Piranha-Whitney Punch Plasma Combination

MORE PARTS PER HOUR. PERIOD.

Producing complex, thick parts with multiple steps can take a lot of time when done on a series of machines. That’s why fabricators worldwide turn to Piranha-Whitney Punch Plasma Combination machines to produce three times as many parts per day, at one third the cost.

Even as laser technology advances to cut thicker parts faster, the Piranha-Whitney combination consistently beats lasers, plasma machines, and water jet machines when it comes to ROI. Our Punch Plasma Combination will put more parts on the floor at the end of the day in steel, stainless steel, and aluminum, than any other process.

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With Piranha-Whitney, You Get the Right Machine!

As a full-line maker of laser, plasma punch combination, and plasma machines, Piranha-Whitney can advise you objectively which type of equipment best meets your needs. Whether you’re cutting, bending, or punching, our productivity engineers study your situation to pinpoint the most effective equipment, specs and processes. Then we test your scenario on a variety of equipment to find the best solution. If that solution involves laser cutting, Piranha-Whitney lasers offer a wide choice of cutting speeds, laser power levels and table sizes to meet every customer’s specific requirements. Keep reading to see what we can do for you!

High Precision Plasma Cutting System

Combines High-Definition Plasma Cutting with Machine Tool Accuracy

  • Laser like quality – 2 to 3 times the cutting speeds, at a fraction of the cost!
  • Highest Accelerations in the industry – Sharp corners, impressive contouring and maximized precision using a heavy duty tubular steel frame for rigidity and accuracy.
  • TrueHole capable – using Hypertherm HPR series HyPerformance plasma, ArcGlide THC, and EdgePro CNC.
  • Drive System isolated from down-draft table – for long term reliability and maximum accuracy.

Specifications

Inch Metric
X-axis 157.5″ 4000 mm
Y-axis 78.7″ 2000 mm
Maximum Material Thickness 2.5″ 63.5 mm
Maximum Axis Speed 1,000 IPM 2,540 mm / min
Positioning Accuracy ±0.005″ ±0.13 mm
Maximum Acceleration 0.3 g 0.3 g
Piranha-Whitney Machining Center

We are proud to introduce the NEW Piranha-Whitney PLASMA MACHINING CENTER (PMC) – providing the ultimate in automated plate loading/unloading, part removal and combined machining capabilities.

The Piranha-Whitney PMC can include options for material loading and unloading and for automatic part removal. Once a part is finished, it can be sent to any remaining downstream operations, streamlining part flow and increasing throughput. There is no need to wait to complete the remaining parts. The Piranha-Whitney PMC is designed to maximize throughput, minimize setups, and produce more cost-effective parts.

A high-performance spindle and automatic tool changer can drill, tap, countersink, and mill providing a robust and reliable alternative to machine shop operations. The Piranha-Whitney PMC can produce high quality fabricated parts that are immediately available for forming and welding operations.

The Piranha-Whitney PMC includes plasma cutting and punching capability. Punching holes is much faster and less expensive than drilling holes so that overall throughput and per part cost can be significantly reduced.

Automation

Introduction

Our automation systems are designed around the principles of:

  • Immediate parts availability.
  • Lowest operator involvement.
  • Heavy duty, rugged equipment, built to last

Our automation systems:

  • Remove parts from the machine immediately, as soon as they are finished – Important for single piece flow (JIT) environments.
  • Sort and stacks parts with no operator involvement
  • Remove skeletons separately from the parts, and stacks them automatically – Operators do not need to remove parts from the skeleton
  • Handle maximum machine capacities

For these reasons, not only can the machine RUN in an unattended operation, it produces parts which can move to the next operation AS-IS with no secondary sorting or handling operations!

PlatePARTNER

  • Semi-automatic loading of material sheets
  • Eliminates loading with fork trucks or overhead cranes
  • Available for up to 1,800# of plate 2m x 3m (80″ x 120″) material
3400 XP, 3400 HEAVY, 3700 SST

PlatePARTNER Gantry

  • Automatic plate loading
  • Automatic cycle control
  • Material storage and retrieval
  • Available for up to 1,800# of 2m x 3m (80″ x 120″) material
3400 XP, 3400 HEAVY, 3700 SST

Skeleton Removal Table

  • Stacks skeletons beneath the left or right hand support table
  • Machine is immediately available for the next sheet of material
  • Available for up to 2m x 3m (80″ x 120″) material
3400 XP, 3400HEAVY

PartHANDLER-II

  • Automatic loading of material sheets
  • Automatic cycle start
  • Automatic skeleton removal
  • Automatic large part removal and stacking
  • Available for up to 1,000# of 1.5m x 3.0m(60″ x 120″) material

Conveyor Feed Loader

  • Automatic loading of material into work clamps
  • Automatic cycle control
  • Available in multiple plate lengths and widths
  • Available for plate thicknesses up to 1″

Conveyor Feed Unloader

  • Remove skeletons
  • Powered or unpowered
  • Available in multiple plate lengths and widths
  • Available for plate thicknesses up to 1″

PartSCHEDULER™ Automation Software

Available on NEW 3400 XP Automated Systems

PartSCHEDULER makes it possible for automated solutions to run in an unattended environment.

Features of PartSCHEDULER are:

  • Automatically loops programs the desired number of times
  • Continually selects the next programs in priority sequence
  • Initiates cycle start automatically for truly unattended operation
  • Selects programs from networks
  • Time and date stamp for job history

Need More Tools?The Tool Caddy increases tooling capacity by 21. Unique software tracks each tool by tool number, not station number, so you never need to move tools again. An economical way to minimize tool preparation time.

3400XP, 3400HEAVY, 3400HXT

Plasma-Punch Combination VS. Standalone LASER

Lower Cost per Part

  • Sometimes a difference of 50% or more of the value-added content

External Cuts

  • Plasma cutting is faster than laser cutting
  • Latest plasma-cutting technology yields cut quality comparable to laser
  • Plasma cutting is a more robust technology – not as susceptible to material chemistry and surface finish

Internal Features

  • Punching is faster than piercing and contouring
  • In thicker material, there is no concern with heat build-up as with laser
  • Quality of a punched feature is more precise; this makes punched holes conducive to processes such as:
    • Tapping
    • Using self-tapping screws
    • Press-fit fasteners and bushings
  • Holes that are pierced and contoured with a laser-cutting machine may not be suitable for these operations
  • Punching leaves no lead-in blemishes
  • Laser-cutting may leave some holes not completely cut, resulting in secondary drilling or hammering to remove the slugs or parts

Other Features

  • Punching technology allows formed features to be produced, avoiding secondary operations.
    • Countersinks
    • Dimples
    • Tread
    • Louvers
  • Holes that are pierced and contoured with a laser-cutting machine may not be suitable for these operations
  • Punching leaves no lead-in blemishes
  • Laser-cutting may leave some holes not completely cut, resulting in secondary drilling or hammering to remove the slugs or parts
  • Optional attachments such as drilling and tapping produce even more features
  • Small holes less than 50% of material thickness
  • Tapped holes

Other Materials

  • Aluminum and Stainless Steel can be processed at speeds comparable to that of mild steel
  • Excellent quality of aluminum parts make combination machines a perfect match for aluminum fabrications.
    • Trailer industry
    • Military vehicles
    • Rail car
    • Dump trucks
  • Recent developments in stainless steel plasma cutting technology provide high quality oxide-free processes
Plasma-Punch Combination VS. Standalone Plasma

Lower Cost per Part

  • Sometimes a difference of 75% or more of the value-added content
  • Overall operating costs are significantly lower.
    • Plasma consumable life is greatly affected by the number of starts and stops. By punching internal features, consumable life is greatly improved
  • Automated small part removal feature gets parts out of skeletons as they are cut
  • Available optional material handling features on plasma-punch machines (plate loading/ skeleton removal) create much higher utilization rates than standalone plasma cutting tables

External cuts

  • Better drive system with high acceleration results in more accurate parts with better corner definition
  • Smoother drives provide dross-free cutting

Internal Features

  • Punching yields higher quality holes–plasma cut features cannot be used in some applications
  • No blemishes at the lead-in / lead-out in punched features
  • Able to punch diameters less than material thickness; plasma is normally limited to 1.5 x material thickness

Other Features

  • Punching technology allows formed features to be produced, avoiding secondary operations.
    • Countersinks
    • Dimples
    • Tread
    • Louvers
  • Optional attachments such as drilling and tapping produce even more features.
    • Small holes less than 50% of material thickness
    • Tapped holes

Other Materials

  • Small plasma cut features in stainless steel and aluminum have marginal accuracy and definition due to lag of plasma stream and excessive blemishes from lead-ins. Punched holes provide accurate holes with no blemishes

BIG TIME PIRANHA ADVANTAGES

NO WARPED OR MISSHAPEN PARTS The punching cylinders on our Piranha-Whitney combination machine are fully hydraulic. Our Reactive Stripping process actually grips the material, and push and pull it through the material, leaving your parts flat and highly accurate. Many of our competitors use a turret style machine, which actually hammers the parts through the material. This can leave your parts warped or misshapen, leaving you with the hours and expense of rework.

BETTER EDGE QUALITY Our counter-balanced cutting head rides on the surface of the material following the contour of the plate, keeping the distance precise throughout the cutting process.

INSTANT REMOVAL OF FINISHED PARTS When the part is finished it goes through the drop door, and sensors indicate that the part has been completely removed. That’s a big benefit to Piranha-Whitney users, because once a part is complete, it’s immediately available for other operations, and the combination machine can continue making more parts.

ELIMINATE DOWNSTREAM PROCESSES The10hp or 30hp Servo Drilling System is a great option if your parts have drilled, tapped, or countersunk holes. This feature integrates your drilling operations to greatly increase efficiency and reduce costs.

ALL THE TOOLS YOU NEED Piranha-Whitney’s Automatic Tool Changer opens wide – up to 2-1/2″ – so that high forms or non-flat sheets can be run reliably. The Tool Caddy can add 21 additional tools to make our combination machines even more productive.

ABILITY TO RUN LONG PARTS The Piranha-Whitney combination machines only move the plate in one direction, while the machine moves over the plate in the other. This means that our machines can run very long parts—up to 24 feet. Because of Piranha-Whitney’s unique design, we can run these parts with a large clamp spread and never torque the X-axis. The result is longer parts that are more accurate.

THE PLATE IS ALWAYS IN PLACE When you’re running parts that are longer than the axis of the machine, the Piranha-Whitney combination machine has an automatic repositioning system. Cylinders come down and hold the plate, the work clamps release, move to a new location, and re-grip the sheet. This allows you to run twice the length of the X-axis, meaning you don’t need to invest in a larger, longer machine just because you have a part that needs it. The Piranha-Whitney combination machine can handle it all.

EASY-CLEAN SLAG CHAMBER Because the Piranha-Whitney combination machine only moves the plate in one direction and the machine in the other, we can capture all your slag material in a chamber underneath the cutting-head. This keeps the cutting area clean, and your shop stays free of smoke.

NEVER MIX UP PARTS AGAIN Many parts can look very similar and be difficult to identify for internal use. The Piranha-Whitney ink-jet marking system can alleviate this problem by putting identifying numbers on parts as the come off the machine. This system can do alpha and numeric characters, as well as graphics anywhere on the plate.

DO MORE IN FEWER STEPS In other machines, forming processes like counter-sinking would have to be done with a cutting tool. Piranha-Whitney combination machines first punch a hole, then use a special tool and form that counter-sink around the pilot. Our machines can make consistent counter-sinks very quickly. We can also do plow-bolt holes, louvering, lance and form, half-shear forms, and any type of form you can do on a turret press.

Unbeatable quality at an affordable price. That’s Piranha.

Affordable Punching & Plasma Cutting

  • High Quality Fabricated Parts are produced by using punching technology for accurate internal holes, and the latest plasma cutting technology for well-defined, clean external features.
  • True Flexibility is achieved with an open throat design, repositioning cylinders for long parts, parametric shape library for fast set-ups, and forming capability for producing countersinks, tread plate, louvers, and many other features that are not possible on standalone laser or plasma-cutting machines.
  • High Levels of Productivity can be attained because punching is faster than piercing and cutting holes; and plasma cutting is faster than laser and waterjet cutting.
  • Affordable Technology – the initial cost of the 657 machine is much lower than laser-cutting machines, and the ongoing operating costs are lower than any other process.

Specifications

Punching Force 360kN 40 Tons
Maximum Work Piece Thickness 12.7mm 0.500″
X-axis Travel 1920mm 75.50″
Y-axis Travel 1250mm 49.20″
Positioning Accuracy ±1.12mm ±0.005″
Maximum Work Piece Weight 222kg 500 lbs.
Rapid Speed (per axis) 25.4M/min 1000 ipm
Stroke Rate (25mm/1.00″ Centers
in 3mm/.120″ Steel)
80 strokes per minute
Stroke Length 25.4mm 1.00″
Maximum Punch Size 127mm 5.00″
Tooling Style Whitney 28XX
Available Plasma Cutting Systems Hypertherm HD130 (standard)
Hypertherm HPR130 (optional)
CNC Control Whitney

3400 Combination Punch Plasma Machine

  • Affordable—less investment than laser machines
  • Machined Quality Holes—with the ProPunch process
  • Productive—out-produce lasers or plasma tables up to 3x
  • Reliable—engineered and built with famous Whitney strength and quality
  • Compact—similar floor space to the Whitney 647 series

Large 60″ x 80″ (1500 x 2000mm) Working Area

  • Heavy duty drives and work clamps move work pieces up to 750lbs (340kg).
  • Material moves in X direction, punch and plasma torch move in Y direction. This prevents the work piece from “whipping”, and helps maintain accuracy on even the heaviest work pieces.
  • Maximum rapid speeds are achieved in all work piece weights.

Five Station Tool Changer

  • Fast, simple tool changer design
  • Any size tool fits any station – up to 5.00”/127 mm diameter.

40 Ton (500 kN) Hydraulic Punching

  • Punch holes in carbon steel up to 1/2″ (12.7mm) thick.
  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically locked in the punching cylinder to maintain precise and consistent alignment.

Uses 36TC Tooling Style

  • Tools can be set-up off line – while the machine is running; tooling cartridges are quickly exchanged on the X-axis rail.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 36TC tooling is available for fast (same-day) shipment.

State-of-the-Art Plasma Cutting Systems from Hypertherm

  • HSD130 system standard
  • HPR130XD HyPerformance systems optional
  • Highly accurate, laser-like quality
  • HPR130XD provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.

Optional Automated Part Removal

  • 24″ x 60″ (600 x 1500mm) drop table removes parts automatically.
  • Part detection system ensures that parts are completely removed before the machine continues cutting.
  • Average part removal time of only 2.5 seconds
  • An optional conveyor brings parts to the operator as they are cut.

3400 XP Heavy Duty Machine/Affordable Price

Large 60” x 140” (1500 x 3500mm) Working Area

  • Heavy duty drives and work clamps move work pieces up to 1,000 lbs (450kg).
  • Material moves in X direction, punch and plasma torch move in Y direction. This prevents the work piece from “whipping”, and helps maintain accuracy on even the heaviest work pieces.
  • Maximum rapid speeds are achieved in all work piece weights.

Nine Station Tool Changer 30 Station Optional

  • Fast, simple tool changer design
  • Any size tool fits any station – up to 5.00”/127 mm diameter.

40 Ton Hydraulic Punching

  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically clamped in the cylinder to maintain precise and consistent alignment.

Uses 36TC Tooling Style

  • Tools can be set-up off line – while the machine is running; tooling cartridges are quickly exchanged on the X-axis rail.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 36TC tooling is available for fast (same-day) shipment.

State-of-the-Art Plasma Cutting Systems from Hypertherm

  • MAXPRO200 Standard
  • HPR260XD or HPR130XD HyPerformance systems available
  • Highly accurate, laser-like quality
  • HPR260XD provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.

Standard Automated Part Removal

  • 24” x 60” (600 x 1500mm) drop table removes parts automatically.
  • Part detection system ensures that parts are removed.
  • Average part removal time of only 2.5 seconds
  • An optional conveyor brings parts to the operator as they are cut.

Need More Tools?

The Tool Caddy expands your available tools from nine to 30. Unique software tracks each tool by tool number, not station number, so you never need to move tools again. An economical way to minimize tool preparation time.

3400 HEAVY: Heavy Duty Machine/Affordable Price

Large 80” x 190” (2000 x 4800mm) Working Area

  • Heavy duty drives and work clamps move work pieces up to 1,800 lbs (800kg).
  • Material moves in X direction, punch and plasma torch move in Y direction. This prevents the work piece from “whipping”, and helps maintain accuracy on even the heaviest work pieces.
  • Maximum rapid speeds are achieved in all work piece weights.

Twelve Station Tool Changer, 33 Station Optional

  • Fast, simple tool changer design
  • Any size tool fits any station – up to 5.00”/127 mm diameter.

55 Ton (500 kN) Hydraulic Punching,  75 Ton Optional

  • Punch holes in carbon steel up to 3/4″ (18 mm) thick.
  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically locked in the punching cylinder to maintain precise and consistent alignment.

Uses 36TC Tooling Style

  • Tools can be set-up off line – while the machine is running; tooling cartridges are quickly exchanged on the X-axis rail.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 36TC tooling is available for fast (same-day) shipment.

State-of-the-Art Plasma Cutting Systems from Hypertherm

  • HPR260XD or HPR130XD HyPerformance systems optional
  • Highly accurate, laser-like quality
  • HPR260XD provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.

Standard Automated Part Removal

  • 24” x 80” (600 x 2000mm) drop table removes parts automatically.
  • Part detection system ensures that parts are completely removed before the machine continues cutting.
  • Average part removal time of only 2.5 seconds
  • An optional conveyor brings parts to the operator as they are cut.

3400 HXT: Combination Punch Plasma Machine Tool

  • Direct replacement for your 661-84 or 661-96 machine
  • 100″ (2.5m) Y-axis to process wide sheets
  • Up to 75 Ton (675kN) Punching Capacity
  • 12 station Rail Tool Changer for 36TC tooling
  • Easy and Efficient Dry Slag Collection System
  • Optional Drilling/Tapping/Milling
  • Optional Loading/Unloading Systems

Large 80” x 190” (2000 x 4800mm) Working Area

  • Heavy duty drives and work clamps move work pieces up to 1,800 lbs (800kg)
  • Material moves in X direction, punch and plasma torch move in Y direction, preventing the work
    piece from “whipping”, and helps maintain accuracy on even the heaviest work pieces
  • Maximum rapid speeds are achieved in all work piece weights

Twelve Station Tool Changer, 33 Station Optional

  • Fast, simple tool changer design
  • Any size tool fits any station – up to 5.00”/127 mm diameter.

55 Ton (500 kN) Hydraulic Punching, 75 Ton Optional

  • Punch holes in carbon steel up to 3/4″ (18 mm) thick.
  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically locked in the punching cylinder to maintain precise and consistent
    alignment.

Uses 36TC Tooling Style

  • Tools can be set-up off line – while the machine is running; tooling cartridges are quickly exchanged on the X-axis rail.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 36TC tooling is available for fast (same-day) shipment.

State-of-the-Art Plasma Cutting Systems from Hypertherm

  • MAXPRO200 standard
  • HPR260XD or HPR130XD HyPerformance systems available
  • Highly accurate, laser-like quality
  • HPR260XD provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.
  • Standard Automated Part Removal
  • 24” x 100” (600 x 2500mm) drop table removes parts automatically

Part detection system ensures that parts are completely removed before the machine continues
cutting

  • Average part removal time of only 2.5 seconds
  • An optional conveyor brings parts to the operator as they are cut

3700 SST: Heavy Duty/High Performance Machine

Large 60” x 120” (1500 x 3000mm) working area

  • Heavy duty high speed drives move work pieces up to 1,000 lbs (450kg) at 2,000 inches/minute (50M/min).
  • Material moves in X and Y direction, punch and plasma torch are stationary.
  • Maximum rapid speeds are achieved in all work piece weights.

42 station tool changer

  • Proven design, updated with high speed components.
  • Any size tool fits any station – up to 5.00”/127 mm diameter.

55 Ton Hydraulic Punching

  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically clamped in the cylinder to maintain precise and consistent alignment.
  • Optional rotary ram can rotate any tool to any angle in any thickness.

Takes 36TC Tooling Style

  • Tools can be set-up off line – while the machine is running.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 36TC tooling is available for fast (same-day) shipment.

State-of-the-art Plasma Cutting Systems from Hypertherm

  • MAXPRO200 system standard
  • HPR260XD or HPR130XD HyPerformance systems available
  • Highly accurate, laser-like quality
  • HPR260 provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.

Standard automated part removal

  • 18” x 24” (450 x 600mm) drop table removes parts automatically.
  • Part detection system ensures that parts are removed.
  • Average part removal time of only 1.5 seconds
  • An optional conveyor brings parts to the operator as they are cut.

Automatic lubrication system reduces the amount of necessary preventive maintenance.
Includes Standard conveyors for removing punch slugs and plasma cut slag

4400 MAX: Maximum Duty Machine – for Heavy Applications

Extra Large 96″ x 170″ (2500 x 4325mm) working area

  • Heavy duty drives and work clamps move work pieces up to 4,900 lbs (2200kg).
  • Material moves in X direction, punch and plasma torch move in Y direction. This prevents the work piece from “whipping”, and helps maintain accuracy on even the heaviest work pieces.
  • Maximum rapid speeds are achieved in all work piece weights.
  • Optional X-Axis extension for processing 20 ft (6000mm) parts without repositioning.
  • Optional 120″ (3000mm) throat machine for extra-wide applications.

Three Retractable Work Clamps

  • Work clamps move out of the way when the punch, torch or drill enter the avoidance zones.
  • This eliminates dead zones – all of the material can be accessed by the machine.
  • Machines with the optional X-Axis extension have four retractable work clamps.

Sixteen station tool changer

  • Fast, simple tool changer design
  • Any size tool fits any station – up to 3.00”/75mm diameter.

100 Ton Hydraulic Punching

  • Double acting hydraulic cylinder keeps punch from “sticking” in work piece.
  • Hydraulic clamping and stripping keeps material flat.
  • Punches are hydraulically clamped in the cylinder to maintain precise and consistent alignment.

Uses 44TC Tooling Style

  • Tools can be set-up off line – while the machine is running; tooling cartridges are quickly exchanged in the tool changer.
  • Fast, easy set-up. Springs hold most components in place with few fasteners.
  • Most Whitney 44TC tooling is available for fast (same-day) shipment.

State-of-the-art Plasma Cutting Systems from Hypertherm

  • MAXPRO200 standard
  • HPR260XD or HPR130XD HyPerformance systems available
  • Highly accurate, laser-like quality
  • HPR260 provides incredible cutting speeds in thick material.
  • Long Consumable Life
  • Very economical system – low operating costs
  • Either process can be used to process Mild Steel, Stainless Steel, and Aluminum.

Standard automated part removal

  • 24” x 96” (600 x 2500mm) drop table removes parts automatically.
  • Average part removal time of only 6.0 seconds
  • An optional conveyor brings parts to the operator as they are cut.

Combination Machine Comparison Chart

Plasma-Punch Applications

Here are some of the ways our plasma-punch combinations have provided solutions for clients.

Wilco Machine & Fab., Inc.

Wilco Increases Throughput 50 Percent With 3400 XP Production Speed and Quality

In the heartland of the U.S., Marlow, OK, there are 27 acres with over 90,000 sq.ft. of manufacturing facilities known as Wilco Machine & Fab., Inc. A good location for shipping world-wide.

Turnkey products produced within the plant walls require machined and fabricated metal parts for a broad range of products primarily used in the oil and gas service and cattle working industries. On any day, items shipped may include small or large ASME pressure vessels, bulk cement tanks and conveying equipment, bulk trailers, cattle loading and working chutes. And then there are the less frequent but important products such as pumping units and road boring equipment.

Offering manufacturing services for over 25 years, Wilco has experienced a rapid level of growth since 2000. The company has added acreage, buildings, employees and machines to satisfy customer demands. As needs arise, Kris Boles, President, doesn’t hesitate to do what it takes to get the job done.

Want It Now

When the production of cut and punched parts started falling behind in 2005, Boles researched equipment via the internet. A Whitney 3400 XP caught his eye. From the first email inquiry to Whitney’s website to shipping the machine, only 16 days elapsed.

Within that time, Wilco erected a new building to house the punch/plasma combination. From building trusses to finished building was just under three weeks. “We moved in a hurry,” says Boles. “That’s how we usually do it. When we decide to do something, we’re going to do our best to make it happen.”

According to Boles, the company philosophy mirrors the requirements of their customer base, “A lot of the time we don’t know until a customer calls and says, ‘We’ve got to have this in 60 days.’ If we don’t have a place to accomplish the job or we have to do something different, we’ve got to move.

“The oil industry is getting back to a point where people want it and want it now. We have to react to that.” That meant more part production.

The addition of the Whitney was based on the need for a machine to rapidly produce parts in a great variety of configurations, from a range of material thicknesses, while holding good tolerances.

Speed and Quality

Plate going across the Whitney ranges from 14 ga. to 1/2″. Many of the higher volume products are run in kits creating the consistent set of parts.

But the variety of products manufactured at Wilco and the flexibility the company offers its customers, demand production flexibility. Two staff engineers and two programmers provide engineering support for Wilco customers to help assure quality construction and efficient flow through the facility.

One individual is assigned the task of creating the nesting programs. Using the nesting software, the 3400 XP provides the part production flexibility needed for quick reaction to orders. An added benefit is an average of 90 percent plate utilization.

“We run just countless different parts,” Boles explains. “For example, in the cattle-working lines there are probably 120,000 different parts between the tubing and the plate. Then there might be parts for a boat trailer or a tank. We build flanges by the thousands. The equipment going out of here is different every time.” It’s not just the flexibility that saves Wilco time. It is also the speed and quality of the finished parts.

The 3400 XP combines the Whitney RAMPAGE!™ Plasma Cutting System, with a cutting speed of 120 inches/minute in 1/2 ” steel, with the speed of hydraulic punching to complete parts in one operation. Parts are in tolerance and ready to go to the next operation with no clean-up.

“Edge quality is real good. And we’ve been able to hold good enough tolerances with the Whitney that we’ve eliminated two processes. We used to cut parts out, machine them, then drill them. Before the Whitney we tried to punch but couldn’t hold the hole sizes close enough.”

Boles adds, “Probably the one thing that’s been as satisfying to us as anything is the tolerances we’ve been able to hold. We’re able to cut the I.D. and O.D. and punch before we machine the parts. It has saved us a tremendous amount of time.”

On the 3400 XP finished dimensions of punched holes are held within 0.001″ accuracy. Wilco has been using Whitney’s patented TuffSkin™ tooling to increase the number of holes per punch (nearly tripled from standard punches).

Boles estimates a nearly 50 percent increase in throughput of parts since the installation of the 3400 XP.

Related equipment

When installed at Wilco, the 3400 XP joined other equipment from Piranha-Bertsch.

Wilco’s Piranha-Bertsch 4R Model 62-10 Plate Roll has been serving the company since 1997. Used everyday, the Piranha-Bertsch is a key piece of equipment rolling not only cylinders but all of the cones used in building pressure vessels, surge tanks and other products.

The digital readout is particularly helpful in rolling the cones which is still considered an art. “You have to set the rolls at different angles but once you get your numbers established it’s pretty easy to repeat. But it’s definitely an art,” Boles says.

Cones rolled on Wilco’s four roll Piranha-Bertsch typically range from 60°to 80°. Plate up to 10’ long and 5/8″ thick can be rolled to a 15-5/8″ diameter.

The Piranha SEP-120 has been punching holes for Wilco also since 1997. Although the majority of parts requiring holes are now produced on the 3400 XP with punching and cutting in one operation, the 120 ton Single End Punch is a good secondary source for holes up to 1-1/2″ diameter in 1″ material or up to 5″ diameter in 1/2″ materials.

Boles anticipates the continuation of the current business level. “We bought the current place in 2000 and we’ve been growing pretty steady ever since. The last two years the market just exploded. Two years ago we had 40 people working for us; now about 160. “We’ve got a pretty good market and it looks like it’s going to stay for a while.

Great Plains Manufacturing, Inc.

Great Plains’ 4400 MAX Produces Heavy Parts For Rugged, Durable Agricultural Equipment

Great Plains Manufacturing, Inc., considered a “short-liner” in the agricultural equipment field, manufactures more than 40 models of grain drills, planters, spraying and tillage systems – different lengths and types of drills, different types of tillage equipment. If their customers and salesmen have their way, the number of models will continue to expand.

With three manufacturing facilities on the company campus in Salina, KS and a fourth about 90 miles away in Tipton, KS, Great Plains Manufacturing has the central location ideal for quick shipping to 1000 farm equipment dealers across the U.S., Canada and overseas.

“We compete with some big guys in this type of equipment,” says Vance Stinnett, Manufacturing Engineering Manager for Great Plains Manufacturing. “In most areas of the country, where they plant crops that require seeding accuracy, our grain drills are considered the most accurate and efficient machines made.”

What makes Great Plains grain drills and other equipment outstanding? All are designed and built with customer input. Agricultural producers want – and need – to produce more with less. To accomplish greater productivity, their equipment must be reliable, accurate, and a size that meets their needs whether they are a small, medium, or large operator.

Great Plains satisfies those needs by providing a range of rugged, reliable equipment. For example, their heavy-duty grain drills are designed for flexibility to provide uniform seeding depth to precisely place seeds in variable field conditions. The variety of size models plus seeding and press wheel options give operators the opportunity to assure maximum productivity based on their individual requirements.

Rugged Equipment; Heavy Parts

To produce metal components strong enough to build their equipment, Great Plains needs heavy-duty, reliable fabricating equipment to efficiently handle thick plate. About half of the metal parts that go into a Great Plains implement are produced from 1″, A36 Steel.

“Farm equipment is heavy. We make big stuff. So we use very heavy material. Years ago we got into looking for a better way to produce parts. Piranha-Whitney was the only one I thought was making cutting equipment for the heavier plate,” Stinnett says.

Parts started coming off the first Great Plains Piranha-Whitney in 1997 when the company purchased a 3400 RTC (Rail Tool Changer), to punch and plasma cut parts up to 1/2″ thick. It’s been running three shifts since installation.

As equipment designs advanced, Great Plains products became larger and the plate size heavier. So when Piranha-Whitney introduced the 4400 MAX which punches and cuts plate up to 1″ thick, Stinnett says “our antennas went up”.

The 4400 MAX joined the smaller punch/plasma model in 2003. Again, running three shifts a day since installation, over half of the plate is 1″ thick with the rest 5/8″ or 3/4″. Parts from 1/2″ plate are still run on the 3400 RTC or sometimes the 4400 MAX.

Constant Parts Flow

Keeping up with part demand to feed assembly for all Great Plains models demands accuracy and productivity. Stinnett explains why they choose the 4400 MAX, “If you’re looking for a big plate processing machine, productivity-wise, you’re not going to produce more parts on anything else. With laser, when you get into that thickness, your productivity goes way down. A 1″ plate on the Piranha-Whitney, with 400 amp cutting, runs about 80″ a minute.”

In addition to the cutting speed, productivity comes from the ability to rapidly punch holes in the 1″ material as part of one fabricating process. Parts are produced faster and material handling time is greatly reduced.

The majority of the Great Plains parts run on the 4400 MAX are automatically removed via the drop door while production continues and go directly to welding, to paint or to a secondary fabricating operation such as a press brake.

“Accuracy is very good. That thing eats 1″ plate day in and day out. We like running 1″ plate on the 4400 because there is nothing that will cut 1″ plate better than that.”

Patrick Enterprises

PATRICK ENTERPRISES SAVES TIME WITH 3400 XP

Pembroke, Virginia, a small community nestled in the Blue Ridge Mountains in the southwest part of the state, is not where you would expect to find a world class supplier of fabricated and machined parts and weldments, but Patrick Enterprises Corporation is well on its way to becoming just that.

Founded in 1984 by Paul B. Collins, Patrick Enterprises began in a small garage in Patrick County, VA, well south of its current location. At that time, there were only four employees and work mainly consisted of supplying carts and maintenance parts for the regional textile and furniture manufacturers. Not that Collins was a stranger to big-time manufacturing. In fact, he was the vice president of manufacturing for a mining equipment manufacturer in Pembroke, with responsibility for several facilities. Eventually, that company shut down the Pembroke facility, and Collins left to work with a family friend who had a machine shop. Quickly, Collins realized a need for a fabricating shop in the area, and he started a new business in a 40′ x 100′ service garage. Eventually, Collins’ former employer left the Pembroke facility vacant, and Collins took the risk of purchasing the 50,000 square foot facility for Patrick Enterprises.

Today, Patrick Enterprises Corporation in run by Mark Collins, the second of three sons, there are 42 employees including Mark’s wife Teresa (controller and human resources), and brothers Dwight (materials /purchasing) and Ken (quality assurance). Patrick now has a full compliment of fabricating, welding and machining equipment that processes material from 28 gauge (0.015″) to 6″ thick plate, and machined weldments up to 20,000 lbs. Processes include laser cutting, plasma cutting, oxyfuel, shears, CNC punching, press brakes, welding, and painting. In addition, unlike many other metal fabricators, Patrick has a large compliment of machining equipment including CNC mills, lathes, and boring mills. In 1999, a 10,000 square foot addition was built, bringing the facility size to 60,000 square feet. Patrick’s customers include major players in the heavy truck and construction equipment industries, and they compete against both regional metal fabricators, and global fabricators from countries like Mexico and India.

At a time where the term “outsourcing” has taken on new meaning (as in “global outsourcing”), Patrick has actually strengthened its position and penetration within its existing customer base. Mark Collins attributes Patrick’s success to a high level of customer service. For example, some of its work is high profile, high priority work where another supplier is unable to ship fabricated parts in time. Patrick receives orders today that need to ship tomorrow morning, or line stoppages may occur. This premium service brought Patrick’s name to the forefront within its customers’ purchasing organizations, and earned Patrick the opportunity to compete for higher volume contract work.

For the last several years, Patrick has been contracted to produce fifth wheel angles for the heavy truck industry. These hole-intensive parts are made from 5/16″ thick high strength steel, and are the mounting surfaces for the fifth wheel assembly at the rear of a heavy truck. In order to fabricate these parts, Patrick took steel plate, sheared it to size (in two directions), punched the sheared blanks on a CNC press, and deburred the sheared edge and punched holes.

Up against both capacity constraints and cost pressure, Patrick set out to purchase additional equipment for the manufacture of the fifth wheel angles in 2004. In March of 2004, they took delivery of a Piranha-Whitney 3400 XP punch/plasma machine, and they hit the ground running.

The 3400 XP now produces fifth wheel angles at a rate of one to two minutes apiece. This represents a savings of 4-1/2 to 5 minutes for each part. Even the deburring operation has been eliminated as they have found that there is no need to deburr either the punched holes or the RAMPAGE! plasma cut edge as produced on the 3400 XP. This time savings translated to an annual savings of approximately $200,000 on fifth wheel angles alone. Additional parts such as fifth wheel ramps and cross-members yield additional savings. For example, the 3400 XP produces cross-members in one-half the time of Patrick’s production laser, located across the aisle from the 3400 XP.

The 3400 XP could not have been purchased at a better time. Like all contract shops, Patrick is constantly under cost pressure from its customers. Steel prices have increased almost two-fold, and the forecast for fifth wheel angles calls for a 40 percent increase over previous levels.

“It used to be that service and quality were most important to our customers” states Mark Collins. “Today, quality is a given, and everyone seems to be putting pricing first. Right now, we would be in major trouble if we didn’t have the 3400 XP. If I knew then what I know now, I would have bought two machines. For plate fabrication, I don’t see another machine that competes.”

Patrick has quickly adapted to its new machine. Instead of just punching holes and contouring the parts complete, Patrick, with the help of Piranha-Whitney’s application services, developed a process to use common line cutting. This both improved material utilization and reduced cutting time. Mark has also embraced Piranha-Whitney’s online ordering system for punches and dies. “It’s easy. I don’t have to worry about calling people and leaving messages. I just do it and it’s done.” Next on his agenda is trying TuffSkin™ tooling.

After three months in production, two employees are trained to run the 3400 XP, and two additional employees are being trained. This is part of Mark Collins’ philosophy that his employees need to be cross-trained on many processes. For example, 3400 XP Operator Jamie Lucas has been with the company for 10 years, and is able to run all CNC punch presses and shears, as well as spray painting. Press Brake Operator Jason Cook can run almost every piece of equipment in the fabrication and weld shops after eight years with the company. “It is impossible to find trained fabricators,” says Collins. “For that reason, we take welders and machinists who are willing to be cross-trained.”

In addition to training, Mark has taken advantage of other opportunities as well. The State of Virginia offers a program for reviewing safety programs proactively to determine compliance to OSHA (called OSHA SHARP—Safety and Health Achievement Recognition Program). A large banner in the lobby proudly boasts Patrick’s compliance, indicating that Patrick Enterprises is a safe workplace.

After several years at the helm (Mark phased in to replace his retiring father in the late nineties), Mark now sees the realities of running a fabrication shop run deeper than just making parts. His three biggest concerns today?

  1. Difficulties in sourcing material. Patrick has found that they need to hedge their bets by stocking at higher inventory levels today in order to meet their quick delivery requirements.
  2. Rising cost of employee benefits. Benefits, most notably health insurance, are rising dramatically. This makes it difficult for a small business to compete against larger corporations for the same labor pool. He finds that employees are more interested in benefits than wages today. This past year, even though health care insurance premiums rose substantially, Patrick actually reduced the employee’s share of the premiums.
  3. Growth under control. Mark feels that he could double his business today—the work is there. But growing too fast is risky. Mark’s goal is to grow his business a modest 30 percent this year, and to double his sales within five years.

Quality Shop, Unmatched Customer Service, Cost Competitive, Safe Workplace, Global Competitor, World Class Manufacturing, Patrick Enterprises.

Degelman Industries

DEGELMAN PRODUCES WITH 4400 MAX

Manufacturers who provide a wide variety of agricultural equipment products can be found throughout North America. The Western Canadian province of Saskatchewan is no exception. A population of just over 1 million people occupies nearly a quarter of a million square miles in “The Land of Living Sky.” Recognized as a world leader in dry land farming technology, thousands of skilled workers make products used for tillage and rock removal, spraying and fertilizing, livestock and forage, zero- and minimum-tillage seeding, and grain handling, storage and transportation.

One of these highly regarded agricultural manufacturing companies, Degelman Industries, is located in Regina, the capital city of Saskatchewan. In 1962 on the family farm in Raymore, Wilfred Degelman developed a uniquely designed rock picker and founded the company that bears his name. A move to Regina in 1966 began a series of expansions. Dozer blades were added in 1969 and commercial rotary mowers in 1998. Their current product lines include land levelers and rollers, strongboxes for snow removal, rock rakes and diggers, and straw control machinery.

Serving the Market

The products that Degelman Industries manufactures are developed after direct communication with the markets they serve. Face-to-face meetings with farmers at agricultural products shows give rise to new ideas. The company considers four factors when deciding if a product should be developed: Is the product salable? Does the product fit into current manufacturing capabilities? Can the product be manufactured at a competitive cost? Is there a readily available market for the finished product? Key to the success of a new product is quality and durability, and each is heavily field tested and scrutinized in a development cycle of six months to two years.

In 2004, Degelman Industries occupies 128,000 square feet and employs 140 workers. Privately held and family owned, Degelman continues to head the company as president, and his six children oversee daily operations including research and development and plant operations. The Saskatchewan labor market supplies a wealth of skilled labor, many of whom come from rural backgrounds and farms. Within the family of current employees, 30 percent have seen over 25 years of service at Degelman.

Traditional methods of manufacturing —shears and oxy-fuel cutters—were used during the early years. As the company expanded, cleaning and painting operations were added and machinery was upgraded. Production requirements and quality expectations demanded that Degelman move to robotic welding. Blair Flavel, operations manager, recalls that traditional manufacturing equipment could not support robotic welding requirements and moved the company into advanced manufacturing technology. Today the plant is populated with CNC milling machines and lathes, multi-axis press brakes, CNC plasma cutters, and CNC punch/plasma.

Customer expectations have led to the implementation of some lean manufacturing concepts. Degelman has reduced lot sizes by a factor of ten. Flavel says that the key is coordination in all aspects of operation. They use a minimum/maximum system whenever possible, both in production and in purchasing. One problem with lean concepts, he believes, is that it does not adequately level the load in seasonal markets.. Degelman’s philosophy is to run in batches large enough to allow reaction to customer demands within seven days yet small enough to equalize production throughout the year and keep production costs competitive.

Searching for Power, Speed and Flexibility

The need for a fast and flexible operation demanded a study of new fabrication manufacturing processes beginning in 2000. The staff was in place and prepared. All that remained was finding the right piece(s) of equipment.

The first step was determining the type and thickness ranges of the materials moving through the shop. Much of the load was in 7 gage mild steel, but most work centered on nearly equal amounts of 3/8″, 5/8″, 3/4″, and 1″ steel. Any considered solution had to process all of the thicknesses effectively. A second concern was the need to produce a high quality, straight hole of 1.25″ diameter through 1″ plate. Degelman uses a compression bushing to improve their product reliability and durability. Unfortunately, a traditional punched hole had too much break out, a plasma cut hole was too inaccurate, and a laser cut hole was too expensive. Drilling and machining historically produced the best hole.

Degelman was also faced with a tremendous amount of outsourcing. Blair Flavel understood that outsourcing could reduce capital investment costs by minimizing the number of machines required, but that it also reduced direct control over production run sizes, quality, response times, and costs.

Laser technology was sometimes used to cut many of the parts that Degelman outsourced. Although the costs were often high, they could be less than in-house production costs that were burdened by multiple set-ups for numerous secondary operation and non-value-added material handling. With the advances in laser plate cutting technology, it was natural that laser-cutting machinery would be a priority. A visit to the International Manufacturing Technology Show (IMTS) held in Chicago, Illinois in 2000 presented a wide array of lasers that might support their operations. It was at this time that Degelman witnessed the capability of punch/plasma equipment. The machine shown at the Piranha-Whitney booth (a 3400 RTC) was able to process a maximum of 1/2″ thick material, but information describing the recently introduced 4400 MAX compelled them to visit the nearby Piranha-Whitney factory to see the machine up close.

The Piranha-Whitney 4400 MAX

Specifications for the 4400 MAX are impressive. It has 100 tons of hydraulic punching force that can successfully fabricate material from 14 gage through 1″. It has a working envelope of 96″ x 160″ that supports larger part sizes. An optional Hypertherm HT4400 oxygen plasma system cuts at very high speeds (70 IPM in 1″; 160 IPM in 1/2″), surpassing the cutting speeds of laser by a factor of two or more. Edge quality and accuracy were well within requirements and dross-free cutting could reduce the amount of grinding. Blair Flavel was well acquainted with plasma cutting but his prior experience with older systems brought some skepticism. Morris Elynuk, who supervised the production floor, also questioned whether the 4400 MAX could truly perform as advertised.

Piranha-Whitney prepared numerous time studies that documented actual floor-to-floor part times. Initial results showed a possible production rate for punch/plasma that was three times that of the laser. Estimated scrap rates were 10 percent that of their current traditional methods. Furthermore, when compared to stand-alone fine plasma cutting systems, production requirements (for the sample) dropped from 50 percent of capacity to 6 percent—one machine could replace several!

Production costs drive profitability. A typical 1/2″ part that was costing $15.94 to produce with current methods would drop more that 50 percent to $7.47 by using a laser. Significant. But that same part would cost only $3.14 if made on a 4400 MAX—a reduction of 80 percent. Similar results were seen in a typical 1″ thick part—traditional processing cost $4.66; laser processing cost $3.73; punch/plasma processing cost $1.66. The economics were clear.

A challenge remained, however. A major part of the justification included eliminating the secondary processing required to make the 1.250″ diameter holes in 1″ plate. Piranha-Whitney produced a sample part that demonstrated the technique of punching and shaving to achieve the straight sided holed needed for the bushing. This involved pre-punching a hole smaller than the desired finished diameter, and then re-punching the same hole with a punch of the final diameter along with a die of minimum clearance. The result was a hole with straight sides suitable for the bushing.

During the sales cycle, the Piranha-Whitney distributor for Saskatchewan, Wallace Machinery, worked directly with Piranha-Whitney to provide information and samples. Dan Joss even drove sample parts from Winnipeg to Regina late one night. The process was validated and verified by demonstration. The 4400 MAX was justified financially. They installed their machine in August of 2002.

Efficient Production

Today, 90 percent of Degelman’s sheet and plate is first processed by the Piranha-Whitney 4400 MAX. They have eliminated shearing as an operation, keeping only a single shear for utility work. The greatest impact has resulted from the punch and shave operation that produces the bushing holes. Instead of requiring multiple secondary operations, the compression bushings are now installed by the operator of the 4400 MAX immediately after the parts come off of the machine.

Half of the parts are created in disposable, ever changing nests (dynamic nesting) to accommodate fluctuations in demand. The remaining parts are made from fixed nests (kit nesting) that supply common product components. Glenna Herman utilizes SigmaNEST® to support the 5 or 6 nests per day that are required. They have a library of nearly 8,000 part numbers and create about 10 new part programs each week. Operators like the Piranha-Whitney a lot. The old plasma only table was dirty and slow. The 4400 MAX is fast, reliable, and clean. Would Degelman Industries purchase another 4400 MAX if needed? Blair Flavel says yes, indeed!

“We probably wouldn’t consider anything other than punch/plasma for future needs. The accuracy on punch/plasma is more that good enough to accommodate robotic welding. 80 percent of everything we robotically weld comes off the 4400.”

The Piranha-Whitney 4400 MAX currently runs 20 to 24 hours per day, seven days per week. Degelman allows four hours per week for routine maintenance and the operators are responsible for daily upkeep and cleanliness. It has been integrated into their lean manufacturing concepts and runs multiple families of parts with low lot sizes without the cost penalties incurred by traditional manufacturing.

Degelman Industries is known for their innovation, product quality and durability, and customer support. The addition of a 4400 MAX to their operation places them in the forefront of manufacturing technology in “The Land of Living Skies.”

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