Company overview:
Regency Glass is a manufacturer of high‑performance insulating glass units, supplying the residential and commercial glazing markets. They are recognised for innovation in energy‑efficient glazing, including their next‑generation ultra‑thin glass triple‑glazed unit, Regency Triple® featuring Corning® Enlighten™ Glass, which is designed to meet evolving performance and sustainability standards. Combining decades of industry expertise with automation and modern manufacturing processes, the business is a trusted trade partner and a leader in the UK’s high‑performance insulating glass manufacturing sector.
Situation:
Regency Glass has introduced a new product to the UK market, Regency Triple® featuring Corning® Enlighten™ Glass. It is a revolutionary solution that delivers the performance of triple glazing but at the same thickness as a double-glazed unit and with a comparable weight. This removes the bulk and handling challenges traditionally associated with triple glazing.
The investment in production equipment to support this new product has made Regency Glass one of the most technologically advanced insulating glass unit manufacturing facilities in the UK. The new product opens high-performance market options for renovations, new buildings, and situations where existing frames are to be preserved.
For Regency Glass, this is more than a product launch, it is about resetting standards, transforming the industry, and enabling customers to go further. To achieve this step change, the business required significantly more space, moving from its longstanding 110,000 sq. ft. site in Leigh to a new 420,000 sq. ft. facility in Warrington.
PPS had previously supported Regency Glass in improving the efficiency of its compressed air system at the Leigh site through pipework alterations, controller settings, and ongoing preventative maintenance. Building on this understanding of Regency Glass’s needs, PPS was then selected to specify the compressed air system for its new high‑precision manufacturing hub.
Task:
To specify the system PPS needed to accurately calculate the air demand for the new site. As the current production from the Leigh site would be moving to Warrington as part of the phased install, PPS data logged this site to give an accurate account of the plant’s compressed air demand, pressure and cycle over a seven-day period.
This was then combined with the specifications of the new manufacturing equipment to give a complete air demand profile for the Warrington site. At this point it was also important to discuss with the customer the plans for future development and how this could influence what air compressors should be specified.
The priority for Regency Glass was a reliable system that could handle their growth plans, but it was also key to ensure the new compressed air system would be working efficiently with low lifecycle costs.
Action:
The new compressed air system included two Atlas Copco air compressors operating in a duty/standby configuration, managed by an Atlas Copco Equaliser Pro 4 controller.
The controller will equalise the wear on the compressors and ensure they run correctly to match the exact air demand of the site. With the capacity to manage up to eight compressors, the controller allows for future expansion of production.
PPS also designed and installed a full compressed air ring main, ensuring consistency, quality, and efficient airflow throughout the site.
During the phased installation of production equipment at Warrington, PPS provided additional support via its hire fleet, supplying temporary compressors to enable commissioning activities without disruption, helping Regency Glass maintain momentum throughout the transition.
On going maintenance of the new system will be looked after by PPS, ensuring the equipment runs at optimum efficiency for the full lifecycle. Regency Glass have taken out a Guardian service contract with PPS giving them complete peace of mind and fixed servicing costs for seven years.
Results:
- A system designed for growth
- Complete support during phased installation
- Energy efficient system to achieve low lifecycle costs
- Reliability and peace of mind with a comprehensive service contract
- Fixed servicing costs for seven years
- Reactive support from the local PPS Team, backed by Atlas Copco
“We have been extremely pleased with the service provided by PPS for our compressed air ring main and compressor installation. From the initial planning stages through to completion, they were professional, efficient, and very helpful throughout. The quality of the installation was excellent, and the work was completed quickly and to a very high standard.”
Paul Crooks, Chief Technical Officer, Regency Glass
