RegaLead’s joint managing director, Guy Hubble, talks about the new Forel automated flexible spacer IGU line that is now up and running at the company’s manufacturing facility in Hawick.
Thin triple glazed units have been high on the industry agenda for the last year, and it’s easy to see why. They offer all the benefits of triple glazing in a 28mm unit that can be treated like double glazing – same profile, same frame fabrication, same installation process.
The arrival of the technology coincided perfectly with our investment and growth plans. The time had come to look at automating more of our IGU manufacturing, and with Forel’s new line, we could make that happen while introducing thin triples to our range. We have invested over £1 million in the new machinery, which has already increased our capacity and set a new standard for our service offering.
The new automated line is a piece of precision engineering. Designed for assembling and sealing units with Thermoflex warm edge spacer and hotmelt, the line not only increases our capacity but delivers a better quality unit on every job. The fully automated hotmelt robot can seal our most popular double-glazed units in as little as 20 seconds, and we are already achieving output numbers of 800+ per shift.
Manufacturing flexibility is crucial for us, and the line supports our continued commitment to offering solutions for all sectors of the door industry. It can produce thin-triple units, units up to 65mm thick for super-insulated, double-rebated door systems, and allows us to manage the varying designs, sizes, and shapes of our decorative units.
Quality matters
Quality is crucial, especially in the door market where glass is so much more than a functional component. It’s a decorative addition that can transform a standard door style into a truly unique entrance design, and with discerning, design-savvy homeowners, there’s no room for imperfections.
The investment with Forel gives us the ability to manufacture the highest quality units, both visually and technically. The line was also specified with a DeltaMax Glass Inspector advanced digital glass scanner that is engineered to catch any glass defects before the unit is assembled, supporting our robust glass quality control processes for perfect units every time.
Future-proofed IGUs
The new line has been installed at our decorative glass and IGU manufacturing facility in Hawick and was the first Forel automated line with flexible spacer and thin-triple capability to be installed in the UK.
It is already improving efficiency, and we are certain this investment will future-proof our IGU manufacturing and prepare us for any future market demand for thin-triples. Automating a large proportion of our IGUs also frees up capacity on the manual sealing side, allowing the team to have a greater focus on creating bespoke glass designs for customers.
This is a timely benefit, as the door market continues to rapidly evolve, and the demand for higher-performance, design-led products shows no signs of slowing down. By combining the latest automated technology with our established expertise in decorative glass, we have created a more robust, versatile solution to support the industry and keep pace with the shifting needs of fabricators, installers, and homeowners.
