The joinery offers a very extensive portfolio in the building components sector. This includes, for example, windows with solar and insect protection, entrance doors, security technology, conservatories, mullion-transom facades, stairs, gates, fire protection, and interior doors. Another important pillar of the Bad Berleburg-based company is its funeral services.
Master joiner and funeral director Andreas Zoll (49), who took over the business from his father in 2002, currently employs twelve people, including his sister Claudia Zoll. A trained master interior decorator, she primarily handles the funeral services side of the business. The team also includes eight journeymen and women, a master roller shutter constructor, and one apprentice.
The joinery boasts a very broad product range and cooperates with various renowned suppliers. Under the motto "Quality over quantity," the company offers consultation, planning, and implementation, including installation, from a single source. In the 300 m² showroom, potential customers can get an excellent overview of the product spectrum.
The joinery produces its own wood and wood-aluminum windows, entrance doors, mullion-transom facades, and frequently, solid wood country-style doors. Currently, this amounts to around 1,000 high-quality windows and 50 entrance doors per year. In the wood-aluminum sector, the company relies on the Gutmann system.
Machine and software from a single source
Just over five years ago, Andreas Zoll modernized his production facilities. It was clear from the outset that a versatile 5-axis CNC machining center should become the new heart of the manufacturing process. The master joiner also had very clear ideas when it came to selecting the right technology. He placed particular importance on the machine and software coming from a single source. Accordingly, he analyzed the market with a specific focus and opted for CNC technology and software from the Felder Group.
Flexible CNC machining
On the machine side, the final choice was a Format4 Profit H500 S-Motion 5-axis machining center. Its working area is generously dimensioned at 3740 x 1570 mm with 350 mm in the Z-axis, making it suitable for all required machining tasks. The CNC has 59 tool changing positions on board (two rotary and one linear changer), and the 15 kW 5-axis spindle offers ample power.
In addition, there is the position-controlled table (S-Motion). This is a self-setting machine table with program-controlled moving consoles. Positioning can occur when the table is empty for placing workpieces, as well as during machining—for example, for the fully automatic reclamping of window scantlings during two-sided profiling.
End-to-end planning and production
From the very beginning, Andreas Zoll was also convinced by Felder's proprietary window software, F4 Frame, which, in combination with the CNC, was the deciding factor for the investment. Because, as mentioned, Andreas Zoll wanted the machine and software from a single source. Looking back, he sees this as an excellent decision: "Everything is pre-configured in the F4 Frame software from the factory and is ready to use immediately. I can actually plan all windows with the software and produce them seamlessly on the CNC. We use F4 Frame both in the office and directly at the machine." The software covers all variants that Zoll produces—for example, arched windows, entrance doors, folding sliding elements, or mullion-transom constructions.
Windows and doors are designed by entering the key parameters.
Corner joints (e.g., scribe-and-dowel, scribe-and-screw, mini-finger joints, mortise and tenon, or milled tenon) can be set independently of each other, and profiles can be easily swapped out later.
At the click of a mouse, a window is finally "broken down" into individual CNC programs. The machine operator can call these up directly and process them on the CNC without any post-editing. The software automatically generates a bill of materials, including an illustration of the window. F4 Frame can also be used to create various production lists, which output an image of the window and an exploded view drawing with the corresponding cutting dimensions. A glass and fittings list can also be generated.
Precision meets safety
Andreas Zoll also relies on Format4 for standard machines. In the summer of 2021, he invested in two Kappa 550 E-Motion panel saws, both equipped with the then-brand-new PCS (Preventive Contact System) safety device. Andreas Zoll states: "The safety of my employees is very important to me. That's why I decided without hesitation to equip the panel saws with the PCS system."
Upon detecting an accident risk, PCS triggers the retraction of the saw blade below the saw table within a few milliseconds. The operating principle, based on electromagnetic repulsion, ensures a very short reaction time. The safety zone surrounds the saw blade, protecting against access from all directions. The safety drop is non-damaging to the equipment. At the push of a button, the panel saw is immediately ready for use again. The globally patented safety innovation is available as original equipment for the Format4 Kappa 550 panel saw and, from Ligna 2023 onwards, also for the Kappa 450 and Kappa 450 X-Motion, as well as the Felder K945 S.
In the E-Motion configuration, the two premium saws also offer features such as an electromotive controlled rip fence, unlimited tool memory locations, and programmable cutting sequences in the smart, in-house software. All machine axes can be intuitively controlled from the central control unit with a 15" touchscreen.
