Investment in Tecnolegno‘s Compact profiling and profile sanding machine has given healthcare furniture manufacturer Deanestor benefits that are being felt at the ‘sharp end’ of the business: the company’s sales team is able to quote shorter lead times with complete confidence.

Supplied by Tecnolegno’s UK and Irish agent Elliot Machinery, the Compact was purchased particularly for worktops. In just one day, the machine prepares a week’s supply of worktops, whereas previously it would have taken three or four days to produce this quantity.

‘We specified the Compact with three profile cutting heads and two profile sanding heads – allowing instant switching between various types of worktop in thicknesses from 18-55mm,’ said Deanestor’s technical and purchasing manager Andy Nally. ‘It does all the preparatory work – profiling the bullnose, machining grooves and then sanding the profiled edges.

‘Although we bought it initially for worktops, we have found many more uses due to the machine’s flexibility, capacity and quality output. For example, we now use it for sanding and sizing flat panels – and even sanding and polishing the edges of compressed solid laminates, which used to be a time-consuming and repetitive, but critical, task for our skilled joiners.’

Healthcare sector

Deanestor is one of Europe’s leading manufacturers of furniture for the healthcare sector, including hospitals, GP surgeries, health centres, residential care homes, prisons and laboratories. The service covers design, manufacture, supply and fit – with the in-house fitting teams handling probably 30% of all sales. Everything, from reception desks to furniture for operating theatres, is supplied fully assembled.

Delivery is an equally critical issue. ‘Hospitals and surgeries can’t close down and builders are not on site all the time,’ said production director Peter Stevenson. ‘So if delivery is required for Wednesday afternoon that’s when it must happen.

‘The Tecnolegno has proved to be a vital tool in terms of allowing us to forecast and achieve delivery on time. Its “right first time” rapid throughput means worktops no longer hold up delivery, and the accuracy and quality of finish has reduced returns to the factory and makes on-site fitting much easier. Quality is all about repeatability and confidence, and this is what the Compact gives us.’

Deanestor operates from a purpose-built factory in Mansfield, Nottingham. The company works mainly with MDF and particleboard, much of it moisture-resistant. Material is either bought-in faced with melamine or real wood veneer (ash, white and steamed beech and oak are the most popular species); or it is laminated in-house with a choice of 400 colours and designs. Most furniture is custom-designed to fit a particular project, aided by a CD-Rom that allows room layouts to be created.

Milling heads

Deanestor’s Compact includes three profile milling heads, which are housed in a soundproof cabinet, and two profile sanding heads which comprise counter-profile pads that press the continuous sanding belt precisely against the contoured workpiece. All heads are PLC-controlled to ensure accurate profiling and sanding (no rounding or ‘dubbing’ of corners) and are set up from the main console. The combination of heads allows fast changing between products of different profiles and thicknesses.

‘Sanding worktops was traditionally a dusty business and workers had to wear full-face masks,’ said Mr Nally. ‘The efficient extraction system on the Compact gives us a clean working environment which is much more pleasant for the operators.’

Many of the processes for which the Compact is used were previously done by skilled joiners, who have been freed for other tasks. In addition, the increase in capacity has enabled Deanestor to offer shorter lead times and accommodate urgent requirements for existing customers, while at the same time taking on new business – not only in the healthcare sector but also in furthering the company’s business plan to expand its existing share of the market for education furniture.

‘It has taken the company another step forward,’ said Mr Stevenson. ‘Healthcare and education are competitive markets and our success is due not only to the high quality of our furniture but also to the support we provide to customers from initial consultation to final delivery.

‘The Compact has allowed us to further improve the service we offer, and this will assist our plans to expand into the educational sector – in which we intend to be competitive while at the same time providing the high quality product for which Deanestor has established a strong reputation.’