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Metal Work: Innovative Pneumatics for Industrial Automation

Metal Work is a leading Italian specialist in pneumatic components, which are used worldwide in automated machines and systems. The company is characterized by exceptional innovative strength, which manifests itself in intelligent, often patented product solutions. The focus is on developing components that not only offer maximum performance and reliability but also simplify installation, reduce energy consumption, and increase the overall efficiency of systems. From highly modular maintenance units made of technopolymer to purely pneumatic logic controls – Metal Work offers a well-thought-out ecosystem for demanding automation tasks.

Modular Compressed Air Preparation: The Syntesi® Series

The basis of every process-reliable pneumatic application is perfectly prepared compressed air. Metal Work's maintenance units, especially the revolutionary Syntesi® Series, set new standards in terms of modularity and flexibility. Clean, dry, and correctly regulated compressed air is crucial to maximize the lifespan of valves, cylinders, and other actuators and to avoid unplanned downtimes.

The Syntesi® System: A Modular Kit for Maximum Flexibility

The unique selling point of the Syntesi® system is its tool-free modularity. Individual components such as filters, regulators, lubricators, shut-off valves, or soft-start valves can be connected or disconnected in seconds using a vertical dovetail guide and a simple locking mechanism. This allows for unprecedented flexibility in the configuration, maintenance, and expansion of air preparation units. A defective module can be replaced during operation without having to dismantle the entire unit. Made from high-strength technopolymer, the Syntesi® units are also lightweight, corrosion-resistant, and impress with a modern, functional design.

The maintenance units include all necessary components for professional air preparation:

• Filters and Water Separators: They reliably remove dirt particles and condensate from the compressed air. Various filter finenesses (e.g., 20 µm, 5 µm) and automatic or manual condensate drains allow for adaptation to every requirement.
• Pressure Regulators: Precise diaphragm pressure regulators ensure a constant and stable secondary pressure, regardless of fluctuations in the upstream network. This is essential for reproducible processes and energy-efficient operation.
• Lubricators: For applications requiring lubrication of downstream components, the lubricators dose a fine oil mist into the airflow.
• Additional Modules: The system can be supplemented with shut-off valves, electrical pressure switches, and filling valves (soft-start valves) for a safe, gradual pressure build-up in the system.

Control Technology: From Intelligent Valves to Pure Pneumatic Logic

Metal Work offers a wide range of valves for controlling pneumatic actuators. The product range extends from highly integrated valve islands with fieldbus connections for complex Industry 4.0 applications to unique logic elements for purely pneumatic control tasks.

Electropneumatic Valves and Valve Islands

The electropneumatic valves of the Series 70 and other series form the heart of many automation solutions. They are characterized by high flow rates with a compact design and low electrical power consumption. For decentralized control of multiple consumers, Metal Work's valve islands are the ideal solution. They significantly reduce wiring and tubing effort and allow direct connection to higher-level control systems via common fieldbuses such as Profinet, EtherNet/IP, or CANopen. This simplifies commissioning and diagnostics during operation.

Practical Example 1: Intrinsically Safe Control with Logic Elements

The Challenge: In a paint shop, a simple lifting and swiveling movement must be controlled to transport components into a spray booth. Since an explosive atmosphere (ATEX zone) prevails in this area, the use of electrical components such as solenoid valves or sensors is complex, expensive, and requires special certifications and encapsulations.

The Solution: The entire control system is built with pneumatic logic elements from the Pneulogic series by Metal Work. These tiny valves realize basic logical functions such as AND, OR, NOT, and MEMORY. A pneumatic limit switch signals the end position of the lifting cylinder. This signal is linked via an AND gate with the start signal to actuate the swivel cylinder. The entire control system is intrinsically safe, as it operates completely without electrical energy and thus poses no ignition source.

System Optimization and Special Components

Beyond standard components, Metal Work offers a range of intelligent products that solve specific problems in pneumatic systems and revolutionize installation.

Pressure Boosters: Targeted Pressure Increase Without External Energy

A Metal Work pressure booster (also called a pressure intensifier) is a purely pneumatically operated piston pump. It uses the existing line pressure (e.g., 6 bar) to generate a significantly higher pressure (e.g., 12 bar) for a specific consumer. This is extremely energy-efficient, as the entire compressed air network does not have to be operated at a high level. Typical applications include increasing the clamping force of pneumatic clamps, performing leak tests with high pressure, or compensating for pressure drops at the end of long pipeline networks.

"Line on Line": The End of Tubing Chaos

The innovative "Line on Line" concept is a modular system that integrates the functions of fittings, regulators, and valves directly into a line. Instead of connecting many individual components with hoses, compact modules are connected directly to each other or to a base plate. T-pieces, regulators, shut-off valves, and quick couplings are available, which can be seamlessly strung together. This drastically reduces the number of potential leakage points, saves enormous installation space, and ensures an extremely clean and clear machine installation.

Water Pressure Regulators for Industrial Processes

In addition to compressed air technology, Metal Work also offers high-precision pressure regulators for liquid media, especially water. Unlike compressed air regulators, these are specifically designed for the higher densities and incompressibility of water. The media-contacting parts are made of corrosion-resistant materials such as brass and stainless steel to ensure a long service life. They are used to precisely maintain water pressure at a constant level in cooling circuits, industrial cleaning systems, or process technology, and to protect downstream components from harmful pressure surges.

Conclusion: A Well-Thought-Out System for Efficiency and Performance

Metal Work delivers more than just individual pneumatic components. The company offers a holistic and deeply thought-out system where products are perfectly coordinated. The consistent use of lightweight, robust technopolymers, the extreme modularity of the Syntesi® system, and innovative concepts such as "Line on Line" or purely pneumatic logic controls provide users with decisive advantages in terms of installation time, ease of maintenance, energy efficiency, and process reliability. With Metal Work, you choose an intelligent and future-proof automation solution.

Frequently Asked Questions (FAQ)

1. What is the main advantage of the Syntesi® system over conventional maintenance units?

The decisive advantage is tool-free modularity. While conventional systems require the entire unit to be dismantled to replace or add a component, with Syntesi®, individual modules can be removed or inserted in seconds using a click mechanism. This saves an enormous amount of time during maintenance, modifications, or initial installation. The flexibility to adapt a unit to new requirements at any time is unsurpassed.

2. When is the use of a pressure booster advisable?

A pressure booster is always advisable when a higher pressure than the normal line pressure (usually 6-8 bar) is required only at one or a few points in the system. Instead of raising the entire compressed air supply to, for example, 10 bar, which would be extremely uneconomical, the pressure is increased only locally for the specific actuator (e.g., a clamping cylinder or a test fixture). This saves significant energy costs and reduces wear in the rest of the system.

3. Are pneumatic logic elements still relevant today?

Yes, absolutely. Although PLC controls are widely used, pneumatic logic elements have their justification in specific niches. Their biggest advantage is intrinsic safety in explosive ATEX zones, as they do not require electrical energy. They are also extremely robust against electromagnetic interference (EMC), dirt, and vibrations. For simple, repetitive sequence controls, they can represent a more cost-effective and resilient alternative to electronic control.