Panel & Joinery Production

July/August 2018

WOODWORK KING MA ACHINER ACHINER RY RY Introducin ng the NEW W CNC Route ers This new range of afffor o dable CNC Routers fro om AT ATA TA Engineering offfeers the same high quality bbuild that you come to expect from a company that has been supplying CNC’’s fo for over 20 years,, along with support and technical back up.

Standard sizes: m 8 x 4,, 10 x 5,, 3m x 2m (Special sizes aavvailablee on request) Standard Features: HSD HSK Spindles,, Rotar R yA AT TC, Location Pins, To Digitizerr..

Tool 3 and 4 Axis machines in stock.

Call us today to arrra ange a Demonsstration!

Castle Pocket Routters from AT TA A Engineerinng

New Improved Model TSM22 Poccket Router Model TSM22,, the most popular p Pocket Router in tthe Castle range has been re--designed with a new lift uup table t to provide the fo top following fe features: • Easier and quickkeer accesss when replacing the routter cutterr,, drill and other parts durring routine servicing and repairr.. • Additional safety fe fe featurre which automatically discconnects the electrical supply to the Bosch motors. motors This long established and widely used model continnues to provide the quickest and strongest method fo for kitcchen and bedroom carcass man nufacture, retail displaayy staands and

Call us today to arrra an nge a demonstration.

AT A TA Engineering Prro TA rocesses Ltd AT A TA T A House, Unit B,, Boun ndary Way, Waayy,, Hemel Hem mpstead,, Herts,, HP2 7SSS t:: 01442 0 264411 e:: saless@ataeng.com www.ataeng.com

Contents

July/August Issue 2018 Published by:

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

EC Media Services 76 Victoria Avenue Westgate on Sea Kent CT8 8BH +44 (0)20 8366 3331 ernie@p-j-production.com www.p-j-production.com Ernie Hollister Ian Curtis, First Sight Graphics www.firstsightgraphics.com The Magazine Printing Company www.magprint.co.uk

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

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

The Kronodesign Global Collection comprises of over 220 decors, featuring 73 brand new designs for this year.

See p20-21 for more information

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

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

£18.50 £34.00 £38.00

© Copyright EC Media Services ISSN 2046-4134

CONTENTS 2............. Brooks Joinery Go For Felder Again 5............. Successful Weinig Appearance In Milan 6-7......... SCM Celebrates A Record Presence At Xylexpo 8 ............ Big Developments At Masterwood 10 ......... Getting Greater Value From Machines 12........... The Kündig Uniq S Has Proved A Significant Time Saver 14-15 ... Homag – Clean Cuts Increase Willerbys Productivity 16 ......... Makita’s Twin 18v Plunger Saw With AWS Technology 18.......... AXYZ Launches New Online CNCRoutershop Facility 20-21.... The Kronodesign Global Collection Succeeds In Style 22 ......... Interior Film Proves To Be A Winner At Olympic Village 26 ......... Three New CLIP Top BLUMOTION Hinges from Blum 31.......... Best-in-Class Results From Alphacam’s New Nesting Engine

36-37...

38 ........

40-41...

DCS Ensures Peak Performances At Seamers Growing With Dustraction Fields Are Greener With Ecogate

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

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Profile

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ased in Leiston, Suffolk, Brooks Joinery have worked with the highest calibre architects and designers over the past 30 years, delivering unmatched designs and attention to detail specialising in quality bespoke windows, doors, conservatories and kitchens. The company was started in 1981 by Colin Brooks where he mostly worked on fitting out and restoring narrow boats. Colin built his first boat at age 11 and his passion for woodworking has developed from there.

Colin first came across the FELDER GROUP at Woodmex whilst looking for a spindle moulder Colin commented “FELDER were the only ones, at that time, that had a spindle moulder that tilted the correct way and since then we have purchased a panel saw which has now been upgraded to a kappa 450, a dual 51 planer-thicknesser and upgraded our original spindle moulder to the profil 45 Z all from the FORMAT-4 range.” He added “All our machines now have the electrical “Power-Drive” controls giving us much greater accuracy and you can just look at

the scales to see where they are set.”

“When buying a machine we look for quality and versatility, I have always said when we buy a machine it needs to do everything we could possibly ever want to do and that is what we have got with the machines from FELDER. Our profil 45 is the first spindle moulder we have had with a

sliding table, which has been great even with our lack of room within the workshop, it’s helped with tenoning and angle tenoning.

Talking about his experience of FELDER, Colin said “we have not had any problems with FELDER, you feel that the Austrian work ethic is more conscientious than some of the other brands that we have previously purchased. The service has always been very good and very quick and over the 10-15 years we have never had a problem; they come back to us very quickly and resolve any issue. The team is very knowledgeable in all departments; I needed a part and it was quickly identified and with me a couple of days later.”

See how a range of machines from FELDER can benefit your workshop.

For further information: Tel: 01908 635 000 www.felder-group.co.uk YouTube at FELDER GROUP UK TV

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PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

Work ssimple p Work o digital

Maestro smartech | Maestro suite | Maestro datalink | Maestro xplore | eye-M Maestro Digital Systems is the result of a steady commitm ment and big investments in R&D. R&D A set of digital prod ducts and services that furtherr expands SCMâ&#x20AC;&#x2122;s woodworkingg knowledge-rich DN A. A dynamic system in con ntinuous development which h promises a simple an nd efficient management of the Digital Factory of the future.

SCM Group UK K Tel. +44 (0)115 Te 5 9770044 - scmgroupuk@scmgrou up.com - www.scmgroup.com

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egistration for the UK’s only woodworking machinery and materials exhibition, The W Exhibition, has now opened. To register your attendance, simply fill out the online form to gain free entry into the event: www.Wexhibition.co.uk/Register This year, the four-day exhibition will be held from the 30th September to 3rd October at the NEC, Birmingham and, following on from its success in 2016, will be co-located alongside the UK’s only dedicated furniture components show, Elements.

Featuring a brand new Education Zone and over 200 of the industry’s biggest names, The W Exhibition is set to be the biggest show to

date. Boasting a blueprint of over 11,000 sqm, visitors to the bi-annual event will be the first to see the latest product launches and innovations to enter the marketplace, whilst also being able to talk to the experts and experience live demonstrations first hand.

Visitors will also have full access to The W Exhibition’s sister show, Elements, which will showcase the very latest furniture trends, design novelties and prototypes for the furniture production and interior design markets.

To see the latest innovations for yourself, register for your free visitor badge today and join the industry this September at The W Exhibition.

For a full exhibitor list and to register for free please visit www.wexhibition.co.uk/exhibitors. For the latest exhibition news follow @W_Exhibition and @Elements_Expo on Twitter and like ‘The W Exhibition’ on Facebook.

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einig continues to press ahead with digitization. In a new step, the market leader in machines and systems for solid wood and panel processing has created the structures for maximum efficiency in dealing with the challenges ahead. The result is the new business unit “Automation & Digital Business”. CEO Wolfgang Pöschl: „With this deci-sion, we are strategically and organizationally aligning our company to the future, which will be characterized by a greater significance of project business and digitiza-tion.”

Consequently, the new company unit will be positioned in Weinig Concept GmbH & Co KG, which bundles Weinig’s engineering activities. Jochen Ganz, who is currently head of the product unit Service, was appointed managing director of the new business unit.

As part of Concept, he will act as the second head alongside Dr. Otto Leible, who will continue to head Engineering, his traditional field of responsibil-ity.

Jochen Ganz has been working at the 4

Weinig site in Tauberbischofsheim for some time in the context of digitization. For example, he was significantly involved in the development of the successful Weinig App Suite. Its current functionality also bears his hallmark. Initially, the head of the product unit Service will continue to work until his successor is settled, before moving to the top of the new business unit.

The establishment of the new business unit Automation & Digital Business is already the third major Weinig initiative in the Industry 4.0 area in a short time. Following the introduction of the W4.0 digital standard in Weinig’s own product world, the digital alli-ance MindSphere World was co-founded in January this year. Under the leadership of Siemens AG, the members of the organization work together on the cloud-based Sie-mens IoT operating system MindSphere. Access to the uniform platform helps Weinig to further develop W4.0 digital and optimize it for the benefit of its customers. Chief Sales and Marketing Officer Gregor Baumbusch: “The

PANEL & JOINERY PRODUCTION – MAY/JUNE 2018

Ready for the challenges of the future: the Weinig management board with Wolfgang Pöschl, Gregor Baumbusch and Gerald Schmidt together with the head of the new business unit Automation & Digital Business, Jochen Ganz and Dr. Otto Leible from Weinig Concept.

customer benefit will remain an outstanding and unique strength of Weinig on the market even in the age of digitiza-tion.”

For further information: Tel: 01235 557600 Email: sales@weinig.co.uk www.weinig.co.uk

Events

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ylexpo was a very successful event for the Weinig Group.

With a generally rather restrained visitor response in Milan, the market leader in machines and systems for solid wood and panel processing benefited from a high proportion of decision-makers and a high willingness to invest at its stand. On an area of more than 1,000 m2, the Weinig Group presented a total of 25 exhibits, all of which were presented live. Potential customers from over 60 countries were welcomed over the five days of the fair.

Klaus Mül-ler, Head of Marketing Communications and responsible for trade fairs at Weinig, was satisfied: “The atmosphere was very positive. We have scored particularly well as a full-service provider for the entire value chain and

underpinned our leading interna-tional position with our two strong brands Weinig and Holz-Her.” The focus of the trade fair presentation was the mega topic of digitization. The Weinig App Suite, the “digital window to the machine inventory”, met with great interest.

With the extended functionality, the current version of the app offers even more practical value. In the “Virtual Reality Corner” visitors to the stand had the opportunity to look inside a highperformance window production line using 3D glasses. Cutting-edge technology, integrated production as part of the Weinig Solid Work Flow and the trend-setting standard Weinig W4.0 digital merged into a fascinating future scenario at the presentation.

At the end of the trade fair, the company management gave a very positive summary of the event: “The Weinig Group returns from Milan with a convincing result.

Compared to 2016, we more than doubled order inflow in the Group”, said Chief Sales and Market-ing Officer Gregor Baumbusch.

Overall, 44 machines and systems were sold. After the excellent result at the HolzHandwerk in Nuremberg, Weinig impressively continued its series of extremely successful trade fair appearances this year.

For further information: Tel: 01235 557600 Email: sales@weinig.co.uk www.weinig.co.uk

Cutting-edge technology with high customer benefits: The wide range of products and services offered by the Weinig Group delighted the professional audience in Milan

PANEL & JOINERY PRODUCTION – MAY/JUNE 2018

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Events

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he new IoT system for Industry 4.0 presented at the show where as many as three XIA - Xylexpo Innovation Awards were granted to SCM. The highest number of awards ever won by the Italian group in the contest organised

by Acimall. First prize awarded to new, exclusive technology applied to edgebanding machines for joinery.

SCM celebrates an edition of Xylexpo featuring big figures, international attendance, innovative technologies and highly specialised training. The Italian Group, a long-standing, reliable partner for the entire woodworking industry, with a high-impact exhibition booth of over 3,000 square metres, has been one of the main attractions at the event held at the Milan Rho Exhibition Centre from 8 to 12 May. Among the many visitors, delegations of professionals from all over the world. A strong upward trend was recorded in orders, negotiations and contacts involving about 500 customers (half of them Italian, with a majority of Russian and French international customers), for an expected

turnover of at least 30 million euro. SCM confirmed once again its leading role in Italy and in Europe, not only for its widest international range of showcased industry-specific technological products, but also for its unique

The Morbidelli M200

ability to innovate and educate, opening the way to future scenarios in woodworking.

INNOVATION LEADERS R&D has always been a key asset for SCM - absorbing 7% of its turnover each year. The three awards received at XIA - Xylexpo Innovation Awards 2018 - the highest number of awards won by any one exhibitor at this edition of the show - are evidence of this commitment. Three very different technologies were awarded prestigious prizes - confirming SCM in its role as a standard-setter for the whole industry, from joinery workshops to the largest

industrial businesses.

The Minimax Me 35 combined edge rounder-trimmer unit

6

presented as a world première at Xylexpo. The award commission acknowledged, as stated

In the "Tooling machine" category, the winner was the Minimax Me 35 combined edge rounder-trimmer unit -

PANEL & JOINERY PRODUCTION – MAY/JUNE 2018

in the award's motivation, its ability to "combine edge rounding and trimming features in a single tool, allowing compactsized machines with minimized footprint to be developed". The applied technology makes of this edgebanding machine a must-have product for small-sized joinery businesses. For the "Finishing" section, the award went to SCM's carving spindle unit for unique three-dimensional finishing effects on panels. "With two routing units integrated into a sanding machine commented the awarding commission - a wide variety of embossed elements can be achieved". Maestro Smartech also made the "podium": among the most innovative solutions in the "Maestro Digital Systems" platform, it can supply technical assistance through remote connection and direct interaction between end users and expert technicians back at the manufacturer's headquarters, also through smart glasses". This solution also received enthusiastic appreciation from the public visiting SCM at the Xylexpo.

INCREASINGLY CUSTOMISED, INTEGRATED HIGH TECHNOLOGY. “Work simple. Work digital”: was the concept underlying all SCM communication at the exhibition, the leitmotif of all the

Events

technological and digital innovations that were introduced. Xylexpo visitors were very interested in the Maestro Digital Systems platform and, in particular, the innovative IoT solution of SCM Maestro connect which, in response to Industry 4.0 requirements, makes the

The technologies with the best outlook in terms of business opportunities in general are the Morbidelli boring equipment, the Olimpic and Stefani edgebanding

once again confirm our global leadership and, at the same time, to strengthen our partnerships in Italy and

The ACCORD 42FX machining centre

most of the potential of the "Internet of Things" concept to create a system for collecting and analysing data from SCM machines, able to increasingly monitor and optimise production processes, offering on the one hand full control of production performance by the customer and, on the other hand, a number of micro-services such as prompt, smart maintenance and optimised spare part management.

Xylexpo visitors were also able to experience the potential of the new IoT equippable machining centres, such as Accord 42 FX, which raised considerable interest among door, window and stairs manufacturers, and Morbidelli M220, the new, exclusive furniture milling and boring machining centre.

machines and Gabbiani cutting machines.

The latest additions to the product range were equally as successful: these included the Celaschi p40 squaring machine, the Balestrini range for solid wood machining and the new, integrated SCM range for surface treatment, which includes, in addition to finishing, pressing and sanding.

ADVANCED TRAINING. The Group's continuous, significant commitment to training, now consolidated by dozens of training initiatives both in Italy and abroad.

In the last few years alone, SCM has supported the upgrading of 11 vocational training centres, 4 of which in the past two years.

"We are very happy with this 26th edition of Xylexpo: it was an opportunity for us to

Europe", commented Luigi De Vito, SCM Division Director. "With the three XIA Xylexpo Innovation prizes that we were awarded, we proved that our manufacturing technology has not only set an acknowledged standard of excellence world-wide, but is also a primary innovation benchmark throughout the wood product supply chain. We are certain that our networking efforts at the show will further expand our market, which has continued to show double-digit growth figures also in the first few months of 2018". This 50th anniversary edition of Xylexpo was important for SCM - continued De Vito also because it was a chance for us to show hundreds of partners from all over the world around our new, exclusive headquarters of Superfici in Villasanta (Monza), with its Technology Center designed to apply SCM business strategies to strengthen the whole surface treatment sector".

An example, among many, of how the Group continues to respond to the needs of a market that is increasingly focussing on the quality of end products throughout the various machining phases.

For further information: Tel: 0115 977 0044 www.scmgroup-uk.com

The MAESTRO presentation PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

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Profile

+C<F"E/E=@17EDABF?AF,?BAE>*@@9 Background We have been producing woodworking machines for over fifty years, helping the furniture, casing, and joinery industry with our passion and professionalism.

The MASTERWOOD brand was born in 1990 out of the merger of two companies that wrote the history of our industry : MUTI, the leader in the production of oscillating chisel mortising machines, and ZANGHERI & BOSCHETTI, specialists in the production of automatic multi boring machines. Under the new banner the dedicated development and building of CNC machinery has flourished.

The synergy of experience and know-how brought in by each partner soon led MASTERWOOD to become one of the reference companies, producing numeric control machining centres for both panels and solid wood, exporting more than 80% of its production to all six continents of the world.

Following extensive negotiations Masterwood Spa are proud to announce a new partnership with the leading Chinese woodworking machine manufacturer Guangzhou KDT Machinery Co Ltd. An agreement has been reached that will bring finance into the Masterwood Group

allowing them to develop the brand further around the world.

The new agreement retains Giancarlo Muti as the company CEO, who explained that “Masterwood's DNA does not change, the future aim will remain to design and produce a high technological product leveraging on quality, customization and "made in Italy". Our first thought was to keep the employment and the Italian technology.

This operation gives us the opportunity to reinforce our international dimension and compete more efficiently with the major players around the world in this industry.

This partnership will greatly facilitate us, not only in the markets where we are present today but in the potentially huge market of South East Asia exploiting the synergy derived by the product range.”

Work has already started at the Rimini site where a large unit is being added to the current manufacturing works; this will give greater space for producing not just the standard CNC machines, but the growing demand on “Special” production machines, many of these are with automated feeds and are often designed and built to suit a customer’s bespoke

manufacturing requirements.

All the Masterwood range of machines will continue to be designed and built at the Italian factories, using the Masterwood engineering plant and parts from leading suppliers around the world like Beckhoff, Yaskawa, HSD, THK, and Schmalz.

The new partnership will also allow Masterwood to sell their products into the Chinese market with the help of KDT. Further big developments are already under way regarding new machines, with “specials” on the way for door frame and window production markets, plus the ongoing software developments that make Masterwood quite unique in the market by supplying not just the machines, but a full range of software solutions to cover panel and solid timber work. Developments continue with their own software house (Tecnos) and other leading software companies that are closely connected.

“We believe this is great news for everyone connected to Masterwood, our staff and customers around the world, as it will allow us to keep them busy and support all their manufacturing requirements now, and for the future” stated Matteo Muti (CFO at Masterwood Spa) A busy year for Masterwood is already underway following exhibitions in Lyon and Valencia during February along with an “open house” for all the Italian dealers, and ahead are the larger shows of HolzHandwerk (Nuremberg), Xylexpo (Milan) and look out for us at W18 at the NEC Birmingham September 30th – October 3rd.

For further information: Tel: 01293 402700 Email: office@masterwoodgb.co.uk www.masterwood.com

The official announcement regarding the new partnership with KDT Machinery

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PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

Brooks Joinery “When buying a machine we look for quality and versatility” Colin Brooks, Managing Director

“I have always said when we buy a machine it needs to do everything we could possibly ever want to do and that is what we have got with the machines from FELDER”

Watch the full testimonial on FELDER GROUP UK TV

Brooks Joinery’s Woodworking Machines profil 45 Z

dual 51

Spindle Moulder

Planer-Thicknesser

Over 150 Woodworking Machines to choose from! Call today and find the right Machine from the FELDER GROUP range!

For more information Tel. 01908 635 000

Unit 2, Sovereign Business Park, Joplin Court Crownhill, MK8 0JP, Milton Keynes

info@felder-group.com www.felder-group.com

Profile

(EAACD<F(>E?AE>F ?=;EF)>@7F,?:4CDEB Biesse Group's SOPHIA platform enables customers to access an extensive range of services to streamline and rationalise work management processes.

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iesseâ&#x20AC;&#x2122;s latest service platform, SOPHIA, launches in the UK this month and will offer users the possibility to improve the overall equipment efficiency (OEE) of their Biesse machines as well as offering a cloud based e-parts system. This is Biesseâ&#x20AC;&#x2122;s initial offering for Industry 4.0 and the IoT (Internet of Things), creating a digital infrastructure to underpin modern manufacturing.

The platform has the ability to collect and send real-time data on connected machines, giving customers the ability to analyse and optimise overall performance and productivity. Additionally there is functionality that will help in detecting potential malfunctions and assisting customers in maintenance operations, as well as ordering replacement parts, ultimately helping to improve the up-time of their machines.

The platform consists of two powerful areas: IoT â&#x20AC;&#x201C;SOPHIA and PARTS - SOPHIA, plus associated apps that provide customers with easy access to SOPHIAâ&#x20AC;&#x2122;S capabilities.

IoT - SOPHIA collects and sends real-time

data on connected machines, allowing customers to analyse and optimise overall performance and productivity. Additionally there is functionality that will help detect potential malfunctions and assist customers with maintenance operations, ultimately helping to improve the up-time of their machines.

-

-

Via an app, users can receive notifications regarding production status, efficiency, machine stoppages, production progress and maintenance.

Customers will have access to information, wherever they are, even if the machine is not in operation.

It will also be possible to facilitate maintenance operations by automatically compiling a shopping cart with spare parts considered to be necessary to carry out operations.

PARTS - SOPHIA is the intuitive and personalised tool for ordering Biesse spare parts.

Customers can create a spare parts cart with information on stock availability and pricing as well as monitor the progress of

orders and access a list of recommended spares. The portal also provides access to machine documentation, machine designs and bill of materials.

SOPHIA in the present and the future Worldwide, over the past five months, connected machines have registered a 60% growth in productivity and the platform has highlighted that Biesse has handled more than 2,000,000 events of various types. â&#x20AC;&#x153;The results registered over these first few months demonstrate how the services we offer our customers help increase the operating time of a machine and promote a proactive approach by reducing diagnostic times by 80%,â&#x20AC;? states Stefano Calestani, the Group's new Service Innovation Director. â&#x20AC;&#x153;It may have only been on the market a short while but SOPHIA is improving the quality of relations with customers who have benefited from using the tool. It is a quick and decisive support, which minimises waiting times previously required to deal with problems, and responds with effective and immediate solutions. This is the substantial opportunity SOPHIA offers our customers."

For further information: Tel: 01327 300366 www.biessegroup.com

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PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

CNC machines for nesting, furniture and door production

The AES group manufactures one of the most comprehensive ranges of flat bed CNC machines for nesting and shaping flat panels. From the entry level FLEXA which is ideal for sign makers, the NOVA for the busy bespoke manufacturer, the EXTREME for heavy duty nesting to the RAPTOR for the ultimate and efficient solution for heavy industry. All machines use Alphacam CAD/CAM software and have linear speeds starting from 70 m/min, future proofing the machines as tooling technology advances towards faster cutting speeds.

Did you know that there is a nesting tool that can cut at 50 m/min?

AES also manufactures a comprehensive range of pod and rail style machines for those looking to drill, shape and process components, along with the SIRIUS through feed drilling, grooving and routing machine. For the processing of internal and external doors, there is a machine with a horizontal routing head or there is even the 5 axis machine for added flexibility and endless possibilities.

J & C O’Meara Ltd Tel: 01704 893109 info@ukwoodworkingmachinery.co.uk www.ukwoodworkingmachinery.co.uk Unit 4, Falcon Place, Burscough, Lancashire L40 8RT

Case Study

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oig Furniture is a manufacturer of luxury bespoke furniture and cabinetry for the high-end residential market. The team of experienced cabinet makers produce beautifully crafted furniture using both traditional hand skills and modern CAD techniques from the Oxfordshire workshops. Backed by a support team of designers and project managers, Doig Furniture works collaboratively with award winning architects and interior designers on large scale projects, as well as working directly with private clients on smaller individual commissions.

Doig Furniture can provide everything from a single piece of furniture, a fitted room scheme or all the furniture elements required in large new build and renovation projects, all with the same attention to detail and exceptional craftsmanship.

Late in 2017, Doig Furniture purchased a Kündig Uniq S edge sander from Kündig agents, Markfield Woodworking Machinery (MWM) Ltd. Doig Furniture managing director, Duncan Doig, added: “Kündig as a brand is the go-to for high end sanding equipment. Everybody is using the sander

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and everyone is pleased with it.”

The Kündig Uniq S has proved a significant time saver. “It has enabled us to carry out processes we were previously doing by hand in a much quicker time frame,” says Duncan.

“It gives a consistent finish on every panel and is a much more efficient way of working. The machine is versatile, is double sided and tilts. We have some optional extras, and will probably add to them down the line.”

Among the options selected Duncan identifies the power feed as something which drew him towards Kündig: “The machine was designed to do the process we were looking to do.” He may also add the bobbin sander attachment in the future, the advantage of which is it allows work on curves to be carried out.

“We typically use the sander to edge sand boards or components in general.

The main reason we bought the machine was the edge sanding capabilities. Equally, the reverse of the machine is an open belt sander, so we use that for shaping as well.

The ability to shape is an added bonus, which you would expect from that kind of quality machine,” said Duncan.

When the need for the edge sander arose, it was natural for Duncan to go to MWM. “We have used MWM previously, having bought three or four machines from them, which we are very pleased with.

Most of the key machines we buy are the best we can source, and typically they come from Germany or Austria. Kündig is another one of the brands MWM supply.

“We typically deal with Gavin [Cooper].

We have been to his showroom and met him at exhibitions. All the service we have received has been excellent, and we have a good long standing relationship with MWM. “I have also seen Kündig sanders in other workshops and my understanding is that they are one of the leading brands in the industry. When you see cheaper

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

sanders, the build quality of Kündig really stands out.”

Gavin commented, “We are proud to be Kündig agents, which allows us to offer premium products to customers like Doig Furniture who are looking for the best in the market.”

The Kündig Uniq-S handles throughfeed sanding of small or large workpieces thanks to the integrated feed system, and can operate manually or with automatic feeding. With a table size of 1,180 mm x 325 mm, the sander comes with two guidepulleys for long workpieces. Pressure rollers hold the workpieces against the feed belt. The solid frame construction features heavy cast iron tables. The belt width is 150-200 mm, and the belt length is 2,000 mm. The working level is approximately 830 mm on the sanding side and 900 mm on the side for veneer sanding. The net weight is 490 kg and the floor space required is 1,150 mm x 800 mm.

When asked if he would recommend the sander and the service he has received, Duncan replied, “Yes, that's easy. On the whole it is a great machine, and the build quality is fantastic. It does exactly what we want it to do. Overall we are really pleased with the machine and the purchase. And when the time comes to update our current wide belt sander, we will definitely be looking for a Kündig as well.”

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

FIN N NI SHIN ING PERFECT SURFACE ES E ES. The minimum pressure mean ns s 100% quality on sanded components.

Viet Opera 5

BIESSE.COM

Case Study

%-,8( F3=E?DF3;ABF&D:>E?BE 6C==E>#. BF0>@9;:AC/CA.F+.F F0E>F3EDAFF With a turnover in excess of £150 million, Willerby is the UK’s largest manufacturer of holiday homes, lodges and bespoke buildings for the leisure industry, a position it has built over more than 70 years. Established in 1946, the company occupies a 90-acre site in Hull and stakes its reputation on dedication to detail and creating a quality product.

“

Our mantra in the business is SQP,” explains Mike Sharp, process manager at Willerby. He continues, “This is short for safety, quality and production. We are passionate about looking after our workforce and our customers.

Consequently, we are always searching for ways to improve the safety of our employees in our facility whilst increasing the quality and speed of our production.”

Comprehensive selection procedure “As you can imagine, over the years we’ve built up a tremendous knowledge and experience of many of the woodworking machinery companies out there and we know which the stars are and which to avoid.

“Despite this, we always approach a new investment from a clean sheet of paper. So, when it came to looking for some new beam saws to replace ageing models which were beyond economical repair, we carried out a thorough due diligence process.

that really impressed us. Not only could its beam saws meet our specification, but also John Shepherd, HOMAG’s area sales manager, was able to take us to a couple of UK installations to see both models of the saw – the HPP 400 and the HPL 500 – working in anger, so to speak, in real manufacturing environments.

“In addition to this, our previous experience of HOMAG, both machinery and service, gave us complete confidence that our significant investment would be in safe hands with them. On the shop floor level, our operators were also very keen to go the HOMAG route because of the positive experience they have of working on HOMAG machines over a period of more than thirty years.”

Getting the specification spot on “From the outset, we worked closely with

John Shepherd to create the exact specification we required for the saws.

John’s knowledge and experience was a vital element in ensuring we got the best saws for the tasks we needed them to perform.

“As a consequence of John’s advice we specified a couple of optional extras on the HPL 500 saw which have proved to be invaluable. We’ve already achieved a 14 per cent increase in capacity with the new saw and there is more to come as we integrate it fully into our work flow.

“The first optional feature is a rotation device for head cuts. This is a real laboursaving device for our operators and has significantly increased output whilst improving health and safety for our people.

They no longer have to perform the energy sapping manual turning of large panels;

“Our maintenance engineer, Sam Buckley, and I approached all the current saw manufacturers with a spec of what we wanted to see if they could satisfy our requirements. Later we met with most of the companies at the LIGNA show to discuss their machine solutions and following the show we drew up a short list.”

Fast, reliable woodworking machinery that delivers “At the end of the process, it was HOMAG

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Rotation device for headcuts – labour saving which significantly increases output

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

Case Study

this work is all done automatically by the saw and ultimately this gives us improved productivity across the board.

“The other option that has helped speed up production dramatically is the Power Concept. This is effectively an additional clamp at the back of the saw that can be moved independently; it enables us to size several panels with different cross cuts lengths by cutting them all together in one pass. This reduces the number of saw operations we have to make and considerably increases our throughput speeds.”

Installation and training – smooth, quick and efficient “The installation process was really impressive for the HPL 500. It’s a big machine and yet the HOMAG engineers working in conjunction with our own team were able to install and commission the machine in one week. I’ve certainly not experienced anything quite so professional before. Everything that was promised was delivered on time and we’re more than happy with the installation.

“The operators were trained on site by the HOMAG engineers and although CADmatic 5 was a brand new operating system for them, they were able to get to grips with it quickly. Combined with the MagiCut

optimiser software we use it is a very powerful system.”

Lasting benefits that we can rely on dayin, day-out “Our main key performance indicator (KPI) is safety and the HOMAG HPL 500 saw has really helped us improve the health and safety for our operators. They are no longer fatigued by having to turn big heavy boards; this ultimately means they are not only healthier, but also more productive throughout the day.

“The other two big KPIs for us, quality and reliability, have been delivered in spades with the HPL 500. On the quality front, our first production process is sizing of the large boards (2070 x 2800 mm); if we can get high quality cuts for this first process then we have the opportunity to maintain that quality throughout the remainder of the production process. Conversely, if we get a poor quality first process, then it is almost impossible for us to pull it back through subsequent processes.

“Reliability is vital for our production. The HPL 500 is so reliable we can plan production for the factory against it running perfectly every time we switch it on; we just don’t envisage any breakdowns or any problems with the saw at all.”

More to come from HOMAG “Looking ahead, we’ve also got two HOMAG HPP 400 beam saws on order; these are due for installation by the end of January 2018 and we expect exactly the same levels of performance from these as the HPL 500 delivers. One of the HPP 400s will predominantly cut work tops and the other will focus on cutting plywood parts “Overall, it is the tremendous communication we have with HOMAG that makes the working relationship so strong.

Whenever we speak to them we always get the answers we require; they keep us informed at all times, never leaving us in the dark.

“HOMAG always delivers on its promises.

Everything it does is first class, from John Shepherd the area manager to the engineers that install and commission the saw onsite; from the team in Germany we met when we went over to sign off the machine in the factory to the visits of UK sites to see the saws in action. There wasn’t anything that HOMAG did that wasn’t short of excellent,” concludes Mike Sharp.

If you would like more information or a demonstration of the latest HOMAG saws or other machinery and software please contact Adele Hunt at HOMAG UK: Tel: 01332 856424.

The HOMAG HPL 500 – a high quality and extremely reliable beam saw with excellent safety features

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

15

Whatâ&#x20AC;&#x2122;s New

,? CA? BF2*CDF F / F+>;B4=EBBF 2 0=;D<EF5?*F'@*F6CA4F865F2E:4D@=@<.

I

n 2017 Makita launched the in-demand DSP600 Twin 18v Brushless Plunge Saw. Now, the same model, but featuring a 36v motor and the Makita Auto-Start Wireless System (AWS) has landed.

AWS technology allows the new DSP601ZJU plunge saw to automatically connect to the compatible Makita dust extractor saving the effort of manually switching it on. A unique chip is supplied with the new plunge saw that enables the user to pair it up with the selected dust extractor. Once paired, the dust extractor will automatically start once the trigger on the saw is pulled.

This plunge saw is powered by two 18v Lithium-Ion batteries in series to supply energy to the 36v DC motor drive system.

It generates as much power as the AC mains machine that can drive the 165mm blade up to 6,300rpm, and provide a maximum cutting depth of 56mm with the vertical blade setting. The bevel range is 1° to +48° and the position of the cutting line is always the same regardless of the bevel angle. Splinter free cutting is achieved by engaging the depth stop which enables a 2mm preliminary groove to be cut before the full depth of cut is made.

As with the DSP600 the new DSP601 is equipped with a variable speed control dial, soft start and electric brake, and the innovative Automatic Torque Drive Technology (ADT), which automatically changes the cutting speed for optimum operation; effectively by sensing the load conditions on the blade and adjusting the power supply will maintain drive shaft speed.

Makita has also introduced a new 1m

16

Makita 1841 Twin 18V Brushless Plunge Saw now with AWS technology

Guide Rail which is sure to be a popular choice for use with this new plunge saw as well as other tools in the Makita woodworking range. It has a replaceable splinter guard, anti-slip strips on the underside and top running strips for a smooth glide. A new Guide Rail Bag is also now available which is designed to hold two guide rails, up to 1.5m in length, and a connector, all designed to provide ultimate protection for these high performance accessories.

The new DVC864LZ Twin 18v (36v) Brushless L-Class Dust Extractor is the first extractor to feature the new AWS technology. It has maximum sealed

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

suction power of 9.8kPa with the powerful 36v motor system producing a maximum air flow of 2.1mÂł/min. This is a dry type vacuum with HEPA filter that removes 99.0% of dust with Limit Value for occupational exposure >1.0mg/mÂł which means this extractor can be used for processes involving mica, china clay and gypsum. Up to 10 tools can be paired to the DVC864LZ via AWS at the same time.

For further information: www.makitauk.com Twitter @MakitaUK Facebook.com/makitauk google.com/+makitauk

What’s New

6C==C?7F%;<4EBF BEBF2EBACD<F2@F(;?>?DAEE 3@71@DEDABF,EEAF$D9;>?D:EF!E ;C>E7EDAB

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illiam Hughes has increased its component endurance testing capabilities with the acquisition of two new compression spring fatigue testing machines from Italian test equipment specialist Micro Studio.

With the investment in these new machines William Hughes can test fatigue on compression, tension and some torsion springs. There are also facilities for endurance testing of torsion bars and seat mats. This enables the company to guarantee its springs will meet customer requirements for a minimum number of cycles without breaking.

Springs in different applications are subject to different levels of usage – from modest usage in an automotive seat mechanism to much more demanding duties in typical aeronautical applications – and it can be important to have data for spring fatigue in these real world tasks.

“Fatigue is not just a body function for athletes,” says William Hughes technical director Emma Burgon. “Any component working in a dynamic application is prone to fatigue. We can – and do – model theoretical lifespan, and that’s useful information, but practice can differ from theory so the only way to guarantee lifespan is to test in real life.”

The new machines enable William Hughes to test large numbers of cycles on compression springs very quickly, establishing the minimum number of operations a component or assembly can achieve. “More and more customers are demanding within their production specification that a certain component must be able to achieve a given number of operations,” explains Burgon.

“If a main assembly has to meet, say, 20,000 cycles, then all of the components within that assembly must be able to meet that cycle requirement, under stress conditions, even if they’re not involved in all actions. Knowing that a particular spring will not fail during those 20,000 operations gives the customer confidence, and means he can in turn guarantee the safety of the whole assembly.”

With two machines, William Hughes can test up to 24 springs simultaneously, with the machines ensuring accurate strain tests of compression springs even at the highest speeds. The equipment gives William Hughes the capability to test springs up to a load of 30kN as standard, and the machines can be equipped to test springs up to a load of 40kN. The company can fatigue springs to specified numbers of cycles without breaking, or until the spring breaks. When a spring does finally

One of the new compression spring fatigue testing machines in use at William Hughes break, the machines record the number of cycles achieved at that point.

“It’s not unusual for us to be asked to produce springs that will offer spring lifecycles of tens of thousands or even tens of millions of operations without breaking,” says Burgon. “With these new machines, we can back up spring theory with real world testing, and offer the guarantees that give our customers the highest levels of confidence.”

For further details, contact: Tel: 01963 363377 Email: sales@wmhughes.co.uk www.wmhughes.co.uk

MA AT TER RIAL HAN HANDLING DLING SO OLUTIONS S FOR YOUR O INDU USTRY Combilift is th he leading supplie er of customised h handling solutions with guaranteed d improved storag ge capacity, safer product handling and incrreased productivitty.

+353 47 80500 combillift.com

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

17

Whatâ&#x20AC;&#x2122;s New

8 F ?;D:4EBF'E*F-D=CDE 3'3!@;AE>B4@1F)?:C=CA. A newly designed and expanded CNCRoutershop 24/7 online facility has been launched by AXYZ International, a leading supplier of routing, engraving, cutting and finishing machines. It is said to be much easier to navigate and locate products of choice and to work better with mobile devices for remote access.

K

ey benefits of the new facility are a Live Chat feature that enables visitors to the site to talk with application specialists whilst browsing the site to help in selecting the product/s of choice, as well as a Loyalty Points initiative for volume purchases that will provide attractive discounts on the products purchased. The facility is described by AXYZ International as the largest source of routing, engraving and cutting tools and accessories currently available, accommodating every conceivable requirement not only for AXYZ and Pacer machines supplied by AXYZ International but also any other machine regardless of type or country of origin.

The CNCRoutershop is clearly segmented to cover the widest range of routing, engraving and cutting tools, accessories, spare parts, consumables and software that can be used to process virtually any kind of material, including all kinds of natural and particle woods, foamed boards and laminates, stainless steel, aluminium and other non-ferrous metals.

The range of tools available includes highquality router bits, collets and cones that will accommodate various spindle types, oscillating and tangential knife blades and special-purpose tooling. Supplementing these is a range of technical support facilities that includes breakdown cover

18

and standard and bespoke training courses that can be conducted at either the customerâ&#x20AC;&#x2122;s own facility or at the AXYZ Training Centre inTelford.

The AXYZ CNCRoutershop is regularly updated with information downloads as well as providing access to a team of

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

application specialists to ensure the correct products are always selected for a specific application. The products displayed have been sourced from the leading UK and Continental Europe suppliers and regularly supplemented with new solutions as they become available.

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

24EF >@D@9EBC<DF(=@#?= 3@==E:AC@DF5;::EE9BF&DF5A.=E Itâ&#x20AC;&#x2122;s no surprise that when Kronospan, the worldâ&#x20AC;&#x2122;s leading manufacture of wood-based panels launched their 2018 Kronodesign Global Collection they score a resounding hit.

A

fter all, the Kronodesign team combined unrivalled insight and experience with extensive research to develop a globally unified range of decorative panels aimed at setting trends in the furniture and interior design sectors.

A range that in a few short months has already inspired designers, architects and interior specialists with its originality, innovation and creativity.

Ranging from authentic woodgrain designs

20

to stone and concrete effects with a variety of finishes from gloss and matt unicolors and stunning metallics, the 2018 Global Collection comprises over 220 decors, featuring 73 brand new for this year.

Success is the new trend A Harmony of Contrasts has been a theme for 2018, combining beautifully contrasting designs, colour shades, surfaces and textures across decorative boards and worktops. The concept of uniting intense,

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; MAY/JUNE 2018

pastel and monochrome colours; dark and light woodgrains; stone, marble, concrete and metals across a range of textures and finishes has had a very positively response.

The innovative Avant-garde combinations of acrylic gloss, mirror gloss and acrylic matt boards with the contrasting sheen of real brushed metallic boards has also made an impact, notably in the high-end residential and commercial areas.

And the new range of Melamine Faced

Decorative Surfaces

Boards, including authentic textured woodgrain reproductions, or unicolors in muted or vivid shades, are finding favour in furniture and interior design projects.

There has been some tremendous feedback on the 2018 Kronodesign Global Collection, not least for the way architects and designers can mix and match, complement and contrast with such creative freedom across the whole range, whatever the project, thanks to the integrated approach and inspirational design.

For further information: Tel: 01691 773361 Email: sales@kronospan.co.uk www.kronospan-express.com

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

21

Decorative Surfaces

&DAE>C@>F)C=7F0>@/EBF2@F+EF8 6CDDE>F8AF-=.71C:F C==?<E Get Living London manages thousands of residential apartments at the former athletes Olympic Village at Stratford, East London â&#x20AC;&#x201C;now converted to a range of modern apartments.

W

hen tenants move out, each apartment is given a thorough inspection and clean before new tenants can move in.

Time is of the essence as these apartments are extremely popular.

Specialist Contractor T6 were called in

by Get Living London to provide an economical solution to refurbish a kitchen in one of the apartments which had become in need of a makeover.

T6 recommended using Interior Film, an architectural, self-adhesive film manufactured by LG Hausys and supplied by surface material distributor David Clouting, to â&#x20AC;&#x2DC;wrapâ&#x20AC;&#x2122; around the existing surfaces rather than simply replace the kitchen units.

T6 were able to match the kitchenâ&#x20AC;&#x2122;s Teak finish to a similar one in the Interior Film range. The whole installation included â&#x20AC;&#x2DC;wrappingâ&#x20AC;&#x2122; the base unit doors, drawers, breakfast bar and skirting.

Sophie Verhoven from Get Living London

said â&#x20AC;&#x2DC;We had only one day to refurbish this kitchen and T6 delivered on this very tight schedule so the new tenants could move in the following day.â&#x20AC;&#x2122; Interior Film can be applied to almost any interior surface including: wood,

metals, plasterboard, plastics and even melamine.

Easy to clean and maintain, it is hardwearing and remains stable if exposed to heat, humidity or low temperatures. It has also passed robust bleach tests when used in hospital applications.

Available in a wide range of designs and finishes, Interior Film which has a CE and IMO classification can be specified with confidence for use on a wide range of applications.

The use of Interior Film on projects like this kitchen refurbishment demonstrates its unique versatility and illustrates why David Clouting are seeing an increasing demand from specialist contractors, shop fitters and interior designers who are looking for cost effective solutions and innovative finishes for their refurbishment projects.

For further information: www.davidclouting.co.uk

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PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; MAY/JUNE 2018

designs for every style bonded to the substrate of choice

With over 300 Abet Laminati decors and 250 Egger laminates, these collections include a wide variety of laminates, providing design solutions for even the most demanding of products. With dĂŠcor, unicolour, woodgrain, material and fantasy designs to select from, the lamination possibilities are endless. Available in quantities as little as just one board.

Contact us for more information.

Century House, Premier Way, Lowfields Business Park, Elland, West Yorkshire, HX5 9HF

T: +44 (0) 1484 658341 E: info@decorativepanels.co.uk www.decorativepanels.co.uk

Decorative Surfaces

5;1E>7?AAF F0E> @>7?D:EF-DF2>ED9F 13 “Supermatt” solid colours are the latest new additions to the company’s RENOLIT ALKOREN range of 3D thermo-formable films and they are all available ex-stock in the UK.

M

att surface finishes continue to increase in popularity and market trends are now diverging into different styles of matt textures. Therefore “Supermatt” has been developed to complement the popular and successful “Suedette Matt” emboss. “Supermatt” is an elegant, low friction, smooth and durable matt surface finish. In addition to providing a stunning and touchable surface, RENOLIT Cramlington’s “Supermatt” has tested as the best performing product when compared against other similar materials for key physical properties such as scratch, mar and stain resistance.

“Supermatt” is available in all of the most widely sold colours in the UK, offering a commercially attractive colour palette combined with a desirable high performing superior matt surface.

In addition 5 more supermatt colours are added to the 2018 Highlights collection, bringing the complete RENOLIT offer to 33 supermatt colours in total.

For further information: Tel: 01670 718244 Fax: 01670 590096 janette.rowland@renolit.com

Product Description

Item Number

Alpine Supermatt

S40.40.23.0077.

Cashmere Supermatt

S40.40.23.0012.

Denim Supermatt

S40.40.23.0040.

Dust Grey Supermatt

S40.40.23.0041.

Fjord Supermatt

S40.40.23.0038.

Graphite Supermatt

S40.40.23.0011.

Indigo Blue Supermatt

S40.40.23.0066.

Light Grey Supermatt

S40.40.23.0016.

Onyx Grey Supermatt

S40.40.23.0058.

Pearl Grey Supermatt

S40.40.23.0064.

Premium White Supermatt

S40.40.23.0010.

Stone Grey Supermatt

S40.40.23.0013.

White Grey Supermatt

S40.40.23.0065.

Modern Light Grey

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PANEL & JOINERY PRODUCTION – MAY/JUNE 2018

Decorative Surfaces

Modern Pearl Grey

Modern Premium White

Indigo Blue V2

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

25

Whatâ&#x20AC;&#x2122;s New

'E*F3 &0F2@1F+ ,-2&-'F F6C9EF8D<=E E>@ 0>@A>;BC@DF%CD<EF)@>F899E9F3@D/EDCED:E Blum extends its comprehensive range of hinges with the new CLIP top BLUMOTION 155° wide angle hinge; now available in the UK.

T

he new CLIP top BLUMOTION 155° wide angle hinge by Blum offers enhanced convenience without taking up more space, as the tried and tested softclose BLUMOTION has been integrated in the hinge arm. This means that now even cabinets with internal pull-outs, like the popular SPACE TOWER larder solution, can use the award winning CLIP top BLUMOTION technology. The use of all the existing storage in the unit, larder or wardrobe for example, means no more wasted space, and the wide angled opening access is much more convenient.

Boss and hinge arm cover caps are symmetrical so they can be used both left and right, making assembly impressively easy. The new wide angle hinge offers the usual advantages youâ&#x20AC;&#x2122;ve come to expect from Blum such as a boss drilling depth of just 11.5 mm and 3-dimensional adjustment.

There is also a deactivation ability for the Blumotion function should that be required.

Its wide opening angle and zero protrusion make it perfect for cabinets with inner pullouts, such as Space Tower.

CLIP top BLUMOTION 155° CGI of hinge with X-ray image

For further information: T: 01908 285700 www.blum.com

This image shows the CLIP top BLUMOTION CLIP top BLUMOTION 155° wide angle hinge with O-protrusion installed in the SPACETOWER

26

CLIP top BLUMOTION 155° wide angle hinge with O-protrusion Standard nickel plating

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

Simple is more efficient All Kundig Sanders are simple to operate. A machine that is simple to operate means it is easy to use.

If it is easy to use then it is user friendly. If it is user friendly anyone can use the machine correctly.

If used correctly not only are the best results achieved, but using the machine correctly means less mistakes. Less mistakes means better efficiency. Better efficiency means higher productivity. Higher productivity means higher profit and as we all know time is money.

Maybe this is why Kündig-sanders are beloved by those who work with them. Easy to use, they help reduce errors under stress. A Kündig always speaks the language of it’s user – whether it be English, German, French or even Russian.

Just contact Carl from Kündig UK He can tell you everything about those iconic Swiss Kündig sanders: T 0845 833 0565 E sales@kundig.co.uk Unit 4, Falcon Place, Burscough, Lancs L40 8RT

www.kundig.co.uk

the Sanding Experts

Profile

%-,8(F$ AED9BF5862$ F!?D<EF6CA4 &DD@/?AC/EF5@=;AC@DBF)@>F0?DE=F"C/C9CD< HOMAG has extended its SAWTEQ range with a host of innovative technologies for panel dividing. These products have been developed to automate batch size 1 production, increase operator accuracy, reduce production times and maximise machinery performance. From robotic technology to cloud-based software, HOMAG is consistently leading the field with its innovative technology.

SAWTEQ B-320 flexTec â&#x20AC;&#x201C; Mass scale production for batch-size 1 workpieces

optimised down to the last detail for cutting single panels. The addition of an automated labelling system for all workpieces guarantees 100 per cent accuracy throughout the ongoing production process.

As part of HOMAGâ&#x20AC;&#x2122;s range of innovative panel saws, the SAWTEQ B-320 flexTec has revolutionised batch size 1 production with its robotic workpiece handling technology. Batch size 1 production was previously seen as expensive and time consuming. The B-320, however, is highly flexible; it can easily handle the increasing production pressures of bespoke customer orders.

Designed with a smaller footprint, the B320 flexTec features only one saw body, one program fence, one machine table and one waste removal system. This allows for powerful production and higher throughput for even the smallest of workshops.

This innovative cutting cell is designed specifically for automatically processing single panels. It completely redefines the flow of parts, whether used as a standalone solution or interlinked in a production line.

With its unique design, the B-320 is

Capable of handling up to 1,500 parts per shift, manufacturers can produce high volumes of bespoke pieces. In addition to all this, the B-320 flexTec also features HOMAGâ&#x20AC;&#x2122;s latest energy saving systems to keep running costs low.

The B-320â&#x20AC;&#x2122;s robotic technology sets new standards in terms of reliability and quality, delivering virtually error-free production.

With unlimited recuts and flexible cutting patterns, the B-320 flexTec has reimagined the panel dividing process. The SAWTEQ B-320 flexTec can also be coupled with a STORETEQ storage system for a fully automated solution. This reduces bespoke production down to just a oneman operation and allows for staff to focus on other areas of production. intelliGuide â&#x20AC;&#x201C; Innovative machine assistance HOMAGâ&#x20AC;&#x2122;s intelliGuide is the first operator assistance system in the history of panel dividing technology. It enables saws to respond to the actions of the

SAWTEQ B-320 flexTec â&#x20AC;&#x201C; automated cutting cell for mass scale batch

28

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

Profile

HOMAG intelliGuide innovative machine assistance with LED guidance strip lights

machine operator in an intelligent manner.

The intelliGuide software packages range from basic, to advanced and then through to professional level. Each of the packages is made up of modules which can be used individually or combined to create an intelligent system that reacts interactively to the operator: • CADmatic 5 – This is the foundation package. It features new assistance graphics that guide the operator through the cutting process step by step via a 3D model on the monitor. This means there are virtually no errors and the operator is always in full control.

• LED strip lights - The addition of different coloured LED strip lights at the cutting line ensures efficiency and safety for the operator. The machine operator can immediately see when the saw is ready for new material (yellow lights), if a part

has been fully processed (green lights), or if waste parts are about to come off the saw (white/orange lights). Even when two strips are being cut to length simultaneously, the LED lights clearly show each work step for each strip, so no mistakes are made.

The intelliGuide module options provide compatible SAWTEQ models with completely intuitive machine operation that verifiably leads to significantly shorter throughput times, increased output and reduced errors. intelliDivide – Software as a Service

• intelliGuide advanced - The addition of a camera system allows the machine to deliver images from the front machine table for production monitoring. This means the saw can always see and know which part or strip the operator is inserting and if it’s in alignment.

Consequently, the machine is able to react and correct any operator errors.

• intelliGuide professional - The laser projection system displays selfexplanatory pictograms on the workpiece to provide the operator with clear handling instructions. Direction guidance and rotation arrows are projected onto the workpiece so no errors can be made.

To further improve panel dividing efficiencies, HOMAG has enabled manufacturers to link SAWTEQ products to intelliDivide high-performance software.

The intelliDivide software provides real time updates on production times, material usage and machinery status.

The software uses the collected data to provide the operator with suggestions on how to improve the efficiency of the production process. These suggestions can include the shortest machining time, how to reduce material wastage or the simplest handling routine perfectly adapted to production requirements.

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

29

Profile

materials can easily be damaged when they are transported from one machine to another. However, module45 eliminates such manual handling errors.

With a stationary saw carriage, the module45 tilting saw blade can be seamlessly adjusted to angles of 0 to 46 degrees. Furthermore, for changing saw blades, the table plate can be opened, allowing easy access to the saw carriage.

Additional benefits include dedicated systems for contact pressure and dust extraction, plus a fold-down right-angled fence for maximum flexibility at the front of the saw.

by up to 40 per cent. With much shorter work cycles and improved material flow, the Power Concept is a potent addition to any workshop. The system is an attractively priced high-tech solution with minimum space requirement that lowers the costs per cut.

module45 allows bevel cuts to be completed directly on a HOMAG beam saw and reduces the process to a one-man operation. The module45 unit also creates less waste and provides a higher quality finish thanks to less transport damage as the material remains on the one machine.

Now available for many HOMAG saws, module45 can be retrofitted to compatible HOMAG machinery. With a low initial investment cost and a whole host of benefits, module45 has an unbeatable cost-benefit ratio.

module45 – Innovation for the craft sector

HOMAG Finance – Affordable solutions for all

With its new module45 unit, HOMAG is moving towards an even more efficient future for cutting processes. This world’s first innovation allows all bevel cuts to be completed directly on HOMAG saws. It is fast, simple and the bevel angle is continuously adjustable.

SAWTEQ’s range of innovative technology is more accessible than ever before irrespective of the size of business. With solutions suitable for entry level businesses, right up to industrial sized manufacturers, there are production enhancements for all companies.

Additionally, HOMAG has a range of finance options available to enable any manufacturers to invest in this advanced technology to automate their facilities.

HOMAG intelliDivide Software – real time updates on production

Operators can access intelliDivide either through permanently installed software or directly from the tapio cloud. This means no additional hardware is necessary so users do not need to worry about maintenance or software updates. With an easy to view comparison of suggested optimisation results, intelliDivide provides a low cost introduction to optimisation.

Power Concept PRACTIVE – Increases saw output by up to 40 per cent HOMAG’s Power Concept PRACTIVE allows several workpiece strips with different cross cuts to be cut to length together. This concept is available for all HOMAG single saws without a lifting table and with a saw blade projection of up to 80mm.

At the heart of this technology is a clamp that can be moved separately. Using this clamp, several strips with different cross cuts can be cut to length together, considerably increasing material throughput.

With the ability to cut several workpieces to length at the same time, the Power Concept solution can increase saw output

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Whether you are looking at shop-fitting, joint work or interior fittings, bevel cuts are an integral part of everyday woodworking production. After cutting has been completed on a panel saw, bevel cuts are usually dealt with on a separate sliding table saw. This not only increases the cost of production and takes up more foot print, but also ties up operators as it increases the amount of manual handling needed.

Another costly disadvantage is that

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

If you would like to see a demonstration of any HOMAG machinery or receive further product information, please call Adele Hunt at HOMAG UK on: Tel: 01332 856424.

Software

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ests on the new nesting engine unveiled in Alphacam 2018 R2 show a 17 per cent improvement in material yield.

Using proprietary technology to deliver what Brand Manager Hector Henry says are “best-in-class geometry,” toolpath optimisation and part handling, the nesting engine also provides faster calculation times, along with improved feedback and graphics.

And he says the overall theme of the latest release is to save time and improve productivity. achieve the same result.”

Parametric Rules have now been migrated to C# and have an enhanced GUI and functionality, allowing for greater control, improved UX and simpler, more streamlined, logic statements, which he says has improved productivity and reliability.

The Face Milling Cycle has been enhanced, and is now part of Alphacam’s Core Functionality, creating intelligent toolpaths, allowing user to face (surface) mill irregular and multiple geometries. “This improves productivity, as the user doesn’t need to create several operations to

Productivity has also been improved through the new Order by Intersecting Geometry function which saves significant time when ordering the sequence of a complex job. It works by letting the user select a previously created geometry to define the order of geometries or toolpaths, based on those which intersect the selected geometry first.

The Parametric Sketcher is now considerably more powerful, thanks to an updated UI, meaning the window can be resized. “This provides greater visibility

over the Parameters and Actions list, which will be essential for managing complex projects.” There are also improvements to the Sketcher’s geometry creation tools, for creating fillets and chamfers as part of the Geometry creation tool set. This improves productivity as it does away with the need to calculate those points.

Enhancements to Alphacam’s dimensioning system provide greater clarity when printing and presenting information. User-defined suffixes for both the primary and alternate units – as well as a scale factor – mean that two separate values can now be displayed.

Importing CAD models has been updated through the support of SolidWorks configurations. “Alphacam now has a new interface for users to select which configuration of an assembly to import, without the need to ascertain that the last version saved in SolidWorks matches the one they want,” says Hector Henry.

For further information: Tel: 01189 756084 E-mail: stewart.bint@verosoftware.com Alphacam: www.alphacam.com

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

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Software

3?#CDEAF CBC@DF5=?B4EBF3;AACD<F CBA 6@> CD<F2C7EF#.F F6EE BF?F E?>F A kitchen company says investing in Cabinet Vision has slashed the working time needed to produce its cut lists by around 20 weeks a year.

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It wasnâ&#x20AC;&#x2122;t until we sat down and looked at how the time added up, that we realised just how much we were saving,â&#x20AC;? says Baker and Baker designer Sam Thornley. Before Cabinet Vision the Essex-based company designed everything in a 2D CAD package, with elevations being produced once they had won the contract. â&#x20AC;&#x153;The Workshop Manager would use those drawings to create the cut lists. Itâ&#x20AC;&#x2122;d take him at least three days a week to work out every component size and put it into an Excel document, which was prone to error.â&#x20AC;?

However, saving that incredible amount of time on cut lists was an added bonus.

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Their investment in Cabinet Vision was actually prompted by a need to speed up their initial drawings. â&#x20AC;&#x153;Using Cabinet Vision means we can also create the elevations and rendering now in the same amount of time.â&#x20AC;?

And how they produce their renderings is set to change, thanks to a major update in Cabinet Vision Version 11, which they have recently installed. The latest release of the software contains a powerful new photo rendering engine geared specifically towards the design market. It provides a massive enhancement on the rendering capabilities in previous versions, and now gives Sam Thornley almost photo-like images which can be used as a sales tool.

PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

He says good renders are a vital part of converting a quote into a job. â&#x20AC;&#x153;Some customers canâ&#x20AC;&#x2122;t visualise the finished kitchen from a 2D plan drawing. Itâ&#x20AC;&#x2122;s so important to show something thatâ&#x20AC;&#x2122;s visually impressive. Iâ&#x20AC;&#x2122;d say a render wins us around 20 per cent more work.â&#x20AC;? Previously, they were producing renders in a different computer program, and are now undertaking full training on how to use Cabinet Visionâ&#x20AC;&#x2122;s new high-end photo rendering capabilities. â&#x20AC;&#x153;It means we can manage every step of the design process without having to transfer data between systems.â&#x20AC;?

The combination of creating cut lists in Cabinet Vision along with its design capabilities means the software is an

Software

integral part of his working day. “It’s as important a tool as we’ve got anywhere in the business...if not more so.”

Producing around 15 large kitchens a year, along with two or three smaller ones, mostly delivered within a 15 mile radius of their showroom which is in neighbouring Suffolk, means that they prefer to manufacture everything in the traditional way, rather than use CNC machines.

The process begins when Graham Baker, who jointly owns the company with his wife Marie, takes laser measurements of the customer’s room, plotting the points. Sam Thornley then draws the room, and builds the kitchen design, producing renders and quotes. “I work through everything, ensuring we have the correct materials, and that the corner mechanisms and doors will fit and work. As long as I put everything in the right place, Cabinet Vision does the rest.”

When the company was established around 20 years ago it predominantly focused on joinery, mainly manufacturing windows and doors, but progressed into high end kitchens, along with some bedroom, home office, study and library work, and now operates with 12 employees.

“Every component we make goes through Cabinet Vision. The reason we invested in it was to speed up the design process, and

to get the cutting lists directly out of the drawings instead of having the Workshop Manager hand writing them for two or three days a week.

“I design everything in Cabinet Vision, and once the cut lists have been produced, I’ll print a door cutting list, panel stock cutting list and drawer cutting list along with the technical drawings and a plan drawing, and take it to the wood machinist on the shop floor.” Using an Altendorf F45 panel saw and spindle moulder, all the cabinetry is machined and spindled to the correct sizes ready for assembly.

He says their biggest challenge is that nothing is standard; everything is bespoke.

Up to around 1,000 individual components go into their average kitchen. All carcass material is oak veneered MDF moisture resistant board, and solid lippings generally comprise tulip wood, oak or maple.

“Many kitchen companies have a drag and drop catalogue of cupboards they use, but with us everything is made to measure. So the fact that Cabinet Vision lets us select a cupboard and readily edit its height, depth and width, is so important. There’s nothing it can’t do in terms of creating our bespoke cabinet quickly and accurately every time.”

Sam Thornley concludes: “In the past, we had to produce the elevations and cut lists after the customer gave us the order. Now, with Cabinet Vision, the cut lists are produced with the original drawings, so we’ve already got them, and can start work as soon as we win the contract.”

For further information: Baker and Baker: http://www.bakerandbaker.co.uk Cabinet Vision: www.cabinetvision.com

PANEL & JOINERY PRODUCTION – MAY/JUNE 2018

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Profile

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or almost 70 years, the SANDTEQ brand has established itself at the pinnacle of high performance wide-belt sanding machines and innovative surface finishing solutions. Rebranded, the newly named ‘HOMAG’ wide-belt sander portfolio includes a wide range of models starting at entry level, specifically designed for small workshops, through to high-throughput machines for advanced manufacturing plants.

Simon Brooks, sales and marketing director at HOMAG explains, “HOMAG’s impressive portfolio includes models for calibrating and finish sanding as well as lacquer sanding. All the models boast German technology and engineering – world renowned for its quality, reliability and innovation.”

The compact entry level SANDTEQ W100 series The HOMAG sanding range starts with the compact SANDTEQ W-100 series.

These entry-level wide-belt sanders are equipped with up to two sanding heads.

This ensures perfect sanding results from calibrating and fine sanding on solid wood and veneered panels to easy lacquer sanding. The SANDTEQ W-100 series offers a working width of up to 1100mm with a sanding belt length of 1900mm.

Moving up – the SANDTEQ W-200 series The next in the range is the versatile SANDTEQ W-200 series for sanding solid wood to veneer and intermediate sealer sanding. It uses either HOMAG’s acp® (air cushion sanding pad) or eps® (electronic pressure system) intelligent pressure pad systems.

The acp® system senses incoming work pieces and activates the rise and fall pad system to give an anti-dubbing facility at both leading and trailing edges of the part.

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It is ideal for use on solid wood or thicker veneers.

The eps® technology ensures the optimum sanding pressure on all areas of a work piece, guaranteeing a perfect sanding result. The eps® works with a segment width of 50mm (optional 25mm) and is suitable for applications such as solid wood, veneer and lacquer sanding.

The individual segments ‘float’ on the part surface with a constant pressure to protect veneered or lacquered surfaces within a tolerance range of 2mm. It is also possible to add or subtract edge segments to modify edge pressure.

The SANDTEQ W-300 series – offering a wide choice of heads The SANDTEQ W-300 series consists of twelve models, each with customisable head combinations to provide specific solutions for each customer. The C head is for solid wood, veneer or lacquer sanding, whilst the R head is designed for calibrating.

The Q head has been specifically designed for veneer sanding, removing tape and for sanding of long crossveneered parts. It is also a good intermediate lacquer sander and can be used to prepare for high gloss finishes.

If you are looking for high quality sanding across different surfaces, the H head is ideal. It is also designed for lacquer sanding with very fine grits and solid wood sanding, especially frame parts.

For fine sanding of wood and wood materials, HOMAG has developed the E head. This is also good for lacquered surfaces and improving the sanding results of pre-sanded processes.

Perfect sanding is about applying the right pressure at the right time and in the right place. On the SANDTEQ W-300 series, the eps® ensures the optimum sanding pressure on all areas of a work

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

Customisable sanding solutions with the SANDTEQ W-300 series

piece, guaranteeing a perfect sanding result.

The SANDTEQ W-700 and W-900 series – heavy duty production These heavier models are available in both 1350mm and 1650mm working widths and can be equipped with any head type in any order to suit special applications and higher production speeds. Up to five heads are possible including brush heads for textured surfaces.

Perfect preparation for the ultimate finish Simon Brooks, sales and marketing director at HOMAG concludes, “At HOMAG, we can offer a huge choice of machines and innovative options to provide the best possible sanding results tailored to customers’ individual needs. The HOMAG Finance team is able to offer flexible finance solutions on any of the HOMAG range, making wide-belt sanding more affordable than ever before.”

If you would like more information or a demonstration of any of the HOMAG sanding range, please contact Adele Hunt at HOMAG on: Tel: 01332 856424

THE WORLD’S #1 WOODWORKING CAM SOFTWARE Alphacam Router is an easy-to-use CAD/CAM solution for manufacturers wanting fast, efficient toolpaths and the generation of reliable, machine ready CNC code.

www.alphacam.com

Dust Extraction

"35F$DB;>EBF0E? 0E> @>7?D:EF8AF5E?7E>B Dust Control Systems Ltd (DCS) has completed the installation and commissioning of a complete energysaving dust extraction system for Seamers Specialist Joinery – renowned manufacturer of beautiful bespoke joinery for the high end residential market, with several notable and prestigious private commissions in its portfolio.

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stablished in 1875 by Mr John Seamer, J Seamer & Son Ltd has recently taken occupation of brand new 17,000 sq. ft. premises on the outskirts of Derby, within 20 miles of the beautiful southern dales of the Peak District; the second most-visited national park in the world. The relocation was masterminded by managing director Richard Latham, who took over the reins at Seamers 4 years ago.

Richard actually joined the company as an apprentice joiner in 1981 and is obviously passionate about the company, its products, and services. The new facility became a practical reality with assistance from the Derby Enterprise Growth Fund, and the company is expecting to increase its current workforce of 28; providing employment opportunities for local people.

Seamers’ highly skilled workforce utilises an eclectic collection of specialist woodworking equipment, ranging from classical machinery through to a state-ofthe-art 6-head planer moulder, enabling the manufacture of joinery items in all shapes, sizes and quantities, and all finished inhouse to ensure optimum quality control.

The company manufactures to customers’ specific requirements, working with most timbers and sheet materials, including specialist veneers, and also offers its own comprehensive design service.

Seamers are a long-standing customer of Dust Control Systems, and Mr Latham contacted Andy Hives, company sales manager at DCS, to survey the new site and provide a quotation to install a complete dust extraction system at the

Just one example of the stunning furniture manufactured at Seamers Specialist Joinery in Derby

purpose-built factory. Initially, the relocation plans included for removal and reinstallation of the company’s existing filter unit and ECOGATE® Extraction-onDemand system. However, the imminent acquisition of additional high-speed machinery dictated the need for a replacement filter unit with increased capacity. Dust Control Systems installed an NFSZ3000 3HJLR filter unit, and the total scope of supply included installation of all new Gallito FastClip ductwork throughout, plus re-configuration of the Ecogate® system.

The externally-sited modular filter unit is mounted at ground level, and twin rotary valves discharge waste, pressure-free, into a closed-loop waste transfer system; delivering collected waste to an enclosed skip. DCS re-used Seamers’ existing 11kW waste conveying fan, but a new 30kW direct drive main dust extraction fan provides a total extraction capacity of 18,500 m3/hr. Although the anticipated total extraction capacity requirement, with

DCS re-installed Seamers’ existing Ecogate system at the new premises.

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PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

Dust Extraction

by ATEX regulations, a CARZ explosion isolation flap valve is also included in the system; preventing the effect of pressure wave and flames, in the event of an explosion, from travelling upstream in the ductwork in which it is mounted.

Seamers operate a wide range of machinery from classical to high tech 6-head planer moulder.

features a reverse air filter regeneration fan all machinery in use at the same time, for filter cleaning. Explosion relief panels would be over 26,000m3 per hour, are fitted to the unit in compliance with inclusion of the energy-saving Ecogate® ATEX requirements and, as recommended system, with automatic motorised gates fitted to all machines in the factory, Just one example of the stunning furniture means that extraction is only required manufactured at Seamers Specialist when individual machines are in Joinery in Derby operation. With the diverse range of machining operations available to the craftsmen at Seamers, it was determined that the maximum extraction requirement at any one time would be just 18,500m3/hr.

Ecogate® motorised damper gates signal the ECOGATE® greenBOX® 12+ controller to adjust extraction fan speed to continually match the changing extraction requirement as machines come on or off-line. Based on Seamers’ average production time of around 2,000 hours per year, running the extraction at full power would consume over 50,000 kilowatt hours of electricity – with ECOGATE® continually optimising fan speed, consumption will be around half of that; saving the company in the region of £2,500 per year on electricity bills.

“The service we received from Andy Hives and the team of engineers from DCS helped to ensure the relocation of our machinery was undertaken as smoothly as possible”, says Richard Latham. “We had invested in a new manufacturing facility that was fit for purpose, but we also needed to be able to maintain efficiency as our customer base grows – the extraction system we have now provides that assurance, and DCS conservatively predict that the installation will realise power savings of over 50%.”

For more information: Tel: 0800 040 7116 www.DCSlimited.co.uk

Return air ductwork is also included, allowing cleaned air to be returned to the building in winter, or be discharged to atmosphere in summer, by the manual operation of summer/winter dampers. The filter unit is fitted with patented antistatic Superbag filter media, and the system also The NFSZ3000 3HJLR filter unit installed at Seamers by DCS – a 30kW main fan extracts up to 18,500m3/hr, and filtered waste is discharged pressure-free via twin rotary valves.

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

37

Dust Extraction

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ive years ago, AVC Classic Woodworkers and Eclipse Joinery joined forces to become a leading British manufacturer of wooden windows and staircases. In the wake of a strong focus on its online offer, the company experienced significant growth and as a result, commissioned extraction experts, Dustraction, to create one of its biggest extraction systems to date.

Selling staircases, wooden windows and flatpack windows online to joiners, house builders and end users, the Staffordshirebased business, which now trades under the names Wooden Windows and StairBox, has grown at an impressive speed and moved to a new site that measures just shy of 100,000 sqft. Mark Winter, Managing Director of Wooden Window’s explains, “We knew we needed space to grow our business and to do this, we needed a bigger site and a purpose built extraction system that could run intuitively with our machines, whilst also offering us 100% expansion.”

Dustraction’s approach to the brief impressed Mark immediately. “The Dustraction team were extremely knowledge about extraction and whilst they were not the cheapest on the market, their detailed plan, suggestions and advice went above and beyond the competition. Not only did they understand the job in hand, they also understood us and the importance of future-proofing our business.

Whilst they designed the initial concept, they were happy to work with us to find a solution that would be equally as effective today as it would be in years to come.”

The design included the Dustrax 9X Cyclo Filter which, as well as handling a total air volume of 102,706m³/hr, also incorporated an additional spare capacity of 20,000m³/hr for future growth.

Manufactured from 3mm thick mild steel sheet, the 0.2 mg/m³ emissions guaranteed by the new installation fell in line with existing European Legislation, and that allowed Dustraction to install a clever return air system. “The introduction of the return air system was Dustraction’s idea. It recycles hot air throughout our site and saves us approximately £20,000 per year on our heating bills.”

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“I saw Dustraction as problem solvers,” continues Mark. “Their approach was flexible which, when faced with a growing company, is a necessity. At the beginning of the project, we were operating nine CNC’s but 18 months later, we are now running almost double that number. The design had to accommodate this and even now, as the company continues evolve, Dustraction’s team is on hand to assist in our future plans.”

As well as general cleanliness and wellbeing on the factory floor and the clever introduction of a return air system, Mark was also keen to tackle vertical waste suction. Mark explains, “With a lot of the staircase machines, you cut overhead so you’re having to suck the waste vertically.

We have the capacity to create 150 staircases and 80 windows and doors a day, so we were keen to boost the level of vertical waste suction to accommodate these kind of numbers.” To over come this and to gain maximum output, Dustraction installed extra booster fans above the CNC’s and saws, which offered an effective, long-term solution when faced with increased production. And, when more CNC’s were added to the floor, Dustraction were on hand to extend the extraction system further to cope with the increased air volume needed. Mark adds, “It’s this kind of in-depth understanding and knowledge of the machines and manufacturing techniques we are using that gave us great confidence in the Dustraction team’s abilities and they didn’t disappoint us.”

The system was also designed with fussfree maintenance in mind. “The cyclo filter is virtually maintenance free, which for a busy team, is exactly what we need. All it requires is the filter bags to be changed every so often,” says Mark. “They are guaranteed for 6,000 hours and for us, this meant we needed to replace them after 2.5 years. We think this is pretty good. Before we introduced the latest CNC machines, we were running the extraction system up to 19 hours a day. We monitor the suction rates carefully so we know when the bags are getting worn. Replacements are then delivered and installed quickly, limiting any downtime. It really is that simple.”

With the recent introduction of two further

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

CNC machines and a workforce fast approaching 100 people, the innovative online manufacturer is already planning its next move. Mark adds, “We’re confident new product lines and continual investment in our facilities will continue to increase production and this will see us needing bigger premises within the next 10 years.

Without a shadow of a doubt, Dustraction will be our go-to extraction company of choice. They are experts in their field and with all equipment supplied though them falling in line with Health & Safety Executive COSHH legislation and ATEX Explosion Regulations, we have complete piece of mind when working with them. We have a great working relationship with the whole team and we hope that next time, our project will be their biggest to date.”

For further information: 0116 271 3212 www.dustraction.co.uk @DustractionLtd on Twitter

Wood Waste

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UK building and timber merchant has purchased two wood waste heaters from Wood Waste Technology to save money on heating and waste disposal bills.

Bolt Building Supplies Limited is an independent Buildersâ&#x20AC;&#x2122; and Timber Merchant with specialist Roof Truss manufacturing that has been trading since 1977 and operates from an 8-acre site in Halstead, Essex.

The business joined the Harlow Brothers group of merchants in 2015, so when Bolt Building Supplies decided to purchase wood waste heaters the team immediately contacted Wood Waste Technology who had supplied Harlow Brothers with several wood waste heaters over the years.

Simon Burgess, MD of Bolt Building Supplies says: â&#x20AC;&#x153;Once we decided we needed to replace our inefficient gas heating with wood

waste heaters we contacted Wood Waste Technology and arranged a site survey. The team at Wood Waste Technology was really helpful and we purchased a WT15 for our Roof Truss Factory and a WT5 for the Ibeam factory area. Weâ&#x20AC;&#x2122;re really pleased with the heaters and excited about how much money theyâ&#x20AC;&#x2122;re going to save us on heating and the waste disposal of our timber offcuts.â&#x20AC;?

Kurt Cockroft, MD at Wood Waste Technology says: â&#x20AC;&#x153;Most of our sales come from the good reputation our heaters have in the market, with every heater ever sold still being in operation today. Weâ&#x20AC;&#x2122;re delighted that weâ&#x20AC;&#x2122;ve been able to help Bolt Building Supplies save money on its business running costs.â&#x20AC;?

Wood Waste Technologyâ&#x20AC;&#x2122;s years of expertise in wood waste solutions has 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 UKâ&#x20AC;&#x2122;s official distributor for Gross Apparatebau GmbH, a German manufacturer of dependable, precision engineered shredders and briquetters. The company is also a distributor for Putzmaus boiler tube cleaning systems - a powerful but gentle routine maintenance solution that is quick and easy to use, and helps to increase boiler efficiency and lower operating costs.

For more information: Tel: 01785 250400 www.woodwastetechnology.com www.grossuk.co.uk www.putzmaus.co.uk

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The WT15 woodwaste heater installed at Boat Building Supplies Ltd PANEL & JOINERY PRODUCTION â&#x20AC;&#x201C; JULY/AUGUST 2018

39

Dust Extraction

)CE=9BF8>EF(>EEDE>F6CA4F$:@<?AE C W Fields was established a century ago, by Charlie Walker Fields, and later became C W Fields & Son when Charlie’s son joined the company in the 1930s. Although the current business would be unrecognisable to Charlie, its roots as a family concern are still at the heart of the company and, over the years, several generations from a number of families have been employed by the South Yorkshire-based firm.

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oday, C W Fields & Son Ltd is an industry leading manufacturer, supplying highperformance security and fire doors, acoustic and hygiene doors, wall panelling, and bespoke joinery to specialist markets. Under the patronage of chairman Toni Dalla-Riva, the business is now forging ahead with a senior management line-up that embraces a new generation of family ownership; with daughter Francesca and son Marc DallaRiva, son-in-law and commercial director John Cowx, and Nigel Fields, who started here as an apprentice joiner nearly 40 years ago.

To satisfy growing demand for the company’s products, a new 12,000 sq. ft. extension to the current building has significantly increased manufacturing

space – facilitating a major reorganisation of the factory layout to deliver a more efficient and streamlined production path, as well as accommodating the installation of a new 5-axis CNC machine; just the latest addition to C W Fields’ existing armoury of hi-tech machinery.

To enable the relocation of machinery it was obviously necessary to re-structure the dust extraction system, and Messrs DallaRiva and Cowx had discussions with Ray Townley, Area Sales Manager for Dust Control Systems Ltd (DCS), regarding design and installation of a complete new ductwork system and, with the expected increase in demand being placed on the dust extraction system, Toni and John had also anticipated the need to replace the existing fan sets and filter unit. Having completed a full survey of the site, Ray

The Ecogate® installation includes 3 greenBOX 12 controllers, 3 Ecogate® PowerMASTER VSD units, and 20 individual Ecogate® dampers fitted to 16 production machines.

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PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

All new FastClip ductwork system, installed

by DCS Ltd,delivers up to 20,000m3/hr of dust-laden air to the external filter unit from the company’s hi-speed CNC machining centres.

Townley prepared proposals for DCS to install a complete new FastClip ductwork system throughout the factory. However, Ray was convinced that DCS could circumvent the need, and the cost, of replacing the existing fans and filter and, in addition, significantly reduce the extraction system’s power consumption.

As Ray Townley explains: “I discussed the project with Ian Rayner, Sales Manager at Ecogate Ltd, and we both agreed that the planned reorganisation presented C W Fields with the ideal opportunity to benefit from the implementation of Ecogate® ‘Extraction-on-Demand’ technology.” After further discussions with Fields, Ian Rayner undertook a full evaluation of the extraction requirements; gathering detailed data on usage, running times, and volume requirements of all the production machinery. “By taking account of all machine downtimes, such as loading and unloading, tool changeovers, as well as operator break times, and the infrequent running of some more specialist machines”, says Ian Rayner, “DCS were able to present a proposal to Fields that

Dust Extraction

plenty of room for expansion at C W Fields.

One of the Ecogate® greenBOX controllers, sited alongside two of the PowerMASTER variable speed drive units which control fan speed.

showed a significant reduction in total extraction volume could be achieved if an Ecogate® system was installed.”

In fact, the data collected at Fields revealed that the expected average reduction in extraction volume requirement, across the complete extraction system, would be around 20% with Ecogate® installed; which meant the existing extraction fans and filter unit could continue to operate well within their specified capacities. The existing system is powered by three independent fan sets rated at 30kW, 37kW and 45kW. With all three fans in operation and running at 90% of full load – all day every day – the total power consumption would be over 100kW per hour; equating to around 225,000kWh per year. With Ecogate® installed, it was calculated that power consumption could be reduced by around 100,000kWh per year – yielding a saving of over 40% on electricity bills, and a return on investment in under 4 years.

The Ecogate® system installed at Fields comprises: 20 Ecogate® dampers, which automatically open as an individual machine starts to process material and require dust extraction; 3 greenBOX 12 controllers, which monitor machine usage;

and 3 PowerMASTER variable speed drive units which, as instructed by the greenBOX controller, independently adjust the speed of each of the main fan sets, in real time, to exactly match the continually fluctuating extraction requirements as machines come on or off-line. There are currently 16 machines requiring dust extraction but, with each greenBOX 12 capable of controlling up to 12 machines, and the flexibility of FastClip ductwork, there is still

“We were very impressed with DCS throughout the whole process”, commented John Cowx. “The company provides a truly professional service and, from the outset, it was clear that both Ray and Ian were keen to ensure that Toni and I were provided with all the relevant information we needed to make an informed decision on this key capital purchase.” As well as the significant cost savings predicted for C W Fields’ electricity bills, the expected reduction in power usage equates to a staggering reduction in annual CO2 emissions of over 57 tonnes, and the installation also fulfils the necessary prerequisites for a Green Business Fund grant application. DCS are fully Accredited Suppliers with the Carbon Trust, and are able to assist with a grant application and provide all the necessary documentation required to support an application.

For more information: Tel: 0800 040 7116 www.DCSlimited.co.uk

Motorised Ecogate® dampers, integrated into the FastClip ductwork, operate automatically as individual machines come on or off-line; optimising extraction and maximising savings.

PANEL & JOINERY PRODUCTION – JULY/AUGUST 2018

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