Insulating Glass and Edge Processing Technology: Forel Innovation on Show Live at Glasstec 2024

At the brink of fifty years in business, Forel’s passion and commitment to Glasstec grows increasingly for the world’s most prominent international trade fair for the glass industry. As an established global manufacturer of flat glass machinery and processing technology, Forel recognises megatrends and innovative products, attentive to the requirements of the market by demonstrating automation through innovation.

Glasstec 2024: a must-see event for all involved in glass

Glasstec 2024 is scheduled to take place in Dusseldorf, 22-25 October 2024: with a focus on trends such as decarbonisation, digitalisation and sustainability, Forel confirms its participation, exhibiting machinery and product solutions associated with todays manufacturing challenges. Forel is proud to represent “Italian Excellence” amongst a backdrop of automation, with an important display of its knowhow, technology and production performance. Showcasing the very latest machine innovations with live demonstrations, Forel will also introduce enhancements in vertical edge processing, production with Thermoplastic and a fully integrated logistics systems for completed glass units directly from the end of an IGU line.

Innovation in Thermoplastics: a new Forel patent

Taking centre stage at Glasstec will be an important patent innovation that allows for the accurate placement, dimension control and management of Thermoplastic spacer beyond 20 millimetres, as part of an automatic inline solution for double and triple glazed units. The development path that led to the latest enhancement began in 2020 after the Forel R&D team succeeded in improving critical aspects associated with the process.

From their research and analysis, the nuances of the extruded material were better understood and led to the innovative implementation of the production control buffer, which is positioned between the thermoplastic applicator and the coupling press. The purpose of the buffer is to consolidate the materials characteristics with best coupling performance without impacting the overall efficiency of the production line. This methodology delivers safer and faster pressing, even when the profile is extruded at 5.3 mm height and 20 mm plus spacer widths too.

The need to expand the processing range of thermoplastic spacer was client led and the new patent allows for the precise extrusion of 20 mm plus spacer, ensuring that the extruded material is placed in its optimal geometric position without any deformation. Another aspect that has been improved is the unloading phase of the completed unit. As the output performance of the line has increased so has the need to handle the high production volume generated by the improved technology. Optimising the use of manpower is always a priority and it was necessary to increase the speed of unloading without using additional personnel or compromising safety.

Handling and Management of Completed Glass Units

Automation, speed and safety are three key words in insulating glass production, and at the end of the line this is particularly important. Addressing all these points is the integrated Sorting and Stocking System for completed units, an innovative automatic logistics system, which generates many production advantages. Especially useful in the manufacture of Thermoplastic IGU’s this warehouse module revolutionises the postproduction management of finished panels. Located directly after the sealing process, patented supports are automatically placed underneath the finished panel, removing any misalignment or deformation of the glass panes during the sealant curing process. The completed unit then transitions automatically into the warehousing system to be sorted and stored pre-transport to site.

Vertical edge processing: further important updates

In addition to double glazing lines, Forel’s entire range for vertical edge processing machines compliments the overall glass factory picture. The bestselling product in this range, the Art. EM edge grinding machine receives a new feature that guarantees a step change in performance efficiency: Introducing the automatic tool cone changer an upgrade that optimises the platforms level of automation. With the ability of adding an 8-position cone magazine that can carry a varying number of tools per cone, increases efficiency and productivity combined with reduced tool handling, all delivered in a single option.

The need to process different thicknesses of glass is a constant necessity with alternating orders and now the automatic tool changing option allows processors an unquestionable advantage in the management and effective efficiency of this module. Another requested improvement to the vertical processing range is the new Art. EG Arrissing Machine which will be demonstrated at this year’s Glasstec, it can now manage both arrissing and coarse edge grinding to meet the constant and progressive demand from the construction industry to flat edge grind laminated glass. Several features have been added to guarantee the correct support, stability and positioning of the glass sheet that now allows for the quality application of this process.

Profile Bender: further important updates

Further enhancements in box spacer profile involving the Art. PB automatic profile bender. Equipped with the revolutionary Smart Arm, a stability device to support the profile during bending that avoids micro fractures at the corners. This ancillary module will be presented and demonstrated with an interesting software update, which simplifies the user interface to facilitate a more intuitive interaction during set-up.

As usual, entering the Forel stand at Glasstec will be an all-round immersive experience, detailing the latest innovations in thermoplastic spacer and vertical edge processing automation. The configuration of the Insulated Glass Unit line and other machine modules will give all visitors a first-hand experience of the glass factory of the future. The Forel expos is the result of months of collaborative planning by the entire Forel team and visitors can expect to attend live demonstrations scheduled daily and take advantage to learn more from industry experts and to enjoy Forel’s legendary hospitality.

For those who attend the show, there will be no shortage in opportunities to visit Forel on stand D13/D17 in Hall 16 and experience the knowledge, advice, and professionalism of the entire Forel team.

Forel in 2024 is not just another machinery manufacturer, but a working philosophy based on its commitment, investment, and innovation, by creating factories for the future with and for its customers.