Behlen Industries boosts profits with plasma technology

Company overview

Behlen Industries is Canada’s largest manufacturer of steel building systems, providing a variety of cost-effective building systems to the industrial, commercial, institutional, and recreational markets. Behlen is the premier choice for pre-engineered steel buildings throughout Canada and beyond. With headquarters in Brandon, Manitoba, and a growing international market, Behlen systems are sold and installed throughout North America and parts of Europe by a network of authorized builder distributors.

Challenge: 10-year-old plasma cutting system needed to be replaced

Behlen’s 10-year-old plasma cutting machine had reached the end of its service life, and the production team needed a new plasma cutting system that could deliver 24/7 service. Doug Riddoch, Production Manager at Behlen, explains, “The plasma system is considered a vital component of the workflow at the company. If it is not working, then it really affects the operation of the shop. It conducts the workflow, with 40 welders waiting for cut parts.”

Solution: Versagraph and HPR260XD significantly improve business processes

Behlen replaced the old plasma system with a new Koike^® Versagraph equipped with SureCut™ technology from Hypertherm – a HyPerformance^® HPR260XD plasma cutting system, an EDGE^® Pro CNC, Sensor™ THC, and ProNest^® nesting software. The new plasma system was designed to increase flexibility and alleviate production bottlenecks.

SureCut technology

SureCut delivers embedded expertise for XPR® and HPR® plasma systems. SureCut technology uses software to automatically embed advanced cutting capabilities into the plasma cutting process, delivering improved outcomes, simplifying cutting operations, and reducing operator intervention. SureCut is designed to maximize cutting performance by automatically applying optimized cutting process parameters to simplify cutting and reduce operator intervention. SureCut is delivered through a combination of Hypertherm products such as automated systems, CNCs, and CAM software.

Most machines equipped with a Hypertherm HyPerformance HPRXD^® or XPR X-Definition^® plasma system come with automatic access to SureCut technologies. The machine operator or CAM software programmer can access these technologies through the user interface, for example, EDGE^® Connect, ProNest^®, or other CAM or CNC software from an authorized partner. Each technology typically runs automatically, without the need for operator intervention.

The Sensor THC

A torch height control (THC) system can significantly improve cut quality and consistency in any plasma cutting operation by maintaining the optimal distance from the cutting torch to the workpiece. The torch height control uses arc voltage to maintain a consistent distance from the plate while the torch is cutting. This allows the system to maintain proper torch height regardless of variations in the material or the flatness of the cutting bed.

The Sensor THC is a full-featured torch height control system that can significantly increase the productivity and profitability of any shape-cutting operation. It is integrated into the CNC, incorporating Hypertherm cutting process expertise at the touch of a button. Built-in cut charts provide all parameters to the plasma system and THC, reducing job setup time and operator errors while increasing productivity. 

With Sensor THC, performance advantages are achievable without operator input, eliminating the need for extensive training and allowing organizations to get the best performance across any shift with any operator at any location. It supports the use of custom lifters for custom performance and unique applications such as plasma bevel, tube and pipe, and waterjet.

Traditional torch height controls require operators to periodically adjust arc voltage to ensure proper cut height. Using Hypertherm’s proprietary techniques, the Sensor THC continuously samples arc voltage and automatically adjusts arc voltage for proper torch height over the life of the consumables – without requiring operator input.

ProNest nesting software

ProNest nesting software for advanced mechanized cutting is designed to supercharge cutting operations, enabling greater automation, efficiency, and profitability. ProNest optimizes performance for plasma, laser, waterjet, and oxyfuel cutting machines. Its powerful, high-yield nesting reduces material costs and increases profitability.

ProNest’s intuitive screens and a wide variety of helpful features make it easy to learn and use. Its faster, fully automated interface can reduce programming time from hours to minutes, while specialized cutting techniques can reduce total cut time by up to 50%.

Business impact: Increased productivity and material utilization enable significant cost savings

In just three months, the new cutting machine delivered significant cost and time savings and changed the way Behlen operated. Riddoch commented, “Since the plasma was installed three months ago, we’ve seen some major improvements in the way we process jobs and the results we achieve.”

The new machine helped Behlen alleviate production bottlenecks. They were able to transfer work from another plate machine, bring work back in-house from outsourced vendors, and consolidate some projects from other company locations. These changes save both time and money, reducing costs by up to 40% or more on some projects.

Programming with ProNest’s automatic nesting lets Behlen achieve high levels of material utilization without programmer intervention. Collision avoidance is applied automatically to each nest, yielding optimized tool paths, lead styles, and positioning. The resulting tool path translates into productivity improvements in cut-to-cut cycle time.

Learn how Hypertherm’s HyPerformance HPRXD^®, ProNest nesting software, and Sensor™ THC can help your business improve material utilization, cut quality, and productivity. Click the button below, fill out the form, and a Hypertherm product expert will contact you.