Laser and punching machines with automated storage

Operating from two sites with a total of almost 100,000ft² of floor space, Holsworthy-based Greenfield Engineering was founded in 1989 with just two members of staff, but fast forward to 2025 and the company is now a major contract manufacturing business supplying ‘fine-limit sheet metal products’ to customers throughout the UK. Products include high-end office furniture, industrial storage systems, commercial lighting, telecoms equipment, retail point-of-sale systems, refrigeration equipment, vending machine components, HVAC systems, electrical enclosures, laboratory cabinets, and partitioning systems, among others.

With a key objective of maintaining its position as the market leader in close-tolerance sheet metal contract fabrication, the company maintains of policy of investment in its staff and advanced manufacturing technology — including that from Kidderminster-based Amada UK Ltd.

Greenfield’s latest investments from the company include two Amada automated machines, one for laser profiling and the other for punching — both with automated sheet storage; and as the company further expands its capacity and capabilities it is also adopting the latest Amada software solutions.

Pictured left: New Amada Ventis-3015AJ 4kW CNC fibre laser cutter with ASLUL twin-tower automation being installed

It was in December 2024 that Greenfield installed an Amada Ventis-3015AJ 4kW CNC fibre laser cutter with ASLUL twin-tower automation, and an Amada EM3612 MKII CNC punch press with an ASIII MP tower. To support these new additions, Greenfield is also transitioning to Amada’s VPSS4ie ‘blank and bend’ software packages; the company is also the first in the UK to integrate Amada’s new LivLots monitoring software — at the core of which is the ability to integrate and manage the entire production workflow seamlessly and digitally, from order intake to final product delivery.

Frank Green, Greenfield Engineering’s founder and director, said: “Our new machines, automation, and software represent a substantial capital investment with Amada; and while we already have an comprehensive portfolio of automated Amada machines we are not replacing any of this equipment — the new machines are all additional capacity. Our markets are extremely buoyant, and the business is in a strong position.”

He added that the Amada LivLots software is set to revolutionise capacity planning and work scheduling in the company’s manufacturing processes, automatically boosting efficiency, reducing waste, and driving cost savings across its operations. “Open book costing is pivotal in our approach to customer partnerships as we build on complete transparency. If requested, we assess early-stage projects with our design team to value-engineer projects or introduce new concepts, removing any unnecessary costs without compromising product functions or performance. Our investment in the latest manufacturing technologies ensures we share savings with our clients for the benefit of all.”

Sustainable manufacturing
A strength of Greenfield is its multiple accreditations. In early 2024, the company added EcoVadis — an internationally recognised ‘gold standard’ in sustainability ratings — to established certifications such as ISO9001, ISO14001, and ISO45001; and since 2016, it has held ‘Zero Waste to Landfill’.

Mr Green continued: “Sustainability is the future for manufacturing, and it has been part of our business philosophy for years, long before it became a hot topic. EcoVadis provides rigorous, third-party independent external assessment of our year-on-year carbon-emission improvements and our corporate and social responsibilities. It even filters down to include our supply chains — and we are proud that in our first year we were ranked among the top 35% of companies assessed.”

Greenfield’s sustainability initiatives include the use of energy-efficient compressors, phosphate removal in powder coating pretreatment, photovoltaic solar panels, interior LED lighting throughout the facilities, and solar-powered lights for the external car park and site. This ‘ecological mindset’ also extends to its manufacturing technology, with ‘Amada innovations’ already reducing Greenfield’s machine energy consumption.

Pictured right: New Amada EM3612 MKII CNC punch press with an ASIII MP tower being installed

“Many companies are drawn to purchasing the highest-power laser machines on offer, but these consume more energy, often unnecessarily; it is almost like using a sledgehammer to crack a nut. Amada’s approach was to run time trials on our material range and thereby identify the optimal ratio of cutting performance to power consumption for our material types and thicknesses. The new 4kW machine aligns perfectly with our focus on manufacturing high-precision, fine-limit components competitively.”

Referring to the use of automation, Lee Harris — Greeenfield Engineering’s production manager — said the ASLUL twin-tower facility will enable the company to achieve true 24/7 production: “Our new Ventis laser cell will be a major game changer for the business, creating additional capacity. Indeed, the automation will pay real dividends after evening shifts finish, operating through nights and weekends with minimal-to-no-staff intervention.”

In conclusion, Mr Green said: “We aim to be best-in-class for our clients, which sees us leveraging our position with customers via the technology we use. Selling our services and promoting our Amada equipment ultimately helps us win new business, such is Amada’s reputation. We are also committed to recruiting and training high-quality engineers via internal and external training sources and the apprentice route. Indeed, we recruit four to five apprentices annually, to ensures long-term business continuity and support the next generation of engineers in building rewarding careers in manufacturing.”