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New World Limited, based in Ballymena, Northern Ireland is a leading manufacturer of exterior and interior UPVC and GRP composite domestic doors. In this highly competitive sector of the building market, New World needs to be extremely cost and productivity focused, but with no compromise on build quality.
Performance and Cost Benefits
The ability of the right type of structural adhesive to produce a lower weight assembled part with superior mechanical performance such as: improved flexural strength, better creep properties and higher impact resistance are compelling enough reasons for a manufacturing company to economically justify making design changes and rethink production methods. The added commercial benefits of major productivity gains and overall lower production costs, has convinced a number of forward thinking companies, such as New World Ltd., to invest time and engineering resources to trial Crystic® Crestabond® and discover for themselves the performance improvements and significant cost savings they could achieve.
Faster Door Production
New World Limited, based in Ballymena, Northern Ireland is a leading manufacturer of exterior and interior UPVC and GRP composite domestic doors. They have an established customer base in the UK and Ireland, which is currently expanding with growing export sales in Europe and the USA. In this highly competitive sector of the building market, New World needs to be extremely cost and productivity focused, but with no compromise on build quality. With this in mind, after successful shop floor production trials, Crestabond M1-05 was specified for the key inner sash frame and door skin structural bonding applications. 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.
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 Ltd in combination with 20 litre pails of Crestabond M1-05. However, for certain bonding applications, such as a 4mm profile, then 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.
Crestabond Range for Composites, Metals and Plastics
Since their launch in 2010, Scott Bader has been converting manufacturers over to their Crestabondrange of primer-less methyl methacrylate (MMA) structural adhesives. The Crestabondrange offers a cost effective alternative bonding solution to the ever growing demand for better, faster performing universal structural adhesives capable of bonding not only composites together, but also commonly used metal and plastic substrates such as: aluminium, stainless steel, ABS, acrylic and PC.
The Crestabond range is aimed at manufacturing companies in the bus, truck, rail, construction, marine and wind energy markets looking for a tough, cost effective, high performance bonding and gap filling structural adhesive, with long term reliability. An additional production benefit is improved shop floor working conditions; using an adhesive for assembly rather than over laminating eliminates grinding dust, reduces styrene emissions and provides a cleaner shop floor environment.
All Crestabond adhesives in the current range have a 10:1 mix ratio, supplied in a choice of pack sizes from 400ml coaxial cartridges, which can be applied using manual or pneumatic hand gun applicators, to bulk pack sizes in 20 litre (18kg) pails or 200 litre (180 kg) drums for use with proprietary dosing machines.
More information: www.scottbader.com - www.nwd.co.uk