Vollmer helps Systco achieve lights-out production

SAW BLADE sharpening firm Systco Unilap acquired its first Vollmer machine in the late 1970s and has bought a complete suite of German-built machines over the years. Initially serving local customers, Systco has invested in state-of-the-art technology and automation. The result is that the company now manufactures more than 5,000 product lines that are shipped around the UK daily. The company has 11 Vollmer machines - three of which were delivered in 2022. 

With 25% annual post-Covid expansion in traditional markets and growth in new segments, Systco needed capacity and acquired a Vollmer CHX840 with an HS loading system was delivered in April last year. This was rapidly followed by a Vollmer QXD250 with the HC5 loader in July and then a Vgrind 260 with an HC4 loading system in October. 

Facilitating light-out operations 

The reasoning behind the CHX840 and the QXD250 was simple. The automated CHX840 saw blade sharpening machine was purchased to add unmanned lights-out running and alleviate capacity on the 22-employee company's other saw blade manufacturing and servicing machines. Systco Unilap already had a nine-year-old Vollmer QXD200 machine running around the clock, so upgrading to a brand-new QXD250 would add capacity. It would also support the rapid growth in the metalworking industry and provide continuity of supply in the event of planned maintenance or machine downtime on the existing QXD200. However, the Vgrind 260 was a completely new technology for Systco.

"The build quality, innovation, reliability and the ability to outperform all other machines is what keeps us buying Vollmer. However, the Vgrind 260 was a completely new concept for us and a huge leap of faith - but it’s a leap we are delighted we made," said the company's MD Carl Hughes.

A paradigm shift

Delivered in October, the Vgrind 260 with the HC4 chain magazine loader incorporates Vollmer’s unique multi-layer machining concept that has two vertically positioned grinding spindles on the C-axis pivot point. Each grinding spindle has a four-wheel grinding pack that sees the machine wheel exchanger loaded with a total of eight wheel sets that are automatically changed and probed - giving Systco Unilap never before seen levels of flexibility and automation.

"The Vgrind 260 has been a revelation for our business. The transition of rotary carbide tools from our other CNC machines to the Vgrind has been seamless. The NUMROTOPLUS software platform makes programming easy, as it combines simulation and collision monitoring in an intuitive control panel. This is perfect for processing new tools and moving existing tools from our other machines has proven to be simplistic," stated Systco Unilap’s general manager Bob Young.

Reducing lead times 

Like any manufacturer that produces and services cutting tools, set-up times can diminish profitability, prolong lead times and require significant staff input - not with the Vgrind. "Previously, we would have to schedule and allocate particular tools to respective machines to minimise the changeover of grinding wheels, collets and re-programming. Now, we can load up the HC4 Plus chain magazine with a range of different tool diameters and the Vgrind will just run," Young continued.

Manufacturing one-offs to batches of new tools as well as regrinding tools on short lead times, and turnaround times to get the first-off tool from the machine are critical. "The Vgrind 260 has slashed our time to get first-of’ tools off the machine by more than 80% - this is an incredible saving. The ability to rapidly set up and run a complete mix of tools automatically on the HC4 Plus automation system doesn’t only slash our set-up and first-off times, it gives us very easy access to lights-out production," Young concluded.

For more information:

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