Welcome to THE GL@ZINE News 3rd February 2004

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Glassex 2004 Gears up for Machinery Extravaganza

With just a few weeks to go before Glassex opens its doors for the 24th time, major machinery manufacturers have begun to announce some of their plans for this year's event. The recent announcement that Promac Window Machinery has once again demonstrated its commitment to the event following a highly successful show last year has created a high level of anticipation for what machinery manufacturers will choose to launch at Glassex 2004.

Haffner GB Ltd described last year's event as '... the best Glassex ever for Haffner, no question about it'and Managing Director Dave Thomas is optimistic that the company will enjoy a similar performance at Glassex 2004:

‘Last year we sold 4 of our new SBA machining centres on the stand, and we sold 30 more during the year following the event. We've had a fantastic year and it just seemed to snowball from Glassex, so we're looking forward to this year's show. We will once again be featuring our SBA centres plus Quad Welders and CNC Corner Cleaners. The trend towards affordable hi-tech machinery continues to run and I believe that Haffner will reap the benefits at Glassex 2004.’

Elumatec, another long-standing Glassex exhibitor, will be introducing a number of new machines designed specifically with UK fabricators in mind. Featured on the company's stand will be a full working model of the new Elumatec SBZ615 Cutting and Machining Centre, incorporating a number of innovative functions and features that are designed for profiles and frame types indigenous to the local market. Elumatec claims that the SBZ615 is up to 60% faster than more conventional equipment, and is able to produce around 800 frames per week in a single shift system, dependent upon style and fittings.

UK-based manufacturer GTI-Kombimatec Ltd last year noted a trend towards 'more careful, pre-planned consideration of machinery purchase' by Glassex visitors, something that the company hopes to take advantage of at Glassex 2004 with the introduction of its new Quad Welder. Launched at last year's event as a prototype only, the Quad Welder will be fully demonstrated on the GTI-Kombimatec stand and promoted alongside its existing range of varied solutions.

Amongst the other big name machinery manufacturers appearing at Glassex this year is Stuga, whose Sales & Marketing Manager Steve Haines was 'delighted' with last year's show and hopes to achieve a repeat success this year. He comments:

‘We plan to exhibit the latest versions of our successful cutting and prepping machines - the Flowline, Ecoline and Autocut - with special emphasis on why these machines are suited to the UK market and British and Irish fabricators.

As usual we will also be carrying out many live demonstrations of the machinery all day every day and will have experts on hand throughout the show to explain the more subtle pros and cons in depth.’

Glassex 2004 also sees a welcome return for Wegoma UK, a major presence in the 1980s, and Scott STB, whose debut appearance last year was extremely successful. Also exhibiting are Bassra Machine Tools, Fux Maschinenbau GmbH, Industrial Washing Machine Services Ltd and Unilam International Ltd.

Click here for our Glassex Exhibitor List.


Yule Transfers to Guardian Low-E Product

Driven to look at alternative to low E hard coat products by ongoing and inexplicable price increases from their existing suppliers, AC Yule began trials at their Elgin factory with Guardian's 1.4D product early in 2003. Six months later, after glowing reports on all fronts, the decision was taken to switch the glass plants at both Aberdeen and Livingston completely to the new product. The company has not looked back and now other unit manufacturers in Scotland have began using 1.4D due to the demand by the trade.

General Manager Alex Gray explained the reasons for the change. ‘There were really four factors that influenced our decision. Firstly during the trial period at Elgin, our reject rate plummeted, operatives all reporting the product as being far better to work with, not so prone to marks and scratches as our previous products, it's aptly named, the 'D' standing for durable.’

Alex continued ‘although unable to match soft coat glass in terms of u value, 1.4D outperforms the old hard coat products we were using. The glass is much clearer with no unsightly haze and maintains the natural colours of everything viewed through or reflected in it. This benefit is particularly evident when white Georgian bar is installed in a unit. The 1.4D gives the bar an iced whiteness as opposed to yellowy nicotine stained or tarnished effect. Once our customers saw this, they had no hesitation in switching to the new product. We do however stock a small amount of the old product lest any of our customers require to match existing glass due to breakage etc., but other than that, everyone wants the new glass.’

Alex concludes: ‘We are now enjoying price stability, which we in turn are able to pass on to our customers, something we were not in a position to do previously due to the stranglehold and ongoing increases being applied by some suppliers. We haven't looked back since we made the change, other than wishing 1.4D was around a few years ago, we really are on to a winner here. We see this as an ideal glass to further enhance and differentiate our unique KeepHEAT range of insulated sealed unit products'

AC Yule offer a wide selection of glass insulating products within the KeepHEAT range of sealed units to meet all requirements and legislation such as heat retention, solar control, acoustic, wind loading, thermal and many other applications.

Contact Susan Adcook
Tele 01224 230006
Fax 01224 238606
E-mail sadcook@acyule.com


Glass the Weakest Link at Saint-Gobain, but Currency Exchange Rates Still the Main Problem

Saint Gobain's Group sales dipped 2.3% in 2003 on an actual structure basis and 3.7% based on a comparable structure. At constant exchange rates (based on average 2002 exchange rates), sales were up 4.1% on an actual structure basis, and 2.5% based on a comparable structure. Currency effects had a 6.1 point negative impact on sales for the year, particularly due to the significant depreciation of the US dollar, pound sterling and Brazilian real against the euro (down 16%, 9% and 20% respectively).

Sales volumes climbed 1.7%, spurred by a recovery in the second half of the year. At the same time, prices increased by 0.8%. France accounted for 32.2% of total sales, with other European countries contributing 42.0%, North America 18.6% and other countries 7.2%.


Operating income contracted 5.4%. At constant exchange rates however, it rose 1.0% on an actual structure basis and 0.1% based on a comparable structure. Operating margin was 8.3% compared with 8.5% in 2002. This change was essentially due to a significant increase in the cost of energy and certain raw materials such as natural gas, asphalt, iron and resins, at the start of 2003, particularly in the United States. However, operating margins did pick up in the second half of the year.



These cost increases also largely explain the contraction in profitability in North America and most European countries, except for France and the United Kingdom. Profitability remained high though in emerging countries.

Consolidated net income is estimated at EUR 1,039 million for 2003, virtually on a par with 2002. Excluding profit on sales of non-current assets, estimated net income came to EUR 1,020 million, 2.9% lower than in 2002. This reduction reflects the negative impact of currency effects including the fall in the US dollar, Brazilian real and pound sterling - which hit the Group's main income statement captions. On a constant exchange rate basis, net income excluding profit on sales of non-current assets would have been slightly higher than in 2002.

Although changes in exchange rates negatively impacted all Group divisions, all three sectors reported increased like-for-like sales (based on a comparable Group structure and at constant exchange rates).

The Glass Sector achieved a 1.5% increase in like-for-like sales but operating margin dipped slightly, to 10.5% from 11.2%. This was due to lower margins across the board for the sector, with Containers and Insulation hit by soaring energy costs in the United States and renewed pricing pressure for Reinforcements. The Flat Glass Division reported sustained sales in emerging markets as well as in the European automobile market but the picture was more mixed in the European construction market. However, the strong price increases seen in South America and Asia since the beginning of the year slowed down towards the end of 2003.

The High Performance Materials Sector posted a 0.5% increase in like-for-like sales and a solid improvenlent in operating margin, to 8.4% from 6.7% in 2002. This was achieved primarily thanks to the cost cutting measures implenlented since 2001. Both manufacturing and capital expenditure began to recover towards the end of the year, particularly in the United States.

The Housing Products Sector was the star performer in terms of organic growth. The 3.9% rise in iike-for-like sales was fuelled by the 14.2% surge in Pipe sales, spurred by major distant export contracts. However, the sector's operating margin dipped slightly, to 6.4% from 6.6%, due to sharply higher raw materials costs for the Pipe division (iron) and particularly the Building Materials division (asphalt and resins). Improvements in Building Materials operating margin were achieved though, as the year went on, thanks to measures implemented to reshape the division's manufacturing and sales operations. The Building Materials Distribution division continued to gain ground, through a combination of organic and extemal growth and also posted a further improvement in profitability with operating margin coming in at 5.0%, despite the persistently dismal conditions in Germany and the Netherlands. On a constant exchange rate basis, operating income for the division was up 8.5% on the 2002 figure.


Palram wins Olympic title with £2m Athens Stadium Roof Contract

Palram Europe has won a prestigious £2 million contract to supply state-of-the-art polycarbonate roof panels for the Athens Olympic stadium. The stunning 24 000 sq m roof of the main stadium has been described as the 'jewel in crown' of the Athens Olympics Stadium Complex, designed by acclaimed Spanish architect Santiago Calatrava and set to be a signature of this year's Olympics in August.

Last minute safety concerns voiced by the Greek authorities prompted designers to veto the original plan to use glass for the roof - the equivalent area of three football pitches suspended 80 metres above the heads of the Olympic crowds.

Thermoplastic sheet specialist Palram was the only company able to match the exacting original design specification on performance, appearance and safety standards.

And the contract was clinched after the company produced - almost overnight - a sample of the result- PALSUN UV2 Solar Olympic.

PALSUN UV2 Solar Olympic will help to create a roof that is not only aesthetically stunning but which will provide 95 per cent of spectators with protection against the searing Greek summer sun.

A unique combination of the most outstanding features offered by Palram, it was tailored to give an exact colour and light transmittance match with the original glass design. Added to this was an anti-abrasion hard coat, UV protection on each side and Palram's latest Solar Control technology.

This unique combination offers unrivalled protection from the elements, reflecting 60 per cent of solar radiation, reducing heat and offering light transmission of 40 per cent while giving spectators essential protection from harmful UV wavelengths.

Commented European Sales Director, Hanoch Goldman: 'PALSUN UV2 Solar Olympic is a technical triumph for Palram and recognises the high quality of manufacturing at Palram Polycarb factory in the UK. Palram was the only company with the technical capability and flexibility to produce a thermoplastic sheet with the performance criterion of heat reflection, light transmission and abrasion resistance whilst also meeting the aesthetic design specification of colour and appearance.'

Production of the 4,750 thermoplastic sheets - each 12 mm thick and measuring 4,942 mm by 952 mm (16' x 3' approx) is already underway at the Palram Polycarb factory in Doncaster. The completed order will weigh more than 320 tonnes.

Each 12 mm thick sheet is extruded to a precise production specification and tolerance and is manufactured in accordance with ISO 9001:2000 quality control.

The roof will be ready for the opening of the main Athens Olympic Games in August and the Athens Paralympic Games in September.

Named the Spyros Louis stadium after the first modern Olympics marathon winner, the main stadium will host the Games' opening and closing ceremonies, football and athletics.


Sliders UK - Investing in Quality

Machinery investment of over £180,000 has provided patio specialist Sliders UK with a platform for continued unprecedented growth in 2004. The latest new machines are from Elumatec and include a double stacking verti-quad welder, CNC corner cleaner, automatic screw fixing station and a computerised saw. A CNC copy router is also on order.

‘Elumatec have proven an excellent partner,’ said director Ian Longbottom. ‘The highest quality products are our goal at Sliders UK, these new machines have already played their part with improvements in overall quality and massively increased capacity.’

Sliders UK is the fastest growing patio door specialist. Since the company was formed in November 2002 its high quality bevelled and fully featured products, aggressive pricing and reliable short lead times have proven a huge success with customers across the UK.

Contact 01772 – 698222 or visit: www.sliders-uk.com


Optima Awarded £1.2m Contract for 'K2' project

Specialist glazing contractor Optima Architectural Glass has won an order worth approximately £1.2 million for work on a new office development designed by the Richard Rogers Partnership. Referred to as K2, the project is located in St. Katharine Dock, London E1. Working with main contractor, Taylor Woodrow Construction Ltd, Optima will commence operations in March 2004.

Glass will be used extensively throughout the new building. Work will include the construction of five internal atrium bridges using surface treated and diffused laminated glass panels to provide non-slip walkways with steel post and glass infill balustrades and handrails. In addition, there are seven floors of lift core glazing including lift landing floors and glass cladding to the lift shafts in the central and outer cores.

Andy Grey, divisional director for Optima Architectural Glass comments: 'Optima has more than ten years experience as a specialist glazing contractor and we are working closely with the world-leading practice Richard Rogers Partnership to meet their design concepts for this contemporary new build project.'

The building will create a window orientated towards the Tower of London with an atrium space accommodating communal facilities such as entrance foyers and exhibition areas. The glass façade, glass support structure, escalators and glazed lifts create a layering of material texture and light animated by movement of the users through the building.

There are four towers located at each corner of the proposed building. The primary tower, located in the north west corner, anchors the building and marks the site with a vertical element allowing it to be linked to the urban space bound by the Tower of London, Sceptre Court and the Royal Mint development.

K2 is a nine-storey building, for which planning permission was granted in March 2000. It is built on the site of the former 1960s office development known as Europe House, which was demolished in 2002. K2 will provide retail outlets facing into the St Katharine Dock environment with eight storeys of offices above, approached from the Tower Hill intersection.

K2 is located on the corner site created by Tower Bridge approach road and East Smithfield, and faces the West Dock towards the River Thames.

www.optimaglass.com


Pertici Trials new Scarabeo 55 Cutting Center at KEB Fabrications

Pertici announces the successful completion of an operational trial of the new model of Pertici Scarabeo 55 Cutting Center at KEB Fabrications Ltd.

This model has been in full operation in KEB Fabrications Ltd for eight months without any problems.

“We are really impressed by the new model of Scarabeo 55, during the trial period we had no problems at all and now we have achieved an overall production of 700 windows per 40 hour week with this machine” said Mr Berwick, Managing Director of KEB Fabrications Ltd. 'We are planning to add a second machine to support the continuing growth of KEB and to take the total window and door production to 1350 items per week' Mr Berwick concluded.

The new model, despite being of a very similar mechanical structure, has improved efficiency and performance. In particular a new and unique system for re-usable off-cuts has been proven to be easy and efficient. The operator can fill the loading unit with new bars and off-cuts with unknown length. The machine has a device for the automatic measurement of the bar’s length that, together with the new software, optimises in real time the cutting list for the maximum re-use of the off-cuts.

Up to now the off-cuts re-use, in the machine available in the market, was so complex and slow a procedure that window fabricators were discouraged to use it. The new model of Scarabeo 55 offers the solution to this with a simple and fast procedure.

The new Scarabeo 55 integrates an advanced software tool for the collection of production data from the machine. This data can be easily exported into Excel spreadsheet, to produce weekly or monthly reports of the events that caused a slow-down or a stop of production.

This utility has been particularly appreciated as a management tool from Production’s Managers able, now, to monitor and optimise the production process.

Keeping track of the market tendency, the new model of Scarabeo 55 includes special sliding devices with rollers allowing the proper management of profiles with pre-inserted or co-extruded gaskets keeping the same production quality and performance.

As far as the production level is concerned, the accurate work done in the optimisation of the working cycle by Pertici’s Software Development Department, has produced a significant performance improvement, putting the new Scarabeo 55 at the top of its sector in terms of produced number of pieces.

The new model will available at Glassex 2004
Contact: Luca Giorgi – Sales Director Pertici S.p.A.
Tel. +390571 651130, Fax. +390571 652991
E-mail: Giorgi@pertici.it


Complaint about Safestyle UK Advert is Rejected by ASA

An objection was made to the Advertising Standards Authority by a member of the public in Staffs to a directory advertisement for window and door manufacturing company Safestyle UK. The advert stated '0% interest free credit' in the bottom right-hand corner. The complainant challenged the availability of loans with 0% interest-free credit for the advertisers' customers.

The complaint was not not upheld: The advertisers said they offered their customers a choice of payment methods including loans with 0% interest-free credit. They stated that First National Consumer Finance Ltd, the bank that handled their finances, provided both interest-free and interest-bearing loans for the advertisers' customers. The advertisers submitted a facsimile from First National, dated 14 November 2003, that confirmed the level of interest-free business so far that year. The facsimile showed that the term of the contract varied from six months to 36 months. The number of business cases for each term was listed; the total number of cases was 236. The advertisers also submitted First National interest-free and interest-bearing loan application forms with full terms and conditions. The Authority was satisfied that the advertisers had proved that loans with 0% interest-free credit were available to their customers.


3 Men + 1 Robot = 1000+ Sealed Units per Day

McIlhatton and Co Ltd in County Antrim needed a cost effective way to increase the company’s production capacity and satisfy the growing demand for higher spec sealed units. 'An increase in customer demand - showing no sign of slowing down - meant we simply had to find a way to increase our production capacity,' explains Paddy McIlhatton, Owner of McIlhatton and Co Ltd. ‘So in July we took the decision to invest £1 million in a glass cutting machine centre, and a robotic, fully automated Super Spacer® bar application TSS ® line from Lisec – the global leader in high tech production lines for the insulating glass industry.

‘At the same time, we took the opportunity to change from all aluminium bar to all Super Spacer to enable us to offer customers a superior product. We have upped production from 2500 to 4000 units per week, with capacity available for even more as and when required. Not only have we increased capacity, we have vastly reduced labour and associated costs. Customers love the Super Spacer, especially as we can also now offer an extended guarantee from 10 to 15 years’.

Tel: 02476 363614


Profile 22 Moves into Top Gear

Profile 22 is driving enhancements in customer service and company growth through substantial investment in a new delivery fleet.

The high-specification vehicles include five rigid lorries, four tractor units and four 45-foot trailers - all sporting the new Profile 22 livery.

Both the rigid lorry bodies and the trailers are curtain-sided, with a personnel lift on the inside between the rear doors, enabling the driver to be lifted to a safe height for handling the product, therefore reducing the risk of damage. Each is also equipped with a mounting kit at the rear, allowing the vehicles to carry a ‘Moffett’ forklift truck.

Storage compartments running the length of the vehicle either side of the chassis can be used for carrying small store items, and are concealed behind side skirts running the length of the body. This will improve aesthetics and reduce drag, resulting in better fuel efficiency.

In addition, the trailers have three axles, with the rear axle being self-steer. This has the benefit of giving the vehicle a tighter turning circle - assisting the driver to gain access to customers' premises, reduce tyre wear and assist in fuel saving.
Managing Director of Profile 22, Keith White, comments, ‘This investment is part of our commitment to our customers, and will help us transport and deliver their orders on time and in perfect condition.

‘We are also dedicated to our environmental responsibilities, and are always looking for ways to reduce fuel consumption and generally be more efficient.’

Tel: 01952 290910


CertainTeed and 3M Partner to Offer Bevelled Glass Alternative

CertainTeed Corporation and 3M have partnered to produce Prism GridTM, a new window application that offers the look of custom bevelled glass. Employing 3M's patented optical film technology, Prism Grid transforms the appearance of glass in a way that allows light to filter through, casting a rainbow of colours and creating the look of bevelled glass at an affordable cost.

Homeowners can now design their own windows using Prism Grid, as the technology can be applied to any CertainTeed vinyl, replacement or new construction window or door. While bevelled glass can prove costly and difficult to keep clean, Prism Grid gives the same custom look, yet is affordable and requires virtually no maintenance. It is also highly resistant to delamination and fading.

Prism Grid applications combine elegance with functionality, providing a full unobstructed view. Virtually any straight-lined pattern can be utilised. Popular patterns include Colonial, Valence, Diamond, Prairie, and Jewel.

‘With the Prism Grid feature, homeowners can afford the custom look of bevelled glass that's backed with the high quality standards both CertainTeed and 3M are known for,’ says Maria McDonagh-Forde, marketing communications manager, CertainTeed Window Group. ‘Prism Grid is available on all CertainTeed windows and patio doors, allowing homeowners to further customize their homes.’

With more than 200 years of combined experience represented by CertainTeed and 3M, Prism Grid is backed by a history of quality. Prism Grid is available nationwide on all CertainTeed windows and patio doors and is being produced at CertainTeed's Corona, California,; Auburn, Washington; Lebanon, Indiana; and Richmond Virginia facilities.

Web: http://www.certainteed.com


Alcoa sets New 3-Year Cost-Savings Challenge; Company Seeks Additional $1.2bn in Annual Savings by 2006

At a meeting with analysts and investors on 22nd January, Alcoa Chairman and Chief Executive Officer, Alain Belda, announced a new company-wide, three-year cost savings challenge, following the successful completion of Alcoa's 2001-2003 cost-savings programme in which it achieved $1.012 billion in annual savings.

Belda also reaffirmed and expanded upon the Company's goal of striving to join the first quintile of S&P Industrials in return on capital (ROC) performance.

The new 2004-2006 cost-savings programme, which is based on the principles of the Alcoa Business System, calls for a reduction of $1.2 billion in annual expenditures by the end of 2006. Upon completion of this programme, the company's third three-year cost savings challenge, Alcoa will have eliminated more than $3.3 billion in costs, while building closer ties to its customers and building for the future. Cost savings within this programme are sustainable reductions in expenditures and exclude certain items such as energy and currency impacts. These savings have helped offset unfavourable effects since the beginning of the first challenge, including those in energy, health and welfare benefits, currency, and declines in price and mix.

'Alcoans' continued implementation of The Alcoa Business System - our management system that begins with an understanding of customers' requirements, identifies the activities and items needed to meet the requirements, and then enables all employees throughout the company to eliminate anything that is unnecessary - has dramatically increased our productivity and brought us closer to our customers,' said Belda.

'Since 1998 the Alcoa Business System has helped deliver more than $2.1 billion in cost savings,' added Belda. 'Through our employees' continued application of ABS, we will seek to eliminate an additional $1.2 billion in waste; it is important to note that this is not a people-reduction initiative.'

Significant savings have been garnered in a number of areas of the company, including, procurement via improved purchasing practices and global sourcing, manufacturing productivity via improved flow paths, and administrative savings through streamlined processes. These areas and others throughout the company will continue in this new cost savings drive.

At the meeting with analysts and investors, Belda also discussed the company's goal of providing superior returns, including a renewal of its aspiration to join the first quintile of S&P Industrials in return on capital (ROC) performance. Belda said that in pursuit of this ROC goal, the company would seek to provide, at a minimum, returns in excess of the cost of capital, regardless of general economic and aluminium cycles. The cost of capital is currently approximately 9%.
Alcoa's fourth quarter ROC on an annualised basis was 7.6%, versus a company ROC of 4.2% in 2002. The first quintile hurdle currently is approximately 16 percent.

Belda noted that the company's most senior executives will now have more of their compensation at-risk, and directly linked to the attainment of financial goals relative to the performance of other top-tier companies. This will be achieved through a new performance share design, which is at risk depending on Alcoa's relative ROC performance each year.

Web: http://www.alcoa.com


CertainTeed Windows to Open New California Facility

As part of CertainTeed Corporation's strategy to become a nationwide, fully integrated vinyl window manufacturer and supplier, the company has announced plans to open a 229,000 square foot production facility in West Sacramento, California for the manufacture of its vinyl windows and patio doors. Centrally located between CertainTeed's Auburn, Washington and Corona, California window facilities, the West Sacramento plant is expected to begin fabricating windows in the summer of 2004.

‘This facility will provide us with the potential to tap into a number of high growth markets in the Western United States,’ says Harald Jacobsen, President of CertainTeed's Window Group. The Sacramento plant falls closely on the heels of the company's opening of a new window fabrication facility in Lebanon, Indiana in the summer of 2003.

The new facility, situated in the Southport Business Park, has easy access to the San Francisco Bay area and is expected to draw a heavy concentration of both the new construction and replacement vinyl window and patio door business. The plant will initially employ about 125 people, but could reach 500 within five years and will manufacture the company's Insulate Standard and Slimline Series Products as well as New Castle XT™. In addition, the facility will offer CertainTeed's new PrismGrid™ option on all of its products. PrismGrid is an optical film technology from 3M Corporation that offers the look of custom bevelled glass but at a more affordable price.

Experienced employees from both the Auburn and Corona plants will provide assistance during the facility's start-up this summer. ‘The support that these knowledgeable and seasoned employees offer will help assure an efficient and effective start-up there,’ says Jacobsen. ‘We can expect this facility to deliver a high level of service for our customers throughout the region.’

When the West Sacramento facility opens this summer, CertainTeed's Window Group will have five window fabrication facilities and two extrusion operations strategically located nationwide. ‘We are very excited at the prospects this opportunity holds for the Window Group and CertainTeed,’ Jacobsen says. ‘The West Sacramento facility fills in a key piece of our strategic direction for the future.’

Web: http://www.certainteed.com


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