Kramer & Best Process Engineering offers you professional engineering both in traditional plant engineering as well as specialized in the fields of:
Glass and glass processing industry
Beverage and pharmaceutical industry
OUR MAIN TARGETS:
- Media supply (air, cold and hot water, vapor, natural gas, technical gases, etc.)
- Process optimization for the glass and solar industry
- Coater optimization regarding reduction of dielectric and improvement of layer properties
Customer-oriented solutions and solutions individually tailored to the corresponding requirements of the customers
on the basis of standardized components are the main focus of our commitment towards our customers. We guarantee short response times and competent advice thanks to our worldwide available knowledge of air engineering and control systems. The field of activity ranges from analysis by measurement and optimization of existing subsystems or plants up to overall deliveries of air technology – including automation – of large systems.
PROCESS OPTIMIZATION IN THE GLASS INDUSTRY
YOUR PROCESS IS IN THE FOCUS OF OUR ACTIONS
The technological process of the glass manufacturing starting from the melting process up to the coated fi nished product is highly specialized and automated. Nevertheless the rejection rates in the fi eld of the glass production caused by process faults and production defects are estimated to 4 – 5%. The process air technology conditions in particular with regard to the content of humidity have an enormous infl uence on the quality of the end product and on the manufacturing cost. Here we actively intervene in the process with our innovative processing air systems in order to optimize it.
PROCESS OPTIMIZATION BY AIR CONDITIONING
Kramer & Best Process engineering is having the best preconditions to optimize the glass quality as well as the efficiency of the process using highly specialized air technique by the core concept and innovative system concepts.
It is possible to reduce glass defects and coating defects by means of our system concepts and system components. We aim at creating optimum basic conditions for the customer to attain highest product quality and economic production. At this the interfaces to the existing process and to the existing plant technique are precisely defined. We focus on optimizing existing installation up to complete concepts for new plants.
Furthermore, our innovative solution concepts also consider the requirements regarding the optimization of energy cost, operation cost and pollutant emission. At this special modules are used to optimize the production processes, to improve the quality and to reduce the cost. Kramer & Best is offering complete systems for all production areas.
Kramer & Best – Process optimization plants may be applied for:
Plants of Swiss Galss Industry
AIR CONDITIONING FOR COOLING ZONE
This part of the glass production is playing a key role in the orientation of our activities regarding process optimization. At this serious problems are originated
Technology for process air conditioning in the cooling zone:
- Formation of a glass surface (Gel layer) which is insufficient for the following processes due to increasing variable humidity of the ambient air and of the process atmosphere
- Beginning of glass corrosion
- Formation of a haze dome in the production hall with a measured relative humidity of up to 70 % at about 35°C
- Spreading of this humidity to neighboring production areas such as glass stacking and storage
- Progression of the glass corrosion
- High rejection rates and increase of claims
The existing process makes sufficient waste heat available in order to generate the necessary cooling capacity cost-efficiently and to use it in order to optimize the process. A plant had been designed which makes available the necessary cooling capacity to supply our coolers in the conditioning devices only by using the existing waste heat by means of absorption cooling machines in a redundancy circuit.
The necessary cooling which is required for the process air conditioning as well as the necessary heating capacity to achieve the corresponding process temperature can be centrally generated from the waste heat of the existing process. These media supply the cooler and heater of our conditioning units at the desired partial processes. Interfaces to the existing system engineering are only the heat exchanger to the hot water respectively to the vapor generation.
Result of the process optimization:
- Noticeable equalization of the surface properties of the glass in the course of the year at a qualitativly high level by creating a constant and improved manufacturing and process atmosphere for glass conditioning
- Considerable reduction of glass corrosion as well as its progression in technological subsequent processes
- Little susceptibility to scratch strain (i.e. improved scratch hardness)
- Improved shelf life, extension of the storage periods
- Reduction of the type of defect “Sucker marks“
- Reduction of reject rates and claims by external coating companies and end customers
AIR CONDITIONING FOR COATING PLANTS
The coating of flat glass is processed industrially by means of a pass-through-plant and a so-called inline-vacuum plant (Magnetron) where the panes are introduced by means of sluices. Finally the panes are passing coating chambers which are arranged according to the layer structure one after another and are then discharged to the atmosphere. The quality and efficiency of this process is depending on the environmental air conditions (degree of purity, temperature, variations in temperature and relative humidity) to a great extent. In order to create optimum conditions for the coating process it is necessary to minimize the water inlet into the coating plant and to create constant coating pre-conditions adapted to the process throughout the year.
THE FOLLOWING FACTORS ARE HAVING A PARTICULARLY NEGATIVE EFFECT ON THE COATING QUALITY:
- Permanent water input by the washer due to the casing in the coating plant
- Additional humidity peaks during the summer months
- Dust content and content of external particles in the ambient air of the casing in front of the Magnetron plant
- Different dwelling times of the panes inside the casing are causing that the panes are again covered with water
- Lack of thermal and mechanical tightness of the casing
THE FOLLOWING DEFICIENCIES AND COATING DEFECTS MAY RESLUT HEREOF:
- PIN-Holes on panes with low transmission (Haze) for tempered layers
- Pure silver crystallinity deficiency regarding the layer hardness and layer thickness
THE PLANT DESIGNED FOR THIS PROCESS IS RUNNING BY MEANS OF CIRCULATING AIR WITH THE AIR CONDITIONING STEPS:
- Mixing and filtering in order to minimize the penetration of dust and external particles and in order to reduce PIN-Holes
- Cooling and drying in order to condensate the water from the environmental air and to minimize the water input into the plant
- Air changing and conveying in order to supply the required volume flow for the blocking air jet to the washer and the constant fanning of the panes with conditioned air
- Reheating in order to achieve a relative humidity from 20 % at 25 °C up to 12% at 35 °C and offer variably adjustable process parameters.
IT IS POSSIBLE TO ACHIEVE THE FOLLOWING RESULTS WITH THIS PLANT:
- Reducing the permanent water input of the washer by means of casing in the coating plant and smoothing the humidity peaks in the environmental air in particular during the summer months
- Creating a constant and process-optimized coating atmosphere in order to decrease the thickness of the water film on the panes by means of fanning with dry air
- Decreasing the water content in the ground layer by a factor of about 3.5 to 8
- Reducing the PIN-Holes on panes with lowest transmission reduction of the Haze on tempered layers of up to 50 % which is no longer visible
- Improving the silver crystallinity by dry flooding and temperature adaptation of the dry air Improving the layer hardness and layer quality
DECONTAMINATION FACILITIES FOR AUTOCLAVES
When manufacturing laminated safety glass two glass panes are joined together by means of an adhesive film lying in-between in an autoclave under pressure and temperature. There are mainly two options to produce the ready-made end product.
OPTION 1: The laminated safety glass pane is first laminated in the autoclave and finally coated.
OPTION 2: The panes are first coated and then joined in the autoclave.
Both technological options are showing weak points which may lead to considerable deficiencies in quality and problems in the further processing, e.g. if you are manufacturing layered glass panes.
THE FOLLOWING SIDE ISSUES ARE RESULTING OF THE CONVENTIONAL PROCESS:
- The softeners which are evaporating during the pressure relief period are contaminating the glass panes and it is difficult to wash them out.
- The softener oil dust mixtures also contaminate the inside of the autoclave (precisely the inside insulation) which requires several hours of weekly service intervals and necessary and causes downtimes.
- In order to generate overpressure in autoclaves oil lubricated compressor stations are often used which may lead to formation of interfering oil dust inside the autoclave which may possibly result in dangerous deflagrations.
ADVANTAGES DUE TO PROCESS INTEGRATION :
- Reduction and immediate evacuation of process interfering factors such as oil dust and vapors of softener
- Reducing the risk of generation of conveyance scratches during lamination of the coated glass
- Stabilization of product quality on highest level and generating optimum conditions for further processing with regard to coating and MIG production.
- Omitting the weekly maintenance cycles on the autoclaves due to continuous process integration Reducing the downtimes caused by replacement of the inner isolation by means of the now enabled permanent autoclave hygiene
- Reducing the risk of deflagration
- Reducing the emission of order and pollutant in the production area