Eastern Metal Supply Inc. (EMS), a value-added distributor of aluminum extrusions and sheet products, is committed to delivering high-quality solutions to a wide range of industries. Serving markets such as railing, marine, signage and security, EMS continually invests in advanced fabrication technology to enhance efficiency, precision and customer service.
As part of this commitment, the company has integrated a Behringer HBE-321A horizontal bandsaw into its operations, significantly improving cutting accuracy, reducing material waste and streamlining production.
Cutting challenges
Before acquiring the HBE-321A, EMS faced significant hurdles in speed and accuracy. The previous saw was unable to keep pace with the demands of the CNC machines, leading to inefficiencies and inconsistencies that impacted production downstream. The need for a more precise and efficient cutting solution was clear.
David Pullaro, director of value add machining at EMS, described the challenges, saying the old saw was slowing the team down.
“It just couldn’t keep up with our CNC machines,” he says. “And we were constantly dealing with inconsistencies that led to material waste and extra labor. We needed something more reliable.”
The inconsistencies in cuts required additional labor to correct errors. Team members had to spend extra time on rework, which affected overall productivity.
Additionally, machine downtime due to the previous saw’s inefficiencies created bottlenecks in production, delaying orders and increasing lead times. EMS knew that upgrading its cutting technology was essential to meeting growing customer demands.
Saw selection
The decision to invest in the Behringer HBE-321A stemmed from extensive research and first-hand observation. While attending Fabtech in Chicago, the EMS team explored various saw options and was particularly impressed by Behringer’s demonstration, where steel was consistently cut microns-thin with ease. The saw’s robust servo-driven grippers, blade guiding system for increased blade longevity and overall precision set it apart from the competition.
“The Behringer saw cut steel so thin it was like a potato chip,” Pullaro recalls. “That level of precision made us confident that it could handle our aluminum cutting needs with ease.”
Behringer’s reputation for reliability and innovation also played a role in the decision. The company’s long-standing history of producing high-performance saws gave EMS confidence that the HBE-321A would be a durable and long-lasting investment. The ability to hold tolerances as tight as ±0.003 in. – far exceeding actual production requirements – was an added advantage that made the choice even more compelling.
Enhanced efficiency
Since implementing the HBE-321A, EMS has experienced remarkable improvements in its operations. As expected, the saw has significantly reduced material waste, increased machine efficiency and decreased downtime. According to Pullaro, over the past couple of years, productivity has surged by an impressive 40 percent.
Additionally, training time for team members has been minimized, and learning to use the saw has fostered a sense of pride among operators. The ease of use and intuitive user interface have empowered team members to quickly learn the saw and pass on their knowledge, streamlining workflow and enhancing shop floor organization. The increased precision has also led to better quality control, reducing defects and ensuring that parts are consistently within required specifications.
“Our team loves working with this machine,” Pullaro says. “It’s easy to train on, and the repeatability of cuts has made a huge difference in our efficiency. It’s taken a lot of guesswork out of the equation.”
One of the most significant impacts has been on operational costs. With reduced material waste and improved efficiency, EMS has been able to reduce costs while increasing output. These savings have allowed the company to reinvest in other areas of its operations, further driving growth and expansion.
Seamless integration
The installation process was seamless, with Behringer’s knowledgeable technicians ensuring a smooth transition.
“Purchasing was very straightforward and installation was even easier,” Pullaro says. “The technician was very knowledgeable and made it easy enough for a four-year old to understand.”
The learning curve for operators was minimal, thanks to the saw’s intuitive controls and well-designed interface. Team members quickly adapted to the new system, and many found the transition from the old saw to the HBE-321A to be a welcome change. The automation and precision of the saw have also reduced physical strain on operators, making their jobs easier and more efficient.
Beyond its ease of use, the HBE-321A has proven to be highly reliable, even in the challenging conditions of a non-air-conditioned shop environment in South Florida. The only minor issue – a heat alarm – was easily resolved by placing a fan near the electrical cabinet. Behringer’s customer service has been responsive and efficient, reinforcing the company’s confidence in its investment.
“We’ve had almost no issues with this saw,” Pullaro says. “Even in our hot shop environment, it has held up incredibly well. The only time we had a problem, it was an easy fix and Behringer’s support team was great.”
The saw’s durability and ability to withstand demanding conditions make it an ideal solution for the company’s high-volume operations. The robust build quality ensures long-term performance with minimal maintenance requirements, further increasing its value.
Looking ahead
With the success of the HBE-321A, EMS is exploring additional Behringer equipment to expand its capabilities, including light fabrication tasks such as straight cuts and hole drilling. Pullaro notes that standardizing with Behringer machines across all 15 fabricating locations would be a strategic advantage, allowing for easier troubleshooting and maintenance.
“It just makes sense to stick with Behringer,” he says. “Having the same equipment across our locations makes it easier to train operators, troubleshoot issues and keep everything running smoothly.”
The ability to rely on a single manufacturer for sawing solutions would streamline operations across all EMS facilities. With consistent equipment, team members across different locations can share expertise and best practices, improving efficiency across the board.
Recently, the company quoted two additional saws: another HBE-321A and the larger HBE-411A, reflecting its satisfaction with the brand’s performance. Investing in additional Behringer machines will allow the company to further optimize its production processes and increase output to meet growing customer demand.
When asked whether EMS would recommend the HBE-321A to others, Pullaro jokingly says, “Yes – unless they’re competitors.” The machine has set a new standard for operations. “This saw allows us to outperform the competition.”
A game changer
The Behringer HBE-321A has exceeded expectations, setting a new benchmark for efficiency and reliability at EMS. As the company continues to grow, the saw remains a vital asset in achieving its production goals. With ease of training, repeatability and strong operator approval, EMS sees Behringer saws as an integral part of its future success.
“The bar has been raised with this saw,” Pullaro says. “It would be hard to even consider another brand now. The productivity gains and ease of training have been a huge win for us.”
Looking ahead, EMS aims to continue expanding its capabilities and maintaining its reputation as a leader in aluminum extrusion distribution. By leveraging advanced cutting technology like the HBE-321A, the company is well-positioned to meet the evolving needs of its customers and stay ahead in an increasingly competitive market.
With its impressive performance, reduced material waste and increased productivity, the HBE-321A is more than just a saw – it is a cornerstone of the operational success at EMS. The investment in this cutting-edge technology has already paid dividends, and as the company continues to grow, Behringer will remain a key partner in its journey toward greater efficiency and innovation.
Now that you’ve read about how a quality saw can change the production environment, go to our sawing archive and take in a treasure trove of articles we’ve curated over the years. You’ll see Behringer Saws Inc. in the mix going back to some of our first issues as well as other hugely important sawing brands.
