Reducing waste and increasing efficiency with Randek at Donaldson Timber Systems.

Donaldson Timber Systems (DTS) is one of the UK’s leading timber frame manufacturers, providing modern offsite construction solutions for residential and commercial developments. A division of the Donaldson Group, a company with a 164-year heritage, DTS operates nationwide, producing timber-based panelised building systems that contribute to faster, more sustainable construction. With manufacturing capacity for up to 10,000 units per year, the company’s automated facilities create high-quality walls, floors, and roofs that align with industry standards and client specifications.

At the helm of manufacturing operations is Frank O’Reilly, Manufacturing Director of DTS. With over 23 years of experience spanning Ireland, Australia, and the UK, Frank has developed a deep understanding of timber frame construction, trusses, and prefabricated building elements. Having joined the company in 2011, he has played a key role in driving automation and process refinement.

The Importance of Randek Machinery in DTS Operations

DTS has long been at the forefront of offsite timber construction, and its collaboration with Randek has been central to achieving manufacturing efficiency. “Our original site in Westhill, Scotland, has had Randek framers for over 30 years,” Frank explains. “We were probably one of the earliest Randek customers in the UK. The technology we had back then was quite basic, but even then, it was a game changer for framing speed and precision.”

Over the decades, DTS has expanded its use of Randek’s automation solutions to optimise production. “About 24 years ago, we invested in what was then one of Europe’s most advanced wall production lines,” Frank continues. “That was a bold move, but it established our reputation for investing in quality manufacturing. More recently, we’ve taken another step forward with highly advanced Randek robotic systems.”

Advanced Automation for Timber Frame Construction

The introduction of a new robotic wall line has been a defining moment for DTS. “We started discussions with Randek in 2019, and after extensive collaboration, we developed a solution that suited our needs,” Frank says. “It took nearly a year of back-and-forth engineering work to refine the specification, and we placed our order just before COVID hit. The system has now been in operation for 18 months, and we continue to fine-tune it.”

The fully automated robotic system includes three robotic cells with a total of eight robots. “This investment allows us to manufacture closed panel products with greater precision,” Frank explains. “Previously, it was a more manual process, but now we have a properly industrialised workflow. Randek was willing to customise the system to meet our exact requirements, which made all the difference.”

Panelised Systems Over Volumetric Construction

While volumetric modular construction has been a growing area within offsite building, DTS has remained focused on panelised systems. “There is a place for volumetric, particularly in high-rise applications, but for the UK market, we believe panelised is the right solution,” Frank states. “We’ve got 50 years of experience in timber systems, and our decision to stick with panelised has been validated by its adaptability, cost efficiency, and lower logistical risks.”

Many volumetric manufacturers in the UK have faced financial and operational challenges. “It’s difficult for a volumetric business when site teams aren’t fully prepared,” Frank explains. “With panelised solutions, we manufacture elements just 10 days before delivery, ensuring a smooth installation process. Volumetric companies often have houses sitting in storage, which ties up capital.”

Addressing Industry Challenges Through Automation

One of the key drivers behind DTS’s investment in automation is the skills shortage in the UK construction industry. “It’s an ageing workforce,” Frank notes. “I believe around 50% of the industry is due to retire in the next 10 years. We recognised early on that builders were struggling to get trades on-site, so we aimed to do as much as possible within the factory.”

Randek’s robotic solutions have been instrumental in reducing reliance on site-based labour. “By closing panels in the factory, we remove a lot of the uncertainty from site work,” Frank says. “We insulate, batten, and prepare the panels so that builders can achieve a watertight structure in 24-48 hours. It’s about giving them the tools to work more efficiently.”

Material Handling and Logistics Efficiency

Beyond the manufacturing process, efficient handling of materials is crucial for an operation of DTS’s scale. “We run a double shift across our factories, producing around 34-35 homes per day,” Frank explains. “That equates to between 80,000 and 100,000 linear metres of timber being processed each month.”

Maintaining Quality Control in Offsite Production

Ensuring consistent product quality is a priority at DTS. “All our timber frame systems undergo full fire testing, which is something not every manufacturer in the UK offers,” Frank states. “When we introduce new systems, we take a cautious, research-driven approach to ensure everything meets the highest standards.”

The precision of Randek’s robotic systems plays a vital role in maintaining this quality. “Automation has allowed us to eliminate a lot of the inconsistencies that can happen with manual processes,” Frank says. “We know exactly how much material we need; we minimise waste, and we maintain high repeatability.”

The Future of Offsite Timber Construction in the UK

As the industry evolves, DTS remains committed to refining its processes and expanding its capabilities. “We’ve seen more and more of the construction process moving into factory environments,” Frank notes. “That’s only going to increase as builders and developers look for ways to improve efficiency, quality, and sustainability.”

While DTS continues to explore new innovations, Frank emphasises that any advancements must be well-researched. “We’ve seen trends come and go, and we approach every change with due diligence,” he says. “The UK’s construction industry is complex, but by focusing on reliable, scalable solutions, we can help our customers build better.”

DTS’s approach to offsite timber construction is rooted in experience, adaptability, and strategic investment in technology. The company’s partnership with Randek has allowed it to enhance its manufacturing capabilities and meet the evolving needs of the market. “Randek has been an integral part of our journey,” Frank says. “Their willingness to work with us and refine their technology has helped us push the boundaries of timber frame manufacturing. By focusing on efficiency and quality, we’re not just keeping up with industry demands—we’re shaping the future of timber construction in the UK.”