No setup times for a batch size of 1

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industrial

No setup times for a batch size of 1 - Two linked Heckert H80 machining centers ensure efficient valve housing machining

What can be done to make single-part and small-batch production at facilities in Germany globally competitive? SAMSON, a manufacturer of specialty valves, chose a solution from Starrag as the general contractor. It consists of two Heckert H80 machining centers, fully automated by an Erowa Load- Master Compact pallet system, which enables the machines to operate autonomously for many hours using up to 69 preconfigured pallets. The system is complemented by a Gebhardt material storage system, which automatically provides the appropriate raw materials for loading based on the production order.

SAMSON AG, a global provider of valve and process technology solutions, is undergoing the largest transformation in its history. The company’s headquarters is being relocated from Frankfurt to Offenbach, including more than 120 machines and systems, as well as nearly 2,000 employees covering the full range of functions, from administration and development to production, sales, and service.

The relocation brings many advantages, as Dr. Alexander Epple, Head of Manufacturing Technologies, explains: “Over the past 120 years, we have grown significantly here in Frankfurt, and we have now reached structural limits in terms of space and intralogistics. In Offenbach, we can completely reorganize our operations across approximately 140,000 square meters and continue to grow.” Alexander Epple is responsible for the redesign and relocation of the manufacturing operations: “As part of establishing the new site, we have the opportunity to comprehensively modernize our machine fleet and replace around 40% of it. In doing so, we are laying the foundation for an efficient, future-oriented manufacturing operation that can compete successfully on the global stage.”

Focus on automation

Since the beginning of 2026, the manufacturing operations have been relocating approximately 120 machine tools in phases while maintaining full production capacity. The installation of new equipment is also well underway, with a strong focus on automation. “Our goal is to increase productivity and address the skilled labor shortage through unmanned shifts,” emphasizes Alexander Epple. “To achieve this, we need to decouple employees’ working hours from machine operating times and eliminate setup times.”

The challenge is that SAMSON’s portfolio of valve housing components is highly diverse, as the company specializes in control valves for special applications. The workpieces vary in terms of the materials to be machined, as well as their geometries and sizes. Very small batch sizes, including single-unit production, are the norm. “That’s why we need a flexible automation solution with preconfigured pallets,” explains Uwe Berger, who is responsible for operations in the Valve Housing department. “Only in this way can we implement unmanned shifts.”

Specifically, the focus is on the machining of valve housings with nominal diameters of up to 150 mm. In addition, intermediate pieces, insulating components, and similar parts are to be machined in a fully automated process. This work was previously carried out on four-axis horizontal machining centers. “From a machine technology standpoint, they were entirely adequate,” says Uwe Berger. Initially, he did not want to change that in order to avoid unnecessarily increasing the programming effort. “However, we adopted Siemens NX as our new CAM platform to ensure reliable machining through simulation using a digital twin. This is a fundamental prerequisite for automated machining.”

Partner sought with automation experience

Since this type of automation was new territory for SAMSON’s manufacturing operations, those responsible looked for a partner with relevant experience – “ideally a German machine manufacturer, as we place great importance on short distances and the fast, reliable service that comes with them,” says Alexander Epple. The existing machine fleet includes fouraxis machining centers from various manufacturers that generally meet the requirements. However, additional criteria played a role in the selection process. It was particularly important to Alexander Epple and the SAMSON decision-makers that the machine manufacturer act as the general contractor: “During the relocation phase, we are not in a position to take on the coordination tasks ourselves. We need a reliable partner who understands our requirements and can implement them.”

Three companies were shortlisted. They submitted proposals for an automation concept consisting of machining centers and a pallet system. “Ultimately, Starrag developed the technically best overall solution for us within an affordable cost framework,” explains Alexander Epple.

“A major contribution to this came from Guido Steinbrück, the Starrag sales representative responsible for our account. He has known our company for many years and is a very good listener. As a result, he quickly understood what was important to us and presented a proposal that was precisely tailored to our needs.”

For the flexible manufacturing system, Guido Steinbrück recommended two four-axis Heckert H80 machining centers from the compact modular series developed at the company’s Chemnitz plant: “These are space-saving horizontal machining centers with the characteristic Heckert DNA – precise, powerful, fast, and exceptionally reliable over many years.” SAMSON has already been gaining experience with a Heckert H80 in valve housing machining for the past two years. Uwe Berger is very satisfied with it: “The machines fully meet our requirements,” Uwe Berger confirms. However, with this latest order, he took the opportunity to incorporate a few special requests. One of the Heckert H80 machining centers is equipped with a facing and pull-down clamping function to produce a sealing edge with micrometer- level precision. “We also chose the larger tool magazine with 265 tool positions so that duplicate tools can be loaded, enabling extended periods of autonomous operation.”

Heckert compact machines also available in a 5-axis version

Another factor in favor of Starrag as a partner was that the Heckert compact machines are also available in a five-axis version – a key consideration for SAMSON, as the company is currently developing a modular valve platform. The housings incorporate numerous features, increasing machining complexity and making five-axis machining an attractive option. “We also intend to manufacture these components in a single setup using automated machining in the future. That is why, when planning our new manufacturing system, we have already reserved a third machine position for a 5-axis machining center.”

In this context, Uwe Berger expresses another wish: “In our system, we want to have standardized machine pallets – for the two four-axis machining centers and the future five-axis machining center.” No problem for Starrag. This is because Heckert compact machines are designed from the outset for standardized machine pallets.

An automation concept that delivers results

Even more important than the proven machines for Alexander Epple is the automation concept developed by Guido Steinbrück and his team. The Starrag representative gave the SAMSON decision-makers a choice between proposals that he had developed together with three leading pallet system manufacturers.

The contract was awarded to the Swiss supplier Erowa with its LoadMaster Compact 1400. Erowa Sales Manager Alexander Winter explains what makes his system so suitable for this application: “The LoadMaster is a modular, high-performance automation system. With its robust construction and long linear travel axis, it is particularly well suited for supplying multiple machines, which it can connect in a single line with magazines and setup stations.“

Compared to the other options, the Erowa LoadMaster resulted in the leanest overall system. Alexander Epple also highlights a special technical feature of the solution: “We need to be able to insert the pallets into the rack from both sides and, if necessary, rotate them as well. For this purpose, there is a 360° swiveling function developed by Erowa, which works perfectly.”

The LoadMaster system installed at SAMSON provides 69 pallet storage positions. These are equipped with high-precision machine pallets from Starrag – one of the machine manufacturer’s core competencies. “At our request, these were fitted with a hole pattern that allows us to mount our fixtures,” explains Uwe Berger. “These remain permanently on the pallet, meaning that the setup process for the raw material requires hardly any effort.”

High-bay warehouse for raw materials and finished parts

Speaking of raw materials: Guido Steinbrück’s proposal to automatically supply the four Erowa loading stations with blanks stored on Euro pallets was very well received. This is provided by a storage system from Gebhardt, which also accommodates the finished parts and stores them until further processing or completion of the production batch.

Control system manages the entire manufacturing process

To control the orders and all processes – including the precise provision of the required raw materials – a powerful control system is required. “We already use PROCAM’s EMS software in other areas of the company,” explains Alexander Epple. “So we also preferred to use this for our flexible manufacturing system. Communication between EMS and the Starrag machines and the Erowa pallet system was not a problem.”

Today, PROCAM EMS assumes overall control. This includes, among other things, the optimized planning of orders and determining the sequence in which they are processed on which machine. EMS also takes into account constraints such as the remaining tool life, allowing the machines to operate autonomously for as long as possible. In addition, EMS supplies the machines with the respective NC programs.

“The major challenge in digitalization is ensuring a functioning data exchange between different systems,” emphasizes Alexander Epple. “The communication between the control system and ERP system, the tool management system, the CAM and CAQ systems, as well as the CNC – for fully automated operation, this has to work 100% perfectly. These are, of course, tasks that largely fall within our area of responsibility. But Starrag and Erowa have also been very open and cooperative in this regard.” Since May, the flexible manufacturing system has been in operation at the SAMSON plant in Offenbach. Alexander Epple praises the achievement: “What Starrag accomplished as the general contractor for the new flexible manufacturing system was outstanding. The schedule, execution, and costs have all remained completely on track.” And Uwe Berger is confident that the targets set will be achieved: “At the moment, we are only utilizing the system to around 80% capacity. But we can already see that the setup cost share, which accounted for around 15 to 20% of the total costs for our small batch sizes, is being reduced to almost zero. In addition, this automation will allow us to gain around 30% more capacity compared to two standalone machines.”