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CONTENTS
& JOINERY
PRODUCTION July/August Issue 2017 Published by:
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BA Components operate their Acrylic Lamination Line from their Doncaster factory – see pages 30-31 for more information
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© Copyright EC Media Services ISSN 2046-4134
CONTENTS 8-11 14-15 16-17 18-19 24-25 30-31 34-35 36-37 39 40 42 44-46 51 52 58-60
Homag Automatically Leads The Field A Huge Success for SCM At Ligna Biesse Display Innovation To 4,500 Visitors Felder Launch New Machines at Ligna Industry ‘THINKS WEINIG’ At Ligna 2017 BA Components Inside Range Of Acrylic Lamination Authenticity At The Centre Of Egger’s Show Offering Blum Is An Innovative Service Partner Interzum – A Resounding Success For The Ostermann Group Genisis 512S – “It Can Do Everything For Us” Blumotion S – One Runner, Many Possibilities AR18 Doubles Production, Improves Quality Latest Alphacam Features New Key Automation Capabilities New Cabinet Vision – Milestone For Productivity And Efficiency DCS Wrap It Up At Crystal Doors
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SPECIAL FEATURES 6-23 28-35 36-39 51-55 56-60
LIGNA REVIEW DECORATIVE SURFACES INTERZUM REVIEW SOFTWARE DUST EXTRACTION/WOODWASTE
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CHARITIES Blum UK’s BUK-aneers Support One Of Milton Keynes Biggest Fund Raising Events The Dragon Boat race in Milton Keynes is one of the main fundraising events of the calendar, and this year will be raising money for Age UK Milton Keynes. One of Blum’s main interests is to help kitchen companies make “future-proof” products, so this seemed a perfect fit for the fundraising event this year. With a crew of 16, covering every area of the business, it’s also a great way to get the whole company involved in a fun event. Blum are looking to raise £1,000. The BUK-aneers: front to back, Andrea Hillier (Retail Services Manager) Kathryn Jenkins (Order Processor) Billie Watts (Business Trainee) Emma Fletcher (Sales Administrator) Helen Mossman (Order Processor) Russell Green (Warehouse Operative) Andrew House (Technical Assistant) Rhys Peak (Customer Service
Representative) Peter Sharratt (Technical Assistant) Amanda Hughes (Customer Experience Manager) Jonathan Wan (Technical Assistant) Mark Richardson (Managing Director) Thomas Winfield (Sales Administrator) Tibor Magos (Warehouse Operative) Wayne Macainsh (Warehouse Administrator) Ben Pollard (Warehouse Manager) ALSO included but not in the photo – David Sanders Snr, David Sanders Jnr, Allen Carter, Rob Guerin, Craig Johnson Dragon boat racing is an ancient Chinese tradition and the fastest growing water activity in Britain today – as well as the most fun! Up to 16 people paddle each 40’ boat with a drummer at the front beating time and a helm at the tail steering a straight course. The Dragon Boat Race was on Sunday
25th June at the Willen Lake in Milton Keynes. http://dragonboatfestivals.co.uk/dragonboat-festivals/milton-keynes/about-themilton-keynes-dragon-boat-festival/
Leitz takes on 53 miles non-stop Ultra Marathon for special children’s hospice Donate now to raise money for the Leitz Team in support of children’s hospice Haven House held on 24th June’s Race To The King Ultra Marathon across the South Downs from Arundel to Winchester Cathedral. https://www.havenhouse.org.uk/fundrais ers/brian-matt-leigh-anna-and-rob-areracing-to-the-king Leitz Tooling has been proud supporters of Haven House over the past three years and have collectively raised over £6,000 for their services which help life-limited children and their families. At the end of June, a team from Leitz is taking part in the Race To The King: an Ultra Marathon, 53 miles non-stop across the South Downs to raise further funds for the hospice. Brian Maddox, Leitz sales manager and resident philanthropist said, “This is a big challenge and we are all training very hard any sponsorship we can raise from industry is greatly appreciated and goes a long way
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to helping Haven House raise the £3.6m it needs each year to support all those who need them. “I am sure that, like me, you cannot contemplate what these poor children go through and the effect their illnesses have on their families. A couple of years ago a few of us from Leitz were invited to the hospice to see the work they do. It is an unbelievably wonderful place and the positive nature of everyone, the support they give to children during their short lives and the families, is inspiring and humbling. “The Ultra Marathon is going to hurt …a lot…but worth it to give every penny to support Haven House”. Leitz is extremely grateful for all those who have supported previous events. We hope those kind people plus many more would be able to offer support again. Of the team, Brian said “Matt Turner is a great guy who works in our engineering department. He is always very helpful, has
Brian Maddox, Leitz UK Sales Manager & Matt Turner ready for the “off”
an amazing skill set and worked for Leitz over 20 years. He has helped all of us, directly or in directly to make us the quality company we are. Me and my son Leigh are also taking part, as are Matt’s friends Anna French and Rob Hamill, although they might have to cross the finish line carrying me on a stretcher!” Donate now at https://www.havenhouse.org.uk/fundraiser s/brian-matt-leigh-anna-and-rob-are-racingto-the-king
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PEOPLE Graham Horton Retires From The “Strange But Wonderful” Kitchen Industry After Over 28 Years With Blum UK One of Blum UK’s longest serving sales managers, Graham Horton, has just retired after 28 years and 10 months with the company. Horton was Regional Sales Manager for the South West of England, and was well known throughout the industry for his knowledge and love of Blum products. Employed by Michael Powell in the late 1980s, Horton has seen the company grow from 4 employees to over 60 today. He joined as a young man after a few years as a salesman with Hygena, and also a kitchen fitter, and then spent the rest of his working career with Blum UK. A retirement party was held in Milton Keynes for Horton, which was not only attended by current Blum staff, but also by the MD of Blum Austria, Gerhard Blum, as well as a number of Horton’s customers who have become personal friends over the years. Graham is looking forward to his retirement in the West Country, where he Blum UK will concentrate on golf, gardening & glorious getaways in the sun! Tel: 01908 285700 www.blum.com
Graham’s working-life history 44 years in this strange but wonderful industry. I would like to start by saying thank you to a friend who helped me celebrate my recent retirement at Blum UK's head office in Milton Keynes for the title I have chosen, the words "strange but wonderful industry" were included in the retirement card given to me and sometimes "you know they just fit" so thank you Gerald and Rhi, you know who you are. It all started back in 1972 when as a young man I had just completed my apprenticeship as a joiner cabinet maker at a small company in Wolverhampton and at the same time having just got married was looking for a change in career to earn more money to be able to buy a house. Browsing through the local paper one evening I noticed a small advert: "Technical Representative required for the Midlands and North Midlands area, company car provided, applications to John Menard Technical Services Manager, Hygena Ltd.” I subsequently applied for the job was interviewed and offered the position, all in the space of two weeks, things happened much faster in those days! I had no idea at the time where this career change was going to take me. I was just twenty-one years old, but eager and willing to learn, and to earn the respect of the older guys I worked with on the team. I have a lot to be thankful to John Menard and Hygena for, the training at the time was first class. I was taught the correct way to survey a kitchen, how to design and how to get every piece of information out of
the customer, so you had every opportunity to fulfil their expectations and I loved it. For me the best part of the job was dealing with customer complaints, this taught me so much more about people and how to handle them in different situations, I didn't know it at the time but this was the skill that would get me through my whole working life and not a day went by when I didn't look forward to going to work. Alas all good things come to an end and I was made redundant in 1980 when the company was closed. Fortune came knocking when I was approached by several companies looking for kitchen fitters to install their displays, so I decided I would work for myself and spent the next 8 years traveling the length and breadth of the country. But only coming home at weekends couldn't last, as we had a young child and I was never around when needed, so I started looking for a new position. Browsing through the KBB magazine one night I saw a job advertisement for a Midlands and South West area sales manager for Blum UK Ltd. I knew the product as we had used Blum hinges and runners at Hygena, so thought "I can do that", so I put pen to paper and sent my CV to Michael Powell at Blum UK. I didn't get a response for weeks, then one day my wife rang me to say a Mr Mike Powell had been on the phone and wanted me to call him asap. At the time I was setting up an exhibition stand at Alexander Palace for Glendale furniture and forgot all about it, a couple of days later my wife rang again: Mr Powell had been chasing me, so I called him
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back. Quite fortuitous really as I was in London at the time so we arranged to meet and I was interviewed. Again nothing happened for a couple of weeks then I was asked to attend a second interview where I was introduced to Mark Richardson who at the time was general manager at Blum UK. The interview went well and I was offered the job and started in July 1988. The past twenty eight years have been an incredible journey and I feel privileged to have been part of the team at Blum UK. Through all my years at Blum I have always held firm to one belief, people buy from people, not from companies, and I always treated people as I would want to be treated myself; I like to think it worked. At my recent retirement party I was given what can only be described as a This Is Your Life book, the kind words written by my colleagues on every page will serve as a reminder of the 44 fantastic years I have spent in this strange but wonderful industry. There are far to many people to mention and thank for making my journey such a memorable one, but I cannot go without saying thank you to Gerhard Blum for making the journey to Milton Keynes to help me celebrate my retirement, my thanks also to Mike Powell for having the courage to employ me, a huge thank you Mark Richardson for his friendship and cooperation over all these years, thanks also to Gerald and Rhi, Eddie and Wendy, Danny, Carol, Jean and Phil, my friend Tim Bills, Peter and Gloria and of course all the wonderful people at Blum UK, especially Mark Rider. Thank you one and all.
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PEOPLE
DCS Named Top UK Reseller 2016 Camfil APC (Air Pollution Control) is the world’s largest manufacturer of dust, fume and mist collection equipment. ISO 9001 certified manufacturing facilities, operating across three continents and supported by a state-of-the-art dust testing laboratory, ensure the quality of every piece of Camfil APC equipment. Leading dust and fume extraction engineers, Dust Control Systems Ltd (DCS), have been a reseller of Camfil products in the UK for several years and, along with delegates from around the world, Managing Director Philip Oldfield, fellow Director Chris Oldfield, and Company Sales Manager Andy Hives, were invited to attend the European Reseller Conference – held over two days in April, at the luxury Hyatt Regency Cologne, Germany.
Following a full day of product presentations and workshops, the second day was set aside for a series of discourses on the company’s various global successes during the previous year, culminating in an award presentation made by Alex Weis, Vice President of Camfil APC Europe, for the Camfil APC UK Reseller of the Year. Dust Control Systems were presented with the award in recognition of the value of Camfil products sold in the UK during 2016. Philip Oldfield accepted the award on behalf of the company, and spoke eloquently to delegates about the company and how DCS operates in the UK. “I was genuinely surprised when the award was announced”, said Philip Oldfield, “but I was delighted to be able to receive this recognition of achievement on behalf of everyone who works at DCS, and
Philip Oldfield, managing director at Dust Control Systems Ltd, receives the award for Camfil APC UK Reseller of the Year 2016.
who all play a valuable part in the success we have sustained over recent years.”
For more information: Tel: 0800 040 7116 www.DCSlimited.co.uk
Blum Trains The Brains Of Tomorrow With Its UK Apprenticeship Interiors fittings specialist Blum not only designs, innovates and manufactures quality fittings for today’s modern homes but this family company also offers a fantastic, forward-thinking apprenticeship scheme. Pioneering the way for tomorrow’s engineers, designers and creatives, Blum has recently taken on three business apprentices here in the UK. Billie Watts, Sam Daniels and Nicola Cox will all undertake the two-year course, which includes a six-month rotation between Technical; Sales Administration and Order Processing; and the Accounts Department; with a final six-month vocation split between Marketing, Sales & Warehousing and IT. The trainees are Billie Watts, a photography graduate with a passion for modern art; Sam Daniels, a psychology graduate with a keen interest in football and Nicola Cox, who has previously worked as a make-up artist for Bobbi Brown cosmetics. All three have developed an interest in kitchen planning and fitting and are looking forward to the new challenges ahead. “This is a chance to work with a
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recognised, established company,” says Sam Daniels, “who are going to give me the chance to experience many different roles within a business, helping me discover what I am best at and what I enjoy while enhancing the skills I already have. Hopefully in two years’ time, I will be an established, fully fledged member of the Blum team, working in a role that I love and excel in.” Nicola Cox is also looking forward to the opportunities that lie ahead. “I am very eager to learn and understand how each department operates,” she says. “Blum is forever growing and I am keen to see what exciting new doors may open within the company over the coming years.” “I was attracted to a company who obviously value training,” adds Billie Watts. “After doing my research about Blum, I was impressed with the company’s reputation, culture and values, and I jumped at the opportunity to become a part of it.” The aim of the scheme is to build up a bank of knowledgeable staff members who understand the business from all angles.
L-R – Sam Daniels, Nicola Cox and Billie Watts
There is also the guarantee of a role at the end of the two-year placement. In Austria, Blum offers one of the biggest apprenticeship schemes in the country with 80 new apprentices beginning their technical training in September 2016. This brings the total number of Blum Group apprentices to 309 with 13 based in the US and 3 in the UK.
For further information: Tel: 01908 285 700 www.blum.com
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The ultimate sanding machine Wide-Belt Sanders: 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.
Edge Sanders: The Uniq, Uniq-S and Flash offer Heavy cast iron working table Sand solid wood on one side and veneer on the other Motorised height adjustment Motorised tilting of the abrasive belt Straight or bevelled, veneered or solid edges sanded with ease Technology patented worldwide The Kündig edge sanding range offers exceptional construction quality, versatility, ease of use, and an extremely high quality of finish on both solid wood and veneered edges.
Contact us for the latest developments in wide belt & edge sanding technology
Kündig Ltd
Tel 0845 833 0565 Fax 0845 833 0567 Email sales@kundig.co.uk www.kundig.co.uk
REVIEW Ligna 2017 Delivers Big On Innovations Ligna 2017 drew to a close on Friday 26th May, having delivered big in terms of innovations and global appeal with a significant upsurge in the number of visitors from abroad. More than 1,500 exhibitors including 900 from outside Germany were on hand to showcase innovative plant, machinery, tools and solutions on some 129,000 square metres of nett space. Ligna 2017 attracted a total of 93,000 visitors including 42,000 attendees from outside of Germany who had come to Hannover from more than 100 different countries. The next Ligna will be staged from May 27-31 2019.
TM Machinery Launch New Products At Ligna TM Machinery’s distribution partners were angle cutting unit for precision mitre cuts out in force at this year’s Ligna exhibition on wood and composite materials. An Xin Hannover, with new product launches axis measuring system can also be added from German dust extraction specialists, during the build. AL-KO and Swiss vertical panel saw Germany’s leading extraction experts, manufacturer, Striebig, taking centre stage. AL-KO, also showcased two new products Available exclusively in the UK from on its 75sqmt exhibition woodworking machinery supplier, TM stand, which are only Machinery, Striebig, the world’s leading available in the UK from TM vertical panel saw manufacturer, has Machinery. Making its debut launched its brand new saw, the ‘Standard at Ligna, AL-KO’s new, entryS’. Based on the original ‘Standard’ model, level sanding table, the AST which has been a best seller in the UK for 1.0 Basic, has been over a decade, the ‘Standard S TRK1and introduced to offer a priceTRK2 Comfort’ and ‘Standard S TRK1 and sensitive solution for TRK2’ feature new, integrated features to manufacturers who use hand assist the user even further. tools. Working alongside a Differentiated by either an aluminium or dust removal and filter wooden support, the Comfort model system, the design is made from galvanised features a digital measuring system with sheet steel and equipped with a manual, motorised Y-axis as standard. The new tool-free height adjustment mechanism digital display also features simple to and handy scale for simple and effective operate positioning buttons that allow the use. It also benefits from an offset user to adjust a panel’s location longitudinal sides for edge at the touch of a button. A sanding, a Beechwood rack to new VSA scoring saw unit – prevent damage to the work which is fully adjustable piece and a funnel-shaped air has also been added to the guide for the extraction line-up, allowing the saw to nozzle. The AST 1.5 Basic work with coated panel sanding table joins the AST materials with ease. It’s also 1.0 – 3.0 Premium model as equipped with 17 rollers and the company continues to either pedal or pneumatic expand its portfolio. AL-KO’s Power Unit 350+ brakes, as well as a TRK dust It’s also the first time AL-KO was exhibited at Ligna extraction system. has demonstrated its 350+ Key accessories also include extraction unit at Ligna. reversible carbide tips for effective grooving Featuring new, patent pending technology and routing work from 8-15mm and a WSG and a unique design, and benefiting from
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Above: The Striebig Standard S launched at Ligna Left: The new Striebig Scoring Blade featured on the Standard S
the company’s ‘Made In Germany’ ethos, the innovative 350+ boasts a powerful but economical 15kW IE3 motor that offers 10,000 m3/h, ALKO’s biggest flow rate to date. It also offers a filter surface of 73 m2, which is enough to lower the residual dust content of the recycled air to 0.1 mg/m3 (H3). Featuring AL-KO OPTI JET® technology and an integrated pre-separator as standard, the compact design measures 3,077 x 1,058 x 2,351mm. It’s also extraordinarily quite at just 72 dB (A), thanks to the unit’s sound absorbing panels. Additional accessories also include a briquette press or rotary lock valve, which can be added to the unit for a tailor-made solution. TM Machinery is the exclusive UK distributor of Striebig vertical panel saws and AL-KO dust extractors. For further information: Tel: 0116 271 7155. www.tmmachinery.co.uk Twitter: @TM_Machinery
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REVIEW Leitz Tooling Crafts “Solutions In New Dimensions” At Ligna 2017 At this year’s LIGNA, the leading the wood machining industry exhibition, Leitz once again demonstrated its dedication to innovation and focus on productivity solutions for customers. With its new booth concept and exhibition statement “Solutions in New Dimensions”, Leitz presented its total range of expertise and technical know-how. The world market leader in tooling solutions has tackled issues currently faced by the wood machining industry. This includes meeting the need for faster and more efficient production processes, increased flexibility and cost effectiveness, whilst continuing to improve the already excellent machining quality delivered by Leitz tooling systems. UK managing director of Leitz Tooling, Simon Liddell said, “Our new concept and tooling exhibitions worked exceptionally well at LIGNA. Considering the show runs for a week, there was not a quiet moment and the interest and enthusiasm for new, innovative, efficient and cost effective tooling solutions from all our visitors was excellent. From the UK, we welcomed many existing customers and met with
more new companies looking for the best solution for their specific production; a challenge we are always happy to deliver on.” Leitz expertise was demonstrated by innovative tool solutions. The new cutterhead system ProfilCut Q Diamond with indexable inserts sets new standards as a pioneer in machining wood. The unique combination of its ultra-light aluminium tool body and resharpenable, diamond edges with constant diameter ensures maximum productivity combined with significantly higher efficiency. The profile tooling system is used in numerous sectors of both wood and plastic processing. With the WhisperCut circular saw blade, Leitz has designed user-friendly and futureoriented saw technology. Due to the intelligent arrangement of various edges, perfect staggered cuts and reduced cutting forces are achieved. When used on circular saw benches and cross cut saws, even at idle speed, the noise level is dramatically reduced. The proven HeliCut program for timber construction was expanded for LIGNA and has transferred its benefits to numerous
Leitz WhisperCut sawblade
Leitz HeliCut display Ligna
other applications. LIGNA in Hannover is the international leading fair for machines, systems and tools for the machining and processing of wood. The complete value-added chain of the wood industry is represented – from timber harvest, through to industrial production. For 2017, LIGNA reorganized its floor space concept to reflect the convergence of the processing technology in the woodworking sector. About 1,500 companies exhibited and a total of 93,000 people visited the show, of which approximately 45 percent came from outside Germany.
For further information: Email: salesuk@leitz.org www.leitz-tooling.co.uk To make a purchase online: www.shopuk.leitz.org Leitz stand at Ligna See our website and interactive magazine www.p-j-production.com
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REVIEW HOMAG Automatically Leads The Field At LIGNA 2017 This year’s LIGNA show was all about Industry 4.0 and as we’ve come to expect from the world’s largest woodworking solutions company, HOMAG put on an impressive display. The company showcased 50 machines covering every performance category using smart technologies and processes which communicate with each other to provide end-to-end production automation. HOMAG’s new software platform delivers total solutions from the point of sale through to production and packaging. The company’s marketing theme, ‘Your Solution’ encompasses machines and technologies that will grow with your business. This enables joiners, cabinetmakers and industrial furniture producers not only to address the individual needs of their customer, but also to handle challenging products and process a raft of traditional and modern materials.
Furniture Production – from bespoke to industrial HOMAG’s show piece in Hall 14 was its completely networked batch size 1 plant. This high-tech furniture production plant consisted of seven machines linked together. The networked production
Two Profit KAL 610 edgebanders running in tandem
solution included a horizontal storage system, the TLF 411 with a suction traverse ST 71 for handling a diverse range of materials. The cutting cell featured the new HOMAG HPS 320 flexTec beam saw with fully automatic part stacking. This robot cell has the option of an automatic outfeed, various lifting table options for automatic stacking or a combination of roller conveyor and lift tables. Edge processing was handled by two
Profi KAL 610 edge banders running in tandem. The machines glued all edges using PU adhesive and a unique offsetting station provided unprecedented work piece circulation to substantially reduce the floor space required. To maintain a constant flow of materials, the networked plant utilised the HOMAG TLB 321 order picking centre. The TLB buffers, sorts and picks the material flow over the entire process chain. The drilling and hardware fitting was
HOMAG lead the field at LIGNA 2017 showcasing its latest innovations
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REVIEW Edge banders for woodworking shops
HOMAG showcases the latest innovations in panel sizing technology
handled with the HOMAG ABF 600, a CNC-controlled machine especially designed to handle sensitive materials used for front facing parts. Its advanced clamping system is particularly suited to the gentle and efficient processing of materials susceptible to damage. Once all the carcass parts were produced the electrical throughfeed case clamp, MDE 120, was used to construct the furniture carcases. This advanced machine produces ultra high-quality or mitred carcases. Completing the production, the cardboard cutting machine VKS 250 produced just-in-time custom packaging at minimal piece costs.
Standardised operation and control software
HOMAG demonstrated an entry level production concept which saw mitre cuts being carried out by a HPP 130 panel dividing saw. The workshop was supplemented by a case clamp and HOMAG 050 CNC machine for vertical drilling for complete processing.
Workshop for the industrial entry level Catering for all, HOMAG also demonstrated advanced entry level solutions for industrial sized manufacturers. Placing an emphasis on woodworking shops, a highlight at LIGNA was the fully networked HOMAG sawingstorage-nesting cell. With a drilling and dowel driving machine it provided a full end-to-end production solution.
All the machines in the networked plant were operated using powerTouch which ensures a familiar look and feel for the users. The networking of the machines in the batch size 1 plant was controlled via the woodFlex software. This groundbreaking software future-proofs the plant, creates security, optimises work sequences and enhances efficiency.
For maximum edge quality for entry level users, HOMAG machinists demonstrated the popular Ambition 1120 FC. With a joint-trimming unit and a profile trimming tool for perfect corner rounding, it allows for complete workpiece processing. The flexible finish zone features two free spaces which were equipped with a profile scraper blade, with standard quick-change heads, and a glue joint scraper blade. Operated by a 7” easyTouch control system with clear graphic display and 20 storable production programs, the 1120 FC is small yet mighty. Equipped with all the impressive standard specification of the entry level Ambition 1100 series, the 1200 series boasts a tiltable end trimming unit for both straight and chamfer trimming and a top/bottom trimming unit for perfect edge finishing. The added bonus of HOMAG’s airTec system is available from the Ambition 1200 series onwards for manufacturing with invisible joints. During the five day event, HOMAG announced that PU processing is now available from entry level edge banding machines upwards. Many companies are utilising the benefits of PU adhesive to ensure that manufactured furniture is resistance to conditions such as water and heat. Due to popularity, a standardised topmounted glue application system for entry level edge banders will be available from the LIGNA onwards. HOMAG also demonstrated its latest zero joint technology, laserTec – Next Generation. HOMAG has built upon its successful airTec system with a solution that offers zero joint quality for both batch
Small entry level workshop solutions over 80 sq m Visitors to Hall 14 found an array of entry level technology. This included both stand-alone machines as well as the latest smart solutions for kitchen, office and bedroom furniture manufacturers.
The LP 300 series from HOMAG’s new range of planer moulders
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REVIEW
LIGNA 2017 saw the launch of tapio – HOMAG’s new digital platform for the woodworking industry
size 1 and in series production. Offering a more compact and reliable system, laserTec – Next Generation is an ideal solution for the faster production of invisible joint edges.
Panel dividing technology Experts demonstrated the latest innovations in panel dividing technology. One clear theme emphasised the importance of giving more control to the operator. In turn this improves the cutting process with a greater degree of safety than ever before and increases overall efficiency in production. HOMAG presented the significantly updated and improved CADmatic 5 machine control unit which is more strongly oriented on the behaviour of the user than ever before. The CADmatic 5, available from series 3 upwards, has been redesigned to be easy, efficient and intelligent. The innovative graphics guide the machine operator through the input and
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processing steps. Not only can the operator see what the machine is currently doing but they will also see what work step comes next. Controlling the machine via the keyboard and the mouse has become a thing of the past. For simplicity and convenience, the user is now able to navigate the screen by touch. HOMAG also presented its revolutionary new panel dividing modular solution, intelliGuide. Demonstrated at LIGNA, there is are two versions: intelliGuide advanced and intelliGuide professional. In both versions, the saw is fitted with a camera system, providing a second set of eyes for watching moving parts on the saw. The more advanced version, intelliGuide professional uses a laser projection system. It projects handling instructions, in the form of symbols, directly onto the parts being processed. Not only does this increase safety and accuracy for the operator but it means that the operation of the machine is not restricted to viewing a screen only.
Surface technology Trends within the furniture industry have seen the demand for PUR laminating adhesive grow significantly. This has led to HOMAG extending its product range of laminating machines to include the FKF 200 and 250 for both high-gloss and laminate coating. Using HOMAG’s dedicated control system and customtailored automation, they provide individual solutions for coating furniture parts. In addition, the operation of the SWT 300 series sanding machines has been simplified. Now, the user interface has been integrated into the machine and is used in a similar way to an app on a smartphone. Users can operate the machine by touch, simply using swiping or drag and drop actions for faster set up.
CNC technology Making its debut at LIGNA was the new BMG 310 CNC series. Building on the success of HOMAG CNC machines, the
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REVIEW
HOMAG debuted the easy access BMG 310 CNC series
310 series is more freely accessible with more space for tools. With the addition of a robust and stable sliding gantry system, the CNC offers unlimited production possibilities. Due to popularity, the feature of operators being able to access the machine from the front has stayed. This makes it more convenient to operate the edging tape magazine and access the drill block and routing spindle. The latest feature of the machine is that the operator has easy table access for loading and unloading the machine. The 310 series is now accessible from all three sides making production fast and easy, as the operator has more freedom of movement when loading and unloading the machine. With a new 32-slot tool changer the operator is given rapid access to tools, providing the machine with a high level of versatility. The design features a plate that has an outer ring with 24 slots and an inner
ring with eight slots, ensuring optimum use of space. In terms of the latest nesting technology, HOMAG demonstrated its solution for cutting customised front designs so that the panels match perfectly later in the assembly process. The new nesting method entails precision cutting of individually designed fronts to create a perfect overall appearance.
Software and servicing HOMAG demonstrated at LIGNA that it has completely revised its software portfolio, for the whole production process, from point of sale to packaged product. HOMAG presented its new ‘One Platform for Integrated Solutions’ software which configures smart solutions for the factory, product configuration and servicing for both woodworking shops and industrial producers from the same modular site. The software offers faster production times from design to delivered product, operator
support on daily tasks and predictive maintenance and remote servicing.
Technology of Tomorrow “Over the years, LIGNA has consistently been a very successful show for HOMAG and 2017 was no exception,” claims Simon Brooks, sales and marketing director for HOMAG UK. He concludes, “From the 100m networked production cell through to the latest software, it is clear that HOMAG has increasingly aimed to create solutions that are easier, faster and more efficient for operators of both entry level and industrial size. “Not only did visitors see the latest technology for this year but HOMAG also teased at its future innovations. At the heart of Hall 14 was HOMAG’s InnovationCenter which explored new patent-registered technologies and smart Industry 4.0 applications. Visitors were able to explore the influencing HOMAG trends and technology which are set to change the furniture industry in years to come.”
For further information: Tel: 01332 856500 Email: info-uk@homag.com www.homag.com The HOMAG GSH 100 throughfeed spraying machine
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JULY/AUGUST 2017 Panel & Joinery Production
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T. +44 (0)1327 300366 info@biesse.co.uk
biesse.com
The evolution of perfection Entry level with a touch of class
REVIEW
A Huge Success For SCM At Ligna SCM attended Ligna 2017 exhibition displaying the most innovative woodworking solutions. Thousands of customers and business visitors flocked to the splendid SCM stand, where over sixty technological solutions were presented, including the “Cell Lean 4.0” for highly automated industrial production. Compared to the 2015 edition of the fair, the number of orders, agreements and contacts increased considerably. This confirms the sharp growth in the sector, which after the positive signs registered in 2015, is now enjoying a period of full-blown expansion. SCM had the pleasure of being represented at the closing press conference by Luigi De Vito, Director of the SCM Woodworking Machinery Division and vice president of Eumabois. This was a prestigious honour for SCM that has been a worldwide leader in this sector since the 1960s. In his address, De Vito emphasized the increasing internationalization of the event. In fact, SCM was contacted by customers from over 60 different countries from all around the globe and succeeded in creating new relationships with a number of up and coming countries.
Luigi De Vito's speech underlined the importance of Industry 4.0 technological solutions for the future growth of the entire sector, “Companies, today, are ready for Industry 4.0. The wide use of robotics should not be confined to a simplistic and incorrect equation of saving labour costs, but should be focused on creating and forming a more highly qualified workforce. In our sector, human labour will never lose its central role. The use of advanced technology allows our companies to appeal increasingly to highly qualified young people who represent the future and already feel completely at home with these new techniques.” The German market displayed its considerable strength and SCM registered a 35% increase in German visitors attracted by “Made in Italy” technology. In its refined, white and blue booth, SCM presented a vast range of woodworking. This range stretched from classical machines to automated systems for industrial-scale production. A particular favourite was “Cell Lean 4.0”, an integrated solution for flexible production that applies “Industry 4.0” and “mass customization” concepts in a way that is concrete and feasible. The solution
The SCM Stefani Kd edgebander proving of great interest
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Andrea, CEO of SCM Group at the SCM press conference
Luigi De Vito, director of the SCM Machining Division and vice president of Eumabois addressing the press conference
presented is completely automated, controlled by Maestro Watch software and served by an anthropomorphic robot fitted with a piece recognition viewer. The cell uses standard, absolutely reliable, high performing, easy to use and configure machines. The system operates automatically from the moment the order is launched and can be used with any operating system. The cell is therefore able to manage automatically and with only one operator, all machining phases, from standard panels to furniture assembly. Cell Lean 4.0 demonstrates the skills of the SCM engineering division, whose aim is to present simple, functional solutions that allow work flows and times to be calculated precisely, and a quick and certain return on investment to be guaranteed. The SCM booth was one of the busiest in the entire event. Its main focus was a large square, the SCM Arena, that featured a tribute to the heroes of Ground Zero, in the
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REVIEW
Part of the SCM stand prior to opening
shape of a 12 metre long table made by Riva1920 from thousand-year-old kauri. The concept of the square was used symbolically to represent the way people have met to talk and exchange goods throughout history. In the same way, people came together in the SCM Arena to share their knowhow, experience and the latest trends in woodworking technology. For four days, SCM specialists, together with
customers and guest speakers took part in a packed programme of daily events. Ligna closed its doors with almost 100 thousand visitors and 2.8 million contacts on its various communication platforms. SCM arrived at Ligna 2017 strengthened by a continuous and brilliant growth. 2016 ended with a turnover of 600 million up 15% compared to 2015, confirming its solid financial position with a good cash flow. An
extraordinary result that has been driven by the wood sector, which has exceeded 430 million in turnover, with a growth of over 15%. 2017 began with a double digit increase in orders and turnover, a further improvement on the already good results of recent years. SCM’s presence at Ligna confirms its leadership position in technologies for wood working processes, that today are represented by a single brand: SCM. The models inherit the distinctiveness and names of the original brands. The doubling of the turnover for cell systems, plants and production lines for flexible industrial productions has been particularly satisfying for SCM. They are demanding orders, with investment costs that range from one and a half million to ten million Euro and the leap forward of this sector proves the maturity achieved by SCM Engineering.
For further information: Tel: 0115 977 0044 www.scmgroup-uk.com SCM’s Flexstore system prior to opening See our website and interactive magazine www.p-j-production.com
JULY/AUGUST 2017 Panel & Joinery Production
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REVIEW
Biesse Display Innovation To 4,500 Visitors The 2017 edition of the Ligna trade show in Hanover was a special time for Biesse. The great number of visitors from all over the world who came to the over 5,000 square meter stand and the positive feedback received from customers, partners and the press were a significant and gratifying response. They are the fruit of the company's investments toward providing increasingly efficient services, offering innovative products and strengthening its presence in markets throughout the world. “We were particularly proud of the innovations Biesse presented at this edition,” stated Federico Broccoli, Division Director Wood/Sales & Branch Division Director. “The layout of our stand was entirely based on the 4.0 concept," Broccoli continued, "with interconnected technologies that offer customers the significant benefit of reducing production times and creating efficiency. We like to refer to these solutions as IoB – Internet of Biesse”. The interest garnered by the Machines Knowledge Centre, a new platform
Busy as ever on the Biesse Stand
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Demonstrations and viewing throughout the show
developed in collaboration with Accenture that guarantees a series of features and services for obtaining more value from the machines, and by the renewed bSuite, a software suite made in Biesse that makes the most advanced technology accessible to anyone, are a testament to how strongly
customers need products and services that can revolutionise traditional production areas. Over the 5-day trade show a full 4,500 visitors from all around the world visited the Biesse stand, generating 45 million euros worth of incoming orders, 35% of which are 4.0 lines. Never before had the company achieved such figures at any trade show. More than 40 fully-functioning technologies were on display at the trade fair, designed for companies of all sizes that work with wood and other materials, enabling them to discover how the digital factory can change the way they design and produce objects, through integrated, complex solutions that are easy to use. Biesse is committed to transforming customer factories into digital factories, which enable them to benefit from the opportunities offered by being Industry 4.0 ready. Visitor turnout in the Services area bears testament to the success of Biesse's investment in various advanced digital projects and tools, MKC – Machine
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REVIEW
The virtual reality headset
Knowledge Centre – and Parts portal, designed to provide customers with the possibility to obtain ever greater value from their machines, thanks to an increasingly direct connection with the company, and the professionalism and experience that characterises it. The Housing area was also the focus of
major interest, with turnkey technological solutions and projects for the production of doors, windows, beams and lamellar walls, exhibited at a dedicated stand in Hall 13, as well as on the Group's main stand. The Biesse Collection also made a sparkling debut, with a range of branded clothing and merchandising capturing the
style, the practicality and the exclusivity of the brand. The range includes a host of everyday items, clothing and accessories for adults and children, as well as pieces for the home and for the office, and for play and leisure time. On the first day of Ligna (May 22nd), the collection.biessegroup.com site was launched, enabling visitors to buy products, view the real- time availability of all the items, and check out the constantlyupdated catalogue. At the trade fair, the launch of the Biesse Collection has been combined with support for a charitable cause - indeed, all of the profit from the products sold on the LIGNA stand will be donated in full to the Fondazione Francesca Rava NPH Italia to help fund a project for the reconstruction of a school in Cascia.
For further information: Tel: 01327 300366 www.biessegroup.com Part of the SCM stand
REVIEW Felder Launch New Machines At Ligna More technological advancement, more possibilities and more perfection, FELDER have once again put their innovative capabilities to the test. With plenty of new innovative solutions that will continue to inspire as well as great new ideas and creations that will continue to drive development FELDER launched a host of new machines at Ligna 2017, here are some of the highlights.
Creator 950 The Creator 950 is the all new, advanced, efficient and compact CNC technology from FELDER’s FORMAT-4 range with a space requirement of only 4.8m2. The Creator 950 comes with attractive equipment as standard, modern CNC technology and individual additional options. With no vacuum pods and console positioning, no field selection and no lost time changing tools, which is a major advantage when compared to other
Profit HO8
Tempora 60.06 EL
CNC machines, you just put your piece in and start working.
Tempora 60.06 / Tempora 60.06L The Tempora 60.06 and 60.06L models make processing edges quick, easy and as efficient as possible. to achieve this, the tempora models combine the core skills of speed, productivity, flexibility and ease of use in a convincing complete package and the final
finish when processing both coiled and strip material convince with incredibly high standards. As an option both models can be equipped with the patented "zero-line aggregate" bringing "invisible joints" to your workshop. You can also equip your tempora with a single or dual motor corner rounding unit and there are three free spaces for your choice of finishing units. The smartouch intuitive control unit with a 10" or 16" touch screen ensures maximum operating convenience and productivity.
Zero- Joint with PUR Glue or now available with the new zero-line The patented zero-line aggregate from FORMAT-4 can be activated and deactivated directly from the control unit and enables the optical zero joint when processing coextruded edge and laser edge material. Zero-
Safe Space
Finish 1353
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REVIEW enable you to have the optimal adaptation to suit your requirements and ensure maximum efficiency and time saving.
FAT 300 S and FAT 500 S The New FAT 300 S and FAT 500 S machine equipment trolleys, stacking trolleys or additional work space, both of these tables offer you more space for larger components and can be equipped with a
Creator 950
line offers the homogenised optic finish of the workpiece with the panel and edge material and in particular with high gloss material. An edge material suited exactly to the workpiece ensures a zero-joint line and as no time-consuming glue change of various colours is required, you profit from considerably reduced changeover times.
Profit H500 MT Modern CNC woodworking with individual flexibility as efficient and simple as possible, the new Profit H500 MT CNC machining centre puts industrial use at the forefront of this innovative operating concept. As standard, the machine comes equipped with an aluminium table which your components can be clamped to as well as a 34 position tool changer, 24 spindles and a 5 axis offering a wide range of processing possibilities. The Large dimensioned matrix table, made from phenolic resin, guarantees secure processing of workpieces no matter the material or the size because of the optimal vacuum distribution.
Safety in the smallest of spaces The CNC machining centres profit H350, H300 and H200 can be enclosed on all sides making it possible to bring the most modern of CNC technology to even the smallest workshops. With up to 5.3m2 less installation space required and massively increased working safety. The FORMAT-4 safeSpace is equipped with a large monitor and with wide viewing panels alongside the immediate status overview showing the current machine
status you will always have the best view of all processing steps. safeSpace also comes with a 3.3m door opening making it easy and comfortable to load and unload.
Profit H08 21.31 The Profit H08 21.31 has been developed for universal application, this profitable CNC all-rounder convinces with top precision and impressive productivity when processing various different materials. The CNC machining centre offers maximum flexibility and efficiency and already convinces in the basic equipment with 15 tool positions. For perfect, chip free results, the main spindle is equipped with a 12 kW motor. The main spindle is completed by a drilling head with 8 spindles. Due to the smart zoning vacuum control, the vacuum zones can be switched to either fully automatic or manual control and activated depending on the workpiece size. Individual workpieces with variable sizes can also be positioned and processed in the zones 1 to 6.
Tempora 60.06
panel tilting device. These highly adjustable working tables are versatile in their use, always offering maximum stability and simple mobility. The solid frame on robust wheels with easy to use foot pump hydraulics and extremely durable working surface ensure that stability, manoeuvrability and a comfortable working height are always guaranteed.
Finish 1352 / 1353 modular wide belt sander with planning head The cutterblock planning head with a processing 1350 mm width is available as an option, as first processing unit for maximum cutting performance on this wide belt sander. You can decide the individual equipment and the design of the processing units and make it either a 2 or 3 belt sander. The free aggregate configuration options
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Profit H500
For further information: Tel: 01908 635 000 www.felder-roup.co.uk
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REVIEW
European Launch Of The New Combi-MR At Ligna Combilift, the Irish specialist manufacturer of materials handling solutions, exhibited over 15 of its models at Ligna, including the new Combi-MR which made its official European debut at the show. This stand-on multidirectional reach truck (a sit-down option is also available) combines the capabilities of a reach truck with the versatility of multidirectional travel for operation in tight spaces. Its extreme manoeuvrability enables it to work in reduced aisle widths for maximum use of storage space in the warehouse. The Combi-MR is characterised by its unique steering function: the joystick enables seamless switching of the direction of travel and compact turns. With the ability to handle both palletised and longer loads, this innovative electric powered forklift enables operations to benefit from faster procedures. The design of the cab and the overhead guard offers excellent all round visibility and driver protection, offering a high level of ergonomic comfort and safety for the operator. The 4-wheeled model features a large single drive wheel, fitted with a 400 mm diameter rubber tyre with 360° steering rotation. This is positioned at the rear right hand corner to enable low level entry and exit for the operator and is therefore less tiring when a lot of picking is involved. The rear articulated axle provides maximum traction and a smooth ride for the operator even across uneven surfaces, inside and out. With a lift capacity of 2,300kg, it comes with optional lift heights. “We originally developed this model following demand from the US market and having seen the very positive reaction to it there we believe it will become equally popular in Europe, which is why we chose the Ligna show as the perfect platform to introduce this to a wider audience on this side of the Atlantic,” said Combilift MD Martin McVicar. For further information: www.combilift .com
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REVIEW
J & C at Ligna 2017 The Ligna trade show which is hosted every 2 years In Hanover, Germany is one of the largest international woodworking machinery exhibitions. This is the venue where manufacturers from around the globe go to meet new and existing customers and look to make contacts to supply their goods into new markets. Some brands will be familiar names which have already been introduced to UK furniture manufacturers, whilst others may be less familiar and may just be waiting to be discovered. Having attended these exhibitions over the last 25 years, J & C O’Meara Ltd have seen many changes to the markets where the quality of some lesser known manufacturers have made them comparable with the more renowned top brands and where some of the top brands have had to adapt to more intense competition. As a totally independent supplier of machinery, we are not bound by contracts to supply from individual sources where machines go through various channels pushing up prices etc, but enjoy the freedom of choosing what we believe to be the highest quality equipment imported
directly from the manufacturer to give a range of premium quality products but without the premium quality price tag. At Ligna, as well as looking for new and innovative products, we were also working alongside our existing suppliers and assisting them with demonstrations and enquiries from all corners of the globe. These included the manufacturers of our best selling and innovative Genisis 512S edge bander with pre-milling and corner rounding. With over 60 machines sold in the last 3 years, this machine has proved to be simply unbeatable for the small to medium sized kitchen/bedroom furniture manufacturer. The manufacturers of our Genisis range of sliding table panel saws. These have been our best selling panel saw to date with over 120 installations throughout the UK. From the industrial grade Genisis P32 to the heavy duty flagship of the range, the CNC Genisis X3 Plus. All machines use the same heavy duty, reinforced sliding table which remains accurate and easy to use even when under stress as was demonstrated at the show Did you know that we have been selling our range of briquette machines since
The Prodeco stand showing their latest Briquetter
The AES machining centre will be distributed in the UK and Ireland by J&C O’Meara
2008 and with 15 different models to choose from there is a machine suited for almost any application. We have supplied machines for briquetting MDF dust, leather dust, paper, cardboard, polypropylene as well sawdust and wood shavings. Finally Ligna allowed us to cement our partnership with the AES group who are specialist manufacturers of CNC machinery. This is a particularly exciting venture as we believe AES are a hidden jewel just waiting to be discovered. Imagine a high quality, highly productive industrial CNC at an entry level price...watch this space... For further information: Tel: 01704 893109 www.ukwoodworkingmachinery.co.uk Testing the strength of the Doway Sliding Table Saw
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JULY/AUGUST 2017 Panel & Joinery Production
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REVIEW
Kündig Success At Ligna 2017 As always the Kündig stand at the recent International woodworking machinery exhibition staged in Hanover, Germany was a place buzzing with activity with both existing and potential new customers converging for demonstrations and to see the latest developments in both wide belt and edge sanding technology. On display was a selection of the traditional style machines from the Premium range including a compact 650mm wide machine that could sand components up to 400mm in height. For high volume manufacturers an example of the Botop top and bottom sanding machines was on display. This particular machine had 2 upper and 2 lower sanding heads with each part of the machine having a dedicated calibration roller followed by an oblique segmented pad. This machine being ideal for the large scale production of veneered boards where the raw MDF core can be accurately calibrated and once pressed the board can then be finished using the segmented pads. Each segment is action controlled and therefore offers equal and even sanding across the surface. This system protects the
vulnerable parts of the board, namely the corners and the edges by sensing the area to be sanded and also protects any areas where there maybe cut outs, for example vision panels in doors. For manufacturers of kitchen doors there was quite a selection of machines of differing configurations and specifications, these included a number of lacquer sanding machines all of which had at least one of the heads in the Oblique position to ensure the highest possible surface finish and free from the defects associated with straight line sanding. An example of the high gloss cross belt was also shown which can finish sprayed surfaces using a 2,000 grit abrasive. The Kündig ‘bk' brush system was also shown which is the ideal solution to those who manufacture either 5 piece or routed MDF doors. The ‘bk' uses a cup brush system which both oscillates and orbits giving an intense yet random sanding into profiled surfaces whilst also ‘breaking’ the edges in preparation for sealing and spraying. Showcased for the first time was a new and quite unique multi purpose inner cross belt which is ideally suited to the company
who are looking to generate a number of different surface finishes. This all new system can be used for veneers, lacquered surfaces and can even generate a rustic style finish especially popular for manufacturers of floorboards. Another popular system for manufacturers of floorboards demonstrated was the structure brush which can be supplied as a dedicated machine with multiple heads or as an option on a wide belt machine once again expanding the possibilities of surface finishes. Last but by no means least was the selection of popular edge sanding machines which included the new Uniq-S Lacquer for the pre sanding of MDF edges and then using the action controlled sanding pad can be used to de nib sealed and then sprayed edges. This machine along with the lacquer specification wide belt sander gives an all round solution to those producing high gloss doors.
For further information: Tel: 0845 833 0565 www.kundig.co.uk
The latest sanding techniques were on offer on the Kündig stand
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A COMPLETE RANGE OF 3, 4, & 5 AXIS CNC ROUTERS MANUFACTURED TO THE HIGHEST QUALITY FOR PERFORMANCE AND RELIABILITY
EFFICIENCY SQUARED. THE NEW VOLLMER VGRIND 160
Whatever your requirements Onsrud has a solution ATA ENGINEERING PROCESSES Tel: 01442 264411 Fax 01442 231383 Email sales@ataeng.com
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www.ataeng.com www.cronsrud.com
& JOINERY
PRODUCTION
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
The one-of-a-kind, multi-level machining of the Vgrind 160 uses two vertically arranged grinding spindles to provide the highest standard of efficiency for the production of solid carbide tools. Further highlights include its sophisticated wall design for optimum accessibility and clear viewing, flexible automation solutions and tried and tested operating software. Are you ready for precision at its best?
www.vgrind.com VOLLMER UK LTD. // Orchard Park Ind. Estate // Town Street Sandiacre // Nottingham NG10 5BP info-uk@vollmer-group.com // Phone: +44 115 9491040
REVIEW
Industry “THINKS WEINIG” at LIGNA 2017 At the world's leading trade fair for the wood sector, LIGNA in Hanover, the Weinig Group was one of the stand-out exhibitors at the event. Under the motto “THINK WEINIG”, the market leader in machines and systems for solid wood and panel processing shared its 4,000 m2 stand with group company and panel specialists Holz-Her for the first time. The impressive line-up of over 40 feature machines packed with innovations across the group showcased their comprehensive offering for all performance classes and sizes of operation, and proved a magnet for thousands of professional visitors from around the world. The new W4.0 digital standard enables the Weinig Group to provide forwardlooking responses to the challenges of networked production, and this solution met with particular demand from the international audience. Weinig used linked production lines to demonstrate solutions for the entire value chain, with customer benefits and practicality front and centre of the live demonstrations.
Weinig UK managing director Malcom Cuthbertson (right) with sales agents Steve Cracknell (left) and Andy Moxey (centre)
One of the biggest attractions at the Weinig Group trade fair stand was the unveiling of the new Powermat 2400, available in the UK from the end of 2017. With its camoflague prototype livery, this high-performance moulder was demonstrated live throughout LIGNA, showcasing its many updated features and
technological edge. Holz-Her announced and showcased the new ACCURA and LUMINA edgebanders, equipped with the new Glu Jet PUR 2K for use with 2 kg PUR glue sticks on a newlydeveloped changing station. The design of the new station is based on technology from the LUMINA series with HSK
Weinig stand at Ligna 2017
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REVIEW
Powermat 2400 at Ligna 2017
adapter. The station is easily removed via a change-over carriage, which makes cleaning the glue application nozzle even more simple. In addition, further Glu Jet stations can also be exchanged on the same machine and even combined with LTRONIC on the LUMINA Industry version to activate laser edging. The new vertical panel saws SECTOR 1255 and 1260 have a footprint from as little as 5 m2. They are unbeatable in this area and simple to use, saving you the cost of additional space and prolonged training.
Holz-Her has also tackled the issue of manufacturing cabinets on CNC machines without any programming with the new NEXTEC models. Derived from “Next Technology”, users can produce furniture even more easily and quickly with this new nesting technology, without programming. Simply select, position, and you‘re ready to go. At LIGNA, the Supervisory Board of the Weinig Group announced extremely positive growth of the Weinig Group at the end of the 2016 financial year. Order inflow rose by 16% compared with the previous
year and this trend has continued into 2017. Orders to the end of April showed 17% growth. The Board passed an investment budget of more than 30 million euros, and plans include a new administrative building and showroom at the Holz-Her site in Nürtingen at a cost of 10 million euros. There was also a focus on growing the group’s personnel, with plans to increase the number of employees to 2,100. The personnel at Weinig Head Office in Tauberbischofsheim, Germany alone is expected to grow by 6% to a total of 900 employees. Also opening this summer is the UK’s a brand new centre of technical excellence at its Weinig’s long established location in Abingdon, Oxfordshire.
For further details of Weinig and Holz-Her product launches, innovations and demonstrations: Tel: 01235 557600 Email: sales@weinig.co.uk www.weinig.co.uk Holz Her in full flow at Ligna 2017 See our website and interactive magazine www.p-j-production.com
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BOARDS & PANELS A Room With A View A pavilion designed and built by architecture students at Kingston University, Surrey, under the watchful eyes of tutors, Takeshi Hayatsu and Simon Jones, was shortlisted in the Architectural Journal’s 2017 Small Projects Awards. The structure, entitled Seminar House Pavilion, was constructed in the grounds of Dorich House Museum in Kingston, Surrey. Spanning three storeys, it incorporates a meeting room and viewing deck complete with picnic area. The entire structure was constructed from 100 sheets of SterlingOSB, the supporting legs clad in decorative zinc, a middle tier with attractive timber lattice sections and chestnut wood shingles and the top tier sporting planks of charred timber, all linked by internal ladders. Takeshi Hayatsu explained the reasons for turning to SterlingOSB: “On this project we wanted to look at a contemporary method of timber construction and also wanted to use
Seminar House Pavillion
materials sourced in the UK. We needed a light-weight panel due to limited funds and machinery and SterlingOSB is much lighter in comparison to plywood and easier to handle”. The Seminar House Pavilion was one
of twenty projects shortlisted from nearly two hundred entries. For further information: Tel: 01786 812 921 www.norbord.co.uk
CaberWood MDF – The Legend Continues Norbord’s CaberWood range of Medium Density Fibreboard (MDF), the longest standing portfolio on the market, is one of the most versatile. The resulting board is tough, easily worked and ideal for a mindboggling range of building applications – from skirting boards, architraves and mouldings to furniture and fittings. Norbord boasts one of the most comprehensive ranges of MDF products currently available with key features and benefits of the board including finish, routing capability and screwholding. Five grades are available from the basic lightweight general purpose grade, CaberWood MDF Trade, to the top-of-therange, CaberWood MDF Industrial, a hardworking, deep routing, moisture-resistant product with uniform density all the way through the board. Also available is CaberWood MDF Pro, CaberWood MDF Pro MR and CaberWood MDF Trade MR. Each designed for a specific range of duties,
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Norbord boasts one of the most comprehensive ranges of MDF products
the five products in the CaberWood MDF range offer unbeatable quality and “legendary” performance; something that Norbord has raised awareness about via a recent promotional campaign.
For further information: Tel: 01786 812 921 www.norbord.co.uk
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DECORATIVE SURFACES & EDGINGS Fletcher Building Invests £40m Into Formica Group’s European HQ In North Shields Formica Group, the original inventor of High Pressure Laminate (HPL), officially opened its European HQ on the North Shields site on 6th June. To celebrate the opening of the new head office and improved manufacturing plant, dignitaries, customers and the media were invited to usher in the next era of Formica Group’s 104-year-old history. As part of its strategy to grow the business and remain competitive, Formica Group is investing £40million into staff and facilities in its strongest market, the UK, over the next three years. The investment sees the installation of new machinery and technology to create a state-of-the-art laminate manufacturing plant in North Shields, which is celebrating over 70 years of operation this year. Speaking at the official opening of the new European HQ, Peter Rush, President of Formica Group Europe, comments: “When it comes to UK manufacturing, we know Formica Group has the credentials to be a world leader. As the only global laminate brand the investment is a step forward in fulfilling our potential. In addition to improving our laminate production we are also focused on increasing our sales, as the doubling of our UK sales team indicates.” Driving innovation and increased production, the investment will improve operational performance, including better service levels, shorter lead times, and improved visibility and communication of product availability. Arlen Pettitt, Policy Advisor, North East England Chamber of Commerce, comments: “The investment is a vote of confidence for the North East and shows a brand with a rich heritage in the region moving forward to increase its competitiveness and productivity in the global market. The modernisation of the office and factory is a reaction to the changing market place and shows a signal of intent, along with the initiatives like their apprenticeship scheme, for a long and successful future in the region.”
Fletcher Building, Formica Group’s parent company, decided to invest in the plant shortly after the UK vote to leave the EU. Formica Group’s UK management team views Brexit as an opportunity for the manufacturer to become more competitive in Europe, while at the same time making the UK a less competitive market to its rival European manufacturers. The investment also sees Formica Group HQ return to its original UK location on Coast Road, having been relocated to Cobalt Business Park in 2008. The art-deco Formica building in North Shields which opened in 1946 has been refurbished to become the company’s new European HQ, having formally been the UK HQ. The manufacturing operation is now centralised and under the same roof as the sales, marketing and management teams. In addition, a new Fabrication Support Unit training area and programme is being launched to assist Formica Group’s customers. Formica Group is the only UK laminate manufacturer to be aligned with Made in Britain, an organisation designed to promote and celebrate the manufacture of
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UK-made goods. John Pearce, Chief Executive, Made in Britain, comments: “Building upon its 100 year legacy, Formica Group’s investment is about increasing its UK market share and providing stability both in terms of pricing and manufacturing. Made in Britain is part of the support story for stability and we are pleased to help Formica Group in the provision of a network and community to help sales”. The investment has been supported by a Lets Grow grant of £1,600,000. Let’s Grow is a £60m regional growth fund programme which is operated by business services company BR Group and Newcastle accountancy firm UNW LLP in partnership with The Journal and its sister paper on Teeside, The Gazette.
For further information: www.formica.com
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DECORATIVE DECORATIVE SURFACES SURFACES & EDGINGS
New Designs From Decorative Panels Decorative Panels Lamination produces over 300,000m2 of the highest quality laminated products each week. These are used throughout many market areas including; furniture manufacture, Shop fitting and architect specification. The dp-decor and dp-specialist ranges of surface products is enormous, comprising woodgrains and solid colours in standard papers, high gloss and matt acrylics, PP, PVC gloss and matt finishes and thin laminates - many of which are available as stock items. The NEW dp-limitless range of surface finishes has no commitment to purchasing in bulk, the products in this offer are deliverable from single sheets up to full load quantities- all from stock. Ranges include HPL, gloss and matt acrylics, faux-leather, real stone and real wood veneers. In addition to a wide range of finishes a variety of substrates are available including chipboard, MDF, plywood and in-house manufactured dp-lite hollowcore board - in total Decorative Panels Lamination offers over 100 different board sizes. Decorative Panels Lamination have introduced a further five designs to the dp-decor and dp-specialist collections. New to the dp-decor collection is Arona Oak, a beautiful, elegant design in a stylish grey colouration, complete with characteristic
Arona Oak
Merino
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Fudge
oak features - pips, classic planking and a fully synchronised wood structure to the surface of the design. The many tones in this design really complement the grey natural hues that are much in evidence at the moment. Complementing this is Hickory Oak which is available in both white and grey tones. These two understated painted timber effects would give a modern classic look to any piece of furniture. There are two new exciting additions from Senoplast to add to the ever increasing dp-specialist collection - Fudge and Merino. These high gloss colours develop the theme of the naturally toned unicolours and really add to the options that can be mixed and matched to create a stunning look. Samples are available of all designs with sheet material available in bulk direct from Decorative Panels Lamination and regionally available through their nationwide distribution partners.
For further information: Tel: 01484 658341 Email: info@decorativepanels.co.uk www.decorativepanels.co.uk
Grey Hickory Oak
White Hickory Oak
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rooms reshaped
BROUGHT TO LIFE 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 Find out more about our exciting range of contemporary LG Hausys PVC foil materials for kitchen, bedroom and bathroom.
deco foil Call: +44 (0)1376 518037
DECORATIVE SURFACES & EDGINGS
Infinity lamination range from BA Components without limits Established in 1990, BA Components operate their OEM service from their Doncaster factory. Manufacturing doors, profiles, sheet material and components to customers original specification throughout the world, BA Components offers a design and development service in partnership with their client’s requirements. From laminated sheet material, to doors and frontals in five piece, membrane pressed or acrylic edged, from furniture components drilled, dowelled, end capped and wrapped, to profiles and mouldings in veneers, papers or foils. BA Components wide range of product offering means you are sure to find the solution you need. Standard sheet sizes for acrylic lamination are 3050x1220 and 2440x1220 and for other face finishes BA can also add 3660x1220 with the ability to laminate to a finished board thickness from 3mm
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up to 60mm on various core materials. BA produce sheets using Fiberboard, MDF, Chipboard, Composite board, Plasterboard, Metal, MR board and FR board. BA Components offer a compressive range of stock colours with a full range of gloss, fingerprint-free matt, wood grain, textured, mirror and metallics and also colour matching is possible. For volume work, BA Components can provide an edging service for finished products to your specification in a matching and 3D/2 in 1 edge on our three top of the range edgebandger machines. Edged only using PUR( POLY Urethane Reactive) Glue, with a much higher heat and moisture resistance than normal hot melt glues. Catering for small quantities from 250 right up to many thousands, BA Components can produce what you require with a fast turnaround, delivering worldwide or direct to the manufacturer for their own processing. For further information: Tel: 01302 890555 www.byba.co.uk
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DECORATIVE SURFACES & EDGINGS
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DECORATIVE SURFACES & EDGINGS
Interior Film From David Clouting Proves A Success In Demanding NHS Environment The Weybourne Day Unit, part of the NHS Norfolk & Norwich University Hospitals Trust, provides a nurse-led oncology and haematology service. Specially trained chemotherapy nurses and specialists administer outpatient chemotherapy regimens, supported by consultants and specially trained doctors. The unit was an expansion of existing services provided by the hospital to create a new 22 bed facility. The inspiration for the artwork on the interior walls of the Unit was the flora and fauna of the surrounding the area of Weybourne, with research carried out so the right plants and leaf patterns could be used by the artist Vicki Johnson, Creative Director and Cofounder of Print to the People – a Norwich based organisation. Her art has a varied imagery, combining both digital and traditional printmaking techniques. Emma Jarvis, Environmental Arts Manager responsible for the project said “Our decision to use a film to cover the walls and as a base for the artwork was determined by a number of factors including; infection control, cleaning and fire safety” Emma continued “We trialed a range of different films printing Vicki’s designs directly onto the film and then tested it with actichlor which is a hospital bleach used throughout our hospital.
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We selected LG Hausys Interior Film from David Clouting because it not only passed the bleach test but the quality of the white colour of the film was also significantly better than the others we tested. It has a slightly softer tone and worked best with the building finishes within the unit. Installation was also a key factor together with the type of glue on the film itself. We needed to ensure that the film would not fall off the wall in any way and also peel off and replace with ease when required. The air channels and the slightly thicker make of Interior Film helped significantly in ensuring first time placement and installation with no repositioning required.” Available in a range of over 400 designs and finishes, Interior Film is available to view on the BIMSTORE website and is also CE and IMO Certified so can be specified with confidence across a wide range of applications.
For further information: www.davidclouting.co.uk
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Suitable for your industry y
the decorative panels group YOUR PERFECT PARTNER A
dp-specialist dp-decor p There are over 200 stock designs in the dp-decorr and dp-specialist ranges at Decorative Panels Lamination Ltd. With matching edgebanding available, a perfect finish is always ensured. • • • • •
High abrasion resistance surfaces Antimicrobial 99.9% germ free finishes 3D Reality designs Heavy weight paper and paper backed vin nyl. High gloss acrylics, PVC, PP and paper glloss and super matts
The scale and versatility of the range will inspire a and enable manufacturers and specifiers in the challenge of an ever changin ng market place. Combine such an offer with the vast range of sub bstrates available from Decorative Panels Lamination and you can see w why there is product suitable for your industry.
Kitchen
Furniture
Com mmercial/ Arch hitectural
Marine
Contact us for more information.
Century House, Premier Way, Lowfields Business Park, Elland, West Yorkshire, o HX5 9HF
T: +44 (0) 1484 658341 F: +44 (0) 1484 658812 E: info@dec corativepanels.co.uk www.decora ativepanels.co.uk
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DECORATIVE SURFACES & EDGINGS
Authenticity At The Centre Of EGGER’s Show Offering Europe’s largest manufacturer of laminate and wood-based materials for the KBB industry, EGGER, brought all of its recent product introductions together under one roof for its offering at this year’s Interzum trade fair. Its stand at the leading show for furniture manufacturing and interior design in Cologne Messe showed highlights from the newly-launched EGGER Decorative Collection 2017-2019 as well as some recent innovations and inspiring applications. The company also picked up two awards from the show organisers for ‘high product quality’ and ‘intelligent materials and designs’ – in a competition judged by a panel of leading international design and architectural specialists. What EGGER calls its ‘matt concept’ likewise created a lot of interest. Its premium PerfectSense gloss and matt lacquered boards – with the proven quality of an EGGER MDF core – are well-suited for applications in residential and commercial areas, and in upscale retail as well as for furniture design. PerfectSense Matt has a warm velvety feel with anti-fingerprint characteristics, which makes it ideal for elegant, modern fronts without handles. The super-smooth MDF boards used allow for a flawless surface, and a unique UV lacquer makes them highlydurable. This surface is very well suited for use in furniture frontals or for
Authenticity was at the centre of Egger’s show offering
sliding doors and wall cladding. Texture innovations give even more choice and more authenticity – and matt is finding favour for interiors, doors and open shelving. Complementing its PerfectSense Matt board, is a new EGGER PerfectSense Topmatt laminate that it unveiled at the show. Seen for the very first time, this shares the matt surface and antifingerprint features, but was specially developed for use on high-
Natural Davos Oak
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DECORATIVE SURFACES & EDGINGS
Doppla Black-Gold
stress surfaces such as worktops and tables. ABS and PMMA edges with coordinated decors and textures matching the matt surfaces are available, and EGGER anticipates that manufacturers will have specialist fabricators use it to create worktops with an upmarket understated look. “Many of our customers have already seen some of what we were showing at Interzum, said EGGER UK’s head of décor design Elliott Fairlie. “We have been organising our in-house EGGERZUM exhibitions for clients in the furniture industry for more than 20 years. “But In the years in which Interzum in Cologne also takes place, we always try and have something new to reveal to a large international trade fair audience – and this year was no exception. “The launch of our 2017 décor collection in January has been very successful, and reaction from the market shows that the efforts and investment involved in the development and introduction of such a diverse collection were well worth it.” Authenticity remains the main focus for all EGGER decors. In addition to appearance, the feel of the surfaces is also particularly important. Textures are expressive – and have character, depth and naturalness. EGGER’s objective is to come as close as possible to the original, and it consistently invests in new technologies in order to develop decors and surfaces that feel as real as they look. High-quality design accents such as the Doppia edge in PMMA are available in numerous eye-catching decor options, and the black-gold colour received a ‘special mention’ in February at the
German Design Awards – with visual perfection achieved thanks to the narrow join. Doppia edging perfects the illusion of real glass on furniture and follows the design trend towards accents and contrasts. The bicoloured appearance also creates a high-quality colour transition to the surface decor. “The launch of the 2017 collection gave our customers access to our biggest-ever range of related decorative products, added Elliott. “The collection has been massively expanded to cater for an increasingly wide range of applications and styles. The more diverse collection makes it possible to combine different materials, colours, types of wood-grain and style directions. “But as our range increases, so does the need to make things easier for our customers – and technology is helping us to do that. We are already supporting furniture makers, architects, fabricators and retailers with comprehensive services such as the updated VDS Online with numerous new features, the EGGER App, the new customer portal myEGGER and the sampling service. “And for worktop buyers our recently-launched worktops visualiser – accessible with a tablet or smartphone – makes light work of selecting from the 6,500 possible combinations of worktops and décor panels.”
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For further information: Tel: 01434 602191 www.egger.com
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REVIEW
Blum Is An Innovative Service Partner For Furniture Manufacturers Support with planning, ordering, manufacturing and installation. Austrian fittings manufacturer, Blum, offers innovative services and assembly devices that provide ongoing support along the entire production process – from planning and ordering to manufacturing and installation. New! Blum’s Cabinet configurator makes cabinet planning quick and easy; Easystick helps you transfer dimensions to Minipress and automatically sets stops on the drilling and insertion machine; and Blum’s Easy Assembly app now has additional interactive features. Industry 4.0, digitalisation and interconnected manufacturing are today’s buzzwords and are relevant to industrial furniture manufacturers, distributors and cabinet makers alike. This fourth industrial revolution will, however, only work if a complete set of error-free data is available to users. The focus is on the interconnectivity of machines, electronics and data. Blum sees itself as an innovative service partner who strives to improve these processes. Consequently, the company has extended its
Blum’s Easy Assembly app has new features – making installation even easier
offering of assembly devices and services. Blum has added a Cabinet Configurator, Easystick (a computer-aided device for calculating the fixing positions of its fittings) and additional features to its Easy Assembly app.
Easystick sets stops automatically, making assembly precise, quick and easy
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Cabinet Configurator – the easy and efficient way to plan furniture Blum’s new Cabinet Configurator makes cabinet planning easy and is the successor product to Dynaplan, Blum’s existing cabinet planner. The Cabinet Configurator automatically works out and provides all the information you need for manufacturing, such as wooden parts and drilling positions. The information is immediately available at the press of a button – provided as a drawing or as CAD data. Further features include a userfriendly interface and clear 3D visualisation. The right fittings are selected by Blum’s tried and tested Product Configurator. Thanks to integrated collision checks, no more planning errors are made and trial applications are no longer necessary. In addition, users can collect compiled parts lists in their shopping basket and then simply transfer them to their distributors’ ordering system.
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REVIEW
Easystick for efficient and precise assembly Complex fittings systems require precise assembly techniques. Easystick for Minipress consists of a ruler with automated stops and a control unit with a display. The device makes it easier to find the right drilling positions and set up the drilling and insertion machine. Thanks to the new assembly device, users no longer need to set the stops by hand. The drilling positions can be directly entered into the machine. Manufacturers and cabinet makers can also use the Cabinet Configurator to plan their furniture and then simply transfer the data to Easystick. The stops (which are computer controlled) automatically move to the right position. The new device supports assembly regardless of working method or equipment. Easystick is available as a complete package (i.e. with the Minipress drilling and insertion machine) or as a retrofit set.
New features for Blum’s Easy Assembly app Blum’s app answers any questions users might have about assembly, e.g. safe installation, how to accurately position
Blum supports its customers with innovative services along the entire production process – from planning and ordering to manufacturing and installation
Blum fittings and carry out precise adjustments. The app has been revised and upgraded with more smart features. A special blog has been set up which provides news and tips on general assembly topics and information about the app itself. Here users can ask questions and discuss issues with experts –
providing an interactive and immediate form of communication. Blum will also provide pilot markets with live support – with a phone, chat and video feature. In future, app content can be compiled and managed to meet the cabinet maker’s or fitter’s personal needs. Information that is actually needed for installation on site can be downloaded to the corresponding end device. Menu navigation has also been optimised and is now easier and faster. • Blum is an innovative service partner for planning, ordering and installation • Cabinet configurator makes cabinet planning quick and easy • Easystick ensures that dimensions are accurately transferred to the Minipress drilling and insertion machine • Easy Assembly app now available with additional interactive features
For further information: www.blum.com Easystick sets stops automatically, making assembly precise, quick and easy
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REVIEW OVVO WINS “BEST OF THE BEST” AWARD FOR V-0930 AT INTERZUM 2017, The World’s Leading Trade Fair For Furniture Production And Interior Design In the stunning setting of the Rheinterrassen a glittering awards ceremony held on Monday May 15th marked the start of the Interzum 2017 trade fair in Cologne, Germany, where the OVVO® V-0930 Connection system was awarded “Best of the Best” - the top prize awarded only to innovations that feature ground-breaking design and set new standards for form and function in their industry. The Interzum 2017 awards, hosted by Koelnmesse in collaboration with Red Dot, emphasise the significance of design as a value-added factor, and is an internationally-recognised label by which winners can be set apart from their competitors. OVVO® is now confident of delivering against its global growth ambitions and looks forward to exciting times. Application for “Interzum Award: Intelligent Material & Design” was open to all exhibitors at Interzum 2017, and the submissions were assessed in late March by an expert jury of five respected and independent international experts from design and architecture, who assessed the products’ design quality and made a final decision concerning the industry award. The judging criteria were as follows: Degree of innovation, Functionality, Material Quality, Design and Sustainability. The innovative new OVVO® V-0930 Connection system received the top prize of “Best of the Best” from the judging panel, setting it apart from its competitors and confirming the high quality of the product. The new smaller connector greatly extends the range of materials, industries and applications in which OVVO® can be used, and will amplify the scale of efficiencies that manufacturers will achieve when OVVO® is incorporated into
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(L-R): Katharina C. Hamma (COO Koelnmesse), Sean Phillips (inventor and Co-Founder OVVO®), Prof. Dipl. -Ing. Martin Stosch (lecturer Wood Technology at Ostwestfalen-Lippe University of Applied Sciences & Judge), Dick Spierenburg (Designer & Judge), Brendan Phillips (Chief Executive Officer, OVVO®) and Prof. Dr. Peter Zec (founder and CEO, Red Dot & Judge) OVVO® Logo
production/manufacturing processes. It is available in both permanent and releasable versions. It works best in high-grade board with thickness of 12 mm and above, and can also work in slightly thinner materials that are more dense, such as high pressure laminates, composite material and solid wood for certain applications. The innovative dovetail design delivers increased intrinsic tolerance which leads to enhanced shear and tensile strength of the joint created; the new design also features a solid central rib that confers increased joint rigidity. The new single piece housing also makes automatic insertion possible – a significant enhancement on the design of the original connector. OVVO® inventor Sean Phillips said “To win a “Best of the Best” award at
Interzum 2017 means a lot to OVVO® – it is a fantastic endorsement and validation of our product, into which we have put a huge amount of effort and time to develop and design. We are now more confident than ever that OVVO® will transform the woodworking industry and look forward to working with more and more customers to revolutionise their businesses”.
For further information: Email: sales@ovvotech.com http://ovvotech.com/product/#V-0930
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REVIEW Interzum 2017 - A Resounding Success For The Ostermann Group Interzum, the international trade show for suppliers to the furniture and interior design industries, took place from 16th19th May 2017 in Cologne. Ostermann was there with a stand in Hall 10.2, where it presented its “World of Edgings”. The products on show naturally included edgings to match the new collections from Pfleiderer, Egger and FunderMax. There was also huge interest generated by the latest trend-setting edgings featuring concrete and metallic looks, as well as the company’s huge range of technical profiles. The new-look trade show stand with its restrained, yet expressive design drew in numerous visitors from Germany and abroad. With 16 edging panels on view, trade visitors could see the huge diversity of the edging range for themselves, and Ostermann Group reps from Germany, the Netherlands, Belgium, the UK, France and Italy were on hand to help them with professional advice and assistance.
product walls, but they were free to touch them too. These articles already form part of Ostermann’s diverse range of plain and decorative edgings. Of course, the products on view included the wide range of solid wood and 3D acrylic edgings, accompanied by trend-setting edgings in the latest concrete and metallic looks.
Variety of adhesives, cleaning agents and technical profiles Ostermann also presented its broad range of adhesives and cleaning agents, not to forget its numerous technical profiles. After all, the edging specialist not only stocks hot-melt adhesives, but also white glues and veneer glues, special adhesives and contact adhesives, as well as urea resin glues. As with every other trade fair, the company’s numerous technical profiles attracted a great deal of interest among visitors to the show.
Multimedia at the trade show stand New edgings for Pfleiderer, Egger and FunderMax products Another particular point of attraction came in the form of new edgings for the latest collections from Egger, Pfleiderer and FunderMax, and visitors not only had the opportunity to see these displayed on the
All the products on view, whether it was the edgings, adhesives or RollBeton – were flanked with informative video tutorials displayed on the monitor. How is the displayed product actually applied? What benefits does it have? At this point, Ostermann’s experts divulged some of their
Ostermann Group reps from Germany, the Netherlands, Belgium, the UK, France and Italy were on hand to help with professional advice and assistance.
World of Edgings”, the header under which Ostermann showed off innovations and a wide range of accessories for the furniture-making trade.
very best tips and tricks. All videos can be viewed right now on the OstermannTV YouTube channel. Aside from the videos, Ostermann had also installed a cuttingedge touch screen terminal on its stand. Under the heading “Digital@Ostermann”, the company presented all the essential information about its Online Shop and interfaces to link to carpentry software from various vendors.
For further information: Tel: 01905 793550 Email: s.parsons@ostermann.eu www.ostermann.eu The new Ostermann trade show stand at a glance: Under the huge Ostermann banner, there was much for visitors to the Interzum to see and discover. See our website and interactive magazine www.p-j-production.com
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INSTALLATION
Genisis 512S – “It Can Do Everything For Us” Cheshire Custom Kitchens Ltd was launched in 2013 by Les Sutton, and has gone from strength to strength. Offering quality kitchens in a range of colours and styles, including painted style doors, gloss, country and Shaker, the company has a strong customer base in the North West of England. Purchasing his machinery and equipment exclusively from J & C O'Meara, Les upgraded his edgebander to a Genisis 512S in October 2014. Les has purchased all his woodworking machinery from J & C O'Meara. When he was just starting up, he could only visit the showroom on a Saturday: and Carl O'Meara was willing to open up for him. That, and the service that Les received, have earned his loyalty. The first edgebander Les bought was, as he says, “the only one that we could afford at the time. As we started making a bit of money we were able to upgrade the machine.” He is delighted with the quality of the Genisis 512S. When asked about the advantages of the new machine, Les particularly quoted the pre milling station. This allows the operator to reference the edge prior to edge banding, removing any scorer marks or chips caused during handling. Les reports that the superior quality this produces has led to considerable repeat business, and to new business coming to Cheshire Custom Kitchens through word of mouth.
Another advantage of the Genisis 512S was the option to use PVC. “With the PVC edging, we can do our own doors as well. When we first started up we used to buy in our doors: then we thought, we can do it ourselves!” He continues, “Made to measure doors often attract a high premium, but for us it is just a board cut to a certain size that we can edge.” Les is also considering moving into worktop production, made possible by the Genisis 512S edgebander. The new machine has brought the ability to apply 1 mm or 2 mm edges as opposed to 0.4 mm on the original machine: and while the original only worked at 5 m/min, the Genisis 512S runs at 12 m/min. Time had also been lost as the trimming stations had to be permanently kept clean due to having to also machine away the soft glue on the excess of the tape. This problem has been eliminated with the Genisis 512S. Now, the scraping, solvent spray and buffing stations restore edge quality after trimming, and the edge pre heating station assists bonding of the edge, particularly during the colder months. Les comments, “On the old edgebander we would have to clean and sand after edging, now it goes into the machine one side and comes out the other, clean. It cuts the time to produce a kitchen by half!” Before purchasing the Genisis 512S, Les would allow a day and a half to produce
each kitchen. Since then, he has gradually increased production so now he can produce two kitchens a day, or in other words up to 10 kitchens per week. “At first we had little niggling problems, as you always do, but through speaking to Carl we were able to solve them. He talks you through any problems, and so we have speeded up the process while we have had the machine, as we learn how to adapt and change things,” Les said. When asked if he would recommend the edgebander, Les replied, “Yes, I would definitely recommend the edgebander as well as the company. And I would definitely recommend the pre-miller as well: it saves you so much time and the work goes out in so much better quality. “We have never advertised our business, and yet since we have had the new machine from Carl it has just had so much repeat business and recommendations by word of mouth that we have been kept very busy. People are being recommended to come to us because of the quality of the cabinetry.” Adding that the edgebander “has made our lives an awful lot easier,” he concludes, “It can do everything for us,” For further information: Tel: 01704 893109 Email: info@ukwoodworkingmachinery.co.uk www.ukwoodworkingmachinery.co.uk
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CASE STUDY Fixings And Surface Matter In London Using the flexibility and strength of Button-fix fastenings, Surface Matter has created a wall of interchangeable materials and a reconfigurable work hub in its London studio. Working with exciting surface materials and pushing the boundaries of material use, Surface Matter research, curate and distribute materials to architects, fabricators and designers. Seeking to educate the true capabilities of materials, Surface Matter endeavour to present high quality materials that ‘make the job’ not ‘do the job’. The Surface Matter studio in London is therefore constantly evolving; with new sample materials added and showcased every day on a large, Mondrian style, material feature wall. A place to explore, collaborate and experience new materials, it was of significant importance that the materials used to decorate the feature wall could be easily replaced, rearranged and taken down for closer inspection. Discovering the Button-fix fastening whilst the innovative fixing was still in development, Surface Matter knew the exact solution required to create its interchangeable material wall. Jane Campbell, Marketing Director at Surface Matter said, “Having previously used Button-fix on a collapsible exhibition panel that travelled across Europe, we knew that the
fixings would be ideal for securing material samples to the wall. “Making it easy to unclip and remove, replace or rearrange the panels, the Button-fix fastening system is ideal for our wall, which is consistently updated when we’re introduced to new materials!” Used to panel the wall with large material samples, four Button-fix fastenings were used per panel, with more than 200 Type 1 and 2 Fixes used throughout the studio. An extremely diverse product, Button-fix fastenings can be used in parallel, 90o connections, horizontal and vertical applications. Type 1 Fix fastenings are ideal for screw fixing parallel panels, where proven strength and invisibility is paramount. Type 2 Fixes connect 90o panels; ideal for concealing pipework or cabling as the Fix requires no clearance around the panel for removal for access to the services. For a fast onsite installation; the Fix can be surface-mounted on the panel. When no gap is required behind the panel, Button-fix gives the option of a rebated mounting. This was the method chosen to create the large focus wall in the Surface Matter studio. Recognising the unique flexibility of the product, Surface Matter also used Button-fix fastenings to create a reconfigurable work hub. Consisting of four desks, the
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reconfigurable workspace allows for the desks to be rearranged depending on the workplace requirements and then safely secured. Jane Campbell explains, “The use of Button-fix for our rearrangeable work hub is a perfect example of how diverse the products are. Creating a low cost, easy to arrange work space with invisible fastenings, the Surface Matter workspace can now be easily adapted for the wide variety of services we provide. “The positive feedback we receive surrounding the material wall and our experience working with a variety of new and innovative materials, means we do not hesitate in recommending Button-fix fastenings to architects, fabricators and fitters.” Julie Freedman, Head of Sales and Marketing at Button-fix said, “Panelling applications, such as the feature wall at Surface Matter, are a great demonstration of the original design ideas that can be achieved through the use of invisible, secure fastening systems. “Extremely versatile and capable of accurately aligning panels, Button-fix ensures that creative designs can become a reality.”
For further information: http://button-fix.com/ @ButtonfixUK on Twitter
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PROFILE
Blumotion S – One Runner, Many Possibilities For combination with different motion technologies by Blum. Blum offers four motion technologies and consequently the right solution for every level of user convenience. The range, however, remains slim – thanks to the new Blumotion S runner which is compatible with two different product categories. The different motion technologies offered by the Austrian fittings manufacturer give cabinet makers and industrial manufacturers plenty of scope for design and differentiation. Yet Blum is keen to ensure that its range is manageable. Consequently, the company now offers a single runner – Blumotion S – for three different motion technologies: Blumotion, Servo-Drive and Tip-On Blumotion. What is more, the runner provides the full range of functions and is compatible with two different product categories, i.e. a single runner for the Legrabox box system and a
single runner for the Movento runner system. No matter whether you opt for the electric or mechanical opening support system, Blum’s various motion technologies give you the right solution for every living area and every convenience level.
Getting the right mix With four Blum motion technologies (and different convenience levels) to choose from, you are sure to find the right solution for every application and living area. Blum’s motion technologies can be easily combined as required. Blumotion ensures that pullouts, wall cabinets and doors close softly and effortlessly. Furniture equipped with the Servo-Drive electric motion support system glides open at a single touch – as if by itself (which is particularly handy for waste pullouts). Tip-On Blumotion gives you mechanical one-touch opening and soft and effortless closing. And the doors of tall
cabinets equipped with Tip-On will open with ease at a single touch. You can mix and combine Blum’s motion technologies as you like to bring enhanced convenience to kitchens – and to other living areas throughout the home. The level of convenience you choose depends on users’ needs. In other words, you can tailor solutions to meet requirements. • Blum is an innovative partner offering motion technologies for different convenience levels • Blumotion S can be combined with 3 different Blum motion technologies • Slim product range because it can be used for Legrabox or Movento
For further information: www.blum.com
Three different motion technologies can be implemented with the new Blumotion S runner – with Legrabox or Movento
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PROFILE Festool Launches Cycle Challenge With Charity To Promote Lung Health To UK Tradespeople Festool, the leading supplier of high-end power tools and accessories, has launched a new Cycle Challenge to raise money for the British Lung Foundation (BLF) and to promote lung health to UK tradespeople. The Cycle Challenge will feature two static Wattbikes that will join Festool’s impressive UK roadshow on its European leg in July. Members of the trade will have the chance to win £500 of Festool prizes if they bike the fastest mile, three miles or five miles. Featuring Festool’s premium range of tools, the fully equipped truck will also provide visitors the opportunity to receive information, get hands-on with the tools and learn from a team of experts. With approximately 200 sq m of space, visitors will find new products for 2017, as well as Festool’s complete range of dust extractors that help safeguard a dust-free work
environment. The company has been selling top quality cycling tops as a fundraising initiative on its eBay page here: http://www.ebay.co.uk/itm/152528024920 and will be raising thousands of pounds for the BLF as part of the Breathe Easy with Festool Dust Extraction campaign. The truck tour began in Portsmouth on 5th July and will call at Twickenham, Sittingbourne, Leyton, St Albans, High Wycombe, Nuneaton, Derby, North Shields, Glasgow, Dunfermline, Blackburn, Warrington, Belfast and Dublin. See the
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full list here: www.festool.co.uk/campaigns/roadshow.
To find the right dust extractor for you, visit www.festool.co.uk for more information.
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CASE STUDY AR 18 Doubles Production, Improves Quality And Reduces Waste By Over 50% With HOMAG UK AR 18 Limited has been in the CNC routing trade for around 15 years, producing high quality retail furniture and display stands, reception desks, feature walls and cladding panels for shop fitters. It also provides a full service offering to small joinery companies and sign makers without in-house CNC facilities. “Over the years, we’ve amassed considerable experience in CNC machinery,” explains Antony Cockerell, managing director of Uxbridge based AR 18. He continues, “With the business expanding rapidly, we realised it was time to invest in new equipment that would drive our business to the next level. “Obviously, as global market leader, the HOMAG name was known to us and so we short-listed them alongside a couple of other well-known brands as we began our
search for equipment ideal for multiple shift production. It didn’t take us long to narrow down our search to just two companies, one of which was HOMAG. “To be honest, there wasn’t a huge difference between the qualities of the machinery on offer. After visiting shows and seeing machine demonstrations, however, we made our decision. HOMAG came out on top in terms of cost, reliability, service, support, build and finish quality, but in the end it was my gut-feel that swung the day.”
HOMAG UK – Trust, knowledge, patience and understanding “The refreshing quality about HOMAG UK is that all the people there seem knowledgeable and willing to help. The HOMAG manager for our area, Roger
Wilks, is a case in point; he has been a real champion for us. From the word go, he clearly wanted to find out exactly what we were looking to achieve so he could help us configure the best solutions. “He was very patient with us as we reconfigured our needs several times before settling on the ideal solution. The space available was quite awkward; we had a lot of height restrictions and building infrastructure to contend with. Roger, however, remained calm and relaxed throughout. He kept us up to date with how the changes would affect lead-times in the build-up of the machines whilst ensuring we still hit our target date for production. “Throughout the sales process, I never felt pressure from HOMAG to ‘sign on the bottom line.’ This was markedly different from the approach of the other potential
WEEKE Vantage 200 CNC processing centre
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CASE STUDY
BRANDT Ambition 1440 airTec edgebander
supplier who was ‘hard sell’ from the word go. Their priority seemed to be on getting my signature on the contract, rather than developing the right solution for our business. “Both in Germany and in the UK, HOMAG handled the sale and installation process superbly; it all went to plan and was completely drama free. From my perspective, it couldn’t have gone any better. They dealt with all the other trades including Indusvent who did an excellent job on the dust extraction.” Investing in a quality edgebander delivering invisible joints At the end of 2015, AR 18 invested in four machines from HOMAG UK – a BRANDT Ambition 1440 airTec edgebander, a WEEKE BHX 055 vertical drilling and routing machine, a WEEKE Vantage 200 CNC processor and a storage system from HOMAG Automation, the TLF 411. Antony Cockerell again, “Prior to our deal with HOMAG, we didn’t have any edgebanding facilities in-house. Our business was a relatively low production run environment, manufacturing a lot of one-off high-end production pieces, so we’d always found it beneficial to hand-finish or sub-contract the edgebanding work. “With the business growing, however, we had started looking at some higher volume jobs where it would be expedient for us to have our own edgebander. One of the advantages of the BRANDT Ambition 1440
that we particularly liked, was the airTec system for invisible joints. That gave us the ability, even on high volume jobs, to get the quality of finish we were looking for, especially with white finishes.”
WEEKE machines save time and improve quality “Another issue we needed to address with our old machinery set up was the ability to do edge drilling. We didn’t want to tie up the new WEEKE Vantage 200 CNC processing centre with basic edge drilling tasks, so we decided to handle the edge drilling as a secondary process. It was this function that attracted us to the extremely good value for money WEEKE BHX 055. “The other benefits of the BHX 055 are that it takes up very little floor space and is a great back up machine to our other routers. If the routers are all busy or have maintenance issues, the BHX is able to handle 90% of their work. Not only is it is a very reliable machine, but also the quality of the drilling and routing is first class, making it the ideal complementary machine. “As part of our expansion plans for the business we linked up with Brunel University to carry out some time and motion studies on our existing processes. Results showed that one of the slowest areas in our work flow was the manual loading and unloading of the routers. With this in mind, we wanted to invest in a new CNC that could alleviate this issue.
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“This objective led us to the WEEKE Vantage 200 CNC processing centre. The beauty of the Vantage 200 is it has selfloading and off-loading options. I’d seen a couple of other machines do self-loading and unloading very badly, but the WEEKE Vantage 200 was the first machine that I’d witnessed that looked like it would consistently work properly. “I was very impressed with it and I am happy to say that, on the loading and unloading side alone, we have doubled throughput. What’s more, the Vantage 200 has enabled us to replace two of our existing routers with just the one machine.”
Automatic stock control and handling – the unsung hero “The last, but by no means least, addition to our plant was the HOMAG Automation TLF 411 stock control and handling system. This is just an incredible piece of equipment. “As someone interested in manufacturing and processes, when I first saw it, I was amazed. The TLF 411 quietly works away in the background like an unsung hero. It organises all the board stock and mitigates issues that can become problems down the production stream, such as marked or damaged boards. The love and care of the boards is now entrusted to the machine rather than having to rely on a forklift truck operator or an employee dragging the boards across the factory floor. “We now QC (quality control) the raw
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CASE STUDY
HOMAG Venture 200, Homag Automatiion TLF 411 & Weeke BHX 055 at AR
boards as they arrive in from the supplier; from that point on, I know everything about each board we have in stock. I know where it is stored, I know when it came in, what size it is and what colour it is, so in terms of knowing what’s what, I have all that information on hand. “When I first saw it, I said to my management team that if we don’t invest in this technology, in five years we’re going to be struggling to keep up with the competition. Since its introduction into our production facility I can safely say that the TLF 411 stock control and handling system has transformed our business.”
Ease of operation with fingertip controls in a calm working environment “Another big advantage is the ease of operation of the HOMAG Group machinery. All the models we have added to our plant use the HOMAG PowerTouch screen, making it very easy for the operators to switch from machine to machine.
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“It’s not the same interface necessarily, but it looks and feels very similar. Consequently, for the shop floor machinists it provides a very familiar operating environment, so they are very relaxed and keen to get on another machine and try it out. “All in all, the investment in HOMAG Group machinery has had an extremely positive impact on our business. Not only has the volume of production more than doubled, but also we’re able to take on larger jobs than we could previously. We can now service a more cost conscious sector whilst maintaining our ability to handle our one-off and high-end production pieces at a higher quality standard. “In terms of stock control and management, the TLF 411has made a huge difference. It has helped speed up production whilst at the same time giving us more control over our stock than ever before. In turn, this means we are achieving over 50% less stock wastage than before.
“The stress and pressure we used to work under have gone and consequently reworking has been dramatically reduced, as have the need for overtime and weekend work. Overall, we are producing more finished goods in a calmer, safer environment and our turnover and profit margins have both increased. “As a company, HOMAG is very proud of what it does and that really comes across. The quality of their products speaks for itself so they don’t have to resort to the hard sell approach. With HOMAG, there is a real sense of building a long-term relationship for the future and that is very comforting,” concludes Antony Cockerell. If you would like more information or a demonstration of any of the HOMAG Group machinery, please contact Adele Hunt at HOMAG UK on 01332 856424.
For further information: Tel: 01332 856500 Email: info-uk@homag.com www.homag.com
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CASE STUDY HOMAG SWT 124 Raises The Quality Bar For Dominic Ash Kitchens Dominic Ash Ltd specialises in high-end joinery and interiors. It produces premium quality designs in hard wood and contemporary materials for both the trade and general public. The company, based in Gloucestershire, has extensive experience in designing and building bespoke kitchens and in creating individual pieces of furniture for interiors. Founder and director of the business, Dominic Ash, trained for six years with a Quaker furniture maker in Somerset, before working on boat restoration in the Caribbean. His experience led to the development of his individual practice, with an emphasis on attention to detail, simple design and the use of quality materials. He opened his own workshop and established Dominic Ash Ltd in London in 1994. The company’s skilled team of joiners work on a wide range of commissions, from complete kitchens to individual pieces like teak basins. “Our business is focused on first class quality and individualism,” explains Ash. “The projects we undertake are bespoke and finishes range from solid wood and veneers to painted surfaces. Whatever the finish, however, we have to be absolutely certain that each piece we produce is sanded to give the perfect surface finish.”
The search for a new sander “Last year, we decided that the time was right to replace our old sander which was getting very long in the tooth. As a small business, we have to make sure that every piece of machinery we invest in not only does the job required, but also offers value for money. “The woodworking exhibition at the NEC in October was the ideal place for us to see all the manufacturers under one roof. It enabled us to evaluate the wide belt sanding machines on offer and get a feel for each supplier. “In terms of our manufacturing requirements, we were looking for a simple and easy to operate sander that could
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Dominic Ash, company founder, with the new HOMAG SWT 124 sanding machine
handle solid wood and veneers with equal proficiency. Our existing sander was only 950 mm wide and ideally we were looking for a machine that would allow us to process larger parts.”
HOMAG fits the bill “Having seen the various wide belt sanders in action, the one that impressed us most was the HOMAG SWT 124. With an 1100 mm width capacity, simple operation and the ability to handle both solid wood and veneers, it was the perfect solution for our business.
“Simon Brooks, sales and marketing director for HOMAG, was very helpful and extremely knowledgeable. He didn’t try to sell me the machine; he was straight-talking and very confident that the SWT 124 was the right model for our needs. “It was a refreshing approach as others had tried to sell us machines with ‘bells and whistles’ that we just didn’t need. HOMAG has given us the right machine at a competitive price. It is an excellent all round sander perfect for our bespoke work.”
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CASE STUDY
First class installation and training “As one would expect from a brand with the pedigree of HOMAG, the delivery, installation and training went exactly to plan. Our operators found the training very informative and were able to get the best out of the sander almost immediately. “Naturally with a new piece of equipment we experienced the odd teething issue, but hats off to HOMAG, these were sorted quickly and efficiently. All in all, our experience with HOMAG has been excellent and they will certainly be at the top of our short list when it comes to replacing other woodworking machinery,” concludes a delighted Dominic Ash.
HOMAG SWT 100 Series The space-saving design of the HOMAG SWT 100 Series includes easy access to all functions to make changing sanding belts
quick and easy. The 100 Series includes single or twin-head options with either the air cushion sanding pad (acp®), perfect for flat work pieces or the electronic pneumatic system (eps®) which, due to the small segment width of 50 mm, provides optimal pressure across non-uniform work pieces. Dependent on the head combinations, the machines can execute sanding tasks including calibrating, fine solid wood sanding, veneered panels as well as intermediate lacquer sanding. Single-head models feature a combi-head with profiled steel contact roller and a work piece controlled air-cushion sanding pad. The twin head models feature a calibrationhead with profiled steel contact roller and a combi-head with profiled, rubberized 60° shore contact roller and a work piece controlled air-cushion sanding pad. The twin-head machines offer sanding in a single pass with a 2 grit sequence plus
optional lacquer sanding. Both single and twin-headed machines provide a working width of 1100 mm, variable feed speed controlled by frequency invertor, a colour touchscreen operator terminal, a maintenance free DC braking system, independently driven sanding heads and poly V-belt drives. If you would like more information or a demonstration of any of the HOMAG wide belt sanders or software, please contact Adele Hunt at HOMAG UK on 01332 856424.
For further information: Tel: 01332 856500 Email: info-uk@homag.com www.homag.com
Casadei-Busellato Open Days Casadei-Busellato presented their annual Open House entitled ‘Techno Highlights Thiene 2017” at their showroom from June 15-17. On show was the new JetMaster 35 CNC working centre with numerical control for machining of panels and windows. The innovative machining centre is equipped with a positioning system of the panel support, suction cups and clamps. Also on show at the event was the new edgebanding machine with controlled axis – FLEXA47XE, equipped with a hot air gluing system “Air Jet Package”, the new rounding unit “A2 Super” available on edgebander FLEXA 207 Super and FLEXA 307. The CNC work centre Jet Optima S20, dedicated to windows can be equipped with automatic positioning and clamp quick release system.
For further information: www.casadeibusellato.com Email: info@casadeibusellato.com
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PROFILE
What You Should Know About CNC Router Maintenance ‘As a follow on from the article ‘Avoiding Pitfalls When Purchasing A CNC Router’ in our last issue, Noel Archie, Product Manager at AXYZ International’s parent company in Canada, submits this article which has helpful information for the potential CNC user.’ When properly maintained in accordance with the guidelines provided by the manufacturer or supplier, a CNC router will function continuously to its full potential for many years. All too frequently, the cause of downtime has nothing to do with the design and construction of the router but everything to do with how it is maintained. Noel Archie, Product Manager at AXYZ International’s parent company in Canada, provides some useful hints as to what form this maintenance should take and how it needs to be implemented. Every CNC router will come with its own recommended maintenance programme and whilst this may be conscientiously followed companies can sometimes fall short on what is actually required to ensure trouble-free operation. This shortcoming can often be attributed to an innocent oversight caused by a rushed production schedule or a temporary shortage of manpower. For example, it can be the result of a failure to ensure adequate lubrication of machine parts or incorrect specification of the routing spindle, both of which will create problems and lead to a shorter than predicted machine life. Murphy’s Law claims that anything that could go wrong will do so at the worst possible moment. This is especially true of routing when recommended maintenance guidelines are not adhered to at the specified times. Occasionally, machine downtime can be due to something unrelated to maintenance procedures such as an electrical failure caused by extensive dust particles in the production environment. This would be avoided if recommended maintenance guidelines are followed. It is important never to cut corners in order to speed up production or save on manpower costs. It should also be recognised that maintenance is a relatively short process, with the greasing of racks and bearings requiring only a few minutes of an operator’s time. It is the technology that goes into the construction
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of a CNC router that helps simplify maintenance. Routers now incorporate automated logs that provide machine updates on daily activity and remedial measures for any malfunctioning detected. This reduces the possibility of unexpected complications that could lead to machine downtime during a critical production run. A recommended maintenance schedule Many of the more advanced CNC routers include an entire maintenance log covering daily, weekly and monthly inspections. Contingent upon the type and make of router, maintenance schedules tend to vary but the following five guidelines apply to all machines: Cleanliness: Routers invariably operate in a dusty environment and it does not take long for bearings and controls to become polluted and this is a sure recipe for operating problems if not rectified on a daily basis. Manufacturers and suppliers recommend hand-sweeping of the router, while an air gun can be used to blow debris away from the bearings. Another fairly standard recommendation is to lower the air pressure during the cleaning process. Change filters: If this sounds like an instruction found in an automobile manual there is a reason for the similarity. Just as clogged filters reduce engine efficiency, the same applies to a router’s controller, vacuum pumps and air lines. The frequency with which filters are replaced will vary, depending on the type of material being processed and environmental factors like the presence of dust and dirt. There is no standardised maintenance protocol but as a rule of thumb filters should be checked weekly and replaced as considered necessary. Lubrication: This is a fairly basic consideration that can sometimes be overlooked. Generally, routers do not require extensive lubrication but as with all production machinery breakdowns are inevitable if adequate lubrication is not carried out. An important consideration for router owners is that if it is found that a machine malfunction was caused by a failure to lubricate sufficiently the manufacturer’s warranty would be voided. Bearings, pumps, router spindles and knives need regular
lubrication but the frequency with which this is carried out will again be influenced by the type and make of machine, the extent of its use and the work environment in which it operates. Air supply cleaning: Most routers operate using air that has to be clean, dry and maintained at a steady pressure exceeding 80psi or six barometric. Damage to the router is likely in the short term if air pressure is not checked regularly and maintained at the recommended level. Safe and appropriate electrical power: The caveat for electrically-powered machines applies equally to CNC routers, with the power connected safely as required by local regulations. Router failure is likely to occur in cases of poor electrical grounding, low voltage or insufficient capacity. As with all computeroperated machinery, power spikes will cause serious damage. Daily and weekly maintenance protocols invariably come with every CNC router. They include times for logging operation hours, general cleaning, air pressure readings and lubrication. Monthly inspection protocols include greasing of the racks, pinions and bearings, repair or replacement of the vacuum table gasket should this be necessary and cleaning of all filters. In addition, bi-annual maintenance protocols include replacement of all filters, vacuum performance testing and inspection and tightening of timing belts and transmissions. Published on behalf of AXYZ International. For further information: Tel: 01952 291600 www.axyz.co.uk
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SOFTWARE
Latest Alphacam Features New Key Automation Capabilities The latest release of Alphacam, from Vero Software, continues to intuitively automate key CAD/CAM operations, improving manufacturing productivity and efficiency. Automation Manager includes enhancements to simplify the workflow, including Multi-drill control, new Styles functionality, and further support for additional CAD file formats. The introduction of Automation Manager Plus across all levels of Alphacam allows advanced automation to support the processing of Constrained Drawings and Parametric Sketches, and Part Grain Direction through sheet Grain Direction and Alignment Vector options. It also includes the Cabinet Door Manufacture (CDM) module. Alphacam 2017 R2 also sees the first release of its integration with robot simulation software, meaning that output toolpaths generated within Alphacam can be passed directly to RoboDK’s Offline Programming (OLP) to simulate robot kinematics, along with a range of applications and activities such as robot milling. RoboDK then outputs the OLP to the robot controller. As part of the Vero Customer Experience Improvement Program, Alphacam integrates Microsoft Analytics to gather software usage statistics. A new Reverse Cut Direction option has been added to Rough/Finish, creating toolpaths in the opposite direction to the
tool direction on the geometry. Alphacam Brand Manager Simon Mathias says this is particularly useful when creating multiple passes around a shape which need to go in alternate directions, such as polishing and sanding profiled edges. Sawing has been enhanced by controlling how the foul avoidance is applied. It can be applied to None or All of the selected machining geometries. Alternatively, a separate selection can be made for the avoidance geometries. Foul avoidance geometries appear in a new branch of the Operation tree, where geometries can be added or removed, and the selection remade. In Alphacam’s powerful nesting function, offcuts generated from nested sheets are now written to the new Sheet Database. Sheets may have been created from the database or just-as-drawn in the active drawing. The offcut will be created under the correct sheet, matching the material and thickness, which can be viewed as Attributes on the sheet. The new release also continues Alphacam’s theme of improving user experience, by updating many Dialog boxes, including Profiling, 3D Machining, Lathe Turning Cycles and Stone, providing a
more intuitive and consistent approach across the modules, to include new Images, Tooltips and Help Links. Support for 4K monitors has been improved with the addition of Scaling Options, to make the icons larger for higher 4K dpi settings – accessed from the Appearance section in the Ribbon Bar Configuration. The Input CAD Extensions add-in now supports all imported file types. “And the dialog will only be displayed if the CAD file imported something that can be processed – for example, at least one instance of geometry, text or spline. Otherwise the dialog won’t be shown.” There is also a new tool which he says is useful for tidying up imported geometry from CAD formats such as DXF and DWG, where the designer may have created several overlaying entities which are used in design, but are not required for manufacturing via CNC. “This is the Common Line Removal option which has been added to the dialog, enabling it to run automatically on CAD import. It will be particularly valuable when batch processing CAD data through Automation Manager.” In conclusion Simon Mathias says: “The automation enhancements in Alphacam 2017 R2 assist manufacturers to improve productivity and profitability by speeding up their manufacturing processes.”
For further information: www.alphacam.com
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SOFTWARE
New Cabinet Vision: “Milestone For Productivity and Efficiency” Vero Software have issued Version 10 of their industry-leading solution for cabinet and casewoods manufacturers. The latest release of Cabinet Vision is designed to help woodworkers take their businesses to the next level. Product Business Manager Marie Cassidy says Version 10 represents the next milestone in continuing on their goal of delivering the most powerful and flexible software on the market, while retaining ease of use, both in the design module, and Screen-To-Machine (S2M) which sends accurate, optimised NC code to the machine tool. “From entry level cutlist packages to fully integrated Screen-To-Machine solutions, this latest release has been developed specifically to give woodwork companies even more productivity and efficiency.” A major asset in Version 10 is the ability to export entire rooms and import them into another job. “This allows users to save time by capitalising on the work they’re already done.” Another completely new feature is the ability to set and save camera angles and viewpoints when viewing rooms in 3D mode. “These viewpoints mimic the way the eye creates depth and perspective, based on the location and height of the observer, giving a more realistic and creative look at the rooms.” There is no longer any need to type the name of an object when creating CAD leaders, saving time and effort. Cabinet Vision now gives the ability to select any object in any view to quickly create a CAD leader to identify it. These ‘smart’ CAD leaders know what the selected object is and automatically add its name in the text. An enhanced light editor is displayed in its own resizable dialog box, giving more space and flexibility when working with lighting. “This is better for users when setting and adjusting lighting for renderings,” says Marie Cassidy. And a new ghost rendering feature means varying degrees of transparency can be set when rendering jobs, meaning both the inside components and outside features can be
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shown in the same view. Cabinets can now be copied and mirrored, reversing all the sectioning both inside and out. This new feature saves time as users no longer have to manually recreate a perfect mirror image of an assembly, piece by piece. Version 10 features a complete hatching overhaul, with the use of vector hatch patterns supporting the .pat file format, allowing the use of industry standard hatch patterns when creating submittal drawings. When working on sliding or pair doors, each door can now be independently sectioned, giving more scope for design creativity. The Bid Centre’s reporting capabilities have been completely enhanced in the Solid Ultimate module, and for Solid Advanced users with the Report Editor add-on. This new feature gives more power and flexibility when creating customised bid reports. There is now the ability to layout mouldings around curved arches, making it easier to ‘dress up’ a room or object, enhancing design. The S2M Centre automatically processes part geometries and produces machine ready G-Code to send straight to the workshop CNC machinery, eliminating time and costly errors. Amongst a number of new features: Using the Machine Set feature, users now have the ability to create a Workflow process streamlining the process for parts to flow through production, including information for labels and reports. This leads to better utilisation of both labour and the machine tools. Machine operations which have been generated through the S2M Centre’s machine links can now be simulated, meaning users can visually check the operations before machining. Perimeter Nesting is an innovative S2M Centre start point methodology. “It maximises the part hold on the sheet during cutting, reducing movement on the nested sheet,” says Marie Cassidy. “This decreases the amount of rework needed,
and machine time.” In conclusion: “Cabinet Vision is used extensively by companies designing and manufacturing kitchens, bedrooms, bathrooms and furniture for schools and offices, along with bespoke case goods. Every user will find many of the updates in the latest release invaluable in improving their processes even further, whether they have manual cutlists or use CNC equipment.”
For further information: www.cabinetvision.com
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SOFTWARE
Alphacam Macros Provide A Step Up For Stairplan Purpose-written macros in Alphacam software have slashed programming time of bespoke projects from a day down to an hour, for a staircase specialist. “Every staircase we make is individual,” says Stairplan Managing Director Graham Thomas. “And Alphacam takes the awkward machining we need to do, in its stride.” The Telford-based company averages around 100 staircases a week, from spacesavers through recessed, to high-end £60,000 staircases. “We never make two the same, and we don’t produce the same type in any order. But whatever we need to manufacture, we can do it with Alphacam. Without it, we simply couldn’t provide the service we do.” Many of their products have a standard core which is designed with specialist staircase software, but Alphacam is used to add the bespoke elements, and the macros enable them to produce items extremely quickly. “For example, when we make bolted treads, a macro creates all the drilling, where everything has to line up with the strings. And another macro manages our special fixings. The latest macro means we
get drawings and toolpaths with just one click. It cuts the programming time by 90 per cent. Programming the internal aspect of a staircase used to take a day – now it takes an hour. “We import a DXF file of the core staircase into Alphacam and the macros apply all the alterations with one click. It puts in all the connections, the drilling, the dowels, and the toolpaths.” He says automating their processes in this way with Alphacam…part of the Vero Software suite…makes long, laborious tasks, very simple, and enables them to adhere rigidly to their maximum ten-day turnaround promise, even on the most complex shapes and curved handrails. Graham Thomas began his career as a carpenter and joiner with a five-year apprenticeship, then decided his future lay in making the parts, and he focused on staircases and roofs. He started manufacturing in his garage before moving into a workshop, and then his first factory. Expansion followed, eventually moving into his current 30,000 square foot factory – which has room for further growth – where he now employs around 30 people. Customers include joiners and both domestic and commercial sectors with developers, high-end builders, and the general public including self-build. “Our biggest single market are joiners, who appreciate the high quality we’re able to provide.” Describing Stairplan as ‘engineers in wood,’ they use all the main species of timber, including pine, oak, beech, ash and walnut. Everything is now manufactured on their CNC machine tools: five 5-axis Makas and three twin-headed 5-axis and 4-axis Homags with automatic tables. “We went down the automatic table route because of the time it saves with loading, and the accuracy. It now takes us literally 20 seconds to set up a table, and it’s far more reliable. Pre-automation it could take up to 15 minutes to position the pods, and then they weren’t always in the right place.” Another aid to accuracy is the SL-Laser system that they use on all their CNC
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machine tools where every setup is simplified using laser projection for the exact positioning and alignment of machines and workpieces. Once the components come off the machines they are thoroughly checked and assembled before being despatched around the world. “We send staircases to a wide variety of countries, including Sierra Leone, Australia, Gibraltar, France, Cyprus, and the USA.” In conclusion, Graham Thomas says: “We can now make difficult components very quickly, and that’s because Alphacam’s engineers looked at what we needed to know and produced a bespoke automated solution for us. It’s tailored machining.”
For further information: Stairplan: www.stairplan.com Alphacam: www.alphacam.com
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SOFTWARE Cabinet Vision Nesting And Labelling Helps Double Crown Output In Six Months “Cabinet Vision’s nesting function is as important to us as the electricity supply in our workshop.” Those are the words of Jake Gregory, Business Development Manager at Burnley-based Crown Cabinets Ltd. The company manufactures cabinets for around 200 kitchens and bedrooms a month, and says Cabinet Vision, from Vero Software, has been key to doubling their output within six months of installing it, and enabling them to offer a fully bespoke service. Before upgrading their CNC machinery with a Biesse flat top nesting machine, and investing in Cabinet Vision Solid Ultimate with Label-IT and Screen-To-Machine at the same time late last year, Crown produced their cabinets on a point-to-point machine. “A standard eight-to-ten-cabinet kitchen used to take at least two hours…now it takes me about 15 minutes to optimise. We’re averaging eight full jobs a day, compared to
54 Panel & Joinery Production JULY/AUGUST 2017
four previously. And we now have the capacity to accommodate for even more customers.” Not only has Cabinet Vision increased their output, but he says being able to store cabinets in their library means they can offer bespoke products to their customers quickly and cost effectively. And that library is constantly growing. It began with Jake Gregory spending an entire weekend going through their price list and building everything using Cabinet Vision’s powerful Alias feature. “I created a cabinet in one size and called it made to measure…then used aliases to do four more sizes.” It provided the ideal opportunity to relaunch their entire product range, with a number of changes which they could not have done without Cabinet Vision. “Previously, for instance, it wasn’t economical for us to have a different sink base from the standard base unit, because
we had to write a new program for the point-to-point, as it wouldn’t save completed cabinets. But when we were creating the Cabinet Vision library we came up with a new sink base and oven housings, which can be easily adapted every time for completely bespoke products. “And as we add every cabinet we make to the library, when we’re working on a new project there’s nearly always a unit in there that is a close reference to the one we want. We simply pick it from the catalogue and easily adapt it. “We have a saying: ‘if you can draw it, we can make it.’ And the process is easier because I put all the textures in there, too. It was certainly worth the upfront investment in time to do that. It saves us a lot of time every day now.” He says it is a major plus to see onscreen exactly what is being created. “We went from the point-to-point system where
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SOFTWARE we had to visualise everything mentally, including where to place the cams and pins to ensure they matched. Now, using Cabinet Vision’s master and slave system, all I need to do is to build the cabinet in the 3D space, and the system automatically figures where everything goes. “I think of it as the same as 3D printing. I build my cabinet in 3D on the computer, and Screen-To-Machine creates the necessary NC code which cuts it on the Biesse. Although they have a retail branch in Burnley, the bulk of their customer base is trade, dealing with joiners and independent showrooms. “We supply assembled cabinets to the trade, but we don’t fit – we only fit for end-user customers who buy through our retail outlet.” He describes their principal operation for the trade as being the cabinet supplier of the full kitchen jigsaw. “When a showroom designs a kitchen it’ll source its worktops, doors and appliances from individual suppliers. We supply their cabinets.” Three Cabinet Vision functions are essential in helping Crown Cabinets take their products, and indeed the business, to the next level. Firstly: photorendering. “I recently created a 1200mm high drawer unit with three single drawers along the bottom, two sets of two drawers, and one set of three drawers. It was a completely bespoke unit. I
designed it while the customer was here, and opened all the drawers to show her what all the drawer boxes would look like, then photo-rendered it for her.” Secondly: labelling. Crown Cabinets have set up their system so Cabinet Vision produces labels for each panel at the same time as the NC code goes to the Biesse. The labels show the job number as a bar code, the customer name, part name, colour, size, the cabinet it belongs to, and the delivery date. “As we create thousands of panels a month the label system is vital to keep track of everything and differentiate between the jobs. We stack the panels before we edge them, and need to be able to see which ones belong to each customer.” Thirdly: nesting. “Nesting is integral…we
couldn’t run the business without it now. It’s as important to us as the electricity supply in our workshop.” He says as they need to cut a lot of shaped units, it helps them gain maximum yield from their material, which is usually 18mm MFC board, and MDF for doors. “The reduction in material wastage is especially important to us. Previously, if we were doing an Lshaped base unit, we’d have to cut the full square and take to the nesting machine and then cut the further square to make it an Lshape, which meant there was some waste. Now, because it cuts true to shape it simply places the L-shapes next to each other and saves a lot of board.” Concluding, Jake Gregory says Cabinet Vision’s support team are always able to show the best way of implementing Crown’s new ideas. “For example, we do scoop drawer fronts on our internal drawer packs, and I wanted to change the design to a square front for an internal drawer on a wardrobe. I’d had a bit of experience with the User Created Standards (UCS), but wasn’t completely confident of how to achieve what I wanted. The support team showed me exactly how to do it.”
For further information: Crown Cabinets: www.crowncabinets.co.uk Cabinet Vision: www.cabinetvision.com Jake Gregory, Business Development Manager at Crown Cabinets Ltd See our website and interactive magazine www.p-j-production.com
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DUST EXTRACTION & WOODWASTE Makita Introduce Improved M-Class Dust Extractor • 110v and 240v models with Power Take Off options • Increased airflow and new automatic filter cleaning system Makita’s 447M M-Class dust extractor has set high performance and reliability standards throughout industry since its introduction and the latest version of the MClass extractor, the new VC4210M, bristles with new features whilst maintaining a highly competitive price point. The new Makita VC4210M fully meets the EU standards of protection demanded of the M-Class dust control regulations. This is the minimum standard permitted for legally compliant work in construction environments. The updated design has moved the motor, control module and main filter higher up into the upper body housing which increases the tank working capacity. This enables a 30 litre disposable bag to be filled and for wet suction the tank will hold 29 litres before the new, automatic fluid level valve shuts off the motor, protecting the machine from flooding. The tank sits neatly inside the double-wall moulded body housing on big rear wheels and robust front steel castors.
Available in 110v and 240v modes there are three variants: 110v models with and without Power Take Off to drive integrated power tools and a 240v model with Power Take Off. When connected to a power tool, the extractor switches off automatically when the power tool is shut down. The motor input wattage is 1000W for the 110v model and 1200W for the 240v machine. The 110v model with Power Take Off will provide 1750W for tool power and the 240v model 1800W. Maximum airflow and filtration performance have been substantially increased for the new VC4210M extractor with max air flow now 4.5m /min. The latest Makita automatic filter cleaning system uses the strong airflow reversed regularly through each of the air filter routes to ensure the durable PTFE filter is kept clear. Access to this high-efficiency filter is through a new large hatchback port in the rear of the housing, enabling access to the
filter without having to remove the motor head. An air flow sensor will bleep a warning if the filter becomes clogged, the tank is full or there is a restriction in the suction pipe. The new Makita VC4210M dust extractor has a flat top housing design, useful for depositing hand tools and accessories, and Makita Makpac cases can be attached using an optional accessory adaptor plate. Delivered with a 5m long, 32mm diameter suction tube, this versatile extractor has individual operating settings for hose diameters of 21, 27, 32, 36 and 38mm. Dust extraction is a health and safety ‘must’ on all sites and the new Makita VC4210 M-class unit protects the working environment at an affordable price. Makita’s 447 MM-Class dust extractor
For further information: www.makitauk.com. Twitter @MakitaUK Facebook.com/makitauk google.com/+makitauk
Company Turns Waste Wooden Pallets Into Free Factory Heating With Help From Wood Waste Technology A manufacturing company will no longer have heating and waste disposal bills going ‘through the roof’ since buying a new wood waste heater from Wood Waste Technology. Weatherfast Ltd manufactures and supplies a wide range of high performance Fatra PVC membrane steel in sheet or coil form for use in the roofing industry. Set up 5 years ago, the business is run from its 8000 square metre factory in Great Barr, Birmingham. The directors at Weatherfast Ltd started to research the benefits of investing in a wood waste heater once they realised the business was spending around £500 a month to heat the factory during the winter, and about £300 a month to have its wood waste, including redundant wooden pallets and packaging removed. Director, Orry White explains: “We soon realised that investing in a wood waste heater would pay back really quickly, as we could burn the waste wooden pallets to provide free factory heating – saving the business around £800 a month.” Orry searched the internet for wood waste heater manufacturers and contacted Kurt Cockroft at Wood Waste Technology, who arranged for Orry and the team to go and visit a neighbouring company who’d already invested in one of Wood Waste Technology’s biomass systems. Following more information and a site
56 Panel & Joinery Production JULY/AUGUST 2017
survey, the team at helped many companies Weatherfast Ltd purchased a reduce their waste disposal and WT15 towards the end of last heating costs. As well as year, and Wood Waste offering site survey, design, Technology’s specialist manufacture, installation and engineers installed it a few on-going maintenance for new weeks before Christmas. wood waste heaters and boilers, Orry says: “We’ve been really the company also services all impressed with the wood waste types of wood waste heaters and heater so far. We have to walk supplies genuine spares up to through another factory to 60% cheaper than other enter ours, and the difference suppliers. in temperature is really In addition, Wood Waste The WT15 wood waste heater noticeable, as you leave their Technology is the UK’s official installed at Weatherfast Ltd cold factory and walk into our distributor for Gross lovely warm area. I can highly recommend Apparatebau GmbH, a German Wood Waste Technology’s products and manufacturer of dependable, precision service – we’ve definitely made the right engineered shredders and briquetters. The decision with this investment.” company is also a distributor for Putzmaus MD of Wood Waste Technology, Kurt boiler tube cleaning systems - a powerful but Cockroft says: “We’re delighted to have gentle routine maintenance solution that is customers who are so pleased with their quick and easy to use, and helps to increase wood waste heaters and boilers that they’re boiler efficiency and lower operating costs. happy for other businesses to visit them to see our biomass technology working in situ. For further information: We’re really proud of the good reputation Tel: 01785 250400 our heaters have developed, as every wood www.woodwastetechnology.com www.grossuk.com waste heater we’ve ever sold is still in www.putzmaus.co.uk. operation today, and it’s been a pleasure For further information about helping Weatherfast Ltd save money on its Weatherfast Ltd: business expenses.” www.weatherfast.co.uk Wood Waste Technology’s years of expertise in wood waste solutions have See our website and interactive magazine www.p-j-production.com
F O R A C L E A N E R E N V I R O N M E N TA L F U T U R E At Dust Pollution Systems, we have been busy systemizing spot extraction in the industrial working environments. Our systems cover all aspects and working methods from the small, mobile dust extractors to large turnkey stationary industrial installations.
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Nederman’s Solutions Team Delivers : Pre-studies Planning Design Installation Commissioning Training Maintenance
DUST EXTRACTION
DCS Wrap It Up At Crystal Doors Dust Control Systems Ltd (DCS) has recently completed installation work on a substantial new dust extraction system for Crystal Doors – one of the UK’s leading manufacturers of vinyl-wrapped doors. From its 30,000 sq. ft. manufacturing facility, just off the M62 on the outskirts of Rochdale, Crystal Doors’ 34-strong workforce is dedicated to the production of bespoke vinyl-wrapped doors and accessories for kitchens, bedrooms and bathrooms, and manufactures over 200,000 pieces a year. The company offers a vast selection of designs, foils and materials, and has the capability of profiling doors up to 3 metres in length, as well as custom-printed, curved and 3-dimensional panels. More recently, the installation of high-tech robotic paint and glue spraying equipment, which utilises 3D laser technology, has increased production speeds and ensures a perfect finish for painted doors. Established in 1994, by Managing Director Richard Hagan, Crystal Doors has
With assistance from a 25-tonne crane, the team of DCS installation engineers made light work of positioning and securing the new filter.
earned a distinguished reputation for its environmental quality and efficiency achievements, with year on year
improvements in environmental performance indicators, and has gained recognition from industry, business and
Richard Hagan checks air quality readings of cleaned air being returned to the factory.
58 Panel & Joinery Production JULY/AUGUST 2017
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DUST EXTRACTION environmental organisations, including being named Business of the Year 2015 in the Rochdale Business Awards. The company is FSC and PEFC accredited and certified by BM TRADA, and is currently progressing towards ISO 14001 environmental management certification. Over 99% of all waste is recycled, including collection and onsite storage of wood waste to fuel a 980kW biomass boiler; providing heat and hot water for the factory and offices. Since re-locating to Rochdale 6 years ago, energy consumption and electricity costs for the building have been reduced by replacing over 90% of the lighting with LED units, or high efficiency alternatives. However, in common with most production units, dust and fume extraction is the biggest single energy consumer and, although Crystal Doors had previously invested in high-efficiency extraction equipment from DCS, the existing filter unit pre-dated the relocation to Rochdale. DCS Sales Director, Melvyn Bathgate, explains: “With the increased levels of production that Crystal Doors has achieved through investments in new equipment, the 20,000m3/hr capacity filter was working close to its limit – even with our Ecogate energy-saving technology installed.” “DCS and Crystal Doors go back over 20 years” says Richard Hagan, “and I had no hesitation in asking Melvyn to put forward a proposal for a new system which would fulfil both our current and future needs. Also, our factory is situated alongside Rochdale Canal – which is designated as a Site of Special Scientific Interest by Natural England – so, as well as being energyefficient and ‘future proof’ in terms of its capacity, it’s very important that the system design and engineering quality safeguards against the risk of MDF dust ending up in the canal.” Having considered all of Crystal Doors’ extraction requirements, including further planned investments in new production equipment, DCS submitted designs and costs for a comprehensive installation project which would need to be implemented to a very strict deadline, over a long weekend shutdown. “Our design and project management team had planned the work to the last nut and bolt, and our installation engineers worked with military precision to meet the deadline”,
DCS installed a Schuko ECOVAR VALIDUS modular filter unit with 80,000m3/hr extraction capacity.
commented Melvyn Bathgate. “Production at Crystal Doors finished at the end of the late shift on the Thursday night and we were committed to commissioning the new system for production to start up again at 6.30am the following Tuesday. The Schuko filter was delivered to site in preconstructed sections then built-up in advance, on adjacent ground, ready to swing into place on the Friday morning.” The old filter unit has been replaced with an ATEX-Certified Schuko ECOVAR VALIDUS modular chain filter, with a flowoptimised cascade system of 5 x 30kW fans, capable of extracting up to 80,000m3/hr from 4 separate lines. Dust-laden air
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extracted from the factory is drawn through anti-static, polyester needle-felt tubular filter bags, and waste dust is continuously removed from the filter media by a pulse jet cleaning train, with secondary removal of any remaining deposits by a pneumaticmechanical shaking system. The waste dust falls into the lower hopper section of the unit and is then discharged, pressure-free, by means of a rotary valve, to a screw conveyor which in turn feeds a bucket elevator; finally delivering the waste into a large storage silo. The installation also includes four ATEXapproved CARZ back-pressure flap valves; one in each of the 4 main ducts. In the
JULY/AUGUST 2017 Panel & Joinery Production
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DUST EXTRACTION event of a dust explosion, the valves prevent the effects of a pressure wave and flames travelling from the filter, back along ductwork, and into the factory. DCS have also provided additional fire safety and air quality monitoring at Crystal Doors: a 4zone spark detection system will trigger a fast acting water extinguisher if a spark is detected in either of the 4 main ducts, and the integrity of the system’s cleaning efficiency is constantly monitored by a particulate emission measuring system which has sensors fitted to each of the 4 return air ducts. As well as delivering clean warm air to the factory to maintain optimum temperature for vinyl application, one of the return air outlets replenishes air extracted from the spray booth; ensuring a warm, dust-free atmosphere for a quality finish and quick drying times. Key to achieving the energy-efficiency targets projected by DCS is the installation of an Ecogate greenBOX MASTER SRL 200. With the capacity to control and interrogate up to 200 motorised gates, and up to 4 variable speed drives, the MASTER SRL 200 is the most sophisticated control unit in the Ecogate technology range. The system auto-starts when the first machine is powered up, constantly optimises fan speeds throughout a 3-shift production schedule, and auto-stops when all machines are shut down. Setup, monitoring and service functions are all accessible via the colour touch screen, and stored machine activity data can be download to a
Extraction control, monitoring and safety provided by Ecogate greenBOX MASTER SRL, PCME particulate emissions monitoring unit, BS&B spark detection system and Carz back-pressure flap valves.
removable flash drive. Furthermore, all control functions, activity logging and data storage can be securely accessed from any authorised internet-connected PC. The MASTER SRL also maintains minimal airflow to ensure a balanced system, programs filter cleaning cycles, and generates status indicators for system errors.
The benefits of the Ecogate ‘Extractionon-Demand’ system have been welldocumented in the press since DCS first introduced the brand to the UK in 2010, and it’s now a ‘must have’ component for any extraction installation; whether it’s a new system or a retrofit installation. Ecogate optimised extraction systems automatically adjust power output to the fans, in real time, to match the exact requirements of the manufacturing process, resulting in significant energy and cost savings – at Crystal Doors, early indications show that the new system is running at almost half the cost of the previous installation. Richard Hagan concludes: “As always, the service provided by DCS was exemplary, and we now have the most efficient extraction system possible for our business, with capacity to spare and a life expectancy in excess of 20 years.”
For further information: Tel: 0800 040 7116 www.DCSlimited.co.uk Three separate inlets allow cleaned return air from the filter to replenish exhausted air and balance pressure in the spray booth.
60 Panel & Joinery Production JULY/AUGUST 2017
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Panel & Joinery Production lists the major manufacturers and suppliers to the UK woodworking industry under easy-to-find product headings. If you think that your company should be included in this list, please contact us immediately.
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