Efficient Rim Processing for Glass Industry

1. MACHINE MAKER FOR THE GLASS INDUSTRY

2. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM OPERATING COSTS SCRIBING / LASER EFFICIENCY AND PAY BACK CONCLUSIONS

3. Searching New designs Top quality At low cost HOW CAN WE FACE THE MARKET REQUIREMENTS?

4. WHAT TO DO When the market is asking for: Stemware with thin and long stem Open shape Tumbler with polygonal design……..

5. WHAT TO DO When the market is asking for:

6. MARKET AND ORDER BOOK PRODUCER INTERNAL IMPROVEMENT TEAM Major Targets: Trying to improve the productivity by itself Avoiding any expenses And finally Contacting the potential suppliers if no internal solution has been found.

7. ►Producing new design at same costs ►Improving productivity on existing products That means: increasing the production speed 30-50-60-75-100 pcs/min with same or less labour costs Keeping or improving the efficiency Ability to process all kind of products with same performances Reducing the uncontrolled factors as human factor Stabilising repetitive sequences and reproductible set-up Improving equipment reliability THE CHALLENGE OR CHALLENGES

8. The efficiency of a production line is the results of the multiplication of the efficiency of each processing steps composing this line. 90% x 90% x 90% x 90% x 90% = 60 % THAT MEANS IMPROVEMENTS IN EACH MANUFACTURING STEPS Raw material constancy Glass melting Blowing Press Annealing Finishing Packing THE CHALLENGE OR CHALLENGES

9. Specialized companies can be found in any segment of the production line BUT The major concern for the IMPROVEMENT TEAM would consist in determining the best partner for the corresponding segment. BIEBUYCK In the rim processing THE CHALLENGE OR CHALLENGES

10. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM OPERATING COSTS SCRIBING / LASER EFFICIENCY AND PAY BACK CONCLUSIONS

11. RIM PROCESSING OF TABLE WARE HIGH SPEED RIM PROCESSING LINE • THE HANDLINGS • CRACKING-OFF • THE GRINDING AND BEVELLING • FIRE POLISHING

12. THE MOIL REMOVING CAN BE DONE BY: BURN OFF CRACKING-OFF MECHANICAL BY SCRIBING BY LASER RIM PROCESSING OF TABLE WARE

13. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM OPERATING COSTS SCRIBING / LASER EFFICIENCY AND PAY BACK CONCLUSIONS

14. RIM PROCESSING OF TABLE WARE Mechanical Moil cracking-off: A tungsten carbide wheel applied elastically on the glass surface. In some cases, the scribing can be made with a diamond disc. Burners achieve the process by creating stresses in the cutting area. 2 scribing devices are available: Classic TSD

15. RIM PROCESSING OF TABLE WARE • MECHANICAL Moil CRACKING-OFF • ADVANTAGES • Relatively cheap solution • Mechanical assembly • Easy to use • Easy to understand • Easy to repair • INCONVENIENTS • Limited efficiency mainly with shaped glasses • No warning when worn out • Limited and no regular life time • Determinant human factor • May damage the diamond tools

16. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM OPERATING COSTS SCRIBING / LASER EFFICIENCY AND PAY BACK CONCLUSIONS

17. RIM PROCESSING OF TABLE WARE LASER MOIL CRACKING OFF A CO2 laser beam is applied under certain sequences to scribe the glass surface. No Burners are required to achieve the process.

18. THE RIM PROCESSING OF TABLE WARE • LASER MOIL CRACKING OFF • ADVANTAGES • Better efficiency on all kind of designs • Regular cuts even on irregular surface • Wider in glass tolerances • Easy to use via PC and datas • INCONVENIENTS • Investment • Complex installation • Require data control • Safety

19. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM SLOW FLOW SLAB OPERATING COSTS SCRIBING / LASER EFFICIENCY AND PAY BACK CONCLUSIONS

20. LASER GENERATION 1 C02 Slow Flow Historical decision state of the art in 92 First approach with the laser Top beam quality Too maintenance intensive CO2 Bottles Not handy To big Not easy to install on high speed machines Installed in Weiden in cooperation with Nachtmann in 1997 RIM PROCESSING OF TABLE WARE

21. Laser GENERATION 2 200 and 100 w C02 Slab Alternative to the SLOW FLOW Required Beam Optimisation Require C02 refill Compact Handy Power stability Allow preventive maintenance Allow modular pack More than 130 lasers installed worldwide since 2000 RIM PROCESSING OF TABLE WARE 1. Output beam 2. Output window 3. Cavity optic 4. Water out 5. RF input 6. Water in 7. Cavity optic 8. Laser discharge 9. SLAB electrodes 10. Earth connection

22. The Laser generation 2 module is composed by: The resonator The optical box The Laser can be installed: vertically horizontally. RIM PROCESSING OF TABLE WARE LASER GENERATION 2: MODULAR DESIGN

23. RIM PROCESSING OF TABLE WARE LINEAR MACHINE DESIGN Makes the laser integration easier MODULAR MACHINES and MODULAR LASERS PACK offer configurations adapted to the end-user requirements.

24. RIM PROCESSING OF TABLE WARE THE COMPACT LASER GENERATION 2 MODULES MAKE THE DESIGN OF RIM PROCESSING MACHINES AT SPEED CORESPONDING TO THE HOT END 75 pcs/min 40 pcs/min 60 pcs/min

25. RIM PROCESSING OF TABLE WARE S2TC37 TWIN PRODUCTION UP TO 100 PCS/MIN

26. RIM PROCESSING OF TABLE WARE EXISTING MACHINES CAN BE UPGRADED SPEED 20 / 2 lasers Production speed up to 20 pcs/min.

27. RIM PROCESSING OF TABLE WARE EXISTING MACHINES CAN BE UPGRADED SPEED 50 / 3 lasers Production speed up to 30 pcs/min.

28. ICF MEETING WEIDEN OCTOBER 2006 INTRODUCTION EXAMPLE OF RIM PROCESSING LINE MECHANICAL MOIL CUTTING LASER MOIL CUTTING LASER SYSTEM OPERATING COSTS SCRIBING / LASER Direct consumables Power water EFFICIENCY AND PAY BACK CONCLUSIONS

29. The operating costs based on : S2TC37 mechanical and S2TC31 laser. Production speed : 35 pcs/min Efficiency difference: 2 % TSD Scribing and diamond tools. LASER G2 2 x 200 w and 2 x 100 w. and diamond tools Electricity S2T31 L including chiller and dust exhauster Electricty S2TC37 including hydrogen oxygen generator Water and additives OPERATING COSTS MECHANICAL / LASER

30. OPERATING COSTS: SCRIBING/ LASERCUTTING Scribing wheels lifetime: 13 000 PCS Laser refill: 16 000 Hours. Cutting depht may be reduced when cutting with laser: Scribing : 1,2 mm Laser : 0,8 mm Less Tools damages due to better laser cutting

31. OPERATING COSTS: SCRIBING/ LASERCUTTING RATIO BETWEEN SCRIBING AND LASER: 7,8 % in favour of the scribing.

32. OPERATING COSTS: POWER CONSUMPTION S2TC31L –S2TC37 RATIO BETWEEN SCRIBING AND LASER: 5,7 % in favour of the laser. 0,403 0,380

33. OPERATING COSTS: WATER CONSUMPTION S2TC31L –S2TC37 RATIO BETWEEN SCRIBING AND LASER: 21,5 % in favour of the laser

34. RATIO BETWEEN SCRIBING AND LASER: 4,8 % in favour of the laser OPERATING COSTS: conclusions

35. HOW CAN WE BALANCE THE INVESTMENT BETWEEN THE BOTH TECHNOLOGIES: By designing equipment specifically for the G2 laser S2TC31L instead S2TC37 Compact 9 L2 instead of the Combi 12 Combination of 200 and 100 w lasers . RIM PROCESSING OF TABLE WARE

36. RIM PROCESSING OF TABLE WARE PRICE BALANCE BETWEEN CLASSICAL AND LASER MACHINES.

37. RIM PROCESSING OF TABLE WARE PRICE BALANCE BETWEEN CLASSICAL AND LASER MACHINES. Water remains the major consummable Rejects reduction becomes the major pay-back factor

38. EXAMPLE OF PAY BACK SINGLE INDEXING MACHINE 3 LASERS IN MONTHS REJECTS SAVINGS

39. EXAMPLE OF PAY BACK S2TC31Laser AND S2TC37 IN MONTHS REJECTS SAVINGS

40. RIM PROCESSING OF TABLE WARE THANK YOU FOR YOUR KIND ATTENTION CONCLUSIONS: Consumables are balanced between both systems Less water use Less dust due to less glass grinding Realistic pay-back even on classical glasses Allow the processing of difficult products in reasonnable conditions.