This article explains how coil to window Dallan systems can generate savings over 219.000 Euro every year for the rolling shutter window producer, what are the main factors that generate such high savings and why this production method is more sustainable and eco-friendly.
Aluminum PU-foamed rolling shutters are more and more popular in Europe and abroad thanks to their multiple advantages: energy saving, increased privacy and safety, easy automation, high quality and resistance to atmospheric agents.
The standard production cycle for rolling shutter curtains starts form 6 meter long bars, that are cut to length and assembled with a scrap rate between 10 and 15%.
Modern coil-to-window production systems, instead, start from the aluminum coil and produce cut to size rolling shutter curtains with a scrap rate close to zero.
Follow the link and discover more about coil-to-window rolling shutter production systems.
The most common production system starts from roll formed slats, cut in the length of 5,6 to 6 meters. The bars are cut to length and depending on the width of the window, a piece of bar remains unused. The following table shows scrap rates on a 5,6 meter long bar, for different curtain widths.
Rolling shutter window producers have tried different ways to optimize the scrap rate, for example by cutting different sizes on the same bar, sorting them afterwards. Clearly, these operations are time consuming and need to be assisted by an operator.
Generally, the scrap rate assumed with this production method is between 10 and 15%.
Coil-to-window production systems produce assembled and fixed curtains directly from the aluminum coil.
Production data such as the window width, height and quantities are loaded via simple excel tables to the system.
This automatic line includes:
Such line requires the presence of just one operator during the production. The following video shows the machine in operation.
25000 windows require between 2 and 2,5 million linear meters of profiles, depending on the profile size. Let's now analyze the savings in raw materials generated by the coil-to-window system for different sizes of profiles.
The following table shows the aluminum and PU foam weight per linear meter of rolling shutter slat. The cost for the aluminum and polyurethane are variable and can be required to PU and coated aluminum producers.
The slats have been selected among the most significative out of a 300 profiles catalogue. The offer of rolling shutter profiles has segmented to cover high quality profiles and first-price products ("eco" profiles). Eco profiles have generally a smaller band width and a lower thickness: Aluminum, in fact, represents 86 to 92% of the raw material cost.
The production of 2,5 million meter of products, results in the following cost in raw material. The table shows also the saving generated by reducing the raw material purchase by 10 to 15%.
The scrap on 2,5 million meter of profiles equals in average to 300000 linear meters of aluminum and PU, which in turn correspond to 30,8 tons of aluminum and 2,7 tons of polyurethane foam. These materials need also to be disposed of: in European countries they are considered a special waste, and companies need to pay for the disposal.
By reducing waste, coil-to-window production systems reduce the impact of the production on the environment, AND introduce additional savings for the rolling shutter window producer.
In the search for efficiency, innovative technologies introduce new paradigms, increasing productivity, efficiency and sustainability in the production.
Coil-to-window technology is a great opportunity for the rolling shutter window producer to introduce advanced automation, continuous processes, quality control, process control and integration with ERP systems.
In this article, I focused on how coil-to-window technology easily introduces a 10 to 15% saving in raw material, in particular producing of the same quantity and quality of final products, with less raw material and less scrap.
This makes the production of rolling shutter windows a lot more profitable, and also more sustainable and eco-friendly.