Machinery and Plant Manufacturing Sector shows Innovative Production Technology

Visitors to glasstec can see for themselves in Halls 11 through 17 that the machinery and the plants used to manufacture, process and finish glass are as varied as the material glass itself. In 2012, more than half of the entire display area is used as a demonstration area for machinery, plants, equipment and components.Mega Topic SustainabilityThe industry organised in the German Engineering Federation (VDMA) shows sustainable solutions for the future at glasstec. These solutions relate to all levels of the value chain, from the final product via the glass production process to the production of the plant. In connection with the VDMA sustainability campaign “Blue Competence”, companies present technologies that use minimum amounts of energy at maximum productivity, save resources, reduce emissions and effectively improve the living conditions of humans. Items on display include insulation glass plants for non-foil, thin-film photovoltaic modules, furnace systems that save up to 30% energy during the production of laminated safety glass, washing machines that significantly reduce water consumption, new energy-saving drives, recycling techniques and, last but not least, fully automated systems for the production of multifunctional glass with features for thermal, solar or noise protection.Individual Problem Solutions and Innovative Complete SolutionsThanks to their high level of automation, plants allow for individual problem solutions in order to make glass processing even more diversified, cost effective and sustainable. However, the European glass machinery and plant manufacturing sector is also a partner for innovative complete solutions, where consultation, project management, planning, design, realisation and commissioning are done under the same roof.Better Quality and Energy-Efficiency in Stemware Glass ProductionLaser Hot Cutting improves the technology of hot cutting and replaces the conventional process of the cutting of the moil after the lehr. Compared to other technologies LHC allows to process geometries that are quite complicated, like for example a cocktail coupe or glasses with more than one corner. LHC guarantees excellent edge qualities and a high yield at the same time. A very important point refers to the energy-efficiency the technology offers. The glass needs not to be heated again. It is possible to work with one heat. Since the moil is already cutted from the glass, the energy amount needed in the lehr is reduced significantly. In addition, the glass needs not be grinded or polished. Thus considerable energy can be saved. Also cost intensive waste water recycling or disposal of grinding debris is not necessary. This is good for the environment.Energy and Cost Savings for SmelteriesThe production of glass, in particular the melting process, is energy-intensive. The machinery and plant manufacturing sector offers solutions for consistent energy savings that lead to lowered operating costs – for example, during the process of pre-heating the batch. In contrast to conventional processes, the raw materials are mixed together in a pre-heated state and thus use less energy. Flexible melting units allow for the melting of glass of various colours and are suitable for high variations in the melting load. During a change of colour, the melting process can carry on continuously. The operator experiences fewer down-times. Operators who want to keep an eye on energy savings should also check out optimised heating systems with minimal cooling output, or oxy-fuel heating, as well as all-electric melting furnaces. Generally they are used for smaller melting loads of 20 or 50 tonnes per day. The machine manufacturers also offer units for melting more than 100 tonnes of glass per day. This offers advantages with a view to the CO² emission trade. In addition, the lifecycle of melting equipment can be extended through targeted cooling of highly stressed areas and the use of new materials such as platinum, iridium or molybdenum. At some point, all components of melting units will break. Weak points can already be addressed during the design and construction of the system. This makes the system more effective in the long term.Energy saving can also be achieved by using higher cullet amounts for melting. Precondition, however, is that those cullet will be processed and treated professionally. All requirements of the glass industry with regards to removal of impurities and obtaining a correct grain size have to be strictly respected. Each 10% of cullet used instead of batch are lowering the melting energy by 2.5 to 3% compared with pure batch melting. Energy can also be saved by charging melting material into the furnace using advanced technologies. Experience shows that batch and cullet, charged in form of " parcels " or "cushions " into the furnace by respecting determined directions will melt faster with higher energy efficiency.New Production Technique for Modern Façade Glass One major topic for architects and planners relates to modern façade glass. It is nowadays expected to generate and conserve energy at the same time, and also protect from sun and heat. The glass industry needs machinery, systems and processes that aid in fulfilling these requirements. New coating technologies involving glass and films, or innovative production techniques that can reduce the weight of triple glazing to that of double glazing units while maintaining the same performance, are displayed at glasstec.The machine producers also offer the right technology for the currently very popular lightweight, break-proof and coloured safety glass. Thanks to a special, newly developed production process, an optimal and even heat distribution in glass is guaranteed, so no cold cracks develop. It is not susceptible to nickel sulphate cracks, and if breaks occur, it remains intact, smooth and safe. The glass is produced completely from regenerative and recyclable materials, contains no heavy metals or toxic elements, and for its production, only low levels of energy are required.Quality Assurance thanks to Highly Sensitive Scanning SystemsAdvances are continuously being made in the area of quality assurance, as well. In this connection, the market is offering highly sensitive scanning systems that test not only single glazing, but also multi-layer and insulation glass for visual defects in continuous operation. For example, the optical in-line measuring technique for functional glass façades uses five inspection devices in one system to detect the smallest defects in float glass and/or the smallest colour deviations in the coating. It guarantees correct functioning of the glass façade with regards to heat protection and visual cover. In addition, the glass displays its best visual and architectural features.New Float Glass Systems for Display and Touch Panel Glass Especially in Asia, demand is rising for very thin glass for the production of displays and touch panels. This type of glass is increasingly also being produced in float glass systems. The extremely thin glass poses new challenges for the cold end. The fundamental challenge is the prevention of scratches. Scratches on a display or touch panel are immediately visible and annoying. In China, a new German-produced system is running that includes numerous innovations specifically for thin glass.In order to fully support the glass from below, cutting is done on a belt instead of on rollers. The breaking of the cuts of thin glass also requires special machinery design. During transport, a very small distance between the rollers is used in order to avoid bending. Adjustments for stacking are not made by using the conventional technique of pushing the panes against arrestors (risk of scratching). Rather, the glass is positioned on a “floating” frame and is aligned using an edge sensor system. In addition, the horizontal application of paper onto a glass in the flow path was further developed in order to conform to the special requirements of thin glass. Specific motion sequences were developed for the stacking, particularly gentle handling and special packaging.Glass Systems Engineering and the Solar SectorAgain, a connection is made in Düsseldorf between the glass and the solar industry. Glass is not only extremely important as a material to nearly all areas of solar technology. In fact, many glass systems producers, mainly from Germany, have developed into indispensable partners of the international solar industry. They supply machinery and plants that make sure that solar energy is becoming more competitive all over the world, and they are showing their latest production techniques at glasstec.Highly Efficient High Performance Cutting Systems for Solar GlassOne example are highly efficient and energy-saving high performance cutting systems for solar glass. In this connection, the engineers have focused on the energy efficiency of electric drives. While they used to rely on controlled drives on pumps and exhausters, the current trend aims to replace pneumatic and hydraulic systems with electric drives. Depending on the required process engine speed and torsional moment, losses occur in the drive components. Well utilised components are highly effective. Oversized or maladjusted systems significantly reduce efficiency. The new systems use energy intelligently, convert it with high efficiency and utilise fed back breaking energy. The system forgoes the generally common portal charging and the glass warehouse. Software is used to calculate the efficiency levels of different optimisation options. The result: The level of utilisation and the energy footprint of the system are improved.Highly Efficient Inspection Systems in Module ProductionSignificant savings can also be achieved in the production of solar modules by integrating highly efficient inspection systems. The latest technologies cannot only be used to remove defective items from the production process, they also recognise weak areas in components. In addition to the inspection and measuring functions, the new 3D option also includes reliable inspection of chips and other relevant structural defects. This way, cell breakage can be reduced, capacity improved and machinery operating times increased.VDMA Technology Symposium at gtlOn 24 and 26 October 2012, VDMA organises two technology symposia in connection with the glass technology live exhibition. Here, systems engineers and users present innovative solutions with regards to the two topic clusters:•Energy and resource efficient technologies in glass systems engineering•Innovative production technologies for solar products and applicationsThe focus will be on processing, melting and forming technologies, thin glass, triple glazing, bending technologies and concepts for the production of new PV modules or laser technology in solar glass processing.Video “The people behind glass – Mechanical engineers are shaping our environment” at http://www.vdma-webbox.tv/english/filmdatabase/the-people-behind-glass-mechanical-engineers-shaping-our-environment.html 23.10.2012, VDMA