For over 30 years, Taunton-based Pattern Forme Ltd has been at the forefront of thermoforming mould tool design and manufacture, mainly in the food industry. The company can take projects from initial concept to finished mould tool in lead times as short as 2-3 weeks.

Recent demand has been for larger mould tools to increase productivity, which has led to a need to drill deeper holes. Typically, these holes would range in size between 6 and 10 mm diameter, with depths up to 1000 mm. The traditional solution would be to purchase a dedicated deep-hole drilling machine or subcontract the work. However, the former would require significant investment, whereas the latter brings logistical problems and a lack of control over production. XYZ Machine Tools was able to propose and deliver a quicker and more cost-effective solution.

“It was a chance conversation with XYZ Machine Tools, who have supplied us with several machines, where I mentioned that we needed this extra capacity,” explains Paul Wilkins, managing director at Pattern Forme. “They immediately suggested modifying one of their XYZ 1000 LR vertical machining centres to give the extra Z-axis capability we required. The simple and cost-effective solution was to add a 1050 mm riser block to the machine, which would allow us to drill these holes from either end using the 500 mm Z axis.”

By reconfiguring the machine, XYZ Machine Tools was able to increase the minimum distance from spindle nose to table by 1050 mm. Including the standard Z-axis stroke, this made the maximum distance 1550 mm, which is more than enough to accommodate Pattern Forme’s components. The order for the machine was placed in November 2019 and delivery took place in April 2020.

For further information www.xyzmachinetools.com

Since 1995, an automated storage tower manufactured by Kasto has been installed at stockholder Heine + Beisswenger, underpinning fast, punctual delivery of an extensive range of steels to customers. However, 25 years of constant operation had impacted performance and availability, so Kasto recently updated the Unitop storage system with a comprehensive retrofit.

The Kasto Unitop automatic cassette system measures 68 m long by 13 m, with space for 1300 cassettes, each of which can hold 4 tonnes of material up to 7 m long.
A feature of the system is the storage and retrieval machine (SRM), which automatically removes a cassette containing the required material and transfers it to a carriage that then makes the stock available at ground level at one of two storage and retrieval stations.
During the retrofit at Heine + Beisswenger, Kasto replaced the existing S5 system control with a modern Siemens Simatic S7 400 PLC and updated the drive controllers, as well as the SRM’s positioning sensors and Profinet connection. The hoisting gear was given an efficient, three-phase drive, while the power supply to the SRM and carriage was renewed to improve reliability.
Another modernisation task was the replacement of the carriage that receives the cassettes and delivers them to the storage and retrieval stations at the front of the Unitop.
The carriage now has two roller conveyors instead of one to allow simultaneous handling of two cassettes. Additionally, the longitudinal travel speed of the new carriage is twice as fast, at 120 m/min, increasing efficiency further. According to the company, 35 seconds is saved per storage and retrieval cycle.
Retrofit works were completed in just two weeks.
The storage facility is now controlled and managed by KASTOlogic warehouse management software, which is connected to the MRP system at Heine + Beisswenger.
For further information www.kasto.com

Meggitt PLC has received a three-year continuation contract with Northrop Grumman Corp for the supply of fuel bladders on the F/A-18 Super Hornet.

The contract is valued at around $20m and deliveries are scheduled to commence this month. Using innovative polyurethane technology, Meggitt’s fuel bladders offer a long-life, lightweight solution that is highly flexible, durable and maintenance-free.
Chris Allen, president of Meggitt’s airframe division, says: “The F/A-18 Super Hornet is the tactical aircraft of choice for the US Navy. We’re very proud that our innovative fuel cell technology has been selected to support this next-generation fighter, protecting both pilots and aircraft in mission-critical situations around the world.”
For further information www.meggit.com

At the height of the pandemic, XYZ Machine Tools reduced overall staffing levels while maintaining those crucial areas of customer support, service, programming support, spares and sales, with a core of 22 employees.

A strengthening in sales throughout June and July have seen that number increase to 56, with the prospect of more people being pulled off furlough in the coming weeks.
“Thanks to our strong financial position we’ve been able to weather whatever COVID-19 threw at us,” states Nigel Atherton, managing director of XYZ Machine Tools. “We were resolute in maintaining core customer service functions and this has paid dividends as customers have continued to accept existing orders, while we’ve also seen relatively strong sales of new machines during the pandemic. We must obviously remain focused and wary of the ongoing situation, but it’s encouraging to see customer confidence returning, with positive signs of a willingness to invest in new machine tools.”
For further information www.xyzmachinetools.com

Protolabs has secured a global accolade for demonstrating excellence in health and safety.

The company received a RoSPA Gold Health & Safety Award for ensuring its staff, customers, contractors and any visitors to its manufacturing facility in Shropshire remain safe. “Great pride is taken in achieving excellence in the workplace, whether that is being at the forefront of innovation or creating the safest possible working environment for our employees,” states general manager Lee Ball.
The RoSPA Awards scheme is the longest running of its kind in the UK and receives entries from organisations around the world, making it one of the most sought-after global accolades in health and safety. Andrew Green, facilities manager at Protolabs, says: “As an organisation we always seek to do the right thing by our employees and all visitors to our facilities, which makes this award even more special. It reinforces our commitment to excellent standards.”
For further information www.protolabs.co.uk