Tuesday - Friday | August 25-28, 2020

Georgia World Congress Center | Atlanta, GA | USA

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IWF Education: “When to Outsource”

30. March 2020 09:48
 

 Presented by:

 

 

Sponsored by: 

 

By: Joe Knobbe, Past President: Cabinet Makers Association

How do you determine the value of and when you should outsource? Whether it’s doors and drawer fronts, the cabinet boxes, finishing, installation, or any other aspect of your production process, you should know why it may or may not make good business sense to do everything yourself.

Just because you can do it doesn’t mean you should do it.

Outsourcing makes a lot of sense for smaller companies, especially those who don’t have the sophisticated equipment to do every type of project. Machinery is a really big investment for smaller shops, so outsourcing the various components is a viable solution, especially for unique projects.

Learn what is right for your business during the "When to Consider Outsourcing" session at IWF 2020.

IWF Education: The Most Successful Companies Are Run by Owners Who Understand the “Business” Side of Their Business!

24. March 2020 16:47

By: Tom Grandy, Founder: Grandy & Associates

Let’s face it, you used to work for another company and then decided you could do it better and faster and make the big bucks the owner was making if you went out on your own.  Bingo, you leave and start your own company.   Things go well the first year or two then you start doing more and more work…..while making less and less profit.  What’s going on?

First of all, 90% of all small businesses started like you did.  You’re strong on the technical end (getting work done) and weak on the business side.  There are two things that put most small companies out of business.  Number one is improper labor pricing, not know what YOU have to charge per hour in order to cover your costs of doing business while generating the profit you desire.  The second killer is cash flow.  A company can be priced perfectly…..and still go out of business because of cash flow issues. 

The good news is that Grandy & Associates will be offering a seminars on labor pricing, and cash flow, at the IWF Conference.  Hope to see you in the sessions!

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IWF Education: Understanding your Cyber Risks

23. March 2020 08:06
 

 Presented by:

 

 

Sponsored by: 

 

By: Dominic Vogel, Founder & Chief Strategist: CyberSC

While you are working a building a winning business, cyber criminals from around the world are scheming to steal your data. Be proactive about the projection you need and determine your level of risk.

Most companies are unaware of the high risk they face from cyber attacks. Even the smallest security breach can compromise the trust and integrity between you and your customers, your partners, and your vendors. It might also result in the loss of assets, future revenue, and potentially cause crippling litigation for your business.

Learn what you didn’t know you needed to know about cyber security during the "Cyber Security: What You Didn't Know You Needed to Know " session at IWF 2020.

Stretch Wrappers, Packers, Palletizers - Choosing a Secondary Packaging System

22. March 2020 00:07

By Derek Jones, Marketing Manager, Robopac USA

Let’s face it. Secondary packaging equipment is a broad category with multiple product lines and a variety of features with varying performance levels. From stretch wrappers, packers and palletizers to case equipment and laser-guided vehicles, and with so many companies touting the benefits of their product, how do I decipher which is the right product for me?

Robopac USA is exhibiting in Booth B8285 at IWF 2020

The best way to determine the right equipment in each of the product lines is to understand the best fit for your application. Think of it this way. When you decide to purchase a new vehicle, there are key “application” factors that come into play. If I have a family of four then I probably need a vehicle that has four doors, more room, third-row seating and maybe a built-in DVD player to keep the kids occupied on long trips. If I live in a harsher environment or like to off-road, then I may choose a more rugged vehicle with four-wheel or all-wheel drive. There are several application factors always in play when purchasing a vehicle.

The same holds true for deciding on which secondary packaging equipment is right for my operation. Let’s go through each of the product lines that make up secondary packaging equipment and uncover the key application decision factors:

Stretch Wrappers
Stretch wrappers are made up of two main categories: Semi-automatics and Automatics. Both categories are made up of sub-categories: Turntable, Vertical Rotary Arm, and Horizontal. Robots are a sub-category primary to semi-automatics. In most cases, if the loads you wrap are heavy (over 4,400 lbs.), very light, or unstable then they will need to remain stationary on a solid surface instead of a spinning turntable. If that is the case, you will need a vertical rotary arm stretch wrapper. 

Turntable stretch wrappers are ideal for wrapping stable loads that weigh under 4,400 pounds. Since floor space is at a premium in most facilities, choosing a reliable turntable wrapper with a small footprint is key. Depending upon the number of loads you wrap per hour, you can determine which turntable in the product line is right for you. 

If you wrap long products such as lumber, doors, windows, carpets, textiles, copper piping, or corrugated tubing then a horizontal wrapper may be the right solution for you. 

Flexibility is extremely important. Robot semi-automatic stretch wrappers are portable providing a 25% increase in productivity. Loads do not have to be taken to a set area to be wrapped. The machine comes to you. Plus, they can wrap loads of any weight, length and width.

Semi-automatics may require some human intervention like pushing a button to start the machine, attaching the film to the load before starting the wrap cycle, or cutting the film at the end of the load. Statistics show that the less the operator engages with the load directly, the safer and more productive they will be.

For example, if your semi-automatic stretch wrapper includes an automatic film cutting and sealing device, then the equipment will cut and seal the film to the bottom of the load at the end of the wrap cycle automatically.

Why is this important? It allows the operator to stay on the fork truck to stage other loads or perform other functions while the machine is wrapping the load increasing productivity. Keeping them on the fork truck keeps them safe preventing injuries by bending over time and again to attach the film to the load or cut it at the end of the wrap cycle.

Remote controls to start and stop the wrap cycle are also available to increase productivity. Keep in mind, some manufacturers include extended wrap height, a remote control, and other key features as standard which is very important in determining total value in your purchase decision. 

If you have more demanding, higher speed applications then an automatic stretch wrapper may be the right solution. Automatics can include conveyor systems to stage and run multiple loads, corner board placers to protect sides of loads and dual wrap arms for increased productivity.

Cutting edge manufacturers are now providing remote connectivity to your stretch wrapper operation which allows managers to monitor and improve performance. Remote assistance minimizes machine downtime and permits better maintenance management, also including an immediate troubleshooting procedure and full remote machine management software updates.

At the end of the day, the reason we stretch wrap loads is to protect the products that are being shipped. Choose a manufacturer who will deliver the right amount of film, at exactly the right position, with exactly the right amount of containment force to protect your products during shipment.

Packers
Most industrial manufacturing plants deal with large-scale production every day. Unreliable or incapable machinery may break down frequently. When this happens, production must cease, and costly downtimes are the result. The right wrap-around case packer and shrink wrappers must be able to reliably handle heavy-duty production. To keep the packing process moving forward, wrap
goods tightly for intact delivery. Flexibility in product application, changeover time, machine capabilities (film, pad + film, film + tray, tray only), speed, reliability/uptime and the need for a packer, wrapper, or combination will drive your decision making.

Palletizers
Automatic palletizing eliminates unnecessary labor, improves productivity, and increases safety in your shipping operation. Floor space an issue? Then consider a palletizer manufacturer with small footprint machines that offer concurrent stretch wrapping within the palletizer. This reduces floor space requirement by palletizing and stretch wrapping in once process. Positive product handling
that confirms proper load construction prior to layer deposit is vital in the purchase process. Safety is imperative in any operation. Identify manufacturers which build their palletizers to a minimum Category 3 safety standard.

Case Equipment
Case erectors and sealers may be the most difficult product line to determine which manufacturer’s machine is the right for my application. Case erectors and sealers eliminate costly labor and ensure cases are square for the unitization process during palletization and stretch wrapping. My advice…Don’t get caught up in the suction cup and folding arm rhetoric.

There are a few questions you need answered when choosing a case erector or sealer:

  • Can they at least handle all types of flutes, double wall and single wall, and most common case sizes?
  • At the end of the day, does their machine have a proven track record of erecting square cases squarely so they don’t jam in the machine?
  • And finally, can they reliably transition the box through the taper efficiently so that the box is squared
    and sealed correctly?

Laser Guided Vehicles (LGV)
Laser Guided Vehicles, or LGV, may be the coolest product in secondary packaging. It almost seems futuristic to see an army of unmanned forklifts in an operation working tirelessly 24/7 to meet shipping demands. The labor and safety savings for these machines are unmatched. When considering an LGV purchase, there are several key questions to consider.

  • Will it be operating in narrow spaces and tight passages?
  • Does the LGV need to handle multiple pallets?
  • Do I have very heavy product loads?
  • Do I need to move my products from one specific conveyor line to another?

Over time as your operation continues to grow, your end of line packaging strategy will become more diverse. Consider sourcing through one single provider to build consistency, trust, and efficiencies.

ROBOPAC USA is the leader in the design, production, and service of secondary packaging machines and equipment. We offer a full line of configurable machinery to stretch wrap, pack, palletize, erect, and seal any product in the logistics industry. If you would like more information on this topic or to schedule an interview, please contact Derek Jones at 678-908-7909. 

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IWF Education: Making the Leap from Residential to Commercial

20. March 2020 15:24
 

Presented by: 

 

 

Sponsored by: 

 

By: Rick Thaler, Former Owner: OGB Architectural Millwork

I’ve been through the transition from residential to commercial work and lived to tell the tale.

I’m happy to report that I would never go back. I like commercial work better, and I find it more rewarding. I get to do the kind of work that turns me on, and at a scale that I find satisfying, and I’ve built a set of systems from the ground up that have served me quite well through the growth of my company.

If you’re considering taking up commercial work, you need to know the answer to this simple question: Why?

Do you want more opportunity? Diversification? More profit? More interesting work? The chance to work with different kinds of customers? All of the above?

These are all good reasons. The key is to do some soul-searching and make absolutely sure you have a good reason.

After all, if you’re happy with what you’re doing, and you’re making the money you want to make, don’t change. Change for the sake of change is not just worthless – it can be downright murderous, and many of the business failures I’ve seen involved people getting out of an area of competence and into one of high risk.

Learn more during IWF 2020 by attending the “Diversifying your Business: Think Outside the (Cabinet) Box” session.

Join Me at IWF 2020 for a Holistic Approach to Finishing Symposium

15. March 2020 20:12

By: Joe Baggett, Innovative Wood Process Solutions

We are really excited about the IWF 2020 Holistic Approach to Finishing Symposium. There is renewed interest and passion in wood finishing! We have a vision of the symposium being a time to share information, experiences, technology and offer a process of “A Holistic Approach to Finishing” that will empower the professional wood finisher to keep up with coatings, equipment and processes in a rapidly changing world.

We have prepared a thoughtful program “for the people by the people!” We know that past feedback has indicated that attendees want a “take away.” So, this year if you plan to attend, we would like to hear your questions, thoughts, and concerns ahead of time. Please email us your questions iwpsolutions19@gmail.com by June 30.

So, we are trying something new within the format of the program will attempt to address the questions as much as possible. If a question is non-program related, we will be available to give personalized attention during the show after the symposium as much as times allows.

During our consulting engagements over the past year and half we have noticed several things that we believe wood finishing organizations experience:

  • What new looks, colors, effects, touchable/visual aesthetics, performance in color fastness and scratch/moisture/chemical, can we create that will drive value?
  • What are the best coatings, application and curing methods to repeatably produce these finishes?
  • <https://www.iwfatlanta.com/Education/FIN" target="_blank" rel="noopener">Can these new looks be created through automatic methods?
  • What does the leadership and workforce look like for the next generation of wood finishers?
  • What are the permit implications to accomplish the first two questions?
  • Can I create more value in my finish without adding lots of cost?

Also on the program is a special guest speaker, Robert Chickey, a finishing specialist of national renown. He will be giving a presentation on designing finishes with new coatings. 

We can’t wait to be with you all! Along with the wood finishers we want to invite the designers, marketers, sales, and executive leaders. We will have some great interactive activities and door prizes! See you all in Atlanta at IWF 2020 in August.

5 Tips for Laser Cutting and Engraving Wood

14. March 2020 19:58

Technical Advice from Trotec Laser

Laser engraving wood offers the freedom of creating precise and personalized custom-made materials, which adds value to any business. Make your products unique by engraving images, names, or even logos into your materials. Laser cutting provides precision to custom-fit parts within a tenth of a millimeter, even with small or fine shapes. Compared to other technology, laser systems save time and can accommodate even the thinnest materials with its non-contact processing. 

Does laser cutting wood cause burning?
Yes. However, laser cutting wood is a sublimation process and is often considered highly desirable. Laser cutters offer accurate focusing, customized selections of the appropriate parameters, as well as use of suitable optics and compressed air supply for cutting and engraving of the highest quality. 

Can all woods be laser processed?
Since wood is a natural and organic material, laser users must evaluate a number of parameters including density and resin content prior to processing. For example, softwoods such as balsa will require less laser power, and cutting can be completed more quickly. On the other hand, hardwood, which is typically a dense material, will require more laser power. We recommend using compressed air for processing MDF since it consists of wood fibers that are glued.

 https://iwf20.mapyourshow.com/8_0/exhibitor/exhibitor-details.cfm?exhid=12602

Trotec Laser will be in Booth BC 1233 at IWF.  

 

Will the laser engraving always become dark?
Laser processing wood can result in a brownish-coloration on the material depending on a variety of factors. However, when processing varnished wood utilizing the appropriate settings can avoid this issue and a white engraving can be achieved. We recommend using a very low power at a high speed for this application

Can dark engraving be achieved?
Yes. Defocusing the laser beam to about 0.5-2 mm will result in the laser spot becoming larger, and the power density is then reduced. Some details may be lost in processing, but this method will produce a particularly dark engraving and we highly recommend trying it for these types of applications.

Should there be smoke in the processing area?
Laser processing wood is a sublimation process, and since the material is solid it is converted directly into a gaseous state from combustion. 

 

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Getting Grain Effects in Wood Composite 3D Printing

24. February 2020 10:35

 Wishing you could print wood in a 3D printer? Hatchbox is among a number of firms that offer filaments for 3D printing. The Wood PLA Hybrid is universally designed to be compatible with printers using 1.75mm diameter filament, with a dimensional accuracy of +/- 0.03mm.

Wood PLA Hybrid - Polylactic Acid with fine wood particles mixed in (below)  is a commonly used thermoplastic material that does not require the use of a heated print bed. Blending a mixture of plant-based materials, polymers, and wood particles creates a material that is more earth-friendly than plain plastic.

Hatchbox notes you'll be able to sand and stain the finished product to give it a wood finish, and that is exactly what Justine Haupt did in replacing the moulded wood top plate on her concertina using its wood composite filament. A concertina is a free-reed musical instrument, like a small accordion.  It has an expanding and contracting bellows, with buttons (or keys) usually on both ends.  

The Suttner concertina shown here by way of explanation can be ordered with flat ends made from German silver, rosewood, ebony or cocobolo, or raised ends made from German silver or hardwood in black. Haupt was replacing an end piece that was raised, and so decided to replicate it with a  printed piece using Hatchbox Wood-Filled PLA. After printing it was sanded, stained, and varnished. 

"Fresh out of the printer doesn't look like wood at all," Haupt notes. "I used 60-grit sandpaper to completely remove the printed surface finish. 60-grit might seem excessively course but I feel the results are better this way, in part because one must be sure to completely remove the natural finish. Also, the deep gouges left by the coarse grit seem to more closely match natural wood grain."

Since the sandpaper is what leaves a wood-like grain, "It's important to sand in one direction only. In this case, it was much easier to sand the perimeter wall, as I was able to take advantage of the printed layer lines. In hindsight, it might be better to print something like this on-edge to take advantage of this effect where it most matters. In the end, even with all the sanding, the perimeter walls were most convincingly wooden. " 

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How to Build an Infinity Cube Table With 18 Continuous Joints

23. January 2020 10:57

Jonathan Katz -Moses shows an intriguing woodworking project: an Infinity Cube Side Table. It consists of 18 continuous joints in a row. "Tons of Joinery!," says Katz-Moses. 

"I found a really cool way to cut the bridal joints without having to reset my equipment. This was an engineering problem project to the max, but I think we found some really cool ways to get past some roadblocks.   

"The finished project came out really cool," Katz-Moses says. Yes, it did.  

"When I pitched this to my friends, they said it was impossible," Katz-Moses says. "I've seen this done out of metal. I don't think it has ever been done out of wood before."

Katz-Moses describes himself as a woodworker, inventor, and "father to a beautiful girl and a dog." He also made a nice tour of IWF in Atlanta, in a video that tells a lot about the kind of excitement woodworkers will find at IWF 2020. 

"Woodworking is my passion and there is nothing I won't try to build, fix, or improve on my own. I got into woodworking and the passion has completely consumed me," he says, and that excitement shows in his travel to Atlanta and tour of the show. 

"Becoming a great woodworker and do it yourself-er is about finding the right information and creative solutions with the materials and skill sets available to you. I eagerly look forward to showing you how I accomplish my projects."  

 

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Last Word on Establishing A Holistic Approach to Finishing - Step 5

13. January 2020 13:44

By: Joe Baggett, Innovative Wood Process Solutions

The other day while on a plane coming home and contemplating the final articles of this series. I was listening to my favorite 80s mix, and the song “Should I Stay or Should I Go?” by The Clash came on and I was inspired.

While the paradox of the song was about indecision in a romance gone bad it is very analogous to many finishing journeys that are stuck or will be stuck in indecision. In the famous words of Strummer, "If I stay there will be trouble and if I go it will be double."

This is symbolic of how many feel about finishing. It doesn’t have to be that way! It has been the goal with this series of articles to provide a holistic strategy and some of the best questions to create emotional permission and empowerment to move forward and take advantage of the advances in coatings, delivery and curing technology in the wood finishing industry.

So, get ready and go the next level in your finishing journey! 

This last step in the holistic finishing process really is about putting it all together. After having gone through the previous steps the last one is about how it all fits together, sometimes literally. When completing the design of the lines and equipment many times the underlying questions are what are the easiest and lowest cost ways to get into finishing or attempt to make the next step.

 

Meet Joe Baggett August 26 when he
leads the Finishing Symposium at IWF 2020. 

This usually results in the scenarios that have the highest amount of labor or lowest productivity, the lowest transfer efficiency and the longest cure times/cycles. As a general rule the largest amount of real-time and cycle that product sits in the production facility is for finishing. Just recently there was a furniture manufacturer that went from air curing their coatings (1-3 days) to force curing them in a batch oven (8-10 mins).

It shortened their internal lead time by several days. Some of the higher-performing newer coatings that are more compliant with environmental regulations (an example would be water-based 2k) are best applied with forced curing as it significantly reduces cure time. This is an example of how the previous steps in this Holistic process fit together. 

Joe Baggett and a cabinet design engineer at the
Microvellum console and overlooking the plant floor.

After the questions from step IV are answered we suggest significant testing before ordering new equipment or committing to any new formulations.

We also suggest creating buy-in from the coatings suppliers, equipment companies, and the fluid delivery providers, to agree and commit to the anticipated intended results. We suggest taking the formulations and multiple substrates like the ones that will be used in a production scenario and the proposed lines, equipment and fluid delivery system and complete testing in the scenario that will most likely represent the production scenario. Most of the major finishing equipment manufacturers have labs and testing facilities and can make accommodations for this testing. Have a representative from each group, coatings, equipment and fluid delivery present at the testing.

I want to take a moment and emphasize the environment in which the finishing operation will occur. Besides the coatings, equipment and fluid delivery system the environment and most specifically how clean the air is and the temperature of the air in the finishing area and coming into the finishing area is and should be?

Cold air that is contaminated is an enemy of good finishing areas. Then the environment of the area where the wood substrates are kept before finishing is also important. Keeping the BST (board surface temp at 77-100°F and clean is helpful. Many people go and test in a clean environment without temperature extremes or contaminated air, this must be considered in the final design and decisions.

During the testing bring the leaders and operators that would be operating the equipment and applying the new coatings to be a part of the test. This creates buy-in.

Complete the testing confirming or understanding the difference in the intended outcomes. For instance, if the fluid transfer is projected to be 70% and during the testing is resulting in 60%, discuss this with the fluid delivery rep and the coatings rep and the finishing equipment rep. The purpose of this is to create commitment from all parties, not only that the new coatings can perform as intended but to what level of time to cure, transfer efficiency, productivity in labor, and repeatability.

Once successful testing is done the final design of the line and any finishing are environment requirements can be finalized. Many times, the footprint of an existing building becomes a constraining factor. This will also be an opportunity to work on the curing cycles which usually results in smaller line footprints.

While all improvement is change, not all change is improvement. It is very important to engage the internal members of the organization and the equipment, coatings suppliers and fluid delivery in a way communicates the importance, value and purpose of the new finishing strategy. Usually, the finishing area requires the most and best leadership due the definition and adherence to processes. Because there are more variables to finishing than in most other parts of wood working, a good leader of people who is also technically astute with designing and following finishing processes is key to the sustained success of the finishing strategy.

To create buy-in and commitment we encourage the development of a document describing and defining the operation and performance of the new finishing system and AutoCAD layout of the new finishing system. It is even better is all involved parties commit with their signatures.

After final testing is complete, samples of the new finish system should be made and signed off by marketing, manufacturing and all parties involved. Ordering of the new equipment would occur at this point and the permitting process from step three should be finalized at this point with while being synchronized with the permits to construct the new finishing system by the time the new system would arrive and be installed.

The future isn’t what it used to be! It is common when we engage wood finishers to hear of how long they have been doing wood finishing. Let me say it is good to be proud of what one’s accomplishments. However, because of the pace of change it matters less how long something has been done and more how well it is and will be done. I want to reiterate the importance of this being a cycle and journey and not destination.

In Wood Finishing, there paradigm shifts every 3-5 years. It is a good exercise to go through this Holistic Finishing Process as a cycle every 3-5 years.

We aren’t done yet with finishing,  just stopping for now. We would love to continue the discussion with you and your teams at IWF 2020 as we will presenting this same subject but in more detail at the Finishing Seminar. Good luck, see you all at IWF in Atlanta in August 24-28, 2020!

 Joe Baggett is President of Innovative Wood Process  Solutions. Reach him at iwpsolutions19@gmail.com,    817-682-3631. www.iwps.biz

 

 

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