Turbo-charging efficiency and quality in door fabrication

Ensuring precise hinge and outer-to-sash alignment has traditionally been a time-consuming and labour-intensive process for door fabricators. However, the new KT tables from Haffner have revolutionised the process. Matt Thomas, managing director at Haffner, takes us on a tour of this transformational machinery, and discusses its efficiency and impact on the industry.

Getting the alignment right on the outer frame and sash is crucial for both hinge placement and overall aesthetics. Unfortunately, as every door fabricator knows, it’s the most difficult part of door fabrication to get right.

The traditional solution is to use jigs and to pre-drill and screw hinges manually to centralise the frame in the sash. The trouble is, it’s labour-intensive and prone to inconsistencies due to variations in welding accuracy.

One alternative is to pre-drill on a machining centre. However, the variability in weld sizes can result in misalignment post-welding, complicating the assembly process. Consequently, fitting hinges becomes a time-consuming task that requires manual adjustments with packers to centralise the door sash within the door outer frame.

For high-volume door manufacturers and door fabricators in general, especially those struggling to find skilled labour, the process can often cause a bottleneck that significantly slows production efficiencies, impacts quality and increases costs.

It’s why we developed a solution. Our innovative range of KT tables for door sash assembly are, quite simply, a game-changer for the industry. They allow the serial and high quality standard assembly of single or tilt and turn opening system window and door sashes in various dimensions.

They eliminate the time-consuming and manual alignment processes, and deliver precise hinge and outer-to-sash alignment. They optimise sash assembly by combining multiple processes in a single automated table. Plus, taking these operations off a conventional machining centre helps fabricators increase the output of their other machines too.

In short, they boost productivity, reduce overheads and increase quality, thereby adding substantial value to fabricators’ bottom lines.

Take the KT808-50 assembly table for door sash as an example. It works by automatically clamping and centering both the door frame and the door sash. It’s a process that eliminates any anomalies and ensures an even gap around the door sash when fitted.

Once the frame or sash is central, the KT808-50 automatically pre-drills holes for the hinges using an intelligently designed drilling unit that suits the specified hinge. The operator then inserts the hinge ready for the semi-automatic screwing unit to fix the hinge firmly in place to the profile. The sash is then spun around so the operator can crop the hardware to size before inserting it and screwing to the profile.

The accuracy is far better than the traditional manual method of a tape measure and jig. CNC positioning of the frame and sash ensures all hinges are in the correct place, leaving little adjustment on the finished door. This unique measurement system allows for tolerances in welded frames. It also reduces the time needed to check and adjust each door on the bench, which further improves production output.

Processes that were once labour-intensive and time-consuming are now fully automated, improving manufacturing efficiencies and enhancing quality. Plus, it doesn’t need skilled operators, so it relieves the burden on fabricators struggling to find and retain skilled labour in the current climate.

These benefits are much more than marginal. It’s fair to say that they are genuinely transformational.

Some fabricators report that with the KT808-50 two operators can fabricate over 90 doors per day. This equates to one door every five minutes. Others report that the table can prep three hinges on a door in under three minutes, saving approximately 40 minutes per set of French doors. One fabricator commented that the KT table saved the time of around four people.

These benefits are being harnessed by fabricators up and down the country. Quite simply, our range of KT tables enable high-volume output with consistent accuracy and reliability. It’s why they are an essential addition to the factory floor for any serious door fabricator.