Production Process

PRODUCTION PROCESS

Source of Raw Materials

Glass Raw Materials are supplied by well known Glass Manufacturing companies from America and Europe. Among these suppliers are Pilkington, Guardian, Euroglass, St. Gobain, Arcon and Asahi Glass. The glass cases are unloaded using the 5.5 Overhead Kone Crane and are safely placed on the A Frames located in the glass Warehousing Section.

CNC-Glass Cutting Process

The Process formally begins after the Sales Order and Optimization disc containing detailed instructions are released by the Estimation/ Marketing Department to the Production Department. Upon receipt of the Sales Order and Optimization Disc, the Production Department delegates the Job Order to a particular Section.

With the Overhead Crane, The glass is loaded on the CNC cutting line table which then freely and slowly pushes the glass to the Lisec Cutting Machine for automatic cutting of the glass. The Operator sets the mode of operation on the CNC Cutting Machine either manually or automatically. The operator retrieves and optimizes the program according to the sizes required considering minimal glass wastage. Once cutting is done, the glass is transferred to the breaking table for the breakout operation using the pneumatic push.

GLASS TEMPERING PROCESS

From Cutting, the glass is transferred to the Arising/Polishing Section where sharp edges are arised. The glass is washed in the Washing Machine and then loaded in the Loading Station of the Tempering Machine. The furnace is heated at 700C with appropriate timing based on the type and thickness of the glass. The glass then proceeds in the Furnace for Tempering.

GLASS INULATION Process

Insulated glass (in pair) is assembled in the machine loading area. The paired glasses pass through the Vertical Washing Machine whereby quality is being checked prior to matching. After the quality has been checked and approved, the aluminum spacer is assembled onto the unit. The aluminum spacer is placed in between two glasses and the unit passes through the pressing process. To seal the double glass, Tremco Silicon 562 or Polyurethane or equivalent quality is carefully applied in its four sides by the LISEC Robotic Sealer machine.

The insulated glasses can also be sealed with silicon or polyurethane back-up pumps. Bur-IG is either processed with aluminum spacer, modified shuco spacer of shuco aluminum spacer according to the requirement of the client. The glass is stored for eight hours for curing or drying prior to delivery.

FLAT LAMINATION PROCESS

If the glass requires lamination process, it is loaded to the Loading station and is transferred to the Washing Machine for Cleaning using treated water from Reverse Osmosis (R.O.) Plant. Once the glass has been washed, using the Over head Crane with Automatic Lifters the first glass is lifted thereafter, the PVB is automatically applied to the surface of the glass, after which the second glass is lifted glass and placed for accurate pairing applying PVB interlayer in between.

PVB film is cut and trimmed according to the size of the glass and the unit is transferred to the heating Furnace. The glass batches of pre-laminated glass are fed / placed into the Autoclave cycle for final de-airing process. Glass processing in Auto Clave is a five hour - cycle for pressurized heating, cooling and re-pressurizing process.

Glass Ceramic Fritting Process is as follows:

• Washed glass is loaded to the loading station.
• As per Client approval, the Glass is positioned to the Printing Machine (Keraglass) in which appropriate parameter is applied by the operator, for Silkscreen Printed design.
• The paint is poured to the silkscreen frame which is the n applied by squeegee, signaling the start of the production.
• Once the printing is finished the glass is transferred automatically to the heating chamber for the drying process. The glass is then transported to the Tempering Machine for the final curing of paint.
• The Ceramic Fritted glasses can also be laminated or double glazed if required.

PACKING AND DELIVERY

After tempering quality has been checked and ensured, the glass units proceed to Double Glazing, Laminating, and Ceramic Printing Sections or directly for Packing and Delivery in cases of single tempered glass.

Each glass is ensured to have no damage or scratches and has passed Quality Control checking before sending to Packing Division.

The glasses are covered with plastics and placed in wooden cases. These cases are finally sealed and tied with steel belt straps and are made ready for Delivery.

Delivery is done through BGF vehicles that have been specially modified for carrying glasses.