Making Change Happen

With new machinery in short supply and the need to upgrade its traditional joinery workshop fast becoming a priority, Bowkirk Joinery Solutions turned to reconditioned machinery specialist, Ferwood in a bid to source readily available machinery that not only met the specification requirements but also the company’s budget.

The phrase speculate to accumulate couldn’t be more fitting for commercial joinery company, Bowkirk Joinery Solutions. In the midst of a global pandemic and facing a rapidly changing market, the successful commercial fit-out company took the opportunity to diversify and become a commercial furniture manufacturer in its own right. But, with new machinery in short supply and the need to upgrade its traditional joinery workshop fast becoming a priority, the Pontefract-based business turned to reconditioned machinery specialist, Ferwood in a bid to source readily available machinery that not only met the specification requirements but also the company’s budget.

“We’d been offering a commercial fit-out service since 2013 but we saw great potential in opening our own manufacturing division and making our own kitchens and bedroom furniture for the commercial sector,” explains Paul Bowkirk, owner of Bowkirk Joinery Solutions. “We had the contacts and the right skill set in house but setting up a production line was new territory for us. We didn’t have the right machinery to do the job or vast sums of money to invest in new kit but these were minor obstacles for Ferwood. They worked with us to find the best machinery for our business and their direction played a huge part in how our business is run today.

“We originally thought an entry-level three-axis CNC with nesting capabilities would have been a good starting point for us. It was affordable and would have done the job but it was Ferwood that opened our eyes to the level of versatility and scope a larger machine could offer our business and the additional time and cost-saving credentials it would bring to the table,” says Paul. “Unlike smaller models, Ferwood’s used Biesse Rover A came with an automatic in-feed table and conveyor belt capable of working with up to 28 jumbo sheets at a time. It also featured a separate drill bank which could allow us to machine multiple holes at once and required just one operator. This machine could offer more flexibility and wouldn’t limit production growth as the company grew.

“We could see the potential immediately. We would be competing against more established businesses in the commercial joinery market so we needed to hit the ground running. With this machine, we could do just that.”

To purchase the machine, the joinery took advantage of the government’s Bounce Back Loan and, as the claim was being processed, Ferwood lent the joinery company a Biesse Rover B. “In order for us to get to work quickly, Ferwood let us borrow a CNC from their existing stock. I don’t know another company that would go to the same lengths to help their customers.”

The company started winning business immediately and, with their Biesse Rover A installed in a newly-designed workshop, it set to work on its first project: the machining of 250 student bedrooms. “It did this with ease,” recalls Paul. “What we didn’t expect is that we’d also need a quicker and bigger edgebander. We had a CNC that was churning out panels at a fast rate but our old edgebander couldn’t keep up. It was proving unreliable and the team was spending more time fixing it than they were running it. We needed a CNC-operated edgebander that was easy to set-up and simple to maintain and that could work with hotmelt. It also needed to offer us the flexibility to handle hardwood lippings so we could eventually produce fire rated doors up to 54mm using a PUR system. Ferwood was our only port of call.”

Ferwood suggested a fully-reconditioned Brandt single-sided edgebander which had been put through Ferwood’s rigorous 10-step refurbishment programme. It not only offered simple handling but could also work effectively if production continued to increase.

“It looks and performs like a new machine,” says Paul. “With minimal skill required, we doubled our output immediately. Working in tandem with the CNC, we now have a full machining cycle that allows us to cut and edge a complete kitchen (90 panels) in half a day, reducing machining time by 75%. There’s no stopping and starting and no unnecessary labour costs. Plus, with the potential to increase our production by a further 100%, we’re also in a position to explore several new revenue streams.”

Not only is the newly-expanded company continuing to win FF&E contracts throughout the UK, production is also being supplemented with private kitchen work – upwards of 10 kitchens per week, as well as kitchens for smaller homebuilders and a cut and edge service. Paul and his newly appointed Business Development Manager are also in talks with nationwide house builders about supplying kitchens to multiple development sites.

“There’s no way we could have achieved this level of production with the machines we originally had in mind,” admits Paul. “Our business model has become much more fluid and as a result, our business is working on numerous projects across different sectors. We certainly didn’t expect the company to grow so quickly. It’s not been without its challenges but Ferwood have been behind us every step of the way. Their technical knowledge and direction has ultimately helped us get to where we are today. The increased investment in machinery has paid off.”

Six months on from the installation of the edgebander, Bowkirk Joinery Solutions is seeing a return on its investment. Paul says, “We wouldn’t have seen a return on a new machine this quickly and I don’t believe the output or potential to grow our business and branch-out would have been any different. Ferwood is a great business model. They offer good-quality machines and the option to fully recondition them to an exceptional level without the hefty price tag. Would I buy from them again? Without a shadow of doubt. Their support and guidance has been a huge factor in our success and even now, several months on, they’re continuing to help us with ongoing changes to our business.”