The glass industry is currently undergoing a profound transformation. Skilled labor shortages, rising energy costs and growing expectations regarding the environmental footprint of production processes are fundamentally changing the requirements placed on machinery and equipment. At the same time, automation, digitalization, self-optimizing machines and comprehensive data monitoring are creating new opportunities to make glass production more efficient and sustainable.
A clear trend in modern insulating glass production is the seamless integration of individual process steps. LiSEC has already implemented one example of this approach: edge processing and the insulating glass line are connected so that glass panes are automatically transferred from one station to the next in the correct sequence.
The sequence plays a crucial role, as the insulating glass line processes the panes immediately after transfer. At the end of the production process, the finished units are automatically placed onto glass racks, sorted by product type and sequence, ready for the next production stage.
Sustainability is increasingly becoming a key factor in investment and production decisions. On the one hand, large customers and regulatory requirements are driving greater transparency regarding the environmental performance of manufacturing processes. On the other hand, operating costs are prompting glass processors to closely examine the energy and water consumption of their equipment.
For machine manufacturers, this means designing systems that remain productive for as long as possible. At LiSEC, the LONGLiFE department is dedicated to this objective. Through software, hardware and electronics upgrades, even older machines can be kept up to date and continue operating efficiently for decades. It is not uncommon for systems to remain in service for 20 to 30 years.
At the same time, significant optimization potential exists during day-to-day operation. One example is the further development of the KSD-A edging and grinding machine. Feedback from customers revealed that fresh water consumption was higher than desired. A newly developed solution has reduced it to almost zero. The recycled process water now only needs to be replaced every four to five weeks, lowering operating costs while significantly improving the environmental footprint of the process.
The shortage of skilled workers is affecting the glass industry worldwide, making it increasingly difficult to find qualified machine operators. LiSEC is addressing this challenge in two ways:
Machines are becoming easier and more intuitive to operate: Parameters and measurement results are automatically analyzed and fed back into so-called recipes. A recipe is a stored set of parameters for a specific glass type or process step. This allows the machine to continuously optimize itself while significantly reducing training requirements for new personnel.
The level of automation across entire production lines is increasing: In glass cutting, for example, the process can run fully automatically, from glass storage through to finished laminated glass cut to size.
As digitalization advances, the systematic collection and analysis of operational data is becoming increasingly important. While machine connection values were often the primary focus in the past, attention is now shifting toward actual consumption data and measurable savings potential. This data enables investment decisions to be evaluated with far greater precision.
For example, on the cutting table, the grinding dust extraction system based on the Venturi principle, where compressed air generates a vacuum, has been replaced by an electric system. By measuring actual energy consumption, it is now possible to accurately quantify annual energy savings for single-shift and two-shift operations. As a result, the payback period of an upgrade can be calculated with confidence.
Another example is the SIR infrared power heating system for laminated glass cutting tables. Instead of using continuous infrared elements across the entire machine width, SIR operates with individual heating segments. Only the area actually covered by glass is heated. This reduces energy consumption, shortens warm-up times and increases overall system throughput.
The demands placed on glass processing will continue to increase. Fully automated production lines, self-optimizing processes and transparent consumption data are steadily becoming industry standards. At the same time, the environmental assessment of production processes is gaining further importance.
The glass industry is currently in a phase where some developments are already clearly visible, while others are only beginning to take shape. Technologies such as artificial intelligence are expected to play a central role in future glass processing applications. Exactly how these opportunities will evolve remains to be seen, but their potential is already becoming increasingly apparent.
For additional insights and real-world perspectives, tune in to LiSTEN LiSEC, podcast for the glass industry, season 2 - Deep Dives!