Great craftsmanship combined with innovative technology 
for exceptional design ideas in metal

Those seeking to turn original and distinctive ideas into metal products would be well advised to make the trip to Burgwedel near Hannover, where Rosenhagen Metallbau’s state-of-the-art production facilities are located. Operating under third-generation management, Rosenhagen Metallbau provides customers with custom-built products, whether classic wrought-iron work or contemporary metal items. We focus mainly on indoor and outdoor staircases for non-commercial customers, commercial enterprises and public institutions. Our 23-person team handles every step in the process, from planning to manufacturing and installation – turning even the most unusual ideas into reality. Rosenhagen General Manager Heiko Rosenhagen sums up the secret to his company’s success this way: “We combine tradition with innovation. We employ advanced CAD technology in planning and development and apply the best technical and mechanical means to production, together with our long tradition of craftsmanship.”

Our customers‘ special needs and unique design ideas require not only the highest levels of professional skill but also the equipment and methods necessary to carry out projects with the requisite precision and efficiency. Individuality often goes hand in hand with complexity. But particularly when it comes to stairways, the variety of materials used for railings, handrails and steps place great demands on production. A variety of railings, steps, handrails and spindles may produce a very individualized design, but that in turn requires the right kind of processing methods and technologies to achieve the proper balance between precision manufacturing, optimum use of materials and efficient use of personnel. Moreover, where creative designs are involved, the proper labeling of the numerous components often involved in such designs can greatly simplify both shipping logistics as well as subsequent assembly – an economic consideration that should not be overlooked.

Innovation that meets even the most demanding needs

Technical innovation and maximum precision are especially important when individual components need to be cut to meet a set of specified requirements. It’s no surprise, therefore, that we at Rosenhagen decided a year ago in favor of the universal miter saw KKS 463 NA from KALTENBACH, the leading producer of equipment used in working with steel, aluminum and other non-ferrous metals. Sawing technology used in manufacturing and production has for a long time involved more than simply cutting various kinds of materials. It now involves the combination of advanced technology with multi-purpose software applications and other functions to produce long-term savings and optimum manufacturing processes. This is certainly our business philosophy at Rosenhagen and the KKS 463 NA provides what we need to make it reality.

At our facilities in Burgwedel, we make use of every type of miter cut the KKS 463 NA offers, whether it’s the 45 degree zigzag cut for stair steps or the +30 to -30 range of miter cuts used for various types of handrails and railing spindles. The servomotor makes it’s possible to place the rotary table in practically any position and automatically set it to a pre-selected cutting angle. Another important advantage: changing the bevel angle has no effect on operating speed because this occurs as the material is being fed in or components are being extracted.

In addition, a vertical clamping vice on the side of the saw bench automatically pivots to a pre-selected bevel angle. This ensures that residual lengths are kept as short as possible (< 15 mm) and that materials are clamped firmly in place. Moreover, this unique technology eliminates the need for so-called aluminum yokes. These are cut by bevel angle and must therefore be switched out at regular intervals. The KKS 463 NA thereby reduces recurring costs for replacement parts.

The fully-automated circular saw KKS 463 NA has replaced the manual saws previously in use at our company and scores high marks by allowing us to make optimum use of personnel. Automation results in changes in terms of cost planning, which in practice lets us shift more personnel over to final assembly. In addition, it also improves production times while lowering error rates. For us, this means higher productivity at less time per unit – which really pays off in terms of competitive advantage.

The KKS 463 NA is programmed and operated entirely via touch screen using the Windows graphic user interface PROFICUT. Rosenhagen uses specialized software specifically designed for stair manufacturers (from Hartmann). Component lists, along with all programmed geometries and bevels, are exported via a special interface directly from the stair production program in CSV-format (Excel) or via DSTV files (NC files, German Stahlbauverband). Precision and optimum use of materials play a decisive role in stair construction. Only precision cutting ensures a proper fit while the costs for material mean waste should be avoided as much as possible. At KALTENBACH, mechanical and software innovations were employed to minimize projecting edges and to reduce minimal offcut lengths to roughly 15mm. In addition, the program automatically calculates feed rate and cutting speed and transfers this information directly to the saw. This results in the kind of precision cutting and perfect beveling that we at Rosenhagen have come to appreciate.

Because we have to handle a large variety of different materials and dimensions, the employees at Rosenhagen have come to value this saw’s tremendous flexibility. Clamping vices and clamp pressure (e.g. when manufacturing thin-walled profiles) are set automatically through the use of a long-stroke tensioning cylinders, requiring no action on the part of the operator. Maximum allowable clamp pressure can be recorded in a database for raw materials.

Smart accessories: Inkjet system for marking saw cuts

In order to keep packaging and installation of the many components that go into a stairway from turning into an indecipherable puzzle, the KKS 463 NA uses inkjet labeling system so that parts can be easily identified later on. This helps avoid errors during shipping and final installation. Components are marked with UV-resistant ink that is either waterproof or can be wiped clean. Components are marked automatically as they are being transported to a predetermined sorting position, so no additional processing time is required. Since final, customized painting is usually carried out by the customer on site, Rosenhagen considered it especially important that the ink not show through after painting is completed. Customer-specific software is employed to set the labeling to be used on each individual component. This process has been perfected to the point that it’s now possible to automatically program 80% of the information used in labeling.

Modular and flexible material feeding

Materials are fed to the fully-automated KKS 463 NA saw via a flat magazine. The material is transported over a powered roller conveyor to the saw and cut as instructed by the program. After that, the parts are then automatically sorted to pre-selected positions, separating out first cuts and remnants.  The flat magazine lets you handle materials in a variety of different dimensions successively without needing to take time to re-set the equipment. Employees at Rosenhagen have also found that the loading magazine’s advanced configuration places less stress on the back. Materials used to be lifted by hand out of crates on the ground but now they are transported from the truck directly into the magazine.  

Smart solutions

KALTENBACH, manufacturer of the universal saw, has dedicated itself to developing smart solutions aimed at satisfying customer needs. “We want to provide our customers with more than just a saw, we want to be able to supply them with an all-round solution, so professional and dependable systems-level consultation is built into all our equipment,” says Rene Eger, Head of Sales at Universal Sawing Machines.  What’s crucial is making sure that a client company’s every need is taken into account. As a result, a company like Rosenhagen can face the future with confidence. Those interested in providing excellent services at the highest levels of quality need not only know-how but also a close and trusting relationship with leading manufacturers. General Manager Heiko Rosenhagen goes right to the crux of the matter: “We set high standards for the equipment manufacturers we work with. And in the case of KALTENBACH, we’ve found a partner who emphasizes quality as much as we do. We also appreciate KALTENBACH’s commitment to innovation and their consistent ability to develop solutions to problems. Those are the kind of assets that will help us keep the respect of our own customers in the future.”