Estetiko’s recent expansion into a new 20,000 sq ft London facility marks a decisive step forward for a business built on precision, design-led manufacturing and long-term client value. The company has doubled its footprint to support growing demand and increase production efficiency, with Lamello’s P-System playing a central role in how Estetiko now designs, machines and assembles its furniture at scale.
The strategy is clear: invest in the right technology, partner with the right suppliers, and standardise processes that deliver consistent, high-end results. For Branko Georgiev, Head of Operations at Estetiko, the move was as much about future-proofing as it was about immediate gains. “We needed the space to grow, but more importantly we needed the right setup to avoid inefficiencies,” he explains. That mindset drove the transition from an older Felder CNC to a new four-axis Biesse CNC, supported by upgraded edgebanding and an automated finishing system, all aligned with a fully integrated Lamello workflow.
The new Biesse Rover Multi Up CNC represents a step change in production capability. Moving from a standalone system to a fully automated nesting line has reduced labour requirements while increasing output. “With the old setup, you needed two operators. Now one person can handle loading, labelling, cutting, drilling and offloading. It’s all about efficiency,” says Branko. While the machine delivers speed and capacity, it is the combination with Lamello’s P-System that unlocks real gains across the business.
Estetiko’s relationship with Lamello began with the handheld Zeta P2, initially used for detailed applications and tighter spaces. That experience led directly to adopting Lamello within CNC production. “We’ve used Lamello for years and we’ve always been happy with the connectors,” Branko says. “Before that, I used other systems, but Lamello is simply a different level – stronger, more flexible and far more suited to what we do.” As the company invested in nesting technology, the decision followed naturally. “If you have a nesting machine, you should be using nesting connectors. Lamello was the best solution.”
Strength and versatility are key advantages. Unlike alternative connectors that remove more material and weaken panels, Lamello maintains structural integrity while offering flexibility across different applications. “You’re not limited,” Branko explains. “Different thicknesses, different lengths, screw or direct fixing – it covers everything and keeps furniture strong.” While Lamello machining can take slightly longer per fixing, Branko emphasises that focusing on machining time alone misses the bigger picture. “You might spend a few extra seconds per fixing on the CNC, but you make that back and more during assembly. That’s where the real efficiency is.” With pre-aligned holes and simple installation, assembly becomes fast and repeatable. “You can build a wardrobe in ten minutes with Lamello instead of spending ten minutes just figuring out the drawings.”
This has a direct impact on productivity and profitability. “Faster installs mean more jobs completed each week. We pay installers by job, so quicker installs benefit everyone,” he adds.
Cost also becomes a strength at scale. “At smaller volumes, Lamello might be a few pence more,” Branko explains. “But when you’re using 2,000 to 5,000 a month, the price drops. Multiply that by thousands and you’re saving hundreds while getting a better product.” This efficiency is reinforced by Estetiko’s use of Polyboard software, which integrates design and manufacturing. Designs can be created in under two minutes, with automatic fixing placement and production-ready drawings. “We’ve reworked the business so we spend less time designing and more time producing,” says Branko. With Lamello fully integrated, what is designed is exactly what is manufactured.
Aesthetics remain key, particularly in high-end environments. Lamello’s concealed connectors support clean designs, enhanced by Estetiko’s investment in finishing technology, including what Branko describes as the first self-teaching spray robot of its kind in the UK. “Preparation is key. We prime and paint everything, including the Lamello fixings, to achieve a perfect finish,” he explains.
Looking ahead, Estetiko is focused on scaling production through automation, with Lamello embedded in every product. Currently operating at around 30% capacity, the facility has significant room to grow. “We can increase output by 270% with what we have, and even more with additional machines. Lamello is key to that because it’s used in everything we make.”
For Branko, the long-term value of Lamello extends beyond efficiency. It enables flexibility, durability and repeat business. “We’ve had clients ask us to dismantle furniture and reinstall it in new locations multiple times. You can do that with Lamello and keep the same strength. You can’t do that with screws. That’s real value.” As Estetiko continues to grow, its approach remains focused on delivering high-quality, efficient and future-proofed solutions. “You can make furniture without Lamello,” Branko concludes, “but you have to ask if you’re using the right product for the value you want to deliver. For us, it’s simple. Lamello saves us time, saves us money and gives our clients a better product.”
