UK plant boosts production with SafanDarley

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

Olicana builds success on tube benders from BLM

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

Choosing a roll former for light-to-medium gauge

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

TAEGUTEC CUTTING TOOLS DRIVE PRODUCTIVITY AT PRECISIONENGINEERING COMPANY

A decades-long relationship between a Gosport-based precision engineering company and
cutting tool specialist TaeguTec demonstrates that the right combination of tooling
expertise and new machine tools can unlock substantial productivity gains.
 
Mathison Engineering, established in the 1980s, has evolved from a one-man operation into
a respected precision engineering business serving the marine, aviation and food industries.
Managing director Steve Mathison, who took over from his father, has recently invested in
new SYIL machining centres that have transformed the capabilities of the business, finally
allowing TaeguTec’s tooling to perform as designed.
 
The partnership between Mathison Engineering and TaeguTec stretches back over 20 years,
originating with Steve’s father, John Mathison. In this time, TaeguTec has established itself
as Mathison Engineering’s primary cutting tool supplier, with TaeguTec senior technical
sales engineer Iain Lacayo becoming a trusted technical adviser and problem solver.
 
“Iain has always been our go-to man,” says Steve Mathison. “If there are issues or problems
with machining, he’s been there to help and advise us on the correct tooling, speeds, feeds
and all those little issues that come along which you don’t think of.”
TaeguTec has remained constant throughout the company’s journey, as Lacayo confirms:
“We were one of many initially, but it’s been filtered out. Now, we’re the main supplier for
indexable turning, parting-off and milling tools.”
 
Mathison Engineering faced a frustrating paradox of high-performance TaeguTec cutting
tools with machinery that could not exploit their full potential.
“Some of our machines were too old; they were struggling to keep up with the
recommended tooling,” says Mathison. “Where TaeguTec tooling could run at speeds well
beyond 20,000 rpm, our machines could never get that fast.”
 
The company’s three ageing Fadal machining centres, limited to approximately 10,000 rpm,
meant the potential of TaeguTec’s advanced tooling had never been fully utilised.
“We had to divide everything by half – half the speed, half the feed. Sometimes that’s not
good for a tool, but the cutters still did the job better than anybody else’s products.”

 
Despite these constraints, TaeguTec remained the primary supplier.
“We’ve got all the TaeguTec tool holders and tips,” says Mathison. “The tooling is brilliant, it
works wonderfully.”
 
The turning point came in March 2025 when Mathison Engineering took delivery of a SYIL X5
machining centre with a 20,000 rpm spindle. The results were immediate and dramatic.
“That machine can turn out work twice as fast compared with our Fadal models: a 100%
productivity improvement.”
For the first time, the machinery and TaeguTec tooling were properly aligned.
 
Mathison Engineering’s reliance on TaeguTec spans virtually every cutting operation. The
breadth of TaeguTec’s product range means that whether drilling, milling, turning or
parting-off, TaeguTec provides the solution. For milling operations, the company depends
heavily on TaeguTec’s indexable solutions. The WinMill system’s 8 mm two-flute indexable
end mill with CVKT inserts has become indispensable for small slots and detailed work,
effectively replacing solid-carbide tooling with a more economical solution.
 
“It’s quicker and more repeatable than solid-carbide tools because you don’t have to do
offsets,” explains Lacayo. “You just turn your insert around and away you go. The
Chase4Mill system, with its 90°, four-edged inserts, handles everything from rough milling
to precision shoulder work, while the ChaseMold system with RYMX inserts excels at
stainless steel milling common in marine component work.
 
TaeguTec’s DrillRush indexable drilling system covers hole-making from 8 to 80 mm
diameter.
“The workhorses at Mathison are the little end mills, indexable tools from 8 to 25 mm
diameter,” says Lacayo.
For turning and parting operations on the CMZ lathes, TaeguTec’s face grooving systems and
parting tools deliver the reliability and surface finish required for challenging marine
applications.
 
What distinguishes TaeguTec is the consultative approach.
“We quite often pick a tool out of the book, and Iain says no, you want that other one
because it’s got double the number of edges on the tips, for example,” reveals Mathison.
“I’d much rather pay a little more for a tip and have eight edges than just two. He saves us a
lot of money with his knowledge of the TaeguTec range.”
 

With the SYIL X5 running TaeguTec tools at their designed parameters, improvements across
every metric have been substantial.
“Tools are definitely lasting longer because we’re now able to use the right speeds and
feeds.”
 
Impressed by the transformative results, Mathison Engineering has purchased a SYIL X11
machining centre with a five-axis rotary table.
“We’ve never done five-axis before, but when we need to talk to someone about five-axis,
we go straight to Iain for his advice.”
TaeguTec is already positioned to support this development. The X11 is equipped with 20
bar coolant pressure specifically to enable TaeguTec’s Typhoon high-speed machining
system.
 
“We’ve already started asking Iain questions about the Typhoon and how it works,” says
Mathison. “We’ve now got the equipment that will handle his tooling, allowing us to take on
more complex work.”
Operating at 35,000 rpm with high-pressure coolant delivery, the Typhoon system will
enable even more aggressive cutting parameters.
“The X11 will take Mathison into the area where small cutters are in the ideal window of
where they should be,” explains Lacayo.
 
The relationship extends well beyond cutting tools. Mathison particularly appreciates
TaeguTec’s comprehensive spare parts support: “We can buy screws, seats, clamps –
unbelievable. We can buy those parts, so the expensive holder doesn’t become obsolete.
We can just refurbish it, and we’re off and running again.”
 
Looking ahead, TaeguTec is working closely with SYIL to provide integrated tooling packages
for new machine installations through a voucher programme. This ensures that from day
one, machines and tools are optimally matched.
 
“Now the tooling and the machine are paired together; they work well as a team,”
concludes Mathison. “That’s what makes the difference.”
For Mathison Engineering, that team will always include TaeguTec as the go-to solution for
every cutting challenge. As the relationship between Mathison Engineering, TaeguTec and
SYIL continues to strengthen, it serves as a compelling study in how long-term supplier
partnerships, expert technical support and perfectly matched tooling solutions combine to
deliver measurable, transformative business benefits.
More information www.tageutec.com

Next Phase For LSIC

The NCC, part of the High Value Manufacturing Catapult and the University of Bristol, has confirmed that the Large Structures Innovation Centre (LSIC) will be located on the Isle of Wight. The LSIC will be an open-access national facility to support the development, demonstration and industrialisation of large, high-performance structures across multiple sectors, with an initial focus on wind energy. It will equip industry with end-to-end innovation capabilities, supporting progress from concept through to end-of-life. NCC has announced Vestas as the LSIC’s launch partner.

More information www.nccuk.com