Technology

One of the pillars of success of the company is continuous striving for the highest quality of our products. We achieve this thanks to the passion, commitment and state-of-the-art production technology. The combination of automated processes and work of experienced staff allows us to implement even the most complex projects of windows and doors in a very short time and with the highest quality.

Selection of material


The final product can only be as good as the material from which it is made. That is why we attach great importance to the selection and preparation of wood for production.

We use selected wood from reliable suppliers that we work with for many years. We precisely control each batch of wood, selecting only that which bears no signs of structure weakening, features adequate moisture and shape. When buying wood laminate we pay particular attention to the accuracy of bonding, proper positioning of grain of each layer, and control whether the material is properly seasoned.

In any case, we use wood from FSC certified sustainable forestry, often harvested near the place of production, which further reduces the negative environmental impact associated with transport.

Machining of wood


In the production process we use modern, computer-controlled machinery of the renowned German company - Weinig. As the only company in Poland holding a fully automated UC-matic production line each time we achieve perfect and reproducible machining accuracy.

In addition, all unusual, customised constructions delivered on the special requests of customers and architects are also made on fully digital and automated CNC machines by Reichenbacher and Weinig Conturex. As a result, manual processing is a very rare phenomenon in our production halls, end even where it is necessary, experienced and well trained staff care about the proper quality.

With the full digitisation of computer control which takes place entirely from the desktops (a production worker does not need to enter any data manually), the total production capacity at the level of 14 500 m2 per month has been achieved.

Equipping machines with appropriate tools is also very important. We only use heads and knives of the reputed German manufacturer, Leitz. This ensures a perfectly smooth surfaces with even the most complex shapes of profiles. The advanced tool design allows us to offer you profiles of 24 different thicknesses. The design "splitowa" makes it possible to create components 68 mm to 92 mm thick, in increments of 1 mm. To make your choice easier, in our basic offer we singled out a few, in our opinion, the most practical profile thicknesses.

Modern production halls with a total area of almost 15 000 m2 allow us to maintain clean and uniform production conditions and provide our workers with comfort required for precision machining.

In the large part, the automated process also enables a very fast execution of orders. Even with complex projects it may take only 21 days.

Impregnating and applying the primer


The great technological advances took place in recent years as regards the composition and properties of lacquers with which we paint the windows and doors. The coating processes are 4-step and for each of these steps special type of coating is applied. Each layer performs a special function, for example, closes the pores of wood, reduces discolouration, ensures proper adhesion of layers as well as mechanical ans chemical resistance.

As a result of the recent investments, we have become the owner of one of the most modern paint shops in Europe. The stage of manual paint application has been eliminated, thus we achieved perfect reproducibility and consistently high quality of paint coating.

The first layer - impregnation, is applied by spraying in a dedicated chamber before gluing frames and sashes, which ensures complete protection of each element. A special drying system accelerates the process of absorption, and brushes automatically adjusting to the profile and size of the component level any rise in graining after the impregnation

The primer is applied using the SuperJet float coating technology The entire process takes place in special chambers controlled by spraying pneumatic pumps. This eliminates the risk of foam formation and the internal chamber shape and arrangement of the nozzles provide even application of the primer. The chambers are also equipped with a complete recovery system, so the whole excess paint dribbling down due to the gravity is recovered and purified. The device is equipped with three such chambers, so that in the case of colour change the application chamber is simply changed instead of washing. The process takes place several minutes so there is no need to stop the production line.

Impregnating and applying the primer
Impregnating and applying the primer
Impregnating and applying the primer
Interlayer and topcoat
Interlayer and topcoat
Interlayer and topcoat
Interlayer and topcoat
Interlayer and topcoat

Interlayer and topcoat


Interlayer is applied using Dynflow ® technology. It is a high-tech fully automated system for waterborne paint coating application. This technology thanks to the optimized conditions within the coating paint line (relative humidity of 85-90%, 20 g/m3 H2O/m3 of air) helps fully exploit the properties of paint. The result is an outstanding quality of the coatings archived with very low loss of varnish material.

Dynflow ® technology reduces deviation of paint spray pattern and increases its force, thus, paint drops reach all profile bends. Drops of paint whose viscosity is maintained almost at the same level are not subject to evaporation, and their mass and capacity practically do not decrease. As a result of very good properties of paint spreading with its increased thixotropy, Dynflow ® eliminates the need for further paint retouch work and sanding. The technology is ideally suited for painting complex details with corners and notches as the applied coating in these critical and very difficult areas is uniform.

Surface painting is also automated, and all through the use of electrostatic applicationsand recovery system Prolac. Electrostatic application is powered by high voltage of 100 kV/1 mA. Charging the paint particles with static electricity occurs in the tank and through electrode on the nozzle of the gun. The high degree of electrostatic charging of paint particles (e.g. 70 kV) drastically reduces overspray phenomenon. An additional effect is very good trim quality of the lacquered edges. Large material losses occurring in the traditional spray painting constitute additional burden for the the environment. With Prolac technology, the overspray paint can be collected, sorted and introduced back into circulation directly at the user. Rolling cylinders for collecting overspray are placed inside the spray booth between the lacquered part and filters to capture the post-painting mist. The spray guns are positioned in such a way that the jet is directed towards the cylinder. As a result, the overspray is collected continuously at the surface of the cylinder causing the full recovery of the paint.

To paint the most complex, unusual and longest components we use Fanuc painting robot controlled by Reiter systems. The robot adapts to a given component regardless of its size, shape and colour. All thanks to 3D scanners, cameras and advanced software. Scanners sweep the component body with lasers which are reflected on the surface and recorded by cameras. Then, by interpolation using a triangular mesh CAD 3D model is generated. The software analyses the model and "in flight" generates the kinematic software for the robot. This ensures extreme precision of application of individual paint layers, which translates into a perfectly uniform coating which far exceeds current market standards, where most of the producers paint windows manually using a gun. This significantly increases the durability of coatings, and thus, windows and doors themselves. The robot can also choose paint colours itself, and the change takes itless than 2 minutes.

Complete automation of paint processes also affects performance. The entire paint shop has been designed in such a way that none of cross beams carrying the window has ever stopped and constant feed speed of 3 meters per minute is maintained. Total monthly capacity of our paint shop is estimated at 27 000 m2, operating only at one shift. It is an amazing achievement considering the diversification of production.

It is worth mentioning that we use water-based paints that are safe for workers of the paint shop, final product users and the environment.

Hardware assembly


The recent investments allowed us to automate the installation of hardware. With digital screwdrivers controlled by specialist production software, the installation of window sash hardware is fully automated. This ensures a perfect assembly of every screw with an accuracy of one-tenth mm and provides a perfectly equal tightening force which translates into the proper functioning and comfort of use of the window.

In addition, we use only high-quality hardware of German companies - Siegenia, Roto and GU for the production. These are the manufacturers with very extensive experience in the industry, which makes the selection of components is always perfect and even the largest structures open effortlessly.

Glass installation


Contemporary, energy-saving windows with large glazing contain very advanced glazing units. They are usually three-glass but it is possible to use four panes of glass. Such panels often weigh hundreds of kilograms. Due to the recently installed a modern glazing line, even such packets pose no problem. All glazing stations are fitted with special suction cups, so you can easily pick up the package weighing up to 400 kg.

In addition, the glazing department has been equipped with an automated window warehouse. All packets are checked for quality and then entered into the buffer using barcodes. As a result, each glazing station may call within several seconds the right pane of glass via the barcode, which then is automatically mounted to the suction cup.

Packaging and shipping


We make sure that finely crafted windows are delivered to customers intact, even if they have to cross the Atlantic Ocean. We always match the type of packaging to the means of transport. We have a separate hall where we carefully pack the windows, which minimizes the amount of damage during transport and installation. Special foliating machines automatically wrap windows. We also use disposable pallets for shipments over long distances, and all the windows are fitted with special handles to facilitate unloading.

Pozbud T&R Spółka Akcyjna