From the initial idea and customer request to product finalization and assembly. In the PPS Group’s production process, modern, efficient processes, digitalisation and automation are applied in all steps. However, the main asset in our machine shops remains the experience and skilled hands of our qualified employees. We produce large products in small batches, for which it is not always worthwhile to set up robotic lines.
Our designers and technical staff are able to provide partners with technical support services such as: drawing up 3D models, drawing up design documentation (technical drawings), drawing up accompanying documentation or a spare parts catalogue. Drawings and models are processed in AutoCAD and Autodesk Inventor.
Based on the supplied technical documentation, we are able process the required type of material by cutting, sawing and burning.
For burning, oxy-acetylene (CombiCut 15001.55 GbkGGG and Picorex) and plasma burning machines are used.
|Plasma machines||Number of burners||Number of tables||Table dimensions (mm)||Max. sheet thickness (mm)|
|OMNIMAT 5000||1 – beveled||1||13000 x 3000||80|
|SPLR 12001.25 PrP||1 – straight
1 – beveled
|1||12000 x 2500||38|
|MG 12001.25 PB*||1||1||12000 x 2500||50|
*Model MG 12001.25 – MG PB is equipped with a vertical burner for burning sheets up to a thickness of 50 mm and a mechanical drilling head for drilling holes up to 29 mm.
|Oxygen – acetylene machines||Number of burners||Number of tables||Table dimensions (mm)||Max. sheet thickness (mm)|
|CombiCut 15001.55GbkGGGG||4 – striaght
1 – beveled
|1||5500 x 150000||200|
|Pikorex (burning with template)||4||1||2000 x 2500||100|
|Shears||Max. sheet thickness (mm)||Max. board width (mm)|
Press brakes (TRUBEND 800, CTO 400A, LODD 315, SAFAN H-Breke 320, LO 50. ) are able to create pressures from 50 to 800 t, with a maximum length of the material to be pressed of 6000 mm, bending radius up to 200 mm. There are also sheet metal straighteners (UBR 18×200, XRM 2000×12, XRM 2000/6,3), roll bender (HR4W3840 a XZMP 2000×12), tube benders (XOTH 40, B 60).
LODD 315 Press brake
|Forming equipment||Table dimensions (mm)||Clamping (mm)|
|Press brake 800 t (TruBend)||6050 x 250||6 osí|
|Press brake hydr. 400 t (CTO 400 A)||5000 x 300|
|Press brake H – Breke 320 (Safan)||4100 x 250||635|
|LODD 315 Press brake||4000 x 200||250|
|Hydraulic straightening press HPR 800||1600 x 2700||750|
|Hydraulic straightening press 400 t CDN 400B||6000 x 3100|
|Press brake 50 t (LODD50)||2500 x 200|
Manual welding is carried out by highly qualified personnel using MIG/MAG, TIG, CMT welding equipment. For submerged arc welding we use GOLEM 1200 welding machine. Welding especially of rotary assemblies and booms is carried out with IGM and OJ 10 welding robots. Welded materials: Grades S235 to S960. Special steel types (thickness 1 to 150 mm). PPS Group a.s. holds welding certificates.
|Welding equipment||Current (A)||Protective atmosphere|
|Welding sources – MIG / MAG||250||82 % Ar, 18 % CO2|
|Welding sources – MIG / MAG||220||82 % Ar, 18 % CO2|
|Welding sources – MIG / MAG pulse||up to 400||82 % Ar, 18 % CO2|
|Welding sources – CMT||up to 270||97,5 % Ar, 1,8 % CO2|
|Welding sources – TIG||up to 315||100 % Ar|
|Submerged arc welding||up to 1200||flux|
|Welding robot||up to 400|
|Welding positioners||1000 x 640 mm||Load capacity up to 10 t|
Mechanical machining of details and smaller assemblies is carried out using lathes, drills, milling machines and grinders. For the machining of larger welded structures, the company is equipped with modern NC and CNC centres.
|NC / CNC centers||Workpiece size||Table size|
|SHW – UFZ – duo||15000 x 1200 x 2500||16000 x 1500|
|2 x FFDQ 125 – duo||13000 x 1000 x 2000||14000 x 1250|
|FUQ 150||4500 x 1500 x 2500||2 – 3000 x 2000|
|FUQ 125||4000 x 1500 x 2000||2 – 2000 x 2000|
|WRD 150 Q (with turntable)||15 000 x 1800 x 4000||10000 x 3000 / 2500 x 3000|
|SORULACE FX 10 000 (with turntable)||10 000 x 1600 x 4800||7000 x 3500 / 2500 x 3500|
|Lathes||Running diameter||Tip distance|
|Center lathes||400 / 1000||800 / 2000|
|Workpiece diameter||Max. workpiece length|
|SKIQ8 vertical lathe||800||630|
|Carousel lathe SK16||1620||800|
|SPT 32NC semi-automatic lathe||320||800|
|Drills||Workpiece size (mm)||Table size (mm)|
|Radial drill||25 – 100||850 x 780 – 2000 x 3000|
|Coordinate drilling machines||50 – 100||500 x 830 – 1000 x 1600|
|Horizontal boring machines||63 – 100||320 x 320 – 1000 x 1120|
|130 – 160||1800 x 1600 – 4000 x 2500|
|Milling machines||Clamping area (mm)||Movement x, y, z (mm)|
|Milling center – FFQ 100A OR / AG||6000 x 1000||6200 x 1500 x 1400|
|Milling center – FSQ 100OR / A3||3000 x 1000||3000 x 1000 x 1600|
|Horizontal milling machines – WFQ 80 NC||850 x 1600||1600 x 980 x 950|
|Table type milling machine – FSQ 80-GM / A2||2000 x 800||2000 x 900 x 800|
|Table type milling machine – FCQV 63||630 x 2200||1500 x 630 x 630|
|Portal milling machines||1250 x 3500||3200|
We have the technology of sandblasting and degreasing by high pressure spraying with passivating agent before surface finishing and painting.
Depending on the parameters of individual products and customer requirements, wet painting is carried out, mainly with 2K paints:
PPS Group a.s. can offer complex surface treatment of products by sandblasting and painting processes. The company has a robotized sandblasting workplace consisting of a HOLLAND MINERAAL sandblasting chamber and a BLASTMAN sandblasting robot. At an operating pressure of 8 bar. and a 19 mm nozzle used, the sandblasting output is approx. 225 m2/h. The sandblasting process can be pre-programmed or programmed by the robot for manual sandblasting (the robot stores the manual sandblasting process in memory). We also use the workstation for manual sandblasting without the sandblasting robot.
The pre-treatment of the surface of the parts (degreasing + iron phosphating, rinsing and drying) is carried out in the tunnel line in a shower way using the Henkel products. Subsequent painting and drying of the base and top coat is carried out in separate painting and drying boxes. The base paint is applied with TRITON 308 low-pressure HVLP equipment, the topcoat is also applied with 2K WAGNER TWIN CONTROL 35-70 high-pressure equipment. The tact of the line is determined by the painting time and lasts about 10 – 20 min, on 43 hinges. The maximum dimensions of painted products are 4 x 1.8 x 1.35 m with a weight of up to 2 tons.
Surface pre-treatment (degreasing + iron phosphating) is carried out with the high-pressure equipment RB-30E using the Henkel products. Painting of the base colour is carried out with medium pressure spraying equipment KREMLIN 20.25, topcoat with high pressure equipment 2K WAGNER TWIN CONTROL 35-70. The maximum dimensions of the products are 14 x 4 x 2.5 m weight up to 10 t.
Surface pre-treatment (degreasing + iron phosphating) is carried out with the high-pressure equipment RB-30E using the Henkel products. The fully automated BLOWTHERM T1 multi-mode paint booth ensures the entire painting and drying process. The paint booth is 16 x 5 x 5 m after modification and the transport of the parts is carried out by rail trolleys. The painting of the base colour is carried out with a KREMLIN 20.25 medium pressure sprayer, the top-coat colour with a 2K WAGNER TWIN CONTROL 35 – 70 high pressure sprayer.
The assembly process in the company represents the final cumulative operations of joining parts and components up to the final product in a certain technically expedient sequence. The assembly process is currently dominated by manual operations and integrates all aspects of quality assurance from previous processes. The assembly process takes place in dedicated production areas that are exclusively dedicated to the assembly process.