Taiwan's Grinding-Machine Makers Move Upstream Amid Pricing Pressure

Thanks to collaboration among the academic, industrial and research sectors, Taiwan's grinding-machine manufacturing industry has made great progress in developing sophisticated models for the high-tech industry, let alone the well-established technology for the production of computerized numerically controlled (CNC) models.

Over the past several years, grinding machine manufacturers in Taiwan have faced price competition from lower-end models produced in developing nations. As a result, some companies in the line have forged strategic alliances with foreign partners, while others have stepped up R&D capacity to develop high value-added models to compete in the international marketplace.

The government-backed Precision Machinery Research & Development Center (PMC), one of Taiwan's leading machinery research institutes, recently unveiled new nanotechnology grinding machines suitable for the dyeing, pigment, chemicals, pharmaceutical, and plastics industries.

The PMC has been helping domestic manufacturers to apply nano materials in their products, by selecting appropriate materials and developing interface-control mechanisms and efficient manufacturing equipment.

The PMC's nano grinding machines are divided into three types, including research (desktop), laboratory, and mass production, weighing 70 kgs, 500 kgs, and 1,300 kgs, respectively. The ball-grinding rooms of the three types measure 400cc, 600cc, and 3,000cc, respectively.

The research and laboratory types are suitable for use in laboratories and training institutions, while the remaining type is used in industries for volume production. The desktop-type nano grinding machines are small, lightweight, structurally simple, and easy to operate and maintain, according to PMC.

These machines are also much cheaper than imported models and suitable for small-volume production by laboratories, instructive institutions and small-quantity producers. PMC says there is an enormous demand for nano processing equipment worldwide.

The outlook for Taiwan's grinding machine sector is very promising as many manufacturers in this line have seen substantial growth in orders received and requests for shortening delivery time in the first four months of this year. C.C. Wang, CEO of the Taiwan Machine Tool Foundation (TMTF), says that domestic manufacturers of grinding machines would see growth in orders from domestic market, mainland China, Southeast Asia, Southwestern Asia, the U.S. and East Europe in the months to come.

According to statistics compiled by the TMTF, Taiwan exported US$68.54 million worth of grinding machines, including CNC and conventional models, in the first four months of 2011, up 59.3% from US$43.04 million registered in the corresponding period of last year.

Super-precision Machines for the High-tech Industry
One of Taiwan's most professional manufacturers of surface grinding machines is Seedtec Machinery Co., Ltd. The company is dedicated to developing high-value-added precision machinery to meet increasing demand from emerging markets. After years of development, the company has attracted major customers specializing in IC packaging molds and connectors, in addition to universal mold developers.

In the beginning of 2011, Seedtec inaugurated a new headquarters in Taichung, central Taiwan. With overall investment of NT$250 million (including land costs), the 57,600-square-foot headquarters is more than double the size of the old one.

The company focuses production of CNC surface grinding machines in Taiwan and rolls out NC models at a factory in mainland China.

Over the past few years, the company has cooperated with domestic research institutions, including the Industrial Technology Research Institute and Chung-Shan Institute of Science and Technology, to upgrade manufacturing skills.

"Although some of the technologies under development with partner institutions have not yet been used for commercial production, we have learned a lot of advanced manufacturing techniques that will help us to upgrade our manufacturing skills in the years to come," says Stephen Hou, president of Seedtec.

Thanks to long-term efforts to develop innovative products and technical cooperation with domestic research institutions, Seedtec has gained sophisticated skills needed to make high-end CNC surface grinding machines.

For instance, Seedtec's NSG618 super-precision surface grinding machine can be used for mirror finishing, achieving a 0.1μm downfeed/infeed rate and an average roughness of 0.005~0.01μm.

Seedtec has installed top-grade production equipment in its new headquarters, and Hou says his company will cooperate with first-tier manufacturers to upgrade manufacturing skills in the years to come.

Hou holds very optimistic view on Seedtec's development prospects. In the past few years, Seedtec has established marketing channels in the coastal areas of China and plans to extend its reach into such inland cities as Chengdu in Sichuan Province.

High-value-added Models
To penetrate the upmarket worldwide, Joen Lih Machinery Co., Ltd., one of Taiwan's leading manufacturers of grinding machines, including conventional and CNC models, has recently switched focus to the development of high-value-added models for sale to highly industrialized nations.

Joen Lih, established in 1988, manufactures a wide range of surface grinding machines, including high precision CNC profile surface grinders, hand-operated surface grinders, and semi-automated precision surface grinders. Over the past few years, the company has been making all-out efforts to upgrade production technology to make sophisticated machines for the high-end market globally, says company president H.T. Lin.

The company recently debuted a new line of high-precision wafer grinding machines for the high-tech industry. Lin says global demand for wafer grinding machines is increasing and the outlook for the product is very promising.

Lin notes that wafer grinding machines inherit much from vertical grinding machines in terms of design. A diamond grinding wheel is fitted to the air floating spindle. The wafer grinding machine performs vertical grinding on hard and brittle workpieces, which require a high degree of surface accuracy and flatness. One example is the use of wafer surface grinding in the semiconductor manufacturing processes, where the grinding process determines the minimum size for wafer sealing.

The machine is designed for precision grinding jobs on various workpiece materials, such as wafers, ceramics, quartz, glass and gems. The machine motor is built in the air-floating spindle. Variable spindle speeds range from 1,000 to 5,000 rpm. The air-floating table meets rigorous requirements for grinding accuracy. The rapid traverse rate is 300mm/min, and a powerful 'Fanuc Oi' controller provides full digital control.

Joen Lih says the wafer grinding machine comes with diamond grinding wheel, ceramic vacuum suction table, spindle temperature controllers, vacuum pump, and tool box with tool kits. There is also an optional precision air dryer, height gauge, and high-precision spindle.

The machine is equipped with a high-performance temperature controller, employs a highly efficient plate-type heat exchanger, and has a comprehensive safety protection device to ensure safe operation.

The optional air dryer removes dust in the compressed air and has a highly accurate pressure and temperature control. The company currently distributes the high-precision wafer surface grinding machines to Southeast Asian countries, the United States, and Canada.

Universal Tool & Cutter Grinder
Chi Tseng Machinery Industries Co., Ltd., established in 1980, is among Taiwan's pioneer manufacturers providing various kinds of universal tool and cutter grinders sold under the 'Chi Tseng' brand.

The company is dedicated to developing innovative machines and a variety of optional accessories to meet the special demands of customers in Taiwan and abroad. To that end, the company has established an in-house R&D department in charge of developing advanced manufacturing skills and cutting-edge product functions.

The company has a 5,400-square-foot plant in Taichung, central Taiwan. The company can turn out 20 to 30 universal tools and cutter grinders per month.

Chi Tseng chief executive Wu Cheng-sheng notes that his company is dedicated to cooperating with partners to steadily upgrade quality. The company also employs high-end components and parts in its major machinery mechanism to ensure high quality. It also regularly adds new models to its product line.

The company's CT-610 universal tool and cutter grinder is driven by steel rollers to ensure smooth movement of work table. The machine's pneumatic axis seat is made of heat-treated aluminum alloy to ensure high operating accuracy and easy operation. The machine column can swivel 360 degrees.

The company's CT-305 universal tool and cutter grinder is suitable for use as a sharpening end mill. The 90-degree V-type slideway is heat-treated and can bear force from various directions.

Over the past few years, Chi Tseng has enjoyed brisk sales at home and abroad. Major export outlets include the United States, European Union nations, and Southeast Asian nations.

Sawblade Grinding Machine
Eyan Machine Tools Co., founded in 1996, specializes in the development and manufacture of a wide range of grinding machines, including manually operated and computerized models.

The company says that most of its exported products are sold under the 'Eyan' brand. The company also welcomes orders on the OEM and ODM (original equipment/design manufacturer) basis.

The company's major product lines are sawblade sharpening machines, quick sawblade chamfering machines, precision drill sharpeners, tungsten steel sawblade and drill sharpening machine, and CNC tool grinder. The unit prices of the company's products range from US$3,000 to US$5,000.

Eyan president Kuo Chun-lin says his company has expertise to develop state-of-the-art grinding machines to meet special requirements of customers around the world. "Over the years, we have registered 30 new-model patents in Taiwan, the United States, mainland China and Japan," Kuo notes.

Poised as a specialist manufacturer of grinding machines, Eyan claims it has won good reputations at home and abroad. "In the past several years many customers have expressed their strong confidence in Eyan brand grinding machines," Kuo says. "The Eyan brand stands for high quality and rapid after-sale services in the grinding machine sector."

Recently the company introduced a new product series—the EMC-500 CNC sawblade sharpening machine with three-axis servomotor control for automated operation.

The company's in-house R&D unit can develop a brand-new product in three months. "Thanks our efforts to develop sophisticated products and the acquisition of patents, we have seen sales grow at the pace of 20% annually over the past three years," Lin boasts. "As the world economy is back on the right track, and with an influx of foreign orders, I believe our sales will continue to grow in the coming few years."

Major export outlets include Germany, the Netherlands, Italy, Japan, Thailand, Malaysia, the United States, India, and mainland China.

Eyan currently has a production facility of 7,200 square feet in Taichung. The company is planning to expand production space in the foreseeable future to meet rising demand.