An edge bander, like a CNC processing centre, or nesting machine is a major capital investment for any company producing cabinets. While a simple machine is still available, most are now fitted with some sort of logic control that have simplified the setup of these once difficult to use machines.

The range of edge banding machines is almost as long as there are machinery suppliers; almost everyone can sell you one. And while it makes a lot of sense to get a machine by the same supplier that sold you the CNC machine, with an edge bander this is not always the most astute purchase decision. It all comes down to what you want to do with your new machine. (Image 1)

If long runs of whiteboard are your major requirement, then you need a reliable machine without the unnecessary option of automated changeover from one edge type to the next. If your production is typical of most Australian manufacturers and your batch sizes are between ten and fifty pieces, then some sort of programmable logic control, or even computer control is essential.

Programmable Logic Control (PLC) are used to automate industrial processes such as a manufacturing plant’s assembly line. They are used effectively on the edge banding machine. A PLC can perform discrete, repetitive functions and is suited to rough industrial environments. The CPU reads the input data from sensors, processes it, and sends the command to controlling devices to operate saws, trimmers and buffing units. Since the PLC was invented by Dick Morley in 1964, they have revolutionized the industrial and manufacturing sectors. (Image 2)

Automation is Key

Manual set-up machines can, in some cases, require five to fifteen minutes just to change from one edge thickness or edge detail to another. With this loss of production time every fifty pieces or so, it’s little wonder that manufacturers are turning to edge banding equipment with more and more automation. Another factor to consider is the speed at which your other equipment works, and your production not being held up by a slow, outdated edge banding machine.

In some ways, the decision on which edge bander to purchase is a far more important one than the CNC processing centre. When you discover that the controller for a new edge bander is capable of changing the program to a new one, while the previous panel is still in the machine; that’s a revelation you can see will certainly reduce your down time and increase your daily production of edge banded panels. If it costs 20% more to buy an automated machine, it’s worth every cent.

Many Australian machinery suppliers have been selling edge banders for a long time, some over 40 years so there is a lot of experience and know-how behind the product. Equipment is becoming more sophisticated as the years roll on, and manufacturers becoming more confident in the performance of the machinery. In the past the actions of an edge bander were controlled by limit switches; very unreliable and prone to inaccuracy. PLC and computer control is now the norm and is very reliable. In the case of a machine part failing, it is a simple matter to order a new part and simply plug it in. (Image 3)

And when it comes to maintenance, the modern edge bander can be diagnosed from the country of origin if its attached to the internet. Your problem could be diagnosed by someone in Italy, Germany or Austria, that actually had a hand in designing the machine. It’s also possible through the use of apps, to monitor your edge bander from wherever you might be, even on holiday.

Make it Stick

The heart of any edge bander is the gluing station. Whether its state of the art laser, hot air application, near infra-red or the traditional glue pot or stick, the quality of the finished product will be determined by the glue line that is either visible but not noticeable, or nearly invisible, to the human eye at least. With an edge band product, it’s what you don’t see that matters. When the first hot air machines came out, it was thought that an invisible glue line was only capable with a laser edge strip, but a near invisible joint is achievable with good equipment using PUR glues. (Image 4)

The PUR bond forms in two stages. The adhesive cools and solidifies like a hot melt, reaching its holding strength, then the moisture-curing reaction acts over the next 24 hours to reach its final structural strength. The bond is tough but flexible, has a higher heat resistance than EVA adhesive, and resists moisture. It does have some considerations such as shelf life after opening, and so, should be stored in sealed containers. Unlike the lower-cost EVA hotmelt glues, PUR cannot be stored for extended periods of time.

You can get expert advice about using PUR glues from adhesive suppliers. Most of this product comes from Europe where it is heavily researched and provides a level of confidence every manufacturer needs. There’s a lot of Chinese-made edge bander adhesive on the market but as the glue is literally the bond between the board and the edge, is it worth the small cost savings to risk your company’s reputation?

Keep it Clean

Whatever edge bander or type of glue you use, keeping it clean “Puts you 70% ahead of everyone else” according to one expert at SCM. Another expert at HOLZ-HER says dust can be an issue. An expert with the Homag brand speaks highly of allotting five minutes to blow the machine free of debris every day. Other leading people say dust collection is one of the main issues leading to poor edge bander performance and yet another speaks about the perils of using low-cost glues. (Image 5)

Advances in edge banding technology are now mostly in software that reduces setup times and provide more production flexibility. Return systems are also gaining momentum, not only to provide a one-person operation, but to load from a part library or to rout the part to other machinery. Almost every supplier can provide a hot air or similar solution, and true laser edging is almost never heard of, except in the largest producers so there is very little interest here in Australia. The ability to automatically apply different radii on the edges is something relatively new and is a joint initiative with some of the tooling manufacturers. No doubt about it, the right edge bander can certainly provide the winning edge.