L to R: David Howard and DW Moulding’s production manager, Brian Dawes check real-time power levels on variable speed drives, controlled by Ecogate greenBox 12+ units.

In a bid to improve energy efficiency at their factories, DW Group called in DCS to carry out energy appraisals on their existing dust extraction plants. DCS engineers surveyed both installations and calculated that installing Ecogate technology, with variable speed drives, would result in a combined annual reduction in electricity usage of a massive 240,000kW hours. “DCS put forward an extremely compelling case for their Ecogate system and, with a return on investment of just three years, it was an easy decision to make”, says Brian Dossett, Chairman of DW Group.

At the Bedfordshire site, DCS installed two ECOGATE greenBOX12+ controllers, 15 automatic motorised gates with sensors, and fitted variable speed drives to 75kW, 55kW and 30kW fan units. As machines come on-line, or shut down, the Ecogate controllers automatically detect changes in load and adjust fan speeds accordingly. The system also detects when groups of machines served by a particular fan are off-line and shuts down the fan until required. The net result is a total power saving of around 60%.

At the Tottenham factory, two 30kW fans were converted to variable speed operation, and a total of 24 woodworking machines were fitted with motorised gates linked to two ECOGATE greenBOX12+ controllers. Power usage at Tottenham has been reduced by 58%.

Extraction volumes are automatically adjusted as machines become active or are shut-down.

David Howard, managing director of DW Mouldings says: “Dust Control Systems managed every aspect of the contract extremely professionally. They worked hard to operate around us without causing any disruption to production and always left the place clean and tidy. We are delighted with the system which is actually producing better results than forecast and will pay for itself much sooner than anticipated. Generally,when buying major plant and equipment, there’s always something that niggles you. With this project I can honestly say that everything was done right and there is nothing to criticise.”

Not so long ago, D W Mouldings Ltd, of Sandy, Bedfordshire, had eleven conventional moulders – now they have just four, and 99% of the work is done on the three Weinig’s. With a lot fewer operators and more floor area to accommodate work in progress, the company production throughput has increased to meet demands and provide spare capacity for further growth. High quality finish was always their claim, but now they achieve it with faster feed speeds, minimal downtime and quick changeover times.

With conventional moulders, the average job changes they achieved per day was four. Now on an average day, they changeover 10 to 12 jobs and, when they have a lot of short runs, they can do up to 25. Customers often remark on the quality and speed of service.

“Before we invested in our first Weinig Powermat 3000, we were sceptical that it could replace three conventional moulders”, says Brian Dossett, Chairman of DW Group. “We were also concerned about what would happen when it ‘went down’. But we were soon convinced that the new Weinig technology was the way to go, thanks to the reliability of Weinig’s engineering and back-up service”.

“The three Powermats are providing excellent benefits”, adds David Howard, Managing Director of D W Mouldings Ltd. “I particularly like the PowerCom quick setting feature, the faster throughput at 12,000rpm cutter speeds and the super finish achieved by the HSK PowerLock tooling at the higher speeds. The technology will meet our needs for the foreseeable future”.

The heart of the Powermat moulding system is the patented PowerLock HSK tooling which incorporates the spindle into the cutterhead. It’s light and easy to use and is changed in seconds at the press of a button. No spindle. No spacers. No spindle nut. No wrenches. And no possibility of mistakes. With cutterhead speeds up to 12,000rpm it doubles the feed rates in comparison to conventional moulders.

The PowerCom system offers the advantages of a memory system plus almost unlimited memory for profiles and tooling measurements. With the easy-to-use touch screen, you are guided through every decision. Enter the tooling measurements and the dimensions of the profile, and the PowerCom software calculates where the cutterheads should be positioned, and displays this on an electronic readout.

The tool room at D W Mouldings is very important for ensuring tooling management and record keeping for quick and easy access of information – particularly for re-runs. The key toolroom feature is the OptiCom measuring stand which serves all three Weinig Powermats and ensures the first piece through is perfect with minimal set-up time on the moulder. DW also has two Rondamat 960 profile grinders and a computerised template maker in their toolroom.

D W Mouldings is part of the DW Group of Companies with their headquarters in Tottenham. Their Tottenham factory, DW General Wood Machinists Ltd, established in 1948, also has a substantial size wood mill and showroom. They compliment each other, with DW in Sandy focusing on mouldings and the Tottenham factory producing a wide variety of products – from components for Formula 1 wind tunnels, parts for underground trains, point of sale displays and products for the gaming industry. In fact, anything a customer may request.

DW in Sandy, established in 1971, is a specialist hardwood timber merchant, timber supplier and wood moulding mill. The latter is the fastest growth activity, hence the heavy investment in the latest technology.

DW stock and supply North American and European temperate hardwoods including Oak, Ash, Maple, Cherry and Beech, and also various species of tropical hardwoods, including Sapele, Iroko, Meranti and Seraya. All their timber is purchased from approved sources and when necessary FSC, PEFC & MTCC certified.

Their customers, who comprise contractors, shopfitters, Flooring companies, builders, carpenters and joiners, can be provided with any moulding profile and if required, primed and lacquered with water based products, in their in-house finishing line. Quality of finish is guaranteed, and short run orders are just as easy to meet, as long runs.

Part of the London-based timber suppliers and wood machinists DW Group, the Bedfordshire company has recently invested more than £700,000 in its timber moulding mill. Its four moulding machines, including three new Powermat moulders, are able to produce a wide range of standard and non-standard sections, predominantly in north American and European temperate hardwoods.

The high quality finishing line has been set up to use only water-based primer and lacquer, a further demonstration of the company’s commitment to the environment, said Managing Director David Howard. He is proud of the fact that in its 50-year history the family company has not lost sight of his grandfather’s and great uncle’s commitment to quality rather than price. The company maxim is ‘ Moulding your future’.

The decision to pursue chain of custody certification was driven as much internally as by customer demand, said Mr Howard. ‘We are aware of our responsibilities to the environment and we do foresee demand for certified products growing, particularly in and around London as work for the 2012 Olympics gets under way.‘ That said, the company will deliver nationwide, using its own fleet of vehicles or reliable couriers for smaller orders.

In addition to flooring accessories such as thresholds and reducers, DW Mouldings supply other key sectors including construction, shop fitting, DIY and the window/conservatory market.