Roller shutters manufacturing: more profits and sustainability with coil-to-window systems

Aluminum PU-foamed rolling shutters are more and more popular in Europe and abroad thanks to their multiple advantages: energy saving, increased privacy and safety, easy automation, high quality and resistance to atmospheric agents.

The standard production cycle for rolling shutter curtains starts form 6 meter long bars, that are cut to length and assembled with a scrap rate between 10 and 15%. Modern coil-to-window production systems, instead, start from the aluminum coil and produce cut to size rolling shutter curtains with a scrap rate close to zero.

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Traditional production method from roll formed bars

The most common production system starts from roll formed slats, cut in the length of 5,6 to 6 meters. The bars are cut to length and depending on the width of the window, a piece of bar remains unused. The following table shows scrap rates on a 5,6 meter long bar, for different curtain widths. 



Rolling shutter window producers have tried different ways to optimize the scrap rate, for example by cutting different sizes on the same bar, sorting them afterwards. Clearly, these operations are time consuming and need to be assisted by an operator. Generally, the scrap rate assumed with this production method is between 10 and 15%.

Coil-to-window rolling shutter production system

Coil-to-window production systems produce assembled and fixed curtains directly from the aluminum coil. Production data such as the window width, height and quantities are loaded via simple excel tables to the system.

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