Alwayse Engineering boosts production with DN Solutions Lynx 2100B lathe from Mills CNC

Alwayse Engineering's investment in a new DN Solutions Lynx 2100B lathe from Mills CNC marks a significant step in their production capabilities, particularly as they prepare to launch their redesigned 805 series of heavy-duty ball transfer units. This high-performance machine, equipped with a HydraFeed bar feeder and parts handling system, is crucial for meeting the anticipated demand for these units, which are a staple in air cargo materials handling. The Lynx 2100B's ability to machine the 805 unit bodies in one setup, with cycle times as short as 80 seconds, ensures both efficiency and precision, which are critical for maintaining the high standards required in this sector.

For UK engineers, this development underscores the importance of integrating advanced machining technology to stay competitive in demanding industries. The Lynx 2100B's capabilities allow for tighter tolerances and improved surface finishes, which are essential for components like the 805 ball transfer units that operate in harsh environments. The investment also highlights a broader trend towards automation and continuous production, which can lead to increased productivity and reduced downtime.

Why should you care? This move by Alwayse Engineering exemplifies how adopting advanced machinery can enhance production efficiency and product quality, ultimately established to stronger market positioning and customer satisfaction.

As quoted by a spokesperson from Alwayse Engineering, "The new Lynx 2100B lathe has significantly improved our machining capabilities, allowing us to produce higher quality components more efficiently. This is crucial as we prepare to launch our new 805 series, which promises to set a new standard in air cargo materials handling."

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In March 2025, Mills CNC installed a new DN Solutions two-axis lathe at Alwayse Engineering's Birmingham facility. The machine, a Fanuc-controlled Lynx 2100B lathe with an 8" chuck and 65mm bar diameter, was selected to meet the high demand anticipated for Alwayse's redesigned 805 series of heavy-duty ball transfer units. This investment underscores Alwayse's commitment to maintaining its position as a market leader in air cargo materials handling solutions.

The Lynx 2100B lathe is equipped with a HydraFeed MSV65 servo-driven bar feeder for continuous, unattended production, and a HydraFeed ROTA-RACK parts accumulator with an integrated belt conveyor for improved part storage and protection. The machine is specifically tasked with machining the single-piece, carbon steel bodies of the 805 series units. These bodies, with a diameter of 62mm and a length of 34.5mm, are machined in one setup on the Lynx 2100B. The machining operations include rough and finish boring of the interiors to produce the required internal hemisphere-shape, as well as burr-free parting-off operations. The Lynx 2100B achieves a part cycle time of approximately 80 seconds, ensuring high productivity and consistent quality, which are critical for Alwayse's 'core line' products that are always kept in stock for quick supply to customers.

The 805 series ball transfer units are designed for air cargo movement applications and are known for their reliability and durability in tough materials handling environments. These units are part of ball transfer decks that Alwayse designs in close collaboration with customers, tailoring the shape and number of units to the specific requirements of each application, such as aircraft cargo decks, warehouse floor space, and the type and size of goods being transported. Alwayse's in-house fabrication operation allows them to manufacture the top plates and sections for these decks, providing complete turnkey solutions or supplying units to integrators and resellers who design them into the final application.

The new 805 series units offer specific advantages over their predecessors, including enhanced performance in both wet and dry conditions. This redesign is the result of extensive research and customer feedback, initiated in 2023 following Alwayse's acquisition by Lifco, a Swedish investment company focused on developing market-established niche businesses. With prototyping and pre-production testing completed, Alwayse is now in full production, preparing to launch the new 805 series into the market.

Mills CNC, as the exclusive distributor of DN Solutions and Zayer machine tools in the UK and Ireland, continues to support companies like Alwayse Engineering with advanced machining solutions that meet their specific production needs. The Lynx 2100B lathe, with its precision and efficiency, is a key component in Alwayse's production line, ensuring the high standards expected by their global client base. For more information on the Lynx 2100B lathe or to discuss similar applications, interested parties can contact Mills CNC directly.