Automated Cutting Line
Automated cutting line for complex metal processing
SafanDarley develops and builds automated cutting lines for heavy, irregular and difficult-to-handle metal materials. These customer-specific solutions are designed for manufacturers and processors who need more than a standard cutting machine.
From material infeed and handling to measuring, cutting, weighing, filling and transport: SafanDarley integrates the complete process into one automated production line.
The result is a smarter, safer and more efficient way to process complex materials such as nickel, copper and cobalt cathodes.
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Complete automation for demanding cutting processes
Processing heavy metal plates or cathodes requires a robust and reliable solution. Especially when the material is irregularly shaped, uneven in thickness, sharp-edged or difficult to handle manually.
SafanDarley automated cutting lines are developed around your specific production process. This means the line is not based on a standard machine concept, but engineered to match the material, required output, available floor space and operator workflow.
Each line can combine several process steps, including:
- Pallet infeed
- Automatic picking and positioning
- material measuring and assessment
- controlled cutting
- Weighing
- Drum or container filling
- Product transport
- Process monitoring
- Safety integration
By automating these steps, SafanDarley helps manufacturers reduce manual handling, improve process control and increase production efficiency.
Designed fornickel, copper and cobalt cathodes
SafanDarley has almost 40 years of experience in cathode processing. Since the introduction of its first cathode shear in 1986, SafanDarley has continuously developed and refined its cutting technology for rough and irregularly shaped cathodes.
Cathodes are often heavy, sharp and difficult to process manually. In some cases, material thickness can be up to 30 mm. This requires specialised cutting technology, strong material handling and smart automation.
SafanDarley develops stand-alone machines as well as complete processing lines for cutting and handling nickel, copper and cobalt cathodes. These solutions are used by leading cathode producers and warehouse operators worldwide.
One integratedsolution
An automated cutting line from SafanDarley brings together all essential technologies in one complete system.
The solution can include mechanical engineering, shearing technology, material handling, software, controls, HMI and safety systems. Because these disciplines are combined within one integrated line, every step of the process can be aligned with the customer’s production requirements.
This makes the automated cutting line suitable for applications where reliability, repeatability and controlled material flow are essential.
Proven in complex nickel processing
For a customer in South Africa, SafanDarley developed a fully automated cutting line for processing nickel cathodes.
Before this solution, the customer handled the nickel plates manually. This made the process labour-intensive, physically demanding and less efficient. At the same time, the customer needed a reliable solution to cut the material into custom-sized nickel blocks for further use in applications such as alloys, melting processes and automotive batteries.
SafanDarley engineered a complete automation line that processes the nickel plates from pallet infeed to final drum filling. The plates are automatically picked, positioned, measured and assessed. The line then determines how the material can be processed efficiently and cuts the plates into smaller blocks.
The installation is designed for operation by just one operator and has a processing capacity of 2 tonnes of nickel per hour.
Advanced controland process monitoring
SafanDarley automated cutting lines can be equipped with advanced control architecture, integrated sensors and smart monitoring systems.
The nickel cutting line developed for South Africa includes:
- 300 remote I/O units
- 15 servo axes
- 2 heavy-duty hydraulic axes
- 8 cameras for process monitoring
- A clear and user-friendly HMI
- Integrated safety systems
Through the HMI, the operator has full insight into the process and the status of the complete line. This makes it possible to monitor the installation from one central point, improving efficiency, safety and process control.
Benefits of an automated cutting line
An automated cutting line from SafanDarley helps manufacturers improve their complete production process.
Key benefits include:
- Reduced manual handling
- Improved operator safety
- Higher process efficiency
- Better control over material flow
- Reliable cutting of irregular materials
- Customer-specific engineering
- Integration of multiple process steps
- Scalable automation possibilities
- Suitable for heavy-duty industrial environments
Built around your production challenge
Every production process is different. That is why SafanDarley looks beyond the cutting machine itself.
We analyse the material, handling requirements, desired output, safety requirements and process flow. Based on this, we develop a solution that fits your specific application.
Whether you need a stand-alone cathode shear, an automated cutting solution or a complete processing line, SafanDarley helps you create a smarter, safer and more efficient production process.
