Most Innovative Machine

2010 Crystal Achievement Award Winners

Frame, Sash or Door Fabrication
 

The ColorTru machine uses heat and pressure to bond decorative foils to window and door profiles.

ColorTru Decorative Foil Bonding System

GED Integrated Solutions

Twinsburg, Ohio

Said to be the most cost effective and production friendly alternative to painting and laminating, the ColorTru system automatically transfers solid color and woodgrain foil to vinyl window and door profiles.

Offering unlimited graphic/color and design capabilities, foils are comprised of multiple layers of material.  They do not interfere with cutting, welding or cleaning operations, the supplier notes. In addition, the foils eliminate the need for methyl ethyl ketone solvents/cleaning, and have no separate adhesive process.  As an alternative to painting, the process eliminates labor-intensive coating, surface prep and priming processes.

The machine automatically transfers the foil, using heat and pressure bond it to the vinyl profile. The process ensures no de-lamination, no trimming of excess, and an instant cure that allows parts to be processed immediately, according to the supplier. A controlled series of driven rollers process the profile through the machine. Contoured silicon rollers conform the foil to shaped profiles, affording a throughput of up to 40 feet per minute, depending on the profile. A modular system, ColorTru processing stations can be added sequentially to make additional profiles. Manufacturers can use a single pass station or multiple foiling stations for processing with quick changeover from profile-to-profile and color-to-color in minutes.

Glass/IG Processing
 

sashline

Bystronic Glass.

Aurora, Colo.

From start to finish, the sashline requires only four to five workers to operate and has
a throughput of up to 800 integrated sash windows per shift.

The Bystronic sashline produces Sashlite integrated sash units, which eliminate separate IG units by integraing the spacer directly into the window sash.

Configured in the form of a “Y,” the sashline features a glass processing line on one leg  and a sash processing line on the other. Glass and sash elements move down the line via a flat belt drive and meet at the junction of the legs at a swivel station where they are positioned for final assembly. The glass processing line incorporates a washing machine and a glass inspection station. The sash processing line consists of an automated desiccant applicator, a muntin station and an automated sealant applicator.

When the two lines come together, before reaching an assembly robot, a “preparing robot” positions the sash in the center of the assembly and the two glass lites on the outer sides. Once the units are in place, the assembly robot creates a vacuum in the chamber, and with suction cups, grabs one edge of each glass plate, bending them out slightly. At the same time, gas is introduced into the air cavity while sensors measure the amount and flow of gas. Once the air space has been filled with gas, the glass is released and robotic "fingers” press the plates onto the sealant for a perfect seal and a complete, precision created window unit.

From start to finish, the sashline requires only four to five workers to operate and has a throughput of up to 800 integrated sash windows per shift. The new line, capable of producing both dual- and triple-glazed units, is said to feature the highest level of automation in the industry and allows the fabricator to achieve maximum efficiencies and a superior ROI. The automated equipment also allows manufacturers to make windows that comply with any current standards, as well as future standards such as R-5 and beyond.

Other 2010 Crystal Achivement Award Winners:

TECHNOLOGY

Most Innovative Window

Most Innovative Door

Most Innovative Component

Unique Innovation

MANUFACTURING

Most Innovative Plant

MARKETING

Most Innovative Marketing Progam

Best Product Literature

 Best Industry Web Site

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