In a Q&A session, global pultrusion, pull winding and filament winding machine supplier, Pultrex provides Composites in Manufacturing with the lowdown on the latest trends, demands and challenges in this busy manufacturing sector.
Q) What are the types of performance demands placed on your company by today’s customers?
We work with the customer through the whole life of the project to ensure we provide a true reflection of their specification. We then assist with the development of their winding programmes and continue to offer support once offsite. Some customers have a service and support contract where we attend site on an annual basis to assess the machine and undertake preventative maintenance.
We’ve worked with customers to integrate our machines with other equipment and production control software and have developed and interactive messaging system to allow flexible programme flow. The winding process exposes the operator to various hazards and we’ve introduced safety systems which allow the customer to develop products with lower risk.
Q) Is there a particular customer product or application that really stands out and gave you a lot of satisfaction?
We’ve produced machinery to integrate with customers’ SAP systems. This can be used to record material data, i.e. when material is loaded to the machine, which tension spindle and which winding spindle was used. The wind time and duration are recorded and it’s possible automate interrupt routines to improve the repeatability and product traceability of the parts. The system can be developed to meet customers diverse requirements, such as the production of manufacturing traceability reports, which are printed on completion of the wind to be used as part of a traveller system.
Q) With increasing demands for faster and more efficient production rates, plus the reduction of the more manual layup processes, how much consideration are you giving to the implementation and use of automation?
We work with our customers to integrate with external equipment to improve their production processes and have integrated with loading and unloading systems, laser projection systems for the placement of patches. We’ve developed systems for the removal of a turnaround section on the mandrel prior to curing and systems for the application of shrink tapes. Machines have been fitted with probing systems for the accurate positioning of winds on intricate mandrels.
Q) How much importance, if any, are you placing on Industry 4.0 (i4.0) and the advent of ‘smart tools’ in general?
The use of our machine’s Siemens controls allows the flexibility to work with customers as the machine will be part of an integrated solution for Industry 4.0 and the data will be accessible from the control. To some degree, Pultrex has been providing data from the machine to external systems for some time. The next stage would be the self-learning from the i4.0, but the nature of the end products for filament winding can preclude the exchange of data and so is likely to limit the implementation of i4.0 in the industry.
Q) What is the main focus areas of your current R&D efforts? Are there any particular ongoing research programmes you can talk about?
We are investigating the use of different resin systems processes for the winding of thermoplastic tapes. We’ve been involved in R&D projects for the development of clean filament winding and are currently active in the European funded Amblifibre project for the development of an adaptive laser placement winding system.
Q) Do you find the current manufacturing industry an easy industry in which to do business and keep pace with changing trends, pricing and new legislations?
Being a small manufacturer, keeping abreast of current trends and legislation can be challenging, but is necessary to maintain a good service to our end users and ensure we provide compliant machinery into the market. The uncertainties over Brexit and changes in the raw materials markets for aluminium and steel cause fluctuations on the prices for the machine components and fabrications, making the pricing of the machinery a challenge - especially maintaining the balance between sales price and profitability.
Q) What do you feel are the most important assets of a company?
Pultrex has a proven track record in the industry and has developed relationships with customers. This support for the customer - from order to production and beyond - has led to many customers returning for additional machines or expansion of their existing machines, as their company grows. Our dedicated team has been with the company for many years and is able to provide knowledgeable support for the machine over its lifetime.
Q) Any thoughts on additive manufacturing?
Additive manufacturing techniques are in the early stages of commercialisation and may develop to meet some of the industries need. It’s more likely these technologies will be used to enhance the capabilities of the filament wound products by creating formers for winding. Or, in the case of additive manufacturing, cloth patches with Z direction that can be built onto the wound part and then wound over prior to impregnation and curing. Additive manufacturing may offer the ability to produce cellular pressure vessels, which can be overwrapped.
Q) Where do you see the biggest business challenge coming from this year?
Being part of a global market always provides challenges, and the unknowns of Brexit combined with the protectionist approach of some countries will lead to challenges in the purchase of raw materials and components. We will need to adapt out designs and technology to ensure we remain competitive.
Q) Finally, what differentiates your company from the competition?
Pultrex produces machinery of a design that is flexible to meet the customers requirement. Based around modular elements, the design of a machine to a customer specification is therefore simplified. Most of the machinery supplied is for customers producing a variety of components not specific to an individual product. We can supply equipment for a complete production cell and if required, can source all element and project manage the supply of a complete production cell.
Pultrex endeavours to listen to its customers’ needs and designs machinery to meet their requirements. We then provide continued support and can help develop the machine to the customers changing markets. We are supporting machinery on six continents, 37 countries and offer a flexible machine range. Our machines have been used to produce parts from underground pipes to parts for Space rockets.
