Friday, February 6, 2026
In August 2025, Gresham Office Furniture, a staple of British craftsmanship and innovation in the workspace furniture industry, took a bold step forward in modernising its manufacturing operations. By replacing multiple standalone machines with a cutting-edge HOMAG Batch Size 1 system, Gresham has not only increased efficiency but also ensured enhanced cut consistency, reduced labour needs, and maintained production output while reducing shifts from two to one.
A Strong Legacy of Innovation and Craftsmanship
For nearly 50 years, Gresham Office Furniture has been at the forefront of the UK furniture manufacturing industry, known for blending traditional British craftsmanship with innovative, cutting-edge technologies. Operating from its sprawling 14-acre site in Bolton, the company’s 200,000 sq. ft. manufacturing facility employs over 200 people, and continuous investment in technology has been key to its ability to maintain high quality and competitiveness in a fast-evolving market.
The latest investment, a HOMAG Batch Size 1 board system, has been the catalyst for significant improvements in Gresham’s production process, particularly in its panel processing operation. This new system integrates various HOMAG technologies, including the SAWTEQ S-300, SAWTEQ S-320 flexTec, two STORETEQ P-500s, EDGETEQ S-810, LOOPTEQ C-500, and XES 200 – all seamlessly connected into one streamlined production cell.
Solving Consistency and Labour Challenges
The decision to integrate HOMAG’s Batch Size 1 system was born from two critical challenges that many modern manufacturers face: consistency and labour shortages. As David Openshaw, Operations Manager at Gresham, explains, “We had a couple of older saws, and one of the things we were struggling with was getting consistent cuts.”
With fewer people entering the manufacturing sector, finding skilled labour has become a growing concern. As David notes, “It’s becoming harder to find people with the right skill sets. Fewer people are going into manufacturing, so we needed to bridge that labour gap.” By replacing its older saws and multiple edge banders with a single integrated solution, Gresham has successfully addressed both issues, achieving greater consistency and reducing its reliance on a large workforce.
A Trusted Partner for Seamless Integration
Gresham’s long-standing relationship with HOMAG made the choice to adopt the Batch Size 1 system an easy one. Having relied on HOMAG machines for decades, Gresham knew the brand’s quality and the familiarity of its software would make the transition smoother. “We’ve always had HOMAG machines,” David says. “We know how HOMAG works, we know the quality is there, and our operators are already familiar with the software. That made it an easy decision.”
Working closely with HOMAG, Gresham explored various options to find the ideal solution for its production needs. “HOMAG really understood what we were trying to achieve,” David recalls. “Their knowledge was invaluable in helping us land on the right solution.”
Training and Installation: Setting the Stage for Success
To ensure a smooth transition, Gresham made substantial investments in training. Operators were sent to Germany for in-depth training on the system, followed by on-site support during installation. “Installation went very smoothly,” David reports, attributing the seamless process to the dedicated support from HOMAG engineers. This thorough training allowed Gresham’s team to utilise the new system confidently, achieving its full potential right from the start.
Efficiency Gains and Labour Reduction
The impact of the new Batch Size 1 line has been transformative. “Previously we were running two shifts,” David explains, “Now we can achieve the same output in just one.” This reduction in shifts not only improved efficiency but also led to a significant decrease in labour costs. The number of employees required in the department dropped from 28 to just 9, enabling Gresham to redeploy skilled workers to other areas of the business. The result: increased cost efficiency and a more agile workforce.
Unmatched Quality and Consistency
Beyond operational improvements, the new system has significantly enhanced product quality. David highlights, “The finish is consistently perfect. That level of consistency is a huge benefit for us.” For Gresham, the ability to deliver flawless products with minimal variability is a key competitive advantage in a market where precision and consistency are highly valued.
A Future-Ready Partnership with HOMAG
While the integration of advanced automation can come with challenges, Gresham’s long-standing partnership with HOMAG has proven invaluable. “With machinery like this, there are always teething issues,” David acknowledges. “HOMAG understands that. Their customer service matches the quality of their machines; they’re always available and happy to help.”
As Gresham looks to the future, David is excited about the possibilities this new partnership will bring. “We’re excited to see what our long-standing partnership with HOMAG will bring in the future.”
Conclusion: A Bright Future for Gresham Office Furniture
By integrating the HOMAG Batch Size 1 board system, Gresham Office Furniture has set itself on a path towards greater efficiency, consistency, and quality. With improved labour efficiency, fewer shifts, and streamlined operations, Gresham is well-positioned to continue leading the UK’s furniture manufacturing industry for years to come.
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Tags: board system, consistent cuts, furniture manufacturing, Gresham Office Furniture, HOMAG Batch Size 1, manufacturing efficiency, panel processing, reduced labour
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