":"
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\n \n Case Study <\/span>\n
\n \n <\/svg> 14 kwietnia 2025<\/span>\n <\/span>\n <\/span>\n \n <\/svg> 1 min read<\/span>\n <\/span>\n <\/div>\n <\/div>\n \n

\n Turnkey Gutter Line for a \u2028Polish Manufacturer \u2014 18-Week Delivery<\/span>\n <\/h1>\n\n <\/div>\n\n \n

How Blachprofil expanded aluminium gutter capacity with a complete coil-fed press-and-roll solution, from kickoff to first-part approval.<\/p>\n \n <\/div>\n <\/div>\n\n \n

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The Challenge: Capacity Without Floor Space<\/h2>\n \n

Blachprofil 2000, based in \u0141\u00f3d\u017a, produces aluminium and steel rain water systems for the residential and commercial construction market in Poland and Germany. By mid-2024, demand for their K-style aluminium gutter had outpaced the output of their existing press line \u2014 a 15-year-old machine running at practical capacity with no realistic headroom for volume growth.<\/p>\n

The constraint was not just throughput. Their floor was fully committed. Any new equipment had to fit a 22 m \u00d7 8 m bay that also housed a packing station and a raw coil buffer \u2014 leaving a usable machine envelope of roughly 18 m in length. This ruled out several standard line configurations and required a custom coil handling sequence.<\/p>\n<\/div>\n \n \n<\/div>\n\n\n

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The Blachprofil press bay before installation \u2014 coil buffer zone on the left, packing station rear-right.<\/figcaption>\n <\/div>\n\n \n <\/div>\n<\/figure>\n\n\n\n\n\n\n\n\n\n\n
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Specification and Machine Selection<\/h2>\n \n

After a site visit and production audit in September 2024, Macring’s projects team proposed a 160-tonne coil-fed hydraulic press line<\/strong> with an integrated servo decoiler and a 7-station forming die. The key specification targets agreed with Blachprofil were:<\/p>\n

The 160 T press was selected over the 120 T alternative specifically for its ability to handle the thicker 0.9 mm gauge without exceeding 75% of rated force \u2014 a margin our tooling engineers consider the minimum for die longevity in aluminium forming.<\/p>\n<\/div>\n \n \n<\/div>\n\n\n

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Engineering Timeline: 18 Weeks Broken Down<\/h2>\n \n

The project was contracted in October 2024 with a factory acceptance test (FAT) deadline of the last week of February 2025. The 18-week schedule was tight but achievable with parallel workstreams:<\/p>\n<\/div>\n \n \n<\/div>\n\n\n

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Phase<\/th>\n Duration<\/th>\n Milestone<\/th>\n <\/tr>\n <\/thead>\n \n
Engineering & die design<\/td>\n Weeks 1\u20134<\/td>\n Drawings approved<\/td>\n <\/tr>\n
Raw material procurement<\/td>\n Weeks 2\u20135<\/td>\n All stock on-site<\/td>\n <\/tr>\n
Press frame & structure<\/td>\n Weeks 4\u201310<\/td>\n Frame assembly complete<\/td>\n <\/tr>\n
Die set machining<\/td>\n Weeks 5\u201312<\/td>\n CMM sign-off<\/td>\n <\/tr>\n
Electrical & PLC build<\/td>\n Weeks 8\u201314<\/td>\n Panel tested<\/td>\n <\/tr>\n
Assembly & tryout<\/td>\n Weeks 14\u201317<\/td>\n Internal FAT<\/td>\n <\/tr>\n
Customer FAT<\/td>\n Week 18<\/td>\n Signed acceptance<\/td>\n <\/tr>\n <\/tbody>\n \n <\/table>\n <\/div>\n<\/div>\n\n\n
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Die machining \u2014 Tampere workshop<\/figcaption>\n <\/div>\n\n \n
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Press assembly \u2014 week 15<\/figcaption>\n <\/div>\n \n <\/div>\n<\/figure>\n\n\n
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Factory Acceptance and First-Part Results<\/h2>\n \n

Blachprofil’s production manager and quality engineer attended the FAT in Tampere on 24 February 2025. The line ran a 2-hour continuous trial at 0.7 mm AA3105-H14 material. Key results against contractual targets:<\/p>\n

Output rate:<\/strong> 15.2 parts\/min (target \u2265 14)
\nProfile dimensional accuracy:<\/strong> all 12 check dimensions within \u00b10.15 mm
\nScrap rate during trial:<\/strong> 0.28% (target \u2264 0.4%)
\nChangeover to 150 mm profile:<\/strong> 22 minutes (no contractual target, noted for reference)<\/p>\n

The acceptance certificate was signed on the same day. Installation in \u0141\u00f3d\u017a is scheduled for April 2025 with our commissioning engineer on-site for 6 days.<\/p>\n<\/div>\n \n \n<\/div>\n\n\n

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"We were sceptical about the 18-week commitment. Macring hit every milestone and the first-part quality was better than our existing machine after 10 years of tool wear."<\/p>\n\n