Econ at 50: True grit and laser accuracy

30/08/2019 | DOMINIC BROWNE

It's not rare for the people of Yorkshire to hit half centuries, but it is always worthy of celebration. Econ Engineering - the UK's most popular gritting manufacturer - has reached this milestone in style and shows no signs of slowing down.

The company is the largest British manufacturer of gritting vehicles, controlling 80% of the bought or hired gritting market and producing 360 units per year at its 88,000 sq ft factory, which opened in 1980 on Boroughbridge Road in Ripon, North Yorkshire.

It also operates a growing hire fleet, currently numbering more than 800 units, which has boosted annual turnover to over £34m.

This family-owned UK business is experiencing an unprecedented order book, which it put down not just to harsher winters, but also to its 'multibody products that allow customers to utilise one chassis for multiple tasks, such as road repair as well as winter maintenance, making the investment usable throughout the year'.

The 220-employee company carries out all design and manufacture of its products in-house including painting of components, and for nearly one-third of its life has worked with Swiss supplier of sheet metal processing machinery, Bystronic, to maintain the high level of component accuracy.

The road to success

The company was created by the late Bill Lupton, who single-handedly started a business towards the end of the 1950s in a barn on his family's farm.

He began by making flail mowers and hedge trimmers to cut verges and hedgerows more efficiently.

After exceptionally cold and freezing weather during the winter of 1962/63 brought England to a standstill, with many being cut off for weeks, Mr Lupton was inspired to put his mind to developing the first salt spreading vehicle that would keep the country moving and the wheels of industry turning.

This led to the creation of Econ Engineering in the autumn of 1969 on an old brewery site in Ripon.

By then, the M1 motorway had opened as well as sections of the M2, M4 and M6 and local councils, notably Lancashire and Westmorland, were interested in winter maintenance operations such as salt spreading and gritting to make driving safer.

True grit and laser accuracy

In 2003, the second generation of Luptons – Jonathan and Andrew – took over running the company and were instrumental in developing contract hire for gritters and snowploughs at a time when public spending cuts were making new equipment purchase difficult.

To ensure a leading position in this market, in 2005 they increased the fleet size through the acquisition of a major competitor, Municipal Hire Services.

They also added new technology to the business strengthening its reputation for precision and quality combined with bespoke design.

It was in the early 2000s that the company bought its first Bystronic laser machine, which replaced a turret punch press and a plasma profile cutter for processing the majority of components made from mild steel plates.

The components are used in Econ's shop, to work on gritters, snowploughs as well as bodies for highway maintenance and road patching that Econ mounts onto lorry chassis, often Mercedes and DAF, supplied to clients’ specification.

This ByStar 4020 laser machine with a 4kW CO2 power source supplied by Bystronic UK, greatly increased production efficiency and component accuracy.

Sheet metal up to 4 metres x 2 metres could be processed on the machine, while its 4.4kW and then 6kW successors were able to accept sheet up to 6.5 metres long and nominally 2 metres wide (in practice they use 1,830mm wide stock).

This is the maximum size readily available in the UK - Econ's sheet is cut from coil produced in Europe to meet the company's required steel specifications.

This matters because larger body panels can be produced without welding and the productivity of smaller components is boosted by the ability to nest and cut more parts in one sheet, reducing the amount of wasted material in the skeleton.

Econ's current laser machine was installed in 2014 and works 24/7, processing up to 35 tonnes of steel a week into any of 87,000 different components. These are produced in batch sizes ranging from 5- to 30-off and to an accuracy in some cases down to ± 0.5 mm.

Keeping track of this operation is no small feat and extensive use is made of modern MRP (manufacturing resource planning) software as well good old colour coding of components on the shop floor.

The effectiveness of the procedures - including planning cutting schedules 14 days ahead is evidenced by an above-average OEE (overall equipment effectiveness) of 63%, representing the proportion of time the laser is actually cutting metal.

Among the other equipment on site are three Bystronic press brakes on site, an Xpert 40 tonne / 1 metre press brake, which arrived in 2018 for bending smaller parts more efficiently, a VR 10x4000 jobbing guillotine and a belt grinder from German firm Weber.

Jonathan Lupton, joint managing director said: 'We have always tried to innovate and strive for excellence and nowhere is that more apparent than in our use of the laser to cut steel in our body shop.

'Despite the Bystronic machine representing a considerable expense at the outset, it was another example of how we always lead the way in our industry. The investment has more than paid off in terms of higher production output, while improved accuracy has almost eliminated fit-up during assembly and cuts costs further.

'We have gone from strength to strength by focusing not only on quality but also on the needs of our customers. That is why we have a UK-wide network of depots for servicing and recalibrating our equipment in the field, including a new one that opened recently in Alloa and another due to open in Cardiff in spring 2020.'

Staying ahead

Econ was the first in 1989 to invent the quick change body (QCB) system that allows a single chassis to have multiple applications, for example by the addition of an asphalt hot box for road repairs or for use as a tipper, crane or gulley emptier.

This was one key step in a long history of innovation, which has moved into software as well as hardware.

A recent Econ invention was a Spargo system that controls grit or salt spray and width patterns from the cab, automatically optimising the amount of product used and hence saving cost as well as protecting the road surface.

It also provides one-touch control for lowering the snow plough, turning on the gritter's beacon bar and performing other functions, making the driver's tasks easier and less tiring. And it is connected to the vehicle's GPS to help plot the most effective route.

The Econ story is far from over and the company has said it already has driverless vehicles and liquid de-icers in its sights.

That is the kind of ambition that takes you to a century.

Highways InProfile

latest magazine issue
Highways jobs

Flood Risk Engineering and Strategy Officer

£49,764 - £55,623
In line with our One Coventry Values, we want to ensure that our communities are represented across our workforce Coventry, West Midlands
Recruiter: Coventry City Council

Senior Integrated Transport Officer

£34,324 - £37,529
Are you an experienced transport planning professional ready to influence strategic policy and drive real change Matlock, Derbyshire
Recruiter: Derbyshire County Council

Street Cleansing Operative

£25,584.00 to £27,269.00, Grade 5
An opportunity exists in the Council’s Street Scene Services for a Street Cleansing Operative Wakefield, West Yorkshire
Recruiter: Wakefield Council

Highways Gully Operative

£25,584.00 to £27,269.00, Grade 5
Are you a hard-working looking for career in highway maintenance? Wakefield, West Yorkshire
Recruiter: Wakefield Council

Roadworker Trainee LGV Driver (3 Posts)

Grade 6 £25,183 - £25,638 per annum (Pay award pending)
We’re looking for Roadworker/trainee LGV drivers to be part of our team undertaking major highway, bridge and related construction and reconstruction Derbyshire
Recruiter: Derbyshire County Council

Highways Operative - WMF3003e

£27,711 - £28,624
We are looking to recruit Highways Operatives to our Highways Service. Kendal, Cumbria
Recruiter: Westmorland and Furness Council

Engineer

£44,430 - £51,663
This post is within the Highways Design and Delivery Team. London (Greater)
Recruiter: Tower Hamlets London Borough Council

Highways Policy and Procedures Officer - WMF3011e

£37,035 - £37,938
This is an exciting opportunity to support the Asset Manager in developing policies and procedures Cumbria / Various
Recruiter: Westmorland and Furness Council

Highway Maintenance Bridge Engineer

Band G, SCP 32 -37 (£41,511 - £46,731 per annum)
We have an exciting opportunity available within the Highways Service at Sandwell Council House based in Oldbury. Sandwell, West Midlands
Recruiter: Sandwell Metropolitan Borough Council

Civil Enforcement Officer - WMF3013e

£27,711 -£28,624
Are you seeking an active and challenging role, part of a friendly and welcoming team? Cumbria / Various
Recruiter: Westmorland and Furness Council

RCHW Site Operative - Dovercourt Recycling Centre

Up to £25081.00 per annum
RCHW Site Operative - Dovercourt Recycling CentreFixed Term, Full Time£25,081 per annumLocation
Recruiter: Essex County Council

Highways Maintenance Manager

£49,764 - £53,817 per annum
We are looking for an experienced co-ordinator to join the team as a Highways Maintenance Manager Skipton, North Yorkshire
Recruiter: North Yorkshire Council

Civil Enforcement Officer

£25,183 - £26,409
Are you looking for a role that allows you to earn whilst been outdoors across the district of North Yorkshire? Whitby, North Yorkshire
Recruiter: North Yorkshire Council

Civil Enforcement Officer

£25,183 - £26,409
Are you looking for a role that allows you to earn whilst been outdoors across the district of North Yorkshire? Northallerton, North Yorkshire
Recruiter: North Yorkshire Council

Senior Street Cleansing Technician (CDC)

Grade 6, £25,175 - £25,983 (Pay award pending) + 6% AIA
We are about to embark on an ambitious programme of change in our city centre Doncaster, South Yorkshire
Recruiter: City Of Doncaster Council

Highways Improvement Manager

£49,764 - £53,817 per annum
Would you like to be part of our friendly, supportive, Highways team? Scarborough, North Yorkshire
Recruiter: North Yorkshire Council

UGO Bus Driver

Up to £25081.00 per annum
UGO Bus DriverPermanent, Part TimeUp to £25,081 per annum (full time equivalent)Location
Recruiter: Essex County Council

Highways Officer

£33,366 - £37,035 per annum
We are seeking to recruit a Highways Officer based at our Highways Office in Whitby. Whitby, North Yorkshire
Recruiter: North Yorkshire Council

Project Engineer - Forward Programmes

Grade 11 £38,629 - £41,928 per annum (Pay Award Pending)
At Derbyshire, we have been on a journey to transform the way we deliver highway services Derbyshire
Recruiter: Derbyshire County Council

Head of Highways Operations

Salary
Somerset Council
Recruiter: Somerset Council
SUBSCRIBE NOW

Latest Video

Subscribe to Highways today to ensure you keep your finger on the pulse of everything happening in the UK road network throughout the year.

SUBSCRIBE NOW