Global packaging machinery leader Krones AG has installed a fully automated machining cell featuring three Soraluce PM35 bridge-type multitasking machines integrated within a flexible manufacturing system (FMS). The large-scale Smart Automation solution minimizes operator involvement, runs lights-out, and achieves over 95% system availability — setting a new benchmark for automated large-part machining.
AUTOMATION ON A GRAND SCALE
NITTENAU, GERMANY – At its Nittenau production facility, Krones AG has taken a major step toward the future of large-part machining. The company’s newly commissioned automated manufacturing line — engineered and integrated by Soraluce — brings together three Soraluce PM35 bridge-type multitasking machines connected through a Flexible Manufacturing System (FMS). The result is a fully automated machining cell capable of operating around the clock with minimal operator input.
This installation is part of a broader Krones initiative to enhance productivity and competitiveness across its machining operations. Headquartered in Neutraubling, Germany, Krones Group is a global leader in process, filling, and packaging technology. Its portfolio extends well beyond packaging equipment to include digital factory planning, intralogistics, and precision valve manufacturing — making advanced machining central to the company’s success.
The new Soraluce installation is designed for machining a wide range of medium-sized aluminum and stainless-steel components. The system runs three shifts per day, six days a week, and requires only two operators per shift for part loading, unloading, and tool maintenance. Later this year, the cell will transition to unattended weekend operation — true “lights-out” manufacturing.
Despite its scale and complexity, the cell is already meeting performance goals, achieving more than 95% system availability and over 80% productive uptime, thanks to close collaboration between Soraluce and Krones throughout the design and commissioning process.
“I’m very satisfied with the whole system. We achieved all our targets,” says Roland Sommer, Head of Shared Services Production at Krones AG. “We’re now running 17 shifts a week — and it’s a manless production. That’s perfect.”
“This gives us the advantage of reaching the shortest possible lead times for large parts while reducing product costs,” adds Cristian Tremmel, Production Engineer, Center of Competence, Krones AG.
DESIGNED FOR FLEXIBILITY
While automation is the headline, flexibility is equally central to this installation. The 14-pallet pool allows for a mix of part sizes and materials, enabling efficient production in both high-mix, low-volume environments — a hallmark of modern manufacturing.
The automated line spans 52 meters (171 feet) in length and 19 meters (62 feet) in width, and integrates:
- Three Soraluce PM35 Portal Multitasking Machines, each equipped with a Siemens Sinumerik One control, feed rates of 30 m/min (98 ft/min) on the longitudinal axis and 35 m/min (115 ft/min) on the vertical and cross axes, and a 43 kW / 900 Nm (57 hp / 664 lb-ft) spindle drive.
- Universal multitasking head with stepless 0.001° × 0.001° positioning, plus an angular head with C-axis and 0.001° indexing supported by a pick-up station.
- Automatic Tool Changers with 120-tool capacity, full machine enclosures, and integrated fume extraction systems for safety and cleanliness.
The Pallet Changing System employs dual transport shuttles to minimize changeover time and can handle workpieces up to Ø4000 mm (157 inches). Two loading and presetting stations with elevating platforms improve ergonomics and accessibility for operators.
A Central Tool Management System supports 520 tools, complete with robot-assisted loading/unloading, automatic QR-code identification, and centralized tool life management via RWT and TDM software. A shuttle system transports tools between the central magazine and each machine’s local toolchanger.
At the heart of the cell, a central control system manages job scheduling, tool life, and system-wide coordination — ensuring traceability, optimized utilization, and consistent part quality across every process.
SMART AUTOMATION BY SORALUCE
What sets this project apart is that the entire FMS — from the machines and tool handling to the pallet logistics and supervisory control — was designed, engineered, and integrated by Soraluce. Under its Smart Automation banner, Soraluce delivers turnkey systems that merge large-scale machining capability with the intelligence and adaptability of a modern digital factory.
For Krones, this represents more than just higher efficiency. It’s a tangible step toward a future where machining systems can scale, adapt, and run autonomously — without compromising flexibility or quality.
SMART AUTOMATION COMES TO THE U.S.
Manufacturers in North America can now access this same advanced automation expertise through Select Machining Technologies, the exclusive U.S. partner for Soraluce. Based in Connecticut, Select provides complete solutions for large-capacity machining and Smart Automation integration — from system design and installation to training, service, and ongoing technical support.