The introduction of a new tube manipulation system at Daventry-based Alltube is making a significant difference to the business in terms of productivity and manufacturing versatility, along with reductions in operating costs and environmental impact.

Alltube, which was formed in the mid-1980s and is still run by the same family, is a well-established specialist supplier of ‘manipulated’ tube, as well as pipe components and assemblies. However, the recent decision to bring in fresh management to work with the younger family members has resulted in a dramatic change in fortunes: sales have increased dramatically, and a more diverse customer base has been established.

Monthly turnover has risen eight-fold, and there has been investment in new equipment — including an all-electric tube manipulation system from Ampthill-based BLM Group UK Ltd (www.blmgroup.com).

The installation of the BLM Elect 102 system has increased Alltube’s machine capacity and significantly improved its manufacturing efficiency.

Speaking about the changes made at the company, managing director Kevin Cope said: “We recognised where the problems lay and set about rebuilding relationships and delivering to customer expectations, with the strict scheduling of lead times.

“Adding value for customers was also part of our strategy; this involved manufacturing kits of parts, delivering to line-side storage, and taking over the stock management of all parts supplied by us to our customers’production lines. Putting these changes in place gave us the confidence to look for new business and to increase the variety of industries that we work with.”

Alltube now produces a range of manipulated tube products. These include hydraulic tubing, tubular welded fabrications and hose assemblies for customers in the commercial vehicle, construction equipment, agricultural machinery, mining and automotive after-market sectors. Mr Cope said: “The first four months of 2016 have all been record breaking in terms of turnover.”

Machine details

The BLM Elect 102 is a 10-axis machine that can bend tube up to 102mm in diameter with a wall thickness of 2mm. It is part of a family of seven Elect machines, the largest of which can handle tube up to 150mm in diameter. Another key feature is its ability to stack eight sets of tooling, which helps to reduce set-up times considerably.

Paul Fuller, who was responsible for purchasing the BLM machine, says: “One of the first jobs that we put onto the Elect 102 was a 50mm-diameter stainless-steel tube that had five bends, each with differing angles and rotations. We previously did this job on an old hydraulic single-axis machine, but the new machine has greatly improved our efficiency. The change-over time with its tool-stacking capability is measured in minutes — and most set-ups need little more than a change of mandrel.”

This increase in productivity is due in part to the BLM Elect’s control system, which manages all the critical machine-setting parameters. The Siemens control also manages the all-electric activation of the 10 axes, with each position and adjustment saved with the individual part program.

This means that when a tool is changed, there is no need to perform adjustments, as these are done automatically by the electric movement of the axes.

The result is a significant reduction in set-up times. The Elect 102 also makes use of BLM’s VGP3D programming software, which guides the operator through the process (it highlights possible collision points and optimises bending operations to generate the most efficient cycle time).

“The method that BLM uses for training operators is excellent,” says Mr Fuller. “Since BLM left our factory, we haven’t had to go back to them once with any questions. The all-electric system used by BLM is a huge benefit compared to our old hydraulic machines.

“The Elect 102 simply draws the power it needs, when it needs it; with our old machines we had to have the hydraulic pumps running constantly. This makes a big difference to our energy consumption; and the reduction in noise is a benefit to the working environment.”