Lean Solutions for Lighting Profile Production with Dallan

In the lighting industry, profile production has evolved significantly, from incandescent light bulbs to fluorescent tubes, and now to modern LED systems.

Thanks to its specialization in thin pre-finished and pre-painted materials, Dallan has developed advanced technological solutions that have followed the industry’s evolution.

Dallan’s machines, embracing LEAN production principles, have enabled manufacturers to adapt their production lines effortlessly, improving efficiency and reducing production costs.

Let’s take a look at some of Dallan’s LEAN solutions for the lighting industry.

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PXN Flexible Punching System

The Dallan PXN is a flexible coil-fed punching machine, specifically designed for producing linear lighting profiles for LED systems.

With the PXN, Dallan introduced a significant innovation by replacing costly extruded profiles with pre-painted sheet metal profiles.

This has led to substantial cost savings and significant productivity gains.

Additionally, the PXN is capable of producing both the fixed lamp housing body and the cover that hosts the LEDs, all in one process.

The machine’s versatility is demonstrated by its ability to create linear profiles used in various lighting sectors.

This technology allows companies to optimize production times and dramatically reduce material handling costs.

➡️ Watch Dallan’s Masterclass on the PXN here:

Machine for Producing 600x600mm Lighting Bodies

Originally designed for producing lighting bodies for fluorescent lamps, this high-speed production line has been adapted for the production of LED lighting bodies.

The machine includes a pre-punch press, a roll forming system, and cutting tools, followed by a second press to create the covers.

Thanks to Dallan’s flexible solutions, lighting manufacturers can quickly adapt to new technologies, maintaining low production costs and ensuring high performance in terms of speed and product quality.

➡️ Watch more about this machine in this video:

Linear Lighting Profile Production System

The third system we present is specifically designed for the production of complex linear profiles used in lighting, including both the fixed body and the cover.

The process starts with a press that performs all pre-punching operations, followed by a roll forming machine that shapes the edges, and then a series of presses for cutting and head-to-tail bending of the profile.

Thanks to Dallan’s in-house designed molds, the machine can produce these profiles in less than six seconds per piece, with a maximum length of 1200 mm, ensuring high productivity and precision.

➡️ Watch the machine in action:

The Benefits of Dallan’s LEAN Solutions

• Production Flexibility: Dallan’s LEAN approach allows manufacturers to quickly adapt to market changes, such as the shift from fluorescent systems to LED.
• Cost Optimization: Using pre-painted sheet metal instead of extruded profiles significantly reduces material costs while maintaining high-quality standards.
• High Speed and Productivity: Dallan’s advanced roll forming and punching systems allow for the production of complex parts at high speeds, ensuring high volumes.
• Material Waste Reduction: By working directly from coils, Dallan’s machines optimize material use, drastically reducing waste.

Dallan’s technological solutions for lighting profile production are a concrete example of how the LEAN approach can transform manufacturing, improving efficiency, quality, and flexibility.

If you’re interested in optimizing your production and reducing costs, contact us for more information about our lighting machines.

For more details or to watch our full Masterclass, write to us, contact us.

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