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Soudronic is a leading global supplier of metal packaging production systems and laser welding systems for automotive parts. It develops and installs welding solutions for metal packaging and automotive industries. Key products include canbody production lines, which typically include a slitter, transfer system, welder, seam protection system, and bodyformer. Soudronic aims to provide maximum efficiency and flexibility to customers through customized, high-quality solutions.
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- 1. SETTING THE INDUSTRY STANDARD FOR METAL PACKAGING PRODUCTION SYSTEMS M E T A L P A C K A G I N G
- 2. G R O U P O V E R V I E W SOUDRONIC IS THE WORLD'S LEADING SUPPLIER OF COMPLETE METAL PACKAGING PRODUCTION SYSTEMS AND OF LASER WELDING SYSTEMS FOR LIGHTWEIGHT CAR BODY PARTS.
- 3. We develop, build and install superior laser and resist- ance welding solutions for a variety of applications specific to the M E TA L PA C K A G I N G and the AUTOMOTIVE INDUSTRIES. The range of prod- ucts includes single components as well as compre- hensive, turnkey manufacturing systems. Founded in 1953, Soudronic's headquarters are located in Bergdietikon near Zurich. Today, the com- pany employs a staff of more than 600 people in its development and production facilities through- out the world. The company's sales and service net- work covers more than 120 countries, reflecting a large and globally spread customer base. Thanks to its sound financial basis, Soudronic remained independent throughout its 50 years of history. UNDERSTANDING OUR CUSTOMER'S NEEDS Highest engineering standards, long-lasting quali- ty and maximum system efficiency are the basis of our outstanding reputation around the world. By investing a high percentage of our annual sales in 3 GROUP OVERVIEW STRONG CUSTOMER COMMITMENT AND SUPERIOR TECHNOLOGY research and development and in the continuous refinement of our products, we make sure that our systems represent state-of-the-art technology. An impressive number of long-term patents is proof for our high innovation rate. Although we are very meticulous about every single technological detail and quality aspect of our products, the needs of our customers are always in the center of our attention. Our customers typically do not invest in showroom equipment nor in tech- nical gadgets. Quite the contrary is true: they are looking for maximum efficiency and flexibility, user- friendliness and a committed customer service. Working in an extremely competitive environment, they are keen on increasing productivity while fur- ther reducing reject rates and scrap material. And they often have to react quickly to changing mar- ket demands and therefore need to rely on a flexi- ble production infrastructure. By providing tailor-made solutions to each and every customer, we have become a reliable partner of an increasing number of customers.
- 4. 4 GROUP OVERVIEW SPEARHEADING THE PRODUCTION OF LIGHTWEIGHT CAR BODIES Soudronic's automotive division supports carmakers all over the world in their efforts to produce lighter, safer and better cars in an economical way. By offering superior welding solutions for the manufacturing of tailored and tubular blanks, patchworks and other demanding parts, we provide the tools necessary to produce lighter and safer car bodies. As a partner and supplier to steel converters, car manufacturers and other industrial companies, we design, build and install everything from stand-alone laser weld- ing machines to turnkey high-speed manufacturing plants for very large volumes production. The vast majority of the 40 million car bodies produced annu- ally feature a growing number of tailored blanks. And more and more cars are built with tailored blanks in combination with hydro- formed steel parts made of tubular blanks. The installed base of our welding machines and manufacturing plants already produces several million of such blanks per year. A U T O M O T I V E PRODUCTION SYSTEMS FOR LASER WELDED CAR BODY PARTS ARE THE CORE BUSINESS OF THE AUTOMOTIVE DIVISION.
- 5. 5 GROUP OVERVIEW A KEY PLAYER IN THE METAL PACKAGING INDUSTRY With an installed base of more than 15 000 machines and sys- tem components, our production systems for three-piece cans, pails and drums can be found in virtually every country and region of this world. We provide a complete range of machines and com- ponents – including slitters, transfer systems, welding machines, seam protection systems, bodyformers, two-piece can production lines and end-making systems – to meet the requirements of any canmaking installation. Being a customer of Soudronic often becomes a lifelong liai- son. We do not only stock all the necessary spare parts for every piece of machinery ever produced, but we also offer solutions to upgrade and convert older systems with the latest technology, thus helping our customers to keep the productivity of their canbody production line up-to-date for many decades. FORMING TINPLATE BLANKS INTO CANBODIES M E T A L P A C K A G I N G
- 6. 6 CUSTOMIZED SOLUTIONS TURNKEY SYSTEMS FROM A SINGLE SOURCE With our comprehensive range of machines and components, we are able to meet the requirements of any manufacturing line for cans, pails, drums or irregularly shaped containers. Our systems cover the entire manufacturing process for complete two- and three-piece tinplate cans – from the lowest to the highest production speed and from the small- est to the largest size. In addition, we also offer turnkey manufacturing systems for ends and indus- trial packaging. The following four group companies represent the industrial core of Soudronic's metal packag- ing operations: SOUDRONIC IN SWITZERLAND Located in Bergdietikon near Zurich, Soudronic in Switzerland is the industry's premier source for canbody welders, bodyformers, two-piece can- making and endmaking systems. Our engineers also design complete canbody production lines, according to customer requirements. Thanks to our large assembling facilities, we are able to thor- oughly test complete systems before their shipment. Since its foundation 50 years ago, our company has produced and installed more than 5'000 can- body and drum welders. CEPAK IN ITALY Cepak is a well recognized manufacturer of high- quality slitters and transfer systems. Acquired by Soudronic in 1995, the company has sold more than 800 installations up until now. Most of our low- and medium-speed canbody production lines fea- ture slitters and transfer systems from Cepak.
- 7. 7 CUSTOMIZED SOLUTIONS METAL – A VERSATILE AND MODERN PACKAGING MATERIAL OCSAM IN ITALY Ocsam is the leading manufacturer of high-capac- ity slitters and transfer systems and has been acquired by Soudronic in 1995. The company's reference list comprises more than 800 installations. Our high-speed manufacturing lines for three-piece cans typically feature slitters and transfers systems from Ocsam. SABATIER IN FRANCE Sabatier is one of the world's premier suppliers of complete production systems for industrial packag- ing. A member of the Soudronic Group since 1995, the company both produces stand-alone machines and takes over responsibility for large customized turnkey projects. With a world-wide annu- al consumption exceeding 100 billion pieces, tinplate cans represent probably the universally best available and proven packaging material. Metal cans are produced in a broad variety of shapes and sizes and are used for every imaginable kind of food and bev- erage. Due to the outstanding properties of metal pack- aging, industrial and technical goods such as lubricants, paint, lacquer or aerosols are often packaged in cans, pails, drums or irregularly shaped containers as well. Although the production process is identical to food and beverage cans, the forming, shaping, endmaking and testing of industrial packaging requires a special- ized know-how. IMPRESSIVE ECONOMICS Tinplate cans are tight, taste-neutral, safe and easy to store and transport, diffusion-proof and fire-resist- ant. The production is cost efficient and saves ener- gy and time. Due to the magnetic properties of the raw material, tinplate cans can be easily recycled on an industrial basis. In fact, steel happens to be one of the most recycled materials all over the world. Even if not recycled, the material corrodes complete- ly and naturally without harming the environment. Since the material consumption counts for about 2 /3 of total production cost, savings are best achieved by reducing the amount of material needed to an absolute minimum. Thanks to new technologies, three- piece cans can now be produced using sheet grades as thin as 0.12 mm, and forming methods such as triple and quadruple necking allow for maximum tightness and stability with minimal material require- ments. With top-end production lines, reject rates remain far below the 1-percent-mark.
- 8. C A N B O D Y M A N U F A C T U R I N G SLITTER SOUDRONIC DESIGNS, BUILDS, INSTALLS AND MAINTAINS FULLY INTE- GRATED MANUFACTURING LINES WITH PRODUCTION SPEEDS OF UP TO 1200 CANBODIES PER MINUTE. PALLETIZER
- 9. A typical canbody production system consists of the following components: a slitter to cut the tinplate base material into body blanks of the required size, a transfer system, a canbody welder, a seam pro- tection unit, a curing system to dry and harden the seam protection and a bodyformer to give the can- body its final profile and shape. A single control system, equipped with a touch screen panel, allows for central operation and con- trol of the entire production line. CANBODY WELDER CURING SYSTEM SEAM PROTECTION SYSTEM UNIFORMER TRANSFER SYSTEM COMPLETE PRODUCTION LINES FOR EVERY NEED 9 CANBODY MANUFACTURING TESTER
- 10. WELDING THE MASHED SEAM OF A CANBODY 10 CANBODY MANUFACTURING SLITTERS AND TRANSFER SYSTEMS CANBODY WELDERS The heart of a three-piece can production line is the canbody welder. That is where the body blanks receive their basic cylindrical shape and where the seam overlap is welded. The Superwima welding principle, developed by Soudronic, requires only a minimal overlap of a few tenths of a millimeter. Optimal control of the welding current in combina- tion with an accurate pressure on the overlap guar- antees a mashed seam of only 1,4 times the thick- ness of the sheet metal. Soudronic offers a broad range of canbody welders for low, medium and high-speed applica- tions. High precision, unmatched flexibility, top security in operation, low use of raw material and energy as well as a minimal reject rate are but a few features of our state-of-the-art welding machines. CUTTING METAL SHEETS INTO BODY BLANKS Slitters are the first component of a three-piece can- body production line. They cut the printed and lac- quered base material – large sized square metal sheets – into body blanks of the required size. Body blank transfer systems automatically feed the blank magazine of the canbody welder with the cut blanks from the slitter. They are indispensable for a fully automated production line. Our slitters and transfer systems, built by our affil- iate companies Cepak and Ocsam, meet the most stringent demands with regard to versatility, preci- sion, reliability, fast and easy adjustability as well as production speed.
- 11. 11 CANBODY MANUFACTURING Having passed the weld seam protection unit, the canbody enters into the curing system. On a belt conveyor, the canbodies run through a gas operat- ed heating system with automatically regulated hot air burners. Thanks to the magnetic properties of the conveyor belt, the canbodies remain centrally positioned during the entire heat treatment. Soudron- ic has developed a modular range of curing sys- tems, available in varying lengths and accommo- dating any required production speed. PROTECTION OF THE WELD SEAM SEAM PROTECTION UNITS Subsequent to the welding of the canbody, a durable protection of the inner and outer weld seams against oxydation and other chemical reactions is an essen- tial step in the manufacturing process of top-quali- ty cans. Be it for slow pail manufacture or for high- speed tinplate can production, we offer an impres- sive range of fully automated systems for powder coating or liquid lacquering of the inside seam and roller or brush lacquering of the outside seam. CURING SYSTEM HEAT DRYING THE SEAM PROTECTION LAYER
- 12. FLANGING THE CANBODY I/O BOX SLITTER I/O BOX AUTOMATIC BLANK FEEDER I/O BOX WELDER I/O BOX WELDER C A N B U S I/O BOX WELDER DRIVE AXES COORDINATOR FIBRE OPTIC BUS BODYFORMERS Once the raw canbodies leave the curing system, they are ready to be processed into their final form and to be prepared for the endseaming process. Our highly flexible and fully automated bodyform- ers combine all the necessary functions in a sin- gle machine: shaping (mainly for optical purpos- es), necking (for good stacking properties after the filling), flanging (necessary for the subsequent seaming process), beading (for additional stabil- ity) and seaming (of either bottom or top end). Soudronic's bodyformers are famous for their sturdy construction and for their unique cam concept. 12 CANBODY MANUFACTURING
- 13. IN COMMAND OF A COMPLEX MANUFACTURING PROCESS 13 CANBODY MANUFACTURING I/O BOX COATING I/O BOX OVEN I/O BOX SEPARATOR I/O BOX POWDER I/O BOX UNIFORMER C A N B U S INTEGRATED LINE CONTROL With Soudronic's UNICONTROL Control System, an entire canbody production line can be operated from one single touch screen panel. The easy to handle Windows-based system uses simplified graph- ics to guide the operator, thus reducing instruction time and enabling a “training on the job”. Standard- ized and reproducible settings, predefined values and checklists guarantee highly efficient production cycles. The system is capable to guide and support the operator in several languages and allows sim- ulations on standard PC monitors in order to facili- tate training setups for machine operators. UNICONTROL provides plant management with production statistics and other relevant data and can be linked to ERP systems.
- 14. E N D M A K I N G S Y S T E M S BY IMPLEMENTING THE LATEST TECHNOLOGIES, SOUDRONIC'S END- MAKING SYSTEMS OFFER UNMATCHED EFFICIENCY AND FLEXIBILITY AND THUS VERY COMPETITIVE PRODUCTION COSTS. SHEET FEEDER
- 15. 15 ENDMAKING SYSTEMS HIGH-QUALITY ENDS IN ALL SHAPES AND SIZES DRYER STACKER LINER CURLER SHEET-FEED PRESS Be it for conventional ends or for technically demanding peel-off lids, we offer turnkey solutions for both medium and high-speed applications. Typical medium-speed endmaking systems con- sist of a scroll shear to cut the base material into scrolled strips, a strip feed press, a curler, a compound lining system, a drying oven and a packing system. For high-speed endmaking we use UNIPRESS sheet feed presses with multi-die tooling, reach- ing output capacities of up to 2000 ends per minute. The curlers, liners, ovens and packing systems are designed to match the output of the highly productive presses. Our endmaking lines can be centrally operated by a single control system with touch-screen panel. In addition to that, our high-speed lines can be equipped with video inspection and control systems.
- 16. STAMPING AND FORMING TWO PIECE CANS TURNKEY SYSTEMS FOR CONVENTIONAL ENDS Regardless if round or irregular, fully or partially open- ing, out of steel or out of aluminum, when it comes to the production of high-quality ends, the press is what matters most. That is why we offer a broad range of strip-feed presses representing state-of-the-art technolo- gy and long lasting quality. Thanks to a very rigid construction of the frame, our strip-feed presses work extremely accurate and require low maintenance. They stamp and form lids and bot- tom ends for 3-piece cans and pails and are also suit- able for the production of pre-drawn caps for 2-piece cans and twist-off caps. A comprehensive range of components including scroll shears, curling machines, compound liners and drying ovens – all built in our Swiss plant in Berg- dietikon – enable us to offer systems tailored to indi- vidual customer requirements. HIGH-SPEED ENDMAKING LINES The production speed of an endmaking line can be significantly increased with the integration of a multi-die press. UNIPRESS, our sheet feed multi-die press, is capable of stamping and forming up to 8 ends in one stroke. Via conveyor system the ends are trans- ported to the curling machines operating in parallel. Further down the line, compound liners and drying ovens apply the compound and dry it on each end. Since a manual quality control becomes impos- sible at such high production speed, our multi-die lines are equipped with a video monitoring and inspection system. TRANSFERRING ENDS FROM THE CURLING STATION TO THE COMPOUND LINER 16 ENDMAKING SYSTEMS
- 17. PEEL-OFF ENDS FOR 2- AND 3-PIECE CANS As a consumer-friendly alternative to convention- al ends, peel-off lids enjoy an increasing demand. With the development of the UNISEAL peel-off ends we aimed at a flexible but reliable solution suitable for both 2- and 3-piece cans. UNISEAL endmaking components can easily be added to existing can production lines thus enabling metal packaging producers to react to market demands without being burdened by major investments. Our UNISEAL peel-off ends can be used on existing seamers and they allow for a brand name embossing on the outside surface. BRAND MAME EMBOSSING FOR STRONG PRODUCT IDENTITIES 17 ENDMAKING SYSTEMS
- 18. I N D U S T R I A L P A C K A G I N G SOUDRONIC OFFERS SUPERIOR PRODUCTION LINES FOR A STURDY AND SAFE PACKAGING OF INDUSTRIAL AND TECHNICAL AS WELL AS EDIBLE GOODS. STACKER WELDER
- 19. 19 INDUSTRIAL PACKAGING LINES UNSURPASSED FLEXIBILITY THANKS TO MODULAR SYSTEMS Within our Group, Sabatier S.A.S in Vitrolles (France) designs and manufactures a comprehensive range of modular, compact and flexible assembly lines for industrial metal packaging. Thanks to our highly specialized know-how, we provide packaging solu- tions for cylindrical, conical, rectangular, oblong or square metal containers, including the necessary end- making systems and leak testing units. Due to the outstanding properties of metal pack- aging materials, industrial and technical goods as well as edible oils and certain food are often best packaged in metal containers such as pails, drums or cans of various shape and size. Metal containers are tight and fire-resistant, they can be transported safely and stored for an extend- ed period of time. EXPANDER DRYING OVEN CURLING/ BEADING STATION NECKING/ FLANGING/ SEAMING STATION EAR-WELDING/ BAIL PLACING STATION TESTER
- 20. MODULAR SOLUTIONS FOR CYLINDRICAL PACKAGINGS For the production of round cans of sizes ranging from 0.2 up to 70 litres or drums up to 200 l, we offer solutions based on our Bodypack assembly line. The name Bodypack stands for compact, flexible and modularly designed assembly lines incorporat- ing latest technologies. Added to our canbody or drum welders and seam protection units, they are capable of performing all operations required for the production of tapered or cylindrical can bod- ies, including body expansion, shaping, flanging and beading. Bodypack lines can also be used for the assembly of bottom and top ends by means of seaming as well as for the mounting of lids or han- dles. Supplementary machines and functionalities can easily be added to any Bodypack line. ASSEMBLY LINES FOR IRREGULARLY SHAPED CANS With our Squarepack concept, we provide a com- pact and modular system family for the assembly of irregularly shaped cans ranging from capacities of 0.2 up to 20 litres. The highly flexible assembly lines typically consist of a stretch former, a can erector plus two squeeze flangers and two seamers. It can be easily attached to our welding machines and seam protection units. Be it rectangular, square, oval or oblong – Squarepack assembly lines provide convincing ans- wers to an exceptional variety of packaging needs. Depending on the size and design of the packag- ings, panelling machines as well as leak testing units can be easily added to the lines. THE SHAPING AND FORMING OF CANBODIES IS A STEP-BY-STEP PROCESS 20 INDUSTRIAL PACKAGING LINES FORMING RECTANGULAR CANBODIES
- 21. ENDS AND LIDS FOR BOTTOM AND TOP For the endmaking of industrial packagings, we offer a broad variety of proven and efficient solutions, ranging from conventional ends to easy-open tech- nologies. Our curling-lining and handle-welding machines for round, square or oblong ends and lids make sure that metal containers can be tightly closed and transported in a safe manner. TESTING UNITS FOR GUARANTEED TIGHTNESS When it comes to industrial packaging, canmakers often have to guarantee for an absolute tightness of their pails, drums and cans. That's why we devel- oped leak testing units for metal packagings. Our range includes both carrousel as well as linear test units which can easily be adjusted to various sizes and shapes and added to our assem- bly lines. The packagings can be tested by means of a vacuum or a pressure application. Any leak detected will lead to an automatic ejection of the faulty container. WELDING THE EAR TO THE CANBODY HIGH PRESSURE OR VACUUM TESTING FOR GUARANTEED TIGHTNESS 21 INDUSTRIAL PACKAGING LINES
- 22. HIGHLY CUSTOMIZED METAL PACKAGINGS We provide a broad range of custom-made solu- tions for unique requirements. The list of special machines, tools and components for individual cus- tomer needs is almost endless. For the manufactur- ing of specially designed cans, for instance, we have developed high performance vertical body shapers which can be easily integrated into existing assem- bly lines. Or for the final closing of rectangular cans for fish, meat and processed food, we offer atmos- pheric closing machines. Our engineers and pack- aging specialists have a broad experience in devel- opping appropriate solutions for new metal pack- aging challenges. BREAKING THE LIMITS OF CONVENTIONAL CAN DESIGN 22 INDUSTRIAL PACKAGING LINES
- 23. A F T E R S A L E S S E R V I C E SOUDRONIC'S CUSTOMER SERVICE STARTS WAY BEFORE AN ORDER IS PLACED AND IT DOES NOT END WITH A TIMELY DELIVERY AND INSTALLATION.
- 24. PROFESSIONAL MAINTENANCE AND RELIABLE SPARE PART SUPPLY Our worldwide after sales service organization takes care of a preventive maintenance and of regular inspec- tions of your production machinery. A trouble shooting service by phone takes care of fast help and remedy. We keep all the technical data and records of every machine and production line ever installed in our data- base. This enables us to answer requests for spare parts in a prompt and competent manner. In our central store in Switzerland we have a com- prehensive stock of more than 20 000 genuine spare parts ready for immediate dispatch. Thanks to a well adjusted worldwide distribution network we can guar- antee an ultra-fast delivery, in most cases within 24 hours. Our team of experienced spare parts specialists makes sure that the maintenance and repair of our machines is a matter of hours, not days. TROUBLE SHOOTING SERVICE BY PHONE FOR FAST HELP 24 AFTER SALES SERVICE Our primary goal is to keep our customers happy. Happy, because they got a solution that exactly matches their needs, and happy because they can rely on our support, no matter what happens. We advise our customers with regard to the on- site storage of wear and tear parts in order to avoid costly downtimes. We support them on site during the production start-up. We conduct training semi- nars for the operating staff. And we stay prepared, just in case our help is needed one day. Our global after sales service network makes sure that our technicians and specialist can be avail- able on any customer site on short call. Customer support as we understand it is not only a global, but also a lifelong commitment. FAST AND RELIABLE GLOBAL CUSTOMER SUPPORT QUALITY SPARE PARTS READY FOR ULTRA-FAST DELIVERY
- 25. APPLYING HIGHEST STANDARDS TO MACHINE OVERHAULS 25 AFTER SALES SERVICE PERFORMANCE BOOST FOR OLDER CANBODY WELDERS Thanks to the outstanding quality and precision engi- neering, our canbody welders virtually last forever if properly maintained. However, older welders are by far not as economical as today's generation of canbody welding machines. With well proven and standardized solutions for conversion and retrofit of older machines, we offer our customers the oppor- tunity to both increase the performance and improve the cost-effectiveness of their canbody production line at reasonable costs. Depending on the customer's needs, we carry out complete machine overhauls, upgrades and conversions both on site as well as in our own facilities. SOUGHT AFTER SECOND-HAND MACHINES A well maintained second-hand machine can be the ideal solution for an urgent customer need. Often, customers who upgrade their production lines with our latest machines ask us to support them in the re- marketing of the equipment to be replaced. Thanks to the long-lasting quality of our prod- ucts, such equipment can be easily overhauled and retrofitted. Therefore, second-hand machines offered by us are in an excellent working condition. HIGH DEMAND FOR WELL SERVICED SECOND-HAND MACHINES
- 26. 26 AFTER SALES SERVICES CUSTOMIZED TRAININGS AND INSTRUCTIONS Even the most sophisticated production line can only deliver satisfactory results if the operating personnel has been carefully instructed. That's why we offer trai- ning programs individually tailored either to specific machines or to entire production lines. Our aim is to enable all participants to operate and to maintain our machines in a safe, efficient and economic way. Training seminars can either take place in one of our training centres in Switzerland, France, Germany, Italy, Mexico, Singapore, the USA or in China – or on customer site. Participants will receive a person- al and comprehensive documentation with all the necessary step-by-step instructions and manuals. PROFESSIONAL ON-SITE- INSTRUCTION FOR MACHINE OPERATORS
- 27. FOR FURTHER INFORMATION, TECHNICAL SPECIFICATIONS AS WELL AS THE ADDRESSES OF ALL OUR AFFILIATE COMPANIES, SALES AND SERVICE OFFICES, PLEASE REFER TO WWW.SOUDRONIC.COM.
- 28. Soudronic AG Industriestrasse 35 CH-8962 Bergdietikon Phone + 41 1 743 66 66 Fax + 41 1 743 66 99 E-Mail info@soudronic.com www.soudronic.com M E T A L P A C K A G I N G