Abcell has completed the installation of a cutting-edge Graf Synergy SL4FF seamless corner welder and FOM LMT65 aluminium machining and cutting centre, as part of a major investment in its Warmcore fabrication facility.
Manufacturing conservatory roof systems from Global and the Guardian solid roof, Warmroof system, Abcell added Synseal’s PVC-U aluminium hybrid, Warmcore to its trade offer in June this year.
Supplied by the Promac Group, this new product offer is underpinned by a six-figure investment in the Graf welder and the high-volume and high precision, FOM LMT65 aluminium machining centre.
Paul Ford, Managing Director, Abcell, said: “We have been really pleased with the LMT65. The precision that you get out of it is incredible. It maximizes outputs and minimizes waste. It’s incredible and key if you want to do volume but do it well.
“The SL4FF gives us a great end-product, with a far stronger welded corner and precision finish. It’s what people want – mechanical joints and cleats don’t deliver on strength or finish and they don’t allow you to do the volume.”
The FOM LMT65 delivers major efficiencies and exceptional precision in volume manufacture of aluminium products. It features a multi-spindle preparation unit with 360⁰ variable angle access to all four sides of the profile. This is automatically linked to the sawing unit which features a 650mm diameter blade with electronic tilt control.
A bar feeder and pick up system with adaptive rotating gripper, means that the LMT65 has the in-built flexibility to handle different profiles with ease and requires just a single operative.
The SL4FF has redefined the PVC-U systems market. Pre-cleaning to exacting tolerances, it zip welds the corner joint whilst controlling the flow of sprue, delivering a seamless but incredibly strong corner joint.
FOM and Graf Synergy announced the formation of a new partnership, the FOM-GS Group, at the end of last year. This pools significant resource and expertise in cutting edge innovation in PVC-U and aluminium machining technologies, while Promac Group is exclusive supply partner for both in the UK.
Joe Hague, Managing Director Promac Group, said: “The SL4FF has been instrumental in making the welding of Warmcore possible, perfectly aligning aluminium internal and external faces, while zip-welding the PVC-U core.
“This not only delivers a better quality product but can also deliver a twofold increase in productivity compared to other traditional manufacturing processes.
“The precision that the LMT65 brings to the table is equally impressive. It combines operation to an accuracy of 02.mm with exceptionally high output.
“In real terms and as a practical example, this includes the capability to cut and machine a three-pane bi-fold in less than 12 minutes. Together, they deliver exacting manufacture, efficiency and volume.”
Aluminium is forecast to reach a 17-year high topping 220,000 frames by 2020 (Palmer). This includes growth in the bi-fold door market of 30% in the same period to 55,000 door sets. Of these Palmer predicts that that aluminium will account for sales of more than 35,000 units.
Paul added: “The LMT65 and Graf, give us the capacity that we need to meet the growth that we’re forecasting and to guarantee consistent and high quality manufacture of those products. It’s about volume, efficiency and precision.”