Choose the best thermal break assembly layout for your business

Thermal break assembly machines play a crucial role in constructing thermal breaks which are essential components designed to enhance energy efficiency and structural integrity in various products. From aluminum windows and doors to curtain walls, thermal breaks have become indispensable for manufacturers. At Starlight, each of our layouts are customizable to fit what your business needs. You can begin with a small layout and easily add more machines to get to layout 51 whenever you feel it’s right. Before choosing which layout would work best for your business, let’s dive deeper into the basics of thermal breaks processes.

What Are Thermal Breaks?  

Within the domain of windows exists a crucial element known as a “thermal break.” Think of it as a protective barrier that stands between the inside and outside sections of a window preventing the escape of heat (in the winter) and preserving the cold (for warmer days!). This barrier serves as a secure connection between the inner and outer metal parts of a window frame, effectively combating the loss of heat or preserving the cold air inside. Collaborating with advanced windows featuring three layers and insulating gas in between, it plays an important role in maintaining a favorable indoor temperature. Interested in buying a thermal break machine? Read more about their benefits on our other blog post.

Thermal Break Assembly Line VS. Thermal Break Assembly Machine

When you’re deciding between using just one machine or setting up everything, it’s all about how much you’re making and how fast you want things done. If you’re doing smaller stuff, one machine can do the trick, but it’ll always be more complicated than using a layout with 3 machines. But if you want to do more and do it really well, having a smart setup can turn your place into a super productive hub. Everything fits together smoothly, making your thermal break work even better.

Optimizing your thermal break assembly layout is a critical factor in enhancing productivity and efficiency. A well-designed layout includes the arrangement of machines, workstations, and material flow within your manufacturing facility. It ensures seamless coordination and minimizes unnecessary movements, resulting in streamlined operations and reduced production times.

When considering a layout, factors such as the size and shape of the workspace, the flow of materials, and the proximity of different assembly stages play an important role. A thoughtfully crafted layout not only accelerates the production process but also reduces the risk of errors and rework. By strategically placing thermal break assembly machines in relation to other manufacturing equipment and workstations, you can eliminate obstacles and ensure a continuous, harmonious workflow. Note that our machines feature 8 discs that apply gradual pressure to the extrusion process, which is more effective than applying pressure all at once.

Not sure about what thermal break machine to opt for? Read our blog post or contact us to discuss your needs.

Starlight’s personalized layouts 

Starlight always goes the extra mile to cater to your specific needs, which is why we specialize in tailoring custom layouts that perfectly suit your space and production flow. Our dedicated team collaborates closely with you to understand your unique setup and devise a layout that optimizes efficiency, minimizes obstacles, and ensures seamless operations. Moreover, we offer tailor-made tools and expertise that can accommodate even the most complex realizations. For more information about this service, contact us to discuss your needs.

Starlight’s Thermal Break Assembly Layouts 

Layout 51: For large-sized companies with large productivity and less operators

Number of operators needed: 3
Amount of machines included: 3
Bar per hours: 120 of the same profile

Layout 51 is made up of three machines, each doing a different job in making thermal breaks:

1. Knurling machine
2. Inserting machine
3. Crimping machine

This layout is super fast, making around 2 aluminum bars every minute, which adds up to 120 bars in an hour. It’s a top choice at Starlight because it’s really efficient and automated.

Layout 51 is a bit bigger and needs more room, but it’s popular with our customers, especially if they also use CNC machines. These machines make all the adjustments automatically. Using a CNC layout reduces your changeover time to approximately 2 to 5 minutes, while a manual setup could extend the time to anywhere between 10 to 45 minutes.

For more information on this machine, check this out.

Layout 41: For startups with increased productivity but a low amount of operators 

Number of operators needed: 2
Amount of machines included: 3
Bars per hour: 65 of the same profile

 

Layout 41 has three machines, and each one does a different thing for making thermal breaks:

1. Knurling machine
2. Inserting machine
3. Crimping machine

Although quite similar, this layout is different from Layout 40 as it has something called a “retention buffer” at the end of the process, which means you don’t need an extra person. This setup for making aluminum with thermal breaks can make about 65 bars of aluminum in an hour. You only need two people to run it, and it’s always the same kind of aluminum, so no changes needed.

What’s interesting about this layout is how fast you can get started. Companies can begin with Layout 40 and, in about two years, upgrade easily to Layout 41 by adding a special moving part.

For more information on this machine, check this out.

Layout 40: Perfect for startups with very little space 

Number of operators needed: 3
Amount of machines included: 3
Bars per hour: 55 of the same profile

Layout 40 has three machines, and each one does something different for making thermal breaks:

1. Knurling machine
2. Inserting machine
3. Crimping machine

Layout 40 is the simplest, smallest, and most affordable setup which makes it the top choice for new companies or someone who wants to start doing thermal break. With this setup, you can make about 55 bars of aluminum in an hour. Plus, you can easily switch it for different patterns, and it works with big aluminum pieces, adding special strips is quick, and it holds the aluminum steady when rolled tightly.

For more information on this machine, check this out.

Starlight is the solution for your thermal break needs

In summary, selecting the best thermal break assembly layout is essential for enhancing productivity and efficiency in modern manufacturing. Thermal breaks have become indispensable components, and finding the right layout can significantly impact your production process. Starlight offers a range of layouts catering to various needs, ensuring streamlined operations for startups, medium-sized companies, and larger operations alike. Customized solutions are also available for unique requirements. Efficiency, productivity, and tailored layouts are the keys to success in thermal break assembly and Starlight is here to help you take your business to new heights. Contact us today to get a quote on your new thermal break assembly line. Scroll to the bottom of this page to fill out the quick form and one of our experts will contact you shortly.