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New World Composite Doors Made Using Crestabond Structural Adhesives

13 March 2012

New World has invested time and engineering resources to trial Crystic Crestabond which has resulted in performance improvements and cost savings whilst offering commercial benefits.

New World, based in Ballymena, Northern Ireland manufactures exterior and interior UPVC and GRP composite domestic doors. According to Scott Bader, after successful shop floor production trials, New World specified Crestabond M1-05 for the key inner sash frame and door skin structural bonding applications.  They say that since mid 2011, Crestabond M1-05 has been phased in and is now used on 85% of the New World range of doors.  This includes being used for their new all-GRP Apeer 70 and 44 doors, constructed with a bonded inner sash made from a pultruded GRP profile which replaced UPVC; the advantage of having the entire door designed with the same material is the elimination of any distortion once installed. 

Scott Bader say that switching to using Crestabond M1-05 to bond together the cut to size GRP or UPVC profiles used to make the rectangular inner sash frame of their door designs has had a major impact on increasing New World’s overall production line productivity and build quality, as well as reducing scrap levels.  Asa McGillian, Managing Director of New World explained “With Crestabond M1-05, due to its significantly faster fixture time we have made significant productivity gains in our door production. The overall cost benefit analysis is commercially very attractive for the business relative to the price of Crestabond.” 

For the pultruded GRP inner sash frames, New World now has a 25% faster cycle time in the bond and assembly stage, down from 16 to only 12 minutes.  Productivity gains were even better for the UPVC inner sash production line, where the cycle time reduced by 73% since switching to Crestabond M1-05 with its 12 minute fixture time; it replaced a two part polyurethane (PU) adhesive which needed 45 minutes before the assembled frame could be moved to the next production stage. 

McGillian went on to say “Product quality has definitely improved, particularly during colder periods, as Crestabond has proved to be a tougher, more reliable and consistent adhesive, which gives us fewer breakages and scrap loss compared with other MMA and polyurethane adhesives previously used.”  

To help with productivity, New World use automated 10:1 dispensing machines from the UK equipment manufacturer Liquid Control in combination with 20 litre pails of Crestabond M1-05.  However, Scott Bader explain that for certain bonding applications, such as a 4mm profile, using a hand held pneumatic gun with 400ml cartridges of Crestabond has proved faster to use, with much better application control of small beads of adhesive, so is less wasteful.  New World has found that using cartridges is overall more cost effective for the smaller, more intricate bonding applications.





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