1985 was a year like no other. Film fans soaked up Back to the Future, Beverly Hills Cop, and Amadeus. Live Aid brought musicians like U2, David Bowie, Phil Collins, and Queen together to raise $70 million for Ethiopian famine relief. Today, much has changed over 40 years, but North Star Windows & Doors is as dedicated to outstanding quality and service as it was in 1985 when it was created.
North Star Windows & Doors was founded with a simple, yet ambitious vision: to build better products for Canadian homes. Starting off on Hargrieve Road in London, Ontario with a team of 30, the company manufactured sunrooms, aluminum shutters, and eavestroughs.
Since that time, destined for big things, North Star has become a leading window and door manufacturer, thanks to products that have their finger on the Canadian pulse.
“From the very beginning, North Star was committed to doing things differently,” says Sheldon Dyck, Director of Operations. “Recognizing the limitations of traditional painted profiles still seen in the market today, North Star adopted the little-known vinyl lamination process, dubbed the Fusion Colour Wrap™—a colour application method that offered superior durability and long-lasting, rich colour. This early innovation set North Star apart, ensuring its windows and doors would withstand Canada’s toughest climates without fading or losing their quality over time.”
In 1988, North Star turned its attention toward the growing vinyl window and entry door market. Unlike some in the industry that relied on third-party suppliers, North Star began making its own windows—at first to support the company’s own sunroom business but soon after, to market this outstanding product through a growing network of dealers. Always innovating—and focusing strongly on quality and craftsmanship—North Star quickly developed its own vinyl extrusion process. This laid the foundation for its vertically integrated business model and the brand’s reputation for precision.
Strategically growing over the years, 2004 saw North Star consolidate its operations into a 170,000-square-foot facility in St. Thomas, Ontario, which was later expanded to 225,000 square feet to meet demand. “What began as a small local business had become an industry leader, employing over 450 Canadians and serving homeowners across the country,” says Dyck.
Since its early days, North Star has dedicated itself to creating products which are not only beautiful but also functional and long-lasting. From slider and awning windows to bay windows, picture windows, ComfortStar™ sliding patio doors, and Sentinel™ entry door systems, the company has products to satisfy virtually every need.
The past two years have seen North Star focused on purposeful innovation, elevating the customer experience, and building long-term growth. And one of the most exciting milestones during this period has been the launch of ULTRASTAR™, the company’s proprietary co-extruded reinforcement. Made from a blend of polyvinyl chloride (PVC), known for durability and versatility, and 55 percent fibreglass, it delivers extreme stability across climates.
The ULTRASTAR™ co-extruded reinforcement is the first of its kind in North America. Developed through close collaboration with global chemistry leaders, ULTRASTAR is a lightweight yet incredibly strong alternative to traditional metal reinforcing, improving thermal performance and long-term durability. This innovative product also reduces the risk of heat-induced expansion and shrinkage, which is especially important in dark-coloured window applications. The result: a stable, high-performance vinyl window profile built to last in any climate.
The result of rigorous testing, ULTRASTAR profiles were subjected to extreme temperatures as high as 82°C (180°F). Even in this blistering heat, the product did not shrink, warp, or move, maintaining full long-term stability.
“Leading up to the launch of ULTRASTAR™, we made significant investments in our manufacturing technology, including the expansion of automation in key areas of our production process,” says Glenn Schmitchen, Director of Engineering. “These updates improve our efficiency and support our ability to scale and maintain our high standards of quality as demand grows.”
Beyond production advances, North Star is also investing in tools and technology, making the buying process smoother for its network of dealers. This year, the company will introduce a new, web-based ordering platform which will provide dealers with a more intuitive, visual, and user-friendly experience so they get exactly what they need the first time.
“We’ve built our operations around consistency and accountability, and we’re consistently fine-tuning ourselves to be better every day,” says Dyck. “Our delivery schedules are automated and reliable, with KPIs and metrics focused on on-time performance. Every product is tracked from production to loading dock to final delivery, and issues are resolved quickly thanks to the continuous effort put forward by our service and production teams.”
And vertical integration is at the heart of North Star’s quality promise. By controlling every major aspect of the manufacturing process—extrusion, lamination, glass cutting, insulated glass units, and screen production—the company maintains outstanding quality control, without any reliance on third parties. From automated pre-machining on casement lines to four-point welders ensuring every frame is square, precision is engineered into all products.
Every window and door from North Star’s operations in St. Thomas and Woodbridge goes through a detailed manual inspection and operational check before leaving the facilities. And the company’s entry doors go a step further; every unit is documented on video pre-shipment, and the video archived for six months. This ensures total transparency and accountability.
“We’ve built in safeguards throughout our processes, like our pick-to-light system for hardware verification, critical-to-quality stations for added training, and a company-wide culture of continuous improvement,” says Schmitchen. “Daily cross-functional meetings and our Voice of the Customer (VOC) Program ensure that if something ever does go wrong, we know about it fast—and we fix it faster.”
For Sheldon Dyck, it’s hard to believe four decades have passed since North Star first opened its doors. “In some ways, it feels like a lifetime, marked by steady growth and purposeful innovation. In other ways, it feels like we’re just getting started. For us, we’re looking back at all we’ve achieved in what feels like a flash—the millions of homes our products have touched, and the strong relationships we’ve formed across the nation. Just as importantly, we’re looking ahead. We’re using this moment to refine our vision and set the foundation for the next 40 years.”
“That means investing in manufacturing automation, advancing our products through innovation, deepening our dealer partnerships, and staying relentlessly focused on what homeowners and builders truly need. Our focus is on forever building and forever learning.”
Today, as North Star Windows & Doors celebrates 40 years, the company remains as committed as ever to its founding principles: exceptional quality, purposeful innovation, and products designed to thrive in Canadian conditions. “North Star’s journey is a testament to hard work, ingenuity, and our dedication to building something better.”
