JW Laycock has transformed its plate profiling capability with an Ultra 3500 combination plasma and oxy-fuel cutting machine from Kerf Developments, reducing subcontract profiling lead times from four or five days to just hours. 

The Keighley-based steel stockholder, which traces its origins back to the 1740s, has progressively brought more processes in-house, including sawing, angle-cutting, guillotining and drilling. Profiling was the final piece of the jigsaw. 

“Our business is very much built on being reactive,” explains managing director Mark Sugden. “We could supply 9.7 tonnes of a 10-tonne order immediately, but a few profiled parts meant relying on a subcontractor and subsequently delaying delivery.” 

Installed in December 2025, the Kerf Ultra 3500 features a 3 x 4 m bed and both plasma and oxy-fuel cutting heads. Its 300A Lincoln Electric FineLine plasma technology handles the majority of JW Laycock’s work, typically 8-30 mm plate, while oxy-fuel cutting  accommodates thicknesses up to 150 mm. 

A Burny CNC controller simplifies operation through its integrated shape library and process database, automatically configuring cutting parameters for different materials and thicknesses. Automatic nesting also helps minimise material waste. 

Installation and training were completed smoothly, providing a welcome contrast to the company’s previous machine experience.  

“The Kerf experience has been seamless,” states Sugden. “I’ve handed responsibility to my team, and they have just got on with it.” 

The machine now operates around 10 hours daily, delivering at least 10% material savings and improving responsiveness. Sugden expects the investment to pay for itself within 12 months. 

With profiling now firmly under its control, JW Laycock has also recovered customers lost through previous delays. Turnover is forecast to increase from just over £2m to approximately £3.5m. 

More information www.kerfdevelopments.com