Glazerite East has gone from producing around 200 frames a week to a capacity of around 700 thanks to investment in machinery, improvements in production and enviable staff continuity.
After four decades at Glazerite East’s Peterborough factory, which became part of the Glazerite Group 10 years ago, one face is well placed to comment on its evolution over the years.
Starting out as an office junior under the business’ previous ownership, fresh from school aged 17, General Manager (Glazerite East), Mark Smith, has worked at the site ever since. His constant presence, over 40 years, brings a level of experience and continuity that has been key for the site's development.
“I've been here forever, so I know it inside out and I've seen a lot of changes,” says Mark.
“The business has just developed and grown massively. We've been building up from 200 frames a week to our current capacity which is about 700 frames a week.”
As well as the retention of loyal and experienced people, like Mark, investment in machinery and improvements in production processes have been instrumental in supporting this increased output.
“We've still got our original cutting and prep centre; our Stuga,” explains Mark. “That's our workhorse; it’s 23 years old. We also invested in the Haffner cutting centre during COVID and that's our main cutting centre currently. So, we do invest in kit... We've got a new welder coming tomorrow…” he adds.
Keeping staffing levels consistent, growth has been achieved through improved production processes, as opposed to significantly increasing its workforce.
“We haven't increased people a lot more, or got rid of people,” Mark explains, “we've just increased our numbers and our production output.”
An added benefit for customers is a marked drop in lead times.
“We are making stuff quicker than we've ever made it,” explains Mark. “We used to have the luxury of a four-week turnaround on lead time. Our luxury now is two weeks – or less in a lot of cases.”
Product development has also played a key role in the site's evolution. Over the years, the factory – which has always processed Halo and subsequently VEKA/Halo systems – has seen a shift, not just in volume, but also in the complexity and range of products it manufactures.
Recent years, for example, have seen the introduction of the patented Timberweld process; an innovative milling and welding technology that fuses the internal chambers and faces of the window frame while maintaining a clean, straight-cut mechanical timber butt joint effect, on the external and internal corners.
“The joint looks like a traditional timber window where you cut and scribe the joint together, and it looks like a line, literally, as opposed to a 45-degree angle cut and weld,” explains Mark.
Increased demand for flush window styles also goes hand in hand with the need for greater choice when it comes to colour and finish, as consumer tastes shift.
“Flush has taken over to some degree,” says Mark. “But we are producing casements still equally. Foils have also increased considerably and the colourways and the number of different options from VEKA is huge. So, we are seeing a big increase in volume in flush and in foil.”
This growth in output, investment in machinery and continued product development have transformed what was once a much smaller manufacturing operation.
For Mark, who has seen this evolution first-hand during his impressive tenure at the East Anglian site, the result is increased efficiency, higher capability and a generally more responsive operation that is well-equipped to meet changing customer requirements. All while retaining the experience and knowledge built up over decades.
“Before Glazerite bought us, we were a little fish in a big pond,” he says. “We were a very small business, and we found that we struggled.
“Now being part of a bigger group, we have a lot more chances and we’re able to pass that benefit onto our customers. It’s a win-win all round.”
