Most Innovative Machine

2011 Crystal Achievement Award Winners

 

Glass/IG Processing

 

 
  The OptiGas unit provides manufacturers with precise control of gas mix ratios in their IG units.

OptiGas 500 with ThermalCert

 

Integrated Automation Systems LLC

Aurora, Ohio

 

Fenetech Inc.

Aurora, Ohio

The OptiGas process automatically fills units with argon and/or krypton in a way that eliminates gas loss. This process enables manufacturers to provide better U-values at half the previous cost, according to the supplier.

The unit works automatically, first filling the IG airspace with argon and forcing air out. More expensive krypton follows, without any gas loss. The machine allowing the manufacturer to precisely tune the percentage fill for each gas and reach the specific U-value desired at the least cost.  The machine also eliminates undetected leaks, as the OptiGas system monitors cylinders and sounds an alarm if there is a leak. The unit provides accuracy by measuring krypton and argon at input.

 
The ThermalCert unit verifies gas fill rates.  

Reinforcing that accuracy, ThermalCert performs complex gas filling statistical process control data collection, calculations and analysis quickly and accurately in standard production flow.  The in-line SPC program that verifies gas fill rate as well as thermal performance and is said to be the first scientifically valid system for gas fill quality assurance. It keeps a permanent record of fill rates, assuring customers that they in fact received what they purchased.

The OptiGas 500 filling station fills up to six air spaces simultaneously, three triples or six doubles, with both argon and krypton going through one nozzle per air space. The company also offers the OptiGas 1000 for higher volume operations. Both are said to be fully automated and integratable.

 

 

  

Frame, Sash or Door Fabrication

SCF 430 Multiprocessing Machine

 

Joseph Machine Co.

Dillsburg, Pa.
 

 
  Video created by Joseph Machine Co. to demonstrate the SCF 430.

An automatic 90° saw and four-axis CNC fabrication processing center (five axis including the In-feed), the SCF 430 is designed to process multiple parts per cycle while fabricating assembly, hinge, and drainage holes, or machining patterns for accessories, suited for light aluminum alloys, PVC and fiberglass extrusions.

The SCF 430 is a small footprint machine said to offer the practical functionality of four standalone work stations. The base machine provides for two universal fixture sections, an industrial grade HMI and is network capable. All machine sequencing and CNC movements are controlled through a PLC controller with EtherCAT drive communication for precision accuracy on part fabrication. There is a bottom mounted 90° direct drive saw assembly with an oversized 30” carbide-tipped saw blade powered by and 11.5 HP variable frequency motor which utilizes a hydro-pneumatic vertical saw blade feed with the chassis guided on precision rails and linear bearings.

It’s the four-axis CNC spindle with absolute encoder feedback that performs the work with a smooth and symmetrical fashion. The reach and tool selection (five slot automatic tool changer) affords the possibility of many diverse types of action while the versatility makes this a great answer to almost any machine question, including drill and tap applications. This machine is extremely precise and accurate, with the 430’s fast cycle time and multiple part concept said to make it one of the fastest cut-to-length saw lines on the market today.

 

 

 

Other 2011 Crystal Achivement Award Winners:

 

TECHNOLOGY

 

Most Innovative Window

Large Manufacturer
Essence Series
Milgard Windows & Doors

Small/Medium Manufacturer
Series V-100 Tilt & Turn WinDow
Windoor Inc.

 

Most Innovative Door

Large Manufacturer
Sliding Glass Door Series 470, 570,
2770 & 2870

PGT Industries

Small/Medium Manufacturer (Tie)
SecuraSeal Sliding Patio Door
Haddon Windows & Doors

The Nantucket Collection
Simpson Door Co.

Most Innovative Component

Window
Double Snap Trim
Royal Window & Door Profiles

Door
Sentry Multipoint Hinged Patio Door Hardware
Truth Hardware

Glass/Glazing Component
Pleotint SRT Film
Pleotint LLC

 

Unique Innovation

Implementation of QR Codes
Seaway Manufacturing Corp.

 

MANUFACTURING

Most Innovative Plant

MasterGrain/Weber Manufacturing Technologies

 

MARKETING

Most Innovative Marketing Progam

Large Manufacturer
No-Leak Skylight Introduction
Velux USA

Small/Medium Manufacturer
Sentinel by CGI Product Launch
CGI Windows & Doors

Industry Supplier
Project Nexus Launch
Quanex Building Products
 

Best Product Literature

Large Manufacturer
The Design Center Literature System
Jeld-Wen Inc.

Small/Medium Manufacturer
Tru Tech Magalogs
Tru Tech Doors

Industry Supplier
Sentry Multipoint Hardware System Brochure
Truth Hardware
 

 Best Industry Web Site

Large Manufacturer
Windsor Windows & Doors

Small/Medium Manufacturer
Lincoln Wood Products
 

Industry Supplier
Phantom Screens

 

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