Shaping the

of bondedabrasives

The Raleigh Hall PlantEccleshall

FUTURE

Saint-Gobain AbrasivesDoxey RoadStaffordST16 1EA Tel: 01785 222 000 Fax: 0845 602 6211

www.saint-gobain-abrasives.com

Form# 2114

3The Raleigh Hall Plant | Eccleshall

Moving Production to Raleigh HallProduction of abrasive grinding wheels began

in Stafford over 100 years ago. Since then

change, innovation, investment, new technology

and increased levels of expertise has led to

worldwide expansion and market leadership in

the aerospace industry.

Today, the Saint-Gobain Abrasives production

plant at Raleigh Hall, Eccleshall manufactures

a range of grinding wheels under the leading

brand, Norton. The purpose built factory

produces high precision, technical innovations

for high performance grinding in the aerospace

market.

NEW RALEIGH HALL PLANT, ECCLESHALL, STAFFORDSHIRE

World Class Abrasive SolutionsSaint-Gobain offers a number of high performance bonded abrasives designed to assist in

the manufacture of the entire structure and construction of aircraft. We are committed

to using the latest technological developments to revolutionise material removal

processes for turbine part production.

Whatever the manufacturing requirements for turbine parts, from initial foundry and

forge applications, to precision machining and finishing operations, Saint-Gobain has the

right abrasive solution.

OUR PRODUCTS

World Class Abrasive SolutionsSaint-Gobain offers a number of high performance bonded abrasives designed to assist in

the manufacture of the entire structure and construction of aircraft. We are committed

to using the latest technological developments to revolutionise material removal

processes for turbine part production.

Whatever the manufacturing requirements for turbine parts, from initial foundry and

forge applications, to precision machining and finishing operations, Saint-Gobain has the

right abrasive solution.

OUR PRODUCTS

5The Raleigh Hall Plant | Eccleshall 5The Raleigh Hall Plant | Eccleshall

Norton Quantum Norton Quantum is the new generation of ceramic

grain, with an innovative bonding system specially

developed to enhance grain performance.

The revolutionary ceramic grain multiplies cutting

efficiency by controlling grain breakdown at

micrometric level, optimising sharpness (free

cutting) and toughness (life). The newly developed

bonding system optimises grain-to-bond adhesion

and improves grain retention.

Quantum wheels can be used in low, medium and

high pressure applications, on even the hardest to

grind materials such as inconel and titanium.

OUR PRODUCTS

6 Shaping The Future of Bonded Abrasives

Altos & Altos IPX The unique elongated, extra sharp ceramic grain is

combined with a highly porous and permeable open

structure, allowing coolant maximum access to the grinding

zone and providing improved chip removal and reduced

friction. This provides high metal removal rates, improved

form holding, longer wheel life and reduced dressing with

a greatly reduced risk of metallurgical damage.

Perfect for creepfeed and surface grinding on hard to

grind materials and nickel based alloys, Altos and Altos

IPX reduce cycle times by up to 50% and increase the

number of pieces ground by 3 to 4 times, the best solution

for productivity improvement and cost savings for turbine

blade grinding.

Norton Vortex Vortex features optimised 3D grain spacing for

improved chip clearance and reduced friction. This

patented grain technology increases metal removal

rates, reduces cycle times, increases wheel life and

reduces wheel dressing when creepfeed grinding.

Poros 2 Poros 2 is a vitrified bond system specifically

designed to provide high accuracy grinding of hard

or heat sensitive materials across large areas

of contact. Accurate spacing of abrasive grains

is controlled independently of porosity, enabling

the specification of the wheel to exactly meet the

grinding parameters.

7The Raleigh Hall Plant | Eccleshall

Health & SafetyAt Saint-Gobain Abrasives, health and safety is our

highest priority and bonded wheels are produced to

the most stringent quality standards to guarantee

optimum end user safety.

Saint-Gobain is an active founding member of FEPA,

(Federation of European Producers of Abrasives) and

oSa (Organisation for Safety of Abrasives), dedicated

to the promotion of safety in the use of abrasives.

We also implement the European (EN) and

International Standards (ISO) for abrasive and

grinding machines.

QUALITY, HEALTH & SAFETY

QualityThe Raleigh Hall factory is fully ISO accredited:

ISO 9001: certifies Quality Management system

is in accordance with requirements of quality

standards.

ISO 14001: certifies Environmental Management

system is in accordance with requirements of

environmental standards.

OHSAS 18001: health and safety at work

certification.

9The Raleigh Hall Plant | Eccleshall

Health and Safety Awards

In 2005 the Stafford factory received the Diamond Award for Safety, a Saint-Gobain accolade

for exceptional achievement for safety in the plant. In addition, in 2009 the site was awarded

Millionaire status – a significant achievement of a million hours without a lost time accident.

Environmental ProtectionWaste management is undertaken to optimise

recycling activities and zero pollution of air, water

and land is defined as a major objective.

Reduction of Natural Resource ConsumptionNew production processes and procedures are

regularly implemented to help minimise the amount of

waste created during the manufacturing process.

Product DevelopmentBoth Norton Altos and Vortex wheels do not require

artificial pore inducers to achieve a high level of

porosity. By choosing Altos and Vortex you help

preserve the environment and contribute to reducing

the carbon footprint.

Eccleshall BiomassWaste and energy reduction is a high priority and

the Raleigh Hall plant is part of a groundbreaking

project; ‘Eccleshall Biomass’, a response to

Government targets to reduce greenhouse gases

and utilise alternative renewable energy sources.

Using Biomass to generate electricity, the 2.6

megawatt generator located at Raleigh Hall is

fuelled by the energy crop ‘miscanthus’ and clean

wood chip. The electricity is generated using

steam turbine technology and by tapping into this

system, Saint-Gobain Abrasives is reducing carbon

emissions, saving money and helping to preserve

the environment.

Saint-Gobain Abrasives prides itself on having

an environmentally friendly approach to all its

business activities. OUR ENVIRONMENT

10 Shaping The Future of Bonded Abrasives

Throughout history, Saint-Gobain Abrasives has

employed a highly skilled production workforce, fully

trained in all stages of the manufacturing process

from mixing and pressing to firing and finishing.

Today, the workforce has an average of 22 years

knowledge and expertise in the production of

bonded grinding wheels, a valuable asset to

Saint-Gobain Abrasives and

our customers.

OUR PEOPLE

The Raleigh Hall Plant | Eccleshall 11

Mixing All orders and recipes are viewed via the system

interface then selected to ensure the highest

standard of service can be maintained. Raw

material addition sequences, material weights

and blending times are controlled to optimise

homogenisation and minimal mixing standing time

reduces product variations.

Pressing System tools used when mixing also provide a work

to list, ensuring smooth continuation of orders from

the mixer, through pressing, to the kiln. Rotary fill

and spreading, coupled with isostatic plates ensure

even density throughout each product. This provides

consistent high quality, in-balance products. ‘Pressing

to Density’ reduces product density variations and the

fully automated handling system from mould enables

the manufacture of very soft, fragile products.

MANUFACTURING EXCELLENCE

World Class ManufacturingWCM is an international programme designed to improve productivity, quality and customer satisfaction.

Raleigh Hall has utilised the latest concepts in WCM including Value Stream Mapping (VSM), to reduce end-

to-end distance travelled from start to finish of the production process. Also, by eliminating process queues,

training operators and changing shift patterns to working 24 hours a day, 7 days a week, product lead times

have been significantly reduced, a major benefit for our customers.

12 Shaping The Future of Bonded Abrasives

Firing The end to end firing cycle of the tunnel kiln takes

two and a half days, including first stage drying.

Computer control provides consistent drying and

firing. Minimal handling is required due to firing on

refractory plates. The automatic handling system

enables smooth transfer of the unfired product to

the kiln truck.

Finishing The auto machining cell provides very fast-end

production. On-time performance is assured with

system planning tools. The cell works on a one piece

flow principle, enabling work in progress (WIP) to

be kept to a minimum and orders to be processed

in minutes. Diamond cutting, coupled with tool wear

compensation provides consistent, high quality

products.

13The Raleigh Hall Plant | Eccleshall

1893 W.O. Rooper began manufacturing rubber bonded wheels at Castle Works, Stafford.

1905Rooper & Harris Ltd. purchased by Moser, West & Bateman.

1912Universal Grinding Wheel Co. Ltd. registered to sell vitrified wheels under the trademark UNI, and Universal works started at Doxey.

1921Castle Works closed and all manufacturing concentrated at Doxey.

ABRASIVES IN STAFFORD

14 Shaping The Future of Bonded Abrasives

1933First tunnel kiln introduced.

1935Universal Grinding Wheel Co. Ltd. registered as a public company. Small housing estate built for workers at Greensome Lane, Doxey.

1937Doxey Road office block was built.

1950’sThe Doxey factory was the largest of its kind in Europe, covering a 44 acre site.

1970’sUniversal is Europe’s largest manufacturer of grinding wheels, employing 1600 people in May 1977, rising to over 2000 in the next few years.

1980’s & 90’sA number of aquisitions took place including to Foseco Plc in 1980 and Burma Castrol in 1990.

1997Unicorn Abrasives was aquired by Saint-Gobain.

1997 - 2000£6million invested into the factory, renovating building infrastructure, improving lighting, heating and ventilation, and automating production processes.

2011Production at Doxey Road plant ceases.

2012Production starts at Raleigh Hall, Eccleshall.

15The Raleigh Hall Plant | Eccleshall

Shaping the

of bondedabrasives

The Raleigh Hall PlantEccleshall

FUTURE

Saint-Gobain AbrasivesDoxey RoadStaffordST16 1EA Tel: 01785 222 000 Fax: 0845 602 6211

www.saint-gobain-abrasives.com

Form# 2114