Products

The Flintshire company based in Mold, North Wales, has been using the Hoffmann system for some 20yrs now. MD Gordon Cook is such an enthusiastic devotee that he originally helped Hoffmann UK MD, John Galvin, develop and fine tune the system. That system originally incorporated the Morsø guillotine alongside the Hoffmann MU2 to manufacture the perfect Face Frame joint every time.

Because all products end up being fully bespoke, the speed and accuracy of the Hoffmann system has been crucial to Truwood’s success. At the workshops in Mold, they operate two Morsø guillotines and still use the original Hoffmann MU2 router (now superseded by the greatly improved MU3).

The latest Guillotine is fitted with the Glide stop positioning system on the fence which gives Truwood instant and accurate setup times for different components. “It’s a superb system” says Gordon “which saves us significant time, is easy to use and 100% accurate every time.

The guillotines will cut out joints, including haunch joints, in hardwood components that have been pre-moulded to include an integral cock bead. The perimeter and internal cross section of the face frame fit together perfectly and once the Hoffmann key has been inserted into the routed keyway slot the frame will have permanent and accurate structural strength and accept the cabinet door or drawer front as a perfect fit”.

“By employing the Hoffmann system rather than using traditional jointing methods we can save up to 70% of time, eliminate any bad fitting joints and rejects and save all the time, space and cost of having to glue and clamp with the associated curing times. The system is incredibly user friendly and any one in the workshop can learn to use it in a very short time”.

The Hoffmann system is used worldwide in the construction of every type of joint in furniture making, joinery – kitchens, door frames and staircases – construction, framing and many others. After almost a quarter of a century in service, the MU2 was upgraded to suit todays and tomorrow’s industrial needs. – enter the new MU-3.

This thoroughly revised machine has been reworked, updated and adapted to suit the current and future needs of the industry, with many new additional features and is available in four versions: – MU-3 Basic version for the quick and precise routing of dovetail slots – MU-3 D Digital version, with electronic two-axis display for the adjustable routing depth as well as the positioning of the centre fence for the routed slot location. It is ideal for high precision work. – MU-3 P Pneumatic version for series production and high throughput. Pneumatic workpiece clamping and controlled router feed. The MU-3 P is operated by foot-pedal control. –MU-3 PD Pneumatic/Digital version – the top machine with the highest operating comfort for a wide range of requirements. Functional features are similar to MU-3 P with a digital twoaxis display for the adjustable routing depth as well as the positioning of the centre fence for the routed slot location.

The MU-3 and the MU-3 D have a workpiece thickness capacity of up to 140mm – in the versions MU-3 P and MU-3 PD this increases to 170mm. Infinitely adjustable routing depths up to 95mm and protection against breakthrough of the finished surface. Also new is the two-function hand lever for even faster machine cycles when routing smaller workpieces. The scale tapes in the table and now also in the rear fences assist the quick and precise positioning of the workpieces. All versions of the new MU-3 routing machine are equipped with a motor carriage which has vernier adjustment for the fine setting of the router cutter and hence the tension of the joint.

All of the machines and the full range of products and methods are detailed on the Hoffmann website. 01524 841500 info@hoffmann-uk.com www.hoffmann-uk.com

The characteristic grain of stone pine is combined with a wide range of colour décors at Ostermann – here you can see a selection of ABS edgings with stone pine décor

In the past, stone pine was traditionally used for the masts of large ships. In living rooms, its warm wood tone and distinctly contrasted grain add a Mediterranean touch. However, the processing of the soft wood with many resin inclusions is not easy. High-quality décorative surfaces help circumvent this problem and still achieve a natural look and feel. At Ostermann, carpenters/cabinet makers will find matching ABS edgings. The spectrum ranges from a naturally light stone pine décor to almost white tones to grey, brown and even black variants. For the entire range, type in the search item “#Highlights06” on the Ostermann website www. ostermann.eu.

The stone pine, also called Italian stone pine or, after its external shape, umbrella pine or parasol pine, is a subspecies of pine and its lightest representative. Due to its yellow tint, the wood appears warm and has a fine appeal. The grain clearly stands out against the light base tone, creating a contrasting play of colours that gives the elegant softwood a rustic mark. The Ostermann edging Fano Pine nature wooden structured is based on exactly these natural stone pine characteristics. And not just that: the “wooden structure” of the ABS edging also feels deceptively real.

Tip: To really bring out the natural stone pine décor of your board and edging, you can combine them with white furniture elements. The mix will create a nice but subtle contrast.

The chic pine grain is extremely versatile and by no means only suitable for lovers of Mediterranean interiors. Those who prefer clear lines in Scandinavian style will find in the ABS edging White Loft Pine wooden structured an even lighter décor with a white base that combines particularly well with pastel shades or maritime blue tones. If you want to apply a delicate blue directly on the edge, check out the ABS edging Jacobsen Pine blue wooden structured. It shows grey and cool blue veins that harmoniously complement each other. Perfect for Scandinavian design!

It’s getting darker - but by no means less homely. If it is well combined, dark wood makes for a stylish interior without being oppressive. The black edging Jacobsen Pine black wooden structured is softened by grey and brown lines. It thus combines the elegance of dark furniture with the comfort of natural wood décors. A slightly lighter variant with a finely structured base is the ABS edging Silver Pine wooden structured.

In addition to the Mediterranean stone pine, Ostermann also offers a décor variant “from overseas”. The ABS edging Ponderosa Pine wooden structured owes its name to the Pinus ponderosa, the North American counterpart of the Mediterranean stone pine. The edging shows a greyish-brown colouration with typical strong grain. Its rustic look perfectly matches brown ponderosa surfaces with annual rings and knotholes. In terms of colour, it combines well with for example warm and dark colours, such as a strong burgundy or a deep fir green. 01905 793550 www.ostermann.eu

Stoneleigh Timber Engineering Ltd is an independent manufacturer of roof trusses, floor joists, stairs and timber wall components based in Wiltshire.

The business manufactures its products from a 1940’s building that used to make spitfire components. Although the large building provides the business with lots of manufacturing space, it’s a cold, draughty building to work in during the winter.

When managing director, Adrian Hall took over the business five years ago, the building already contained a wood waste heater, but it was quite old and hadn’t been very well looked after. Adrian didn’t want to be without a wood waste heater, having become reliant on it to dispose of waste wood and generate free heating, so he decided the business needed to replace it with a newer model. As Wood Waste Technology had been out to service the original boiler, Adrian contacted Kurt Cockroft at Wood Waste Technology to purchase a replacement.

Adrian explains: “We generate 40 cubic metres of waste wood each year, so a wood waste heater is vital to our operation, especially as we aim to make our business as carbon neutral as possible. The WT15 burner ticks a lot of boxes for us, as it’s a good piece of kit at the right price – plus we’ve always found the team at Wood Waste Technology to be especially helpful. The new heater is fantastic, and performs even better than we hoped it would, giving us greater heat output than the original burner. We’re delighted we purchased a new one from Wood Waste Technology.”

MD of Wood Waste Technology, Kurt Cockroft says: “Wood waste heaters help businesses to save money on heating, reduce waste disposal costs and provide carbon neutral energy, which are all extremely important factors in today’s economic climate.”

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. 01785 250400 www.woodwastetechnology.com www.grossuk.co.uk

Pfau Joinery from Pfungstadt (near Darmstadt/Frankfurt am Main, Germany) worked on windows up to five metres high in the Grand Ducal Palace of Darmstadt. Every single window is examined, repaired, sanded and then painted so that it shines with renewed splendour

Philipp Stahl – skilled master painter and application engineer at Festool – shows how a meticulous refurbishment with the appropriate expertise can work true wonders in window restoration

The professional renovation of old windows is normally a complex endeavour for the craftspeople who are tasked with this. So it’s all the more important to give thought to the work well in advance and to make decisions based on sound knowledge and, ideally, on experience – not theoretical, but practical. Suppose you’re suddenly presented with a hundred-year-old window in need of restoration. A tricky task.

After all, a window that has “aged gracefully” has more than earned the right to be treated with care – not to mention the pretreatment and aftercare.

First and foremost, care means preserving as much as possible of the original material. The same applies, of course, to window constructions in typical old buildings in need of modernisation. Before a window renovation begins, it is essential to assess its current condition in advance.

This is easiest to do if the window is removed and placed on a suitable underlay so that it can be examined in close detail: Where are defects present? How badly is the paint peeling off? Is the window putty still intact? Can the frames still be used? How much of the frames can be preserved? How old is the wood and the coating? What kind of coating system is in place?

“Old coatings that are no longer intact and loose sections of wood need to be removed or, if necessary, rough-sanded for closer examination. Areas of failed adhesion or defective knotholes have to be removed first.

A particularly good way to get this done quickly and accurately is with the VECTURO OSC 18 cordless oscillator,” insists Philipp Stahl – skilled master painter and application engineer at Festool. “If you meet resistance when cutting, it’s advisable to ease off rather than use force because too much heat doesn’t do the old wood any good.

Going full speed ahead isn’t necessarily the best way to reach your goal. And that applies to oscillating as much as it does to the sanding work that comes after it. Of course, the aim of coarse sanding is to remove material, whereas fine sanding is all about the quality of the sanding finish. Yet there are subtle gradations in between.

Application pressure and speed control are excellent ways to adapt to the work,” says Stahl. In terms of technology and ergonomics, the VECTURO has everything you need for sawing, parting, scraping and cutting. Yet more importantly, however, it makes working in each of these applications every bit as easy as it is precise. And it starts with adding and changing attachments. In this regard, Festool trusts in the innovative tool holder StarlockMax.

Thanks to the intelligent quick-change system, the saw blades can be changed in under three seconds with no additional tools required: Simply release the clamping lever, eject the tool, position the new tool and click it into place.

The cordless oscillating tool with StarlockMax tool holder works as a system to provide 100% power transmission and maximum work progress. “This means that, when sawing, cutting or making ultra-precise plunge cuts, you can work even faster and more accurately. As an addition to the positioning accessories, we’ve developed a dust extraction device specifically for the cordless oscillator. Dust-free working is therefore possible in any situation without your view of the cut being restricted,” Stahl explains.

“Particularly practical: The battery pack is not an intrusive clip-on module, but is instead incorporated ergonomically in the handle. The brushless EC-TEC motor is impressively smoothrunning and its speed can be electronically adjusted with stepless control. Just like the gear unit, it is connected to the case by means of elastic damping elements, an arrangement that reduces vibrations to allow continuous use for up to eight hours.”

The next work step, where necessary, entails the meticulous removal of the window panes. “For the complete removal of the existing window putty, the cordless oscillator in conjunction with the SSB segment saw blade proves ideal,” Stahl advises.

“For the next work step – the removal of the old coating in the defective areas – we recommend the ROTEX RO 90 geared eccentric sander with the four functions of coarse and fine sanding, polishing and delta sanding.

“In the coarse setting, the gear drive is engaged, providing excellent material removal capacity and ensuring the fast and effective eradication of the old coating. For finer material removal, you set the RO 90 to fine.

Intact coatings can then be lightly sanded and roughened for subsequent coatings. For corners and rebates, the delta sanding pad can be fitted without any additional tools. In this way, the same tool can be used to sand or roughen the surface in every corner.

As window frames and casements have few flat surfaces and many edges, the sanding disc size and geometry and the material removal capacity of the RO 90 make it ideal for window restorations. “It’s right here that the RO 90 demonstrates its advantages over hand sanding or other types of sander. I know that sanding by hand is very popular at this point but, in the long run or with too many window frames, it isn’t particularly effective. Also, particular care is called for when sanding close to the edges on windows – whether by hand or with a sander.

“For precisely these kinds of applications, we recommend the use of our protectors. These protect against damage to the window pane. From experience, we craftspeople know that sanding damage to the glass is difficult to rectify afterwards.

The same applies to silicone joints, by the way, because once these are damaged, they almost always need to be completely replaced – and then it starts to get really expensive,” explains application engineer Stahl.

With the VECTURO OSC 18 cordless oscillator and the Starlock universal saw blade, unstable and rotten wood can be removed easily and sparingly.

Where necessary, old window panes should be removed. The VECTURO cordless oscillator in conjunction with the StarlockMax segment saw blade can also be used to remove the window putty completely

Application engineer Philipp Stahl recommends removing the old coating from the defective area using the ROTEX RO 90 geared eccentric sander set to “coarse” for heavy material removal

For fine sanding, simply set the RO 90 to “fine”. In addition, the sander can also be fitted with the delta pad quickly and without any additional tools, which enables craftspeople to sand narrow rebates and corners on the windows without any fuss

After old coatings and the defective material have been removed, it is advisable to inspect the condition of the repair area once more

Work the DRY FLEX smooth and make sure that the voids are completely filled in with no inclusions of air For the rebuilding of the window, the best way to start is by applying the DRY FIX UNI wood stabiliser from Repair Care with a soft brush. This increases the adhesive strength of the coating and the lifespan of the wood

After the DRY FLEX has sufficiently cured, any excess build-up can now be sanded level. Stahl recommends using the ROTEX RO 90 geared eccentric sander set to “coarse” The repair area is now filled with DRY FLEX compound and worked to a smooth finish with the putty knife – and the same applies to knotholes

After it has been sanded level, the worked area should be inspected: The most important factor is a flat surface on the transition between the wood and DRY FLEX wood repair compound

After the old coating and defective material have been removed, the condition of the repair areas is inspected again. “For the rebuilding of defective areas on windows, we’ve discovered that the system from Repair Care combined with our own system solutions delivers optimum results,” says Stahl.

Following the condition inspection, the DRY FIX® UNI wood stabiliser is applied to the defective areas with a soft brush. This strengthens the adhesion of the subsequent DRY FLEX® wood repair compound and thereby prolongs the life of the window. For application of the wood repair compound, the two components are mixed with a putty knife on a smooth surface.

The repair area can then be built up with DRY FLEX and worked to a smooth finish with the putty knife. Afterwards, the DRY FLEX wood repair compound is worked smooth across the defective area. It is essential to ensure that the voids are completely filled in with no inclusions of air. After the wood repair compound has cured, any excess build-up can now be sanded level.

“We recommend using the ROTEX RO 90 with the “coarse” setting. After sanding, the worked area should be inspected once again. Particular attention should be paid to the transition between the wood and DRY FLEX wood repair compound. It must produce a flat surface,” Stahl explains.

If windows need renovating and there is no power source nearby, the new SYS-PowerStation can quickly remedy this situation – for any kind of corded tool

Before the pane is fitted, the rebate must be primed and the DRY SEAL® window putty applied in the rebate with a cartridge gun. After this, the pane can be fitted and the second layer of the DRY SEAL window putty applied and smoothed to a water-repellent finish. The finishing touches involve the obligatory primer, undercoat and top coat or paint, which can be applied by brush or roller.

Modern and long-lasting window restorations are today subject to quite different stipulations, often also from a cultural heritage point of view: We preserve what needs to be preserved. It is crucial that all craftspeople approach the work with great care backed by professional experience.

A comprehensive and high-performance feature set for tools – stationary and mobile – helps craftspeople to carry out their work successfully and efficiently with utmost attention to detail. If windows need renovating and there is no power source nearby, the new SYS-PowerStation can quickly remedy this situation – for any kind of corded tool. www.festool.co.uk/knowledge/refurbishingold-doors-windows

Discussing the concept behind the two new machines that will supersede the CHD 270 and CHF 270 saw blade processing machines, Thomas says: “The CHD and CHF machines were based on a completely different construction to our new technology. The CHF side grinding machine was designed in 2000 and the CHD face and top grinding machine was designed in 2004-05 – we continually evolved these machines, but we reached the limit of what could be achieved with the existing construction and this was reflected in the machines at the end. Now, with new drives and software technology on a new foundation – we can add new features for our customers.” “We identified our development goals and we started to design the CS and CSF machines. So, the base, the housing and many other elements are completely different to before, but components that have proven their stability and accuracy over many years remain. We have designed both new machines with the same kinematics, housing, structure and polymer concrete base, so we can have a modular foundation. This makes it easier for us internally to streamline production and reduce lead times. It also makes the machine easier for the operator to handle as there is greater synergy between the CS and CSF machines. This creates uniformity with regard to loading, setting-up, the view and ergonomics and also the programming.” “This uniformity of technology was our target, adopting the same CNC, operating philosophy and also the latest drive technology. In the past, we used some servo motors with standard synchronous motors. Now, all motors, grinding spindles and axes are servo driven. We have seven motors on the CSF side grinder and eight on the CS face and top grinder, this includes linear CNC axes plus three CNC grinding spindles on the face/topper and two CNC grinding spindles on the side grinder. The servodriven grinding spindles provide a higher quality saw blade and we can now conduct different in-feed and cutting speed rates on each tooth.

Thomas Wenger presenting the two new machines to the press at the GrindingHub Show

This improves the surface quality of the cutting edge and brings more flexibility into the grinding process. Customers can now do whatever they wish.” Expanding on the servo motors, Thomas says: “Previously, standard motors had power and encoder cables, by evolving to the OCT (one cable technology) hyperface technology there is just one cable. This means there are fewer cables and switches, reduced power consumption and it is easier to change a single cable – something that reduces the future service costs for the customer.”

With any new concept, the experts at Vollmer aim to achieve four key delivery parameters for customers. These are increased flexibility, productivity, reliability and quality. Alluding to this, Thomas adds: “We met the goals by creating more stable processes in the new machines to provide better grinding results at the cutting edge. This was the fundamental reason for the new CNC control, motors, new features for oscillation, grinding and cutting speeds.”

“Looking at flexibility, one important thing is the integration of an additional axis, the R2 axis. This cross-axis at the saw carrier makes it possible to grind saws with a flange. Flexibility was previously limited because saws were manually set. Now, this is completely flexible as you can mix saws with different flange heights and even mix saws with and without flanges.” “Flange saws are very prominent in the wood industry and this will make it much more flexible to accept different types of saw blades. Previously, a customer would need 10-15 minutes to undertake this reset/change-up. Of course, some customers only undertake this saw type change once a day, but others repeat this a few times a day. It’s now done immediately, saving the customer time.” “We also have a new ‘centre brake’ feature. In the past, we would put the saw carrier on the machine and the saw blade would rotate on the flange. When processing coated or strobe saw blades, the carrier could leave scratches on the blade - so we created a carrier that rotates with the blade. In the end, there is a centre brake and clamping plate on the gullet that opens when we push the tooth to the next grinding position. If it is left closed, there will be scratches in the gullet area, if you open the clamp and push the next tooth - you need to hold the saw blade somewhere. This is why we use the rotating flange together with the centre brake, so we can open the clamp and push the tooth to the next position. This eliminates scratches at the centre or around the gullet area at the end of the process.”

The four pillars of flexibility, productivity, reliability and quality are often interwoven in the very DNA of machines – overlapping with each other. With the new CS and CSF machines, Vollmer has pushed the boundaries of software technology on all fronts. As Thomas states: “On the CHD machine, the software automatically recognised the end point of grinding, and that was it. We have evolved this to increase output

by up to 20%.”

“The new optional software takes the calculation work away from the operator. At present, the operator measures the grinding length on the face, top and chamfers. If the customer has trapezoid geometries, the straight part of the tip can be longer than the chamfer, which means some faces may need more grinding than others. The new software calculates where the customer starts and finishes the grinding pass - doing everything automatically. The customer no longer has to measure the difference between the flat surface and chamfer. The in-process cycle reduces noncutting times. For example, a tip with a 15mm surface area on the top face may only require 12mm of grinding on the chamfer. Our software automatically calculates this, so 3mm of ‘aircutting’ per tooth is eliminated.”

“This patented technology reduces production times. As an example, if you eliminate 3mm of air cutting on a 60 tooth saw blade, that is 180mm of air cutting. If you are grinding at 4mm/sec that is a saving of 45 seconds on a single blade.”

Emphasising the software evolution with the new CS machine, Thomas says: “In addition, the customer now has less data to input. There are just two main pages and this has always been our strength, but we have now simplified this furtherby integrating more measurement functionality. One page for the face and another for the top grinding - and the customer can activate particular features just by entering a one or a zero. Previously, the operator would measure each parameter and programming was a combination of having the saw blade on the left-hand and the programming screen on the right side. Vollmer only used to measure the hook angle, but now we also measure the clearance and bevel angle. Once the operator activates the feature, he no longer measures – just inputs basic data like tooth shape, number of teeth – and that is it. This eliminates much of the ‘pre-measuring process’ that can be two-tothree minutes per blade.” “Nowadays, we are increasingly calculating production costs per square metre, especially in saw service centres that have limited space. To free up capacity without building a new hall or facility, this new technology will reduce the production cost per square metre for customers, as the machines can produce more blades per day.” Software for the Sawmill

“One cost reduction per square metre contributor is the new pocket grinding feature. The guys in the sawmill industry are re-tipping saws and using the saw body 2, 3 or 4 times. These companies heat off the old tips and before brazing-on new tips, they manually regrind the pocket seat – a labour intensive job. We’ve added this is a fully automated process. So, if customers have taken the teeth off the saw body, it can be added to the stack and the pocket will be reground. In the high-end metal industry, pocket seat grinding has to be very precise. They may be milling or laser cutting the saw body to tolerances of +/-0.1 or 0.2mm, this is too high for manufacturers producing metal cutting saw blades – we can now automate to much higher precision levels.” “From a flexibility perspective, we also added a multi-surface program where the customer can input up to 30 lines. This allows the user to program three multi-surfaces, and the multisurfaces can be added to one facet or 90. We have also extended the diameter range to 860mm from 840mm.”

The evolution of software is also helping Vollmer to bridge the skills gap for its customers. As Thomas continues: “If you look at our VPulse or

Vgrind, we have a different user interface that is more well-known in 5-axis CNC grinding, but operators in that field are different to the sawmill industry. Our software explains everything with pictures, simplifying the process for operators with no background knowledge of saw blades. The two pages of content that an operator has to complete, are the same as before - but data input is significantly less. We always aim to increase automation, as our customers have a challenge with staff skill levels. Once upon a time, a saw shop would have many staff that could programme machines. Now, companies with 30 to 40 staff may only have one or two employees that can do this. This is a challenge we are undertaking to support our customers.”

Expanding upon customer support: “We have also incorporated Industry 4.0 technology with our software. Now, if an end-user has quality concerns with their saws, our customer can undertake a final inspection before dispatch. When a saw is complete, a measuring sequence can be applied to one tooth or all teeth on the blade. Our customer can select their measurement parameters. This process creates an XML file for quality and traceability to ensure each saw is 100% correct. Previously, saw manufacturers and service shops used manual measuring equipment and inspected every fifth or tenth saw blade for conformity - and then recorded the data. Now, a fully automated sequence can be integrated to save considerable time.”

With Thomas already emphasising how software is reducing data input requirements, ‘air-cutting’ times and manual measuring processes – the software cannot undertake such tasks without the supporting hardware. And here, Thomas acknowledges the ingenuity of the new measuring technology: “The stable production processes are derived from three measuring devices. First, we have the Renishaw MP250 measuring probe repeatable to 1µm. It has high-end 3D precision unnecessary on machine tools that only require single point contact. We use the Renishaw MP250, as its spherical system provides remarkable accuracy regardless of contact point direction and we need this as our face and top grinders, measure all around the tooth.” “The second system is the brand new measuring cube for the grinding wheels. It has an absolute fixed point and it gives absolute knowledge of the grinding wheel position. If there is a temperature fluctuation in the machine or spindle, this fixed point will compensate for all other parameters. It is very stable and fast. We can measure the grinding wheels whilst

the machine changes the saw blades. In the past, it was necessary to compensate the grinding wheel by measuring the tooth - this was unproductive time. Integrating this process increases grinding stability whilst reducing unproductive time.”

“This grinding wheel measurement is preprogrammable, but the manufacturer generally knows they need to recalibrate the wheel every 5 or 10 saw blades. The customer can define the measuring point, whether it be by the number of teeth or saw blades processed. Furthermore, the customer is not losing production time – a concern in the past. As an example, the wheel measuring process takes 20 to 25 seconds and it can be undertaken simultaneously with the saw blade changeover takes 25 to 30 seconds when using a double gripper system or roughly 50 seconds with the single gripper system. This effectively enables every saw blade to be measured to a precision level of roughly 2µm to guarantee process stability without losing production time.”

“We have now added our third measurement device to the new side grinder - our acoustic sensor that was on the CHD machine. This promotes very fast setups by combining technologies. With the Renishaw probe, we probe the raw and finished tooth, with the measuring cube we measure the grinding wheel and with the acoustic sensor, we are bringing everything together by checking the tooth with the wheel. The wheel senses the tooth and the acoustic sensor knows if we have the right infeed – making all three measuring devices work together.”

To achieve such precision demands a robust foundation as Thomas says: “Vollmer is the only manufacturer that uses a concrete polymer base. Very few competitors use a cast iron base; most build machines by constructing steel machined components. Our polymer concrete foundation makes our machines different from our competitors - it puts our quality and precision on a completely different level.”

From a productivity perspective, the automatic blade measuring calculation is saving 5-20% of in-cycle ‘air-cutting’, the new saw carrier and flange system eliminate 10-15 minute changeover times, manual measuring of 2-3 minutes per blade is eliminated and there is also the elimination of 25 seconds of non-productive wheel checking, new automated pocket grinding and much more.

Despite all this, Thomas adds: “The new machines are much faster than the older machines. The new base models are 2-4% faster than the old machines and this is credit to the new drive technology. The new drive technology enables us to locate and move the

Thomas Wenger with the new Vollmer CS860 machine at GrindingHub 2022

axes more dynamically. This has also enabled the automatic sensing of the grinding passes, which is reducing the air cutting. The machines are consuming upwards of 10% less energy, as the drives are more efficient than before. So, you have 10% less energy consumption with a 20%+ productivity improvement. By adding these factors together, we are reducing the ‘cost per saw’ for our customers and reducing their cost per square metre of production.”

Adding to the reduced energy consumption comments, Thomas is keen to allude to Vollmer’s sustainability credentials: “Vollmer always aims to drive down energy consumption costs for our customers. LED lighting has been used for some time, but we also incorporate technologies like automatic ‘end of shift’ switch off. Furthermore, no Vollmer machines use hydraulic systems. This eliminates hydraulic oil, the potential for spillage or contamination of the coolant and the wider workshop. This also removes the need for filter changes.” “What’s more, with Industry 4.0, we can undertake service from anywhere. We can update the machine components and software remotely. Our remote system can also email the customer when a batch of saws is complete, or if there is a disruption during a production cycle - emailing the customer their complete machine status. The active dashboard can be accessed via a mobile phone or tablet to provide a complete up-to-date status report.”

“I’ve been having weekly meetings with my worldwide sales colleagues for over 14 years. We collect all the sales engineers and customer requests - the list is huge. The base point for our development is the well-built technology from before. We analyse the technology and how we can improve the machines, but on the other side, there is a huge list of customer requests or needs. So, we have to understand the customer requests and integrate them with product development - and from that point, we identify what functions we need, and how they can be incorporated into the hardware and software.”

“For example, in the past, we had the electrical cabinet at the back of the machine - but if you have three machines alongside each other, there is only 900mm of space between the machines. The customers have fed this response back to us and on the new machines, we have moved the electrical cabinet to a side where customers would have the gangway.”

With regard to the changing requirements of the market in the face of the pandemic and rising energy costs, Thomas says: “The level of automation is the biggest factor. Machines need to make more and more by themselves. This is what we see in the market and it is one of the most important factors for us. "Our Industry 4.0 technology has provided comprehensive remote support during Covid and our energy efficiency and productivity enhancements are reducing the cost per square metre of production for our customers – we will always drive this forward.”

From an internal perspective, Thomas concludes: “We are now moving to a point where 90% of our new machines will be built upon a modular platform. In our ‘frozen zone’ from order to delivery, this time can now be much shorter because we can be more flexible in building up the machine. We can change from one machine to another and add the optional units more flexibly – this will reduce our lead times, costs and increase our production flow.” 0115 9491040 www.vollmer-group.com