Choosing a Vertical Panel Saw
With the new economy’s costly labor supply, it is increasingly imperative to incorporate as many process improvements into your business as possible. One of the most overlooked opportunities for labor efficiencies is with respect to materials handling and workflow. Consider how much time and effort is put into moving materials around the shop area from one workstation to another. Consider how much time is spent preparing materials for your actual production process. Consider what this time is worth to your business and how you could reallocate it to drive other initiatives.

When processing sheet goods or other large stock, most fabricators use some type of saw to size their material. There are basically two types of saws widely employed in processing – vertical panel saws and horizontal panel saws.

Horizontal panel saws are similar to table saws but with a very large platform for supporting materials as they are passed through the cutting blade. Many high-end horizontal saws also have a sliding table that helps feed material into the blade. These sliding table saws tend to be a bit easier to use and more accurate than stationary horizontal table saws but the trade off is a higher cost and the dedication of more floor space than the already large stationary table saws.

Vertical panel saws are just what they sound like – vertically oriented saws for processing panels. These vertical panel saws have several key benefits. They take up very little floor space compared to horizontal saws, the bottom roller fence allows them to handle full sized sheets of material very easily with one operator, most manufacturers typically guard the blade more substantially than many horizontal machines, and they can be relatively low cost. An effective vertical panel saw for plastics processing can cost as little as $2,000 or as much as $50,000. The best option for your business depends on your requirements and the demands of your production process. Ninty percent of the applications can be well served for less than a $5,000 investment in a vertical panel saw.

There are several factors that will have a major impact on the performance and longevity of your vertical panel saw investment. It is important to have a fully welded frame and guide system rather than a bolt together apparatus that can shift out of alignment with use. It is critical to have a smooth running bottom roller fence that rolls on cams or bearings to ensure unalterable alignment and accuracy. It is important to have a totally enclosed saw blade to minimize the risk of airborne debris and to protect the machine operator from blade contact. It is also important to use an industrial-duty saw motor that has been engineered to handle your application. Using an industrial saw motor will also ensure the availability of high quality blades for use on sensitive materials as well as low cost blades for rough cutting.

Other benefits of a vertical panel saw include a three-point footprint that will bridge all but the most severely uneven shop floors. This provides machine stability and safety and avoids placing stress on the welds of your machine frame thus eliminating the need for regular adjustments. Vertical panel saws also use gravity to hold material on their roller fence, which dramatically reduces the potential for inaccurate cuts and wasted time and material. One manufacturer also makes backer boards that will prevent flexing and vibration while cutting thin materials thus further reducing cutting error and wasted materials.

Vertical panel saws tend to be easily maintained. Operating expenses are minimal and repairs and adjustments can be all but eliminated by choosing the right model from the right manufacturer. Training is also a non-issue as these machines are very straightforward and simple to use. Just slide your materials in and let it rip (…or crosscut)!

Advances in blade technologies have enabled the achievement of clean, accurate edges on many different types of material. Remember – the quality of your saw blade has a direct correlation with the quality of the finish cut you receive on your materials. Investing up front in a premium quality saw blade will save your business time and materials down the road.

These industrial blades are not typically available in the contractor variety 7 ¼" diameter but rather in the larger industrial sizes ranging from 8" to 12"+. The key here is tooth configuration and angle of approach, or "rake". With a brittle material that contains essentially no grain, a blade should have a triple chip tooth configuration. This triple chip configuration will have the appropriate strength and resilience to cut synthetic materials like plastic for the longest possible duration before requiring sharpening or replacement. There are several high quality, triple chip blades available; your blade supplier will have access to them or you can utilize the expertise of your saw manufacturer. Remember they should have a vested interest in the best possible performance of your equipment and therefore can provide plenty of tips and recommendations.

As a general rule of thumb, the more teeth on your blade the more smooth the cut will be. The logic is simple; the more teeth over a fixed diameter, the smaller each tooth needs to be. The smaller the tooth, the less aggressively each tooth attacks your material. A potential drawback is that the less the amount of space between the teeth on the blade, the faster it heats up. A hot blade will cause the plastic dust to melt back on the edge of the piece you are cutting. Depending on your needs, you may be required to then sand or scrape the edge of the material to remove this melted debris.

Another rule of thumb is the more teeth on your blade, the slower it will cut through your material. The fewer the number of teeth, the more aggressive and thus rougher the resulting cut. This is one of those situations where it pays to call on experience. Consult your blade supplier or panel saw manufacturer; they can make sample cuts on your material so you know exactly what to expect for performance.

It has been my experience that one of the more cost-effective ways to streamline the operation of a plastics processing business is with a modest investment in a vertical panel saw. Typically, the time and materials saved offset the initial investment in less than a year’s time. How many of our Dot.Com investments have been as sure?

For more information, contact Tom Anderson, President of Safety Speed Cut, manufacturers of a full-line of vertical panel saws for cutting a variety of materials including plastics. For additional information, contact Safety Speed Cut, 13460 Hwy. 65, Anoka, MN 55304, 800-772-2327, 763-755-1600, Fax: 763-755-6080, E-mail: ssc.mail@safetysspeedcut.com, Web: panelsaw.com.