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5 Most Important Factors for Successful Glass Lamination (2022 Updated Guide) - Glass Industry Social Network

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Glass Community Forums Flat Glass Processing Laminated Safety Glass 5 Most Important Factors for Successful Glass Lamination (2022 Updated Guide)

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    • #6177
      Martin
      Keymaster

      Glass Lamination

      Glass lamination, as we all know, is the process of bonding two or more panes of glass with a flexible interlayer in between. It appears straightforward. But is this always the case in practice? How can you ensure that your end result is consistently excellent while keeping your glass lamination process efficient?

      Many of the requirements for your lamination process will be determined by your business segment. For example, if you work in the façades industry, your glass requirements will be different than those in the interior glass market. The glass specifications will not be the same, nor will the line settings. Furthermore, for many producers, the line’s ability to easily adapt to different types of production is the most important factor. As a result, regardless of business model, let us concentrate on the factors that are equally important for all glass processors.

      Glass lamination is used to produce laminated glass. Those laminated glasses can be used in variety of ways in glass industry such as insulated glass, glass tempering, glass bends and so on.

      If you are looking more information about insulated glass, you can read our “What is Insulated Glass?” article.

      5 Most Important Factors for Successful Glass Lamination

      Let’s take a look at the top 5 most important factors for successful glass lamination in details:

      1) Optimal heating technology

      The heating technology you select has a direct impact on the day-to-day operation of your laminated glass production line. There are primarily two options to consider:

      Most furnaces still use infrared radiation technology today. If this is the case for you, keep in mind that radiation efficiency is highly dependent on the type of glass you process. Infrared radiation is most effective in heating thick, clear glass with no coating. Unfortunately, glass processors who only work with this type of glass are scarce.

      When it comes to truly optimal heating, full convection is far superior. This is primarily due to the fact that full convection is completely unaffected by the type of glass used. It consistently and uniformly heats the glass. Convection heat is not reflected by coated Low-E glass. As a result, you won’t have to adjust the furnace temperature as frequently, saving you a lot of time.

      2) Choosing the best pre-press technology

      The pre-pressing unit on the laminating line influences how easy it is to operate the press and how uniform the pressing result is for different glass sizes and shapes.

      Laminating lines are frequently outfitted with two pressing units. Less is more in this case! With only one press, a good press design combined with precise heating is more than enough. Furthermore, you avoid the awkward situation of having a long glass pane beneath two press units at the same time.

      The most modern pressing machines are built in such a way that the press unit does not need to be adjusted based on glass width or shape – even automatically.

      3) Capability for mixed production

      The mixed production capability of the line is frequently the most important factor to consider. This means that switching between products is quick and simple, whether it’s changing the coating, glass size, shape, or sandwich thickness. The most important factors influencing this are the design of heating and pre-pressing, as well as the design of cleanroom operations.

      When comparing capacities between different lines, keep in mind the actual output of the line as opposed to theoretical capacity values. It’s especially important to understand the type of changeover time between products, because changeover times can cause a significant difference between actual and theoretical output.

      The most important thing in the cleanroom is that the line allows for simple switching between automatic and manual modes – depending on the products used. Pay close attention to how easy it is for operators to work around the line when manually trimming and positioning the glasses. A well-designed trimming station makes trimming easier and faster for operators, and it also leads to better trimming quality.

      4) Clean Room Design of Laminated Glass Production Line

      The clean room is an integral part of the laminating line, ensuring smooth operation when loading foils and making operators’ jobs as simple as possible. Considerations for a well-designed cleanroom include ease of movement around the line, automated and offline methods of storing PVB rolls, and adequate lighting, particularly in the assembly area. In glass lamination there are two types foils as knows as films are used as named PVB foils an EVA foils.

      You may interested to read this great article which explains “What is the Difference Between PVB foil and EVA foil?” with all aspects and details.

      You should also be aware of and adhere to the recommended temperature and humidity levels for your cleanroom, as well as the air filtration requirements. These are not standard values, but rather very specific values based on the type of foils stored.

      5) Machine Size Optimization

      Choosing an appropriate line size is critical, especially if you intend to produce in large quantities. Because of the longer travel distances of the conveyors and glass lifters, the length of the line has a direct impact on the capacity you can achieve. The larger the line, the larger its footprint – a disadvantage.

      If long glasses are only a minor part of your business, consider purchasing them elsewhere rather than investing in a larger machine.

      The list goes on.

      The ease of use of the line, glass lifter design, best glass cutting machine, glass washing machine, foil type, foil cutting methods, and line automation all play a role in the overall success of your laminating process efficiency and business.

      I hope that this “5 Most Important Factors for Successful Glass Lamination” article will help you to make succesful glass lamination. If you have any recommendation to our readers or questions, please freel free to reply.

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