Manufactures precision machine components and welded assemblies using CNC machining and grinding processes for mechanical and plant engineering.
Kersten Maschinenbau GmbH
Niederau OT Ockrilla (near Meißen), SaxonyNew on Amplifa
About Kersten Maschinenbau
Kersten Maschinenbau GmbH is a contract manufacturer based in Niederau OT Ockrilla near Meißen that produces complex, ready-to-install machine components and assemblies to customer specifications. The value chain ranges from raw parts procurement (bar stock, thermally cut parts, castings, forgings) through CNC turning, 5-axis milling, mill-turn complete machining, cylindrical and surface grinding, to welding, stress-relief annealing and assembly; heat and surface treatments are arranged through a partner network. Materials processed include steel (material groups 1.1, 1.2 and 8 per CEN ISO/TR 15608, including stainless steel), castings and forgings with component weights from 10 grams to 10 tonnes and dimensions up to 6 metres. Lot sizes range from single pieces to 5,000 pieces. Customers are found in mechanical and plant engineering as well as rail vehicle manufacturing. Production runs on a three-shift system with over 120 skilled workers and engineers at the site in Saxony.
- Site
- Niederau OT Ockrilla
- Processes
- Turning (CNC turning), Milling (5-axis machining), 5-axis complete machining, Mill-turn complete machining, External cylindrical grinding, Internal cylindrical grinding, Surface grinding, Centreless grinding
- Materials
- Steel, Material group 1.1 (CEN ISO/TR 15608), Material group 1.2 (CEN ISO/TR 15608), Material group 8 (CEN ISO/TR 15608), Castings, Forgings, Steel, material group 1.1 (CEN ISO/TR 15608), Steel, material group 1.2 (CEN ISO/TR 15608)
- Certificates
- EN 15085-2 (welding of rail vehicles, class CL1, activity P, S), DIN EN ISO 3834-2 (welding), EN 15085-2 (rail vehicles, CL1), Measuring instrument management, Production-accompanying QA on a three-shift system
- Founded
- 1965
- Employees
- 120
- Industries
- Mechanical engineering, Plant engineering, Rail vehicle manufacturing, Rail vehicle manufacturing (components for rail vehicles)
- 01
Quotation calculation
- 02
Order acceptance (PPS system)
- 03
Raw parts procurement
- 04
Production planning / CAM programming (TopSolid CAM)
- 05
CNC production on a three-shift system
- 06
Welding & heat treatment
- 07
Assembly
- 08
Quality assurance
- 09
Warehouse and shipping
Materials & Processes
Steel, material group 1.1 (CEN ISO/TR 15608)
Unalloyed steel for welded components and machined machine parts.
Steel, material group 1.2 (CEN ISO/TR 15608)
Higher-strength or quenched and tempered steel, permissible for FW and BW welding up to 40 mm.
Stainless steel, material group 8 (CEN ISO/TR 15608)
Stainless steels for welded and machined components.
Castings
Procured as raw parts and mechanically machined in-house.
Forgings
Procured as raw parts via the supplier network and machined.
Locations
Niederau OT Ockrilla
DEHeadquarters and production (Gewerbegebiet 5 industrial estate)
- Part weight / size
- 10 g to 10 t; milling up to 5 t
- Lot size
- Single piece to 5,000 pieces
- Materials
- Steel (MG 1.1, 1.2), stainless steel (MG 8), castings, forgings
- Hermle C52U MT with PW3000 (mill-turn machining center, 2023, x1000/y1100/z750 mm)
- Reiden RX 18 (mill-turn machining center, 2013, x2200/y2200/z1600 mm, turned parts up to Ø 2400 mm)
- 2x Alzmetall GS1400 FDT (mill-turn machining center, 2013/2017, turned parts up to Ø 1400 mm)
- Hermle C42U (5-axis MC, 2011, x800/y800/z550 mm)
- Hermle C50U (5-axis MC, 2008, x1000/y1100/z750 mm)
- Hermle C30U (5-axis MC, 2008, x650/y600/z500 mm)
- Hermle C800U (5-axis MC, 2002, x800/y600/z500 mm)
- Ibarmia ZVH 58 (5-axis MC, 2004, x4000/y1000/z950 mm, rotary table Ø 1100 mm)
- DANOBAT WT-92-B8 (CNC cylindrical grinding machine, 2013, Ø 1000 mm × 6000 mm, in-process measurement)
- DANOBAT HG-72-B10 (external & internal cylindrical grinding machine, 2006, Ø 1000 mm × 3000 mm)
- Multiline 3007 (surface grinding machine, 2003, x3000/y800/z600 mm)
- Supfina 210 (band finishing machine, 2023, down to Ra 0.1 / Rz 0.4)
- ERP/PPS system PPS2000 with production control station and machine data acquisition
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Turning (CNC turning)Machining | – | 6 metres | 10 grams – 10 tonnes | 1 piece – 5000 pieces | Steel, Stainless steel, Aluminium, Castings |
| Milling (5-axis machining)Machining | – | 4000 mm × 1000 mm | 5 t | Single pieces – larger series | – |
| 5-axis complete machiningMachining | – | 2200 mm × 2200 mm × 1400 mm | 5 t | – | – |
| Mill-turn complete machiningMachining | – | Ø 2400 mm | 5 t | – | – |
| External cylindrical grindingMachining | Ra 0.1 / Rz 0.4 (finishing) | 6000 mm × Ø 1000 mm | 8 t | – | components with various coatings |
| Internal cylindrical grindingMachining | – | – | – | – | – |
| Surface grindingMachining | – | 3000 mm × 800 mm | – | – | – |
| Centreless grindingMachining | – | – | – | – | – |
| Welding (welded assemblies)Joining | – | – | 10 tonnes | – | Steel (material groups 1.1, 1.2, 8 per CEN ISO/TR 15608) |
| Heat treatment (stress-relief annealing)Heat treatment | – | – | – | – | – |
| Surface treatment (via network/cooperation partners)Surface | – | – | – | – | – |
| AssemblyAssembly | – | – | – | – | – |
| Quality assurance/metrologyTesting | – | – | 10 grams – 10 tonnes | – | – |
| Complete machining / CNC parts productionMachining | – | 6 metres | 10 grams – 10 tonnes | 1 piece – 5000 pieces | Bar stock, Thermally cut parts, Castings, Forgings |
12 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Mill-turn machining center | Hermle C52U MT with PW3000 | 1 | x 1000 mm, y 1100 mm, z 750 mm | 2023 | Niederau OT Ockrilla |
| Mill-turn machining center | Reiden RX 18 | 1 | x 2200 mm, y 2200 mm, z 1600 mm | 2013 | Niederau OT Ockrilla |
| Mill-turn machining center | Alzmetall GS1400 FDT | 2 | x 1200 mm, y 1300 mm, z 800 mm | 2017/2013 | Niederau OT Ockrilla |
| 5-axis machining center | Hermle C42U | 1 | x 800 mm, y 800 mm, z 550 mm | 2011 | Niederau OT Ockrilla |
| 5-axis machining center | Hermle C50U | 1 | x 1000 mm, y 1100 mm, z 750 mm | 2008 | Niederau OT Ockrilla |
| 5-axis machining center | Hermle C30U | 1 | x 650 mm, y 600 mm, z 500 mm | 2008 | Niederau OT Ockrilla |
| 5-axis machining center | Hermle C800U | 1 | x 800 mm, y 600 mm, z 500 mm | 2002 | Niederau OT Ockrilla |
| 5-axis machining center | Ibarmia ZVH 58 | 1 | x 4000 mm, y 1000 mm, z 950 mm | 2004 | Niederau OT Ockrilla |
| CNC external cylindrical grinding machine | DANOBAT WT-92-B8 | 1 | Ø max = 1000 mm, L max = 6000 mm | 2013 | Niederau OT Ockrilla |
| CNC external & internal cylindrical grinding machine | DANOBAT HG-72-B10 | 1 | Ø max = 1000 mm, L max = 3000 mm | 2006 | Niederau OT Ockrilla |
| Surface grinding machine | Multiline 3007 | 1 | x 3000 mm, y 800 mm, z 600 mm | 2003 | Niederau OT Ockrilla |
| Band finishing machine | Supfina 210 | 1 | down to surface finish Ra 0.1 / Rz 0.4 | 2023 | Niederau OT Ockrilla |
Additional services
Quality & Certification
Quality assurance monitors quality characteristics throughout production across all three shifts and creates inspection reports and documentation of product parameters; measuring instruments are systematically managed. The welding department is certified to EN 15085-2 (class CL1) and DIN EN ISO 3834-2.
| Evidence | Niederau OT Ockrilla |
|---|---|
| EN 15085-2 (rail vehicles, CL1) | |
| DIN EN ISO 3834-2 (welding) | |
| Measuring instrument management | |
| Production-accompanying QA on a three-shift system |
History
- 1965
Company founded; according to the website, over 50 years of experience in mechanical engineering and parts production.