With one of the most advanced manufacturing capabilities of any systems house supplying the UK, aluplast’s next generation products are built on a foundation of next level manufacturing.
Over four decades, systems house aluplast has earned its stripes as a global leader in window and door system expertise.
At the heart of its next-generation product offering is a 50-hectare, state-of-the-art smart facility, where the latest automated technology meets cutting-edge innovation.
“Our substantial manufacturing capabilities give us the benefits of speed, high-quality and scale and that translates to significant opportunities for our customers,” says Ian Cocken, spokesperson, aluplast. “Our facilities, manufacturing processes, and the products those things create, really make us stand out against our competitors.”
The aluplast manufacturing process begins with two high-capacity mixing lines, producing more than 200 tonnes of dry blend daily, with the installation of a third line set to increase capacity further.
“We’re set to exceed 300 tonnes per day by the end of July this year,” confirms Ian. “We’re setting a new benchmark when it comes to efficiency and it’s this kind of scale advancement that allows us to forge ahead and maintain a truly competitive offer,” he adds.
Key components including PVC, fillers, stabilisers and modifiers, are precisely combined to ensure the durability, performance, and consistency of aluplast’s profile systems. Once fully homogenised, the dry blend moves into aluplast’s extrusion lines, ready to be transformed into premium quality window and door profiles.
“With up to 51 active extrusion lines running dual and twin strand systems, we have the capacity to output more than 100 lines of profile at any one time,” explains Ian. “We’re continuously investing in cutting-edge technology to facilitate this and ensure that every profile meets the highest standards of quality and consistency.”
High-speed extruders with rapid change dies are the latest state-of-the-art investment to enhance aluplast’s capability, combining speed with precision and surface perfection.
“These lines can produce 6m profiles every minute,” says Ian. “It’s today’s high-performance extrusion, built for the demands of tomorrow.”
aluplast’s unique ecotech process embodies this forward-thinking mind-set, by setting what the systems house says is a new standard in sustainable extrusion. Co-extruding both recycled and virgin PVC-U in a single profile, ecotech locks recycled material into the profile’s core, while the outer walls maintain a flawless, high-gloss finish.
“With the ecotech process, we’re reducing environmental impact without sacrificing quality,” says Ian. “It’s a smarter, cleaner way to extrude PVC-U and as a result of this method of manufacture, we’re, building sustainability into every aluplast profile.”
With next generation innovations including the ultra energy-efficient Ideal neo casement window and neo smart-slide inline sliding door, as well as a brand new aluminium window and door offer unveiled at this year’s FIT Show, aluplast products combine exceptional levels of performance with flexibility in finish and design.
Part of aluplast’s energeto family, Ideal neo achieves U-values as low as 1.2W/m2K, using standard double-glazed units and 0.67W/m2K triple glazed.
Built around hardware from Maco, Siegenia and Roto, neo smart-slide delivers superior performance, achieving BS6375 for weather tightness and PAS24 for security. Achieving heights of up to 2.5m and a span of 6m with just two panels, as well as Passive House standard U-values as low as 0.63W/m2K, neo smart-slide brings all the advantages of PVC-U into a high-end space, usually reserved for more expensive aluminium products.
The complete aluplast range is available in the systems house’s premium aludec and woodec foil finish options. Replicating a natural timber appearance, woodec is available in six ultra life-like woodgrains, including Turner Oak Malt for a subtle light oak finish; Turner Oak Walnut for a mid-tone and the darker Turner Oak Toffee.
Creating an aesthetic almost indistinguishable from natural timber in a low maintenance PVC-U product, aludec foil applies the same principles as woodec to create a premium aluminium look that can even replicate textured powder coating, with Anthracite Grey and Jet Black among its seven finish options.
Combining traditional rolling foil lines with the latest high-speed CNC technology to deliver more than 40 foil finishes, aluplast can handle everything from high-volume orders to one-off colour requests, with a dedicated a specialist line for added flexibility.
“woodec and aludec are truly next generation foils,” confirms Ian. “Not only do they look like the real thing, but they bring that authentic tactile experience for the end-user that really adds to their premium status.”
Reinforcing the strength of their appeal, aludec and woodec have been central to the concept of aluplast’s Engineered Door. Unveiled last year by launch partner, Regalead, the Engineered Door revitalises the PVC-U door sector by elevating aesthetics and performance to produce a viable alternative to the composite door, .
“With options for both our Ideal 70 and Ideal 4000 profiles, the addition of aludec and woodec to our Engineered Door allows it to replicate timber and aluminium doors so closely, that it brings a new level of authenticity that can really extend market reach,” adds Ian.
“Our next generation manufacturing capabilities and sustainable processes allow us to produce competitive, next generation products and finishes with true consumer appeal, and we’ll continue to innovate to provide the best quality and the best value for our customers today, and tomorrow,” he concludes. matters to us,” he concludes.
For more information call 01684 273401 email info@aluplast.co.uk or visit www.aluplast.co.uklast.co.uk