Cut pieces being offloaded from angular saw. HFL
33 features t win saw carriage, strip collector, and
beefed-up material handling for input and output.
Laminated panels queued up for the angular
saw. Greater capacity reduces forklift traffic
and results in predictable output.
on saw efficiency
Cardell Cabinetry is changing
its focus from builders to
designers, with the goal of
building a kitchen at a time.
“This company changes fast to meet
demand, and it’s very responsive,” says
Tom Moodie, director of manufacturing. Moodie adds that Cardell should
be classified as more than semicustom.
“If the customer wants an unusual
cabinet, we’ll build it,” he says.
“We are focusing on moving from
a builder mentality to the dealer business,” he says. “That will get us into the
whole new world of kitchen at a time.”
Cardell is an integrated cabinet
manufacturer, starting with dimension
lumber and ending with a finished
cabinet. Orders come in daily, are broken down into routings and cutlists,
and two weeks later the cabinets are
built and loaded into trucks.
“We want to make what the market
demands,” Moodie says. “Right now,
there’s more demand for a glazed
finish, so we just changed our entire
standard overlay product line so we
can glaze a standard overlay product.”
Cardell’s primary operation in San
Antonio includes a 450,000 square
foot main building and more than one
million square feet of space overall,
including the rough mill, flat
mill, (panel processing), laminating,
door assembly, finishing, cabinet
assembly and a separate drawer box
operation named Timko, after the San
Antonio street on which it’s located.
A separate plant in El Campo, Texas,
makes lower-end products.
Due to the housing slowdown,
Cardell is down to one shift, which
produces about 4,000 cabinets a day.
There are 1,400 total employees, including 1,100 in manufacturing.
Closeup of screen showing jobs in progress.
Automation and large capacity increase efficiency.
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Cardell’s biggest recent addition
is the Holzma HFL 33 angular saw
system. It has over two times the capacity of Cardell’s rear load saws, uses less
space and less manpower, and has a
built-in waste management system and
off stacking system that is ergonomic
and production oriented.
Brian Kosa, director of panel processing and door assembly, says that
everything in the flat mill starts with
incoming plywood or raw particleboard, much of which is laminated on
a Harlan double-side line, or a Monco
machine for thin material. Laminated
pieces then go to panel processing,
where they are cut to size. In addition
to the angular saw, there are three
HPL 33 Holzma saws.
“All of the heavy mill or Kanban
products go through one of our two
Celaschi double end tenors, one of
which is dedicated to wall end panels,
which also applies edgebanding, and
Angular saw advantages
Material handling into angular saw
reduces forklift traffic
Automatic cover sheet removal
Less dependent on operators
Less manpower required than rear-load saw
Machine dependent cycle time
(not driven by operator)
Twin saw carriage provides high cutting
speed, extended blade life, eliminates
blade deflection, offers higher output
Strip collector increases yield,
Automated waste removal
Material handling out of angular saw keeps
up with output of saw, reduces man power,
provides “slide and place” moving of panels