& JOINERY
PRODUCTION
May/June 2016
Celebrates
by Investing for the Future
Tel. 01925 223965 www.starbank-uk.com
“I Demand Quality” Adam How we e, Managing Director
“In order to gro ow my business, I need ded qualit y machinery and qualit y back up and support. I received and still i receive both fro om Felde er and would recomme end them everyday“
Profit H08
G 330
K 940 S
Ove er 150 Woodw oo oodw wo orking Machi hine nes to choose from! fro om! Call today to find the right Felder Machine for yo our business!
Felder Group UK
Unit 2, Sovereign Business Park, Joplin Court, Crownhill, MK8 0JP P, Milton Keynes. Tel: 01908 635 000, info@ukfelder.co.uk, www.felderr- group.co.uk
CONTENTS
& JOINERY
PRODUCTION May/June Issue 2016 Published by:
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Forty years after it was founded by Gordon and Kathleen Darbyshire in a small village in Lancashire, Starbank Panel Products is celebrating much more than a big anniversary in 2016 – see page 18
Reproduction of articles: All material appearing in Panel & Joinery Production is strictly copyright, and all rights are reserved. No part of the publication may be copied or transmitted in any form whatsoever, including photocopying, without the prior permission of the publishers. Publishers’ note: The editorial opinions expressed in Panel & Joinery Production are not necessarily those of the publishers, who shall be under no liability with respect to any article published herein. Distribution: Panel & Joinery Production is published six times a year and circulated to designers, individual purchasers and specifiers who are manufacturing within the wood-based panel, board and solid wood industry in the UK and Ireland. Annual subscription is at the following rates, which include postage: UK & N. Ireland Mainland Europe Elsewhere
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CONTENTS 4-5 6-7 8 9 10 11 12-13 14-15 16 18-20 28 30-31 32-33 35 39 40 42 44 50-51
Homag UK’s May Open House Great Anticipation For SCM Group At Xylexpo Out Of This World – Blum’s Storage & Motion Sorted Weinig Doubles Show Sales At Holz-Handwerk More ‘Open House’ Success For Daltons Wadkin AXYZ Routers On Song At Wilcare Wales The Winline One Line – Simple, Autonomous, Productive The New Homag Ambition Range Constant Growth From The Felder Range Starbank Celebrates 40 Years Ostermann Has The Matching Edgings The Brandt Ambition – Affordable Entry Level Edgebanding Alphacam Is Music To Guitar Maker’s Ears SCM Group At IDEA Welcome Furniture Invests In A Fourth Schelling fh6 Salvador Hat Trick For Daltons Wadkin deVol Invest In A Kündig Again Viet Slashes Sanding Time At Door Makers DCS Extraction System For New Starbank Facility See our website and interactive magazine www.p-j-production.com
SPECIAL FEATURES 18-20 22-27 28 32-34 38-40 42-44 46-52 IBC
COMPANY PROFILE – STARBANK PANEL PRODUCTS LTD DECORATIVE SURFACES EDGINGS SOFTWARE SAWS SANDERS DUST EXTRACTION/WOODWASTE WEBSITE DIRECTORY MAY/JUNE 2016 Panel & Joinery Production
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NEWS Joinery Firm Wins National Apprenticeship Award Adary Joiners from Challerton has been revealed as the Unilever Small Employer of the Year at the National Apprenticeship Awards at an exclusive ceremony at London’s Grosvenor House. The Awards, now in their twelfth year, are run by the National Apprenticeship Service and recognize excellence in two areas: businesses that grow their own talent with apprentices and apprentices who have made a significant contribution to their workplaces. The company was chosen as the inner in recognition of its commitment to developing young people through apprenticeships. Adary Joiners is a small joinery business. Partners, Lucy and Gary Sidlow, set up the business three years ago with just two sub-contracted joiners. The business grew rapidly and they soon realised that the sub-contracted joiners were free to leave the company at a moments notice so started employing joiners directory. In order to future proof the business, they decided to employ their first apprentice in September 2012 and have taken on three more since. On accepting the award, Gary Sidlow, Company Partner at Adary Joiners, said: “Our strategy is to build a core team of enthusiastic and skilled joiners, specialists in our field, ensuring the continuity of our business.
IDS Appoints New Marketing and E-Commerce Manager Sabine Mané is the new marketing and e-commerce manager at International Decorative Surfaces, the UK’s largest distributor of surface materials. Sabine is responsible for all aspects of marketing the company’s product portfolio which includes worksurfaces, flooring, sinks, taps, wall panelling, laminates, panel products and solid surfacing. Sabine has a wealth of industry experience, having worked for Twyford Bathrooms for 18 years, where she was latterly the Head of Marketing.
EVENTS Reminder 2016
Milan 24-28 May
NEC Birmingham 2-5 October
Norbord Wins Timber Supplier Of The Year At Fortis Supplier Awards Norbord has been crowned Timber Supplier of the Year 2015 at the 2016 Fortis Building & Timber Conference. The Supplier of the Year Awards - alongside the annual Fortis conference - were held at the Hilton Metropole Hotel in Birmingham and were hosted by comedian, Dara O’Briain. David Mills, Norbord Europe Key Account Manager, comments: “Norbord is thrilled to have been awarded these prestigious awards, especially as we are only in our second trading year with Fortis. Special thanks should go to our sales and logistics teams for engaging with the Fortis members who have been very receptive in developing our trading relationship. We are looking to improve further and look forward to another successful year together.” For further information: Tel: 01786 812 921 www.norbord.co.uk
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Sabine Mané, Marketing & E-Commerce Manager at IDS
For more information: Tel: 08457 298 298 Email: info@idsurfaces.co.uk www.idsurfaces.co.uk
Paris - France November 22nd - 25th
See our website and interactive magazine www.p-j-production.com
bWindows
biesse.com
TRAINING
PIABC Approval for Daltons Wadkin Training Woodworking machine operator training, which forms a significant part of the services provided to the industry by Daltons Wadkin, is now backed by respected quality assurance assessors PIABC. Daltons Wadkin were approved as a quality assured centre for woodworking machine operator training last December and Francis Dalton commented, “We are delighted to have received PIABC approval for our operator training in recognition of the hard work and dedication put in by our training team. Working initially with experienced training provider John Gubb our company provides a most comprehensive training service on a daily basis to organisations throughout the UK and Ireland, ranging from public authorities
and high end joinery and furniture manufacturing companies through to the smallest of workshops and individual operators. PIABC approval is the ‘icing on the cake’ and gives us further impetus to drive our training services onwards ad upwards.” Daltons Wadkin Sales Director Andy Walsh added, “This approval confirms our position as one of the leading woodworking machine operator trainers in the UK and it doesn’t stop here. We have our own specialised trainers, ie ‘The Red Team’, and will have no hesitation in taking on additional trainers as work demands. We have training materials that are second to none and incorporate health and safety
information and advice in everything we do including the provision of risk assessments as required.”
Further information concerning the training services operated by Daltons Wadkin can be obtained from the website (www.daltonswadkin.com) or by contacting the sales team on 0115 986 5201.
In Vogue with Mundy Veneer Woodworking machine operator training, which forms a significant part of the services provided to the industry by Daltons Wadkin, is now backed by respected quality assurance assessors PIABC. Daltons Wadkin were approved as a quality assured centre for woodworking machine operator training last December and Francis Dalton commented, “We are delighted to have received PIABC approval for our operator training in recognition of the hard work and dedication put in by our training team. Working initially with experienced training provider John Gubb our company provides a most comprehensive training service on a daily basis to organisations throughout the UK and Ireland, ranging from public authorities and high end joinery and furniture manufacturing companies through to the smallest of workshops and individual operators. PIABC approval is the ‘icing on the cake’ and gives us further impetus to drive our training services onwards ad upwards.” Daltons Wadkin Sales Director Andy Walsh added, “This approval confirms our position as one of the leading woodworking machine operator trainers in the UK and it
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TABU - showroom
doesn’t stop here. We have our own specialised trainers, ie ‘The Red Team’, and will have no hesitation in taking on additional trainers as work demands. We have training materials that are second to none and incorporate health and safety information and advice in everything we do
including the provision of risk assessments as required.” For more exhibitor information please visit www.wexhibition.co.uk/Elements or follow @Elements_Expo on Twitter for the latest exhibition news.
See our website and interactive magazine www.p-j-production.com
PROFILE Blum now offers a mechanical opening support system combined with soft close Tip-On Blumotion – an inspiring combination of opening and closing ease To provide enhanced opening ease for handle-less fronts, Blum not only offers an electric opening support system but also a mechanical solution: Tip-On. Tip-On is now available in combination with Blumotion for soft and effortless closing. Tip-On Blumotion brings utmost ease of use to handle-less furniture – in kitchens and throughout the home. The innovation is the winner of this year’s Red Dot Award 2015 for top quality design. • An inspiring combination of mechanical opening ease and soft and effortless closing – bringing enhanced convenience to handle-less pull-outs • Impressively large trigger area despite small front gap of just 2.5 mm • 4-dimensional adjustment for precise gap alignment • Reliable function (even after unit has been pulled open and pressed shut) Tip-On Blumotion combines easy onetouch opening with soft closing. Handleless pull-outs and drawers open with ease thanks to the mechanical opening support system and always have a feather-light glide. Tried and tested soft-close Blumotion ensures that they close again softly and effortlessly. The new and inspiring quality of motion of Tip-On Blumotion is not only
available for Legrabox, the elegant box system by Blum, but also Movento, Blum’s runner system for handle-less wooden pullouts and drawers can be combined with the latest innovation for easy one-touch opening and soft and effortless closing.
Small range, great convenience Tip-On Blumotion can be assembled quickly and simply without tools. The solution can also be optimally integrated into existing planning dimensions because it needs little space. No additional modifications need be made to cabinet, front or box for assembly. There are different Tip-On Blumotion units to choose from to suit nominal length and weight. With a minimum front gap of just 2.5 mm, Tip-On Blumotion is ideally suited for implementation in kitchens but also for furniture throughout the home. The trigger function of Tip-On Blumotion is guaranteed despite the small front gap. Blum in fact offers an optional synchronisation feature to further enlarge the trigger area. Gap alignment is easy thanks to 4-dimensional adjustment. And Tip-On Blumotion will still work perfectly even if the pull-out is pulled open or pushed shut.
For further information: Tel: 01908 285700 www.blum.com See our website and interactive magazine www.p-j-production.com
MAY/JUNE 2016 Panel & Joinery Production
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PROFILE Great Anticipation for SCM Group’s Attendance To The 25th Edition Of Xylexpo FieraMilano-Rho, 24-28 May Hall 2 – stand A01 Scm Group, the leading group in the design, production and distribution of technologically advanced solutions for the furniture industry and wood-working companies, will be the protagonist of the 25th edition of Xylexpo, which will be held at Fiera Milano-Rho in Milan from 24 to 28 May 2016. Scm Group’s leadership position is confirmed by the excellent results of 2015. THE “SMART MANUFACTURING” LOGIC At Xylexpo, Scm will present the latest developments of the group and its brands in a large exhibition space of over 2600 square
SOFTWARE
metres. These will include integrated solutions and modular cell systems, which reflect the intelligent innovation approach, a direct interpretation of the “Smart Manufacturing". In particular we will present integrated production processes for machining panels and solid wood, all “intelligently flexible”, and capable of combining different levels of profitability/productivity, utmost customisation and extremely easy reconfiguration possibilities. The aim is to provide the industry with solutions for productions with shorter time-to-market, to increase competitiveness on the markets and at the same time allow for a greater level of specialisation. The technologies presented by the Scm Group are therefore designed to optimize and facilitate the creativity of small wood working workshops and large industries, supporting them in the process towards “mass customization”.
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The software, a centrally important aspect to the “Smart Manufacturing” logic, will be one of the strong points at Xylexpo. Scm Group will bring to the show all its know-how and a suite of state of the art, and continuously evolving, programs, designed to guarantee the complete use of the machines’ functions and achieve a more agile and customised production and industrial process.
INTEGRATED SYSTEM OF INTELLIGENT CELLS At the show the group will present its unique scalable cell systems. This range of solutions can meet the production demands of an industry that is increasingly looking for greater flexibility, easy integration and profitability. Many of the technological developments of the group will be found in the integrated and modular production processes. This choice reflects the extensive and comprehensive competence of the Scm Group’s specialists in all the application fields of the sector. Two integrated cells for machining panels will be on show. 1. Cell system for high production capacities (up to 800 pieces per shift) that consists of the following:
• “batch one” panel sizing cell Gabbiani, Mahros, Morbidelli to obtain any type of cut in “real time”, thanks to the intelligent management of the automatic three-axis magazine Flexstore EL, based on advanced software and increased automation; • flexible squaring edge banding cell to achieve an extremely diversified production within the reach of any company; • line boring Morbidelli Powerflex S, the true reference point for the furniture industry that has now reached new standards: up to 30 panels per minute. • the process is completed with the highperformance boring/routing/edge banding work centre Morbidelli Planet P800, designed to simplify the machining process of shaped panels up to 6360x1905 mm. 2. Cell system for medium production capacities (up to 500 pieces per shift), that consists of the following: • work centre Scm Pratix S expanded with new functions, designed specifically for nesting machining operations, such as the new labelling function managed by the Xilog Maestro software, which makes it even it easier to control the entire process and the greater level of integration in the automatic processes that render it
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PROFILE a veritable cell or integrated solution; • the industrial edge bander Stefani Solution XD is the ideal choice to produce high-design furniture; • the boring work centre Morbidelli Cyflex hp, is one of the most eagerly awaited products in terms of productivity increase. This solution, requires less than 10 m2 of space, and achieves lower cycle times than any other alternative in this market segment; • the frame press CPC Action is a highly automated solution for furniture assembly. The following integrated systems to machine solid wood will be on show: • the pressing system for sandwich panels with the press Sergiani Las 335 • the work centre for machining parts of doors and windows Scm Accord 25 fx, fitted with the automatic table Matic, Prisma 5-axes machining unit and ProSpeed safety system, and the automatic thicknesser and spindle moulder Scm Superset NTPL, with the following working capacities: max 260x200 mm and min 25x6 mm.
FOCUS ON SPECIFIC TECHNOLOGIES Edge banding Perfect edging finishes and an extremely diversified production within the means of any company; these are the key aspects of the edge banding systems that Stefani and Scm will have on show at Xylexpo. In particular, the focus will be on the wide range of gluing systems, the new SGP glue tank, Air Fusion technology, and the new integrated pre-melter PU BOX L, found on the whole range of Stefani and SCM Olimpic edge banders. Panel sizing Gabbiani’s presence at the show will focus on the panel sizing machine Galaxy 3 110 A, integrated in the “batch one” panel sizing cell and augmented with the new electronic carriage that ensures extremely competitive performance levels. The panel sizing machine will be fitted with the single clamp unit “Flexcut/1S”, the ideal combination to achieve utmost flexibility and increase performance, now also available with the wheeled table for delicate materials.
Sanding DMC will take part in the show with the range of System flexible sanding belt sanders. This modular system features unique new devices that allow for prestigious finishes found in hand-made pieces such as the saw cut, woodworm, structured and wave-effect, as well as the most varied brushing and rustication effects. The range of Scm sanders, will be represented with the Sandya 900, which will be presented with new configurations featuring the introduction of machining units. Finishing Surfaces, the brand specialised in finishing surfaces, will present state of the art solutions for painting panels, furniture parts and door
and window frames, with a specific focus on flexible applications and using the most advanced painting cycles. Machines for small woodworking workshops Scm will bring to Xylexpo the solutions of the L'invincibile range. This has always been the reference point for small to mid-sized companies and for larger saw mills that produce non-standard items or with prototyping departments, The circular saw “L’invincibile Six” with +-46° blade cut, the pinnacle of the design and technological excellence of the group, will also be on show. Machining advanced materials The new work centre SCM Accord 50 fx, presented for the first time on the Italian market, will be demoed on specific applications not only for wood, but also plastic and advanced materials. This 5-axis work centre with fixed table and mobile upright can perform routing and boring on pieces up to 500 mm high, with large tools. C.M.S. The Bergamo-based company will bring to
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the show 4 work centres, which represent the ideal solutions for the most demanding sectors that have to marry versatility, precision, highvolume productions and a complete automation of the process. These work centres are the result of C.M.S.’s vast and consolidated experience at the service of the woodworking industry. The group closed the year with a turnover of more than 500 million Euros, up 10% compared to 2014, with a 28% growth in the Italian market in the machines sector. The group’s international growth was also very successful, with the opening of three new branches: Scm Group Middle East in Dubai, Scm Group Malaysia in Kuala Lumpur and the new Scm Group North America centre on the West Coast. This has strengthened the group’s global presence that, with 20 branches and over 350 distributors and agents, boasts the most extensive distribution network of the sector, allowing us to provide advanced technological solutions, a comprehensive support service with the best specialists in the individual machining operations and an excellent after sales service. This year, the group will implement an important investment plan aimed at consolidating its international presence and to the development of new technological solutions for the industry. For further information: Tel: 0115 9770044 Email: scmgroup@scmgroup.com www.scmgroup-uk.com
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EVENTS
Out Of This World: Storage & Motion Sorted Blum’s highly successful appearance at March’s KBB exhibition was down to showing innovative and exclusive products – appealing to, and sparking the interest of, manufacturers, designers and specifiers, kitchen fitters and buyers alike.
TIP-ON BLUMOTION Star of the show was the newly launched TIP-ON BLUMOTION – a combined concept that effortlessly (literally) blends the TIP-ON push latch one-touch opening system with the BLUMOTION soft-close drawer mechanism. TIP-ON BLUMOTION brings streamlined ease of use to handleless furniture – not just in the kitchen, but throughout the entire home. All pull-out systems and drawers can benefit from TIP-ON BLUMOTION, which can be optimally integrated into existing planning dimensions. To set designers minds at ease, no additional modifications to cabinet, front panel or box need be made. A minimum front gap of just 2.5mm is required for the opening trigger function to operate, and fourdimensional adjustment means that TIP-ON BLUMOTION can be used in any situation.
SERVO-DRIVE FLEX Blum has extended the handle-less concept to include integrated fridges and freezers … or combinations thereof. SERVO-DRIVE flex is a new electrical opening system for integrated
An entirely new form of motion technology which combines the mechanical benefits of TIP-ON and BLUMOTION
cooling appliances; all it needs is a 60mm space above the appliance door. Cool.
SPACE TOWER As always, the Blum concept is to make life easier for everyone, with the help of clever storage and accessibility concepts. Studies by Blum concluded that their movement and technical solutions can improve useable storage space by up to 55% when compared with ‘standard’ drawers and fixed shelves in a kitchen. The SPACE TOWER larder unit has
been made even easier to use and specify, thanks to the new ‘one box order’ system, which streamlines the ordering process. A SPACE TOWER larder unit allows every inch of space to be used, the full extension of each shelf means that no ‘reaching in or over’ voids are needed. The easy-order one-box system comprises Stainless Steel LEGRABOX drawers, each of which can hold up to 40 kg (that’s 40 bags of sugar) with BLUMOTION soft-close technology.
AND FINALLY … David Sanders, Sales & Marketing Director at Blum UK said: ‘The show was a great success for us. It’s always a pleasure to meet our customers from the KBB industry, and to hear their comments about both our new and existing products. We’re always excited and enthusiastic to demonstrate our new developments and technologies, and it’s inspiring to hear the responses and reactions from our valued customers. We were particularly pleased with the reaction to SPACE TOWER and look forward to seeing the product on display in showrooms.’
The Blum team
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For further information: Tel: 01908 285 700 www.blum.com
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EVENTS
Weinig Doubles Show Sales at Holz-Handwerk The Weinig Group was represented in Nuremberg across 1,600 sq m with an integrated stand concept for solid wood and panel processing. The full stand over all four days of the trade fair reflected the company’s excellent sales - twice as high as those in 2014. It was the first time that the trade fair presence was shaped by the company’s THINK WEINIG motto. The slogan represents the new sales and marketing strategy, with which Weinig aims to communicate its unique group expertise in the sector: "Whatever the challenge they face, our customers should think of Weinig first," said Chief Sales and Marketing Officer Gregor Baumbusch. 39 innovative exhibits covered the entire value chain in solid wood and panel processing. The extensive line-up proved a particular draw for the specialist audience. Professional visitors from more than 50 countries were registered on the stand, bearing testimony to the growing international attraction of Holz-Handwerk. Central themes on the Weinig stand included linking and networking, which are increasingly important and in demand today, even in small businesses. With solutions that connect all processes from the idea to the finished product in a single, integrated overall system, the Weinig Group demonstrated that it is optimally equipped for the challenges of the future. One innovative highlight was the premiere of the Powermat 1500, coming to the UK later in 2016. The high-performance
moulder has the new ComfortSet simple operating concept and is equipped with CNC-controlled axes. The modular system makes the Powermat 1500 extremely flexible. Besides the planing and profiling machines, Weinig's window production technology also met with great interest. The spotlight was on Industry 4.0, which is synonymous with intelligent production and has been broken down by Weinig to meet the requirements of window manufacturers, particularly in small businesses. Weinig exhibited a comprehensive system of components, based on an integrated, modular complete control concept, which is available in all Conturex series. Automated complete solutions that network the crosscut saw with pre-planing machine and the downstream Conturex CNC processing center also attracted significant attention. The other Weinig product units also experienced strong demand. There was a particular focus on cutting, where Weinig impressed with innovative crosscut systems and scanner technology. The increasingly important Weinig Service division was presented in a dedicated information area. With its comprehensive Service package, including the Weinig App, Financing, Education/Training, Pre-owned Machines and project specialist Weinig Concept, Weinig precisely met the needs of customers that demand optimal support with the production process in a time of increasingly complex challenges. There was a tremendous response to the
panel processing business unit from HolzHer, part of the Weinig Group since 2010. Holz-Her exhibited its complete portfolio from CNC processing and panel splitting to edge banding with a proprietary, particularly cost-effective zero joint process, proving its extraordinary expertise in this market segment. Planing and profiling machines accounted for a remarkably high proportion of orders placed at the show, including a number of deals for its entry-level four-sider, the Cube, which has proved to be hugely popular in the UK. Other success stories included the Conturex systems, which have enabled Weinig to reassert its leading position in window production technology. There were also several pleasing sales of Multirex systems for surface processing, as used in window, door and joinery production. "Our efforts in Nuremberg paid off once again," said CEO Wolfgang PĂśschl. "Our appearance and product range formed a perfect unit. Our solutions are tailored to the market and met perfectly with customer requirements." For further information: www.weinig.co.uk
Great interest: the Weinig trade fair stand was a constant draw for visitors See our website and interactive magazine www.p-j-production.com
MAY/JUNE 2016 Panel & Joinery Production
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EVENTS
More ‘Open House’ Success for Daltons Wadkin Attendance at all time high The Daltons Wadkin open house exhibition from 8 to 10 March proved to be an outstanding success. Visitor numbers were up and interest was high, particularly in the rapid performance and technically advanced equipment such as the Salvador crosscutting range and Kimla CNC routers. Some 25 machines were on display and available for demonstration throughout the period and although interest was perhaps greatest where the Kimla and Salvador machines were concerned there was also considerable activity around the Elcon vertical panel cutting range and the Altendorf sliding table panel saws as well as the newly acquired Cehisa range of edge banding machines. Also featured were a range of Wadkin classical machines, Stenner ST100R band resaw and the all new, never before seen in the UK, Maggi
Evolution 1000 CNC multi-spindle borer with router. Alex Dalton commented, “We have had success in recent years with open house exhibitions but nothing which quite compares with this one. The range of equipment on show was extensive and reflected the development of our product range and our highly successful advance into CNC and other automatic machines such as the Salvador crosscutting systems. Prospective clients came from far and wide, orders were taken during the show including a high specification Kimla CNC and we fully expect that many orders will result from the amount of interest and the significant enquiries we received during the show.” The recent event in Nottingham is the first instalment of what will prove to be a
very busy exhibition year for Daltons Wadkin. They will be showing a Kimla CNC at the Sign and Digital UK show at the NEC, 19 to 21 April, and of course the company will as usual have a wide range of equipment on show at the W16 exhibition, again at the NEC, 2 to 5 October, where particular emphasis will be placed on the highly successful Salvador crosscuts, the Kimla CNC range, Cehisa edge banders and Elcon vertical panel saws.
Further details regarding any of the products marketed by Daltons Wadkin or information concerning any of the forthcoming show dates can be obtained from the website (www.daltonswadkin.com) or by contacting the sales team on 0115 986 5201.
Interested visitors being explained the advantages of the Salvador Crosscut Saw
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EVENTS
Holz-Handwerk: A Great Result for Leitz Tooling At this year’s Holz-Handwerk in Nuremberg, Leitz presented its products and services on a 370m2 booth. The full-range supplier additionally focused on window production and solid wood processing which was of particular appeal to visitors to the Fensterbau Frontale exhibition, which took place at the same time at the Nuremberg exhibition grounds. “For us, the Holz-Handwerk had been a great start to the new quarter”, said Alessandro Telesio, CEO of the Leitz Group. “We have shown an excellent performance. Our messages of a being a manufacturing service provider and partner for optimal processes were well received by our customers.” Many visitors of this year’s event for wood- and plastic-processing had detailed investment plans and required specific information which Leitz was able to deliver at the exhibition, and will continue to do so directly at customers production sites. Leitz also saw considerable increase of incoming orders from the OEM sectors: “Users, who have invested in new machine technology, subsequently also require the tools and processing know-how”, explains Telesio. The Leitz-CEO thanked everyone involved ensuring that Leitz was a success at the exhibition: “Having a presence at the exhibition is very challenging. It only becomes really successful if you have a good team. And our team was excellent.”
According to the organizer, 110,000 people visited during the four days of the Holz-Handwerk. As in previous years, the majority of visitors were from Germany and the neighboring countries. However, Leitz welcomed numerous customers from overseas on its booth. Many of these visitors also took the time to visit the main Leitz factory in Oberkochen to discuss current international processing trends.
Window production and solid wood processing focus At its Holz-Handwerk booth, Leitz showcased tooling highlights and innovative technologies for window production and solid wood processing, for which the ProfilCut Q profile tooling system remains unchallenged. In its Premium version, the profile tooling system can operate with cutting speeds of up to 120 meters per second. Leitz presented its powerpack on its own exhibit; its eight tool- and technologycomponents was aimed at window and door producers who are interested in optimising their machining processes. Other exhibits on the Leitz booth showed technologies for furniture production, extracts from the full range of tools, tool solutions for timber construction and circular saw blades with new laser ornaments filled with a specific damping mass resulting in increased stability and quiet running of the saw blades.
A selection of tooling from the Leitz stand
Leitz stand at Holz-Handwerk
Tools – good as new Under the slogan “Tools as new” Leitz also gave a peek behind the scenes of its AfterSales-Service. The service sector on the booth showed what happens from between when the service salesman collects a tool for sharpening or repairing from the customer to returning the tool to the customer. Leitz believes that when leaving one of their services stations, tools should be ‘as new’. Each of their service processes have been optimised for original producer quality. Cutting edge service techniques enable Leitz to give like-new performance throughout the lifetime of the tool, and reliable pick-up and delivery is tailored to your needs. Leitz Tooling UK is the UK’s largest supplier of tooling to British industry and all Leitz tools are safety tested to BS EN 847 standards.
Visit Leitz YouTube-Channel for background and Holz-Handwerk videos: www.youtube.com/leitztooling. For further information: Tel: 01279 454530 www.leitz-tooling.co.uk Leitz ProfilCut Q profile tooling system See our website and interactive magazine www.p-j-production.com
MAY/JUNE 2016 Panel & Joinery Production
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PROFILE
The Winline One Line: Simple, Autonomous, Productive Biesse technological solutions are at the service of the Revoluton 4.0, helping customers to become ever more competitive. The conception of a specific line for windows and doors reaffirms the capacity of Made In Biesse technologies to contribute to the creation of fully-automated factories, perfectly interpreting the needs of the market. In this instance, the customer seeking assistance from the Biesse team of experts is headquartered in the heart of Central Europe, where plants are characterized by extremely high technological content and cutting-edge production. The requirements were clear: to integrate the new line with the machinery already used in the production process, to increase plant productivity without complicating the management of operations and to reach near-flawless levels of working efficiency.
The Made In Biesse Solution. LINE INTEGRATION Out team of Biesse sales engineers interpreted the needs of the customer, designing a line which was tailored to the customers’ requirements and could be perfectly integrated into the factory, allowing for the automation of the entire production process. The line consists of the Winline ONE multicentre with double multilevel warehouse, connected to a moulding machine and a grader, two machines already present at the customer’s facility. The work table is specifically designed for
the production of windows and allows for pieces of up to 140mm thick, 260mm wide and 6 metres long to be machined. During the production phase to verify the full automation of the entire machining flow, the machinery was transported to Biesse directly from the customers’s premises, in order to integrate the line. Ensuring seamless integration with the two machines already owned by the customer was not straightforward by any means, but the flexibility that sets Biesse solutions apart allowed everything to work perfectly.
MACHINING AUTONOMY The double magazine allows the user to manage the flow of incoming materials and the output of the finished product, as well as
providing the scope to machine up to 162 pieces autonomously. The entire system, including the customer’s machinery, seamlessly integrated into the line, can be managed by a single operator: indeed, it is the machine that manages the complexity of the whole process.
HIGH LEVELS OF PRODUCTIVITY The line is equipped with a double beam which allows for 2 panels to be machined at the same time, or alternatively for two machining operations to be performed on a single piece. This feature permits a production output of up to 300 panels per shift.
PROCESS EFFICIENCY The production output can be changed at any time to achieve customised large-scale manufacturing results with no operator intervention. A printer installed on the line also allows for the immediate identification of the panel, so it can be quickly and correctly directed towards the next phase of assembly. Accordingly, the line thus allows for increased production flexibility, as well as optimising the work of the operator.
CLOSE UP: High-performance
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PROFILE
electrospindle A distinctive feature of the entire line is the presence of a 30kW electrospindle which provides double the power of standard devices on the market, for machining up to 16 metres per minute, with increases in work speed advancement of 30%. A greater amount of waste material is generated as a direct consequence of this increase in power. However, in this case too, Biesse’s expert technicians have been able to provide an immediate and effective response to this
potential issue. A new chip deflector has been mounted on the machinery that maximizes the suction of the chips even at the maximum machining speed.
The WINLINE range: all your WINDOW solutions Biesse has developed a range of machines dedicated to the production of windows and doors, all of which are integrated and easy to use, with automatic loading and unloading and modular buffers. These features reduce
the working time for the operator and make it possible for the machine to be managed even by non-specialised staff, thus allowing for significant reductions in production costs. These Biesse solutions now allow the implementation of integrated cells “without supervision” synchronized with the “upstream” and “downstream” processes, eliminating carriages and reducing the costs of intermediate magazines. Winline One, designed for the production of standard and special door and window frames, including arcs, is intended for medium and large companies manufacturing window and door frames that want to supplement and/or replace existing non-flexible lines and systems. Uniline is dedicated to craftsmen and small to mediumscale industry. It produces standard and special linear frames with the utmost simplicity, leaving the operator free to deal with other tasks. It takes up just a few square metres and autonomously loads/unloads and positions the pieces with great accuracy. Simplicity and precision at reduced costs.
For further information: Tel: 01327 300366 Email: info@biesse.co.uk www.biesse.co.uk
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PROFILE
The New HOMAG Ambition Range – The Gold Standard In Edgebanders The latest Ambition range of energy-saving and environmentally friendly edgebanders from HOMAG has set the bar at a new height with the comprehensive equipment that comes as standard on every Ambition model. The Ambition edgebanders feature a top pressure beam made of steel with double Vbelt which forms the basis for outstanding quality. This ensures that work pieces are always securely clamped for processing. The machines also come with all the trimming tools complete with the I-system for optimum chip disposal and processing quality. Customers can choose steplessly adjustable performance levels to meet their own production demands, 16-20 m/min, 16-25 m/min or 16-30 m/min for high productivity. Simon Brooks, sales and marketing director of HOMAG UK comments, “The latest Ambition models offer a high level of equipment as standard, however, to cover all eventualities HOMAG has also included a free space. This enables customers to extend the machines with additional processing units such as grooving or belt sanding.
“We are finding the new Ambition edgebanders are particularly attractive to quality furniture manufacturers who have high volumes of bespoke work to process. The Ambition models provide enormous flexibility through their capacity to process all types of materials whilst the reliability and robust nature of the design provide real peace of mind.”
together the exact specification for our needs. “It became apparent that this new Ambition 2474 would not only replace the old HOMAG edgebander but also make redundant the BRANDT machine we had. This was a real plus because it meant we could free up much needed space in our mill facility and reduce the labour required for this work cell.”
Improving productivity at Stoneham Kitchens with the Ambition 2474
High quality increased productivity with no hand finishing required
“We have a long history of dealing with HOMAG,” explains Mike Stoneham, a director at Stoneham plc. He continues, “So when it came to replacing our aging edgebander, HOMAG UK was our first port of call. To ensure we got the exact specification we wanted for the new machine, Charles Smith, HOMAG UK’s area manager, invited my brother and I out to the HOMAG Treff show in Germany. “It was really useful to be able to go from machine to machine picking the units we required on our edgebander. By walking around and seeing all the different machines in action we were able to piece
“The Ambition comes with a lot of units as standard, but it has been designed in such a way that you can extend the capabilities of the machine to match your specific production requirements. “Our machine has a host of features including a pre-milling unit, two quick-melt glue pots so we can glue in different colours and cleaning units front and rear with an anti-static unit half way down the machine to make sure debris doesn’t stick to the panels. “Because we use an amount of solid timber lipping as well as PVC, it also features an up-graded heavy-duty snipping unit. It then has rough and profile
The HOMAG Ambition 2474 – high quality and flexible capacity edgebanding for all materials
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PROFILE
HOMAG’s new edgebander range boasts simple and reliable operation with powerTouch control screens
trimming units with different radii and bevels, followed by scraper units and various cleaning buffers and a cleaning unit at the end as well. “We have also added a Boomerang ZHR 05 return system to the machine. This enables the edgebander to be easily operated by one person, freeing-up a junior team member who has now become a trainee cabinet maker. The return system has significantly increased the throughput of the machine as one person now controls everything. He is able to start set-up for different edging, profiling or thicknesses as soon as he has fed the last part into the edgebander. “The finishing of the Ambition is first class and when work comes off the
machine we never have to do any hand finishing. We have paired it with a WEEKE BHX 055 CNC drilling machine and they work perfectly together as a work cell for the high volume bespoke work we do.”
Easy to use, robust and reliable “The operators love the Ambition 2474; it’s very stress-free to use with the powerTouch control screen. They find it so much easier than navigating with a keyboard and mouse. Also, the cleaning units not only keep the work pieces clean, but they also prevent the machine itself from getting too dirty. In turn, that helps minimise any downtime required for maintenance. “Overall, because of its speed of set up
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and ease of use, we have been able to reduce our machine inventory by one, giving us more space to work with whilst at the same time processing more individual parts,” concludes Mike Stoneham. If you’d like to arrange a demonstration of any of the new HOMAG Ambition edgebanders call Karen Payen at HOMAG UK on 01332 856500.
For further information: Tel: 01332 856500 Email: info@homag-uk.co.uk www.homag-uk.co.uk
MAY/JUNE 2016 Panel & Joinery Production
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INSTALLATION
Constant Growth with Machines from The Felder Range Edward Williams Furniture, owned and founded by Adam Howe, are specialists in manufacturing bespoke furniture from boardroom furniture to reception desks. Able to plan space for a variety of needs and cater for all furniture requirements, they offer a complete service to suit any environment. Regardless of what stage a client is at, be it with complete designs and only manufacturing required; or an idea that is still being formed, Edward Williams can cater to all needs and bring visions to life. Every step of the way is a well thought out process and their aftercare service compliments the bespoke and unique nature of the company. Equipped with numerous Felder machines, Edward Williams Furniture upgraded their workshop, significantly increasing their productivity and diversity of their services. Adam explained how they no longer need another company to manufacture certain components, as they are now able to offer the complete service from start to finish. He went on to say that “the machines from Felder make all the difference and I cannot fault Felder or ask for any more”. The Format 4 Profit H08, the K940S Panel Saw, G330 Edgebander are to name some of the machines that have enabled their vast business growth. Edward Williams Furniture has gone from strength to strength and their continued success is a result of their high-
The Format 4 Profit H08 in action at Edward Williams Furniture
spec range of Felder machines that tick all the boxes. Adam can’t speak more highly of Felder, saying that he is “absolutely pleased with everything- anytime you need them, they are always there and the service is brilliant - all you have to do is ask for help”. Having just ordered a tempora 60.12 emotion Edgebander and Interested in more machinery Adam says “it’s all about taking that next step and the reward is always worth it, as we are now able to offer exceptional accuracy and perfection in all services we offer”. They are able to meet any design brief due to the diversity of their
Through their numerous Felder range, Edward Williams Furniture are able to offer a complete service from start to finish
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Adam Howe, founder of Edward Williams Furniture
workshop, as a result of their H08. “Jason works with our designers and he comes up with ideas, so we are able to find a solution to any brief and execute the job to the highest possible standard with our H08. We can do a number of things, the possibilities are endless” says Adam. Not to mention that “we have cut down on labour time and the H08 helps us to achieve a very sophisticated look in everything that we produce”.
For further information: Tel: 01908 635 000 www.felder-group.co.uk
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PROFILE
Starbank Celebrates 40 Years by Investing for the Future Forty years after it was founded by Gordon & Kathleen Darbyshire in a small village in Lancashire, Starbank Panel Products is celebrating much more than a big anniversary in 2016. With a new manufacturing facility and substantial investment in new technology completed this year, Starbank Panel Products, now 2nd generation familyowned and run by Philip Darbyshire and Wendy Elsworthy remains focused on the future as one of the UK’s leading fabricators of decorative panels for interior fit out. Located on Sankey Valley Industrial Estate, Newton-le-Willows since 1991, Starbank’s new factory of 116,000 sq ft sits comfortably within the 16.5 acre site. This has effectively doubled manufacturing space with substantial expansion potential for the foreseeable future. Philip Darbyshire Managing Director: “We have spent the best part of 18 months completely refurbishing the existing building and in doing so have created a highly flexible and efficient facility. We have fitted out the factory using top-of-the-range equipment to ensure the sustainability of the business for many years to come. With roof mounted Solar PV panels and intelligent LED lighting installed by Solarking, a Biomass heating system provided by Mawera UK and the new Ecogate extraction system installed by DCS our systems are designed for a sustainable future. Further investments are planned for the summer with a second Schelling FH6 saw, which will be fed from the impressive storage and retrieval system, amongst others. All in all we’ve been quite busy!” Paul Atkinson Production Director: “An example of the level of investment can be seen in Starbank’s second BAZ 723 processing centre. With the Powertouch interface and automated feeding and stacking this remains the highest output machine for shaped components that
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The new DCS extraction filter plant, Becker vacuum system, and concrete storage silo for the Biomass system.
Homag offer. With a fixed gantry, twin routers, twin tables and a separate third head for contour edgebanding this highly
specified machine can route, drill and apply ABS or veneer edging, with an accurate butt joint if required. Our customers are
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PROFILE demanding ever increasing levels of quality and efficiency, and rightly so. By focusing on the best machinery the industry has to offer and with the support of a highly engaged and dedicated workforce we are in a prime position to offer our services to a variety of industries across the country and beyond.” An addition feature on the new BAZ 723 is the ability to process3D Acrylic edgebanding, which has been notoriously difficult to apply on shaped panels. For office, contract, healthcare &educational shaped furniture components this is without doubt the best machine on the market.
First of its kind Another key investment for Starbank at the new facility has been in throughfeed postforming. The new state of the art VFL610 postforming line is the first of its kind and specification in the UK, and Starbank’s first Powerline model. Designed for heating, folding and gluing a variety of decorative materials onto pre-profiled workpiece edges it has been specifically configured to also wrap postformed fire doors and complex frame components, an area of rapid growth for the company. Philip explains further: Starbank offers a one-stop shop for outsourced panel processing with an amazing array of skills and machinery. Amongst others the highly specified facility includes matrix bed machining with 5 Axis technology on an
Kathleen Darbyshire (Co Founder), Philip Darbyshire (Managing Director), Gordon Darbyshire (Chairman), Wendy Elsworthy (Financial Director) in front of the Schelling VS16 Storage and Retrieval system
enormous 7.4m x 2.2m BMG 512, 4 head routing on a twin table BOF 714, throughfeed drilling from Weeke and edgebanding from Homag’s KAL 310 and 526 double –sided edge banding lines. We have very efficient, batch or volume PUR edging of ABS and Veneer coil, for example, on workpiece thicknesses from 10mm to 60mm. With the ability to also process strip material we can edge in laminate or solid hardwood up to 60mm x 20mm, essential for Fire Door and highend furniture component manufacture. Wendy Elsworthy – Financial Director,
was also keen to point out the energy efficiency and green manufacturing elements of the project. Solarking has fitted a 250 kWp solar PV array, comprising around 1,000 solar panels which generate up to 70 percent of the site’s energy requirements. The solar PV array is linked to a new high efficiency HV transformer incorporating voltage loss optimisation features. Solarking also supplied energyefficient LED lighting system inside and out with full control including presence detection and daylight harvesting, which regulates the amount of electric light according to the natural light available. Whilst they represent long-term investments they are ultimately the right thing to do for the sustainability of the company, and the environment. Mike Durham Commercial Director: Another significant contributor to the sustainability of Starbank’s new factory is the Viessmann biomass system for heat generation supplied by Mawera UK. The system includes an automatically fed silo with the capacity to store 900 cubic metres of wood dust and chips, equating to six months’ worth of heat for the site. It builds up chips and dust over the summer months so in winter, when the Viessmann Vitoflex biomass boiler typically gets through 35 tonnes of biomass per week, there is plenty of fuel to keep it running. Back up is
Compact Laminate machining on the technical BOF 714
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PROFILE
Throughfeed drilling and routing on the Weeke BHT500
provided by a Viessmann Vitomax gas boiler. The biomass boiler plant is automatically controlled with a flat moving grate with water cooling, designed to handle dry materials such as MDF, chipboard and melamine-faced boards. Oxygen control and flue gas handling are designed to minimise nitrous oxide emissions, while larger and smaller particles are also removed effectively. A large proportion of the biomass fuel comes from the Dust Control Systems (DCS) extraction installation. Starbank’s brief was for a single, externally-sited, high–efficiency filter which would serve the whole factory, as well as feeding woodwaste to the biomass heating system whilst minimising noise levels. The Validus 2330 filter extracts from 16 machines across the factory. Waste collected by the filter is discharged, pressure-free, into a screw conveyor, which feeds a bucket
20 Panel & Joinery Production May/June 2016
elevator. The waste material is then discharged to the silo via a second screw. Fans are brought on and off line according to extraction demand. Extraction ductwork throughout the factory is designed to optimise extraction velocities and pneumatic dampers located in the ducting enable plastic and wood waste to be extracted separately. The ductwork between the fan outlet and filter inlet incorporates ATEX-approved CARZ back-pressure flap valves which prevent the effects of a dust explosion from travelling from the filter, back along the ductwork and into the factory. All the production machines are fitted with Ecogate automatic dampers, which open and close as machines come on-line or are shut down. The end result is a highefficiency, optimised system that only uses energy when required. Starbank has ensured its new factory is sustainable both environmentally and
commercially, although the green aspects of the project provide production efficiencies in their own right. Sales Director John Roper: “This essential move provides us with a platform to further grow the company and just as importantly, ensures that the services we provide will not only meet but exceed our customers’ changing demands in the future.”
For further information: Tel: 01925 223965 www.starbank-uk.com
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PROFILE IDS Showcases Products and Provides Unmissable Offers at a Series of Open Days for Customers IDS, the UK’s largest distributor of surface materials, is holding a series of open days running between May and September at its showrooms across the UK. In addition to raising awareness of their product portfolio in flooring, worktops, sinks, taps, wall paneling, laminates, panel products and solid surfacing, each of the open days will also include exclusive offers and discounts. Visitors can drop in anytime throughout the Friday and Saturday morning to enjoy hospitality from a free burger van, product giveaways and will have the chance to meet
with IDS product experts. IDS has also teamed up with Bushboard to deliver mini demonstrations on professional worktop installation. There will also be a raffle at each event to raise money for a nominated local charity. The open days are being held on the following dates: Leeds – 20th May/21st May Southampton – 3rd June/4th June Nuneaton – 17th June/18th June Stoke – 1st July/2nd July Exeter – 8th July /9th July
Cardiff – 15th July/16th July Norwich – 9th September/10th September Rosyth – 16th September/17th September Gateshead – 23rd September/24th September
For further information: Tel: 08457 298 298 Email: info@idsurfaces.co.uk www.idsurfaces.co.uk
The IDS showroom at Parkhouse Interchange, Parkhouse Industrial Estate, Newcastle-underLyme, one of the IDS open day venues.
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DECORATIVE SURFACES Kronospan Introduces 27 Exciting New Decorative Surfaces for 2016 with its Latest Collection - Trend 16/17 At the forefront of innovation and building on the success of Trend 14/15, Kronospan is leading the way with its new range of exclusive designs. From Scandinavian influenced Beeches to sophisticated Elms, the new designs are expertly characterised into three colour palettes - Nordic, Metropolitan & Luxury – sharing the story behind the indepth selection process. The collection is a result of Kronospan’s ongoing design journey, travelling the world to discover matchless materials and researching the latest trends. Whether drawing from the cool functionality of a Nordic palette to the sophisticated urbanity of Metropolitan and the unapologetic indulgence of Luxury, Trend 16/17 consists of 11 contemporary wood designs, 6 real metal designs and 10 elegant worktops. Craig Holt, Kronospan’s marketing manager, says: “The Kronodesign team work tirelessly, picking up on the shifts in style and taste that feed the next trend.” “The challenge is not only to discover new designs, but provide inspiration and possibilities which we hope can be used to create some of the world’s most stylish interiors. Mix and contrast with our Color range to take inspiration to a whole new level”. The Nordic palette combines light woods with natural tones and concrete – think all things minimal, functional and beautiful. Today’s world is more urban than rural – following this Metropolitan blends grey tones with Metalics, black and graphite woods. Luxury is a story of comfort, extravagance and high living – gold,
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copper and bronze complimented by rich tones, exotic woods and marbles. Trend 16/17 is available in Melamine Faced Particleboard 2620 x 2070 x 18mm (wood designs), laminated MDF 2800 x 1300 x 18.7mm (metal designs) and laminate worktops 3050 x 600 x 38mm – all with colour matching HPL and edging.
To find out more or request samples of Kronospan’s new Kronodesign Trend 16/17 collection: Tel: 01691 773 361 Email: sales@kronospan.co.uk www.kronospan-express.com
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DECORATIVE SURFACES
New B9 & Gloss Colours Added to Stock Range from David Clouting New B9 Emboss colour added to range – Fjord - match to Egger U636 Fjord. New texture with the most effective emulation of a painted wood panel. • Oak wood effect. • Achieved in combination of print and texture. • Also a new Gloss added to our very successful Premium Gloss range – Denim – match to Egger U540 Denim. Hard Coat PET • For lamination only. • Will be available in gloss and super matt in each shade. • Comes with protective film. • Hard Coat technology provides a significant improvement in scratch and marr of regular lacquers. • Significant improvement on the handling of the super matt finish. • Similar / equivalent quality of look to the acrylic panel in gloss and super matt. • Cost effective alternative to other gloss and matt flat panels. • Hard Coat PET lamination colour range matched into existing press grade foils to enable complete product portfolio, such as
curved doors and glass doors. Stock colour range: White Pale Cream Alabaster Oyster Cashmere Mussel Light Grey Graphite Grey Available in one roll quantities. Roll length 400 lm. Roll width 1250mm Make to Order availability from 3,000 lm, which can be taken as a mixture in both super matt and gloss. E.g. 1,500 lm gloss, 1,500 lm super matt. Passed FIRA tests and has certification. Edging matches available.
BET 09
For further information: Tel: 01376 518037 www.davidclouting.co.uk
Fjord GAQ36-B9
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DECORATIVE SURFACES
Ocean Drive – Ideal For Surface-Coating Decorative Panels Lamination recently introduced the heavilystructured finish, Ocean Drive, as a stock design. It is a Wood Plastic Composite (WPC) substrate, coated with a polyolefin-based (PO) film. Ocean Drive is ideal for the surface-coating of various wood-based materials and is used in the production of high-quality furniture components, wall and ceiling panels. A key feature of this surface material is its unique, heavily-textured surface, which boasts a threedimensional quality. At first glance this material may appear tricky to edge – however, it is actually straightforward and can give an impressive result, as Julian Tatham, Decorative Panels’ design director, explains: “Any edging material from 0.8 to 3mm can be used,” he says. “Our view is that the best visual results are obtained with 0.8mm edging, although thicker edging will allow a larger tolerance when setting the chamfer, as detailed below. “First, measure the thickness of the finished board – Ocean Drive material is up to 2mm thick, so the width of edging used and the height setting on your edgebander needs to account for this extra thickness. “Next, select the chamfer cutting section of your trimming blocks, set the trimming block so they trim back the edging and also cut back into the surface material, but go no lower than the lowest valley in the surface material. “The trimmer can be set lower than the lowest valley but only to trim into the edging – so the thicker the edging, the lower the chamfer can go. A little trial and error may need to be used to refine the setting and get the look that you are happy with.”
For more information, interested parties can request a copy of Decorative Panels’ new corporate brochure, or explore it online via the group’s newly-updated website, the primary point of reference for design selection from the group’s extensive collection of dp-décor and dp-specialist finishes. The site features every design on screen, and offers the ability to filter through species, collections and shades. Design assistance is provided, through swatches featuring complementary and alternative colourways. All company literature and design swatches are available to view on screen and download.
Ford further information: Tel: 01484 658341 www.decorativepanels.co.uk
Photos courtesy of Renolit
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DECORATIVE SURFACES
Lathams Latest Surface Makes a Big Impression James Latham is seeing the popularity of Xylocleaf - the innovative and highly textured range of premium Thermo Structured Surface (TSS) decors which offers a variety of wood grains, linens and other unique materials – soar within the A&D sector. Unlike anything else on the UK market, XyloCleaf is a highly original and exclusive range of decors which are created using a unique process of thermal fusing in which decorative papers are treated with melamine resins, that under heat and pressure become part of the panel itself, hence the term Thermo Structured Surface. This process provides not only a stunning end result, but also a product that is strong, durable and highly scratch and chemical resistant, meaning that as well as looking great, it will stand up to the toughest of challenges when used in high traffic areas. The sensational and inspiring XyloCleaf collection is perfectly suited to premium design schemes within the retail sector and is perfect for furniture, fixtures and wall panelling. In addition, it is also popular for high-end commercial, leisure and hotel specifications. The deep textures and intricate detail of XyloCleaf makes it
XyloCleaf shelving unit
difficult to distinguish from the real material it is designed to mimic and the portfolio includes 50 different colours and patterns, all of which come with ABS edging as standard. Plus, it is also available as HPL in 16 decors. Paul Morson, James Latham’s Group Product Champion for Melamine said, ”XyloCleaf represents a new generation of panel product and one which offers extraordinary potential, delivering a complete solution of innovative products to suit all retail decorative tastes, trends and applications and it has quickly become a real success story for Lathams.” XyloCleaf is available nationwide and directly from stock through James Latham and is supplied in panel sizes of 2800 x 2070 x 18mm.
XyloCleaf offers a variety of wood grain, linens and other unique materials
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For further information: Tel: 0116 257 3415 Email: marketing@lathams.co.uk www.lathamtimber.co.uk
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Kronodesign®
Design flexibility Kronodesign® Express Melamine Faced Boards Open up a world of design inspiration with Kronodesign® Express, mixing cutting edge, on-trend decors with everyday classics. From vibrant Colors to sophisticated Mirror Gloss, from 17 new Trends including fabulous Metal effects to the latest Color Woodgrains that mimic the look of painted timber, principally with matching Laminates. Mix, match, contrast, complement; subtle or shocking, surprise yourself with the palette of endless possibilities. To order your free samples, email: samplerequests@kronospan.co.uk or visit: www.kronospan-express.com
Kronodesign® Express consists of: 59 Colors, 10 Color Woodgrains, 65 Woods & Materials ,17 new Trends (including 6 Metals), 20 Mirror Gloss, 9 Acrylic Gloss, 9 Synchronised and 154 matching laminates
EDGINGS Ostermann has the Matching Edgings The Swiss Krono Group introduced the new "One World Swiss Collection" at the Swissbau in Basel. Therefore the edgings specialist Ostermann added new edgings especially for this collection to its range. Customers can look forward to 28 plain colours with the new surface velvet structure as well as 40 new decor edgings with different surfaces. By enhancing the edgings with matt lacquer they get a discreet filigree, fine pearled feel and an eye-catching look. This allows the new Ostermann edgings with velvet structure not only to match perfectly in colour but also with a particular feel to the corresponding surface of the Krono Swiss board with velvet structure.
28 new plain colours The new velvet structure is already the seventeenth surface variant at Ostermann. Currently, you can find Uni edgings with this structure in 28 different colours. The palette includes white, grey and beige as well as black. However, the eye-catching plain colours
such as pacific blue, pink, orange, saffron yellow or raspberry are also particularly striking.
40 new decors In addition to the 28 plain colours, Ostermann added 40 new decors with different surfaces matching to the One World Swiss Collection to its range. They include numerous wood and fantasy decors. Here we would in particular highlight 4 edgings with the latest metallic decors.
Fast delivery of edgings from 1 meter All above mentioned edgings are available in every length from 1 meter, in 1 mm thickness and standard dimensions 23, 33, 43 and 100 mm. However, on request Ostermann slits the 100 mm edging into every width needed and supplies them as Laser, Airtec or Infratec edging for processing with Laser, hot air technology or the new NIR technology within 4 working days. Ostermann Services at one glance • Edgings from 1 metre
• Edgings in every width up to 100 mm • Edgings in various thicknesses • Edgings in ABS, Melamine, 3D-acrylic, Aluminium, Real wood veneer • Airtec edgings despatched after 4 working days • Laser edgings despatched after 4 working days • Infratec edgings despatched after 4 working days • Edgings pre-glued with hotmelt adhesive upon request • The largest Cross-Reference-List in Europe with over 120,000 matches • Europe‘s largest edging range • All orders placed before 4.00pm are delivered within 24 hours • 2 % discount on every online order (Shop and App)
For further information: Tel: 01905 793550 www.ostermann.eu
Ostermann now provides the matching edgings to the new One World Swiss Collection from Swiss Krono
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PROFILE The BRANDT Ambition 1100 And 1200 Series – Affordable Entry Level Edgebanding HOMAG understands the challenges that smaller sized businesses face whilst trying to survive in a fiercely competitive market. Companies are expected to be fast and flexible with an efficient production process, yet still be able to produce premium quality products with costeffective pricing. To provide an effective solution, BRANDT has developed the powerful, but compact BRANDT Ambition 1100 and 1200 edgebander series. These models ensure that even the smallest of workshops are able to invest in the latest technology. The entry level range provides flexible production whether it is for batch size 1, bespoke products or mass panel production.
Entry level edgebanding with the powerful BRANDT Ambition 1100 series The highly flexible and intuitive 11101120 FC series can be configured with EVA or PUR precision gluing units for perfect edgebanding on a variety of materials. The automatic fixed length magazine can be used for coiled and strip material at fixed lengths of up to 3mm thick for flexible
edgebanding. The easy to use trimming unit allows a quick changeover between chamfer, straight and radius units for optimum edge joint quality. Users can choose from a number of configurations to give them additional facilities including pre-milling and even corner rounding. Additionally, the 1100 series is available with two free tool spaces to offer a bespoke solution for every company. Three different unit tools are available to be mounted in the spaces, including profile scraping, glue joint scraping and buffing, in a variety of combinations. These unit options reduce the need for hand finishing and increase the production capabilities of the machine. The beauty of the 1100 series is that it can be configured to suit most requirements, despite its compact footprint, making it ideal for the smaller business.
An upgraded edge for Colemans Kitchens and Bedrooms Colin Coleman, managing director of Colemans Kitchens and Bedrooms explains, “We purchased the BRANDT Ambition 1110 F when we needed to replace
our existing edgebander. After installing the BRANDT Ambition 1110 F, we looked to add an additional pre-milling tool. HOMAG UK made it affordable for us to invest in such machinery when we thought it wouldn’t be possible for a smaller-sized company. “Overall we are able to achieve a far better finish and handle thicker edging on products than before with less time in production. On top of this it has expanded our production capabilities allowing us to produce new products and finishes. The operating software is easy to use and I can’t praise the machine enough for what it’s done for a company the size of mine.”
Extended production capabilities for Philip Dowse Interiors Philip Dowse Interiors invested in a BRANDT Ambition 1110 F edgebander when its work load changed. Chris Needham, workshop manager at Philip Dowse Interiors explains, “As a bespoke cabinet maker, our cabinets were always faced with a hardwood frame so we rarely had to carry out any tape edging work. However due to trends changing within the
The BRANDT Ambition 1110 – powerful yet compact entry level edgebanding
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PROFILE
Joint trimming unit for optimum edge joint quality for the BRANDT Ambition edgebander range
marketplace, we needed to be able to achieve a high quality finish carcass with a durable edge. “To achieve this, we chose to install the additional pre-milling tool, profile scraper and glue scraper units to our BRANDT Ambition 1110 F. The edgebander has given us the ability to add solid lippings, which makes the whole solid lipping experience more user-friendly and efficient. The added pre-milling tool was an invaluable extra as it ensures we receive a clean finish every time for perfect results. The machine has not stopped working since installation and it has transformed the way we do things. It’s more efficient and produces a much better product.”
Perfect edge finishing with the BRANDT Ambition 1210-1230 FC range Within the entry level BRANDT Ambition series, the 1210-1230 FC models offer a complete processing solution, previously only available on larger machine. Equipped with all the impressive standard specification of the BRANDT 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. For optional finishing extras, the 1200 series can also be configured with a joint trimming unit, contour trimming unit, radius scraper, glue joint scraper or a buffing unit to eliminate the need for hand
finishing. As standard, the 1200 series is fitted with a contact heating shoe that, when optionally activated, directly transfers contact heat into the board edge prior to the glue application to the workpiece edge. This notably optimises the edgebanding quality, especially with difficult edging materials or when used in very low ambient temperatures. With fast feed speed of 11 m/min, the BRANDT Ambition 1200 series offers an affordable solution for entry level sized companies. In a recent development, BRANDT’s 1200 series is now available with airTec technology. This addition to its armoury means that invisible joint technology is now available for the entry level user.
Extended benefits for Made 2 Measure with the BRANDT 1230 FC edgebander HOMAG installed a BRANDT Ambition 1230 FC edgebander for bedroom, fitted kitchens and home office furniture manufacturer, Made 2 Measure Fitted Furniture. Matthew Bates, managing director at Made 2 Measure Fitted Furniture comments, “Our main reason for purchasing the new edgebander was to guarantee the consistency of the finish quality of our products. “After six months, we are already seeing the consistent high quality we needed, as well as achieving significantly faster
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production speeds. We have never had an edgebander with a corner rounding unit before and it’s opened up door production capabilities for us, in addition to reducing edge thickness changeover times.
Simple, fast and intuitive edgebander operating software Another key feature across BRANDT’s entry level ambition edgebander series is that it is fitted with HOMAG’s easyControl EC 10+ software as standard, offering both quality and precision with the touch of a button. Utilising a clear, 7” graphic display users are able to use the simple and fast touch operation to check machine production status. With a simple menu format, the operating system offers fast access to the machine’s unit functions through dedicated control buttons. The easyControl EC 10+ software also enables users to quickly change edge banding material through user-defined programs and access error diagnostics for efficient operating. If you would like more information or a demonstration of any of the BRANDT Ambition 1100-1200 edgebander range models, please contact Adele Hunt at HOMAG UK on 01332 856424. For further information: Tel: 01332 856500 Email: info@homag-uk.co.uk www.homag-uk.co.uk
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SOFTWARE
Alphacam Is Music To Guitar Maker’s Ears Alphacam software was instrumental in helping a cabinetmaker turn his passion into his living. Neil Haynes has been making guitars as a hobby, entirely by hand, for 25 years; and established Haynes Guitars around two years ago to combine his love for music with woodworking. There are two strings to the company’s bow: firstly, making complete custom-built guitars for individual customers, and secondly, producing necks and bodies for other luthiers. “It’s great making things by hand, but there’s not a lot of money in it. Everything I’ve ever made is a good instrument, but using Alphacam to drive my CNC router means I can produce a lot
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more guitars, and every one will be to the highest standard. “When I’m making repeat guitar bodies I need to be able to walk away from the machine knowing each one will be perfect when the cycle finishes. I invested in a Felder Format Profit HO8 router, and have been using it with Alphacam for the last 12 months. It’s the only way I can show a profit.” He says it has revolutionised the way he works, and given him a business with a future; already exporting to many countries, including New Zealand, USA, Norway, Germany, Italy and Northern Ireland. Currently selling around 40 bodies and
necks a month – which he says makes up around two-thirds of his total output, with the remaining third being complete custommade guitars – he says each body used to take around two days to produce by hand. Now, the back and front of a guitar body with 2D geometry is done in about 30 minutes using Alphacam, while a 3D carved top takes around 45 minutes. He says this will lead to him doubling that output in the coming months. “And I can create a neck with fingerboard and inlay in about an hour and a quarter. Previously I’d spend well over a day just on the woodwork side of it.” As a complete novice for both CAD and CAM, the quick learning curve was music to
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SOFTWARE his ears. “I now enjoy programming with Alphacam just as much as I did doing everything by hand. There’s still some hand finishing, but Alphacam does all the actual woodworking and carving, and gives me full confidence that each guitar will come out exactly as I want it to.” The components making up the guitar have to be 100 per cent accurate, he says, especially the pockets for attaching the neck to the body. “If it’s not a good joint, the instrument’s tone won’t be right.” A luthier’s skills also include knowing which timbers work well together, and the finish required. Bodies are made from various woods, including Alder for its strong, clear, full-bodied beefy mids and excellent lows; Swamp Ash, with its twangy, airy sound; and the warm, resonant Korina. Maple and Walnut are also popular for veneered tops. The fingerboards are mainly Padauk, Rosewood, or Maple. The biggest challenge to his manufacturing process is continuity of quality – which Alphacam overcomes with ease. “For instance, the fretwork has to be
Neil Haynes turned his passion into a living
perfect. If a slot for the wire should be 0.6mm wide, that’s what it has to be. And using Alphacam to program the router, that’s never going to waiver...it’ll be the
same on every guitar. If the fingerboard needs a 7.5-inch radius, that’s exactly what it’ll be.” He says Alphacam’s ability to easily manipulate toolpaths is one of its best features. “If someone requires a neck which is a little deeper in some parts, and thinner in others, it’s so easy to alter it. Or if a customer wants dot inlays to be 4mm instead of the traditional 6mm I simply change the diameter of the circle with a tick of the box, and that updates the toolpath. It takes seconds, but doing it by hand would take hours.” Being a one-man band, Alphacam has given him a business that turns a profit, and worth investing his time in. “At first I was nervous about learning and using CAD and CNC machinery, never having done it before. But I needn’t have been. Alphacam means I can draw a product that is easily machineable, maintains consistent quality through perfect toolpaths, and sells.” All in all, Alphacam struck just the right note in ensuring Neil Haynes’ dream of turning his passion into his living was not only possible, but enjoyable, too.
For further information: Alphacam: www.alphcam.com Haynes Guitars: www.haynesguitars.co.uk
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SOFTWARE
Call Of Duty? – Cabinet Vision Makes it a Pleasure When duty calls for John Dunne, owner of Mother Hubbards Cupboards, to design a new kitchen, he says it’s a pleasure and not a chore, thanks to Cabinet Vision. “Some people play computer games such as Call Of Duty for leisure, as a past-time. I have Cabinet Vision – that’s gaming for me.” Designing bespoke kitchens for individual customers in and around Leeds, John Dunne finds it ideal for his popular lay-on, modular system. And he says it is the only CAD software he has come across that can handle his speciality – a traditional frame system. Cabinet Vision is able to create the frames as one continuous run of bespoke units, as opposed to the modular system where all the separate units butt together. “Before installing Cabinet Vision I had to physically draw my frame system designs using pencil and paper on an old-fashioned drawing board. No other software could do it.” Even curved frames incorporating the front and side of the cabinet can be handled with ease by Cabinet Vision. “I call it a traditional frame because this is how cabinets used to look in the old days, before the advent of modular systems. I first saw a skilled joiner in Ireland use this traditional structure, creating cabinets by hand, and I thought they looked so much better than the lay-on modular cabinets.” He says another of Cabinet Vision’s great strengths is not only its perfect 3D rendered
image of the design, but its ability to show the engineering behind the kitchen, with the wire frame view detailing exactly how everything is put together. “Many kitchen design systems seem more geared towards presentation than technical substance, but I find this software’s constructional detail to be particularly valuable. “It will also give me the sizes of housings for the standard drawers, tool and pan containers and storage boxes, along with housings for ovens and microwaves.” As he became more confident with using Cabinet Vision he found he was re-honing his drawing skills and becoming a better designer. “And that’s after 14 years experience on a traditional drawing board. It allows me to ‘go into’ each cabinet and literally re-invent its properties. I can customise its dimensions, composition and functionality. “As a design tool, I’ve found that Cabinet Vision has an almost molecular grasp of detail and an ability to re-jig and move that detail around as required.” Which is a vital aspect for every kitchen produced by Mother Hubbards Cupboards. “The bespoke element of my work means everything comes down to detail, and I frequently need a cabinet that’s 1mm or 2mm above or below a normal size.” Because the software allows him to readily design such bespoke cabinets, he is able to use standard timber doors. “With standard
doors I need greater flexibility in the cabinets to compensate. And, as a technophobe, even my limited knowledge of the software means I’ve been able to take my business to another level.” Regarding his own cabinetry, he says nothing is off the shelf, unless he puts it there. “I’ve built my own library, which helps to enhance the overall design process of each individual kitchen.” Whether customers choose the modular kitchen or the high end traditional frame system, they always experience what he calls an ‘eureka’ moment when he shows them the 3D image of how it will look in situ. Summing up, he says the software gives him a feeling of positivity and confidence, lightening the workload because he now regards designing as a pleasure, rather than work. “Cabinet Vision provides a win, win, situation – I love the designing side of the business, and it’s the closest customers will see what their kitchen’s going to be like without it actually being there.” For further information: Cabinet Vision: www.cabinetvision.com Mother Hubbards Cupboards: www.motherhubbards.co.uk
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PROFILE SCM Group at IDEA Innovation Design Expo Area with the World Premiere of its First Prototype for the “Close To Customer” Project, Based on the Idea of Furniture on Demand Fiera di Bergamo Exhibition Centre, 12-15 April. A “mini-factory on display”, in a shopping centre, where the customer can use a simple interface to “draw” the piece of furniture he or she would like to buy customizing its shape, size, colour, etc. which is then immediately produced, onthe-spot, and delivered. This cuts associated transport costs and pollution. It is the ultimate in “Mass customization”. Design, production and delivery, all in one step: fully automated production, but at the same time an expression of something unique and extreme customization, which puts the customer at the heart of the process, so he becomes his own furniture designer. The Furniture on Demand concept is the basis of the “Close to Customer" project that Scm Group, a leader in the production of high-tech solutions for the woodworking industry, unveiled to the world at the first IDEA Innovation Design Expo Area trade fair, which ran from 12 to 15 April, at the modern Fiera di Bergamo exhibition centre. On a huge screen set up in the Scm Group display area, a video presented the “mini-factory” installed in the Shopping Centre in Brianza, Paderno Dugnano (Milan province), the first prototype of the project dedicated to Furniture on Demand, opening a captivating window onto what could be the future of furniture production. It was an Scm machining centre that produced “live on demand”, in a fully automated way, the furniture that was configured – starting from a ready-made portfolio of products - directly by customers, who were able to immediately “take home” an object made with an industrial process but which is the only one of its kind in the world. The “Close to Customer” project, financed by the European Community, is the result of more than three years of research involving not just Scm, but another 10 European partners, including companies that are leaders in their sectors,
and universities (http://www.mckn.eu/projects/CTC/). It was conceived with the aim of supporting the furniture industry, providing real tools for responding to changes in the world market, by developing innovative methods and technologies for flexible and local production of sustainable and customised products, which are increasingly close to the customer in terms of the features offered, the production location, delivery times and price. On this subject, Scm Group also held a workshop at the Caravaggio Hall, on 13 April, with the participation of Federico Ratti, the group’s technical director, where visitors experienced a live demonstration of the project and all of its innovative features. Scm Group’s presence at the IDEA exhibition was also be an opportunity to display some of the company’s most innovative technologies, able to make important contributions to the future of the furniture sector. These include: • five new machining units for edgebanding by STEFANI, guaranteeing perfect finishing quality, together with the Scm Olimpic K800 industrial edge-
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banding machine; • System, the DMC sanding machine with flexible abrasive, a modular “technological triumph” that, with its innovative devices unique in the sector, allow prestigious effects achievable to date only by experienced craftsmen; • the Gabbiani blade carriage, a solution designed for single-blade panel sizing machines to provide top quality finishing and cutting combined with high productivity; • Hiteco electro-spindles and aggregate units, high-tech functional components for achieving top performances with machines for wood, light alloys, plastics and composite materials.
For further information: Tel: 0115 977 0044 Email: scmgroupuk@scmgroup.com www.scmgroup-uk.com
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CASE STUDY HOMAG Automation Delivers 60% Productivity Gains For Delta Laminates Established in 1995, Delta Laminates designs, manufactures and markets a wide range of bespoke laminated furniture and components. It supplies leading building trade customers with washrooms, special contract furniture, reception desks and other laminated products. End users include hospitals, dental surgeries, schools and universities. “Our business is quite niche,” explains Garry Rowland, Delta Laminates’ managing director. He continues, “We work closely with leading construction companies such as, Balfour Beatty, Carillion and the Kier Group, so it is vital for our business to maintain the highest quality and service standards. “This has been a major driver in our decision to invest in the best woodworking machinery available. We find that all the HOMAG Group equipment is outstanding. The innovative German engineering and attention to detail means you can rely 100 percent on the machinery to consistently produce the very best results, time after time.”
Need to increase capacity “We’ve relied on HOMAG equipment for many years and so when it came to looking for ways to increase the capacity of the business, my first port of call was HOMAG UK. “One of the bottlenecks in the business was our old saw, so naturally we began by looking for a replacement and possibly a new edgebander that would allow us to increase our capacity. We arranged to fly over to Germany to visit the HOMAG Treff to see the latest models and it was there that we saw the automated storage system in action. “I didn’t even know such a piece of kit existed, let alone seen it working. Robotics used to be the reserve of the big car manufacturing plants; a small laminate fabrication company near Wigan could never justify the costs of such a fully automated and computerised piece of kit. “I was stunned at what it could achieve and how it would transform our business. Furthermore, I was amazed to discover that a small company like ours could afford such a wonderful robotic system. It was like, why
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The affordable HOMAG Automation Storage System has delivered significant productivity gains to Delta Laminates
would you not have it? “I was so excited by the prospect of introducing this system to our business that I had done the number crunching before our return flight home left the tarmac in Germany. It was a no brainer; it was a case of how soon can I have one.”
HOMAG Automation Storage System “It’s a great piece of kit. It’s created output far beyond what I imagined. It drives the production, giving the operators the next job as soon as the previous job has been processed. “Prior to the new system, we had a traditional beam saw and a fork lift truck which used to pick the materials out of a rack, if we had them in stock that is, and if they weren’t scratched or bowed because they hadn’t been stored properly. “All those issues have been eliminated with the HOMAG Automation system; I know how many boards I’ve got, I know what job they’re allocated to; the system knows where they are, they don’t get scratched because nobody touches them and
they don’t bow because they are stacked neatly and flat. “I just send the next job to the system and tell it what tomorrow’s cutting is. It puts it on order and it keeps one operator busy instead of two as before. What’s more, the one operator is now producing twice as much.”
New HPP 300 HOLZMA Beam Saw “The replacement saw we bought is the new version of the HOLZMA we had previously, but it is much improved, with better software. The new HPP 300 saw fits inside the HOMAG Automation storage system; so where I once had storage area for materials I now have my saw that fits in the middle of that. This has saved me massive amounts of space and increased the efficiency. “We did evaluate other equipment before we committed to HOMAG, but we’ve always used HOMAG because I just think they are the best. They may not be the cheapest, but I consider their quality of machine, the German engineering, the backup and the service have always been the best.”
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CASE STUDY
The HOMAG Ambition 2264 with powerTouch – outstanding Speed and control.
Increase capacity led to a need for a new edgebander
A smooth installation with excellent training
“With the new storage system and saw we anticipated an increase in our capacity and felt that 12 months down the road we would need a bigger and better edgebander to cope with the output. “When we discussed this in more detail with HOMAG, however, it became clear that the volume of work the new system would create meant we would need the new edgebander from day one. “Our BRANDT edgebander had done us proud over the years, but there was no way it could keep up with the volumes the new saw would create, so we decided to invest in a HOMAG Ambition 2264. The new edgebander is twice the machine; the quality of finish, speed and robustness are outstanding. If we wanted to run it 24 hours, I’m sure it would cope.”
“As you can imagine, with so much new kit to install and old equipment to either move or remove, the installation had the potential to cause massive disruption. In reality, however, the whole process was managed superbly by HOMAG and, given the number of different engineers and installation people on site at the same time, it couldn’t have gone any better. “The installation was completed within three weeks and we were immediately up and running. Nobody left until the work was done, the German engineers made sure everything happened when it should, our guys worked tirelessly with them. Everyone pulled together to make it happen. “During the installation the engineers were training our operators on the new equipment. I must say, I thought we’d have serious teething troubles, but I have to hand it to our lads for how they’ve adapted to it. A couple of our operators went over to Germany for two days training on the storage system, but it speaks volumes for the simplicity of the system that the chap in our office who runs the system did not go on the training and has managed to learn on the job.
Reduced overtime working “The new equipment has enabled us to significantly reduce the amount of overtime we need to do to get the work completed. In fact, we’ve incentivised the team by saying that if they can get the week’s work completed by Thursday night, they can have the Friday off. The good news is that, with no impact on quality, they are having Fridays off on a regular basis.
HOMAG Finance “When it came to the finances, HOMAG couldn’t have been more helpful. Their specialist finance division, HOMAG Finance brokered an arrangement which was structured over five years to give us the best deal. The whole process was very straightforward and they even helped us with a European Growth Fund grant which reduced the cost further.”
The best investment “The new system has taken us to the point where we can concentrate on growing the business; we couldn’t have done this before, we’d have struggled to increase capacity. “We’re now planning the next three years of growth and considering which pieces of kit we’ll need to support that growth. The new equipment has given us the ability to produce 60% more with the same hours. The impact on the bottom line is even more impressive, it has given us a massive financial benefit and real flexibility in our production processes. “We’re planning an open day to bring customers down to see the system in operation because with everybody that has come to date, their jaws just drop and they say,
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“Wow!”. They just can’t believe what it can do; it is such an impressive piece of kit. They can’t quite get their heads around how such a relatively small business like ours can afford such advanced automation. “By the virtue of the efficiencies it creates, the system pays for itself straight away. We are now in the process of restructuring the rates we charge for various activities because we can now cut twice as fast. “The system has also enabled us to reduce labour by eliminating the need for a forklift truck driver. In addition, because nobody has to touch the full-size boards anymore, health and safety has been significantly improved.”
A happy workforce “It’s really rewarding to hear our workforce say, ‘How on earth did we manage before we had this system?’. That back-breaking two man operation of having to lift big, massive panels onto the saw is gone; the machine automatically loads the correct panels onto the back of the saw and the operator only has to lift off the cut-down-to-size panels from the front of the saw. Nobody has to lift a full sheet anymore. “Working with HOMAG is a pleasure. The machines are amongst the best in the world, but we tend to take that as read. It is the service that makes the difference to us. The machines rarely breakdown, but if they do, the service from HOMAG is fast and professional. “I can’t recommend this system too highly,” concludes Garry. If you would like more information or a demonstration of the HOMAG Automation storage system, HOLZMA saws or HOMAG edgebanders, please contact Adele Hunt at HOMAG UK on 01332 856424.
For further information: Tel: 01332 856500 Email: info@homag-uk.co.uk www.homag-uk.co.uk
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SAWS - INSTALLATION Salvador Automatic Crosscuts – A Technical View from Daltons Wadkin Daltons Wadkin has already seen record sales of Salvador automatic crosscut saws in 2016. Having just returned from a visit to the Salvador production facility Alex Dalton enthuses on all things Salvador. ‘As the long standing main distributors for Salvador in the UK and Ireland we have established ourselves as crosscutting experts with extensive experience with industries manufacturing a range of products including sofas and beds, garden buildings, pallets, packing cases, timber framed buildings, as well as high production saw mills.’ Founded 35 years ago by Giorgio Salvador in Northern Italy, the family run business now solely concentrates on the production and continual development of automatic crosscut saws. This dedicated focus has seen the name Salvador become synonymous with high quality, reliable crosscutting solutions. There are three models most suited to UK manufacturing from the Salvador range, all available for viewing and demonstration from specialist supplier Daltons Wadkin. SuperPush 200 For automatic optimising and defecting at 90° the SuperPush 200 has a 30° inclined working plane making loading simple and ensuring the workpiece is kept square. The heavy-duty pusher runs up to 120 m/min and will process pieces up to 110 kg with an accuracy of +/- 0.1 mm. The actual cutting time can be regulated between 0.1 to 2 seconds depending on the material with an automatic pressure beam adjusting to the
material height minimising processing time. Varying lengths of timber can be individually pre-loaded onto the infeed table and the machine will scan and measure each piece individually, looking for marked defects before optimising the lengths to be cut to ensure maximum yield. Alternatively multiple lengths can be stacked in packs and the cutting lists optimised further increasing processing efficiency. SuperPush 250 For maximum crosscutting speed and efficiency at 90° the SuperPush 250 features a chain infeed loading system allowing single or multiple stacked workpieces to be automatically and continuously fed into the machine. The range of out feed options available for the SuperPush range include waste trap door, tilt-and-return collection plane, automatic outfeed length selector and label or injet printing. SuperAngle 600 Increasingly popular in the UK market the SuperAngle will optimise and defect angled cutting lists up to +/- 70° with a precision of +/- 0.1° taking no more than 1 second to position from 0 to 70°. As with the SuperPush models the SuperAngle is available with chain infeed loading and automatic outfeed options depending on your requirements. As with all Salvador automatic crosscuts the SuperAngle is equipped as standard with a full PC control running powerful but simple to operate cutting software. The machine can run in standard automatic cut
to length mode, optimising mode, or defecting mode. Cutting lists can be programmed quickly at the machine using a standard keyboard and large 19” monitor, or remotely at an office based PC via a spreadsheet or from third party production software. ‘We have customers wanting to remove the skill level entirely from the machine operator, while other customers want the operator to double check cutting lists from the office to spot any human errors. The Salvador will work however you want’, says Alex. ‘Each Salvador installation is different. Even within the same industry each customer has a different working process. At Daltons Wadkin we involve our highly skilled technicians from the start to analyse cutting lists, existing production methods and provide a recommendation for a suitable specification and crucially a reliable time scale for return on investment. With everincreasing competition squeezing margins it is not enough to simply say “you need an automatic crosscut”. The correct specification with reliable back up is key. With almost limitless configurations within the Salvador range we take great care in our responsibility to suitably advise our customers’. ‘There are some exciting new developments in the Salvador range this year and we will be exhibiting with our largest ever Daltons Wadkin stand at W16 with Salvador taking centre stage’. For further information on the Salvador range of products from Daltons Wadkin telephone 0115 986 5201 or visit www.daltonswadkin.com
Salvador SuperPush 250 with automatic chain infeed from UK and Ireland distributors Daltons Wadkin
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SAWS - INSTALLATION
Welcome Furniture Invests in a Fourth Schelling fh6 The stage is set for future expansion at Welcome Furniture following their recent investment in a fourth Schelling fh6. North Wales based, bedroom and living room furniture specialist Welcome Furniture has recently invested in a Schelling fh6 cut-to-size saw to improve its capabilities and strengthen it’s offering to the market. “Delighted with this major new investment, John Peterson sees the investment opening the door to exciting new opportunities: As an innovative company, we have been instrumental in developing new markets and our latest investment will enable us to support our long-term growth ambitions”. At Welcome Furniture, our techniques unite the best of modern technology with time-hallowed craft skills. We operate a state-of-the-art facility almost entirely fitted out with Schelling technology, which ensures absolute precision time after time, yet every finished wardrobe or cupboard is also the result of hand craftsmanship. Many of our skilled craftsmen and women have been with us since joining the company as apprentices, and now in turn help to pass on their expertise and skills to the next generation. Now and for years to come. We feel that our customers want to make informed decisions about what they buy, and that they're interested in the provenance and sustainability of our products. All of our furniture is “Made in Britain” and we're proud to offer British design and quality and celebrate the nation's skills and craftsmanship, it’s also great for promoting the region as an area where manufacturing can thrive. As well as investing in a new Schelling saw we have also made a considerable investment in the development of our premises, including a new energy efficient Biomass boiler. John Peterson commented: “As a business we are continuing to grow year on year and are prepared to invest in our future. These most recent investments support our future growth and our plans to improve our efficiency.” At Welcome Furniture we knew that
material loading and handling were essential performance characteristics, which would increase the efficiency of our cutting operation. Often manual labour is used to convey large panels to a saw, which creates huge inefficiencies. But on our fh6 material loading was automated with a scissor lift, powered roller tracks and a
Welcome Furniture is made to order and dispatched to retailers already built up
come as standard, which automatically detect the panel size and book height, making life easier for the saw operator. Also the double strip aligners placed before and after the saw line, which remain on the material to provide precise angular The Schelling fh6 saw installed at Welcome Furniture alignment when cutting. With an alignment range of 40mm to separate push-off carriage all these resulted 2200mm this was ideal because Welcome in a far more reliable and predictable Furniture knew the fh6 could deliver high transfer of components, creating a more cutting accuracy even with the narrowest efficient production process. strips. Also thanks to a 21 kW motor and a This new machine is highly accurate and 460 mm diameter saw blade, the fh6 consistent, enabling more precision for delivers a maximum a saw blade projection improved quality and fit. It’s also very fast of 135 mm. “The ultimate test of a and efficient allowing us to be more Schelling fh6 for us is its repeatable responsive and offer shorter lead times to product performance, a company like our customers. And because all Welcome’s Welcome Furniture trades on the furniture is made to order and despatched reputation of its brand, so this makes to retailers already built up, via their own consistent accurate, repeatable cutting a fleet of vehicles, it is important to match critical component of manufacturing and it their customers expectations every time. delivered on all counts,” commented John. With over 30 door finishes to inspire its Welcome Furniture’s investment in customers, Welcome Furniture demanded Schelling is a resounding 'vote of a versatile machine with the ability to cut a confidence' - Back in 2009, Welcome variety of materials. The solution was the Furniture invested in their first Schelling, Schelling fh6 cut-to-size saw because it John Peterson commented “based on its delivered high quality cuts with the performance and reliability we didn’t flexibility, accuracy and capacity required hesitate to buy our fourth Schelling saw by their production process. It was because they have played such an important to have a sawing system which important part in delivering our success at was adaptable to changing customer needs, Welcome Furniture ”. particularly with regard to board For further information: dimension and board surface quality. Tel: 01937 586340 Another impressive aspect of the fh6 are www.schelling.co.uk the automated integrated sensors, which
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MAY/JUNE 2016 Panel & Joinery Production
39
SAWS Salvador Hat Trick for Daltons Wadkin Westbridge Furniture originally contacted Daltons Wadkin to assess the working process at one of their four UK production sites. Specialists in solid wood and panel processing technology, Daltons Wadkin soon identified solutions to bottlenecks within key areas including crosscutting and panel sizing. The first installation included a Salvador SuperPush S200 automatic optimising crosscut saw with tilt-return outfeed station, replacing 4 manually operated radial arm saws. Combined with an Altendorf F45 panel saw with CNC rip fence, what once were bottlenecks quickly become shining examples of efficiency with a reduction in labour, decreased waste, and an increase in productivity and improved accuracy. ‘Typically we find that a Salvador SuperPush S200 will replace up to 4 or 5 manual crosscutting operations, reducing labour from 5 skilled operators to 1 or 2 flexible operators. The savings in labour alone return the investment within 6
months,’ comments Andy Walsh, Sales Director at Daltons Wadkin. Westbridge Furniture operates principally out of the UK with sites occupying in excess of 400,000 square feet, employing just over 900 people who manufacture and service over 7,500 pieces of upholstery per week. In addition they employ over 100 people in their dedicated cut and sew factory in Romania. ‘Flexibility was a key point for Westbridge’, comments Andy. ‘Boasting made-to-order manufacturing capabilities for their full product range exceeding 109,000 different options the machinery needed to be quick to program and adaptable to ever changing production demands’. The success of the first Westbridge Salvador installation was quickly repeated across the other two manufacturing sites with a total of three SuperPush S200 saws installed and a number of Altendorf F45 panel saws.
The Westbridge story is testament to what a Salvador can do for customers using manual crosscutting methods, or older generations of automatic saws. Anyone who thinks they may be missing out should contact us for a working demonstration at our extensive show room facilities in Nottingham, or to arrange a visit to an existing Salvador customer in a relevant industry’, comments Alex Dalton. ‘As the long standing main distributors for Salvador in the UK and Ireland we have established ourselves as crosscutting experts with extensive experience in industries manufacturing a range of products including sofas and beds, garden buildings, pallets, packing cases, timber framed buildings, as well as high production saw mills.’
For further information: Tel: 0115 986 5201 www.daltonswadkin.com
The Salvador SuperPush S200 automatic optimising crosscut saw installed at Westbridge Furniture
40 Panel & Joinery Production May/June 2016
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INSTALLATION
AXYZ Routers on Song at Wilcare Wales Since the commencement of business in 2001, South Wales-based Wilcare Wales has seen extraordinary year-on-year growth, having operated initially from a 500 square feet factory housing just a handful of employees to the present 30,000 square feet facility with a staff of 50. The company has achieved virtual market leadership with its brilliantly designed and engineered electric rise and recline chairs which meet all Class 1 medical devices requirements as defined by the EC Directive 93/42 and which are widely specified in the mobility sector. The company is also CE registered with the MHRA (Medicines & Healthcare Regulatory Agency). In addition to the production of rise and recline chairs, Wilcare Wales has recently expanded its wood-based offerings with the newly created accentu8 brand of furniture, developed in association with the awardwinning furniture designer, Angela Gidden, who now functions as the consultant creative director for the company. Having earlier installed its own wood mill incorporating routers supplied by AXYZ International, the company has subsequently expanded its production capacity to accommodate further third-party
requirements and most recently gained preferred supplier status with a large manufacturer of wood-based furniture products. Over 90 per cent of the materials used by the company are locally sourced and Wilcare Wales is one of only a few companies that handles all of the elements of its rise and recline chairs, from the design and construction of the wooden frames to the processing of the fabric coverings and the sewing and upholstering of the finished chairs. The company also operates a ‘green’ sustainable refurbishment programme. According to managing director Anthony Kiff, much of the company’s success can be attributed to the performance of the AXYZ routers that have been installed. These have now been supplemented with the purchase of a top-of-the-range AXYZ Twin Head large-format CNC router. Anthony Kiff commented: “As a result of the generous trade-in offer made by AXYZ International, it was possible to exchange one of our old AXYZ machines for a brand new higherperformance AXYZ 8016 larger-format router. This has helped speed up production and further enhanced the
quality of our work as well as dramatically reducing material wastage.” The AXYZ Twin Head 8016 is a highvolume and high-performance router with a standard processing width of 2565mm and a length of 3048mm that is extendable up to 10 metres in increments of 610mm. It has a maximum positioning speed of 25m/min with the option of higher speeds if required and gantry clearances of up to 300mm to accommodate thicker materials. Key features of the router include the latest A2MC machine control system that intelligently regulates acceleration and deceleration during the routing/cutting process, the AXYZ SmartConsole that rides alongside the gantry for ease of start-up and a helical rack and pinion drive system. Other optional machine enhancements include a range of collet spindles and drills, direct-drive motors on all three axes, an expanded (up to 33 stations) ATC (Automatic Tool Change) facility, the AXYZ AVS (AXYZ Vision System) for optimum accuracy, a range of knife heads and multiple carriages. In conclusion, Anthony Kiff stated: “Although AXYZ International has been and remains a preferred supplier, we did look at other machines on the market prior to purchasing the AXYZ 8016 but none matched this router in terms of the improved quality and reliability demanded by one of our biggest clients. Furthermore, we have enjoyed a long and successful business relationship with AXYZ International and have been particularly impressed with its customer support facilities, reliability and overt commitment to client satisfaction.”
For further information on AXYZ routers: Tel: 01952 291600 www.axyz.com To find out more about the products manufactured by Wilcare Wales: Tel: 01446 772227 www.wilcarewales.co.uk
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MAY/JUNE 2016 Panel & Joinery Production
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SANDERS - INSTALLATION
deVol Invest in a Kündig – Again From humble beginnings in 1989, deVOL has grown into a renowned design led manufacturer of bespoke kitchens, interiors and bedrooms, all designed and built in Leicestershire. The company is continually moving forward, as shown by its purchase of Cotes Mill, a historic 16th century water mill, which now boasts four floors of showrooms displaying not only the company’s four kitchen ranges but an eclectic mix of vintage furniture, gifts and unusual home wares all sourced and bought especially for Cotes Mill. In 2013 bathroom cabinets were added to the Shaker range, part of the continual process of designing new pieces to add to the company’s ranges. In 2014 a showroom opened in Clerkenwell, London, and in 2015 the Sebastian Cox Kitchen was launched: a kitchen that utilises sustainable British timber combining good taste, modern innovation, traditional techniques and true inspiration. Managing director, Robin McLellan, is always seeking that extra 1% of performance that will enhance the quality of the company’s offering. As part of this process, deVOL invested in a Kündig Premium-3 1100 RRP sander, delivered and commissioned in September 2015. Robin commented: “deVOL had already had a wide-belt sander but it was a five-yearold twin belt sander which had been second hand when bought, and after a pass through the machine each component also needed to be sanded by hand. “The company is
growing, we were up 48% last year, and so we are continually trying to improve the quality of the product and make sure the processes are as efficient as possible.” “In the search for a new sander, we worked through Markfield Woodworking Machinery (MWM), with whom we have a long standing relationship. We have bought a lot of machinery from them in the past, and they introduced us to Kündig Ltd and to Carl O’Meara.” The Kündig sander was one of several that deVOL investigated: Carl says. “Robin went to see an example of one of our machines working locally to him at Wreak Valley Craftsmen (who have a Premium-2 1100 RE with vacuum belt) where I met him with our area representative, Mr Gavin Cooper of MWM, and we went through the machine and carried out various demonstrations using different grit configurations on a selection of kitchen doors and components brought by Robin for test purposes. Following further trials using the demonstration machine at our works, Robin ordered a new Kündig Premium-3 1100 RRP sander.” Robin says, “We tried a variety of machines, and the Kündig sander was the one we had the best experience with finishing wise. We were aware of their reputation, and wanted to get the best machine on the market. The advantages of the Kündig were all very subtle things, and that is often the case with fine finishing. These subtleties become quite critical in creating a finish that
is spot on compared to one that is 99% there. We just wanted to make sure we got the belt and braces right.” Robin highlights as a particular advantage the fact that this is a three belt machine with a roller-roller-pad configuration, and credits this as one of the reasons that further hand finishing is no longer required. The sander is used to sand doors, including maple doors; worktops and countertops; plywood carcass material; in fact, most things used in the kitchens and other furniture ranges will pass through the Kündig sander. “We require a particularly high finish on the doors, and the Kündig sander gives that,” says Robin. Kündig’s Premium range is especially designed for the sanding and finishing of solid wood and panels, including veneers, and can be configured for lacquer sanding. The sanders are designed to be easy to operate, with a well-designed control panel. An often-quoted advantage is the fact that it is the sanding heads that rise and lower, rather than the workpiece. Kündig engineers design and manufacture the sanders in such a way that they should give reliable service for many years to come. When asked if he would recommend the Kündig sander, Robin replied, “Yes, it is lovely.” He continued, “One of the big reasons for buying the machine was because we had worked through MWM previously and had a good relationship with Gavin. There is a lot of trust there, and in addition to our own assessment of the machine, Gavin’s recommendation was key. We received excellent service both from Carl O’Meara and from MWM.” For further information: Tel: 0845 833 0565 Email: sales@kundig.co.uk www.kundig.co.uk
42 Panel & Joinery Production May/June 2016
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The ultimate sanding machine Standard working widths: 650 mm, 1,100 mm, 1,350 mm and 1,600 mm (1,900 mm and 2,200 mm available on request). All machines have a fixed working height (it is the sanding group that adjusts from 3-200 mm with 400 mm available on request). Enormatic ‘smartset’ standard on all machines for ease of setting and registering off the highest point across the full working width. All machines now incorporate ‘Eco’ energy saving mode. All machines have both colour touchscreen and manual control elements. For solid wood, veneer and lacquer sanding. Choice of cutterblock, combi unit, calibrating roller, standard pad, electronic segmental pads and cross belts for veneer or high gloss.
Premium: Traditional style straight line sanders with 1 to 3 sanding heads for solid wood and veneer sanding.
Brilliant: For the utmost in surface finish using oblique sanding technology where at least one of the sanding heads is placed to give a shear cut across the surface effectively cutting away surface fibres, eliminating oscillation marks whilst giving a flatter surface and suitable for solid wood, veneer and lacquer sanding. Available with single or multiple sanding heads.
TECHNIC RANGE Technic CNC
For heavy stock removal and for shaping the surface
Technic BOTOP
Top/bottom sanding machines
Technic Precision
Sanding accuracy of 0.02 mm
Contact us for the latest developments in wide belt sanding technology
Kündig Ltd
Tel 0845 833 0565 Fax 0845 833 0567 Email sales@kundig.co.uk www.kundig.co.uk
SANDERS - INSTALLATION
Viet Slashes Sanding Time at Door Makers A Viet wide belt sander has boosted efficiency at an Oxfordshire door manufacturer. Shakers Doors, a family-owned business employing 12 staff, specialises in the manufacture of high-end bespoke ‘Shaker Style’ kitchen cabinet doors as well as internal and external doors. The ‘description ‘Shaker Style’ refers to a frame and panel door with a flat centre panel and generally square edges without any profiling, giving a simple straight and clean look. Shaker Doors’ customer base is split equally between trade and domestic customers. An important part of its domestic revenue stream is the production of replacement IKEA kitchen and wardrobe doors, or made-to-measure doors for consumers who have purchased IKEA carcasses. A fitting service within a 50 miles radius of Oxford is available. The quality doors are produced using MDF and a wide variety of hardwoods such as tulip, oak and walnut. Before buying the Viet the joinery company was equipped with two sanders, an entry-level 900mm wide belt model and a 1300mm wide brush sander. Managing director Oliver Bryan said: “Unfortunately the wide belt sander wasn’t really satisfactory. After the doors had passed
through it they had to be sent to the bench for sanding with an orbital sander before being put through the brush sander. They were then oiled or sprayed in our spray shop.” As part of a drive to improve efficiency Mr Bryan decided to buy a wide belt sander that would take away the need for the additional bench work. He carried out some initial research on three sander manufacturers before deciding to take a closer look at the Viet, whose artisan models are supplied by T.M. Machinery of Leicester. “I went along for a demo at T.M’s showroom and told them exactly what I needed the sander to do,” he said. “I was impressed with the quality of the finish produced by the Viet as well as the build of the sanders. I then spoke to an impartial service engineer who works in the woodworking industry and he said I couldn’t go far wrong with a Viet.” The S1 model he has bought is a popular 1350mm twin-head wide belt sander that offers a winning combination of high precision, versatility and a tough build quality to give it a long working life. It’s the ideal sander for use where high levels of throughput are required at an affordable cost. Featuring a thick anti-wear steel work bed
Shaker Door’s Viet sander has cut sanding time considerably.
that guarantees precision for any job, it has a wide range of sanding units allowing customisation to suit a range of applications. There’s a choice of push button or touch screen controls with automatic positioning for thickness setting, while adjustable pressure rollers guarantee the stability of items placed on the work bed. “Having the Viet has meant we have become far more efficient in our joinery workshop,” said Mr Bryan. “The quality of the machine’s calibrating and fine sanding means that doors can now go straight to the brush sander without the need for any additional bench work. “When I bought it I calculated it might save us between 15 and 20 per cent of the time it used to take to prepare doors for the brush sander, and this is exactly what we are achieving with it. As well as saving on time and labour it has also substantially reduced the amount of product handling required.”
For further information: Tel: 0116 271 7155 Email: sales@tmservices.co.uk www.tmmachinery.co.uk The Viet S1 wide belt sander at Shaker Doors.
44 Panel & Joinery Production May/June 2016
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DUST EXTRACTION
Dustraction’s Biggest Cyclo-Filter Underwrites 24 Hour Working at Jeld-Wen Dustraction has installed its largest model cyclo-filter at JELD-WEN, in Melton Mowbray, to underwrite a reliable ‘24-hour operation initiative’. Architectural joinery specialist JELD-WEN is manufacturing timber windows, patio door frames and staircases at Melton Mowbray on a new layout at the factory and to link major joinery plant in line with JELD-WEN management’s very high standards of waste management. JELD-WEN is a world-class architectural joinery manufacturer seeking optimal energy efficiency and air quality in a new round-the-clock working environment. As one of Britain’s most forward thinking users of sustainable timber, JELD-WEN management is also dedicated to optimal waste management and recycling efficiency and the maximisation of waste as a valuable bio-fuel resource. The old high-volume throughput working techniques of the 20th century are gone now at JELD-WEN. They are increasingly manufacturing bespoke these days, or making ever smaller batch sizes, and are continually investing in more flexible machinery. Management is committed to maximisation of resources whenever and wherever it can, including working on a new 24 hour cycle. Dustraction’s Steve Matuska says: “At this project there are three main duct runs, each measuring a 1000mm in diameter and running externally for around 40 meters before entering the main building, at which point they disperse to pick up at an ever increasing variety of machines. The new cyclo-filter is our largest range model; the whole set-up is now a Class A balanced, quiet and efficient layout for rigid, vibration-free operation in order to shift around 14,000 tons of wood waste daily at upwards of 160,000m /hr. Waste is transported by three Dustrax No.
66 heavy-duty paddle-blade, vee-belt driven fans powered by 110kW motors and each incorporating a control panel with periodic soft starts to dislodge cake waste from the large capacity filter sleeves; these sleeves are circular to prevent excessive build up. Waste is then discharged directly to two 40ft trailers for recycling. Manufactured at their Oadby,
Leicestershire, factory, cyclo-filters are big business for Dustraction. With 95% cyclone separation of large particulate matter before even reaching the filters and involving no moving parts, cyclo-filters are virtually zero maintenance and are guaranteed for 6,000 hours operation – or for three years of continuous, round-the-clock use. Emissions are guaranteed at or below
Dustraction have now installed their largest-capacity cyclo-filter at JELD-WEN in Melton Mowbray. It’s a busy site!
46 Panel & Joinery Production May/June 2016
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DUST EXTRACTION
Three main duct runs, each 1000mm in diameter, are running externally for more than 40 metres before entering the factory and dispersing to service state of the art processing machinery.
0.2mg/m3 using tubular filters in heavy filter-fabric and reducing the risk of bridging and blocking through caked dust. Cleaning is by pulsed jets of compressed air; Dustraction’s filter tubes are cleaned automatically and boast collection efficiencies of 99.99% enabling full recirculation of filtered air back into the factory environment. Dustraction’s reverse air pulsing mechanism ensures superior collection efficiency and is used throughout many industrial sectors where heavy dust burdens are handled on a continuous basis. The system is low in energy use, high in filtration efficiency and designed for 24/7 operation. The JELD-WEN legend began in Oregon in the United States in 1960 and the Group now employs 20,000 people worldwide; the UK company is Britain’s number one manufacturer of key architectural joinery products. JELD-WEN incorporates the John Carr and Boulton & Paul brands and the Group is operating from five factories across the UK.
For further information: Tel: 0116 271 3212 Email: steve.matusca@dustraction.co.uk The new Dustrax 10 cyclo-filter at JELD-WEN discharges around 14 tons of waste daily directly to two 40ft trailers and is built to operate now 24/7. See our website and interactive magazine www.p-j-production.com
MAY/JUNE 2016 Panel & Joinery Production
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DUST EXTRACTION Dutch Industrial Vacuum Range Proves its Worth The Dutch industrial vacuum product range from Verhagen Leiden, newly available in the UK via sole agent, Industar, looks really set to prove its worth in the woodworking sector. Launched here a few months ago, Yorkshire-based Industar, say the feedback about the vacuum is really positive and everyone who has trialled it, comments on its superior performance. An early customer to purchase the Verhagen F3313 Industrial and Turbo model, Christopher Shaw, director of Essex-based Garner and Shaw, says that since investing in the vacuum he has been very impressed at how easy it is to use and its overall performance. Operating in the architectural and wood finishing sector, Garner and Shaw has been providing specialist wood spraying services to architects, door manufacturers, joinery companies and interior designers for over 30 years. With a 32-strong workforce employed over two sites, Mr Shaw takes his responsibilities to
create a safe working environment seriously, making the removal of waste from dust and wood shavings a key priority. When looking to purchase a new industrial cleaner he was impressed by the features and cleaning ability of the Verhagen F3313 model and delighted with its performance. Verhagen Leiden has been established for over 50 years and its name is synonymous with quality in its native Netherlands. The product range is well known for its durability and low maintenance requirements. Given the onerous health and safety requirements within the woodworking industry and the necessity to keep the environment dust-free, Verhagen Leiden products have a ready-made
market here, says Industar director, Ad Klabbers, also from the Netherlands. He says: “The Verhagen Leiden range offers superb quality. I have grown up with the brand back home where it is a household name in the Netherlands. When we were selecting an industrial vacuum range to promote in the UK, this brand stands head and shoulders above the rest in terms of its performance and durability. It also comes with a range of additional attachments to make it particularly adaptable for most workplaces, able to penetrate the tightest corners where dust may collect. For further information: Email: info@industar.co.uk www.industar.co.uk
Makita Add New Dust Extractors Makita is adding two new, M-Class approved dust extraction vacuum units to its already extensive range as the campaign for improved dust management, especially on site and in the workshop, takes construction industry priority. In addition Makita has introduced a dual power extractor that can be powered by mains or battery and will be a very useful cleaner for maintenance teams. The new Makita VC2201MXI/VC2211MX1 M class dust extractors bristle with innovative features. Powered by a 1,050 watt motor, available in either 110v or 240v mode, which delivers a quiet 22.0 kPa maximum suction with an air flow of 3.5 m /min to pull material into the 22 litre stainless steel tank. These extractors feature a new automatic selfcleaning filter system achieved by two triple function filter units. These are composed of a powder filter, damper and pre-filter which use a valve system to redirect airflow through each of the filters in turn to release the collected dust into the retainer. The audible air flow sensor bleeps a warning when the tank is full or the pipe is blocked.
48 Panel & Joinery Production May/June 2016
The Class M approval allows use with mica, china clay, gypsum, wood dust, masonry, GRP and concrete. Weighing just 16.3kg, and with a useful 5 metre power cord, a new design of chassis includes large bumpers to protect walls and cabinets from travel damage whilst the new castors have a lock to stop the extractor moving unintentionally during operation. The new Makita DVC861LZ L-class extractor is operated by both AC mains power and DC batteries, using the twin 18V battery system that is storming the construction and outdoor power tool market with its 36V performance. This will prove invaluable in a location where mains power is not available. The new dry material vacuum has a 1,050watt motor that will generate 24 kPa maximum, suction in mains mode, and a useful 9 kPa suction when powered by battery. If the batteries are in place and at the same time the mains cord is connected and power available, the mains power takes priority and an indicator lamp shows when AC power is operating. The useful storage box on the top of the machine, as well as
MAK1610 VC2211MM class
the power cord can be removed. A 2.5metres suction hose is provided together with long lance and roller collector head. Strong polymer bumpers protect property and the castors can be locked for stability. For further information: www.makitauk.com. Twitter @MakitaUK, Facebook.com/makitauk google.com/+makitauk
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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
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DUST EXTRACTION
DCS Extraction System for New Starbank Facility Dust extraction specialist Dust Control Systems (DCS) has recently completed a major installation at Starbank Panel Products’ new manufacturing facility at Newton-le-Willows on Merseyside. After almost 2 years of planning and construction, Starbank Panel Products Ltd is now fully operational at its new 16-acre site on the Sankey Valley Industrial Estate, just a short distance from the premises occupied by the company for the past 26
years. Starbank’s managing director, Phil Darbyshire, explains: “This move provides us with a platform to further grow the company and, just as importantly, ensures that the services we provide will meet our customers’ changing demands in the future. Since acquiring the site we have comprehensively redeveloped the existing 116,000 sq ft building; doubling our manufacturing space, and allowing the opportunity for increased production
capacity and flexibility.” Investment in production machinery for the new site includes the introduction of a second Homag BAZ 723 CNC processing centre, complete with bespoke 3D acrylic edgebanding facilities and automated loading gantry. The company has also installed a customised Homag VFL 610 through-feed postforming line which is configured for fabrication of wrapped fire doors and frames.
Melvyn Bathgate and Phil Darbyshire at Starbank’s impressive new filter unit.
50 Panel & Joinery Production May/June 2016
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DUST EXTRACTION
New generation ECOVAR Validus filter extracts waste from all production machinery at Starbank, and woodwaste is delivered into a 16 metre tall storage silo.
For dust extraction at the new site, Starbank’s requirement was for a single, externally-sited, high-efficiency filter that would serve the whole factory, as well as efficiently feeding woodwaste to a new state-of-the-art biomass heating system. Melvyn Bathgate, sales director at DCS, says: “Having worked with Phil and his team for many years we are aware of the company’s commitment to a green manufacturing strategy, and DCS were able to propose an energy-efficient dust extraction scheme which featured an ECOGATE energy-saving extraction optimisation system, together with the latest ECOVAR Validus filter from Schuko.” The Validus 2330 filter, sized at an air volume of 115,000 m3/hr, extracts from a total of 16 machines. Waste collected by
the filter is discharged, pressure-free, into a screw conveyor which feeds a bucket elevator. The waste material, via a second screw, is then discharged into a large storage silo. The new generation Schuko filter features a 5 x 37kW fan cascade system whereby fans are brought on-line or taken off-line according to extraction demand. Cleaning cycles are also tailored to specific needs by employing a cleaning train regeneration system. Extraction ductwork throughout the new factory is designed to ensure optimum extraction velocities, and pneumatic dampers strategically located in the ducting runs enable plastic waste and wood waste to be extracted separately. Furthermore, the ductwork between the fan outlet and filter inlet incorporates ATEX-approved CARZ back-pressure flap
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valves which prevents the effects of a dust explosion from travelling from the filter, back along ductwork, and into the factory. All production machines are fitted with Ecogate automatic dampers which open and close as machines come on-line or shut down – the end result is a highlyefficient, optimised system that only uses energy when required.
For further information: Tel: 0800 040 7116 www.DCSlimited.co.uk
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WOODWASTE State of the Art Biomass Boiler Installed Into One of the UK’s Oldest Shop Fitting Companies The team at Wood Waste Technology has installed a state-of-the-art biomass hot water boiler system into one of the UK’s oldest shop fitting companies, Kiddie of Southport. Kiddie started in 1869 as a small cabinetry business that has evolved through time to become a modern manufacturing base with services including shop fitting, bespoke joinery and aluminium curtain wall and window fabrication and installation, for commercial clients as well as schools, hospitals, medical healthcare practices and care centres. The new wood waste boiler was installed into Kiddie’s 25,000 sq ft factory in Southport, which is based in a residential area, with 40 employees working under its roof. Wood Waste Technology’s revolutionary boiler is one of the most efficient wood waste boilers available in the UK, having been designed and tested to BSEN303-52012, the highest standard for efficiency
The new woodwaste boiler installed at Kiddies of Southport
52 Panel & Joinery Production May/June 2016
and emissions. It was also the first in the UK to be declared fully compliant with the Renewable Heat Incentive (RHI) scheme without the need for additional flue gas filtration equipment (significantly reducing the investment and on-going maintenance costs of a RHI compliant boiler). Wood Waste Technology boilers can also operate in clean air zones under the Clean Air Act, as the boilers meet the two highest standards in emissions regulations, so are able to be used in even the sternest of jurisdictions in the UK. The team at Wood Waste Technology designed a complete system for the Kiddie factory, to give free heating to the factory area just as the old wood waste heater did, but also to send heat to radiators in the office area. As the office previously had to be heated separately by a gas boiler, the management at Kiddie are delighted to be saving around £1500 in heating bills each year, in addition to the money being saved on heating the factory and waste disposal. Stephen Holmes, Managing Director at Kiddie says: “The new system is fantastic. It gives out so much more heat, is far more efficient than our old boiler and offers more functionality too. Unfortunately our old boiler failed before we had the new one installed, which made us realise how much money a biomass boiler saves us each year, as all of a sudden we had to hire skips to take away our wood waste, and were spending around £1000 every few months just on waste removal! It was such a relief when we could burn our waste wood again, to heat the factory, offices and also provide hot water. The team at Wood Waste Technology has given us excellent service, and they even helped us in our application for the Government’s Renewable
Heat Incentive (RHI), which now generates extra income into the business.” Kurt Cockroft, MD of Wood Waste Technology says: “Our engineers were the first to use purely primary methods to reduce emission levels in a biomass heating solution, which allows customers to maximise their return from the RHI scheme by getting more money from every kilogram of fuel burnt. So, as well as companies making considerable savings on heating and waste removal bills by burning waste to create energy, it means companies with successful RHI applications could earn around £17,000 - £21,500 a year, for 20 years, with a 209kw boiler. Wood Waste Technology also has a 100% success rate in RHI applications for companies burning chipboard and MDF.” Kurt continues: “Kiddie’s new boiler offers 92.4% efficiency compared to the 68% efficiency of its old boiler. By getting 26.5% more energy from the fuel, the new 209kW boiler will use only the same amount of fuel as a 150 kW one, yet makes the factory much warmer, and substantially increases the RHI payments the company is entitled to. That’s why many companies are now realising the benefit of replacing their older wood waste boilers with newer, more efficient ones that can qualify for RHI.” Kiddie has also invested in a Putzmaus boiler tube cleaning system from Wood Waste Technology, allowing them to quickly and easily clean the boiler, to help keep it running at maximum efficiency. As well as being a distributor for Putzmaus, Wood Waste Technology is also the UK official distributor for Gross Apparatebau GmbH, a German manufacturer of dependable, precision engineered shredders and briquetters, available in various size and specifications to suit all business applications.
For further information: Tel: 01785 250400 www.woodwastetechnology.com www.grossuk.co.uk www.putzmaus.co.uk
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