Gemini 100-3 by RALC Italia raises the bar for industrial cutting

The Gemini 100-3 by RALC Italia stands as a benchmark in industrial cutting technology, combining mechanical power, digital intelligence, and factory connectivity. Ideal for cutting tubes, bars, and profiles in steel, aluminum, brass, and ecobrass, this automatic sawing machine is designed to achieve high production standards while ensuring maximum operational flexibility, precision, and cost efficiency.

Reinforced mechanical structure for maximum stability

At the heart of the Gemini 100-3’s performance is a completely redesigned structure. The new 3,500 kg monoblock base, machined using high-precision CNC centers, ensures excellent vibration absorption and mechanical rigidity—essential for cutting quality and blade life. The machine can be configured for single, double, or triple cuts, adapting perfectly to customized production needs.

Unlimited cutting optimization and intelligent interface

One of the main strengths of the Gemini 100-3 is its cutting optimization software, developed entirely in-house by RALC Italia. Unlike standard solutions, the Gemini 100-3 is capable of processing a large number of different lengths per bar, enabling complex and highly efficient programming.

The machine is also equipped with a high-resolution touch screen operator interface, allowing users to:

- manage multiple and alternative cutting plans with just a few taps;
- monitor cycle times and overall performance;
- schedule the entire production flow, even across multiple shifts;
- send and receive data from customer ERP and management systems.

Connectivity with the customer’s warehouse

Integration of the Gemini 100-3 into the production cycle goes beyond just programming: the machine can interact directly with both automatic and manual warehouses, using industrial protocols or customized software, to autonomously manage loading and unloading phases. This enables dynamic inventory management and continuous production planning, fully aligned with smart factory principles.

Smart sensors for predictive maintenance

The Gemini 100-3 is equipped with accelerometers and smart sensors that continuously monitor:

- abnormal vibrations;
- operating temperature;
- oil quality in the gearbox;
- transmission condition.

All data is collected and displayed in remotely accessible graphs, enabling predictive maintenance instead of reactive interventions. This translates into greater machine availability and significantly reduced extraordinary maintenance costs.

Extreme modularity and full customization

The Gemini 100-3 is available with a wide range of automatic loaders and unloaders, featuring modular structures that can be adapted to:

- material length;
- profile type (round, square, rectangular, etc.);
- the customer’s logistical layout.

This level of flexibility allows for complete customization, making the Gemini 100-3 the ideal choice for companies aiming for efficiency, quality, and advanced automation.

RALC–CONNI integration: from cutting to a complete work cell

The Gemini 100-3, like other systems in the RALC Italia range, is a tangible result of the technological integration between RALC Italia and CONNI, a company acquired and integrated into the group. This synergy has enabled the development of complete, highly automated systems, where the cutting machine becomes the core of true multifunctional work cells.

Thanks to this combination of expertise and solutions, today we can offer much more than just cutting: we integrate deburring, washing, marking, quality control, packaging, and internal handling—all within a single line. This offers a real advantage to customers, who receive a compact, smooth, and optimized system that reduces time, footprint, and production costs.

Continuous research and cross-range development

For the entire RALC Italia cutting line range, innovation never stops. The R&D departments are constantly working on new technologies to:

- further simplify operator tasks;
- reduce operating and maintenance costs;
- further shorten production changeover times, which are already remarkably low and easy to manage.

This philosophy of constant evolution aims to maximize the real productivity of RALC Italia customers, even in highly variable industrial contexts.

The Gemini 100-3 is more than just a cutting machine: it’s an intelligent production center, ready for Industry 4.0 and 5.0, capable of interacting with the customer’s digital environment, optimizing every bar, preventing downtime, and supporting complex productions with flexibility and reliability. Today, thanks to the combined strength of RALC Italia and CONNI, it is part of a comprehensive offering that transforms a simple machine into a complete, tailor-made system solution.