In the competitive shelf and display rack manufacturing industry in Poland, efficiency, precision, and operational safety are essential for maintaining production performance and reducing labor costs. One of our clients, a manufacturer specializing in shelves, display racks, and storage units, required a solution to improve production efficiency and ensure precision in punching operations for rectangular steel tubes.
Challenge: Efficient and Safe Metal Processing
The client produces structural metal shelving and display racks, which involve repetitive punching operations on rectangular steel tubes to create holes for assembly and component installation. Previously, these operations were performed manually, presenting several challenges:
High labor costs: Manual punching required multiple operators for each production batch.
Low operational efficiency: Processing large volumes of rectangular tubes was time-consuming.
Safety risks: Manual operation involved direct contact with machinery, increasing workplace accident risks.
Consistency and quality concerns: Minor variations in hole placement and spacing sometimes led to assembly difficulties or material waste.
The client outlined key requirements for a new machine:
- Precision punching: Accurately punch rectangular tubes with two different hole sizes in double-row configurations.
2. Efficient operation: Reduce manual labor while increasing throughput.
3. Safe operation: CNC-controlled system separating human operators from moving machinery.
4. Flexibility: Support standard rectangular tube sizes used in shelving and display rack production.
Solution: CNC Punching Machine for Double-Row Tube Holes
To meet these requirements, we provided a CNC punching machine designed for the client’s production line. The machine combines precise punching, efficient operation, and safety-focused automation.
Key Features:
- Single-station CNC punching: The machine has a single punching station with a hydraulic drive system for consistent batch processing.
- Double-row punching dies: Produces multiple hole sizes accurately with uniform spacing for rectangular tubes.
- CNC automation: Operators load materials while the machine completes punching sequences automatically, ensuring human-machine separation and improved safety.
- Material handling efficiency: Supports the full length of standard rectangular tubes, guiding them precisely for each punch.
- Flexibility: The system can be adjusted for minor variations in tube sizes or hole arrangements, accommodating future production needs.
Implementation and Workflow
The machine was integrated into the client’s production line with a structured workflow:
- Material loading: Rectangular tubes are loaded onto the machine.
- CNC-controlled punching: The machine executes double-row punching sequences on each tube.
- Automated stacking: Finished tubes are processed according to production workflow and prepared for assembly or shipment.
- Optional adjustment: Die configurations can be changed for different tube sizes or hole layouts.
This workflow maintains consistent production pace, improves operational safety, and ensures uniform hole placement.
Performance and Operational Benefits
After implementation, the machine delivered measurable improvements:
- Increased production efficiency: Continuous CNC operation allows higher throughput than manual punching.
- Consistent hole precision: Double-row dies and CNC control ensure uniform holes, reducing assembly challenges and errors.
- Enhanced workplace safety: Operators no longer directly interact with punching mechanisms.
- Material optimization: Accurate punching minimizes errors and scrap.
- Scalable production: Capable of handling different batch sizes and minor configuration changes.
Technical Overview (Machine Features)
For clarity without overwhelming technical detail:
- Single CNC punching station for reliable operation
- Hydraulic-driven punching system for consistent hole quality
- Double-row punching dies for rectangular tubes (30×50)
- CNC automation with human-machine separation for safety
- Guided tube handling for accurate positioning
- Adjustable for minor tube size variations
Conclusion
Automation in metal processing, especially repetitive punching operations, is essential for manufacturers in competitive markets. The CNC punching machine with double-row dies provides:
- High efficiency with reduced manual labor
- Consistent hole precision for easier assembly
- Enhanced safety with human-machine separation
- Material optimization with minimized waste
- Flexible adaptability for future production changes
This solution enables shelf and display rack manufacturers to streamline operations, reduce labor costs, and maintain consistent quality in high-volume production environments.
