TURNING CRISIS INTO OPPORTUNITY – KALI

CUSTOMER INFORMATION

Founded in 1993, KALI produce a variety of tools, hose clamps, and other types of metalwork. The company uses laser cutting of sheet metal, precision bending, CNC lathes, CNC milling, stamping, punching, turning, threading, welding and more.

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MACHINE INFORMATION

In 2008, as the economic crisis swept the entire world, a Polish metalworking company made a bold move, introducing innovative machines and purchasing their first laser system in order to expand their business profile from manufacturing to services.

P.P.H.U. KALI has been on the market since 1993. In the early years, the company, founded and owned by Janusz Krawczyk, focused on the production of band clips, as well as developing the possibilities of mechanical processing.

2008 was a year of change and saw the introduction of innovative machines for KALI. It was at that time that the company decided to purchase its first laser, a 2.5 kW HT-X 3015 model from Mazak. “The investment in the laser-cutting machine allowed us to expand our business profile,” says Krawczyk. “A company that so far had been focused strictly on manufacturing, started to provide services for other manufacturers. This development was possible only thanks to the use of numerical machines in our work.”

Over the years, KALI has been gradually making investments in the purchase of modern equipment: more lasers, CNC machines (lathes, milling machines), as well as bending brakes. In 2011, KALI invested in the most advanced laser on the market at that time, the 4 kW HyperGear 510 model by Mazak. In 2014, the company decided to steadily replace CO2-based laser cutters with those based on fiber technology. “We were the first company in Poland, and one of the first in Europe, to become a user of the OPTIPLEX 3015 FIBER 4 kW laser-cutting machine, working in fiber optic technology,” Krawczyk says. The quality and cutting capabilities of the fiber machines resulted in the acquisition of another fiber optic machine in 2016, the OPTIPLEX 3015 FIBER 6 kW.

KALI acquired an OPTIPLEX 3015 FIBER laser processing machine

Technology that makes a difference

Regular investments in new technologies and care for continuous expansion of the machine park enable the Polish company to offer their customers an ever-wider range of services. “The confidence we place in manufacturers of innovative devices – such as those of Mazak – pays off, as we obtain excellent results in the form of high quality and precision of our elements,” Krawczyk says. “What also sets us apart from the competition is a full array of CNC machines, from laser-cutting to machining equipment. Thanks to this, we can offer comprehensive services and meet various customer expectations. Also, we are very satisfied with the results delivered by our machines and are sure our customers are of a similar opinion.”

KALI works on fiber lasers, cutting elements made of black steel, stainless steel and aluminium (in thicknesses from 0.5 mm to 20 mm). “We cut out a very wide range of products. These are parts for various industries, including automotive, railway, electrical engineering, and construction. Our production is highly diversified – we process approximately 150 tonnes of metal sheets per month, producing about 2.5 thousand different elements (30 thousand per year)”, Krawczyk says.

“What sets us apart from the competition is a full array of CNC machines, from laser-cutting to machining equipment. Thanks to this, we can offer comprehensive services and meet various customer expectations.”

Janusz Krawczyk, Owner
OPTIPLEX 3015 FIBER 6 kW at KALI

Plans and strategies

In 2020, KALI started using another production hall with an area of 2,500 square metres. The creation of the new workspace is in line with the policy of expanding the KALI machine range and offer – a strategy adopted years ago. “A total of 4,000 square metres of production and office space enables us to realise even more fully the business model of KALI, a company that thanks to the capabilities of various innovative machines can win ambitious and demanding projects,” says Krawczyk.

As a service company, Kali needs to maintain dynamics of flexibility and growth, as well as meet the expectations of customers. Therefore, they keep track of advances in the field of new technologies and production solutions related to their business. “Currently, our priority is to follow the trend of improving energy efficiency. Moreover, with the rapid development in digitalisation, at KALI we use the latest software for designing and programming machines as well as optimising production. We also implement the solutions in the field of automation, production optimisation, and waste management that are very up-to-date in the context of market trends,” Krawczyk says.

The best from the start

Back in 2008, when Krawczyk had to decide on a new technology, he was entering into an area he was not familiar with at the time. “I was advised that I should start with the best on the market because, in addition to the machine itself, I needed training and technological support in the first steps. Therefore I decided to buy a laser from Yamazaki Mazak,” he says.

“I am very pleased with the cooperation with Mazak. In addition to offering and installing the right equipment, Mazak trains our operators and clarifies any doubts that may arise. I also appreciate the very fast response from Mazak to reported machine failures, which is especially important in an almost-continuous production cycle. The Mazak company is not indifferent to even the smallest comments and suggestions concerning the operation of machines and, if possible, implements them. In the KALI machine fleet, there are Mazak machines whose factory software has been changed and adapted to our needs at the request of operators and a production manager.”

According to Krawczyk, Yamazaki Mazak machines are characterised on one hand by excellent cutting quality and, on the other, by a low failure rate. Laser-cutting machines operate at the plant 24 hours a day, 6 days a week. Thanks to the combination of good results delivered by the machines and low number of failures, KALI can maintain smooth production, meet deadlines, and satisfy customer expectations. All this allows the company to increase profitability and to develop constantly.

“An additional advantage is the recognition of the Mazak brand around the world. The fact that the majority of machines in our park comes from Mazak’s ‘stables’ improves our image and reception of our company abroad. Foreign auditors and potential business partners can be sure that we produce with innovative and reliable machines, and consequently decide to cooperate with us,” Krawczyk concludes.

“I was advised that I should start with the best on the market because, in addition to the machine itself, I needed training and technological support in the first steps. Therefore I decided to buy a laser from Yamazaki Mazak,”

Janusz Krawczyk, Owner