The core expertise of KABATEC, based in Burghaun, East Hesse, is the development and production of semi-automatic and fully automatic machines for processing adhesive and non-adhesive tapes. These are mainly used in the automotive sector for manufacturing cable harnesses. This is precisely what makes KABATEC an extremely valuable member of the Komax Group, as it promotes the development of innovative complete solutions along the entire value chain, which strengthen the position of Komax customers in their markets.

Beads wires: key components in modern vehicle tires

In this article, we want to show that KABATEC solutions are also conquering other, unexpected markets. This example focuses on the tire industry and we need need to go into a little more detail here. High-strength steel wires in the form of beads are used to connect the tire to the wheel. These are made of high-carbon steel with red copper or bronze surface coating. They have high strength, good flexibility, excellent fatigue characteristics and linearity. They can also be easily glued to the rubber.

These high performance beads reduce tire weight, fuel consumption and production costs. Tires produced with these beads are safer and meet the requirements for the sustainable development of the tire industry. Multiple steel wires are bundled together to form beads.

These beads must be fixed with adhesive tape to prevent spreading during the entire tire manufacturing process. This ensures greater stability during tire production and prevents risks during the service life of the tire. An open bead joint could destroy the tire itself and the manufacturer would face customer complaints and warranty claims.

KABATEC: recognized far beyond the cable industry 

KABATEC has an excellent reputation far beyond the cable industry. Years ago, the company received inquiries from tire and machine manufacturers looking for strong alternatives for the application of adhesive tapes, which had previously been laboriously done by hand.

KABATEC currently offers three solutions. The most cost-effective is the tried-and-tested KTB P bundling machine. It boasts an impressively efficient, low-wear cutting blade system and a robust design with pneumatic drive. This offers the user time savings of up to 50% compared to manual production.

The Electric Bundling Station developed by KABATEC works semi-automatically. The operator manually guides the shaped bead wires into the system and the fixing process takes place automatically.

The ultimate solution was created together with VIPO a.s. based in Partizánske, western Slovakia. Focused on the tire industry, this machine builder integrated KABATEC technology into a fully automated solution that was first used at Continental’s new plant in Púchov (Northwest Slovakia). The manipulator with integrated bundling station removes the ready shaped beads from the machine. They are automatically fixed with rubber bands while the machine is already forming new beads. A robot transports the bundled beads directly to the trolley. Since a single machine forms and bundles the beads at the same time, different production cycles are no longer a factor. The plant’s output is designed for a daily production of 12,000 tires – for cars, light trucks, industrial and agricultural vehicles.

VIPO is happy with how KABATEC has contributed to the success of the overall solution. According to sales engineer Marian Marko: "The cooperation with KABATEC has been very professional and open to new horizons. Our joint meetings on technical solutions are very fruitful, yield positive results and lead to successful projects that are very much appreciated by end customers."

KABATEC technology for tire production can already be found in Brazil, Germany, Malaysia, Slovakia, the Czech Republic, Hungary and recently also in India, where our customer Apollo Tyres (brands: Apollo, Vredestein, Kaizen, Maloya) has its headquarters.

Global tire production is gradually shifting to low-wage countries, where the need for automation has, of course, been lower. However, Marian Marko is convinced that this will change: "VIPO is seeing a significant increase in the level of automation in tire production worldwide. The goal is to combine several individual processes without an operator having to intervene. The investment in automation is already paying off for the next few years. The market demands the integration and automation of older manual solutions in line with the latest level of automation."

Are there other markets for advanced KABATEC technology? Yes, such as for cutting braided hoses for mixer taps. KABATEC can offer a solution wherever adhesive tape is used. The tightly knit global network of Komax with branches and agencies in over 50 countries and on 6 continents is particularly valuable for the distribution of all solutions.

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