📘 Standard Product Portfolio of Ahlu Engineers Private Limited
Ahlu Engineers Pvt. Ltd. is a trusted leader in press automation, automated press tools, transfer systems, and special purpose machines (SPMs) for the sheet metal industry. With decades of engineering excellence, we specialize in del...
📘 Standard Product Portfolio of Ahlu Engineers Private Limited
Ahlu Engineers Pvt. Ltd. is a trusted leader in press automation, automated press tools, transfer systems, and special purpose machines (SPMs) for the sheet metal industry. With decades of engineering excellence, we specialize in delivering end-to-end manufacturing automation solutions that help OEMs and Tier-1 suppliers achieve higher productivity, precision, and cost efficiency.
🔹 What You’ll Find in This Catalogue:
Comprehensive range of progressive and transfer press tooling solutions
Custom-built press automation systems for mass production
Advanced transfer systems for high-volume, complex components
Tailor-made SPMs for critical manufacturing applications
Industries served: Automotive, White Goods, Electrical, and General Engineering
🔹 Why Ahlu Engineers?
Proven expertise in designing and manufacturing automation-driven sheet metal solutions
State-of-the-art manufacturing facilities and skilled engineering team
Experience working with leading OEMs and Tier-1 suppliers in India and overseas
Commitment to quality, innovation, and long-term partnerships
This catalogue is an essential resource for manufacturing decision-makers, purchase managers, and design engineers seeking reliable partners in the sheet metal domain.
👉 Download the full product portfolio and discover why Ahlu Engineers is the preferred choice for sheet metal automation solutions.
Size: 27.72 MB
Language: en
Added: Aug 29, 2025
Slides: 28 pages
Slide Content
2
ose
Bees
ESPE
Sas?
Fr
CEE
2358
CE“
E
EH
5
Bess
3383
233
zes
Manufacturer
3n901V1V9 LINAOUd
INDEX - GUIDE OVERVIEW
o
3 MILESTONE
History And Development
4 Mission, Vision and industries Served
‘About Ahlu Engineers & ther values.
5 TransferSystom & its related terms
‘Transfer terms introduction
6 AMPTS Series
Alu Muli ress Transfer system |
8 AP2PSeries
Al Pres to Press Transfer
10 ASTZAII Series
Servo Transfer 2 Ans Double Bar Type
12 ASTZAISeries i
Servo Transfer 2 avs Single Bar Type
14 — ASTSAI Series Single Press
Servo Transfer 3 Axis Double Bar Type
16 ACSTS Series
Cantilever Servo Transfer System
17 — AOHSTSeries
‘Ahly Over Head Servo Transfer robot
18 AMP
Alu Mechanical Press Flap
18 ASRF
Alu Sheet Roll Feeder
19 ABFSeries
An Blank Feeder
19 AISBF Series Feeding System
Au Indexing Stacker w/ Blank Feeder
20 Turnkey Project Line
Complete Production Line
21 Turnkey Automation
Complete Forming Solutions
Transfer
High-Volume, Mult Stage Forming
Progressive Dies
High Volume, High Accuracy Stamping
22
23
23 CompoundDies
24
‘Simuttaneous Operations in Single Stroke
SPM Portfolio
Complete Customized portfolio Te
MILESTONES
e
2017 Ahlu Engineers Private Ltd. was incorporated
2018 Designed & successfully commissioned a 2-Axis Servo-based Transfer
System for a Tier 1 automotive component manufacturer - 100% Made.
in india.
2019 Delivered a complete turnkey production line for a pharmaceutical
product. Began importing tech spares to support custom client
requirements
2020 $ Diversified into Textile & Chemical industries with custom maintenance
solutions. Started exporting automation solutions to Gulf countries.
2021 Introduced AMPTS, a multi-press turnkey production line for
household hardware. Scaled import-export of machine spares to
expand global presence.
2022 ‘Streamlined ASTZAII series from 5-servo to 3-servo configuration
setting a new benchmark.
2023 Honoured among India's Top 10 SPM Manufacturers by Industry
Outlook Magazine.
2024 Relocated & expanded manufacturing from Kalyan to 5,000 sq. ft.
facility in Khambha (Rajkot).
Repurposed the old unit for new product development beyond SPM.
Huestones | 03
Vision
Established 2017, Ahlu Engineers modernizes manufacturing with advanced
automation. We empower global manufacturing leaders to maximize RO! from their
‘manpower and technology, staying competitive. Our innovation drives growth,
precision, and efficiency, making us a trusted partner.
Our mission is to equip shop floor teams with advanced automation technologies
tailored to meet global standards. We design innovative solutions that improves
productivity, reduce costs, and ensure safety, enabling manufacturers to grow in an
increasingly competitive global market. We're committed to delivering top-quality,
‘smart industrial automation you can rely on.
Industries Served
General
cia. Hardware
DS
Factory chemical
0% | Mission, vision & INDUSTRIES
Understanding Transfer Systems Terminology
Moving sheet metal parts efficiently through the stamping process is essential in modern operations,
which is why transfer systems are critical Ahlu Engineers understands this, and offers a range of
systems designed to optimize material handling, significantly boost productivity, and ensure pinpoint
precision in manufacturing,
Key Terminologies Explained
+ xd Transfer Pitch: Represents he horizontal movement o the transfer system, typical moving
paris in and out ofthe pres, The transfer pitch isthe distance the system moves parts between
ations eri fo synenniing with press operation.
+ Yas (clamping Stroke: This denotes the lateral movement, allowing parts o be positioned side-to
side. The clamping stroke refers to the movement required to grip or release parts during transfer,
ensuring secure handling
+ Zeus (Ute: Indicates the vertical movement, which is essential for Üfing and towering parts during
{he transfer process, The lift function ensures parts are correctly positioned In dies and
accommodates varying die height
+ Servo Programmable System: Uses precise servo motors programmed to control system movement
and positioning for high accuracy and repeatability. This allows flexible adjustments fr diferent part
‘shapes and press setups.
+ Absolute Encoder A sensor proving feedback on the position, speed, and direction of moving parts,
‘enabling precie control and synchronization,
+ Battery-ess Encoder: An advanced encoder that retains postion information without the need for a
battery, reducing maintenance requirements and enhancing reliability.
+ Passine: The consistent height at which the material passes through the pres, crucial for ensuring
uniformity and alignment during the stamping process.
+ Center to Center Distance: The measurement between the centers of two consecutive stations or
¿ies important fr designing transfer systems that match the press layout
+ Press SPM (Strokes Per Minute): Indicates the number of strokes a press can perform in a minute,
reflecting the speed and productivity ofthe stamping operation,
+ Weight capacity: The maximum load the system can safely handle, Matching it with part weight
prevents overloading and ensures smooth, efficient operation.
+ Feeding Accuracy: How precisely the system positions and feeds parts ino the press High accuracy is
vital for maintaining part quality and reducing waste from misalignment,
+ Finger Changeover: Replacing or adjusting gripping fingers for different part shapes or sles. Eficient
‘changeover reduces downtime during product changes and boosts productivity.
+ Industry 4.0 Ready / Enabled: Designed for seamless integration with industry 40 tech ike OT and
smart manufacturing platforms, This enables enhanced connectivity, real-time monitoring, and better
production decisions. oT features support smarter processes via predictive maintenance, ene
management, and optimization,
+ Remote Monitoring System: A feature allowing remote monitoring ofthe system's performance and
‘status. Provides realtime data on operational parameter, faclitating proactive maintenance and
quick response to issues,
‘TERMINOLOGY EXPLAINED | 05
AMPTS Series
Multi Press Transfer System
‘The AMPTS Series by Ahlu Engineers is a precsion-engineered
multpress transfer system, designed for seamless automation
across three or more stamping presses. Ideal for complex sheet
‘metal transfer operations, AMPTS ensures synchronized, high
speed part movement between presses, improving tine efficiency
and eliminating manual intervention.
GD BB "mm
SPECIFICATIONS
Ae Transtr ieh ‘0500
ZA Ut Amout MM 040 ES EJ
FeedGarSze MM 60 so 9
VioghtCapaciy KG 2 3 s
Feeding Accuracy MM 202 302 102
Maximum Stoke Food SPM 30, ES 15
LAYOUTS APPLICATIONS
+ Automotive subassemblies and structural
? afte . parts using C-Type Double Connecting
inl inl Presses
Sl The + Large component production such as
cross members, subframes, and inner
panel reinforcements
+ Multpress configurations handling
‘sequential forming, trimming, and
purening
+ Agricultural machinery home appliances,
and commercial vehicle part stamping
+ Sheet metal transfer automation where
press accessibility and speed are critical
FEATURES
‘+ High-Riglaty Modular Frame Design - ult for stabilty during mult press operations, ensuring structural
integrity and vibration resistance over continuous cycles
+ Recipo-Based Programmabllty- Tool speciic motion data storage enables fast changeovers and repeatable
quality across product variant.
+ External Die Loading/ Die Maintenance Die can be installed and maintained from Front side allowing easy
‘changeovers and Quicker Die Maintenance
oT & Industry 4.0 Ready - Equipped for smart factory Integration, including remote diagnostics, production
data tracking, and preventive maintenance alerts
‘Standardized & Serviceable Components - Modular construction with common parts across systems ensures
case of service reduced inventory, and lower downtime.
‘Customizable Transfer Pitch & Timing - Adaptable to a wide range of press sizes and component geometries,
‘enabling tailored setups for diverse production demands.
Integrated Passline Management System - Maintains transfer height alignment across multiple presses for
accurate part positioning during sequential forming operations.
AMPTS Series
Multi Press Transfer System
AMPTS is designed to streamline mass production by minimizing manpower and eliminating quality related
‘stoppages between operations. dea for setups involving tree or more presses, ensures consistent, high-speed
transfer with standardized processes, delivering uninterupted performance and significantly higher output across
allie
FRONT VIEW LAYOUT
KEY FEATURES
Mult-Station integration: Coordinates movement between multiple presses to maximize tine
productivity
+ High-Speed synchronization: Ensures precise timing and smooth transfer through intelligent motion
control.
‘+ Modular Desig: Standardized components allow for easy configuration and maintenance,
+ Flexible installation: External mounting options on ether side ofthe press ine
+ Servo Programmable: Supports recipe-based setups for faster changeovers and repeatability.
Industry 4.0 Ready: loT-enabled for remote monitoring, predictive maintenance, and data-driven
optimization.
NEED OF AMPTS
th its modular 2-aÃs servo control and externa instalation capability, AMPTS i ideal for automating the
transfer of large-sized components across three or more presses, while maintaining cycle time efficiency and
‘minimizing manual intervention
‘The AP2P Series by Anlu Engineers e compact,
high-speed servo-driven transfer system designed
for individual press-to-press automation.
Engineered for precision flex, and fast setup,
AP2P lifts and positions components between
presses without needing a lied 3-press
configuration.
SPECIFICATIONS
X Avis Transfer pitch
Z-Axis / LR Amount
Weight Capacty KG
Feeding Accuracy MM.
Maximum Stroke Feed _ SPM
LAYOUTS + APPLICATIONS
independent press Ines where flexible
3 y ‘automation s required between standalone
| presses
+ Automotive components like brackets,
‘mounts, and bush housings that need
precise, point-to-point transfer
+ Appliance and electrical enclosure parts
here press spacing layout, and part varity
demand frequent setup changes
+ Tootrooms and job shops handling short
batch orhigtrmixstamping operations
+ Production setups with uneven passins,
where programmable it and placement
compensate for press height variations
FEATURES
1 Migh-RIgiiey Frame Design Engineered for stable and durability under continuous, high-speed
‘operation,
2.High- Efficiency Transfer Motion - Enable fast and smooth pat transfer, maximising throughput
Precision Transfer Loop - Ensures accurate part positioning for each press strove,
4.Quick Fiture Change (Optional Auto-Coupling) - Reduces setup time and enhances flexibility during
product changeovers.
5 Robotle Communication Ready - Seamlessly integrates with robots for advanced automation setups.
Hot Stamping Compatible - Support insulatedclamp systems for thermal process applications,
8.Integrated Alignment Device - This device guarantees accurate feeding angle and motion throughout
the transfer cycle
9 High Speed Synchronized Transfer - Delivers rapid and stable par transfer between presses wth
precise timing, minimizing cycle losses and ensuring consistency
AP2P Series
Press to Press Transfer
its programmable motion, quick adaptabilty and minimal installation footprint mate it ideal for high, ow
volume, or space-restricted stamping operations,
The AST2AI Series by Ahlu Engineers isa robust 2 axis servo transfer
system designed for high-speed, synchronized component movement
across progressive stamping stations.
Ba Eg
Siena cee |
ESS CE
+ SPECIFICATIONS en
X Asis renato ph
Y Asis / Clamping Soke
Feed Bar Size
Mon Capacty
Feeding Accuracy
Maximum Stoke Feed
LAYOUTS.
S sa
“7 Beopsos
‘Automotive part stamping such as brackets, cross members, and seat reinforcements
‘Appliance panel manufacturing where synchronized transfer without lt is sufiient
+ Electrical enclosures and hardware requiring precision clamping and consistent transfer
+ Progressive tool based setups needing stable, axis part movement between stations
+ Medium to high-speed mass production tines using C-Type, H-Type, or Gantry presses with
moderate component sizes
Bult or medium: o large-format sheet metal parts it offers precise control over transfer pitch Dax) and
clamping stroke (Yaris), ensuring stable part handling during high-speed operations. With modular design,
programmable recipes, and external installation, ASTZAIis ideal for improving productivity in automated
stamping tines using Type, Hype, or Gantry Presses
TOP VIEW LAYOUT
pon
Foray tee pps a ma ay Band RG mp
PASS LINE REPRESENTATION
53
Pase Line Representation for respective Finger designing
FEATURES
+ applicable Press Types: Optimized for press tables up to 2500mn, the system supports external side
‘mounting on both eft and right sides ofthe press, alowing easy retroiting and minimal
‘+ Characteristics: 2-ans synchronize system for high-speed, stable part transfer in continuous stamping lines
+ Applicable Table Size: Optimized for press tables up to 2500 m width, with external ide mounting support
Production Suitability: Best suited for medium to high-volume mass production, particularly for setups:
2 Transfer Dies without the need for vertical ft
2 Staion-wise forming, where the part maintains sel stability
3.Component geometries that do not deform during horizontal transfer
AST2AI Series
Servo Transfer 2 Axis Single Bar
The AST2AI Series i Ahlu Engineers precison-engineored 2-2
servo transfer system, designed to enhance efficiency in sheet metal
stamping operation. Utiizngasingle-bar mechanism, ie delivers
synchronized X-axis (Transfer Pitch and Yon (Lift Stroke)
‘movements, with an additional gripper ais for secure part handling
(Clamping
With its singl-bar transfer and servo: based control, the AST2AIisa
Feliabie solution for Lt to medium duty stamping tasks focused
on productivity and teotprin optimization,
¢_ SPECIFICATIONS compact |
X A Testor pitch
ee al ae
Se:
es
een
ne ee
$ LAYOUTS a APPLICATIONS
ed
ects ein
„FEATURES.
ADDITIONAL RELATED PRODUCTS
VT Sn
MN La
en = $ “D
ABE Seri
AST2AI Series
Servo Transfer 2 Axis Single Bar
Vitis single-bar transfer and servo-based control, the AST?A is a reliable solution for ligt-t0 medium-duty
stamping tasks focused on productivity and footprin optimization
TOP VIEW LAYOUT
“Tar sy teen ores an may ar Encore,
While the AST2AI Series canbe utlized in applications sulted fr the ASTAAI Seres i's not interchangeable.
But change in Finger type is require to achieve tis job with feasibly check on finger construction.
PASS LINE REPRESENTATION
Sat
Pass Line Representation for respective Finger designing
ASTZAL-SINGLE BAR | 13
AST3AII Series
Servo Transfer 3 Axis Double Bar
ASTSAII Series ia high-speed, als servo transfer system
lengineered for advanced sheet metal stamping operations. Featuring
‘robust double bar mechanism, it provides precise X Y-Z motion
control transfer pit, clamping stoke, ft) for rapid, synchronous
part transfersin progressive or transfer des. Multiple transfer pitch
and stroke configurations let manufacturers optimize throughout for
specific stamping task. Equipped with OT connectivity and remote
monitoring, the ASTaAI is Industry 4.0 ready.
Versatile-Precision Controlled Lift Enabled
SPECIFICATIONS
XAxs/Teansterpich MM 012 020 0500
Y As Clamping Stoke MM 040 088 09
ZA (UR Amount MM 020 00 oo
Feedfarsze = MM 6 so 9
Feeding Accuacy MM 404 201 201
Weight Copacty KG 2 3 s
Maximum Stoke Foes SPM 40 3 m
LAYOUTS. + APPLICATIONS
Automotive component manufacturing
Utens production
Defense equipment fabrication
Toy manufacturing
Other sheet metal stamping applications requiring
high precision and efficiency, along wth
Component lit during movement between
Urli Ah ans systems, its triple-servo design enables complex -ansdraw/insertion
operations and higher cycle rates, setting anew standard for high-speed stamping production
+ Customization: Available in multiple variants to sul specific transfer pitches and component
requirements
+ Can be used as ASTZAI series transfer based on applicable specs but cannot be used as vice versa
TOP VIEW LAYOUT
ee
USE CASES FOR AST3AII SERIES
fe [SE CASES FOR AS Tall SEN
Automotive industry
Deep Drawn Oi Pans - Require vertical ft to prevent deformation
Suspension Arms ~ Precise transfer of regular geometries across multiple forming stations
(Cross Members & Floor Panels = Large parts needing safe vertical fing and consistent orientation
Bumper Reinforcement Brackets ~ Complex stamping with multiple folds and forms
Brake Booster Shells - High precision forming involving deep draw and flange operations
Transmission Mounting Plates ~ Heavy gauge parts needing ft and drop with gt pitch control
2. Appliance & White Goods
+ Refrigerator Back Panels ~ Requires large stroke movement with it to avoid seratches
+ Washing Machine Outer Drums ~ Multiple draw and lange stages, supported by Z-ax's motion
‘+ Microwave Oven Chambers = Lightweight deep-drawn parts that need accurate placement
3. Utensil kitchenware Manufacturing
+ Pressure Cooker Bodies - Deep drawing with trimming and hole punching in transfer sequence
+ Fry Pan Shells Draw and trim operations ina 4-5 die sequence
+ Tiffin Containers - Nested forming, needing component it and soft drop
“4 Defense & Industrial Applications
+ Sheet Metal Enclosures = Mult-stage forming with reinforced edges.
{+ Mounting Bases for Electronics ~ Forming and piercing in single Ine without manual ine
+ Electrical Enclosures - Needing accurate forming and timing ina sequence
ACSTS Series
Cantilever Servo Transfer
+ The Cantilever Servo Transfer System converts standard C-typelgap
frame presses ino efficient ans transfer presses using a single-bar
cantilever mechanism. Oriven by high-precision servo motors, it
enables smooth Xand axis part transfers with minimal machine
modification.
+ Compact and easy to mount, it enhances press automation, reduces
‘manual handling, and boosts productivity deal for automative,
appliance, and metal part stamping.
+ SPECIFICATIONS Scalable Customized: Modular
X Avis Toslorpteh MM 0150 0300 0500
Zei LR Amen MM 030 os 09
Food Bar Si MM 65 0 so
Woght Capacty KG 2 3 5
Feeding Acouecy MM +04 204 201
Maximum Stoke Food SPM 50 0 5
LAYOUTS - APPLICATIONS :
| + Generally Suite for Gap Frame Presses
ml + Ideal for2-3 minor operations in one pres ez, small
Applicable Press Types: -Type Single Double Connecting or Hydraulic Presses
‘applicable Table Size Suitable for Presses with tabl sizes les than or equal 102507 Press
For external installation, Either ef or towards right sde.
+ Drive components are modular spare parts are standardized.
+ Customization: Available in multiple variants to suit specific transfer itches and component requirements
BLANK FEED COIL
MOI
ABE Seri
AOHST Robot TE
Over Head Servo Transfer Robot
AOHST is built for maximum structural stably and
Controlled component transfer across wide H-type press
lines, making tte ideal solution for OEM body shops, er 2
panel manufacturers, and other high volume vehicle part
production ines.
FOO AE
SPECIFICATIONS
Heavy Duty Rigid - Heavy Tonnage
Xnes/ Viewing hes E E]
YR (Camp Tavs M 0760 0120 01800 sl
Zhës/U Tel MM 020 020 030 H
FensgAccwacy MM 203 203 03 É
Won Capa KG 5 0 1
Maximum Stoke Food SP 15 2 a
LAYOUTS. APPLICATIONS
rn
4 ch |
FEATURES
+ Very large components such as vehicle body
panels, doors, hoods, and taligates
+ Deep draw and precision forming operations
using H-Type presses with wider bolster areas
+ Fulvbody part production in igh-tonnage
stamping tines
+ Defense and heavy equipment panel forming
were argo sheet sizes require rigid handling,
+ Applications demanding robust Iit-stroke
Control and preciso alignment in large die setups
+ Applicable Press Types: H-Type and Large Gantry Presses with wide bolster configurations
+ Characteristics && Applicable Table Size: Heavy-duty axis servo transfer system designed for large panel
movement in high-tonnage press Ines, Support exra-wide tables exceeding 2500mm, ideal or ul Body and
‘oversized component production
+ Production Suitabiliy: Perfect for mass production of vehicle body panels, structural frames, and deep
‘drawn parts in the automotive, defense, and heavy equipment sectors
BLANKFEED MPG HANDWHEEI
RIPPERS.
N
SONS
AOHST-OVERNEAD | 2
AMPF Series
Mechanical Press Flap
‘+ The Mechanical Ejector Arm is inked directly tothe press am,
‘enabling synchronized to and ro motion for automatic serap oF
‘component ejection. ts mechanical Unkage adusts dynamicaly
With press speed, ensuring consistent performance.
+ Designed for flesibilty it supports variable inclinacion angles as per
tool or layout needs, By eliminating manual removal it reduces
cycle time, enhances operator safety, and supports continuous
press operation-making idea for press automation systems
SPECIFICATIONS Synchronized - Serap / Component - Removal
(ES RECIFICATIONS AA
mm 200
Press Speed Max. mm 100 75 so
Fp Stoke Max. mm 150 200 so
Flap wat. mo 100 150 200
ASRF Series
Sheet Roll Feeder type
+ The Ahlu Sheet Roll Feeder is high-performance servo roll feeder
for press automation, designed witha dualtation system that
‘ensuites continuous contact with the sheet throughout the operation
cycle. Both stations workin precise synchronization, maintaining
‘stable sheet movement for seamless fe
Press synchronization Is essential to this setup, enabling smooth,
uninterrupted operation and ensuring maximum efficiency in high
speed press environments Sees uate sarees
SPECIFICATIONS
MS Series For Thin Sheet Feeding
‘+ Aneconomical solution for feeding sheared
sheets from 0.3 mm to 3.5 mm thickness
Ideal where col feeding is feasible, ine
MS Series offers relabie automation for
light uy applications.
HS Series = For Thick sheet Feeding
+ Ancavy-duty variant designed for sheets
Up to 6 mm thickness, the HS Series
ens res robust performance in demanding,
high-force operations.
AMPF AND ASRF SERIES | 18
ABF Series
Blank Feeder - Magazine type
_LThe Anl Blank Feeder Serie is designed for efficient and
‘automated sheet feeding in stamping Ines. Powered by a
precision pneumatic cylinder, it delivers smooth to-and-ro
motion for continuous operation
2.Bult from durable tool steel, ts heavy-duty Frame ensures low
‘wear and extended ife. Linear bearings and guide ral offer
‘accurate, low clearance movement fr consistent performance
{ite double decker design reduces cyele time, while the magazine
based system eliminates manual hanaling~enhancing operator
safety and reducing human interference,
‘Integrated press synchronization boosts press utilization and
productivity, making it an ideal choice for modern, high-output
manufacturing
SPECIFICATIONS
‘ABF-02.05-160 MM 02150
‘ABF-05-10-160 MM 951-100
ABF-10-15200 MM 10-150
ABF-15-19250 MM 11-190
160
320 1104
400 1105
500 2106
0903
High-Speed Safe - Relable
AISBF Series
Indexing Stacker w/ Blank Feeder
+ Indexing Stackers designed fr precise and efficient blank
feeding. Modular and customizable design allows configuration
of magazin count and layout based on plant space and
component needs
+ Equipped with auto-feed magazines to handle multiple blank
sizes and batch requirements. Indexes blanks in synchronization,
with press cycle ensuring uninterrupted production
LAYOUTS
Continuous Precise - Moduler
APPLICATIONS
+ Functions a a buffer unt between blank
storage and transfer presses
+ Reduces dle time in high-speed
stamping lines by maintaining constant
blank supply
+ deal for space-constrined automation
setups with flexible production demands
+ Compatible with various materials and
‘hieknesses used in sheet metal
stamping
‘ASF AND AISOF SERIES | 19
Turnkey Project line
Complete Production Line
Case Study -
+ Alu Engineers successfully executed a complete turnkey automation project contered around a 4001
Transfer Press Line, designed for high-efficiency component manufacturing from colto finished part.
+ The solution begins with a Blanking Press equipped with a precision-engincered Blanking Die anda high
speed Blanking Conveyor. This setup automaticaly feeds pre-cut banks into the AIBSF (Ahly Indexing
Stacker Feeder, configured with 6 auto-feed magazines for uninterrupted blank management.
+ From the stacker, a dedicated pick-and-place unt transfers each blank to the extended loading position of
the transfer press ne. Here, Al's flagship ASTAAI 3-Axis Servo Transfer System takes over, executing
seven sequential forming operations with precise Xiten,Â¥ (lamp), and 7 (It axis movement across the
press bed.
+ This fui automated flow = from
Go to finished part - completes
ight operations, combining the
blanking process with seven in-die
forming stages. The result isa
streamlined, high-output production
= cell that reduces manpower,
‘minimizes handling time, and
ensures consistent part quality
across shift
+ The entre ne can be effiienty
managed by a single operator,
eliminating the need for upto?
manual operators. Additionally,
Similar ines can be supervised by
the same operator, offering
excallntscalabilty for future
‘Transfer Press 4001 : Completely Automatic Stamping Line growth,
, ADVANTAGES OF TRANSFER LINE AUTOMATION FROM AHLU
+ Made-in-india Expertise -Fuly designed, manufactured, and supported localy~ensuring faster delivery,
reliable service, and affordable spares without import dependency.
«+ Reduced Manpower Dependency - Eliminates manual part handling between operations, addressing skilled
Labor shortages and reducing operator fatigue and errors,
increased Production Output High-speed, servordrven 2-axs or3-axs systems enable continuous part
transfer across multiple dies, maximizing press ulization and throughput
+ Consistent Quality Across Shift-Servo:programmable motion ensures repeatable accuracy in positioning
and movement, minimizing rejection rates and variation
+ Flexible & Scalable Solutions - Modular systems (ASTA ASTZAI, ASTAAI, AMPTS, AP2P) sui a wide range of
Press types and part sizes-ideal for automotive, appliances, defense, and general stamping industries,
+ Shorter Setup Times -Recipe-based tool dat storage, quick finger changeovers, and modular components
drastically reduce downtime during die changes.
+ Integration with Exsting Presses - Transfer systems are retrofitable to many standard indian C-type, Hype,
and Gantry presses, extending the value of current assets
Industry 4.0& OT Ready - Systems come with smart diagnostic, remote monitoring, and real-time data
Logging for predictive maintenance and performance analysis.
Turnkey Automation
Complete Forming Solutions - Engineered,
‘Automated, and Delivered by Ahlu Engineers
Abu Engineers s a leading manufacturer of custom built hydraulic
presses and compact, ful integrated press lines, purpose designed
or demanding sheet metal forming applications, From automotive
structural arts to defense components, and appliance panels, our
systems offer unmatched flexibility, synchronization, and reality.
Whether you need a standalone press or a complete forming ne
Alu Engineers ensures a unified solution where the pres, de, and
‘automation are designed to work in perfect harmony.
Hydeaulle Press - Automation Grade
+ We speciaie in handling complex synchronization between press motion, transfer automation, and tool
‘operations — ensuring flawless coordination through advanced serve control and PLC-based logic. Our
‘engineers conduct fll trials and validations, offering customers completo confidence before ine
deployment.
+ Whether t's a standalone hydrauli press or a fully automated turnkey tne, Ahlu Engineers acts as aone:stop
solution provide, delivering tested, production-ready systems that reduce lead times, improve ROI, and
scale with your future requirements
ALD SPM serles- In Front, Top, Side view ALD SPM serles-150 View
OUR OFFERING INCLUDES:
1 Custom Hydraull Presses
+ Designed for hig-tonnage operations with long stroke lengths and large bed sizes
+ Suitable for deep drawing, coining, embossing, imming and forming
+ Rigid frame structure ensures dimensional accuracy and minimal deflection under toad
+ Avalable in C-Frame, H-Framo, of Four Column configurations
+ Optional features:hydraulie cushion, jectos, de lifters, PLC:1MI based control
2.Compaet Press Lines
Fully integrated units combining: Hydraulic Press + Servo Feeder + Straightener + Decoller
Modular design ideal for space-saving layouts and quicker commissioning
Engineered for continuous, synchronized operation with reduced manual intervention
Custom automation (pick place, transfer, obotic integration) available as per part compleity|
3 Automation & ie integration =
In-nouse capablity to design and validate precision tooling and dies
‘Synchronized automation with PLC + Serv logic to control press stroke, de sequencing, and part handling
‘Custom transfer systems and robotic arms designed per application
‘Seamless operation for multi-stage or progressive forming lines
TURNKEY AUTOMATION | 21
Transfer Dies
Automated Precision Tooling for High-Volume,
Multi -Stage Sheet Metal Forming
Transfer dies area modern solution inthe world of metal stamping, used predominantly in high-volume
production enviconments. Unlike progressive dies that Keep the workpiece attached to acarrier stip,
transfer dies allow each part to move independently from one station to anther within single pres. This
process is ideal for manufacturing large, complex, or deep drawn components,
Each die station i spaced at a consistent interval = known as the pitch — which defines how fara part must
travel between forming operations. The entire system is synchronized within a single pres stroke, enabling
multiple forming stages in a streamned cycle.
ADVANTAGES OVER CONVENTIONAL (MANUAL) DIES
‘+ Full Automation Compatibility - Designed to work with transfer presses and robotic handling systems,
ciminating manual intervention.
+ MuttkStage Flexiblley "Supports more complex forming operations that are not feasible in singlestation or
progressive dies,
+ Handles Larger Parts - Perfect for big components lke body panels, structural reinforcements, and
appliance shells.
+ Improved Accuracy and Repeatability - Consistent ligament and sequencing lead to uniform parts with
minimal reection.
+ Higher Output, Lower Labor Costs - Automation increases speed and reduces dependency on skilled manual
operators.
‘+ Modular Tooting and Easier Maintenance - Station can be adjusted or replaced as per design changes or
new production needs.
Transfer Die stationed
„ WHY AHLU FOR TRANSFER DIES?
+ Transfer Press Manufacturing Expertise - Our experience in building transfer presses enables us to ongineor
is that are perfectly synchronized with automation systems, ensuring smooth, collision free transfers and
‘minimal downtime,
SPM Knowledge for Enhanced Flexibility - With a proven track recordin Special Purpose Machines (SPMS),
we design des that are modula, adaptive, and sclable-perfec fr today dynamic production Ines,
Built for High-Speed Production Our dies are designed to witstand the rigors of high SPM operation wile
delivering precise forming quality and tong tool ie.
Integrated De Design and Manufacturing Al tooling design, simulation, CNC machining, heat treatment,
and tryouts done under one roof, ensuring faster lead times and strict quality contol.
+ Customization with Purpose - Every transfer die from Alu Engineers is tailored to your part geometry,
‘material behavior, and press specs~for an optimized and reliable production experience.
22 | TRansren oes
Progressive Dies
Precision-Engineered for High-Volume, High
Accuracy Sheet Metal Stamping
Progressive dies are multi-stage tools that perform a series of operarions=such as piercing, blanking, forming,
and bending-within a single press stoke. As the strip feeds through, each station incrementally shapes the par,
‘making them idea for high-speed, high volume production with consistent quay and minimal handling,
WHY AHLU FOR PROGRESSIVE DIES?
‘We brings deep domain expertise in tool desig, die manufacturing, and automation integrtion-making usa
preferred partner for progressive de solutions in india and global. Our dies are engineered for durabilty,
repeatablity, and minimal downtime, ensuring optimal performance overlong production runs.
+ Automation-Focused Die Engineering - We specialize in integrating complex operations within the de itself,
Such a: nie Tapping n-Die Riveting, Coining, Marking & Secondary Forming This reduces external
handing, improves cycle time, and simplifies downstream processes,
High Precision, Low Serap Built to micron-ievel tolerances for ight part control and maximum material
efficiency.
ress Compatibility & Customization - Designed to match the customers press tonnage, bed sie, and
pateline to ensure smooth integration
In-House Manufacturing Tryout From CAD to CAM, and from simulation to tryout-we handle all under
One root, reducing lead time and improving quality control
Optimized for Automation Progressive des from hl Engineers are bull with a forward-thinking
approach, ready fr servo fed integration, coil line automation, and smart press interface.
Compound Dies
High-Precision, High-Force Dies for
‘Simultaneous Operations in a Single Stroke
Compound dies are advanced tooling systems that perform multiple operations—
*ypicaly blanking and piercing ina single pres stroke a the same die station. This
results in superior dimensional accuracy, flatness, and clean part edges, making them
deal for disc-shaped fiat, or symmetric components requiring high repeatabily
„_ ADVANTAGES OF COMPOUND DIES
« Singe-Stroke Mult-Operation- Performs two or more operations (e.g, blanking and piercing in one press
Stroke, increasing efficiency
+ High Dimensional Accuracy & Reduced Handling Time - Maintains close tolerances due to al operations
‘occuring ina fied alignment setup, Eliminates the nee for intermediate part handling or repositioning
between operations.
+ Faster Production Rates & Lower Die Maintenance - Shorter cycle times lead to higher output, deal for mass
production environments. Fever moving components and synchronized ations result longer tool ie and
easier upkeep,
Material Cost Savings - Optimized stip layout and precision cutting reduce scrap generation,
(Compact & Space-Saving- Combines multiple processes into a single de, saving floor space and simplifying
press ine layout
Process Reliability & Beter Flatness Control -Ensures consistent part quality with minimal variation across
long production runs. Especially useful for producing at parts where warping must be minimized,
Easy Integration with Automation - Compatible with serve feeders, uncollers, and robotic part pickers fora
fully automated setup.
PROGRESSIVE & COMPOUND DIES | 23
SPM Portfolio
Engineered for Precision, Built for
Productivity
Our Special Purpose Machines SPMs) are custom-
designed automation systems talored to specific sheet
metal manufacturing challenges.
Whether its reducing manpower, eliminating nter-press handling delays, or achieving cyle-time consistency,
our SPA deliver optimized production with unmatched liability. uit for demanding enviconments and high
volume operations, these machines ensure repeatable precise performance with every cycle.
« ADVANTAGES OF USING SPMs
Tallor:Made Automation for dedicated tasks and component types
Reduced Manpower Dependency through fully automated cycles,
Higher Productivity & Throughput with minimized ile time
Consistent Quality by eliminating manual transfer errors
Lower Operational Costs through energy-eficien and Lou
maintenance designs
+ Quick ROI due to performance reliability and minimized downtime
‘SPM Glimpse Top view
KEY FEATURES OF OUR SPMs
Servo-Driven Axis Control or high-speed
precision movements
+ Recipe-Based Programming fr rapid
cchangeovers and mult par enbilty
Modular Frame Design for easier scalability
andintegration
Industry 4.0 Ready & OT Enabled for smart
factory environments
‘Compact Footprint sulted t space-
constrained shopfloors
Custom I/O Logle & Valve Timings for toot
compatibility
Few SPM Glimpse-150 view + Safety integrated Control Systems
adhering to industrial standards
WHY AHLU ENGINEERS FOR YOUR FIRST AND EVERY SPM?
+ Start Smart, Seale Confidentiy- nether i's your first automation investment or your tenth we build SPMS
that grow with your production need,
« Designed for Uptime, Not Downtime - Our machines are engineered for continuous operation = with easy-to-
‘maintain, modular components that keep your line running shift ater shift,
+ Maintenance That Makes Sense - From accessible layouts to standardized spares and butin diagnostics —
we make maintenance simple, quick, and cost-effective.
+ Seams integration, ero Disruption We talior each SPM to match your press ine specs, part flow, and
factory layout — so you get plug-and-play productivity with remote monitoring capability
+ smart. Connected. Future-Ready - Industry 4.0, lloT-enabled, and servo programmable — our SPA are bull
for the digital shopfloo.
+ Compete Lifecycle Support - On-site commissioning, operator training, AMC options, and remote service
assistance, Alu Engineers stays with you every step of the way. You're Backed, Aways,
+ Trusted by the Best- Lending names across automotive, consumer appliance, Pumping, Hardware and more.
sectors rely on us — and so can you.