Innovation and development: the foundation of Exlabesa Architecture’s leadership in aluminium systems
At Exlabesa Architecture, we have been bringing the most innovative aluminium projects to life for over 60 years, thanks to a deep understanding of profile development and a continuous commitment to innovation. As reflected in our activity within the architectural sector, “the close integration between R&D and production is one of the company’s major strengths”, and it is precisely this approach that enables us to meet the most demanding needs of the industry.
For us, the drive for innovation has a very clear foundation: R&D. From our Research and Development department, located at our headquarters in Valga (Pontevedra), we work to transform architects’ and designers’ ideas into real, viable, high-performance technical solutions.
As our Business Area Director, Carlos Negreira, explains in an interview with Novoperfil:
“R&D is the company’s main engine of innovation. Its mission is to develop aluminium systems that meet the highest technical, regulatory and aesthetic standards, anticipating the demands of the market and the construction sector.”
An industrial capability that sets us apart in Europe
Our R&D activity is supported by a leading industrial infrastructure in Europe, which allows us to turn design into real-world solutions with a high degree of precision and efficiency:
- 35 extrusion presses
- 5 anodising plants
- 12 powder coating plants
- 12 thermal break assembly lines (RPT)
- 34 machining centres
- 3 bending centres
Thanks to our high technical capacity and specialist knowledge, at Exlabesa we are in a leading global position in the manufacture and extrusion of large, highly complex aluminium profiles.
To achieve this, we operate two of the largest and most advanced extrusion presses in Europe, of 65 and 85 MN. This capacity enables us to manufacture profiles up to 28,000 mm in length, 700 mm in diameter and 120 kg/m.
In addition, we have four recycling plants that allow us to produce certified recycled aluminium, reinforcing our commitment to sustainability and the circular economy.
The recycling process — from collection and smelting through to the extrusion of new profiles — is certified by Bureau Veritas under the RE-local 100 and RE-local categories, which guarantee both the use of 100% post-consumer aluminium and low-carbon production.
A global team for international development
To develop all the solutions required by architectural projects, it is essential to have a team capable of turning ideas into reality. In this respect, the members of the Exlabesa Architecture Research and Development (R&D) department are responsible for the company’s most representative and innovative systems.
As Carlos Negreira explains, “R&D is the company’s main engine of innovation. Its mission is to develop aluminium systems that meet the highest technical, regulatory and aesthetic standards, anticipating the demands of the market and the construction sector.” This department is also responsible for improving and refining existing systems, combining innovation, design, technology, creativity and technical rigour.
Exlabesa Architecture aims to become an international benchmark brand in aluminium systems for architecture. To this end, it has defined a clear strategy centred on strong investment in R&D, “which enables us to launch innovative products with exclusive design and high technical performance. This commitment to continuous innovation is key to differentiating ourselves and offering solutions that generate added value for our clients,” explains Negreira.
The department currently comprises a multidisciplinary team of more than 30 specialists, including engineers and architects, based between the headquarters in Valga (Pontevedra) and the factories in Doncaster (United Kingdom), Warneton (France) and Tangier (Morocco). From these sites, the design and development of products is carried out for distribution in more than 60 countries. “This international structure allows us to work in a coordinated way, close to the client, and with a global vision.”
To further strengthen this department, the headquarters building in Valga is currently being expanded in order to significantly increase its capacity for developing new products and to reinforce the area dedicated to project design and client advisory services. This expansion will increase the current space of 36 workstations by a further 32.
“This expansion will make us the largest technical and R&D office specialising in aluminium systems in the Iberian Peninsula,” says Carlos Negreira.
Continuous innovation and development of new systems
Our growth strategy is firmly based on investment in R&D, with the aim of consolidating ourselves as an international reference in aluminium systems for architecture. Over the past five years, the work of our R&D department at Exlabesa Architecture has been key to the development of 17 exclusive systems. These include the new window and door platform in ARS-62, ARS-72, ARS-77 Slim and ARS- 82 versions in flush sash, concealed sash and minimal sash variants, compatible with European groove and 16 mm groove systems, as well as the CRS140 minimalist sliding system — “which has redefined the panoramic door category” — the new Iconic range of handles and pull bars, and the IDS30 internal door system.
“In addition to the systems already launched, the R&D department is currently working on a product plan that will enable us to bring another eight new systems to market over the next three years, making our catalogue one of the most comprehensive in Europe,” says Negreira.
In façade systems, aesthetic and regulatory requirements directly influence development. As our General Director acknowledges, “the main challenges lie in enabling large glazed surfaces using lightweight profiles with reduced visible sections that comply with the regulations and technical requirements of each country in which we operate. At this point, it is not only essential to have the right resources and capabilities, but also a highly qualified team with the experience and knowledge needed to face current and future challenges in the architectural envelope sector. This is where our R&D and technical office team at Exlabesa makes the difference, providing solutions and added value to our clients.”
Advanced technology at the service of design
In carrying out its work, our team benefits from a state-of-the-art technological centre that allows us to subject systems to real performance testing. “The expansion of the technological centre will enable us to double the current testing space,” notes the General Director of Exlabesa Architecture.
The department also works with advanced digital tools that enable 3D modelling, structural simulations, thermal analysis and profile optimisation, as well as the use of 3D printers for rapid prototyping and component manufacturing. All of this speeds up design validation, reduces development times and facilitates early identification of improvements, thereby optimising final product quality.
“Thanks to all these tools, engineers can simulate real-life conditions such as structural resistance, watertightness, thermal and acoustic insulation, durability and ease of installation.”
The close integration between R&D and production is one of Exlabesa’s greatest strengths. “As the largest family-owned aluminium production company in Europe, we have distinctive industrial capabilities, such as macro-extrusion of aluminium profiles with the largest presses in Europe, or the ability to powder coat and anodise profiles up to 14 metres in length. This allows us to design solutions and develop façade projects with virtually no production limits,” concludes Carlos Negreira.
For all the reasons outlined, at Exlabesa Architecture we understand that innovation is driven by a strategic combination of technical expertise, continuous R&D investment and strong industrial capabilities. This integration of development, testing and production allows us to anticipate market demands and offer increasingly advanced, efficient aluminium solutions tailored to the challenges of contemporary architecture.
With a clear international outlook and an ambitious pipeline of new systems under development, we continue to strengthen our position as one of Europe’s leading references in aluminium systems for the built environment.
