Product News – April 2006
In response to demands for insulating glass manufacturing equipment
capable of processing different spacer materials, Bystronic now offers
fully automatic vertical insulating glass manufacturing lines capable
of processing all spacer systems currently available on the market.
Built for choice
In response to demands for insulating glass manufacturing equipment capable of processing different spacer materials, Bystronic now offers fully automatic vertical insulating glass manufacturing lines capable of processing all spacer systems currently available on the market. Offerings include first’insulate for conventional ‘box’ spacers, first’TPS for thermoplastic (TPS) spacers and/or first’flexspacer for flexible SuperSpacer) spacers. These lines are designed in a strictly modular configuration, permitting different stages of automation. For example, a basic configuration may initially provide for manual secondary sealing, upgradeable by adding an automatic CNC sealing robot, to improve productivity.
For residential applications, Bystronic’s IG lines are configured to handle a maximum glass size of 63in x 98in (1.6m x 2.5m). However, they may be supplied in other standard sizes including, 90in and 106in (2.3m and 2.7m) high and up to 157in (4.0m) and longer. Increased productivity over conventional IG manufacturing translates into production outputs of up to 1200 units per shift.
Bystronic has also introduced new vertical glass cutting technology that offers the advantages of insulating glass manufacturing in a vertical orientation. Vertical processing saves space, makes integrating various process steps easier, permits enhanced automation of the entire system and creates much less mess.
The verticut embodies the elements of lean manufacturing to ensure efficiency and savings. It consists of several modules: automatic loading; intermediate residual subplate storage and management; automatic shape cutting with optional edge deletion and X breaking; Y, Z and trim breaking may be tailored to specific requirements, either manually on an air float table, or with a vertical automatic breaking system.
Positioned between the loader and cutting machine, verticut’s residual plate storage and management system (called a ‘feeder’) enhances the efficiency and convenience of the entire cutting and handling system. The cutting machine is programmed to cut only what is required at any moment. Residual subplates are then temporarily inventoried in the feeder in an orderly manner for instant access when that type of glass is required. This simplifies production planning, reduces waste of leftover glass and permits sorting of the cut glass in smaller batches.
The cutting and breaking system can be connected to an automatic sorting system for IG line feeding, an automatic seaming machine, or it can be directly linked to a vertical IG line.
The company also has a new cutting and separating table for the economical processing of laminated glass. With its robust construction, the smart’lamicut ensures fast and accurate cutting and separation of glass sizes up to 126in x 100in.
For ease of use and superb processing efficiency, critical processing parameters, such as cutting speed, cutting and breaking pressure and heating periods, are controlled by a user-friendly software system. Digital stops ensure accurate and fast manual glass positioning. With automatic scoring on both sides of the glass, glass separation is clean and accurate. -end-
Bystronic Telephone: (800) 247-3332 Web site: www.bystronic.com
All in one
Glaston Technologies’ Z. Bavelloni has introduced a brand new concept for the glass processing market. The
integrated and double edging and drilling process line is a pre-processing system that stages multiple processes into one line. It is an integrated line that includes a high speed double edging machine VX EVO with premium edge quality, as well as a drilling, milling and countersinking machine HDM. Flexibility of this line also enables work with small or very large glass pieces. The double edger and the drilling machine are also available in Magnum series for jumbo size glass sheets up to 3.3m wide and 7.2m long.
The new pre-processing line is ideal for processing soft coated glass such as low-E. The risk of damaging the glass surface at the stages of pre-processing is minimized through automated operation.
As the new line is a fully automated, it directly improves cost efficiency as well as increases capacity and production flexibility. Automation will reduce glass handling, which brings down production costs and is also a safety factor. The line and the individual machinery enable high efficiency and speed for the pre-processing of glass before tempering.
The new line is an example of a Glaston Technologies One-Stop-Partner concept innovation. It enables integrating and matching pre-processing into the Tamglass tempering furnace family, including the new Tamglass Sonic, the world’s fastest tempering line, says the company. All the machines can also work alone. The pieces of the line can be purchased in different times and integrated together later on, giving customers the possibility to grow in productivity, efficiency and flexibility along with their businesses. -end-
Glaston Technologies Z. Bavelloni Telephone: 011-39-031-728311 Web sites: www.bavelloni.com, www.tamglass.com
Glasstech has developed a wider model of its popular External Press Bending System. The EPB-DS system is 72in wide (1829mm) and can accommodate either a single or dual stream of automotive glass parts.
This versatile system can run 95 percent of the current automotive side lites including front and rear doors, quarter windows, van sliders and van quarters along with sun roofs and a large percentage of the back lites currently on the market. It is ideal for processors who have limited space but need to run a large variety of glass part shapes and sizes.
The EPB family of systems produces parts with very accurate peripheral and body shape and with optical quality that exceeds VW/Audi standards. They are versatile, efficient, high-throughput systems that bend and temper or heat-strengthen. They can form cylindrical, compound and complex-shaped parts as well as symmetrical or asymmetrical parts.
The EPB-DS with its wide bed can accommodate a dual stream of side lites and smaller parts ranging from 14in (356mm) long by 16in (406mm) wide up to 48in (1220mm) long by 34in (864mm) wide. For larger parts, such as back lites, the system processes components in a single stream as large as 40in (1016mm) by 68in (1728mm).
Previously, EPB systems could be configured to process parts in seven seconds, but now the EPB-DS in dual stream mode can process two parts every seven seconds for a marked increase in efficiency. Quick-change pressing stations enable the EPB-DS to switch from a single stream to a dual stream configuration in a minimum amount of time. Tooling is made from iron alloys that are less expensive than stainless steel alloys.
The EPB-DS is equipped with an adjustable quench that uses inexpensive and easily changed templates to set the shape. The quench design and template shaping help to reduce tooling cost and part changeover time. These systems can be equipped with Glasstech’s patented FanRoll System to pre-form glass inside the furnace, reducing the final press motion and decreasing cycle time. These systems also incorporate the company’s positive roll-drive system, with every roll driven independently and positively.
The EPB-DS combines the production-proven heritage of the EPB with the flexibility and productivity of a dual product stream, the economy of lower-cost tooling and a universal quench, and cycle times as low as seven seconds for two parts.
Clear or coated
Glasstech also manufactures architectural flat glass tempering systems such as the FCH2, a gas-fired forced convection system that processes clear or coated glass, including hard and soft coated low-E glass.
Recent comparisons of operating costs for forced convection heating systems show that process costs using gas generally are 50 percent lower than when using electricity, and gas provides 25 percent shorter cycle times. Gas-fired forced convection heating gives processors a definite competitive advantage and offers the lowest energy costs per square foot of glass processed. The studies also show forced convection heating is capable of providing improved finished glass quality, including excellent optics, low distortion and superior flatness, when compared to traditional electric radiant heating.
Under normal circumstances, the FCH2 can heat clear glass at a typical cycle time of 30 seconds per millimeter of thickness and high performance, soft coat low-E glass at a typical cycle time of 33 seconds per millimeter. The latter cycle time is typically half that of traditional electric radiation heating systems. Reduced heating time provides for higher quality with less distortion and dramatically improves productivity and lowers processing costs. -end-
Glasstech Telephone: (419) 661-9500 Web site: www.glasstech.com
Edge seaming quality
Quebec based company, Bromer has an innovative Automatic Seaming Machine that is ideal for tempering lines. The Automatic Seaming Machine is unique in the way that the glass sheet follows a ‘Z’ course on the seaming table surface. The automatic seaming line with the Z pathway seams all glass sheet sizes wherever it is desired. There is no need to re-adjust all of the settings as square sheets or rectangular sheets are automatically ready to be seamed as soon as requested.
The machine can seam four glass edges or three different glass sheets at the same time. The horizontal seaming line even saves on floor space in the plant because it physically occupies only one third of the space required by a regular seaming line. Ultimately, the static seaming increases the quality of the seamed edges. The company says this machine can be applied to any processing line. -end-
Bromer Telephone: (450) 477-6682
High speed tempering
Tamglass has launched the new Sonic, a high convection tempering furnace that represents a new generation of extremely fast tempering machines. It is designed for the tempering of super low-E (E = 0.02 – 0.04) products mainly for IG units and other architectural glass applications.
The company says this furnace sets a world record for speed performance. The new Sonic enables continuing production of window and patio door glass sizes with 65 percent bed utilization. This processing has been carried out with a charted optimum super low-E glass processing speed of 33 seconds per millimetre at the highest quality.
The convection heating system in itself brings important advantages that add up to increased capacity. The new patented profiled convection heating system with ultra speed convection blower technology, always a key consideration with low-E glass, provides up to 60 percent more capacity than traditional technology.
Assurance of maximum up-time and reliability is a crucial production factor, which calls for ease of maintenance and minimum production stops. For example, by placing the convection booster units outside the furnace their maintenance is greatly facilitated and high up-time is guaranteed. -end-
Glaston Technologies Tamglass Telephone: 011-358-3-372-3103 Web sites: www.tamglass.com, www.bavelloni.com
Powerfeed for length
CTD Machines has introduced its new DM200R 12in double end trim cut-off saw with optional lineal powerfeed for length. The table powerfeed moves the right sawhead via an electric motor. This feed mechanism has hand controls for direction, speed and fine adjustments. It also has a rapid mode for quick movement from one dimension to another.
The DM200R comes standard with 2.0hp, three phase motors; magnetic starter; power downfeed of sawheads with air filter, regulator, lubricator; two vertical inside air clamps; 8.0ft centres cutting distance on the rails. Additional lengths are available as an optional accessory. The table powerfeed and digital length readout are also offered as an optional accessory to the standard machine. -end-
CTD Machines Telephone: (213) 689-4455 Web site: www.ctdsaw.com
Cost effective horizontal solution
FlexiGlyde, an automatic flexible spacer application table for IG manufacturing, is the newest addition to the Billco family of IG products. The FlexiGlyde offers manufacturers of IG units a cost effective horizontal solution for the application of any flexible spacer.
Designed with the end-user in mind, the equipment appeals to a wide range of production needs. From large facilities looking for a complete in-line solution, to smaller facilities with existing manual application tables, FlexiGlyde is the right solution. The equipment is designed to integrate into a variety of layouts and easily replace existing manual application tables.
Operating at a sustainable 1000+ UPS, the innovative design of the dual application head opens a range of options for manufacturers. Two identical spacers can be loaded to eliminate unnecessary downtime during spool change or while performing head maintenance. Alternatively, the heads can also be configured to apply different spacer brands, colours or thickness, all with zero changeover time. The heads are interchangeable to allow the machine to convert from one spacer to the next.
A fully automatic glass thickness feature allows for continuously variable glass to enter the machine with zero changeover time. The system can adjust from single strength to support up to 1.25in thick triple units on the fly, without operator intervention.
The fully automated system increases the quality, consistency and throughput of IG units to reduce labour requirements. Drawing from a long history of supplying IG equipment, Billco understands the wide variety of shop layouts in existence today. The FlexiGlyde product has been engineered to work with most configurations and can easily be adapted to new configurations or as plant production needs change. -end-
Billco Manufacturing Telephone: (724) 452-7390 www.billco-mfg.com
Strings of harps
Designed and built with IG manufacturers in mind, Rolltech’s new Lockable Harp Rack is the ultimate
solution to high production material handling and transportation. The concept integrates the old idea of a regular harp rack, with that of a patent pending locking wing system.
The rack is outfitted with all standard features such as casters and floor lock, forklift pockets, HDPE slotted base and painted structural steel frame. Where it differs is in its strings of harps which become PVC coated locking wings for this model. Through the leverage of mechanical handles, the two series of locking wings are pushed against the glass, holding the units firmly in their stored position. Individually tensioned wings allow IG units of various widths to be stored on the same rack. When in their locked position, the wings provide sufficient grip to the units to prevent them from shifting scratching, or breaking, even in the most
rigorous shipping conditions.
By eliminating the need to package and prepare outgoing orders, the Lockable Harp Rack by Rolltech becomes the ultimate time-saving device. Quantifiable hours of inefficient labour can be eliminated from the shipping department creating a true ROI savings over time. Further to that fact is the added security and protection that the rack provides to its load. Eliminating most transportation related material losses adds reliability and peace-of-mind to your orders.
For both monolithic and IG manufacturers, this new racking system equates to decreased loading and unloading time, reduced material loss, reduced labour costs and additional volume delivery per truck. All of these factors combined are an easy justification for re-investment in this new glass transportation system. -end-
Rolltech Systems Telephone: (905) 669-0005 Web site: www.rolltechsystems.com
Grieve has introduced a 1600 degree F gas-heated belt conveyor furnace for forming glass in alloy molds. Workspace dimensions inside this unit measure 24in wide x 12ft deep x 22in high. Workloads travel atop a 6.0in wide, B-30-28-14, type 314 stainless steel mesh conveyor belt with 0.25hp motor drive, fixed speed 12 feet per minute, through a 36in long open belt loading zone, 12ft long insulated heat zone with three direct-fired furnaces and a 24in open unloading zone.
A remote free-standing control panel is also included with this Grieve furnace, which features all safety
equipment required. -end-
The Grieve Corporation Telephone: (847) 546-8225 Web site: www.grievecorp.com
While Glass Canada editors make every effort to be objective when reporting on new products, they cannot be held responsible for claims made by companies. Readers are encouraged to contact the companies for more details.