In an increasingly dynamic market environment, the ability to anticipate change and invest in future-ready technologies has become a decisive factor for industrial success. SCHOLLGLAS and Forel share this forward-looking mindset. From modest beginnings, both companies have been recognized for their innovation in developing benchmarks for improved quality, reliability, and technical excellence within the flat glass processing industry.
The SCHOLLGLAS Group based in Germany, is a major European manufacturer of flat glass products, and has recently installed a new, state-of-the-art insulating glass production line at its facility in Nossen, Germany.
A strategic partnership built on proven expertise
SCHOLLGLAS has been a pioneer in thermoplastic spacer technology since 1996, when it began producing its first insulating glass units using this system. Building on decades of experience, the company chose Forel as its technological partner for this crucial investment, recognizing the outstanding performance credentials of Forel machinery and the consistency in delivering high quality finished product.
The unique line configuration maximizes efficiency, flexibility, and long-term performance, and represents a key milestone in the SCHOLLGLAS Group’s industrial development strategy.
High Tech Jumbo: innovative engineering on an impressive scale
The recently installed system, known as High Tech Jumbo, extends over an impressive 96 meters. More than a production line, it’s a fully customized engineering solution, designed specifically through a close collaboration between SCHOLLGLAS and the Forel development team.
The line integrates multiple operating modules in a sequential and highly optimized configuration, ensuring outstanding product quality while delivering tangible advantages in terms of output productivity and process control.
At the entry point of the line is the CR coating remover, a machine module that is equipped with two operating heads working simultaneously to remove low-emissivity coatings from the glass surface. The machine automatically operates in self-learning mode, detecting glass type, thickness and outer dimensions, efficiently and effectively processing all rectangular formats.
Double thermoplastic application: manufacturing flexibility without compromise
One of the most distinctive features of the line are the two thermoplastic applicators configured in series. This system is designed as a dual-purpose solution, capable of managing diverse and complex production requirements. The thermoplastic spacer is applied by two extrusion robots, in combination with conventional rigid box spacer when needed.
This configuration enables the production site SCHOLLGLAS Nossen to process different spacer materials on the same line without interruption or loss of production during material changeover. The resulting productivity gains enable faster more dynamic responses to SCHOLLGLAS customers as well the evolving demands of the market.
Production Buffer with Automatic Profile Alignment for plus 20mm wide extrusion
The line installation at the Nossen facility also includes Forel’s integrated Production Buffer with Auto Alignment Device for thermoplastic profiles—an exclusive production solution designed and developed to ensure product stability and absolute precision, especially when working with spacer widths greater than 20 mm.
This patented technology allows for the thermoplastic spacer to set and stabilize before pressing, preventing any deformation, guaranteeing repeatable consistent quality. The alignment tool is now considered to be an essential component in the manufacture of large, wide thermoplastic units delivering accurate and reliable linear alignment of the spacer profile.
Tandem coupling press: precision and versatility
The insulating glass assembly process is completed by Forel’s AP HT tandem coupling press, composed of two independent bodies that significantly reduce cycle times. The press is capable of filling units with Argon, Krypton, or a prescribed gas mix and is capable of processing offset IGU’s of up to 100 mm on each side, as well as triple, quadruple, and shaped insulating glass units.
Flawless sealing, without manual intervention
Final sealing is performed by the SR HT sealing robot, a proven solution in high-performance insulating glass production for both residential and commercial applications. The system can manage offset, triple, and quadruple units with panel weights of up to 2,400 kg.
A key contributor to overall efficiency is the innovative automatic corner sealing system, which ensures precise, clean, and uniform sealing along the entire unit perimeter. Thanks to this technology, no manual reworking of the corners is required—an essential factor in achieving maximum thermal performance and long-term durability in line with modern energy-efficient building standards.
Advanced diagnostics to maximise machine availability
The line is further enhanced with a sophisticated multi-level diagnostic system that redefines traditional troubleshooting. In the event of an alarm, operators are guided through a four-level diagnostic hierarchy, ranging from the entire machine layout to individual component parts.
Each interface provides a clear, unambiguous digital representation of the actual installed module, enabling intuitive navigation and rapid fault identification. Operators are also supported by guided recovery procedures, significantly reducing downtime and optimizing overall line efficiency. The diagnostic architecture is based on Edge technologies for plant-wide visualization, combined with dedicated solutions for each individual machine.
A forward-looking investment
With this investment in a Forel insulating glass line featuring dual thermoplastic application, SCHOLLGLAS sends a clear message to the market. The integration of patented solutions such as the Buffer and Alignment solution with advanced performance and diagnostic system, serves to strengthens the Group’s leadership position, providing the delivery of high-performance insulating glass products distinguished by thermal efficiency, durability, and customization.
A strategic investment that positions SCHOLLGLAS to successfully and competitively address the requirements, challenges and opportunities within the European market for years to come.
