2014-07-16
See us at Tube China 2014
from September 24 to 27, 2014 in Shanghai
Booth no. E1D12
We would be glad to welcome you!
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Customer ordered five Fix Length Lines during the TUBE SHOW
Reika und Gräbener Maschinentechnik „extremely satisfied“

at the Tube Show in Düsseldorf and the quantity and quality of queries. As in previous years, the companies belonging to GRAEBENER GROUP
presented their portfolio on a joint stand to show their latest developments.
REIKA was pleased about the large great number of visiting professionals. In particular, the visitors proved to be really competent partners, where most
of them already provided specific projects for the production of pipes in the smaller diameter range. Moreover, REIKA was glad about the large proportion
of customers from Russia, the U.S. and even Spain, providing clear evidence that these markets will return to the global market with new impetus.
Customer interest was paid to the complete range of REIKA’s machine portfolio – from Cut-off machines and RingSaws® to Finishing and Chamfering lines
and, finally to Straighteners and Testing Lines.
One of the highlights during the Tube Show was the handover of the next order for five Fix Length Cutting Lines (chipless cutting, chipforming cutting and
endworking) by one of Europe’s biggest fitting manufacturers. This is a big proof for the customer's confidence in the Hagen company’s products
since the customer’s facilities are already equipped with 15 lines of the same type. The reason is quite clear, REIKA’s machines are best known for
perfect integration into the production progress. In addition, the machines are subject to a continuous improvement process, so current state of the art is guaranteed.
"Extremely satisfied" both Gräbener Maschinentechnik GmbH & Co. KG and REIKA GmbH & Co. KG are glad about the response to their joint presence
 
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Satisfaction secured new job

REIKA delivers API Chamfering Line to the largest International Steel Group

REIKA GmbH & Co. KG, member of the Graebener Group, recently received an order to supply a chamfering line to the largest
international steel group for one of their seamless tube mills. The turnkey line consists of two chamfering machines and an
integrated transport system and will be assembled in a mill for hot-rolled tubes in Romania.
This new order resulted in part from several jobs in the past, with the latest very successful deliveries of straighteners to a
French subsidiary and cutting lines to the group’s Czech tube mill. As the customer is really satisfied with the quality and
the performance of the REIKA products, those responsible recommended REIKA to their corporate headquarters.
On the other hand, the company already convinced its customers with their high precision and rugged chamfering lines,
including those, competitors of the steel group. The customers were also thrilled by the outstanding reliability of the systems,
being a guarantee for high quality tube ends and tool lifetime. So the customer’s decision was clearly in favor of REIKA as
a turnkey supplier for the whole system.
The chamfering line will provide seamless pipes with a diameter of 114 ( 4.5 " ) to 406 mm (16") and a wall thickness
from 4 to 35 mm with bevels for the oil and gas industry. The tubes meet API and ASME standards, are 5 to 15 m long
and have a unit weight up to 3,500 kg. A complete customized tool package will be delivered along with the line, consisting
of chamfering heads, tool holders and clamping tools.
REIKA chamfering lines provide facing, internal and external chamfering to welded and seamless tubes in accordance with
DIN, API, ASME or ANSI standards. The machines can be supplied in single or double-sided design and can be integrated
online into the material- and the entire tube mill work flow.
REIKA chamfering lines are designed for 2 ½ to 24” diameter tubes. All lines can be equipped with special custom-made
features, such as advanced CNC control, a detailed target/actual diameter measurement and a fully automatic tool calibration,
resulting in high cutting speed and short cycle and set-up times with flexible, customized tool systems.
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Focus on profitability
Central America’s largest pipe producer receives first RingSaw®
It was for economic reasons, leading one of the world's largest pipe manufacturers late last year to make a
fundamental decision in favour of REIKA’s RingSaw®. In other words, all production facilities of the leading pipe group
should be gradually equipped with the innovative concept of the inside tooth saw blade.
The first machine is now scheduled to be shipped for coupling production with destination Central America.

The task was not easy, REIKA Managing Director Hans-Jörg Braun remembers well. "The machine is designed
to cut blanks for premium pipe couplings within the diameter range 3-7" from the long tube." The wall thickness is
between 0.5 and 2" and the length of the couplings is 130 to 350 mm, made from heat-treated, high-strength steel
to API 5CT standard with a strength of up to 1200 N/mm ².

The cut blanks shall be clamped precisely and without jamming to the downstream turning or threading machines.
" The customer quickly realized the process advantages of our RingSaw®, Braun says." The rectangular and almost
burr-free cut is not the only advantage of our conceptual design, that ensures exact and absolutely clearance-free
location of the blanks. Another big advantage of the RingSaw® : heavy comma shaped chips and no magnetization
during the cutting process, which will not leave sticky chips on the pipe material. They will be discharged directly
to the chip conveyor.
In total, these advantages save rework and increase the number of blanks, leading to around 150 parts per hour
with the RingSaw®. Another profit is the turnkey handling system for ingoing tubes upto 15 m length.
REIKA’s RingSaw®  offers numerous additional advantages with its internal tooth cutting tool, equipped with four-
side cutting inserts, compared to conventional saws. The name says it all: the inserts can be used up to four times
before they are worn out. The RingSaw® is equipped with a tool monitoring system to detect tool wear and breakage
and to ensure optimum cutting quality.               
The inserts can be screwed into the tool carrier, so complex and time consuming presettings on the machine or on
the cutting tool are avoided. The run times of the tools are much longer, lifetimes correspondingly lower.
And last but not least, there is no wear on the tool carrier.
Keyword cost : The follow-up cost are lower than with competitive concepts due to our machine concept.
" The rotating tool is more comfortable on the machine compared to a cutting tool cutting from outside and the
centrifugal forces are greater" explains Hans-Jörg Braun. Therefore, the follow-up costs are lower, as there are
no forces which may act on the lunettes.
Long tubes will be delivered to the machine via a loading rack with gripper system and fed into the correct position.
The measuring system located in the inlet area automatically registers the tube diameter at the entry side – so
diameter mixup can be avoided – .
First of all the “as rolled” tube end will be cut first and discharged to a separate scrap recycling bin. If there are
colored tube defects on the ingoing tube, they will be cut out and also discharged to the scrap recycling bin.

The cut blanks are automatically removed by a robot, automatically measured and marked on an external station
to be finally stacked into a container according to customer specification.
" Again, we are guided by the customers demands to accelerate the production process as much as possible. "
Hans-Jörg Braun says. So again, REIKA’s focus on profitability is always in first place.
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Amazing and superior technological solutions
Customers fascinated by the Open House event of three Graebener Group companies
 
 
 
The Open House event of the Graebener Group was a resounding success. At the locations Quartier Landeskrone
and Quartier Elkersberg the companies Gräbener Maschinentechnik GmbH & Co. KG, Reika GmbH & Co. KG and
H. Kleinknecht GmbH & Co. KG opened their doors in order to present their latest developments to the visitors.
In addition to this, Reika introduced the new demonstration and processing center.
In this workshop, which is located right next to the highway, the customers were able to survey the quality of the
Reika machines during operation. An operation that has become even more important since Reika, together with
the customer, conducts tool tests and further developments with the machines available at the demonstration center,
especially with the machines of the RingSaw® series. Managing Director, Hans-Jörg Braun, is certain "that this is
the best way for Reika to learn and determine which tool is most suitable for the customer's material thus leading
to optimum results". The customer simply supplies the material and does not need to assign any of his own machines
for the testing process which would impact his production. "On the other hand, this is also an ideal way to convince
the customer of the superior qualities of our RingSaw® technology."
This goal was already met during the open house event. Even though customers already knew the RingSaw®, they
were still amazed at the features of the machine series for the cutting of tubes, profiles and bars and for various
applications concerning the separation of tubes and bars. The cut is almost free of burrs and the tool costs are
significantly reduced in comparison to conventional hard metal saws while at the same time speeding up the performance.
Hans-Jörg Braun: "That is the major advantage of our demonstration center. Here, the customer can experience the
features of our machines directly – under most various conditions with different materials."
While Reika presented their vast experience with the cutting and processing of precision tubes, Gräbener showed
their abilities at the Quartier Landeskrone with machines of completely different dimensions. The two 4-roll
bending machines currently being assembled there are nearly ready to the shipped to a manufacturer of
offshore monopiles. They are used for bending plates with a wall thickness of up to 150 mm to individual pipe sections
with a diameter of up to 10 m. These two machines with the fully adjustable plate handling system represent the
absolute state-of-the-art currently available in the sector of roll bending machines for the preferably automated
bending of cones as well as cylindrical sections of any required plate thickness.
The final participant of the Open House event was the company Kleinknecht having pooled their mechanical
competences at the Quartier Landeskrone. Here, Kleinknecht manufactures test stands for (dual clutch) gears,
components, electronic as well as hybrid motors and electric discharge texturing (EDT) machines for renowned customers worldwide.

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Straightening Machines are selling like hotcakes

Customers purchase another four lines from Reika GmbH & Co. KG

The success just does not stop: This year's spring edition of Graebener Group "Update" reported that Reika GmbH & Co KG

secured several orders for various tube straightening machines. Over the last six months, the Hagen based company has

received four more orders for 10-roll straightening machines. The first of these machines was already delivered to Russia

in the beginning of October. A second machine is currently being transported there. The third machine is built for the French market

and the fourth is intended for the Chinese market. All four machines were purchased by renowned pipe manufacturers as a

replacement of existing machines by other manufacturers.

 

Andreas Zimball, Sales Manager at Reika, explains why these straightening machines are such top sellers at the moment:

"Countries such as France and China are investing in nuclear power stations. The duplex stainless steel tubes for heat exchanger

systems used for such power stations must be of the highest precision." The stainless steel tubes have a length of up to 30 meters,

but the general tube diameter only is up to 25 mm. In order to meet the quality requirements for such extremely sensitive tubes,

the machines are equipped with the corresponding technical features to ensure finest accuracy and high precision.

"By the way, all Reika machines offer high precision, without any exceptions," vows Zimball.

 

Main features of the roll straightening machines built in Hagen are robust, torsion and vibration resistant steel frame

constructions, material saving in- and outlet channels, individual drives for the compensation of the roller wear.

The machines also have a completely closed and compact design in order to meet the market's requirements regarding noise levels

and environmental protection. In addition to this, Reika has chosen rollers with large diameters for the straightening machines in

order to guarantee a low-wear operation. The maintenance free roller carriers are clamped centrally so that a precise angle and

height adjustment without any backlash is ensured. The company of the Graebener Group has also focused on optimum

maintenance and operation: Thanks to the design, the interior of the machine is easily accessible without any interfering edges.

 

Reika and also the customers firmly believe that this state-of-the-art machine design, which is of course engineered using most

modern 3D CAD systems and FEA simulations, eliminates the flaws of comparable products by other competitors. For example,

the adjusting and guiding components are protected against scales, dirt and water in order to prevent corrosion and excessive wear.

The automatic, self-learning and network-compatible CNC machine control, which ensures an optimum operating comfort and

significantly reduces the setup times, is another decisive factor for the customers.

 

For Reika, considering the customers' needs and requirements goes without saying. Zimball: "All our straightening machines aim

at surpassing the customers' expectations regarding the highest straightening accuracy." Therefore, the customer can benefit from

an increased material throughput.

 

"Our machines ensure a high productivity," promises Zimball. "Especially the significantly increased precision concerning the

straightness of the tubes and the elimination of unstraightened tubes provide the customers with an immediate economic

advantage so that the return on investment can be achieved within a very short period of time." This promise applies for all kinds

of tubes and materials: hot-rolled, drawn, cold-pilgered or longitudinally welded, with low and high levels of material strength.



Reika and Gräbener Maschinentechnik still rocking machine tool world
 Innovation all about tubes 
 



 

Positive headlines recently attracted substantial attention on German machine tool enterprises REIKA and GRÄBENER MASCHINENTECHNIK
of the Graebener Group.
The former by receiving considerable attention with their RingSaw® premiere to the machine tool world, a revolutionary design for cutting
of tubes, profiles and bars, the latter recording a big order for the delivery of seven machines to a new pipe mill in Saudi Arabia.
REIKA’s RingSaw® Avantgarde has the potential to become tomorrow's classics:
Detailed test runs together with leading manufacturers of roller bearings confirmed and yet even exceeded their expectations with
remarkable savings by that new technology saw head that orbits the stationary workpiece: cost savings of 50 to 80 percent, compared
to conventional carbide saws and 30 to 60 percent faster, leading to rapid return on investment.
Meanwhile, recent test runs with bars, smaller (40 mm dia.) and bigger (600 mm dia.) tubes, reported impressive results. So everybody
at REIKA is really proud of this machine, performing almost every day since its launch at the TUBE Show in Düsseldorf in April 2010.
But the company, based in Hagen (North Rine Westphalia - Germany), is still anxious to keep the tool technology up to date.
High-tech tools are constantly being developed to optimize the outstanding results.
Continous development is also the Keyword at Gräbener Maschinentechnik. Amongst Hydroforming and Hot-Stamping-Presses
and Plate edge milling machines for manufacture of ship deck sections, there is particular attention for machine tools to manufacture
longitudinal welded tubes. Milling machines, pipe forming presses, 3- and 4-roll bending machines, post-bending presses, continuous
root tacking machines, end facing machines etc., all machines will be constantly updated to the latest technological standards with
special care to well known Gräbener reliability. 
Most recent example is Gräbener’s pipe forming press delivered to a tube mill in Malaysia, being among the fastest in the world.
Gräbener engineers and technicians reduced the real tube bending time to 3 minutes, outstanding proof for Graebener Group performance and success.