One of the UK's leading manufacturers of electrical wiring accessories, has invested in the latest hydraulic press technology, to improve its competitive ability in global markets
The Hamilton Group, one of the UK's leading manufacturers of electrical wiring accessories, has invested in the latest hydraulic press technology of P J Hare to boost its standing in the increasingly competitive global manufacturing environment. This investment in new plant is viewed as a crucial element in enhancing both the company's export potential and in strengthening its long-term position in the home market against overseas competition. Ian Hamilton, Director of Hamilton's, explained: 'In recent years, as with other manufacturers, we've been under increasing competition from cheaper imports.

Obviously we can't compete against the labour costs or overheads of our competitors in the Far East, and have no intention of lowering our quality thresholds in order to compete on price.

Instead we had to find another way of staying competitive.

We've achieved this with a forward thinking approach to our plant investment strategy.' Six months ago the company took delivery of Hare's latest 800kN digital press, the 80HPD.

Within this short space of time the benefits of switching to hydraulic over traditional mechanical presses have been so dramatically demonstrated that the company now intends to replace much of its existing machinery portfolio with hydraulic presses, enabling it to fight off cheap competition from overseas.

It has already ordered a second Hare press.

Hamilton added: 'Currently producing in excess of 500,000 quality components a year we anticipate more than doubling our output to over 1million within 12 months.

Our 'think smart' plant investment approach is already paying off.

It's true that hydraulic presses initially cost more than their mechanical counterparts, but within a very short space of time the digital Hare press has paid for itself by yielding significant benefits through increased productivity, flexibility and tremendous reductions in downtime.

Moving over to the digital hydraulic press has reduced tool change and set-up times by about 85% - a tremendous benefit when working on short or medium run jobs.' Importantly, whilst improving efficiency, this has not been at the expense of quality.

Component quality has actually benefited from the controlled hydraulic stroke of the Hare 80HPD, further enhancing the Hamilton Group's reputation as a high-quality manufacturer.

The ability of the hydraulic press to deliver a constant controlled load, rather than achieving its tonnage only at the very bottom of its stroke, has enabled the group to expand into the pressing of more high-tensile materials.

The group now manufactures stainless steel pressings, which would not have been achievable with its existing mechanical presses.

Hamilton continued: 'The digital hydraulic press stores the settings for each tool in its memory.

Via its colour touch screen, tools can be set-up in a matter of seconds - and as hydraulic presses are not bound by the Power Press Regulations, the operator alone can set the tooling without the need for a qualified tool setter.

Such efficient tool-setting is extremely beneficial anyway, but combine that with the fact that we are now able to manufacture both brass and stainless steel switch plates, and you can see how the ability to swiftly set-up jobs requiring such differing tonnages is an added advantage.' Another benefit of the hydraulic press is the elimination of damage to tooling.

This is attributed to the 80HPD's controlled hydraulic stroke delivering only the preset amount of pressure - thus any accidental double loading of components will not cause catastrophic tool damage, as the hydraulic stroke is set to deliver pre-determined load rather than forcing itself to a set tool height.

Further safety benefits have also accrued from the integral light guards.

These close-proximity guards double as a safety feature and an optical switch, eradicating the need for operators to use foot pedals or hand controls.

Whilst improving operator performance, the light guards also yield long-term health benefits for employees in terms of reduced operator fatigue and a reduction in the risk of RSI.

The hydraulic press is also much quieter, at 75dBA Leq at maximum load, than its mechanical counterparts.

In the next two months Hamilton's will be replacing three of its mechanical presses with a single 630kN Hare press.

The flexibility provided by the Hare presses will allow them to expand their portfolio of more than 15,000 standard products and equip them with the ability to be able to fulfil orders at short notice in the knowledge that long set-up times will have been almost eradicated due to its investment in the very latest digital hydraulic technology.

William Hare, Managing Director of P J Hare added: 'Hamilton's is renowned in its sector for the quality of its products.

We're delighted that our digital press is helping it compete in a fierce international market.

The end result means that Hamilton's will be able to service its UK and overseas customers with a 'best of both worlds' package of competitive pricing with uncompromising quality.' metalworking 2002 - NEC Birmingham.