The Danish Solar Group has almost everything in its range that construction and trading companies need – including a large selection of cables and wires. In order to deliver these to customers in the desired quantities, the company relies on KABELMAT winding technology at its logistics center in Vejen: three fully automatic AUTOLOG winding systems and several individual machines ensure efficient and gentle handling – even of sensitive optical fibers.
From screws to generators, from lamps to photovoltaic systems, from plumbing to smart home systems: the product range of the Danish Solar Group offers construction and trading companies everything they need to realize their projects. The company, founded in 1919, specializes in both purchasing and services in the field of electrical engineering, heating and plumbing, ventilation and air conditioning and energy solutions – and is extremely successful in these areas. The Solar Group is not only active in Denmark, but also in Norway, Sweden, the Netherlands and Poland. In 2021, the company achieved a turnover of almost 12.4 billion Danish crowns (1.67 billion euros) with 2,900 employees.
A major advantage for employees is the high level of user comfort of the KABELMAT machines. (© Solar Group)
CUSTOMIZED CABLES BASED ON CUSTOMER REQUIREMENTS
In addition to a modern logistics concept and excellent service, an extensive product range and high product availability are important assets of the Solar Group. Their portfolio also includes a huge selection of cables and wires: from control and connection cables for industry and mechanical engineering, to cables for infrastructure and construction technology, to fiber optic cables, telecommunications and data cables, no wish remains unfulfilled. “Our ambition is to make our customers' processes more efficient and sustainable,” explains Kim Søllingvraa Nielsen, Team Leader Cables, Volume & Long Goods. “That is why we supply cables and wires not only in standard lengths, but also tailor-made to the customer's needs.”
The company is also well prepared from a technical point of view: in its 45,000 square meter logistics center in Vejen, Denmark, Solar has three automatic wrapping lines. These machines unwind cables and wires from manufacturers' and suppliers' large barrels, which weigh several tons, and wind them onto smaller barrels or into rolls for boxes – cut to exactly the ordered length. “Given the volume of orders we process, this process would be impossible to do manually,” Nielsen explains.
These systems were supplied and installed by HELUKABEL's subsidiary KABELMAT Wickeltechnik. “Until recently we used machines from another supplier,” recalls Nielsen. “However, these became old and no longer achieved the desired results in terms of quality and productivity.” After visiting various manufacturers, those responsible at Solar finally chose the AUTOLOG wrapping machines from KABELMAT.
AUTOMATIC CONTROL PREVENTS OPERATING ERRORS
The systems consist of several machines, each with a modular construction and available in different sizes: three PORTROL unwinders pick up the drum to be unwound with a spindle and bring it into position. They are connected to a conveyor belt so that a barrel can be automatically picked up from the warehouse and transported to the unwinders. On the other hand, two UMROL unwinders and a semi-automatic cable winding machine from the RINGROL series wind the cables onto drums of different sizes and into boxes, while simultaneously measuring and cutting the correct length. Unwinding and winding are controlled automatically, the system receives the order data via an interface with the ERP system. “This eliminates operating errors,” Nielsen emphasizes. Finally, the finished rolls and boxes only need to be removed by forklift and prepared for shipment. “This saves a lot of time and manpower.”
A special challenge at Solar Denmark was cutting high-quality fiber optic cables: these must not be bent too much when rolled up to prevent damage. “We have therefore specially adapted the bending on the systems to ensure that no bending radii are created that are too tight,” explains Manfred Wössner, Sales Manager at KABELMAT. A so-called cable dancer system, which is placed between the unwinder and rewinder, also compensates for speed fluctuations and thus reduces the tensile load on the cable. “This allows even sensitive products such as optical fibers to be cut to length and wound up without loss of quality,” adds Wössner.
The Danish Solar Group's product range also includes a huge selection of cables and wires. (© Solar Group)
HIGHEST QUALITY AND MAXIMUM AVAILABILITY
In addition to the three fully automatic lines, Solar Denmark also uses three UMROL 1000 rewinders. On these more compact machines, the company can wind cables and wires into spools or onto smaller drums without having to use any of the winding lines – for example for orders with small batch sizes. All KABELMAT machines are calibrated according to the European Measuring Instruments Directive (MID) and are therefore approved for use throughout Europe. In addition, they are equipped with data storage equipment that allows all work steps to be traced without gaps. “All this ensures that we can offer our customers the highest quality and maximum availability,” says team leader Nielsen with satisfaction. “With the new equipment it has been possible to significantly increase our processing capacity.”
Another advantage is the user-friendliness of the KABELMAT machines: they are equipped with high-quality Siemens touch panels and have a Danish voice output – the switchover was therefore a piece of cake for the staff. “We also received thorough training from KABELMAT after commissioning, so that no questions were left unanswered,” says Nielsen, praising the collaboration. “We are completely satisfied with our new wrapping technology, and another machine is already planned to further expand our capacity here.”
“With the new KABELMAT systems we were able to significantly increase our processing capacity.” Kim Søllingvraa Nielsen, Team Leader Cables, Volume & Long Goods at Solar Denmark (© Solar Group)