Backdrop & Context
The structural steel fabrication industry is undergoing asignificant technological transformation as manufacturers seek to improveefficiency, precision, and production capabilities in an increasinglycompetitive global market. This shift comes amid growing demands for complexstructural solutions in construction projects, coupled with industry-widepressures to reduce waste, improve sustainability, and address skilled laborshortages. Automation and robotics represent a strategic response to these challenges,allowing fabricators to maintain quality while increasing throughput andconsistency. Caunton Engineering's substantial investment reflects this broaderindustry trend toward digital transformation and advanced manufacturingtechniques, positioning the company to meet evolving client expectations forfaster delivery times and more intricate structural designs.
Who's Involved?
Caunton Engineering, a family-owned business located on theformer Moorgreen Colliery site in Newthorpe, Nottingham, stands as one of theUK's top five steel manufacturing companies with an annual turnover ofapproximately £100 million and a workforce of 250 employees. The company haspartnered with two major equipment manufacturers for this technologicalupgrade: Japanese industrial giant Mazak, which supplied the FG-400 NEO lasercutting machine, and an American manufacturer that provided the PeddiBot-1250robotic fabrication system.
Simon Bingham, Chairman of Caunton Engineering, emphasizedthe strategic importance of this investment: "This investment in the verybest of new and emerging industry technology is a significant statement ofintent by Caunton Engineering as we strive to improve both the quality andefficiency of our production process. We are especially pleased to be workingwith Mazak to bring the UK's first FG-400 Neo laser cutting machine to the CutShack, designed for ultra-high-speed 3D cutting of long tube, pipe and structuralmaterial."
The company has established itself as a major player in theUK construction supply chain, providing steelwork for significant projectsincluding TJ Morris' £118 million distribution warehouse near Warrington,London's Edmonton EcoPark Energy Recovery Centre, and the North Stand ofLeicester Tigers' stadium.
Technological Advancements
The centerpiece of Caunton's investment is the Mazak FG-400NEO, an automatic and continuous 3D laser-cutting machine that represents thefirst installation of its kind in a UK structural steelwork company. Thissystem employs an energy-efficient fiber laser technology optimized forhigh-speed cutting of structural components with exceptional precision.Specifically designed for processing materials with profiles below 300mm andthicknesses up to 20mm, the machine can handle a diverse range of sections includinguniversal beams, columns, channels, tubes, box sections, flats, and anglesections.
The FG-400 NEO's capabilities extend beyond simple cuttingoperations to include complex 3D laser head movements that enable theproduction of intricate joints and shapes with high accuracy. This precision isparticularly valuable for projects requiring tight tolerances and complexgeometrical configurations that would be difficult or impossible to achievewith conventional fabrication methods.
Complementing the Mazak system is the American-manufacturedPeddiBot-1250, a versatile robotic fabrication machine that uniquely combinesplasma cutting, oxy-fuel cutting, and layout marking capabilities within asingle platform. This integration eliminates the need for multiple specializedmachines and reduces material handling between operations. The PeddiBot-1250'sintelligent plasma cutting system is engineered to maximize productivitythrough faster cutting speeds and can process materials up to 80mm thick,significantly expanding the range of structural components that can befabricated efficiently.
Operational Impact
The dual installation represents a transformative approachto Caunton's production processes, with Chairman Simon Bingham noting that"The higher levels of both speed and accuracy that laser cutting andassociated robotic technology brings to our production process will transformour capabilities in delivering larger and more complex steelworkprojects." This enhancement in capability is particularly significant asconstruction projects increasingly demand more intricate structural solutions withshorter lead times.
Both machines will operate within the company's "CutShack," a purpose-built 45,000 square foot facility that opened in 2014 asa dedicated space for advanced manufacturing technologies. The integration ofthese new robotic systems into this existing high-tech environment creates acomprehensive fabrication ecosystem that streamlines the entire productionworkflow from raw material to finished component.
The automation provided by these systems addresses severaloperational challenges simultaneously. First, it reduces the reliance on manualprocesses that can introduce variability in quality and production rates.Second, it enables more efficient material utilization through optimizedcutting paths and reduced waste. Third, it allows for more predictableproduction scheduling and improved delivery reliability. These benefitscollectively strengthen Caunton's competitive position in securing and executinglarge-scale structural projects.
Key Takeaways:
• Caunton Engineering has completed a multimillion-poundtechnology upgrade with two advanced robotic machines installed at itsNottingham facility
• The company is the first UK structural steelworkcontractor to implement Mazak's FG-400 NEO laser cutting system, designed forhigh-speed 3D cutting of structural materials
• The PeddiBot-1250 robotic fabrication machine uniquelycombines plasma cutting, oxy-fuel cutting, and layout marking capabilities in asingle platform
• Both machines operate within the company's 45,000 squarefoot "Cut Shack" facility, enhancing capabilities for larger and morecomplex steelwork projects
• Chairman Simon Bingham emphasized the investment's rolein transforming production capabilities while creating opportunities to upskillthe company's 250 employees
• Caunton Engineering, with annual turnover ofapproximately £100 million, supplies steelwork for major UK projects includingTJ Morris' £118 million distribution warehouse and London's Edmonton EcoParkEnergy Recovery Centre
