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Efficient residual glass handling with the ReMaster

Dynamic and efficient temporary storage of residual leaves above the cutting line.

The challenge in terms of sustainability:

The energy requirement for the production of laminated safety glass (VSG) is high and consequently affects the energy balance of all the resulting products.
In this case energy savings could be mainly obtained indirectly, so a high recovery rate of the VSG is beneficial. Here it is necessary to make especially the processing of laminated safety glass efficiently to keep the energy requirements as low as possible.

The initial situation:

When changing the types of glass scrap sheets had to be manually transported into or out of the manufacturing process. During a production shift there will be approximated 9 pieces of glass with an average size of about 7 sqm. A controllable intermediate storage of this raw glass is usually not possible by the operator. Due to the absence of direct access to all scrap sheets the rate of recovery is lower than possible. In most cases the optimal glass size for cutting is not available and often the remaining sheets are damaged during the entire storage process. Experience shows that by manually handling of the scrap sheets the rejection rate is about 50%.

The solution:

With the dynamic glass storage system ReMaster the recovery rate and energy balance in laminated safety glass cutting can be significantly improved. The integration of the ReMaster is effected in the unused space above the cutting machine inside the production line. By a lifting frame that moves along a vertical column, the usable residuals of glass sheets will be automatically moved in /out during the current process.
The laminated peaces of glass will automatically be stored and managed in up to 40 slots. From the point of maximum waste reduction the ReMaster inserts the residuals of glass back in the running cutting process, thus enhancing the rate of recovery significantly. The glass consumption is reduced. The energy balance through the resource-saving use of materials improved.

The sustainable strengths:

With the VSG ReMaster the rate of recovery (residuals of glass) is increased by about 30%. In two shifts corresponding to a period of 10 years there will be a glass-saving of over 83,000 sqm. This results in significant energy savings and consequently a reduction in CO2 emissions in the laminated glass production by almost 60%. The ReMaster ensures a continuous flow of materials to the production line, and through the optimized cycle times, to a higher efficiency of the cutting system and accordingly an increase in the productivity of around 10%.

Brief profile of the company:

Name: HEGLA GmbH & Co. KG
Headquarters: Beverungen
Year established: 1976
Employees: about 500
Solutions: Glass storage and feed systems, cutting equipment for float glass and laminated safety glass, residual glass storage ReMaster, sorting systems SortJet, Loading and Unload periphery for coating systems, robotics and automation, equipment and production logistics for the photovoltaic production.
Internationality: Offices including England, USA, France, Russia, India, and other agencies worldwide