window production par excellence

A bonded system for sure.

Special reprint from Glaswelt March 2020

Window Production par excellence

Lohmann GmbH & Co. KGIrlicher Straße 55 56567 NeuwiedTelefon +49 2631 34-0Fax +49 2631 34-6661 [email protected]

03.202072th volumeE 3276Gentner Verlagwww.glaswelt.de

March 2020

WINDOW PRODUCTION PAR EXCELLENCE | A bonded system for sure

GLASWELT 03.2020Special reprint from

© Gentner Verlag, Stuttgart

2 GLASWELT | 03.2020

MAIN FOCUS FENSTERBAU FRONTALE: PRODUCTION OF WOODEN WINDOWS

Window production par excellencePeople who drive past Müller‘s company in Essen have no idea what is hidden behind this almost inconspicuous address in the middle of an old mining site. No extravagant showroom is indicative of the products which are created here. There is (still) no administration building to be found. But a second glance is enough to make it clear: Here it is all windows, a lot of windows. This includes a unique machine concept and suppliers who provide important unique selling propositions with bonded systems.

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Müller Holzfensterbau produces wood and wooden/aluminium windows in top quality. The profile depths from IV68 to IV120 are manufactured according to customer requirements.

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The two brothers Stephan and Matthias Müller (from left) manage the company, which is now in its 4th generation, together with their father.

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During the company tour, all suppliers are impressed by the efficient production and large-volume projects which are handled here.

03.2020 | GLASWELT 3

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_ Grandfather Otto Müller was the first to focus on wooden windows and doors.

The current managing directors and his grandchil-dren definitely have wood in their veins - in any case, the concept of producing a window out of plastic would never have occurred to them. As so often, the family business Müller Holzbearbeitung, founded back in the Weimar Republic, developed from being a joinery to becoming proven wood-en window experts. The two brothers Matthias and Stephan Müller have defined their fields of activ-ity clearly: Stephan is the man for sales and cost-ing, Matthias being the technical expert. Each of the two brothers, along with their father, is always informed about what motivates the other at any given moment.

Orders worth millions are commonplaceThe company focuses on large and industrial cus-tomers. The company‘s managers juggle with huge order volumes so calmly that you cannot help but be amazed. “In our company, orders usually start at half a million,“ says Matthias Müller, narrowing down the customer spectrum. They act as part-ners for large projects (e.g. the “Colossus of Prora“) and sometimes as a saviour in times of need, be-cause even with larger projects, window elements are sometimes simply forgotten, according to his brother. “In this case, the housing company is ex-tremely happy if we can deliver 500 or more win-dows within a few weeks.“ The company has com-pletely detached itself from the end customer busi-ness. In contrast, large construction projects in the listed buildings or security sector (up to RC 3) are right up their street: “That is where we feel at home!“

We hear a clear statement on the subject of pub-lic tenders: “They are only interesting for us from June to September - during this period, a stand-ard window manufacturer is working to capac-ity and offers reasonable prices“, says Stephan Müller. Otherwise, the company only participates in property tenders which are too voluminous to appeal to any competitors who are to be reck-oned with. Moreover, the company has its regular customers - and delivery capacity is always a pri-ority. Stephan Müller: “We really don‘t sell by price these days. We sell primarily by capacity.“ It is clear that suppliers cannot arrive on the construction site with less than the highest possible level of

quality, which is what the company is known for. “For our customers, performance and liquidity al-so play an important role.“ Matthias Müller adds that BIM and after-sales service are also important factors. This is why a QR code will soon be issued

for each individual window via window construc-tion software (Prologic). “If a window pane breaks, the customer can read out the technical informa-tion. We then deliver a replacement immediate-ly,“ explains Stephan Müller.

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A Conturex 125 Vario does its job in an outbuilding in cramped conditions. The comprehensive tool magazine (Aigner) ensures low downtimes.

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The Ecoline profile grinding machine was newly configured especially for the company. Thus, the surfaces of the window scantlings can be optimally pre-treated.

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Incoming inspection of the insulating glass units: Here, the glass is checked for defects and then taken into the glass warehouse.

“We sell ourselves via capacity“



The secret of the window manufacturers‘ success includes state-of-the-art processing plants and a very intelligently linked production line. Another factor also influencing production is a curse and a blessing at the same time: the company has only an extremely limited production area of 5500 m² with no possibility of expansion - squeezed between the city park, streets, railway tracks and a car repair shop. This makes it all the more important to have a production line that can make clever use of the lim-ited space available.

New casement line with bonding technologyAn important investment decision was due in 2018: Agreement was reached with the plant manufacturer Lemuth: A new casement line was to make hardware assembly much more efficient. The wooden window makers also targeted the in-troduction of bonding technology - for every win-dow without exception. After all, it was and still

pliers - also suggested involving the bonding tape experts Lohmann: All the above compa-nies have joined forces in an initiative for bond-ing glass panes to defined coated wooden surfac-es. Together, it was possible to prove in an elabo-rate test procedure that this bonding easily with-stands the required loads.Martin Wiesmann, Remmers Technik Service In-dustry Division Manager for wood paints and varnishes, explains: “Bonding glass to raw wood does not fit the production process. We ad-dressed this issue and were able to prove that bonding on coated wood works.“ The joint was tested on 14,400 sample woods and in the end, this gave rise to Part 5 of the ift Guideline VE-08/4 “Assessment fundamentals for bonded glazing systems“.This was the decisive approach for the Es-sen-based manufacturers of wooden windows: “We need security for our designs. We obtain this security from the Guideline and the test proce-

is important to significantly reduce the amount of service required after window installation. This can be achieved with bonded systems, because the stability of a window is guaranteed long-term. Matthias Müller: “Bonded casements give us an-other good argument for our major customers to distinguish us from other players. The custom-er gets a window which involves significantly re-duced maintenance effort. We use that as a selling proposition.“ With the new plant, which has now been in operation since the beginning of the year, bonding technology has been implemented in an automated process throughout. “This means that financial outlay can be kept within limits,“ as Mat-thias Müller concludes from his post-calculations. Application by hand-held cartridge systems is out of the question for them.

A proven system for sure.The long-standing partners - Otto-Chemie for bonding materials and Remmers as surface sup-

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The casement frames are still scanned here and reported to the bonding plant. In the future, an automatic bonding tape assembly line will be integrated into the production process here.

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The heart of the casement line: The glass pane bonding machine “marries“ the casements to the glass panes. It must be possible to lower the table at three points - it also fixes the casement frame for the insulating glass unit.

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TA press unit with pressure rollers ensures that the pane is pressed onto the bonding tape. Once the casement and the pane are fixed, the 2C adhesive is applied into the joint.

MÜLLER HOLZFENSTERBAU FACTSHEET

■Wood and wooden/aluminium windows

■ Turnover between 30 and 40 million euros

■ 60 000 window units/year

■ Security windows up to RC 3

■Windows for listed buildings

■Aluminium shell: Batimet, Gutmann

■ Fittings: Roto since the end of 2019

■Wood supplier: Münchinger, Schiller

■ Software: Prologic

www.muellerholzfensterbau.de

03.2020 | GLASWELT 5

dures preceding it. Now we have an extensive range of bonding systems available, consisting of wood type, coating and adhesive/bonding tape and glass. Moreover, the above-mentioned sup-pliers also enable us to further develop new coor-dinated bonding systems,“ as Martin Stöger, Sales Manager at Remmers, adds: “We are glad that we no longer merely act as suppliers of paint sys-tems, but that we are also able to help our cus-tomers to continue their development - also via our cooperation with the other partners“

Many windows, little spaceStephan Müller estimates the total scope of the plant investment to be around 3.8 million euros and in fact, the promises made by the plant ma-nufacturer and also those of the suppliers were kept. The plant manufacturers Lemuth are pleased about challenges like the ones involved in this project. Meinhard Lemuth: “We can‘t provide just average quality, we‘re too ambitious for that.“ Nothing about the cramped premises and the de-mand for a 2-minute cycle could be changed. The requirement was “to be able to build the largest windows and to provide the smallest space to do so.“ Following the implementation, the mechani-cal engineering expert is certain: “Nobody else in the window universe has anything like that.“ The design of the plant table for bonding proved to be a particular challenge: it must be possible to lower it at three points - it also fixes the casement frame for the insulating glass unit. Lemuth: “What we have proved: even normal wooden windows can be glued automatically.“ Overall, the already high level of quality is raised once again, because “with every automation within the production

the Dupp office of experts has been complet-ed, PfB test certificates should already be avail-able for FENSTERBAU. According to all partners, the demand for matched bonding systems has definitely increased significantly. Nevertheless, at the end of the factory tour, the window expert Müller regrets that the apprecia-tion for a wooden window in Germany is not par-ticularly high - price is the number one concern and it is important to find one‘s way out of this price discussion. On the other hand, it is more im-portant that the customer feels that he has been well advised. “And that‘s what we‘ve always been about: My brother provides the customers with a reasonable price and I provide them with a rea-sonable technical proposal.“ —

Daniel Mund

process, sources of interference are eliminated and value-adding times are optimized“. When everything fits so well, it is not surpris-ing that the next step is to follow immediately after the investment project is completed: This year, the blind frame assembly will be automated - a finished goods warehouse has already been cleared for this purpose.

RC 3 as a secure bonding systemThe project partners Remmers, Otto-Chemie and Lohmann will continue to show window manu-facturers their capabilities for integrating bonding technology on treated wood into their produc-tion processes. Soon, this will even be possible with a RC 3 design - the pre liminary phase at

Special designs in listed building projects up to RC 3: The design is determined individually with the building owners / listed buildings authorities.

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After the bonding station, the casements are further processed on three assembly tables and transferred to the casement buffers.

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LEMUTH PLANT CONCEPT FOR MÜLLER

■Casement feeding station: Automatic removal of

the casements from the trolleys and transfer to the

seal insertion robots

■ Seal insertion robot with 4 seal insertion heads,

incl. seal moistening, primer spraying device

■Casement fitting assembly centre: Automatic

assembly of the casement hinges and centre

locks, processing station as a turntable with

lifting device, automatic assembly and punching

machine for fitting parts to be cut to length, centre

locks, coupling parts

■Clip-on part assembly robot: Setting and screwing

the clip parts for the aluminium shell

■Cross distribution table and reversing device

■ Bonding tape assembly robot with assembly of

the integrated fittings including suction device for

removed protective film

■Glass pane bonding robot: Automatic infeed and

outfeed of the casements and glass panes, glass

pane setting device using 16 suction cups, DYNA-

Flow dosing system for A and B components, 2C

pumping device for adhesive and press unit

■Assembly stations / transfer of the casements to

the buffer system

■ Buffer and sorting station for glass panes and

casement elements

■Glass edge cleaning: Automatic moistening and

cutting off the cleaning felts

www.lemuth.com| Hall 3, Booth 327



REMMERS

“Comprehensive worry-free package“ for the customerAs an allround supplier of paints and varnishes for wood, Rem-

mers bundles its product systems and services in a 360° con-

cept with clear added value for the customer. There is a net-

work of 300 specialist representatives and application engineers

throughout Germany. A logistics concept ensures that individu-

al deliveries arrive within 24 hours. Especially in the case of ma-

jor projects and restorations, Remmers supports specialist plan-

ning with consulting services from analysis to implementation.

Their have their own institute for analytics which offers a wide

range of laboratory and analytical services, including those for

window and door construction. In the two competence centers

in Löningen and Hiddenhausen, application processes and coat-

ing systems can also be tested under real-life conditions for cus-

tomers. Ultimately, the Bernhard Remmers Academy is a central

element in the 360° concept when it comes to technology and

knowledge transfer.

www.remmers.com Hall 5, Booth 251

LOHMANN

The bonding tape experts

Lohmann, the “Bonding Engineers“ from Neuwied, assist window manufacturers as com-

petent partners from their very first idea. Individual bonding concepts, a convincing prod-

uct portfolio, efficient process integration and sustainable optimization ensure success in

window production and constitute the ideal path towards a customized bonding solution.

Lohmann consider themselves as system providers and technology enterprise active

world-wide, covering the entire value-added chain in the production of double-sided

bonding tapes. The bonding tapes provide a secure connection in the following sec-

tors: building profiles, window and door construction, loft conversion, facade bonding

and interior fittings.

www.lohmann-tapes.com | Hall 6, Booth 259

OTTO-CHEMIE

Sealing and bonding on the building shellA number of new products - including Ottoseal M

361, a paintable sealant for structural engineering

and connection joints with textured look, Ottocoll

S81 and S670, 2C silicones for bonded windows,

and Ottocoll S 645 for secure bonding and sealing

of special glass constructions - have prompted Ot-

to to reissue their industry catalogue “Glas • Fen-

ster • Fassade“ (Glass - Window - Façade) on the oc-

casion of the trade fair. The 240-page new edition takes into account changed standards in

building regulations as well as updating of all technical data sheets for the products. Appli-

cation examples, instructions and work steps for sealing and bonding tasks on glass, win-

dows and facades are clearly presented. The Otto industry catalogue is aimed at profes-

sional processors from various trades. It is recommended for experienced craftspersons

as well as for beginners, who will find practical information on the execution of the

work with the many carefully illustrated “step-by-step“ instructions. But even profes-

sional converters can benefit from the solution-oriented presentation of the most com-

mon sealing and bonding tasks around glass, windows and facades.

www.otto-chemie.de | Hall 6, Booth 119

BONDING PROTECTION AGAINST BURGLARS

Remmers, Otto-Chemie and Lohmann will be presenting the

bonding process for coated wood at the FENSTERBAU FRONTALE

from 18 to 21 March 2020. Experts will explain the functionality of

the innovative bonding process and its components on site. ift

Rosenheim had already certified the functionality of the process at

the 2018 fair.

Now the positive results of the RC3 burglary protection tests for

upmarket private use are also available for the two wooden/

aluminium window systems “Mira-CTS“ and “Mira Contour-CTS“.

Besides Remmers, the companies Lohmann, Otto-Chemie, Leitz,

Roto, GU and Gutmann were also involved. In addition to Induline

paint and glaze systems made by Remmers, the bonding tapes,

liquid bonding systems, fittings, aluminium cladding and wooden

windows made by the project partners are also implemented.

The participating companies received the certificate from ift

Rosenheim for the coordination of the individual components with

one another as early as 2018. Induline coatings made by Remmers

therefore harmonize with the bond and fulfil the requirements

of the new Part 5 of the ift Guideline VE-08/4 “Assessment

fundamentals for bonded glazing systems“. The successful

interaction of coating and adhesives was tested using different types

of wood, drying methods and coating structures. The certificate

is valid for both artisan and industrial applications. Systematic

gluing on coated wooden surfaces improves the efficiency of the

manufacturing process by accelerating it. Larger glass surfaces can

also be produced due to the small frame width.

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At the roadshow, the companies Remmers, Otto-Chemie, Lohmann Klebetechnik and Leitz in 2018, presented a RC 3 wooden window system with bonding on coated wooden surfaces.

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The recently published Trade Catalog takes into account the revised standards in the building regulations.

Induline LW-722 [eco] based on renewable resources

How [eco]-friendly are you?

Induline LW-722 [eco]

Sustainable, water-based, transparent coating

Remmers Gruppe remmers.com

° For wood/aluminium windows and other building elements° The first ressource-friendly product in this market segment (based on biomass balance)° 100% of the fossil-fuel raw materials were replaced with renewable raw materials

to produce the binder° No drop in quality compared with conventional products

Induline_LW-722_Eco_Anzeige_187x130_ENGL.qxp_Layout 1 18.02.20 15:34 Seite 1

Für Fenster aus Kunststoff, Aluminium oder Holz

Hochwertige Anlagen vom Stabzuschnittautomat bis hin zum Glasscheiben-Verklebeautomat

von der Einzelmaschine bis zur vollautomatischen Fertigungslinie

von der Projektierung bis zur Schulung der Mitarbeiter: ALLES AUS EINER HAND

www.LEMUTH.comMaschinen für den Fensterbau

Besuchen Sie unsHalle 3 Stand 3-327

Nürnberg, 18.-21.3.2020

Dichtungsmontage

Klebeband-Montage

Klips-Montage

Klebeband-MontageautomatKBA600

Flügel-BeschlagmontageautomatFBA136

DichtungseinziehautomatDAW100

Beschlagmontage

Glasscheiben-Verkleben

Versiegeln

Abstapeln / Puffern / Sortieren

Teilautomatische Fertigungslinien

Vollautomatische Fertigungslinien

Einbruchhemmende Fenster kleben?

… aber sicher!

Bei der einbruchhemmenden Verglasung gemäß den beiden Widerstandsklassen RC2 und RC3 treten OTTOCOLL® S 81 und OTTOCOLL® S 670 den Beweis an, wie sich moderne Fenster auch mit schmalen Profilbreiten heute sicher, normgerecht und effizient herstellen lassen.

Mehr zum Thema finden Sie unter: www.otto-chemie.de

Zielgruppen-Anzeige A5 Einbruchhemmung.indd 1 17.02.2020 14:42:56

Static Direct Glazing® by LohmannCertified and burglary-resistant according to RC2/RC3.

For many years, Lohmann has been offering reliable solutions for bonding windows. In a joint effort with their industry partners, the Bonding Engineers now developed an overall system for wood / aluminum windows. It is suitable for circumferentially coated wooden window profiles (standard systems) and allows for more freedom of design due to narrower profile geometries as well as new material combinations. Further benefits include a high initial tack to the glazing, an even load distribution within the window frame construction as well as a high resistance against temperature, UV radiation, aging and other weather influences.

A wood / aluminum system bonded with Lohmann SDG® tapes fulfills the burglary resistance class RC2. In combination with a rebate base bond, an upscale burglary protection in resistance class 3 can be achieved. Different variations have been certified by the ift Rosenheim and the PfB, e.g. according to the standard DIN EN 1627.

For more information, please visit www.architecture-bonding.com or get in touch via [email protected]

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