Panel & Joinery Production - July/August 2014

& JOINERY

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July/August 2014

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CONTENTS

& JOINERY

PRODUCTION July/August Issue 2014 Published by:

EC Media Services 76 Victoria Avenue Westgate on Sea Kent CT8 8BH

Telephone/Fax: E-mail: Website: Publisher: Designer:

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Reproduction of articles: All material appearing in Panel & Joinery Production is strictly copyright, and all rights are reserved.

No part of the publication may be copied or transmitted in any form whatsoever, including photocopying, without the prior permission of the publishers.

Innovation in design is always at the forefront of Decorative Panels minds with continued development in the latest surface, textures and finishes.

See page 24 for further information.

Publishers’ note: The editorial opinions expressed in Panel & Joinery Production are not necessarily those of the publishers, who shall be under no liability with respect to any article published herein.

Distribution: Panel & Joinery Production is published six times a year and circulated to designers, individual purchasers and specifiers who are manufacturing within the wood-based panel, board and solid wood industry in the UK and Ireland. Annual subscription is at the following rates, which include postage: UK & N. Ireland Mainland Europe Elsewhere

£18.50 £34.00 £38.00

© Copyright EC Media Services ISSN 2046-4134

CONTENTS 2 6-7 8-9 10 14-15 18-19 26 30 31 32 34 35 36-37 38-39 42-43

News Make A Difference Holzma Beam Saw Delivers Increased Productivity New Gabbiani Galaxy 3 Beam Saw A Question of Quality Curved Seating Pods Made Easy With AlphaCam This Is The Future AXYZ Router Doubles Production At Porter & Woodman Rover Skill GFT Nesting Cell Fourth Combilift For Cranwood Industries Vollmer Takes Saw Blade Processing To The Stars Outstanding Artisan Sander Range From Viet Bütfering Delivers Time Savings & Finish Quality For Hazlin DMC’s New System TE For Complete Flexible Sanding Dustraction At The Movies

See our website and interactive magazine www.p-j-production.com

FEATURES 6-7 8-12 14-17 18-21 24-26 33-34 35-40 42-44 IBC

W14 EXHIBITION SAWS EDGEBANDERS SOFTWARE DECORATIVE SURFACES TOOLING SANDERS DUST CONTROL WEBSITE DIRECTORY JULY/AUGUST 2014 Panel & Joinery Production

1

NEWS Xylexpo Success Xylexpo, the biennial International Woodworking exhibition, proved successful with visitor attendance over 5 days of 15,250; up by 7.1% compared to 2012.

Xylexpo, the biennial International Woodworking exhibition, proved successful with visitor attendance over 5 days of 15,250; up by 7.1% compared to 2012.

Premiere Kitchens Honoured with Sustainability Award 2014 The Furniture Makers’ Company, the furnishing industry’s charity and patron, is delighted to announce that Premiere Kitchens has received its Sustainability Award 2014.

Premiere provides cost-effective kitchen and furniture solutions for residential developments, hotels, key worker accommodation, care homes, universities, schools and the MOD. Established more than 20 years ago, Premiere is one of the leading companies of its kind in the UK and its success is based on delivering costeffective, design-led solutions tailored to suit its customers’ specific needs.

Two more finalists, Boss Design and Hypnos Beds, were highly commended, Boss for its people-orientated management style, and Hypnos for its responsive, customer-driven approach.

For further information: Tel: 020 7256 5954 Email: marketing@furnituremakers.org.uk www.furnituremakers.org.uk

BeA Achieves Globally Recognised Quality Standard BeA Fastening Systems, the specialist manufacturer of fastening tools, technology and consumables for the furniture production industry, has successfully achieved ISO 9001 2008 certification.

BeA was awarded its certification following an in-depth assessment conducted by BM TRADA – an appointed service provider to FIRA (Furniture Industry Research Association) member associations.

Anderson Acquires Giben Anderson Industrial Corporation has announced the acquisition of Giben International of Pianoro (Bologna).

Recognised throughout the world as a leader and innovator in panel saw technology and panel production processing, the two companies have grown closer together.

Anderson is a global leader in CNC processing technology for the manufacturing industry and combined with the world class technology of Giben Panel Saw technology and processing knowhow, the Anderson Group with Giben will combine as a powerful contender offering products and expertise to the world markets.

PJP hopes to give readers more information in our September/October issue.

Xylexpo Innovation Awards The award in the ‘Innovation’ category was awarded to the Homag Group followed by the Biesse Group and the Cefla Group .

In the ‘Communication’ category the first place was given to Salvador, followed by runners up the Homag Group and the Biesse Group at number three.

Certification Made Easier Norbord Europe has enhanced the impressive green credentials of its engineered wood-based panel products by extending the Programme for the Endorsement of Forest Certification (PEFC) Chain of Custody certification to UK sites as well as applying for a Group Forest Stewardship Council® (FSC®) certification.

Norbord Europe and Norbord BV now operate on the same FSC® certification

and the successful PEFC application permits the company to sell PEFC-certified board in the UK. Both FSC and PEFC certifications illustrate that Norbord's products originate in forests that operate in an environmentally sustainable way, and are not derived from illegal logging or destructive forest management practices.

Both these certifications require a comprehensive audit trail of timber sources to show independent auditors that they come from sustainably managed forests from around the world.

For further information: Tel: 01786 812 921 www.norbord.co.uk

Where To Go IWF August 20th – 23rd Atlanta, USA W14 October 5th – 8th NEC, Birmingham Timber Expo October 7th – 8th NEC Birmingham SICAM October 14th – 17th Pordenone, Italy Expobois November 17th – 20th Paris, France 2015 ZOW February 9th – 12th Bad Salzuflen, Germany Interzum May 5th – 8th Cologne, Germany Ligna May 11th – 15th Hannover, Germany

DON’T FORGET READER REGISTRATION www.w14exhibition.com 2 Panel & Joinery Production JULY/AUGUST 2014

See our website and interactive magazine www.p-j-production.com

NEWS Top Tips for Running a Joinery Business from BWF Everything you have ever needed to know about running a joinery and woodworking business is now available in paperback.

Fundamental areas that drive business success have been condensed by the British Woodworking Federation (BWF) into a step-by-step guide to keep joinery firms ahead of the game.

BWF’s ‘Guide to running a joinery business’ offers advice on creating a business plan and how it can be a significant tool in securing funding, setting achievable goals, and looking at the past, present and future of the business. It also identifies the importance of knowing your industry and what you should be looking out for.

Joinery businesses have many strict regulations to adhere to in addition to their legal responsibilities as an employer. Therefore they need to be on top of all the latest news and regulations to know what affects their business and what potential changes may be needed.

Training is covered too. In the past year there have been many changes to building regulations and other legal requirements affecting the joinery industry, most recently the updates to Part L. It is the responsibility of an employer to ensure their staff are kept up to date on these changes and receive the relevant training.

The remainder of the guide looks at day-to-day responsibilities of running a joinery business including managing workload, managing cash flow, health and safety, wages, taxes, holidays, maternity or paternity leave, and sick leave.

The ‘Guide to running a joinery business’ is available as a free download for BWF members: http://www.bwf.org.uk/publications/general-business-support

FEATURE More New Technical Reps For Leitz Tooling: West Midlands and North West As part of its ongoing recruitment drive, Leitz Tooling UK has announced the appointment of two more technical sales representatives for the North West and West Midlands regions.

Gerard Maloney and Marco SangerCaizzo bring nearly 50 years’ combined experience of British joinery and furniture manufacturing industries to Leitz’s national service and technical support team.

Covering North West England, Gerard ran his own joinery manufacturing and contracting business for over 15 years before bringing his end-user experience and practical expertise to Leitz Tooling.

Having started his working life as a wood machinist, Marco worked as a building contractor and has long experience in cabinet production for a large furniture manufacturer. His position as production director for the firm gave him invaluable expertise which he now shares with Leitz’s customers in the West Midlands.

Leitz Tooling’s UK managing director, Simon Liddell, said “All businesses need

excellent skilled people, and we warmly welcome Marco and Gerard as our latest technical sales representatives for the West Midlands and North West areas respectively. Leitz customers enjoy a huge range of benefits, and a major one is the hands-on experience of our representatives in their respective industries.” Leitz as a company embrace fresh blood and currently have trainees and apprentices recruited from local colleges within their workforce. “We always look for good people to join the team, and part of this process means working with local colleges on their apprenticeship schemes. We meet very bright young people interested in our business, and this has resulted in more new blood coming into our fold.”

At Leitz’s Harlow head office, the company holds bespoke company seminars on a regular basis to help its customers become more profitable and effective in terms of production.

Leitz Tooling UK is the largest supplier of tooling to British industry and the family-

Leitz new technical sales representatives L-R Marco Sanger Caizzo and Gerard Maloney

owned business is the largest manufacturer of tools for woodworking worldwide. The company provides full nationwide service and technical support with regional representatives and supports its products with the Leitz-Lexicon; one of the most comprehensive and informative publications in the industry.

For more information: Tel: 01279 454530. http://shopuk.leitz.uk

Field Service Technician Retires from SCM Group UK

BWF Appoints New Technical Liaison Manager

Mick Bullers, a Field Service Technician with SCM Group UK, has retired after reaching age 65. Joining SCM in 1994, Mick gave over 20 years loyal service. He was previously with Wadkin Agencies.

Mick specialised in Panel Beam Saws, installing, commissioning and servicing them, but also worked in the Solid Wood Machine Team that included Planer Moulders, Tenoners, etc.

Mick resided in Leicester and was a keen Leicester City fan having a season ticket for many years and is ecstatic his beloved team has just been promoted to the Premier League. In retirement, Mick will be visiting family in Germany followed by some more travelling abroad SCM UK's Service Manager, John Allenby, comments: "Mick Bullers was a key member of SCM's service team and will be greatly missed and we wish him a long and enjoyable retirement."

The British Woodworking Federation (BWF) has appointed a new technical liaison manager to keep on top of its technical advisory service for joiners and woodworkers.

Hannah Mansell joins the technical team following former technical officer Chris Addison’s retirement. Hannah will be responsible for providing both BWF members and non-members with up-to-date, accurate technical advice and responding to their queries.

With a wealth of experience of timber and joinery manufacture Hannah has worked for both large and small companies and has extensive knowledge of manufacturing, developing and testing of joinery products and providing engineering support and project management solutions.

For further information: Tel: 0115 9770044 Email: scmgroupuk@scmgroup.com www.scmgroup-uk.com

4 Panel & Joinery Production JULY/AUGUST 2014

For further information: www.bwf.org.uk/toolkit/technical-woodworking-support

See our website and interactive magazine www.p-j-production.com

The ultimate sanding machine Standard working widths: 650 mm, 1,100 mm, 1,350 mm and 1,600 mm (1,900 mm and 2,200 mm available on request).

All machines have a fixed working height (it is the sanding group that adjusts from 3-200 mm with 400 mm available on request).

Enormatic ‘smartset’ standard on all machines for ease of setting and registering off the highest point across the full working width.

All machines now incorporate ‘Eco’ energy saving mode.

All machines have both colour touchscreen and manual control elements.

For solid wood, veneer and lacquer sanding.

Choice of cutterblock, combi unit, calibrating roller, standard pad, electronic segmental pads and cross belts for veneer or high gloss.

Premium: Traditional style straight line sanders with 1 to 3 sanding heads for solid wood and veneer sanding.

Brilliant: For the utmost in surface finish using oblique sanding technology where at least one of the sanding heads is placed to give a shear cut across the surface effectively cutting away surface fibres, eliminating oscillation marks whilst giving a flatter surface and suitable for solid wood, veneer and lacquer sanding.

Available with single or multiple sanding heads.

TECHNIC RANGE Technic CNC

For heavy stock removal and for shaping the surface

Technic BOTOP

Top/bottom sanding machines

Technic Precision

Sanding accuracy of 0.02 mm

Contact us for the latest developments in wide belt sanding technology

Kündig Ltd

Tel 0845 833 0565 Fax 0845 833 0567 Email sales@kundig.co.uk www.kundig.co.uk

EVENTS Make The Difference

The purpose of a car is to get you from A to B. You can get from A to B reliably, in comfort and safely in any family hatchback on sale these days.

And yet, many will divert more of their hard earned cash towards BMW and Mercedes etc, often paying 3 or 4 times the amount required for a perfectly adequate Ford or Skoda.

We will pay for the difference, once we understand what that difference is. As a furniture and joinery manufacturer you will realise that this applies directly to your own products.

Now think about pricing. Haggling is almost expected on products which appear to be the same. As soon as there is a difference which people want the game changes and people stop talking about price and start think about value.

As a UK manufacturer you will probably have faced facts years ago that competing on price alone is going to make for a very difficult business. The expense of labour, health and safety and welfare in a developed economy just don’t allow you to run in the race to the bottom and win. On the other hand we are brilliantly equipped in the UK to compete on value.

Innovation, design and quality have always been tools to aid the Made in Great Britain badge and this is more easily achieved when you’ve got access to products from across the world. At W14 you can see and experience thousands of products to contribute at every stage of your products design and manufacturing process. That is why W14 is built around the Make the Difference concept.

Most will be totally convinced of a need

6 Panel & Joinery Production JULY/AUGUST 2014

to Make the Difference in their own products. The question is often ‘how do we achieve that? It’s usually not as simple as producing your goods in a different colour or sticking on some appendage. Looking around the terrific product line up already lined up for W14 there seems to be types of route to Make the Difference.

VALUABLE design features can be added

in to manufacturer’s profit, by use of the latest in components from across the world.

Amazingly beautiful products can be built into your own ranges – adding value in both form and function.

UNIQUE looks are on offer as materials and components are combined to raise manufactured products to individual statements of practical design. When

See our website and interactive magazine www.p-j-production.com

EVENTS

nothing quite the same exists the opportunity for increased margin comes to the fore.

BETTER manufacturing leads to better products and better profits! See how up to the minute technology can make the difference for your business. Modern manufacturing capabilities are available to

small businesses – enabling you to bring products to market which could previously only have been dreamt of.

The W shows have always been focussed on the needs of the manufacturer. In fact W14 will be amongst the very largest manufacturing shows in the UK with visitors from a wide range of industries. As

UK manufacturing comes increasingly back into vogue now that we’ve realised as a nation that we cannot survive by being bankers and hairdressers alone, it’s an event with a very serious point.

When you are looking for machinery, materials or components to apply to one of your most precious assets – your product line- simply browsing the internet will not do. As the 8,000 manufacturers who visited the last edition of the exhibition will testify, you have to experience the product hands on. They ask the questions and discuss the deal face to face.

The combination of a knowledgeable trade press, instant access of online and the unique coming together of the UK market at W14 are each vital parts of the mix to help UK manufacturers Make the Difference. Use all of them.

Register to visit w14 at www.w14exhibition.com For further information: Tel: 01629 530998

Dequm – making a difference with storage solutions at W14

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JULY/AUGUST 2014 Panel & Joinery Production

7

SAWS HOLZMA beam saw delivers increased productivity for The Lubina Kitchen Company Established in 1994, The Lubina Kitchen Company is a growing family business which strives to create quality products for the mid to upper kitchen market in the south of England. The business places great importance on personal relationships with customers, suppliers and its own staff; it is also committed to continuous investment in new machinery and processes to drive the business forward.

As part of this strategy, the company recently invested in a new HOLZMA beam saw from HOMAG UK for its 22,000 sq. ft. manufacturing facility in Colchester. “Our old saw was on its last legs; we were having more and more issues with it and so we

8 Panel & Joinery Production JULY/AUGUST 2014

Sound advice with no pressure

proved to me that his recommendation for the HOLZMA HPP 350 38 x 38 was the right one for us. At no point, however, did he try to pressure us into a decision; he just laid out the facts and allowed us come to our own conclusion.

“This is the first product we have bought from the HOMAG Group and the whole process has been so straightforward and easy. What really surprised me was the price. To be honest, I was expecting the HOLZMA saw to be more expensive than the competition, but I was amazed that it was on a par with the competition and offered much better value for money.”

“Charles actually changed my mind about the size of saw we needed because he analysed our processes thoroughly and

“Over the years, we’ve installed a lot of

decided the time was right to invest in a new saw,” explains Robert Byford, works director for Lubina Kitchens.

He continues, “We evaluated three brands, to ascertain which would best deliver what we were looking for. We went for the HOLZMA because Charles Smith, the HOMAG UK area manager was so helpful and knowledgeable. He really knew what he was talking about; he asked some searching questions about our performance requirements for the saw along with the size and type of boards we’d be cutting.”

Outstanding installation

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SAWS equipment in our factories and I can say hand on heart that the installation of the HOLZMA was the smoothest ever. With other companies, when the engineers have left we have had to call them back several times regarding issues that need sorting.

HOMAG, on the other hand, wouldn’t leave the initial installation until we were completely happy.

“Before he left, the engineer said that provided we follow the maintenance schedule we would be fine. True to his word, from that day onwards I can honestly say we have not had any issues, the saw has run perfectly.

“In terms of training, that was done by the installation engineer on site. HOMAG had allowed two days for training, but our operators are very experienced and the software is so simple that they picked it up very quickly and we didn’t need that much time.”

Real business advantages “Since we have had the HPP 350 operational, it has really speeded up our

cutting process. A lot of that is down to the fact that we have a bigger saw, so we don’t have to remove panels from the saw bed and then put them back on to cut in another dimension. Now everything stays on the bed and that alone saves a tremendous amount of time.

“The HOLZMA has a flotation table right through the bed rather than just on the tables. This reduces damage to the panels and makes the handling of them so much easier and safer for the operator.

“The quality and accuracy of the cut is also extremely good. In our business, the importance of having truly squared up panels to construct carcasses with cannot be underestimated. The HOLZMA consistently delivers perfectly squared up panels so that saves us a lot of time further down the production line.

“Overall, the ease of the programming has meant a productivity improvement to the business of 30-40% more than with the old saw which is a significant increase.

“The way it is performing, we would expect the HOLZMA to pay for itself within

a couple of years. It is outperforming our expectations and has enabled us to cut in a more productive fashion. It has just simplified the whole process of cutting on a beam saw.

“As for HOMAG UK, I have found all the team to be extremely helpful and efficient.

They are extremely knowledgeable which is very important to me because their knowledge of woodworking machinery and their understanding of the needs of manufacturers, aid me in specifying the most suitable equipment for our factory.

There is no doubt in my mind that we will be investing in more machines from HOMAG UK in the future,” concludes Robert Byford.

If you would like more information or a demonstration of any of the HOLZMA beam saws contact Adele Dixon: Tel: 01332 856424

HOLZMA HPP350 significantly improves productivity

See our website and interactive magazine www.p-j-production.com

JULY/AUGUST 2014 Panel & Joinery Production

9

SAWS New Gabbiani Galaxy 3 Beam Saw with Excellent Panel Cutting Gabbiani, a division of the SCM Group, has recently introduced a new model, the Galaxy 3, a top quality panel sizing centre with optimised machining cycles, clean precision cuts, high speed operating, extremely reliable, heavy duty construction and is fully customisable.

The pressure beam has a new mechanical design, being higher with a more uniform pressure on the panels being cut, optimum extraction of shavings and sawdust, and with easy maintenance.

The Galaxy 3 has an innovative saw blade carriage with electronic lift and feed on THK guides. The saw carriage and blade run on prismatic guides. Maximum rigidity and perfect perpendicular movement of the blade with respect to the stack of panels being cut. Therefore a drastic reduction of friction and wearing on the materials at even the highest speeds to give an excellent finishing cut.

Electronic setting of the scoring blade is

very fast and with exact adjustment of the scoring blade by means of electrical motors, electronically driven, according to the values set by the operator with the PC. Optimised blade protrusion is changed automatically according to the number of panels being cut with the optimum height of the saw blade to obtain the maximum precision even with one or a number of panels.

The new GALAXY 3 can be fitted with the FLEXCUT unit to turn the beam saw into a versatile panel sizing centre capable of high productivity rates. The modular FLEXCUT system enables the processing of complex cutting patterns in very rapid cycle times. The system allows the simultaneous processing of strips but with different cross cuts, therefore reducing production times.

Automatic grippers can be engaged and disengaged automatically thus enabling the processing of a variety of cutting patterns.

The models T3 and T3R offer a number of systems to feed the panels on to the

beam saw can be employed, such as roller conveyors feeding from either or both sides or the rear combined with lifting tables with roller conveyors, automatic loading of thin panels or those with a delicate surface, and an internal rotating table. Mahros automatic loading and unloading systems can also be accommodated.

The PLC takes care of the running of all the devices on the machine. The management software, WINCUT, operating in a Windows environment, has been especially developed by Gabbiani taking into account all of the end userâ&#x20AC;&#x2122;s work demands and requirements and enables user-friendly management of the machine.

A full range of panel optimising systems is available.

For further information: Tel: 0115 9770044 Email: scmgroupuk@scmgroup.com www.scmgroup-uk.com

Gabbiani Galaxy T3 Beam Saw

10 Panel & Joinery Production JULY/AUGUST 2014

See our website and interactive magazine www.p-j-production.com

it no w vis

& JOINERY

PRODUCTION

A COMPLETE RANGE OF 3, 4, & 5 AXIS CNC ROUTERS MANUFACTURED TO THE HIGHEST QUALITY FOR PERFORMANCE AND RELIABILITY

It’s only a click away www.p-j-production.com • On-line magazine • Quick and easy access • Fast and efficient for news & information in the Woodworking sector • Website Directory To advertise on the website • Video presentations Please contact Ernie Hollister Tel: 0208 366 3331 Email: ernie@p-j-production.com www.p-j-production.com

Whatever your requirements Onsrud has a solution ATA ENGINEERING PROCESSES Tel: 01442 264411 Fax 01442 231383 Email sales@ataeng.com www.ataeng.com www.cronsrud.com

SAWS Striebig is the Repeat Choice for Rugby Joiners When Mick Bevan and Cliff Kenny were made redundant back in 2007 from their jobs at shop fitters Reflections, in Rugby, they decided to pool their redundancy money and set up their own joinery business.

They bought various items of second hand equipment to get them started, including an elderly Striebig Standard vertical panel saw from their former employer, and today their business, Bevenny Manufacturing, is thriving.

Said Mick Bevan: “It was quite tough at first as we began during the challenging times of the Recession, which was not our choice, but luckily things have worked out well and we haven’t looked back.”

So far they have created six new jobs, including hiring several former colleagues, and have taken on an apprentice.

After Bevenny’s Striebig Standard recently reached the end of its working life it was decided to replace it with a more up-todate saw.

“We had both been using Striebig saws for many years and have a good working relationship with the machines’ suppliers, T.M. Machinery, who look after all of our machine maintenance,” said Mr Bevan. “So when it came to choosing a new saw we had no hesitation in sticking with Striebig. There was no need to look anywhere else.”

Their new entry-level Compact 5220 is used to size various types of sheet material ranging from MDF to veneered pre-finished board and laminates.

Bevenny Manufacturing’s co-directors Mick Bevan (left) and Cliff Kenny with their new Striebig.

With a cutting range of 4600 x 2200 x 60mm, the Compact features central support and small parts support over the entire length of the saw, making the cutting of small work pieces very easy. This feature is greatly appreciated by Bevenny’s two owners, who are both a very much hands-on presence in the factory.

“We picked the Compact model because we use a lot of Jumbo size boards measuring 2070 x 2600mm and needed the machine’s height,” said Mr Bevan. “It’s the ideal tool for us as it does exactly what we need it do, and does it extremely well.”

The saw was supplied with an optional scribing blade to prevent chipping, or breaking out, on laminated panels. This is

now a much quicker operation as before the laminate boards had to be taken to a DIM saw for scribing.

T.M Machinery also supplied and installed an AL-KO AAS twin bag mobile dust extractor unit with upgraded fine dust filters, linked to the saw. This reduces the amount of dust in the air during sawing to an absolute minimum.

The Compact is suitable for cutting practically all sheet materials, including MDF, plaster board, plastics and aluminium panels.

Each of the nine models in the Compact series is now available in an AV version incorporating an automatic cut cycle facility to make them even more productive. This feature was previously only found on Striebig’s more expensive models.

After specialising solely on shop fitting at first, working for design agencies commissioned by leading up-market London stores, Bevenny Manufacturing have diversified into supplying educational furniture for schools. They also produce units for museums and make exhibition stands.

The latest Striebig saws will be exhibited on the T.M. Machinery stand (8F 610) at the W14 show at the National Exhibition Centre in October.

For further information: Tel: 0116 271 7155 Email: sales@tmservices.co.uk www.tmmachinery.co.uk

The Striebig Compact vertical panel saw bought by Bevenny Manufacturing.

12 Panel & Joinery Production JULY/AUGUST 2014

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Quality The glue line is invisible, the edge is welded to the panel.

High resistance to heat and moisture.

Simplicity The system is simple and Zero impact on the machine.

No need for glue and the cleaning agents

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Cost/BeneďŹ t The system has an affordable cost and can be integrated in any Biesse edgebanding machine.

BIESSE UK Lamport Drive, Heartlands Business Park Daventry NN11 8YZ Northants T: 01327 300366 www.biesse.co.uk

More than machine.

EDGEBANDERS

A Question of Quality Take a closer look at EBM's new KDP 117 SLK-P Airtronic and you'll see it's much more than an Edgebander. The fully automatic machine, which has long been considered the German manufacturer’s flagship model, is the first Edgebander in the range to include EBM's first zero glueline solution, Airtronic.

Designed exclusively for woodworking machinery and consumables supplier, Ney Ltd, the Airtronic system (which can also be added to the KDP 114 SLK-P, KDP 115 SLKP and KDB 116 SLK-P models) eradicates unwanted glue lines, creating a perfect transition from edgeband to panel and providing a hygienic, seamless join.

Gerd Ney, Managing Director of Ney explains, “The new system will apply premium-coated edging materials up to 3mm thick and, whilst its compatible with hot-melt glues, laser edges and PUR, it doesn't come with the hefty price tag often associated with its laser counterparts.

“Whilst the technology behind the design is complex, the concept is simple,” explains Gerd. “The machine heats compressed air through a fan equipped heater until it reaches its operational temperature. It then irradiates through a nozzle to the inside of the premium-coated edge. It is this process

14 Panel & Joinery Production JULY/AUGUST 2014

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EDGEBANDERS

which creates a perfectly seamless edge that is highly heat, moisture and water resistant.” With a heat-up time of just three minutes, the parameters of temperature, air pressure and speed are optimised for ease of use but can be changed and saved via a touch screen console to work with different edging materials.

All machines in the range feature an extendable panel support to provide stability to large panels during processing and can be specified with a touch screen controller offering the operator the use of 32 pre-defined programmes as well as a full

diagnostic. The flagship KDP 117 SLK-P is the most comprehensively equipped edgebander in the EBM 110 range and includes pre-milling and infeed stations, end trimming, top and bottom rough trim, top and bottom radius trim, corner

rounding, edge scraping, glue scraping and buffing. It will work with components which have a minimum size of just 220mm and will apply edging materials of up to 3mm thick. The addition of the Airtronic system brings increased

productivity and production quality.

Gerd adds, “The EBM Airtronic system is a welcome addition to Ney's woodworking machinery range and, with our new range of zero glue line edging available in stock for next day delivery, Ney will always be a dependable partner for you to rely on.”

For more information, or to arrange a demonstration: Tel: 024 76 308100 www.ney.co.uk

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JULY/AUGUST 2014 Panel & Joinery Production

15

CASE STUDY

BRANDT Edgebanders Deliver Quality and Flexibility for Whiteleaf Furniture Established in High Wycombe by the specialist chair maker William Goodearl in1870, Whiteleaf Furniture is not short on experience. Over the decades it has carved out a niche as one of the leading contract furniture specialists in the country and now has a turnover of around £6m.

“We do a lot of work for care homes, the MOD, student accommodation and the hotel/leisure markets,” claims Neil Thompson, Production Director at

Whiteleaf Furniture. He continues, “We’ve just finished a big job for Centre Parks and, as you’d expect, all our customers demand consistent quality at a price, so it is vitally important to us that the woodworking machinery we use is reliable and delivers first class quality time after time.”

Long track record with HOMAG “Our company first started investing in HOMAG equipment in the early 1970s and we’ve been a fan ever since. The beauty of

all the HOMAG machinery is you can absolutely rely on it to perform consistently to a very high standard knowing that downtime will be minimal throughout the life of the machines.

“BRANDT edgebanders have long been excellent work horses for our business and when it came to replacing an old machine our immediate thought was to talk to HOMAG UK first. Before we did so, however, we thought it prudent to evaluate what other machines were out there and so

BRANDT KTD 720 – the perfect solution for curved parts

16 Panel & Joinery Production JULY/AUGUST 2014

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CASE STUDY

BRANDT Edgebander Ambition 1650FC consistently delivers first class quality

we looked at five or six brands before settling on BRANDT.”

been able to then effectively train other members of our staff.”

Seeing is believing

Quality and flexibility

“We get great support from HOMAG UK. The area manager, Roger Wilks, is always very honest and helpful when we are considering new equipment. He suggested we look at the BRANDT Ambition 1650 edgebander and recommended we visit the HOMAG Open House to see the machine in action.

“Whilst that was very useful, we wanted to see it in a live manufacturing environment and so Roger arranged for us to visit another kitchen manufacturer that had an Ambition 1650. Once you see it operating in anger and talk to the machine operators you very quickly get a feel of whether or not it’s the right model for your business.”

“When we were evaluating the machines the flexibility they offered really stood out and now they are installed we are benefiting from the time savings they deliver. The rapid tape changes in particular give us real flexibility. On some of our older machines tape changing was a lengthy job, now it is literally a press of a button and a minor machine adjustment that can be completed within two minutes. This means we can process a 1000 panel run followed by 30 different sample panels with varying widths and thickness of tape quickly and efficiently.

“The time savings we have gained have been significant; at the same output levels we are some 30% faster with the new edgebanders which makes a big difference to the bottom line. What’s more, the quality of the finished panels is so good that we have all but eliminated the need for stringent quality control. We know that anything we produce on the BRANDT Ambition 1650s will be first class time after time.”

Outstanding after sales service “Any manufacturer will tell you the importance of minimising downtime. It is costly and disruptive to work flow which is

On time delivery and installation “Over the last three years we have bought two BRANDT Ambition 1650 edgebanders along with a BRANDT KTD 720 for curved parts. Each machine has arrived exactly on schedule and been installed quickly and professionally by the HOMAG engineer who has also trained our operators.

“The machines are very, very easy to use and our two operators who have had training from the HOMAG engineer have

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something HOMAG UK are acutely aware of and therefore do everything they can to minimise it.

“They understand the needs of manufacturers to be up and running fast.

So, on the rare occasions we experience a machine issue, they get competent engineers onsite quickly to sort the problem with the minimum of fuss.

“There is also telephone support from the UK and the machines can be linked online to the BRANDT factory for diagnostic purposes, if necessary. Overall, HOMAG is a solid, caring company that holds quality as the foundation of its business and for us, that is really comforting to know,” concludes Neil Thompson.

For further information call Adele Dixon: Tel: 01332 856424

JULY/AUGUST 2014 Panel & Joinery Production

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SOFTWARE Curved Seating Pods Made Easy with Alphacam’s 5-Axis Toolpaths Manufacturing curved components for unique seating pods is a simple process for a leading joinery company, thanks to Alphacam programming 5-axis toolpaths for their Homag router.

Specialist Joinery Group say that creating the pods for the Lakeside Shopping Centre in Essex would take three times longer without Alphacam software, and they could not be competitive. “The pods involve considerable curved work, but the components can mainly be cut in one setup with Alphacam,” says Technical Manager Terry Devlin.

As well as the Homag Optimat BOF 311, Alphacam also programs a CNC edging machine to put a 2mm pvc edge on a curve, and a Homag multi-bore. But it is the 5-axis capability that he finds the most useful. “A growing number of our projects call for 5axis work, and we’d have to sub-contract that part of the operation out if we didn’t have Alphacam.”

Operating with around 100 staff in 80,000 square foot premises at Maghera in

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Northern Ireland, the company recently celebrated their 25th anniversary with a £3m expansion and commitment to create 30 new local jobs over the next three years.

Specialist Joinery Group work throughout the construction sector manufacturing high quality fitted furniture and bespoke joinery items. Marketing Director Paula McCloskey explains that their products include reception counters, feature and acoustic panelling, and a range of furniture for schools, universities, hotels, laboratories and healthcare.

With customers across the UK and Ireland, one contract involved designer items for luxury apartments in London priced between £5m and £8m. Other work has been for a number of hospitals, universities and colleges, Exchange Tower in docklands, The World Wildlife Fund, and the Olympic Village Legacy Project where they provided furniture for residences converted from the athletes’ accommodation.

“We’ve won a number of contracts

because of the 5-axis machining capability that Alphacam gives us, including The Guildhall in London. Very few companies could have handled that particular project because of the complexity of the design which involved curved and profiled acoustic wall panels over several floors. Although an architect’s pen can create any sort of curve, it’s a different story when it comes to actually machining it. Alphacam is paramount in enabling us to carry out 5axis machining within the required tolerances.”

Terry Devlin agrees that Alphacam is vital for their manufacturing process.

“Sometimes we have to work off a plan view, so we model it and bring it into Alphacam...but normally customers send us jobs in DWG format, so we create our own shop drawings and start breaking it down to see how we’re going to construct the project. Once it’s in Alphacam we select the cutting tool, set the toolpaths and calculate the amount of material needed.

“There are two options with the cutting

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SOFTWARE

list: it goes down to the machine shop manager who gets the parts bready and sends them to the router, or we feed the cut list to the beam saw and the parts are cut there before going to the router.” He says most jobs require around 20 per cent machining before they can be assembled, and with the high volume of work on the shop floor the parts would take too long to

complete without Alphacam. And as material utilisation is important to them, to avoid wastage, all nesting is done through Alphacam The Lakeside seating pods are made from several individual layers of MDF. Specialist Joinery Group produce the assembled shell which is clad with Corian.

In addition to the curves of each

component, they create a void in the assembly to house lighting. “Basically we manufacture it as a jig so the Corian can be formed to the correct shape. Being able to machine it on 5-axes, through Alphacam saves considerable time and manpower.

The only alternative would be to laminate it, and that would just be too timeconsuming.”

Specialist Joinery Group procure a range of materials to manufacture their products from MDF to Solid Walnut, it is all dependant on the Client’s specific requirements.

“Alphacam is important for routing and multi-boring all types of material that we use. It guarantees that everything is within the correct tolerance which is especially important for ceiling features and wall panelling. As they’re installed last, often after walls have been painted, everything has to fit together perfectly to ensure there is no mess.”

For further in formation: Specialist Joinery Group: http://www.specialistjoinerygroup.co.uk Alphacam: http://www.alphacam.com

See our website and interactive magazine www.p-j-production.com

JULY/AUGUST 2014 Panel & Joinery Production

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SOFTWARE 2020 Technologies’ Launches Specialist Furniture Manufacturing Software ‘Enterprise Insight’ to UK Market 2020 the world leader in 3D interior design and furniture manufacturing software, recently officially launched 2020 Insight, its comprehensive furniture manufacturing operations management solution in the UK market. Designed to maximise the effectiveness of the entire production process, 2020 Insight manages and automates each individual workflow; from the initial design, right through to the order entry and manufacturing stage, each process is programmed to deliver agility, better performance and cost efficiency back into the business.

Already dominant in the UK design software market, 2020 Technologies boasts over 60% of kitchen dealers and retailers including big names like Ikea, Nobia and B&Q. 2020 is the only software solution currently able to support both the design and manufacturing process, providing

20 Panel & Joinery Production JULY/AUGUST 2014

Steve Edge, Director Sales Manufacturing for 2020

complete end-to-end capability.

Bringing over 25 years of continuous software development and knowledge to an

industry where remaining cost effective is paramount; striking the perfect balance between flexibility and automation is

See our website and interactive magazine www.p-j-production.com

SOFTWARE

essential. From order entry through to the design process, engineering through to shop floor production, 2020 Insight delivers key functionality that enables furniture manufacturers to better manage their production capacity across multiple plants. Combining real-time planning and interactive scheduling from a single source, the master scheduling capability allows the

manufacturer to easily identify potential bottlenecks in production and proactively manage the workload; resulting in a better managed plant and reduced operating costs.

By delivering a product that offers not only considerable functionality and capability, but also reliability and unsurpassed quality; 2020 Insight enables

2020 Insight key business features: • Integrated Order Processing - Manufacturing operations can be tightly integrated into sales processes to simplify order creation, improve price accuracy and improve shop floor execution.

• Engineering Automation - Automation of manufacturing data creation improves and accelerates product innovation without adding new resources.

• Product and Process Configuration - A flexible configuration approach allows you to accurately model products and processes with all the required manufacturing information. Parametric CADbased engineering models and powerful rules-based BoM configurations work in harmony to supply automated data generation for complex products.

• Production Planning - Automated demand planning and purchasing capabilities not only improve productivity and reduce inventory costs but they also efficiently support made-to-order operations.

• Shop Floor Execution - Improve productivity, accuracy and efficiency on the shop floor through automation and real-time production management.

• InResponse Workflow Engine - A real-time system that automates repetitive tasks enforces business rules and automatically generates alerts and notifications, allowing you to resolve issues faster.

• Integrated Business Intelligence - Enhance decision making with an intuitive tool to analyze your operational data through customizable and interactive charts and graphs.

• Business System Integration - Transactional manufacturing data is integrated into your finance, customer relationship management and other business support systems using standard interfaces.

See our website and interactive magazine www.p-j-production.com

furniture manufacturers to combine their traditional processes with revolutionary technology; helping streamline production, improve productivity and maintain cost effectiveness.

Steve Edge, Director Sales Manufacturing for 2020 said “We have our eyes firmly focused on the future of technology within this industry; automation will be a significant and instrumental factor moving forward. 2020 provides an already powerful and highly efficient solution that will enhance the flow of information whilst enabling better coordination and optimisation throughout every step of the manufacturing process. Innovation within this sector will continue to push the advancement of technology even faster; it won’t be long before we start to see the connection between the retailers front-end design tools and the manufacturing backend driving additional efficiency to the whole process, whilst further reducing cost and that all important lead time.”

For further information: Tel: 01204 304304 www.2020spaces.com

JULY/AUGUST 2014 Panel & Joinery Production

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BOARDS & PANELS

FINSA’s “Super” board Panel & Joinery Production visited one of Spanish board manufacturer’s specialist factories near Porto in Portugal where they make their unique wood-based board Superpan.

So what is Superpan? Basically Superpan is a quality and highly versatile wood-based board comprising a chipboard core sandwiched between two layers of MDF-like fibres that is made in a patented continuous process. The result is a strong panel with high quality surfaces which go on to accept finishes like melamine, foils or lacquers with an exceptional quality result.

While Superpan was originally envisaged as a board with the cost savings of chipboard over complete MDF but with a superior surface the board has been so successful that it has found many more market applications and is now produced in 11 different versions. The first Superpan boards came off the line in Porto in 2000 where 350,000 cubic metres are now produced in a highly automated environment. A second production facility is now in the final planning stages and this will increase Superpan capacity by another 250,000 cubic metres.

FINSA have always maintained strict environmental credentials and use local sustainable timber sources and also reclaimed timber. They also manufacture

The BASF Kaurit Light polymer ready for infusion into the chipboard core of Superpan STAR

all their own resins and adhesives. The patents covering the manufacture of Superpan are added to by various

accreditations like PEFC, FSC and AITIM as well as being CE marked.

Among its original qualities Superpan

Above: Superpan STAR Left: Control Room at the Superpan factory

delivers an accurate ease of cutting drilling and edging as well as face routing for Superpan TOP which has a 4mm thick fibre surfacing. It can be postformed and tongue and grooved for floor tiles. It has excellent mechanical properties for screw and fittings fixing, high impact resistance and low surface absorption as well as good bending strength.

Since the first Superpan product was produced FINSA has come to realise its multiple potential uses which has led to

22 Panel & Joinery Production JULY/AUGUST 2014

See our website and interactive magazine www.p-j-production.com

BOARDS & PANELS Natur is faced with natural wood veneers.

One of the most recent incarnations and highly successful in the UK is the lightweight Superpan STAR which is a collaboration between FINSA and German chemical giant BASF where polymer called Kaurit Light is introduced into the chipboard core during the manufacturing processing and resulting in a board 20% lighter but not compromising any of the outstanding physical properties. It won the Design in Manufacturing (DIMA) Award at the W12 exhibition in Birmingham.

Superpan STAR has obvious advantages for furniture manufacturing, transport and handling costs and all interior fit-out applications.

The Superpan TECH variations are used widely for packaging, shelving for industrial Above: Finished Superpan boards cooling for 48 hours Right: The Superpan mat going through the continuous process Below: Superpan Structure

introduction of many variants. These include the (aforementioned) Superpan TOP; an E-Z Class 2 low formaldehyde type; Super Pan TECH P4 (load bearing), P5 (moisture resistant load bearing), P6 (heavy duty load bearing). The Porto factory also has a melamine laminating line to make Superpan DĂŠcor and the Superpan

racking, and flooring for suspended floor and mezzanine applications. Other specific applications include shuttering for a smooth concrete finish and for fitting out the interiors of the fast growing van and delivery vehicle market.

FINSA are working of fire retardant (FR) versions of this highly versatile wood-based board product.

FINSA UK hold extensive stocks of Superpan at their dockside warehouses on Merseyside and also make the product available through appointed national distributors.

Superpan Structure

See our website and interactive magazine www.p-j-production.com

For further information: Tel: 0151 651 2400 Email: uk@finsa.com

JULY/AUGUST 2014 Panel & Joinery Production

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DECORATIVE SURFACES

Innovation In Design at Decorative Panels Lamination Ltd. Innovation in design is always at the forefront of Decorative Panels minds with continual development in the latest surface textures and finishes.

Decorative Panels Group Design Director, Julian Tatham, reports on the companies exciting developments that are ready to sample into the market.

“Working closely with our printing partners we have developed a wide range of 3D designs featuring the latest in textured surface development. The surface creates a premium look, with superb print quality but best of all it makes you want to reach out and touch it to achieve the full sensory experience. It is so authentic that this collection of designs not only looks like, but now also feels like the real thing – natural wood products.

The range consists of nine designs offering a broad spectrum of tonal shades and surface textures, modern and on trend designs suitable for a wide range of markets.

White woodgrain is a clean bright design, the surface texture creates intrinsic interest and adds character to the simplest of decors.

Katthult is a furniture décor that epitomises the current trend for Scandinavian design. Bright, light and full of life with an abundant use of colour that can be appreciated to the full when viewed alongside natural tones.

With gentle planking, an open and structured pore and small cut flowers which together create a remarkable overall appearance for our next design, Redgate. Redgate has a strong structure that is curiously calm and soft.

Iconic Beech brings new life to this recently overlooked design.

24 Panel & Joinery Production JULY/AUGUST 2014

Full of life with a natural fine balance and of course superbly tactile.

Nash Oak is a very different and special design, nothing like the ones we know. Correspondingly lively and natural, it has a mellow, warm & homely used look.

Strong in expression with a distinctive structure, Nelson has a grey-whitish pore and a gold-bronze hue to the overtone, allowing infinite toning with trend colours.

Bobs Pine brings the look of driftwood to the market, textured and sculptured by the elements, roughly honed using basic tools with masses of character.

Maxim Rich is a real eye catcher. A mixture of elegant graining enhanced by the darker lines gives this design real substance and presence reinforced by its power when used side by side with a single colour.

Maxim Dark completes the full of palate of colours and surface textures. The 3D range that we now have available to sample opens opportunities in design like never before.”

Julian goes on to expand on the latest uni-colour offering that Decorative Panels Lamination have ready to launch.

“All woodgrains are now developed to be used with uni-colours, they must contrast, compliment, co-ordinate and create a harmonious combination. The use of uni-colours is evolving and is becoming enormously important within furniture and interior design. To this end we are continuously looking to update our range of unicolours, the latest products ready to launch from DPL are, Ruby Red, Electric Blue, Petrol Blue, Duck Egg Blue, Lime Wash, Shaded White, Virginia Grey, Moon Grey & Praline.

Colours that compliment and work well with our stock

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DECORATIVE SURFACES unicolours such as Sand Beige, Dakar, Mussel, Cashmere and Alabaster plus of course many of the designs in our dp-décor and dp-specialist ranges.”

Finally Julian talks about a ground breaking development in acrylic surfaces.

“We have for many years sought to develop an alternative to traditional glass mirrors and now believe we have succeeded. This acrylic surface is bonded to MDF in exactly the same way as we process all other designs in our dp-specialist portfolio. An easy solution to the developing trend for mirrored plinths in kitchens and mirrored fronts in bedrooms. An added advantage is that this material won’t crack or shatter so is ideal for situations where

safety is a priority. Why not take a look?”

“Book a visit to our brand new Marketing Suite where these and many more innovative products are on permanent display – I am sure you will be amazed at what we have to offer.”

“Keep looking out for the latest development, new designs are coming out all the time.”

For samples, please contact us on our sample hotline number: Tel: 01484 324621 www.decorativepanels.co.uk

F3 Wood Texture David Clouting is delighted to announce the arrival of four new stock Decofoil items.

F3 is the latest texture design development from LG Hausys. It is being introduced in four solid colours, which leads the way forward for inspiring furniture design in the UK. F3 is special, in that the design structure of a sublime oak is paramount within the texture, thus creating the most impressive painted wood effect in Decofoil.

The four colours featuring F3 are: WAR51-F3 Porcelain White YEM18-F3 Alabaster YEM16-F3 Mussel NCAB4-F3 Cashmere

producers.

Technically LG Hausys have done an outstanding job in developing the F3 texture, which can be manufactured in both membrane pressing, wrapping and lamination grade. This provides the opportunity for five piece doors to be used along side the vinyl wrapped doors within furniture ranges.

Whilst F3 is being added to the Decofoil stock range, the lamination and wrapping grade can be purchased in manageable make to order quantities.

Clients may have more colour requirements for F3 and David Clouting can facilitate this with the flexibility that LG Hausys manufacturing capability provides. Please approach our sales and marketing team for further information.

A4 and pressing samples are available for product development, with stock available to purchase.

The four colours are already used widely within the furniture industry, and this enables the F3 colours to be introduced with minimal additional stock requirements in MFC and MDF. Whilst the Porcelain White is specifically an Egger MFC, Alabaster, Mussel and Cashmere are widely available from the leading MFC

Cashmere

Alabaster

See our website and interactive magazine www.p-j-production.com

For further information: Tel: 01376 518037 www.david.clouting.co.uk

Mussel

JULY/AUGUST 2014 Panel & Joinery Production

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EDGINGS

This is the Future Every manufacturer knows the importance of using highquality consumables but when it comes to choosing your edging, what is important to you? Does price dominate your decision or does the assurance of rigorous expert testing, greater production quality and the promise of a perfect finish score highly on your wish list? Or is the importance of a dependable supplier that can guarantee over 10-million linear metres of instock edging, ready for next day delivery a key factor? If your answer is 'all of the above', then Ney's laser edging is certainly worth a closer look.

Designed to create a seamless joint, Ney's laser edging is coated at the time of manufacturing to guarantee a perfect colour match with no visible glue line. By replacing the conventional glue, an edgebander with Laser, Hot Air or Plasma technology can be used to bond the edge and board together - flawlessly.

Manufactured from Polypropylene, Ney’s laser edging has been created to withstand the harshest environmental conditions. Able to endure temperatures of -20 to +75oC, testing has also seen edged doors and carcasses submerged into water and used in rooms with an 85% moisture level to ensure the highest heat, water and moisture resistance possible.

Available for next day delivery in 13 colours (including white, cream and black) Ney is set to extend its range later this year to reflect new and existing trends. A speedy quotation service and a minimum order quantity of only 50 metres is also available – ideal for the smaller manufacturer.

26 Panel & Joinery Production JULY/AUGUST 2014

Gerd Ney, Managing Director of Ney Ltd adds, “This is a new age for furniture manufacturing. Our laser edging has been developed to embrace modern manufacturing techniques and create highquality products simply and effectively. This is the future.”

For more information on Ney's laser edging or to order a copy of Ney's new materials brochure: Tel: 02476 308100 www.ney.co.uk

See our website and interactive magazine www.p-j-production.com

interiors by design

deco foil Find out more about our exciting range of contemporary LG Hausys PVC foil materials for kitchen, bedroom and bathroom...

deco foil 3D Forming Veneers for kitchen, bedroom and bathroom furniture We offer an exciting range of contemporary and traditional styles, all with excellent board matches

Call +44 (0)1376 518037 today for information on our product range E: marketing@davidclouting.co.uk W: www.davidclouting.co.uk â&#x20AC;˘ David Clouting Ltd. Unit 650, The Hub, Skyline 120, Avenue West, Braintree, Essex CM77 7AA

CNC ROUTERS Smart Garden Offices Install SCM CNC Machining Centre Based in rural Suffolk, Smart Garden Offices are specialists in the designing and manufacturing of garden offices and studios and are renowned for their quality and affordability, providing a full customer service including delivery and installation that includes insulation, double glazing, flooring, cabling and internal furniture.

Smart Garden Offices offer an extensive range of buildings with each one being personalised to meet each of their customers individual requirements in terms of overall dimensions and positioning in the garden after a site survey.

Fully fitted interiors include the Smart Versa Desk System offering an ergonomic workspace that has been purpose designed for each one of the Smart office range, optimising internal space and providing work surfaces, shelving and cupboards, all

being installed after the office has been erected.

Smart's unique manufacturing system allows them to complete 90% of the build process within their own factory, with the remaining tasks being final assembly on site. Each building is 'man portable' meaning that Smart ensure all components can be readily transportable through a house and assembled in a rear garden.

Smart Garden Offices Managing Director, Charlie Dalton, comments "Due to more and more people now being able to work from home rather than have to commute long distances to their workplace, we have received a significant increase in both enquiries and orders for our garden offices, so our lead times were increasing.

In order to improve our lead times and also increase capacity in our factory, I decided to investigate the installation of a CNC Machining Centre as I felt it would assist

our machining capacity and provide greater accuracy in assembling our component parts."

"As we had no CNC experience, we knew that we required a degree of 'hand-holding', so we not only looked at Italian and German manufactured machines, but also the training and back-up provided in the short and long term. We approached Phil Vaux of Blyth Machinery, SCM's distributer in East Anglia, as we had previously purchased an SCM combination machine from him. He arranged demonstrations along with SCM's Roger Gabb at customers producing solid wood components."

"After much consideration, and one or two bad demonstrations with SCM's competitors, we decided to purchase the SCM CNC Machining Centre model Tech Z2 with a 5200mm long table to accommodate our 4800mm longest component."

Component being machined on SCM TECH Z2 at Smart Garden Offices

28 Panel & Joinery Production JULY/AUGUST 2014

See our website and interactive magazine www.p-j-production.com

CNC ROUTERS The inspiration behind SCM producing the TECH Z2 is that of providing the very best solution for the most dynamic woodworking, joinery and panel sectors, setting a new benchmark for those markets.

The Tech Z2 is designed to produce top performance and set new standards of User-Friendliness.

The Tech Z2 is ideal for the production of customised furniture, panel machining and it can also be equipped with devices suitable for solid wood machining for the joinery market. It has a vectorial positioning speed of 83 metres/min. (X - Y axes).

High performance is due to the latest "Photobumpers" safety protections (a patented solution), avoiding light cells or floor mats. Also, to save valuable floor space, the electrical cabinet and pneumatics are installed within the machine base. Customisation and flexibility are due to the wide choice of equipment pre-settings, with the high performance worktable with bars and vacuum pods and the "PENTA" function.

The work table consists of 8 - 1300mm TV aluminium bars with pneumatic locking after positioning along the table.

Various suction cups are located along the bars to hold the components to be machined with alignment against 2 rows of pneumatic stops. Four pneumatic loading assistance devices help the operator to position components on the table especially if they are of large dimensions.

The mechanical fixing of the vacuum cups provides the certainty and guarantee of quality results by utilising a powerful

Smart Garden Offices Suffolk Barn Trio

mechanical grip that locks into position the vacuum cups instead of the widespread vacuum system. It is unrivalled when working in heavy duty conditions and unique in being free from dust (an SCM patent).

The machine's cantilever structure is unique and very easy to use. It is the only structure that allows the loading of components along the “Y” axis far larger than the standard working capacity of the machine which is 5200 x 1300mm.

A powerful 11KW electrospindle running up to 24000 RPM enables the Tech Z2 to machine heavy-duty materials and timber without any problems. The electrospindle is fitted with a Vector Axis with Penta Digital Control which provides automatic rotation at 360 degrees in the X-Y directions when Angular Heads are fitted.

Tooling is supplied to the electrospindle by either an R8 Rapid Tool Changer with 8

tooling positions or a TR10 automatic tool changer with a capacity of 10 tools or machining heads and is located at the end of the machines table. An F18 boring head with inverter and with 12 vertical and 6 horizontal independent spindles and including an integrated sawblade for grooving completes the high specification.

Programming of the Tech Z2 using SCM's Group's "Xilog Maestro" with the advantage of having simple and intuitive features and is very easy to use even for the most inexperienced operator. Various modules can be supplied. An additional key was supplied for programming in the office and a movable control panel with a PC adjacent to the machine. Automatic centralised lubrication is included.

Charlie Dalton concludes "We are very pleased with our SCM Tech Z2 and are already experiencing the many advantages the machine provides. For example, a Quarto Base Rail that previously took 40 50 minutes to machine now takes only 10 minutes, so a majority of work is now going on the CNC including wall panels that are machined very fast. Lead times are gradually reducing making all our customers very happy."

For further information: Smart Garden Offices Tel: 01473 833997 www.smartgardenoffices.co.uk

Charlie Dalton and Blyth’s Phil Vaux See our website and interactive magazine www.p-j-production.com

SCM Group (UK) Ltd Tel: 0115 9770044 Email: scmgroupuk@scmgroup.com www.scmgroup-uk.com JULY/AUGUST 2014 Panel & Joinery Production

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CNC ROUTERS

AXYZ Router Helps Double Production at Porter & Woodman An AXYZ CNC router supplied by AXYZ International has helped double the production capacity of West Midlandsbased Porter & Woodman. The company is a major user of wood, primarily plywood and MDF, for a diverse range of products distributed by the various business operations within the Porter & Woodman Group. These include wooden boxes and crates for packaging high-quality wine and hamper gifts and point-of-sale and signage products, including chalkboards, blackboards, Aboards, shop fitting units and menu and poster holders.

The AXYZ 4010 CNC router recently installed supplements an AXYZ machine purchased three years ago. The router is part of phase one of a £100.000 investment programme that has enabled additional staff to be employed and fuelled growth by the introduction of new business. This, in turn, has led to the requirement for a second phase of investment that will see the addition of a third warehouse to enhance the group’s packaging and distribution capabilities whilst enabling more staff to be employed.

Sales and Marketing Director at Porter & Woodman Group, Mike Hodgetts commented: “We are delighted with the new router and how it has helped double our production capacity. Towards the end of last year we experienced a bottleneck in production. This has now been comprehensively resolved with installation of the AXYZ 4010 machine and has enabled us to keep up to speed on existing work whilst securing new business with confidence. It has also helped guarantee jobs for the expanding workforce that now numbers 40.

Manager of the CNC Machining Shop, Colin Inchley added: “I am thrilled with the new machine and how it has helped increase our production capacity. It is much quicker and more efficient but perhaps of greater significance it has assisted the group’s expansion and secured new jobs.

30 Panel & Joinery Production JULY/AUGUST 2014

The CNC Machining Shop at box and crate manufacturer Porter & Woodman, with Manager Colin Inchley in the foreground and machine operative Dave Radford.

The addition of the 4010 router means we can split the workflow between the two machines to ensure that at no time either is tied up on a specific job, leading to guaranteed delivery on time to meet customers’ requirements.”

The AXYZ 4010 router is part of the 4000 Series that is recognised as one of the most popular routing, cutting and drilling solutions for wood processing currently available. It provides a work area width of 1,524mm and lengths starting at 1,220mm, with incremental increases of 610mm. The machine can handle materials in excess of four feet wide by virtually any length, while the 150mm gantry clearance will accommodate thicker substrates.

The AXYZ 4010 router installed at Porter & Woodman is supported by ArtCAM Express Design and Production software.

The router incorporates a seven-tool Automatic Tool Change (ATC) facility and is used to cut out frequently complex shapes and process wooden sheets. In common with all AXYZ routers, however, the machine can be supplied with a host of

optional production enhancements. Most recently, these have included new servo drives and the latest helical rack and pinion drive system featuring multiple gear teeth.

This ensures a more even distribution of the workload, leading to reduced machine wear and increased material feed rates.

These production features are supplemented with the latest A2MC Smart Console that eliminates ‘bounce’ and vibration caused by sudden acceleration or deceleration, while the AXYZ Auto Zone Management System provides a greatly improved material hold-down capability as wells as reducing or eliminating material wastage and machine downtime caused by incorrectly set vacuum valves.

For further information: AXYZ routing solutions: Tel: 01902 375600 www.axyz.com Porter & Woodman Tel: 01384 445844 www.porterandwoodmangroup.co.uk

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CASE STUDY

Rover Skill G FT Nesting Cell DFS is the leading retailer of upholstered furniture in the United Kingdom. They design, manufacture, sell and deliver to their customers an extensive range of upholstered furniture products. The business operates a retail network of upholstered furniture stores across the United Kingdom and Republic of Ireland, together with an online channel. These have been established and developed gradually over more than 40 years of operating history. They attract customers to their stores and website through their substantial and continued investment in nationwide marketing activities as well as their reputation for high quality products and service.

“We had a traditional product manufactured from board and timber using traditional methods such as band saws and pillar drills,” explains Eddie McDermott – Wood Mill Manager at DFS. “Our purchase of the Skill nesting cell reduced our costs from £48 to £22 per unit and increased production to 150 per week, saving us £3,900 per week on this process alone. The purchase of the machine was justified on this one item but we obviously use it to produce many more products now”.

“Biesse went the extra mile and did a lot of work with us in the initial stages on nesting patterns and timings. We sent two packs of material to Biesse in Italy and went over to witness the machine trials and worked closely with their engineers to deliver the performance we required.”

ROVER SKILL 12 in operation

The acquisition of Biesse’s Skill nesting cell has delivered even more benefits to DFS. “Having the CNC has given us the capability to manufacture many more parts so it’s been a fantastic investment. It’s enabled us to change the design of other products to increase efficiency, make us more competitive and hopefully gain us a greater share of the market.”

“The improvements over traditional methods in terms of time, material waste and man hours have been massive. The machine is running 24 hours a day, six days a week and we process between seven and eight boards an hour”.

Other tangible benefits which Eddie mentioned were that it gave DFS greater flexibility and the capability to manufacture intricate components more easily. “It’s also

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enabled us to improve the quality of our furniture as well as helped to simplify our design”.

Space was also at a premium and the smaller machine footprint was ideal for DFS. “If we had the space, we’d buy at least another two Skill’s AG FTs” enthused Eddie, “however, our main reason for choosing the Skill was the cutting speed. We run the machine at 40M/Min to obtain maximum efficiency, so with that and our high production output, reliability is also a key factor”.

Would Eddie recommend Biesse? “I absolutely will and already have” For further information: Tel: 01327 300366 Email: info@biesse.co.uk www.biesse.co.uk

JULY/AUGUST 2014 Panel & Joinery Production

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HANDLING

Fourth Combilift for Cranwood Industries One of Ireland’s leading suppliers of timber and timber-based products, Cranwood Industries, has just added a fourth Combilift 4-way forklift to its fleet, having acquired its first - which is still going strong - in 2002. Since the company was established over 20 years ago it has been involved in some of the most prestigious construction projects in Ireland and as part of the Murdock Builders’ Merchants Group it also supplies its nine depots across the country.

Cranwood’s sawmill at Warrenpoint in County Down has recently been upgraded to a purpose built 3-acre factory to meet consumer demand for its highly specialised custom moulded hardwood and softwood products. Due to the wide variety and varying dimensions of stock, versatile materials handling is crucial for the

32 Panel & Joinery Production JULY/AUGUST 2014

offloading, transport and despatch of the 2,500m of timber and sheet materials that are housed in the mill.

The current total of three 4 tonne capacity C4000 models and one 4-way sideloader, all diesel powered, have replaced 2-directional sideloaders. Their multidirectional capability has been of considerable benefit as Operations Manager Paul Smyth explains: “the manoeuvrability of the trucks was a real attraction – it allows them to nip in and out of aisles and around obstacles making procedures quicker all round.”

The C4000’s are used mainly for loading, offloading and in the despatch area where they handle lengths of up to around 6m. They service a small section of racking as well as a storage area where bales are block stacked four high and two wide. They can access the spaces between bales to pick

wherever and whatever is needed, which was impossible with the previous trucks given their limited manoeuvrability. The higher 5t lift capacity of the SL model is ideal for handling wider and bulkier packs of hardwood and sheet materials.

“We work our forklifts hard here,” says Paul. “They are on the go constantly from 7am to 5.30pm, and it is testament to the quality of the machines that our first Combilift, with over 11 years of service, is still as good as the newer ones when it comes to performance and reliability.”

For further information: Tel: 00353 47 80500 UK Tel: 07870 976 758 Email: info@combilift.com www.combilift.com

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TOOLING BFRC Timber Window Energy Rating Licences Now Available for Leitz ThermoTech Window System The British Fenestration Rating Council (BFRC) and Leitz Tooling now offer 18 different BFRC window licenses for products made using Leitz ThermoTech Window System.

Leading supplier of tooling to British industry, Leitz Tooling developed its ThermoTech Window System tooling for the efficient manufacture of high quality ‘A’ rated thermal stormproof and flush casement timber windows. The system is complete, compliant and scalable, and provides reductions in waste and sanding and increased performance and finish.

Based on 18 variations of energy rated timber window manufacture, the BFRC licenses can be purchased by any company manufacturing timber windows using Leitz ThermoTech Window System stack tooling.

The licences enable manufacturers to respond to increasing consumer requests for energy rated windows and offer a competitive advantage.

At launch, licences are available for 18 versions, accommodating variations in materials, type and thicknesses on designs for 6 types of stormproof and 12 types of flush casement timber windows. More are already planned, including tilt & turn, box sash, aluminium-clad, ‘Passive House’

BFRC energy rating for Leitz ThermoTech Window System

compatible, and others.

How much do the licences cost?

Payable directly to BFRC, a single ThermoTech Window System licence costs £300 excl. VAT per year, or manufacturers can purchase all 18 licences for a maximum annual fee of £840 excl. VAT. Leitz can also help companies arrange the annual audit necessary for licences to be valid. Each licence comes with energy certificate labels for the finished products, PDF versions of the licences and full colour energy certificate vehicle livery stickers. Every licenced company will be listed on the BFRC website and according to a survey of BFRC registered installers last year, 74% of installers get new Solid oak window manufactured utilising Leitz ThermoTech customer enquiries through Window System BFRC registration.

The features and benefits of the ThermoTech Window System mean numbers that will be able to receive a BFRC that on all designs, U values of the timber Homeowner Energy Ratings Certificate.” windows are 1.4 or better, the designs are Leitz Tooling UK managing director, expandable for different hinges, and the Simon Liddell, said “Our ThermoTech profiles on the system are easily changed Window System tooling is not only as without the need to purchase extra tools. accessible and as future-proof as we can The system is available as dedicated sets for make it, but includes all the support our spindle moulders, tenoners, CNC machine customers might need – which now centres and window machines. includes making BFRC energy rated timber BFRC is the independent authority for window licences available for products rating the energy efficiency of windows and manufactured with our system. Modern doors in England and Wales. The BFRC timber windows continue to gain market energy ratings label - similar to those found share in the UK and with companies on washing machines and fridges - means looking to diversify and gain a competitive that homeowners can be sure exactly what advantage, we are doing all we can to help product they are buying and can compare level the playing field for timber window competing products. manufacturers.”

“BFRC is delighted to have signed up Leitz and significantly added to the number of timber-framed windows that will now be For further information: BFRC rated,” commented BFRC managing Tel: 01279 454530 director Chris Mayne. “This increases the Email: salesuk@leitz.org choice available for homeowners and the

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JULY/AUGUST 2014 Panel & Joinery Production

33

TOOLING Vollmer Takes Saw Blade Processing to the Stars Extending its market leading range of automatic saw sharpening machines, Vollmer has now launched its new Loroch PowerStar 850 for the manufacture of metal cutting circular saw blades. The new PowerStar 850 is a flexible CNC controlled machine that has been developed for the precision processing of saw blades from 400 to 850mm diameter with flexibility and ease of use at the heart of the machine.

With a number of circular saw blade processing machines already in its armoury, this latest addition typifies the Vollmer brand by delivering a flexible machine for customers with high expectations. Not only is the new PowerStar 850 capable of machining HSS and segmental saw blades, it can also process friction and solid carbide saws. Utilising user friendly symbols on a large colour touch screen monitor, all settings are available at a glance to enable changes to be made quickly and with confidence. With all rake and clearance angles for standard teeth readily available, the PowerStar 850 also indicates the optimal grinding speed required.

Like the KSC series of machines, the PowerStar 850 incorporates a powerful direct drive for the grinding spindle as well as an expandable shaft for accepting the grinding wheel. This ensures that performance loss and unwanted vibration are eliminated, thereby improving the service life of the grinding wheel whilst enhancing surface finishes.

Following the sharpening or re-toothing process, the PowerStar 850 can move the grinding head and cooling nozzles automatically to commence the chamfering process. A key characteristic of the new machine is its ability to infinitely adjust the chamfer angle up to a maximum of 45 degrees. To start the process, the operator can rotate the electronic hand wheel to locate the grinding wheel in the tooth position.

As the benchmark in saw processing technology, the new Loroch PowerStar 850 from Vollmer incorporates a host of features as standard that include a motor

34 Panel & Joinery Production JULY/AUGUST 2014

The Loroch PowerStar 850

driven diameter adjustment facility for the saw blade, saw blade bracket at the point of grinding, semi-automatic saw blade chamfering and 45degree angle cutting.

Additionally, the PowerStar 850 includes an integrated and adjustable input station with large LCD-Touch screen and a complete coolant system that has a 300 litre tank with a 6bar high volume pressure pump.

For end users with more specific demands, the machine offers a variety of optional extras such as Custom and Vario tooth shape geometries, a precision grinding facility to grind multiple blades to

the exact outside diameter and an external fine filter to extract HSS or carbide chips.

Other optional extras include modification to accept oil coolant or emulsion and internet connection for remote diagnostics.

The wide ranging list of standard options make the new PowerStar 850 the most comprehensive and capable machine in its class.

For further information: Tel: 0115 949 1040 Email: admin-uk@vollmer-group.com www.vollmer-group.com

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SANDERS Outstanding Artisan Sander Range From Viet Becoming increasingly popular with UK woodworkers is the Viet artisan range of wide belt sanders. Now part of the Biesse Group, Viet has specialised in the design and production of the highly efficient wide belt sanders since 1953 Entry level model S219 is a small machine guaranteeing a top performance.

Precise and functional, it is equipped with fixed drums to calibrate and sand timber, preparing it for further processes.

The S1 is a heavy duty twin-head sander with a large choice of sanding and finishing elements. The option to add inverter control of the abrasive belt and conveyor belt speeds gives maximum flexibility from a compact machine. Touch screen controls are also available for operator ease and speed of use.

The S2 series is a highly sophisticated three-head sander for added flexibility, described as the ultimate in surface finishing. The S2 also has an increased range of options to choose from, including a fully electronic cross belt sanding head.

Belt blowers, finishing brushes and turbo panel cleaners can be incorporated for the complete panel finishing solution. Program storage and retrieval along with intuitive

The top-of-the range S3 series delivers first class results

controls are provided via the use of a 15â&#x20AC;? touch screen.

Billed as the ultimate in high production

finishing, the top-of-the range S3 series ensures results beyond expectations. Panels are finely calibrated, while sanding makes surfaces feel perfectly clean to touch.

Unlimited customization makes S3 machines suitable for every kind of sanding requirement.

Vietâ&#x20AC;&#x2122;s artisan range is available in the U.K. from T.M. Machinery Sales, who also service the machines and provide spare parts.

They will be exhibited on the T.M. Machinery stand (8F 610) at the W14 show at the National Exhibition Centre in October.

For further information: Tel: 0116 271 7155 Email: sales@tmservices.co.uk www.tmmachinery.co.uk The versatile Viet S211 entry level model is a popular choice with woodworkers See our website and interactive magazine www.p-j-production.com

JULY/AUGUST 2014 Panel & Joinery Production

35

CASE STUDY

BÜTFERING Delivers Time Savings and Improved Finish Quality for Hazlin of Ludlow Hazlin of Ludlow is an expanding British manufacturer of high quality, bespoke architectural veneered doors, frames, panels, screens, furniture and other joinery items. Since it was formed in April 1974, Hazlin has devoted itself to becoming the best in the market. As part of its strategy to achieve this goal, the business has always invested in the best machinery it could afford.

“We have built our name from manufacturing quality veneered doors and panels,” explains Chris Jones managing director at Hazlin. He continues, “To get the best quality we have always believed in employing first class people and investing in precision machinery that we can rely on.”

opportunity to test the machines using our own samples to see which model was best for us.”

A hard act to follow “They were so helpful, especially Paul Mosley. Twenty years on, Paul is still there and continues to give us excellent advice, especially when we are specifying a new machine. The BÜTFERING SWT 955 is the fifth sander we have bought from Paul so, when we were considering investing in a new finishing sander, it was a no brainer.

“Naturally, we did our due diligence on options, but with its track record, value for money and Paul’s honest approach, BÜTFERING is a very hard act to follow, let alone beat.”

One of life’s happy accidents

Responding to market demands

“We first started dealing with BÜTFERING almost 20 years ago and it happened almost by accident. My father and I were out in Germany testing a new veneer guillotine and when we finished there we were due to go to Heesemann to look at its sanders. However, my father asked the price difference between a Heesemann and BÜTFERING machine. I informed him that the BÜTFERING was about £20k cheaper, so he said let’s go there first.

“We turned up unannounced at BÜTFERING at three o’clock in the afternoon, a day earlier than planned. The factory had finished for the day, but BÜTFERING couldn’t have been more helpful. They bent over backwards, changing our hotel bookings and opening up the factory to give us a quick tour.

“We then took all the parts we wanted to sand to the demonstration room where they had five or six models that were in production at the time. This gave us the

“The reason we bought the SWT 955 was to respond to an architectural ‘fashion’ that has significantly increased the demand for horizontal veneers on doors – a horizontal veneer being when the grain runs across the width of the door rather than the traditional vertical veneer which runs top to bottom.

“Our previous BÜTFERING sander, the SWO 313, which is still a good machine, has a cross belt and two longitudinal belts. So when sanding veneers that were laid horizontal, we had to put the parts through the machine twice using the cross belt on the last pass to remove all sanding scratches in the veneers.

“With our new SWT 955, we have a longitudinal belt followed by two cross belts so we can sand in one pass. This not only saves time, but also gives us an improved finish as each cross belt goes the opposite way to one another.

“Over the years, lacquer sanding has been a bigger part of our work. We can

36 Panel & Joinery Production JULY/AUGUST 2014

sand with up to 1200 grit belts over five heads, so the finish is first class.

“The new pad technology on the SWT 955 is significantly better. The pads respond much faster and more accurately which has all but eliminated any ‘sand-throughs’.

What’s more, the latest software that controls it is more versatile; you can feather the pressure in so, as the part enters the machine, you can slow it down then build pressure up as the part travels through. It is just a very, very good piece of kit.”

Three big advantages “The new sander has delivered three big advantages to our business. Perhaps the most important to us is the accuracy of sand because when you’re sanding various different types of veneer that is very important. “Secondly the ability to take veneer tape off is a great benefit because to get skilled labour to remove veneer tape effectively isn’t easy. Getting the gum residue out of the veneer is tricky but with the SWT 955 we can do it quickly and easily.

“Finally, being a veneer company, we just needed to be able to sand to a much higher standard in one pass rather than two. The new finishing sander gives us this productivity gain with a very high standard of finish.

Confidence, trust and quality “Believe it or not, we didn’t even see the SWT 955 in action before we bought it, such is our trust BÜTFERING’s products and our confidence in Paul to recommend the right machine for the tasks we specified.

“From an operating point, the great thing is that it is very similar to our previous BÜTFERING, so it didn’t take long to master the touch-screen controls which are simple to use.”

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CASE STUDY Substantial gains in productivity “All in all, the sanding on the SWT 955 is significantly better. The lacquer sanding is particularly brilliant because the part is very clean when it comes out; it’s ready for further spraying, the base is so much better.

When we de-nib there is virtually no dust left behind which saves us a lot of time; the belt cleaning, dust extraction and part cleaning is so good, we don’t get much dust at all. It’s a great bit of engineering “From a productivity point of view the

new sander is saving us a couple of minutes a door, so if you’re doing a hundred doors it doesn’t take long to add up to substantial time savings. This time saving has allowed us to move labour to other areas in the production process.”

Well built, easy to use with brilliant results “If you’re looking for a wide-belt sander that is well built, easy to use and gives you brilliant results I would recommend taking

a look at BÜTFERING. The company has served us well for nearly 20 years and as our business has grown it has always given us excellent advice and support,” concludes Chris Jones.

If you would like more information or a demonstration of BÜTFERING products contact Adele Dixon at HOMAG UK: Tel: 01332 856424

The BÜTFERING SWT Profiline

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JULY/AUGUST 2014 Panel & Joinery Production

37

PROFILE

DMC's New System TE for Complete Flexible Sanding DMC, a division of the SCM Group, offers the new compact and reliable "System TE", which has been designed to fulfil the production requirements of companies that do not require specific production processes but prefer versatility of use when sanding, including calibration, sanding and finishing of panels and components.

The new range of DMC's "System" sanders allows the user to create completely customised machine configurations, which can satisfy the most specific production requirements, due to the wide range of technological solutions on offer and the totally modular structural design, with user-

friendliness, multi-directional machining and attractive finishing effects.

Modular Units that can be selected include an infeed Planer, Contact Rollers, Combined Roller / Sanding Pads, Sanding Pads, Superfinishing Pads, Orbital/ Planetary / Oscillating Units with brushes, Crosbelt Sanding Units and various brushing and special sanding units, including a saw unit, at the sanders outfeed.

The "System" T5 / T7 1350 configuration (with 5 or 7 units) for finishing and superfinishing of veneered and painted panels is an example of configurations for the furniture industry and manufacturers who require sanding machines and systems

for intensive use and able to produce excellent finishes on raw and painted panels.

With 5 or 7 units selected from DMC's wide range of units, the System T5 / T7 can provide a perfect specification to meet all sanding and finishing requirements.

The optional “floating tables” can be used to compensate the difference in thickness between the various panels. It is produced in 2 or more sections for each operating unit.

The “EPICS” Electronic Sectional Pad consists of a special monolithic beam which houses the cylinders that activate the single sectors. Due to the wide excursion of the pistons and the double action system (adjustable pneumatic push/counter push),

Digital setting of the system’s units

38 Panel & Joinery Production JULY/AUGUST 2014

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PROFILE

DMC System wide belt sander

the “EPICS” pad guarantees maximum sensitivity and precision in any type of machining. The unique structure of the pneumatic cylinders allows the “EPICS” pad to sand panels with uneven surfaces perfectly.

The “EPICS” pad is available with two different centre-to-centre distances of the sectors: 32 mm and 16 mm. The latter is particularly indicated for machining narrow or shaped workpieces with very tight angles.

The innovative “PWM” system (DMC patent) allows the changing, in real time, the operating pressure of the “EPICS” electronic pad, adapting it to the different panel areas. The PWM technology allows for a reduced sanding pressure to be applied to the front edge of the panel. The pressure is progressively increased to sand the central area of the panel and then decreased once again for the rear edge. A sophisticated workpiece reading device positioned at the conveyor infeed allows the system to manage different pressures on the side edges of the panel. The pressure varies according to the shape and position detected when the workpiece is inserted in the machine.

The “PWM” system is totally managed by the “Hydra PC” electronic control. Due to the advanced operator interface developed specifically by DMC all the device parameters can be displayed, set and saved in the single work programs. The System Hydra Controls all the machine management software is

proprietary, developed specifically by the DMC engineers and perfected with the feedback provided by DMC's clients. This has resulted in an extremely simple and reliable user interface, which is able to perfectly fulfil all the requirements of the most demanding operators. The “Hydra V-Pad” control, fitted as standard on all the System sanders, is used to set all the operating parameters on the touch screen, and to check in real time the correct operation of the machine.

Investing in a DMC Wide Belt Sander Centre does not mean simply buying a machine. It means becoming a partner

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of one of the most important Italian industrial groups and having access to the exclusive services offered by the advanced technological research centre that the company has recently setup inside its site in Thiene (Vicenza), Italy.

For further information: Tel: 0115 9770044 Email: scmgroupuk@scmgroup.com www.scmgroup-uk.com

DMC’s Epic Electronic Sanding pad system

JULY/AUGUST 2014 Panel & Joinery Production

39

SANDERS

Brilliant Sander for Hi-Tec Hi-tec Joinery was established in June 2002, for the production and supply of certificated fire door, linings and screens all to the commercial markets.

Quickly outgrowing its first site, the company has twice moved to larger premises, most recently in 2012. The company supplies doors and screens to schools, universities and colleges; hospitals, care homes and surgeries; as well as refurbished offices or new premises for blue chip companies. The fire doors are certified under the BM TRADA QMark scheme and are tested to BS 476:Part 22 Fire Doors.

As part of his programme of investing in the best machinery to do the job, company owner Ian Matthews recently purchased a Brilliant-2 1350 REd-L sander from Kündig, through Southampton dealer Sawtec, which was delivered and commissioned in March 2014.

As a growing company, Ian explained that his aim is to reduce his dependence on outsourcing by bringing more processes in house, making the company more selfsufficient. This is an ongoing process, and as such further investment is expected in the future. The choice of the Brilliant-2 exemplifies Ian's attitude: although at present it is used for general sanding, Ian selected the “L” option where “L” stands for Lacquer, meaning that he has the capability to sand veneered and lacquered doors as well, as his business continues to develop.

Hi-tec doors are available in a range of veneers, including Walnut, Cherry, Maple, Beech, Oak, Ash, Koto, Eucalyptus and Sapele, and supply a full range of laminate faces from all the main manufacturers, including Formica and Polyrey, so the ability to work with these materials in the future was important to Ian. Ian investigated four different machines, and settled on the Kündig for a variety of reasons. He has a long-standing relationship with Sawtec, which provides the company's saws and cutters for the CNC machinery. Ian also appreciated Kündig's quality: “Because they are a specialist in the field, all they do is sanding: they were the best on the market.”

Ian added, “I like to look at the machines we are considering being made, and I also

40 Panel & Joinery Production JULY/AUGUST 2014

like to have contact with the people doing the manufacturing.”

To this end, says Carl O'Meara of Kündig Ltd, “We took Ian for a tour of the Kündig factory in Switzerland to see what I believe to be the largest static display of sanding machinery in different configurations (and all available for demonstration purposes), along with machines in production and the manufacture of the sanding belts.”

According to Ian, this tour helped influence his decision to purchase the Kündig sander.

When asked, Ian said he would definitely recommend the sander, citing the improved quality of finish as well as the greater control that he has now that he manufactures in house.

The sander selected by Ian was a twinbelt machine configured with a roller and an electronic sanding pad and lacquer options for solid wood, veneers and lacquer.

A constant passline machine, where the sanding group raises and lowers to the desired thickness rather than adjusting the height of the worktable, the machine has a standard working height of 3-200 mm and a working width of 1,350 mm: the Brilliant2 is also available with a working width of 1,100 mm and 1,600 mm, and a wide variety of head configurations are available.

The full Brilliant range offers from one to four working heads, generally with the final head being “oblique”: a Kündig feature believed to be unique which reduces oscillation marks and thereby improves the quality of the final workpiece. Optional foldaway infeed and outfeed tables are also available with this range.

Brian Bourne of Southampton authorised dealer, Sawtec, commented: “I had no doubt that the best machine for Ian would be a Kündig. The demonstration in Switzerland represented a comprehensive range and their knowledge of the machinery with the potential applications is unprecedented. Our visit confirmed that the Brilliant-2 1350 REd-L would not only meet Ian’s exacting standards, but also has the capabilities to help him exceed his exceptional quality.”

The growth that Hi-tec Joinery has seen in the past speaks of attention to detail as well as a focus on quality, and this is where a Kündig sander is a good fit for the company.

The Kündig Brilliant Sander in operation at Hi-Tec Joinery

An example of Hi-Tec Joinery’s fire doors

Brian Bourne (left) of Sawtec hands over the Kündig Brilliant Sander to Ian Mathews of Hi-Tec Joinery

As Carl O'Meara summed up: “We are delighted to welcome Ian as one of our latest customers and for his recognition that at Kündig we are constantly striving to be the best at what we do.

His investment with Kündig also represents a long term investment in the future of Hi-tec Joinery.”

For further information: Tel: 0845 833 0565 Email: info@kundig.co.uk www.kundig.co.uk

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DUST EXTRACTION

Dustraction at the Movies Dustraction won the contract to put a new face on waste at the shopfloor that makes all the film-sets at Pinewood Studios. Pinewood, at Iver Heath in Bucks, is Britain’s Hollywood - the studios that made the Bond Films famous, and made Michael Caine a star, first as Harry Palmer in movies like the Ipcress File and later The Italian Job; Pinewood is also the home of the Carry-On films.

The workshops at Pinewood help make all the film sets for movies which, in the present day, include recently released Maleficent starring Angelina Jolie; manufacturing in wood and wood-based panels for the film-sets of movies like these gets busier and busier. Dustraction’s new installation services many traditional woodworking machines from makers like Wadkin, that have been on the floor at Pinewood doing the same work for years, together now with more up-to-date names like SCM that share the work-load of today.

One of the most important watchwords at Pinewood, whoever you are, is noise because filming is always going on

somewhere on the million square feet of staging the film-makers are now working with.

Dustraction has been tasked with reducing the sounds of dust extraction and disposal, noise with which we, in this industry of ours, is eminently familiar to us but which is outlawed by the sound recording teams working on today’s movies.

Because of the importance of noise abatement around the film sets, Steve Matuska says all the new filters and fans at Pinewood are now located indoors and have been partitioned off inside a dedicated new plant room.

Systems contain several fans and duct mains, each serving a separate area of the shop floor, in a layout that enables individual areas to be shut down when not in use, making savings in power as well as noise.

Dustraction have been working on impeller noise generated by the traditional

New ducting by Dustraction is now feeding many more machine stations at Pinewood Studios in Iver Heath in Buckinghamshire.

42 Panel & Joinery Production JULY/AUGUST 2014

paddle-blade style of fan-set and Steve Matuska reports on big increases in efficiency as well as lower noise output.

Work done by the R&D Team in the drawing office at Oadby has resulted in a new generation of ruggedly constructed wood-waste handling fan-sets that retain the self-cleaning characteristics of the old paddle-blade styles but which can also now operate at much higher pressures with increased efficiency as well as lower noise output due to improvements in blade design.

The new cyclofilters are Dustrax 5s which between them handle a total air volume of 11.3m3/sec which represents a spare volume capacity of almost 50% for the future, which Pinewood’s man Jonathan Ash says may be needed sooner rather than later! At Pinewood, Dustraction have now installed two new indoor cyclo-filter systems together with a number of fansets; one cyclofilter handles clean wood and the other plastics and non-recyclables, each plant discharging to externally mounted skips via closed loop cyclones.

The filter sleeves of Pinewood’s new reverse pulse cleaning systems generate good cake-waste release without significant

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DUST EXTRACTION cloth movement and meet continuous use requirements. Duct mains are run out of the new plant shop to external waste skips. The contract overall carried a completion clause for the end of May 2014, which Dustraction have met.

For further information: Tel: 0116 271 3212 Email: steve.mutuska@dustration.co.uk

The sounds of waste extraction at Pinewood Studios are now housed in a dedicated Plant Room at the back of the Woodworking & Panel Mill where redesigned fan-sets operate at higher pressure and at lower noise output.

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JULY/AUGUST 2014 Panel & Joinery Production

43

DUST CONTROL Single-Source Service from DCS Group GD Woodworking Ltd, a wellestablished joinery manufacturer, has recently invested more than £750,000 in new woodworking machinery and associated equipment in response to increased demand for its solid wood joinery products.

With 29,000 sq ft of modern production space, ‘GD’ is a volume manufacturer of timber staircases, windows and doorsets; supplying nationwide to major private and social housing developers. Combining the latest machinery and production techniques with a local workforce of more than 55 skilled employees enables the company to provide effectively-managed, volume supply chain solutions.

Founder Glyn Ducker says: “We have dealt with DCS for many years and knew that they had the know-how and expertise required to determine the optimum locations for all machines, which in turn would allow them to design an extraction upgrade scheme which would be both efficient and economical to run.”

For the project, DCS engineers were able to call upon the extensive skills and technologies available from within the DCS group of companies to deliver a solution which incorporated: DCS dust extraction and filtration; Ecogate ‘extraction-on-demand’ systems; plus, a customised spray finishing enclosure designed and

44 Panel & Joinery Production JULY/AUGUST 2014

manufactured by its Gallito operation.

Utilising as much of the existing ductwork and plant as possible, a new extraction system layout was devised that includes a total of four fans feeding wood waste to an externally-sited dust extraction system. Designed to handle a total airflow capacity of 22,000m3/hr, the new system employs a high-efficiency modular filter with pressure-free discharge, Ecogate Power MASTER® variable-speed drive units with via a rotary valve, into a wood integral controllers. waste transfer system. The filter unit is fitted with the Superbag polyester new custom-built spray booth and drying filter bags which employ a patented enclosure which would be sited on top of a weaving technique, in tubular format, mezzanine floor at the end of our giving the filter bag a surface that can cope workshop.” with varying filter loads.

Spray finishing specialists, Gallito Ltd, Each extraction fan has an Ecogate Power now a part of the DCS group, worked MASTER® variable speed drive unit with closely with DCS engineers on the project integral Ecogate greenBOX® 12+ which first involved the re-location and controller. Throughout the workshop, DCS adaptation of the complete mezzanine fitted woodworking machines with structure. Designed for the spraying of automatic Ecogate motorised damper gates staircase components, a 25m2 enclosure was designed and fabricated by Gallito which incorporates two 2.5m wide dry-filter spray plenums and a large drying area. An overhead, manually-operated conveyor system, complete with hanging frames and holding brackets, transports components into the enclosure for spraying, and then into the drying area to remain in a dust-free environment until completely dry.

“We believed from the outset that DCS would handle all aspects of the contract in a thoroughly professional way, and they Above: Gallito dry filter spray booth and drying didn’t disappoint”, says Glen Ducker. enclosure with overhead conveyor system Left: High-efficiency modular filter copes with “Their people are extremely knowledgeable, all dust and chips. very flexible, and are a credit to the and sensors, which signal the greenBOX® company. The end result is that we now 12+ controller to open and close gates as have highly efficient extraction system that machines come on or off line. The will save us thousands of pounds on controller automatically detects changes in electricity, and a paint finishing system extraction load and adjusts the fan speed which adds greatly to the quality of our accordingly. This means that power is only staircase products – well done DCS!” used when needed, and results in an extremely efficient extraction system which will significantly reduce electricity usage.

For further information: Glyn Ducker adds: “In addition to Tel: 0800 040 7116 upgrading all our extraction system, DCS Email: sales@dcslimited.co.uk were able to put forward a scheme for the www.DCSlimited.co.uk design, manufacture and installation of a

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