The rise in energy prices has driven up float glass prices, making insulating glass (IG) production more expensive than ever. Since float glass is the main raw material in IG units, manufacturers are feeling the pressure to find smarter ways to reduce costs and stay competitive. The good news? Energy savings are within reach, especially with modern technology.
Start with the washing process
Glass washing and drying are among the most energy-intensive steps in IG production. Upgrading to advanced washing machines can cut energy use by up to 25%. These machines automatically shut off drying zones when not in use and close blower flaps when no glass is present. A closed water circuit with a disc filter system also helps, reducing water usage by up to 15 times and saving even more energy.
Choose the right conveyor system
Roller-driven conveyors may seem efficient, but they can scratch Low-E glass, leading to costly remakes. Modern air-cushion conveyor technology avoids this issue, preserving glass quality and reducing waste.
Optimize component efficiency
Modern IG lines use smart motors and shared drives, so only the conveyors carrying glass are active. This setup significantly lowers power consumption. Additionally, converting kinetic energy back into electricity during deceleration can save up to 20% more energy. Switching from pneumatic to hydraulic or electric drives also cuts energy use by up to seven times.
Go all-in with TPS® technology
For maximum efficiency, consider Glaston’s Thermo Plastic Spacer (TPS®) system. It replaces multiple machines with a single applicator, streamlining production and reducing cycle times. Producing triple IG units in six hours instead of eight means two hours of energy saved daily. The new TPS® drum pump system also improves insulation and avoids unnecessary heating cycles.
TPS® IG units offer better thermal performance, with a 12% lower U-value and 60% less heat transfer at the edges compared to traditional aluminum spacers.
Final thought
With higher energy prices, even small improvements can lead to big savings. Investing in modern, efficient technology isn’t just smart—it’s essential for long-term profitability in the IG industry.