Above: Brütsch/Rüegger Metals AG has significantly improved its operational efficiency thanks to the short output times of the UniTower and UniTop automatic storage systems from Kasto. Photo: KASTO Maschinenbau GmbH & Co. KG
March, 2026- Brütsch/Rüegger Metals AG, a Swiss metal distributor, has upgraded its operations by replacing a semi-automatic honeycomb storage system with the fully automatic UniTop and UniTower long products storage systems from Kasto Maschinenbau. To enhance the process chain, Brütsch/Rüegger Metals also integrated two modified bandsaws from the KastoWin series. In light of growing demands, this combination has become a vital factor for success.
Established in 1877 and based in Regensdorf, Switzerland, Brütsch/Rüegger Metals sells more than 8,000 products and maintains a warehouse stock of 5,500 tonnes (6,063 tons). A supplier of tube, bar and sections, the growing company realized that its semi-automatic honeycomb storage system from the 1980s was reaching its limits. Issues such as inefficient use of space, high search times and safety risks associated with manual operations have hindered operational processes.
The manual setup process using a rail crane became a significant bottleneck, making it impossible to meet efficiency requirements.
“The continual expansion of our product range,” along with the company’s 2023 acquisition of Walter Looser AG, which manufactures semi-finished and finished bronze products, “prompted us to look for a high-performance solution,” explains Patrick Epp, managing director of Brütsch/Rüegger Metals. “Our warehouse stock continued to increase, and we eventually reached our maximum storage capacity.” Expanding the warehouses was not feasible due to existing infrastructure constraints, leaving only one option: consolidation. This led to the initiation of Project Core, whose objective was to increase storage capacity, modernize the warehouse and enhance process efficiency.
COMPACT FOOTPRINT
Brütsch/Rüegger Metals had complex requirements for the new system. It needed to have twice the storage capacity, fit within the 26-meter-wide (85-foot-wide) warehouse, and accommodate goods both 6 and 12 meters long (19.7 and 39.4 feet). Additionally, the system had to be reliable and easy to operate.
The company sought to implement seven different storage and retrieval stations, allowing for simultaneous storage and processing of materials with multiple saws. The capacity requirements presented a particular challenge, as the design had to consider limited floor space and height restrictions due to a photovoltaic system installed on the roof.
“We conducted extensive market research,” reports Epp. “Since 2018, we have been using the KastoWin A 3.3 bandsaw, and we are very satisfied with its performance.” This bandsaw is designed for efficient series cutting, providing fast and reliable operation. It includes automatic functions, minimizes non-productive times and features comprehensive monitoring systems—all of which contribute to high efficiency and safety while reducing tool wear, whether for single cuts or large runs.
“This efficiency was one of the primary reasons we chose to meet with Kasto in person at LogiMAT in Stuttgart in 2022 to discuss our planned warehouse,” Epp says. That is where the Brütsch/Rüegger Metals team found UniTop and UniTower displayed.
“A significant advantage of Kasto over its competitors is that we receive both storage systems from a single source. All other suppliers could only deliver one or the other,” says Epp.
Kasto has long market and technology expertise with metal sawing machines as well as with long goods and sheet metal storage systems and material handling.
TAILOR MADE
The installation at Brütsch/Rüegger features the UniTop overhead storage system, which has a storage length of 6 meters, and the UniTower storage system, with a storage length of 12 meters. Additionally, the installation includes two sawing centers from the KastoWin series: models F 3.3 and A 3.6. This configuration allows the metals company to efficiently store and process long goods within a single building, optimizing the use of space. The overhead storage system is equipped with an operating gantry crane that moves above the cassettes containing the metals, enabling quick storage and retrieval. Special feature: to achieve the required capacity given the limited height of the hall, both systems were installed 4 meters (13.1 feet) down into the floor.
Since the new structure was built, organizing and accessing stored materials has become significantly easier—precisely what was required. Photo: KASTO Maschinenbau GmbH & Co. KG.
The new storage system has increased workplace safety, since goods are now transferred automatically to the saws. This represents a significant improvement over the previous solution. Photo: KASTO Maschinenbau GmbH & Co. KG.
CLEAR VIEW
The UniTop overhead storage system optimally utilizes available space and provides a clear overview of inventory through its computer-controlled features. This system efficiently transfers long materials to three double-output stations in short cycles, seamlessly integrating into the material flow.
By incorporating automatic bar separation and connecting to KastoWin saws, Brütsch/Rüegger Metals has developed a flexible production system that operates largely without human intervention. The metal specialist stores specialized products, such as 12- meter-long cylinder tubes for the hydraulics industry, in the UniTower. This tower storage system enhances material flow and saves significant space thanks to its compact design. It can handle loads of up to 5 tonnes (5.5 short tons) per cassette, which can be provided quickly and easily.
The conversion process occurred in several phases. In the first stage, technicians removed the right half of the old honeycomb storage system and the operating gantry crane, creating space for the new structure.
During this time, Brütsch/Rüegger Metals temporarily stored its goods in other buildings. The left half of the storage system remained operational, with employees managing it manually. Next, a 4-meter-deep channel was created, into which Kasto installed two new storage systems: UniTop and UniTower.
Following this, the KASTOflow align front storage station was integrated into the overhead storage system. This installation enabled Brütsch/Rüegger Metals AG to efficiently transfer long goods from both the temporary storage systems and the remaining old storage half to the new UniTop. In the final phase, specialized personnel completely dismantled the remaining half of the old system and installed three double retrieval stations in the newly available space. These stations automatically supply four sawing centers with materials.
“It was a challenge to coordinate the conversion while managing day-to-day business,” recalls Epp. “However, the Kasto systems - both the storage solutions and the saws - have significantly improved our efficiency,” he praises.
PATRICK EPP Photo: KASTO Maschinenbau GmbH & Co. KG.
SIMPLICITY
The changes are evident at all levels. “The organization and access to the material are much simpler since the conversion.” says Epp. “This improvement is not only seen in the speed of the current honeycomb storage system but also when comparing it to the overhead storage system from another manufacturer that we use.” Thanks to the shorter storage and, in particular, retrieval times, operations have become much more efficient. Additionally, the new storage system has increased workplace safety, since goods are now transferred automatically via retrieval stations to the saws.
“This represents a significant improvement over the previous manual solution,” Epp continues. “The reduction in error rates during the setup process directly impacts customer satisfaction. Faster access to materials leads to shorter delivery times, giving us a decisive advantage over competitors in the JIT production landscape of modern industrial companies.
“Our expectations regarding performance and quality were fully met,” he says. The company successfully completed Project Core with the commissioning of the final saw, a KastoWin A 3.6 at the end of the year. “The key competitive factors are the compact storage and efficient processing of our products. Kasto provides complete systems and solutions from a single source that we can depend on.”
Kasto Inc., 724/325-5600, kasto.com.
