SILCAR CHOOSES FOREL' S Flexible Profile APPLICATOR

 Silcar production plant in Zalau (Romania)

Silcar production plant in Zalau (Romania)

Silcar is a market-leading PVC Window and Door manufacturer, their production and assembly facilities are located in Romania. Silcar historically manufactured and distributed its finished products primarily in the Romanian market but increasingly over the last number of years, it has broadened its scope to a wider range of clients in Europe-hence the creation of Silcar International. Silcar has grown and developed over a period of 26 years and prides itself on customer satisfaction which is reciprocated with multiple repeat orders from satisfied clients from Austria, France, Italy, Germany, Switzerland and Ireland as well as the existing client base in the local market.

SC Lightglass, the Glass production facility of Silcar, has just recently installed an automatic applicator of the spacer profile at its glass facility. Lightglass is the very first company in Romania that has invested in this technology.

The automatic applicator system chosen by Silcar is Forel’s ART. TBB, which feeds a continuous strip of “warm edge” spacer from a reel and applies it directly on one of the two glass sheets, to obtain a closed frame. In the TBB applicator, the butyl extrusion is independent to the spacer application.

The introduction of this new automated system removes the conventional spacer frame processing techniques and improves performance and efficiency of the double & triple glazed units, both in warm edging and argon gas filling.

SC Lightglass is now producing its double and triple glazed glass units with an entire IGU line by Forel consisting of the washing machine ART.VW, the ART.TBB applicator, the coupling flat press unit with gas filling ART. APG and the sealing robot unit ART. SA.

INTERVIEW TO OVIDIU CARABA, GENERAL MANAGER OF SC SILCAR

- What are the strengths, in your opinion, of flexible profile? 

We can say that now we have the best quality available in the market place for our residential doors and windows thanks to the new technology of automatic application of the flexible spacer: SUPER SPACER profile. Some of the new technology advantages are:

- A saving of up to 20% on the heating costs of a building.

- Reduces perimeter condensation by 70% compared to the aluminum spacer.

- Great aesthetics: the self-adhesive band of the spacer prevents the penetration of the butyl inside the visible glass panel; this system also eliminates the gap between the glass panels, which is very visible especially for triple glazed units.

- Due to its flexibility, the spacer better absorbs shocks caused by solar heat expansion and contraction.

- Better argon retention due to the continuous application of the spacer and the automatic sealing of the final corner.

 Ovidiu Caraba, General Manager of Silcar

Ovidiu Caraba, General Manager of Silcar

- What are the benefits of assembling an IGU in line, thanks to an applicator of flexible spacer? 

I think all of the companies in the Romanian market are realizing that it is becoming increasingly more and more difficult to find good employees to expand our existing business. So, we need to invest in new technologies to reduce the dependency on a finite labor market.

This new line vastly reduces our unit production time and as it is a highly automated process by its very nature it gives us a superior high quality finished unit. This gives us great confidence to know that we are giving to our clients only high quality finished glazed units, which outlast the older glazing techniques.

- SILCAR is the first Romanian company choosing the flexible spacer: what do you think about Romanian market? Will it appreciate this? 

Yes, I think so. Indeed, we are the very first company in Romania which has invested in this new technology. After extensive research of the different automatic spacer systems, we choose the Forel Super Spacer system: it’s a proven and tested system, used all over the world.

We have already started to market and advertise the new spacer system in all the major cities in Transylvania. Our sales partners and also our competitors are very interested in this new technology. We are very confident that will be are able to raise the quality standards in the Romanian market for the thermal-insulating double and triple glazed units.

- What do you think about your Forel IGU line? 

We found the Forel company to be highly open and collaborative in conjunction with the technical assistance they given us on an ongoing basis. Forel is always developing new solutions with their end customers in mind, so that we both achieve the highest quality and performance from their automated production lines. The new Forel line we have purchased will serve not just the Romanian market for us but also the European market which is growing year on year.

 Forel IGU line in Silcar plant

Forel IGU line in Silcar plant

- What are the next goals of SC Lightglass?

Our business plan is a long-term one and we are already looking at ways of developing new automated technologically advanced production processes, in order to provide our customers with superior quality products.

FOREL AT GLASS SOUTH AMERICA

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Glass South America 2018 will be for FOREL (stand 679) an important opportunity to present to all visitors the latest innovations developed, especially concerning IGU machinery. In this regard, FOREL staff will be glad to illustrate and describe the cutting-edge technologies implemented in:

  • the applicator of flexible spacer (Art. TBB), to further automate and optimize the process;

  • the flat coupling press with automatic gas filling system (Art. APG), designed to guarantee excellent results even with waved glasses, in the glass inspection station, to ensure effective monitoring of production;

  • the high productivity sealing robot (Art. SRHP), to obtain a high quality insulating glass unit in a quick time.

All these technologies allow FOREL lines to offer a very reliable performance also in the production of triple and stepped units and make them ideal for the production of insulating glass for industrial refrigeration, besides the established standard applications in the residential and commercial sectors and naval sector.

Moreover, FOREL staff will be at full disposal to provide more information on the other products of the range, which include vertical machinery for edge processing and CNC drilling and milling, vertical cutting lines (Art. VC02) for laminated glass (equipped with automatic loading arm, two independent cutting bridges and rotating element) and Sorting Systems (Art. SS) for the automatic handling, reordering and monitoring of the glass panes inside the factory.

THE PROFILE BENDER OFFERS THE ARM TO THE WARM EDGE

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Warm Edge insulating properties, which bring important economical savings, are the reasons for the growing success of this kind of profile. As glassworkers know, the bending of plastic profile is an extremely delicate operation which requires precision and attention.

FOREL developed and upgraded its Automatic Profile Bender (ART. PBA632) to cater to different needs and typologies of material. The Profile Bender can now support the profile during the processing, thanks to the special Smart Arm (an exclusive FOREL patent). The arm works to avoid the risk of breaks or deformations when working with larger sizes. This solution offers high productivity, quality and no risks of damage to the material.

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Specific improvements have been developed to obtain a better bending process which offers two different results:

•          The classical internal fold;

•          An internal fold of 90°, visually identical to the “corner keys” (but without thermal dispersion in the corner) or to the welding junction (but with faster production).

The calibration of the bending is managed by a software, which ensures a complete control and precision of the angle.

FOREL AT CHINA GLASS 2018

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FOREL will attend CHINA GLASS 2018 in Shanghai from 19 to 22 of April and will be
pleased to welcome all visitors to its stand E1 – 214 within the GIMAV Italian
Pavilion.

Among its novelties, FOREL will present the latest developments related to IGU
lines, especially the new Jumbo and “Off Limits” lines, designed to process glass
sheets of extra-large size.

These lines enhance the already wide range of FOREL products that, besides IGU
machinery, includes also Vertical Cutting line for laminated glass, Edge Processing
machinery, Laminating PVB lines and Sorting Systems.

FOREL REALIZES A “NO LIMITS” JUMBO IGU LINE FOR TVITEC

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“The market is moving more and more towards insulating glass with higher quality, as well as large sizes. For this reason, we needed a company that wanted to work with us as a partner, creating for us a particular machine, completely new to the market, able to offer high-tech and high-quality products, while guaranteeing high productivity. And with Forel we found this company.”

These are the comments from Roberto Arias, Marketing Manager at Tvitec, on the conclusion of the project that led to a new Jumbo line for insulating glass, aimed at the production of glass for façades and special glass types, with particular and dedicated requirements and construction features.  The result of this project is a line from Forel with exceptional  performance and features in terms of weight , thicknesses and nonplanarity of the processed glass sheets, aligned or stepped.

“The Tvitec-Forel line can process some of the largest sizes of IG glass requested by today’s market,” explains Stefano Salvian, Sales Director of Forel “The design of the line involved commitment and skills. We had to take into consideration aspects that in the past were almost marginal, such as nonplanarity, which, for extremely large-sized glass sheets can be really important. The result is a line able to adapt itself to glass sheets that are not perfectly flat – and we are talking about centimeters here – with features that are completely different from other lines, with regards to size, accuracy and types of processes carried out.”

This important project took almost two years to be completed – in 2017 – with the delivery of the new Forel “No Limits” Jumbo line at Tvitec’s factory in Ponferrada (Castilla-Leon), northern Spain.

Made up of a loading area, coating removal, washing machine, inspection and frame mounting, glass turning section (180°), assembling press with gas filling (argon and krypton) and automatic sealer, the line was designed and built following a precise list of aims to be achieved:

- processing single glass sheet up to 40-millimetres thickness, and insulating glass up to 100 millimeters. This, in turn, requires load capacity of finished products of up to 550 kilos per linear metre;

- structural stepped units with vertical offset up to 250 millimetres and leading horizontal offset up to 1.000 millimetres;

- processing of bowed glass up to 2,5 millimetres per linear metre (15 millimetres on 6 meters glass length);

- sealing flexibility to use three different materials, and with high continuous material flow rate of 4 l/min;

- stepped unit assembling with the smaller glass in the front;

- dedicated glass unloading section.

FOREL AT FENSTERBAU FRONTALE 2018

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FOREL, leader manufacturer of machinery for flat glass and double glazing industries, will attend Fensterbau Frontale 2018 (21-24 March, Nuremberg-DE, Nurnberg Mess, Hall 3 Stand 153), showcasing some of its best solutions for edge processing and IGU lines:

-          Automatic vertical edging machine (ART. EM), designed for processing the edges of float and laminated glass sheets. It can perform edge arrissing, grinding and polishing. In addition to the selflearning functionality, when processing squares or rectangles, the machine is able to square and bring the glass to the final required dimensions, being therefore very useful even for double glazing and pre-tempering  grinding applications.

    

-        Automatic Profile Bender (ART. PBA632) and Dessicant Filler (ART. DFN): thanks to the special Smart Arm (an exclusive FOREL patent), the Profile Bender can support the profile during the processing, avoiding the risk of breaks or deformations, also when working with large sizes. This solution offers at the same time high productivity, quality and no risks of damage for the material, and it is also suitable for bending plastic profiles. At Fensterbau, the Profile Bender will be showcased along with the Dessicant Filler, which can fill any type of spacer frames with hygroscopic material, both squared and shaped units. The two machines can be easily handled by just one operator.

2017 has been a very satisfying year for FOREL: what the customers appreciated about our way of working is the skill to listen and cooperate with them, in order to find the best technical solutions. In this view, Fensterbau Frontale is an important chance to meet our customers and partners, with the ambition to always achieve more significant goals.

2017 IN FOREL: GROWTH, RECRUITMENTS AND INVESTMENTS

 FOREL Sorting System

FOREL Sorting System

Turnover growth, plant enlargements and new recruitments.

This is the 2017 of FOREL, a year with the “+” sign in sales, thanks to the confirmed appreciation of our traditional customers but also to the increasing trust of the new ones. 2017 will be remembered in FOREL especially for the development of special Jumbo lines, capable of processing very large and heavy glass sheets specifically required for high performance facades: part of the important projects successfully carried out by the Company last year.

The growth was also “physical”: in 2017, indeed, FOREL completed important enlargements of both office and production areas.

The positive moment required also an enhancement on human resources: between 2016 and the end of 2017, FOREL hired many new employees (in production, sales, administration and marketing departments). Currently, the company employs more than 200 people directly, and over 300 people in partner companies and agencies. Other recruitments are expected before the end of 2018.

Therefore, important investments in the plant, in the machinery and in the people, after the achievement of a very important goal:

“We reached our 40th years of activity. Once, there was only an idea and a good young mechanic, today there is a worldwide known brand” says Fortunato Vianello, founder and CEO of FOREL “Though the investment done, our patents and our know-how, we want to grow more”.

Established in 1976, FOREL has two facilities in Vallio di Roncade and Meolo (Italy), a sales and service branch in Minneapolis (Minnesota, USA) and 21 Agencies worldwide: FOREL machines are now operative in over 60 Countries. The product range includes machinery for vertical cutting of laminated glass, automatic sorting systems, vertical edging, drilling and milling, PVB lamination and insulating glass production.

A NEW ORGANIZATION CHART FOR FOREL NORTH AMERICA

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2017 has been a successful and busy year for FOREL in North America.  The support and appreciation received from our customers has validated FOREL as one of the main players in the production of machinery for flat glass processing. FOREL’s growth in the U.S. and Canadian markets has encouraged the company to enhance the North American branch so that we can continue to offer exceptional sales and service support.

As explained by Fortunato Vianello, founder and CEO of FOREL, “Sales in 2017 in North America have been incredibly successful. We believe it is necessary to look forward to the future and more ambitious opportunities offered in this market. In order to maintain our growth Forel North America has been reorganized to accommodate our customer’s needs more closely.  We believe that this is an essential step to establish valuable and long-term relationships.”

Effective January 1, 2018 FOREL NORTH AMERICA organization chart will be as follows:

Chief Executive Officer - Stefano Mauriello
Chief Financial Officer  - Christine Wilson
Sales Manager  - Marco Schiavon
U.S. Service Manager  - Troy Lentner
Canada Service Manager & Sales Support - Owen Allen

Riccardo Vianello is the Chair of the Board of Directors. From the beginning, Riccardo has been instrumental in the development and success of Forel North America and he will continue to be heavily involved.

FOREL TRAINING SESSION 2017

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International attendance from Europe, Russia and North America at the latest Forel Training Session for global technical support. The Training Session took place at FOREL's headquarters November 6th to 17th  covering machinery maintenance, breakdown and technical support.

 FOREL, prioritise post-service support as importantly as the machine itself so training locally based technicians to a competent level is vital.

Our training philosophy is to train technicians practically with live demonstrations held within our production area: in this way participants acquire first hand experience and knowledge of FOREL products, and better prepare themselves to offer better service to the customer.

The attendees were from different nationality, aged between 20 and 40 years old with varying levels of experience. The training sessions focused on the most popular machines within the FOREL range but in particular edge processing and IG production as they are represented in over 60 countries worldwide.

VITRUM 2017 REPORT

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TWO COMPLETE FOREL LINES AT VITRUM 2017

 

A successful 2017 edition for Vitrum, the international exhibition dedicated to the world of glass, its machinery and applications. This event represents an important showcase for FOREL, one of the most important world player in flat glass processing industry.

During the four exhibition days, FOREL booth with more than 1.000 m², has been visited by a
considerable number of visitors.

The visitors attendance confirms the importance of the exhibition for the European market with a growing numbers of them coming from Russia and also overseas from USA and Far East.

On the Forel booth were displayed and fully operating one IG line and one complete vertical processing line for edging drilling and milling. Both of them were equipped with the most advanced solutions developed by FOREL, with the intention to provide lines able to work continuously also for three shifts a day.

The presented insulating glass line was made up of the vertical seaming machine series EG, the vertical washing machine series VW, the coupling flat press with gas filling series APG and the automatic sealing robot “High Performance” series SRHP.

The vertical “Jumbo” size processing line with 6000 x 3210 mm glass capacity and a total length of 40 meters was one of the main attractions of the exhibition.

The automatic vertical edging machine series EM with the drilling and milling machine series DM and the vertical washing machine series VW, is the winning solution for the high productivity and big sheets processing. The exceptional performances of such line represent the best investment for the customers which are looking to increase the production capacity and at the same time are focused on the glass quality and extreme processing tolerances.

These kinds of lines are already installed in 20 different countries over Europe, Asia, USA, Australia and New Zealand.

“After a period of relevant appointments for Forel, Vitrum 2017 was an unmissable opportunity to meet our customers once again” said Stefano Salvian, Sales Director of Forel “In September we attended the GlassBuild (Atlanta, USA), displaying the last release of the Hi Speed IG line and few days later we held in our headquarter in Vallio di Roncade (Italy) the successful Forel Open House 2017. The Open House was as great opportunity to present to our customers the high-level technology which Forel has developed in the last months, but the most important issue during the internal event was the possibility to understand the market needs. As usual listening the customers needs is our main commitment”.

PER LAVORARE SENZA PENSIERI

Qual è una delle problematiche più frequenti nelle vetrerie?
La movimentazione manuale e non ottimizzata delle lastre tra le lavorazioni e il controllo della qualità delle stesse. Maggiore è il volume di lavoro maggiore è la probabilità di intasamento e di perdita di produttività, da cui deriva una perdita di fatturato.

Ma esiste una soluzione completa e automatica a questi problemi?
Il Sorting System studiato, sviluppato e prodotto interamente in Italia da FOREL è la soluzione completa per l’ottimizzazione della produzione e per la movimentazione e lo stoccaggio all’interno delle vetrerie.

Come funziona?
Il Sorting System è un macchinario costituito da moduli di movimentazione su binari che permette di connettere tra loro le diverse lavorazioni, rendendole indipendenti e migliorando la produttività. Inoltre un’innovativa interfaccia grafica dedicata permette di avere una visione in tempo reale sullo stato delle commesse. 

Devo avere macchine a marchio FOREL per utilizzare il Sorting System?
Assolutamente no, l’alta configurabilità di questo sistema gli permette di adattarsi a linee produttive sia a marchio FOREL sia di altri produttori.

Ma serve molto spazio per installare il Sorting System FOREL?
Assolutamente no, uno dei suoi punti di forza è la sua modularità e personalizzazione, permettendogli di adattarsi agli spazi a disposizione.

In conclusione il Sorting System FOREL rende automatica ogni movimentazione e stoccaggio all’interno della vetreria, riducendo al minimo il lavoro manuale degli operatori, riducendo quindi anche i rischi e migliorando la sicurezza sull’ambiente di lavoro.

2016: AN YEAR MARKED BY FOREL

40TH ANNIVERSARY CELEBRATIONS AND THE SUCCESS AT GLASSTEC TO CROWN A FANTASTIC YEAR

The 2016 edition of Glasstec confirmed once again the great success of FOREL within the glass processing industry. Many visitors were present at the stand – the biggest ever for the company – to look closely at the latest technology and cutting edge solutions of the Italian brand. 

In Dusseldorf, the Italian company presented some innovations as well as established products like the Vertical Edging Machine  - Art. EM (Best Seller 2015-2016)

FOREL’s exhibit a this year’s show indicative of this focus. Having come “into its own” with the increased use of laminated glass, particularly in the commercial but also in the residential sectors, the Forel Vertical Laminate Cutting line, attracted significant interest from european glassworks but not only . This revolutionary innovation was first launched by Forel 20 years ago, turning the horizontal cutting process into the vertical, the principle behind the philosophy delivers machinery reduced footprint, increased productivity and performance whilst reducing manpower equivalents and handling. The other main benefit of the vertical cutting line is to reduce breakages thanks to the reduced tension of the applied load on the glass sheet. 

FOREL has introduced the new Gas Fill Analyzer to its IGU line process (world premiere 2016), a revolutionary new technology offering completely automatic in-line monitoring and checking of the gas fill concentrations, in assembled insulating glass units. This revolutionary development released by FOREL R&D can be installed on the conveyor directly after the gas press, offering immediate reporting of the actual gas fill percentage achieved. The speed of this automatic scanning system allows inspection and reporting without affecting the cycle time of the line.

Also on display a new upgraded version of the Profile Bender with “Smart Arm” by adding a new option for bending plastic spacer bars. This upgrade has been carried out in response to the growing market demand to process with precision and quality this new generation of profiles of high energy efficiency performance. In the working process cycle, the profile is heated, bent and then cooled on the basis of a number of parameters optimized according to the type and thickness of the product used

One of the major innovations for FOREL at this Glasstec 2016 event is represented by the Sorting System (art.SS) developed for automatic feeding of the IGU lines or other process lines. Art. SS is a comprehensive and automated solution for the internal logistic of the glasswork. It allows the automatic or semi- automatic offloading of glass from the cutting zone, transport and storing with the possibility to transit through an arrissing line, cleaning and quality control. The system basically consist of handling and storing modules that can be combined together to better meet customer needs

The tradeshow provided important feedback about the philosophy of separating the edging and the drilling/milling processes in the same line has been extremely successful. Particularly, as the Art.DM drilling/milling machine is presented with “finished” glass panels with fully processed edges from the Art. EM edging machine, it is able to guarantee extremely precise references and measurements. This precision has been highly appreciated by those glass processors requiring high repeatability and tolerance in, for example, tempered laminated glass production

The company arrived at the event after celebrating its 40 years of activities a its company headquarters in Vallio di Roncade (Treviso), North East of Italy. These of FOREL have been 40 years of longevity which have been characterized by a constant search for innovation, reliability and quality allowing the company to continue to expand and to respond more efficiently to the needs of its customers.

Forel always thinks, designs, develops and tests its automations within its Italian Headquarters. There is no outsourcing in other Countries or fragmentation of know-how caused by a flow in information split across different production sites. This centralized knowledge and the complete control on the technology is a guarantee for all the after-sales service, from any upgrade to every customer inquiry solution

The Italian company is approaching the end of the year with a renewed awareness and the will to continue to deliver the most innovative machineries and the best solutions for its clients