SafanDarley says one of its UK customers was facing a major problem. Its existing press brakes were struggling with certain parts and new product lines. The issues were causing downtime, production delays and higher costs. A new solution was therefore necessary to help the facility increase capacity, flexibility and precision.

After close collaboration with SafanDarley, the plant chose a 300-tonne E-Brake Ultra with a 790 mm Q and 400 mm stroke. According to SafanDarley, the machine is both powerful and reliable, with Wilson Tools designing specialised tooling to handle complex folds and ensure optimal performance.

The SafanDarley E-Brake delivers 300 tonnes of pressing force through a patented dual-drive double pulley system. This capability ensures fast cycles and energy-efficient operation. Servo motors drive the press beam via a double-pulley system. A balanced interplay between fixed and flexible rollers and flexible belts ensures an even distribution of forces over the entire press beam. Even with 300 tonnes of pressing force the deflection of the beam is minimal. 

Bending aid tables make handling heavy plates easier and remove the need for a second operator, while laser angle measurement guarantees error-free results. SafanDarley’s AutoPOL software allows seamless transfer of bending programs to the new machine.

At the customer, the new solution will ensure reliable and uninterrupted production. Urgent orders can be processed immediately, and products will meet the highest quality standards with minimal rejects. Operators can enjoy a modern, easy-to-use machine. The 300T E-Brake not only solves current challenges but also prepares the company for future growth.

More information www.safandarley.com

Ilkley-based subcontractor Olicana Products provides components to customers involved in the manufacture of commercial seating, as well as the medical, education and bathroom sectors. Central to the company’s offer is its use of tube bending machines from BLM since 2001.

The first BLM tube bending machine on site, an E-TURN 52, could process tube up to 52 mm outside diameter. It was the first electric tube manipulator in the Ilkley factory, the pre-existing three being hydraulically actuated, and was able to execute a wide range of functions such as variable radius bending.

Notable also is that all-electric tube benders have better accuracy than their hydraulic counterparts and are also more environmentally friendly. It is due to the absence of hydraulic fluid, which rises in temperature during operation, leading to thermal expansion. They also tend to leak.

Most significantly, however, the 15-axis E-TURN employs a double head with a novel swinging action, enabling both right- and left-hand bends to be accomplished in the same automatic cycle. It deskills the creation of highly complex tubular geometries and avoids the need for a second operation on the same length of tube, although for some applications that is not possible anyway.

Such was the success of the E-TURN 52 installation that a further two machines, both new but of smaller, 32 mm diameter capacity, were purchased in 2021 and 2023 directly from BLM.

The machine supplier’s offline VGP3D software simplifies operation of all three electric tube bending machines. On receipt of a customer order and component drawing, Olicana simulates the bending sequence on-screen to detect any potential collisions or other problems.

More information www.blmgroup.com

When working with light-to-medium gauge metals, precision, consistency and speed all depend on choosing the right metal roll former. According to Bulldog Industrial, whether producing panels, profiles or custom sections, investing in a roll-forming system that is properly matched to the materials and volumes is key to long-term success.

A metal roll former is a machine that transforms flat sheet or coil into a shaped profile using a continuous process. It works by passing the material through a series of forming stations, gradually shaping the metal without cutting or pressing. For light gauge applications, roll formers offer a low-stress, high-accuracy method of profiling that is suitable for mass production.

Bulldog Industrial supplies metal roll formers tailored to customer needs. The systems are widely used in industries like construction, racking, cold storage, furniture and more.

Light-gauge material (typically up to 1.6 mm mild steel) presents unique challenges. It is more prone to flexing, so maintaining tight tolerances becomes essential, especially at higher speeds. Choosing a machine with the correct number of forming stations, roll centre spacing and entry guide configuration helps ensure accuracy without distortion.

The benefits of choosing the right sheet metal roll former include reduced scrap rates from improved material handling, better finish quality due to smoother transitions, compatibility with accessories such as slitting units or punch stations, and increased output with automated feed options.

Bulldog says itsmachines are designed with a focus on build quality, long service life and British standards. Whether seeking for a compact solution for occasional runs or a full production line for high-volume output, the company offers systems that are custom-configured for the sheet type, thickness and desired profile.

More information www.bulldog-uk.com