Overview
Addressing Challenges in Storage Manufacturing
Kotzur is a leading manufacturer of bulk solids storage and handling facilities for the
agricultural, mining and manufacturing sectors. All of their products are designed and manufactured in Australia, for Australian conditions
Kotzur were looking for a way to enhance worker safety and optimise their labour efforts, redirecting their skilled welders to more specialised and complicated tasks while automating the repeatable processes. As with any initiative, external support from industry experts was a key consideration when planning the installation. During their search, they were drawn to Infinite Robotics’ level of support and experience.
The Challenges
Optimising Labour Efforts & Maintaining Consistency
In 2024, Kotzur’s Toowoomba facility began investigating robotic welding with the key aims of:
Workforce optimisations
Addressing skilled welding labour challenges
Domestic production
Maintaining their Australian made tradition, which has been the case since 1953
Ensuring consistency
Maintaining consistently high quality production
Worker safety
Continually improve worker safety through technologies such as fume extraction.
Tackling high-mix production
We don’t require single production runs of thousands of units. It could be 10 to 20 parts we want to weld. We have a large number of products and jigs.
The Solution
Flexible & Efficient Production
Infinite Robotics installed a custom designed dual-station FANUC welding cell to suit their need for flexible but efficient production. We also recommended the Verbotics Weld software to meet their high-mix programming needs.
Dual Workstations
Allows operators to load and unload parts from one station while the robot continues to work on the other, achieving maximum productivity.
Verbotics Software
This software allowed them to procure and design jigs confidently and transfer programs between the workstations.It also supports smooth communication between teams.
Easy-to-Use Programming
The robotics programming was quick and easy to learn, allowing them to feel like experienced users within a day.
Key Features & Capabilities
Faster, More Efficient Production
The dual-station FANUC welding system delivered various benefits for Kotzur, including:
Streamlined Efficiency
Automation helped to eliminate downtime by allowing programs to be swapped between stations seamlessly, maximising efficiency.
Fast Production
A program that used to take a day is now being achieved with robotics in approximately an hour and a half.
Optimised Labour
The robotic system is handling the repetitive tasks and allowing skilled workers to focus on more complex tasks.
Implementation
Smooth Transition to Automation
Infinite Robotics delivered the system as a turnkey solution, allowing for minimal disruptions to operations. The implementation process included:
Installation and Commissioning
The robotic system was installed in the client’s facility and fully operational in a short timeframe.
Pre-Installation Use
Infinite Robotics allowed Kotzur to use the robotics prior to installation, this assisted with designs and designs. It also gave them a headstart to have jigs prepared for when the robot arrived.
Comprehensive Training
Operators received hands-on training to quickly adapt to the new system and maximise its capabilities.
This straightforward, user-friendly design allows operators to achieve high-quality results and streamlined productivity from day one.
The Results
Future-Ready Production Solutions
The robot system installed in mid-2025 is now a key part of Kotzur’s production. Even before the robot was installed, the Verbotics software allowed them to design and procure jigs with a 4-month lead time with confidence: “being able to use Verbotics before getting the robot helped us to be able to have jigs ready and prepared for when the robot got here”
The software is also a key communication tool for information between the drafting and production teams. Verbotics also eliminates downtime while producing programs for different
models. “I can make changes while they’re unloading and loading the next part, and then you can have the new program there ready for the next cycle”
The software also enables flexible use of their dual station workcell: “the ease of being able to transfer a program from one side to the other was quite seamless”
Kotzur plans to continue to expand their robotic capabilities by investigating technologies to enhance existing through-arc-seam-tracking to robotically weld more variable products. They have already started on the next robotic welding install at their Toowoomba facility.
Ready to Automate Your Welding Process?
Contact Infinite Robotics today to learn how our tailor-made robotic welding solutions can optimise your skilled workers’ processes and help you achieve your goals.