SILVERSTAR glass coating, production of thermal insulation and solar control glass

Euroglas has been producing coated glass since 1998. The coating system in Haldensleben was the first to commence operations. Production was launched at the plant in Ujazd, Poland, in 2009.
The installed coating systems mainly process specific dimensions from our in-house production. Their production focuses on thermal insulation layers, but we also offer solar protection and combination layers. Depending on glass type, the system can produce up to 40,000 m² per day thanks to cutting-edge technology and short cycle times. The plant operates in four shifts.


1. Loading

Straddle carriers ensure the system is constantly supplied. Glass panes are positioned on the production line based on four rack positions. We can also process glass panels with a thickness of between 3 and 17 mm as well as formats from 1,800 x 3,210 to 6,000 x 3,210 mm in mixed operation. Standard panes can thus be inserted between panes with specific dimensions.


2. Cleaning

Panes are thoroughly cleaned in the cleaning unit. Brushes rotating on both sides remove the releasing agent prior to input of the glass panes. Extracting releasing agent prior to the actual cleaning process reduces water treatment costs and protects the environment. The water used during production is fully treated to significantly cut our water consumption.
The incoming glass pane's thickness is automatically recorded to guarantee ideal cleaning unit parameters. The cleaning unit only uses desalinated and decalcified water. An integrated water treatment system purifies the mains water accordingly. The water's purity levels are comparable to those of distilled water. Two subsequent zones safeguard surface cleanliness levels required for the coating process.

 

3. Vacuum coating

Coating occurs in high-vacuum chambers. The vacuum system is 78 m long and the production line consists of multiple chambers:
- Input chamber
- Buffer chamber
- Transfer chamber
- Coating chamber
- Output chamber

The coating station represents the nucleus of the system. Glass panes are coated by means of sputtering. The process is also frequently referred to as the magnetron sputter procedure.
Coats are applied to the glass using direct current and medium-frequency technology. The flexible, extendible production line concept - whereby individual coating stations can be repositioned quickly - enables reconfiguration of the system within a very short time. More complex coating systems can therefore also be realised in the future.


4. Process monitoring

Visual inspection of the coated panes is performed using special lighting. This exposes very minor differences in colour.
The reflectance and transmittance spectra are also measured.
Panes are checked across their entire width of 3,210 mm and the silver film thickness is measured to guarantee thermal insulation properties. This is how Euroglas assures compliance with all technical data and a constantly uniform reflection colour of the glass panes it supplies.


5. Stacking

Panes are stacked on five inside loader racks at the end of the production line in 45 second cycles. Here all packaging can be controlled directly from the central master computer. We can stack with the coating facing the rack or facing the suction cups – depending on customer specifications. A conventional float glass pane is always positioned at the start of a glass package to protect the coated panes. The packages are also sealed against humidity as necessary.

Infeed
Load in glass in manufacturing line
Glass cleaning in an washing machine
Glass cleaning in an washing machine
Coating in a magnetron sputter machine
Coating in a magnetron sputter machine
Process control of thermal glass and other coated glass
Process control of thermal glass and other coated glass
Unloading of coated floatglass
Unloading of coated floatglass