Modern production environments require largely automated processes, clear process logic and minimal intervention points for operators. This is precisely where the update of the SFO-F forming machines from STAUFF comes in. After all, the central question for many users in tube forming is: How can the direct work processes involved in the forming process be made even faster, safer and more reproducible while further minimising the potential for errors?

The STAUFF Form EVO system was presented in 2021 as a further development of STAUFF Form and is enjoying growing popularity on the global market.

In addition to the E for efficiency and the V for versatility in the product name, the O describes the aspiration to adapt the machine to the changing requirements of the market through continuous optimisation.

One example of this is the integration of the cloud module into the forming machine, which has now become an established delivery status. On the one hand, the module gives the user full online access to information about the machine's performance. On the other hand, the interface allows STAUFF to install firmware updates and additional parameter sets (e.g. for different tube materials) on the machine remotely, i.e. from a distance. Machine downtimes, machine returns to the manufacturer's factory and time-consuming and cost-intensive maintenance work can therefore be minimised.

At the turn of the year 2025/2026, STAUFF is now presenting a further update, which will also be integrated into the forming machine as standard: In future, a light barrier module will be installed in front of the work area of all machines.

What does the light barrier do?

• The light barrier automatically recognises when the formed tube is removed from the machine after forming and transmits this information electronically to the machine's control system.

• The control system moves the machine back to the defined starting position.

• The previously required manual reset at the touch of a button is no longer necessary.

If required, the light barrier can be deactivated by the operator via the software.

This further development is not just a convenience feature - the light barrier is another technological milestone that contributes directly to process reliability and improved ergonomics.

The effects of the new light barrier module on the tube forming machine are immediately apparent in practice:

More efficient processes

• Faster cycle times, particularly relevant in series production

• Fewer interruptions due to manual reset steps

Improved ergonomics

• Operators keep both hands on the component

• Particularly noticeable with long and correspondingly heavy or unwieldy pipes with complex geometries

More process reliability

• Clear process logic:
  Removal of the tube = reset = ready for the next forming process

• Reduction of operating errors - especially forgetting to reset

• Clear visual and functional feedback

Consistent quality

• Higher reproducibility of the forming processes

• Significantly more stable processes with changing operators

The result: users now benefit from a fully automated workflow with maximum process reliability.

In addition to the light barrier module, a further improvement to the forming machine has been incorporated into the recent update: The air filter element, which is used to dissipate heat from the inside of the machine, is now accessible from the outside. The condition of the filter can now be checked visually via a flap at the rear. If necessary, the filter fleece can be replaced quickly, easily and cost-effectively - by the user themselves or by STAUFF as part of scheduled maintenance or upcoming repairs.

The integration of the light barrier for automatically resetting the tube forming machine to the starting position offers tangible benefits - regardless of whether small, medium or large quantities are being processed. The function automatically recognises the removal of the formed tube and resets the machine without manual intervention.

Advantages for large quantities (series production)

• Process automation and speed

• Elimination of the manual reset button significantly shortens cycle times.

• Faults caused by forgotten or delayed reset steps are eliminated.

• Ideal for high-frequency processes in series production.

• Greater process stability and reproducibility.

Advantages for medium and small quantities

• Ergonomic improvement for operating personnel

• An additional, frequently straining handle is no longer required.

• Particularly advantageous for complex pipe geometries and heavy, long or unwieldy components.

• Operators keep both hands on the component during removal and work more safely and efficiently.

Accordingly, automatic resetting creates significant advantages wherever pipes are processed in different quantities, e.g.e.g. in the pipework of:

• Steelworks and other plants in heavy industry ,

• hydraulic presses and forming machines,

• pumped storage plants and hydropower plants,

• Construction and mining machinery,

• ships and offshore installations and

• fire extinguishing systems and

• In maintenance, retrofitting and servicing for MRO projects where only individual pipes need to be remoulded.

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