Glass Times editor, Luke Wood, talks to David Cahill, managing director of Flat Glass Solutions, about future-proofing IGU production and automation, and why flexibility may be the most important investment manufacturers make.

Luke Wood (LW): David, there’s a lot of discussion around triple glazing, thermal performance and future regulations at the moment. What are manufacturers telling you?

David Cahill (DH): There’s certainly a lot of conversation about what the next generation of glazing will look like, and manufacturers are understandably considering how best to prepare for it.
While triple glazing is receiving plenty of attention, it’s difficult to predict with certainty what the market will look like in five or ten years’ time. It could be triple glazing, vacuum insulated glass (VIG), enhanced double-glazed units, or technologies that are only just beginning to emerge.

The challenge for manufacturers is striking the right balance between investing for the future and responding to current market conditions. Following a period of softer demand, every investment decision has to deliver both immediate value and long-term flexibility. That’s why I believe the priority should be creating production flexibility that can adapt as the market evolves.

LW: What do you mean by production flexibility?
DC: The ability to adapt.
The most successful manufacturers are usually the ones that can react quickly when customer requirements change or regulations evolve. If specifications shift, they need equipment capable of supporting that transition without having to completely restructure their factory.

The businesses that remain agile are often the ones that come out strongest when markets change.

LW: So you’re suggesting manufacturers shouldn’t become too focused on one particular trend?
DC: Of course it’s important to understand where the market is heading, but committing everything to a single product category comes with its own challenges and potential risks.

We’ve seen this industry evolve many times over the years. Customer expectations change, legislation changes, and technology evolves. Manufacturers need equipment that gives them options rather than limitations.

That’s the philosophy behind our approach at Flat Glass Solutions.

LW: How does your partnership with Tenon support that strategy?
DC: Tenon has been designing and supplying insulated glass manufacturing equipment for more than 30 years, building versatility into every product.

As Tenon’s UK partner, we’re able to provide manufacturers with production lines that can accommodate everything from standard double-glazed units through to larger, more complex and higher-performing products, including single-seal triple glazing.
You’re not locked into a single production model. The equipment is designed to evolve alongside your business.

LW: What makes Tenon different from other IGU line suppliers?
DC: Scalability is a major advantage.
The systems are available in multiple configurations and automation levels, allowing manufacturers to invest at a pace that suits their business.
Options include flexible spacer applicators, TPS applicators, edge deletion systems, sealing robots, automatic loading and unloading systems, smart factory storage and shuttle delivery systems, all allowing a variety of upgrade routes.

That means a manufacturer can install a solution that meets today’s requirements while retaining the ability to automate further as demand grows.

LW: Is automation becoming a bigger priority for processors?
DC: Without question.
Manufacturers are facing pressure from several directions simultaneously. Labour costs continue to rise, quality expectations are increasing, and businesses are expected to deliver more output with greater consistency.
Automation can help address all three challenges.
The important thing is that automation doesn’t necessarily have to mean replacing an entire factory or investing millions overnight. There are many opportunities to introduce automation gradually and strategically.

LW: Cost remains a concern for many businesses though.
DC: Absolutely, and rightly so.
Nobody is making investment decisions lightly at the moment. Every pound spent has to deliver a return.
One of the reasons Tenon has proven popular is because it gives manufacturers access to advanced production technology without the level of capital expenditure that has traditionally been associated with highly automated IGU production.
Not every manufacturer is looking to replace an entire production line. Instead, many are looking for a practical route forward that enhances productivity, quality and efficiency while making the most of their investment while remaining commercially viable.

LW: How important is that flexibility when it comes to future regulations?
DC: I think it is critical. We can say with confidence that regulations will continue to evolve. Thermal performance requirements are unlikely to stand still, and customers will continue to demand better-performing products.

Whether the industry ultimately settles on triple glazing, VIG, enhanced double-glazed units or another emerging technology, manufacturers need the ability to respond.
If demand for triple glazing grows significantly, they should be able to react. If another technology gains traction, they should be able to react to that as well.

That’s why flexibility has become such an important consideration when evaluating new equipment.

LW: If you were advising an IGU manufacturer making investment decisions today, what would your key message be?
DC: Focus on adaptability. While it’s difficult to predict exactly how the market will evolve, manufacturers can make investment decisions that provide greater flexibility and support a range of future opportunities.
The businesses that tend to be best placed over the long term are those that remain agile, continue to improve efficiency and are ready to respond as market demands and technologies develop.

LW: And ultimately, what does that preparation deliver?
DC: Confidence. Confidence that you can meet changing customer requirements, confidence that you can respond to evolving regulations, and confidence that your production capability won’t hold your business back.
In a market that continues to change, that flexibility might just prove to be one of the most valuable investments any manufacturer can make.