AMAG Austria Metall AG: Automated Materials Testing in the Smart Factory with ZwickRoell
Case Study
- Customer: AMAG Austria Metall AG
- Location: Ranshofen, Austria
- Industry: Metals, automotive and aerospace
- Topic: AMAG Smart Factory with ZwickRoell
November 2025
With its Smart Factory, AMAG Austria Metall AG relies on fully automated specimen preparation with integrated materials testing to meet the highest standards of the aerospace and automotive industries. ZwickRoell testing machines enable precise, digital and sustainable testing processes in aluminum production.
AMAG Austria Metall AG
AMAG Austria Metall AG headquartered in Ranshofen, Austria, is a supplier of primary aluminum, recycled aluminum and rolled aluminum products. The company operates its own foundry and rolling mill, supplying international customers in industries such as aerospace, automotive, mechanical engineering and packaging.
AMAG Austria Metall AG prioritizes technological advancement, quality assurance and sustainable production processes. In addition to manufacturing aluminum products, the company is also involved in the development and testing of new materials. Testing processes are closely aligned with the requirements of each industry and are becoming increasingly automated and digitized.
ZwickRoell top competences
- Reliable and precise materials testing machines that integrate seamlessly into automated processes
- Systems that significantly contribute to process stability and efficiency gains
- Expert and customer-focused service
- High satisfaction with the collaboration, driven by technical excellence and collaborative communication
- Machines enable the complete digitization of test data, supporting traceability and quality assurance
- Materials testing machine designed for high utilization and continuous operation. Automated systems designed for nearly 100% availability in 24/7 operation
The task
Meeting the highest quality standards in the aerospace and automotive industries
AMAG Austria Metall AG’s testing laboratory is a central component of its quality assurance. It must ensure that all products, particularly those used in safety-critical applications within the aerospace and automotive industries, meet stringent material specifications. The test requirements are complex: In the aerospace industry, for example, chemical treatments on specimens must be performed over several weeks to detect stress corrosion cracking. In the automotive industry, forming processes and delivery conditions, such as finishes and heat treatments, must be simulated realistically. Additionally, there is a growing demand for efficiency, traceability and reproducibility, alongside increasing production volumes.
AMAG Austria Metall AG aims to automate all individual processes to the extent that manufacturers’ technical capabilities allow. The focus is on integrating automated manufacturing and testing. ZwickRoell plays a central role in this development: The testing processes should be designed to operate entirely without manual intervention – including clamping, reclamping and changing the measuring equipment. Furthermore, the machines must be designed for 24/7 operation, ensuring high availability while remaining accessible to handling systems. The requirements for wear resistance, material selection and ease of maintenance are increasing accordingly.
Specifically, this means that:
ZwickRoell will further develop its testing processes to be fully automated and integrated with production.
The ZwickRoell solution
Smart Factory: Automated testing processes using ZwickRoell Z100 and Z250 technology
AMAG Austria Metall AG addressed these challenges by building a state-of-the-art Smart Factory. At its core is a fully digitized testing laboratory, managed by an autonomously controlled production facility, integrated automatic testing systems and intelligent software solutions. The tensile test is fully automated, from specimen preparation and post-heat treatment storage to the test itself. The entire control system is integrated into AMAG Austria Metall AG’s IT landscape, enabling the seamless digitalization of all test data.
ZwickRoell utilizes six manually operated tensile testing machines – including the Allroundline Z100 and Z250 types – as well as two automated testing systems automated testing systems with a total of three testing machines. The testing equipment is supplemented by a hardness tester, a pendulum impact tester and systems for compression, flexure, bearing and notched bar impact tests. These machines are not only used in the Smart Factory, but also play a central role in traditional product release testing.
The result
Improving the efficiency, precision and sustainability of materials testing
Automating testing processes has significantly increased AMAG’s efficiency. We significantly reduced lead times from production to release, while simultaneously increasing capacity. Automated testing systems are significantly more precise than manually operated machines because they eliminate operator influence. All common quality control methods – from calibration and validation to control chart techniques and round robin tests – are also applied here. Additionally, integrated control and monitoring systems with defined rules ensure continuous process reliability. The automated testing systems are fully integrated into AMAG’s IT landscape.
The AMAG Smart Factory itself exemplifies the successful application of ZwickRoell technology. Automated production and testing of flat tensile specimens have already been fully implemented here. ZwickRoell will continue to play a key role in driving automation forward at AMAG: The system is designed for 24/7 operation and achieves significantly higher utilization than conventional, manually operated materials testing machines, which are typically used for only about 40 hours per week.
Challenge:Maximum efficiency with the highest availability
Continuous use of automated testing systems places new demands on their design and operation. To achieve the desired near 100 percent availability, all components – from seals and belts to material selection – must be designed for continuous operation and minimal wear.
Future Vision:Complete automation of the testing process
The next development steps aim to fully automate the testing process, eliminating any manual intervention. These include:
- Automated specimen clamping and reclamping
- Automatic measurement equipment change
- Seamless integration with existing automated production
This complete automation not only improves efficiency, but also ensures consistent test quality while reducing operating costs.
Optimizing machine accessibility
Another focus is on designing materials testing machines for improved accessibility. The systems should be designed to allow automated handling systems easy access and ample space for their movements. This is essential for seamless interaction between manufacturing and testing. Further projects, such as the automated production and testing of round tensile specimens and K1C specimens, are currently in the planning stages.
Image source/copyright: ©AMAG Austria Metall AG
