New World Composite Doors Made More Cost ... - Scott Bader

PRESS RELEASE March ‘12Higher Performance New World Composite Doors Made MoreCost Effectively Using Crestabond ® Structural AdhesivesFor larger bonding applications, such as fixingdoor skins to the inner frame, New World appliesCrestabond M1-05 from 20 litre pails using anautomated 10:1 dispensing machine.By switching to Crestabond M1-05, New Worldgained a 25% faster cycle time for their all-GRPdoors, with even better productivity gains of 73%for doors with UPVC inner sashes.Performance and Cost BenefitsThe ability of the right type of structural adhesive to produce a lower weight assembled part withsuperior mechanical performance such as: improved flexural strength, better creep properties andhigher impact resistance are compelling enough reasons for a manufacturing company toeconomically justify making design changes and rethink production methods. The added commercialbenefits of major productivity gains and overall lower production costs, has convinced a number offorward thinking companies, such as New World Ltd., to invest time and engineering resources to1

trial Crystic ® Crestabond ® and discover for themselves the performance improvements andsignificant cost savings they could achieve.Faster Door ProductionNew World Limited, based in Ballymena, Northern Ireland is a leading manufacturer of exterior andinterior UPVC and GRP composite domestic doors. They have an established customer base in theUK 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 andproductivity focused, but with no compromise on build quality. With this in mind, after successfulshop floor production trials, Crestabond M1-05 was specified for the key inner sash frame and doorskin structural bonding applications. Since mid 2011, Crestabond M1-05 has been phased in and isnow used on 85% of the New World range of doors. This includes being used for their new all-GRPApeer 70 and 44 doors, constructed with a bonded inner sash made from a pultruded GRP profilewhich replaced UPVC; the advantage of having the entire door designed with the same material isthe elimination of any distortion once installed.Switching to using Crestabond M1-05 to bond together the cut to size GRP or UPVC profiles used tomake the rectangular inner sash frame of their door designs has had a major impact on increasingNew 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 itssignificantly 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 priceof Crestabond.” For the pultruded GRP inner sash frames, New World now has a 25% faster cycletime in the bond and assembly stage, down from 16 to only 12 minutes. Productivity gains wereeven better for the UPVC inner sash production line, where the cycle time reduced by 73% sinceswitching 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 nextproduction stage. McGillian went on to say: “Product quality has definitely improved, particularlyduring colder periods, as Crestabond has proved to be a tougher, more reliable and consistentadhesive, which gives us fewer breakages and scrap loss compared with other MMA andpolyurethane adhesives previously used.”To help with productivity, New World use automated 10:1 dispensing machines from the UKequipment 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 pneumaticgun with 400ml cartridges of Crestabond has proved faster to use, with much better applicationcontrol of small beads of adhesive, so is less wasteful. New World has found that using cartridges isoverall more cost effective for the smaller, more intricate bonding applications.Crestabond Range for Composites, Metals and PlasticsSince their launch in 2010, Scott Bader has been converting manufacturers over to their Crestabondrange of primer-less methyl methacrylate (MMA) structural adhesives. The Crestabond range offersa cost effective alternative bonding solution to the ever growing demand for better, faster performinguniversal structural adhesives capable of bonding not only composites together, but also commonlyused 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 andgap filling structural adhesive, with long term reliability. An additional production benefit is improved2

shop floor working conditions; using an adhesive for assembly rather than over laminating eliminatesgrinding 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 packsizes from 400ml coaxial cartridges, which can be applied using manual or pneumatic hand gunapplicators, to bulk pack sizes in 20 litre (18kg) pails or 200 litre (180 kg) drums for use withproprietary dosing machines.For more information about the range of Crystic Crestomer and Crestabond structural adhesivesavailable from Scott Bader, go to www.scottbader.com/adhesives . Information about New Worldand their range of doors can be found on line at www.nwd.co.uk .About Scott BaderScott Bader was established in 1921. Today it is a £180 million multinational chemical company,employing 560 people worldwide. It is a common trusteeship company, having no externalshareholders, with a strong commitment to support its customers, workforce and the environment.Scott Bader’s headquarters is based in the UK where they have purpose-built, state-of-the-arttechnical facilities that provide R & D as well as complete evaluation, testing and applicationsupport. They have manufacturing facilities in the UK, France, Croatia, The Middle East and SouthAfrica. For further information regarding Scott Bader, please call +44 (0)1933 663100, visitwww.scottbader.com or e-mail info@scottbader.com.3