Italian identity; international presence and focusAfter almost 40 years of company history and important developments, Forel continues to take its market sector by surprise at each trade fair, And glasstec was no exception. A series of developments, new entries and the idea of yet more to come give this company the push to be – as its slogan says - ‘One step above the rest’.

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Forel:

Thanks to its Italian identity, synonymous with the quality and

reliability of its products, Forel has, over the years, become recognized at in-ternational level, for both design and development of automation in the flat glass industry.Innovation and research as a philosophy which, today, gives Forel ‘a step ahead’ in the global market. In fact, ‘One step above the rest’ is the slogan the company used to represent itself at glasstec 2014, where it exhibited numerous new products and updates to its automation range.

CONTINUOUS GROWTH, DEVELOPMENTS AND EXPANSIONFounded in 1976 by Fortunato Vianello, to this day still at the helm of the company, Forel has two Italian-based produc-tion facilities in Vallio di Roncade (Treviso) and Meolo (Venice) and two international branches: Forel North America and Forel Russia, employing a workforce of about 150

people. The Venetian com-pany is now present on five continents, developing business and exporting its own technology and Italian engineering dynamism to over 55 countries.Fortunato Vianello, sole company director, provides vast experience and meets with new employees, re-ceiving ideas, various local market trends and infor-mation indispensable to Forel to move towards fu-ture objectives. “Today we are in a positive phase which confirms and impro-ve the trend of recent years. We will continue a strategy of growth and development with the aim of consoli-dating the Italian market and markets abroad with Forel facilities and services.The two sales offices and technical assistance in Russia and the United Sta-tes - continued Fortunato Vianello - were a choice which immediately show-ed themselves to be win-ners. Small and large reali-ties which also work three shifts a day, must never stop; our new local service centres naturally offer: free telephone support in the

local language, spare parts and personnel trained in Italy according to training programs and periodic updates. A value consolida-ted by the Forel philosophy maintains the entire pro-duction chain and know-how internally at the Tre-viso facility, enabling the company to oversee, and above all, have access to all the resources necessary for the development of pro-totypes, customization of orders and management of after-sales, guaranteeing to the customers the full sup-port of their projects.

CUSTOMIZATION TO THE UTMOST“Our product has never been mass produced but rather designed and built ‘customized’, according to different needs. This is possible only through managing, from within our Italian facilities, the entire production pro-cess,” Fortunato Vianel-lo wished to highlight. “We have also been able to observe that the de-centra-lization of work by some of our competitors has not

always been the

right choice for the success and ‘health’ of the glazing industry. This movement abroad has, in fact, brou-ght to the market solutions of standard economic li-nes, which tie the client to the realization of mass- produced low quality pro-ducts.We, instead, aim to realize the projects and the ambi-tions of clients who, thanks to their professionalism and our machinery, are able to distinguish themselves for the production of glazed panels of a high quality and increased technical perfor-mance.”

EXCLUSIVE VERTICAL DRILLING AND MILLINGSince its introduction, in 2008 the EM grinding ma-chine has been installed in 27 countries, with customer satisfaction daily thanks to Forel’s flexibility solution.A success beyond all expec-tations, built on day after day with customers who ap-preciate the opportunity to grind sheets in vertical and in self-learning mode without affecting the low-E coating, as well as immediate ma-nagement of the change in the type of glass processing (laminated, float, low-E,

Vertical Machines Drilling and Milling (DM) - Grinding (EM)

G L A S S P R O C E S S I N G M A C H I N E R Y

templates) and finishing (se-aming, grinding, polishing).Initially designed for wor-king the glass intended for use in architecture, the grin-der today is used not only at the beginning of the IG line but also as a unit for prepa-ring the glass to be tempe-red, laminated and/or screen - printed.A further analysis has led Forel to design the latest update, which was presen-ted during glasstec 2014, where the company laun-ched the new Vertical Mil-ling & Drilling Machine to complete its range of finishing machines, kee-ping processing in-line and vertical, ensuring high pro-ductivity and reducing set-up time.DM is Forel’s new seri-es of high performance Drilling & Milling machines with two opposing heads and two groups of tools with six positions for the execu-tion of holes, notches, and flares on glass plates for the mounting of hinges, sup-ports, locks.Each spindle is served by an exchange tools in six posi-tions and through a rotary joint, allows the passage of water inside to cool the tool during working pro-

cess. DM is characterized by its system of moving and locking the glass during the process steps which allows a precise machining without ever touching the front side of the plates, ma-king it ideal for the proces-sing of low-E glass.Available in stand-alone or integrated format, with EM vertical edgers, the concept of processing in separated phases also allows a signifi-cant increase in productivi-ty, because all the units can work at the same time.Module numeric control

panel with touchscreen, software interface easy and quick to use with libraries of break-ins and import of DXF files.

LAMINATION LINE – TOP TECHNOLOGYThe Forel lamination line Art. LL is designed speci-fically to satisfy the ever-increasing demand for lami-nated glass. Designed for standard and personalised productions, the Jumbo line is able to pro-cess large dimension sheets 3210 X 6000 millimetres.

Today’s laminated glass market is always in need of more complex products high quality standards.Utilizing the best technology and its long experience ac-quired over many years of qualified research and con-tinued development, Forel has designed a lamination range which satisfies the highest standards of pro-duction, while, at the same time, being friendly to the environment, guaranteeing considerable energy savings.The Forel lamination range utilizes two furnaces/kilns

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Lamination Line

High Performance Sealing Robots

to heat the glass and PVB. The pressing unit is equip-ped with two rollers presses of 360 millimetres of diame-ter of particular shapes.This system ensures greater pressure moving from the centre of the glass outwards to guarantee that all the air is expelled from the glass ‘san-dwich’.Thanks also to the electrical-mechanical control system of the rollers, it can be adap-ted to the different types and thicknesses of glass being processed. The efficiency of the furnaces/kilns is ensured thanks to an innovative up-per and lower infra-red irra-diation heating system.This system of irradiation is customizable and each resi-stor is automatically control-led. Through sensors which constantly control the glass temperature, it is possible to activate or switch off some resistors and as a result of the innovative convention system, the uniformity of temperature across the enti-re surface of the sandwich is guaranteed.This heating system, com-bined with an efficient in-sulation system ensure minimum thermal energy dispersal, maintaining the highest energy performance across the entire line.Forel’s range has been stu-died to guaranty the maxi-mum ease of use, thanks to simple but efficient solutions such as the user interface with touch-screen display and recipe recall.The lamination range can work with all types of glass:

tempered, low-E, acid etched, screen-printed or clear, and any type of PVB.

SEALING ROBOT – HIGH PERFORMANCEForel takes another step forward, updating its offering of automatic sealing robots. The new SR, is an extremely flexible machine presenting complete innovation from a technological point of view, guaranteeing exceptional performance in terms of pro-

ductivity and quality of the finished product, capable of sealing double-glazed, triple-glazed and even quadruple-glazed glass. It can seal stepped glass on all four sides and also apply a thin layer of product to cover the off-set surfaces, rende-ring the process automatic and uniform.Important technical innova-tions have been applied to the most delicate points of the machine.

Forel’s first area of major investment was, in fact, the modification to the sealer head, installing the product dosers directly to it, and suc-ceeding in the achievement of excellent results in the pro-ductive capacity.The mounted dosers, in fact, permit the improvement of pressure control of the sea-lants, guaranteeing optimum results in corner seals, mo-reover permitting a constant production even changing the thickness of the spacer bar frames and the depth of the cavities into which the sealer is applied. In the case where the clients are required to work with two different types of sealant, the sealer SR is equipped with a semi-automatic system of dosers exchange. The changeover from one product to another has been radically simplified and made faster. The entire product circuit, starting from the drum to the sealer head is uniformly heated to a tempe-rature of about 30°C.This permits the maintaining of a constant viscosity of the sealants, resulting in consi-stent quality of production over the work shift. Further-more, using a product at a controlled temperature, al-lows low-pressure operation of the circuit, reducing the strain on the relative compo-nents. Forel is always attenti-ve to the needs of the client, often experiencing the neces-sity to optimize the available space where the system is to be installed, and for which this aspect of the new sealing robot has been considered. In

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Double Doser

Turning Conveyor

fact, the pumping units of the sealants have been integrated with the rear structure of the machine, reducing to a mini-mum the space required and simplifying the removal and replacement of new drums.The conveyor system is a guaranty of safety and relia-bility in that it always remains connected and compact wi-thout ever leaving dange-rous empty spaces under the glazing unit.One vertical move-ment controls: the total thickness and offset up to 100 millimetres, suppor-ting a weight of 450 ki-los per linear meter. Last, but not least, to underli-ne the level of reliability, Forel also supplies a dia-gnostic Software/Hard-ware system. This system includes the signalling of

alarms with photos and de-scriptions on the command panel. In this way, the ope-rator can have information about the problem and solu-tion in the most efficient and immediate way. The machine is also supplied with a moni-toring system via Internet for real-time connection to Forel’s service department.

A SPECIFIC SOLUTION FOR TRIPLE GRAZINGThe vertical turning station is one of the most apprecia-ted accessories in the mar-ket, and is experiencing im-portant growth in requests for triple glazed glass.It allows the reversal of the face of the glass in order to guide the low-emission coating into the desired position to facilitate the production of two or more

sheets of glazed panels.This solution can be used as both a classic linear confi-guration of the system or as an angular station (main-taining, without changes, the inversion properties of the face of the glass) accor-ding to clients’ needs.An angular configuration enables to position a pro-cessing line in the available space without interrupting the production cycle. The section joins the machines forming an angle of between 0° and 180° (usually 90°), performing both clockwise and anti-clockwise rotations.In the vertical turning sta-tion the conveyor system works by rollers on which the lower edge of the she-et is supported. The rear of the glass or glazing unit is supported by idle rollers with special anti-finger-print protective seals. The stations have a unique, singular character-istic: they do not slow down the

production line, but rather optimize it, maintaining a constant working rhythm thanks to the perfect syn-chronisation of the other machines which comprise the Forel line.The length of the moving sheet may also exceed that of the turning station which is only thanks to a patented handling system which is exclusive to Forel automa-ted solutions.

PROFILE BENDING MACHINE - WITH THE EXCLUSIVE SMART ARMThe new spacer-bar ben-ding machine PBA632 with Smart Arm system was introduced to the market for the first time at Vitrum 2013 in Milan.The new PBA is capable of bending both aluminium bars and warm edges, and has been introduced to sa-tisfy the growing needs of the market for a machine

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capable of bending both aluminium and warm edge bars for the production of insulating glass.The evolution and com-mercial affirmation of these warm edge products often made of combined mate-rials such as steel and pla-stic, has pushed Forel to develop new solutions and innovative technologies founded on its long expe-rience in the glazing indu-stry. The new Smart Arm is an innovative Forel system which accompanies and supports the warm edge spacer during the bending process, thus avoiding ro-cking movements.The Smart Arm system al-lows for superior bending speed, in that it holds and supports the spacer during the entire process, avoiding any inertia or friction which could otherwise cause the deformation or breakage of

the medium or large frames due to their own weight.In this way, the quality of the resulting bending meet all the technological featu-res required by recent re-gulations and the exacting standards of customers. Each angle of the spacer frame, after bending, is automatically calibrated, thanks to the system which controls movement of the bending grip, so as to avoid any deformation in width, leaving each angle at the exact size with respect to the nominal width of the frame in use. The new PBA is equipped with a conti-nuous frame feed system which contributes to incre-ased productivity of the ma-chine compared to previous models; also allowing for a reduction in total length of the machine by about two meters.A further benefit is obtai-

ned by the new frame cut-ting system, which permits a clean, precise cut using a single blade for different frame types. This blade is composed of a special me-tal alloy, which does not re-quire sharpening over time and guarantees an incom-parable lifespan.The PBA is supplied with a 12 stock position designed to provide an ergonomic support surface to facilitate the loading of the frames.

VERTICAL CUTTING LINE - CONTINUING TO SURPRISE THE INDUSTRYThe continuing growth in request and need for la-minated glass, and Forel’s intuition to create a verti-cal cutting line, in long ago 1996, still fulfils a need in the market. The system is composed of a customiza-ble, modular-designed au-

tomatic stock that selects the type of sheet to be made available for processing.Next, the automatic loa-der feeds the table, which thanks to the two vertical bridges completes the opti-mized cutting of the large-format sheets to obtain the desired formats.With respect to a traditio-nal horizontal table, the high level of automation of the line improves produc-tion logistics and operator safety, as operators no lon-ger need to handle the glass sheets; while resulting pro-ductivity is doubled.Today, the numerous in-stallations of this machine around the world have de-creed its important com-mercial success, and this new version introduces components which ensure even higher performance. Updates have been imple-mented such as: coating

remover now available in line, sheet feeder, vertical cutting bridge, conveyor system, mobile bridges, vertical turning station, and software with improved performance in speed and precision. Forel’s exclusi-ve vertical laminated-glass cutting line is the intelligent solution for revolutionizing glass business, simplifying and increasing the cut – the first and foremost opera-tion in glass production processing.

AND IN 2015 -AUTOMATIC SPACER APPLICATORIn 2015, Forel will present its new automatic thermo plastic spacer applicator, which enables to apply hot-extruded thermo plastic along the perimeter of the glass directly in-line with an IG line. This thermo plastic product includes desiccant material and is extruded at 110°-130°C, and is cur-

rently marketed in drums by different suppliers. The main advantage of this technology is the automatic applica-tion in line which does not require the classical rigid metal spacer processes: cutting, bending, loading desiccant, butyling and ap-plication on the glass pane. This allows a significant re-duction in manpower and simplification of the pro-cess and logistics, and, in the meantime, an increase in operator safety.Adhesion to the glass is stable over time thanks to the rheological characteri-stics of the material (polyi-sobutylene-based), which guarantees a perfect vapor barrier and the safe sealing of the chamber with the aim of retaining the insulating gas inserted.The secondary sealing is maintained, with the possi-

ble use of the common types of sealant (polysulphide, polyurethane, silicone).Production management is greatly simplified: the ma-terial is supplied in 200 liter drums and ready for extru-sion, change of thickness required in different orders is handled directly by the software and double and/or triple glazing units with different spacer thickness can be processed in the two chambers, structural stepped units with offsets up to 100 millimetres, to use the Forel’s shape data-base for IGUs, to make up structural front shop large size units (6,000 x 3,200

millimetres). The overall thickness of the double gla-zing unit is calibrated.This new proposal expands the company’s offer regar-ding spacer automation, a range of solutions con-tinuously updated to sa-tisfy the requirement of our customers who belie-ve in the evolution of the insulating glass with high energy efficiency.

G L A S S P R O C E S S I N G M A C H I N E R Y

Forel Spa

Via per Monastier 431056 RoncadeTreviso - ItalyTel: +39 – 0422 – 840507Fax: +39 – 0422 – 840900www.forelspa.com

Automatic Spacer Applicator

Profile Bending Machine