Rohr-Mertl has used KASTO sawing and storage solutions for roughly 55 years. The specialist for steel tubes values not only the high-quality products but the exceptional maintenance and repair service as well. Even the first saw, constructed in 1970, still operates just as it did on its first day.

Tubes as far as the eye can see – with diameters ranging from 3 to 660 millimetres and wall thicknesses from 0.5 to 100 millimetres made of steel and stainless steel. Mertl cuts, picks and stores 8,000 tonnes of steel tubes in more than 5,000 dimensions and qualities on 30,000 square metres of building space.

Karl Mertl Handelsges.m.b.H. specialises in steel tubes in various forms. Since its establishment in 1949, the company has consistently broadened its product range and services. The company currently has 90 employees. Mertl is located in Schwechat, southeast of Vienna, and supplies various customers throughout Europe, including industrial corporations as well as workshops. The distributor acquired the 90,000 square meters at the former brewery site from the City of Vienna in 1968. "One of our warehouses is located in the historic vaulted cellar, which also houses one of our KASTO bandsaw machines," explained Marie Gruscher-Mertl, CEO. The family-owned company is currently managed by the fourth generation, with both daughters active in management. Additionally, son-in-law Jürgen Spannraft has served as CEO Ing. since 2019.

Mertl currently operates ten bandsaw machines and two KASTO hacksaws, the oldest of which dates back to 1970. "We've been using the EBS 400 U hacksaw for well over 50 years, and it is still performing superbly," says a satisfied Marie Gruscher. The saw is located in the in-house workshop and is used whenever employees perform any maintenance or repair work on the buildings or racks. "Over this extended period of time, occasional breakdowns occurred, but KASTO promptly restored the machine to working order," Marie Gruscher explains.

This is precisely the customer service that Mertl values in its partnership with KASTO. Christian Wunderlich describes the collaboration as "High-quality products, timely deliveries, and, above all, reliable service." As the warehouse manager, he knows he can count on KASTO. "A new machine is quickly purchased, but when spare parts become necessary, that's when the wheat is separated from the chaff. In this regard, our experience with KASTO has been outstanding.“

Continuous growth

Since 1970, Mertl has continuously expanded its machinery pool with new KASTO sawing machines. For instance, the company purchased two heavy-duty, fully hydraulic, high-performance bandsaw machines, model KASTOhba AU, in 1994. The parallel horizontally moving sawband is ideal for cutting profiles, tubes and solid material in any quality. Even difficult-to-cut materials such as Hastelloy can still be cut reliably and quickly to this day. "The system has been running like clockwork for 30 years," Christan Wunderlich emphasises.

Because the old SNLS 3000 S overhead storage system with 1,012 cassettes was bursting at the seams, Mertl built a new hall in 2012. The new UNICOMPACT 2.0 honeycomb storage system, equipped with 2,633 honeycombs and fully automatic bandsaws, has since provided increased capacity and efficient processes. "It was not a difficult decision to opt for KASTO," recalls Marie Gruscher-Mertl "We were already familiar with the quality of the products and the great service. KASTO's recommended solution was also the best fit for our requirements. We were also able to seamlessly connect it to our packaging machine."

Safe processes

The name UNICOMPACT for these storage systems is well-suited: since the overhead gantry crane (OGC) has a small footprint. Mertl can then utilise a large amount of space for storage purposes. "The new hall was a significant milestone for us", Marie Gruscher-Mertl emphasises. "Not only have we significantly increased our storage space, but also our level of safety." The goods now come to the person and no longer the other way round. "Reduced manual handling and movement in the warehouse leads to a lower risk of accidents. That is very important to us," emphasises the CEO.

Mertl utilises a variety of KASTO bandsaws at the UNICOMPACT stations to process mostly seven-metre standard length bar stock: KASTOtwin LE 4, KASTOssb A 2, and KASTOtec A 4.

KASTOtec demonstrates impressive performance, particularly for large series production and extremely hard materials. Innovative technologies such as the intelligent control system achieve maximum throughput. For example, this includes the automatic assignment and permanent storage of the cutting technology. This can be adjusted to the respective material qualities and the bi-metal or carbide sawband used. KASTOtwin is an all-rounder. The machine can be used flexibly with various sawband models and is suitable for a wide range of applications, thanks to its tried-and-tested technology.

The KASTOssb cuts bars precisely and quickly – particularly in series production. Thanks to the vertically moving sawband, the machine is extremely compact and delivers high performance within a small space. Special feature: The KASTOssb A 2 has a sturdy feed roller conveyor with fixed yet adjustable sides. This makes the saw the perfect choice for bundle and large-scale cutting jobs.

The UNICOMPACT has enabled Mertl to automate the storage and picking of goods since 2012. In conjunction with the sawing machines, the system processes orders without human intervention. The orders are prepared for shipping by a packaging machine at the end of the line. "We use a proprietary ERP system that is tailored specifically to our needs," explains Christian Wunderlich. In collaboration with KASTO, Mertl's IT department connected the high-rack storage system to the ERP system. "This allows us to maximise the use of the automated system," adds Marie Gruscher-Mertl.

Trustful collaboration

The CEOs of Mertl have considered KASTO a reliable partner since 1970. "The sales representative responsible at the time thoroughly impressed us with his solution," recalls Alfred Gruscher, Director and authorised officer at Mertl. "We have never once regretted our decision because the collaboration has been very pleasant over the years, both in person and on the phone."

When new investments are in the pipeline, Mertl gladly accepts KASTO's offer to inspect systems at reference customers and speak with users directly on site about their respective experiences. "Three of our employees are experts on our high-rack storage system and our saws. Over the years, they have gathered a lot of experience," says Marie Gruscher-Mertl. This is hugely helpful when issues arise. "They can speak to the KASTO service technicians at eye level," explains Christian Wunderlich. Which means that each problem can be solved quickly.