From Manual Welding to Automation

Panasonic Welding Robots at the Core of Modern Recycling Plants

Client: STADLER

Location: Altshausen, Germany

Product(s) supplied: TAWERS G4 Controller PERFORMARC FW-3PD-3500

Challenge

The customer was already using robotic welding, yet many components still had to be welded manually. This made production time-consuming, expensive, and inflexible, particularly when dealing with components of varying sizes.

Solution

STADLER Anlagenbau, based in Altshausen in southwestern Germany, combines traditional manufacturing expertise with state-of-the-art robotics. The company develops and produces complex systems for turnkey recycling and waste sorting plants, as well as tailor-made individual components. As a full-service provider with a high level of vertical integration, STADLER handles all production steps of its own products in-house.

Efficiency Meets Flexibility

Until recently, welding for many components was still performed manually or on outdated robotic systems. Some parts required turning devices on cranes, slowing down production and increasing costs. STADLER sought a solution that would reduce time and costs while remaining flexible enough to efficiently handle components of diverse designs and sizes. The goal was a future-proof, reliable, and scalable production system, allowing capacities to be adjusted competitively at any time.

In September 2023, STADLER commissioned the first two Panasonic TAWERS systems. Since then, these systems have taken over all welding tasks on the conveyor belt frame system, pre-assemblies, and assembly. The integrated welding source, broad process range (MIG/MAG, Puls-MAG, CO₂), and intuitive Weld Navigation software provide high flexibility while maintaining stable quality.

Building on this initial success, STADLER worked with Panasonic to develop a customized concept for a third TAWERS system, designed both to automate remaining manual welding processes and to replace older robot welding systems. This upgrade further enhances efficiency and future-proofing. With significantly higher axis speeds, optimized computing power, and improved robot-controller communication, cycle times have been reduced, and productivity increased.

"With the switch to Panasonic robot systems, the cycle and throughput time for some products, including preparations, has been reduced to one-third"

New features such as tip reduction and a high-resolution touchscreen enable even better welding quality and easier operation. The plant was fully commissioned in May 2025.

From Concept to Commissioning

Implementation of the new welding systems began with detailed simulations, cycle analysis, and test welds at the Panasonic Robot & Welding Test Center in Neuss. The focus was particularly on optimizing cycle time. At the same time, selected STADLER employees attended training to program the robots efficiently and maximize system performance.

Maintenance-Friendly and Reliable in Daily Operations

Panasonic systems impress STADLER not only with their high reliability but also with minimal maintenance requirements. Apart from annual scheduled maintenance, no unscheduled repairs have been necessary, saving time and effort.

"Panasonic machines are easy to operate and extremely easy to maintain. So far, no unscheduled repairs have been necessary, and support is fast and reliable if questions arise – this gives us security in daily operations"

Virtual Production Planning

The introduction of Panasonic’s DTPS offline programming software has been a key step toward efficiency and flexibility. With DTPS, robot programs can be created and edited entirely in a 3D virtual environment without stopping production. This enables parallel planning and simulation of manufacturing processes, resulting in significant time and cost savings.

DTPS supports the import of CAD data in various formats and its direct integration into programming. Component geometries can be easily adapted, while features such as collision detection, cycle time calculation, and welding parameter optimization significantly enhance quality and efficiency.

"With DTPS, we can simulate and optimize production processes as early as the planning phase. This not only saves time but also reduces the risk of errors and rework," adds Bruno Stützle.

Future Prospects

Growth and New Markets

With the automated TAWERS G3 and G4 systems, STADLER has made its production processes more efficient. This efficiency is vital for exploring new business areas and markets. Beyond Europe, the company sees strong potential in electronic waste and used clothing recycling, particularly in international markets. The partnership with Panasonic provides a solid foundation for expanding production capacities and implementing innovative recycling solutions successfully.