CNC manufacturing of large-volume aluminium and steel components, tool and model making, steel and plant construction as well as welding technology.
Kalay GmbH
Hardebek (Headquarters) · Kaltenkirchen (Production)New on Amplifa
About Kalay GmbH
Kalay GmbH was founded in 1988 as Kalay Metalltechnik and today manufactures in the fields of tool and model making, CNC machining and steel and plant construction. The company produces large-volume, highly machined workpieces, extra-long constructions as well as precise and complex parts made of aluminium and steel as single parts or small series. The core of production is a temperature-controlled workshop with 2,500 m² of manufacturing space in Kaltenkirchen, where constant production and temperature conditions enable the tightest form and position tolerances. The machine park includes various CNC machining centres from Okuma and Yamazaki Mazak, including a gantry machining centre with a working area of X = 5,000 mm, Y = 2,550 mm, Z = 1,500 mm and a maximum workpiece weight of 27,000 kg, complemented by conventional manufacturing, welding technology and in-house material preparation (flame cutting, sawing). Through partner companies, hardening, grinding, EDM, galvanizing, coating as well as blasting and painting services are offered. Customers come from plant and mechanical engineering, tool and mould making, aerospace, automotive, medical technology as well as design and development.
- Site
- Hardebek
- Processes
- CNC turning, 6-axis mill-turning, Conventional manufacturing (horizontal boring machines, combination milling machines, lathes,, Flame cutting, Sawing (saws and band saw automatic machines), Welding technology (steel and aluminium welding including welding and flame cutting technology), Steel and plant construction (construction of components and smaller systems), CAD/CAM programming (Coskom, Mazatrol)
- Materials
- Aluminium, Steel
- Certificates
- DIN EN ISO 9001:2015, ISO 9001
- Founded
- 1988
- Industries
- Plant and mechanical engineering, Tool and mould making, Aerospace, Automotive, Medical technology, Design and development
- 01
CAD/CAM programming (Coskom, Mazatrol)
- 02
Material preparation (flame cutting, sawing)
- 03
CNC manufacturing (milling, turning, mill-turning)
- 04
Conventional manufacturing (horizontal boring machines, milling machines,
- 05
Welding technology (steel and aluminium)
- 06
Steel and plant construction (components and smaller systems)
- 07
- 08
Quality assurance with mobile 3D measuring system
Materials and Processes
Aluminium
Large-volume, highly machined aluminium workpieces are manufactured, and larger aluminium constructions can also be welded.
Steel
In steel construction, including welding and flame cutting technology, large-volume components up to 25 tonnes can be manufactured and further machined on CNC machining centres.
Locations
Hardebek
DEHeadquarters / Administration
Kaltenkirchen
DEProduction: tool and model making, CNC manufacturing, steel and plant construction
- Part weight / size
- up to 27,000 kg (CNC milling); up to 25 t (welding
- Lot size
- single parts to small series
- Materials
- aluminium, steel
- Okuma MCM-B gantry machining centre (X 5,000 / Y 2,550 / Z 1,500 mm, 27,000 kg)
- Mazak AJV 25-404 N gantry machining centre
- Mazak FJV 60-80 gantry machining centre
- Mazak FH 8800 horizontal milling machine
- Mazak FH 480 horizontal milling machine
- Weiler E80 cycle-controlled lathe
- Mazak VTC 200 travelling-column machining centre
- Mazak V 550 cross-slide machining centre
- Mazak Integrex 200 y 6-axis mill-turning centre
- Flame cutting systems, saws, band saw automatic machines
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Machining | – | 5,000 mm (X, largest machine) × 1,500 mm (Z, largest machine) | 27,000 kg | single parts – small series | aluminium, steel |
| CNC turningMachining | – | Ø 800 mm | 1,500 kg | – | – |
| 6-axis mill-turningMachining | – | 1,000 mm × Ø 500 mm × 250 mm | 250 kg | – | – |
| Conventional manufacturing (horizontal boring machines, combination milling machines, lathes,Machining | – | – | – | – | aluminium, steel |
| Flame cuttingMachining | – | – | – | – | steel |
| Sawing (saws and band saw automatic machines)Machining | – | – | – | – | – |
| Welding technology (steel and aluminium welding including welding and flame cutting technology)Joining | – | – | 25 tonnes | – | steel, aluminium, weldable ferrous and non-ferrous metals |
| Steel and plant construction (construction of components and smaller systems)Assembly | – | – | – | – | steel, aluminium |
| CAD/CAM programming (Coskom, Mazatrol)Engineering | – | – | – | – | – |
| Quality assurance with mobile 3D measuring systemTesting | – | – | – | – | – |
| Hardening (partner companies)Heat treatment | – | – | – | – | – |
| Grinding (partner companies)Machining | – | – | – | – | – |
| EDM (partner companies)Machining | – | – | – | – | – |
| Galvanizing (partner companies)Surface treatment | – | – | – | – | – |
| Coating (partner companies)Surface treatment | – | – | – | – | – |
| Blasting and painting (partner companies)Surface treatment | – | – | – | – | – |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Gantry machining centre | Okuma MCM-B | 1 | X = 5,000 mm, Y = 2,550 mm, Z = 1,500 mm | 02/2001 | Kaltenkirchen / Hardebek |
| Gantry machining centre | Yamazaki Mazak AJV 25-404 N | 1 | X = 1,000 mm, Y = 508 mm, Z = 660 mm | 06/2001 | Kaltenkirchen / Hardebek |
| Gantry machining centre | Yamazaki Mazak FJV 60-80 | 1 | X = 2,240 mm, Y = 1,480 mm, Z = 785 mm | 08/1998 | Kaltenkirchen / Hardebek |
| Horizontal milling machine | Yamazaki Mazak FH 8800 | 1 | X = 1,300 mm, Y = 1,100 mm, Z = 1,000 mm | 01/2002 | Kaltenkirchen / Hardebek |
| Horizontal milling machine | Yamazaki Mazak FH 480 | 1 | X = 560 mm, Y = 560 mm, Z = 510 mm | 07/1998 | Kaltenkirchen / Hardebek |
| Cycle-controlled lathe | Weihler E80 | 1 | max. Ø 800 mm, X = 3,000 mm | 12/2001 | Kaltenkirchen / Hardebek |
| Travelling-column machining centre | Yamazaki Mazak VTC 200 | 1 | X = 1,600 mm, Y = 510 mm, Z = 690 mm | 06/2000 | Kaltenkirchen / Hardebek |
| Cross-slide machining centre | Yamazaki Mazak V 550 | 1 | X = 1,700 mm, Y = 550 mm, Z = 500 mm | 09/1990 | Kaltenkirchen / Hardebek |
| 6-axis mill-turning centre | Yamazaki Mazak Integrex 200 y | 1 | X = 1,000 mm, Ø 500 mm, Y = 250 mm | 08/1998 | Kaltenkirchen / Hardebek |
Additional services
Quality
Tight-tolerance mechanical engineering components are inspected with a mobile 3D measuring system – in the company's own production or on site at the customer; a fully air-conditioned measuring room is available for in-depth quality analysis. The company follows the guidelines of DIN EN ISO 9001:2015 (certified by DIQZ).
| Evidence | Kaltenkirchen |
|---|---|
| ISO 9001 |
History
- 1988
Founded as Kalay Metalltechnik