Trust the
Sharpest Minds
in Metal Cutting
Menu
close
Trust the
Sharpest Minds
in Metal Cutting

How Boltswitch Eliminated a Major Production Bottleneck with Pat Mooney Saws

Boltswitch, a Socomec subsidiary, is a vertically integrated manufacturer specializing in main building disconnects for power distribution systems in large commercial and industrial facilities. Known throughout the industry for expertise in 4000-amp disconnects, Boltswitch relies on efficient, accurate copper processing to maintain production flow and product quality.

For decades, copper cutting remained one of the company’s biggest manufacturing challenges.

Mark Kingston, a 43-year veteran of Boltswitch, has been integral in machine selection and process flow optimization.

The Challenge: Outdated Sawing Technology Slowed Production

Boltswitch originally relied on a combination of non-ferrous cold saws and bandsaws to cut copper bars and tubing to length.

The older cold saws were large, noisy, air-cylinder-operated machines that generated excessive dust and required significant operator effort.

“They were antiquated technology,” said Mark Kingston.

In 1989, Boltswitch purchased a bandsaw to cut copper ranging from 5/16” to ¾”. Over time, the operation expanded to four bandsaws- just to keep up with production demands.

Even with multiple saws running, cutting performance remained painfully slow.

  • A single copper bar could take an entire day to process
  • Simple trim cuts on square tubing could require 10 minutes each
  • Copper cutting had become a major manufacturing bottleneck

Boltswitch knew there had to be a better solution.

The Search for a Better Way

For years, Boltswitch regularly attended IMTS and FABTECH searching for a machine capable of meeting their unique copper-cutting requirements.

Nothing they encountered delivered the combination of speed, cleanliness, and precision they needed — until they visited Pat Mooney Saws for a live demonstration of the PMI-NC24 LS-Type High-Speed Circular Saw.

What they saw changed everything.

“There, Patrick Thornton demoed a PMI-NC24 LS-Type High-Speed Circular Saw that cut copper in 10 seconds. Our mouths dropped open,” Kingston said.

The Solution: PMI-NC24 LS-Type High-Speed Circular Saws

Boltswitch purchased two PMI-NC24 LS-Type High-Speed Circular Saws last year, replacing three of their bandsaws.

The impact was immediate.

Faster Throughput

The PMI-NC24 LS-Type machines transformed copper processing productivity throughout the operation.

  • One bar that previously required all day now takes roughly one hour
  • 12-foot copper bars are processed in approximately 10 minutes
  • Copper tube drop-offs that were impractical to cut with bandsaws are now completed in less than an hour
  • Cuts that previously took several minutes on a bandsaw were completed in seconds

“The PMI-NC24 LS-Type machines were a blessing,” said Kingston, “The same volume of work that used to take us over two weeks with four band saws now takes four days with two PMI-NC24 LS-Type machines.”

The contrast to their existing process was dramatic.

Most importantly, the saws completely eliminated a longstanding production bottleneck.

Cleaner Cuts, Better Accuracy, and Improved Working Conditions

Beyond speed, the PMI-NC24 LS-Type machines delivered significant improvements in cut quality and shop conditions.

Boltswitch immediately noticed:

  • Cleaner cuts
  • Greater cutting accuracy
  • Reduced airborne dust and mist
  • Quieter operation compared to older cold saw technology

Initially, Boltswitch had concerns about the machine’s large air filtration system.

“Part of my concern when we were purchasing was the air filter. It’s nine feet tall, and I was a little apprehensive about that. But it does a great job - no mist coming out of the saws,” Kingston noted.

The minimal coolant usage also created unexpected advantages for operators.

“Because the coolant is used so sparingly, there’s no need to wipe down the parts after cutting; they come out clean and dry,” Kingston explained. “Even after cutting thick copper materials, the parts remain cool to the touch. You’d expect them to be warm, but that’s not the case at all. The operators really appreciate this feature.”

Operator-Friendly Design Improves Daily Workflow

Boltswitch also praised the machine’s ease of use and thoughtful engineering.

Easy Blade Changes

Operators appreciated the accessible blade area and simple blade-changing process.

“Access to the blades is good. Changing the blade is easy, with lock pins to break the nuts loose,” Kingston said.

Intuitive Controls

The HMI control system made it easy for operators to program and repeat jobs efficiently.

  • Programs can be stored for repeat work
  • Operators can quickly adapt to different material sizes and cut lists
  • External software optimizes material usage and cut sequencing

“We move the copper material to the drop stop, hit start, make an end cut, and keep going until it’s done.”

Service and Support That Continued After Installation

Boltswitch emphasized that the support from Pat Mooney Saws extended well beyond the installation process.

After setup, Pat Mooney Saws provided advanced operator training and followed up later to answer adjustment questions and ensure optimal machine performance.

The machines have proven highly reliable.

“We haven’t had to order parts.”

Boltswitch now sends all blades, including those from other brands in the facility, to Pat Mooney Saws for sharpening.

Looking Ahead

The success of the PMI-NC24 LS-Type machines has already influenced Boltswitch’s future equipment plans.

The company is currently looking to purchase a PMI-20 24 upcutting machine in the next fiscal year.

“We’ve been tickled pink by the PMI-NC24 LS-Type machines.”
-Mark Kingston, Boltswitch

Results at a Glance

Before PMI-NC24 LS-Type

  • Multiple bandsaws required to maintain throughput
  • One copper bar could take an entire day
  • Excessive cutting time on trim operations
  • Dusty, noisy cutting environment
  • Major production bottleneck

After PMI-NC24 LS-Type

  • Copper cutting dramatically accelerated
  • Cleaner, more accurate cuts
  • Reduced labor and handling
  • Cool, dry parts directly off the saw
  • Bottleneck eliminated
  • Two weeks of work reduced to four days
  • Planning future machine purchases