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One of the things I enjoy most about my role at MTDCNC is the opportunity to visit manufacturers all over the world. Every month, our team walks through dozens of factories, speaking with engineers, operators and business owners, gaining a unique insight into the challenges and opportunities shaping modern manufacturing.
Some visits stand out because of the products being made. Others because of the technology being installed. Occasionally, however, you come across a company that perfectly demonstrates where manufacturing is heading, and that’s exactly why I wanted to write about Microtherm in this month’s magazine.
Recently, I travelled to the Netherlands with the MTD reporting team alongside DN Solutions and their Dutch partner Dormac. The purpose of the trip was to learn more about how Dutch manufacturers are embracing automation and advanced manufacturing technologies. We visited several impressive businesses, but one story in particular stayed with me long after we left the factory floor. That story was Microtherm.
When people think of the Netherlands, they often think of flowers, tulips in particular. The country is responsible for around 40% of the world’s flower exports and is home to the famous Aalsmeer flower auction, the largest floral marketplace on the planet. Yet behind the tulips and greenhouses sits another world-class industry: manufacturing.
The Dutch have built a reputation for innovation, efficiency and engineering excellence. Whether it’s precision engineering, food production equipment, logistics technology or advanced manufacturing systems, businesses across the Netherlands continue to invest heavily in automation to remain competitive on the global stage.
The company specialises in the manufacture of plastic and nylon components, supplying customers with parts that in some cases reach annual volumes of more than 220,000 pieces. To remain competitive while maintaining quality and delivery performance, the business has adopted a clear strategy: automate wherever possible.
What struck me during the visit was how familiar many of their challenges sounded. Whether I’m visiting factories in the UK, Germany, Spain, the United States or Asia, the conversations are often the same. Finding skilled staff is becoming increasingly difficult. Energy costs continue to rise. Customers expect shorter lead times. Margins are under pressure. The companies that are thriving aren’t simply working harder—they’re working smarter.
Microtherm has embraced this philosophy throughout its operation
The turning department is a great example. Equipped with multiple DN Solutions Lynx and Puma turning centres supplied and supported by Dormac, this section of the business plays a critical role in overall production output. However, it’s not simply the machine tools themselves that make the difference. The company has invested heavily in automation and process control to ensure these machines can continue producing components long after operators have gone home.
One of the most fascinating aspects of the visit was seeing how they handle swarf when machining plastics and nylons. Anyone familiar with these materials knows that chip control can often be more difficult than when machining steel. Long, stringy swarf can quickly wrap around tools, components and fixtures, creating problems that make unattended operation almost impossible.
Microtherm’s solution was both simple and ingenious
A dedicated extraction system positioned directly beneath the cutting tool removes swarf at the point of cut. Rather than allowing chips to accumulate and create problems, the material is immediately extracted from the machining area. The result is reliable machining, reduced stoppages and the confidence to run lights-out. On some components with cycle times of less than a minute, this approach delivers significant productivity gains while ensuring the process remains stable throughout extended production runs.
The same innovative thinking is evident in the milling department. As a high-mix, low-volume manufacturer, unattended milling presents its own unique challenges. Producing a wide variety of components means flexibility is just as important as productivity.
To increase output, Microtherm began exploring 5-axis machining solutions with Dormac and DN Solutions. The initial discussions centred around the DN Solutions DVF 5000, a machine well-suited to the company’s requirements. However, one thing quickly became clear. Simply purchasing a 5-axis machine wasn’t enough. If the objective was true lights-out manufacturing, automation had to be part of the solution from day one.
Initially, discussions focused on pairing the DVF 5000 with an Automatic Workpiece Changer (AWC). While this would certainly have increased productivity, further analysis revealed that another option could provide even greater flexibility.
Dormac proposed combining the DVF 5000 with a RoboJob Tower automation system.
The reasoning was compelling
For genuine unmanned production, pallets alone are not always sufficient. Manufacturers need the ability to manage multiple jobs, change fixtures, prioritise urgent work and maximise machine utilisation around the clock. In many cases, ten pallets simply aren’t enough when the goal is 24/7 production.
The RoboJob Tower addresses these challenges by utilising vertical storage rather than consuming valuable floor space. With capacity for more than 20 trays, the system provides significantly greater flexibility while maintaining a relatively compact footprint.
For a company producing a broad range of parts, it proved to be the ideal solution.
Inside the machine, further technologies help ensure reliable unattended operation. In-process measurement systems continuously verify both tooling and finished components, maintaining accuracy and repeatability over extended periods. Combined with effective swarf management, the result is a production cell capable of running for long periods without intervention. Ultimately, there is little point in running lights-out if somebody has to return every few hours to clear chips or check part quality.
What impressed me most wasn’t any single machine, robot or automation system.
It was the way everything worked together. The machine tool builder, the distributor and the end user had clearly collaborated to create a solution tailored specifically to the challenges Microtherm faces every day. This wasn’t a standard machine installation. It was a carefully engineered manufacturing solution designed to maximise productivity, flexibility and reliability.
Perhaps the most memorable moment came towards the end of the visit:
– The operators had gone home.
– The lights had been switched off.
– Yet production continued.
Machines were cutting material. Robots were moving parts. Measurement systems were checking components. Automation was quietly doing exactly what it had been designed to do.
Lyndsey Vickers and I took the opportunity to walk around the factory and observe the operation in action. Standing in a darkened production facility while parts continued to be manufactured without human intervention was a powerful reminder of just how far manufacturing has evolved. It’s also a glimpse into where many factories are heading next.
Microtherm’s story isn’t simply about machine tools or automation. It’s about a business responding to modern challenges with innovation and investment. It’s about what can be achieved when a manufacturer works closely with trusted partners such as Dormac and DN Solutions. And it’s about embracing technology, not because it’s fashionable, but because it’s necessary.
I visit many factories throughout the year, and every one of them has its own story to tell. This month, however, Microtherm’s story stood out. Not because of the machines they bought. But because of what they’ve achieved with them. Whilst we don’t all need to automate to the level of Microtherm, it’s a stark reminder that without investing in technology to protect and grow your margins, you could, and likely will be caught in the trap of rising energy, material and labour costs eroding margins and preventing investment. If you don’t invest in your business now, your future could be worth ‘Diddly Squat’.
To see the full factory tour and watch us explore Microtherm’s lights-out operation, click here.
