Founded in 1986 by David Packwood with just a couple of capstan lathes, Batchflow Engineering — now run by the founder’s son Steve — is a highly successful CNC sub-contract machinist, with the profits continually ploughed back into the business.

With the company mainly focused on turning, its milling capability had taken something of a back seat, but a growth in demand for low-volume and prototype work — especially for the motor-sport sector — saw an increasing demand for milling.

Batchflow initially considered using its advanced mill/turn capability as an option, but for small batch quantities and prototype work, this wasn’t always the most efficient use of that capacity, and Mr Packwood began considering dedicated machining centres.

“We knew we had to replace our existing and ageing machining centre. While visiting the last MACH exhibition, I saw the XYZ 2-OP and immediately realised that we could make full use of its capacity; moreover, its small footprint was ideal for us at the time. The decision to buy it was one of the easiest I’ve ever made.”

The 2-OP from Burlescombe-based XYZ Machine Tools had a number of features that particularly appealed to Batchflow: a footprint of just 760 x 1,220mm, an eight-position tool-changer, a 3hp 6,000rev/min spindle that allows a variety of parts and materials to be machined efficiently, and the easy-to-use ProtoTrak control system (www.xyzmachinetools.com).

Another key element of the 2-OP was the machine table and its integral Jergens Ball Lock fixture location system.

“The Jergens system is perfect for us, as we produce relatively small batches, so set-ups are frequent. With the Ball Lock, we can quickly position fixtures, knowing exactly where they are on the table.

This reduces set-up time considerably,” says Mr Packwood. The success of the 2-OP meant that Batchflow’s next investment in milling capacity also came from XYZ. The sub-contractor chose an LPM (Lean Production Machine), in part because it also has the Jergens fixture location system and ProtoTrak control.

“The fact that the LPM machine has the same control and fixturing system as the 2-OP made the decision straightforward.

“Among the work we do for the motor-sport sector, there is a significant element of small-batch and prototype work, but lead times are always very short, so anything that helps to reduce downtime is a major benefit.

“These machines are ideal for a sub-contractor like us; with them, we can provide a rapid response to our customers.”

The XYZ LPM expands on the machining capability of the 2-OP with a 15hp 8,000rev/min BT 40 spindle, a 900 ¥ 500mm table and a work envelope of 785 x 470 x 530mm.

The tool changer has capacity for 16 tools, and these can be accurately pre-set using the system supplied with the machine. Moreover, the ProtoTrak PMX control allows users to carry out background editing of programs while the machine is running, providing further opportunities to reduce the set-up time for the next job.

In conclusion, Mr Packwood said: “Only a minimum of training on the ProtoTrak control was required; overall, moving from our previous machines to the XYZs has been a very positive experience.

“Added to that, we have the benefit of fixture interchangeability between the 2-OP and the LPM. This means we can do most jobs on either machine, which is a big advantage with the type of work we undertake.”