Exclusive Designs and Customisation from DOORCO


With the New Year Celebrations still fresh in the mind DOORCO is introducing several exciting new door styles to give the trade and in turn homeowners a wider choice than ever.

Care has been taken to ensure both traditional and modern tastes are catered for. For the traditional four new designs have been launched. Of these St Andrews and Gleneagles are unique to DOORCO, whilst the Sunningdale and Belfry Farmhouse styles are manufactured from brand new moulds, not routed from a flush door a process that inevitably weakens the panel. Thus, aesthetics, operation and performance are authentic and especially pleasing when installed in a traditional setting.

At the opposite end of the styling spectrum are the new contemporary Monza, Seminole, Inox Lyon and Inox Barcelona designs. These set new parameters for modern, upmarket entrances, combining clean lines with a range of glazing options for installations in which personal expression and customisation are key.

All products are available in 44mm and 68mm versions to extend appeal to a wider range of homes. Individualisation of all doors is increased through DOORCO’s in-house paint line providing an almost limitless choice of colours with fast turnaround.

The new doors enjoy the reinforced skins that are standard across the whole DOORCO range. Offering substantially increased resistance to forced entry and violent attack as well as a more substantial feel, the thicker skins anticipate impending changes to the Building Regulations and steal a march on most other door manufacturers that have yet to react.

“We believe that homeowners are increasingly discerning in their choice when replacing their entrance doors,” says DOORCO’s Dan Sullivan. “These are the first of a range of new designs that will be introduced throughout 2015 to ensure that our fabricator and installer customers always have something fresh to offer, to allow them to stand out from the crowd in a busy market.

“The investment we have made during the past two years has led us to this point, where we can continually innovate to bring something fresh to the market, in volume slab supplies just as readily as prepped doors. The choices we are offering are designed to create excitement amongst homeowners choosing a GRP door for their properties.”

Dan advises fabricators and installers to ‘watch this space’ during 2015: “We have a lot more to offer throughout this year. We are door specialists – hence the name – and we promise some nice – and profitable – surprises.”

Looking Beneath the Surface at DOORCO


The ‘DOORCO’ stand at this year’s FIT Show implied that a new exhibitor was taking part selling a wide range of composite residential doors and also featuring a nicely appointed FS, or Folding Sliding door. It was an impressive display and exhibitors and visitors alike looked on bemused at this apparent new kid on the block.

In fact DOORCO is essentially a renaming of the Capstone Door company, on the surface involving little other than a name change, with even the VAT number remaining the same. Behind the scenes however, there is much happening and a whole lot more to look forward to in the coming days…

Capstone remains a key, core product under the DOORCO umbrella, the company continuing under the ownership of Dan Sullivan who together with partner John Collins has been involved with the domestic door market for many years. Their initial business was supplying container quantities of Capstone doors to large fabricators then expanding into door distribution from UK stocks. In the last 18 months the offer has included a pre-prepared product, something that has dramatically increased the customer base as well as margins, simply by adding value.

The company’s investment in achieving this has been substantial with a spend of more than £500,000, resulting in the factory becoming one of the most advanced composite door facilities in the country. Two CNC machines, an edge bander and a paint line allow DOORCO to offer an almost limitless customisation service to its customers.

In addition to manufacturing personnel the support and management team has also doubled in size to ensure that the company has the right technical, administrative and financial skills.

But whilst a great deal has been achieved to firmly plant Capstone in the hearts and minds of UK trade buyers, the DOORCO brand represents a whole lot more as Dan Sullivan explains: “It’s actually very simple. Capstone, as popular as the brand has become, represents just one door product – composite residential – and our future is about a range of doors of all types. DOORCO means just that – there are many more opportunities out there for door products and we intend to look at all of them: we are a door supplier.“

At this year’s FIT Show, the company rolled out new products that included a 68mm rebated composite door solution and a folding sliding door system manufactured in aluminium. Rather than use the bi-fold tag for the latter, Dan has reverted to a term used before these doors became popular in the past couple of years, one that actually is more descriptive and appropriate: “Folding/Sliding or ‘FS’ is another way of distinguishing DOORCO’s products from those of our competitors,“ he says.

Dan explains further: “We could not have offered this product under the Capstone name as it is UK made. Other new concepts that are due for launch over the next few months are also made by other supply partners, further explaining why the DOORCO brand was created; we are a complete door company – it’s part of our DNA.”

A more recent innovation that both illustrates DOORCO’s continuing commitment to both Capstone and to innovation is the DOORCO 6/4 Combi, a composite door that allows fabricators to make seven popular door styles from just one door blank.

Manufactured using a unique midrail that has the woodgrain pattern running through from top to bottom, the 6/4 Combi may be manufactured into a number of popular styles including: Six Panel Solid; Twin Vertical; Twin Top; Twin Top with Mid Panel; Half Glazed; Full Glazed; and Four Glazed (twin and bottom).

“All this is with absolutely no sacrifice to the aesthetics of the door or its quality and specification,” explains Dan “This design innovation is absolutely unique to the 6/4 Combi and another exclusive benefit to DOORCO customers. It is also,” he continues “just the tip of the iceberg. The domestic door market has barely been touched in the UK. We intend to change that.”

DOORCO’s 68mm Sales Hit 3 Year High


DOORCO, the Macclesfield based door specialist, is reporting a 3-year high in sales of the company’s popular Capstone 68mm product across both blanks and prepped supplies.

The first 68mm composite panel to be brought to market by a major brand it was offered originally as a premium door. However, the significantly higher thermal, weather and security performance, coupled with ease of fitting and adjustment has broadened the appeal of the Capstone 68mm as installers and in turn homeowners realise the value for money the option presents.

DOORCO, renamed in mid 2014 from Capstone Doors Ltd as the company’s range of door types blossomed, has also continuously boosted available stock to include 6 panel; 4 panel long; 4 panel blank; Craftsman; 3/4 lite; and flush versions, as blanks or prepped product.

ODL’s Trisys cassettes are provided to offer superb choice, excellent air and water resistance and the ability to re-glaze. Prepped doors are available for Winkhaus’s excellent Edge Lock & Hinge System or the fine Exitex eurogroove lock edge system. Alternatively DOORCO prepares doors to replicate a PVC-U sash to utilise standard 16mm locks.

DOORCO’s offer of an almost unlimited choice and fast turnaround of colours through its in-house paint plant has attracted new customers, as has the wide selection of triple glazed units with matching sidelights.

“From being offered initially as a premium product to give our customers’ additional market opportunities our 68mm range has become very popular for homes in all price ranges and sectors,” confirmed DOORCO MD Dan Sullivan. “The higher basic price of these products is nothing when the advantages and options are made clear to customers,” he added.

DOORCO is Opening Up the Market


We are much more than a name says MD Dan Sullivan as he tells Glass News how… DOORCO is Opening Up the Market

With a ‘Prince’ like swerve the company formerly known as Capstone changed name to DOORCO in December 2013. What’s in the name?

The reason for the change, according to MD Dan Sullivan, is that the company is now so much more than the UK distributor for the highly popular Capstone composite door that have grabbed the attention of a large number of manufacturers and in turn, installers and homeowners. DOORCO will offer an even more diverse range of doors and door options as time goes by: “We are still the UK distributor for Capstone doors, both blanks delivered to door manufacturers in containers, increasing volumes through distribution to major fabricators with CNC facilities and increasingly products in varying stages of ‘prep’,” he explains. “GRP doors are our number one product, and it is no mistake that some of the biggest door fabricators in the UK use our product, but we have aspirations to be a one stop door supplier to all customers. At this year’s FIT Show we revealed several new products in our GRP door range, and also new products developed and designed by DOORCO which takes us into different types or sub sectors of the door markets. The name, therefore, needed to be changed and that is what we greeted visitors to The FIT Show with!”

At the show DOORCO rolled out their first bi-folding – or ‘folding/sliding’ – door system manufactured in aluminium. Rather than use the bi-fold tag for this, interestingly Dan is reverting to a term not used these days for this type of door, one that actually is more descriptive and appropriate: “Folding/Sliding or ‘FS’ was originally the term used before these doors became popular in the past couple of years,” explained Dan. ‘It’s another way of distinguishing DOORCO’S range of products from those of our competitors“.

There is of course, far more to the DOORCO FS doors than a break from the usual nomenclature. “DOORCO aims to always bring something new to the party and the company’s set-sized FS doors certainly promise that,” says Dan: “The FS doors are supplied as kits which allow us to offer substantially greater margins to installers as they assemble the doors themselves, with the savings compared with fully assembled doors going into their pockets. The key is that the system is designed to be fast and simple to assemble whilst still providing the strength, rigidity, security and aesthetics homeowners expect.”

In the meantime, the 68mm rebated composite door is driving the residential door replacement sector upmarket: “There is a very distinct sector that has remained relatively untouched,” explains Dan. “Luxury home owners naturally seek better quality products for their properties both because their homes are generally of higher quality and these people require and are prepared to pay for something that is better in terms of manufacture, aesthetics and of course, performance. The DOORCO 68mm is making inroads already since being launched as a prepped product in June, offering installers an additional product for a lucrative sector”.

Capstone products will remain the cornerstone of DOORCO’S operation and a great deal of time and money has been invested in enhancing the offer. The company initially supplied container quantities of Capstone ‘blanks’ – ex factory, unworked door panels – to large fabricators, rapidly expanding into distribution from UK stocks, which is where the major growth of the company lies. The last 18 months has seen the company offering a prepped door solution for fabricators who wish to add their own uniqueness and so reaching an expanding and growing customer base allowing more companies to use the DOORCO GRP door blank.

The £500,000 spent on this enhancement to the company has elevated DOORCO to possess one of the most advanced composite door facilities in the country, with two CNC machines, an edge-bander and a bespoke paint line, all of which offers almost unlimited choice to customers. The team has also nearly doubled in size to ensure that the company has the right technical, administrative and financial skills to support the different areas of the business. This includes the recruitment of former Price Waterhouse Coopers, Ernst & Young and Astra Zeneca executive Jayne Sullivan into the business, something that Dan says has been crucial to the expansion. “We don’t just need numbers of people in DOORCO, we need expertise to ensure that our systems are in place and are robust, that management also steps up a gear in line with our expansion. We didn’t look far to find the solution in Jayne who has the skills, knowledge and commitment to make a real positive impact” said Dan. The growth and success we have enjoyed from our first recruit from the corporate world, Mike Roe who heads up the sales, has given me the confidence to bring in people of this level and now to have such experienced individuals on board gives me a lot of confidence for the future.

The name change heralds a new phase for the company but the investment and new products are very tangible evidence of commitment to the market. Dan explains: “Doors are in our DNA, we have sold literally hundreds of thousands of doors of all types over the past ten years and we know doors and the markets for them inside out. And if you consider just how many different types of door there are in an average house, for example, we are just scratching the surface…”

Despite our best efforts Dan would not be drawn further on this somewhat enigmatic conclusion to our interview. All he would say was that plans for further new products that would “turn the industry on its head” will be revealed around the turn of the year. We will be the first to bring you the detail.

The Door That’s Seven Doors… The Innovative DOORCO 6/4 Combi


Composite Door CNC fabricators can now make seven popular door styles from just one door blank with the latest innovation from DOORCO – the 6/4 Combi.

The 6/4 Combi has a unique midrail with the woodgrain pattern running through from top to bottom, enabling it to be made into any of the following styles:

  • Six Panel Solid
  • Twin Vertical
  • Twin Top
  • Twin Top with Mid Panel
  • Half Glazed
  • Full Glazed
  • Four Glazed (twin and bottom)

This not only makes the door extremely versatile but also drastically cuts the need for stock, as DOORCO MD Dan Sullivan explained:

“Stock is always a challenge for all door fabricators especially for the lower volume fabricators because of the range of options available. The 6/4 Combi brings together seven of the most popular styles while taking up less space, tying up less money and simplifying ordering and invoicing.

“All this is with absolutely no sacrifice to the aesthetics of the door or its quality and specification. This design innovation is absolutely unique to the 6/4 Combi and another exclusive benefit to DOORCO customers.”

The 6/4 Combi joins the existing comprehensive range from DOORCO, formerly Capstone Doors Limited, which not only imports the Capstone brand of door slabs for major door fabricators but also offers part finished and painted doors for fabricators who wish to add their own style on to the product.

DOORCO Goes On Growing With Jayne Sullivan As Operation Director


DOORCO, formerly the Capstone composite door brand, has announced the appointment of Jayne Sullivan as its first Operations Director.

Jayne, wife of MD Dan Sullivan has years of experience both in the corporate world and the family business environment – where she says she began at the age of ten. Now, after Dan and co-founder John Collins have put seven years into building Capstone and DOORCO into its present form, all are agreed the time is right for her to join the team.

She brings with her an impressive CV with blue chip names including Pricewaterhouse Coopers, Ernst & Young and Astra Zeneca, working fields as diverse as energy & utilities, telecoms, entertainment, betting and local government, in various locations around Europe and the Far East.

Jayne says: “My priority as Operations Director will be to ensure that we have robust processes working well over all areas of the business. The company has relied on a small but dedicated team to operate it but as it grows, we will need to make more use of technology so that our staff can focus on more valuable tasks.”

The company had its beginnings when Dan and John, both with years of experience in the door industry, began supplying container quantities of door slabs to large fabricators. The change of identity came about after it began manufacturing prepared doors of all kinds, not just residential composite and took on DOORCO as a name that was more relevant to its new offering. Dan explained that it was the impact an earlier recruitment from the corporate world – of Sales Manager Mike Roe – that highlighted the benefits Jayne could bring to the business with her own corporate background.

Dan concluded: “We are really turning up our focus on the team, which has grown by nearly double in the last year. We have the right people; we now need to support them to develop skills in areas which we need and will continue to add to this as the business grows.”

DOORCO Celebrates 3000th Door Through Its Custom Paint Line


DOORCO, the recently re-branded supplier of Capstone composite doors, is celebrating the 3000th door to go through the company’s in-house paint line in the two years since the system was installed at its Macclesfield factory.

The system was designed and installed specifically for the GRP door market using Regalead’s Color Spray colour systems and Renolit foils to provide consistently accurate and high quality matches. A full range of RAL colours is provided in addition to authentic stained finishes. Glazing cassettes and accessories are painted with the panels to ensure an exact colour match.

Products and processes including controlled drying techniques have been developed specifically for the company’s Capstone GRP doors. An intensive quality control system ensures that every door that leaves the factory is produced to the highest standards to maintain the exceptional finishes for which Capstone doors have become identified. A 10-year guarantee given with every DOORCO GRP residential door is therefore offered with complete confidence.

DOORCO managing director Dan Sullivan says the milestone is more than just a number: “More than 3000 doors through our own in-house paint line makes DOORCO one of the most experienced suppliers of custom finished resi’ doors in the UK. We control all of our own processes and can therefore offer the highest quality finishes in the market with complete confidence.”