Rieder Windows from Zillertal in Tyrol, Austria, has to live up to its promise of being "state of the art". That is why the company is investing in qualified employees and the latest production techniques and machinery. From the drawing board to final customer installation and throughout the entire production process, the ‘project number’ is critical to the manufacture of quality windows. KBA-Metronic's alphaJET E inkjet printer is used for individually marking the window profiles.
Founded in 1945 as a joinery and carpentry firm, Rieder KG is now an innovative full service provider to the construction and timber industry with around 400 employees. Of these, 90 people are employed solely in the production of windows. The company, a renowned supplier, has consolidated its position as the number one in Tyrol and is known far beyond the national borders. In the construction and timber industry, the name Rieder stands for tradition and reliability, combined with high-tech and innovation.
The demand for certified windows alone, especially for low-energy and zero-energy houses, has been growing steadily over recent years, and this trend is on the up. The demand for products that are "Made by Rieder" even extends to England. Windows have long ceased being mere mass-market products. Each window is created on the basis of the customer's individual wishes, achieved with the innovative specialist company's technology and broad-based expertise.
The project number – the key to smooth workflow
A unique 5-digit project number is assigned as early as the quotation costing stage, and remains firmly linked to the project through every processing step. In addition, the components to be manufactured are divided on the basis of position, sub-position and sub-field numbers. Based on these position numbers and sub-numbers you can see at a glance which position in the overall order is being referred to and where the item is to be installed.
Once the quote turns into an order, all the necessary components are summarised, decentralised, in a bill of materials in an ERP system, and then transmitted to the manufacturing plant - together with the project number and any information relevant to the order.
Based on the project number that has been entered, the modern CNC woodworking centre receives, online, the geometrical data needed for the production of the wood profiles, and it then starts work automatically. By drilling, sawing, and milling, the section pieces need for Rieder windows, designed for high technical requirements and a very long life, are made from high quality "3-layer laminated scantlings". The wood used by Rieder, such as pine, oak and larch, all comes from a variety of timber merchants in the region.
The print head of the alphaJET E inkjet printer is mounted to the delivery conveyor of the CNC machine. At this point, the raw wooden profiles are marked directly with the project number and other production and product data. The network-ready alphaJET E from KBA-Metronic, the German coding and marking specialist. , facilitates communication with the CNC processing machine's software via an RS 232 interface. From this interface, the printer receives the information needed for the clear marking and labelling of the elements in plain text. Once the unfinished window profile has passed the product sensor, the alphaJET E printer prints up to 4 lines with a 24-dot matrix, in the finest print quality - even at high speed.
Out of respect for the individuality of wood, which is a natural material, most of the production steps at Rieder KG are carried out by skilled woodworkers. The clear text marking denotes identification at a glance. Even the technicians installing the windows on site use the markings on the window profiles for orientation purposes.
Far more crucial than the question about the information printed is the question of which marking system can withstand the difficult production conditions?
As early as their development stage, the functions of the alphaJET E were adapted to meet the demands of the food and beverage industry, and at a competitive price. The housing was designed according to the required protection class IP 55 for damp and wet areas, and is incorporated as a standard. Thanks to this protection class, the inkjet is also well prepared for use in other challenging conditions such as dust and sawdust-filled environments. Using compressed air, an excess pressure of up to 0.4 bar is produced in the head of the inkjet printer. This option prevents any dust penetrating the print head. Matthias Fischer, operations technician in the joinery/window construction department says: "Neither the compatibility with the automatic wood-working machines nor the difficult environmental conditions have caused us problems. What we are primarily concerned with is the clarity and consistency of the ink marking."
Readable markings versus surface treatment
By using the unique project number throughout the entire production control system, the clarity of the marking on the profiles is imperative, in spite of the fact that solvent-based varnishes and sealings are used. Conventional ink tends to blur or to fade when it comes into contact with solvents. Yet with well over 50 different inks to chose from, KBA-Metronic's specialists were quickly able to identify the ideal one: on wood, the Freon-based ink chosen has the special property that it lets the (already excellent) print image appear in even better contrast following the various surface treatments. The durability of the marking permits traceability, even years later, and it simplifies any necessary processing.
"Our years of experience, the high reliability of the machine components used, and our highly motivated employees are the cornerstone of our success. KBA-Metronic, with its alphaJET E and durable Freon ink, has given us a reliable and economical way to individually identify our high quality windows" summed up Matthias Fischer. Fenster gegeben.“ resümiert Matthias Fischer.
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