Panel & Joinery Production November / December 2019 by Panel & Joinery Production

November / December 2019

Over 300,000m2 of high quality laminated products produced each week

SHAPING SOLID WOOD SINCE 1952 To meet the specific needs of windows, doors, stairs production and solid wood machining in general, SCM has designed accord, a wide range of 3-4-5 axes cnc machining centres with superior precision mobile gantry structure and a choice of bars and pods or multi-function aluminium worktables. The versatility of accord machines offers outstanding precision, speed and reliability with high performance technological solutions that can satisfy the requirements of an increasingly demanding market.

accord 25 fx

accord 40 fx

accord 42 fx

accord 50 fx

SCM UK Tel. +44 (0)115 9770044 scmgroupuk@scmgroup.com - www.scmwood.com

Contents

Editor’s Pick

Cover Story

4-6

18-19

10-11

Must Read

16 2-3

News

4-6

SCM Presents The New “Batch 1”

26-27 Published by:

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

Advanced Furniture Gains Competitive Edge With Homag UK

Telephone / Fax:

+44 (0)20 8366 3331

10-11

A Polished Performance From Mirka

Email:

ernie@p-j-production.com

12-13

John Worth Shopfitters Invest In Homag

Website:

www.p-j-production.com

AXYZ Router Proves Pivotal To ITC Success

Publisher:

Ernie Hollister

The Unico CNC Range From Protak

Designer:

Russel Goldsmith TRACE Creative Agency www.tracecreative.co.uk

Printer:

The Magazine Printing Company www.magprint.co.uk

7 8-9

18-19 23 26-27

No Job Is A Bridge Too Far For Morris Joinery

Three New Finishes Launched By Decorative Panels TeraBlack From Titus Bespoke Kitchen, But Not A Bespoke Price

An Incredibly Busy Year For Intelligent Fixings Ltd

Makita Expands Its Range Of Cordless Machines

Filtermist Restructure Delivers ‘Clean Air’ Solutions

Merry Christmas & a Happy, Healthy and Prosperous New Year to all our readers, contributors and advertisers.

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 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 liablity with respect to any article published herein.

Panel & Joinery Production - November / December 2019

News Redot Award To The New SCM Group And NiEW Human-Machine Interface SCM Group, world leader in machinery and industrial components, and NiEW, a business design and customer experience company specialising in industry, received acclaimed recognition for the industry and Italian design: the Maestro Active human-machine interface project won the RedDot Award in the Brands & Communication Design 2019 category.

The interface adapts to the user’s characteristics in terms of language, computer literacy and information complexity, providing www.red-dot.org recommendations for an effective www.scmgroup.com use of the machine. www.niew.it

This prestigious global competition is now in its 65th edition, and the jury recognised the high level of design, innovation and creativity behind the “made in Italy” product following scrupulous assessment of more than 8,000 international projects entered into the different categories. Maestro Active, which had already achieved important recognition in February 2019 for the world of industry and design, with a special mention at the German Design Award, is NiEW’s creation of a concept for the corporate operating system capable of adapting to all the product lines and SCM Group devices, with regard to Industry 4.0 and Industrial IoT. Indeed, the objective is to create a single interface across all the Group’s technologies, which not only meets with the most innovative demands of contemporary IT design, but also allows any operator, irrespective of their language, background, culture or professional experience, to have a direct, confident approach with a wide variety of machinery.

L-R: Andrea Violante, CEO of NiEW; Daniele de Cia, Founder of NiEW; Frederico Ratti, Director of SCM Group Innovation; Massimiliano Oliveri, SCM Group Software Design Manager

The Finish To A Great Finishing Career! Having worked in the furniture and joinery industries for over 55 years David Miller has decided it is time to hand the reins over to a younger team. More recently, David, who has specialized in laminating and finishing has been representing Barberan and Venjakob in the UK. His knowledge and cheerful attitude to this market will be missed. He has built up very strong and lasting relations with his many customers and would like to thank them for their support over many years. PJP would like to wish David all the very best on his retirement. For future enquiries: Barberan in the UK will be looked after by Horst Schwesinger who can be contacted at Horst@barberan.com. Venjakob in the UK will be looked after by Brendan Lynch who can be contacted at Blynch@filtrex.ie

Panel & Joinery Production - November / December 2019

News

Martin McVicar CEO and co-founder of Combilift (centre) accepting the trophy at the BITA Design 4 Safety Awards

Combilift Wins Design4Safety Award Combilift added yet another award to its ever growing tally when it won the Industrial Vehicles Category of this year’s BITA (British Industrial Truck Association) Design4Safety Awards. The company’s reputation for designing innovative products and features to enhance safety in the materials handling sector was underlined once again with the success of its patented multiposition tiller arm, which is a feature common to all its pedestrian models. Martin McVicar, Combilift’s CEO and co-founder accepted the trophy from BITA Secretary James Clark during this year’s Logistics awards which took place on 26th September.

“We are very proud to be the winners of such an important award as safety is a crucial issue in our industry. Following the FLTA Safety award we received for the Combi-PPT earlier in the year, this highlights the fact that our product range is designed with the utmost safety in mind - not just for operators but for all employees who work with or in the vicinity of forklifts and industrial vehicles.”

of the operator being crushed or trapped between the truck and racking and the excellent visibility reduces the risks of accidents involving other personnel. Originally designed for the Combi-WR reach stacker, the tiller arm is now incorporated on Combilift’s ever growing range of pedestrian models such as the multidirectional Combi-WR4, the Combi-CS counterbalance stacker and the Combi-PPT powered pallet truck. www.combilift.com

Combilift’s unique multi-position tiller

Combilift’s unique multi-position tiller enables push button rotation of the rear wheel parallel to the chassis and back, allowing the operator to remain in the safest possible position when placing and picking in narrow aisles; at the side of the unit rather than behind it. This reduces the risk

Panel & Joinery Production - November / December 2019

Edgebanders SCM Presents The New “Batch 1” Flexible Edgebanding Systems For Industry 4.0 Industrial edgebanding is increasingly articulated, demanding and connected. Orders are continually changing, modularity is a diktat and the number of processes is on the increase.

The key new entries for SCM edge banding took centre stage during the “On the Leading EDGEbanding” event, from 7 to 9 November 2019 at the Edgebanding Tech Lab in Thiene (Vicenza).

SCM’s new flexible “batch 1” edgebanding systems fully interpret and meet the demands for efficiency, integration and processing customisation made by the current market. These systems guarantee an increasingly more sophisticated productivity thanks to the integration of the edgebanding machine in cells and plants fitted with rollers, panel return devices, automatic loading and unloading systems, assisted by robots and fitted with IoT sensors to control the machine functions in an instant. Equally, they ensure unique machining accuracy and quality on any kind of panel, even the most delicate ones and more complex materials, thanks to a new “Round 2 Servo rounding unit” and “RT-X grinding unit” and the latest optimised devices for a perfect line of glue.

The event was an opportunity to inaugurate the expansion of this production centre in Thiene which has been extended by more than 35% and now covers around 30,000 square metres. All this translates into an increase in space for production lines, modern, clean layout for maximising the storage stages and a Tech Lab that makes its mark as the largest of its kind in Italy for this technology. All this implies an improved, faster response to our clients who can test the best edge banding solutions directly on site and run specific tests on their panels, edges, glues etc. with the aid of specific technicians. Let’s take a closer look at these new “batch 1” flexible edgebanding systems.

Stefani Cell H, flexible egebanding systems

Panel & Joinery Production - November / December 2019

Edgebanders

Stefani Cell E – Robot Loop Version

Other new SCM products for edge banding were also on display during the Smart Days in Thiene:

STEFANI SHAPE TECHNOLOGY: the best in softforming for every kind of profile As part of SCM’s edge banding, considerable focus was also placed on market demands in matters of softforming and “J-Shape”, areas in which SCM has led the way for some time now as a genuine specialist in providing simple solutions for use but ones that produce top quality results. The new “J-Side” kit has been designed to solve the problem of complex profiles so that the straight edging lines up perfectly with the shaped edging without gaps or projections. There is no longer any need to carry out this machining manually or with an additional procedure thanks to the new SCM solution. Everything is much simpler, faster and more efficient thanks to a new unit that can be fitted on a standard edge bander and completes all the essential stages for an all-round edge banding, even this “finishing”. An edge bander equipped like this means any kind of edge banding problem can be resolved while work continues, without any interruption, exactly as though it were working on a normal straight edge. This is a significant step forward in being able to extend the creative potentials of softforming to a growing number of companies, a solution which is effective with any kind of edge and with different thicknesses

that can be applied and worked without interruption. MAESTRO ACTIVE WATCH: from the office to the factory, the entire process under control The Maestro Active Watch supervision and control software will also play a key role. It is perfectly integrated with the flexible edging lines, capable of fully handling all the machines in line. Real time control of the process: the status of the various machines can be set and read, their production tracked and records stored. Plant layout display: optimised in line with the plant under supervision, the SCM software offers a synoptic display of the entire line, a visual inspection in real time of the process at each of the machining phases and a continuous monitoring of the advancement of the pieces along the line. Zero errors in the introduction of panels into the cell: thanks to SIDE FINDER technology, the correct insertion method of the panel is shown so that it can be properly machined. Preliminary simulation of the time-scales for cell productivity checks. Maximum efficiency: the machining of each individual panel can be seen in real time, irrespective of where it is in the plant. A preliminary check can also be run on the machining feasibility of each part Report generator for excellent production: reports can

Panel & Joinery Production - November / December 2019

Edgebanders

be produced per operator, shift, program, etc., and they can be forwarded to the company management Maximum productivity for each program that is running thanks to a line management “per zone”, MAESTRO CONNECT: digital IoT services for the Industry 4.0 It will be possible to run just in time testing on the potentials of the Maestro Connect IoT system at the Edgebanding Tech Lab with collection and analysis of data from the operating SCM edgebanders and draw up processing reports for an ever more immediate feedback on the machine’s functioning

Technological partners were also there for the occasion to provide demonstrations and detailed explanations, in particular, manufacturers of edges, tools, glues and anti-adhesive liquids. Key topics that will be discussed include zero-emission PU glues, the latest trends in finishings (edgebanding products), high performance tools and SCM productivity systems with Threespine™ Valinge technology.

Panel & Joinery Production - November / December 2019

www.scmwood.com

Installation No Job Is A Bridge Too Far For Morris Joinery An enterprising Shrewsbury joinery business has put its considerable skills to use to construct a bridge for a rural Shropshire estate. So big was the timber-clad, steel structure that it was made at Morris Joinery’s base at Bicton Business Park then disassembled so that it could be transported 20 miles away, craned into position and then rebuilt in its permanent position. The bridge was commissioned for a privately-owned south Shropshire Estate to replace an ageing wooden bridge with one strong enough to accommodate the largest tractors and farm vehicles. The replacement bridge, 14 metres long, 4.6 metres wide and weighing 26 tonnes was crafted from timber and galvanised steel. Joinery team members clad the steelwork in prime grade European green oak to give the appearance of a rustic wooden bridge. They spent 10 weeks working on the project at their Bicton Business Park base and a further six weeks on the agricultural and shooting estate, with the foundations and civil works carried out by Morris Property. The installation of the bridge was captured on a time lapse camera, and the footage is available on the Morris Joinery

LinkedIn and Facebook pages. Joinery Manager Matt Tyrrell said: “We specialise in bespoke traditional and contemporary joinery and enjoy the challenge of turning our hands to different projects. Not many joinery companies can say they can make a bridge on this scale.” “This was certainly a big job in more ways than one, including the logistics of getting such a large structure to its rural destination. We had to build it, take it apart and then put it back together again like a massive jigsaw. “We were proud to work on such a project. It looks great and the client is delighted with the results.” The skills of the team were previously called on to provide all the joinery for the estate’s Alpine style shooting lodge which was built by Morris Property. Morris Joinery offers a full range of commercial and domestic services. It is part of a fifth-generation family business group which celebrates its 150th anniversary this year.

t: 01743 851339 www.morris-joinery.co.uk

The timber-clad steel structure – constructed with prime grade European green oak to give the appearance of a rustic wooden bridge.

Panel & Joinery Production - November / December 2019

Case Study Advanced Furniture gains competitive edge with HOMAG UK Gwent based Advanced Furniture is celebrating its 40th anniversary this year. As part of its ambitious growth plans the company has recently invested in an EDGETEQ S-300 edge bander with a LOOPTEQ O-300 return system from HOMAG UK. “Our heritage as a business is rooted predominantly in the educational furniture sector, making tables, plastic polypropylene steel posted and wooden upholstered chairs” explains operations director, Geraint Griffiths. He continues, “Until ten years ago that market represented almost 80 per cent of our somewhat static £2.8m turnover business. And, whilst there was no doubt that the company’s strength in that market was hugely beneficial, it did bring its own challenges. “By its very nature, the educational market has a clearly defined peak in the summer months. During this time schools and colleges want new chairs, tables and other furniture delivered so they are prepared for the new academic year which usually starts in September. We realised, therefore, that to grow the business we had to look for new markets that would give us a more even work flow throughout the year.

“Given that the skills, machinery and expertise we possess in educational furniture manufacturing are very similar to those required in the office furniture market, we made the strategic decision to enter that sector.” New manufacturing facility to meet ambitious growth plans “Although the types of furniture required for the office market are different to the educational sector, our general furniture manufacturing knowledge and experience enabled us to quickly make inroads into this new market. “Consequently, it wasn’t long before our turnover began to increase significantly. In 2017, this led to our investment in a new 100,000 sq. ft. factory to future proof business expansion. Twice the size of our old unit, this new facility has enabled us to maintain a 16 per cent year on year rise in sales, with our turnover this year predicted to hit £8.5m. “Once the new larger factory was operational, the next stage in our expansion plan was to source a new edge banding machine that would enable us to increase our capacity. During my 35 years or so in the office furniture

HOMAG EDGETEQ S-300 edgebander with a LOOPTEQ O-300 return system at Advanced Furniture

Panel & Joinery Production - November / December 2019

The EDGETEQ S-300 edgebander – high performance and throughput capacity

manufacturing business, I have dealt with all the major machinery brands in the industry. This knowledge was invaluable when it came to sourcing this new edge bander. “In my experience, I have always found HOMAG offers the most reliable, technically advanced and best value for money machinery on the market. That’s not to say they’re the cheapest; the initial price can be higher than other brands. The quality, reliability and service back up they provide, however, is second to none. As a consequence, the premium price is definitely worth paying because the lifetime value of a HOMAG machine is exceptional, you definitely get more for your pound notes. “The other massive benefit of dealing with HOMAG is that you are partnering with a global company that has an absolutely solid financial foundation. This base not only gives you long-term peace of mind, but also ensures that the solutions HOMAG provides are at the cutting edge of technology.” A partnership that works “At the end of the day, however, it’s all about people. The team at HOMAG are always straight-talking; they don’t sugar-coat things or try to sell you something you don’t need. You can trust them to sit down with you and work out the best machine specification for your long-term goals. “Before ordering the EDGETEQ S-300 with the LOOPTEQ O-300 return system we supplied HOMAG with data, drawings, specifications, current sales levels and five year sales forecasts across our product groups. Furnished with this information they came back with a few alternative solutions that would give us the capacity we were looking for over the next five years. “The solution we chose was the HOMAG EDGETEQ S-300. This gives us not only the perfect performance levels we want, but it will also handle our capacity as the business continues to grow at 10 to 15 per cent over the next five years. “Adding the LOOPTEQ O-300 return system means, of course, that we can run the edge bander with one operator. It also improves health and safety aspects for our workforce, as colleagues do not have to lift and manoeuvre heavy

Case Study

panels. This in turn eliminates the potential of work piece damage that can occur with manual handling.” Carefully planned and efficient installation “HOMAG worked closely with us to prepare for the arrival of the new equipment. We were able to ensure all the preparation work was done correctly so that the actual installation process itself ran smoothly to plan. “Once the machines were in place and commissioned HOMAG’s engineers trained our people on set-up, operation and maintenance of the equipment. And, because three weeks before delivery we sent our operators to HOMAG for software training, they soon got to grips with the new equipment. “The machines are so well designed and the software so user friendly, it makes life much easier for our operators. They were able to maximise the potential of the edge bander almost immediately.” Delivering significant benefits “The new machines have improved output levels and quality whilst significantly increasing our capacity and ability to deal with summer production peaks. All this has ultimately improved our customer service which was one of our key goals for the expansion plans. “The finance option HOMAG offered made the purchasing process very easy for us and looking ahead, we are confident that the return on investment will be under two years. “All in all, we are delighted with the new machinery from HOMAG and with the ongoing relationship we have established with the team at Castle Donington,” concludes Geraint Griffiths.

If you’d like a demonstration or more information about HOMAG edge banders and return systems, please contact Adele Hunt at HOMAG UK on 01332 856424.

Panel & Joinery Production - November / December 2019

Profile

Mirkaâ&#x20AC;&#x2122;s UK offices and training facility in Milton Keynes

A Polished Performance From Mirka Mirka UKâ&#x20AC;&#x2122;s offices are set in a 2,500 square foot area by a picturesque lake in Milton Keynes. They are fully equipped to deliver bespoke training and demonstrations for surface solutions and so far have had delivered 89 customertraining sessions together with 12 internal training sessions. Mirka Ltd is a Finnish Company and a world leader in abrasives technology innovation, offering a complete range of technically superior high quality abrasives and designed tools. They have a network of UK distributors throughout the UK supplying abrasives, sanding disc pads, wide belt sanding belts and hand finishing tools to the industry.

Novastar The remarkable power of Novastar in course grains and the excellent surface finish of finer grits make the work faster in fewer steps. It is ideal for hard surfaces where a tough film abrasive with a long service life and improved performance is needed. The new precision coating is virtually dust repellent which means there is no clogging.

Deros The Mirka Deros electric sander has been used by thousands of professionals and been awarded both the iF Design Award and the Red Set Design Award. Mirka was the first company to introduce brushless motor technology in a sander and the ergonomic Mirka Deros is the lightest random orbital sander on the market. You can download and install the free Mirka App on your mobile phone and monitor the vibration levels of your Mirka Deros in real time. The ability to keep track of vibration levels means you can make informed decisions, which could reduce any potential health implications.

Panel & Joinery Production - November / December 2019

Profile

Deos The new Mirka Deos electric sander provides that flawless end result available in two sizes â&#x20AC;&#x201C; Deos 383cv 70x198 and Deos 353 cv 81x133. The Deos is the only electric orbital sander on the market that has been optimized for net abrasives by incorporating more than 45 holes in the pad. When the tool is combined with Mirkaâ&#x20AC;&#x2122;s net abrasives it offers an excellent scratch pattern and a dust free work environment. The reduced weight, size and height of the sander provides customers with a compact, lightweight and easy to use tool. Additionally, it has an integrated vibration sensor with Bluetooth technology that can be connected to a mobile device via the new Mirka App to give guidance on vibration levels.

Cordless Sanders Mirka is expanding its power tool range by introducing the first small brushless battery driven spot repair sanders. These strong cordless sanders enable a long working time as the battery lasts for up to 16 hours in industrial use. The lithium-ion battery charges in only 45 minutes and the operator can move freely around the object being sanded, as no hose is required. Cordless sanders are more energy efficient compared to pneumatic tools and do not require oiling which removes the risk of contamination from compressed air supply.

Iridium This product offers fast sanding with a fine surface finish, which saves time and money. It provides consistent quality with a long lasting disc and the effective multi-hole pattern delivers outstanding performance without the problem of clogging. The premium paper backing offers remarkable flexibility and grain adhesion.

To find out more about Mirkaâ&#x20AC;&#x2122;s products or training: T: 01908 866100 www.mirka.co.uk

Panel & Joinery Production - November / December 2019

Case Study John Worth Shopfitters Invests In HOMAG CENTATEQ N-500 CNC Gantry Processing Centre John Worth Shopfitters Ltd is a family run organisation based in the heart of Leicestershire. Established in 1994, the company has built a solid foundation in the retail sector with a reputation for quality, care and customer focus. “Our heritage as a business is rooted predominantly in From the talented workforce to the experienced senior management team, John Worth’s strength is its people. All are devoted, hardworking team players who share an attention to detail and a desire to evolve and meet new challenges. With the business expanding, the senior management recognised the need to add a new CNC processing centre to work alongside the machine that had served them well for the last ten years. “To be competitive,” explains John Worth’s workshop manager, Gary Crump, “You have to invest in the latest woodworking machinery. If you don’t, you simply can’t compete on quality, speed or cost.

“Our existing HOMAG CNC machine has been a real workhorse for the business, however, with increasing workloads we wanted to ensure that we had the machinery that would take us forward and cope with future growth.” Reliable, leading-edge technology “Although we looked at a couple of cheaper alternatives, in the end our decision to purchase the HOMAG CENTATEQ N-500 was a simple one. The quality, reliability and excellence of German engineering gave us the peace of mind to invest in this CNC gantry-style processing centre. “Past experience told us that not only would the new machine deliver value for money over its lifetime, but also the service backup from HOMAG would always be first class. “Most, if not all of the work we do, is bespoke which means the CNC has to be able to handle lots of different jobs rapidly and with ease. The CENTATEQ N-500 is perfect for our needs; we’ve linked its woodWOP software to our CAD system making it quick and easy to setup and operate.”

HOMAG CENTATEQ N-500 – rapidly handles different bespoke jobs with ease for John Worth Shopfitters

Panel & Joinery Production - November / December 2019

Case Study

intelliDivide Software – available option for the HOMAG CENTATEQ N-500 CNC

HOMAG CENTATEQ N-500 CNC Gantry Processing Centre The CENTATEQ N-500 compact nesting machine is specifically designed for the creation of carcass furniture, dividing and refining of furniture fronts and construction of frame furniture. The machine’s gantry style delivers the highest precision over the total working width, whilst its high acceleration gives an X/Y vector speed of 96 m/min. To maximise production, the whole working field is reachable with all processing tools and the CNC has electronic surveillance for all stops. The CENTATEQ N-500’s standard features include two synchronised digital servo-drives in the X-direction to guarantee the highest processing quality; a 13.4 HP HSK routing spindle; a highly flexible matrix table with grid grooves for clamping of templates or workpieces, and from a 7 to 14 tool changing system dependent on the working field size. Controlled with the new powerTouch2 user interface which achieves time savings of up to 30%, the machine has an impressive array of options. These include highspeed drilling blocks, larger tool changers, lowerable fence guides, clamping elements and barcode connection for easy workpiece identification. In addition, software such as HOMAG’s intelliDivide – a webbased cutting optimisation system, and cabinetCreator – a web-based furniture design wizard, are amongst the many solutions that make the CENTATEQ a truly versatile CNC gantry processing centre. The machine is also compatible

with tapio – HOMAG’s digital platform specifically designed for manufacturers to gain more production efficiencies. It provides live updates of machinery status, production processes, servicing requirements and software updates. Tapio also monitors and produces data for capacity and throughput rates as well as any concerns such as machine errors or drops in productivity. Cost savings and efficiencies Gary Crump again, “Although we’ve only had the new CNC for a couple of months, it is clear to see that it will bring improved efficiencies to our business. We have been told that the electricity savings alone will add up to around £2000 a year. In addition, the dust extraction system is incredibly efficient, creating a dust-free environment for our workforce. “From the hassle-free installation, the comprehensive training and the excellent quality of the machine, the CENTATEQ N-500 has lived up to our expectations. The people at HOMAG, from Matt Long the area manager through to everyone at head office, are all competent and highly professional. They always come back to you when you have a query which is not always the case in this industry,” concludes Crump.

If you’d like a demonstration or more information about HOMAG edge banders and return systems, please contact Adele Hunt at HOMAG UK on 01332 856424.

Panel & Joinery Production - November / December 2019

Installation AXYZ Router Proves Pivotal To ITC Success For over 25 years, Tamworth, Staffordshire-based Industrial Tooling Corporation (ITC) has been supplying high-quality cutting/routing tools to a wide range of industries, including the woodworking, furniture production, joinery and panel processing sectors. The tools are produced using specialist materials such as solid carbide and/or PCD (Polycrystalline Diamond), with the latter providing a harder surface to enable greater abrasion resistance and the ability to handle a more diverse range of difficult-to-process materials and radically increasing tool life to reduce production costs. Installation of an AXYZ 4000 series CNC router supplied by AXYZ Automation Group was a conscious decision by ITC to greatly enhance its R&D and production capabilities. Technical Sales Manager at the company, Sally Hunt commented: “Investment in the AXYZ router was made primarily to help the development of new cutting tool technology to meet constantly changing market trends and to facilitate comprehensive in-house testing of nextgeneration substrates, coatings and geometries prior to the introduction of all new and future cutting tools.” By providing this in-house facility incorporating a highperformance AXYZ router, ITC has helped reduce unnecessary and potentially expensive downtime at customers own premises. Sally Hunt added: “Although still in its comparative infancy, this vital customer support facility has enabled ITC to fully evaluate every tooling solution to make sure that it is the most appropriate for the materials to be processed, regardless of how complex and difficult these might be. With the assistance of the AXYZ router, we are able to pre-test, tweak and refine as necessary new tools as well as enhancing the capabilities of existing product lines when required.”

The AXYZ router installed at ITC is the 4008 model. It features a 1.5 x 2.4m processing bed based on a solid steel frame construction to better accommodate more vigorous machine operation required for the testing of certain specialist tools. A powerful 10.8hp 24,000rpm routing/cutting spindle lends further support to the testing parameters in place. As with all CNC machines supplied by AXYZ Automation Group, the AXYZ 4008 router can be supplied with a wide range of optional production tool enhancements. These include the AXYZ ATC (Automatic Tool Change) system that provides up to 33 tool-change stations to accommodate work requiring multiple tools, the AXYZ Zone Management facility for optimum material hold-down efficiency and the latest A2MC machine controller with integrated AVS (AXYZ Vision System) for precise routing/cutting accuracy. These can be supplemented with the latest helical rack and pinion drive system, incorporating a multiple gear teeth configuration. This enables a more even distribution of the workload, leading to faster throughput speeds, reduced material wastage and machine wear and ultimately a longer than normal machine life.

The AXYZ 4010 ATC CNC router installed at ITC

Panel & Joinery Production - November / December 2019

T: 01952 291600 www.axyz.co.uk Industrial Tooling Corporation (ITC) T: 01827 304500 www.itc.ltd.co.uk

What’s New William Hughes Can Now Offer Electrophoretic Painting For The Protection For Metal Parts William Hughes has introduced an electrophoretic paintline at its Plovdiv factory in Bulgaria. This paintline provides a high gloss black finish with strong anti-corrosive properties and is intended mainly for use on the springs, wire forms and assemblies manufactured by William Hughes itself but can also be offered as a service to other manufacturers. A video demonstrating the new William Hughes capability is available on YouTube; simply enter “Electrophoretic Painting William Hughes” into ‘search’ or follow the link: https://www.youtube.com/ watch?v=IedsxsFKoy0

A rinse in de-ionising water prevents bubbles forming on the surface of the part when it enters the electro painting, or KTL stage. The paintline transfers the parts from tank to tank fully automatically in a closed loop system that eliminates waste and is both efficient and environmentally friendly. Finally the painted parts are cured in an oven set at 200 degrees for 20 minutes, and will now withstand corrosion for around 800 hours, according to tests conducted in William Hughes’ salt-spray testing facility.

t: 01963 363377 e: sales@wmhughes.co.uk www.wmhughes.co.uk

Electrophoretic paint – or E coating – is a combination of plating and painting whereby a metal object is dipped in a water-based solution which contains a paint emulsion. An electric current passes through the part causing the paint emulsion to condense onto it. Both the outside of the part and any internal surfaces can be painted, provided the solution can reach the surface concerned. Typical coating thickness is 20 to 22 microns but upwards of 40 microns can be achieved if required. Many of the parts produced by William Hughes are destined for use in the automotive seating industry for which the paint chosen is particularly suitable due to its anti-noise properties. Cleaning is the first step in the process, using an alkaline cleaning agent for the removal of oil, grease and other surface contaminants prior to a rinse in tap water. Then comes an acid bath for more stringent cleaning followed by further rinsing and a passivation procedure designed to remove any remaining iron contaminants from the surface of the material.

The in-house Electrophoretic Paintline demonstrated on William Hughes’ latest video.

WOODWORKING MACHINERY Introducing the NEW ATACAM CNC Routers

Castle Pocket Routers from ATA Engineering

This new range of affordable CNC Routers from ATA Engineering offers the same high quality build that you come to expect from a company that has been supplying CNC’s for over 20 years, along with support and technical back up. Standard sizes: 8 x 4, 10 x 5, 3m x 2m (Special sizes available on request) Standard Features: HSD HSK Spindles, Rotary ATC, Location Pins, Tool Digitizer. 3 and 4 Axis machines in stock. Call for more information or a demonstration, or visit www.atacam.co.uk

TSM22 Pocket Router The most popular Pocket Router in the Castle range has been re-designed with a new lift up table top to provide the following features: • Easier and quicker access when replacing the router cutter, drill and other parts during routine servicing and repair. • Additional safety feature which automatically disconnects the electrical supply to the Bosch motors. This long established and widely used model continues to provide the quickest and strongest method for kitchen and bedroom carcass manufacture, retail display stands and other interior fitting applications.

Router Cutters A comprehensive range of routing cutters in HSS, Carbide tipped and solid carbide to suit a wide variety of applications in aerospace, woodworking, plastics and composites. Enquiries welcomed for special cutters. Extensive Stock ATA Engineering carry an extensive stock of cutters, tool holders and collets, all for next day delivery.

ATA Engineering Processes Ltd ATA House, Unit B, Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

Panel & Joinery Production - November / December 2019

Profile The Unico CNC Range From Protek: Milling Made Easys A new range of CNC-controlled milling machines designed around productivity and ease of use looks set to revolutionise the acts of cutting and milling for the manufacturing applications. Designed and manufactured by Italian specialist PROTEK CNC Technology, the equipment is capable of handling a full range of materials including plastics, wood, alloys, composites, MDF, Foamex/Corex, acrylics, foam, carpet and Dibond. This is a step change into the future, with the units featuring a clever multi-function toolchanging mechanism allowing users to cut substrates normally requiring multiple tools in one operation. The device completes all the required cuts with one tool then automatically changes the tooling and moves on the next. This automatic tool change functionality significantly reduces downtime and saves on machine preparation time. The rack and pinion angled cutting head mechanism improves accuracy and reduces noise, and the process is extremely clean; the vacuum system for removing swarf is very efficient, and works just as well for smaller tasks

thanks to a zoned vacuum bed. The single piece electrowelded structural steel chassis is designed for longevity and reliability, and is less susceptible to vibration for a high-end quality result. The PROTEK UNICO range is designed around ease of use, too, requiring no previous CNC machining experience from the operator and ensuring the training process is quick and simple. The software has been developed in-house and is very user friendly with a simple and intuitive graphical interface and the ability to import 2D drawings in various formats. Applications include sign making, 3D milling/prototyping, routing, cardboard finishing and packaging materials amongst many others. PROTEK equipment is supplied, installed and supported throughout the UK by Dennison Group, who have an established reputation for providing high quality service and support across the printing industry.

The vacuum system

Panel & Joinery Production - November / December 2019

E: karen.wentworth@dennisongroup.co.uk

Make your space the place

S M O O R TO T H G U BRO

LIFE

decofoil deco foil 3D Forming Veneers for kitchen, bedroom and bathroom furniture We offer an exciting range of contemporary and traditional styles, all with excellent board matches Find out more about our exciting range of contemporary LG Hausys PVC foil materials for kitchen, bedroom and bathroom.

Call: +44 (0)1376 518037

Decorative Surfaces Three New Finishes Launched Brand New Surfaces Added To The dp-limitless Collection By Decorative Panels Lamination October marked the launch of three new additional ranges to further enhance the stocked dp-limitless Collection available from Elland-based Decorative Panels Lamination – and alongside stunning products from Pfleiderer and REHAU are out of the ordinary surfaces from Voice Tec. Taking its offer to more than 90 laminates from Pfleiderer’s DST collection, the new additions to Decorative Panels dplimitless range include striking unicolours like Orange, Signal Red and Gentian Blue. Grain embossed unicolours have also been added along with embossed woodgrains like Milano Walnut, Ponderosa Pine, Bordeaux Oak, St Tropez Oak and Zebrano. Unlike traditional bonding techniques which use cold pressed Emulsion Adhesives, dp-lamination bonds the Laminate to the substrate using a high performance PUR adhesive. Not only does this give a higher glue line strength it offers the additional benefits of being waterproof with excellent low and high temperature performance. There is no doubt that Laminate bonded in this way has all round superior qualities when compared to other methods. The new Pfleiderer products are available in laminated board size of 3050 x 1300 x 15mm, or 18mm MDF, and 2440 x 1220mm dp-lite hollowcore in variety of thicknesses and quantities from just one board. Next to be launched in October at UK Construction Week was the REHAU Rauvisio Crystal range – a collection of ontrend surface materials that’s suitable for both furniture and interior wall cladding applications. Rauvisio Crystal combines the visual appeal of glass with the uncomplicated processing properties of an acrylic, and it comes with the added advantage of being 10 times more break resistant than real glass and half the weight. It’s also light, UV, scratch and impact resistant. REHAU’s Rauvisio Crystal décors

– Conglomerato Chiaro, Conglomerato Scuro, Marmo Toscana, Marmo Romano, Marmo Bianco, Marmo Nero and Ruggine – have all been added to the dp-limitless offer and all the designs are available in gloss and matt finishes. All are available laminated on 2800 x 1300 x 15mm MDF and in quantities as low as a single sheet. For a seamless look, matching edgebanding is available directly from REHAU. If you’re looking for a finish that’s very different, you’re sure to find inspiration in a new collection of Voice Tec acrylic textured surfaces that’s been added to the dp-limitless range under the Textured Surfaces category. Decorative Panels Lamination has launched six 1.4mm thick patterns that are supplied in a white matt finish for recoating with a universal 1mm backing sheet, if required. Launched by dplamination at the Surface & Materials Show in October, Voice Tec’s Loop, Cactus, Diamantino, Italian Plank, Juta and Giglio are deeply textured and very tactile. Taking inspiration from flowers and bark as well as metals, weaves and abstract patterns, these totally unique finishes are ideal for any custom project, and the surface can be used either uncoated or with an over lacquer. It can be painted or lacquered using acrylic, polyurethane or water-based finishes, it’s resistant to weather and UV rays and can be processed using normal woodworking tools and machinery. Recoatable edging is also available. If you need a design creating to your own specification, Voice Tec will even do that for you and Decorative Panels Lamination will apply it to 3050 x 1300 x 15mm MDF panels.

For more information on these three exciting additions, contact Decorative Panels Lamination: t: 01484 658341 www.decorativepanels.co.uk

Rehau Conglomerato Chiaro 1966L

Conglomerato Scuro 1967L

Panel & Joinery Production - November / December 2019

Marmo Nero 1971L

Decorative Surfaces

Marmo Toscana 1968L

Marmo Bianco 1970L

Marmo Romano 1969L

Ruggine 1977

Cactus Bianco Opaco

Giglio Bianco Opaco

Juta Bianco Opaco

Italian Plank & Atlier particulate

Italian Plank Bianco Opaco

Loop Biano Opaco

Ponderosa

St Tropez Oak

Orange

Signal Red

Gentian Blue

Bordeaux Oak Light

Voice Tech

Diamantino Bianca Opaco

Pfleiderer

Zebrano

Panel & Joinery Production - November / December 2019

Decorative Surfaces Chubb choose Benif Interior Film to ensure a perfect finish. Chubb is the largest publicly traded property insurance and casualty insurer in the world. As part of a recent refurbishment project at their London headquarters, Chubb selected Benif Interior Film exclusively supplied by leading surface material distributor David Clouting, as the preferred material to help transform a large number of flush office doors, architraves, splash backs and washroom paneling which had become dated. Specialist contractors WRAPT used a Benif Interior Film modern oak finish to carry out the work over seven floors of the building which is set in the heart of the financial district.

The results of the Chubb office refurbishment were not only visually pleasing but also extremely cost effective and practical thanks to the Benifâ&#x20AC;&#x2122;s low maintenance requirements, longevity of performance and importantly, none of the existing doors, splashbacks and paneling had to be scrapped. With over 400 Benif designs and finishes to choose from, walls, doors, paneling, skirting and architrave can be quickly transformed without the need for costly replacements. Benif Interior Film has CE and IMO Certification.

Manufactured by LG Hausys, Benif is a self-adhesive, architectural film that can be quickly and easily applied to almost any interior surface.

www.davidclouting.co.uk

BEFORE

AFTER

Panel & Joinery Production - November / December 2019

If you think you know Lathams, you may only know the half of it! From flexible plywood to coloured MDF, laminates to hardwoods, decking to veneers, reinforced panels to acrylic stone, mouldable substrates to engineered timber, charred cladding to flame retardant OSB, non-slip surfaces to acoustic door blanks and more, thereâ&#x20AC;&#x2122;s bound to be something at James Latham that you didnâ&#x20AC;&#x2122;t know about.

To find out more, visit lathamtimber.co.uk or email info@lathams.co.uk

Tooling Tabling a Motion for Success With its 25th anniversary on the horizon, Uxbridge based Inplas Plastic Fabrications Ltd has spent quarter of a century in the limelight. The ten-employee company designs, manufactures and fabricates projects for TV, the film industry, retail and Point of Sale, architecture, furniture and the interior design sector. The success of the company has seen it work on high profile films and TV shows from Star Wars and Harry Potter to Charlie & the Chocolate Factory, Thunderbirds, numerous James Bond and Marvel (MCU) films as well as producing work for TV programmes as diverse as Hell’s Kitchen, BBC News, CBeebies and more. This prestige extends far beyond the silver screen with a recent project being undertaken for renowned hand-crafted furniture designer and manufacturer Sebastian Blakeley. For those less familiar with high-end furniture design, Sebastian Blakeley is frequently commissioned to design and produce unique furniture for the rich and famous. One recent ‘celebrity commissioned’ project for a 3m long table, was designed and produced in conjunction with Inplas, a company that knew that when it was faced with a seemingly impossible design brief, cutting tools from ITC would be the tool in its armoury to deliver success. With a design brief for a table manufactured from acrylic and walnut wood with no fixings, screws or adhesives, the visionary designer couldn’t find a manufacturing partner to undertake the project – until a Google search led the Cornish designer to Inplas. A number of visits to West London to see Inplas and agree the profile shapes confirmed that the seemingly impossible feat of resting 200kg of Walnut on acrylic legs with no fixings was feasible. Sebastian spent nine months hand crafting the wood for the table and chairs while Inplas got straight on the phone to Sally Hunt at ITC. With more than £3500 of 80mm thick acrylic that needed machining as five separate parts, Inplas recognised the need for high-quality precision cutting tools capable of machining the 80mm thick material. Furthermore, with no fixings involved, the two stringer beams, the connecting stringer beam and the two legs needed a precision interference fit with a polished finish to fit together and remain sturdy – hence the call to Tamworth cutting tool experts ITC. Commenting upon the project, Inplas Director Mr Trevor Smith says: “The 3m long stringer beams slot into the top of the CNC machined legs with a 45degree bevel angle on the corner of the exposed beam. We knew we needed specialist cutting tools and technical support, so Sally at ITC was our first call. The first issue we had was the thickness of the acrylic. It meant we needed a cutting length of at least 80mm and we wanted a balanced tool for optimum surface finish and precision. Sally at ITC supplied a specially modified 2631-12 Series 2-fluted extra-long end mill with additional necking to provide us with 80mm cutting length plus an additional 5mm clearance.” With the cost of the acrylic and the impeccable finish and precision required, Inplas decided to conduct a trial run on an 80mm thick MDF template. “ITC supplied the special tool in just a couple of days and on our MDF trials, Sally was on hand to advise regarding the cutting parameters such as speeds, feeds and machining strategy. The trials went perfectly, and we then had the confidence to machine the acrylic components for the project. We use a number of cutting tool vendors including ITC for general tooling, but when it comes to special projects, ITC is always our first port of call. The quality of the cutting tools is exceptional, but equally important is the technical support. If we have a new project that throws-up challenges from a machining perspective, we will always seek out the advice of Sally from ITC. We have been using cutting tools from ITC for a number of years and the technical support has always yielded benefits for our business. Whether it is productivity gains, extended tool life, surface finishes or the requirement for special tools, ITC has always been there for us.”

The finished project machined with ITC cutting tools hours of machining with an additional 85 hours of hand polishing. Commenting upon this, Trevor continues: “We only needed a single 2631-12 Series 2-fluted extra-long end mill ITC tool for the entire 15 hours of machining and the performance was consistent throughout. This performance highlights what is possible when you combine high-end machine tools and high-quality cutting tools.” Inplas has recently invested in new software, diamond polishing equipment, laser cutting, etching and engraving machines and its MULTICAM 3000 CNC router with an 11-tool carousel. Referring to this, Trevor says: “We are always investing to keep abreast of technology and the MULTICAM machine enables us to work at spindle speeds of 24,000rpm with a high feed rate. The machine also incorporates ceramic spindle bearings to maximise thermal stability and dampen vibration when running at high-speed. The combination of the high-speed machine and the balanced ITC cutting tools has enabled us to increase our depth of cut from 1.8mm to 5mm, this has increased our productivity by up to 30% on a number of jobs. The machine has the speed and power capability to increase our productivity by 40%, so it is vital it is tooled correctly.” Inplas has been using ITC cutting tools for over 10 years and the partnership has flourished in that period. The company specifies ITC’s engraving tools, autocarving tools, single and triple flute and long series, ball nosed cutters and special tools. “Back in the day and prior to the introduction of ITC tools, we suffered considerable downtime from poor tool life. Our previous cutters would break frequently; this would have a detrimental effect on productivity, product quality and it also became a financial burden. The improved tool life from ITC was a revelation, as the tools last an eternity and breakages are very rare. This reduced our tooling costs by at least 30%. Down the years, ITC has continued to serve our company with distinction and when it comes to special projects and technical support, there isn’t a tooling company that comes close to ITC,” concludes Trevor.

The five acrylic components for the table required more than 15

Panel & Joinery Production - November / December 2019

ITC extended length tools used on table E: sales@itc-ltd.co.uk www.itc-ltd.co.uk

Fittings TeraBlack From Titus Is Much More Than A Colour Option With a close eye on emerging trends in the international furniture market, cabinet hardware expert Titus has developed TeraBlack versions of many of its most popular products, including its hugely successful T-type hinges. The new Tera (Titus Enhanced Resistance Application) versions feature an exceptionally attractive non-reflective dark grey finish, which not only retains its superlative appearance throughout its working life but also offers enhanced resistance to corrosion. “At Titus, we put a lot of effort into monitoring developments in the furniture sector and recently we’ve seen a growing demand for matte black cabinet hardware,” said Phil Beddoe General Manager at Titus UK. “We weren’t satisfied, however, with the idea of responding by simply offering another colour option – we wanted to offer a market leading solution that combined a visually appealing dark matt finish with genuine and valuable product benefits. And, drawing on our unique expertise in cabinet hardware development and manufacture, that’s exactly what we’ve done with the new TeraBlack versions of our products.”

TeraBlack T-type-inside out

TeraBlack T-type

Particularly well suited to applications in high-end premium kitchen furniture, Titus TeraBlack products fully meet the requirements of designers and consumers looking for unobtrusive yet attractive cabinet hardware. They have highly uniform surfaces and a velvet feel that complements their quality and enhances consumer appeal. The new TeraBlack products are Titus engineered solutions supported by tightly controlled, repeatable, efficient, flexible and scalable manufacturing processes that provide the performance, consistency and quality essential to manufacturers of high-end furniture.

t: 01977 682582 e: uk@titusplus.com www.titusplus.com/uk

Panel & Joinery Production - November / December 2019

Software Productivity Enhancing Entry Level Software Solutions From HOMAG Due to its continuous product development and innovation, HOMAG has established itself as the world leader in woodworking machinery. HOMAG’s large range of machining solutions caters for companies of all sizes, ensuring it has a solution for each individual workshop. Whilst historically the latest technological developments would be seen as out of reach for the smallest of manufacturers, HOMAG has invested heavily in its entry level technology. Along with the production technology, HOMAG has developed a range of entry level software which enhances and simplifies manufacturing. woodWOP software - easy and efficient CNC programming One of HOMAG’s most popular and well known software systems is woodWOP. Designed for CNC machine programming, the simplicity of the software makes the machine set-up and manufacturing processes quick and easy. Based around the operator’s experience, HOMAG has ensured that the user friendly system is uniform throughout

the HOMAG CNC range. Developed by in-house software experts, woodWOP software is capable of driving 3, 4 and 5-axis CNC machines. This is extremely beneficial for smaller companies where operators need to be trained and able to operate several different machines. The software consistency between the different models makes production easy and efficient. To make production set-up even faster, users can now program their own processing operations and save them within the woodWOP system. These can then be easily accessed and implemented for a speedy start. In order to get your woodWOP journey started, however, there are several component templates available to download for free via the internet. HOMAG’s software forum for woodWOP users Typically, CNC customers will visit HOMAG UK’s headquarters at Castle Donington to learn how to operate new machinery and woodWOP software. However after this initial training, HOMAG is also committed to providing ongoing support.

Easy and quick CNC manufacturing with HOMAG’s woodWOP software

Panel & Joinery Production - November / December 2019

Software The company has created a software forum which allows all woodWOP users to connect and discuss CNC production. Users from all areas of the furniture and woodworking industry can join and follow posts discussing the software. The forum is a great way for real life users to share their woodWOP tips and experiences. It is proving successful at not only answering manufacturers’ specific queries, but also inspiring new programming methods and uses. With an updated design that is mobile optimised, it is now extremely quick and easy to access the forum. Additionally, users can subscribe to forum topics so they need never worry about missing a thread reply. From design to production with woodCAD|CAM software HOMAG’s woodCAD|CAM is a versatile software solution which takes entry level users through the design process from initial concept to end product. Benefitting both the design and manufacturing departments, woodCAD|CAM simplifies the process of designing bespoke furniture components. This ingenious piece of software reduces the time it takes users to create realistic 3D drawings. These drawings can then be given to customers and architects to preview how the finished article will suit the required space. In addition to 3D drawings, the software also programs and compiles needed material lists to free the operator’s time for other important tasks. Additionally, woodCAD|CAM software can further save users time as it is able to calculate a bill of material costs and create quotations for the production of products. For increased efficiencies, users are able to choose additional modules to add to the woodCAD|CAM system. The modules allow design programmes to be automatically created by the system. The operator simply enters the required parameters into the software and it instantly

instructs the shop floor machinery for quick processing. Whether you are a bespoke furniture or a mass volume manufacturer, the woodCAD|CAM system will simplify processes to reduce both production time and costs. MagiCut – production optimising software HOMAG’s MagiCut software is an essential time and money saving tool for entry level manufacturers. The system guides the user to achieve the best yield from boards. The software is able to calculate the most efficient layout for nesting shapes from each board, whilst maintaining quality and production throughput. This feature allows the operator to take individual components and convert full board nests from the production office to the shop floor in seconds. For further efficiency, each component can be uniquely identified throughout the production process as all parts are labelled with part numbers. This makes it easier, eliminating errors within production when assembling components, as each part is clearly marked. Designed not only for CNC machinery, MagiCut can also be used to improve material utilisation and efficiency on beam saws within the workshop. As MagiCut is a modular software, it is easy for users to upgrade their version (adding required modules) at their own pace. This is ideal for smaller manufacturers who can simply build the system as their production needs dictate. Simon Brooks, managing director at HOMAG UK concludes: “Whilst we produce world leading machining technology, it is our outstanding software which really maximises the results produced by the machines. “When designing and developing software, it is always at the forefront of our minds that it must be easy to use, enhance productivity and be accessible to all manufacturers. “Our latest software packages allow even the smallest of entry level technology users the ability to produce first class results whilst saving on both time and production costs.

HOMAG’s woodCAD CAM software simplifies the design process with realistic 3D drawings

If you would like a demonstration on any of our software products please contact Adele Hunt on 01332 856424 or e-mail info-uk@homag.com

Panel & Joinery Production - November / December 2019

Software Paul Kettleborough (left) and James Graves

“Bespoke Kitchen, but not a Bespoke Price.” Full Kitchen Plans Completed in CABINET VISION in 20 Minutes Stage 1: Designing a 20-unit kitchen for a developer took a matter of minutes with CABINET VISION. Stage 2: The material was ordered at 4.55 p.m. the same day. Stage 3: The following day it was cut, drilled, edged, assembled and delivered by 12.30 p.m. “I did that simply to prove a point,” says Paul Kettleborough, Managing Director and Owner of Chris Sharp Cabinets Ltd. “I wanted to know just how quickly we could produce a kitchen. Although we had to machine multiple panels, our CNC machine was running at up to 80 metres a minute.” Employing a dozen people at their 15,000 square foot workshop and showroom in Lincolnshire, the company generally produces two kitchens a week for end-user consumers, with a number of others for property developers. Having recently invested in CABINET VISION software to complement their ALPHACAM package, they have capacity for designing and manufacturing around 20 a week. With a long-standing history of making both softwood and hardwood furniture, the company decided they needed to diversify, as cheap imports began to have an effect on business, and they moved into the purely bespoke kitchen market. Three years ago, Paul bought the company from

Chris Sharp, having worked there for over 20 years, and decided to concentrate just on kitchens. ALPHACAM had been the main software for furniture production for many years, and they continued to use it to design and manufacture the cabinetry components for their kitchens, which Paul admitted was not the optimum tool for casework assemblies. “It was taking a long time to program our 3-axis SCM Ergon machine tool. “We’d have a standard 600 mm base unit with the holes and toolpaths – but if a customer wanted a 550 mm unit, for example, I’d have to take it down by 50 mm. So in time, my ALPHACAM program had up to 150 different units. And if a kitchen contained 600, 500 and 400 mm units, I’d put them on a separate sheet and nest them through ALPHACAM, which was a long winded process when compared to CABINET VISION, because it’s not optimised for that type of work.” So, the natural progression was to invest in CABINET VISION for carcase work. Design Manager James Graves now receives customers’ orders as an ArtiCAD drawing from their external designer, and imports it into CABINET VISION. “As I’ve got a library of the 60 or so cabinets that we use regularly, I create the rooms by dragging and dropping the units into the project, and then editing them. The ArtiCAD file is often just a plan with dimensions on, usually in increments of 50, but with CABINET VISION’s parametric

Panel & Joinery Production - November / December 2019

Software capability and the parameters already set up, if I drop a 600 mm unit in and change it to 587 mm, all the relevant sizes and joins are all changed accordingly. Each one literally takes just seconds, and I can complete a full kitchen plan in around 20 minutes.” Being able to customise each unit is particularly valuable when he is working with their handle-less cabinets. “We prefer to have these carcase-pressed, so we can choose that the jointing technique is all dowelled rather than KD-fitted. However, I can have KD fittings if required and I have full control over their location and orientation. I can make all fittings on shelves up to a certain height face down, and the ones above it face up, so when the customer looks at it they don’t see where the fixing joints are.” CABINET VISION’s powerful communication tool with the CNC nesting machine, S2M (Screen-To-Machine), sends the NC code to the Ergon, which includes all the cutting and drilling instructions for the machine. ALPHACAM comes into play with the handle-less units, notching out the areas on the side of the panels for the profile to fit into, by sending machining code to their Homag Weeke CNC. Paul Kettleborough explains that operation can’t be performed on the Ergon. “As it’s notched out, we wouldn’t be able to put the panel through the linear movement on an edge bander…it just wouldn’t accept it. So we put it through as a rectangular piece which gets edge banded on one edge, and as it’s neatly notched out for the profile on the Homag, the edge band stays intact. ALPHACAM is also used to produce any curved, complex shape and hardwood doors. All these programs are done solely with it.”

And ALPHACAM also indirectly drives a Koch machine tool, by working in tandem with CABINET VISION. “As the CABINET VISION files go to Screen-To-Machine it stores the programs in ALPHACAM, along with the position of the holes that need to be drilled horizontally. All holes, both on the main faces of the panels and the edges, are designed and placed there by CABINET VISION. I pull up the nested program in ALPHACAM, and those on the face are drilled by the Ergon. But I can also get the same file in a different format, which gives the hole sequence for that individual panel, and the horizontal holes are drilled on the Koch.” Concluding, James Graves says another advantage of using CABINET VISION is that it means the company can give an accurate price for the job. “All materials and their price are in the system, so I can see at a glance how much each unit costs, and the price for the whole kitchen, right down to the screws. We can come in with a bottom-line figure to stay competitive. It’s a bespoke kitchen, but not a bespoke price.”

www.alphacam.com www.cabinetvision.com

Panel & Joinery Production - November / December 2019

Software Production Software Turns Designs into Reality for Daw Green Clients Royalty and Houses of Parliament Amongst High End Fitouts To say that Alan Ruddock, Works Director of Daw Green Contracts Ltd., is passionate about the woodworking industry, would be an understatement. He built his own workshop in a shed when he was 14, and had woodworking tools for Christmas as a child, taking his own full set of tools into his ‘O’ Level woodworking exam. And he fully admits that if you cut him, he’d bleed sawdust. “It was just born within me,” he says. “When I started working in the industry, I couldn’t believe I was getting paid to do something I loved so much.” And now, he’s equally as passionate about ALPHACAM software which programs the company’s 3-axis SCM Record 125 router. As well as currently using ALPHACAM on every

project the high-end shopfitting company works on, he is also expanding their use of CABINET VISION, which also drives the Record, through its Screen-To-Machine module. Manufacturing everything from counters to displays, stands, wall panelling, ceiling features, desks and storage units, anything with a curved shape goes through ALPHACAM. “We’ve also had CABINET VISION for a few years, but only recently started to really exploit it for carcases and pure cabinetry components.” Amongst their prestigious clients: the Trailfinders travel agency chain; Royalty, including Buckingham Palace, Holyrood Palace, Windsor Castle and Clarence House; and the Houses of Parliament.

Alan Ruddock, Works Director of Daw Green Contracts Ltd

Panel & Joinery Production - November / December 2019

Software Trailfinders travel agency chain

“Because we only work at the real top end of the market, precision and quality is paramount for us. Our biggest challenge is the complexity of what we do, and with time being one of the major drivers of the industry, we’re always looking to save time, while still ensuring consistently high quality, particularly in the process of converting the original drawings into NC code for the machine tool. This is where CABINET VISION is starting to play an increasingly important role.” When they first invested in CABINET VISION it was part of a period of considerable change for the company, and the software was underutilised. Now, while ALPHACAM will continue to program complex components, he says a lot of the case work is better suited to CABINET VISION. “The difference is, once we import our CAD drawings into ALPHACAM we have to break down the individual components and redraw them in ALPHCAM, then insert all the holes and fixings. But CABINET VISION produces the panels for us from the CAD drawings, and this will save us a tremendous amount of time, while reducing the risk of human error. Those drawings show the entire shop, including all the other trades – air conditioning, electrical, and flooring – and we extrapolate the cabinets, and treat them as individuals.” He says further time savings come from CABINET VISION’s parametric function. “Basically we make boxes – a counter with cupboards and drawers is simply a box with other boxes inside, and as we’ve already invested time upfront with building up libraries and construction methods, we simply drag and drop a cabinet into the job, and when we edit one length, it automatically changes the other dimensions.

“Sometimes those boxes have complex shaped components, and we’ll need ALPHACAM to program those toolpaths, but the majority are now put directly through CABINET VISION now.” As well as accuracy and time savings, he says CABINET VISION offers another huge benefit for the workshop: labelling. As well as the software producing drawings showing all the panels coming off the router, Label-IT enables their operator to clearly visualise the panels, print labels at the machine, and then simply place them on the parts as they’re nested out. The screen is updated automatically to show which parts and panels have been completed. Information on the labels includes the client name, job number, description, and edge banding details. “This is particularly important for the shopfloor to take a pallet of parts and know which ones need to go to the edge bander, or directly to the bench for assembly as a finished counter or desk. It’s like putting a jigsaw puzzle together with the box lid picture, as opposed to doing it without the lid.” In conclusion, Alan Ruddock says ALPHACAM has been valuable and integral to their processes for many years, and CABINET VISION is set to become of equal importance as they fully implement it. “The software turns designs into reality for our high-end customers. Without it, our production would simply stop.”

www.cabinetvision.com www.alphacam.com

Panel & Joinery Production - November / December 2019

Assembley Fixings An Incredibly Busy Year For Intelligent Fixings Ltd Intelligent Fixings has brought to market a connector solution for all types of woodworkers; from the home carpenter with a single hand-held router to the largest manufacturer with many lines of machines. The UK family-owned company who invented and manufacturer the PEANUT® Connecting System, Intelligent Fixings Limited, has had an incredibly busy year. These industry changing connectors have become very popular, particularly since being seen by a global audience at seven trade shows around the world this year, from various European cities to Las Vegas and India. Its recent stand at Sicam in Italy was continuously crowded each day with potential customers, clamouring for information of how to get hold of some Peanuts! As detailed in an article in the March/April edition of this magazine, the PEANUT® 1, a self-clamping, single component connector, for use with CNC machines and requires only one machining process, so makes quick and efficient work of furniture production. The PEANUT®2, is a self-clamping invisible connector, which can also house a screw inside if required, it is ideal for boring machines. The PEANUT®3 is the newest edition to the PEANUT® Connecting System family due early 2020. This is also an invisible single-

component connector, but is designed specifically for insertion machines, enabling high-speed production of furniture. Some of the largest machine manufacturers in Europe are considering how they can integrate the PEANUT®3 into their furniture production machines. Italian machine company Omal S.p.A. are currently working on an insertion machine that will bore the holes, then fire glue and the PEANUT®3 into panels. This will be available at the beginning of 2020. Coming by the end of the year, Intelligent Fixings has developed an ingenious router jig for use with hand-held routers to allow smaller carpentry workshops to get online with this phenomenal connecting system that has gone viral!

Panel & Joinery Production - November / December 2019

For more information, including lots of videos or to order PEANUT® Starter Packs to try the system for yourself, take a look at the IF website: www.intelligentfixings.com

Profile Project Underway At Inverness Wood Panel Plant Following £35m Investment Wood panel manufacturer Norbord is making significant progress at its Dalcross-based factory, following a further £35 million investment earlier this year. This second recent investment into the site, following a £110 million expansion programme last year, will realise the construction of a second wood debarker and flaker, heat plant and a dryer at the Morayhill mill, increasing the production capacity. Set for completion in 2021, the development will allow the mill to meet increased consumer demand for oriented strand board (OSB) across the UK and Europe.

are in prime position to deliver the best service to our customers, efficiently serving their needs across the UK and mainland Europe.” Last year, First Minister Nicola Sturgeon unveiled the new manufacturing line at the plant following the investment, which was supported by a £12 million development grant from Highlands and Islands Enterprise. HRH The Duke of York KG also recently visited the plant to help commemorate one year of production on the new line.

Alan McMeekin, Norbord Europe Managing Director, said: “The plan was always to invest further and we are pleased that the very successful start-up, as a result of great team work and market has enabled us to enhance facilities earlier than we originally anticipated. “This £35 million investment will increase capacity and deliver an increased level of support to our strategic customer base, further underlining Norbord’s status as the world’s number one OSB producer.” Stuart Hendry, General Manager at the Inverness factory added: “This investment showcases our commitment to our Inverness workforce and supply chain, as well as the significant growth potential there is within the European OSB industry.

T: 01786 812 921 www.norbord.co.uk

“I’m delighted to have been able to join the team at Inverness at such an exciting time as these developments ensure that Norbord

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Panel & Joinery Production - November / December 2019

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According to the latest CMA Benchmark Study, more woodworkers choose our products than any other software system. In fact, it’s not even close.

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We may have only a couple of days to do an impossible job, but ALPHACAM makes it possible. Jason Szukalski Director – Anarchy Ltd

Without CABINET VISION, we’d probably need three additional members of staff to achieve what we do. Ruth Lovelock Hetherington Newman

ALPHACAM & CABINET VISION THE WORLDâ&#x20AC;&#x2122;S #1 SOFTWARE SOLUTIONS FOR THE WOODWORKING INDUSTRY ALPHACAM & CABINET VISION offer the complete engineering solution for the woodworking industry. Our strength is in providing innovative solutions that can grow with your company. ALPHACAM provides unparalleled ease of use, process automation, and sophisticated toolpath generation, seamlessly integrating both 2D and multi-axis cutting strategies which can be applied to any type of component. CABINET VISION is capable of custom cabinet and room design, photo realistic rendering, material optimisation, bidding and costing, cutlists and bill of materials. Combined with the powerful Screen to Machine Center, it can automatically create machine ready G-Code for your CNC machinery.

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Power Tools Make Sawing Simple With Makita’s New Circular Saws Powered by Makita’s Twin 18V LXT battery technology, the DHS782ZJ and DHS783ZJU are both high-power cordless circular saws that can be used across a range of tasks. Makita’s DHS782ZJ and DHS783ZJU also utilise 190mm ‘EFFI-CUT’ saw blades – making them perfect for heavy-duty applications. For ease of operation, the DHS782ZJ and DHS783ZJU are compatible with a Makita guide rail, without the need for an adapter; so there is minimal set-up required – improving on-site efficiency. Both machines include Makita’s innovative Automatic Torque Drive Technology (ADT), which automatically adjusts the cutting speed of the machine according to the load conditions. The tools also include an overload warning lamp, to clearly inform the operator when the load is too high. These features mean that the tools can continue to operate at their optimum – preventing them from overloading and overheating and resulting in improved productivity on-site.

The inclusion of Makita’s Brushless Motor ensures that the DHS782ZJ and DHS783ZJU require minimal maintenance. Due to the omission of brushes within the motor, there is no friction – this means that no energy is lost through heat production, making the DHS782ZJ and DHS783ZJU incredibly efficient. This also extends the life cycle of the machines. The DHS783ZJU includes Makita’s Auto-Start Wireless System, which means that it can be easily connected to a compatible dust extractor via a Bluetooth link – optimising the dust extraction process. DHS782ZJ and DHS783ZJU both have a maximum cutting capacity at 0° of 62.5mm (at 45° it is 44.5mm and at 48° it is 42mm). These circular saws also have a net weight of 4.5kg5.1kg. Makita’s new circular saws are both body only machines and come in a Makpac Type 4 case for ease of transportation. www.makitauk.com

Panel & Joinery Production - November / December 2019

Woodwaste “Buying a wood waste heater makes both economic and environmental sense!” A Norfolk cabinet maker has purchased a wood waste heater from Wood Waste Technology to save money on heating and waste disposal costs. Valdivian Furniture in Norwich is a family run contract furniture company that offers companies the chance to buy high-quality contract furniture that is built from sustainable materials and manufactured in the UK. The management team at Valdivian Furniture started doing some research on wood waste heaters via the internet, but then were recommended by one of their business associates to speak to Wood Waste Technology. The company’s 12,000 sq ft workshop is situated on an old RAF base so, whilst there is ducting around the woodshop from an old hot water heating system, there was no actual heating installed, meaning the company had to rely on electric heaters to heat the workshop during the cold winter months, which led to some quite large heating bills. Director, Justin O’Donnell explains: “Once we worked out how much money we were spending on heating the factory and disposing of waste wood offcuts, investing in a wood waste heater seemed the best solution. We also realised

that, if we could get the wood waste heater to link into the original ducting system, we could heat the whole building efficiently by recycling the old ducting system to recycle our waste wood!” Valdivian Furniture’s decision to invest was made even easier once the business realised it could receive some grant money to help with the cost of the investment, and the business purchased a WT15 during winter 2018.

The WT15 woodwaste burner installed at Valdivian Furniture

Justin says: “We’re delighted with our purchase. We use a lot of MDF and hard woods in our manufacture, so it’s great to be able to recycle the offcuts of these instead of having to send them to landfill. We’re saving a fortune on waste disposal, and the heater keeps the workshop nice and warm in the winter. We’ve calculated that the wood waste heater will payback in less than 2 years, which is a fantastic return on investment. Buying a wood waste heater just makes both economic and environmental sense!“ Wood Waste Technology’s years of expertise in wood waste solutions have helped many companies reduce their waste disposal and heating costs. As well as offering site survey, design, manufacture, installation and on-going maintenance for new units, the company also services all types of wood waste heaters and supplies genuine spares up to 60% cheaper than other suppliers. In addition, Wood Waste Technology is 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. Wood Waste Technology: t: 01785 250400 www.woodwastetechnology.com www.grossuk.co.uk

Panel & Joinery Production - November / December 2019

Dust Extraction Filtermist Restructure Delivers ‘Clean Air’ Solutions Industrial air filtration specialist Filtermist has restructured all of its UK business operations to deliver an efficient single-source solution for customers requiring cleaner, safer and more productive work environments. Following numerous acquisitions over the past three years, Filtermist, which recently celebrated 50 years in business, has significantly expanded its product and service offering in dust extraction equipment, air filtration technology and industrial vacuum cleaning products. In order to streamline operations, and improve the ‘turnkey’ customer experience, eight existing businesses have now been merged into just two – Filtermist International Limited and Filtermist Systems Limited. From the company’s modern Headquarters in Telford, Filtermist International Limited will manage the manufacturing function; taking responsibility for production of the extensive portfolio of brands the company has now accumulated. In addition to the oil mist filters that the company is renowned for in the metalworking sector, Filtermist International will continue manufacturing established products that are more widely known in the woodworking industry, such as Ecogate extraction control equipment, Gallito spray booths, and the FastClip extraction ductwork system. Manufacturing will continue at the company’s production sites in Dewsbury, Northampton, Telford and Wetherby. With the creation of Filtermist Systems Limited, which has responsibility for sales to UK customers and management

of the company’s project work, the restructure also brings together a wealth of experience from within recently acquired companies including Dust Control Systems (DCS), Cades, Gallito and Ecogate, and merges this new reserve of know-how with the expertise Filtermist gained through the acquisition of Multi-Fan Systems, back in 2016. Although now operating under the umbrella of Filtermist Systems Limited, and no longer existing as individual trading entities, the people, products and services remain the same. The restructure has been designed to improve group synergies across all of the brands to deliver outstanding customer service. “This change is part of a strategic, long-term plan we’ve developed to help us grow globally,” explained Filtermist CEO, James Stansfield. “As well as increasing our product portfolio through the brands we have acquired, we have also increased our headcount by more than 300%, giving us a substantial nationwide presence. We wanted to capitalise on this by ensuring our customers can easily access the best knowledge and the best skills that suit their specific requirements. “There has been a major increase in demand for turnkey solutions, where customers can go to one organisation and have all of their requirements met to a high standard. This is exactly what we are doing with this approach – we are a single-source solutions provider for clean air in industrial workplaces.” t: 01952 290500 e: sales@fitermist.com

Filtermist’s purpose-built Headquarters building in Telford.

Panel & Joinery Production - November / December 2019

Suppliers Directory Reconditioned machinery specialist, Ferwood Group UK, offers a unique 10-step process that sees machines being stripped and rebuilt to the highest standard. With established machinery partnerships and a global sales network, you can experience its global machinery inventory on its website.

Combilift’s customised handling solutions ensure the safe, space saving and productive handling of long loads, pallets and oversized products. The wide range includes multidirectional forklifts and sideloaders, pedestrian pallet stackers and narrow aisle forklifts, with electric, diesel or LPG power options.

T: 0113 286 6689 E: sales.uk@ferwoodgroup.com www.ferwoodgroup.com Twitter: @FerwoodGroupUK

T: 00353 47 80500 M: 07870 976 758 www.combilift.com

Masterwood have been developing and building CNC machinery for over 50 years for all areas of manufacturing. Supplying machines for the bespoke workshop through to fully automated systems for the larger production companies. Our software range covers doors, windows, stairs, cabinets, and furniture, and 3D.

BA manufacture high quality decorative board panels and laminated sheet material for application in the kitchen, bedroom, furniture fit-out and interiors market worldwide. From industrial, architectural and domestic uses coupled with the widest choice, BA can design and manufacture solutions tailored specifically for your needs.

Masterwood GB Ltd T: +44 (0)1293 402700 www.masterwood.com

Blum specialises in the manufacture and distribution of furniture fittings. Their main product groups are lift, hinge and drawer systems for furniture, predominantly in kitchens. Manufacturers can combine Blum fittings with mechanical and electrical motion technologies to deliver enhanced user convenience. Blum UK T: 01908 285700 www.blum.com

T: 01302 890 555 www.byba.co.uk

A leading producer of machinery and systems since 1952, as well as service provider of the woodworking industry, SCM supply and install equipment that supports customers’ premise application and offer comprehensive demonstrations on the machinery. T: 0115 9770044 www.scmgroup.com

Manufacturers of all sizes and industries can benefit from our knowledge and innovation. We are able to help you achieve a high level of performance and quality with the HOMAG machines and lines.

Decorative Panels is privately owned and managed by the third generation of the founding family and are proud to be Europe’s leading supplier of decorative faced sheet materials, panel components and flat pack furniture.

T: 01332 856500 www.homag-uk.co.uk

Tel: 01484 658341 www.decorativepanels.co.uk

2020 provides software, services and content to help professional designers, retailers and manufacturers in the interior design and furniture industries bring their ideas to life, inspire innovation and streamline processes.

Palamatic provide vacuum lifting systems for top lifting and rotating wood products including doors, large panels, boards and staircases weighing up to 350kg. Systems provide a safe handling solution for operators to load and unload CNC’s, edge banders, saws, laminators and paint lines.

T: +49 541 3550 140 www.2020spaces.com

T: +44 (0) 1246 452054 E: sales@palamatic.com www.palamatic.com

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