Smarter sawing software from Kasto

Digitalised and networked sawing is an indispensable part of efficient metal processing in warehouses and factories. The German manufacturer of bandsaws, circular saws and hacksaws, Kasto, is at the forefront of the technology. Through its subsidiary in Kibworth Harcourt, Leicestershire, the group offers to the UK and Irish markets intelligent solutions such as system connectivity through KASTOlink, optimised cutting plans with KASTOoptisaw, mobile control via KASTOapp, and automated cutting optimisation with KASTOrespond. Users benefit from maximum operational efficiency, lower costs and high process reliability during sawing operations.

Sönke Krebber, member of the management board at Kasto said: “In discussions with customers, we no longer focus solely on an individual machine, but instead consider the entire material flow. Our engineers develop solutions that optimise cutting strategies, automate processes and intelligently network machines. Interfaces play a vital role. We have been offering OPC UA and various other standards for more than a decade. Integration turns every saw into a component of a well-designed digital process chain, ensuring maximum efficiency, safety and transparency for our customers."

KASTOlink enables seamless networking of Kasto saws with other machines, storage systems, and warehouse management and ERP systems. It ensures a continuous, digital process chain from order to production and on to dispatch. The versatile interface enables integration not only with Kasto equipment but also machines from other manufacturers. Users can efficiently and transparently network their Kasto products with the entire IT and machine environment through interfaces such as OPC UA, MQTT, REST API, DSTV+, CSV or KASTO's own HOST link.

Minimising waste
During the sawing process, users face the challenge of maximising material usage while minimising waste to minimise resource consumption and costs. This is where KASTOoptisaw software comes into play. Integrated into the KASTOlogic warehouse management software, KASTOoptisaw optimally assigns stored long stock to specific sawing orders, taking into account various machine parameters such as kerf width and minimum trim cut length. It can handle bars, tubes, profiles of different lengths, and various mitre angles.

This not only reduces costs but also saves storage space, as unusable remnants no longer need to be returned to storage. Additionally, KASTOoptisaw assists by automatically determining the most efficient cutting plan by repeatedly exploring various possible arrangements, combining them to find the optimal solution. Users can also create cutting plans manually using a graphic wizard based on geometric data. The wizard allows further optimisation by selecting optimal lengths of a given stock type to complete an order.

KASTOapp provides a real-time overview of the status of all Kasto sawing machines within a network. When a saw is operating in automatic mode, the app accesses the information stored in the respective machine control system. One or more users can receive information about all relevant parameters, including data relating to the component type, cut length, target quantity and actual parts sawn, as well as feed rates and cutting speeds.

In the event of an error during operation, the app promptly displays the relevant error message, allowing users to respond quickly and minimise downtime. To ensure security, Kasto protects a user’s information from unauthorised access by transmitting it through encrypted connections using Hypertext transfer protocol secure and using its own servers located at its head office and main factory in Achern, Germany.

KASTOrespond optimises the settings of the sawing machine to maximise blade downfeed, according to whether it is processing solid material, tube or profile, individually or in bundles. The system continuously measures the forces acting on the blade, without the need for additional sensors, and uses the information to determine the appropriate feed rate.

Reduced production time
The software can detect variations in wall thickness, differing contact lengths and particularly hard areas in the material, adjusting automatically to accommodate these factors. For the operator, it means that only a few relevant parameters need to be input, such as cutting length, quantity and material type. As a result, production time is reduced and the service life of the blade is significantly extended.

Kasto is currently rolling out a new control generation as part of its comprehensive package of intelligent solutions. ProControl technology, previewed at EMO 2025 in Hannover, has been developed from the ground up to streamline daily operations, making them easier, faster and more efficient. The new user interface features a modern design, smart functions and a role-based user guide, all designed to enhance clarity and efficiency.

A Simple Mode allows rapid and secure processing of sawing orders with fewer clicks, while access via a browser provides flexible and convenient machine control via a PC or tablet. Various different lengths of the same material can be bundled in one cutting plan, allowing multiple orders to be processed automatically, one after another. Important statistics are clearly displayed on a dashboard and, if questions arise, context-related help is available to provide targeted assistance, exactly where it is needed.

New also is an updated version of Kasto’s high-end ExpertControl for users requiring integration of robotic handling, for example KASTOsort, complex material and parts tracking, and deep integration with large-scale automated warehouses.