Watch below as Viwinco President, David Barnes, gives a quick behind the scenes look of how we produce our windows! We compiled a list of 7-steps of Viwinco window manufacturing to show the different stages a Viwinco window goes through before it is delivered to our distributor locations.
Behind the Scenes at Viwinco Windows
7-Steps of Viwinco Window Manufacturing
Cutting Glass for Custom Window Orders.
We start by sending a 72″ x 84″ sheet of glass, through GED’s CleanCut i – 3 Cutting & Edge Deletion system. The cutter separates the sheet into various sizes depending on window sizes in the batch. The table will first edge delete the Low-E coating from all four edges of the glass. Then glass will then get scored to the correct size. The edge deletion process helps create a better glass seal by ensuring the spacer is sealed to the actual glass and not the Low-E coating.
Batch by Window Style and Recycle.
Once scored, it will easily snap apart. Windows are batched via optimization software that sorts windows by size to reduce waste. We recycle all scrap glass and vinyl that is not used.
Create the Energy Efficient Insulated Glass Unit (IGU).
The glass lites will then go through the glass washer to be cleaned of all debris. After being cleaned, an energy efficient spacer is sandwiched between the two glass lites and run through an oven to be sealed. Once sealed, the completed IGU is set aside to cool off, before an argon gas fill is applied. Finally, the argon filled IGU is sent the appropriate assembly station depending the product type and line. When creating OceanView impact-resistant products, our new high-speed automated IGU line by Erdman handles this whole process.
Window Frame Assembly.
Window framing starts with importing all of Viwinco’s various vinyl profiles from our vinyl supplier Deceuninck North America. Deceuninck is a fully integrated design, compounding, tooling, and PVC extrusion company that produces energy-efficient vinyl window and door systems and composite applications for the building and construction industry. The vinyl profiles arrive at Viwinco in bundles of 20ft “lineals”. A lineal is inserted into a multiprocessor machine to cut all the appropriate hole for hardware, including weep holes and installation holes. Once fabricated, a unique label is printed and placed on the frame which includes important information such as the order number and date.
The frame pieces are then assembled in a corner welding machine which melts the vinyl corners at 480 degrees Fahrenheit and joins them as one structural frame. Next, theframe goes through a corner cleaning robot fitted with saws, drill bits and knives to trim excess welding material. Viwinco uses some of the industry’s latest advancements in automation to ensure consistent high-quality products.
GED Roboclean at Viwinco
Glazing and Sealing the Vinyl Window Frame
Next, the vinyl frame goes to the Glazing table. This station applies the sealant that adheres the glass to the vinyl frame. The corresponding IGU is then inserted into the frame. Setting blocks and an exterior glazing bead are applied for cosmetic and water run-off purposes.
During final assembly the upper and lower sashes are cleaned, labeled and installed into the vinyl frame.
Prepped for Distribution
Finally, the windows are packaged and sent off to the shipping department! Windows with certain options and upgrades are fully boxed for added protection. Windows are sorted by routes and sent off to their designated distributor.
That concludes our 7-steps of viwinco window manufacturing. This quick list only scratches the surface of our manufacturing operation. If you’d like to get a better understanding, ask your distributor about scheduling a plant tour at Viwinco. Our in-house manufacturing operation is one of many things that set us apart from the competition. If trying to choose the right window manufacturer for your next project, be sure to check out our “5-Reasons Why You Should Choose Viwinco” article.