Invests in 18 new CNC machines in three years.
PTF Manufacturing has been ready for growth for some time but did not expect the growth in demand for precision machined components that the company is experiencing currently. Two years ago, the company installed its first 5-axis machine – a Mytrunnion 4G from Kitamura. This was the seventh machine that the company had installed over the previous 18 months, such was the need for capacity and to a lesser degree their capabilities although the 5-axis Kitamura opened up the possibility of a whole new area of clients.
However, one of the reasons that the company purchased the Kitamura was because what the owners understood about one of the repercussions of Covid – reshoring. “It has never been a fashionable word in South Africa because many work on price alone, even if it is only 5% cheaper when getting components or product from China. Well, Covid spoke out in more ways than one. Suddenly availability and costs were important factors in getting components into the country. The decline in the rand did not help as well,” said joint owner Brandon Morris.
PTF have acquired their first Wire Electric Discharge Machine (EDM) – a Fanuc Robocut C400iC Wire EDM machine. It sits alongside another recent acquisition – a DN Solutions DVF 5000 5-axis mill
“Even though the availability and freight forwarding aspects are now back to normal many are very wary of ending up in a similar situation. I am no economist or expert but I believe this happened to many around the world and business owners would rather now source locally. This could be a contributing factor to as to why China is not growing at such a rapid rate any more. Who knows?”
“At the time when the Kitamura arrived, we needed a couple more lathes and because of availability we acquired two DN Solutions Lynx 2100LSY turning centers that were set up in a cell type layout alongside a Fanuc α-D14LiB5 Robodrill and a Fanuc α-D21LiB5 Robodrill, both small high-speed machining centers, which were acquired at virtually the same time.”
“This was in 2023. Fortunately for us the demand for our services has continued to grow and of course we have had to invest in equipment to match the demand. Amongst them have been a number of new DN Solutions Puma 4100 series turning centers, which is primarily aimed at precision component manufacturers machining large to medium parts for many different industrial sectors.”
PTF have also taken their Fanuc α-D14LiB5 Robodrill tally up to three
“The new Pumas have maximum travels/turning lengths of up to 990mm and a maximum turning diameter of 550mm and are equipped with powerful, high-torque 2-speed gear-box driven main spindles up to 45kW and up to 3 000rpm depending on the model.”
“In fact, a new DN Solutions Puma 4100 big bore turning center is being installed today and we still have a few more on order, which are due to arrive in the next few months.”
DN Solutions DVF 5000 5-axis
We have also invested in our second 5-axis machine – a DN Solutions DVF 5000, which is a second-generation series machine. The machine comes with X, Y and X-axis rapids of 42m/min, acceleration/deceleration rates of 0.4g, B and C-axis rotation speeds of 25rpm, impressive tool-to-tool changeover times of 1.3 seconds and a directly-coupled 18.5kW/15 000rpm spindle.”
The DN Solutions DVF 5000 5-axis mill is fitted with Lang Technik fixturing
“The DVF 5000 can handle larger workpieces than their predecessors, and feature 630mm diameter rotary-tilting tables that can accommodate workpieces up to 600mm in diameter and 500mm in height.”
Victor P76 VMC
“We have also seen the arrival of a new P76 vertical machining center from Victor CNC. The Victor CNC 3-axis VMC incorporates a 30 tool ATC that can change tools in a blistering 1.6 seconds with a chip-to-chip time of 4 seconds, has rapid feed rates of 48m/min in the X and Y-axes with 32m/min possible in the Z plane, its XYZ work envelope is 760mm by 500mm by 510mm and the machine also demonstrates rigidity and stability through its BBT-40 face and taper contact spindle configuration.
The new P76 vertical machining center from Victor CNC
To increase material removal rates, the P76 has an 18.5kW spindle motor that delivers high torque levels throughout the speed range that reaches a top spindle speed of 12 000rpm. The maximum component weight of 500kg on its 840mm by 500mm table.”
First Wire EDM machine: Fanuc α-C400iC Robocut
“We have also acquired our first Wire Electric Discharge Machine (EDM). The Fanuc Robocut C400iC Wire EDM machine features the Fanuc 31i-WB control with the new iHMI User Interface, enhanced Automatic Wire Feed System and an advanced all digital power supply. The AWF3 system has been engineered to thread workpieces of up to 250mm thick. The EDM is able to process workpieces of up to 500kg with an XYZ-axis capacity of up to 730mm by 630mm by 250mm, offering significant versatility for a number of applications.”
PTF have invested in a number of new DN Solutions Puma 4100 series turning centers, which is primarily aimed at precision component manufacturers machining large to medium parts for many different industrial sectors
“All Robocut machines feature the patented twin servo automatic wire tension control ensuring accurate, straight parts. Above all, the Robocut CiC-Series EDMs are built 100% in Japan and offer exceptional reliability that Fanuc is known for worldwide.”
Forging press
“This is another process that we have recently added. Basically, material is rough machined by us then we coat the material with graphite grease before it is heated up in the induction furnace that we purchased at the same time. It is then transferred to a jig on the press that holds the die before a component is pressed. The component then comes back to the machine shop for finishing.”
A DN Solutions Puma 4100 series big bore turning center arrived to be installed on the day of the interview
“To eliminate human error and fatigue we have added a Fanuc robot for the machine tending and material handling aspects.”
“We have also taken our Fanuc α-D14LiB5 Robodrill tally up to three.”
“Although PTF Manufacturing had zeroed in on machining components for the pump and valve industry as its primary business strategy, this has changed in recent years.”
PTF have also purchased a number of DN Solutions Lynx 2100LSY turning centers
“Machining of components for the pump and valve industry is still very much part of the mix and accounts for most of our machining output. We have been operating in a niche area of the industry whereby we are known for machining the more complex components and not the ‘dog eat dog’ side of the business. These parts consist largely of axisymmetric shapes, so lathe work is the main part of the production, but as we have grown and added more equipment to the shop floor, we have increased the variety of operations and components that we are able to machine,” explained Morris.
For further details contact PTF Manufacturers on TEL: 011 825 3590 or visit www.ptf.co.za
