Manufactures precision mechanical engineering components and welded assemblies – from turning, milling and grinding to ready-to-install assemblies.
Kersten Maschinenbau GmbH
Niederau (district of Ockrilla), GermanyNew on Amplifa
About Kersten Maschinenbau
Kersten Maschinenbau GmbH manufactures mechanical engineering components and mechanical assemblies with precision and quality in Niederau (district of Ockrilla) near Meißen. The manufacturing spectrum includes CNC turning, turn-mill machining, milling, grinding (external, internal and surface grinding) as well as welding of assemblies using MAG, TIG and submerged arc welding, followed by mechanical machining and heat treatment. Materials processed include structural steel, stainless steels and aluminium, as well as purchased blanks such as bar stock, castings and forgings. Components from 10 grams to 10 tonnes and dimensions up to 6 meters are produced in lot sizes from 1 to 5,000 units. More than 120 skilled workers and engineers manufacture in a three-shift system, controlled via an ERP system (PPS2000) with production control station and machine data acquisition. Customers come, among others, from mechanical engineering, rail vehicle construction, electrical machine manufacturing, as well as from manufacturers of coating systems, glass machinery and printing machinery.
- Site
- Niederau
- Processes
- Turning (CNC turning, complete machining of shafts, rollers, axles), Turn-mill machining of chuck parts, Milling, Grinding (external cylindrical, internal cylindrical, surface grinding), Band finishing, Welding (MAG, TIG, UP, arc welding with stick electrodes), Heat treatment (annealing oven for preheating, circulating air chamber oven), Assembly of subassemblies (including welded assemblies, mechanically machined)
- Materials
- Structural steel, Stainless steels, Aluminium, Bar stock, Castings, Forgings, Turning / Turn-mill machining, Milling
- Certificates
- DIN EN ISO 3834-2, DIN EN 15085-2 (CL1), EN 15085-2 (CL1), ISO 9001 (badge on website, certificate not documented)
- Employees
- over 120
- Industries
- Mechanical engineering, Rail vehicles, Electrical machines, Coating systems, Glass machinery, Printing machinery
- 01
Quotation calculation
- 02
Order acceptance
- 03
Purchasing (raw and bought-in parts)
- 04
Production planning / CNC programming (TopSolidCAM)
- 05
Manufacturing (three-shift system)
- 06
Quality assurance
- 07
Warehousing and shipping
Materials and Processes
Structural steel
Suitable for welded and machined mechanical engineering components using the MAG, TIG and submerged arc welding processes.
Stainless steels
For corrosion-exposed components and welded assemblies in mechanical engineering.
Aluminium
For lightweight welded assemblies and machined components.
Castings
As purchased blanks for subsequent complete mechanical machining.
Turning / Turn-mill machining
Complete machining of shafts, rollers and axles up to Ø 1100 mm and 6000 mm length on five WFL MillTurn centers.
Milling
Machining of complex components with unit weights up to 10 t.
Grinding
External, internal and surface grinding up to Ø 1000 mm and 6000 mm length; band finishing to Ra 0,1.
Welding (MAG, TIG, UP)
Certified production of welded assemblies made of structural steel, stainless steels and aluminium up to 4 t.
Heat treatment
Preheating before welding and annealing treatments in the circulating air chamber oven (1000 × 900 × 4000 mm).
Assembly of subassemblies
Fully assembled subassemblies up to 3 t total weight on 500 m² of assembly space.
Sites
Niederau (district of Ockrilla)
DEProduction, Assembly, Administration
- Part weight / size
- 10 g to 10 t
- Lot size
- 1 to 5,000 units
- Materials
- Structural steel, stainless steels, aluminium
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Turning (CNC turning, complete machining of shafts, rollers, axles)Machining | – | 6000 mm × Ø 1100 mm | 10 grams – 10 t | 1 unit – 5000 units | Structural steel, Stainless steels, Aluminium |
| Turn-mill machining of chuck partsMachining | – | Ø 700 mm | – | 20 units | – |
| MillingMachining | – | – | 10 t | 1 unit – 5000 units | – |
| Grinding (external cylindrical, internal cylindrical, surface grinding)Machining | – | 6000 mm × 3000 mm × Ø 1000 mm | – | – | – |
| Band finishingSurface | Ra 0,1 / Rz 0,4 | – | – | – | – |
| Welding (MAG, TIG, UP, arc welding with stick electrodes)Joining | – | 3000 mm × Ø 1300 mm | 4000 kg | – | Structural steel, Stainless steels, Aluminium |
| Heat treatment (annealing oven for preheating, circulating air chamber oven)Heat treatment | – | 4000 mm × 1000 mm × 900 mm | – | – | – |
| Assembly of subassemblies (including welded assemblies, mechanically machined)Assembly | – | – | 3 t | – | – |
| Complete machining / CNC parts productionMachining | – | 6000 mm × Ø 1100 mm | 10 t | 1 unit – 5000 units | – |
| Quality assurance / metrologyTesting | – | – | – | – | – |
18 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Turning, drilling and milling center (MillTurn) | WFL M120 | 1 | Ømax 1100 mm, Lmax 6000 mm | 2013 | Niederau |
| Turning, drilling and milling center (MillTurn) | WFL M80X | 1 | Ømax 1000 mm, Lmax 4500 mm | 2020 | Niederau |
| Turning, drilling and milling center (MillTurn) | WFL M65 | 1 | Ømax 800 mm, Lmax 4000 mm | 2006 | Niederau |
| Turning, drilling and milling center (MillTurn) | WFL M50 | 2 | Ømax 670 mm, Lmax 4500 mm / 3000 mm | 2023 / 201 | Niederau |
| Turning, drilling and milling center (counter-spindle) | Index G400 | 2 | Ømax 400 mm, Lmax 2000 mm | 2006 | Niederau |
| Turning, drilling and milling center | Monforts UniCen 1000 | 1 | Ømax 1000 mm, Lmax 1500 mm | 2004 | Niederau |
| CNC lathe | Boehringer VDF 400 Cm | – | Ømax 750 mm, Lmax 3000 mm | 2015 | Niederau |
| CNC lathe | Monforts RNC 700CNC | 1 | Ømax 700 mm, Lmax 1000 mm | 2002 | Niederau |
| CNC lathe | Monforts RNC 400 AC | 1 | Ømax 700 mm, Lmax 1000 mm | 2003 | Niederau |
| CNC external cylindrical grinding machine | DANOBAT WT-92-B8 | 1 | Ømax 1000 mm, Lmax 6000 mm | 2013 | Niederau |
| CNC external & internal cylindrical grinding machine | DANOBAT HG-72-B10 | 1 | Ømax 1000 mm, Lmax 3000 mm | 2006 | Niederau |
| Surface grinding machine | Multiline 3007 | 1 | x 3000 mm, y 800 mm, z 600 mm | 2003 | Niederau |
| Band finishing machine | Supfina 210 | 1 | – | 2023 | Niederau |
| Submerged arc longitudinal seam welding system | – | – | Welding length up to 3000 mm, Ømax 1300 mm | 2006 | Niederau |
| Welding manipulator | Demmeler Ergonomix M4000 | – | Load capacity 4 t, swivel range 180° | 2018 | Niederau |
| Welding power source (MIG/MAG/TIG) | Fronius TPS 500i | – | Welding current range 3–500 A | 2017 | Niederau |
| Circulating air chamber oven | Linn High Therm | 1 | x 1000 mm, y 900 mm, z 4000 mm | 2006 | Niederau |
| Welding robot system (MIG/MAG) | – | 1 | x 2000, y 2000 mm, 2 t unit weight, 6 m length | 2024 | Niederau |
Additional services
Quality
Quality assurance monitors compliance with all quality characteristics across all three shifts during production and documents the product parameters with reports. In the welding area, an IWE-certified welding supervisor is responsible for the quality requirements according to DIN EN ISO 3834-2 and EN 15085-2.
| Evidence | Niederau (district of Ockrilla) |
|---|---|
| DIN EN ISO 3834-2 | |
| EN 15085-2 (CL1) | |
| ISO 9001 (badge on website, certificate not documented) |
History
- 1965
Manufacturing of machine components according to JSON-LD since 1965; website cites over 50 years of experience
- 2013
Commissioning of the WFL MillTurn M120 (Ø 1100 mm, length 6000 mm)
- 2020
Commissioning of the WFL MillTurn M80X
- 2023
Expansion of the machine fleet with another WFL MillTurn M50 and the Supfina 210 band finishing machine
- 2024
Commissioning of the welding robot system (MIG/MAG)
- 2025
Re-certification to DIN EN ISO 3834-2 and EN 15085-2 CL1 (valid until 2028)