may 2016
On the cover: new doors from BA showcased at KBB BA invests in Biesse Mirrors and ultramatts Holz-Handwerk review Tips from the experts for better edges
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may 2016
contents 2 FILLING THE SKILLS GAP
Morbidelli’s Planet P800 is a fully automatic machining centre and edgebander in one.
4 LOOK WITH YOUR FINGERS
Looking for an entry level nesting machine with a compact footprint? Masterwood’s MW 12.25 K-series might just be the answer.
Hornschuch used ZOW 2016 to present a broad portfolio of décors - and an holistic approach to room design.
cover photo Fabulous finishes, contemporary designs: BA’s latest doors, launched at KBB. Story: page 10.
6 GLOSS LIKE GLASS Great gloss, super satin and an amazing mirror foil from Bonlex were shown on Plasfilms’ KBB stand.
8 HARD COAT UPS THE ANTI Anti-scratch and anti-fingerprint, the new Hard Coat range of PET foils from David Clouting contains the ultimate matt soft touch surface as well as high gloss.
10 BA REFLECTS ON KBB BA Components treated KBB visitors to a preview of its latest door collections, available from May 2016.
editor: Melvyn Earle email: Melvyn@FurnitureJournal.co.uk Direct Tel: 01502 733438
circulation: Marie Earle email: Circ@FurnitureJournal.co.uk www.furniturejournal.co.uk
12 BA INVESTS IN BIESSE Furniture Journal visits Ireland to see BA Components’ new automatic manufacturing facility.
16 BUSELLATO The new Jet Smart makes its UK debut at RW’s Open Day
18 FH6 IS WELCOME Please note: points of view expressed in articles by contributing writers and in advertisements included in Furniture Journal do not necessarily represent those of the publishers. While every effort is made to ensure the accuracy of information contained in Furniture Journal, no legal responsibility will be accepted by the publishers for incidents arising from use of information published. All rights, including moral rights, reserved. COPYRIGHT: No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means without the prior written consent of the publishers. Copyright CPC Ltd, 2016.
ISSN 13653-8969 Readers should note that a charge may have been made by the publishers to cover the cost of reproducing some colour photographs in this publication.
origination: CPC Ltd printing: Barnwell Print published by: Craftsman Publishing Company Ltd, Landings House, Lound Road, Blundeston, Suffolk, NR32 5AT, England. www.craftsmanpublishing.co.uk
26 DISCOVERING PLANETS
According to K3 Syspro, UK furniture manufacturers struggling to fill 750,000 vacant positions are turning to technology for solutions.
The stage is set for future expansion at Welcome Furniture following recent investment in a fourth Schelling fh6.
21 FURNITURE ON DEMAND More than three years went into the development of SCM’s Close to the Customer project, a world first launched at the Fiera di Bergamo in April 2016.
22 HOLZ-HANDWERK REVIEW Holz-Handwerk 2016 was bigger than ever with over 110,000 visitors.
24 MAKA MULTI-TASKING Integrating the controls of a robot and a machining centre have enabled Maka to offer a system that makes small run specialist component production simple.
28 MINI MARVEL
30 FELDER’S TRILOGY Three machines in particular impressed the crowds on the Felder stand at Holz-Handwerk.
32 IM-PRESS-IVE PERFORMER The new Performer press from Columbus made its debut at Holz-Handwerk.
35 EDGES TO PUR OVER Holz-Her’s Angelo Amico demonstrates how to make your zero glueline edges worthy of a product guarantee.
38 FIT FOR PURPOSE Matching the adhesive to the end use of the product will go a long way towards eliminating problems - and returns. Bradly Larkan from the adhesive specialist Kleiberit offers a few pointers.
41 RESOLVING EDGE ISSUES Is a zero glueline finish evading you? Biesse UK’s Robbie O’Neill talks about some possible reasons and presents Biesse's ultimate edge solution.
45 EASY EDGING Students demonstrate why you don’t need to be a big user to take advantage of Döllken’s range of edgebands.
46 CLEAN EDGING If you’re not getting clean edges from your edgebander, you might need to look at your surface cleaner.
48 DUSTRACTION ON THE CASE When GP Cases wanted to combine a new dust filter and extractor with the installation of a biomass heating system, they called in Dustraction.
2 • FURNITURE JOURNAL MAY 2016 – BUSINESS NEWS
filling the skills gap A
According to K3 Syspro, UK furniture manufacturers struggling to fill 750,000 vacant positions are turning to technology for solutions.
t the EEF’s National Manufacturing Conference 2016, 31.6% of delegates cited a lack of skills as the single biggest barrier to increasing productivity in UK manufacturing. However, while the survey was a cause for concern for some, a further 51% of those surveyed at the event stated that they felt that, while productivity may be lagging, technology is key to remedying this. K3 Syspro Managing Director, Cathie Hall explained: “We all know there is a skills gap across the manufacturing sector and the furniture sector has been particularly hit by this. The problem is not going away for a while but with the right use of technology, furniture manufacturers can still increase productivity and make the most of new opportunities, even if they are struggling to build an extensive workforce.” Furniture businesses are being urged to utilise transactional data held in their ERP systems, to better understand customer buying habits, improve production efficiencies and empower existing workforces with greater intelligence. This means that any gaps in a workforce’s production knowledge can
be filled by automating processes. Production scheduling can help employees to better plan and prepare for demand, while regularly analysing inventory levels can demonstrate to purchase managers where raw material investment is being wasted. K3 Syspro offers solutions in enterprise resource planning (ERP), customer relationship management, advanced planning and scheduling, warehouse management, human resources and e-business. A division of K3 Business Technology Group, K3 Syspro provides nextgeneration enterprise software for businesses in the retail, manufacturing and distribution sectors. “There is no doubt that technology will prove key in the overcoming the long term challenges facing UK manufacturing, however for some businesses, it is the here and now which is a more pressing issue. By better utilising the technology already available to furniture manufacturers they can improve productivity and really take advantage of the current upturn across the sector.” Cathie Hall concluded. For help bridging the skills gap contact K3 Syspro on 0161 876 4498.
Exposicam srl Via G. Carducci, 12 • 20123 Milan • Italy Tel: +39 0286995712 • Fax: +39 0272095158 info@exposicam.it
www.exposicam.it INTERNATIONAL EXHIBITION OF COMPONENTS, SEMIFINISHED PRODUCTS AND ACCESSORIES FOR THE FURNITURE INDUSTRY
18/21 October 2016
PORDENONE FAIR
4 • FURNITURE JOURNAL MAY 2016
look
with your
Shown here, on a bed frame and nightstand, skai® Perfect Touch is the gold standard in the area of matt plains.
T Hornschuch used ZOW 2016 to present a broad portfolio of décors - and an holistic approach to room design.
here’s one thing in particular that the décor specialist Hornschuch has always done exceptionally well and that's provide high performance surfaces for practically every application you can image. You'll find Hornschuch products in every room of the house from the trendiest kitchen cabinetry to the floor; on car dashboards and seats; in boats; on window frames; adorning the chairs in care homes; even on walls. The Hornschuch motto for 2016 is ‘All in One’ and it's no surprise: in addition to furniture films and upholstery materials, Hornschuch will shortly present Design Click Vinyl, which enables designers to decorate any room holistically with surfaces by Hornschuch.
“People always strive for the whole, the intact, the complete,” says Ralf Imbery, Hornschuch’s Director of Design. “We yearn for harmony, perfection and balance. This is true for the design of each piece of furniture as well as for applications in the room, even for the effect of the room itself. Wall and door coverings with artificial leather (including digital printing) have become increasingly important in the past few years, as has furniture film on counters, room dividers, wall panels, or on creative accessories like lampshades, for example. The Hornschuch Group remains a productive partner for the furniture industry but is also open to new, more individual requirements.”
FURNITURE JOURNAL MAY 2016 • 5
fingers
Natural stone in the décor skai® Sahara
The delicately grained skai® Sahara harmonises both naturally and stylishly with various interiors.
Natural skai® Riviera Oak, a new interpretation of an old favourite.
For the furniture manufacturing sector, skai ® furniture films include wood, stone and metallic décors, which are not only natural and unique, they are also very tactile. Hornschuch offers surfaces for furniture that can harmonise or contrast with upholstery surfaces and floorboards to suit any application. The skai® Perfect Touch collection is the gold standard in the area of matt plains. It has a very pleasant feel: not dull, but warm. It presents a direct tactile experience that invites you to touch, begging to be experienced with the senses, reinforcing the visual impression with a soft and delicate feel. The brand-new skai® Riviera Oak is the epitome of the subdued rustic look and includes elegant reflections and distinctive
rays. Stripes and cathedrals alternate harmoniously to form a subdued plank pattern. Combined with Rustico it brings to life classic and modern oak colours from very light and untreated shades to almost brown colours. Contrast wood with a natural stone and you bring warmth and a calming stability into the home. As a traditional building material, stone radiates dependability and security. The designs from Hornschuch give a very realistic impression of sandstone, quartz, or concrete. Subtly grained, with a natural dull surface finish, they carry the tactile experience to a new level. To find out what Hornschuch can offer you call 01327 877646 or visit www.m-f-s.co.uk
Denim
Graphite
Frost White
A stunning rusted metal effect décor. Combine with timber or a unicolour for a stunning effect. Light Grey
Arctic Grey
6 • FURNITURE JOURNAL MAY 2016
gloss
like glass
The new mirror foil, shown right, used to good effect on large doors provides all the reflective character of a mirror with none of the weight.
Great gloss, super satin and an amazing mirror foil from Bonlex were shown on Plasfilms’ KBB stand.
I
Pure, clean and unfussy: that's flawless white high gloss from Bonlex.
f you visited the Plasfilms stand at KBB, you won't have failed to notice a roll of mirror foil among the high gloss and satin rolls that bordered the stand. Aware of the high gloss levels produced by Bonlex, it probably came as no surprise that the next step in the race for the ultimate gloss would be a true mirror. And that’s exactly what Plasfilms showed: a flawless, silvered reflective surface from Itochu Group member Bonlex that provides a perfect mirror image, just like glass - except it's on a roll. At a fraction of the weight of a glass mirror and completely unbreakable, the new foil is perfect for display cabinet backs, for environments that require enhanced safety like schools and prisons, for creating an effect of space on the doors of kitchen, bathroom or lounge cabinets, or as a replacement for a silvered glass mirror in a bedroom door or dresser unit. And
installation is simpler than a real mirror, requiring no second fit. The new mirror foil, which is presently available in silver and gold, joins a lineup of high gloss neutrals (Cashmere, Stone Grey, Light Grey and Dark Grey) that have been finished with a special top coat to increase depth as well as scratch and chemical resistance and offer high colour consistency. By adding a satin top coat to its high gloss products, Bonlex broadened its offer last year into a range of softly embossed satin unicolours. The satin top coat provides a soft, silky finish and enhanced scratch and chemical resistance, while the gloss underneath enhances the depth of colour. White, Cream, Light G r e y, C a s h m e r e , M u s s e l a n d a sophisticated Black Satin are all available ex-stock from Plasfilms in the UK. For more information call 01530 561962 or email chris.green@plasfilms.co.uk
8 • FURNITURE JOURNAL MAY 2016
hard coat Anti-scratch and antifingerprint, the new Hard Coat range of PET foils from David Clouting contains the ultimate matt soft touch surface as well as high gloss.
FURNITURE JOURNAL MAY 2016 • 9
ups the anti G
loss looks fabulous. Of that there is no doubt. In the kitchen, reflective high gloss surfaces add a special quality and the trend is increasingly moving towards contemporary styling with high gloss doors used more and more. Handle-less, slab designs such as the new do o rs seen on t h e B A Components stand and the new designs on the O&S Doors stand at KBB, are the perfect way to show really good gloss to its best effect. But gloss has one major drawback, especially in a kitchen: the slightest touch of a finger leaves an unsightly print on its pristine surface - and for the fastidious, that means only one thing: out with the paper towels and cleaning products. Always astute and eager to stay one step ahead, BA Components found the
solution to fingerprints in David Clouting's Hard Coat collection, a range of on-trend unicolours that brings both antifingerprint and anti-scratch properties to high gloss and the very latest supermatt finishes. On show at KBB were several new doors from BA that had been finished with Hard Coat in supermatt and despite rigorous "testing" by visitors, not a fingerprint, nor a mark were to be seen on any of them. Described as having “a similar look to acrylic panels in gloss and supermatt”, the Hard Coat PET collection provides significant improvement in scratch and mar resistance when compared with regular lacquers and comes at a price that makes it a realistic, cost-effective alternative to other gloss and matt panels and is intended for flat lamination.
Colour matched to existing press grade foils, BA and O&S have adopted several foils from the Hard Coat PET range (currently available ex-stock from David Clouting), which includes White, Pale Cream, Alabaster, Oyster, Cashmere, Mussel, Light Grey and Dust Grey in both gloss and supermatt. The Hard Coat range is available in one roll quantities (400 linear metres x 1250mm) or made to order from 3,000 linear metres (that can be a mix of supermatt and gloss). David Clouting is stocking exact colour matched edging for all the Hard Coat products. For more information on the Hard Coat PET range, contact David Clouting Ltd on 01376 518037, or visit www.davidclouting.co.uk
10 • FURNITURE JOURNAL MAY 2016
BA Components treated KBB visitors to a preview of its latest door collections, available from May 2016.
ba reflect W
Valore: Coco Bolo with Mussel
hen is a door more than just a door? The answer has to be when it helps define the style and personality that lies behind the kitchen. With the latest additions to the Kitchen Collection by BA Components, showcased at KBB and due for official launch in May 2016, BA has purposely set out to give consumers more choice by taking the trend for contemporary lines, tactile surfaces, neutral colours and beautiful décors to the next level.
Included in the new additions are handleless and J-pull options finished with sumptuously soft Ultramatts; square-edged slab doors that make the most of beautiful prints; and deeply structured oak grain embosses that highlight contemporar y lines. A flawless mirror door, shown for the first time on BA’s KBB stand, is also among the new additions to the Zur fiz collection and is undoubtedly the first of its kind in the market.
FURNITURE JOURNAL MAY 2016 • 11
Bella Cambridge in Oakgrain Light Grey
Pronto Wilton in Oakgrain Graphite and Oakgrain Grey
Zurfiz Ultramatt Cashmere & White and Gladstone Tobacco Oak
ts on kbb Matt Graphite, Oakgrain Light Grey and Oakgrain Cashmere are the latest additions to the Bella range of PVC wrapped doors, while the 1mm edged Zurfiz range now includes four new fabulous anti-fingerprint, HardCoat Ultramatts (Cashmere, Dust Grey, Light Grey and White) and five inspired stone and wood effects with deep structure embosses (Driftwood Light Grey, Evora Stone Graphite, Halifax Natural Oak, Gladstone Tobacco Oak and the flawless
Mirror). Pronto benefits from eight new additions ranging from Wilton Graphite to Rothwell and Firbeck in White, while the no compromise Valore range now includes ten new décors, among them four unicolours, Concrete and four beautifully figured woodgrains - White Swiss Larch, Mali Wenge, Coco Bolo, Grey Brown Ontario Walnut - as well as the strikingly different Grey Brown Metallo. Details: 028 8676 4600 or www.byba.co.uk
From the Bella range: Matt Graphite with a centre pull (left) and Oakgrain Cashmere with a J-pull on the left (centre). Shown right is a Pronto Rothwell in high scratch and fingerprint-resisting Ultramatt Dust Grey with full width J-pull.
12 • FURNITURE JOURNAL MAY 2016
ba invests
Furniture Journal visits Ireland to see BA Components’ new automatic manufacturing facility, masterminded by Kieran McCracken and built by Biesse.
K
ieran McCracken was very clear on what he wanted to achieve when he challenged Biesse to provide BA Components’ Cookstown factory with a new, fully automatic manufacturing facility: “One of our key selling points is any size, any door,” he told Furniture Journal during a visit in mid March. “We wanted to completely automate our routing department with a highly flexible system that would enable us to run special colours or boards without disrupting production and run other parts, such as plinths, automatically
through the night. Per eight-hour shift, the new system gives us a capacity of around 3,300 pieces. That’s one board from store in just under two minutes, 260 boards in an eight-hour shift, or one machined panel coming off the end every eight seconds. The average moving time for one board is fifty seconds, which means the system has over a minute spare to reload the store. “I started looking at the design of the system in 2012 and talked to a few companies. Biesse offered the best allround package and had the ability to
FURNITURE JOURNAL MAY 2016 • 13
Right. The CNC feeding section takes boards from the store and feeds them to each of six routers. Below right. Board storage is taken care of by a Winstore 2D K1 that shows the position of every stack on a concise graphic display (below).
s in biesse demonstrate it to us. They’d already done something similar with three CNC routers, so we could easily see it working with six.” Occupying around half of the available manufacturing space in BA’s Cookstown factory, the new system, which represents an investment of around £2.5 million, is split into five sections: automatic board storage with a vacuum lifter; a very flexible CNC feeding section that automatically provides for flexible work patterns; six Biesse Rover B CNC machining centres,
each equipped for nesting operations; an unloading section beneath a viewing platform with bridge access; and a parts labelling/sorting section. Automatic board storage is provided by a Winstore 2d K1. “It has a capacity of 38 positions and just over 4,000 sheets,” explained Kieran. “That gives us 38 fixed locations, six loading spaces in the feed section and two additional loading spaces at the far end. It means we can load six pallets directly onto the machines without them going into storage, so we can
Above. Director, Kieran McCracken.
14 • FURNITURE JOURNAL MAY 2016
Above. Foreseeing problems with doors being dropped, Kieran didn’t want the vacuum lift options offered by some manufacturers for unloading. Instead, he had Biesse design a twin shuttle system on rails the first their engineers had produced. Below. Occupying around half of the factory, the Biesse installation includes automatic board storage (1), a feed section with vacuum lift (2), six routers (3), a shuttle unloading section (4), labelling/sorting (5).
1
run special colours in the middle of a production run, or add eight pallets (by using the two secondary loading areas) for overnight working and refill the eight spaces in storage.” Having secondary loading areas means any boards that the system determines are problematic - something it does with twin lasers that also square the board (ensuring its set on the belt properly) and a weighing device - can be called off automatically. “Something I particularly wanted was automatic stock rotation,” added K i e r a n . “We vis ite d a co up le o f factories where boards had been sitting and had swollen. I didn’t want that. With this system, board stocks are automatically rotated. Some of the
2
3
stacks can even be rainbow stacks of multiple colours. It sorts everything during the night, then every morning it reports what’s running low to the CRM system. The forklift drivers can stack up one or two days in advance.” During night time operations, the vacuum lifter separates out the protective cover and base boards, stacking these in the secondar y loading areas where they can be forklifted off the following morning. 2.8 x 2.1m boards are collected on one side while 3 x 1.2m boards are stacked on the other. “We can also use any of the eight stations to run test boards, or we can load one-off boards onto the front face of the router manually.” A single
4
5
FURNITURE JOURNAL MAY 2016 • 15 Far left. A conveyor takes nested parts to operators who label and sort them. Right. Additional cleaning following the nesting operation. Below and below right. The six Biesse Rover B machining centres are equipped for nesting with 12 tools in the head and a further 30 in the tool changer. The software is Biesse’s bSolid, an intuitive suite with clear and concise 3d graphics.
vacuum lifter works the entire length of the feeding section, taking panels from the storage area and placing them on feeders ahead of each of the six routers between re-stocking the Winstore. The six CNC routers are all Biesse Rover B models, equipped for nesting operations with automatic loading and squaring tables, 12 tools in the head and a further 30 in the toolchanger. “Our other machines had 12 plus 24 and we needed at least that in the new ones to cope with the increasing number of door designs we produce,” commented Kieran. “These are third or fourth generation routers that are equipped with automatic cleaning systems on the beds. The quality they produce is very high, especially with the PCD tooling and the Aerotec system we’re using that removes dust. That’s a must for nesting operations. We also wanted additional cleaning before the unloading section. “With this system, we can decide which machines we want to use for which operations, controlling production exactly, even dropping machines out for maintenance without interrupting the work flow.” The new facility is extremely impressive, not least because of the number of unusual processes Kieran wanted to include in the scheme that Biesse’s design team had to invent and
build from scratch. “Everyone we talked to wanted to offer us vacuum lifters for unloading. That’s fine for full sheets but I could see too many problems with doors being dropped. We’d already got a shuttle system on our press line and that’s what I wanted here. Like the faulty board detection and removal system, Biesse designed the shuttle specially for us with two shuttles. It’s the first time they’ve done a shuttle.” Another unique aspect of the system that Kieran was instrumental in pressing Biesse to design was multi-batching: “We can pick and choose batching to ensure the same colour and make different designs from it, running one batch on machines one to four while machines five and six are running something different. Different doors take different times to machine. Some might take three to four minutes while others might take 13. At every stage, the board storage system works this out based on rules we decide like how many routers will run it and whether it should finish one batch before starting the next. It’s all about flow and making sure boards go through at the right pace. It’s a very, very clever system.” Kieran’s enthusiasm for the system is matched by his praise for Biesse’s designers and engineers who, he says, have “done a great job”. Biesse UK: 01327 300366, email info@biesse.co.uk, visit www.biesse.com
16 • FURNITURE JOURNAL MAY 2016
RW opened its doors for an in-house show to mark the launch of a new boring and grooving centre from Busellato.
busellato on sho T
he UK launch of Busellato’s automatic boring and grooving centre, the Jet Smart, brought visitors from far and wide to RW’s inhouse exhibition. Shown alongside Casadei Flexa 47 and Flexa 407 edgebanders and a Busellato Easy Jet CNC machining centre, the flexibility, speed and ease of use of the new Jet Smart captivated furniture and joinery manufacturers, for whom high productivity and an eight square metre footprint were particularly important. Capable of up to 400 batch-size-one pieces in a shift, the Jet Smart comes with automatic workpiece dimension reading for error-free alignment and a flexible, reduced maintenance head, which provides exceptional accuracy
during horizontal drilling. It can be supplied with the option of a vertical electrospindle. Motors are brushless and high speed linear fences ensure excellent productivity. For processing dowelled pieces, the Jet Smart is equipped with a zero reference stop. Workpiece stability is assured by an adjustable side-aligner and an adjustment-free table with grooves that accommodates any configuration of the heads. The optional in-built Eco System reduces consumption by putting the machine into standby mode when not working. The Easy Jet may not be new but the flexibility of specifying the table for nesting or with vacuum cups made this compact, easily accessed machine a
hit with manufacturers of furniture and doors. Adaptors simplify assembly of the drilling bits, while the PT1 tool-changer accepts between eight and 19 tools, subject to model. The head can be configured for hinge drilling and sawing. The Casadei Flexa 47 automatic edgebander, with its Casadei Mega control, pre-milling, end cutting, trimming, edge scraping, rounding and anti-adhesive unit, is aimed squarely at the smaller workshop while the Casadei Flexa 407 drew attention from larger, industrial users. It’s ideal for edging thick, solid wood panels and offers feed speeds of 12-18m/min. For more information contact RW Woodmachines Ltd on 01869 244943.
FURNITURE JOURNAL MAY 2016 • 17
Two edgebanders were shown at RW’s Busellato event: the Casadei Flexa 47, above, is a feature packed machine for the smaller user, while the Flexa 407, below, is one of Casadei’s larger machines for industrial edgebanding.
Making its UK debut, the Jet Smart, left, was the star of RW’s in house event. This machine has a tiny eight square metre footprint, yet its capable of drilling 400 batchsize-one pieces both vertically and horizontally in a shift.
ow at rw The Easy Jet provides easy access to three sides. Shown right is a basic head configuration.
18 • FURNITURE JOURNAL MAY 2016
fh6
is welcome N
The stage is set for future expansion at Welcome Furniture following recent investment in a fourth Schelling fh6.
orth Wales-based, bedroom and living room furniture specialist Welcome Furniture has recently invested in a fourth Schelling fh6 cutto-size saw to improve its capabilities and strengthen its offer to the market. I m p r ov in g m ate rial lo adin g an d handling were essential to achieving the objective of increasing the efficiency of the cutting operation at Welcome. “Often manual labour is used to convey large panels to a saw, which creates huge inefficiencies,” commented Welcome's John Peterson, “But on our fh6, material loading was automated with a scissor lift, powered roller tracks and a separate push-off carriage. All these resulted in a far more reliable and predictable transfer of components, creating a more efficient production process.” The new machine is not only fast, accurate and consistent, allowing Welcome to be more responsive and offer shorter lead times to its customers, many of its features - such as the automated integrated sensors, which automatically detect the panel
size and book height - make life easier for the saw operator. Automatic integrated sensors are standard equipment on the fh6. Additionally, including double strip aligners before and after the saw line, provides precise angular alignment when cutting within an alignment range of 40mm to 2200mm - and that means high cutting accuracy even with the narrowest of strips. The 21kW motor and 460mm diameter saw blade provide the fh6 with a maximum saw blade projection of 135mm, enabling substantial books to be cut, if required. Welcome Furniture’s investment in Schelling is a resounding vote of confidence. Back in 2009, Welcome Furniture invested in its first Schelling. “Based on its performance and reliability, we didn’t hesitate to buy our fourth Schelling saw because they have played such an important part in delivering our success at Welcome Furniture,” concluded John Peterson. For more information on Schelling cut-to-size saws call 01937 586340 or visit www.schelling.co.uk
60 years of Felder Anniversary model K 940 Panel saw 2016 Edition
+ Patented "X-Roll" sliding table with 10 year guarantee + "Easy-Glide" tilting segment guide with 6 year guarantee + "x-motion" LCD-screen control with touch-button function + Scoring unit + 2,800 mm sliding table + Automatic rip fence + 1,250 mm rip capacity Specification: Motor power 7.5 PS (5.5 kW), star delta start, 133 mm cutting height, 90°–45° saw blade tilt
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www.cookstownpanel.com facebook.com/cookstownpanelcentre
Craig Burney Sales Manager (UK) Cookstown Panel Centre - Manchester Branch, Unit 4C, Stanley Green Trading Estate, Stanley Green Road, Cheadle, SK8 6RB T: 0161 485 3492 F: 0161 488 4559 Cookstown Panel Centre, Derryloran Industrial Estate, Sandholes Road, Cookstown, Co.Tyrone, BT80 9LU T: 028 8676 2685 F: 028 8676 3275 Direct: 028 8676 0358
PVC Coating International would like to introduce GlossMax by Kastamonu, the Turkish manufacturer of high gloss panels • Super high gloss, high scratch resistance • Available in full sheet 2800 x 2100 x 18mm, Cookstown Panel Centre also have the ability to cut and edge • A full range of colours will be stocked in our Northern Ireland and Manchester based Panel Centre’s
GLOSSMAX GlossMax High Gloss panels are produced with an advanced unique technology, going through a variety of industrial processes, in which adhesive and UV lacquer is applied to melamine coated MDF or particle boards to achieve a decorative, shiny surfaced wood panel. In the hot coating process that achieves excellent adhesion to the melamine coated surface, PUR (Polyurethane) adhesive coating is applied to the melamine surface. Once the Polyurethane adhesive has gone through chemical curing an outstanding hard surface which is resistant to scratches, impacts and wear is achieved. The PUR substance is also durable against UV rays. The outer layer, which hardens with the UV rays applied directly after, provides an excellent level of gloss. This technology has forged a new path in surface coating, brought forth the natural appearance and texture of solid wood and provided a solution which has simplified the surface finish application. GlossMax panels create modern, graceful furniture combinations with mirrorshine for kitchen, bath, home, office and all other decoration projects.
PVC Coating International Ltd: Dublin Office T: 00353 8625 97251 Email: pvccoatinginternational@eircom.net
www.pvccoating.ie
The GlossMax glossy panels resistant to wear, impact and scratches, reflects the naturalness of wood and enriches interiors with a variety of colors and a mirror like gloss. The GlossMax glossy panel products used in furniture production as an example of stylishness and quality, have started a whole new era in the sector with a technology that maintains its glossy appearance for a long time.
FURNITURE JOURNAL MAY 2016 • 21
furniture I
magine a mini-factory in a shopping centre where the customer can use a simple interface to draw the piece of furniture he or she would like to buy, customise every aspect of it and then have it produced, on-the-spot, and presented for him to take away. There’d be no mixed up deliveries, no transit issues and no transport costs. Impossible? On the contrary, this futuristic vision has just become a reality. Putting the customer at the heart of the process so he becomes his own furniture designer is an innovative idea, unveiled and presented as a world first by SCM at the IDEA Innovation Design Expo Area in the Fiera di Bergamo last April. On a huge screen set up in the SCM Group display area, a video presented the mini-factory SCM had already installed in a shopping centre in Brianza - the first prototype of the project dedicated to Furniture on Demand - opening a captivating window into what could be the future of furniture production.
on demand
At the heart of this live, on demand demonstration stood an SCM machining centre. Starting from a ready-made portfolio of products, shoppers configured and designed their own furniture, watched as it was produced on the machine and took home an authentic, one-of-a-kind piece as it emerged from production. The Close to Customer project, financed by the European Community, is the result of more than three years of r e s e a rc h i n v o l v i n g S C M a n d 1 0 European partners, including universities. For more information visit www.mckn.eu/projects/CTC/
More than three years went into the development of SCM's Close to the Customer project, a world first launched at the Fiera di Bergamo in April 2016.
22 • FURNITURE JOURNAL MAY 2016
holz-handw W Held every other year in Nürnberg alongside the window exhibition, Fensterbau, Holz-Handwerk 2016 saw record visitor numbers and hosted almost 1300 exhibitors.
hen it first started, the concept of Holz-Handwerk might well have been to provide German furniture, woodworking and window manufacturers with a comprehensive home show for machinery and materials but the pull of Holz-Handwerk and its sister exhibition, Fensterbau, has moved way beyond the local market. The Nürnberg Exhibition Centre was fully booked for the event in March 2016, hosting a total of 1,296 exhibitors - about two-thirds of them from outside Germany - and on the second day of the event alone, visitor flow through the halls reached a record of 38,568. That’s a record not only for the exhibition but also for the exhibition centre. In total, HolzHandwerk and Fensterbau saw 110,581
visitors pass through the gates between 16th and 19th March 2016 - an increase of just over 1,600 on the previous event, held in 2014. Inevitably, such large numbers of visitors arriving within a relatively small time window brings logistical issues. In an attempt to alleviate traffic problems and smooth the flow of visitors coming by road, the organisers had intentionally shifted the opening time of the exhibition by an hour. It didn’t seem to matter what time we set off, the traffic still ground to a halt on the Autobahn, delaying our entrance for up to an hour and a half. Plans to start on the dot were further confounded by car park officials who seemed intent on preventing rather than assisting drivers to park - and none
FURNITURE JOURNAL MAY 2016 • 23
werk: review could have been worse than the Rottweilers guarding the gates to the press and VIP car parks. They seemed oblivious to the chaos they were contributing towards outside the exhibition grounds. More efficiency and organisation here would undoubtedly have impacted positively on Autobahns that by 10am had already turned into car parks. Once inside, navigating between the halls of the Nürnberg exhibition centre is never easy (hall signage is atrocious) but, as always at Holz-Handwerk, the spread of products and machines is very broad, encompassing larger producers and smaller specialists. All the big names in machinery - Homag, SCM, Weinig, Biesse, IMA, Maka, Reichenbacher,
Felder, etc - were present alongside the German distributors of other manufacturers. Décor specialists like Hornschuch, Renolit, Egger and Kronospan showed in the adjacent halls of Fensterbau, while some materials suppliers (Jowat, for example) showed in both. So close to Ligna, genuinely new machines were never likely to be thick on the ground, though several German manufacturers used the occasion to debut their latest developments. Most of the Italian manufacturers seemed to be keeping their powder dry for Xylexpo in May and confining their Holz-Handwerk exhibits to Ligna models with added functionality and value. In the pages that follow you'll find several of the highlights.
In conclusion, is Holz-Handwerk a show that British furniture manufacturers should put on their 2018 calendars? Much depends on whether you make your purchase decisions in the wake of Ligna. Not all the machinery manufacturers had UK representation on their stands, suggesting some had decided to give this year’s event a miss, and for sure, if it’s components or materials you want to see, HolzHandwerk doesn’t pretend to incorporate Interzum. Nevertheless, this is a show that packs a punch, there is plenty to see and if you know what you’re looking for there’s a good chance you'll find it here. It's on our 2018 calendar. Maybe it should be on yours, too.
24 • FURNITURE JOURNAL MAY 2016
maka:
multi-task I
Integrating a Kuka robot controller into a Siemens controller has enabled fiveaxis machining centre specialist, Maka, to provide a system that requires the same commands for robot and machine, making small run specialist component production simple.
t may have been a mini Maka on the stand at Holz-Handwerk but paired with a Kuka robot, its capacity to perform multiple fiveaxis machining tasks simultaneously both amused and amazed visitors. “The robot runs the Maka,” says technician, Alex Hiller. “Once the robot is programmed, it does everything, picking and placing parts on the table, removing offcuts while the table is in motion, drilling, cleaning and boxing finished parts, whatever you need. There’s one language to learn and the robot coordinates machining operations so there’s no need to program two independent machines. It’s ideal for small batch work.” Its party trick at HolzHandwerk was serving water to visitors throughout the day. As soon as it had spare time between main tasks, the Kuka responded to visitor requests
by opening a refrigerator, taking out the bottle and placing it in a chute. Once dispatched, it returned to main duties, having worked out precisely the time it had available without operator input. “Programming is very easy,” says Alex. “We use a Siemens CNC program - the only one that’s needed to operate both machines - called Run My Robot. Every place has a zero point that is taught to the robot using a teach button. The axes can then be moved very easily. With PLC functions, parts can be gripped or released. Apart from the zero point, all other movements are determined by programming.” Although the Maka MK7 was much more compact than the one shown at Ligna 2015, the programming system remains essentially unchanged. It can run any Maka. “We have done a lot of work on the diagnostic interface since Ligna, but it’s essentially the same, simple-to-operate program.” To find out more call Maka UK on 01952 607700.
FURNITURE JOURNAL MAY 2016 • 25
REVIEW
king Supplying a Maka MK7 with components on fixtures was a simple task for the multi-tasking Kuka robot at Holz-Handwerk 2016. Both are programmed using the same language and work hand-in-hand, the robot supplementing machining operations as well as supplying components for machining. The Maka spindle (above left) includes a special tool that sends data on each part manufactured to a master hard drive, where it is stored for analysis. More than 12 month’sworth of data can be archived.
26 • FURNITURE JOURNAL MAY 2016
Above. The table is automatic. All supports move independently. Place a panel on the table, the P800 will cut it, move four separate parts to four areas of the bed and manufacture four different, fully finished components, saving you both time and materials. Above right. The edgebanding unit includes a Sbrindle device for near invisible joints and, at Xylexpo, Morbidelli plans to show a system with a variable pressure roller that will facilitate softformed edges. The new pressure roller will allow users to edgeband 20mm internal radii, or 105mm when using solid wood lippings or veneer.
REVIEW
discovering More than just a rising star, Morbidelli’s Planet P800 is a fully automatic machining centre and edgebander in one.
A
workcentre for drilling, routing and edgebanding curved panels, the Morbidelli Planet P800 took pride of place on the SCM Group stand at Holz-Handwerk. “The big advantage for office, bedroom and bathroom manufacturers, or shopfitters, is that you don’t need to move the workpiece,” commented Bruno Di Napoli on the stand. “You position the panel and the Planet P800 will cut to size, drill and then edgeband
planets both the external edge of the board and any internal cut-out that may be needed. And it’s designed for just-intime work with zero set-up time.” Working panels of up to 80mm in thickness and applying strips or coils from 0.4mm to solid wood, the P800 runs on drag and drop Maestro and Maestro Edge software. It’s a custom built machine, available with four or five axis routers, or several routers in combination, such as a three axis and
a five axis. “It’s very strong on routing and we can offer anything from 12 to 50 spindles, customise the toolchanger to accommodate up to 40 tools and make it any size you need,” says Bruno. The edgebanding unit includes a Sbrindle, a device that detects and adjusts the cutting of the tape to create a near invisible, zero waste joint. “We can make that in linear space of 80mm - less than half of normal.”
FURNITURE JOURNAL MAY 2016 • 27
Above. The toolchanger will accommodate up to 40 tools and the edgebander can be fed from up to six reels automatically (shown right on the Holz-Handwerk model are two).
The machine at Holz-Handwerk, above, was equipped with a five-axis and a three-axis main electrospindle, an additional three-axis spindle; 38 vertical spindles, 12 horizontal spindles and a 0-90o 160mm saw in the drilling head (boring uses Ro.Ax ‘no clearance’ technology) and an H80 edgebanding unit. Available working areas run from 5020-6360mm in the x axis, 16051830mm in the y axis and 220mm (80) in the z axis. Details: 0115 977 0044.
Right and above right. Zero setup time and concise graphics that show exactly the task being performed make the Morbidelli Planet P800 fast and efficient.
28 • FURNITURE JOURNAL MAY 2016
REVIEW
Look! No guards! Masterwood's mini K-Series nesting machine is tiny but super efficient.
mini
marvel Looking for an entry level nesting machine with a compact footprint? Masterwood's MW 12.25 K-series might just be the answer.
I
Top: With the 1250 x 2550mm bed machine comes an 8-14 position toolchanger. Bottom: Three-axis machining with the option of aggregate heads for edge working.
f it’s a small footprint, entry level CNC machining centre you’re l o o k i n g f o r, t h e M a s t e r w o o d MW 12.25 K-series shown at Holz-Handwerk 2016 might just be the ticket. The smallest in a stable of four machines (MW 12.25K, MW 15.38K, MW18.38K and MW 21.38K), the MW12.25 K-series is primarily designed as a flatbed nesting machine. Driven by Masterwood’s own intuitive Masternest software (part of Masterworks), the CNC machining centre shown at Holz-Handwerk had three axis control and was equipped with a 1250 x 2550mm (12.25 model) matrix table for nesting operations in wood and wood-based panels, plastic or
composite materials. It can be equipped with aggregate heads for edge working, optional outfeed and infeed tables, or an automatic unloading system that converts it into a work cell with very high productivity for furniture and panel machining. Especially suited to small or medium-sized companies, the Nesting K-series guarantees easy access from all four sides thanks to safety buffers replacing normal cages and mats. For maximum flexibility and safety, there's little to rival this mini marvel. Masterwood will be running demonstrations on a CNC at the AMS “Woodfest” open house on 17th to 19th May. Further details: 01293 402700.
See Masterwood 5 axis CNC and Software Demonstrations at AMS WoodFest 17-19 May 2016 www.advancedmachinery.co.uk
Masterwood will be featuring the 5 axis Project 265 at the AMS “Woodfest� Open House in May. The low cost entry level Project 265 will run various demonstrations for solid timber and panel work.
Master 3D software will be demonstrated during the show for 3, 4, and 5 axis work
MasterSoftware New Master 3D software allows our 5 axis CNC machines to be used to their full potential, including checking for any possible collisions with full 3D visuals in real time. This reduces programming and machine setting time to a minimum. For more information please contact : Masterwood GB Ltd Phone : +44 (0) 1293 402700, Mobile : +44 (0) 7930 407084 E-Mail : davek@masterwoodgb.co.uk - www.masterwood.com
30 • FURNITURE JOURNAL MAY 2016
REVIEW
Three machines in particular impressed the crowds on the Felder stand at Holz-Handwerk.
felder’s trilogy
F
rom a packed stand at HolzHandwerk, Felder unveiled its portfolio of machines for the smaller specialist user - and the stars of the show at the smaller end were the compact Tempora edgebanders, the now popular H08 machining centres and the Classic sander. Felder believes edge processing must be as fast, easy and efficient as possible. To achieve this, the new Tempora models combine speed, productivity, flexibility and ease of use in a convincing overall package. Heavyweight edge processing units and an optimised machine body ensure absolute stability even at high processing speeds, while user-friendly control - X-Motion Plus and E-Motion ensure repeat accuracy and ensure minimum set-up times and fast material changes. Two processing packages, Professional and Performance, enable the Tempora to be adapted to suit your exact processing requirements. The Tempora, with its single (60.08) or twin-engine (60.12) double corner rounding units,
adds a new dimension to edge processing in the post and soft-forming areas in particular. Corners with different profiles can be machined in a single operation using continuous edging material from 0.4 to 3 millimetres and solid wood strip material up to 12 mm on workpieces from eight to 60mm. Feed rate is up to 20 metres per minute. Two counter rotating, separately operating and controllable premilling units with diamond-tipped spiral jointing cutters make for first-class edge processing, ensuring tear-free edges with laminated workpieces. The teflonlaminated glue pot can be changed in record time without tools, reducing set-up times, even when switching between EVA and PUR edge processing. For many years, Format-4 wide belt sanding machines have been characterized by solid construction, highquality system components and excellent results. At Holz-Handwerk, the premium model series, Finish, was expanded to include two additional wide belt sanding machines: the Finish 1350 classic and the
Finish 1350 classic gloss. Brand new are a combined super-finishing unit with chevron band and segmented electropneumatic sanding shoe and a touchscreen control, which enables the saving of different sanding pressure settings for different jobs. Five different sanding units and numerous individual optional extras are available. Visitors interested in a CNC machining centre crowded around the Profit H08 - a machine that has become the benchmark for smaller users wanting to process panels with CNC technology. Launched four years ago, it now sports numerous options, among them off-loading tables, vertical and horizontal drilling aggregates, matrix tables for nesting, or pod and rail beds for solid wood processing. Designed primarily with nesting operations in mind, the rigid construction of this small footprint CNC machine ensures high quality machining and drilling of all wood-based panel products. For more information call 01908 635000 or visit www.felder-group.co.uk
FURNITURE JOURNAL MAY 2016 • 31 The Format-4 control options on the Tempora edgebander, X-Motion Plus and E-Motion, provide ease of use and intuitive control of all central control unit settings. Selfexplanatory symbols and clearly arranged menu navigation on a 10.4" colour touch screen make operation of the Tempora very easy.
Felder’s Format-4 H08 was originally designed for nesting operations but the versatility of this small footprint machine means it can be equipped with pods for solid wood processing.
The innovative unit arrangement of the new Finish 1350 Classic wide belt sander and the motorized adjustment of the contact rollers (accurate to within hundredths of a millimetre) are controlled directly from the panel ensure maximum productivity. The brushing device fitted on the extending side can be equipped with a variety of brushes and cleans, polishes or structures workpieces. The feed rate can be continuously adjusted to different surfaces from 3 to 20 metres per second. The sanding shoe in the combination unit is designed for fine, veneer or lacquer sanding depending on the design and adapts perfectly to the workpiece contour. An optical sensor controls the sanding belt oscillation without any contact, thus ensuring optimum centring and high running smoothness.
32 • FURNITURE JOURNAL MAY 2016
REVIEW
im-press-ive
The new Performer press made its debut on the Columbus stand at Holz-Handwerk.
performer The new Performer press from Columbus made its debut at Holz-Handwerk - and it has some impressive features.
T
Top: Simple to use, absolute control - what more could you ask for? Bottom: The pre-heating drawer will also make this press a firm favourite for forming solid surfacing materials.
he new Performer press from Columbus is a real star and it's in a class of its own. Well-suited to both single component and batch production, the Performer will press dĂŠcor foils or laminates (both high gloss and the new breed of satins and supermatts) as well as offering sublimation, vacuum forming and laminate bending. With its bed size of 1480mm x 2800mm, the Performer will also do real time three-dimensional forming of up to 900mm x 2700mm and it's stroke of 600mm means this impressive, compact machine is competing directly with presses in the 250-500,000 Euro range. Ideal for workshops that offer an all round service, or have a demand for samples for large size workpieces, the Performer offers huge advantage for lamination onto wood-based panels - but it also has an ace up its sleeve for thermoplastic forming, too: the Performer has a system that provides a constant hot air
stream, preventing unwanted cooling of plastic materials during processing. The pre-heating drawer will also make this press a firm favourite for forming solid surfacing materials, as it copes easily with materials of up to 12mm in thickness. It can be equipped with an optional ionisation unit, if required, eliminating issues caused by static electricity. The Performer is one of the first in a new line of vertical presses for Columbus. The company has made a conscious decision to move away from clamshell design in the belief that the vertical design of its newest presses gives better performance. The Performer exerts 1kg of pressure per square centimetre evenly across the bed and employs Festo pneumatics rather than potentially leaky hydraulics. It really is an impressive performer. For more information please call Columbus on +43 5332 72 468 or visit www.columbus-tech.com.
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FURNITURE JOURNAL MAY 2016 • 35
REVIEW
edges
Accelerated by conditions in a steam oven at 85 degrees, the edgeband glued with EVA fell off in just ten minutes.
to pur over Zero glueline has been the holy grail for a number of years but achieving it in the factory is no guarantee of long-term customer satisfaction if it isn't done the right way, as Holz-Her's Angelo Amico demonstrated at Holz-Handwerk.
T
ake a close look at the picture above. This was a perfectly good MFC panel, edged with a perfectly good edgeband using a reputable brand of EVA adhesive on one of the latest generation edgebanders. It might have been expected to give years of trouble free service in a lounge or a dining room but simultaneously subjected to heat and moisture, the edgebanding didn’t have to be prized off, it simply fell off. And, accelerated by conditions in a steam oven at 85 degrees - conditions not unlike a hot bathroom environment - it did so in just ten minutes. This very graphic demonstration by Holz-Her’s Angelo Amico is the party
piece he uses to show would-be purchasers of Holz-Her edgebanders why, if you want the holy grail of a waterproof zero glueline between your panel edges and your panel surfaces to remain perfect long after your furniture has left the factory, and you are manufacturing kitchen furniture, bathroom furniture, or furniture for any hot and humid environment, you need to be casting aside old school ideas and prejudices and switching to a PUR adhesive. “Most customers are not aware of the difference between a PUR and an EVA adhesive,” says Angelo, who is the Product Manager for Holz-Her based in Nürtingen. “We want to focus on how important PUR is for achieving a near
Angelo Amico
36 • FURNITURE JOURNAL MAY 2016
Above: Holz-Her’s solution for the application of PUR is the GluJet system.
Right: Uniquely, if you also want to apply laser edges, Holz-Her’s Ltronic laser unit can be exchanged for the GluJet in a few seconds.
invisible glueline on furniture that will go into bathrooms, or other damp environments. It is the only realistic option because PUR reacts chemically with humidity. If the edgebanding has been properly applied, after 48 hours, it is so well sealed you will break the material before you will break the bond.” Holz-Her’s solution for the application of PUR is the GluJet system, a system that copes with higher viscosity PUR adhesives and facilitates easy cleaning. Cleaning the glue station before switching adhesive, or at the end of a shift, is something manufacturers who have adopted PUR often see as a downside. With some systems, it’s not a quick job and it’s not something that can be given cursory attention because, once exposed to moisture, PUR will begin to harden quite quickly. Even a small amount left in a glue application system can impair its performance. With the
Holz-Her GluJet system, it takes only the press of a button at the end of a shift to release a PUR neutralising agent that purges the entire system. How well the adhesive is applied can also have a bearing on its performance. “With a PUR adhesive, it’s very liquid, like honey,” says Angelo. “There's a much better chance of penetration into the panel itself if you apply PUR with a GluJet system because the glue is applied in strips 1mm apart. If you look at the strips of glue close up, it’s like small mountains and valleys [furrows in a newly ploughed field] across the width of the edge, so not only does it penetrate the board, it squashes out in two directions to seal the edging to the panel and provide a waterproof glueline between the edge and the surface of the board.” Holz-Her is currently running a campaign, which is specifically for manufacturers who want to switch to
PUR GluJet technology. Included in the campaign are the economically priced Streamer 1054 (White Edition), the Auriga 1308 and 1308XL, the Sprint 1327 and the Sprint 1329 (Black Editions). “All these PUR models are based on our best selling machines, except everything you need to work with PUR adhesives is included on them,” assures Angelo. “We’re also offering a multi-tool package that will do radius one, two, three, 45 degree and 8mm flush-trimming as well as multi-stage that includes trimming, corner rounding and a scraper unit as a package. It comes with revolver technology that makes constant profile changes within small production lots very easy.” For more information on how to make the change to PUR (and still retain the facility to use other adhesives at the push of a button), call Holz-Her on 01235 557600 or visit www.holzher.co.uk
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38 • FURNITURE JOURNAL MAY 2016
REVIEW
fit for p C Matching the adhesive to the end use of the product will go a long way towards eliminating problems - and returns. Bradly Larkan from the adhesive specialist Kleiberit offers a few pointers.
hoosing the right adhesive for the job might seem obvious but many of the problems with edgings delaminating, or panels and doors deforming at the edges, are the result of the wrong choice of adhesive during manufacturing. The point is made very clearly with the two examples on this page: exposed to water, the EVA adhesive used to apply the edge to the white panel didn’t seal the edge and allowed water ingress, which swelled the chipboard; bonded with PUR, exposure to water made no impression on the edges of the panels in the other picture. No single adhesive offers a panacea, though some technologies are more versatile than others. It’s up to you to know the end use of the product and make the right choice. “There are two main reasons that govern choice of adhesive,” explains Kleiberit's Bradly Larkan. “Performance and aesthetics - and it's the end use that should drive the decision. Normally, producers who are making doors and panels for kitchens and bathrooms require a high performance finished product that will withstand high temperatures and high humidity. The choices available from an adhesive perspective are Ethylene Vinyl Acetate
(EVA) technology, Polyolefin (PO) technology, or Polyurethane (PU) technology. EVA performance levels are ideally suited to household furniture items but their performance-limiting factor is that they are thermoplastic. They will perform differently under hot conditions, for example near an oven, or a radiator, depending on the softening point of the particular adhesive you choose. “Polyolefin (PO) technologies have a very high heat resistance, which you might think would be ideal for kitchens, but their weakness is the bond performance in high humidity conditions. Polyolefin technology, even though inherently hydrophobic when used in edgebanding, shows limitations in damp conditions or high humidity and hot conditions - for example where kettles are likely to be used. Therefore, Polyolefin technology would not be the best choice for use in bathroom furniture from the standpoint of humidity resistance of the bond. The better solution would be Polyurethane (PU) adhesives because, once cross-linked, Polyurethane gives the highest performance, penetrating the substrate and chemically bonding the edge to the panel, thereby providing the finished piece with very good water resistance.
FURNITURE JOURNAL MAY 2016 • 39
urpose “From an aesthetics point of view, the target is always zero glueline. All three technologies have their pros and cons. It is possible to achieve a very thin glue line with an unfilled EVA, or an unfilled Polyolefin. However, even though these unfilled options give a high performance rating in this aspect, they are still thermoplastic in design and will still perform poorly in dampness or heat. Reactive polyurethane adhesive on the other hand, applied with the same coat weight, consistently has a higher performance. Furthermore, due to its polarity and ability to chemically react with the hydroxyl groups (which are typically found in wood-based substrates), it is possible to reduce the coat weight without sacrificing performance. Summarising this, PU adhesives are the right choice on your path to the invisible glue line. “All the technologies are available in various grades that vary in viscosity from low to high, and from low, or non-filled products to highly-filled products. Depending on the end requirement, if you want the thinnest glue line, you need the lowest viscosity and that comes from an un-filled product. If the driver is cost, then a filled product might be the better choice. The flip side with a filled
product is you have to apply more to get the performance and that results in a thicker glueline. You need to decide what's right for you.” The choice is vast but Kleiberit’s specialist engineers and sales people can help you make the right decision. “We have field-based sales engineers, who are highly qualified and can support on-site productivity improvement, helping to improve your processing and, if necessary, helping you to get more out of the machines you have. If need be, they will look at every aspect of your production and it’s surprising how things you probably wouldn’t think of - things like repositioning an edgebander away from a door so the adhesive doesn’t cool every time it opens can have a significant effect on the way the adhesive and, ultimately, the finished product will perform.” Kleiberit supplies EVA, PO and PU technologies in different colours to match the most popular edgings in the marketplace. Pack sizes are available to suit every possible manufacturer from small, 300 g cartridges all the way up to 200 kg drums with delivery in the week of order on ex-stock items. To find out more, or to discuss a particular adhesiverelated problem, call +44 1530 836699 or visit www.kleiberit.com
The two pictures above illustrate how, if the edging on a panel is applied with EVA and the panel is subsequently exposed to water, it allows water ingress and the chipboard swells - but when the edging is applied with PUR, it remains well bonded, even in extreme conditions such as complete water immersion.
Bradly Larkan
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FURNITURE JOURNAL MAY 2016 • 41
REVIEW
Fusing the edgebanding to the surface of the board provides the ultimate zero glueline but if you‘re using EVA or PUR, there's plenty you can do to get it close to this.
resolving edge issues Is a zero glueline finish evading you? Biesse UK’s Robbie O’Neill talks about some possible reasons and presents Biesse’s ultimate edge solution.
A
rguably the most misunderstood part of an edgebander, the glue roller plays a major role in both the quality and the thickness of the glueline, yet many operators set this critical component incorrectly without realising. The result can be as ugly as it is frustrating. According to Biesse UK’s Commercial Manager, Robbie O’Neill, a good glueline should be 0.2mm (unless you’re using PUR, if it's any thinner the bond strength could suffer; any thicker and the glueline will be too obvious) but for various reasons, many operators find it difficult to achieve. “There can be a number of reasons for this,” explains Robbie. “If we look at the panels themselves, nowadays almost
65% of chipboard is made from reclaimed timber and that creates a lot of dust. Dust is very abrasive. As it’s channelled across the surface of the board it leaves a witness mark and that can be the start of problems with the edge. Because a lot of the substrate in the centre of the chipboard is looser bound, as we apply glue onto a board we draw loose chips onto the glue roller. These tend to sit on the roller and eventually they’ll jam in the gate. They show as a black line on the glue roller and the result is the roller doesn’t apply as much glue to the joint. When the operator sees this, the natural reaction is to add more glue, which
Robbie O'Neill
42 • FURNITURE JOURNAL MAY 2016
A realistic alternative to laser technology at 10% of the cost is Biesse's Airforce.
results in a thicker glue line - sometimes as much as double what it should be. If you are working with EVA, you need 280-310g per square metre to get a good bond. With PUR, you need much less - between 180-210g per square metre. “When adding more glue doesn't provide the result they are looking for, that's when operators start adjusting the roller, assuming something is wrong mechanically. It usually makes things worse because there doesn't need to be a lot of glue on the roller for it to do its job well. Most people go by feel when they’re adjusting things and sometimes operators get involved too much. Glue weight adjustments aren’t too obvious on Biesse machines. Once set, they don’t need adjusting. The main problem arises because most people don't realise the glue roller should never make contact with the panel. If it does, the glue is squeezed out. The glue roller is set 0.2mm away from the panel, which enables the glue to be ripped off the roller and spread across the edge. You’d be surprised how many companies I go into where the glue roller is touching.” In an effort to alleviate this particular problem, Biesse’s designers have made the
contact point on the Biesse Stream e d g e b a n d e r l o n g e r s o i t ’s m o r e forgiving - and Biesse UK has embarked on an education programme to help operators understand their machines better and show them why, once the glue roller has been set in the factory, it shouldn’t be adjusted. For the ultimate zero glueline, however, some of the bigger budget furniture manufacturers have gone down the laser route. With a properly set up machine and the right edgeband, the result is near invisible, fused edge joins. However, appreciating not all manufacturers can run to the cost of a laser machine, Biesse has come up with an alternative to the laser that utilises hot compressed air and will run conventional edgebandings with EVA and PUR adhesive as well as laser edges. Called Airforce, it is providing solutions not only for those who want laser comparable edges with no joint, no glue line and perfect fusion, but also for manufacturers who want to cut the cost of painted doors by edging them ahead of lacquering. “We no longer sell laser technology,” says Robbie. “Airforce technology is about 10% of the cost, it gives comparable results and it’s simpler to look after. In Milan we’ll be running
Airforce at 30m/min as standard. At the rate technology is developing, we’ll soon be up to 60m/min. “To get the best out of Airforce, you need to make sure you have the right tape. There are two types of tape: one has a form of glue on the back while the other uses a polypropylene. The PO is cheaper, so people will use the cheaper tape and expect brilliant results. That doesn't always happen. In reality, they need to start with the best, see if it does the job, then experiment and see if the PO back layer suits.” The Airforce system can be used with co-extruded PP+PP, PP+ABS, PP+PVC or PP+PMMA as well as preheated TPU or pre-glued edgings with thicknesses of 1-3mm. It is claimed to offer optimum resistance to heat and humidity and requires no anti-adhesive or anti-static agents. Air force is currently available on the single-sided Biesse Akron 1400 range of edgebanders (the entry level Akron 1300 series will be shown with Airforce at Xylexpo) as well as the automatic industrial Roxyl line (now rebranded Stream A) and the Biesse Stream range. For more information call Biesse UK on 01327 300366, email info@biesse.co.uk, or visit www.biesse.com
Increase your panel productivity! Complete turnkey production lines, together with integrated Biesse Group solutions and software. With over 300 systems installed globally, Biesse can help you realise your potential. A perfect combination of Biesse Group’s experience and Italian genius. T: +44 (0)137 300366 info@biesse.co.uk
biesse.com
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www.edgeband-finder.co.uk The perfect edgeband for your project. An individual edgeband range directly from stock. • Décor combination with 10,000 board surfaces • Numerous dimensions • Precise printed image and natural embossing • Short lead times • Worldwide availability from a single roll
SURTECO UK Ltd. · Widow Hill Road, Burnley · Lancashire BB10 2TB · UK Phone: +44 1282-686861 · Fax: -412361 · info@uk.surteco.com · www.surteco.co.uk
KSP_ANZ_210x149mm_EN_2016_DR.indd 1
19.01.16 15:56
FURNITURE JOURNAL MAY 2016 • 45
REVIEW
easy edging
Döllken enlisted the help of students and an edgebanding machine to illustrate you don’t have to be a big user to take advantage of Döllken’s range of edgebands.
S
urteco Group member Döllken chose Holz-Handwerk to demonstrate to the crowds that you d o n ’t h a v e t o b e a b i g u s e r o f edgebanding materials to be a Döllken customer - and that Döllken’s offer includes high-tech options as well as more widely used edgebands in every conceivable colour. “We’re here to show our complete KSP stock programme,” commented Dennis Kathage from a packed stand. “We are able to offer more than 1400 different colours and designs in different dimensions from stock. “Demand is especially high for products that provide an edge that has been seamlessly bonded. Our main focus on the stand is the Döllken Fusion Edge. A lot of people think Fusion Edge is a product that’s exclusively for larger
companies that have laser edgebanders. We want to convey the message that if you are a smaller user and you only want one roll at a time, we can supply a single roll for all modern zero-bondtechnologies direct from stock.” To illustrate the point, the stand was given over to a demonstration: using a simple edgebanding machine, two students showed how easy it was to apply a perfect edge every time. Both were applying a special ‘Holz-Handwerk 2016’ edgeband that had been printed digitally with the names and logos of compatible Fusion Edge technologies, including Laser, Hot Air, Near Infra Red and Plasma, Döllken is offering within one product. For more information on the full range of Döllken edgebands call 01282 686850 or visit www.doellken.co.uk
46 • FURNITURE JOURNAL MAY 2016
clean edging It doesn't matter how good your edgebander is, if the finished product doesn’t come off the machine immaculate, you might need to look at your surface cleaner.
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e’ve all seen it and experienced it at one time or another: glue that's not where it's supposed to be on an otherwise perfectly edged product. With the new R e d o c o l Te c l i n e x O n e - f o r - a l l , Ostermann provides a solution in the form of a new generation of inline surface cleaners that's been developed for use on all common plastic surfaces. Optimum milling and cleaning results are assured, say Ostermann, when used in automatic edgebanding machines. Suitable for ABS, Acrylic, PVC, PP, aluminium, melamine and real wood, and extensively tested on edgebanding machines using EVA hot melt adhesive, PUR adhesive, as well as machines with hot-air and laser technology, the name One-For-All tells you immediately where Redocol Teclinex can be used: at each section of the edgebander. Advanced chemistry allows the residuefree cleaning of EVA hot melt adhesive,
PUR adhesive and contact adhesive. At the same time the product can be used as a release agent for dirt and glue. Residue-free drying means no problems when post forming and the absence of silicones means over-painting is possible without any problems. Redocol Teclinex One-For-All is based on a vegetable-based alcohol (wheat distillate) and contains no emulsifiers or Formaldehyde. The legally required environmental details are clearly displayed. At the same time, compliance with the Hazardous Substances regulations is simplified due to lower inventory levels. Redocol Teclinex One-For-All is available in many pack sizes. The practical two-litre container can be used in commercial spray systems. For further information, see the new Ostermann catalogue, call 01905 793550 or visit www.ostermann.eu.
Ostermann: always matching Are you looking for the matching edging? Find a whole world of matching edgings at Ostermann!
Edgings pre-glued with hotmelt adhesive upon request
Europe‘s largest edging range
2 % discount on every online order (Shop and App)
Edgings from 1 metre
2%
1m
Edgings in every width up to 100 mm The largest Cross-ReferenceList in Europe with over 120,000 matches Edgings in various thicknesses MEL
All orders placed before 4.00pm are delivered within 24 hours
ABS ACRYL ALU
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Edgings in ABS, Melamine, 3D acrylic, Aluminium, Real wood veneer
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Airtec edgings despatched after 4 working days
Laser edgings despatched after 4 working days Infratec edgings despatched after 4 working days
United Kingdom
Phone: 01905 793 550 · Fax: 01905 793 559 sales.uk@ostermann.eu · www.ostermann.eu
Ireland
Phone: 0044 1905 793 552 · Fax: 0044 1905 793 559 sales.ie@ostermann.eu · www.ostermann.eu
48 • FURNITURE JOURNAL MAY 2016
A 27 RV four-section modular filter by Dustraction is mounted on a steelwork support and discharges all waste at GP Cases via a Dustrax 33 floor-mounted, heavy-duty fanset.
dustraction
on the case When GP Cases wanted to combine a new dust filter and extractor with the installation of a biomass heating system, they called in Dustraction
Wood and panel dust, along with chips, are now being transported into a storage silo automatically and fed into a biomass boiler from Wood Waste Technology.
U
pgrading to a new dust extraction system for their 20,000 sq. ft. factory in Royal Wootton Bassett, GP Cases wanted dust extraction and waste wood fuel to be chipped, integrated and conveyed into a purpose built storage silo to feed a biomass boiler that would generate heat and supply hot water to radiators throughout the factory buildings and offices. “The old extraction system was inefficient and very labour intensive,” says MD, David Waldron. “Filtered waste was discharged into plastic bags which, as they were filled, were taken off outflows manually. The bags were replaced and the waste then taken outside to a skip for dumping to landfill. This, together with the disposal of offcuts, represented at least five manhours per week.” T h e n e w s y s te m , in s talle d by Dustraction with a biomass boiler from
Wood Waste Technology, converts waste into fuel using a chipper, transporting it along Dustraction’s ductwork to a filter system and up an inclined conveyor to a new purposebuilt storage silo. Dustraction replaced all ducting mains throughout the factory, transporting waste from around a dozen individual machines via noise reducing, aerodynamically designed branch ducts on tapered sections. Fully enclosed fans on anti-vibration mounts reduce break-out noise to an absolute minimum. Dustraction’s filter system comprises more than 1,000 sq ft of cloth with a filtration velocity of around 2.38m/min and an automatic shaker system. To find out how Dustraction could help improve the environment in your factory, call 0116 271 3212 or visit www.dustraction.co.uk
USING SPACE INTELLIGENTLY MEANS RETHINKING CORNERS. Although many kitchens all over the world are designed around corners, the existing storage space is often not utilised to its full potential, and is neglected or even completely ignored. Vauth-Sagel thinks differently, Vauth-Sagel thinks innovatively: with our CORNERSTONE system solutions, we bring the corner cabinet out of the corner. CORNERSTONE moves the entire contents in front of the cabinet, unlocking completely new possibilities: Since so much storage space can now be reached with one easy movement, the corner cabinet is turned into the kitchen’s new centrepiece.
RETHINKING THE CORNER. CORNERSTONE. The new corner cabinet solutions by Vauth-Sagel.
Scan and discover CORNERSTONE
Available from
www.hafele.co.uk