Apeer Doors
Intruder-proof ‘fit & forget’ doors
Background
Based in Ballymena, Northern Ireland, Apeer Doors are today a leading supplier of A++ energy rated, highly secure composite doors.
Challenge
20 years ago, Apeer were manufacturing PVC doors, supplying largely to the social housing sector. At the time, an industry report confirmed that door manufacturing was trending towards composite construction.
Apeer secured an Irish Government grant to explore composite manufacturing, and approached our expert team to answer the following questions:
- Are composite materials a viable alternative to PVC in door manufacturing?
- Can the RTM process produce doors that have better stability, longevity and security over PVC alternatives?
- Can RTM produce complex parts with a wood-grain effect?
- Can we produce doors that we can ‘fit and forget’ for social housing?
- Can the RTM process produce doors that can withstand shot-gun and axe damage?
- Can RTM produce 20,000 door panels a year with a consistent thickness and structural tolerance?
- Can RTM produce doors to our specifications with an 8 minute turnaround?
- Can the RTM set-up produce 6-7 different door designs?
Solution
Working collaboratively with Apeer, our CI experts:
- Reviewed Apeer’s specifications & requirements.
- Specified a new RTM production process.
- Specified and commissioned new RTM tooling.
- Specified and sourced a supplier for the right resin mix, and supplied a 3,000 kilo resin and handling and mixing vessel.
- Specified and built a customised CIJECT 2 machine.
- Specified and supplied the tool handling and injection valve system.
- Specified and integrated a 3rd party Hydraulic press, with one-button operation.
- Tested and installed the first production cell, integrating it into the production line.
- Trained and supported the production line personnel.
Results
Following the success of the first production cell, Apeer scaled up their RTM production line, ordering a further 3 cells. They have refined their production process to achieve an extensive range of aesthetically pleasing, A++ energy efficient, highly secure doors.
