Sind individuelle Lösungen zur Kabelbearbeitungen überhaupt noch bezahlbar?

Absolut. Zum einen müssen für die meisten Sonderanwendungen bestehende Lösungen mit Sonderelementen kombiniert werden. Kabel im Eisenbahnbereich z.B. müssen speziell bedruckt werden, ansonsten aber kommen Standardlomponenten zum Einsatz. Auch bei Netzwerkkabeln agiert man mit einem Mix aus Sonder- und Standardlösungen. Echte Sonderlösungen kommen bei wenigen Branchen zum Einsatz.

When Standard Solutions Reach Their Limits

CUSTOM AUTOMATION

Metzner develops and manufactures custom machines and automation solutions for cable processing. From modifying existing machines to integrating complex processing steps, we create solutions tailored to your materials, production processes, and quality requirements.

Your specific manufacturing task

Requirements Become Production Solutions

Not every cable, material, or production process can be processed cost-effectively using a standard machine. Unique material properties, multiple coordinated processing steps, or specific requirements for positioning, marking, and storage call for a customized solution.

METZNER combines mechanical engineering, control technology, and process integration into a comprehensive manufacturing solution. Machines and systems are combined within the corporate group to meet specific needs—including, when necessary, specialized solutions from our subsidiaries RAMATECH or METZNER E-Mobility.

For you, this means: a single point of contact and a complete solution from a single source—from technical coordination to ordering through METZNER. The goal is a reproducible process that reduces manual intervention, ensures product quality, and integrates seamlessly into your manufacturing operations.

In accordance with the process

Tailored to the material, processing steps, and production requirements.

Throughout

Material feeding, processing, and transfer are seamlessly integrated.

Economic

Fewer manual steps and consistent process quality as development goals.

Technology that takes your production to the next level.

A well-thought-out, customized solution combines the technical requirements of a product with the economic goals of its manufacturing.

Fewer manual interventions: Automated material handling and coordinated process steps reduce repetitive handling tasks.
Consistent machining quality: Defined processes and controlled positioning ensure reproducible results.
More efficient material flows: Coordinated feeding, machining, and storage systems reduce unnecessary transfers.
Investment tailored to needs: Modifying an existing machine can be a cost-effective alternative to developing a completely new one.

Applications

The starting point is not the machine, but the specific manufacturing task. Material properties, quality specifications, and existing production processes determine how the technical solution must be structured.

Understanding requirements: We examine the material to be processed, the necessary processing steps, the quality specifications, and the material flow requirements.
Developing a technical concept: Based on this, we assess whether an existing machine platform should be adapted, supplemented with peripherals, or whether a custom system should be designed.
Integrating processes: Machining, control, and material handling are coordinated according to the defined task.
Integrating the solution into production: The design is based on the agreed-upon production requirements and the conditions at the future site of operation.

Metzner Reference Projects for Specialty Cables & Wires

Three applications. Three customized solutions.

These three implemented solutions demonstrate just how varied the requirements for automated cable processing can be.
Each project addresses situations where material properties or process requirements call for a specialized technical solution.

Multiple process steps in a production line

THE CHALLENGE: Network cables must not only be cut to length, but also labeled, prepared for further processing, and stored in a defined manner. THE SOLUTION: An automated line combines unwinding, straightening, printing, roughening, cutting, stripping, winding, and bundling. QR codes and serial numbers enable the cables to be tracked throughout the rest of the manufacturing process. THE BENEFITS: Fewer manual hand-offs, automated process sequences, and improved traceability.

Precision Machining of Complex Cable Assemblies

THE CHALLENGE: Mineral-insulated cables are particularly stiff and have a multilayer structure. Processing them places high demands on material guidance, cutting position, and the controlled removal of individual layers. THE SOLUTION: A specially developed system combines material-specific straightening with rotary cutting, sawing, cutting to length, stripping, brushing, and unloading. Processing positions and overall lengths are maintained with an accuracy of 0.2 mm. THE BENEFITS: Reproducible processing steps, precise positioning, and controlled processing of sensitive material structures.

Precise cut lengths without frayed ends

THE CHALLENGE: Steel cables and textile-sheathed cables cannot always be cut cleanly and to the exact length using conventional methods. At the same time, marking and fastening positions must be strictly adhered to. THE SOLUTION: A motorized feeding system with non-contact loop control, laser-based length measurement, programmable marking, and a special cutting process enables the automated processing of ropes up to 20 mm in diameter. A material stacker collects the cut ropes up to a length of 12 m. THE BENEFITS: Clean cut ends, precise cutting to length, and organized storage for subsequent processing.

Flexible & process-oriented.

Scope of Services

From machine customization to complete systems

Not every individual manufacturing task requires a machine developed entirely from scratch. Metzner evaluates which technical solution best meets the requirements: from adapting an existing machine platform to combining multiple machining and handling steps into a single automated system.

Customize Machines for Specific Purposes

Adjustments to the PLC control system, user interface, and program sequences allow for customization to meet specific production requirements. For example, additional scanning operations, material stops, or other operator actions can be integrated.

Integrating Peripherals and Material Handling

Active and passive unwinding, winding, and unloading units complement the processing machine. Material feeding and product unloading are tailored to the respective process.

Automate multiple processing steps

When individual process steps need to be integrated, machining modules, marking, and handling are combined into a seamless manufacturing solution.

What challenge would you like us to help you solve?

Whether it involves unusual material properties, multiple processing steps, or a complex production process: Tell us about your requirements. Together, we’ll determine which technical approach makes the most sense for your application.