Address:
704 West Park Rd.
Union, Missouri 63084
Phone: 636.583.7755
Fax: 636.583.1937
Crystal Extrusion Systems in the News
Our news releases:Crystal Extrusion Systems Upgrades With Hot Log Saw
Crystal Extrusion Systems named approved applicator by Sherwin-Williams
Crystal Extrusion Introduces New Metal Paint Finish
Verical Integration Leads to Horizontal Expansion
CES Celebrates 5 Year Milestone
CES Achieves Architectural Metal Finishing Certification
Crystal Extrusion Systems invests in powder coating to finish its products as well as generate new revenue streams by offering its services to others.
Crystal Extrusion Systems manufactures aluminum extrusion profiles used in residential and commercial window manufacturing as well as other building and industrial products. Based in Union, Mo. (about 50 miles west of St. Louis), Crystal Extrusion Systems was originally launched in 2003 as a means of improving material control and reducing costs for its parent company, Crystal Window & Door Systems. Crystal Extrusion Systems has since expanded its services to new markets. Attention to quality, investment in leading-edge equipment and technology, and staff expertise have been key factors in its successful expansion.
Crystal Extrusion Systems has installed a
powder coating system that has two powder coating booths.
Entrepreneurial vision drives international success
The story of Crystal Window & Door Systems and its subsidiary companies such as Crystal Extrusion Systems invokes entrepreneurial spirit, ingenuity, and hard work. Thomas Chen, a Taiwanese immigrant with a high-school education who was raised in rural southern Taiwan founded the company in 1990. In 1982, Chen, his wife, and young son arrived in New York City with very little money and even less knowledge of the English language. He worked in typical lower-skilled jobs, first in a sweater factory and then in construction. To make ends meet, Chen began fabricating and installing window security bars in houses and apartment buildings as a second job. One thing led to another. He received so many requests for replacement windows while installing security bars that he learned the window trade and launched the company that eventually became Crystal Window & Door Systems.
From these humble beginnings in 1990, with only 10 employees working out of a commercial garage, Crystal has grown to one of the top 60 window manufacturers in North America. The company headquarters and main production plant are in the College Point Corporate Park in the New York City borough of Queens. It sells not only to other New York City businesses, but also to companies throughout New York State, the East Coast, and the Midwest. Crystal has sales and distribution offices in Allentown, Pa., Cleveland, and St. Louis; affiliate manufacturers in Chicago and Boston; and some modest operations overseas serving foreign markets.
Under Chen’s leadership, the company has developed a broad product line of aluminum and vinyl windows and patio doors for every application -- residential, commercial, and institutional -- for both replacement and new construction. The company has expanded into fabrication of proprietary curtain wall systems for high-end specifiers and owners. Branching out from window products, Crystal established aluminum ornamental fence and fiberglass residential entry door subsidiaries.
Company expands into aluminum extrusion and finishing
As it grew, Crystal Window & Door Systems was constantly seeking ways to increase its bottom line in the highly competitive fenestration industry by reducing costs and increasing market share. One area Crystal targeted for improvement was its supply of extruded aluminum profiles used in the assembly of its aluminum window and door products. However, with New York’s relatively high energy costs, and space constraints at its New York plant, Crystal ruled out adding aluminum extrusion to its production.
Then early in 2003, Crystal learned of an existing aluminum manufacturing plant that was for sale in the St. Louis area, in Union, Mo. The plant had been owned by a succession of fabricators over the years, many involved with metal and industrial products. Crystal determined that it could vertically integrate aluminum extrusion with its current window manufacturing processes efficiently to reduce overall material costs and improve quality and control. Local officials worked with Crystal to facilitate buying the plant and starting up operations. Crystal began renovating the plant and investing in equipment.
The new system allows Crystal to offer various finishing options
for its extruded aluminum profiles, especially custom colors for the
finished window and door products.
By June 2003, Crystal Extrusion Systems was open for business. Before long, the extruders and coating line were hard at work. Crystal Extrusion Systems retained most of the plant’s original employees. Moreover, the operation added new positions. "We were very impressed with the caliber of the local workforce and were glad to have their support as we revamped the factory," noted Steve Chen, executive vice president of Crystal Window & Door Systems. "They made the transition and successful start up go very smoothly."
Investment leads to new opportunities
In late 2004, Crystal decided to install a new finishing line. By the end of 2005, Crystal Extrusion Systems had completely replaced the old equipment with a $1.4 million powder coating system. A five-stage stainless steel pretreatment washer prepares extruded pieces for powder coating. One 37- foot-long powder booth, equipped with 16 spray guns, can be operated automatically or manually. The integrated control system provides automated processing of every type of surface and profile configuration processed. Recently, the company has in stalled an additional booth: a twin cyclone. The booth also has a suppression system. A powder spray handgun provides flexibility for line operators.
Crystal Extrusion Systems extrudes aluminum profiles up to 300 inches long in mill finish.
A 248-linear-foot curing oven with a maximum temperature of 450°F completes the coating operation.
Crystal Extrusion Systems uses powders by several leading suppliers including Akzo Nobel. The company’s finishing line can accommodate profile lengths up to 22 feet.
The new system allows Crystal to offer various finishing options for its extruded alumi num profiles, especially custom colors for the finished window and door products. The powder coating pro cess enables the company to lower operating costs, minimize envi ronmental im pact through powder reclamation, reduce volatile organic compound (VOC) emissions, and shor ten production times.
Experienced leadership guides expansion
With the latest powder coating technology and equipment in place, Crystal Extrusion Systems wanted to expand its operations beyond service to its parent company. Joining the company in late 2006 as general manager (and subsequently promoted to vice president), Thomas Ziegler brought expertise and a wealth of experience in large-scale extrusion and finishing operations. A 20-year veteran of the industry, Ziegler directed production plants for Alcoa before coming on board with Crystal Extrusion Systems.
Ziegler identified target markets outside the fenestration industry that offered business expansion opportunities. Ongoing quality improvements enabled Crystal Extrusion Systems to achieve certification as an approved applicator of powder coat finishes of Akzo Nobel, meeting all three levels of certification to American Architectural Manufacturers Association (AAMA) performance require ments. The com pany also has aluminum extrusion thermal break and de bridging capabilities. Crystal Extrusion Systems now offers extrusion and finishing services independently to customers as well as combined into a one-stop service. "We have a strong team of professionals who are making in roads into new markets because of the advantages our superior finishing services offer," Ziegler said.
Company reaches goals step by step
Crystal Extrusion Systems has begun to see the fruits of its labors and investments by reaching new and related markets for aluminum extrusion and finishing. In addition to providing the majority of aluminum profiles for window and door products assembled by parent company Crystal Window & Door Systems and other fenestration fabricators, Crystal Extrusion Systems is actively involved with other types of products such as marine craft components, sunrooms, signage, shelving, office furniture and partitions, and containers. The firm is also working to develop business in automotive-related fields. "This is an exciting time for our subsidiary Crystal Extrusion Systems," said Steve Chen. "We are on the ground floor of the transition to powder coating by the architectural product and light metal industries."
Crystal Window & Door Systems achieved remarkable growth from startup in 1990 to more than $60 million in sales by focusing on goals and consistently investing in people and technology. Its subsidiary, Crystal Extrusion Systems is applying these same principles to achieve its growth goals through incorporating powder coating capabilities. "By making a firm commitment to quality and significant investments in people and technology, we are wellpoised for expansion," observed Ziegler. "We are branching out from vertical integration within one industry to new markets. The potential is enormous."
Editor’s note
For further reading on the topics discussed in this article, see Powder
Coating magazine’s Web site at [
www.pcoating.com 
]
. Click on Article Index and search by subject category.
Have a question? Click on Problem solving to submit on
Extrusions and powder finishing:
Crystal Extrusion Systems
Union, Missouri
(636) 583-7755
www.crystalextrusions.com
Powder coatings:
Akzo Nobel-Interpon Powder Coatings
Houston, Texas
(713) 684-1282
www.interpon.com
