Editorial: Modern Woodworking article titled "Trends"

Changes in production philosophy drive moulder advancements 

Just a few years ago in the millwork industry, molding runs of 10,000 feet or more were commonplace. As the industry has shifted toward just-in-time manufacturing, however, runs between 500 and 2,000 feet to meet individual customer demands are the norm rather than the exception today.

As a result, machinery manufacturers had to rethink the design of their moulders to maximize production and efficiency. What resulted are advances in moulder design engineered to reduce changeover and setup times. In the past, setup and changeover could take 30 minutes or more, significantly reducing the moulder's ability to operate efficiently. Today's machines boast much faster and accurate setup, reducing setup scrap.

"Today, with properly organized tool rooms, accurate tool measuring equipment and profile grinding techniques, changing molding patterns within two or three minutes is well within the realm of possibility," says Bob Metz, product manager for SCM's moulder division.

One way moulder productivity is increasing is advances in the tool room, including axial constant grinding. Axial constant grinding of the cutter heads uses a series of reference points so that when you grind the knives in the tool room and transfer the cutter head to the spindle in the moulder, the reference points remain the same.

"When you put the cutter head on the spindle, you don't have to make the axial positioning move to get your profile right," says Kurt Quade, national sales manager for Weinig. "Axial positioning of the cutter heads is where most of the time is spent in the setup process. By grinding knives to an axial constant reference, you don't have to make that adjustment, so you eliminate some of the changeover time by doing things smarter during the grinding process."

Digital readouts and automatic adjustments are eliminating the number of processes needed to set up the moulder between runs, which in turn increases the amount of time the moulder is actually in production. Some moulders have digital controls that allow you to preset the chip breaker, pressure shoe and feed rollers — rather than manually setting each of these elements — to further reduce setup time and simplify operation.

"With SCM's system, you just have to measure the tool diameter and dial that in to the digital counter, enter in the thickness of the finished product and you're finished," says Metz.

Spindle design has also improved to allow feed speeds of 8,000 to 12,000 rpm (rather than the traditional 6,000 rpm) on some models when equipped with the proper tooling. The higher spindle speeds allow between 30 percent to 40 percent faster feed speeds without the need for jointing technology.

Advances in moulder design aren't limited to the flagships of manufacturers' lineups. Smaller moulders have benefited from a trickle-down of technology, as many of these improvements are found as standard or optional on most machines.

Price points are also encouraging to woodworkers looking to add a moulder to their production lines and enter other markets to expand profits.

"More people are finding that selling rough lumber is profitable, but value-adding is going to get you that much more," says Nikki Nichols, public relations specialist for Wood-Mizer. "You can double the value of your lumber after drying and molding it. The woodworking market is getting wiser in terms of recognizing the benefits of value-adding."

Manufacturers also say the ability to quickly react to the demands of the market is another reason to invest in a moulder.

"With shortened lead times today, you lose business if you can't adapt to changes," says Quade. "With a moulder, you can concentrate on making profit because you're not paying someone else to do it, and you can realize the advantages of fast turn-around without having to outsource."

Small moulders add versatility
Small moulders in the marketplace aren't designed for the same type production as large high-speed moulders. These machines are used to complement their larger counterparts. Their key advantages are smaller footprints and lower utility requirements.

"Smaller moulders are the perfect machine for short runs of 300 or 400 feet," says Jeremie Paulin, sales manager and head technician for Mikron Machinery. "They are quick to set up and fairly simple compared to large moulders. They can be cost-effective to use even if they aren't needed every day."

On the horizon
Manufacturers continually update their machines with new features. Advances in spindle technology are on the near horizon — at least one manufacturer has already equipped its moulder with HSK spindles for quick tool change, using smaller diameter tools to enable higher rpms, and others are sure to follow suit. Also look for larger capacity machines with the ability to do bigger cross sections.

Tooling systems are also becoming easier to use for faster changeover. Some of today's models already allow you to replace cutter heads on the spindle with the push of a button that controls the locking mechanism. As alternative materials to wood are increasing in popularity, tooling technology is adapting to cut such materials as MDF, plastics, cellular PVC and solid surface.

Perhaps the most enticing change on the horizon is cost-effective computer-aided setting systems. As the technology becomes more commonplace, prices will come down, making moulders more affordable and making your purchase decision easier.

-Jeff Crissey

For more information on SCM, circle 781; on Weinig, circle 782; on Wood-Mizer, circle 783; on Mikron, circle 784 on the Reader Service Card.

MODERN WOODWORKING | MARCH 2003

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