Air-Chek Window Depot manufactures it's vinyl windows in our own 43,000 square foot factory in Clifton, New Jersey. The manufacturing process begins with our Order Entry department, where your order is entered into our computer system.
After the order is entered, orders are processed in "batches" by factory line, and factory cutting and assembly instructions are printed so that the windows can be made in the factory.
Once the cutting sheets are prepared, they are brought to the vinyl cutting department where we cut the sizes needed from sixteen foot long vinyl profiles.
After the profiles have been cut to the length needed, they are brought to the punching department where the lengths are punched with assembly holes and weep holes.
Frame material for double hung windows is then brought to the balance installation department where block & tackle balances are installed. The frame material for Econotherm factory line are then screwed together.
The frame material for our fully welded Maxiweld, Ultra, Casement, and Awning factory lines are brought to the welding department where they are welded by our computer driven four point welder.
The four point welder is computer driven, and the 4 servo motors move the welding fixtures to the custom size needed for each window. The double-hung windows sashes are "double stacked" when they are welded.
After the sashes are welded, the corners are cleaned, and then a router cuts the corners for placement of the flush mount tilt latches.
Spacer and grid material for the insulated glass units are cut on chop saws that incorporates digital read outs. Muntin bar is punched according to computer printout sheets, so that grids of top and bottom sashes are properly aligned.
All our windows come with 3/4 inch insulated glass units. These units are made with 9/16 inch aluminum or vinyl spacer, the spacer is filled with desiccant to help prevent condensation, and the units are hermetically sealed with a hot melt butyl.
In some instances, customers order energy saving glass options, such as vinyl spacer and inert gas filled insulated glass units. Gas filled units are filled with Argon or Krypton with a machine that fills the units based on a time fill for a volume.
The cut sash material has been welded and then hardware such as tilt latches, locks, and pivot bars are added to the sashes.
Once the insulated glass units are complete, they are placed in the sash. The IGUs are held in place by silicone on the inside and vinyl glazing strips on the outside of the sash.
At Air-Chek Manufacturing we also manufacture custom sized Bow and Bay windows. The windows may be made with Ultra double hung windows or our Casement windows. The seat board is insulated and covered on the outside with white aluminum coil material.
The sashes are then placed in the frames, screens are placed in the frames, and the unit is cleaned and inspected. After this final step in the assembly process, the window is wrapped in stretch wrap and placed in our shipping department.
Once the windows have been wrapped, they are moved to our warehouse and placed in numbered areas for pickup by our customers or installers. Our warehouse area also stores over 5000 Maxiweld windows in 50 popular sizes.
We'd like to thank you for taking a look at our factory, and seeing how we assemble our windows. Once again we'd like to remind you that our factory showroom is open to the public, and we invite you to come down and compare.
