LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 MACHINE MAKER FOR THE GLASS INDUSTRY

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 HOW CAN WE FACE THE MARKET REQUIREMENTS? Searching New designs Top quality At low cost

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 WHAT TO DO When the market is asking for: Stemware with thin and long stem Open shape Tumbler with polygonal design……..

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 WHAT TO DO When the market is asking for:

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 MARKET AND ORDER BOOK INTERNAL IMPROVEMENT TEAM Major Targets: Trying to improve the productivity by itself Avoiding any expenses PRODUCER Contacting the potential suppliers if no internal solution has been found. And finally

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 ►Producing new design at same costs ►Improving productivity on existing products That means: increasing the production speed 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 THE HANDLINGS CRACKING-OFF THE GRINDING AND BEVELLING FIRE POLISHING RIM PROCESSING OF TABLE WARE HIGH SPEED RIM PROCESSING LINE

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 RIM PROCESSING OF TABLE WARE THE MOIL REMOVING CAN BE DONE BY: BURN OFF CRACKING-OFF MECHANICAL BY SCRIBING BY LASER

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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: TSD Classic

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 Laser GENERATION 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 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 RIM PROCESSING OF TABLE WARE

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 LASER GENERATION 2: MODULAR DESIGN 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 IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 LINEAR MACHINE DESIGN Makes the laser integration easier MODULAR MACHINES and MODULAR LASERS PACK offer configurations adapted to the end-user requirements. RIM PROCESSING OF TABLE WARE

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER pcs/min 60 pcs/min 40 pcs/min 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 S2TC37 TWIN RIM PROCESSING OF TABLE WARE PRODUCTION UP TO 100 PCS/MIN

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 RIM PROCESSING OF TABLE WARE EXISTING MACHINES CAN BE UPGRADED SPEED 20 / 2 lasers Production speed up to 20 pcs/min.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 RIM PROCESSING OF TABLE WARE EXISTING MACHINES CAN BE UPGRADED SPEED 50 / 3 lasers Production speed up to 30 pcs/min.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS MECHANICAL / LASER 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS: SCRIBING/ LASERCUTTING Scribing wheels lifetime: PCS Laser refill: 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS: SCRIBING/ LASERCUTTING RATIO BETWEEN SCRIBING AND LASER: 7,8 % in favour of the scribing.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS: POWER CONSUMPTION S2TC31L –S2TC37 0,4030,380 RATIO BETWEEN SCRIBING AND LASER: 5,7 % in favour of the laser.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS: WATER CONSUMPTION S2TC31L –S2TC37 1,165 0,914 RATIO BETWEEN SCRIBING AND LASER: 21,5 % in favour of the laser

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 OPERATING COSTS: conclusions RATIO BETWEEN SCRIBING AND LASER: 4,8 % in favour of the laser

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 PRICE BALANCE BETWEEN CLASSICAL AND LASER MACHINES. COMBI 12 COMPACT 9 L22,77% S2TC37 S2TC316,92% S3TC45 S3TC45 HQ 6L15,33% RIM PROCESSING OF TABLE WARE

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 RIM PROCESSING OF TABLE WARE Water remains the major consummable Rejects reduction becomes the major pay-back factor PRICE BALANCE BETWEEN CLASSICAL AND LASER MACHINES.

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 Production speed25 pcs/min IN MONTHS EXAMPLE OF PAY BACK SINGLE INDEXING MACHINE 3 LASERS REJECTS SAVINGS

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 EXAMPLE OF PAY BACK Production speed35 pcs/min IN MONTHS S2TC31Laser AND S2TC37 REJECTS SAVINGS

LASER IN TABLEWARE RIM PROCESSING ICF MEETING WEIDEN 08 OCTOBER 2006 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. RIM PROCESSING OF TABLE WARE THANK YOU FOR YOUR KIND ATTENTION