WEINIG Powermat 700: The new generation of moulding and planing
With the introduction of the Powermat series in the year 2004 WEINIG began a new era for planing and profiling. Now, with the Powermat 700 the next generation has arrived; offering undreamt-of possibilities.
The Powermat 700 is designed with a revolutionary new operating concept which no other moulder can offer. The result: improved ease of operation and very short setup times offer the highest degree of flexibility. With these outstanding qualities the new Powermat is the perfect response to the market demands of today and sets a new standard for four sided processing.
Operating concept Comfort Set
The new operating concept Comfort Set comprises a great number of wrench-free adjustments for pressure and guiding elements which can be performed quickly, accurately and without error. With features like this the machine operator will experience a new degree of comfort in performing the moulder setup like he never experienced before. The final proof of the new setup procedure can also be seen in the quality of the products you produce.
With 7,000 rpm spindle speed in standard the new Powermat 700 offers even more performance. This means more linear production every day without sacrificing high surface quality. Compared to conventional moulders, the production increase is up to 15%.
The option of 8,000 rpm spindle speed allows an even higher increase, which perfectly meets the current requirements in terms of productivity and cost effectiveness.
Options for extension
At the point where the cutting edge meets the work piece for cutting is where surface quality is determined. Precision tools are therefore essential. However, even the best tool needs spindles with perfectly true running accuracy.
PowerCom Plus: Networked with your environment
Extremely high performance yet surprisingly simple - that is PowerCom Plus, the top solution for management and work organization of your Powermat 700.
Pressure roller moving with the left spindle
Pressure elements and guides are responsible to guide the work piece smooth and safe through the machine. Therefore, they need to be setup properly. In this context, the pressure roller from above located opposite the left spindle and moving with the left spindle offers significant advantages.
“All types of corner joints are possible”
Austrian carpentry firm Nagl specializes in windows. To ensure the required precision, the company has worked with WEINIG technology for many years.
Axamer Lizum is not only the largest ski resort in the vicinity of Innsbruck. It is also home to Nagl. The small business supplies primarily private customers with wood and wood/aluminum window elements. Some 2,500 units are designed and produced each year, comprising windows as well as many large lift/slide doors. The company has been using WEINIG machines in its production for 40 years. However, requirements in the market have changed dramatically in recent years. Today, individually designed windows, special sizes of up to 6 x 12 meters and stronger profiles due to multiple glazing are a reality at Nagl. “Our old WEINIG system could no longer meet these requirements so we had to look around,” says Franz Nagl. Ultimately, they decided on WEINIG technology once again. “WEINIG plays a leading role in the window manufacturing sector. So it made sense to stick with the brand,” says Franz Nagl.
The new Powermat 700 moulder and Conturex Compact CNC machine are designed specially for profitable window production for smaller operations. An important criterion for switching to the new technology was the potential for flexible single-part production with relatively short set-up times. The two machines are now responsible for the complete processing of windows. The Powermat 700 performs pre-planing on all four sides of the window scantlings. Then, the Conturex Compact “takes over” and completes all required work stages in a single pass. The tool changer provides space for 70 tools for milling, drilling or profiling. Window frames can be produced in their entirety. “With the Conturex, we can produce all corner joints required by the market as well as processing slanted and round work pieces,” says a delighted Franz Nagl.
Heading for success as a family: Gerhard, Verena, Franz and Hildegard Nagl (from left)
Source: Tischler Journal
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
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.
All stages of the processes on one machine
Profiling window scantlings on the long side and the cross side of the window scantling, and shaping and drilling are carried out on the processing center that outputs the fully processed scantling. However, the moulder still has an important role in window production as it is needed for 4-sided planing of the window scantling, to remove and to profile the blank glazing bead.
The WEINIG Powermat has a special window package that was precisely designed to complete these three process steps. Using the press of a button the user can select whether the four sides should only be planed or whether the blank glazing bead should be removed as well. Safety prompts ensure that an adjustment can only be carried out when there is no work piece in the machine and that there will be no collision between the saw blade and contact pressure elements. The PowerLock system means that the machine can be retooled in a very short time so that the glazing bead can be profiled.
The WEINIG system also enables the moulder to be connected to the cross-cut saw and the processing center. Thus, WEINIG offers the ideal solution for window production because it is the safest and most efficient.
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.