Kingstown Invest In Latest Manufacturing Technology
Kingstown Furniture are a leading UK manufacturer of preassembled quality bedroom and dining room furniture. The company was set up 30 years ago by Mike Sharp and from humble beginnings has grown in to a very successful multi-million pound turnover business operating from a 17,500 sq/m modern manufacturing facility based in Hull. Under the current management headed by MD Richard Sharp the company aim to stay at the forefront of manufacturing excellence, furniture design and customer service. To achieve this they have in place a continued investment plan covering all areas of the business, with machinery being a key element.
Comec Frontal BorerWith this in mind Kingstown are continually looking for equipment that can help increase productivity, efficiency and quality. For 2009 several key areas of production were assessed for investment, one of which was the drilling and grooving of drawer front components. While they already had a machine dedicated for this work it was apparent that they needed to increase output. Also, as new painted ranges and components with delicate foil wrapped edges had recently been introduced a machine was needed that would handle these without marking or damage.

During a visit to an overseas trade show, Richard and engineering manager Dave Busby spotted the Comec Frontal CN drawer front machine in operation which had the base general specification they required. However Kingstown had some specific requests that needed to be incorporated in to the machine and these were discussed in detail with Comec, and their UK agent JJ Smith, during a visit to the Comec factory in late 2008. One particular area Kingstown had significant input in to was the design and operation of the transfer system. It was critical that the components were transported smoothly out of the machine and that one operator could easily load and unload. Also another criteria was the ability for quick and simple change from one drawer front size to another. Dave Busby Comments " Due to our experience in processing drawer front components we new exactly the type of machine we needed and how it should operate. Comec's design team were very happy to work with us and understand our particular requirements. The end result was a machine specification that ticked all our boxes".

The compact design Comec Frontal CN consists of an automatic vertical loading system that the operator fills with the drawer fronts or panels. These are then transported through the machine by a 'gripper system' to the drilling area were a bank of 11 independently controlled drills bore the holes. The component then moves to the next area were the grooving saw or router produces the slot for the drawer base. All the loading and feeding sequence is PLC controlled, while the actual drilling and grooving operations are CNC controlled. Programming is extremely quick and simple and is done through the colour graphic touch screen controller. The standard max length of component is 1000mm x 280mm wide, although larger components can be processed on request. The machine for Kingstown was also specified with a rear lateral outfeed conveyor, cross belt tilt transfer and side return conveyor. The operation of which was all linked to the PLC control sequencing.

Final tests and pre delivery inspection took place in June with the machine being delivered shortly afterwards. It has now been in operation several months and Kingstown have been very pleased with its performance. Dave Busby says "The Comec Frontal is working really well and is achieving everything we wanted. Accuracy is excellent and average production is around 9 to 10 drawer fronts per minute. The loading, return and unloading system handles the drawer fronts very well without any damage or marking, while the change over time between different drawer front sizes is only two to three minutes. Also a single operator can comfortably run the machine and still maintain maximum production output".

The Frontal CN is in fact one of a family of 'Frontal' machines that Comec manufacture for panel or solid wood production. They can be specified with a variety of vertical or horizontal drilling configurations and on request can equipped with dowel insertion units. Final specifications can be tailored to suit customers specific production requirements.
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Quick Set Tenoner Proves A Hit At Sturrocks
A. Sturrock and Son of Kirkbuddo near Forfar are a long established architectural joinery manufacturer specialising in high quality windows, doors and staircases. To keep them at the forefront of flexible manufacturing techniques the company have a philosophy of investing in the very latest machine technology that can give them added versatility, quick set up times and improved quality.
Saomad Quick Set TenonerOne area of production that was recently identified as in need of improvement was the tenoning. While Sturrocks for many years had been successfully using a traditional single ended tenoner with manual settings, it was apparent that they needed a machine with faster set up times thus giving more flexibility. Aware that JJ Smith had recently introduced a new programmable machine from Saomad, Alex Strurrock contacted the company for further information and to arrange a demonstration. Following successful tests an order was placed for a Saomad 'Quick Set' Evolution fully programmable 4 head heavy duty single end tenoner. It has a head configuration of cut off saw, top and bottom tenon, and 200mm long vertical scribe shaft. All the head movements are programmable via a user friendly Siemans Semantic touch pad control unit and the only manual adjustment is to set the pneumatic workpiece clamps.

The machine has now been installed several months and Alex Sturrock has been delighted with the purchase. He comments " The Saomad 'Quick Set' takes a fraction of the time to set up compared to our old manual tenoner and it is so easy to program. Another big plus is that we now get a very high level of repeat machining accuracy. It is also important that the machine itself has a strong heavy frame which is important when machining 150mm long tenons in hardwood for door rails". The 'Quick Set' Evolution can on request be equipped with a 400mm long vertical scribe shafts, additional vertical shafts along with a motorised carriage. Saomad manufacture a full range of standard and programmable tenoners along with profilers and NC window centres.
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Sashless Windows Improve Hardware Machining with Centauro Alfa NC
Sashless Windows based in Northallerton have recently invested in a new Centauro ALFA NC machining centre for milling the hardware recesses, slots and holes for their window ironmongery. They are also using it to produce the slots in window heads for trickle vents.
Centauro Alfa NC Machining CentreThe company had been investigating the purchase of a CNC machine for some time, but given that they were only machining mainly components it did not justify the expenditure on a large bed CNC which could cost in excess of £60,000. Therefore when JJ Smith introduced them to the new Centauro ALFA machine, which is available at an extremely competitive price when compared to other types of NC controlled milling / routing machines, Sashless were off course keen to learn more.

The ALFA has been specifically aimed at the joinery market for machining window and door components. As standard it is equipped with a single milling / router head that automatically swivels through 90 degrees from the vertical to the horizontal. The bed length is 3m although this can be extended if required. It has 3 axis NC control with the option of extending the Y axis stroke from 150mm to 400mm. Programming, which is parametric, is extremely simple thanks to the colour graphic touch screen controller which incorporates electronic macro templates for various hinge designs, lock plates, holes, lock slots etc. On request the machine can be equipped with ISO 30 tool change, a front retractable table for end boring, uprated milling head motor 5.5kw and a drilling head for Anuba type hinges. The ALFA is ideal for machining 3 point locking systems including handle holes and key slots, hinge recessing, grooving and boring etc. The 2 x front table extensions also mean that a frame or door can also be clamped.

A demonstration was arranged at JJ Smith's Liverpool showroom and Sashless brought with them various timber samples for machining along with the hardware that required fitting. Company MD Alistair Chown comments "All the programming and machine set up took place while we were present and it was apparent that this was a very simple and quick process which was just what we were looking for. Also the actual machining accuracy was excellent". An order was confirmed shortly afterwards and the machine delivered and installed on schedule. It has now been working several months and Mr. Chown adds "We have been very pleased with its performance. Previously this work was being done on various manual machines and by hand tools which was obviously quite time consuming. Now with the ALFA it is taking half the time also we are getting improved accuracy. Another big plus is that we feel the machine is exactly in the right price bracket meaning we have not had to over invest in equipment that really would have been over the top for what is required".
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Roger Haydocks Invest In New Laminating Equipment
Roger Haydock & Co Ltd are based in Widnes, Cheshire and are one of the North Wests leading specialist hardwood timber suppliers. With branches in North Liverpool, Whitchurch and Colwyn Bay, this family run company was established in 1875 and have always prided themselves on offering their customer base the widest possible range of timber products. With this is mind the company have recently installed a new Taylor rotary solid wood edge and face laminating clamp.
Taylor Rotary Solid Wood Edge & Face Laminating ClampMark Harris the company's hardwood sales director started investigating the potential for the supply of 'in house' laminated components in the summer of 2008. After speaking with several key clients came to the conclusion that this was a service that Haydocks should consider. There were a number of laminated components identified that could be produced including panels, newel post blanks, joinery sections for windows/doors and kitchen worktops but there was one product that Mark thought could be of particular interest to staircase manufacturers. This was face laminated stair strings made up of two 250mm wide x 25mm thick pieces of timber and laminated in to a 250mm x 50mm section, anything up to 4800mm long. Primarily these would be made from American White Oak with the main feature being that there would be no visible laminated joint on the edge of the string. A t this point Haydocks contacted JJ Smith, who they new were specialists in the supply of laminating equipment. Having worked with JJ Smith for all of their 86 years, Andrew Haydock, David Shaklady and Mark Harris arranged a visit to see a machine in operation. Detailed discussions took place on what type and specification of machine would best suit their production requirements. Following advice from Taylor themselves, a 5m capacity 6 section semi automatic hydraulic machine was specified. It would be equipped with 2 rows of special 401 heavy duty clamp arms suitable for laminating material up to 250mm in thickness. The other 4 rows were fitted with the standard 302 type clamp arms that can laminate up to 150mm when fitted with rocker plates. The special clamps would be used for the stair strings, while the standard clamps could be used for the remainder of the laminating work. Tightening and loosening of the clamps, along with the frame rotation would be hydraulic operation while a pneumatic component flattener was also fitted. For glue application a PVA motorised roller applicator was specified. An order was placed and the machine delivered and installed on schedule 4 months ago.

Mark Harris states that the response Haydocks have received from their customers for this new laminating service has been "excellent". Andrew Haydock adds "The new Taylor clamp is working extremely well, not only has it opened up new sales opportunities at a very challenging time, it has complimented the existing mill facilities on offer. We have also been delighted with the advice and service we have received from both JJ Smith and Taylor. The facility to supply laminated components to customers specific requirements is another string to our bow and strengthens our position as a leading independent supplier of quality hardwood and softwood products.
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Log Cabin Notcher For Tunstall
Tunstall Garden Buildings based in Stoke On Trent have recently installed a new Auer four way notching machine which is able to produce the high quality notched corner joint used in continental style timber cabins and chalets
Auer Four Way Notching MachineTunstall already manufacture an impressive range of quality garden buildings including summer houses, workshops, sheds and garages and so it was only natural that they wanted to start producing the 'log cabin' type building which is becoming increasingly more popular and desirable in the UK.

The company were established in 1989 and since this time have steadily grown now employing 14 staff and supplying on a nationwide basis. The Austrian built Auer machine, supplied and installed by JJ Smith, was specifically designed for this type of work and as standard is equipped with two horizontal and two vertical milling heads which are sequenced by PLC control. Various types of notch can be produced depending on the section of timber used and the design of the TCT tooling supplied. Generally for the UK market the most popular wall thicknesses are 34 and 44mm, although for very heavy duty buildings you can go up to 75mm. The section is normally single or double tongue and groove meaning each level of the wall slots in to each other. Tunstall opted for tooling that was adjustable for timber from 28 to 50mm thick making a classical half lap joint with chamfered edges. The machine is equipped with the optional heavy duty infeed and outfeed roller tables and adjustable pneumatic reference stops set to suit the required notch length position. On request it can also be supplied with an integrated up cut saw to 'square end' the timber prior to notching, a horizontal drilling unit that enables a steel tie rod to be used during assembly of the building and lastly an end grooving unit in case long timber lengths need to be jointed together.

Tunstalls owner Mark Jobburn comments " We are very impressed with the build quality of the machine and how easy it is to use. In particular the quality and fit of joint is excellent". He adds " Not only are we now able to offer a new standard range of log cabins, we are also giving customers the option to design their own and we will build it to their required specifications. As we manufacture all our own windows and doors we can offer a complete bespoke service".
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Bayram Increase Cross Cutting Capacity
Bayram Timber located in Hull were established in 1977 supplying general rough sawn and machined timber to the joinery and furniture industry. Since then the company has gradually grown year on year with 2007 seeing a significant investment in a new 28,000 sq.ft purpose built factory. This makes a total of two sites employing over 100 people in all. They have a nationwide client list, but with a focus on serving the caravan leisure industry with a variety of timber components, manufactured on a 'just in time' basis to meet customers individual stocking and production requirements
Stromab CT600 Automatic Programmable Cross Cut SawCross cutting is an important area of Bayrams production facility, and prior to the new factory being built they had purchased a number of new and used machines from cross cutting specialist JJ Smith. These included two new Stromab Matrix programmable push fed automatic saws, an H&M Anglemaster saw along with four used automatic cross cuts saws which were recently supplied with upgraded software .Therefore when Bayram decided they needed to further increase their sawing capacity there was no hesitation in contacting Smiths for advice.

After several discussions with Martin Smith from JJ Smith, it became apparent that Bayram would greatly benefit from an additional programmable saw for both straight or angled cuts. The new machine that was specified was a Stromab CT600 automatic programmable cross cut saw with a 6m infeed capacity and a blade that can swivel and cut anywhere between +70 and - 70 degrees. Cutting height depends on the width of timber and the angle being cut but the maximum is 160mm. The machine incorporates a heavy duty rack and pinion drive for the pusher fence and a magnetic strip encoder for maximum cutting accuracy. The saw blade dia is 600mm and motor size as standard is 10hp.

Due to the angle cutting facility the machine uses a vertical and horizontal clamping system that is sequenced with the pushing and cutting cycle. Programming is extremely simple thanks to a colour graphic touch screen controller with the facility of remote programming of the cutting list with data transfer via a USB key. Full optimisation is standard. Options include defect cutting, windows operating system, label/inkjet printing and electronic workpiece sorter for the cut components.

Bayram's Technical Director Tony Clarke comments “The CT600 is a very user friendly machine offering a quick and accurate cutting facility. We produce many different angled cuts for a wide variety of components and these can now be automatically produced with extreme confidence which is great for both us and our customers", The machine has now been installed for just over two months and Mr. Clarke adds " JJ Smith gave us a wonderful overall package with delivery and installation bang on schedule. It was also refreshing to already know that we could relay on excellent back up and service if and when it was needed"

The Stromab CT600 supplied to Bayram is just one of a family of crosscuts that JJ Smith from manual pull over saw with programmable stops to complete lines including infeed and outfeed handling that J J Smith offer, making them the leading supplier of this type of machinery to the woodworking industry..
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Mortising Made Simple At Joinery Craft
Joinery Craft based near Cheltenham in Gloucestershire are a specialist manufacturer of bespoke high quality window and doors, supplying mainly new build developments and working with some of the UK's leading house builders. The company was formed almost 13 years ago by Adrian Robson and now employ 10 people in the workshop. As the business has grown they have invested in various items of new equipment to help improve delivery times, efficiency and quality.
Centauro CNC Beta MortiserOne of the latest additions has been a new Centauro model Beta 3 axis programmable automatic swing chisel mortiser supplied by JJ Smith of Liverpool. Like many joinery manufacturers Joinery Craft had been using traditional hollow chisel and chain mortisers. However this area was proving to be a real production bottleneck, especially for door manufacturing and for windows that required mortise slots for glazing bars.

Adrian Robson had previously purchased a number of machines from JJ Smith and had no hesitation in contacting them for advice on how to improve the mortising operation. They suggested that the new Centauro Beta CNC 3 axis automatic swing chisel mortiser would prove ideal, and that it should be supplied with the additional optional programmable hollow chisel head which is particularly suited to making the small mortise slots required for window glazing bars.

Adrian arranged to view the machine at last years W6 exhibition and was very impressed with its operation. He comments ' It ticked all the boxes we were looking for. The programming was extremely easy thanks to the colour graphic touch screen controller, quality and accuracy of the mortise slots was spot on, and the programmable hollow chisel head really gave the machine that extra versatility with the ability to make vertical mortise slots by means of the programmable Z axis operation. We also liked the fact that as the component is automatically moved and ejected by the gripper mechanism this would leave the operator free to perform other tasks while the mortising cycle is taking place " An order was placed and the machine was installed on schedule at the end of last year. Adrian has been delighted with its performance and adds " We must have speeded up our mortising operation by at least 60% since we have had the machine and we are now doing work that would have taken far too long using traditional machines. For instance making a 9 panel window, which can have a total of 26 mortise slots is so easy on the Beta machine. Typically we can now produce a run of up to 50 windows requiring 1300 mortises with no problem at all. In addition door production has improved and is particularly easy as you are able to select a single program to accurately machine both left hand and right hand stiles with haunched and through mortises. Another advantage has been that we can use the machine to produce the night vent slots in the window frame heads".

Other features of the machine include step by step graphic set up on the controller which includes calculating the oscillation swing of the chisel along with a graphic representation of the mortised component which Adrian says is a "real plus". In addition a USB port / key allows for back up storage of memorised programs and machine parameters. Also on request the Beta can now be specified with a programmable milling head instead of the hollow chisel head. This can be used for operations such a louver door slots.
Centauro BETA Graphic Controller
Centauro BETA Programmable Hollow Chisel Head
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