JJ Smith automation unlocks new capacity at Donaldson Door Systems
- 1 day ago
- 3 min read
Faced with rising demand, capacity constraints and a need to improve manual handling processes, Donaldson Door Systems partnered with JJ Smith to transform its production capabilities.
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 business has continued to invest in automation to stay ahead in a competitive construction landscape.
The challenge
Prior to automation, Donaldson Door Systems operated its internal door production across three shifts, running 24 hours a day to meet demand. Its CNC machines were operating at full capacity and further scaling with existing equipment was no longer viable.
There was also a heavy reliance on manual handling throughout the production process. The company needed a smarter, safer way to increase output without compromising quality or placing additional strain on its workforce, as Billy Cameron, Director at Donaldson Door Systems, explains: “We were operating across three shifts and maxed out throughout the factory. We needed to introduce more capacity into the business, which meant investing
in new door and frame lines.”
The solution
Donaldson Door Systems engaged JJ Smith, a specialist in woodworking machinery and automation solutions, and provided a clear brief: significantly increase door production speed, reduce manual handling and accommodate custom ironmongery specifications for a range of clients.
The result was a custom-built Essepigi door and frame line, integrated with industrial robotics for loading and assembly. The new system allows doors to be processed from raw material to fully assembled – complete with ironmongery – in just one minute. What previously took 12 minutes with multiple manual steps is now fully streamlined and automated.
“We set JJ Smith the challenge of helping us produce a door a minute while removing a lot of the offline manual handling,” Billy added. “Now, the product is loaded by a robot, comes off the other end fully assembled and goes straight to final assembly. It’s been a game-change.
The results
The impact has been transformative:
3x increase in productivity: What previously required three shifts can now be achieved in one.
Improved safety: Manual handling has been significantly reduced, enhancing workplace safety.
Greater flexibility: Increased capacity allows for additional shift options or diversification.
Consistent quality: Automated ironmongery insertion reliably meets stringent client specifications.
“The solution we provided was designed not only to boost throughput but also to address key operational pain points 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 bring that to life with a high-performing automated solution.”
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 greater agility while maintaining high-quality output.
“We gave JJ Smith a very specific set of criteria – from increasing capacity to managing complex ironmongery setups – and every challenge was met. It’s been a very positive experience,” Billy concluded.
For further information from JJ Smith, call 0151 548 9000, email sales@jjsmith.co.uk, or visit www.jjsmith.co.uk.
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