Turnstar upgrades sheet and tube cutting options

Invests in new Bodor 12kW flat-bed fiber laser and a Bodor 3kW tube laser cutting machine with a loading system.

“Normally a company spokesperson would say that the company’s recent machinery and equipment investments would be to open the door to new markets. In our case it is not so, well not directly. We don’t intend to be a service centre or offer our excess capacity to outside parties,” explained Sid Sacks, founder of Turnstar, one of Africa’s largest manufacturers of secure physical access control products, offering a host of solutions, ranging from turnstiles and revolving doors to vehicle barriers.

“We have created both opportunities and challenges for ourselves in the last few years. The opportunities are that our production levels have grown to the extent that they have outstripped the capacity of our existing equipment. Up until recently this was the challenge as we had not invested in equipment to meet our requirements. We have done other equipment investment but not in the flat sheet or tube cutting departments.”

Turnstar is one of Africa’s largest manufacturers of secure physical access control products, offering a host of solutions, ranging from turnstiles and revolving doors to vehicle barriers

“As is the case with everyone in South Africa another challenge has been load shedding, which has not made it easy, but we have invested in the alternative power supply equipment to smooth the curve. Already in 2020 we installed a 450kVA generator in order to ensure continued operations even during load shedding. The generator is fitted with an Volvo diesel engine that was manufactured by EngineCO. The generator replaced the existing smaller units which were not able to supply sufficient power for our requirements. The generator integrates with our existing grid tied solar system for maximum fuel efficiency during operation,” continued Sacks.

“Since we invested in our Durma 4kW fiber laser in 2016 we have regularly added more equipment to various departments. Our 11 500m² factory in Wynberg, South Africa, is fitted with over 130 machines for various applications and jobs. The more recent installations were in 2021 when we added an Amada turret punch in order to improve production quality and speed. The punch is operated with a sophisticated hydraulic actuating system which ensures high speed metal work and precise repeatable results. The punch complements Turnstar’s 4kW fiber laser cutter and comes into its own in terms of speed when working with materials of 3mm and under.”

“The 12kW Bodor P4 fiber laser, supplied by Integral Machine Tools, has a table size of 3m by 1.5m and will provide the company with a significant boost in productivity and allow us to offer better laser cutting lead times. Every increase in power delivers a cleaner cut edge, especially on mild steel. We can now cut mild steel up to 30mm thick used for our turnstile mechanism components.”

“That same year we put in our second Amada machine – an automatic band saw model HA 250. With a cutting and feed tolerance of 0.2mm and hydraulically tensioned cutting blade, the machine has brought increased cutting speed in the band saw department, accuracy and high throughput, aiding in the production of turnstiles, solenoids and torque motors. Amada is a well-known and respected Japanese company in the field of metal work and manufacture all types of laser cutters, CNC punches and CNC press brakes. In total, Turnstar now has four band saws in operation on a daily basis.”

“In 2022 we purchased five new machines to improve overall productivity and add an extra layer of capability. Included in the purchase were two pneumatically operated circular saws, a large hydraulically operated circular saw for bundle cutting, a hydraulic tube notcher for radiusing of tubes and a CNC tube puncher for punching of holes into tubing. The machines were commissioned and started producing from September 2022.”

“Turnstar manufactures a number of standard products. For example, we manufacture scores of different sizes and types of turnstiles daily. These include full height industrial turnstiles, three-quarter and half-height turnstiles, waist-height and portable turnstiles and many other different style turnstiles. It all depends on the client requirements and the situation for and what the product will be used for. As we manufacture from scratch, we also get numerous requests for product customisation.”

“The investment in the Bodor 3kW tube laser cutting machine with a loading system is way overdue. The Durma laser cutter is fitted with a tube attachment, which enables the company to laser cut holes on steel tube and pipe. As tube and pipe makes up a sizeable portion of our metal processing, we have now decided to have a stand-alone processing option, again for the exact same reasons why we purchased the Bodor 12kW flat-bed fiber laser – capacity enhancement and not being reliant on one machine.”

“Because we have our own product lines, I have a research, design and development team that is able to assist Turnstar clients from project conception, all the way through to on-site installation. They help bring new products to market and we can also use them to benefit our custom customers, whether it’s to tweak designs or to develop process improvements.”

“This has led to us developing and manufacturing associated products including speedgates, revolving doors, man-trap cubicles, vehicle barriers, high security spike barriers and anti-terror rising bollards and road blockers. We offer a total solution for all physical access control and time and attendance applications. The company is driven to provide products that are a fit-and-forget solution.”

“Next time you visit a building or a factory with controlled entrance access and exit measures you will more than likely find one of our products. When you enter gym there is always a waist height one-way single turnstile with an access control system in place. We are suppliers to most of the recognised gym companies.”

“We have also waded deep into the security market, providing secure entrances for airports, financial institutions and organisations where there is limited or no access to the public. Such doors can have a variety of features, from card-swipe units to sophisticated biometric identification systems. They can even be bullet-resistant.”

Turnstar have also invested in a hydraulic tube notcher for radiusing of tubes and a CNC tube puncher for punching of holes into tubing

“Another example are the manual or automatic revolving doors at banks or shopping malls. They are available in many different sizes, shapes and access-controlled configurations. For all metal visible to those walking through cosmetics are paramount but again it all depends on the client requirements. We can manufacture with all types of finishes.”

“We have been operating a modern powder coating line for over 13 years and no powder coating is sent out to sub-contractors. With the process contained in-house, Turnstar is able to control quality, lead time and pre-treatment. Pre-treatment is the most critical and the most often overlooked aspect of powder coating as you can’t see the metal under the cured paint. Turnstar operates a state-of-the-art 10-tank pre-treatment plant which degreases, removes rust and scale and then coats the metal with a multi-metal phosphate. After chemical processing the iridescent coating allows for great adhesion as well as corrosion protection.”

“We also operate a zinc plating plant for components that require a zinc finish.”

“The one constant though is that products have to offer fully integrated performance.”

In total, Turnstar now has four band saws in operation

The company has recently taken delivery of a vibratory finishing machine

“The products can be as basic as necessary or as aesthetic and design noticeable as required but all must be durable and reliable. This is where we rely on the latest state-of-the-art production processes and machinery as we like to do most of the manufacture of components and systems in-house so we can monitor complete quality control.”

“You might think not much goes into the manufacture of a turnstile. It’s like a sliding gate motor. There are covers, the working parts such as gears and wheels and the electronics. All the holes and punches have to be exact otherwise all the tubing and fasteners used will not line up and you certainly don’t want walk into a turnstile that stops dead on you – it can be painful, especially for men.”

New Bodor 12kW flat-bed fiber laser and a Bodor 3kW tube laser cutting machine with a loading system“Our recent equipment investments have been very necessary. On the laser side we became too reliant on the one machine. It churns out hundreds of components daily and if we have a breakdown, production will be severely disrupted. Hence our investment.”

Turnstar manufactures working parts such as gears and wheels for its products

“The 12kW Bodor P4 fiber laser, supplied by Integral Machine Tools, has a table size of 3m by 1.5m and will provide the company with a significant boost in productivity and allow us to offer better laser cutting lead times. Every increase in power delivers a cleaner cut edge, especially on mild steel. We can now cut mild steel up to 30mm thick used for our turnstile mechanism components.”

“The more significant factor is that it takes care of our increased capacity requirements and having plan B in operation.”

“The investment in the Bodor 3kW tube laser cutting machine with a loading system is way overdue. The Durma laser cutter is fitted with a tube attachment, which enables the company to laser cut holes on steel tube and pipe. As tube and pipe makes up a sizeable portion of our metal processing, we have now decided to have a stand-alone processing option, again for the exact same reasons why we purchased the Bodor 12kW flat-bed fiber laser – capacity enhancement and not being reliant on one machine.”

“The effective cutting length of our T-230 model is 6 500mm, the round tube cutting diameter is 8mm to 230mm, and the square and rectangular tube cutting diameter is the same 8mm to 230mm. It also comes with a semi-automatic loading system.”

As there are many different working parts in the products there is a big requirement for turned and drilled components

Turnstar have been operating a modern powder coating line for over 13 years

“Both were installed in May 2023. Fiber laser processing is no longer an emerging technology. It is efficient, accurate, clean, quiet and flexible. The shapes and sizes obtainable are virtually unlimited.”

“You could say that the heightened security concerns are a big contributor to Turnstar’s growth and this cannot be denied. However, it’s the company’s willingness to adapt to market demand and the company’s changing production operation that have also made a contribution to the company’s significant growth.”

Over time the company’s offering has evolved from that of just being a turnstile manufacturer to one that is relied upon by global mining companies and financial service providers to single-site retailers for all their secure physical access control systems.

For further details contact Turnstar Systems on TEL: 011 786 1633 or visit www.turnstar.co.za