Breaking new ground: Emplas Factory Expansion

At 50,000 sq ft, Emplas already operates from one of the UK’s largest window and door manufacturing facilities. 

As part of its new development programme, it will add new factory floor space, loading bays and offices – increasing its size by a third again.

Kush Patel, Operations Director, Emplas said: “As a business, we are very much looking to the future. We have seen some solid growth but recognise that if we want to keep growing into the future, we need to invest in our products, services and our manufacturing capability to support it.

“This includes bringing more people into our business to ensure that we continue to deliver the highest levels of customer service but also investing in our manufacturing and distribution facilities and we need space to do it.

“Increasing our factory space by a third allows us to continue to grow but importantly plan for far longer term growth going forward.”  

The expansion of the factory floor follows the investment that Emplas has already delivered on it. This includes the purchase of new welders, digital measurement systems and the centre-piece of the six-figure spend – its’ new Schirmer saw centre.

The new dispatch facility is a key element of the extension. Already operating a barcode system across its manufacturing workflows, Emplas has extended its order tracking capability right up to the point of delivery.

This includes tracking of IGU orders through a ground-breaking tie-in with the barcode tracking system offered by its glass supplier, Pilkington in addition to order tracking through its own production process.

It means that Emplas customers can track orders through its digital portal and the Emplas Virtual Assistant, right through from the point of order to delivery.

“The new dispatch facility will allow us to work smarter. It’s a critical check point - each order is scanned as its prepared in the loading bays and then re-scanned onto the lorry”, said Kush.

“In identifying or eliminating any delays at this point of the supply chain, we give ourselves time to take corrective action before it has any impact on the customer.

“A little more space, including space for wrapping and protection of products, will be a real asset to us and most importantly, our customers – supporting us in continually improving product service and quality.”

Emplas’ complete and on-time deliveries currently run at 99.3% compared to an 84.6% industry average. It also has a product quality rating of good or excellent by 98.7% of its customers compared to an industry average of 79.2%.