Soraluce Showcases Smart Automation Solutions with Krones Case Study

Smart Automation in Action: The Krones Project

The newly commissioned automated line at Krones’ Nittenau plant forms part of a broader investment program aimed at enhancing productivity and competitiveness across Krones’ machining operations.

The Krones Group, headquartered in Neutraubling, Germany, designs, develops, and manufactures as a global leader machines and complete systems for process, filling, and packaging technology. Information technology, factory planning, and numerous products from Krones subsidiaries, such as intralogistics and valve production, complement the Krones product portfolio.

This installation represents a fully integrated Flexible Manufacturing System (FMS) based on three Soraluce PM Portal Multitasking machines, designed for the machining of medium-sized aluminum and stainless-steel components.

Operating three shifts per day, six days a week, the system minimizes operator intervention—requiring only two operators per shift for loading, unloading, and tool maintenance—while running unattended over the weekend at the end of this year. 

The system is designed with ambitious performance objectives, targeting a system availability above 95%—measured as Available Time over Planned Activity Time (Uptime)—and a system productivity exceeding 80%, calculated as Machining Time over Planned Activity Time (Uptime). These results have been successfully attained thanks to the close collaboration between Krones and Soraluce throughout the project. 

“I’m very satisfied with the whole system. We achieved all our targets. We are running now 17 shifts a week... at a man-les production. Thats perfect”

Roland Sommer, Head of Shared Services Production Krones AG 

“This gives us the advantage to reach the shortest possible lead times for large parts together with the reduction of product costs”

Cristian Tremmel, Production Engineer Center of Competence Krones AG 

Technical Highlights 

The automated line measures 52 meters in length and 19 meters in width, and is based on three Soraluce PM35 Portal Multitasking machines equipped with the Siemens Sinumerik One control system.

Each machine features feed rates of 30 m/min on the longitudinal axis and 35 m/min on the vertical and cross axes, and is powered by a 43 kW / 900 Nm motor spindle drive. The configuration includes stepless (0.001º × 0.001º) universal multitasking heads for milling and turning, as well as an angular head with C-axis and 0.001º indexing capability, supported by a pick-up station. Each unit is equipped with an Automatic Tool Changer (ATC) for 120 tools and a full enclosure with a fumes exhaust system for enhanced safety and cleanliness.

The Pallet Changing System comprises a 14-unit pallet pool and a double transport shuttle to minimize changeover times. It accommodates workpieces up to Ø4000 mm, with two loading/unloading and presetting stations featuring elevating platforms to improve operator ergonomics.

The Tool Management System integrates a central magazine for 520 tools, with robot-assisted loading and unloading and automatic tool identification via QR code. Tool data and lifecycle are managed through RWT and TDM software, while a shuttle transport system with a five-tool capacity connects the central magazine to each machine’s tool magazine.

Automation across the cell is managed by a central Control System, which oversees job scheduling, tool life management, and overall cell supervision, ensuring optimal performance, coordination, and traceability throughout the line.

This installation demonstrates how automation, tool management, and process integration can be combined to deliver exceptional efficiency, reliability, and operational excellence in a modern production environment.

Soraluce Smart Automation Solutions 

At Soraluce, every production environment is unique. Our modular, intelligent automation systems are designed to adapt to each customer’s parts, volumes, and workflows—ensuring reliable performance and increased productivity. 

From pallet handling to advanced process control, Soraluce automation covers different scalable levels, supporting everything from a single machine to a full production cell. 

Each system is designed and manufactured in-house, including heavy-duty milling and multitasking tables, quick-change pallets, set-up stations, and transport shuttles. 

Our advanced tool management systems ensure tool readiness, traceability, and efficiency, reducing downtime and operational costs. Combined with the Soraluce Control System, operators can manage machines, tools, pallets, and CNC programs through a single, intuitive interface. 

With real-time monitoring, job queue optimization, and flexible decision-making, Soraluce Smart Automation Solutions provide full visibility, traceability, and control — empowering customers to achieve new levels of efficiency and competitiveness. 

A Glimpse into the Future of Manufacturing 

To close this presentation, we invite you to watch a video of the automated installation at Krones’ Nittenau facility, illustrating how Soraluce’s smart automation and integration technologies are shaping the future of manufacturing: https://www.soraluce.com/en/automation-solutions