KOHLER's Leveling Technology Eliminates Residual Stress in 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

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Simon McLoughlin