Press Glass – a giant in the manufacturing industry
The largest independent European producer of insulated glass units for the construction industry, with factories located in several countries. We implemented the IPLAS system in branches in Radomsko, Miętno, Tczew, Tychy and Varazdin (Croatia).
Press Glass is aware of the need to improve the quality of its products and optimise the consumption of resources used in production processes. The goal of many activities carried out in the enterprise is to improve customer satisfaction and the company’s impact on the environment. One of the utilities used in the production process of insulated glass units is demineralised water used for washing glass. In order to maintain the proper quality of products, it is necessary to periodically replace the water in glass washers and ensure its proper filtration.
PROBLEM: periodic excessive water consumption in the production process of insulated glass units, in this case demineralised water used during glass washing.
Monitoring water consumption in a manufacturing company
SOLUTION: Ongoing monitoring of water consumption for technological purposes. Notifications in the form of emails or SMS messages sent to designated persons when the system detects excessive utility consumption within a predefined time window.
Based on the technical infrastructure developed and installed by the Press Glass maintenance department, as an in-house improvement for the existing production lines, and the data collected by the enterprise, we developed a digital interface that imports data into the IPLAS system and presents it online.
This enabled seamless monitoring and constant supervision of water consumption, as well as early notifications for the maintenance department when excessive consumption is detected. The system informs about consumption via an email notification, along with instructions on what actions should be taken to resolve the issue.
Screenshots from the IPLAS system showing the control of measurement points at the plant in Miętno:
Case No. 1 – clogged filter in the water filtration station.
Case No. 2 – a production operator did not close the valve at the outlet of the washer supply tank, and water was slowly draining into the sewage system.
Reducing production costs thanks to utility consumption monitoring
Results of the combined implementation of technical infrastructure and data collection at Press Glass, and the deployment of the IPLAS system:
- Reduction of monthly water consumption by up to 60% when comparing 2019 and 2020. A huge impact on reducing water consumption costs, while limiting the factory’s negative impact on the ecosystem in which it is located. Providing customers with a higher quality product.
- Increased response speed of the maintenance department in case of emergencies, while maintaining a high standard of the glass washing process.
