Date: 25 March 2011
Source: HSC Communications
Precision engineering, superior quality standards and the cost saving benefits of the Hegla range were the key elements to leading independent commercial sealed unit manufacturer Dual Seal investing over £1million in state-of-the-art Hegla cutting equipment.

In an industry first, Hegla’s machinery will now enable the company to set new standards in the architectural market.

The Hegla system provides fully automated cutting capability faster than ever previously known, with two tables synchronised to work together to enable Dual Seal to cut jumbo sized glasses from a diverse range of products for items such as large curtain walling projects. A new, dedicated cutting bay now houses the progressive Hegla installation which has already helped to substantially increase output.

The advanced cutting equipment installation combines two sophisticated, re-master sub plate management systems with two jumbo cutting tables. These two advanced Hegla jumbo cutting tables encompass a Pro-Lam combination float/laminated cutting table with twin soft coat edge deletion, as well as a Hegla Optimax jumbo float table, both of which are served from a gantry system that includes two tandem concertina racking systems holding up to 47 glass substances.

The challenge for the Hegla team regarding this installation was to supply a system capable of holding a large and varied range of glass types including float and laminated, whilst automating the cutting process to achieve greater throughput and reducing cutting time and waste. Whilst other manufacturers’ products were considered, the technical benefits and cost savings provided by the Hegla equipment were clear. In particular the unique, cost saving features perfectly suited Dual Seal’s demands with the level of investment further substantiated by the design, engineering and product performance of the Hegla range.

Hegla’s innovative laminate foil trimming solution ensures that the reference edges of the glass have no PVB overlap, guaranteeing perfectly flat edges that sit better and are more aligned on the sealed unit manufacturing lines. Other modern features such as twin edge deletion and the new Guardian “Hi-Selective” edge deletion system were also fitted. The payback advantages are already proving beneficial for Dual Seal as there is no longer wastage in respect of sizeable offcuts, which since installation have reduced by half from 30% to just 15%. Geoff Hancock, Managing Director at Dual Seal accredits this to the efficiency of the Hegla equipment. He comments: “I would attribute offcut reduction savings to 5% glass optimisation, 5% machinery and 5% optimisation of equipment. There is complete synergy in respect of all cutting aspects so we are now realising the potential of Hegla’s equipment.”

In another first, the warehouse management system is proving very important as this controls stock levels, residual plate allocation, and management statistics, therefore with the press of a button operators can obtain a printout giving them batch traceability, stock control and stock evaluation which provides an instant overview. For the Hegla team, fully understanding customers’ manufacturing requirements and developing tailored plans accordingly is the key to success and of paramount importance. CAD drawings and spreadsheets were meticulously planned and produced before installation at Dual Seal by a dedicated team of specialist Hegla engineers who ensured that installation, trialling and start up was smooth and efficient.

Geoff Hancock was particularly impressed by Hegla’s ‘new users’ comprehensive training programme which proved invaluable and ensured an easy transition from initial installation to final handover, thanks to the specialist engineering team. Ultimately, the finished installation now gives Dual Seal more control, more diversification possibilities and helps to improve quality standards. Geoff Hancock Managing Director at Dual Seal considered technical investment at the company of vital importance because of the increasing market demands in product specification, quality and building regulation specifications. Mr Hancock comments, “As one of the largest installations of its kind in the UK we know we have expanded our horizons dramatically. Quite simply, the equipment was chosen because of the superiority and reliability of the Hegla brand and the edge that will give us.

This company has developed a reliable standing in the commercial sector throughout the UK and with this installation we intend to further raise our standards. We approached Hegla because of the formidable reputation the company has in the market, knowing we could achieve excellent results with the machinery.” “We are now in a position to increase production and diversify the products knowing that we can attain consistently high standards for our customers at a realistic price. This investment has extended our size capabilities adding another dimension to our current extensive range and will help to strengthen our market position within the UK” Steve Goble, Managing Director, Hegla UK comments: “Hegla provides customers with efficient, tailor-made solutions. We look forward to continuing our working relationship with Dual Seal as their corporate position strengthens and their key target sectors expand.”


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