Acorn Aluminium has significantly enhanced its manufacturing capabilities following a substantial investment in new production technology.
Growth needs to be sustainable. Having secured a series of major projects in the last year, Acorn Aluminium has continued to invest in its manufacturing capability, increasing its capacity and bringing new precision and even higher quality to its offer.
This includes the acquisition of an Elumatec SBZ140 CNC machining centre and an advanced automated saw, which has already delivered measurable improvements in speed, accuracy, and operational efficiency.
The decision to upgrade was driven by an increase in project demands and the need for higher machining capacity.
This was something highlighted by a large-scale two-year programme for Nottingham Universities Hospital Trust, to replace 10,000 windows in the Queen’s Medical Centre, completed in September 2024.
Craig Key, Operations Manager at Acorn Aluminium, highlights the rationale behind the investment:
“Following the completion of QMC, it was clear we needed to expand our machining capacity. Project specifications are more demanding, and our existing CNC couldn’t meet our growing output requirements.
“We’re already seeing significant performance gains. For example, transom preps that previously took six minutes now take just 1 minute 20 seconds. That’s a considerable reduction in cycle time.
“The new CNC is not only faster but also more accurate. Before, certain prep work had to be done manually on the shop floor. With the SBZ140, these tasks are automated, resulting in increased throughput and greater consistency.”
An operator’s perspective
CNC Operator Luke Goode, who works on the SBZ140, underscores the advantages from a technical standpoint.
“Compared to our old MC700, this machine is up to 60% more efficient,” Luke explains. “The key difference is that the head rotates instead of the bed, which allows for faster, more accurate machining and higher-quality results.”
This upgrade in capability is not only improving production times but also enhancing the quality and precision of the final product, reducing the need for rework and adjustments later in the process.
Investment in advanced sawing technology
Acorn Aluminium didn’t stop at upgrading its CNC capacity.
Recognising the opportunity for broader process improvements, they also invested in a new, fully automated saw. This saw integrates directly with Acorn’s design software, enabling digital file transfers for precise, error-free cutting.
“We saw an opportunity to remove manual input from the process,” Craig explains. “By sending data files directly from the computer to the saw, we’ve eliminated the need to manually type in sizes. This reduces human error and speeds up the entire cutting process.”
“The double-cut functionality allows us to cut two bars at once, effectively doubling throughput with a single operator,” says Craig. “We’ve gone from needing two operators to one, and output has remained consistent or improved.”
The new saw brings the capability for barcode traceability — a key step towards improved quality control and process transparency. Once implemented, this system will allow Acorn Aluminium to track every component from cutting through to final assembly and dispatch.
“Historically, sizes and part information were handwritten,” explains Craig Key. “With this new functionality, we’ll be able to introduce barcodes for every component, giving us full traceability from raw material to finished product.”
This development will streamline production, reduce human error, and strengthen quality assurance. While not fully operational yet, barcode traceability is seen as a crucial part of Acorn’s plan to enhance production accuracy, accountability, and overall process visibility.
Looking ahead
Acorn Aluminium’s investment in the Elumatec SBZ140 CNC and automated saw is a strategic move to future-proof its manufacturing process.
With faster production times, greater capacity, and the foundation for full traceability, the company is enhancing its ability to meet the growing demands of complex, large-scale projects with precision and efficiency.
“These machines have already made a clear impact, but we know there’s more to come,” Craig concludes.
“With continuous input from our design, operations, and production teams, we’ll continue to optimise our processes and get even more out of these investments.”
For more about Acorn Aluminium please call 0115 928 2166, email [email protected] or visit www.acornaluminium.com