Paul King is a man who knows what he wants. And when it came to specifying a new fiber laser, he knew he wanted automation. “I’ve always been a believer in automation, pushing to run machines lights out wherever possible. I don’t understand why more laser users aren’t using it.”
Founded in 1978 and inspired by its motto, “From Concept to Creation”, UK-based CSM specialises in the design and manufacture of sheet metal, to create a wide range of commercial and retail products on a sub-contractual basis. The company’s capabilities stretch from design and development work through to laser profiling and cutting, MIG, TIG and robotic welding, shot blasting, and assembly. Products include clean-room filtration equipment, wood-burning stoves, trailers, and components for brands such as McDonalds, JD Sports, Subaru, and Debenhams – all of which require the utmost precision in cutting and speed in production.
Logistic requirements
Like many, Paul was a CO2 laser user but, after 18 years, he was keen to investigate fiber laser technology. However, any new solution also had to take into account the logistics of the company’s Swansea Mill layout. “We operate out of a former cotton mill, so it is hard to accommodate a large laser machine because of the type of building with all of the columns that are in the way,” says Paul. “Laser machines lend themselves to big, sprawling factories, so while the easy option is often to buy another machine, the footprint doesn’t always suit the space you’re trying to put it into. My first thought was therefore: what fits the space?”
As well as being appropriately sized and more energy-efficient, any prospective system needed to exceed the automation capacity of the earlier installation. “Our previous laser had automation and that had been successful, so I was interested in any new automation system that offered multi-cassette capacity.”
Laser machines lend themselves to big, sprawling factories, so while the easy option is often to buy another machine, the footprint doesn’t always suit the space… My first thought was, what fits the space?
Paul King, Managing Director
A perfect fit
Requiring a solution that would meet CSM’s footprint, technology, and capacity demands, Paul King contacted Yamazaki Mazak to see what it could offer. Mazak suggested an OPTIPLEX NEXUS FIBER 4 kW laser machine with bespoke 10-shelf automation towers. “What really won me over was that Mazak’s technical team was very accommodating, providing constant dialogue and feedback whilst configuring the system’s layout. They were able to make it fit my space and, more than anything, they didn’t compromise on the efficiencies I was getting with the existing machines.”
The automation system arrived soon after the fiber laser processing machine, replacing the previous 18-year-old model. The automation featured a bespoke design, taking into account the pillars and limited tower space available at Swansea Mill, whilst allowing easy access for loading sheets.
What really won me over was that Mazak’s technical team was very accommodating… They were able to make it fit my space and, more than anything, they didn’t compromise on the efficiencies I was getting with the existing machines.
Paul King, Managing Director
Impressive capabilities
Paul King has been particularly impressed by the speed and the power of the OPTIPLEX NEXUS FIBER, from the very start of the project all the way to post-installation. “Before choosing the OPTIPLEX NEXUS FIBER, Mazak showed me some time studies on a given set of components. Right then, I realised that, despite being the same power, the fiber laser was running twice as quick as my CO2 machine and nearly seven times quicker than my other older laser. Everything up to 4 mm is now being processed on the Mazak because of its efficiency but we are, on occasion, even cutting thicker material up to 12 mm.”
Complementing the speed and power of the OPTIPLEX NEXUS FIBER is the new multi-draw system, which has transformed CSM’s automation capability. “I would load up my previous machine on a Friday afternoon with a big stack of 5-mm and 6-mm material and it would still be running on Monday morning but with the replacement technology, the capacity is less than a day,” Paul says. “The automation has given us an incredible capacity and the machine seems to crunch through any amount of work. I can’t physically feed it enough.”
Benefits today and tomorrow
The new fiber technology laser system has also helped CSM reduce its overall energy consumption and has provided further operational benefits for the company.
“From a profitability point of view, we need to be looking at both ends of the process – both cutting performance and energy consumption. With that in mind, we’ve seen that the Mazak uses roughly half the electricity of our CO2 machine for the same amount of power. We’re also seeing reduced maintenance bills, mainly due to the fact that it doesn’t have mirrors that need replacing and cleaning, which also impacts on our machine uptime.”
This combination of improved speed, power, and efficiency provided by Mazak is helping CSM move forward and expand. Indeed, with the company now shipping products as far as Oman, Malaysia, and Argentina – along with its traditional UK market – CSM’s new laser and automation solution is crucial to the company’s future plans.
“I’ve always said to the workforce that technology and automation have never made anybody redundant in CSM. The business has continued to grow in numbers and those people have remained and been redeployed in higher-value roles,” concludes Paul King. “We’ve nearly 100,000 square feet to grow into at Swansea Mill and we’re continuously growing commercially too. We’ve set ourselves a target to get to £6 million revenue, and the new OPTIPLEX NEXUS FIBER will be vital in helping us achieve this.”
From a profitability point of view, we need to be looking at both ends of the process – both cutting performance and energy consumption… the Mazak uses roughly half the electricity of our CO2 machine for the same amount of power. We’re also seeing reduced maintenance bills.
Paul King, Managing Director
