WEINIG Powermat 2400: The high-end solution for industrial production.
The variety of products in industrial series production is immense. However, no matter which market you are servicing, you will always have the right machine concept in the Powermat 2400. The Powermat 2400 offers you both a high-performance platform for the demanding requirements of everyday multiple shift operation as well as great flexibility. This is assured by a modular system with a wide range of aggregates, tools and feed speed solutions. The modular design and large number of options enables the most diverse applications.
Whether planing beams at 10 m/min or producing mouldings at 100 m/min; whether 4,000 rpm or up to 12,000 rpm – we can build the ideal Powermat 2400 for your requirements. With spindle speeds up to 12,000 rpm, jointing technology and strong feed systems, the system provides optimal conditions for series production in the legendary WEINIG surface quality. The Powermat 2400 is truly state-of-the-art technology in profiling.
The Powermat 2400 already fulfills high demands as a stand-alone machine. However, the full potential could be far greater. By upgrading the machine with the PowerMech automation system, you can increase efficiency significantly further. The PowerMech modules are the key to maximum profitability and optimal productivity. The functional units range from an infeed or outfeed system through scanning and conveying to packing and stacking. With the high level of automation you can decide how far you want to exploit the amazing capabilities of your Powermat 2400.
WEINIG challenges itself to manage resources efficiently in a number of ways – including via modern planing technology, which opens up the potential for material savings. This particularly makes solid wood construction timber (KVH) and glulam timber, which are pre-planed in order to make it easier for the scanner to examin the surface, more profitable.
The opposing floating spindles that follow the curve of the wood plane the glulam lamellae, for example, in parallel in the same width and this reduces the chip removal to a minimum.
The gaps between the work pieces required by the floating spindles increases the risk of impact on the first bottom spindle. The spindle mounted at a 30° angle to the machine table avoids this effect. Heavy pressure elements can also be used from above, which enable minimal chip removal at the horizontal spindles.
Jointing technology and hydro tools produce excellent surface quality. Together with the WEINIG PowerLock system, they are unbeatable. In the Powermat 2400, you can choose this combination and easily benefit from it: Jointed tools developed by WEINIG ensure that all knives in the cutterhead have an absolutely identical cutting circle.
This means PowerLock produces excellent surface quality at up to 10,000 rpm and maximum feed speeds! Both the straight jointer for four-sided planing – automatic or manual operation – and the fully automatic profile jointer can be used. WEINIG know-how and experience guarantee complete process reliability of our leading edge technology.
Depending on the condition of the raw material, it may be advisable to have a strong machine infeed. Particularly with bent, damp or heavy pieces, it is advisable to have a strong machine infeed that supports the transport of parts through the machine.
The 3-roller infeed ensures optimal feeding force for strips and boards, particularly when combined with infeed mechanization. A heavier version is available in the 4-roller infeed with two opposing roller pairs. In either case, it is not possible to straighten the work piece.
Options for extension
The WEINIG System enhances your Powermat 2400 to become a highly efficient overall concept that raises productivity. The individual system modules fit together like building blocks to produce the perfect result.
Added value with rods
When it comes to producing rods, the Powermat 2400 impresses with its outstanding repetition precision and high surface quality. The PowerLock tool, PowerCom axis control and a feed system specially adapted to the production task make the Powermat 2400 the best performing profiling machine in the world.
Underpass axes for pallets, barrel staves and all other non-continuous grooves are a challenge for production. With the CNC-controlled WEINIG jumping spindle, you can integrate this demanding processing reliably into your production process and achieve high cycle rates.
Bringing processes together – working more efficiently
The WEINIG System Plus connects all processes through to setup of the machine. Following a positive start in Europe, the technology is now taking the USA by storm.
Sitting comfortably at the office PC, managing the entire automated process from the profile idea to the finished product is a philosophy currently taking hold in more and more countries. In the USA, the Legere Group recently became the first genuine sector heavyweight to invest in WEINIG System Plus. In this instance, it was the difficulty in finding well-trained, skilled personnel that prompted the decision in favor of the simple, networked solution. Like all other users of WEINIG System Plus, Legere’s production is characterized by profile diversity. The same is true of Anderson & McQuaid Co., Ltd. in Massachusetts. The company’s product range includes more than 240 different profiles. This spectrum ranges from rough-sawn to fine-planed, from cherry wood to mahogany. Everything is produced in the company workshop and is either held in stock or may be picked up as early as the same day.
Besides quality, flexibility is the primary USP of Anderson & McQuaid in the market. The company's high standards demanded a contemporary solution for work preparation. They found it in WEINIG System Plus. The centerpiece is the Moulder Master software. This is complemented by hardware components comprising the OptiControl Digital measuring stand, Rondamat 1000 CNC tool grinder and Powermat 700 profiling machine. Like Legere, Anderson & McQuaid also opted for the big CNC solution for grinding and sharpening. The Rondamat 1000 CNC delivers consistent quality and maximum processing precision – regardless of the complexity of the contours or the number of cuts.
Sales manager Patrick McQuaid is delighted with his new investment. “WEINIG System Plus can do everything we can as good craftsmen but faster and more precisely,” he says. Since the technology was introduced, his business has increased its throughput significantly.
When it comes to quality, no distance is too great
Tasmania is way off the beaten track for most people on earth. Even there, however, in the extreme east of Australia, wood processors rely on the German premium brand with six letters.
Brittons Timber has an excellent reputation as a producer of high-quality timber products for interior fittings. The company is also renowned for its spectacular timber construction projects and the use of exotic Tasmanian wood types. When it comes to surface quality, Brittons Timber does not entertain any compromises. Company boss Shawn Britton knows what he wants:
“I have been a proud WEINIG customer for 25 years and look forward to continuing this partnership for another 25 years.” In 1994, when the company acquired its first WEINIG moulder, planing facility manager Jock Dawson traveled to Tauberbischofsheim for extra training. He says the principles he learned there about wood processing to the highest standard continue to serve him well today. His first machine has since been replaced by a 10-spindle Powermat 2400, whose jointing system guarantees optimal finishes even at high feed speeds. Furthermore, WEINIG fan Shawn Britton quickly recognized that WEINIG’s all-round expertise could help him to further optimize his production process. He now has a WEINIG optimizing cross-cut saw OptiCut 200 Elite linked to the Powermat. For its facility in Melbourne, the model Tasmanian business also invested in a further WEINIG automatic moulder plus two saws. This production technology helps Brittons Timber to fulfill its advertising promise day after day: Timber products that give every project a new definition of style and beauty.
Doing the job properly
Vietnam is among the “Tiger countries” of South-East Asia. San Lim Furniture is one example of the impressive growth in the region. The company's factory halls contain more WEINIG technology than the Expo Center in Tauberbischofsheim.
With GDP growth of more than six percent in 2016, Vietnam was among the fastest-growing nations in the world. The furniture industry is a significant contributor to the boom. San Lim Furniture is one of the companies in the sector that has particularly succeeded in exporting high-quality products to North America. During their rapid expansion in recent years, they have also invested in production technology. In doing so, they have set out a clear path: Only the best and only a complete solution from a single source. Their search for a partner who could fulfill these requirements led San Lim almost inevitably to the WEINIG Group. Owner Tony Sulimro underlines: “The brand name and the pioneering technology were instrumental in our decision.” Outstanding service was another key factor according to the customer. In our Singapore subsidiary, WEINIG has a point of contact in the region with an excellent track record. In 2015, San Lim purchased 14 machines and systems covering almost the entire value chain in wood processing. The spectrum ranges from an automatic moulder and tool grinding machine to an optimizing cross-cut saw and CNC center as well as automation and scanner technology. “With this production line, San Lim is a technological trailblazer in the region,” says Anthony Teo of Michael Weinig Asia. The company’s experiences with the highly-efficient technology have been positive from the outset. So much so that San Lim ordered another 16 machines in 2016. “Such confirmation of customer satisfaction may be almost unique worldwide,” beams Anthony Teo.
The ingenious sandwich for creatives
Anybody who nibbles on a pencil while thinking normally does so on a pencil from world market leader Faber-Castell. It may not taste like a sandwich, but the wood-cased writing implement is the epitome of a perfect sandwich design.
Few companies have as long a tradition as German firm Faber-Castell. Joiner and family forefather Kaspar Faber manufactured the first pencils with graphite leads and wooden casing back in 1761 and sold them at Nuremberg market. More than 250 years later, the largely unchanged product is still here. Moreover, 2016 was the most successful year in the history of Faber-Castell. The drawing equipment manufacturer produces 2.3 billion writing utensils each year.
The timeless benefits of the pencil lie in its simple handling, its versatility of use owing to the different levels of hardness and the ability to remove that which has been drawn or written with an eraser. However, these are only some of the secrets to the company's success. The decisive factor is the unique cult status the Faber-Castell brand has been able to generate. In the high-end market segment, the German manufacturer’s products are synonymous with quality and style. As “creative instruments”, they have become treasured means of expression for art and leisure activities. Not least because stressed-out, modern humans have discovered drawing as a means of relaxation.
Faber-Castell currently manufactures in nine countries and has sales companies in 23 countries as well as sales representatives in more than 120 countries. To secure its market position for the long term, the sector giant values efficient and ecological production with high quality standards. For years, the manufacturer has trusted in WEINIG as a partner for producing its wood-cased pencils. In partnership with the world market leader from Tauberbischofsheim, they have developed solutions specifically tailored to their individual requirements, which are in use in a variety of international production facilities.
WEINIG machines play a central role in the manufacturing process for pencils and colored pencils. The first stage involves sawing thin lamellae. A Powermat then cuts parallel grooves in the lamellae, which are around half as thick as the final pencil, before the leads are laid in the recesses. The next stage is to glue on a second, identical lamella from above. The “sandwich” is then planed to produce round, triangular or hexagonal end products. What appears simple is actually quite demanding to produce. Pencils pose particular challenges for machine technology owing to their small work piece dimensions. The WEINIG solution primarily impressed Faber-Castell with its minimal tolerances of 2/100th millimeters as well as its high level of repetition accuracy and extremely fast retooling.
The more challenging the better
The Louis Vuitton Museum in Paris is a veritable feast for the senses in steel, glass and wood. The planning and design required boldness and inspiration. Precisely the right kind of challenge for Mathias Hofmann and his company Hess Timber.
Louis Vuitton is renowned worldwide as a manufacturer of exclusive luggage, handbags and champagnes. Behind the brand is France's richest man Bernhard Arnault. An art lover who recently commissioned the construction of the museum of the Louis Vuitton foundation in the south of Paris. The plans were drawn up by renowned North American architect Frank Gehry. Costs were not high on the agenda and the individual works were subject to the highest demands in quality and creativity.
Mathias Hofmann and his company Hess Timber won the tender for the timber sections of the winding and sophisticated roof structure comprising 12 sails. "The more challenging the better. I love such projects," says the man from Kleinheubach, Bavaria, of his philosophy. With his unconventional thinking and bold attitude to risk, Mathias Hofmann has earned a lofty status in international timber construction engineering. He somewhat regrets that his highly competitive day-to-day business, building supporting structures for standard buildings, has taken something of a back seat. The costs for major projects are high. "Each time you need practically new technology," he says. This was also the case for the Louis Vuitton Museum. The ridge girders required, partly comprising two arches, were produced on an in-house press bed. The client was impressed during the tender process by Mathias Hofmann's unusual style of rod-based block gluing. The highlight is a rod cover lamella that has the same visual appearance from above and below as from the sides.
That transporting the laminated beams, which are up to 28 meters long, through the Parisian metropolis did not cause chaos is attributable to another unorthodox idea of Mathias Hofmann – Hess Limitless. The procedure is based upon a special adhesion geometry and, in principle, enables girders to be transported in short, individual segments without length restrictions or loss of bearing capacity. The girders are then put together at the construction site. Mathias Hofmann can rely on excellent partners in WEINIG. Defects are cut out by an OptiCut at Hess Timber. Two PowerJoint systems take care of finger jointing the lamellae. A Powermat then planes the workpieces ready for gluing. "I have never regretted opting for WEINIG," says Mathias Hofmann.
Photo: HESS-TIMBER / © Rensteph Thompson
Pros in good company
When it comes to distilling a good Bourbon whiskey, Jack Daniel’s has long set the standard. Now, the production of the barrels is also state of the art.
The taste, aroma and color of the whiskey is largely determined all around the world by the barrels in which the whiskey is stored for years. However, Europe and the USA prefer different processes.
While in Europe, the whiskey producers swear by the qualities of old oak barrels, in the USA they prefer new barrels that have been charred. This creates the strong vanilla aroma during the aging process. Before filling the barrels, the distillate is also slowly dripped through a meter-high stack of charcoal. This makes the whiskey softer and purer.. Each barrel must only be filled once.
Naturally, this also applies to traditional company Jack Daniel‘s: 3,000 barrels of the famous Bourbon whiskey are distilled every day in the computerized production facility in Alabama. Until recently, the complex barrel staves were still made by hand. This meant poor wood recovery. So it was little wonder that parent company Brown-Forman decided to re-consider the production process. They opted for WEINIG. Now three Powermat 2400 moulders are on hand for the task. The solution is customized for the high demands of the special cross-section of the barrel staves and includes CNC-controlled jointing technology. Even at high feed speeds, geometrically identical workpieces can be created.
"With the help of WEINIG and the Brown-Forman specialists, we are now able to produce better barrels more quickly, more safety and with less effort," summarizes Larry Comps senior, Vice-President and Managing Director of Jack Daniel‘s.
The know-how also impressed the US association of wood processors. The WMIA awarded Brown-Forman the honor of "Innovator of the year". WEINIG is happy to have played our part and says "cheers"!
No regrets about using outsiders - the Dauerholz story
Peter Weller says: "If I want an entire concept, there is no alternative to Weinig."
The idea started in Hamburg. The production was outsourced to MeckPom. Using outsiders has really given the company a boost. But the Dauerholz decking boards are an obvious hot topic.
A few years ago, a Hamburg carpenter made a sensational discovery: Unlike similar preservatives, hot wax seeps into the core of the wood ensuring genuine deep protection. The researcher found bold investors who believed in the idea, primarily because the outdoor area, with decking and construction timber, provides vast scope for ecological wax-impregnated wood with its high resistance to weathering, moisture and pest infestations. A production plant was built in the perfect spot in Dabel near Schwerin.
The customized Dauerholz production line was designed and installed in close cooperation with the project specialists at Weinig Concept. As well as a planing and profiling machine, a high-speed optimizing cross-cut saw, a curve cross-cut saw, a scanner and a finger-jointing line, the site also includes a tool grinder machine from the Weinig portfolio. “We wanted to keep the entire process in-house as well as being completely autonomous in terms of tool preparation,” says Peter Weller, explaining the decision.
Dauerholz placed greatest emphasis on optimization of wood recovery and finishing. We performed a recovery analysis and established that we had more than halved cutting losses, reports Peter Weller. This success is also partly attributable to the new moulder. The moulder is equipped with “floating” vertical spindles whose flexible bearings allow it to follow the natural curvature of the wood over long lengths. This prevents “snipes” and “dips” on either end of the work piece and eliminates finish planing with further chip removal.
Intelligent feat of strength
The glulam lamellae at Pfeifer in Imst, Austria, are pressed at 160 m/min and subsequently planed. The throughfeed press replaces four old machines.
The Pfeifer group commissioned its modernized production facilities in Imst at the start of 2013. Performance and wood savings were decisive in awarding the order, recalls authorized representative Dietmar Seelos. "We required a press with a feed speed of 160 m/min." This feat of strength was necessary because the new single pressing line was replacing four existing lines. The company chose a WEINIG DKK 115 through-feed press. Its role is to create a continuous strand from the pre-milled and glued infed timber. A feed unit accelerates the lamellae and transports them to the feed-in station, where they are handed over to two servo-controlled, synchronous aligning chains. This ensures continuous jointing with no offset. The master computer knows exactly which infeed lengths and cross sections are coming to the press. The DKK 115 adjusts itself automatically. At the end is a continuous flow of glulam lamellae, which is pushed relentlessly towards the planing. This is a special case as the feeding power of the DKK must also be sufficient for downstream planing. Two 90 kW electric motors are therefore used. The improved chip removal of the WEINIG planer proved decisive. The Powermat 2500 saves at least one millimeter. Since the Kundl sawmill invested in the same planing technology in its quality sorting, it has benefited from the combined effect of the two machines. Performing the cutting in its own sawmill also allows the smaller input dimensions to be reflected one-for-one in the cutting dimensions. For a glulam factory with an output of 100,000 m3/year, this represents an enormous saving.
The Swiss are accustomed to precision workmanship. Still, Lüchinger AG struggled with an automatic moulder from the Far East for four years. Then they had enough.
Full order books are a fine thing. However, it can be a problem if your production capacity is not up to the task. That is why Lüchinger AG were delighted when an Asian manufacturer offered them an immediately available planer that was a perfect complement for their long-serving Weinig Hydromat. The Swiss firm accepted and bitterly regretted it: There was one material defect after another and breakdowns were a daily occurrence. The promised performance was far from being achieved. When the local service operation closed its business, Max Lüchinger drew a line in the sand. “We realized in that moment that you have to take your time to obtain a functioning, customized solution,” says factory manager Arthur Pfiffner. The road led back to WEINIG. The Tauberbischofsheim specialists partnered with Lüchinger to develop a customized production concept based upon the Powermat 2400. With the Uni spindle and state-of-the-art technology for structure planing and carving, Lüchinger now handles every market demand with complete process reliability. After years of uncertainty, we are very relieved, Arthur Pfiffner admits. And if Lüchinger ever need any advice, the Weinig telephone hotline is at their disposal. There is always an expert contact partner immediately on the line who can help, Arthur Pfiffner underlines.
The power of the mountains
Alois Prader GmbH is fighting back against the quick-turnaround wood industry with quality. The firm compensates for its disadvantages in terms of location with modern, customized production technology.
The wild and beautiful Villnöss Valley, home of the extreme mountaineer Reinhold Messner, is also home to Prader. However, holidaymakers' joy is a wood processor's sorrow: The mountain timber takes twice as long to grow as that on the lowlands and is destroyed by the mass-produced wood industry, says Managing Director Peter Prader, voicing his frustration. To assert themselves, Prader invested in new production technology. The objective was to increase value creation while maintaining top quality, an extensive product range and the shortest possible delivery times. The centerpiece of the production line is two Weinig planers. While the old machine is used for special applications, the new investment is purely aimed at productivity and flexibility. This is achieved via 11 shafts, "floating spindles", which allow the lowest possible chip removal thickness, and a tilting cleaving saw unit, which allows several workpieces to be produced in a single pass. The results speak for themselves – Prader are doing brisk business. And the quality has also impressed the die-hard wood enthusiast: With Weinig technology, we get surfaces that are so good, our scanner detects significantly more defects than previously, said Peter Prader. His verdict on the new planing line: We are better and significantly more productive and the flexibility it has given us has opened up new markets.
Ready for the future with solid wood panels.
Since 2001 the hardwood sawmill owner Walter Ohnemus has been running a cutting line. In 2011 he dared to take the next step towards further processing: solid wood board production in Kappel-Grafenhausen with the ProfiPress T 3500 from Dimter.
Areas of application
Produce innovative products economically
Creative surfaces are in fashion, whether for furniture frontages, flooring or facades. Previously, things that you could only produce at high cost by hand or in processing centers can now by produced in the moulder in one run.
The WEINIG structure planing technology makes it possible to move the spindle relative to the work piece as it is fed through and in this way to create a three-dimensional surface. Using CAD software the structured surfaces can be checked and simulated in advance and then actually produced on the moulder.
This puts WEINIG at the forefront again, setting new standards with this new development that could open up new market opportunities for you. You can let your creativity run wild with this technology, producing new products - along with short run times, high productivity and low unit costs.
Our core competence
Profiling mouldings of all types has always been WEINIG’s core competence. Profiling includes a wide range of end products that nevertheless set the same challenges for machine technology: high levels of profile precision with excellent surface quality and regular cuttermarks.
WEINIG technology is always setting new standards in this area. The basis for this are the solid machine bases with precise machine tables and the fence at exactly the right angle to this. The superiority of the WEINIG machines is seen overall when dynamics are brought into the equation: spindles with high true running accuracy, a strong feed system and the corresponding pressure elements.
The perfect interaction of these components guarantees smooth transportation in a defined position through the machine. The result is the legendary WEINIG quality of your products: high profile precision, excellent surface quality and regular cuttermarks.
The importance of solid wood as a construction material has grown constantly over the last few years. This means that there are high demands on the surface quality, particularly for the visible areas. The largest area of application are beams, which are planed on 4 sides and chamfered.
Depending on your requirements, WEINIG offers the right solution, from a small machine to a large line; but they have one thing in common: a high level of flexibility because of the 90° chamfering unit.
The chamfering unit is used to produce the fourth chamfer on the beam after the other chamfers have been produced by the vertical spindles and the horizontal top spindle. The chamfering unit control means that dimensions can be changed quickly and a change in the strength of the chamfer can be made without changing the tool and simply by positioning the spindles.
With this technology WEINIG enables small companies to work with the same economy as a large organization.
Planing glulam lamellae
Glulam is increasingly being used in recent years and therefore more and more importance is being given to planing glued laminated timber lamellae. This depends on achieving a glueable surface at high speed with the lowest level of chip removal. Even the curve of the timber does not make a difference, and can be kept, because the lamellae are glued afterwards and then finally planed again.
WEINIG meets this challenge with innovative machine technology. The combination of slanted horizontal spindles and floating vertical spindles allows the lamellae to be planed with a minimum of chip removal on all four sides while maintaining the curvature of the wood. These WEINIG solutions increase material yield and thus also resource efficiency.
In industrial wood processing, material yield plays an ever greater role. Scanners are used in this context to identify places with defects and to cut them out. Pre-planing is necessary at the start of the entire chain in order to provide the scanner with a clean surface. Accordingly, chip removal should be minimal and a high feed speed is usually required.
In this segment, WEINIG offers both simple solutions with excellent value for money, as well as innovative solutions with unique technology: from hydro-tools to jointers, slanted spindles and floating spindles up to a feed speed of 300 m/min. As well as the necessary machine technology, WEINIG, of course, also offers suitable mechanization. We can meet your pre-planing needs perfectly!