The addition of the high-performance Biesse Rover B FT HD has significantly transformed Unitech Oxon’s kitchen manufacturing process, enabling the Banbury-based company to achieve faster production times and a vastly improved working environment. Founded by Kevin Crouch over 20 years ago, this family-run business is known for its high-end, bespoke kitchens and bedrooms, with a mix of clientele that includes direct-to-public customers, trade retailers, and fitters. More recently, Unitech Oxon has expanded into the contract market, producing kitchens for new housing developments—a strategic move that called for greater production capacity.
In late 2022, a booming demand for contract work created an urgent need for a faster CNC machine. The company identified Biesse’s high-speed Rover B FT HD as the optimal choice due to its innovative design and unmatched productivity for nesting operations. By rethinking machine design, Biesse has achieved a 30% faster cycle time, enabling Unitech Oxon to accomplish in three days what previously took five. The Rover B FT HD’s structure includes a self-contained enclosure that allows operators to work safely while the machine operates at higher speeds. Key components, including the machine’s motors, rails, racks, and pinions, were upgraded to handle the added inertia that comes with increased speed.
Streamlining Workflow and Reducing Costs
Just after installing the Rover B, Unitech Oxon faced a shift in the property market as rising interest rates began to cool demand. To adapt to these new conditions, the company restructured its CNC workflow to take full advantage of the Rover B’s productivity. By consolidating CNC work into three days, Unitech Oxon reduced energy costs and operating expenses while redeploying labour to other areas of the business.
“We had less work to process but a much faster machine,” explains Adam Watts, Unitech Oxon’s head of sales and business development. “Instead of running the machine and extraction systems for five days, we compressed operations into three days, which helped reduce costs like electricity and freed up labour for other tasks.”
However, this increase in speed required the team to rethink how they handled loading and unloading, as well as general workflow management. With the new machine’s speed, efficiency in these supporting tasks became crucial to keeping up with production demands.
Enhanced Drilling Efficiency
Biesse provided valuable support in optimizing the Rover B’s efficiency by equipping it with a 32-spindle drill block, allowing for a dramatic improvement in drilling productivity. Drilling can account for up to 60% of nesting time, and maximizing this part of the process was essential. According to Biesse’s area sales manager, Mark Trapnell, having an efficient drilling setup is crucial for high-speed operations like Unitech Oxon’s.
Previously, Unitech Oxon’s old machine required individual drilling for each hole, which was time-consuming. Trapnell showed Unitech Oxon how to make better use of multi-drilling capabilities: now, when multiple holes are needed, the drill block can drop down multiple drills to drill them simultaneously. This adjustment saves about one minute per panel, which adds up over the course of the day.
“With these optimizations, we’re saving up to an hour a day in drilling time alone,” notes Adam.
Cumulative Time Savings and Increased Output
When the drilling time savings are combined with the improved loading and unloading efficiency, Unitech Oxon saves up to two hours per day, in addition to the Rover B’s faster processing capabilities. With the new machine, they’ve seen a remarkable increase in output. According to Kevin Crouch, where an operator could previously process 40 sheets of board in a day, they can now handle more than 60 sheets with the Rover B.
The company plans to maintain this efficient three-day production schedule when demand increases, allowing flexibility in production planning. “The Rover B has essentially forced us to work smarter, giving us flexibility to manage fluctuations in workload,” says Adam.
Enhanced Dust Control and Work Environment
With the Rover B installation, Unitech Oxon also invested in a new dust extraction system to improve the workspace environment, addressing the considerable dust generated by machining MFC and MDF panels. This addition, combined with Biesse’s T-JET feature, has proven to be transformative.
The T-JET system, which uses high-pressure nozzles to clean the cut line as dust is produced, mitigates dust buildup directly at the cutting channel. This advanced air jet system dislodges dust before it accumulates, allowing the extraction system to efficiently remove it. “It’s a different workplace now,” says Kevin. “Previously, dust was everywhere—in the offices and on screens. With the T-JET and our new extraction setup, dust in the workspace is no longer an issue.”
The T-JET system not only improves air quality but also saves time. Without dust settling on the bed, operators no longer need to clean between programs, allowing them to immediately start the next job, increasing overall workflow efficiency.
Adding the Stream A Smart Edgebander
Following the positive experience with the Rover B, Unitech Oxon has invested in a Biesse Stream A Smart edgebander with the innovative AR70 corner rounding unit. This addition will enhance the finish on doors for the contract market and further improve efficiency. Historically, the company used coloured glues, which required frequent colour changes based on board types. The Stream A Smart will facilitate the switch to transparent PUR glue, which is suitable for all colours, resulting in a thinner, moisture-resistant glue line.
The decision to switch glues and upgrade equipment stemmed from a Biesse Edgebanding Masterclass. Kevin acknowledges that despite his years of experience, learning directly from Biesse’s experts has been invaluable: “There’s no ‘university of edgebanding.’ The team at Biesse has been generous in sharing their expertise and has guided us at every step.”
Both the Rover B and Stream A Smart represent part of Unitech Oxon’s broader investment strategy, aimed at streamlining operations and positioning the business for growth. “These investments have set us up to operate more efficiently, giving us the best chance to expand and take on new projects,” says Kevin.
For more information, contact Biesse at 01327 300366, email [email protected], or visit biesse.com/uk.
