SENNEBOGEN increases cutting speed and flexibility with XPR170 plasma

Customer overview

SENNEBOGEN Maschinenfabrik GmbH is a global market leader in material handling and timber handling machines. Headquartered in Straubing, Bavaria, the family‑owned company designs and manufactures excavators, cranes, and specialized machines for demanding applications in ports, recycling, construction, and timber handling.

With more than 2,200 employees and production sites across Bavaria and Europe, SENNEBOGEN delivers high‑quality, engineered solutions to customers in over 100 countries worldwide. To support this global reach, the company relies on highly flexible, efficient, and precise manufacturing processes, especially in steel cutting.

Challenge: Higher productivity and quality without sacrificing in‑house flexibility

Steel cutting is a key process in SENNEBOGEN’s production flow. While the company primarily works with external suppliers for plate cutting, maintaining in‑house cutting capability is essential to ensure flexibility, short lead times, and independence.

At its main plant in Straubing, SENNEBOGEN previously operated a conventional oxyfuel cutting system. Over time, increasing requirements for shorter throughput times, higher cut quality, and faster processing made it clear that the existing solution could no longer meet production needs.

SENNEBOGEN typically processes high‑strength structural steels and fine‑grained steels ranging from 3 mm up to 100 mm, requiring a cutting solution that could efficiently handle both thin and thick materials while also supporting downstream processes such as weld preparation.

Solution: MicroStep cutting system powered by Hypertherm XPR plasma

After extensive evaluation and discussions with technology partners, SENNEBOGEN selected a MicroStep MasterCut‑X CNC cutting system equipped with Hypertherm XPR170^® plasma technology.

The system combines multiple cutting processes on a single platform, allowing SENNEBOGEN to process a wide range of material thicknesses efficiently:

• Hypertherm XPR170 plasma power supply with automatic gas console for high‑precision plasma cutting
• 3D plasma cutting head with automated beveling up to 47° for weld seam preparation
• 2D oxy‑fuel cutting head for cutting material thicknesses up to 100 mm
• Net cutting area of 6,000 × 2,000 mm

The system has been in successful operation since 2021, supporting SENNEBOGEN’s need for speed, flexibility, and consistent quality.

Technology spotlight: Hypertherm XPR170 plasma cutting system

The Hypertherm XPR170 mechanized plasma cutting system delivers next‑generation X‑Definition^® cutting performance for materials ranging from very thin sheet through mid‑range plate. Designed to expand plasma cutting capabilities, XPR170 delivers high cutting speeds, excellent cut quality, and strong process consistency on mild steel, stainless steel, and aluminum.

Key benefits of the Hypertherm XPR170 include:

• Industry‑leading X‑Definition cut quality across a wide range of materials

• Higher cutting speeds and improved productivity, particularly compared to conventional oxy‑fuel processes

• Improved consumable life and reduced operating costs

• Advanced diagnostics and system monitoring to support reliability and uptime

• Multiple gas console options that enable optimized cutting performance for different materials and applications

At SENNEBOGEN, the XPR170 is integrated into a MicroStep MasterCut‑X platform with an automatic gas console and supports automated bevel cutting up to 47° using the plasma rotator. This capability enables SENNEBOGEN to reliably prepare weld seams directly on the cutting table, typically processing material thicknesses from 3 to 40 mm during bevel-cutting operations.

Results: Up to five times faster cutting with improved productivity

By integrating Hypertherm Associates’ advanced plasma technology into the MicroStep cutting system, SENNEBOGEN achieved a significant increase in productivity.

 

The system delivers high cutting speeds and consistent cut quality across a wide range of material thicknesses, ensuring reliable, repeatable results.

Automated bevel cutting for weld preparation allows SENNEBOGEN to complete more processing steps directly on the cutting table, reducing downstream work and manual reprocessing. Since commissioning, the system has processed approximately 600 tons of steel, reducing lead times and increasing manufacturing flexibility.

Reliability, service, and a long‑term partnership

Beyond performance, SENNEBOGEN values reliability and responsive support. The integration of the new cutting system into the existing production environment was completed smoothly, and the system has proven itself in continuous operation.

According to SENNEBOGEN, both MicroStep and Hypertherm stand out for their technical expertise, responsive support, and close collaboration.

 

Hypertherm plasma technology supports future‑ready manufacturing

By investing in a MicroStep cutting solution powered by Hypertherm XPR^® plasma technology, SENNEBOGEN has created a flexible, high‑performance cutting environment that supports its global manufacturing strategy—today and in the future.

The combination of speed, precision, and process reliability enables SENNEBOGEN to respond quickly to changing production demands while maintaining the high-quality standards expected by customers worldwide.