Custom component maker at meridian of success: Meridian Products combines handcraftsmanship and high-technology to produce custom cabinet components for high-end residential applications

Wood & Wood Products, April, 2006 by Karen M. Koenig

It's not every day a company literally lives up to its name. But then again, not every company is named Meridian.

The word "meridian" is defined as "highest part or point." It's an apt description for Meridian Products, a custom cabinet component manufacturer at the peak of success.

Based in New Holland, PA, Meridian Products specializes in mortise-and-tenon as well as miter-style doors. The company also custom manufactures face-frames, drawer boxes and architectural mouldings, plus a range of accessories for today's high-end kitchens.

A typical job with Meridian Products components can fall anywhere in the $40,000 to $100,000 range, "based on the size of the kitchen and sophistication of the cabinets," says Marty Ness, owner and CEO. He attributes the rising popularity of high-end custom kitchens to changing trends in home entertainment.

"The kitchen has become the central area for entertainment in today's modern society," Ness says.

According to Ness, this has resulted in a surge of business as homeowners seek to turn their kitchens into an extension of the living room. Furniture-quality finishes and more elaborate mouldings, corbels and trim are just some of the elements employed by homeowners to achieve the desired effect.

"The beauty and sophistication of today's cabinetry have helped make [the kitchen] really become the primary place in the home for entertaining," Ness says. "Our customers are the high-end manufacturers who build the cabinets."

Precise Milling

"We don't build to stock--we're 100 percent custom, so we also have to be flexible enough to accept one order or a highly repetitious order, and do it quickly and accurately," Ness says.

The majority of components produced at Meridian Products are made from solid wood, typically domestic species, with maple, cherry and oak among the most popular. Other species, including mahogany, Lyptus and exotics, also are available upon request.

Lumber comes into the rough mill area already kiln dried and ready for processing, says Steve Groff, COO. The boards are run through a planer, graded and designated for either the framing or panel line, based on the best optimization of yield.

According to Mike Morse, purchasing supervisor, Meridian Products maintains 50,000 to 90,000 board feet of lumber for inventory. Lumber designated for framing is sent to the Mereen-Johnson ripsaw, then to a Wadkin moulder for processing into architectural or applied mouldings.

On the door framing line, a Weinig Dimter 104 scans and processes S4S lumber. Purchased less than two years ago, the CNC optimizing saw can be programmed with a cutlist of 10 orders to generate optimal yield, Croft says.

Next, a Diehl straightline ripsaw removes defects and prepares two sides of the lumber for gluing. Pieces are then hand matched for door blanks and marked for color and grain consistency. A glue spreader applies Titebond glue on the pieces, which then are assembled and damped on a Doucet clamp for approximately one hour.

The door blanks are inventoried and as orders come in, they are pulled and cut to size on Original Saw machines equipped with TigerStop measuring devices, says Croft.

"This is the only place we build to inventory," Groff adds.

On average, approximately 1,100 doors are produced per day, Morse says. Products are shaped, finished and assembled at a plant located adjacent to the rough mill facility.

Secondary Processing

There is an organized flow to the machines in the secondary processing area of the plant. In what Ness calls three "hybrid" flow tines, mortise-and-tenon doors, miter doors and dovetail drawers are produced.

On the mortise-and-tenon line, for example, the rough cut door panels are first run through a two-head Timesavers sander using 80/120 grit, shaped, then sanded a second time on a Timesavers wide-belt using 180 grit abrasive. "We'll then match the framing and panels, and then we assemble," explains Mike Strickler, production manager.

A recently purchased Accu-Systems HTH is used to produce face frames. A second Accu-Systems MMTJ is used on the miter-style door line.

"We use Accu-Systems equipment now for the face frames as well as the miter doors," Ness says. Since the company switched from using metal splines to this new system, "We've found we get a vastly improved fit and finish for the miter products" Ness adds.

A Carlson ProMax 1000 press squares and pins all four corners automatically. The doors then are allowed to set before moving to the next staging area for lipping.

Meridian Products offers approximately 34 different profiles as standard, with custom options available. Using Saber diamond tooling, the doors are run through the Unique Machine automated shaper/sander, which performs lipping and sanding in a single pass. The machine is equipped with a Doucet Feedback 36 return conveyor for one-person operation.

"It has tripled our volume with the same labor," Strickler says of the single-pass shaping and sanding machine.

After a last tolerance and square check, the door panels are sent through a DMC Unisand top and bottom inline sander, followed by a DMC cross-grain removal sander.