An image of two float liners - pilkington and Guardian An image of a factory worker holding stained glass A worker lifting a float of glass Two workers cutting floats of glass A worker adding some lead to a pane of glass

Our flagship purpose built branch in Swansea is the heart of our operation, and where we produce 30,000 insulated glass units per week.

Our continual investment in state of the art machinery, combined with our high calibre workforce allows us to lead the industry in insulated glass unit production methods.

Our dedicated fleet of transportation vehicles get our products to the centre of your operation, whether that be your warehouse or a worksite.

Our dedicated stained and bevelled glass studio and the attention to detail we’re known for allows us to provide our customers with the very best option each and every time.

Products & components

Our Sealed Unit manufacturing process

All our sealed units are bespoke and are made to our customer’s specific order depending on the glass type, size and any decoration required.

Long gone are the days when our standard sealed unit was made with two pieces of 4mm clear float. In today’s energy conscious world and as a result of legislation change sealed units are now made with glass containing highly complex low emissivity coatings.

Also advances in the technology of glass have enabled more benefits to be gained from the sealed unit. Self cleaning and noise reduction (acoustic) options may now be demanded, combined with the more traditional options of obscurity, or solar reflection. It may be that decoration such as coloured film, lead or Georgian bar inserts are required. A large percentage of what we make contains all of the above in safety glass – laminated or toughened as opposed to normal annealed glass.

Whatever glass is ordered the two panes are washed in order to remove grease and fingerprints and are then set either side of a spacer bar. Historically the spacer bar was aluminum or steel, but the shift towards more energy efficient sealed units has seen an increase in warm edge spacer bars made of materials more thermally efficient than metal.

Our Tri-seal applicator automatically applies the Edgetech Tri-seal product during the production process on our automated production line. It allows for non interrupted production of IGUs with various spacer widths.

Maximum / minimum sizes of the sealed units we make

Please CLICK HERE to view the maximum / minimum sizes of our sealed units.

An image of the glass systems furnaceToughened Glass

Toughened or tempered glass is a type of safety glass processed by controlled thermal treatments to increase its strength compared with normal glass.

Glass is cut to the size required and then its edges are ground or arrised. It then goes through a toughening furnace where the glass is heated up very quicly and then quenched and cooled very quickly. This process of taking the glass up to 750 degrees and then cooling it, changes the molecular structure of the glass and gives it a very high outer tensile strength.

When broken, toughened glass breaks into small, relatively harmless pieces of glass which minimize the risk of injury. It is used in an increasing amount of applications where safety glass is required such as doors, side screens and low level glazing.

Glass Systems' dedicated toughening company, Vizor Tempered Glass, supplies the toughened glass requirements for our different divisions. Three automatic cutting lines, three arising lines and three toughening furnaces, give us the capacity to produce 50,000 pieces of toughened glass each week. Toughened glass is available in thicknesses from 4mm-10mm and in the different glass types we stock - clear, patterned, low-E, solar control and self-cleaning glass.

Laminated GlassLaminated Glass

Laminated glass is a type of safety glass that holds together when shattered. In the event of breaking, it is held in place by an interlayer, typically of polyvinyl butyral (PVB), between its two or more layers of glass. The interlayer keeps the layers of glass bonded even when broken, and its high strength prevents the glass from breaking up into large sharp pieces. This produces a characteristic "spider web" cracking pattern when the impact is not enough to completely pierce the glass.

PVB interlayer offering a high level of sound insulation

Laminated glass is normally used when there is a possibility of human impact or where the glass could fall if shattered. The PVB interlayer also gives the glass a much higher sound insulation rating, due to the damping effect, and also blocks 99% of incoming UV radiation. Laminated with specialist PVB interlayers, known as acoustic laminates, which further improve sound reduction are also available.

Glass Systems stock laminated glass in thicknesses of 6.4mm and 6.8mm, available in clear, Pilkington K, Ecopane, antisun, opal and obscure.

an image of Obscure glassObscure Glass

Glass that maintains privacy in a range of stylish designs

For privacy, pure style or to allow more light into internal rooms, obscure glass gives you a whole range of attractive options. We stock the Pilkington range of patterned glass which gives no fewer than 18 different patterned glass designs – from classic to contemporary, no one offers a bigger choice.

Please note, with the exception of Satin, the maximum size sheets available are 1320mm by 2140mm.

None of the Pilkington patterns are designed to have an orientation (an up side) but care needs to be taken with adjacent panes that the pattern direction is maintained. There is a linear nature to Pilkington Texture Glass Warwick and so householders should be aware that there could be aesthetic implications when choosing this design. Also, for the glass supplier the result may be that this pattern is less accommodating when cutting and may result in a greater proportion of selvedge from the original glass plate.

Ecopane Glass

Ecopane is Glass Systems branded name for the soft coated low emissivity glass we use.

The hard coated low emissivity glasses of yesteryear have given way over recent years to the new generation soft coated low E`s, largely due to changes in legislation. These more complex products give much better thermal performance and are a lot more neutral than the hard coats they are replacing – no more unsightly tints on the white net curtains!!

Three times more thermal insulation than standard double glazing

Sealed units using Ecopane offer three times as much thermal insulation than standard double glazing and will depending on the window frame, easily exceed the requirements of the latest building regulations, whether by WER or by Overall Window U value route to compliance.

Double glazed units incorporating Ecopane and having an argon gas filled cavity are some of the best performing sealed units on the market. In a double glazed unit they will have a centre pane U value of 1.20, and in a triple glazed unit a this can go down to 0.60 U value.

Our Eco Plus 1.0 range uses a higher specification Low Emissivity soft coat glass that will give a U value of 1.0 in a double glazed and 0.50 in a triple glazed unit.

An image of decorative or stained glassDecorative glass

Decorative glass has experienced a recent revival as modern homeowners look to this ancient craft to add character and originality to their doors and windows. As market leaders of decorative glass since 1989, Glass Systems has the skills and resources to provide you advanced performance decorative products that will help you capitalise on this growing market and win new business.

A wide variety of designs

Our wide variety of designs range from traditional motifs to contemporary styles and are produced using a technique called overlay, a method whereby all the materials are applied to the outer leaf of an insulated glass unit. This provides the unit with greater strength and insulating properties than traditional stained glass whilst retaining the vibrancy and classic beauty that traditional stained glass is renowned for.

tested to meet high standards and supplied with a 10 year guarantee

The materials we use are rigorously tested to ensure they are suitable for use in modern windows and doors that are exposed to extreme climatic conditions, giving your customers a highly personalised and durable product. Our entire selection of decorative glass units come with a 10 year guarantee and Glass Systems can even produce a bespoke design so you can give your customers exactly what they want.

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Energikare by PilkingtonPilkington energiKare Glass

Pilkington energiKare is a unique double glazing unit that is comprised of two different types of intelligent glass. Pilkington K Glass, the UK’s best-selling low emissivity glass, makes up the inner panes of the sealed unit. Its primary function is to prevent heat escaping through windows by reflecting it back into a room.

Increase heat gain with Pilkington energikare and Optiwhite

Pilkington Optiwhite possesses ‘extra clear’ properties and makes up the outer pane of the unit. It allows more sunlight and heat to enter a room through the window. Combining these two types of thermally insulating glasses creates an effect known as solar gain which uses free energy from the sun to heat a room. The solar gain effect can reduce the amount of heat lost through windows by up to 75% and heating bills by up to 20% a year.

By integrating the glass with a Swisspacer V warm edge spacer bar and filling the unit with argon gas, Glass Systems are able to fabricate a sealed unit that can easily achieve an energy rating of B and above.

An image of an Argon Gas tankArgon Gas

As a double glazed unit is sealed, the space between the two panes of glass is filled with air in order to improve the insulation properties of the unit. Whilst air is considered a good insulator there are better options available.

For Optimum thermal insulation use Argon Gas

At Glass Systems we use argon gas as a filler for our insulated glass units. Argon gas is a colourless, odourless and tasteless gas that provides optimum thermal insulation whilst being both non-toxic and inert. Using argon gas in our products allows them to achieve a higher energy rating compared to units using air.

All of our sealed units hold BS EN1279 Part 3 pass certificates, meaning our sealed units comply with the legal requirements for the testing of rates at which gas leaks from a unit.

Products that are energy efficient for longer

Over time the concentration of gas present within an IGU decreases as it escapes, once the concentration falls below 80% the insulation properties are lost. Even after 20 years a Glass Systems sealed unit will still retain 80% of the argon gas it was filled with during the manufacturing process. This helps to raise the internal glass temperature, eliminating condensation and providing eco-conscious consumers with a product that will reduce their energy consumption, thereby cutting energy costs.

Warm Edge Spacer Bar

Most heat loss from windows occurs at the sealed unit edge where the spacer bar touches the two panes of glass and creates a thermal bridge. Heat has a direct passage from inside to outside which causes condensation to form in a ‘u’ shape at the bottom of the sealed unit.

Reduce heat loss with warm edge technology spacer bar

Glass Systems Direct supply the Edgetech Tri-seal Warm edge Spacer product, made from a highly insulating Flexible Silicone Foam that reduces the thermal bridge, therefore also reduces condensation and cold spots.

The Edgetech Tri-seal product is a triple seal warm edge product that complies with BS EN 1279 part 2 and 3.

Fast production with the new Tri-seal applicator

Glass Systems Direct has recently invested heavily on a new Tri-seal Applicator, this automatically applies the Edgetech Tri-seal product during the production process on our automated production line. This process allows us to acchieve our current production capacities and produces a consistently high quality sealed unit enabling our units to achieve energy rating of A.

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