A mid-sized Austrian sheet metal processor invested in a KOHLER part
- leveling machine to solve a bottleneck that most shops ignore:
- internal stress in cut sheets ruins downstream operations and burns
- hours on rework.
- ALCOLOR GmbH (Nenzing, Austria, ~35 staff, €6.5M turnover) processes
- 50+ tons of steel and ~150 tons of aluminum annually across a 5,300 m²
- facility.
- Their kit includes laser cutting, plate shear, stamping, two Amada
- press brakes, and a Schröder folder — but cut sheets still arrived at
- bending and welding with hidden stress.
- The Peak Performer 60P.1600 from KOHLER Maschinenbau flattens and
- stress-relieves parts before downstream ops, cutting throughput time
- and raising finished-part quality.
- The payoff: fewer rejects, tighter compliance with
- construction-industry standards, and reliable delivery to
- international customers who won't accept warped or spring-back-prone
- components.
- Takeaway for shops running similar volumes: if you're not leveling
- between cutting and forming, you're likely eating cost in rework,
- setup time, and scrapped batches.
Relieving the stress in modern sheet metal processing
Flat and low-tension metal sheets shorten throughput times and increase productivity. Flatness and low tension in sheet metal are crucial factors for further machining in the metalworking sector, including cutting, bending, punching, edge trimming, welding, and assembly. ALCOLOR GmbH is using the Peak Performer 60P.1600 part leveling machine from KOHLER Maschinenbau GmbH to great effect to meet the high demands of international customers and the construction industry in particular.
ALCOLOR GmbH is a leading powder coating and sheet metal processing company based
in Nenzing, Austria. The company employs around 35 people and generates an annual
turnover of approximately € 6.5 million. ALCOLOR produces anything and everything made
of sheet metal – be it window sills, coverings, facades, electronic housings, or ventilation
grilles. Over 50 tons of steel and around 150 tons of aluminum are processed by the sheet
metal specialist every year.
ALCOLOR's production site covers 5,300 m² and boasts modern machinery: 1 laser cutting machine, 1 plate shear, 1 stamping machine, 2 press brakes from Amada, and 1 folding
machine from Schröder. To improve quality, comply with strict standards, and reliably
shorten throughput times, the production line has recently been expanded with the addition
of a Peak Performer 60P.1600 part leveling machine from KOHLER Maschinenbau GmbH.
The sheet metal specialists in Nenzing know only too well that punched and laser-cut sheets
have to be leveled before they can be further processed. The lower the stress and the more
level the parts are, the easier it is to edge, weld, and assemble them. Advantages include a
higher repeatability of the bending angle during edge trimming and the accuracy of fit of the 2 parts during welding thanks to tensions in the sheet metal being reduced to a minimum and
the parts exhibiting less distortion. As a result, downstream work becomes more reliable and
more efficient.
Precisely meeting tight tolerances
The Peak Performer 60P.1600 part leveling machine has been in operation at ALCOLOR
since the end of January 2025 and is responsible for the entire leveling process in
production. Regardless of whether parts are made of steel or aluminum, a flatness tolerance
of up to 0.1 mm/m can be continuously achieved with professional leveling. “Before we purchased the 60P.1600 part leveling machine, we had to outsource leveling to
an external partner, which led to additional costs and delays. We needed a solution that
would not only ensure the quality of the sheet metal parts, but also shorten production times
and increase flexibility. We opted for the KOHLER 60P.1600 part leveling machine because
of its ease of maintenance, energy efficiency, and optimal leveling quality,” emphasizes
Sandro Vonier, Head of Sheet Metal Technology at ALCOLOR GmbH.
The sheet metal specialist was impressed at how easy and intuitive the machine is to
operate as well as the advanced cleaning system. It is important not to forget to regularly
clean the leveling rollers and supporting rollers to remove dirt particles, especially when
processing a mix of steel and aluminum. This prevents abrasive particles from being
deposited on the leveling material and dirt or even scratches impairing the material being
leveled. The rollers can be cleaned effortlessly thanks to the fully extendable leveling
cassette. This additional feature not only improves leveling results by preventing
contamination, but also reduces unwanted scrap.
Leveling the way forward
The KOHLER part leveling machine has proven to be a valuable addition to ALCOLOR's
machine fleet. ALCOLOR is now optimally equipped for future requirements and can deliver
high-quality results at all times, even with deteriorating sheet qualities and tight tolerances.
Using the KOHLER machine has not only allowed the sheet metal professionals to increase
production quality and optimize processes, but also successfully open up new business
areas such as contract leveling.
For more information contact: www.kohler-germany.com
Matthew Hayward
* * *
M4S TAKE
My take: this development is worth tracking, but the critical question is whether it translates into measurable operational improvements. I will watch for customer adoption data and performance benchmarks in the next quarter.
Simon McLoughlin
Is this your company?
This article features your business. Claim it to add your logo, contact details, and a link to your website — or upgrade to reach more buyers.
Did you know 80% of Press Releases trigger AI content warnings? Reach out and the M4S team can assist.