CT5000SC
Process blocks efficiently and cut them in series
Semi-automatic line with block handling, cut-to-length station and multi-wire gang cutting machine.
More throughput with just one operator
Anyone who regularly processes Styrofoam or Neopor blocks loses a lot of time on material handling, cutting to length, repositioning and transport between individual machines.
The CT5000SC combines block handling, cutting to length and gang cutting into one continuous production process. One employee can operate the entire line and accompany the block from placing it to the finished cut.
This significantly reduces staffing and handling effort, while at the same time enabling a high material throughput.
The line is therefore an economical solution for companies that regularly process larger quantities of Styrofoam or Neopor blocks, but deliberately want to do without a technically complex and expensive fully automatic line.
Semi-automatic instead of fully automatic
The CT5000SC is not a fully automatic line, of the kind used by large block manufacturers, for example, and is not intended to replace such systems. It is designed for processors who regularly work on whole blocks, but deliberately want to do without cost-intensive full automation.
Block handling and material transport between the stations are carried out by the operator. The cutting wires are also set manually for the respective job.
The actual cutting operations are automated. This keeps the line simple and flexible, while the process logic significantly reduces the time required compared with individual, separate machines.
How production works
The block is brought to the line vertically with a forklift and block gripper and placed on the block turner.
The block turner then moves the block in a controlled manner from the vertical into the horizontal position and sets it down on the roller conveyor.
The block is then pushed manually along the roller conveyor up to the length stop of the cut-to-length station. Cutting to length then takes place at the push of a button.
The cut block sections are pushed on to the gang cutting machine and taken over there by the conveyor belt. They are then automatically transported through the cutting gang and cut.
Horizontal and vertical cutting takes place according to the previously set cutting wires.
The finished cuts run onto an outfeed roller conveyor or mobile roller conveyor. A mobile roller conveyor can then be moved away from the line and replaced by another roller conveyor.
Machine features
The CT5000SC combines several coordinated machine functions into one continuous production process. Each station handles a clearly defined work step, so that one employee can operate the line from placing the block to the finished cut.
Block turner
The block turner moves the vertically delivered Styrofoam or Neopor block in a controlled manner into the horizontal working position.
This allows one employee to place the block on their own and prepare it for further processing. Additional people to tilt or reposition the block are not required.
Cut-to-length station
The block is pushed along the roller conveyor up to the manual length stop. Cutting to length then takes place at the push of a button.
Cutting speed and wire temperature can be adjusted at any time to the material and cutting task.
Optionally, the cut-to-length station can be equipped with the multiSTOP CNC positioning system. This allows the length stop to be set automatically to the desired block length.
This allows block sections to be brought to the desired length quickly, before they are passed on to the gang cutting machine.
Multi-wire gang cutting machine
The gang cutting machine handles the horizontal and vertical cutting of the previously cut-to-length block sections.
Up to 60 cutting wires are available in total. The distribution of the wires between the horizontal and vertical cutting unit can be done individually to suit the respective job.
The desired wire spacing is set manually. The cutting wires are hung and positioned according to the required cut dimensions.
Cutting speed and wire temperature can be adjusted at any time to the material and cutting task.
Enclosure and extraction
Hot-wire cutting of Styrofoam and Neopor produces smoke and odours. On the CT5000SC, up to 60 cutting wires work at the same time. Without extraction, smoke and odours would spread throughout the entire working area within a short time.
The cutting area is therefore enclosed and fitted at the top with an extraction hood. This captures the smoke right where it is produced during cutting.
The connection is made via an extraction hose with a diameter of 500 mm. The line can be connected to an existing company extraction system or to a separate air filter unit.
Outfeed roller conveyor
After cutting, the finished cuts are transported onto the outfeed roller conveyor.
Optionally, a mobile roller conveyor can be used. It can be moved away from the line with the finished cuts and replaced by another roller conveyor.
Less handling, more production
The biggest advantage of the CT5000SC lies in the continuous material flow. From placing it to the finished cut, the block stays within one connected line and does not have to be constantly picked up, repositioned and re-aligned between individual machines.
This allows one employee to operate the entire process alone. While the operator moves the material on from station to station, the cut-to-length station and gang cutting machine handle the actual cutting operations.
In practice – depending on the material and cutting task – around 1 m³ of Styrofoam can be processed in about 3 minutes. This corresponds to a possible throughput of up to 20 m³ per hour.
This throughput is achievable above all when producing with the same cut dimensions over a longer period. If the wire spacing has to be changed frequently and the machine set up again and again, the actual throughput is reduced accordingly.
For series with consistent dimensions, this results in a very economical production process with low staffing requirements, without the high investment costs and the technical complexity of a fully automatic block line.
Set up cutting wires to suit the job
Before production starts, the cutting wires are set manually to the desired cut dimensions. The horizontal and vertical wires are positioned and hung accordingly.
Up to 60 cutting wires can be used in total. The distribution between the horizontal and vertical cutting unit can be adapted individually to the respective job.
Setting up the wire spacing takes time. The CT5000SC is therefore particularly suitable for production runs that work with the same or similar dimensions over a longer period.
Once the cutting gang is set up, large quantities of identical cuts can then be processed quickly and continuously.
Which cutting wire is used?
The CT5000SC works with cutting wires with a diameter of 0.4 mm.
The cutting wires are hung manually and kept under tension by tension springs. The springs compensate for the change in wire length as it heats up and ensure even tension during cutting.
Cutting wire and tension springs are wear parts and can be obtained directly from cnc-multitool when needed.
Technical data
| Model | CT5000SC |
|---|---|
| Working area L × W | 1,250 × 1,250 mm |
| Working height | 1,250 mm |
| Wire length | 1,300 mm |
| Number of cutting wires | 60 |
| Drive type | Conveyor belt |
| Extraction connection | Ø 500 mm |
| Power supply | 400 V 3~, 50–60 Hz |
| Footprint L × W | approx. 12,000 × 2,500 mm |
| Machine height | 2,600 mm |
| Weight | approx. 1,250 kg |
| Technical data sheet | |
| Request |
Scope of delivery
Included:
- Multi-wire gang cutting machine
- Block support and manual block turner
- Cut-to-length station with length stop
- Machine control
- Power supplies for cutting wires
- Cutting wires and tension springs
- Operating manual
- 12 months warranty
Options and accessories
Mobile roller conveyor
Additional mobile roller conveyors can be used as an option.
The finished cuts run directly onto the mobile roller conveyor. Once it is loaded, it can be moved away from the line and replaced by a second roller conveyor.
This allows the finished parts to be transported on, while the CT5000SC keeps producing. The line does not have to be stopped to remove and transport the cuts.
Side walls
The CT5000SC can optionally be equipped with side walls. They guide standing panels during transport and prevent them from tipping over.
At the same time, with small cuts the side walls prevent small blocks from falling off the side of the roller conveyor or table.
multiSTOP CNC positioning system
Optionally, the cut-to-length station can be equipped with the multiSTOP CNC positioning system. This positions the length stop automatically for different block lengths.
Extraction system
A suitable extraction system or external filter unit with a 500 mm connection can be used for operation.
Installation and operation
The CT5000SC is delivered in individual machine modules. These include the respective machine elements such as the block turner, cut-to-length station, gang cutting machine and roller conveyors.
The line can be set up and aligned by the customer themselves. The individual modules are positioned at the place of use, connected to each other and connected electrically.
The cutting wires are then set to the desired dimensions, the extraction is connected and the line is set up for the first production run.
Installation and commissioning by cnc-multitool can also be arranged if required.
What happens in a service case?
Questions about operation, adjustment or troubleshooting can be clarified directly with our technical support.
Spare and wear parts such as cutting wires and tension springs can be obtained directly from cnc-multitool. Many components are easily accessible and can be replaced by the customer themselves if needed.
Frequently asked questions
Which companies is the CT5000SC intended for?
For companies that regularly process whole Styrofoam or Neopor blocks, but do not need a fully automatic production line.
How many employees are needed for the line?
The complete process of block handling, cutting to length and gang cutting can be operated by one employee.
Is the CT5000SC fully automatic?
No. Material handling and setting the cutting wires are done manually. The actual cutting-to-length and cutting operations are carried out by machine.
What is the possible throughput?
Depending on the material and cutting task, around 1 m³ of Styrofoam can be processed in about 3 minutes, i.e. up to 20 m³ per hour.
How are the cutting wires set?
The cutting wires are hung manually and positioned according to the desired cut dimensions.
Can the length stop be automated?
Yes. Optionally, the cut-to-length station can be equipped with the multiSTOP CNC positioning system.
Is an extraction system needed?
Yes. For CE-compliant operation, a suitable extraction system with a 500 mm connection must be provided on site.
Experience the CT5000SC live
Visit us in Ilmenau and see the CT5000SC in practical use. We will be happy to discuss your block sizes, desired cut dimensions and production volumes.
Request a demonstrationOther interesting products and accessories
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