FW5000HR Series
for tapered insulation and roof insulation components made from stone wool, PIR, PU and PUR

Board operation

In board operation, individual boards are fed via the front roller conveyor onto the conveyor belt integrated into the machine table.

The conveyor belt transports the boards continuously through the inclined cutting wire. The starting boards are cut into two tapered boards.

The finished boards are then discharged via the rear roller conveyor and can be removed directly or processed further.

Block operation

In block operation, the block is fed via the front roller conveyor onto the conveyor belt integrated into the machine table and transported into the machine.

A light barrier detects the leading edge of the material and automatically determines the defined material zero point for the subsequent cutting process.

During cutting, the CNC machine table moves the block through the cutting wire in a controlled manner. The two Y axes can move independently.

This makes it possible to produce different slopes, valley and hip boards, roof crickets and other roof insulation components directly from the block.

After the cutting process, the material can be transported via the integrated conveyor belt either back to the starting point or to the opposite side of the machine, where it can be removed or processed further.

CNC contour cutting

In addition to typical roof insulation components, the FW5000HR Series can also cut custom contours from boards or blocks under CNC control using one cutting wire.

This also makes it possible to produce more complex roof insulation components precisely and reproducibly.

Cut blocks to length

Larger PIR, PU or PUR blocks can be cut to the required starting format directly on the FW5000HR before the actual roof insulation production.

For example, standard blocks measuring 2,000 or 2,500 mm in length can be cut into the 1 × 1 m starting formats required for further roof insulation production.

Alternatively, blocks can be cut to length separately using an additional cut-to-length machine. The prepared starting formats are then processed further on the FW5000HR.

The material determines the cutting speed

For stone wool, typical cutting speeds are approximately 1.0–1.5 m/min.

PIR, PU and PUR are cut at approximately 1.0–2.0 m/min, depending on material density and material structure.

The usable cutting speed depends on the material and material density.

Typical production times

2 tapered boards, 1 × 1 m: approx. 1 minute.

1 valley board and 1 hip board: approx. 2 minutes.

1 roof cricket: approx. 30 minutes.

These figures are practical values and may vary depending on material, dimensions and cutting task.

The FW5000HR cuts abrasively. The fast-running saw wire separates the material mechanically, not with heat. It saws through the material.

There is a suitable cutting wire for every material. Using the wrong wire can significantly reduce its service life.

The cutting wire consists of several cores wrapped with a saw wire. The design of this winding determines which material the wire is suitable for.

Depending on the material, cutting wires with a diameter of 1.2 to 1.6 mm are used. The endless Fastwire runs at up to 300 km/h.

You do not need to write CNC programs to operate the FW5000HR. The important thing is knowing which roof insulation component you want to produce.

Tapered boards and cutting blocks to length run directly via the supplied Roof Standard machine plugin of the machine software. There you enter the dimensions and parameters directly, and the software automatically calculates the required wire position and cutting sequence.

Valley and hip boards as well as roof crickets are created with the optional Roof Pro machine plugin – likewise parametrically and no more difficult to operate. Custom contours can additionally be prepared using the styroCAM CAM software.

Many of our customers familiarize themselves with the applications independently using our instructions or use an application training session with one of our application technicians – at our facility or optionally at your site.

Produce customer orders

Tapered boards, valley and hip boards, roof crickets and custom roof insulation components can be produced directly to customer order.

This allows you to respond directly in your own production to different roof geometries, changed dimensions or components required at short notice.

Smaller quantities and replacement production can also be manufactured flexibly without having to order finished roof insulation components from external suppliers.

Produce roof insulation components for stock

Regularly required roof insulation components can be pre-produced and stocked.

Frequently required tapered boards and standard dimensions can therefore be produced before a specific customer order exists.

This creates your own inventory and allows you to respond to new orders faster and more independently of external lead times.

Machine table with integrated conveyor belt

The machine table is designed as a stable, open steel structure for processing boards and larger material blocks.

A conveyor belt is integrated into the machine table. This allows the material not only to be positioned, but also to be moved through the machine in a controlled manner during the production process.

An integrated light barrier detects the leading edge of the material and provides a defined material zero point for the cutting process. This simplifies repetitive production processes in particular and ensures reproducible material positioning.

The open design keeps the work area easily accessible. Boards and blocks can be placed and aligned easily and, if required, processed directly on the machine table.

Independently controlled Y axes

The FW5000HR Series has two independently controlled Y axes on the left and right sides of the cutting wire.

This allows the cutting wire to be positioned at different heights on both sides of the machine. In addition to straight cuts, this also enables defined slopes and different height profiles.

This independent axis control forms the technical basis for producing tapered boards, valley and hip boards, roof crickets and other more complex roof insulation components.

For normal straight cuts, both axes can operate together. If different heights are required, YL and YR are positioned independently as needed.

Pneumatic wire tensioning with wire-break shutdown

The continuously running cutting wire is tensioned during operation by a pneumatic wire tensioning system.

Consistent wire tension is important so that the cutting wire is guided cleanly and achieves precise and reproducible results even during longer cuts.

The cutting wire is also monitored continuously. If a wire break is detected, the machine shuts down automatically and stops.

After the cutting wire has been replaced, the cutting process can be continued from the last position.

Enclosed cutting arms with extraction ports

Fastwire cutting generates dust and fibers depending on the material. The cutting arms of the FW5000HR are therefore enclosed and prepared for connecting a suitable dust extraction system.

For this purpose, two 100 mm extraction ports are available directly on the cutting arms.

Front and rear roller conveyors

Roller conveyors for material feeding and unloading are installed in front of and behind the machine.

Boards and blocks can therefore be moved to the machine at working height and transported out of the working area again after cutting.

Especially for larger or heavier materials, the roller conveyors simplify handling and reduce the amount of manual movement required.

Together with the integrated conveyor belt, this creates a continuous material flow from loading to unloading.

Control PC package

Together with the machine software, control and Roof machine plugin, the computer system forms the operating environment of the FW5000HR Series.

The system is prepared for machine operation and is supplied with a current Windows Pro license, ensuring that the computer, interfaces and software are coordinated with one another.

All cnc-multitool computer systems feature a second SSD as a backup drive.

Dust-protected operator console directly at the machine

The operator console is located directly at the FW5000HR and is designed with dust protection for use in the production environment.

Computer, monitor, keyboard, mouse and the operating elements required for machine operation are arranged clearly at a fixed workstation.

This means machine operation, software and production documents are located exactly where they are needed in daily production.

The operator can monitor the machine, set up the material and control the cutting process directly from the workstation at the machine.

Dust extraction and occupational safety for stone wool

Fastwire cutting generates cutting dust. Stone wool additionally produces fiber-containing dust, which should be captured as close as possible to the cutting area.

A suitable dust extraction system is therefore required for production operation.

We offer a dust extraction solution matched to the FW5000HR that can be switched on and off via the machine software.

Alternatively, a customer-provided dust extraction system can be integrated into the machine.

Safety system

A suitable safety system is required for machine operation.

Depending on the installation and production environment, it can consist of a safety fence and safety light barriers.

The safety system can be ordered from us or provided by the customer in accordance with the applicable safety regulations.

Lifting aid for board loading

For heavy or large-format boards, the FW5000HR Series can be equipped with a lifting aid for material loading.

This allows stone wool, PIR, PU or PUR boards, for example, to be picked up and ergonomically positioned on the front roller conveyor or at the machine infeed.

The lifting aid reduces the physical strain on the operator and simplifies regular machine loading.

Roof Pro machine plugin

The Roof Pro machine plugin expands the machine's standard functions to include the production of valley boards, hip boards and roof crickets.

The operator enters the required dimensions and parameters. The software automatically calculates the geometry, required wire position and complete cutting sequence.