PRESS GLASS UK & LiSEC: Automation is key
With the launch of its new state-of-the-art facility in Port Talbot, Press Glass UK has successfully brought three sites together under one roof. LiSEC played a key role in the transition, providing customised machinery and software solutions to support a more streamlined and consistent production process. The collaboration has helped lay the groundwork for greater efficiency and future scalability.
Press Glass UK Launches New Facility in Port Talbot
In November 2024, Press Glass UK began production at its new 23,000 m² factory. The site features six LiSEC insulating glass lines, seven cutting tables, and three KSR arrising machines, as well as three tempering furnaces from another supplier. It currently produces 32,000 insulating glass units (IGUs) per week, with capacity to scale up to 55,000.
Khaled Elleboudy, managing director, on his plans for the Port Talbot production: “We wanted to move three factories into one, to improve efficiency, reduce costs and offer a higher level of automation. Automation is going to be key for the future.” Engineering Director Lukasz Matlingiewicz adds: “Our goal with this new glass manufacturing facility is to significantly increase production capacity, improve quality standards, and meet the growing demand in the market. This investment reflects our long-term commitment to innovation, sustainability and job creation in the region.”
One of the main challenges Press Glass faced was to carefully plan and coordinate efficiency and precision across all production lines. Khaled looks back: “The machinery installation progressed more smoothly and quicker than what I expected. Installation began mid-July 2024 and successfully transitioned all our production into the new factory by the first quarter of 2025.”
LiSEC: A Trusted Partner
The decision to partner with LiSEC was driven by a long-standing relationship and proven experience with the company’s machinery. Press Glass had already been using LiSEC cutting tables and KSRs for decades – some for as long as 30 years – demonstrating their exceptional reliability and longevity. The software, once configured, also proved to be highly dependable. “LiSEC was able to meet all our project requirements, including the software integration around the machines,” Khaled says.
He also highlights another factor: project competence. “John Foster’s engineering expertise was instrumental in the project. Although in sales, his deep knowledge of LiSEC machinery helped guide design decisions and recommend tailored modifications. The team customized several machines – including cutting tables and production lines – based on project needs. With experienced support from both the UK and Austrian teams, LiSEC delivered a highly competent and knowledgeable partnership.”
Seamless Systems, Smart Production: Press Glass UK’s Software Solution
The transition to higher automation was supported by existing operator knowledge, with software integration posing the main challenge. A custom monitoring system was developed to streamline production and order tracking. LiSEC’s GPS.autofab was implemented across the factory floor for remake management, while GPS.prodcontrol handles scanning and tracking processes. Simplicity was prioritized from the outset, with GPS.order processing retained to ensure continuity.
Kasia Golembowska, Technical Development Engineer, shares: “At Press Glass UK, our main goal with the LiSEC software is to optimise production by reducing waste while increasing output. The more efficient we can make that process – especially through automation – the better. We have customised a lot of elements within the LiSEC system to suit our specific workflow, which has helped making the software an integral part of our daily operations. Ultimately, we want to make life easier for our operators and keep the plant running as smoothly as possible.”
At Press Glass, real-time insight across the entire factory is essential for improving tracking, planning, and decision-making. While automated sections are fully integrated, the same level of transparency and control has not yet been achieved manually. Kasia adds, “That said, we have been fortunate to have had exceptional LiSEC software engineers on site who have gone above and beyond during the start-up phase and training. That level of experience and dedication has been invaluable.”
Automation in Action: The First Buffer System in the UK
Among the most significant changes in the new production facility at Port Talbot was the introduction of a LiSEC sorting system and buffer, the first of its kind in the UK. While upgrades to cutting tables, KSRs, and IGU lines were seen as improvements on existing equipment, the buffer system introduced an entirely new operational process. Adapting to this change required a shift in mindset, particularly in how glass is tracked. Previously, glass and batch numbers were visible and manually managed. With the new system, tracking is handled entirely through the GPS.autofab software, requiring operators to rely on digital visibility.
Managing buffer levels also presented a learning curve. In older factories, production was driven by volume – cutting as much glass as possible to meet targets. However, this approach proved incompatible with the new sorting system, which requires careful planning: Batches must be fully loaded into the buffer before they can be transferred to the IGU line. Despite these challenges, the benefits of the buffer system – especially in annealed glass processing – have become increasingly clear. Glass is now cut directly into the sorting system and flows seamlessly to the IGU line, streamlining the entire process. Khaled on the buffer system: “We see several benefits: reduced manual handling, fewer errors, improved quality, and higher output. The process is more efficient and keeps production moving.”
Looking to the future, Khaled says, “Our goal is to complete the software solutions we have developed with LISEC. We are planning to implement the same software solutions across our other three UK factories, including Barnsley, Peterborough and Scotland. Each factory operates slightly differently – different software versions, different monitoring setups. Unifying these systems is essential. Once we finalize the solution here, we will implement it across all sites to ensure consistency and efficiency.”
Press Glass UK – Company Snapshot
Market Focus: Press Glass UK primarily serves the UK residential window market, supplying insulating glass units (IGUs) to window fabricators and installers.
Product Offering: The company specializes in double glazing, with a small share of triple glazing, conservatory roof glass, solar control glass, and laminated glass. Around 60-65% of output is tempered glass, and all products are made to order.
Key Strengths
- Customization: Every unit is tailored in size, colour, and specification.
- Speed: Short lead times help customers stay competitive.
- Support: Technical assistance, training, and co-branded marketing materials are provided
