In 2004 ITW implemented a dedicated unit in Barsbuttel, near Hamburg, Germany, to design and manufacture automated fastening systems, leveraging the many years of experience accumulated by Paslode, Duo-Fast, Haubold and Kartro in this field. This encompasses the development of the quiet, controlled “Pusher” fastening technology from Kartro and the “Module III” from Haubold which can drive staples up to 150mm in length.


Optimised design
Toolmatic tools are specifically designed from the outset to be incorporated in automated production lines of all leading machine builders. This provides optimal performance, little to no downtime for reloading, fast interchanging of tools and more. However, we recognise that on some low volume production lines, a modified hand held tool can still provide a satisfactory automation solution, so we continue to offer such tools in our range.

Modular system
Our Toolmatic equipment is developed in a modular form. The range of five core pneumatic power units can be teamed with seven loading mechanisms, providing many options to suit a variety of applications. 

The power unit range can drive the following fasteners:

• Nails collated on Duo-Fast 0° plastic coils
• Nails collated on Paslode PL (Paper Laminated) tape
• Nails collated on wire welded coils
• Corrugated fasteners
• Light, medium and heavy gauge staples
• Brads / finish nails and headless pins

This approach makes Toolmatic suitable for all manner of applications from packaging, furniture & pallet making to timber frame manufacturing - even incorporating robot magazine replenishment for very high volume lines.

Research & development
Our overall objective is to fully understand the requirements of each production line, working with both machine builder and the client to find the best solution. We believe that we achieve this with our dedicated Toolmatic design and manufacturing unit which can tailor tools to suit specific fastening stations.

Why automate the fastening process?

Migrating the fabrication process offsite and performing it under factory conditions is a response to the need to control and reduce costs, whilst also leading to quality improvements that enhance the marketability of the end product. 

Quality

• Eurocode 5 requires tighter manufacturing controls for timber frame buildings which automation provides, and subsequently improves quality and consistency.
• Toolmatic can position fasteners precisely to achieve optimum design loads and cost efficiency.
• More accurate placement and embedment of fasteners improves the appearance of finish applications like exterior cladding and plasterboard sheathing.
• Similar benefits can be obtained in the manufacture of packing cases, furniture, sheds and fences.

Health & safety

• Automated manufacturing processes reduce the risk of industrial accidents, RSI and manual lifting injuries.
• The new 800 series Toolmatics with “Pusher” technology operates much more quietly providing an improved working environment.

Labour turnover

• Automation reduces manning levels by replacing simple repetitive tasks with more satisfying machine control operations, reducing staff retention problems.

Space Utilisation

• Automation provides the opportunity to optimise production processes and factory routing.

Higher productivity

• Automation improves productivity, measurable both per employee and per factory square metre.
• Links to software such as hsbCAD reduces setup time.

Why choose Toolmatic?

Toolmatic brings major benefits in reliablility, durability, high speed and long service intervals. We provide onsite Toolmatic training and service with our mobile service mechanics and offer spare part kits specific to each tool. We work continually to advance the Toolmatic range, working with our customers to develop areas that will be of most benefit to the production process.

• Toolmatic tools are designed specifically for automation with only one air feed and one power line to attach. This simplifies attachment and eliminates the mess of wires required for modified hand tools.
• Toolmatic modular construction allows us to create a solution geared to the precise requirements of each production line, from a wide range of optional features and fastener systems. This maximises productivity, whilst eliminating the cost of unnecessary features.
• Toolmatic tools re-cycle exhaust air to cool the bumper (1). This enables faster fastening rates and reduces maintenance requirements.
• Toolmatic tools feature large air reservoirs to prevent choking at high fastening rates. This prevents miss-fires or inconsistent embedment depths. Higher fastening rates reduces the number of tools required per station / bridge.
• Toolmatic pistons are PTFE/copper alloy sealed, requiring no lubrication and ensuring clean operation (2). This eliminates maintenance downtime, reduces wear & tear and avoids damage.
• Toolmatic tools can be equipped with onboard magazine and miss-fire sensors monitoring the nailing process. These enable our customers to guarantee high quality and consistency, eliminating re-working or rejection of finished product.
• All mechanical characteristics are designed to extend service intervals. Increasing productivity and reducing maintenance costs.
• Toolmatic tools are supplied “ready to mount”, with appropriate mounting brackets (3). No unnecessary time or cost is wasted.
• Toolmatic solutions include the ability to fire from all angles, including upside down. Our tools can therefore be designed round the production process rather than re-engineering the line to suit the tool.