The Bradbury Group News

FAQ: How is End Flare controlled in Roll Formed Profiles?

Posted by Matt Werner on Jun 18, 2020 9:21:49 AM

End flare can be inherent in roll formed parts, especially when produced on a precut roll forming line as opposed to a post cut line which forms the panel first and then shears it to length.  The amount of flare depends on the tooling design, the use of anti-flare fixtures, material type and strength, profile or a combination of these factors.  Excessive end flare in roll formed shapes can cause issues when installing and end lapping panels. Purlins used in rigid frame building structures are heavy gauge deep sections which can have more end flare.  When forming a purlin, it will naturally flare in on the leading edge and out on the trailing edge. In other words, the leg angles on the leading edge are typically over 90 degrees, while the trailing edge leg angles are under 90 degrees.  The returns lips can also have flare making it difficult when face to face welding cee sections.  Just a few degrees of end flare on an eave strut can cause a high spot in the roof panel that is fastened to this section.  

To minimize and control flare in purlins, Bradbury incorporates an anti flare fixture into the straightener at the end of the machine.  Both the drive and operator side have a three-roll configuration to independently control the flare on either side of the part.  The position of the center roll must satisfy both the leading and trailing flare. This can be a balancing act, due to a single adjustment affecting both. With that said, operators will typically find that middle ground on the center roll adjustment that adequately reduces the flare on the leading and trailing ends to within tolerance.

Servo driven auto anti flare fixtures are different to stationary anti flares on the straightener fixture.  

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Topics: Metal Building Roll Forming, Product Spotlight, Metal Roofing, Steel Framing, FAQ

Bradbury Flat Trak CL Removes Stress

Posted by Rachel Grilliot on Jun 3, 2020 10:30:00 AM

REDUCE SCRAP AND OUT OF FLAT MATERIAL 

The Flat Trak® CL Strip Evaluation System is Bradbury's recent technological evolution that utilizes artificial intelligence to analyze strip condition and provide suggested adjustments to your leveler to process flat material. 

How does it work? Bradbury’s Flat Trak® CL continuously scans the strip surface for shape defects. The included video monitor depicts actual shape conditions in real time and allows the operator to make an informed decision for adjustment to improve flatness. The operator can adjust the leveler and see in real time how the changes affect material shape. When installed with the Bradbury e•Drive® Leveler, the Flat Trak® CL System can automatically adjust the leveler to maintain a flat strip, allowing your operator to focus on other production line tasks.   

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Topics: Leveling and Coil Processing

Athader's Packing & Strapping Automated Solutions increase production

Posted by Rachel Grilliot on May 27, 2020 9:00:00 AM

Most Cut to Length lines suffer from a bottleneck in production at the exit end of the line due to customers' unique requirements for packaging the CTL sheets or plates. These customer-driven stipulations can be quite extensive and labor-intensive for the line operators. End customers today are requesting smaller stacks and more frequent deliveries to manage their cash flow more effectively. This puts additional pressure on the line operator due to the increased number of packaged stacks the line must produce. 

Requirements from the end customer might include the following:

  • Strapping sheets both horizontal and vertical directions.
  • Strapping dunnage to the sheets both horizontal and vertical directions.
  • Protective wrapping such as paper or plastic.
  • Stacks with or without wooden skids.
  • Corner protectors
  • Shrink wrap

Athader S.L., a company within The Bradbury Group, offers the following automated stacking and packaging solutions to improve throughput efficiency:  

  • Storage of packs via roller and chain type conveyors.
  • Ability to discharge scrap pieces without manual lifting.
  • Automated insertion of corner protectors. 
  • Pack Lifter – This is used to elevate a stack of sheets that have exited the stacker. Once elevated the package can be easily wrapped.
  • Wrapping Systems - Height wrapping can be manual or automated; Width wrapping can be automated via an orbital wrapper.
  • Automatic dunnage retrieval from an organized pack by robot or by a dunnage cartridge system.
  • Automatic dunnage insertion under the stack of sheets.
  • Automatic strapping of the dunnage to the stack of sheets.
  • Automatic formation of a master stack of sheets via an automated sheet lifter and/or gantry crane.
  • Once the master stack of sheets is built, the sheets are deposited onto the floor for removal by the main overhead crane and put into the storage area.
  • Cloud-based data storage/tracking system including package specific details, machine status, faults or stoppages, and production levels. Over time this system can provide information on areas of needed improvement to further increase production or help the owner identify the packaging costs to improve the management of as sold costs. 
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Topics: Company News, Athader

FAQ: What does a Calendering machine do?

Posted by Rachel Grilliot on May 21, 2020 9:00:00 AM

Calendering:  A process that plays a part in all our lives, yet most of us have no idea what it is. From disposable diapers to dryer sheets, to disinfectant wipes, to rubber tires, to PVC films used on laminate floors, to healthcare protective equipment, and many more - calendering  is vital to the production of thousands of products used every day.  

Calendering is the process of pressing a continuous web or substrate, such as cloth, rubber, paper, film, nonwoven, composite, wire mesh, etc., between rollers to create specific physical characteristics. These can include controlled thickness, surface finish, and required properties such as structural reliability, liquid absorption, and abrasion resistance.

Alliance Machine and Engraving, LLC manufactures custom calender machines for numerous industries. The calenders employ two or more steel rolls that close under pressure to smooth, compress, and in some cases partially bond a nonwoven, plastic, paper, or another substrate. The rollers may be mirror-smooth, embossed with a pattern, or porous, and are usually heated with hot oil or electric elements. The calender machines can be utilized in an independent converting setting or an integrated production facility. Each designed with a specific application, Alliance calenders currently in use range from 260” wide to less than 12” wide.   

When processing certain webs such as fine paper or precision magnetic tapes, a calender will have a stack of rolls through which the web is threaded. This is referred to as a supercalender. 

Many nonwoven’s need to be calendered as part of their production or finishing process. The combination of heat and pressure seals and consolidates the random fibers in the web, yielding a sturdy, cost-effective replacement for woven fabrics in applications such as disposables (medical masks, dental bibs, diapers, wipes, dryers sheets), semi-durables (filters, packaging, scouring pads) and durables (automotive, home furnishings, garment bags, geotextiles).

Alliance is currently working with a major supplier of woven fabrics for various markets including healthcare. Many of their materials have a cotton and a synthetic component. The supplier wants to investigate how calendering one such blend could help reduce porosity by partially melting and sealing the surface, therefore making the material better suited for a protective garment barrier application. The supplier sent material samples to Alliance and the samples were run on a test lab calender at various speeds, temperatures, and pressures. The materials have been returned to the supplier to test results. Helping find ways to improve the material used for healthcare gear is an honor for Alliance. 

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Topics: Company News, FAQ, Alliance

Bradbury COVID-19 Update

Posted by Rachel Grilliot on Mar 23, 2020 2:55:12 PM

Providing great service to our customers is something we take pride in.  During this everchanging COVID-19 pandemic, we want you to know that our facilities are open and we are here to provide support.  We are receiving daily updates and continually communicating with our staff while endeavoring to support you to the best of our abilities. 

While we have limited some of our travel, our sales and service teams will continue to make calls to discuss your needs.  We will contact you prior to any visit that is scheduled.  We can also connect with you remotely via our meeting software or another way.  Technology allows us to be on-site virtually with you to support equipment. 

Safety for everyone is our priority.  We will continue to monitor the situation and communicate with you.  We will adhere to the guidelines as presented by the Center for Disease Control, State Health and Environment Department’s and the World Health Organization.

Please contact us with any requests and we will assist you during this time.  Our main phone number is 620.345.6394.  Our email is bradbury@bradburygroup.com

With regards,

President

The Bradbury Co., Inc.

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Topics: Company News

Bradbury Promotes Ben Schmidt to Industry Sales Manager

Posted by Matt Werner on Feb 17, 2020 11:20:25 AM

Bradbury announces the promotion of Ben Schmidt to Industry Sales Manager. He has been with Bradbury for 14 years, serving as Industry Sales Leader since 2015.  In this new role Ben will lead a team to manage all facets of sales and customer relationships in the Metal Building, Decking and Trim Shop industries as well as speak directly into equipment Research and Development.  Ben will work closely with Ryan Durst - Bradbury President, Matt Werner - Senior Manager Inside Sales and Global Marketing, and Greg Smith – Vice President R&D Engineering & Market Development. 

“Ben has consistently proven his ability to sell into multiple industries and build personal connections and relationships.  He has a deep understanding of customer requirements and technical industry needs.  We are very pleased to promote him to this leadership role,” commented Ryan Durst. 

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Topics: Company News, Promotions

Bradbury Group Australia Announces Promotion and New Hires

Posted by Rachel Grilliot on Sep 4, 2019 1:13:07 PM

Bradbury Group Australia, a member of The Bradbury Group, looks to future growth and development with the announcement of the following promotion and company new hires.

Mark Osborne transitioned into his new role as General Manager of Bradbury Group Australia. Mark brings over 30 years of experience in engineering to his position. He joined Hilleng International as a Production Manager in 2004 where he was heavily involved in the manufacture of laminated panel equipment for insulated panels, roofs, and walls. In 2010, when Hilleng International and Die-Craft Engineering were acquired by Bradbury to form Bradbury Group Australia (BGA), Mark became Engineering Manager. His duties included conceptual equipment design, customer service and sales, and management of the Bradbury Group Australia design team. As a customer-focused general manager, Mark will lead the direction for continued industry advancement at BGA.

Adrian De La Cruz recently joined the team at Bradbury Group Australia as Senior Sales Engineer. Adrian will work closely with the management team at BGA to drive sales and find new market opportunities. Previously, Adrian worked for Savaria Australia where he was instrumental in introducing the Canadian designed elevators to the Australian building industry. Prior to his time at Savaria, Adrian worked in the sky light industry as a manufacturing engineer and sales consultant, where he was associated with many BGA customers. Adrian has a bachelor’s degree in Civil Engineering and approximately 13 years of experience selling metal roofing, steel decking, steel cladding, and other roll formed metal building products.

Pete Kenny joins the BGA team as the company accountant. With a degree in accounting from Queensland University of Technology, he is a CPA with 15 years of knowledge in the manufacturing, mining services, and construction industries. His duties include continuous improvement for BGA, driving cost efficiencies, and providing support to the sales process.

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Topics: Company News, Promotions, Bradbury Group Australia

Bradbury Names Ryan Durst as President and Announces Senior Management Team

Posted by Rachel Grilliot on Aug 6, 2019 11:05:36 AM

The Bradbury Co., Inc., a global leader in the design and manufacture of roll forming and coil processing systems, is celebrating 60 years of growth and innovation in 2019. With company progression comes the opportunity for leadership changes to best serve Bradbury customers and employees. Bradbury’s investment in employee leadership development reflects directly on its Vision and Mission.

Bradbury announces the promotion of Ryan Durst to President. He has been with Bradbury for 23 years, serving as VP - Sales & Marketing since 2002.  As President, Ryan will focus on sales, engineering, manufacturing and service; bringing a vast amount of knowledge and experience to his new role.  “Overall, my focus will be to sell it, engineer it, build it, and service it; on-time and on-budget.  My goal is to advance our Vision & Mission and our overall corporate strategy as the parent company of The Bradbury Group.  I want our customers to have an exceptional customer experience in choosing us as their trusted supplier.”  Ryan will work closely with David Cox - Bradbury Group CEO, Bradbury leadership teams and all Bradbury employees.

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Topics: Company News, Promotions

ALLIANCE joins forces with MEMCO® in the metal embossing market

Posted by Rachel Grilliot on May 28, 2019 11:42:38 AM

Alliance Machine and Engraving, a member of The Bradbury Group, announces a formal agreement with the Memco® division of Pamarco Global Graphics. Alliance is now the exclusive provider of all marketing, maintenance and production of Memco® brand Metal Embossing Machinery and Roll Sets, Matched Steel Roll Sets and Mill Engraved Products. 

“We celebrate the next step in our continued growth by teaming up our engraving expertise at Alliance with the well-known, highly respected and long-standing Memco® brand in metal embossing machinery and matched steel roll sets,” said Alliance’s Vice President of Sales, Brad Foster. 

Tom Greenberg, Alliance president and founder commented, “We are pleased to finalize this Agreement.  Our customers gain technology benefits from the synergies created by the Alliance-Memco® Agreement and the quality and service Alliance has become known for in the industry.” 

Memco® brand components and units can be seamlessly manufactured and serviced from our modern Alliance facility in Ashland, VA, or through The Bradbury Group divisions around the globe.  Hardened steel mill masters and engraving stands from Memco® will be transitioned to Alliance over the next 12 months as we ramp up manufacturing. The plan going forward is to retain all Memco® agents in Europe, Central America, South America, Asia and Africa.   

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Topics: Company News, Alliance

Bradbury Celebrating 60 Years of Innovation

Posted by Rachel Grilliot on May 22, 2019 10:52:06 AM

2019 marks the 60th year of continued growth and innovation at The Bradbury Co., Inc. We pride ourselves on being a global company which is still family owned and operated. Building on the solid work ethic of our employees and the guidelines of our company’s “Values & Beliefs,” our team focuses on creating a work environment that promotes integrity, trust, personal growth, communication, and strong relationships.

The Bradbury Co., Inc. was founded in 1959 by Floyd Bradbury and Jack Lacy as Roll Formed Products, Inc. They manufactured roll formed products and roller die tooling for customers involved in production roll forming. In 1964 Floyd renamed the company The Bradbury Co., Inc. and moved the company to an egg room of an old creamery building in Moundridge. It was in the creamery building that Floyd Bradbury designed the company’s first roll former to form awnings for a Hutchinson, KS, company. Today, you can find the first roll former on display in the Bradbury “Hall of Fame.”

In 1972 The Bradbury Co., Inc. purchased 12.5 acres of land at the south end of the Moundridge Industrial Park and Airport Complex. A 25,000 square foot building was built on the site. Currently, the Moundridge location serves as The Bradbury Group World headquarters with 350 employees and approximately 222,000 square feet of office and manufacturing space. Through acquisitions and partnerships, The Bradbury Group brings together manufacturers of related products from around the world; employing 665 people, utilizing 600,000 square feet of space in 10 manufacturing facilities around the world. We have a presence on 5 continents, in 9 time zones, with equipment operating in 89 countries.

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Topics: Company News