Complete timber solution, ‘factory in one machine’ is ideal for small batch production

Demonstrations of Biesse's UniWin production centre drew large crowds when it was launched at the Ligna international woodworking machinery exhibition in May.

Biesse makes impressive claims for the UniWin: 'in one machine you have everything needed for a single operator to manufacture timber windows of any shape – at a rate of 35 units (four-element sash plus four-element frame) in an eight-hour shift.'

The 25 square metre footprint compares with around 100m2 that would otherwise be needed for a production line offering the same range of functions, which include cutting, tenoning, profiling, boring and milling (for locks, handles and hinges), and jointing (tenon, secret tenon, dowel, mechanical, fingerjoint). And by integrating the whole process, UniWin reduces the risk of damage as components are moved between different machines, as well as improving productivity.

Above all though, the zero set-up time means that special designs of windows – and doors – can be produced as easily as standard units. All components for each window are produced as a set – with curved parts for arch designs machined from a straight piece of timber and fingerjointed at the ends for subsequent gluing – and are then ready for immediate assembly.

Testing environment

One of the first to install a UniWin is Comeca of Rimini in Italy, which has 140 employees, an annual turnover of more than 20 million euros – and manufactures 10,000 timber windows and 70,000 doors in hundreds of designs each year.

This makes for a pretty testing environment and Comeca's Managing Director Giancarlo Signorotti admits to having some initial reservations – but says these were soon dispelled. ‘By working with Biesse we were able to understand the opportunities that the UniWin and its easy-to-use software could offer us. We are seriously reviewing our entire production process and working methods.’

Comeca now designs windows in the drawing office, and the data is then downloaded to the UniWin. The software includes parametric programming, so different sizes can easily be produced by adjusting just a few values rather than having to produce complete designs for each size. With fully automatic adjustment of all the working units, the UniWin offers 'real time' production of windows in the same or different styles, with zero set-up time and no further involvement by the operator once the raw materials have been loaded.

‘Previously, any order that included an arch, a sliding portion or other complex elements was almost a nuisance – one that we would have willingly avoided,’ said Mr Signorotti. ‘With the UniWin, everything is standard – including designs that from habit we still call 'specials'. The operator loads the raw material onto the automatic table and removes it after just one cycle.

‘It's all so simple that we are considering using the machine more and more – even for standard products.’

Signorotti adds: ‘In view of the results obtained and having assessed the machining times, we decided to manufacture our top line 68mm thickness standard windows entirely on the UniWin. This also allows us to produce the glazing beads – perfectly cut from the same piece of timber and stapled to the relevant component – which saves time and improves quality through the precision machining and continuity in colour and grain.’

UK potential

Biesse says the UniWin offers exciting potential for UK manufacturers.

‘There are three distinct markets for the machine,’ says Max Manina, Managing Director of Biesse UK. 'Smaller businesses that want to produce standard or bespoke windows and doors with few employees and a small factory unit; medium to large sized companies who could base their complete factory on UniWins to achieve higher production but still with the flexibility to manufacture ‘one-offs’ as standard; and larger organisations like Comeca who could use the machine for custom designs as well as offloading some operations on standard windows and doors from the existing production line.

‘Today, manufacturers are looking for technology that allows versatile, small batch production but with high volume efficiency and costs, and which also addresses the problem of skills shortages. For timber window and door manufacturers, the UniWin answers all these needs.’