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The name Green Build Systems (GBS) summarises very well what we actually do: we are developers and manufacturers of green building products, green buildings and the systems through which the manufacturing can take place.

Not only have we developed an eco-friendly energy saving range of construction products, but we have also developed an efficient process by which these products may be made, and have developed a three-tier factory blueprint which licensed owners or partners may use to replicate the successful manufacture of GB Eco Panels.

Level 1 – An initial starter factory / manufacturing system. This is how we started, and it is our fundamental tried and tested system.

This is a 20,000 foot semi-automated factory which can produce 80,000 sq. meters of panels per annum – with minimal manpower – and with shift patterns running 12 hours / continuously. It comprises:

  • a Structural Insulated Panel (SIP) line (as internal components for the GB Eco Panel)
    – but these panels can also be sold as a stand-alone products;
  • a fibre-glass spray facility;
  • vacuum tables;
  • one or two CNC machining robots;
  • dedicated lifting equipment and fork truck/s;
  • standard storage systems;
  • full training / commissioning / operating systems package and blueprint.

Level 2 – A single line fully automated factory of 50,000 sq. meters which can produce 700,000 sq. meters of panels per annum, operating on two tiers (including a mezzanine floor) in order to maximise on height and minimise the costly footprint. Two 12 hour shifts. Comprises:

  • an automated SIP line;
  •  up to 10 Robots per automated line;
  • an automated fibre-glass spraying facility
  • automated vacuum tables, with robotic lifting and turning facilities;
  • CNC machining facilities;
  • dedicated lifting equipment and fork trucks;
  • vertical automated storage facilities;
  • full training / commissioning / fully integrated software operating systems package and blueprint.

Level 3A Super Factory – a double line, fully automated factory, operating in virtually the same floor area as a single line unit. with two floor manufacturing and producing 1.4 million square meters per annum. This system is even more cost efficient as it requires no more staff (which is already minimal) than it does to run a single line. Two 12 hour shifts.

Why produce our own process?

The manufacture of many construction products is based upon tradition – traditional ways of building houses, using traditional materials, made in the same labour-intensive ways.

Green Build Systems sought to break the mould – not only by creating a unique cost- effective, energy saving and flexible range of insulated eco-panels for walls, floors and roofs, but also in the manner in which these construction grade eco-panels are manufactured.

Many board materials manufactured for construction are made to the nearest few millimeters, and there is the assumption that there will be craftsmen on site who will modify them to ensure that windows and doors fit snugly and that joints are even, so that minimal fillers are then needed to seal these areas.

GBS set out to design and construct a factory that is not only efficient and can produce consistently high quality work in volume, but where the panels produced are so precision engineered that the standards are not +/- 3 mm but can be measured in microns. This not only dramatically reduces time on the construction site, but by working to such accurate levels, we also ensure virtually perfect fits for windows and doors, without unnecessary modifications, so the end user can readily construct an air-tight envelope.

A factory designed as a centre of excellence and utilising internationally acclaimed equipment

Many machines that are designed to manufacture traditional materials are made in such a way that they replicate traditional manual processes. We have applied known robotic and automated systems from a selection of industries (automotive / aerospace / hi-tech manufacturing) and built them into a manufacturing system designed to dramatically reduce manpower, speed up the process, reduce unnecessary multiple handling (and thereby reduce the risk of damage) and replicate the highest quality standards by sustained accuracy throughout the entire  process.

The majority of cost reduction is obtained by reduced manning, speed of operation, reduced damage, reduction of multiple-handling and, via vertical systems, a reduced overall factory footprint unlike traditional manufacturers, thereby reducing the necessity of underutilised and expensive floor space.

Components will be palletised by suppliers prior to delivery and entered into the manufacturing software system to ensure traceability for quality and date of use purposes. When they are required, the software system will advise the forklift driver.

Similar to an MRP (Manufacturing Resource Planning) system, the software system will control production scheduling with major customers linked to the system for ordering and scheduling purposes, and, for example, to instruct the robots to take the required materials for the shift production.

From the internal SIPs to the range of finished products, all items are manufactured in-house in order to maximise quality control, and all processes, material purchasing, distribution and processing is controlled via a central computerised control system.

Using in-house expertise in industrial engineering, manufacturing process design and construction standards, we have designed the system to be highly accurate, efficient and cost-effective by minimising all unnecessary material handling and duplication of effort.

Total traceability is the key

It is now our intention to commence the process of application of ISO 9001 and ISO 14001 compliance standards, so that we can offer total traceability throughout the process, maintain the highest levels of quality consistently, and ensure that we meet the highest available environmental standards.

Benefits of GBS Construction Methods

GBS’s methods deliver sustainable and low cost benefits in comparison with those deployed traditionally, through:

  • The minimisation of raw materials;
  • Precision engineering within automated processes;
  • Production accuracy in microns as opposed to the traditional standards of millimeters, creating the need for decreased manpower and wastage at constructi stage;
  • GB Eco Panels are produced to provide better insulation and thermal efficiency in the light of growing stringency in EU and UK building regulations regarding eco-standards;
  • The GBS manufacturing centre requires much less manpower than
    traditional/conventional manufacturing methods;
  • The methods used accommodate upcoming changes in EU legislation and the growing
    prominence of voluntary energy efficient standards such as Passivhaus.

So what are our strengths?

  • A modern factory, with the most up-to-date equipment and advantageous manufacturing capability;
  • A superior product: patents have been applied for, for a unique product which will satisfy a major market requirement;
  • A ready-made market place, with letters of intent and forward orders already in place;
  • Sister companies already operating within high-end leisure and construction markets;
  • The ability to operate within a niche market, and expand into a market which is under-supplied;
  • Manufacturing systems flexible enough to cope with panel size fluctuations and demands, with rapid response if required;
  •  A hand-picked management team, with wide experience and success across multiple disciplines – especially operations management, start-up businesses, engineering, construction, and composite industries;
  • A business run by a successful entrepreneurial and innovative team;
  • A good location – for docks, airports and major motorway systems;
  • A system which will offer high level and consistent quality, due to automated methods and operating within ISO 9001 modules;
  • A product which is a highly cost-effective solution to a market requirement;
  • A product which helps to achieve eco-friendly status and improve green credentials, and is energy saving.
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