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Our Process

• About Us
• Design Process
• Planning-Survey
• Order Processing
• Manufacturing

Manufacturing of Orangeries and Conservatories

Now all the information has come together we are ready to start the real making. It takes between eight and 15 working days to complete most of our conservatories and orangeries. Each project large or small goes through the same processes. There are no stock sizes and everything is individually made for each customer.

The first process is to take the stock timber and convert it into the items on the cutting lists, then mark them with a code.

The next process is planing, and every component is Planed All Round to the cutting list profile. This is known (unsurprisingly!) as PAR. We are starting as we will continue - with precision, and all profiles are planed to a tolerance of +/- 0.1mm.There are three cutting lists, Roofs, Windows & Door and then Ancillaries.

Roofs

Roof making, is our most impressive process. We worked together with a German company - Maka, to design a unique self loading twin channel 5 axis CNC routing machine, that produces completed roof components in all their variety and complexity. Rafters with sliding tapered dovetail joints, roof bosses mortised to take the rafters at the apex, ring beams and fascias.

This technology is limited only by your imagination and provided you had the right program, you could carve a bust of your grandfather! Components are fully specified in 3d on the computer screen and the machine code is then sent to the server where it waits to be called by the right bar code on the timber.

The philosophy is "complete components", and even the screw holes are pre drilled and the code engraved on. This all sounds high tech and it is, but the flexibility allows complete bespoke manufacture. You have the look and feel of a hand crafted product but engineered in a way that would never be possible by hand.

Unlike our competitors, we never preassemble roofs, they are designed to fit together perfectly and when they arrive to site it is the first time they have been assembled. This may seem obvious in todays technological environment, but it isn't. We are the only conservatory company that can make truly bespoke roofs without 'trial and error'.

Windows & Doors

The same philosophy that applies to roofs applies to our window and door manufacture. Our window line is highly sophisticated going from computer screen to finished component. All items from window frame to door frame, opening sash and door leaves are produced automatically without any operator setting between components. Hinge and handle locations are machined at the component stage, to human error at the hanging stage.

Once machined all components go onto the hydraulic press to be glued up into sub frames ready for painting. Although highly automated for our main product lines, we have retained a base of skilled joiners which enables us to produce the individual touches that make our conservatories and orangeries stand out from the crowd. We often make shaped frames, windows and doors either in response to a specific  requirement, or as a feature in a larger project.

Painting

To be continued.......................!

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