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Choosing the Right Packers for Manufacturing: A Guide for Window & Door Fabricators

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Why Fabricators Need the Right Packers

In a fabrication environment, every millimetre matters. The packers used during assembly directly influence:

  • Frame alignment
  • Reinforcement stability
  • Glazing fitment
  • Drainage accuracy
  • Long-term product performance

Unlike on-site installers who adapt to each property, fabricators need repeatable, precise, and consistent results across hundreds or thousands of frames.
This makes the correct choice of packers — and the correct stock levels — essential to efficient production.

The Role Packers Play in Fabrication

Packers are used throughout the window and door manufacturing process, including:

  • Supporting reinforcement
  • Aligning frame sections
  • Squaring outer frames
  • Preparing sashes for glazing
  • Creating consistent positioning for hardware
  • Ensuring drainage paths remain clear

Using the wrong packer type or thickness during fabrication leads to misalignment that installers cannot fix later.

The Most Common Packer Sizes Used in Fabrication

Fabricators typically work with predictable, standardised spacing.
As a result, certain packer thicknesses are used far more frequently than others.

High-usage fabrication sizes:

  • 3 mm (most used in manufacturing)
  • 5 mm (commonly used for reinforcement and frame assembly)
  • 4 mm (for balanced spacing across systems)

These three sizes often represent 90% of all packers used on a fabrication line.

Fabricators should always buy these sizes in bulk (1,000–5,000 per box).

Lower-usage sizes (for special cases):

  • 1 mm
  • 2 mm
  • 6 mm
  • 8 mm and above

These should be kept in smaller quantities but still available for custom profiles.

Flat Packers: The Fabrication Essential

Flat packers are the backbone of manufacturing because they:

  • Maintain even spacing
  • Work perfectly inside sash and frame chambers
  • Support sealed units during final glazing
  • Allow consistent squaring of frames
  • Ensure alignment for hardware fixing points

Fabricators should stock:

  • Bulk packs of 3 mm, 4 mm, 5 mm
  • Smaller quantities of 1 mm, 2 mm, 6 mm
  • Colour-coded sets for quality control and speed

Flat packers are used at almost every stage of the build process.

When Fabricators Should Use Bridge Packers

Bridge packers are essential when fabricating frames with reinforcement screws that fall directly under glazing areas.

They allow the packer to:

  • Sit over the screw head
  • Maintain stable support
  • Prevent pressure points on the glass
  • Ensure drainage channels remain unobstructed

Fabricators producing reinforced sashes or large doors should always stock:

  • 5 mm bridge packers
  • 6 mm bridge packers

This guarantees smooth glazing and reduces risk of unit stress.

When Fabricators Should Use Wedge Packers

Wedge packers are less common in fabrication than on-site installation, but they are still crucial for specific manufacturing tasks.

Use wedge packers for:

  • Minor adjustments during sash assembly
  • Aligning mullions and transoms
  • Leveling frame connectors
  • Compensating for profile variations between batches

Wedge packers provide micro-adjustments that flat packers cannot achieve.

How Packers Improve Manufacturing Consistency

Quality control is a priority for all fabricators.
Packers help ensure:

  • Every frame leaves the factory with consistent spacing
  • The sash opens and closes correctly
  • The reveal gaps are uniform
  • Drainage channels match system specifications
  • Glazing beads fit securely and evenly
  • Hardware sits correctly without twisting

By standardising packer use, fabricators can maintain identical results across high-volume batches.

Colour-Coded Packers Improve Factory Efficiency

Fabrication teams benefit from colour coding because:

  • Workers identify sizes instantly
  • Production speed increases
  • Mistakes are reduced
  • QC inspections become faster
  • Training new staff becomes easier

Colour-coded packers offer both speed and accuracy — essential for manufacturers aiming for efficient throughput.

How Many Packers Should Fabricators Keep in Stock?

For small to mid-sized fabrication shops:

  • 3 mm: 3–5 bulk boxes
  • 5 mm: 2–3 bulk boxes
  • 4 mm: 2–3 bulk boxes

For larger factories producing 300+ frames per week:

  • Keep pallet quantities of the three core sizes
  • Store bridge packers for reinforced frames
  • Maintain wedge packers for adjustments
  • Keep mixed sets for custom batches and special orders

Fabricators should never run low — production downtime costs far more than packer stock.

Final Thoughts

Choosing the right packers is essential for window and door fabricators who want to deliver consistent, high-quality products.
By stocking the correct types and thicknesses in bulk, fabricators can improve production speed, reduce errors, eliminate glazing issues, and ensure every frame meets exact standards.

A complete fabrication packer setup includes:

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