CUTTING EDGE MACHINES

Drawing on a long tradition of superior engineering, TOS VARNSDORF a.s., a leading Czech producer
of horizontal machines, tops the world. Janusz Mondry reports.

Plans for improvement

Though it serves a different market,
Duplomatic Hydraulics is facing changing
customer demands and this requires nothing
less than a radical change of culture, says
Minetti. We are working toward a lean
organisation. Our strategy is to outsource
as much as we can, while keeping the
knowledge in our hands.
One hundred per cent of Duplomatics
products are tested on the companys
facilities before they are shipped.
Manufacturing, administrative and financial operations are managed by a new
ERP system that was implemented at the
end of 2005. Again, says Roberto
Minetti, there is no longer a predictable
demand for volume products, so the factory has had to become highly flexible and
efficient. The customers want reduced
lead time so we have to do the same thing
in a shorter time.
These measures are part of a long-term
plan to restore the clout of the Duplomatic
name. It is a well-known and respected
40 Industry Europe

name in machine tools, but has slightly

lost its strength in hydraulics. We did some
advertising and stepped up direct contacts
with our customers. That was the first
phase and we are now in the second, which
is to completely renew our range of products, giving them the kind of technological
edge we have been talking about. I think
we have raised the profile of the
Duplomatic name and succeeded in
showing that we are serious in sticking to
our commitments. We are a people
company and we like to have a
personal approach to our customers.
In both the automation
and hydraulics

segments, Duplomatic looks on itself as

occupying the top of the world class and
it will undoubtedly be sought out in China
by customers who need this sort of
quality as it is now becoming valued
in that most exacting of machine tool
markets, Germany.

ounded in 1903, TOS VARNSDORF a.s.

ranks among the world leading manufacturers of metal working machines
and is widely recognised for its state-of-theart horizontal machining centres. TOS
VARNSDORFs machines, mills and related
products are known for their high performance, progressive design, forward looking
technical solutions and reliability.
The company benefits from its long tradition of superior know-how and unmatched
engineering experience to compete successfully in the most demanding markets
worldwide. Since its privatisation in 1995,
It ranks among the most successful and
dynamically developing engineering companies in the Czech Republic, with
exports constituting the bulk of its revenue. Last year it sold 44 million worth
of products, becoming the worlds top
producer and supplier of horizontal
machining centres, according to managing director Miroslav Biciste.

Long history of success

The roots of the companys foundation stretch
back to the period of intensive industrialisation in Czech lands starting in the mid

19th century. The rapid development of

the textile industry in north-western
Bohemia prompted the development of
machine and metal working industries, with
many foundries and machinery works being
set up in the 1980s. One of the first was
the North Bohemia Metalworking Works,
founded by Otto Petschke who was later
joined by an ambitious entrepreneur, Arno
Plauert, who eventually took over the whole
factory and named it after himself.
In addition to metalworking, the Plauert
factory started the licensed production of
steam pumps as well as venturing into
automotive production, but without much
success. The most successful development occurred in the core business of
metal cutting, with the development and
construction of modern machining and
production techniques.
In the 1920s, with the rising demand for
metalworking machine tools, the company
started manufacturing products which were
capable of competing with Germany and
the USA, as well as selling to USSR where
demand was growing rapidly. It was at this
time that the production of horizontal drilling
machines was started, setting the course

for future market and exports growth.

In 1949, the company was nationalised
and re-launched as the independent national
enterprise TOS VARNSDORF n.p. During
the construction boom in the 1960s and
1970s, it grew to become a leading producer and supplier of horizontal machines
in Czechoslovakia, constantly innovating
its production techniques. Benefiting from
its superior technical know-how, it had
already established itself as a recognised
world player before its privatisation in 1995.

Smart business strategy

The companys strong performance at
home and in the world markets owes much
to its superior know-how and product
quality, but also to its good management
skills. A smart business strategy has been
at the heart of its successful development
right from its inception. Unlike some other
post-communist companies, Czech producers are thriving in free market conditions; this is illustrated by the success of
TOS after its privatisation.
In the 1970s and 1980s, the company
turned its attention to making exports a
top priority. In the 1990s, only 10 per cent
Industry Europe 41

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STAPI
Kladensk 78, CZ-273 45 Hebe , t f/fx +420 312 253 473, -486, e-mail: stapi@stapi.cz

55 years of experiences in research and development

research, development and
manufacturing of machines for
processing industry
development and manufacturing of
manipulating machinery
development and manufacturing of
measuring appliances
calculations of mechanisms,
mathematical analyses
calculations, design and
manufacturing of cams
manufacturing of machine
components

Tool manipulator for

TOS VARNSDORFs machining centers
Axial and radial cams

VTS Liberec Plc.

U Jezu 525/4,
CZ 461 19 Liberec 4
Czech Republic

42 Industry Europe

Tel: +420 485 301 111

Fax: +420 485 302 402
E-mail: vuts@vuts.cz.
www: www.vuts.cz

of output was sold at home with the rest

exported to Germany, the USA and other
key markets. The US market became
increasing significant with the setting up
of a subsidiary company: TOS America.
Building a stable and reliable sales network and long standing customer base is
one of the key factors behind our successful

marketing strategy, says Mr Biciste.

In addition to the aforementioned markets, the company also exports to Finland
and Poland, and is progressively targeting
Russia, China and other markets further
east. At the same time it is refocusing on the
domestic market, which is now becoming an
important European motoring centre.

Working horizontally
The companys slogan of machining future
points most definitely towards horizontal
drilling and boring machines. The TOS
horizontal boring mills include four-, fiveand six-axis manual, NC and CNC, and
are all assembled and machined in Varnsdorf.
Castings for the machines come from
within the Czech Republic and the control
systems from abroad mainly Germany.
Most of the horizontal boring mills models
made by TOS have an option of automatic
tool changers with standard 60 tool slots
and an automatic pallet changer.
The W 100 A model has been in production since 1964 and is still very popular. The WH 105 CNC is an up-to-date
NC mill that can be easily retrofit with
CNC. Another popular design, selling well
in the USA, is the WHN (Q) 13 CNC horizontal boring machine with cross-adjustable
rotating table, continuously controlled.
Mills are ideal for machining box sections, flat or intricate work pieces of cast
iron, cast steel or heavy steel. Half of the
machines made at TOS are five-axis
models with a 60-station tool changer.
WHN (Q) 13 CNC is a standard model.
WHN 110 (Q, MC) is a horizontal boring
mill with cross-bed arrangement coming
in three versions: the WHN 110 standard
Industry Europe 43

H y d r a u l i c e n e rg y s t o r a g e
Hydro-pneumatic Accumulators
Pulsation Dampers
Air driven HP Pumps
Accessories

controlled by Heidenhain containing CNC;

the WHN 110 Q, standard but equipped
with ATC, and the WHN 110 MC, which is
a machining centre version with an APC
in addition to ATC.
The WH (Q) CNC is a four-axis machine
available as NC or CNC. It is known for its
efficiency and is especially well suited for
short run production and roughing and finishing operations. The machine has a sliding
spindle, fixed columns and cross-travel
rotating table. The necessary retrofitting
components are also part of its basic design.
WHN 130 (Q, MC) belongs among
44 Industry Europe

the more recent innovations, being a

five-axis system with ATC and APC.
It has two pallets that shuttle between
the machine pallet base and either of
the stationary bases. The WRD 130 (Q)
is a floor-type horizontal boring mill
with ATC and rotary table options.
The clamping area can also comprise
a number of floor plants for very large
work pieces. Another model in this line
is the WRD 150 (Q) floor type range,
continuously controlled.
The TOS tec series are the new generation line models, allowing for greater pro-

ductivity from larger capacity machines.

Launched in the year of the companys
100th anniversary, they are a fitting reminder
of its long tradition of continual innovation
and drive to enlarge the horizontal production range.

Reaching out to the customer

Among the companys wide and varied
customer base are the traditional manufacturers of shapes and moulds for the
automotive, aircraft and shipbuilding industries. Orders from distributors are received
three to six months before the machine is

Industrial cooling
Air/oil Coolers
Plate Heat Exchangers
Tubular Heat Exchangers
Oil and Water Chillers
Switchboard Cooling Units
OLAER CZ, s.r.o.
Videnska 125
CZ-619 00 Brno
Tel.: +420 547 125 601
Fax: +420 547 125 600
E-Mail: info@olaer.cz
Web: www.olaer.cz

Industry Europe 45

completed, giving ample time to customise it if this is required. It can anticipate requirements but can also handle
unexpected customisation requests to full
customer satisfaction, using its versatile
and flexible servicing system. Delivery
terms are usually up to six months for
machines, except for the TOS-tec series
for which delivery is arranged individually
according to specifications.
Among TOS significant agents are the
Czech firm Strojimport for Iran, India and
other countries, Forest Engineering for
South Africa, Alta for Russia and C Dugard
in the UK and Ireland. Sales in most

European countries and beyond are usually handled by Strojimport, while sales in
the Balkan region are handled by TMH
Werkzeugmaschienen.
Among the companys technical
suppliers are Siemens, Fanuc and
Heidenhain. Comprising all the features
of standard horizontal machining centres,
they provide for greater productivity
whilst still allowing for complete customisation to suit individual customer requirements. The new generation of TOS-tec
models will carry the company forward to
yet another successful century of horizontal machining.

Tos Varnsdorf and Stasto Automation - 10 years

of successful collaboration
Since 1996, successful collaboration of manufactures of top quality
cutting systems, TOS Varnsdorf Inc. and suppliers of automation
components, STASTO Automation s.r.o (Ltd).
In over 30 years of operation on the European market, the STASTO
Automation brand has gained the position of a stable and reliable supplier of industrial fittings, pneumatic and hydraulic components, rotation
positioning tables and other automation components.
STASTO Automation primarily supplies TOS Vansdorf valves and fittings
for distribution and control of cutting and cooling mediums, muler co-az
coaxial valves, ODE electromagnetic valves, ball valves and check valves
RB and other components.
Further information available at www.stasto.com

46 Industry Europe

Walter CZ, s.r.o.

Blanenska 1769
664 34 Kurim
tel: +420 541 423 340
www.walter-ag.com