With over 20 years experience in manufacturing fenestration products in aluminium, steel and timber, Crown Aluminium take an ‘engineering’ approach to everything they fabricate. An engineer by trade, Roger Phillips has successfully built Crown Aluminium based on his experience and continues to develop his staff’s skills to ensure both quality and efficiency in manufacture.

As a fabrication only service offered by Crown, both the number of systems fabricated and the customer base is very broad. Crown source and populate the latest software systems to ensure accurate data is translated into accurately manufactured product. Running three Elumatec CNC machines being fed by two automatic double headed mitre saws, means there are few projects that Roger would not tackle.

Roger’s willingness to discuss engineering solutions for projects being worked on and long term relationships that the business has forged with systems companies, installers and envelope contractors, reveals his passion for Crown Aluminium.

What’s the secret to success for Crown Aluminium?

“There is no one answer, its a combination of things, but one thing is clear, we are asked to undertake work that is difficult or cant be done elsewhere. We certainly can’t do the ‘impossible’, but if there’s a solution and there is time to undertake the work, both in our production schedule and capability, we’ll quote the work. If it can’t be done, we’ll say so and turn the work away.”

“Working today with the latest software and CNC machines may seem to be a simple solution and make fabrication much easier, in some respects that's true for standard products. As systems have become more complex, with more options and the fact that Crown manufacture a very wide range of products from the main systems companies in the UK, we couldn’t work without the investment in CNC machines and software.”

“I think if we were to to summarise, it’s down to our experienced staff and relationships with our customers, sometimes undertaking what seems ‘impossible’ sometimes helps!”.

Your background in engineering, how do you think that has helped Crown?

“Engineering principles are not new, everything we make we use sound engineering principles that keep us both striving for improved efficiency and continued quality.”

“How many window manufacturers look to the ultimate ‘engineers’ in our society? I recently took some of my managers to the Toyota production plant in Derby to see their production facility. The ‘just-in-time’ principles, ‘value engineering’, ‘KISS’ (keep it simple stupid),‘time and motion’ are all very valid in todays fenestration production shop and we have implemented many of the principles from my experience and visits we have undertaken.”

“Take for example macro’s written for a single prep on a length of material, depending on how it is written can effect efficiency of the whole project. Sometimes the most logical way of programming the macro is not the most efficient, its all about experience. Cutting the macro’s operating time not only ensures greater efficiency but ensures more time for other projects in the production schedule without effecting quality. Macro’s themselves have also now been built into a library of preparations, reducing the need to write typical macro’s and ensuring that only the most efficient continue to be used.”

You mentioned customer relationships - how important do you feel this is in Crown’s success?

“Crown Aluminium sits in a unique position between systems company and installer, rather than being a company experienced in manufacture and contracting, which is typical for the sector, we just have to concentrate on fabrication. We work very closely with the systems companies in the UK and carry accounts with the majority of them, we are also seen by some of the very large envelope contractors in the UK as their fenestration fabrication facility, its almost like we have a foot in both camps. But relationships do win business and good relationships, based on honest discussion, agreement and meeting promises, last a lifetime and I’m proud that we have quite a few long term customers that we work for.”

“These relationships have opened up new customers where systems companies have put us forward to fabricate complex or difficult projects on behalf of some of their existing customers.”

So what about the future for Crown and the industry?

“We’ve diversified now into new products and systems, apart from manufacturing most aluminium systems, we are now manufacturing aluminium timber composite windows and curtain wall, we manufacture steel systems from several systems providers, we are registered as a ‘Secure by Design’ fabrication facility offering certified SBD products and we are equipped to manufacture unitised systems, again from various systems in the UK and Europe. Despite the downturn in the construction sector we remain very busy and have a healthy order book well into 2011.”

“As fabrication becomes more complex and sub-contracting on-site also becomes more complex and onerous, I think more fabrication only services will be set up in the UK. Our challenge is to continue to look at ways of improving manufacturing efficiency whilst keeping quality and of course meeting our customers expectations.”

“We welcome any enquiry for standard or complex projects from the UK and Europe, we will continue to specialise in manufacture and supply but leave the contracting to the specialists in the industry - our customers!”

Crown Aluminium is based in Stroud, Gloucestershire and was formed in 1987. For further information on Crown Aluminium and services offered, please visit their website at www.crownaluminium.co.uk or contact their offices by phone on 01453 753222.

‘Efficient manufacture’, ‘reduced labour costs’, ‘minimising error’ and ‘reducing wastage’ are all buzzwords for today’s successful window fabricators. Getting these issues under control is the difference between loss and profit.

One company, Crown Aluminium, are utilising the best equipment available and the latest software to ensure clients orders meet the very high standard that is expected by discerning clients and main contractors. Over 10 years ago, Crown were one of the early adopters of CNC machines. After installing their first Elumatec, almost immediately the investment started to pay for itself. At the time it was thought by many that such machines would put people out of work, on the contrary, these machines enabled businesses to take on more work due to the increased capacity such machines offered.

Today Crown run three Elumatec machines on a daily basis, two SBZ130’s and one SBZ150. The machines supply an experienced workforce of 50 with accurately prepared material making fabrication efficient and consistent. Data for the machines is supplied by Crown’s drawing office, which is no mean feat as Crown work with all the major systems companies operating in the UK to provide manufactured windows, doors and curtain wall assemblies in various materials.

The Jewel in Crowns success as being the largest independent systems fabricator in the UK can be attributed to these efficient Elumatec machines. Crown’s customers are long standing and are some of the largest facade an envelope installers in the UK.

Crown Aluminium is based in Stroud, Gloucestershire and was formed in 1987. For further information on Crown Aluminium and services offered, please visit their website at www.crownaluminium.co.uk or contact their offices by phone on 01453 753222.

Crown Aluminium’s position in the commercial fenestration market is balanced perfectly between the major systems companies in the UK and the major building envelope contractor/installers. The company is founded on sound engineering principles and is recommended by some of the major systems companies.

Schüco, Kawneer, Reynaers, Seniors, Technal and many other systems companies products are available through Crown’s fabrication service. In addition to systems fabrication, engineering solutions for complex or large assemblies can also be accommodated using some of the latest CNC machines from Elumatec.

Technical excellence is only half the story, a close working relationship between Crown and their customers ensures that the ‘partnering’ solution works effectively and efficiently, and above all, ensures customers long term relationship with the company.

Roger Phillips, Crown’s founder and head of the engineering facility, has almost 40 years experience in the industry and explains the ethos behind Crown’s success. “If a jobs worth doing, it’s worth doing right first time! That includes a clear brief of what is required, where it’s wanted and when. We work closely with our customers and can negotiate and agree what is required. Where it’s required is usually not a problem for us. The when is not a problem either - as long as we are in early and regular communication with the customer.”

Roger is well known for being straight talking and will do as much as he, and his company, can in order to meet customers realistic requirements. This flexibility to meet customers needs is reflected in Crown gaining a licence for ‘Secured by Design’ fabrication. Working in conjunction with the major systems companies, customers can now gain SBD licensed fabricated product in their specified system.

“Partnering can be put down to simply doing the job right first time, every time! I have been proud to work with some of the largest external envelope companies in the UK, many of whom Crown still work with today, it’s about reaching an understanding and having satisfaction in what you can achieve. It’s something that everyone at Crown takes home with them at the end of the day.”

Crown Aluminium is based in Stroud, Gloucestershire and was formed in 1987. For further information on Crown Aluminium and services offered, please visit their website at www.crownaluminium.co.uk or contact their offices by phone on 01453 753222.

Crown Aluminium are well known for offering a nationwide fabrication and engineering service for the supply of windows, doors and curtain wall systems from the major systems companies in the UK. Adding to their wide range of services the company is now set up to manufacture timber aluminium composite windows, doors and curtain wall systems from the award winning ‘Hybrid’ range of systems from Senior Architectural Systems.

Roger Phillips of Crown explains, “Over the last few years we have invested heavily in automated equipment and software, this has enabled us to take on a far wider range of systems as much of the machining is now automated and stored on our systems. There is no doubt that the use of composites is quickly growing in the UK and we wish to be able to offer our customers a broad range of systems to meet their needs. I believe Crown’s success is based on our partnering ability, both with the systems provider and our customer, this allows our customers to concentrate on programme responsibility and installation.”

Crown already supply aluminium systems from the major UK systems companies, together with steel systems and unitised systems, ‘Hybrid’ will complement their portfolio and help their customers reduce the long lead times for composites which are often imported from northern Europe.

With ‘Hybrid - Series 2’ recently launched, Crown can now also offer a continental style composite window which will meet specific commercial requirements in the UK.

Crown Aluminium are now registered with ‘Secured by Design’ to offer a range of commercial door and window systems that meet the new SBD standard. Working closely with Schüco, a wide range of systems can now be manufactured by Crown and offered complete with certification to ensure compliance with SBD requirements for any project. Products for other systems companies, which are tested and SBD certified, can also be manufactured under the Crown SBD licence.

As Crown Aluminium specialise in fabrication and do not undertake any installation or design of systems, they make a perfect partner for specialist fenestration installers across the UK. This specialist service often bridges the gap between systems company and installer and offers high quality fabrication coupled with realistic lead times. Crown Aluminium already supply some of the largest building envelope specialists in the UK with fabricated commercial door, window and curtain wall systems.

The new SBD service from Crown Aluminium is aimed at installers of doors and windows who require SBD certified products without having to register and maintain their own licence.

Crown Aluminium are now registered with ACPO to fabricate product that meets the new standard for 'Secured by Design'.

In the last 12 months there has been a change in the way products are tested to meet the standard. Originally the products were tested by the systems companies or the original designers, then the method of fabrication was passed to the fabricator to follow. This method has worked well but there is a need now for complete traceability for projects to be completed and awarded a 'Secured by Design' certificate which should help the building owner resist crime and attempted break-ins. This should ultimately lead to reduced insurance costs for the building owners.

Crown Aluminium have gone through the registration process and have worked closely with Schüco International to build a list of tested products which Crown can manufacture and pass onto clients who require this service. Should products be required that have not been tested, Crown Aluminium will advise and offer the customer a testing service to ensure conformance with the new standard.

Becoming and maintaining ACPO status may not be economical for most fabricators as the Secured by Design product is only required on ground floor applications. Crown Aluminium therefore becomes an ideal partner who can offer this fabrication only service.

Crown Aluminium have recently updated there website to showcase their range of services and products to the fenestration industry.

Now partnering with more systems companies and offering a wider range of specialist products Crown Aluminium is one of the UK's leaders in specialist manufacture.

The new site gives customers and specifiers a clear and quick view of the companies products and services to the industry.

A further 500 square metres of factory space has been acquired by Crown on their Stroud site in order to meet demand for future orders.



The company continues to diversify and have acquired equipment for the manufacture of unitised curtain wall systems.

In order to ensure the highest levels of accuracy and efficiency Crown are currently trialling a ground-breaking new software system. The new system allows fenestration contractors to communicate direct to Crowns' production team and help reduce transcription error.

Crown installs a new SBZ-150 elumatec CNC machine at their factory in Stroud making a total of three SBZ CNC machines now fully operational.

Roger Phillips has been appointed President of the Council for Aluminium in Building.