Greater precision, increased added value, and independence: To remain competitive in the international plant engineering sector in the long term, Kremsmüller Industrieanlagenbau KG relies on state-of-the-art cutting technology and has made a targeted technological leap. At the heart of the new manufacturing strategy is an OmniMat® from Messer Cutting Systems.
In industrial plant engineering, the highest precision, tight tolerances, and absolute process reliability are indispensable. For Kremsmüller Industrieanlagenbau KG, headquartered in Steinhaus near Wels, this is daily practice. The Austrian family-owned company, with approximately 2,300 employees, realizes plants from engineering to assembly for industries such as petrochemicals, energy and environmental technology, metallurgy, paper, chemicals and pharmaceuticals, food, and manufacturing. The highest quality standards are a given. Accordingly, the demands placed on its own production processes are equally high.
Deviations, for example in cutting, have a direct impact on downstream processes. Inaccurate contours mean increased adjustments during joining and welding, longer lead times, and in the worst case, a loss of quality. Therefore, in 2023, the modernization of the existing flame cutting system became a priority. "We were increasingly reaching the technical limits of the existing system," explains Hannes Gattermayer, Head of Production at Kremsmüller. "Maintaining tight tolerances was becoming particularly difficult. For our standards as a premium supplier in plant engineering, this was not a sustainable solution in the long run."
At the same time, vertical integration was limited: container bottoms had to be machined externally, and there were also restrictions on pipe cutting with defined bevels. This resulted not only in lost value creation potential but also in reduced flexibility in project execution. "For us, it was clear: if we were going to invest, it would be in a solution that could do more than just cut. We wanted to significantly increase precision while simultaneously expanding our vertical integration and incorporating new machining capabilities," adds Hannes Gattermayer.
Technological leap instead of machine replacement
The replacement of the flame cutting system was therefore deliberately conceived as a strategic technological leap. The goal was a highly flexible CNC cutting platform for large-format sheets that combines oxyfuel and plasma technology, bevel cutting, pipe processing, boiler end processing, and marking on a single system, while simultaneously offering ergonomic improvements.
In addition to the technical performance data, the long-term partnership played a crucial role. "For us, it wasn't just what the machine could do that mattered, but also who was behind it," emphasizes Gattermayer. Short response times, service availability in Austria, and structured project management were decisive criteria. Given the strategic importance of the project, implementation had to be completed without long waiting times. Messer Cutting Systems was able to score points here with structured project planning and clearly defined milestones. In the end, the decision was made in favor of the OmniMat® from Messer Cutting Systems.
High-performance platform for the highest demands
With the OmniMat®, Kremsmüller relies on a heavy-duty CNC cutting machine specifically designed for large work areas and demanding applications in metal processing. It combines modern technology, intuitive operation, and high precision. Thanks to its robust gantry construction and precise guide profiles, it ensures high cutting accuracy and contour fidelity, even under the toughest production conditions.
The cutting table, with a maximum support area of 4,000 x 18,000 mm, enables the processing of large-format components. The system also features two cutting areas separated by a partition. Furthermore, the high positioning speed of up to 50 m/min, combined with high acceleration and rapid height adjustments, significantly reduces unproductive downtime.
The system is controlled and programmed using Messer's proven OmniWin® CAD/CAM software. It supports oxyfuel, plasma, and laser cutting processes and enables fast, efficient production of varying quantities and small batches, typical in plant engineering. OmniWin combines flexibility with fast, efficient processing. Operation with CAD, import, and nesting for vertical and beveled parts drastically simplifies your workflows.
The overall solution also includes the newly developed "BoilerEnd NT" module, specifically designed for the dimensionally accurate machining of boiler ends. An executable program can be generated in just a few steps, starting with the import of the geometry in STEP format. "The new software module is a particular highlight for us. It makes programming and machining boiler ends significantly easier and, at the same time, very precise," explains Hannes Gattermayer.
Versatile solution for complex applications
“A major advantage of the OmniMat® is its flexibility. Whether oxyfuel, underwater, or dry plasma, whether vertical, bevel, or with a drilling unit and marking tools – it is suitable for a variety of cutting and processing applications,” says Abraham Balendran, Head of Product Management at Messer Cutting Systems. “To meet Kremsmüller’s requirements, we combined various equipment options and created a multifunctional processing platform.”
Technologically, the machine covers a broad spectrum. The ALFA oxyfuel torch cuts sheets up to 300 mm thick and reduces setup times and wear thanks to integrated height sensing and tool-free nozzle changes. The automatic, infinitely variable D/AFL three-torch unit for V-, X-, Y-, and K-cuts enables precise bevel cuts at angles from 15° to 60° and tight tolerances on sheet thicknesses up to 80 mm.
The HiFocus 600i neo plasma cutting system enables precise cutting of materials from 0.5 to a maximum of 150 mm thick, even underwater, with high cut quality, especially with CrNi materials. Thanks to the unlimited, continuous rotation of the C-axis, the Skew Rotator Infinity plasma torch ensures precise bevel cuts, even underwater, on virtually any contour.
Part marking is also automated via an integrated dot peen marker. This allows for high-speed marking of text, numbers, lines, and contours directly on the component.
Greater independence through increased vertical integration
Plasma cutting technology provides the foundation for integrated boiler end machining. Boiler ends with a maximum diameter of 4,200 mm can now be precisely machined directly on the system. Laser measurement ensures that component geometries are accurately captured and cutting paths are adjusted accordingly.
With the PTC500 pipe cutting system, Kremsmüller expands its cutting technology with another strategic component. Tubes up to six meters in length and 500 mm in diameter, including weld bevels up to 45°, can be manufactured directly on the system. This largely eliminates external machining steps.
"The independence from third parties gained with these new machining capabilities is a tremendous advantage for us," emphasizes Gattermayer. "We are more flexible, faster, and can better control our quality standards."
Efficiency and ergonomics in focus
In addition to the core focus, Kremsmüller also prioritized optimizing working conditions. The goal was to increase productivity while simultaneously reducing the physical strain on employees. The centerpiece of this is the waterjet cutting table with integrated water level control and a belt conveyor system. The water cutting table is designed for both above-water oxyfuel cutting and underwater plasma cutting. By raising and lowering the water level, emissions, noise, and thermal stress are reduced.
The conveyor belt system offers a significant advantage. It automatically transports the slag out of the cutting area. "Previously, the tables had to be emptied and cleaned manually. This was physically demanding and time-consuming," explains Gattermayer. "Today, the slag removal is automated. This protects our employees and simultaneously increases efficiency."
The system is complemented by a plate cleaning system with high-pressure nozzles. This ensures clean sheet metal surfaces before the cutting process and contributes to consistently high cutting quality.
Partnership as a success factor
In a project of this scale, the technical solution is only one part of the equation for success. Equally crucial is the collaboration. Until its completion in July 2025, the project proceeded with close coordination between both teams. The goal was to minimize downtime and bring the new system into production quickly. "The collaboration was very cooperative and solution-oriented from the outset," says Hannes Gattermayer. "Coordination was straightforward, adjustments were implemented quickly, and agreements were consistently honored."
Just three and a half weeks after assembly began, the first cutting operation was completed – a clear indication of the well-structured project organization. The integration of the pipe rotary axis and the implementation of the tank bottom processing were also carried out without any problems. "Projects like these only run smoothly when both sides communicate openly and make quick decisions," explains Gerhard Wimmer, Head of Messer Cutting Systems Austria. "The clear structure at Kremsmüller and the short decision-making processes contributed significantly to the smooth progress."
Technological leap with strategic added value
With its investment in the OmniMat® from Messer Cutting Systems, Kremsmüller has technologically realigned its cutting and prefabrication capabilities. The combination of high-performance gantry technology, state-of-the-art plasma and oxyfuel technology, precise bevel cutting, an integrated pipe rotary axis, and tank bottom machining makes the system a key component of the company's value creation.
The result is a solution that unites precision, versatility, and process integration. Dimensionally accurate cuts, reproducible bevels, internal machining of complex components, and automated marking work seamlessly together to create continuous workflows. "For us, the new system represents a true technological leap," summarizes Hannes Gattermayer. "We have increased our vertical integration, stabilized our processes, and simultaneously improved working conditions. This strengthens our competitiveness in the long term."
A look into the future
Kremsmüller sees itself well-positioned for the future with the new OmniMat®. "We would choose this solution again without hesitation," emphasizes Hannes Gattermayer. "It gives us the necessary flexibility and vertical integration to remain competitive even under challenging conditions." Rising energy prices, high costs, and increasing bureaucracy pose significant challenges for plant engineering. "Our task is to continue supplying our customers with the same high quality they have come to expect," says Gattermayer.
Therefore, one focus is on greater energy efficiency and the expansion of energy projects, for example, in the areas of process heat pumps, storage solutions, and heat exchangers. At the same time, the further development of in-house manufacturing remains a key priority. Hannes Gattermayer adds: "The more value creation we can handle internally, the more stable we are, even in times of crisis." He also has clear advice for companies that want to invest: “Machines should be designed to be as versatile as possible. This ensures utilization and future viability. Those who thoroughly research and compare options have a clear advantage and find the right solution for their needs, just like we do at Messer Cutting Systems.”
