With a history that can be traced back over 125 years through four generations of the Hudson family, Harlow-based Gratnells Ltd has consolidated its position as a leading supplier of storage equipment, furniture and staging to schools, industry and the medical sector. The company is now embarking on the next stage of its development, based on using the latest in tube-cutting technology.
The decision to install a BLM LT5 Tube Laser machine from Ampthill-based BLM Group UK Ltd (
www.blmgroup.com) — the
first in the UK — is allowing Gratnells to meet the increased demand for its tray-storage products, which were previously made using manual machines.
Managing director Murray Hudson said: “Within a very short space of time of installing the BLM Tube Laser, productivity had doubled. Batches of racking that would previously have taken two people two days to complete were being produced — mainly unmanned — in less than a day.
“Not only that, we are now able to process shapes on tubes that would have been impossible to achieve previously, and this has led to innovative new product designs that will have a significant impact on the market. The speed
at which the BLM LT5 operates has also created extra capacity, which we are able to offer to those in need of quick-response low-volume laser cutting.”
The BLM Laser Tube machine has not only improved productivity, but also taken the business in directions it had not envisaged — including motor-sport. Mr Hudson’s son Rory is among the top 10 Kart racers in the UK and
has been selected to be part of the team at the McLaren Performance Academy; in fact, he is currently the Academy’s only UK driver. “It was the connection between BLM and the Italian manufacturer Tony Kart, whose karts Rory drives, that sealed our interest in getting the BLM LT5 machine.
“All of the Tony Kart chassis are cut and bent on BLM machines; having this information has enabled us to work with two universities, manufacturing the chassis for their Formula Student cars. Moreover, the LT5 is allowing us to achieve multiple-angle cuts that in turn create complex joints on these chassis — joints that we couldn’t achieve without the laser. Working in a racing environment breeds quality; and while motor-sport is just one area where we can see potential for our laser cutting service, the capability of the BLM LT5 means that this potential is huge.”
Leap forward
The move from the manual slotting and cutting of tubes to the use of the BLM LT5 Tube Laser has been a massive leap forward in technology for Gratnells, but it is one that is paying dividends, as the company now has the ability
to quickly and efficiently process batches of any size of tube within the machine’s range.
This comprises round tube up to 120mm in diameter, square tube up to 100mm, and rectangular, oval and elliptical semi-flat stock up to 120 x 70mm. It can also cut wall thicknesses up to 6mm (mild steel), as well as process stainless steel, aluminium alloys, copper and brass.
For the larger batches of Gratnells’ own products the BLM LT5 maximises efficiency by using the automatic tube manipulation that comes with the machine. This automation handles everything from loading the raw material to measuring and unloading the finished part; the unloader can also separate, collect and palletise the finished parts, with every operation synchronised by the Siemens 840D control.
This level of automation means that the machine can run unmanned for a significant length of time. The control can also use the measurements of the tube, plus orientation of the weld seam, to optimise part nesting and reduce waste material. During the entire process from loading to cutting, the tube is fully supported and guided, ensuring maximum accuracy of cut parts and protection of the tube surface.
Further efficiency of the BLM LT5 comes in part from its fibre laser, which allows a wide variety of materials to be cut. This cutting capability is complemented by the flexibility provided by the six digitally controlled axes and
the ability of the machine to be changed quickly from one job to the next.
New business
This versatility has enhanced Gratnells’ production and created other business opportunities — including offering a sub-contract laser cutting service. Indeed, Gratnells has created a business within a business (Gratnells Laser Cutting) to provide a rapid-response laser cutting service for small to medium batch quantities — typically, the type of work that wouldn’t be commercially viable for traditional sub-contractors to accept.
Richard Picking, Gratnells’ international marketing director, says: “We justified the purchase of the BLM LT5 on the work that it would be undertaking on our products, so any spare capacity that we have allows us to be very competitive in the sub-contract market.
"We are not looking for large-batch work, as we do not want to commit the BLM LT5 to extended periods on sub-contract work — the main focus remains our own products. However, this spare capacity does allow us to provide a niche bespoke service for customers.”
The installation of the BLM LT5 Tube Laser machine is just another step in the 125 years of development at Gratnells. The company has constantly evolved, moving from manufacturing metal cornice poles and curtain fittings to cornering the market for television stands in the post war boom years; it was also one of the first businesses to develop flat pack wardrobes.
Indeed, it was the latter that paved the way for the current business success, as each wardrobe included slotted frames to allow shelving to be positioned.
When schools changed their curriculum to include more science experiments by pupils, Gratnells took the design of the wardrobe shelving system and added standardised plastic trays.
As a result, the company became one of the largest suppliers of storage systems to schools. Current production stands at 10,000 plastic trays per day, along with their associated shelving. Moreover, these products are shipped world-wide.