In August 2025, Gresham Office Furniture invested in a HOMAG Batch Size 1 board system, replacing multiple standalone machines with a single, integrated production cell. As a result, Gresham has significantly improved cut consistency, reduced labour requirements, and maintained output while moving from two shifts to one.
About the company
As one of the UK’s longest-established designers and manufacturers of workspace furniture, Gresham Office Furniture has spent nearly 50 years combining British craftsmanship with progressive manufacturing methods.
Operating from a 14-acre site in Bolton, with over 200 employees and a 200,000 sq. ft. manufacturing facility, continuous investment in technology is central to maintaining quality, consistency, and competitiveness.
Most recently, Gresham has restructured its panel processing operation with a HOMAG Batch Size 1 board system, bringing together a SAWTEQ S-300, a SAWTEQ S-320 flexTec connected to two STORETEQ P-500’s and an EDGETEQ S-810, a LOOPTEQ C-500, and an XES 200 – all integrated into one production cell.
Addressing consistency and labour challenges
Gresham’s decision to invest was driven by two familiar challenges in modern manufacturing: consistency and skills. “We had a couple of older saws, and one of the things we were struggling with was getting consistent cuts,” explains David Openshaw, Operations Manager at Gresham. “At the same time, it’s becoming harder to find people with the right skill sets. Fewer people are going into manufacturing, so we needed to bridge that labour gap.” Previously, Gresham operated with two angle saws and multiple edge banders.
The new HOMAG solution replaces that setup with a streamlined board system, designed to deliver accuracy, repeatability, and efficiency with fewer operators.
A natural choice: HOMAG
Gresham’s relationship with HOMAG stretches back decades, making them the natural partner for this latest investment. “We’ve always had HOMAG machines,” says David. “We know how HOMAG work, we know the quality is there, and our operators are already familiar with the software. That made it an easy decision.” Working closely with the HOMAG team, Gresham explored a number of options before settling on a cell that best suited their production mix. “HOMAG really understood what we were trying to achieve,” David adds. “Their knowledge was invaluable in helping us land on the right solution.”
Training, installation and confidence from day one
To ensure a smooth transition, Gresham invested heavily in training. Operators were sent to Germany for in-depth instruction on each part of the system, followed by on-site support during installation.
“Installation went very smoothly,” says David. “HOMAG engineers were on-site, providing additional training to both operators and maintenance staff. That meant we could use the cell confidently and to its full potential almost immediately.”
Doing more with less
The impact of the new Batch Size 1 line has been significant in terms of efficiency. “Previously we were running two shifts,” David explains. “Now we can achieve the same output in just one.” The labour savings have been equally impressive. “We’ve gone from 28 people in that department down to nine. That’s allowed us to redeploy skilled people elsewhere in the business and become far more cost-efficient.”
Beyond productivity, quality has also improved. “The finish is consistently perfect,” David says. “That level of consistency is a huge benefit for us.”
A partnership built for the future
While advanced automation inevitably comes with a learning curve, David is clear about the value of HOMAG’s support. “With machinery like this, there are always teething issues,” he says. “HOMAG understand that. Their customer service matches the quality of their machines; they’re always available and happy to help.”
He concludes: “We’re excited to see what our long-standing partnership with HOMAG will bring in the future.”
For more information or a demonstration of HOMAG’s machinery and software, contact HOMAG UK on 01332 856500, option 4 for the sales department, or email [email protected].
