Reflections Windows in Boston approached KallKwik with a growing challenge: an increasing volume of customer orders paired with a shortage of skilled staff to operate multiple pieces of machinery meant that meeting deadlines while maintaining high quality had become increasingly difficult.
KallKwik’s Business Development Manager, Andy Worrall, drawing on extensive experience leading production teams at respected manufacturers such as Polyframe and Glazerite, collaborated closely with Technical Director Josh Goodwin—who brings over 18 years of in-depth machinery expertise—to develop a practical, cost-effective, and space-saving solution tailored to Reflections’ needs.
The answer was the Fenstek C3 Sawing and Machining Centre. This powerful machine eliminated the need for six separate machines, enabling one operator to complete an entire week’s worth of cutting and prepping in just a single day. Its exceptional precision—accurate to within 0.1mm for tasks such as handle holes, trickle vents, drainage, and V-notches—marked a substantial upgrade in production accuracy and consistency. At 17 metres in length, the machine and its integrated safety guarding fit seamlessly within the factory’s existing floor plan.
Carl from Reflections shared the benefits firsthand:
“I no longer need to wear a face mask when cutting because it’s all enclosed, and the noise is much lower. Not to mention, my back is a lot better because the loading is easier and I don’t have to lean over on the old hand drainage machine anymore.”
From order to installation, the full process was completed in just 96 days, with the on-site installation taking only 9 working days, including full integration with Business Micros software. During this time, the part-exchanged machinery was safely removed, and a refurbished 4-head welder and a brand-new bead saw were also brought into production to enhance capability even further.
Since the upgrade, Reflections Windows has seen substantial improvements in meeting delivery deadlines, while “right first time” production figures have reached record-breaking levels. The investment has dramatically improved operational efficiency, working conditions, and overall output—positioning Reflections for continued growth and success.
