Leap-frogging into action: K-seal makes the most of ashton’s superspacer solution

K-Seal Glass’ commissioning of Ashton Industrial’s patented Leap-Frog I.G. technology takes the company’s five-year capital investment plan sailing through the £1 million barrier. The line is designed for high-speed high-spec manufacturing of insulating glass incorporating Edgetech’s Warm Edge SuperSpacer, a non-metal structural foam flexible spacer. Aluminium is 950 times more conductive of heat, says Edgetech.

Further investments are imminent with the addition of upgraded QC, a modernised despatch area, and installation of a new state-of-the-art tempering furnace. More than 60 people are employed at K-Seal’s busy 30,000 ft2 facility in Birkenhead, which started life in a small factory just 10 years ago with a workforce of four, including founding Directors Keith and Karen Nethercott.

Keith explains: ‘Part of our policy is to invest in the latest technologies to ensure our products not only meet, but surpass all relevant regulations and requirements. We are now increasing output capacity while still providing the quality that earned us EN1279.’

K-Seal also promotes Pilkington Activ self-cleaning glass in the form of easy-clean units, a great selling point especially for conservatory roofs and difficult to access glazing areas.

Co-Director and partner Stephen Woolley is equally enthusiastic. ‘The Ashton Leap-Frog provides us with a continuous production process compatible with Edgetech’s SuperSpacer which we’ve been using for 10 years on shaped units and special projects. We’re now dramatically increasing the volume of those units. It is innovative technology and we use that to achieve superb thermal efficiency. It differentiates us from the competition and helps us tap in to the commercial market with all its stringent requirements’.

Karen Nethercott makes sure there’s investment in people as well as automation. There are individually tailored training packages for staff. ‘We are pleased that a high percentage of employees has enrolled on NVQ training courses, which benefits the company and its clientele and, ultimately of course, the employees themselves’.

K-Seal is an important key player for Edgetech, which has seen sales of its SuperSpacer rise in UK and Ireland. Sales Manager Andy Jones enthuses on how his product helps manufacturers’ units reach and exceed Part L or Part J. ‘The direction in which Part L is heading means increasing numbers of I.G. manufacturers are seeing the benefits our product brings to their business.’

‘Since introducing the Leap-Frog, the response from existing and new customers has been fantastic,’ says Keith Nethercott. ‘We were expecting a good uptake, but even we have been surprised at how quickly our new range of Kplus+ units have taken off. In the next few months we expect the volume to increase by 50%. Several of our larger accounts are already using the superior Kplus+ warm edge product range as a very successful selling tool. It is now at the centre of an intensive joint venture local radio advertising campaign with one of our major customers’.

www.kseal.co.uk

www.ashton-industrial.com

www.superspacer.com

The birth of Leap Frog

Ashton Industrial’s high-performance line was conceived during a transatlantic flight following comments from a USA sealed unit manufacturer about lost production. He had good, fast operatives, but for as long as his tilting spacer application table was lowered there was a gap in the production line, so everything had to stop and wait.

The estimated loss in output exceeded 20% for that alone.

Some way of allowing the rest of the line to continue operating without waiting was obviously the answer.

In one fast, smooth four-second swoop Ashton’s application table tilts down and simultaneously drives forward right out of the vertical production line, while the gap thus created is instantly filled by another vertical conveyor moving in behind it. The next glass, which will be paired with the one being applied with SuperSpacer, can carry on through to the following automatic assembly and pressing station without waiting. The whole super-fast action is via PLC controlled precision servo drives capable of tilting down and back up in just 8 seconds. Glass is easily manoeuvred on the table’s air floatation, which switches over to suck the glass down and hold it firmly while SuperSpacer is applied.

The washer constantly monitors water quality and has its own RO demineraliser, compensates automatically for all types, sizes and thickness of glass, as does the assembly and pressing station, all without manual intervention. Shapes and conservatory roof panels are all catered for.