Press Glass - Case Study
Press Glass S.A. – the largest independent European producer of insulating glass for the construction industry with factories located in several countries. We have implemented the IPLAS system in the branches in Radomsko, Miętno, Tczew, Tychy and Varazdin (Croatia).
Press Glass is aware of the need to improve the quality of its products as well as to optimize the consumption of resources used in production processes. The aim of many activities performed in the company is to improve both customer satisfaction and the company’s impact on the environment. One of the media used in the production of insulating glass units is demineralized water for cleaning the glass. In order to maintain the proper quality of products, it is vital that the water in the glass washers is periodically changed as well as properly filtrated.
Periodic excessive use of water in the production of insulating glass units, in this case demineralized water used for glass washing.
Ongoing monitoring of water consumption for technological purposes. Notifications in the form of e-mails or text messages sent to designated recipients in the event that the system detects excessive consumption of the medium within the assumed time frame.
On the basis of the technical infrastructure developed and installed by the Press Glass maintenance department, as a proprietary improvement for the existing production lines, as well as the data collected by the company, we have been able to develop a digital interface which imports data into the IPLAS system and presents it online.
This solution has enabled the smooth monitoring and continuous supervision of water consumption as well as early notification of the maintenance department when abnormal consumption has been detected. The system informs of the consumption via an email notification along with instructions on what actions to take in order to fix the problem.
Screenshots from the IPLAS system showing the control of measuring points in the Miętno plant:
Case No. 1 – clogged filter in the water filtering station.
Case No. 2 – the production operator did not close the valve at the outlet of the washer supply tank and, as a consequence water slowly poured into the sewage system.
The effects of the combined implementation of the technical infrastructure together with the data collection in Press Glass as well as the implementation of the IPLAS system are as follows:
- Reduction of monthly water consumption by up to 60% per month as compared to 2019 and 2020. A huge impact on reducing the cost of water consumption and simultaneously reducing the negative effect of the factory on the ecosystem in which it is located. Providing customers with a higher quality product.
- Increasing the speed of reaction of the maintenance department in case of emergency situations while maintaining a high standard of the glass cleaning process.
Will it be like that for you?
IPLAS will not solve the problems that affect the low production efficiency for you, but it will precisely indicate their occurrence and duration. Thanks to proper data analysis, you will be able to take action aimed at problems found and ultimately improve the efficiency of the production process.