MDF Profiles Ltd, the newly established subsidiary of Stairways Holdings, has picked a Masterwood Winner to machine doorsets featuring the company’s Frame Master internal frame system. It is the sixth Masterwood CNC machining centre to have been installed at Stairways Group factories.
Housed in a new 15,000ft2 factory on a three acre site outside Welshpool, MDF Profiles became operational in October last year. It has been set up to capitalise on the expanding market for internal house doors in the UK, with builders estimated to require around two million each year, and represents an investment of around £1m.
Frame Master is an easily adjustable internal door frame, also available in veneered versions, that is designed to fit all wall thicknesses from 75-160mm. It was developed jointly by Stairways Group managing director Roger Stevens and MDF Profiles’ David Alcock and features a self-locating architrave with a mitre locking system.
“The use of Frame Master is intended to make life far easier for house builders as it eliminates error and waste and its flexibility will allow them to reduce their internal door stock holdings,” says David Alcock. “The building companies we have already demonstrated it to have been highly receptive and we have received some substantial orders. We are confident it will be extremely popular with builders and eventually become the industry standard.”
The Winner machine they have purchased is the 2.45S model, a variation of the standard machining centre. It is purpose-designed for door and door frame machining, incorporating three routers, one vertical and two horizontal.
The 2.45S is a cantilever type machine with an
X axis of 2450mm, Y axis of 1300mm and Z axis of 110mm (useable), all with brushless motors. Standard features include a 10.5hp router with four-post automatic toolchanger and two working zones. It comes with an option to replace the four-post tool changer with an eight- or 14-post carousel toolchanger that travels with the carriage.
The software is Masterwood’s own easy-to-use Masterwork, a Windows-based program that works with any PC and incorporates CAD for design work.
MDF Profiles uses the Winner to machine out recesses for the hinges and latch on the MDF door frames as well as for the hinges, latches and lock openings on the hardboard doors. Both components are machined speedily and accurately in batches prior to being assembled.
It also handles subcontract CNC machining work on door sets and doors that the company produces for other leading manufacturers.
The Winner is at the heart of the new manufacturing venture and is the single most expensive machine bought for the factory. Other equipment installed includes a veneer wrapping machine, a mitre saw, cross-cut saws and a double end tenoner.
Jason Beecroft, the Winner’s operator, says the training he received from Masterwood engineer Mark Flesher, who installed and commissioned the machine, was first class.
“After the three-day training session with Mark I felt really confident in using the program, which is very user-friendly. The machine is extremely accurate, which is essential when producing doorsets that have to be married up, and the quality is superb.”
Three Masterwood CNC machining centres, a Tecnomat, a Project 327 and an Atlas, have been in use for some time at Stairways’ Cannock factory which specialises in the production of stairs. A Winner 2.2 door line and a Winner 3.2 have been installed at the company’s Leamington Spa site, where doorsets are made.
“There was no hesitation in choosing the Winner for our latest venture,” says Roger Stevens. “We were highly satisfied with the five Masterwood machines which take care of all the CNC work at our two other factories, as well as being impressed with the thorough level of training and after-sales service provided. As far as machining centres are concerned, we are a Masterwood-only zone.”
