Market-leading conservatory roof, window and door

CI/SfB | (31.4) | Xn
Market-leading conservatory roof, window and door systems,
insulated glass units, portal frames and ancillary products
Company overview
Synseal is a leading UK manufacturer of
conservatory roof, window and door systems
Synseal’s main site and manufacturing centre
Synseal at a glance
Synseal is the largest UK-owned PVC-U systems
company, designing and manufacturing high quality
window, door and conservatory roof solutions for
both UK and international markets.
For over 30 years Synseal has put its customers first,
working with select industry partners to deliver a 1st class
service with products that are straightforward to fabricate,
easy to install and highly efficient in use.
Synseal aims to help customers achieve success in
the refurbishment, new build and commercial market
sectors, working in partnership with customers from
project conception through to successful completion.
A no compromise approach to design, functionality,
environmental impact and product sustainability is
adopted at all times.
Synseal is committed to innovative product development
and continuous improvement processes to ensure that the
right products and services are delivered to customers in
the UK, Ireland and across the globe, time after time.
Originally established in 1980 as a direct selling window
business, Synseal is now a market-leading systems
provider with main operations located at a substantial
headquarters complex in Huthwaite, Nottinghamshire:
• 35 acre site providing 1 million ft2 of business facilities
• 900 employees
• 55,000 tonne mixing capacity
• 34 extrusion lines in a 100,000 ft2 PVC-U extrusion hall
• Specialist areas include 4 foil finishing lines, 2 gasket lines
and 6 injection moulding machines
• 100,000 ft2 manufacturing and value-added
production facility
• 200,000 ft2 warehouse
• 39 vehicle in-house distribution fleet
• 40,000 ft2 glass plant capable of making 3,000 insulated glass units per day
• Over 700 trade customers nationwide purchasing over 25,000 miles of PVC-U extruded profile and
50,000 conservatory roofs per year
• Synseal recycled 1,800 tonnes of PVC-U waste in 2011
and achieved ‘zero waste to landfill’ in April 2012
Accreditations
Synseal is ISO14001 accredited which ensures that all
company environmental management systems comply
with and even exceed government mandates.
Profiles are extruded under accredited ISO9001
Quality Management Systems in accordance with the
requirements of BS EN 12608 and are BBA registered.
All quality management systems are ISO9001 accredited
which ensures that all processes are constantly checked and
improved upon, to reduce waste and increase efficiency.
Synseal holds a number of accreditations from recognised
authorities, such as the British Standards Institute (BSI)
and the British Board of Agrément (BBA). To maintain
registration, licenses and certificates, periodic on-site
audits are carried out by the regulatory authority to
inspect systems and where necessary take product
samples for independent third party testing.
ISO14001
BBA
ISO9001
Environmental
management
accreditation
Construction industry
accreditation
Quality systems
accreditation
Commercial focus
As expert system suppliers of windows, doors and glazed
roofs, Synseal are on hand to provide assistance from
the inception of a specification project right through to
successful completion on site. A wide range of building
projects boast Synseal products, including:
• Private sector new build developments
• Private sector commercial offices
• Public sector housing
• Public sector non-housing projects
• School refurbishments
• Hospital and medical facility refurbishments
• Leisure facilities
• Retail projects
• Local authority regeneration schemes
Planning is essential for any successful project, ensuring that
the right supply and delivery partners are involved from
the outset will achieve the best results for the end client.
Synseal’s commercial team can focus on working closely
with the client and also indirectly via contractors if required,
always offering the best advice to ensure cost effective
solutions in full compliance with project specifications.
Synseal overview | 3
Window and door systems
Synseal offer three proven PVC-U window and door
systems, with casement, tilt and turn and French
windows, together with residential, French, patio and
bi-fold doors. Legend is an industry leading profile
range offering many specification options. All systems
offer A-rated solutions and are available in 15 foiled
finish colourings.
Chamfered
Ovolo
Legend 70
The Legend system is one of the most comprehensive
70mm window suites available and is suitable for both
domestic and commercial applications. Legend incorporates
over 150 different profiles, ensuring it can tackle any issue
that an installation may face.
• Chamfered and ovolo options with a 70mm front to
back dimension
• 3 outer frame sizes in both styles along with a composite door outer frame
• Equal bead and up stand sightlines for improved aesthetics
• 3 multi-chambered outer frames for cost-effective energy efficiency including an A-rated door option
SynerJy
• Range of 5 plastic thermal reinforcements for improved thermal performance
• Sash horn, Georgian bar and arched insert decorative options
• Choice of 4 single leg J beads for quick and simple
glazing, including a 40mm triple glazing bead
• Low sightline gaskets as standard for increased visible
glass area
• BBA accredited
• PAS023/24 (security) accreditation on single doors
• BS7950 for enhanced security performance of casement
and tilt/turn windows
Shield
• 100% lead free
SynerJy incorporates an elegant sculptured design which
is very popular with homeowners, as it closely resembles
traditional window beading. Featuring a single leg J bead
for quick and simple glazing, SynerJy has been designed
to be as fitter friendly as possible.
The Shield window system is a fully chamfered system,
with a clean, modern look particularly suitable for
commercial applications. Shield is a fully BBA accredited
and Kitemarked 70mm window system designed and
manufactured to exceptional standards.
• Sculptured frame styling with a 70mm front to
back dimension
• Chamfered frame styling with a 70mm front to
back dimension
• 3 outer frame options
• 3 outer frame options
• Equal bead and up stand sightlines for improved aesthetics
• Equal bead and up stand sightlines for improved aesthetics
• Standard White and Blu White options
• Shares common components with SynerJy to give you a
cost effective fully sculptured option
• Multi-chambered outer frame for cost-effective
energy efficiency
• Range of 4 plastic thermal reinforcements for improved thermal performance
• Sash horn and Georgian bar decorative options
• Choice of 4 single leg J beads for quick and simple
glazing, including a 36mm triple glazing bead
• Multi-chambered outer frame for cost-effective
energy efficiency
• Range of 5 plastic thermal reinforcements for improved thermal performance
• Sash horn and Georgian bar decorative options
• Low sightline gaskets as standard for increased visible
glass area
• Choice of 3 single leg J beads for quick and simple
glazing, plus 10 traditional beads including a 40mm
triple glazing bead
• BBA accredited
• Low sightline gasket option for increased visible glass area
• PAS023/24 (security) accreditation on single doors
• BBA accredited
• BS7950 for enhanced security performance of casement
and tilt/turn windows
• PAS023/24 (security) accreditation on single doors
• BS7950 for enhanced security performance of casement
and tilt/turn windows
Synseal overview | 5
Evolve fully-manufactured products
Synseal has developed a range of fully-manufactured products that are specially built for customers – the Evolve range.
The strategy is to make only ‘niche market’ products on behalf of Synseal’s fabricators, to add value and offer an easy
way to meet occasional sales demand.
Evolve VS windows are manufactured to maintain the elegant proportions of traditional sash
windows, whilst incorporating the very best of modern day technology.
• Choices of sill sizes available
• ‘A’ WER as standard with ‘B’ and ‘C’
rated options
• Low maintenance PVC-U profiles with traditional styling
• Guaranteed for 10 years
• Georgian or Astragal glazing bars
• Sill jointers for professional detailing
• Fully featured sculptured profiles
• Decorative sash horns/run through sash horns*
• Equal sight lines for top and bottom sashes
• Anti-jemmy bar*
• Easy clean tilt facility
• Child/travel restrictors*
• 24mm glazing as standard for enhanced
weather performance
• Deep bottom rail for a period look*
*Optional
Evolve fully manufactured PVC-U bi-fold doors offer an open, flexible and modern space for
both living and working environments.
• Door fully assembled for easy installation
• Top and bottom aluminium tracks are thermally broken to improve thermal
efficiency and reduce condensation
• Utilises high quality Siegenia gearing
• Available in a range of finishes with either
White or Brown tracks
• Choice of leaf configurations to create bi-fold
doors up to a maximum of 5.4m in width
• Lower thresholds for ease of access as there is no need for bulky add-ons
• Sealing weather strips conceal unsightly gasket lines to complete the professional look of the door
•
Rigid aluminium tracks increase structural strength enabling easier door transportation and prevent excessive flex to ensure that doors run smoothly, even on long spans with multiple door configurations
Designed to maximise daylight and provide panoramic views, the patio door remains a
classic home improvement product offering a combination of elegant style and simplicity
of use. Synseal’s 70mm inline patio door is the UK’s number one selling design.
• The patio door proportions have been
designed for neat coupling to adjacent
70mm window frames
• Patio doors offer both 24mm and 28mm
glazing options
• Aluminium interlock and patio door furniture screw directly into steel reinforcement
• Patio doors facilitate 2, 3 and 4 pane
sliding options
• Patio doors have concealed gaskets
• Enhanced noise insulation and
thermal properties
• Patio doors can also be purchased in bar length or box kit options
• Recessed patio mid-rail section
• Available in a range of attractive
foiled finishes
Roof products
Synseal’s proven and market-leading Global roof has
been the UK’s best-selling conservatory roof since
2005. The roof is designed to be easy to fabricate,
easy to fit and easy to sell. Global conservatory roof has
been engineered to deliver peace of mind for both the
fabricator/installer and the homeowner, with an array
of key features.
• Low level gasket system
• High strength rafters
• Aluminium external top caps
• Insulated box gutter
• End caps with drainage
• Variable pitched valley
• Watertight lead flashing
• Unique fitter friendly single rafter fixing bolt
• Range of finial and cresting options
• System features an aluminium skeletal core
with PVC-U internal claddings
• Global Plus complete external aluminium solution is also
available, designed for export market applications
Global Summer is an elegantly styled and easy-to-fit fascia cladding and internal soffit
design enhancement for the market-leading Global conservatory roof. Global Summer
gives the distinguished look of a traditional orangery without the need for expensive
parapet walls, leak prone flat roofs or the added engineering complexity of a lantern roof.
• Aluminium orangery fascia
• Easy-fit pelmet and mullion pods
• Fluted pilasters to match
• Raised line and low line solutions
• Quick and easy to install
• Retro-fit design option for existing
conservatory roofs
• Affordable orangery solution to meet
consumer demand
• Unbeatable aesthetic appeal
• Existing proven water drainage system
Synseal overview | 7
K2 Conservatories
SkySpace
K2 is one of the UK’s largest suppliers of advanced, fully
sculptured conservatory systems and a trading division
of Synseal Extrusions Ltd. K2 enjoys BBA accreditation on
its conservatory roofing system with an accredited life
expectancy of 25 years or more. K2 operates a continuous
product improvement program and invests heavily in
research and development. With products including a range
of orangery solutions as well as traditional conservatories,
K2 strengthens Synseal’s proven conservatory offering.
SkySpace wide-spanning portal frames are designed for
both residential and commercial market applications.
From sizeable conservatories with traditional styling to
more contemporary roof glazing solutions for buildings,
such as offices, sports halls, restaurant facilities, hotels
and conference centres. SkySpace portal frames are
custom-made to meet project requirements and deliver
versatile architectural spaces.
A complete range of products:
• Flexible design capabilities
• Multiple roof systems, including a market-leading aluminium system
• Suitable for glazing projects from 30m2 to 2000m2
• Unsupported clear spans of up to 35m
• Clip-in gutter systems
• Powder coated to any RAL colour
• Fully adjustable ridge wings
• Aluminium portal framing is strong yet lightweight
• Low pitch roof kits
• Ease and speed of construction
• A wide range of glazing options
- including Celsius high performance glass
• Accurate precision-engineered joint details
• High standard of paint finish
• Aluminium roof vents
• Reduced risk of corrosion compared to steel
• K2 Architectural, specialists in large scale
glazed constructions
• A unique modular system - for complete turnkey conservatory solutions
• First class service and support
• More conducive to multiple roof systems
• Expert technical advice and back up
• CAD drawings service provides 2D or 3D visualisations
Global Glass
Celsius
Insulated glass unit (IGU) manufacturing for windows,
doors and conservatory roofs is undertaken on-site at our
specialist glass plants; sited close to Synseal’s HQ in Huthwaite
in Nottinghamshire and also at Blackburn in Lancashire.
Benefiting from continual investment to deliver operational
efficiencies, these in-house facilities ensure efficient control of
manufactured product quality, stock, cost base management,
reliability of supply chain materials and, even more importantly
for customers, precise management of price, lead times and
product availability.
Celsius is a range of high-performance climate control
glass that also features ‘Easy Clean’ technology. The Celsius
range is available from Global Glass and was one of the
first glazing solutions on the market to offer the unique
combination of heat reflection and thermal insulation.
Celsius Performance Glass utilises a Low-E and Solar control
combination coating, with an Argon filled cavity, to control
the amount of visible light, UV and heat that pass through
the glazed unit. Easy Clean technology has also been added
to reduce maintenance requirements.
Celsius benefits:
• The range includes Celsius One, Celsius Elite and Celsius Clear
• Heat reflection up to 78% - Celsius One reflects approximately 3 times more solar energy than standard glass
• U-values as low as 0.9 for greater thermal performance
High quality toughened and annealed IGU options:
• Clear glass
• Low-E Clear glass
• Low-E Bronze glass
• Solar coated glass
• Low maintenance glass
• Destructive UV rays are reduced by up to 94%, offering protection for furniture and fabrics from sun damage
• ‘Easy Clean’ technology means glass will require much less maintenance
• Visible light transmission up to 61% - Celsius Clear maximises natural light, this neutral tinted glass is an ideal product for the side frames of conservatories
• Rainfall and traffic noise are dramatically reduced when compared to 25mm polycarbonate
• Celsius performance glass
• Argon or Krypton-filled glass units
• Triple-glazed units for windows and doors
Synseal overview | 9
Hardware
Plastic thermal reinforcements
Synseal’s new comprehensive hardware range brings
together the very best residential handles, hinges,
shootbolts and accessories to provide you with reliable
products that offer affordable quality you can trust.
With hardware from such industry leaders as Yale and
Mila, Synseal have sourced the best products, at the
best prices to deliver a commercial edge.
Using Synseal plastic thermal reinforcements is
the easy way to improve the thermal performance
of the windows you offer, whilst improving
manufacturing efficiency. They also cost less than
the steel alternative.
CavSeal cavity closers
Envirosill
Envirosill is made from post consumer recycled
windows, with a skin of virgin pvc-u applied to
the seen faces to ensure that the aesthetics and
performance are not compromised.
Synseal’s frame forming cavity closers are vital
components for all new build developments.
Made from 100% recycled PVC-U and BBA accredited,
CavSeal cavity closers are the simplest and most
effective way to seal cavities around wall openings
to provide a rigid window or door acceptor.
CavSeal requires no tools, adhesives or screws as the
system simply clicks together. Manufactured entirely
from recycled post consumer PVC-U, CavSeal cavity
closers are the perfect choice for every new build
housing project as the Code for Sustainable Homes
offers credits to builders who use sustainable
materials and energy efficient products.
Quality and corporate responsibility
Quality control
Corporate responsibility
Every aspect of the manufacturing process, from blending
to extrusion, injection moulding to foil finishing, from
product design and development to the full-manufacture of
vertical sliding sash windows, patio doors, bi-fold doors and
conservatory roof kits, is undertaken on-site. One principal
location allows Synseal to control not only the quality
of manufactured products, but also reliable delivery via
Synseal’s own fleet of transport vehicles.
As a major local employer in the Nottinghamshire area,
Synseal takes a rigorous approach to all corporate
responsibility matters. Responsible business is embedded
within the company’s core strategy and Synseal is
committed to ethical business practices across all its
activities. Fully committed to progress, Synseal embeds
this vision into all areas of the business to support strategic
delivery and build strong relationships with customers,
regulators, investors and employees.
Equal opportunities and diversity
Synseal supports a culture that respects and values personal
differences. The business is committed to the promotion of
equal opportunities in employment and will not tolerate
discrimination on any of the grounds designated as
protected characteristics in the Equality Act 2010.
Production techniques are largely automated and testing is
computerised to ensure a consistently high quality product.
Boasting the latest technologies and modern machinery,
Synseal is able to deliver extruded PVC-U profiles which are
consistent in colour, shape and finish.
Synseal is focused on finding new ways to design, produce
and deliver products to its customers. Operational processes
are continually evaluated to find improvements, reduce
waste, identify problems and then define solutions quickly
and systematically. All products undergo a wide range of
QC inspections during and after the production process.
All equipment is checked following every extrusion run
and maintenance schedules are strictly adhered to.
Health and safety
Synseal makes proper provision for the health, safety and
welfare of its people, visitors and contractors and those
in the community who may be affected by its activities.
The company aims to protect people’s health at all times
and achieve zero injuries and incidents. By utilising
a structured risk management approach, Synseal is
committed to providing the necessary support and
resources to ensure a safe working environment.
Synseal overview | 11
Why choose Synseal?
Clients trust Synseal for their projects because a wide
choice of high quality products is backed up by a well
resourced and full-service systems company that truly
understands technical requirements and will capably
deliver solutions to guarantee success in a highly
competitive marketplace. Synseal are best placed to
advise on how to manufacture and install the most
appropriate products for specific end-user clients and
will take the following parameters into consideration:
• Energy efficiency
• Environmental impact
• Ease of use
• Supply continuity
and guarantees
• Security
Choose from fully-integrated Synseal window and door
systems, quality hardware solutions, accessories, market
leading conservatory roofs, portal frame structures and
low-level door thresholds which are Part M compliant;
all designed with social housing, new build, private home
refurbishments and commercial buildings in mind.
Environmental responsibility
All Synseal products are manufactured under environmental
management systems which are third-party accredited to
ISO14001. Synseal works to optimise production processes,
reduce costs and minimise environmental impact at all times.
Synseal was awarded with ISO14001
accreditation in 2009 as a result of
its commitment to environmental
improvements across the whole
organisational structure.
As global changes continue apace, Synseal fully accepts
environmental responsibilities and to ensure compliance
has developed a comprehensive management system
that regularly monitors performance against a set of
challenging objectives:
• Achieve zero waste to landfill
• Reduce electricity usage
• Increase reuse of PVC-U
• Encourage closed loop PVC-U recycling
• Reduce emissions and business mileage
• Develop 100% recycled product solutions
• Work with customers to reduce their impact through recycling collection schemes
• Develop products which allow customers to achieve
the best WERs, DSERs and U-values
• Conduct environmental management workshops
for customers
Synseal will always seek to reduce its carbon footprint
and continue to maintain its ISO14001 Environmental
Management Systems certification.
In 2011 Synseal was nominated and short listed for the
Green Manufacturer of the Year Award at the ‘Insider Made
in the Midlands Awards’, a scheme that rewards the work of
manufacturers across the region.
Synseal impressed the judges with ongoing environmental
strategies that include a year-on-year reduction in energy
consumption of 8%, producing an average saving of 600
tonnes of carbon; a 30% reduction in vehicle emissions
through the introduction of new delivery vehicles;
and a target objective of zero waste to landfill which
was achieved in April 2012.
Other initiatives include the reduction of tyre wear and
replacement, and a saving of 15% in office paper usage.
Also of considerable significance is the company’s focus on the
introduction of A-rated windows throughout its range, and the
use of recycled PVC-U in the manufacture of new products to
virtually eradicate waste of this valuable raw material.
Recycled windows for truly sustainable homes
Disposal of PVC-U in an environmentally responsible way
The Code for Sustainable Homes (CSH) was developed by
the Building Research Establishment (BRE) and Construction
Industry Research and Information Association (CIRIA) to
promote sustainable building practices for new house
building in England & Wales. It provides a single national
standard for the construction industry and helps to
drive continuous improvement, greater innovation and
exemplary achievement in sustainable home building.
Homes are measured against design categories, rating the
‘whole home’ as a complete package.
There is a range of alternative methods available for deriving
residual value from used plastics products. The optimal
route for a given product will be determined by assessing
a combination of environmental, logistical, economic and
market considerations. Therefore, the whole range of waste
management options should be considered when deciding
on the treatment of plastic waste, including PVC-U windows.
Design categories included are:
• Energy/CO2
• Pollution
• Water
• Health and well being
• Materials
• Management
• Surface water run off
• Ecology
• Waste
As the public are becoming increasingly conscious of the
environment there is a growing requirement for more
sustainable products and services, and choosing recycled
windows from Synseal helps to meet these demands.
The use of recycled PVC-U windows allows specifiers to
tick the boxes for many of the CSH design categories.
Recycling
One of the many benefits of PVC-U as a material is that
it is readily and economically recyclable like all other
thermoplastic materials. The primary aim of recycling is to
elicit a net environmental benefit through reducing the use
of primary resources and/or diverting resources from landfill.
PVC-U is…
• Low maintenance
• Durable
• Economical and energy efficient
• Safe and secure
• Versatile
• Environmentally sound
• Recyclable
PVC-U windows
can be recycled
up to 10 times,
with a life span
of 400 years.
Synseal overview | 13
Window Energy Ratings
Synseal continually seeks to improve the energy efficiency
of its windows and doors, to ensure that products can
easily achieve best-category ‘A+’ and ‘A’ ratings, without
compromising on performance or security. By introducing
plastic thermal reinforcements and multi-chambered
profiles, specifiers have peace of mind that they are selecting
products that have been engineered to deliver the highest
ratings without compromise.
Multi-chambered frame and plastic thermal reinforcement
Window Energy Ratings are design simulations that can
accurately calculate how energy-efficient a specified
window will be in use. The WER system is based on a scale of
A-G, with A-rated windows being the most energy-efficient.
As up to 25% of heat within homes escapes through
windows, consumers are increasingly demanding A-rated
windows to retain domestic heat and lower energy bills.
Window Energy Ratings apply to a whole window (frame and
glass) rather than the frame or glass components individually.
A combination of multi-chambered PVC-U window frame
profile, spacer bar and high performance glass will create the
most thermally-efficient project solution. Door Set Energy
Rating (DSER) calculations provide similar thermal evaluations
for doors. Synseal can provide expert advice to assist in all
aspects of WER and DSER specification, with simulations
carried out in accordance with BS EN ISO10077-2.
Multi-chambered frame and sash, triple glazed
Commercial market expertise
Synseal’s commercial team is able to create innovative
solutions that comply with Building Regulations and
other key specification standards, such as the Code for
Sustainable Homes. With many years of experience
serving the commercial arena, Synseal’s dedicated
commercial team can support with:
Lead generation
Synseal works on a nationwide basis to identify and assist
with commercial project opportunities for its fabricators.
Tender/e-tender support
The completion of pre-qualification questionnaires and
commercial tenders can be complex, time consuming, cost
money and tie up valuable resources. Synseal’s commercial
team will work with architects and fabricators/installers to tick
all the boxes necessary for a successful submission.
Specification advice
Support is readily available for all customers when
completing commercial tenders, including assistance with
wind load calculations and advice concerning all aspects of
product performance and Building Regulations compliance.
CAD service
Synseal’s research and development department can prepare
drawings and design calculations to support commercial
tender submissions.
Site visits and training
The commercial team assists with specification, design,
product selection and training for installation staff on site.
Synseal works with a network of expert fabricators and
installers who will supply high quality products backed by
reliable delivery and installation services.
Workshops
Synseal regularly hosts workshops covering a range of
fenestration topics, including WER product performance
and certification, Secured by Design specification, lean
manufacturing, environmental management and CE Marking.
Synseal overview | 15
Synseal is a leading UK manufacturer of
conservatory roof, window and door systems
Synseal has evolved steadily as
a business over the years and,
following a management buy
out in 2010, all Directors are now
shareholders with a common goal
to forge winning partnerships with
customers and achieve mutual success:
1980
• Synseal founded, initially fabricating aluminium and then PVC-U windows and doors
1991
• Synseal concentrates on trade sales, closing retail showrooms
1994
• Synseal now self-sufficient in blending with a mixing plant investment
1995
• Synseal becomes a 100% extruded PVC-U systems supplier, selling window fabrication business
2005
• Permacell Finesse acquisition
including the Legend window system
• SynerJy window system launched
• Global becomes the UK’s
best-selling roof system
• Synseal is acknowledged as the UK’s
No. 1 extruder of PVC-U profile systems
2009
• Evolve fully-manufactured vertical sliding windows launched
2010
• Management buy out (MBO) successfully completed
• Portal frame division created
2011
• Global Glass acquisition and
plant investment
2012
• K2 Conservatories acquisition,
including Celsius performance glass
• Global Summer orangery launched
1999
• Shield window system launched
• Profile bending plant investment
at the K2 site in Blackburn
2002
• Shield conservatory roof system launched
• Evolve fully manufactured bi-fold
and patio doors launched
2003
• Global conservatory roof system launched
• Zero waste to landfill achieved
2013
• Synseal Registered Installer business support launched
Tel 01623 443200 | Fax 01623 550243 | www.synseal.com
Synseal Extrusions Ltd. | Common Road | Huthwaite | Nottinghamshire | NG17 6AD
ZMSE/BROCHUREv2
Company timeline