forming & fabrication
Air Cleaning Systems, manufacturer of coolant and emulsion mist control equipment for machine shops, has
installed a new press brake at its Cardiff HQ - raising capacity, reducing bottlenecks and easing labour overheads.
Breath of fresh air
A new generation of
electronics and
software on the Safan
machine makes operation
extremely fast, easy and
precise. These features are
combined with low noise
levels, 50% reduced energy
consumption, extremely low
maintenance costs and an
integrated safety system.
read more about
forming & fabrication
at www.mwponline.com
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FOR twenty years, ACS has supplied engineered
solutions to a range of air filtration problems, helping
manufacturers and their staff benefit from cleaner, safer
working conditions. Specialising in control of coolant/oil
mist/smoke from machining applications such as turning,
milling and grinding, ACS tailors its products and services
to deliver practical solutions. With business growing by 17%
in the past 12 months, the demand for ACS products is
rising from both its OEM sales to machine tool companies,
and retrofit business direct to end users around Europe.
Boosting growth is a subcontract sister business
launched two years ago at the same site - ACS Sheet Metal -
whose customers include the construction division of
Corus. ‘What with the success of our core air cleaning
business, as well as ACS Sheet Metal, it was clear we had
some thinking to do regarding the expansion of our
manufacturing capacity; forming was becoming a real
bottleneck’ says the company’s Managing Director, Mark
Lemkey. Although happy with its existing press brake, ACS
decided to fully assess the market for a new machine, and
chose a Safan E-Brake.
Its underlying concept is built around a servo-electric
drive based on a patented pulley principle that results in a
very even distribution of forces, such that in 98% of cases
no crowning table is required. A new generation of
electronics and software makes operation extremely fast,
easy and precise. These features are combined with low
noise levels, 50% reduced energy consumption, extremely
low maintenance costs and an integrated safety system.
ACS is to install a laser cutter to complement punch
press capability. This will allow the company to venture
beyond its current 3mm maximum sheet thickness for
subcontract work. With this in mind, it was imperative the
new press brake could cope with thicker material. ‘Not only
do we enjoy the benefits of all-electric technology such as
faster bending speeds, lower maintenance and less energy
consumption, we can also move seamlessly into thicker
gauge processing as and when required’ says Lemkey.
Speed is critical at ACS, on both sides of the business.
Although the specification for each air cleaning system
depends on the application, lead-time for new equipment is
quoted at just two weeks. Similarly, it is the speed of
turnaround at ACS Sheet Metal that has helped the
company enjoy considerable success in its first two years of
trading. ‘For batches of 50-off and over, I can’t think of any
competitors in the area that can beat us on turnaround;
and now that we have the Safan E-Brake, we will move
even further in front as we can run two processes
simultaneously. The days of bottlenecks in the forming
section and the resulting overtime required to dissipate the
problem, are long gone.’
The 4m bed on the E-Brake has already proved itself
very useful. ‘Originally we were looking for a 3m machine,
but it so happened that Safan had a 4m model available; at
86 MWP march 2008
first I didn’t think we would need the extra bed length but
as things turned out, the first job that arrived after
installation was 4m long material.’
Before buying the machine, ACS employed a new press
brake operator and sent him and his supervisor to see the
prospective Safan machine. The machine was ordered as a
package that included tooling and software, and is now the
centrepiece of ACS’s manufacturing facility. ‘As the
business grows we are getting more and more customers
coming to see us. The Safan E-Brake confirms to our clients
that we are investing in both our future and theirs.’
As well as subcontract work, the E-Brake has been set to
work producing a number of parts for the company’s air
cleaning systems. The ACS range of air cleaners are
designed for direct attachment to most machine tools -
removing respirable particulate from the machining
enclosure thereby protecting people, computers,
machinery, air conditioning and heating plant. All mist is
filtered, with the moisture draining back to the coolant
system or into disposal trays while the clean air is vented to
the workshop.
‘Although uptake is strong, the potential market for this
type of equipment remains vast, says Mark Lemkey. ‘Some
manufacturers struggle justifying the investment because it
doesn’t add value to the end product. However, what is the
cost of a lawsuit from a retired worker who develops a
cough only to discover he has lung complications from
years spent working in a mist-laden machine shop?’ It’s a
salutary point which will prompt many manufacturers to
ponder the benefits of working environment filtration.
Since 1932 Safan has established a series of technical
breakthroughs and patents, from the first hydraulic shear
in 1965 to the first servo-electric press brake in 2004, the
Safan E-Brake. Other innovative milestones include the
first servo-hydraulic press brake (1980), the first press brake
with robotics (1988), the first servo-mechanical press brake
(1995) and the first shear with hybrid drive (1999).
www.safan.co.uk
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