Homag likens the evolution in moulder technology represented by its Mouldteq M-300 to the transition from the push-button Blackberry to the touch-screen iPhone.
Underlining the advances over conventional moulders of the machine – part of the German manufacturer’s strategic move into solid wood processing – technicians at the W18 show used it in conjunction with an augmented reality tool. Loaded on a tablet, the software flags up when cutter heads need changing, or maintenance or adjustment is required, and shows how to do it on screen.
This illustrates perhaps the key trend in moulder development. The hardware itself is moving on. Machines are becoming more robust, low maintenance and flexible, with more technology crammed into smaller footprint packages and tooling that delivers a more consistent quality finish and is easier to change. But underpinning this are increasingly all-embracing intuitive control systems that keep the operator one step ahead on maintenance and set up.
The controls also aid integration of moulders with other machinery to create manufacturing cells, a development expected to figure highly at the upcoming Ligna show.
While latest developments don’t make the moulder sector immune to wider market and economic conditions, manufacturers believe they do also help justify a purchase to a highly competitive and cost-conscious wood processing sector given the cost effectiveness and flexibility they deliver.
That said, some still detect a greater degree of caution on investment decisions in the solid timber processing sector recently.
“Inevitably political instability has knocked market confidence,” said Andy Walsh, sales director at Daltons Wadkin, which supplies Kuper moulders. “Demand was buoyant through 2018, but, while we’re still selling strongly into the composites sector, solid wood has slowed somewhat. However, the enquiries are still there, so we believe it’s decisions deferred, rather than purchases cancelled and when we have greater political clarity, customers will re-fan the flame.” SCM painted a similar picture.
“Brexit is bringing uncertainty, delaying some investment decisions,” said SCM group managing director Gabriele de Col.
But he agreed too, that underlying market conditions are robust.
“Over the past year, demand has not only been strong, it’s been for a wide variety of moulder applications,” said Mr de Col.
“Customers have ranged from those requiring mass production capabilities, to those who need technological solutions to handle special machining and manage hundreds of different profiles.”
At Leadermac, there are signs too that customers are deciding orders have been deferred long enough and that, regardless of Brexit, they need the technology now.
“We’ve had the best January in our history,” said Kevin Wright, managing director of Leadermac UK. “We can’t put our finger on exactly why, but think customers just need the capabilities new machines offer, and we’ve also sold associated equipment; mechanical infeed and outfeed, grinders and measuring stands. We’ve had Speedmac orders from Beers Timber and Building Supplies, Colin Myers Timber and Prowood and installed a Hypermac at door maker E&SW Knowles. After installing one Speedmac last year, Bayram Timber have since ordered another two to replace old machines. They reported that the finish quality was such that their sales team were specifically asking for orders to be put through the Speedmac.”
The trend Homag highlighted is for moulders to be regarded as one step in the machining process.
“They are becoming increasingly connected with subsequent systems, like profile wrappers and painting equipment and we can now offer this complete process chain from one source,” said Josef Zerle, of Homag business unit BU Surface.
The new Homag Mouldteq M-300, is produced in 5 to 8-spindle variants, with variable feed speeds from the second spindle onwards of 4,000 to 8,000rpm, and capacity to handle work pieces up to 300mm long. Controlled via Homag’s powerTouch interactive software system, which also generates performance data for process optimisation, the Mouldteq has the added option of a universal spindle which can move through 360 degrees.
“If you need frequent changes to multiple spindle configurations, this option is for you,” said Mr Zerle. “And powerTouch enables even inexperienced operators to make perfect profiles first time.”
He added that the software system can also connect to tapio, the woodworking IoT (Internet of Things) platform, allowing offsite control.
Most Homag sales of integrated planer/ moulder lines have been to larger companies, but it sees the cell concept filtering down to smaller processors.
“Ligna visitors will see Homag entry level, single-operator moulding cell solutions,” said Mr Zerle. “In partnership with Makor we’re offering complete profile and panel paint lines, and we also produce a lamination cell – the Lamteq F-200 Ergoline.”
With customers facing the challenge of having to react ever faster to market demand, Homag predicts still more opting for comprehensive system control and machine integration. And it believes new technologies, such as augmented reality, will accelerate this process. The system demonstrated at the W Exhibition linked a tablet to the Mouldteq’s control. When this receives information a tool change is necessary, for instance, the operator points the camera at the machine interior. The augmented reality software superimposes a 3D drawing on the area needing attention and presents action to be taken as an animation. SCM’s focus is also on process integration and automation.
“In 2018 we sold moulding machines in conjunction with window/door centres and CNC machining centres, particularly to window manufacturers,” said Mr de Col. “There is also increasing demand for automation, mainly related to machine set up, loading and unloading.”
He highlighted in particular the capabilities of the Superset range. The machine’s set up time is claimed to be 20 times faster than conventional technology, which combined with the HSK tooling system, reduces downtime and increases productivity.
The company has also developed its electronic control systems, from the entry level control 10, to the top end mobile PC variant.
“The controls enable operators to integrate photos of profiles to be machined and tools to be programmed, and to generate machine usage statistics,” said Mr de Col. “It’s also possible to define different access levels to the PC, for optimal process control.”
A new development from Leadermac is a cloud-based technical support service that enables the company’s technicians to interface with its moulders’ Proset control system to assess and resolve any problems. Operators, said Mr Wright, can also specify one of three degrees of sophistication for their control system, Easyset, Smartset or Proset, and, besides Siemens, can now opt for Beckhoff control technology hardware.
“Each machine is tailored to the user,” he said. “For instance, Bayram wanted a high output machine, with straight and profile jointers, capable of feed speeds up to 100m/min. So the top feed section on their Speedmacs is effectively taken from the bigger Thundermac. It features 205mm diameter feed rollers, heavier duty gearboxes and two spindles are inverter-controlled, with variable rpm from 6,000 to 9,000.”
The Kuper SWT XL, one of Daltons Wadkin’s most popular moulders, also has three capability options in its K2 control system; Basic, Professional and Advanced, providing options from simple four-sided operation, to server-based management.
“It suits a range of processing needs, with a five-head model ideal for smaller joinery companies, which focuses on bespoke production and may not run the machine continually, and a six-head for the highoutput processor,” said Mr Walsh.
Among Kuper’s developments, is the latest version of its Fenster window components machine, based on the Super SWT XL-6. “It’s now even more of a catch-all machine for window producers, featuring six heads and cutting speeds of 7,200 to 8,000rpm,” said Mr Walsh. “With K2 control software, it takes seconds to change axes position.”
He also emphasised that “moving metal” and introducing latest technical advances – and further Kuper innovations will feature at Ligna – has not been Daltons Wadkin’s sole focus. It has also continued to develop service and support operations.
“We now employ four trainers, who are in constant demand,” said Mr Walsh. “We also have 15 engineers undertaking repair and maintenance on all brands. In today’s more cautious market environment, where some companies are hesitating over signing off on a new machine, even greater priority is being placed on keeping existing equipment operating effectively, so they’re in more demand than ever.”
Weinig technology a game-changer at Brooks
The latest investment at Brooks Bros is in a Weinig Powermat 1500 moulder and Weinig Rondamat 1000 CNC grinder with Opticontrol Digital Measuring Display System and Moulder Master software.
The moulder replaces two traditional machines, providing faster setting and higher run speeds. The automatic grinder frees up a skilled operator from the tool room to work directly in production, whilst also allowing all Brooks’ moulders to run faster, thanks to more accurate CNC grinding.
“The Rondamat is a game changer in automated grinding and replaces what was a very labour intensive operation,” said Brooks managing director Mark Fleming.
“It even carries on when everyone has gone home. And what Weinig has done with the Powermat 1500 is to make the few remaining manual operations very user friendly and faster than previous models.”
He added that assimilating the new grinder and software was a learning curve, but support from Weinig had been excellent. Brooks was also likely to order at least one more Powermat in Q2.
