Effortlessly to the bicycle garage
Schröder folding machine at ZIEGLER Metallbearbeitung GmbH
Customer
As part of strategic considerations for expanding its machine park, ZIEGLER Metallbearbeitung GmbH recognized the need for a folding machine. The choice fell on the MAK 4 Evolution UD from the Schröder Group. Even a year and a half after its purchase, the machine is still unlocking additional potential.
ZIEGLER Metallbearbeitung GmbH develops, manufactures, and assembles lightweight steel structures. Founded in 1993, the company is one of the most versatile suppliers of street furniture. Bicycle shelters and bus shelters, benches and bench-table combinations, waste bins, bicycle racks, locking bars and much more – urban and landscape planners, architects and decision-makers from administration, trade and industry will find not only a wide range of standard products here, but also individual complete solutions from a single source on request. The company employs more than 250 people. The headquarters and management are located in Weissach-Flacht near Stuttgart, while the production, administration, and logistics site is in Nebelschütz near Dresden. ZIEGLER maintains a Germany-wide sales network, has an Austrian subsidiary, is represented throughout Europe by cooperation partners, and has been part of the Dutch CROWD group of companies since 2020.
More thin sheet metal processing, more efficiency
Where are the opportunities for growth? Given the boom in e-bikes, demand for bicycle garages is expected to rise. In order to be able to manufacture larger quantities of these, among other things, ZIEGLER should specifically expand its thin sheet metal processing capabilities. A laser cutting system and modern coating options have already been added in recent years. However, since processing large sheets of metal, such as three-meter-long wall elements, on press brakes is labor-intensive, time-consuming, and prone to errors, the next logical step was to move into sheet metal folding.
With a specification sheet and CAD data for components, ZIEGLER contacted a number of manufacturers. The offers were evaluated and the three most convincing suppliers were visited. “When investing in new machines, we always involve our workers in the decision—they know exactly what matters in practice because they work with the technology every day,” explains production manager René Handrik. A delegation from ZIEGLER also traveled to Hans Schröder Maschinenbau GmbH in Wessobrunn-Forst, Bavaria, with customized sheet metal in tow. Based on the requirements, the manufacturer of sheet metal working machines recommended the MAK 4 Evolution UD motorized sheet metal folder. The Saxon steel fabricators tested the machine and were impressed. The up-and-down folding beam eliminates the need to turn sheets for counter-folds, and the suction plate stop enables all bends to be performed automatically on one side after a single stop.
In line with requirements
After intensive testing with typical workpieces, the decision was made in favor of the MAK 4 Evolution UD Type 4000×5.0. This machine can fold steel sheets up to 5 mm thick over a usable length of 4040 mm. With a clamping beam stroke of 1090 mm, it also offers generous working space – another decisive criterion. A key requirement was met by Schröder’s in-house development, the POS 3000 NC control system. “We work with Solid Works. The machine control system therefore had to be able to seamlessly transfer our design data,” explains Fabian Koreng, team leader for work preparation at the ZIEGLER plant in Nebelschütz. “Schröder’s POS 3000 3D graphics control system not only meets our data processing requirements, but also provides the machine operator with an excellent overview and good orientation in the process thanks to the 3D representation of the tools and the sheet metal – especially for more complex workpieces.” The control system’s touch display is mounted on a swivelling arm so that it can be moved closer when folding short flanges from the front of the machine.
Set up stations
The swivelling arm with the control system has proven itself with many users, but the metalworkers at ZIELGER preferred a different solution. One of the requirements was station edges; the Schröder control system also provides excellent support for setting up two adjacent folding stations. “The screen shows which tools are required for each station and where the respective zero point is located. This makes setup much easier,” says Wagner, steel construction team leader. For this reason, the machine was ordered with two monitors as optional equipment. A conscious decision was also made regarding the tool changer: “The automatic tool changer for the MAK 4 Evolution is impressive,” admits René Handrik, but he and his colleagues decided against this option. “An automatic tool changer is recommended, for example, for contract manufacturers who produce many individual pieces and small batches. However, since we knew that we would mainly be producing series of 50 to 100 pieces on the folding machine, we can manage well without this equipment option. In fact, the tools can be changed just as quickly and you have even more folding freedom.”
A learning process
The MAK 4 Evolution UD, delivered in November 2023, has since been used primarily as planned for large and bulky parts that can only be processed by one person on the folding machine. In addition, all parts with counter edges are also processed on the machine with the bidirectional folding beam. The machine also has a clear advantage when it comes to electrolytically galvanized sheets, because folding is gentler and prevents scratches. For the steel construction team leader, it is clear that the learning process is not yet complete. Daniel Wagner explains: “The machine currently only runs in one of two shifts – mainly for large sheets between one and three millimeters thick. But the range of applications is constantly growing. Our colleagues are constantly coming up with new ideas for components that can also be manufactured with the machine.” The selection of components for the folding machine, the material flow from the laser cutting system to the folding machine, and the handling of the finished workpieces are all being further optimized. For ergonomic reasons, lift tables with wheels are currently being used extensively.
Growth and technology potential
With the MAK 4 Evolution UD, ZIEGLER has sufficient capacity for further growth in sheet metal processing. But the functionality also opens up new possibilities for manufacturing and thus product design. “The machine control system enables step bending, which allows the clamping beam to be bent against the bottom beam and the folding beam to be set at an angle – in any small increments. This is a fine art and very material-dependent, but the results are amazing,” says Production Manager Handrik happily. He is not only very satisfied with the machine, but also with the service provided by the Schröder Group: “The service is first-class. Right from the start, the Schröder employees took the initiative to contact us to check that everything was working properly. So far, there have only been three service calls, and each time the help was prompt – and each visit also turned into a spontaneous training session that deepened our knowledge of folding.”
Machine used
MAK4 Evolution UD
- Folding machine for sheet metal thicknesses up to 6 mm
- 3240 mm working length
- Clamping beam stroke 1090 mm
- Folding beam adjustment 180 mm
- POS 3000 3D graphic control
- Up-and-Down folding beam
Published in:
BLECH 04/2025
