Welding

Our team of highly skilled metalworkers and welders has the experience and expertise to construct products to the highest degree of precision assurance, ensuring a product that is designed to perform, deliver and last for years to come. Plant includes sixteen various Mig and Big Welding machines, with two spot welders and tables, and a new automated robotic welding arm, recently introduced to increase productivity in our classic range of steps. A new state-of-the-art extraction system, installed to Government guidelines, remove welding fuels and grinding dust from the air, creating a safer, cleaner welding environment.

New Powder Coating System

In 2020, we invested in a state-of-the-art Powder Coating System, comprising a massive overhead monorail track that runs throughout the factory, ensuring total integration between product preparation, paint application and powder curing. Components enter the system at various points along the production line, automatically entering the bespoke new drying oven, powder booth and curing oven. When the powder coating process is complete, items are automatically returned to the appropriate location for assembly, checking and despatch. The automated, intelligent system provides a purpose-built solution to our powder coating requirements, producing a higher quality, more consistent finish, faster turnaround, greater flexibility and improved safety.

New Robotic Welding Cell

In 2020, we invested in a new Robotic Welding Cell, manned by a state-of the art, collaborative robotic arm, designed by Universal Robots and installed by WeldAbility. Easy to programme, fast to deploy and safe to use, the robotic arm works within a fully automated cell, utilising a spot weld template to perform welding where required, introducing new levels of speed, flexibility and accuracy and further enhancing the quality, build and longevity of our products. Combined with the time-honoured skill, expertise and experience of our metalworkers and welders, it gives us a manufacturing capability that is second to none, significantly increasing efficiency and productivity.

Robotic Arm

In 2013, we took delivery of a Robotic Arm to work with the press. With human-like dexterity but greater accuracy than a human worker, and faster working speeds with no down time, it revolutionised our production capability, significantly reducing cycle time and maximising throughput. Delivering 24/7 automation, it has given us game-changing benefits in terms of speed, safety, consistency, reliability and productivity.

CNC Tube-bending

Our Pedrazzoli BM42 CNC Tube Bender features state-of-the-art technology, with the capability to process tube from 10 – 42mm and the option to position automatically in a right or left tube bending configuration or change direction via a rotative head. Fixed and variable radii can be bent within the same cycle, and the machine also facilitates bends with no straight between them. Equipped with the latest software, it enables us to program via computer, ensuring precision accuracy and drastically reducing cycle time.

Laser Cutting

In 2016, we invested in an Amada LCG3015-AJ flatbed laser cutting machine, equipped with an Amada developed fibre engine, ensuring high cutting speeds and low running costs. Capable of cutting copper, brass and titanium, the machine sets a new benchmark for precision performance, speed and efficiency. With up to 38% high processing speeds and fastest in class feed rates, processing time is greatly reduced, while laser precision cutting ensures exceptional accuracy. The fibre laser is environmentally friendly and the Amada LCG3015-AJ uses a combination of compressed air and Nitrogen assist gasses. Reduced steel loads allied with precision cutting ensure wastage is kept to a minimum.

Nano Pallet Wrapper

Our state-of-the-art, automated Robopac Nano Pallet Wrapper has significantly increased packing efficiency. Utilising a special nano film that can be stretched to higher tensions than a standard pallet wrapping machine, it produces a better quality wrap to pallet, making packing easier and quicker, with less waste. Coupled with a newly sourced ‘U’ shape foam protectors and micro foam rolls, it enhances product protection during transit, reducing possibility of damage. The machine also provides real time data, enabling performance and expenditure to be closely monitored.

CAD Drawing and MRP Software

In 2019, we introduced a Solid Works 3D CAD package, which revolutionised our drawing capability. A powerful 3D design and manufacturing solution, the system has provided us with specialised tools for sheet metal, weldments, surfacing, moulds, product configuration and design analysis, enabling us to develop a sophisticated components and parts library, with automated cost estimation, design & drawing checking, and collaboration capabilities. Incorporating sales, manufacturing, engineering and accounting functions, the new system also facilitates faster sales order processing, shipping and invoicing, and allows a more speedy, accurate response in such areas as quoting, costing, reporting and stock control.

Prototypes

We specialise in conceptual design and bringing new products to market. We can create prototypes and full design specifications from a description, drawings or a copy of the item, creating a bespoke manufacturing solution to match your exact requirements. During manufacture, we continually revise our processes, working with you closely until completion to ensure maximum design consistency and efficiency, and that your expectations are always exceeded. From a modified cabinet to additional rungs on a step ladder, we can cater to your specific needs, manufacturing in volume to meet demand.

Cabinet Section

Our cabinet section is equipped with three manufacturing presses and a steel CNC Turret Punch, enabling us to bend and punch the parts required for cabinet manufacture, with items then assembled on our spot welding tables. This on-site facility gives us the capacity to offer an extensive range of cabinets, designed to withstand usage in the toughest environments, with many options, from freestanding to wall and mobile units, with a choice of drawers, shelves and bins, and wide range of accessories, to create bespoke storage solutions.

Storage and Fast Despatch

We are continually expanding our warehousing facilities, providing additional storage for finished stock, ensuring it is available for immediate despatch. Our current premises span 63,000 square feet, with an additional mezzanine floor in Unit 2 providing extensive storage facilities, enabling us to provide a ‘next day’ or ‘soon as’ delivery policy on the majority of our products.