Fast Manufacture of Triple Glazed Units

Lisec will show you how to achieve considerably reduced cycle times by using Opti-Mode, a simple concept involving two gas-filling presses.



In many companies today the manufacture of triple glazed units constitutes the largest share of production. Manufacturing triple glazed units usually does not pose any problem for existing machines, even though it obviously takes longer than manufacturing double IGUs. By using two consecutive gas-filling presses, manufacturing speeds can be increased substantially. The so-called ‘Triple Opti-Mode’ now used in insulating glass production lines from Lisec ensures that both presses operate to capacity at all times, which increases production efficiency significantly.



The idea of using two gas-filling presses is not a new one. Many double IGUs are manufactured using the so-called 'tandem mode': One cover sheet is fed into the first and the second press, respectively. After that, the two second glass sheets with a spacer frame applied on each sheet will enter the presses. Gas-filling and pressing of the two units is carried out nearly simultaneously. In fact, this is the fastest way of producing double IGUs. By making use of the new Opti-Mode, however, the configuration with two presses features some further improvements.



A 25% Gain in Cycle Time Thanks to Triple Opti Mode



A major advantage of Opti-Mode is that it does not influence on the production flow, as the two presses alternate. In the manufacture of double and triple glazed units, the use of two presses instead of one can lead to a reduction in cycle time of between 20 and 25 %. These savings are made possible through the maximum utilization of the presses. By using Triple Opti-Mode, and thanks to the availability of sufficient storing zones for all the different elements (cover sheets and second and third sheets with applied spacer frames), the presses never stand idle.



Two Frame Processing Lines for Optimal Supply Rates



In the way described above, the gas-filling presses can achieve cycle times down to 36 seconds for triple glazed units (sheets of 1 x 1 m). Needless to say that spacer frames must be processed within a similarly short time as well. So, what do I need if I want to use Opti-Mode presses?



There are several possibilities, depending on your personal needs. If you wish to process flexible spacers, then you will probable use the Lisec VSA-D2 applicator, which is capable of achieving the same cycle times as the gas-filling presses. If you wish to process conventional spacer frames, then you will probably use the automatic frame mounting station (Lisec RAL). If you wish to work with traditional (manual) frame mounting systems, then we will recommend integrating two consecutive manual systems. Through Opti-Mode, an IGU production line's bottleneck moves from the gas-filling presses to the frame mounting zone.



Two parallel frame processing lines will guarantee that spacer frames are supplied continuously. Due to time constraints, the frames processed with a fast bending machine (Lisec BSV-45ANK) must be split onto two automatic butyl lines, which are fed by an automatic conveyor and consist of two desiccant fillers (Lisec A2RL) at the infeed and two butyl applicators (Lisec LBH-AR) at the outfeed. The butyled frames are then put on the frame conveyor and transferred to the frame mounting station. This entire process allows a very simple and effective work flow.



Ideally with Line Server Connection



The information whether double or triple units are processed can either be transferred via the line server or entered by the operator (at the frame mounting station). Triple Opti-Mode is a configuration mode of the presses, and not even shapes require a line server connection. In the event of many different production orders, however, the operator will have difficulties in keeping track of all the processes. For line server connections, mixed production is usually not a problem anymore, as the server automatically switches between the different press modes.



Retrofitting



Triple Opti-Mode can be retrofitted to nearly any production line from Lisec: a second press needs to be integrated, the line needs to be extended accordingly, and some of the systems will have to be moved. If you want to achieve cycle times lower than 40 seconds for triple glazed units, then Triple Opti-Mode will definitely be the right decision for you.