28.09.2026
In the North American insulating glass market, particularly in high-volume production for the residential sector, speed and productivity are becoming increasingly strategic. However, increasing production rates also means ensuring precision, repeatability and consistent quality at every stage of the process.
Against this backdrop, Forel took part in GlassBuild America 2026 in Las Vegas, showcasing the latest developments of the Dura High Speed Line, with solutions designed to further increase productivity and efficiency in insulating glass production.
High-volume production requires lines capable of maintaining fast, consistent production rates while reducing processing times without compromising the quality of the finished IGU.
For residential applications, high speed must therefore go hand in hand with other essential factors: process continuity, precision and repeatability.
The Dura Line is designed to achieve an average cycle time of 24 seconds for a 36” x 24” double-glazed IGU with gas filling, combining high productivity with precise process control.
The line is designed to process Quanex Duralite® and Duraseal® spacer profiles, which can be used interchangeably or combined within the same line configuration. This setup enables the production of insulating glass units without the need for manual or automatic secondary sealing.
The Dura Line can produce double- and triple-glazed IGUs with automatic gas filling and can also process certain types of shaped glass. The configuration accommodates units up to 2,500 mm long and 2,000 mm high, with individual glass thicknesses ranging from 2.2 to 12 mm and spacer profile widths from 6.5 to 20.5 mm. The line can also process glass with bow of up to 2.5 mm per linear meter.
One of the key components of the line is the automatic Dura applicator, developed to apply the spacer profile with high precision along both straight sections and corners.
The system also monitors the amount of material remaining on the reel and alerts the operator when there is not enough to continue production. The reel is housed directly on the machine and maintained at a constant temperature of 25°C, while material management is designed to minimize waste.
Another critical stage is the heating of the Dura profile. Before assembly, the entire perimeter must reach a preset temperature to promote proper butyl adhesion.
The Forel module applies heat evenly and directly to the butyl surface using infrared heating elements. A multi-axis positioning system provides precise process control when working with different profiles or widths, ensuring complete and uniform heating before pressing.
The assembly press is designed for fast and precise argon filling of double, triple or shaped IGUs, with a maximum overall thickness of 60 mm.
The automated sequential process promotes effective gas distribution and adhesion between the glass and spacer. In the double-press configuration, the required butyl contact time can also be managed without slowing down the line’s overall takt time.
At GlassBuild America 2026, Forel showcased the latest developments of the Dura High Speed Line, designed to further enhance productivity and efficiency in insulating glass production. These included a new Forel-patented solution, developed to further improve the line’s performance.
The Las Vegas event also provided an opportunity to preview another major innovation: the new High Speed Thermoplastic IG Line, which will soon make its official debut at Glasstec in Düsseldorf in October.
Two different technologies sharing the same direction: pushing productivity standards even further, with solutions developed to meet the real-world requirements of modern insulating glass production.
