7 tips for your insulating glass business Start Up.

How to start a new insulating glass production business?

How to start a new insulating glass processing business?  It maybe very complicated, and seems too many things to do. However, it is not so difficulty after your reading and follow the steps and suggestions below.

What is insulating glass?

Let’s see what Wikipedia says below?

Insulating glass (IG), more commonly known as double glazing (or double-pane, and increasingly triple and quadruple glazing/pane), consists of two or more glass window panes separated by a vacuum or gas filled space to reduce heat transfer across a part of the building envelope.

Insulating glass units (IGUs) are manufactured with glass in range of thickness from 3 to 10 mm (1/8″ to 3/8″) or more in special applications. Laminated or tempered glass may also be used as part of the construction. Most units are produced with the same thickness of glass used on both panes[citation needed] but special applications such as acoustic attenuation or security may require wide ranges of thicknesses to be incorporated in the same unit.

Now it is clear that the insulating glass (insulated glass) is the glass processed for windows and doors and buildings, so what’s the necessary tips for start a insulating glass factory?

7 tips below for insulating glass processing company:

1.       Where to buy insulating glass machine? 

2.       Which insulating glass machines are necessary? 

3.       Which insulating glass machines are not necessary? 

4.       What are the insulating glass production consumables? 

5.       Insulating glass production cost?  Machine after service and maintenance cost?

6.       Insulating glass workshop size and production process.

7.       Production key point and insulating glass standard.

1. Where to buy the insulating glass machine?

 1.1 Germany. BYSTRONIC LENHARDT GMBH.

 1.1.1 FINNISH OWNER

  As of April 2019, Bystronic glass is member of the Glaston Group.

 1.1.2 Introduction

Bystronic glass is an international brand with globally operating companies that support their customers on site and through own sales and service companies.   

Bystronic glass symbolizes innovation with machinery, systems and services for the processing of architectural and automotive glass focused on tomorrow’s market.

Besides the blue Bystronic glass  for glass processing,

there is red Bystronic focus on laser cutting, bending machine.

1.1.3Cut the B.S:

1. Vertical insulating glass production line

2. Butyl extruder machine

3. Auto sealing robot.

4. Sealant spreading machine

5. Auto spacer bending machine

6. Auto desiccant filling machine

7. Low-E deleting machine

8. TPS- thermal plastic spacer application machine

1.1.4 Histroy

Bystronic glass based in Buetzberg (Switzerland) looks back upon a successful 50 year company history.

1.1.5 Contact

Website: www.bystronic-glass.com/en

Global contact: www.bystronic-glass.com/en/contact/

1.1.6 Advantage

3300mm×6000mm jumbo size insulating glass line(max.3300 x 18000 mm)

Top technology

Professional

Good quality

1.1.7 Disadvantage

High price

Expensive service

Expensive spare parts

Not all machines running the same good smoothly

1.1.8 Suggestion

  Good choice for those company who has lots of money, or public company that ROI is not their priority.

  Make sure machines are not manufactured in China, at lease price cannot be same as European.

  Check the brand parts list, Originally Siemens parts.

  Keep research of other suppliers if you want co

st effective insulating glass machine.

1.2. Austria. LISEC AUSTRIA GMBH

1.2.1 Introduction

   Manufacturer of flat glass processing machinery in Austria. LiSEC has been producing glass processing machines, offering innovative single and system solutions in the field of flat glass processing and refining.

YOUR GLASS PROCESSING MACHINE IN AUSTRIAN TOP QUALITY

The glass processing machines are manufactured in Austria. Our customers benefit and trust LiSEC worldwide. LiSEC has an export quota of over 95%. The hallmarks of our glass processing technology are durability and longevity.

1.2.2 Cut the B.S:

1. Vertical insulating glass production line

2. Butyl coating machine

3. Auto sealing robot.

4. Sealant spreading machine

5. Auto spacer bending machine

6. Auto desiccant filling machine

7. Low-E edge deletion machine

8. Thermoplastic Spacers (TPA) application machine

 9. Laminated glass line

 10.Tempering glass line

 11. Glass cutting line

 1.2.3 History

  Over 50 years.

 Contact

  Website: www.lisec.com

  Contact: www.lisec.com/about-lisec/locations-contact/

1.2.4 Advantage

One-stop solution for glass processing

Easy for supplier management

3300mm×6000mm jumbo size insulating glass line(max.3300 x 18000 mm)

Top technology

Professional

Good quality

1.2.5 Disadvantage

High price

Expensive service

Expensive spare parts

1.2.6 Suggestion

  Top glass processing company

  Modern glass management solution

  Good for the rich company

  Check not the basic line, not high technology, but high price.

  Keep research of other suppliers if you want cost effective insulating glass machine.

1.3. Italy. FOREL SPA 

1.3.1 Introduction

MACHINERY FOR THE FLAT GLASS & DOUBLE GLAZING INDUSTRIES

1.3.2 Cut the B.S:

1. Vertical insulating glass production line

2. Manual butyl extruder

3. Auto sealing robot.

4. Two component extruder sealant

5. Automatic profile bender

6. Cork pads applicator

7. Automatic flexible spacer applicator

8. Vertical cutting and storage

9. Edging machine

10. Laminating glass line

1.3.3 History

Since 1976

Contact

Website: www.forelspa.com

Contact: www.forelspa.com/agencies

1.3.4 Advantage

3300×9000mm jumbo size insulating glass line

European market

1.3.5 Disadvantage

High price

Expensive service

Expensive spare parts

Not so high-tech compared.

1.3.6 Suggestion

European customers

Not good choice out of European

 Keep research of other suppliers if you want cost effective insulating glass machine.

1.4. China. Hanjiang, TENON, DETEK, WEILI

1.4.1 Beijing Hanjiang Automatic Glass Machinery Equipment Co., Ltd.

1.4.1.1 Introduction

Insulating glass machine manufacturer, official introduction B.S.

1.4.1.2 Cut the B.S:

1. Automatic insulating glass line

2. Butyl extruder machine

3. Sealant spreading machine

4. Spacer bending machine

5. Desiccant filling machine

6. Auto sealing robot

7. Low-E deleting machine

1.4.1.3 History

Since 2002

1.4.1.4 Contact

Website: www.hjglass.com.cn

1.4.1.5 Advantage

Export many countries

China machine market share in middle east and European market

Not bad quality

1.4.1.6 Disadvantage

Too high price

High sales and management cost

Overseas market

No domestic market

Make money from foreign customer only

No mass production cost advantage

Not enough service ability

1.4.1.7 Suggestion

 Nearly same price as Bystronic/Lisec, but not so good quality or high-tech technology.

 Keep research of other suppliers if you want cost effe

ctive insulating glass machine.

1.4.2 TENON(BEIJING)EQUIPMENT CO.,LTD

1.4.2.1 Introduction

Insulating glass machine manufacturer, official introduction B.S.

1.4.2.2Cut the B.S:

1. Automatic insulating glass line

2. Butyl extruder machine

3. Sealant spreading machine

4. Spacer bending machine

5. Desiccant filling machine

6. Auto sealing robot

7. Low-E deleting machine

8. Flexible spacer applicator

9. Horizontal seaming machine

1.4.2.3 History

Since 1988?   Really?  Found in 2002. 

1.4.2.4 Contact

Website: tenon.com.cn

1.4.2.5 Advantage

Butyl extruder machine

Horizontal seaming machine

1.4.2.6 Disadvantage

Little bit high price

Moderate technology

Moderate quality.

Poor service ability

1.4.2.7 Suggestion

 Horizontal seaming machine very good.

 Keep research of other suppliers if you want cost effective insulating glass machine.

1.4.3 Jinan DETEK machine co., ltd

1.4.3.1 Introduction

Insulating glass processing machines manufacturer since 1999.

1.4.3.2 Cut the B.S:

1. Auto online Argon gas filling vertical insulating glass production line

2. Auto sealing robot

3. Auto butyl extruder machine

4. Auto spacer bending machine

5. Auto desiccant filling machine

6. Silicone extruder pump

7. Vacuum glass loading/unloading lifter

1.4.3.3 History

Found in 2016, technical develop engineer experience since 1999, enough experience and training from Bystronic.

1.4.3.4 Contact

Website:  www.detekmachine.com

1.4.3.5 Advantage

High-tech technology

Same steps with European machine suppliers

Stable quality

Cost effective machines

Adequate service team

One year service parts storage

24/7 reachable sales technical service

1.4.3.6 Disadvantage

Not so famous

Not so many reference in overseas market.

1.4.3.7 Suggestion

 Good shot for a try.

 Good quality, good technology, good price.

 Keep research and maybe it’s good choice.

1.4.4 Jinan Weili Machine Co.,Ltd

1.4.4.1 Introduction

Insulating glass processing machines manufacturer

1.4.4.2 Cut the B.S:

1. Insulating glass production line

2. Butyl extruder machine

3. Sealant spreading machine

4. Auto spacer bending machine

5. Auto desiccant filling machine

6. Auto sealing robot

7. Auto low-E deleting machine

1.4.4.3 History

Found in 2001

1.4.4.4 Contact

Website: www.weiliglass.com

1.4.4.5 Advantage

Reasonable price

1.4.4.6 Disadvantage

No technology develop engineer

Not enough technical support

1.4.4.7 Suggestion

 Good choice for some windows and doors manufacturer.

 1.5 USA. GED, ERDMAN

1.5.1 GED Integrated Solutions. 

1.5.1.1 Introduction

GED is a Worldwide Supplier of fully-integrated insulating glass (IG), vinyl window and door fabrication systems and software solution systems, as well as the revolutionary Intercept® 2.5 Warm Edge spacer frame production system.

1.5.1.2 Cut the B.S:

Intercept® horizontal insulating glass production line

Windows fabrication machine

1.5.1.3 History

Since 1977

1.5.1.4 Contact

Website: www.gedusa.com

www.gedusa.com/contact/

1.5.1.5 Advantage

Automatic and fast

Over 2000 units per 8-hour shift.

Windows solution

1.5.1.6 Disadvantage

Very expensive

Heavy investment

Too much spacer occupation

Horizontal

1.5.1.7 Suggestion

 Good choice for those windows manufacturer in North America.

1.5.2 Erdman Automation Corp.

1.5.2.1 Introduction

Windows and doors machines and insulating glass machine.

1.5.2.2 Cut the B.S:

1. Erdman High Speed Parallel Process Flexible Foam Spacer IG Line

2. Horizontal secondary sealer

3. Window glazers

1.5.2.3 History

Found in 1993

1.5.2.4 Contact

Website: www.erdmanautomation.com

1.5.2.5 Advantage

Super spacer or quanex spacer

Automatic

Suitable for windows makers

1.5.2.6 Disadvantage

Slow

Horizontal structure occupy space

High price

1.5.2.7 Suggestion

Good choice for window makers in north America

 1.6 Turkey. CMS, BEST Makina

1.6.1 CMS machinery

1.6.1.1 Introduction

Founded in Istanbul-Turkey (1995), CMS Glass Machinery continues to design, produce, market and offer technical service for Float and Laminated Glass Cutting Lines and Machines, Glass Washing Lines and Machines, Glass Sealing Robots and Extruders, Spacer Frame Processing Machines, Glass Processing Machines, Laminated Glass Production Lines and Flat & Bending Glass Tempering Furnaces.

1.6.1.2 Cut the B.S:

1. Insulating glass machine

2. Laminating glass machine

3. Tempering glass machine (Purchased from Henan company)

1.6.1.3 History

Found in 1999

1.6.1.4 Contact

Website: www.cmsmachine.com

1.6.1.5 Advantage

Asia-European machine

One stop shop

1.6.1.6 Disadvantage

High price

No high-tech technology

Not professional

1.6.1.7 Suggestion

 Keep research of other suppliers if you want cost effective insulating glass machine.

1.6.2 Best Makina Sanayi ve Tic. A.Ş.

1.6.2.1 Introduction

BEST MAKINA , as a professional IGU machinery supplier, keeps pioneer position in Turkiye and find a place among worldwide known suppliers.

1.6.2.2 Cut the B.S:

1. Insulated glass production line

2. Horizontal butyl extruder

3. Two component hydraulic extrusion pump

4. Automatic two component extruder

5. Automatic spacer bar bending machine

6. Automatic desiccant filling machine

1.6.2.3 History

Start IGu machine in 2008.

1.6.2.4 Contact

Wenbsite: www.bestmakina.com

1.6.2.5 Advantage

Save freight for Middle East market

1.6.2.6 Disadvantage

High price

Normal technology

1.6.2.7 Suggestion

Keep research of other suppliers if you want cost effective insulating glass machine.

2. Which insulating glass machines are necessary for me?

2.1 Insulating glass production line with Argon gas filling.

2.2 Secondary sealant sealing robot.

2.3 Primary butyl sealant extruder machine.

2.4 Aluminum spacer bending machine.

2.5 Auto desiccant filling machine

2.6 Glass unloading vacuum lifter after insulating glass sealing robot.

3. Where to buy the insulating glass production consumables?

 3.1. Glass

Float glass, China, Malaysia, and local market etc 

1. NSG group/ Pilkington  http://nsg.com  www.pilkington.com
2. Asahi Glass Co., Ltd. www.agc.com  www.aisglass.com
3. Saint-Gobain www.saint-gobain.com 
4. Guardian Industries www.guardianglass.com
5. Tempering glass, China, local market
6. Laminated glass, China, local market

 3.2. Spacer

3.2.1 Aluminum spacer

1. Austria Lisec www.lisec.com/spacer/products/
2. USA Allmental www.allmetalinc.com
3. Turkey Tek Mental www.tek-metal.com
4. Lisec Shanghai www.lisecasia.com
5. China supplier

3.2.2 Warm edge spacer

1. USA Quanex Edgetech/Super spacer  www.quanex.com
2. Switzerland Swiss spacer www.swisspacer.com
3. England Thermoseal www.thermosealgroup.com
4. Denmark Rolltech www.rolltech.dk
5. Germany Technoform www.technoform.com
6. Italy Thermix  www.thermixspacer.com
7. TPS
8. TPA

 3.3. Butyl sealant

1. Germany kommerling     www.koe-chemie.com
2. USA   H.B.FULLER  www.hbfuller.com
3. Italy Fenzi Group SpA  www.fenzigroup.com
4. China Baiyun   www.chinasealant.com     www.china-baiyun.com
5. China Zhijiang www.chinazhijiang.com
6. China Guibao www.cnguibao.com
7. China HOT www.jinanhot.com

3.4. Secondary sealant

  3.4.1 Polysulfide

1. Italy Fenzi Group SpA  www.fenzigroup.com
2. Germany kommerling     www.koe-chemie.com
3. China Baiyun   www.chinasealant.com     www.china-baiyun.com
4. China Zhijiang www.chinazhijiang.com

  3.4.2 Silicone sealant

1. USA Dow Corning www.dowcorning.com
2. USA GE   www.siliconeforbuilding.com    www.gesilicones.com
3. Italy Fenzi Group SpA  www.fenzigroup.com
4. Germany kommerling     www.koe-chemie.com
5. China Baiyun   www.chinasealant.com     www.china-baiyun.com
6. China Zhijiang www.chinazhijiang.com
7. China Guibao www.cnguibao.com
8. China BAOLONGDA www.baolongda.net

  3.4.3 Polyurethane

1. Italy Fenzi Group SpA  www.fenzigroup.com
2. Germany kommerling     www.koe-chemie.com

3.5. Molecular sieve

1. Italy Fenzi Group SpA  www.fenzigroup.com
2. Turkey Tek Mental www.tek-metal.com
3. China Seily www.seily.com

3.6. Argon gas

  Local market

4. How or to whom can we sell these insulating glasses?

4.1. Own glass or windows business

4.2. Glass processing company

4.3. Windows and doors maker

4.4. Real estate developer

4.5. Furniture makers

4.6. House owner

5. Do you know the production cost for insulating glass?

5.1. Production consumables  .5.2. Labor cost.  5.3.The electrical, water, and compressed air consumption  5.4. Service cost

5.1 Production consumables cost

Name	Qty	Unit price reference	Total price
Aluminum spacer	4m	0.1USD/m	0.4USD
Butyl sealant	0.05kg	5USD/kg	0.25USD
Silicone sealant	0.25Kg (6mm aluminum spacer)	2USD/kg	0.5USD
	0.35Kg (9mm aluminum spacer)	2USD/kg	0.7USD
Molecular sieve	0.1Kg	1.2USD/kg	0.12USD
Corner key	4pcs	0.001USD/pcs	0.004 USD
Straight connector for bending spacer	1pcs	0.05USD/pcs	0.05USD
Argon	25L ( 12mm air gap)	0.001 USD/L	0.0375
		Tota cost	1.3USD/sqm
		Tota cost	1.5USD/sqm

5.2 Labor cost

The whole production line usually needs 3-4 operators(automatic insulating glass production line ), or 6-8 operators(Semi-auto insulating glass production line).

5.3 The electrical, water, and compressed air consumption

1. Power consumption total power 60-80KW
2. Compressed air 1.2m³/min
3. Water consumption 80L/shift

5.4 Service cost

Spare parts or service engineer cost: 2000USD/year

6. Insulating glass workshop size and production process.

6.1 Insulating glass workshop layout and size

There are two options for different insulating glass manufacturer: windows maker, and glass processing company.

Semi-auto or fully automatic insulating glass solution below

6.2 Insulating glass production process analysis

7. Production key point and insulating glass standard.

7.1 How to spread the butyl right? And how is the thickness for secondary sealant?

The secondary sealant depth should be ≥5mm.

Gas filling percent: 85%.

Lifetime of the insulating glass 15-20 years.

7.2 Insulating glass standard

China national insulating glass standard GBT11944-2012
European Standard for Insulating Glass Units EN 1279

Australian/New Zealand Standard™  Insulating glass units  AS/NZS 4666

Finally, shall I invest the insulating glass machine? Or how is the insulating glass trend?

Yes, you need to invest the insulating glass production line and manufacture the insulating glass by yourself. Two reasons: the first one, big profit space compared with buying from other, 30-50%. Secondly, you are the master of fast insulating glass production lead time.

Right now, more than 80% is aluminum spacer insulating glass process machines, with auto sealing robot. In the next 20 years, insulating glass manufacturers and machine suppliers will switch to warm edge insulating glass gradually.

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