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Waste avoidance when bending heated glass - novaTEX GOLD Pressing Wheels

novaTEX GOLD Pressing Wheels redesign an inconspicuous spare part and avoid waste on an ongoing basis when bending heated glass

The challenge in terms of sustainability:

Bending heated flat glass requires a high temperature of about 650°C and is a process that is in widespread use in the glass industry in many different forms. The machine components therefore need to be configured to observe this parameter, i.e. they must be able to withstand high temperatures. This case study involves a bending process that gradually shapes the heated glass with the help of a large number of small wheels. In this specific case, the wheels consisted of three materials: metal and plastic in the core with textile covering to make sure the glass is handled gently. These materials are bonded together irreversibly, i.e. when the wheels are worn out, the individual components cannot be recycled. The challenge in terms of sustainability is to design the wheels in such a way that all the individual parts are not waste materials once the textile covering is worn out.

The initial situation:

There are machines of many different sizes to bend panes of glass. A medium-sized machine has about 700 of the small wheels outlined above. Although the only real wear was of the textile covering, the entire wheel had to be replaced. A waste of resources, which is reflected in high spare part costs too. Experts from Frenzelit Werke GmbH liaised with the customer to find a solution.

The solution:

The original core of the wheel made of metal and plastic has been replaced by a metal support supplied by Frenzelit that can, however, be reused repeatedly. The newly created "pressing wheels" now form the textile covering. These pressing wheels are applied to the metal support using appropriate tools in a process specially adapted for the application. When they are worn out, they can be removed from the wheel core and replaced just as easily using the special tool. In additional features, the Frenzelit solution is considerably more wear-resistant than the standard fibre and has very good temperature resistance properties thanks to the choice of specific raw materials for the product known as novaTEX GOLD Pressing Wheels.

The sustainable strengths:

The metal core, which acts as the support for the novaTEX GOLD Pressing Wheels, is available from Frenzelit, but is no longer replaced; it lasts for the entire service life of the machine instead. The reusability of the metal support means that waste is avoided, which reduces spare part costs by 60% on an ongoing basis. Thanks to its higher wear resistance, the novaTEX GOLD fibre has a service life that is up to four times as long as conventional textile fibres.

Brief profile of the company:

Name: Frenzelit Werke GmbH
Headquarter: Bad Berneck
Year of foundation: 1881
Employees: 480
Solutions: Dichtungen, Technische Textilien, Kompensatoren, Isolationen, Neue Materialien
Internationality: Produktionsstandorte in Deutschland, in den USA und in Tschechien sowie weltweite Vertriebspartner