Residential Line

The coupling press Art. AP ES automatically manages the coupling and pressing of IG units efficiently and with absolute precision. Processing rigid box and or flexible spacer frame units, with either double or triple glass pieces is seamless (one or two chambers up to 65 mm of thickness). The platform can be specified with an associated gas filling system (argon). The inbound glass piece is automatically scanned for height, width and thickness as are the subsequent glass pieces with the addition of the spacer width. The onboard system then calculates the amount of gas required to fill the associated cavity.

The “Residential” range offers different versions of the frame positioning stations Art. FP ES:

• The first version is the “basic” frame positioning station, available in two models it is equipped with defused neon lights and can be specified with different maximum workable formats of up to 3,600 x 2,500 mm. The station in equipped with vertical and horizontal references for easy frame positioning.
• The second version is available in four different models with different maximum workable formats (up to 6000 x 3300 mm), with horizontal and lower manual references. During processing, sensors acquire the glass pane size and the mobile support bars, which are equipped with an LED light system, are positioned automatically. The inspection room is a matt black structure and allows for the easy inspection to the rear side of the glass.

The “Residential” range offers different versions of the inspection station Art. IS, to better fit the various requirements of the IGU manufacturer.
The first version is the “basic” inspection conveyor for the visual check of the individual glass pieces. Equipped with lights, it is capable of processing glass sheets of up to 3,600 x 2,500 mm.
The second version is a “plus” inspection cabinet equipped with an accessible rear chamber. This allows for the easy inspection to the rear side of the glass sheet and is equipped with an LED light system. Automatic reference bars facilitate frame application. The cabinet can be specified to process glass pieces up to 6,000 x 3,300 mm.

Forel developed the coating removal machine Art. CR to precisely remove the coated surface from the glass edge, this allows for the correct application of the spacer frame and the perfect sealing of the unit. The coating removal machine Art. CR is equipped with 2 operating heads with peripheral abrasive grinding wheels: the heads work simultaneously, significantly reducing production cycle times. In the “Residential” version, the Art. CR is available in two models, to process glass sheets of up to 4.000 x 2.500 mm. The coating removal machine Art. CR can process rectangular sheets automatically and shaped glasses from file. Art. CR is equipped with a dust extraction system and a specific tool for the automatic redressing of the abrasive wheel.

The Art. AC ES automated corner turning conveyor rotates individual glass sheets or double-glazed units safely and efficiently. This specialised unit optimises factory floor space without increasing overall production time. The conveyor can be installed at various points within the production line layout and joins together machines that cannot be connected in a straight line (usually 90°). The rotation process is fully integrated into the line’s synchronization optimising performance and output. The overall length of the glass sheet can exceed that of the corner conveyor, thanks to Forel’s exclusive and patented handling system.

The Art. SH ES is an automatic sealing robot, developed to maximize the production of IG units with “hot melt” single component sealant. The extrusion head is equipped with a depth measuring device, ensuring that the volume of sealant is precisely managed. A volumetric dosing unit ensures that the hot melt material is constantly and correctly extruded. The entire extrusion process is monitored and controlled by easy to use and intuitive software, which manages the thermo-regulated sensors and resistors throughout the system. Precisely managing the temperature of the product and therefore its viscosity is necessary to the performance and quality of this platform.

The “Residential” Sealing Robot Art. SR ES has been developed for the efficient processing of double or triple glazed units with the common size and thicknesses characteristics associated to the domestic residential market. The platform can use up to two sealing products, extruding at a sealing depth of up to 15 mm. The Art. SR ES is available in two models, capable of processing a maximum size of unit of 4,000 x 2,000 mm or 4,000 x 2,500 mm.

The Art. AT ES developed specifically for the accurate and seamless application of “T-Shape” flexible spacer. The flexible profile is stored on up to 4 reels within a hermetically controlled cabinet situated next to the applicator. The Art. AT ES is available in 2 models, to process IG units of up 4,000 x 2,500 mm. Art. AT automatically removes the protective film from the edges of the profile and infills the “T-Shaped” spacer with the measured amount of butyl pre-glass application, in a non-stop extrusion system.
The profile buffer (patented) allows for continuous application of the spacer to the glass pane enhancing quality and overall output. Art. AT ES can process rectangular glass pieces automatically and shaped glass from file. Once the application process is completed, the final corner is closed by a Corner Tape applicator.

The turning conveyor Art. RC ES can rotate to any angle either clockwise or anticlockwise. Usually, this type of rotating conveyor is utilised by turning the glass piece 180° tilting automatically, for the correct orientation of coated glass within the specified unit. It can be used in-line straight or as a corner conveyor, depending on the floor space available and the user’s requirements. This module can be installed at various points along the production line layout and is fully integrated within the production lines synchronization. The operational process of Art. RC ES has been optimised to remove any interruption to the output performance of the line.

The vertical washing machine Art. VW is one of the most versatile and appreciated solutions of Forel. In the “Residential” version, Art. VW is available in two models, which correspond to two different maximum size (4.000 mm x 2.000 mm and 4.000 mm x 2.500 mm) with up to 200 kg per linear meter of capacity and 25 mm of thickness. The washing machine is equipped with 6 x 200mm diameter brushes. Standard features such as the glass thickness reading device and automatic low-e detection device, the Art. VW ES can manage the total washing process to ensure the highest standard of glass cleanliness every time.

The Profile Bending Machine Art. PB is a strategic tool for any insulating glass unit producer and one the world’s highest performance solutions for the bending of rigid box spacer. It can easily process all types of bendable spacer bar, perfectly calibrating each single bend with the aid of dedicated software. The important features of this particular machine is the innovative Smart Arm (patented) which accompanies and supports the spacer frame during the process: this feature allows for the processing of large spacer frames avoiding any deformation or micro cracks appearing at the corners.

The Art. MB butyl extruder ensures full compliance with the most stringent standards required for the primary seal. The polyisobutyle (PIB) rubber is extruded through two separate dispensers and then applied via the application nozzles. The utilisation of a measured dozing system guarantees the uniformed distribution of the PIB around the entire perimeter (a special feature unique to Forel). The touch screen unit manages the automatic opening of the nozzles (width adjustment) and the positioning of the pre-extrusion guides, according to the selected spacer width value. The injection capacity (grams of PIB per linear metre) can be set directly. Art. MB can also apply PIB to shaped profile or Georgian bar frames, with the same accuracy and simplicity of operation. Preproduction heating of the product can be pre-set by timer.

The Automatic Desiccant Filler Art. DF completes the Forel spacer bar processing range and can be specified with an option for automatic loading. This standalone platform automatically drills, fills and closes the backside of the spacer bar frame, injecting the prescribed amount of desiccant into the boxed void. The automatic loading of spacer frames can be specified as an additional option allowing the Art. DF to collect, process and then send spacer frames directly to the butyl operation.

The Art. CA automatic cork pad applicator further enhances the IG unit production process. This solution is equipped with 4 or 5 application heads, that position automatically according to the height of the individual glass unit. Each movable head is fed from a material reel, which can easily and quickly be replenished. The applicator applies the protection pads to the surface of the unit according to customer requirement. The operator can set the distance between each pad via the intuitive onboard software. This applicator is completely self-learning and requires no operator supervision and is integrated fully to the IGU lines synchronization.

The Art. SQ scans for and detects various types of surface defects to the entire glass piece faces in real time. All defects that are detected such as inclusions, fingerprints, scratches etc. are immediately notified to the operator via an alarm and PC display. The operator is quickly directed to the defect which can be prioritised based on classification. All defects detected can be archived for post-production analysis which includes pictures, processing time and corrective action. This quality control station is fully integrated into the IGU lines synchronisation, taking care of any necessary upstream or downstream production control.