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Posts Tagged ‘quality custom shutters’

Kirtz Shutter Craftsmanship; what a quality finish adds to your custom shutter

Thursday, August 20th, 2009
Without a quality finish on  a custom shutter, the value created by using a high quality wood, and rigorous construction standards would be minimized.   Let’s take a look at how Kirtz Shutters achieves a  quality finish on our custom shutters. 

Linear Priming (painted shutters only)

Components of our painted maple shutter are primed in lineal form.  By priming in lineal form we can ensure an even coating of primer, up to two mill thickness on each part of the shutter.  A high quality prime helps the shutter take finish coats well.

Wood Grading (painted and stained shutters)

Not all components make the final cut for a Kirtz Shutter.  All of our components are inspected before they reach the production line and undesirable sections of wood with flaws are marked as not suitable for a Kirtz Shutter.

Prep Work~ Where the Magic Happens

Even the best quality wood has some imperfections.   To get a smooth finish involves a high level of attention to detail during prep work.   Imperfections are fixed during 2 different stages of manufacturing.  

The Production Line — Filler is applied to the any noticeable flaws in the wood and sanded out smooth.  

Brown and Sand — Shutters enter this area after they are built, and before they enter the finish room.  High intensity spotlights shine down upon the shutters, highlighting any slight flaw that might show up in the final product.  These minor flaws are fixed with putty and sanding, and then the finish sanding begins. 

Finish sanding is done by hand, with very fine sandpaper.  Every inch of the Kirtz Shutter is finish sanded, including the top of the tilt rod, an area that few manufactures take the time to address.  After final inspection, they are ready for finish.

shutters are inspected for flaws under hign intensity lights

shutters are inspected for flaws under hign intensity lights

 

any small flaws are fixed before finish is applied

any small flaws are fixed before finish is applied

During finish Kirtz Shutters are hung from a track system on cars that allow the shutter to rotate completely.  This makes sure, whether painted or stained, each shutter receives an even amount of paint/stain on all parts of the shutters resulting in a smooth, even finish from any angle.

plantation shutters in the paint finish room

plantation shutters in the paint finish room

Painted Shutters receive  two coats of  lacquer paint finish on top of the primer.  In between coats, shutters are quality inspected.  All our paint has UV inhibitors in it to help keep your custom shutters looking great, even in the most intense sun.

Stained Shutters are sprayed with your stain color, typically a custom mix done just for you.  Each shutter receives two coats of stain.  In between coats, the shutters are taken down off the track, hand wiped and lightly sanded    This step is the differential between standard finish and a truly furniture quality finish.    Without it the shutter color would appear a bit opaque, what some people call “muddy” .  To finish up, we put two coats of clear finish on the shutters to protect the wood and bring up the beauty of the grain.   We use a 20 sheen, which gives a nice luster to the wood and provides the finish with depth.  

After finishing is complete, Kirtz Shutters sit overnight to let the finish have time to cure.  Depending on the time of the year, painted finishes are given extra curing time in a cool room.

While each area of our factory plays a key role in making the Kirtz Shutter a bench quality product,  the finish department plays a critical role in making the work of all the other departments really shine.

Kirtz Shutter Craftmanship; assembling a quality custom shutter

Monday, August 17th, 2009
The assembly department is responsible for turning lengths of components into a plantation shutter.

First, all parts are cut to length according to the exact specifications for your custom shutter.  After parts are cut, they are placed onto a cart with job sheets that details each opening in the order.

At Kirtz we take a few extra steps during assembly before the panel comes together to make sure that your shutter is built to the highest of quality standards.

Each tilt rod is given personal attention.  We shape the top of the tilt rod in a machine we designed to give the rounded top that is unique to a Kirtz Shutter.  Then, the top of each rod is sanded smooth so it has the same quality finished look as other parts of our shutters.

tilt-rod-shaping

After shaping it is sanded smooth

After shaping it is sanded smooth

Before the shutter is put together, each louver end is burnished with a sander.  Again, this extra step allows the ends of the louvers to accept the painted finish better, and eliminates the rough ends you would typically find with louvers that are cut, but not sanded.

Burnishing louver ends

Burnishing louver ends

Next, the louvers and tilt rod are fed through a machine that attaches them together with staples and puts pins in the end of each louver, and your shutter panel is ready to be put together.

Joinery of a Kirtz Shutter

At Kirtz we use dowels to join the stiles and rails of each shutter together.   Wood glue is put into each hole that will be receiving a dowel.  Then we use dowels that are slightly larger than the hole they are inserted into.   This requires the use of a hydraulic clamp to put the stiles and rails together.  After the shutter has been clamped together, small pin nails are applied to the backside of the shutter through the dowels, giving it an extra dose of reinforcement.

This method has been used by Kirtz for many years, and we confidently stand behind the joinery of a Kirtz Shutter for a lifetime.

The shutter comes together on the clamp table and is pin nailed for extra strength

The shutter comes together on the clamp table and is pin nailed for extra strength

Framing

Just like a door hangs in a frame, many times your  hardwood shutter will be in a frame.  We have several framing options at Kirtz to accommodate a variety of decors and types of windows.    After your shutters have been assembled, the frames that surround them are built.

At Kirtz we customize many of our frames so that they fit around window cranks and lever locks.  By doing these notches in the factory when possible, the notch receives a finish coat of paint instead of touch up in the field.

For more information on notches, see my post about plantation shutters in casement windows.

This completes your shutter assembly, next stop finish department!

Kirtz Shutter Craftmanship; Making the parts makes the difference for your custom shutters

Thursday, August 13th, 2009
Most shutter manufacturers buy their shutter components from large milling companies that deliver ready to assemble pieces to the manufacturers.    These components can be from the US, Mexico, and even China.   At Kirtz Shutters, we have rigorous quality control standards, and we use a variety of hardwoods, so components are made in-house in our milling department.

Hardwood shutters by Kirtz start at our factory as raw lumber.  We typically buy direct from the best lumber mills across the country, with a great deal of our lumber coming from the Northern US. 

A load of lumber for Kirtz Shutter, before sorting

A load of lumber for Kirtz Shutter, before sorting

 Lumber goes through the following process to become parts for your plantation shutters.

All lumber is tested upon arrival for proper dryness.  Using lumber that has been wet, or is not properly kiln dried could result in warping.  Obviously, this would be bad news for a shutter, so each load is tested immediately upon arrival to be sure that it meets the criteria for furniture quality use.

After unloading, lumber is sorted and it is determined what component part each board will be used to make.   Next, the lumber is fed through our Weinig molder and shaped into the different parts needed to make your shutter order.  As lumber is shaped into parts, each part is quality checked to see that it does not vary from our standard, which are +/- 5000 of an inch, a more exacting measure than industry standard, which is +/- 10,000 of an inch.

lumber being milled into components for plantation shutters

lumber being milled into components for plantation shutters

Verifying the milled parts meet quality standards for Kirtz Shutters

Verifying the milled parts meet quality standards for Kirtz Shutters

Since we use so many different types of woods in our shutters, the milling department must constantly calibrate the machine to handle the varying density of each wood.  Although this is a time consuming process it is the only we can maintain the rigid quality standards of a Kirtz Shutter.

After the louvers are molded they are run through a specially designed sander.  The belt of the sander is contoured so that it follows the shape of our elliptical louvers.  As the louver passes through the oscillating belt provides a random orbital sanding, the industries highest standard.  The louvers are now ready for the assembly line. 

Sander designed for elliptical shaped louvers for custom shutters

Sander designed for elliptical shaped louvers for custom shutters

The milling department is also responsible for laminating our stiles, which glues together two opposing pieces, resulting in a longer, straighter stile than industry standards.  
Once shutter parts finish the above processes, production is notified and your shutters are ready for the assembly department!

Painted Custom Shutters… Why Use Maple?

Friday, July 31st, 2009

At Kirtz we like to do things different, not just simply for the sake of being different, but because we want to bring something above average and a little special to our customers.  In our painted plantation shutter, that something special is the wood we use.

The founder of our company was a woodworker, in fact he got his start in the industry as a trim carpenter until the economy and life took him a new direction (I’m sure a few of you can relate given the world’s present state).  So when he decided to make shutter, he picked the wood that from his experience, would the best wood for a plantation shutter– MAPLE.

Why Maple?   In one word, STRENGTH.

 Maple is about twice as dense as shutter industry standard woods such as basswood and poplar.   What does that mean for the you, the buyer?  An awful lot in the long run.  Your shutter is put together with fasteners, staples that hold the louvers into the tilt rod.  Time and use of the product stresses these fasteners.  In softer woods, such as basswood and poplar, they often come loose over time.  The result is that the shutter does not function as it was originally intended.   A Kirtz Shutter is guaranteed never to have this problem, and if it did, it would be covered by our warranty.

Have you ever had a piece of pine furniture?  Did you notice how easy it was to dent the wood if something accidently bumped or banged into it?  The same is true of a poplar or basswood shutter, they can easily dent and ding at the slightest impact, thus increasing the look of wear and tear on the shutter.

The strength of maple also gives us ultimate FLEXABILITY IN DESIGN. 

In Height:  The Kirtz Shutter does not need a midrail (also called a divider rail) until after 96″ in height.  Industry standard is 72″.  That means you can have two more feet of unobstructed louver space by using a custom shutter by Kirtz out of maple.

In Width:  With shutters warrantied up to 38″ in width, customer’s have the ultimate flexibility in designing their shutters for the best fit to their space without the constraints of industry standard shutters.

Often I meet with customers who are confused with the variety of materials that a plantation shutter can be made from and the variety of pricing that goes along with them. 

My advice to them, and to you, is this – 

Plantation Shutters are one of the largest financial investments in window treatments that you can make.    They will provide beauty and protection for many, many years.  All shutters are NOT created equal.   In an economy where every dollar counts,  we all want to make sure we spend our money wisely.  

Choose the plantation shutter that will provide you the best product experience over the life of your shutter, not just in the beginning.  And just as important, choose a company that you can trust to provide you great customer service, both before the sale and years after your shutters are installed.  That, in my life experience, is true value that pays dividends long after the check has cleared the bank. 

I’ll end this (and step off my soap box) after I share my favorite quote.  I try to live it every day, in the products I represent to the products I purchase for myself and my home.

“The bitterness of poor quality, lingers long after the sweetness of low price is forgotten.”

Plantation Shutters on French Doors

Monday, April 20th, 2009

waterfront-master2

Many people are at a loss with how to do window treatments  on doors, especially when a lever handle is involved and it is in a high traffic area.

Lets look at some common window treatment solutions for these doors.  Our in- home sales division (in OK and KS)  has put all these products on doors for customers,  so the basis for this blog is our experience.

Wood blinds-  Many blind manufacturers solution is to do a cut out of the blind slats around the handle, thus preventing the slats hitting the handle when they are opened and closed.  The drawbacks of this solution, is that is does not offer as much privacy as many homeowners desire and clearance is still an issue when raising or lowering the blind.   Another option is to order a very small slat so that the blind fits behind the handle.    This can be a good solution, but small size slats are only offered in certain product lines, so your options are a bit more limited.  Also,   if you want the larger slats for other windows in the room,  it breaks the flow a bit.

Fabric Shade- These would include roman shades of fabric or grass, cellular shades, or any type of woven product.  Pro’s are that these are very lightweight, if you like the idea of rasing your blind completely every day,this may work for you.  Many times the shade lays very close to the glass, and fits behind the handle with ease.  The drawback is that when they are down, they tend to bang around and swing with the open and closing of the door.  To prevent that, most companies offer hold down brackets that hold the blind in place at the bottom of the door.    If you want the brackets you are left with two options- undoing the bracket every time you want to raise or lower the shade.  Or, ordering a shade that operates “top-down”, meaning you can lower it from to top down to the bottom to see out the window.  Keep in mind that a top down product will have strings that run through the blind and are visible when the shade is in the open (or lowered) position.

Kirtz plantation shutters on french doors can be a great option.    The shutter is housed in a frame that gives enough projection for the louvers to pivot.  (2 1/2″, 3 1/2″ and 4 1/2″, consider 2 1/2 if you have wood blinds on the other windows) The frame wraps around the shutter on four sides so that it can be secured top, sides and bottom.  This means no swinging back and forth as the door opens and closes.  Inside the frame the plantation shutter mounts on hinges, so you still can access the glass for cleaning and such.  If you have a lever handle, we do what is called a radius cutout around the handle with a solid area behind it.  This makes certain that you have complete privacy whether the louvers are open or closed.

door-close-up-2

Something to keep in mind;  if your doors are double and one is  fixed and the operable door opens back onto the fixed door, applying a window treatment of any kind will affect how far the door will open back.    The degree to which it will be affected will vary from one door manufacturer to another, and from one window treatment to another.  An experienced window covering salesperson should be able to address any concerns you may have and discuss this on the front end.   Many times with shutters, we can make a few adjustments to insure the door opens to the greatest degree possible.  However, if it is not addressed on the front end, little can be done.  Just another reason to allow your window covering sales person plenty of time to identify and address all possible concerns with your custom shutter order!

What makes a good plantation shutter design?

Monday, April 13th, 2009

Kirtz Plantation Shutters are all custom designed and produced.  So when you choose to order plantation shutters from Kirtz Shutters, you have a variety of  shutter layout and design options.  Two major areas for discussion are – How do I choose a louver size?  And how many shutters should I put in each opening?

First, let’s talk about louver size.  This depends on a variety of factors, such as the style of your home architecture and design.  However, this comes down to personal preference.  Part of the beauty of plantation shutters is that you can get such great visibility and light control just by slightly adjusting the louver angle.  It stands to reason that the larger the louver, the better the view.    Many people are simply amazed at how much visibility you can get with a shutter.  In fact, during our in- home consultations we typically bring one sample of each louver size, set it in the window, ask the client to step back and take a look at the different proportions of each louver size and how that impacts the feel of the room.  Well, I can’t do that in a blog, but take a look at this picture.  Each opening shown is 72″ x 72″; the only thing that changes is the size of the louver.

louver-options-open

Now to be frank, most people choose 3 1/2″ louvers.  However, I can make a case for the larger 4 1/2″ louvers in many homes, and we see more orders all the time with this size.    On occasion, as we do add on orders for a homeowner, they will tell me that they wish they had chosen a larger louver size.   I have never heard a customer tell me the wish they had chosen smaller.

Now for the shutter configuration.   The first thing you need to look at is the configuration of the window you are going to shutter.  You will get the best look if you try to mimic the window layout.  This minimizes the appearance of extra vertical distractions.  For instance, say you have 3 or more windows mulled together.  You want to try to place the shutters where the vertical members of the shutter line up with the vertical mullions of the windows.  This will give you the cleanest, most open view possible and will also provide for a more flattering appearance on the outside of the windows.

Let’s go back and look at our typical window again, a 72″ x 72″ (typically two 36″ x 72″ windows mulled together.)  Many time clients think they want to have four shutter panels in an opening this size.  This is based upon their assumption that they will open the shutters back regularly.   However, with a larger louver size, folding them back is not necessary for great visibility.  And the larger the panel you can put in your window, the more unobstructed view you have.  Take a look at these drawings showing that same window size, 72″ x 72″.  Both drawings show the same louver size, but with 2 versus 4 panels in the opening.

panel-distribution

By choosing the four panel configuration you lose almost 8″ of your window that you could otherwise see through.

Of course, we always make what the customer wants, and if you are confident that you want to open you shutters back everyday, then the four panel configuration is probably the best layout for you.  For opening shutters daily, a two shutter panel configuration would not work for most room layouts.  Each shutter would have a 36″ swing when it opened.   Even a 4 panel layout deserves some thought, as it would come into the room and need 18″ of wall space to fold against.

What this all comes back to is the importance of working with someone who is knowledgeable about the process, and can help guide you through the ins and outs of all these design decisions.  The sales staff at Kirtz makes giving you a great buying experience a priority.  We want your shutters to look and function just the way you had imagined, and we take great care in making sure we provide that experience to each and every customer.  Feel free to call us with your shutter design dilemmas and we will do everything in our power to find a great solution!

Hidden Tilt ~ The Best Way to Maximize Your View

Monday, March 9th, 2009

Hidden tilt, one of the newer custom options available with Kirtz Shutters, has become increasing popular since its introduction.

How it works

On a traditional plantation shutter louvers are fastened to the tilt rod with staples and you use the tilt rod to contol the position of the louvers.   With a hidden tilt rod, a narrow metal rod is attached to the backside of the panel at the end of the louver on the hinge side.   We then finish the hidden rod a similar color to the panels.

hiddentilt2

Although we can build shutter panels to our standard height of 120″ with hidden tilt, the rod must be broken at a certain point so that the weight of the louvers does not prohibit the mechanism from working appropriately.

The standard cut off points for each louver size are as follows:

  • 2 1/2″ at 36″ or 18 louvers
  • 3 1/2″ at 48″ or 16 louvers
  • 4 1/2″ at 60″ or 15 louvers

These break points can be modified to less than the stated split, if it is a better compliment to your windows.  That’s something that you can request during your onsite consultation.

If you favor clean lines, perhaphs a more contemporary look, or just want to insure you have the maximum amount of view, then hidden tilt may be the option for you.

hidden tilt in bath

shutters-mc-009

Tulsa Home Show — Mar 12 thru 15 2009

Tuesday, February 24th, 2009

Shutters of Tulsa, the Kirtz representation in the Tulsa area for many years, will have a booth during the Greater Tulsa Home and Garden Show Mar 12-15  in the Quicktrip Center at Expo Square.  Come by, say hello to Don and see the quality that Kirtz has to offer!

Company Lunch at Kirtz

Friday, February 20th, 2009
Last Thursday, Feb 12th, we had a company lunch at Kirtz.    It was a special lunch because everyone was treated to steak by Click’s Steakhouse in Pawnee.   If you live in the area and you haven’t been to Click’s, you are missing out.  Between the homemade rolls, steaks marinated to perfection and awesome desserts (I recommend the tollhouse pie) you will be amazed.    However, I digress.

The reason for this meal is workplace safety.  Every month The Shutter Mill is accident free, all employees are treated to a lunch.    That’s always great, but when we go 3 or more months with out an accident everyone is treated to steak for lunch.  Not bad, huh?

After the lunch we have a safety meeting, and also an update on what’s going on with the company.  This month we recognized two employees for five years of service at Kirtz.   We have an every increasing maturity in our work force.  More employees have been with us 5+ years than we can ever remember.    This seasoned group of employees greatly helps contribute to maintaining, and continually increasing, our quality standards and efficiency.    You can see it in every shutter that leaves here.

I guess that’s why we get the opportunity to install our shutters all over.  Last year we went to St. Lucia,  and the Bahamas for shutter jobs.  Right now I have jobs in process for Frisco TX, and Kansas City, MO — all because these people want the quality that Kirtz has to offer.

If you have a project, give us a call.  Have car (or plane ticket) —will travel.

Guys from stain, specialty shapes and shipping

Guys from stain, specialty shapes and shippingour assembly team leader enjoying his dinner

How Do We Define “Plantation Shutter”?

Thursday, January 22nd, 2009

Kind of like a lot of design terms, there can be multiple ways to describe the same thing and it really isn’t consistent throughout the industry, much less the country.  Plantation Shutters can refer to shutters in general, and depending on the person is usually indicative of a louver (slat) size.

What is commonly referred to as traditional shutters are small louvered, small paneled.  These are most common in the NE and upper midwestern United States.  The louver sizes are usually anywhere from 1 1/4″ up to 1 7/8″, sometimes 2 1/2″ louvers (which we carry) are included in that description.  These shutters often are built “cafe” style, meaning they cover only the bottom 1/2 to 2/3 of a window, and are very narrow (think 8-20″ wide per shutter panel)

The term plantation shutter is typically associated with the 3 1/2″ and 4 1/2″ shutters.  This style is more common south of the Mason-Dixon line, and in Western United States like Arizona and California (both big shutter states).  Sometimes the 4 1/2″ louver and 5 1/2″ louver (we don’t carry 5 1/2″) are referred to as California style shutters.  Plantation shutters tend to be larger panels, with one shutter panel often covering an opening 36″ and up to 72″ tall.

We sell more of the plantation style, as it is more in demand and our machinery accommodates it best.  However, we will sometimes do the traditional (to us that means smaller than 2 1/2″ louvered) look if a customer requests it and is willing to pay for it.

Usually these customers, in addition to wanting small louvers,

  • have large projects (not a one off scenario),
  • need a special wood
  • have unique specifications (special panel thickness, louvers fixed at a certain angles) that other shutter companies don’t want to mess with.