We operate two automated horizontal lines designed to facilitate speedy processing of material to allow us to offer rapid turnaround (ordinarily three-to-five working days).
The Company operates a policy of continuous investment. 2016-2017 has seen us invest heavily in plant and infrastructure specifically to build flexibility into our process, as we firmly believe that this is key to delivering exceptional standards of customer service. The combination of two differing sized modern lines and a bespoke ERP system allows us to change powder many times a day and yet still achieve high throughput.
Goods inward receives & locates all incoming material ready for processing, any discrepancies are reported within one day of receipt. Material is matched to a unique planning ID for that order, so that it can be identified throughout each point of the production process. This gives total traceability in accordance with our BS EN ISO 9001:2015 accreditation.
We carry out immersion chromrate pretreatment to BS EN 12206-1:2004 a superior process witch ensures optimum surface finish & paint adhesion which allows us to guarantee our powder coating for up to 30 years.
All material is degreased, acid etched, rinsed, chromated, further rinsed & then drained prior to jigging. This allows for a pristine finish to aluminium in readiness for painting. There is minimal delay between our very efficient pretreatment process.
The pretreatment section also houses our stripping & strip anodising tanks which allows us to strip material which has been previously powder coated or anodised.
We have worked alongside our chemical suppliers for many years to continuously improve our pretreatment process as well as to address the environmental impact of our operations.
Jigging, Painting and Curing
Material is hung on our flight bars ready for painting, each item is hung to provide perfect coverage & to ensure safe passage through our tunnel ovens. Where a standard jig cannot be used the jigging team work creatively using flight bars & a combination of cross-bars, wire, fixings and clips in order to achieve the desired result.
We operate three painters over two spray booths to oversee the coating process, ensuring that the automated electrostatic equipment performs as expected, whilst also manually ‘touching in’ as appropriate. The painters work to exacting standards to ensure consistent quality and a durable finish. Our usual coating observes a minimum thickness of 40 microns, although 60 micron coating for industrial/marine/swimming pool environments is also carried out where requested.
We can coat a wide variety of colours and hold several RAL and British standard colours in stock, as well as special ‘house’ matts and metallic from Axalta, Syntha Pulvin, Tiger and Interpon D systems. We can obtain various bespoke architectural grade metallic and textured powders, which are becoming increasingly popular.
We closely monitor our ovens using temperature profiling and data logging equipment from Datapaq to ensure excellence in the curing process.
Inspections and testing of every flight bar of material coated is carried out, along with a test panel for each colour we powder coat.
We test for visual appearance, film thickness, gloss level, adhesion, impact resistance, flexibility, cracking, flaking, blistering and weathering. All work meets the exacting standards required in the architectural sector, both domestic and commercial.
Our excellence is recognised by our approved applicator status from all of the leading powder manufacturers, and by our BS EN ISO 9001:2015 quality assured accreditation.
High quality packaging materials are used to ensure the safe transportation of material in metal stillages. Material such as corrugated paper, protective taping and layflat tubing are all available. We are happy to discuss customer specific packing requirements where required.
We have our own fleet of vehicles consisting of three 18 tonne wagons. We deliver to our customers 5 days a week (weekends available on request). We also collect from various extruders such as Technal, Senior Architectural Systems, KBS typically 3 times a week. Our fleet currently cover from Scotland to Leicestershire. We can also offer nationwide courier/pallet courier delivery upon request (at additional cost).
Additional services we offer are:
- Protective taping of profile
- Stripping of previous powder coated material
- Stripping of anodised material
- Touch up paint or aerosols
- Rolling of Schüco profiles
We have extensive experience of coating profile from all major systems suppliers, including Alumil, Beaufort, Comar, Ikon/Jack, Kawneer, Metal Technology, Reynaers Aluminium, Sapa Building Systems, Schüco, Senior Architectural Systems, Smart Systems, Technal, and Universal Aluminium Systems. We use 7000mm x 1500mm flight bars which allow us to process section up to 7.0 metres in length.
Stripping of previously coated material and of anodised sections is available and stripwork is fully covered by our guarantee. Overcoating is also available for emergency situations, but it is important to note that overcoated sections are not covered by any guarantee (if in doubt, please contact our Customer Services team for advice).
We also coat sheet and pressings (such as angles and flashings) which do not exceed an oven envelope of 1.55m high x 0.45m wide x 7.0m length, and which can be accommodated in a 6500mm x 600mm x 1500mm depth Pretreatment tank. If you have a query on whether a particular item can be coated, then please use our Enquiry Form, attaching a dimensioned PDF drawing.