Value vs. Price: A new generation of value-added components boost bottom line for shutter fabricators |
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A NEW STANDARD IN FINGER-JOINTING
Ultimately, it took an entity outside of the shutter industry-Glen Oak Lumber & Milling-to produce finger-jointed shutter components that could meet Salomon's and others' exacting standards. While Glen Oak did not initially know a shutter "stile" from "style," producing moulded products with high-quality finger-jointing was nothing new for the high-tech manufacturer of hardwood interior trim.

Glen Oak Lumber & Milling has led the paint-primed millwork industry in product quality and sales since it began finger-jointing and priming poplar in 1996. Recognizing that it could parlay this experience into producing superior shutter parts, as well, Glen Oak introduced its defect-free poplar Arrow-Straight F.J. shutter components in December 2001.

Product trial has been critical to the Arrow-Straight F.J. products' quick acceptance and success. When shutter fabricators tried Glen Oak's shutter components they realized the finger-joint quality was very different from anything they had tried in the past. "Glen Oak has mastered the finger-jointing of the shutter components," states Salomon. "Because of the technology they have, the finger-jointed product they produce is exactly what we are after."

David Hayes of Hayes Manufacturing in Ellijay, Georgia agrees and has made a complete switch from solids to these finger-jointed components. "Producing 1,000 panels a week, we used to have to throw away at least a quarter of our stiles because they were so crooked or flawed, they weren't useable," recounts Hayes. "But, now that we're using Arrow-Straight F.J. components, our waste factor is down to just two or three percent! The parts are so straight and defect-free we can cut a large amount of stiles in no time-stacking and cutting them two at a time.

"Before switching from my own solid poplar shutter components, I put the Arrow-Straight F.J. shutter parts to the test," Hayes explains. "I ran my finger-nail along the length of the tilt-rods and couldn't feel the joints. I also purposely ran over some stiles with an 8,000 pound forklift and they were so strong they didn't break!"

SANDING AND PRIMING AT THE MILL SAVES TIME AND MONEY
Ed Salomon is quick to point out another value-added feature savvy fabricators take advantage of when purchasing shutter parts: wood shutter components can be thoroughly pre-sanded and pre-primed at the mill.

"Priming and sanding is 50 percent of the finishing cost for a shutter fabricator," estimates Salomon, easily justifying why he spent years trying to get quality pre-primed components for his shutters-testing numerous suppliers and product, from coast to coast. He was thrilled to discover Glen Oak could solve this issue for him as well.

When Salomon received a sample louver primed with Glen Oak's special water-borne stain-blocking primer, he inadvertently tested it under extreme conditions. "I sprayed the Glen Oak sample with my lacquer top coat," relates Salomon. "It did a very good job and I was eager to see the finished results. So, to speed up the drying process, I set the sample outside the building, but got busy and forgot about it. That night it rained like a son-of-a-gun and the next morning I discovered the painted sample floating in water 100 yards from where I left it. But, because of the water-borne base the lacquer top coat did not crack-that is extremely good.

"After that test, I placed a very large order with Glen Oak," says Salomon. "With the Glen Oak components, it is very hard to see where the finger-joint is because of the priming," he observes. "I believe using these components is going to cut my costs by 50 percent. I should also be able to cut time to deliveries of my finished product by at least 50 percent."

According to Salomon, this more than justifies the slightly higher cost he pays for Glen Oak's finger-jointed, pre-sanded and primed components. He also contends that these high quality domestic products will make fabricators think twice before looking to the Chinese to provide material and labor savings.

While Salomon, Hayes and other US shutter fabricators are clearly pleased with the overall value they derive from this new generation of wood shutter components, Glen Oak is always working to make things even better. For over a year, Glen Oak has been testing and developing a proprietary primer, identified as SB43. This unique primer combines anti-fungal additives along with a high-opacity stain blocker which hides the colorful minerals inherent in poplar hardwood.


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