Fabricator Focus January 2004

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Grand Designs for Tradesmith

A Sussex window, door and conservatory fabricator is using graphic design to develop its market share in the South East. To commemorate its tenth anniversary last year, Hailsham based Tradesmith has developed a new consumer brochure with the help of its profile supplier James Harcourt.

'Over the last two years we have enjoyed unprecedented growth and made substantial investments to improve the infrastructure of the business,' said Jason Smith, director for Tradesmith. To complement this, with the help of James Harcourt’s in-house designer Ak Suggi, we have undergone a review of our marketing materials to ensure they fit with the high quality nature of our business.'

The brochure showcases Tradesmith’s extensive window, door and conservatory product offering – which includes the WHS Halo System 10 and Esthetique ranges – and has been designed to present a fresher, more contemporary feel to help differentiate the business from its competitors.

Jason Smith concludes: 'The window market in East Sussex alone is worth around £24 million. By working closely with the James Harcourt design service, we have been able to put together a new customer brochure that not only reflects our growing position in the market, but also represents our fresh, high quality approach.'

Tradesmith operates from two sites and employs 40 people. The company reported an annual turnover of over £3 million in 2002.

Web: http://www.jamesharcourt.co.uk


Paladin - A Shining Example for Newglaze

Taking pride of place in a busy roadside showroom setting, this red Paladin door from Portal Products is helping Newglaze Windows Ltd to attract new custom.

A steel-faced version of Portal's bespoke composite door made its debut at the opening of Newglaze's new Blandford Forum showroom in May.

The company took a novel approach to its showroom design, using several conservatory styles, water features, paved patios and even a small bridge, to display products to their best advantage.

Newglaze Sales Manager, Annabel Simmons comments: 'The Paladin door certainly attracts attention, particularly when it is illuminated at night. We wanted to create a cosy 'lifestyle' feel to our displays and demonstrate how new doors and windows can enhance the home.

'People invariably choose a door they can see and touch, so we always keep a large range of door styles on show. We chose the Paladin door because we liked it - and it's the best-looking composite door we've seen. It has been very well-received,' adds Annabel.

As an existing PVCu panel customer, Newglaze decided to stock the quality Paladin door as it complements and widens the company's existing product range.

Cheltenham-based Portal Products recently launched a GRP version of its Paladin steel-faced composite door to meet demand for a sturdy, yet good-looking product in this fast-growing sector.

Portal, the UK door panel manufacturers, says the addition of the fibreglass door completes its product range to maintain its niche as a 'one-stop shop' supplier to installers.

And companies such as Newglaze find this service useful in helping them to expand their product offering.

Recently, GRP has become an increasingly popular choice for entrance doors due to its inherent strength and high resistance to denting, warping or twisting. The strength of the material is testament to its use in the manufacture of racing cars, speedboats and even British Army tanks.

Portal Products offers its customers a totally bespoke service in size, style and glazing options for the GRP door. Frames are also supplied so that installers can simply order a complete door set and fit on site.

All GRP Paladin doors can be painted to any RAL colour and with up to six times greater heat insulation than a comparable timber door, the product meets the requirements of Part L of the Building Regulations.

Portal's Managing Director, Peter Shears, comments: 'Our sales growth reflects the popularity of Paladin with smaller independent fabricators who often cater for niche markets. With our comprehensive range of door types, styles and decorative glass, we aim to provide customers with a wide choice of products.'

Portal's portfolio comprises PVCu panels, aluminium panels and composite doors in steel and GRP, giving the company flexibility to cater for all markets. Similarly, the launch of new products such as Amatis and the resin-bevelled glass range has also increased the appeal, and sales, of the range.

Contact: Haydon Statham
Tel: 01242 267000


A & D Joinery gets Commercial

The buoyant social housing sector is opening up new opportunities in the North West for long-established Profile 22 PVCu window fabricator, A & D Joinery with the completion of several major contracts in the Lancashire area.

The Westhoughton-based company has recently invested in new machinery, including a new computer-controlled corner cleaner and created three new jobs to cope with rising production levels.

In addition, the company has turned a neighbouring factory unit into a new glass shop to store sealed glazed units prior to frame manufacture.

As an approved fabricator for several local Housing Associations, the company is securing more and more work having taken a successful partnering approach with Bradford and Northern Housing Association.

Directors Dave Smith and Tony Lowe set up the company in 1987 and have been using the Profile 22 system since their shift from timber to PVCu fabrication in 1991.

Says Dave: ‘Partnering has worked well for us and our customers. By being involved right from the outset, we have been able to advise on the best specification for the job. In the case of a recent contract for Bradford and Northern Housing Association, we produced savings for them by advising on their choice of ironmongery.

‘The projects have also progressed more smoothly with much fewer snagging problems thanks to the partnering concept of promoting easier and open communication between all the parties involved,’ continues Dave.

A & D Joinery's more recent projects for the BNHA included two sheltered housing complexes, Kirk House in Church, near Accrington and another in Kay Street, Oswaldtwistle.

At Kirk House, old single-glazed timber windows were replaced with 275 Rosewood casement windows to complement the 1980s building. The work was completed in six weeks, two weeks ahead of schedule to the delight of the client.

In nearby Kay Street, 195 white PVCu windows were installed, along with new doors and a large glass porch. Again the contract involved replacing single-glazed timber windows and took a total of four weeks to complete.

While the company's production is split equally between the domestic, trade supply and commercial sectors, it is the latter where Dave expects to see growth throughout next year and beyond.

‘We have also completed work at local schools, including curtain walling and PVCu panel replacements as well as windows and this type of work is also increasing for us.

Being a local fabricator and offering a quality, prompt service is paying dividends for us and the commercial sector is one where we see a lot of potential,u adds Dave.

A & D Joinery is actively seeking similar projects for the New Year and if any social housing provider has any requiremements, Dave Smith would like to hear from you on 01942 840337.


Versatile Elumatec Saw helps Airedale Tackle 'The Big Ones'

Aluminium fabricator and installer Airedale Architectural Ltd of Leeds is now able to tackle both larger aluminium sections and, in turn, larger-scale contracts following the installation of an Elumatec AKS134 Notching Saw. The saw, which is described by Airedale's Works Manager Rob Martin as being 'unusually versatile', was specifically introduced by Elumatec to cater for larger aluminium profiles, such as mullions and transoms used in curtain walling applications.

Founded in 1975 and an aluminium fabricator since 1983, Airedale Architectural is just one division of the Airedale Group, which also has a glass laminating and toughening plant. A specialist in curtainwalling, Airedale had long wanted to take on bigger contracts but had found that some of its older machinery was holding the company back.

Says Rob Martin: 'Our existing machines were not only very slow but did not have the capacity to handle larger sections easily. The Elumatec saw impressed us because it could not only handle these sections but could also be used across our entire range of aluminium products. It was the only machine of its type that could offer us these benefits, and it has proved incredibly useful to us during a period of extensive growth for the company.

Designed and engineered to offer the power and consistent performance required for heavy duty applications, profile sections are clamped firmly into place whilst the twin saw units of the AKS 134 are moved according to the cuts to be made.
This enables greater accuracy and a smaller working area as the profile remains fixed throughout the working cycle. A tilting range of 45 degrees to the front and 60 degrees to the rear allows the widest notching range, with powerful 3000 W motors driving the 500mm top and 550mm lower saw blades.

Since installing the machine, Airedale Architectural has been able to take on bigger contracts, with recent projects including the construction of a tower block in Old Street, Liverpool - a contract worth £1.5 Million to the company - and a similar project in Scotland worth £2 Million. The company has also purchased further Elumatec machinery, including a bead saw with digital stop and a copy router.

Contact: Phil Heavey
Tel: 01908 580800
Web: http://www.elumatec.com


MFH Demonstrates Real Need for Medium Sized Fabricators

As it celebrates its 17th year of trading, Status fabricator Maintenance Free Homes reinforces the very definite and continuing need for medium sized fabricators offering a good local service at reasonable process. Since it was first established Maintenance Free Homes has weathered many an economical storm and industry changes to maintain a solid, financially independent and profitable infrastructure.

The Midlands based company is particularly strong in the local housing association market place, having developed successful working relationships long before HA projects became the hot news they are today. Managing director Paul Allen feels that the best approach to working with housing associations is to completely relieve them of any hassles that come with the job.

'Problems are dealt with there and then, by us, on site,' he said. 'Then when we report back to the relevant housing association, we present them with a fait accompli. Certainly the housing associations we deal with on a regular basis come back to us now again and again, so this approach has more than proved itself over the years.'

Paul admits that a few years ago he did feel threatened by the reported rise of the super fabricator. Despite the pressures however, and thanks to a sound financial foundation, Maintenance Free Homes maintained its strong hold on the local market place, highlighting the need for a local supplier that provides a more traditional hand holding, flexible, personal service - price becomes a secondary issue, providing it is in the ball park.

'We have been comfortable manufacturing 300-350 windows per week for a few years now, and are comfortable and profitable at this level,' continued Paul. 'We know our market place extremely well, and are able to focus on our customers' needs, rather than pushing for ever increasing sales. As such Maintenance Free Homes continues to be an extremely dynamic company that embraces change and developments to help a market place that we know will always be there for us.'

Email: mailto:sales@status-systems.co.uk
Web: http://www.status-systems.co.uk


Diamonds and Pearls

It’s all change at Pearl Window Systems in Bolton. The fast moving fabricator has just relocated to new premises and has introduced Duraflex’s Featured Suite. A major investment in new machinery, including a state-of-the-art saw centre, is also underway as part of Pearl’s three-year growth plan.

Set up just five years ago, Pearl Window Systems looks all set to reach a ten-fold increase in capacity by the end of 2003. At 38,000 sq ft, Pearl’s new facility will enable the company to increase output to 2000 frames a week when new machinery comes fully on stream.

The decision to introduce the Duraflex Diamond System was to further enhance Pearl’s product range. The company now fabricates the Duraflex 70mm Featured Suite with Rolled-in gasket (RIG) and finds Duraflex’s fully integrated product range covers all the company’s customers’ requirements in terms of window configurations. Pearl has also taken on the K2 conservatory roofing system in bar length and kit form. In addition to roof only supply, the company offers a complete conservatory service and like many fabricators sees this side of the business as a major growth area.

In addition to an experienced and highly-trained team, Pearl’s co-founder, Jeff Walsh, puts the company’s continuing success down to competitive prices and a quick turnaround, ‘plus, of course, a genuine commitment to getting it right on time, every time,’ he adds.

Tel: 08705 351351
Web: http://www.duraflex.co.uk


Alternative and Eurocell Hit the Q-Mark

Alternative Windows is based on the Cross Green Industrial Estate, just outside Leeds, in two units, which are ideal to serve the company’s growing customer base. The first unit spread over 12,000 sq ft houses the firm’s fabrication and administration departments, the second a 11,000 sq ft recently acquired unit is mainly concerned with the production of sealed units combined with the storage of ‘ready glazed windows’ for the company’s Commercial sector work. Alternative currently produces an average of 400 windows per week using Eurocell’s Ultimate 70mm PCE Window System.

Nigel Fletcher and Darren Barraclough set up Alternative Windows (Leeds) Ltd over thirteen years ago and little did they know that they would grow into becoming one of the window industry’s success stories.

Initially the company supplied a number of frames to trade customers as well as serving its niche within the domestic market. However, around seven years ago the company was asked to complete a local authority contract. Since then its business has grown to the extent where local authority contracts make up 50% of the company’s output.

During this period Alternative has not rested on its laurels, quite the opposite. A major investment programme, particularly over the past 18 months, has ensured that the company is very much a cutting edge fabricator and one which will continue long into the future. Towards the end of 2002 a new Cutting Centre and quad welder were installed at a cost of over £400k which has led to increased efficiency within the fabrication process, allowing one man to do what four had done previously.

Further to this over £70k has been invested in improving the level of software both administrative and production based. Indeed Nigel Fletcher is very positive when describing the new fully integrated ‘single view’ system employed by the company. Effectively this bespoke system allows anyone employed by Alternative to look at one screen, pick a job (completed or uncompleted) and know exactly where in the manufacturing process the work is. The system enables all documents coming into or out of the company to be scanned and placed into the software, e.g delivery advices, quotes, invoices etc; allowing any problems to be overcome immediately and correctly, increasing efficiency and building strong working relationships with customers.

Alternative is one of the new breed of window fabricators, the focus being on a commitment to quality and further investment. Indeed gaining further accreditations comes high on the company’s wish list. Alternative has recently completed the respected BM TRADA Q-Mark schemes for IGU’s and PVCu windows and is further involved in testing for enhanced window and door security with the same certification body, which further adds to the company’s credibility as a local authority supplier. With additional growth expected over the next few years Alternative is laying a firm foundation and allied to the support from Eurocell the future looks bright.

Alternative: 0113 248 3773
Eurocell: 01773 842 100


P & P Windows Celebrates Expansion

P & P Windows is celebrating the opening of its new factory in Peterlee, County Durham. Having outgrown its old premises, the Duraflex fabricator and installer has just relocated to a new 12,000 sq ft facility as part of a major investment and expansion programme. The move follows continuing success for the company, which has doubled its order book over the past year.

Alongside the acquisition of a larger site, P & P Windows has also been investing in the latest fabrication machinery to optimise production levels in line with demand. In fact, the company is aiming to boost output from 150 frames per week to around 400 frames by the end of 2004.

P&P Windows started fabricating the 70mm Diamond Suite in 2000 and recently began using Duraflex’s new Rolled in Gasket (RIG).

Director, Paul Gregory comments, ‘We seem to be challenging all the talk of a slowdown in the window industry with our commitment to offering top quality products at best value prices. The new site in Peterlee provides a great strategic base for us and the space we need to continue our expansion plans, which also include a brand new showroom.’

Tel: 08705 351351
Web: http:www.duraflex.co.uk


New Fabricator has the Everite Stuff

A fabricator that only began manufacturing just over 12 months ago has seen its output leap from 20 to over 200 frames per week within a year. Everite Windows of Wirral puts this rapid growth down to several key factors: product quality, efficient service and up-to-the-minute machine technology provided by its chosen supplier, Elumatec.

Everite Windows, a trade and retail supplier servicing Merseyside and North Wales, had ambitious growth plans from the outset according to company partner Brian Vincent:

‘We knew that we wanted to be producing at least 100 units per week by the end of our first year, so we were determined to get things right first time. We started manufacturing from a 10,000 sq ft unit to allow for future growth potential and we also thought it was sensible to invest in good quality, new machinery sooner rather than later.’

Having thoroughly investigated the various options, Everite Windows chose Elumatec machinery because it represented the best value for money in terms of technological capability and performance. Says Brian:
‘We felt we could rely not only on the machines themselves but also on Elumatec to provide us with the service levels we really needed as a new start-up’

The company has a wide range of Elumatec machinery in its factory, including a DG142-550 disk-fed Double Mitre Saw, DS703 3 Head Welder, ES710 Double Reverse Butt Welder and EV834 Corner Cleaner. Brian Vincent is pleased that the company made the right decision in its machinery purchases:

‘We could never have grown this quickly and still satisfied our customers without having made the decision to invest in the new machinery from the start. It has allowed us to really move forward at the pace we wanted to.

‘Our next step is to move into a new, purpose-built 20,000 sq ft factory unit in around 3 months time, and I’m confident that we will invest in more Elumatec machinery to cope with further growth and development.’

Everite Windows has already achieved a turnover of around £2 million and will also shortly be opening new showrooms in North Wales to stimulate further sales opportunities.

Web: http://www.elumatec.com


Sentinal Scores 95% in CPA Survey

Bournemouth based Hallmark fabricator Sentinal Home lmprovements, a small family run company, supplies doors, windows and conservatories to companies in the adjacent Dorset area and is a member of the Consumer Protection Association (CPA), the independent body that offers purchasers of home improvement products valuable protection.

The CPA provides a Consumer Guard lnsurance Backed 10 year Guarantee of the work undertaken by member companies and, on producing the guarantee to the customer, asks a series of questions about the work provided by the company. lnformation is then entered into a database for analysing and closely monitored on a yearly basis. Sentinal's achievement for 2002 came in at an impressive average of 95% on all sectors of the survey.

The company's owners pride themselves on keeping the business small which enables them to give a more personal service to their customers. But despite wanting to remain at the smaller end of the scale Sentinal is also forward thinking and has taken on the role of partnering Pilkington to increase the awareness of the company's self cleaning glass Pilkington ActivTM within the Dorset area.

Sentinal's Managing Director Mark O'Hanlon commented 'We are of course delighted to have achieved such a high percentage in the CPA survey but are focused to improve even more in the coming year'.


Status Fabricator Achieves 40 per cent Growth

Status fabricator MB Frames has achieved a growth of 40 per cent in the last year, and is well on track to overreach its target of 20 per cent for this year.

This growth is the result of a concerted push by Bristol based MB Frames into proactively growing and developing its business. By strengthening its infrastructure both externally and internally, the company is better placed to survive an increasingly competitive and changeable market place.

'We have spent a lot of time and resources increasing our efficiency and accuracy both in the factory and in administration,' said MB director Andy Burns. 'Simply by investing heavily in IT infrastructure and software training has allowed MB to get true up to date costings which in turn leads to instant quotation. These developments, combined with a consistency in product quality development, ensure our growing customer satisfaction throughout the south west.'

Status general manager Chris Foreman added: 'MB's commitment to working proactively for growth and its subsequent on-going success demonstrates the amount of potential that is still out in the market place. Status actively encourages and supports this positive attitude.'

As a side line, MB has opened its car park to the BBC Casualty production team. This does mean a degree of inconvenience when filming takes place, but does generate curiosity and helps pay the rent.

'However, with out health and safety record, I am pleased to say that none of our employees are ever used as ailing extras', said Andy Burns.

Tel: 01457 875731
Email: mailto:sales@status-systems.co.uk
Web: http://www.status-systems.co.uk


Star Glazing

Spectus customer T. Giles Glazing is going from strength to strength. Its latest project to come out of a long-standing relationship with Laing Homes has coincided with a BSI qualification, membership of HW Plastics AIMS scheme and the beginnings of big plans for the future.

Contracting for Laing Homes for the past 11 years has taken T. Giles across the Midlands, providing Sightline 70 profile to a wide variety of properties. Laing spokesman Rob Jones sees the relationship as a partnership: ‘T. Giles has always provided a quality service, a quality product, and a great finished job – so we keep using them. The most recent development is another success.’

With 17 staff and 30 years experience, T. Giles is equipped to take on more that just the Laing jobs. With a recent BS 7950 under the company's belt, the team is well prepared to expand. T. Giles is the first Spectus fabricator to gain this certificate for windows with an egress hinge.

As a family-run business, T. Giles also appeals to the consumer. Director Darren Giles felt that membership of AIMS has given them a boost: ‘We feel that AIMS membership and the Quality Mark are an essential tool. When trading with the public we are now able to assure them of peace of mind when purchasing from us’.

Future plans include expansion into the conservatory and roofing markets, in which the company already has a small foothold. As Darren says, ‘to be able to offer the customer a wide range of products is an essential part of business today. Offering choice and quality as well as competitive pricing has always been our strategy’ – and it seems to be working.


Modplan – Home of Investment

‘Our commitment to quality product and service couldn’t be sustained without consistent investment’, says Chris Reeks, trade sales manager of Modplan Ltd.

Over the last two decades, the company has grown to become one of the largest Veka fabricators in the UK, with a loyal, but diverse, nationwide customer base. ‘At Modplan, we work hard to ensure that we are responsive to the changing needs of our customers’, explains Chris. ‘We are constantly reviewing processes and improving plant and machinery in our endeavour to prevent any growth in sales exceeding our ability to produce the highest quality product.’

In the past twelve months, throughout the 35,000 sq. foot purpose built factory based in South Wales, investment in new machinery has been substantial, providing a third computerised saw, three CNC corner cleaners and recently a 4 head turret welder to complement two new welders purchased last year.

With quality high on the priority list, further new equipment has been purchased to test the quality and impact resistance of profile and frames. Modplan exercises a stringent quality procedure, with operators taking individual responsibility throughout the process, resulting in less wastage, improved cost efficiency and customer satisfaction.

‘This ongoing investment will help not only to create additional capacity but will also provide greater efficiency combined with an improved, consistent finish’, continues Chris. ‘Our new operating system, which we began implementing a few months ago, has already made a huge impact on the efficiency and speed of order processing and production schedules and will provide even greater benefits as we roll out the rest of the system.’

Chris concludes, ‘With our on-going investment programme, Modplan will successfully maintain the strong commitment to quality product and service which has made us so successful.’

Tel: 01495 246844


Winning more Business with Windowlink

Nuglas, a long established fabricator and installer in East Sussex, is about to go live with Vector Plus, Windowlink’s new fully integrated conservatory pricing program. A long-standing user of the Vector conservatory sales presentation package, Nuglas had no hesitation in upgrading to Vector Plus, which enables production of professional quotations complete with a total cost at the click of a button.

With sales of conservatories now accounting for just under half the annual turnover, Nuglas recently opened a Conservatory Centre with a dedicated sales team. Since the company started using it in 2000, Windowlink’s Vector software has enabled the sales team to deliver a more polished presentation to prospective customers, as Kevin Holland, Sales and Marketing Director explains, ‘A rough pencil sketch is a thing of the past and just doesn’t compare with what we can do with Vector.’

Incorporating Windowlink’s pricing facility, new Vector Plus includes stored price matrices and pricing rules, together with a checklist of prompted questions based on information provided by each individual user.

These are programmed into the software by Windowlink - Nuglas has seventy-two questions on its customised module. The checklist ensures that nothing that could affect the price or timescale for completion is overlooked. Customers can also see the effect of any changes as the sales person works through the design process on screen.

Nuglas has, in fact, updated all its terms and conditions relating to conservatory sales in line with the introduction of Vector Plus. Every quotation will now be calculated on the new software and they are investing in portable sales presentation kits for every member of the sales team, including a laptop and printer. So although Kevin is keen to stress that there will be no pressure to place an order on the night, they will now be able to give homeowners an accurate quotation on the spot rather than them having to wait a day or so,
‘I believe Windowlink’s Vector is the best of its kind on the market and it’s certainly contributed to our sales success.’

Vector Plus is available either as a complete design, sales and pricing package, or as an upgrade for existing users to their current Vector program. For further information or to arrange a free no-obligation trial of Vector Plus, call 0870 770 1640.