Neuson Hydrotec GmbH, based in Linz, Austria, has achieved a significant leap in production efficiency with its recent investment in a Starrag HEC 800 X5 MT five-axis machining centre. This advanced machine has allowed the company’s team to reduce production time for complex components by 50%, enabling them to manufacture intricate housings with multiple holes at various angles in a single clamping position.
Karl Kordik, who oversees contract manufacturing at Neuson Hydrotec, emphasizes the company’s commitment to high-quality standards. He explains, “Only the best is good enough for our customers,” and with the new machining centre, the company is able to meet these standards with even greater precision and efficiency.
Neuson Hydrotec’s Contract Manufacturing Focus
The company specializes in integrating mechanical engineering, mechatronics, and hydraulics. Contract manufacturing is a key part of its business, contributing significantly to overall turnover. Walter Füreder, co-managing director of the contract manufacturing division, notes that nearly half of the company’s revenue comes from contract work. He explains that 20% of this revenue is generated by preparing components for other business units, while the remainder is earned by working with leading companies in sectors like plastics recycling, railway, and mechanical engineering.
Karl Kordik has a deep understanding of his customers’ needs, with a particular focus on providing components for the plastics recycling sector. He adds that nearly 40% of their work is dedicated to this area, supplying parts like shredder shafts and bearing blocks to manufacturers of injection-moulding machines.
From Raw Material to Complete Components
Neuson Hydrotec’s services cover the full manufacturing process, from sourcing raw materials to CNC milling, grinding, welding, and final pre-assembly. Kordik highlights that customers appreciate the comprehensive service, which includes a 3D measurement report for every component delivered.
The company’s previous machining setup involved various CNC turning, grinding machines, and machining centres with pallet pools. However, a new challenge arose when the company needed to produce a complex component for a plastics recycling machine. This component required both turning and milling, with holes drilled at precise angles, making it ideal for the capabilities of the new five-axis machining centre.
The HEC 800 X5 MT: A Game-Changer in Precision
In May 2024, Neuson Hydrotec purchased the HEC 800 5X MT five-axis machining centre, designed to streamline production. The component in question is part of a recycling machine that processes used plastics by heating them to 400°C. After shredding, the liquefied plastic mass is pressed through a perforated plate, which filters out contaminants. A rotating scraper disc helps to remove these impurities. The company manufactures the housing for this filter, which has intricate channels and several holes that must align perfectly for optimal fluid flow. Kordik explains that even slight misalignments can affect performance, requiring extreme precision when drilling.
The old process involved multiple clamping positions, with the company using a vertical turning and boring mill alongside a three-axis milling machine to produce the housing in seven separate clamping stages. As demand for larger quantities increased, Neuson Hydrotec sought to modernize its process to reduce manufacturing time.
Why the HEC 800 X5 MT Was the Ideal Choice
The HEC 800 5X MT was selected for its ability to clamp the component vertically, a task that would be difficult with traditional horizontal turning and milling machines. The dual pallet changer on the HEC 800 allows for quick, automated workpiece changes, reducing downtime during set-up.
Additionally, the machine’s design places the fifth axis in the workpiece, rather than the tool, eliminating the need for re-clamping. The decision was further supported by the machine’s extended travel paths, which allowed for components up to 1.1m long to be clamped and drilled through without issues.
Kordik explains, “The standard Z-axis path was not long enough for our needs, but Starrag’s customized extension of the Z and Y axes provided the solution. No other manufacturer offered this level of flexibility.”
Enhancements for Greater Efficiency
To further improve precision, Neuson Hydrotec invested in additional features such as a cooling lubricant temperature control system. This system ensures that heat generated during roughing operations does not affect the components’ accuracy after cooling.
The new machine’s software also includes capabilities for interpolation turning, which is crucial for creating eccentric holes, like the 350mm hole offset by 8mm in the filter housing. Kordik notes that, with this feature, they can complete tasks like these with ease, significantly cutting down on additional clamping steps.
Time Savings and Future Growth
The results have been impressive. The number of clamping positions needed to produce the housing has been reduced from seven to just one, cutting production time by 48%. The reduction in non-productive time has been particularly beneficial, as it gives operators more time for other tasks.
Kordik estimates that the new system has made production 20% faster for other components as well, thanks to faster tool changes and shorter cycle times. With these improvements in mind, Neuson Hydrotec is already considering purchasing a second HEC 800 5X MT to further expand its capacity.
In summary, the Starrag HEC 800 X5 MT machining centre has provided Neuson Hydrotec with a highly efficient and precise solution, significantly reducing production time and enhancing the company’s ability to meet growing customer demands.
