An Innovative Step Forward from V.A.V. Group
Installing balcony window panes has traditionally required two separate profiles: a hard U-shaped profile to attach the glass in place and a soft seal to ensure a proper fit. Why not combine the two into one product to make the installation simpler, while also offering an alternative to PVC?
This was the idea behind a new profile developed by V.A.V. Group. By combining hard and soft sections into a single TPE profile, we set out to simplify the customer’s production process and replace the two separate materials with one solution. In this article, Mia Ahlgren, our Sales Manager, and Arttu Juntunen, our Development Engineer, share the conception and development of a product years in the making.
This kind of approach can also be utilised, for example, in shower enclosure seals and similar applications, to replace PVC profiles with recyclable products.
One Profile, Two Functions
The idea originally came from Ahlgren, V.A.V. Group’s Sales Manager, who saw an opportunity to make the installation process easier for manufacturers of balcony glazing systems. Previously, the hard U-shaped component was made from PVC, while the softer sealing component was supplied separately. Both had to be fitted together before the glazing could be installed, something that Ahlgren saw as a problem that could be fixed:
“With a single TPE profile, the customer could receive both functions in one product from one supplier, reducing the work required during assembly.”
Ahlgren pursued the project persistently, and the concept attracted interest from two potential customers, each approaching the development at a different pace. Eventually, one project moved forward, bringing the idea closer and closer to practical use.
Juntunen, V.A.V. Group’s Development Engineer, joined the project while development was still underway. His role was to help resolve production challenges and ensure the profile would work not only for the customer but also within V.A.V. Group’s manufacturing process.
One of the main challenges was maintaining a consistent profile shape during production. The customer’s preference for a transparent material added complexity, requiring adjustments to the manufacturing process and some new approaches to production.
Although challenging, Juntunen describes the design process as rewarding: “After working through it and mapping out all the requirements, our team succeeded in producing a functional profile for the different glass thicknesses used by the customer.”
Positive Results in a Real Construction Project
Our customer has tested and approved the new profile, and it has already been used in a completed construction project. The initial results have been very encouraging, with positive feedback on both the profile’s performance and its ease of installation.
The profile provides the stiffness needed to hold the glass securely while retaining the flexibility required for sealing. According to the feedback received, its fit and staying power in the window frame have also compared favourably with the previous PVC solution.
Installation was intended to be simpler, and the first results suggest that the approach is working as planned. Instead of handling two separate profiles, the customer can work with a single product supplied in the required lengths, reducing steps in the installation process.
The material choice brings another advantage. TPE is mechanically recyclable, offering a more sustainable alternative to the PVC component used in the previous solution. The material is also easier to cut to length, helping streamline handling during installation.
Packaging has been designed with practicality in mind, too. The profiles can be transported in reusable AluBasket cages supplied by Mäkelä-Alu. These cages can be returned and stacked compactly when empty, making the packaging convenient to circulate between V.A.V. Group and our customers.
Preparing for the Next Stage
As the concept has proven its potential, Ahlgren and Juntunen agree that there is now work to be done so that we can take up wider-scale production.
The most significant manufacturing challenges have been resolved, and V.A.V. Group is continuing to refine the process. Investments in equipment and further improvements, including updates to cutting capabilities, will make production more efficient and prepare for potential increases in demand.
For the team, seeing the product move from an idea to a solution used in a completed construction project has been an encouraging milestone, and the positive customer feedback has given us a strong foundation for further development.
We are very excited about the possibilities this profile can offer, and are ready to continue development and manufacturing readiness.
Are balconies your business? Do you want to replace rigid PVC profiles with a recyclable alternative? Interested in the new profile? Get in touch with V.A.V. Group to discuss the solution and its potential applications. We look forward to sharing more about this development as the work progresses.
