Uudella Raleigh Hallin tehtaalla sovelletaan korkeateknologian tuotantoa, missä tehokas robottivalmistus ja automatisoidut prosessit takaavat lyhyemmät valmistusajat ja korkean laatutason. Nykyaikaisilla tuotantometodeilla pyritään myös mahdollisimman vähäiseen ympäristövaikutukseen.Myös tuotteet on suunniteltu mahdollisimman ympäristöystävällisiksi.

1. Shaping the
FUTURE
of bonded
abrasives
The Raleigh Hall Plant
Eccleshall

3. NEW RALEIGH HALL PLANT,
ECCLESHALL, STAFFORDSHIRE
Moving Production to Raleigh Hall
Production 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.
The Raleigh Hall Plant | Eccleshall 3

4. OUR PRODUCTS
World Class Abrasive Solutions
Saint-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 Solutions
Saint-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.

5. The Raleigh Hall Plant | Eccleshall 5

6. OUR PRODUCTS
Norton Quantum Altos & Altos IPX
Norton Quantum is the new generation of ceramic The unique elongated, extra sharp ceramic grain is
grain, with an innovative bonding system specially combined with a highly porous and permeable open
developed to enhance grain performance. structure, allowing coolant maximum access to the grinding
zone and providing improved chip removal and reduced
The revolutionary ceramic grain multiplies cutting friction. This provides high metal removal rates, improved
efficiency by controlling grain breakdown at form holding, longer wheel life and reduced dressing with
micrometric level, optimising sharpness (free a greatly reduced risk of metallurgical damage.
cutting) and toughness (life). The newly developed
bonding system optimises grain-to-bond adhesion Perfect for creepfeed and surface grinding on hard to
and improves grain retention. grind materials and nickel based alloys, Altos and Altos
IPX reduce cycle times by up to 50% and increase the
Quantum wheels can be used in low, medium and number of pieces ground by 3 to 4 times, the best solution
high pressure applications, on even the hardest to for productivity improvement and cost savings for turbine
grind materials such as inconel and titanium. blade grinding.
6 Shaping The Future of Bonded Abrasives

7. Norton Vortex Poros 2
Vortex features optimised 3D grain spacing for Poros 2 is a vitrified bond system specifically
improved chip clearance and reduced friction. This designed to provide high accuracy grinding of hard
patented grain technology increases metal removal or heat sensitive materials across large areas
rates, reduces cycle times, increases wheel life and of contact. Accurate spacing of abrasive grains
reduces wheel dressing when creepfeed grinding. is controlled independently of porosity, enabling
the specification of the wheel to exactly meet the
grinding parameters.
The Raleigh Hall Plant | Eccleshall 7

9. Health and Safety Awards
QUALITY, HEALTH & SAFETY
Health & Safety Quality
At Saint-Gobain Abrasives, health and safety is our The Raleigh Hall factory is fully ISO accredited:
highest priority and bonded wheels are produced to
ISO 9001: certifies Quality Management system
the most stringent quality standards to guarantee
is in accordance with requirements of quality
optimum end user safety.
standards.
Saint-Gobain is an active founding member of FEPA, ISO 14001: certifies Environmental Management
(Federation of European Producers of Abrasives) and system is in accordance with requirements of
oSa (Organisation for Safety of Abrasives), dedicated environmental standards.
to the promotion of safety in the use of abrasives. OHSAS 18001: health and safety at work
We also implement the European (EN) and certification.
International Standards (ISO) for abrasive and
grinding machines.
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.
The Raleigh Hall Plant | Eccleshall 9

10. Saint-Gobain Abrasives prides itself on having
OUR ENVIRONMENT an environmentally friendly approach to all its
business activities.
Environmental Protection Eccleshall Biomass
Waste management is undertaken to optimise Waste and energy reduction is a high priority and
recycling activities and zero pollution of air, water the Raleigh Hall plant is part of a groundbreaking
and land is defined as a major objective. project; ‘Eccleshall Biomass’, a response to
Government targets to reduce greenhouse gases
Reduction of Natural Resource Consumption and utilise alternative renewable energy sources.
New production processes and procedures are Using Biomass to generate electricity, the 2.6
regularly implemented to help minimise the amount of megawatt generator located at Raleigh Hall is
waste created during the manufacturing process. fuelled by the energy crop ‘miscanthus’ and clean
wood chip. The electricity is generated using
Product Development steam turbine technology and by tapping into this
Both Norton Altos and Vortex wheels do not require system, Saint-Gobain Abrasives is reducing carbon
artificial pore inducers to achieve a high level of emissions, saving money and helping to preserve
porosity. By choosing Altos and Vortex you help the environment.
preserve the environment and contribute to reducing
the carbon footprint.
10 Shaping The Future of Bonded Abrasives

11. OUR PEOPLE
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.
The Raleigh Hall Plant | Eccleshall 11

12. MANUFACTURING EXCELLENCE
World Class Manufacturing
WCM 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.
Mixing Pressing
All orders and recipes are viewed via the system System tools used when mixing also provide a work
interface then selected to ensure the highest to list, ensuring smooth continuation of orders from
standard of service can be maintained. Raw the mixer, through pressing, to the kiln. Rotary fill
material addition sequences, material weights and spreading, coupled with isostatic plates ensure
and blending times are controlled to optimise even density throughout each product. This provides
homogenisation and minimal mixing standing time consistent high quality, in-balance products. ‘Pressing
reduces product variations. to Density’ reduces product density variations and the
fully automated handling system from mould enables
the manufacture of very soft, fragile products.
12 Shaping The Future of Bonded Abrasives

13. Firing Finishing
The end to end firing cycle of the tunnel kiln takes The auto machining cell provides very fast-end
two and a half days, including first stage drying. production. On-time performance is assured with
Computer control provides consistent drying and system planning tools. The cell works on a one piece
firing. Minimal handling is required due to firing on flow principle, enabling work in progress (WIP) to
refractory plates. The automatic handling system be kept to a minimum and orders to be processed
enables smooth transfer of the unfired product to in minutes. Diamond cutting, coupled with tool wear
the kiln truck. compensation provides consistent, high quality
products.
The Raleigh Hall Plant | Eccleshall 13

14. 1893
W.O. Rooper began manufacturing
ABRASIVES IN STAFFORD rubber bonded wheels at
Castle Works, Stafford.
1905
Rooper & Harris Ltd. purchased by
Moser, West & Bateman.
1912
Universal Grinding Wheel Co. Ltd.
registered to sell vitrified wheels under
the trademark UNI, and Universal works
started at Doxey.
1921
Castle Works closed and all
manufacturing concentrated at Doxey.
14 Shaping The Future of Bonded Abrasives

15. 1933 1970’s 1997 - 2000
First tunnel kiln introduced. Universal is Europe’s largest £6million invested into the factory,
manufacturer of grinding wheels, renovating building infrastructure,
employing 1600 people in May 1977, improving lighting, heating and ventilation,
1935 rising to over 2000 in the next and automating production processes.
Universal Grinding Wheel Co. Ltd.
few years.
registered as a public company.
Small housing estate built for workers 2011
at Greensome Lane, Doxey. 1980’s & 90’s Production at Doxey Road plant ceases.
A number of aquisitions took place
including to Foseco Plc in 1980 and
1937 Burma Castrol in 1990.
Doxey Road office block was built.
2012
1997
1950’s Production starts at Raleigh Hall,
Unicorn Abrasives was aquired by
The Doxey factory was the largest of its Eccleshall.
Saint-Gobain.
kind in Europe, covering a 44 acre site.
The Raleigh Hall Plant | Eccleshall 15

16. Saint-Gobain Abrasives
Doxey Road
Stafford
ST16 1EA
Tel: 01785 222 000
Fax: 0845 602 6211
www.saint-gobain-abrasives.com
Form# 2114