Warm Edge Spacer Manufacturing

Manufacturing innovation is at the heart of the business at Thermoseal Group where there is complete control over the development and quality of the products from initial design through the complete production process.  We are the only British company to set up a manufacturing facility and Technical Centre to develop energy efficient IG products.  We manufacture two of the highest performance warm edge spacers currently available including Thermobar and Thermoflex Warm Edge Spacers.  Following an initial investment of £5 million we plan to continue to invest in our production facilities, staff and Technical Centre to launch further warm edge products – some specifically to suit export markets.

Like any responsible manufacturer, we see it as our responsibility to analyse, monitor and take continual steps to reduce our carbon footprint. As a result, the latest addition to our production facility is our new Plastic Recycling Plant which has already seen a six-figure sum investment. 

Since we produce our products using lean manufacturing initiatives from Six Sigma and Kaizen manufacturing strategies, we have already taken strides to continually decrease the plastic waste from our production facility. Therefore, the new recycling plant was the only way to improve on our current efforts.

This new plant will enable us to recycle all of our plastic waste including the unusable sprues that injection moulded fittings are attached to when they come off the machines. There is also inevitable waste on start-up of the extrusion lines which can also be recycled.

Our new equipment includes a grinding machine which converts the plastic waste material to fine shavings. These shavings are fed into our recycling plant and mixed with the exact percentage of virgin material. This blend is repackaged and used for normal production of Thermobar or fittings with no detrimental effect on the finished product.

Thermobar Warm Edge Spacer Tube is a rigid plastic spacer tube made with engineering plastic and a unique gas barrier tape.  It is produced from our Wigan manufacturing site with the support of our Technical Centre to ensure that the product is subject to continual development and is monitored and batch-tested to adhere to our strict quality control procedures. All bespoke fittings for Thermobar are manufactured in our own injection moulding division and are colour-matched to suit.  We manufacture to a very slight product tolerance and drive changes based on working closely with our customers to suit current sealed unit manufacturing methods and machinery.

Thermoflex Warm Edge Spacer is a flexible silicone foam spacer system which is also made with a unique gas barrier tape.  This requires a completely different manufacturing process and is also produced from our Wigan site.  Like Thermobar, this product is subject to rigorous testing and quality control.

Thermobar is our highest performance rigid tube spacer offering a best thermal conductivity value and has a phA+ Passive House ratings for Arctic Climates with hot melt secondary sealant.  Thermoflex is also rated phA+ for Arctic Climates.