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“We were producing good quality doors, but the volume just wasn’t there,” explains Dave Burke. “We needed to scale up fast without compromising on quality.”
After evaluating offerings from several machinery suppliers, Western Joinery found most solutions were just iterations of what they already had – until they encountered the Essepigi Doormatic at a trade show. This thrufeed door production system stood out immediately for its speed and versatility.
With fully automated setup between jobs and the capability to handle all aspects of door machining including squaring, splayed edge, 3-point locks, hinges, drop seals, top closers, letterplates, window cut-outs, and spyholes, the Doormatic was a perfect fit.
A visit to the Essepigi factory in Fano, Italy, sealed the deal. Watching the machine handle a range of fire-rated doors with remarkable ease and speed impressed both directors.
“It was unlike anything we’d seen,” says Paudie O’Callaghan. “The speed, the automation, the flexibility – it ticked every box. We placed an order straight after the demo.”
However, as production ramped up, a new challenge emerged: the existing frame production process couldn’t keep pace, creating a bottleneck. Once again, Essepigi had the solution. The Horizon Plus – a fully automatic frame machining centre with an integrated loader, twin saws for straight or mitre cuts, end drilling, a CNC milling head, and a secondary head for pilot hole drilling – fit seamlessly into the production line.
“Adding the Horizon Plus was essential,” Paudie notes. “It completed the workflow and eliminated the bottleneck.”
Since installation, the results have spoken for themselves.
“Thousands of fire-rated doorsets have already been delivered across Ireland,” Dave reports. “Without a doubt, this has been the best investment we’ve ever made.”
Paul Parker, Sales Director at JJ Smith, who supplied the equipment, reflects on the success of the project:
“Western Joinery had a clear vision to dramatically increase output without sacrificing quality. With the Essepigi Doormatic and Horizon Plus, we delivered exactly that. It's rewarding to see a forward-thinking company achieve such rapid success with the right technology.”
With increased capacity, streamlined operations, and nationwide delivery of high-spec fire doorsets, Western Joinery is now positioned as one of Ireland’s most agile and capable door manufacturers.
