Embed Size (px)
Citation preview
Decorative & industrial panel
fabricators for the interior fit out market.
2 3
Grow by working together.
Use us as your preferred outsourcing partner.
Get in touch with us today to arrange a consultation visit with one of our regional account managers.
01925 223 [email protected]
4 - 7
8
Introduction
Company Growth
15
12
11
22
20
16
18
25
Plastics
Solid Surface
Laminates & Woods
GoDesign™
Substrates & Cores
Our Services
26
34
33
29
31
37
38-45
Aquaform® Postformed Panels
PurEdge® PUR technology
Cubico® Washroom Systems
STARlite® Lightweight Panels
Shield® Non FR & FR Doors
Carv3D CNC Panels
Contact Us
Case Studies
Our Accreditations
The Environment
47
4 5
HelloWe have been manufacturing bespoke decorative laminate panel products for the interior fit out market since 1976. Our wealth of experience and quality of craftsmanship has built up a strong customer and supplier relationship.
Trust in us to be your preferred outsourcing partner.
Our continued investment in the latest technology as well as staff training and knowledge gives us the ability to say ‘yes’ to your project demands. We are able to work through small and large quantities as well as working with you to advise and guide you to get the best results possible for your intended project.
Family Ethics, Customer Focused
6 7
We FabricateWe have built up a strong industry presence as fabricators of high quality, value for money laminate and decorative wood based panels.
Design and material trends within the UK’s interior fit out industry are ever changing and developing. To ensure we are always able to meet your project requirements we continually invest in technology and training.
These investments have enabled us to not only increase our service offers but also the types of materials we can fabricate your designs from.
Today we fabricate panel products from laminates and woods as well as solid surface and plastics, including both flat as well as 5-axis 3D CNC panel details.
8 9
Company GrowthSince our beginnings in 1976, We have managed to secure and sustain a strong customer base which has enabled us to grow and develop into the business we are today. Over that time as our customer base grew so did our need for increased manufacturing space.
Our first site that was used from establishment in 1976 was 6000 sq ft of rented manufacturing space in Wigan. The business steadily grew and the decision was made in 1991 to move sites and purchase our own, larger manufacturing unit. This led to the purchase of a 12,000 sq ft site on Sankey Valley Industrial Estate in Merseyside. Over the years as sales increased we bought adjoining units and knocked through; until in 2006 we built a custom add on which included more manufacturing space as well as an office block. This expansion along with the previous expansions totalled a workspace of 63,000 sq ft.
Our latest acquisition is a 116,000 sq ft factory space which sits on 16 acres of land. This has allowed us to re-organise the flow of machines to improve efficiency and productivity of our workloads. The site also lends itself to future expansion plans without the need to move altogether.
1976 1991 2006 2016
= 1,000 sq ft
6,00
0 sq
ft
12,0
00 s
q ft
63,0
00 s
q ft
116,
000
sq ft
10 11
Laminates & WoodsHigh pressure laminates and wood based products from the wide scope of manufacturers has been at the core of our business offer since the beginning.
Over the years we have seen more and more varieties of laminates and wood based products come to market. Embracing and understanding all of them; we are now able to advise our customers on correct specification of materials depending on their project requirements.
The list of laminates and wood based panels we fabricate with include: MFC, MF-MDF, HPL, CGL, SGL, solid woods, plywoods and veneers.
If you would like to gain a better understanding of these materials then please refer to our separate Material Guide, which explains all the different materials that we fabricate from.
12 13
Solid SurfaceWe have seen solid surface work rapidly grow over the past few years. This versatile material is the designer’s dream with almost limitless potential. Our investments in technology and training alongside our future plans ensure we are able to accommodate any solid surface fabrication.
Although it is initially more expensive than other materials; solid surface can be reconditioned over time back to its original state making it more economical in the long run. It can be thermoformed and jointed to create 3D pieces with the joints being finished to an almost invisible state.
Solid Surface can been used for humble bowl designs right through to exterior cladding for buildings. If you can design it then you can almost guarantee you can fabricate it out of solid surface.
Technical details and properties of solid surface can be found in our Material Guide alongside all the other materials we fabricate from.
Image courtesy of Hanex®
14 15
PlasticsPlastic fabrication is the latest string to our already extensive bow. With the principles of fabrication similar to laminates and wood, combining the machines in our factory to handle plastics is quite straightforward.
All the CNC capabilities that we already use can be applied to plastics with the addition of an edge polishing tool to give you the crystal clear edge details most common with acrylic panels. We also work with thicker polycarbonate plastics seen predominantly in healthcare environments, which we can post-formed if required.
Our most popular plastic offer at the moment is post-formed PVC wrapped doors and fire doors (Q-Mark Certified). However we are more than happy to work with you on alternate plastic projects.
16 17
Substrates & CoresWe are able to laminate panels with a variety of substrates including Chipboard, MDF, and Foam (for use in our STARlite® panels).
Whatever grade of substrate is needed; be it moisture resistant, fire resistant or lightweight, we can work easily within our supply network to source you the right product at the best price.
Image courtesy of Egger®
18 19
Laminating
Panel Sizing
Edgebanding
CAD & CAM
CNC
Postforming
Accuracy is Key. Starbank are equipped with two state of the art beam saws as well as a robotic storage and retrieval system. We ensure your panel products are cut right first time, every time.
Since 1976 Starbank have been bonding decorative panels to all kinds of substrates. We laminate on average 50,000 panels per year, with the capacity to double that if needed. No job is too small or large for us.
Starbank’s PUREdge™ technology provides you with the strongest hold for all your straight edge panels. Sophisticated machines and techniques for both straight and shaped edge panels ensures we are always have the edge on our competitors.
Starbank have developed bespoke machinery and techniques to offer you the highest quality in postformed panel fabrication. We even get involved in testing our suppliers products so if we can’t bend it then it probably cant be done.
Holes, grooves, rebates, edge profiles, pockets, patterns, nesting, 3D designs. Whatever your CNC needs we can achieve it. Equipped with the industries best technology we have yet to find a limit on what we can CNC for our customers.
We have a dedicated CAD & CAM team to work alongside you to ensure your products; no matter how complex are able to be machined precisely. With our extensive tool library we are able to programme the most efficient production schedule, after all time is money.
20 21
Bankfield High School: Beauty Salon
Our GoDesign service allows you to collaborate with our design team in order to help you design furniture specific to your interior space.
It works with you initially giving us a design brief and then we create mood boards and concept furniture designs for your approval. Once everything is signed off, it all gets fabricated in our factory. All you have to do is get your contractor to build and install the furniture once we delivery it to site.
This is exactly what happened when one of our customers asked us to help design furniture to be used in a high school beauty salon.
The design brief was for ‘funky’ engaging pieces of furniture for hairdressing and nail bars along with storage for beauty products and equipment. All of which had to include pink.
If you would like to take advantage of our GoDesign service on your next project, then get in touch with us on 01925 223 965 or e-mail [email protected] with your query.
22 23
With decades of experience in laminate fabrication we have introduced the Aquaform® collection – a cost effective post-formed laminate panel product that will exceed expectations when it comes to performance, durability and aesthetic appeal.
Post-formed Aquaform® can be manufactured from either a solid SGL or CDF sheet, or by utilising sections of solid cores which are over laminated with HPL and then post-formed into the desired shape.
The ability to withstand wet and humid environments or where hygiene is of paramount importance makes Aquaform® very popular within healthcare, leisure and washroom facilities.
The types of products we have made from Aquaform® includes anything from vanity units, pharmaceutical worktops, window sills, post formed wall panels and leisure facilities.
More information including technical details on Aquaform® can be found in our separate Aquaform® Booklet.
24 25
STARlite® panels un-edged to expose our unique composite core.
We have seen an increase in the specification of thicker panels being used in all areas of interior fit out especially retail POS and display stands.
The problems faced with traditional fabrication methods, made the panels heavy, cumbersome, and a nightmare to install, even when using lightweight MDF or Chipboard cores.
We took it upon ourselves to design and develop a solution for our customers, which is exclusive to Starbank. The result is our STARlite® lightweight foam core panel.
STARlite® is constructed by removing most of the heavy core material and replacing it with high density foam. The construction method that we have developed ensures ordinary fixings can be used with the panels whereas similar products on the market require specialist fixings.
STARlite® has undergone specialist testing at FIRA UK. The test was to measure how a finished STARlite® panel performed against FIRA’s Load and Deflection Test. It also included the BS 6222 Part 3 Adhesion Test for the edge banding detail using our PUR Edge adhesive system. The STARlite® lightweight panel achieved the highest rating given by FIRA, with results similar to standard MDF and chipboard. Once again proving the quality of products produced by Starbank.
More information including technical details on STARlite® can be found in our separate STARlite® Booklet.
FIRA TestedDetails on Request
26 27
Shield is our dedicated Q-Mark certified fire door brand.
We fabricate Q-Mark Certified fire doors for a whole range of market sectors. We specialise in FD30 and FD60 rated doors with future plans to extend our scope to include FD90 and FD120.
Our scope allows you to include customisable design options such as vision panels and ironmongery. There are also alternate door leaf designs available to fit any door opening including specification details to ensure the doors comply with Part M: Mobility compliant where necessary.
We have been fabricating straight edge laminate fire door leafs for years. With recent investments in technology we have been able to develop our techniques and we are now able to offer you postformed PVC doors complete with matching door set.
For more details on our Fire Door offer, please visit the Starbank website at www.starbank-uk.com/q-mark-fire-doors/
28 29
Cubico® is Starbank’s dedicated washroom and cubicle system offer.
Our customers wanted simple washroom ranges specific to key markets that could be specified easily. We listened. The Cubico® brand is built around maintaining this customer focused ethos.
We have four main brochures; each dedicated to a specific market sectors including:
Education: cubicle ranges that are designed for use in nurseries through to universities.
Leisure: Fully framed systems that can withstand wet and humid, high traffic environments.
Healthcare: These cubicles are designed to cover all areas on healthcare for simple hygiene conscious systems to anti ligature designs.
Commercial: The commercial ranges cover all budgets and styles to ensure their is a cubicle for everyone.
We can supply you with not only the cubicle systems but the duct panels and vanity units as well as appropriate lockers and benching. A complete washroom offer.
If you would like more information regarding our Cubico Range, then please request a brochure or visit our website: www.cubicowashrooms.co.uk.
30 31
PUR (Polyurethane Reactive) glue technology is the ultimate solution were high bond strength and moisture resistance are required. Its high specification is ideally suited for the application of solid hardwood, high pressure and even compact grade laminates as an edging material.
We bond all decorative straight edge edge-banding using PUR technology as standard.
The high bond strength is maintained for panels that are to be used in high traffic areas where the edging may come under excess stresses than usual. The specification of PUR allows us to work to the following:
• Panel thickness up to 60mm (Please check with the sales office at the time of enquiry)
• Thin melamine up to 3mm ABS• 3D acrylic edging• Solid edges up to 20mm thick• 44mm & 54mm Solid core fire doors• Wide choice of Solid hardwood finishes available• Wide choice of HPL edging and faces• Straight line edging application before or after face laminating
32 33
Carv3D 3D CNC panels allow you to create a statement piece within any interior market. With many pattern options available as well as tailor made designs, Carv3D is the new era of decorative panel fabrication.
We recommend specifying Carv3D panels when using through colour materials such as solid surface or acrylic. Bonded panels with a core material of solid wood or plywood can be used to create an interesting layering on the finished panel.
34 35
Our AccreditationsWe have worked hard as a business to ensure that our working practices meet the recognised standards. We were the first manufacturer in the UK to be awarded all three ISO accreditations for quality, environmental and occupational and health and safety management.
We achieved the gold standard from Investors in People, ensuring we are getting the very best from our staff and them from us, increasing productivity throughout each stage of your experience with us.
When it comes to fire doors we are fully accredited by our governing body Q-Mark. This assures you that along with Q-Mark approved installers your door will perform as it should in the event of a fire. Alongside our Q-Mark accreditation we are members of ASDMA: Architectural and Specialist Door Manufacturers association. This allows us to work with other experts in the fire door fields regarding hardware, glazing and all the other components that make up our fire doors.
Being members of BCFA: British Contract Furniture Association, assures you that the products we manufacture are of the highest standards and quality.
36 37
As well as meeting the criteria for our OHSAS 18001 accreditation, we have many other environmentally conscious procedures in place. We are FSC® and PEFC® certified and are able to supply you with full chain of custody products. This is specified more and more by architects and specifiers, and therefore only fabricators with our credentials can take on those projects. Any fabricator who isn’t certified with the relevant bodies, regardless if they buy FSC or PEFC material will break the chain of custody once they start manufacture, and the FSC and PEFC credentials along with it.
Our factory facility currently has 96 solar panels installed on the roof to help offset our power usage. The solar panels are still able to harness the sun’s energy on cloudy, dull days, which we can say are more often than not where we are.
To accompany the solar, we have installed a biomass system with a silo that is 10m wide and over 17m tall. This large biomass system will work off most of the waste products we produce and provide the factory and working areas with enough heating.
Overhauling our lighting system to smart LED lighting helps improve our electricity consumption as the lights only work when their sensors pick up movement. This type of system is in place across our extraction system as it is only operational for the machines that are working.
We hope to continue to add and refine our environmental credentials as this will help us to invest whilst maintaining our value for money ethos for our customers.
The Environment
38 39
Manchester RoyalInfirmary
40 41
Boeing 757-200Air Astana
42 43
Royal Bank of Canada
44 45
Retail Display & POS Units
46 47
We have an extensive supplier network & excellent buying power, just for you.
Bringing Value To The Surface®
We hope our brochure has inspired you to get in touch. To arrange a consultation with one of our regional account managers, contact us by your preferred method.
01925 223 [email protected]
External Sales & Support
Starbank Panel Products LtdSankey Valley Ind EstNewton-le-WillowsMerseysideWA12 8DJ
01925 223 965 [email protected] www.starbank-uk.com
This brochure has been printed in house on FSC® certified paper
