When Cambridge-based Diba Industries identified a bottleneck in its production of connectors, fittings and adaptors for the fluid-handling industry — caused by a single-spindle machine with a full-time operator responsible for programming, loading and unloading machine — the problem was solved by acquiring a Tornos Delta 12/5 turning centre (www.tornos.com).

Engineering project manager Paul Wright says: “We wanted to replace the single-spindle machine with a more productive twin-spindle unit to eliminate the bottleneck for parts under 16mm in diameter. The new machines available from our existing supplier had too many axes and features, so they were overpriced for what we required.

"While Tornos also has high-end turning centres, the Delta 12/5 proved a perfect fit for our parts, offering the right specification at the right price. What sealed the deal for us was the guide-bushless running, which reduces the bar remnants and the associated waste at the end of each bar.”

Turning costly materials such as PEEK and PCTFE, Diba was previously left with 250mm remnants from each bar — a waste of around 10%. The guide-bushless system on the Delta has cut this waste rate by up to 60%, which equates to a 4% overall saving on material costs.

With regard to productivity, the Delta 12/5 has reduced some cycle times from 4min to 1min per part, saving 60hr a month, while completing parts in one operation ensures component quality, consistency and overall accuracy. With typical batch sizes up to 500 parts, there is no need for an operator to be constantly in attendance.

Mr Wright adds: “As a fist-time Tornos customer, we are delighted with how easy the machine is to program and set up. The bar-feed integrates with the machine perfectly, and it is easier to conduct bar diameter change-overs than on our other machines.

The set-up times are drastically reduced, which is ideal as we may run two or three different jobs on the machine each day. In addition, the high-pressure coolant delivery has been a revelation in managing the long string-like swarf that is commonplace with the materials we machine.”