AMCC's 2023-2026 investment plan at the Châteauroux (36) plant: Concrete results meeting the expectations of the French joinery manufacturer

A modernization of the industrial construction system

The investment program enabled the creation of a new building of 4 500 m², integrated into an existing site of 23 000 m²This facility houses a fourth assembly line as well as a workshop dedicated to the manufacture of composite windows.

From an industrial perspective, this expansion follows a classic logic of flow separation and optimization of production rates. In particular, it helps to limit interference between lines and improve process continuity.

In the industrial joinery sector, this organization is part of an approach similar to that of lean manufacturing, often managed by a methods design office or an industrialization engineer.

Rooftop photovoltaics and partial self-consumption

The energy transition is a key element of the project. The new building incorporates 1,970 m² of photovoltaic panelsi.e 886 modules for a total power of 320 kW.

Commissioned in April 2025, this installation will cover:

• 50 to 90% of annual electricity needs
• up to 80% of consumption occurs during the day

This type of system falls under the French regulatory framework applicable to rooftop photovoltaic installations, particularly in connection with the Energy Code and the obligations to integrate renewable energies into industrial buildings.

However, an operational limitation emerges: the production shutdown on weekends and during the summer months reduces self-consumption capacity. The energy produced is therefore injected into the network as part of a purchase agreement, a common pattern in the industry when consumption patterns are discontinuous.

Automation of production lines and reduction of handling

A significant portion of the investments, amounting to 4,95 million, concerns the modernization of equipment.

The replacement of a welding line with a fully automated one illustrates this evolution. The system incorporates automated transfers that allow the joinery to be moved flat.

Announced results:

• -70% reduction in handling
• elimination of product returns
• complete automation of hardware screwing

"The result: a 25% increase in productivity, but above all, a 20% increase in production capacity."

On the ground, these changes reflect a reduction in physical constraints and better control of flows. They are in line with the requirements for preventing... musculoskeletal disorders (MSDs), a major issue in manufacturing workshops.

Enhanced machining and product quality

The acquisition of an automated machining center makes it possible to centralize several operations: cutting, machining and strengthening of profiles.

This type of equipment, often used in the manufacture of PVC or aluminum joinery, reduces manual rework. It contributes to:

• reduce productivity losses
• improves the repeatability of operations
• limit manufacturing defects

In a quality-oriented approach, this equipment meets the requirements of industrial standards, particularly in terms of dimensional tolerances and product conformity.

Automation of glazing bonding

Another notable development: the integration of a robot dedicated to glazing bonding on a specific range.

This process aims to standardize two critical parameters:

• the positioning of the glazing in the opening
• the amount of glue applied

"The process becomes repeatable in terms of both framing and the amount of glue applied."

In the joinery sector, mastering bonding techniques is essential to guarantee the mechanical and thermal performance of the finished product. It can also contribute to improving theairtightness, a key criterion within the framework of the RE2020 environmental regulations.

A CSR approach that includes the recycling of joinery

Beyond production, the system includes a recovery system for end-of-life joinery.

In 2025, 592 tonnes of joinery were collected and then sent to dismantling and recycling facilities. The stated objective is to reintegrate up to 80% of the materials in new products.

This type of approach is in line with the principles of the circular economy, encouraged by French regulations, particularly through the sector EPR building (extended producer responsibility).

In practical terms, these flows require a specific logistical organization, involving carriers, sorting centers and recycling industries.

Measurable gains, but dependent on exploitation

The announced results reflect an overall improvement in the production system:

• +25% productivity
• +20% production capacity
• Significant reduction in handling

These gains, however, remain subject to several factors:

• continuity of production volumes
• maintenance of automated equipment
• adapting teams to new processes

In industry, the upskilling of operators is a key lever for ensuring these performances over the long term.

All of these investments illustrate a shift towards a more automated, more energy-efficient industrial tool that is better integrated with environmental issues, while also revealing the operational constraints specific to intermittent production sites.