For 35 years, Derw Glass has quietly built a reputation as one of the UK’s most respected insulated glass manufacturers. Hidden away in the West Wales countryside, the family-run business has grown from a one-man operation into a modern manufacturing company.

Now, after nearly a year of automated insulated glass production powered by Edgetech’s Super Spacer, Derw Glass is said to be looking firmly to the future.

Founded by Julian Palmer in 1991, Derw Glass began with Julian cutting glass, manufacturing units and delivering them himself. Over three decades later, the company remains proudly family-owned, with Julian’s wife Noella Palmer and daughter Angharad Palmer helping drive the next chapter of the business.

“We are well known in the glass industry but because we are so tucked away, we are West Wales’ best kept secret,” said Noella Palmer. “But over the years we’ve progressed and now we’re celebrating 35 years this year which is really exciting.”

That long-term mindset played a major role in Derw Glass’ decision to invest in a new automated IGU line using Edgetech’s flexible Super Spacer. After years of working with rigid spacers, the business recognised the need to modernise production, improve efficiency and increase output without compromising on quality.

The right time

“We decided that the time had come to move to automation and we invested in the new line to improve quality, and moving from rigid to flexible spacer bar has been 100% better,” explained Noella.

“The number of actual returns is so little compared to what it was. We’ve had the line now for a year and there is less wastage compared to the rigid spacer.”

Automation has streamlined operations across the factory floor, reducing manual handling improving workflow and delivering significant labour savings. Where once up to eight operatives were required, the new system now runs efficiently with just three, a labour saving of more than 60%, all while delivering a much higher output.

The impact on product quality was immediate.

“The quality is much better, customers are happier, and we’re able to meet demand more effectively because we can produce a lot more units because of the speed of the line,”

added Angharad Palmer.

As well as increasing production capacity, automation has helped Derw Glass create a more consistent manufacturing process, reduce waste and improve overall operational efficiency.

The perfect support
Crucially, Derw Glass says its success with automation has been strengthened by the support it received from Edgetech throughout the process that made for a smooth and confident transition.

“Edgetech have been fantastic from the very beginning,” said Noella. “Even before the line was fully installed, Tony Palmer and the team were helping us analyse usage, forecast volumes, and guide us through the process. When we were putting the first orders through, they were on the other side of the phone to help.”

“The ongoing support has been invaluable, and any issues, they’re so easy to deal with,” added Angharad. “We see Edgetech as more than a supplier because they go beyond the product; it’s a genuine partnership.

“They were involved from the very early stages, sharing their expertise, helping us understand our options and providing advice throughout the project. Having that level of support and knowledge gave us real confidence in the move to automation.”

Tony Palmer, head of sales at Edgetech, said:

“It’s been fantastic to support Noella, Angharad and the wider team throughout the project.

Our involvement started long before the line was installed. We initially supplied Super Spacer and hot melt products, provided glazed samples for Derw Glass to showcase to its customer base, and supplied marketing materials highlighting the benefits of Super Spacer.

“We also worked closely with the team on factory layout considerations, machinery options, spacer usage calculations and sealant requirements, while providing full technical support throughout. It’s exactly the kind of collaborative approach we pride ourselves on.”

Making the automation move
For manufacturers considering automation, Angharad said: “You’ve just got to make the leap. It’s the way the industry is going and if you don’t go with the times, you will be left behind,” while Noella advised: “You must really think about your supplier and help you will need because you will need to lean on them for advice.”

Tony believes Derw Glass’ success demonstrates what can be achieved when manufacturers fully embrace automation and flexible spacer technology.

“Derw Glass is a great example of a forward-thinking manufacturer, and they understood the advantages automation could bring. The move to Super Spacer has helped them improve efficiency, reduce waste and create a more streamlined manufacturing process while maintaining the high standards their customers expect.”

Futureproofing
That next phase could include thin triple glazing, which Derw Glass sees as a major opportunity for future growth, and in which Edgetech can support.

For the Palmer family, however, this and any future investment is about more than machinery. It’s about protecting the future of the business for generations to come.

“The investments that we’ve done will take us forward for the next 20 years,” added Angharad. “We’re building a future we can pass on to the next generation of the family and my two boys to keep the Derw Glass legacy going, and we definitely see Edgetech as part of that journey.”