When Fletcher Dimond’s Purlin Line reached end of life after 30 years of service, replacing it presented two challenges; firstly, the new machine had to handle Dimond’s innovative product range, meaning several profiles could be built with one machine. Secondly, the new machine must be efficient. To change profiles with their previous machine took almost five hours. This machine needed a fast changeover time with minimal operator intervention. These important requirements meant the new Hayes machine required unprecedented customization. Communication between teams of engineers had to be flawless through every phase of the build process — from specification to building and delivery.
After being at Hayes for over 40 years, Shop Floor Manager John Hornfeck has seen hundreds of machines leave the shop floor to begin their working lives all over the globe. But none matched the scale of the new Fletcher Dimond Purlin Line. For this line, John needed 70 people involved on the shop floor, all working to tight specs and tight timelines. His team considered everything — production rates, exact floor space requirements, operator numbers, and general infrastructure — all the while maintaining a direct line of communication with the engineering team at Fletcher Dimond. The result was a heavy industrial Purlin Mill and stacking system capable of running Fletcher Dimond’s diverse product line with minimal change time between lines. Plus, a product that John is proud of — both to make and to see out the door.
General Manager Damien Sauni is always looking to invest in the future success of Fletcher Dimond Roofing, and as they grow, Damien will continue to work with Hayes International to supply their Rollforming equipment. The strong relationship has been paramount to the success of the project. Damien says: “The relationship with Hayes has been incredible — and it’s a critical part of our success. They have physically walked us through this machine from start to finish. They have helped us specify, build, and implement the machine. The machine is fantastic, and we’re thrilled to have it, and the relationship with a strong New Zealand OEM (Original Equipment Manufacturer).”
General Manager Damien Sauni needed a partner to build a fully custom Rollforming machine — one that could manage the high output of a diverse product offering, with minimal operator intervention. After a long relationship of 40 years, Hayes International was, in Damien’s eyes, the best partner for the job.
Custom Metal Industries is a 4th generation family business based out of Greenfield Indiana and has used Bradbury Group and Hayes Machines since 1960. Custom Metal Industries and Hayes have grown together, in a true partnership lasting for generations.
Hayes Rollformers are built for the most robust production lines. Hayes International has been manufacturing Rollformers for over 60 years and have a reputation as one of the world's top manufacturers of Rollformers and Rollforming equipment.
