Automation breakthrough: Donaldson Door Systems triples output with JJ Smith

Donaldson Door Systems, part of the Donaldson Group, is one of the UK’s leading manufacturers of high-quality door sets, supplying internal and external doors, staircases and bespoke joinery products

With a commitment to delivering value to major housebuilders and local authorities, the company continues to invest in automation to stay ahead in a competitive construction landscape.

Faced with rising demand, capacity constraints and the need to improve manual handling processes, Donaldson Door Systems partnered with JJ Smith to transform its production capabilities.

Automated ironmongery insertion has drastically reduced manual operations

The challenge

 Prior to automation, Donaldson Door Systems was running its internal door production across three shifts, operating 24 hours a day just to meet demand. 

CNC machines were at full capacity and scaling further with existing equipment was no longer feasible.

The business also relied heavily on manual handling throughout the process. A smarter, safer way to increase output was needed – without compromising quality or overburdening the workforce.

“We were operating three shifts and were maxed out across the factory," said Billy Cameron, Director at Donaldson Door Systems. "We needed to introduce more capacity into the business, and that meant looking at new door and frame lines.”

The solution

Donaldson Door Systems brought in JJ Smith, specialists in woodworking machinery and automation solutions, with a clear brief: dramatically increase production speed, reduce manual handling and accommodate bespoke ironmongery requirements.

The result was a custom-built Essepigi door and frame line, integrated with industrial robotics for loading and assembly. The new system processes a door from raw material to fully assembled – complete with ironmongery – in just one minute. What previously took 12 minutes with multiple manual steps is now streamlined into a fully automated process.

“We set JJ Smith the challenge of helping us produce a door a minute while taking out a lot of the offline manual handling,” added Billy. “Now, the product goes on via a robot, comes off fully assembled and goes straight to final assembly. It’s been a game-changer.”

The new system allows doors to be processed from raw to fully assembled in just one minute

The results 

The impact has been transformative:

• 3× productivity increase: What took three shifts can now be completed in just one.

• Improved safety: Manual handling is drastically reduced, thus enhancing workplace safety.

• Greater flexibility: Freed-up capacity allows for additional scheduling or diversification.

• Consistent quality: Automated ironmongery insertion meets stringent client specifications, every time.

“The solution we provided was designed not only to boost throughput but also to address key operational challenges, such as safety and labour intensity,” said Paul Parker, Sales Director at JJ Smith. “Donaldson Door Systems had a clear vision and we were proud to help turn that into a high-performing, automated reality.”

Looking ahead

For Donaldson Door Systems, this investment is about more than technology – it’s about future-proofing the business. By automating a once labour-intensive process, the company can now scale with agility while maintaining quality at volume.

“We gave JJ Smith a very specific set of criteria – from increasing capacity to handling complex ironmongery setups – and every challenge was met. All in all, it’s been a really positive experience,” Billy concluded.

For further information on JJ Smith Woodworking Machinery, call 0151 548 9000, email sales@jjsmith.co.uk or visit the website: www.jjsmith.co.uk.