Hydraulic press has allowed a gas boiler manufacturer to double output from the production cell, eliminate scrap and reduce the amount of raw material required.

The next generation of gas boilers will be more efficient and kinder to the environment following the introduction of the latest premix gas burners from the UK's largest gas boiler burner manufacturer, Aeromatix. Efficiency and environmental friendliness not only relate to the final product - the production process also achieved the same benefits with the application of digital technology, in the form of the 63HPD Hare press. Installed at its headquarters in Derbyshire, the new press has allowed Aeromatix to double output from the production cell, eliminate scrap and reduce the amount of raw material required.

In addition, whilst allowing the entire cell to be run by a single setter-operator the time for tool changes has also been reduced by 70%.

'Forward thinking plant investment has been one of the key factors in the success of this project, and it will continue to play its part as production grows,' stated Andrew Stewart, Aeromatix's industrial engineer on the project.

'By opting for the latest in hydraulic press technology we've managed to achieve efficiencies and quality improvements in virtually all of the crucial areas of the manufacturing process.' Aeromatix's new burner delivers a controlled mixture of gas and air via a high temperature ceramic distribution system, enabling very high heat output and low pollutant emissions.

Whilst the product is revolutionary in the UK market, take-up by leading boiler manufacturers has been swift, and as more and more customers come on board the company's lean manufacturing strategy is proving itself to be extremely well thought out.

Servicing varied customers with differing requirements will mean that efficiency, output and reliability will be key issues.

With the digital press, five tool changes can be completed so quickly and accurately, that one press can be used to achieve the same end that would otherwise require 5 mechanical presses.

Stewart continued: 'We've managed to increase production from 170 units to 350 units per hour with the new press - that's double what we would have achieved with traditional presses.

The use of light actuating guards over pull down guards has played a big role here.

Couple this with tool changes and set-up taking only 10 to 20 minutes and you can see how production benefits.' The swift tool changes are due to the digital press storing tool settings for each job.

The 10 to 20 minute tool change compares to the 30 to 60 minute changes associated with traditional presses.

This simple set up facility means that tool changes are performed by the operator without the need to call on a skilled setter.

As a result, Aeromatix will potentially save hours on each production run, and in the long-term, as hydraulic presses do not fall under the power press regulations, the press will not need to be taken out of action and stripped down annually for insurance inspections.

With the first pressing following each tool change yielding a perfectly formed component (as a result of the precise setup and the controlled hydraulic stroke) the digital press has also eliminated the wastage associated with setup procedures.

Working on consistent pressure settings rather than tool height, the product quality is higher than from a mechanical press, with a better draw and less splitting.

Stewart added: 'This precision has also allowed us to reduce the size of the blank for each component.

The controlled pressing action always yields a component of accurate dimensions hence no slack material is required from the blank.

Less metal equals lower costs.' A further result of the controlled pressing action has been a reduction in the amount of lubrication required on each component.

Reducing scrap and the need for lubricants will save on costs and prove environmentally beneficial.

The new premix burner was conceived and developed at Aeromatix's own research and testing facility in Denby.

Heralded as the future of gas burners, demand for the product will continue to grow, and due to the company's open-minded approach to plant investment, it will comfortably be able to meet the needs of a varied client base without the need to hold stock or suffer long lead times.

Stewart concluded: 'With increasing overseas competition, investment in productivity improving plant is essential.

The digital Hare press has provided us with the perfect platform for short-, medium- and long runs that will allow us to maximise component quality, production rates and meet quick turnaround schedules.' Aeromatix manufactures 1 million gas burners a year at its Denby facility.

The company supplies the UK and World's major boiler and heating companies.