New machining center responds perfectly to drive toward Industry 4.0.

The machines and machining centers of the Italian brand Emmegi have long been known in the Benelux. For more than 25 years, the machine builder was represented by its own reseller, but since the end of 2021, a team of commercial advisors and technicians has been at the ready at the Benelux branch in Zaventem. They offer customers purchase support and after-sales service for all systems, including the +Quadra, the newest member of the already well-known family of profile machining centers, fully ready for Industry 4.0 applications.

Emmegi's history dates back to 1970, when Giuseppe Caiumi started in Limidi di Soliera near Modena, Italy, to develop, produce and sell machines for machining profiles and parts in aluminum, as well as PVC, light alloys and steel. Meanwhile, the machine builder is part of the Voilàp group. In addition to the development of mechanical technological innovations, equal importance is attached within this group to specific software programs.

"Emmegi's range includes a suitable solution for every customer and application: from a simple single-head sawing machine over automatically controlled double-head sawing centers to highly automated CNC machining centers with or without feed and/or outfeed warehouse. There are also angle presses, profile trolleys, reel trolleys, assembly tables and numerous other complementary products," explains new managing director Bas Ladestein.

"We want to build a long-term relationship with every customer. Then both the quality of machinery and service and the expertise of our employees are decisive. Each project starts with a conversation in which we listen to a customer's needs and predetermined budget. After all, we want to advise from the outset how that amount can be spent as efficiently as possible. In this way, we can ensure that they invest in the most appropriate hardware and software options while ensuring that important options for their specific application are not overlooked. We always start from a standard machine configuration, but since we will work with the customer to determine all options until there is a 100 % match between needs and capabilities, rarely are two machines completely identical."

With every Emmegi product, design, ergonomics, accessibility and safety are as important as efficiency, robustness and precision. Meanwhile, the Italian manufacturer's R&D department continues to develop new solutions and optimize existing systems on a daily basis. Evidence of this include efforts in the area of software to digitize the production process, the integration of larger touchscreens on the systems, allowing the operator to maintain a clear view of workpiece and operations at all times and minimizing the risk of errors, and the introduction of new systems. Today, with the +Quadra, the machine builder presents a versatile 20-axis machining center for drilling, milling and sawing aluminum and light metal profiles, including end machining.    

This new machining center is based on the successful platform of the Quadra family, of which more than six hundred different machines have since been delivered and installed worldwide.

According to Emmegi, the +Quadra is a clear response to the increasing demand for high-end solutions for the intelligent, flexible, automatic and fast machining of profiles in the most diverse shapes and sizes. After all, Industry 4.0 is a theme for many companies today in order to continue to grow. This machine is equipped with an automatic magazine for feeding eight profiles up to 7,500 mm (optionally up to 9,000 mm) weighing up to 120 kg. However, there is also an alternative solution with shuttles that allows the loading platform to be completely filled with the maximum number of profiles each time. Using an NC-controlled gripper, the profiles are clamped, picked up and rotated into the correct position both horizontally and vertically, before being taken to the machining stations for milling, drilling and sawing. Since the user can program specific settings for a range of profiles, the machine recognizes the cross-section and, based on the geometry, can optimally adjust the vices and their pressure.

"The milling module consists of a rotary table, on which up to eight electrospindles with an output of up to 5.6 kW - optionally even 7 kW - can be positioned. This allows a profile to be machined on all sides in one motion. To increase capacity, each head can be equipped with an area decoupling system by means of a slide on ball-bearing slides. In the saw module, profiles can be machined both horizontally and vertically. Indeed, this +Quadra is equipped with a 350 mm blade for horizontal movements at an angle between -45° and +45° and a 600 mm blade for vertical cuts with a range of 0 to 360°. The setting of the cutting angle is fully automatic and CNC-controlled," explains Branch Manager Stefaan Barra of the machine's functionalities.

"Optionally, we can also integrate a final milling module, which processes pieces at a maximum speed of 8,000 rpm, or a module on four NC axes to perform drilling, milling and tapping operations at both ends of the profile at any angle. After machining, the workpieces enter an unloading magazine, available in two versions for profiles up to 4,000 mm and 7,500 mm, respectively. One can also opt for a high-capacity magazine, which uses a motorized roller conveyor to align the machined parts before they are then fed further through. The machine can also be equipped with an automatic labeling system. The shavings and residual pieces, created during the operations, are also disposed of. Thus, companies can easily collect them for subsequent recycling, in accordance with the requirements for environmentally friendly production. All these elements make it possible to produce unmanned for long periods of time."

There is more, because during development, Emmegi's R&D department also took into account operator safety and ergonomics, and the aesthetic aspect was considered together with the Stile&Design Center within the Voilàp Group. Among other things, their research is reflected in the functional and attractive cabin with large windows and access points that allow the operator to clean the machining module quickly and safely. This closed cab model guarantees quiet operation and its combination with fume extraction systems also ensures total protection of operator and surrounding working environment. In short, the +Quadra is powerful, fast, flexible, reliable and automated, as well as safe, ergonomic and aesthetic.