FIND OUT OUR TECHNOLOGIES
We have glass tempering equipment for all business needs. We have been working alongside craftsmen, small, medium and large companies for more than sixty years. Our quality and professionalism is recognized worldwide.
WITH OUR TECHNOLOGICAL INNOVATIONS, WE PROVIDE CUSTOMIZED SOLUTIONS.
The numerous patents we have filed are the result of the most technologically advanced solutions that we adopt for our machines and their particular functions. On this page you can learn more about the main technologies used in our machines.
POWER SAVING SOFTWARE
All our plants are managed by an intelligent software focused on increasing performance and not only on thermoregulation.
Thanks to this software we are able to regulate the plant (responsive changes in thickness, better performance). each kw is used to its maximum potential (very low energy dissipation).
Saving energy is just one of this software advantages.
In fact besides consume reduction we can mention:
optimizes the performance of even the least experienced operator
optimizes the quality of the final product as it is responsible for how the glass is processed.
optimizes consumption peaks (less expensive electrical system costs).
INTELLIGENT HEATING ZONE
The Multi-zone control system allows both the lower and upper heating chambers to be divided into many small independent zones, each equipped with their own heating element and thermocouple. Everything is managed in a completely automatic way by sophisticated software developed by our team of engineers. This happens through the numerous sensors positioned inside and outside the furnace. Complex optimization algorithms implemented within the software allow the system to automatically recognize which areas of the furnace are occupied by glass and at what percentage. As a result, only the portions of the furnace that are actually occupied by glass are lit and only when it is required. With this system we obtain greater precision and containment of current peaks by reducing the deviations between the average power and the peak power, ensuring an intelligent use of energy and an optimal and precise control of the oven temperature.
OPTIMIZED CONVENCTION PROCESS
The innovative eco convection system, also managed by the intelligent software, is based on the same functioning of the multi-zone control; since it recognizes the position of the glass inside the heating chamber and is fractioned, it allows us to use the hot air in only the exact portion where the glass is located and in the required percentage, obtaining a double benefit: a convection system of the latest generation focused on the glass actually present in the heating chamber, so as to obtain a higher quality. All this with incredibly lower consumption.
OPTIMIZED AIR CHARGE STUDY
Our team of engineers, after having completed studies on the complex thermo-fluid, has allowed us to make important modifications, especially when it comes to the hardening and cooling area, with the aim of significantly reducing pressure loss and consequently energy. Thanks to these studies we were able not only to reduce energy consumption even more, but especially the consumption peaks during the process.
HIGHLY RESPONSIVE FURNACE STUDY
An accurate study of materials and shapes allows us to have a very low thermal inertia inside the heating chamber. The entire heating chamber is built with special materials (strictly non-toxic) with low mass and little absorption. This gives the furnace great reactivity and allows it to adapt quickly to different work requirements.
JUST IN TIME IGNITION FROM 20° TO 680° IN 1H
Quick start (just in time) from 20°c to 680°c in 30 minutes.
It will be possible to turn off the plant completely every day = zero unproductive costs
This characteristic is conferred by the use of low absorption materials and a contained thermal mass inside the furnace, which is made in such a way as to be able to absorb high and continuous temperature excursions. The use of special materials, together with effective technological solutions implemented in the construction of the “heating chamber” section, allow to reach the working temperature of about 680°C starting from room temperature (about 20°C) in 60 minutes. This means that it will be possible to completely switch off the plant every day. On the first day of switch-on, the oven will reach the operating temperature in about 60 minutes, while on the following days about 30 minutes will be sufficient. The rapid start-up system allows our customers to use the machinery only when they really need it, in this way there is a significant reduction of semi-finished products in stock or on the move and at the same time unproductive costs are reduced to zero. The machinery is specially designed to ensure daily shutdown, so it will not be compromised at all, nor will it suffer any damage or acceleration of wear. There will not be any problem concerning the dilatation of the components inside the furnace nor the classic chalking of the insulation materials.
RESPONSIVE THICKNESS SYSTEM
Maximum Flexibility of use.
Responsive thickness changes = zero waiting time and zero unproductive costs.
Thanks to the intelligent management software and to the constructive peculiarities of the heating chamber, our plants are very fast and flexible when adapting to the production needs of the glassworks, thus allowing to change the thickness of the load in a consecutive way and without wait times. In this way, it is the plant that adapts to the production needs, automatically changing the process parameters, thus allowing our customers to offer a timely and immediate service, eliminating the long waiting times for thickness change typical of obsolete furnaces for glass tempering.
POWER SAVING UP TO 70% COMPARED TO COMPETITORS
Reduction of the electric system. Electric system costs up to – 70% compared to our competitors.
Our plants boast the lowest energy consumption in the industry, estimated at about -50% compared to our competitors, so even the electrical system needed to power the oven will be reduced, thus leading to significant cost savings.
97% ANISOTROPHY REDUCTION
As it is well known, iridescent birefringent zones, the slang term being “tempering spots”, are originated by an uneven heating of the glass inside the furnace or by a concentrated cooling in zones that generate a slightly different tension along the glass surfaces. Although it is impossible to eliminate 100% of the anisotropy, all Mazzaroppi plants, thanks to the automatic multi-zone control and to the eco convention system governed by the intelligent software 4.0, are able to minimize the zones with differential temperature. Relying on this sophisticated heating system that focuses only on the glass panes actually present inside the plant, and thanks to a particular handling of the glass itself, we were able to achieve incredible results up to a decrease of 97% of anisotropy.
EDGE LIFTING REDUCING SOFTWARE
The term Edge lifting means the deformation present on the sides and/or corners of the glass due to the non-optimal management of the heat between the upper and lower surface of the glass sheet. Thanks to the precise automatic multi-zone control and to the intelligent software that recognizes in real time the position of the glass inside the heating chamber, we are able to heat homogeneously the glass sheet on both surfaces. Thanks to this management, so precise and dedicated to each individual glass sheet, we can significantly minimize the phenomenon of edge lifting.
EXTRA SAVING MAINTENANCE
In the design of the machines, numerous measures have been implemented to ensure easy and infrequent maintenance.
All the materials mounted on the plant are of European origin and have been carefully chosen so as not to require major maintenance activities. In addition, thanks to a project specifically designed to minimize downtime resulting from maintenance activities, it will be possible to carry out these activities very quickly and easily, affecting as little as possible the productivity of the plant.
Maintenance-free solutions include, for example, reducers, motors and gearboxes. The fans of the hardening and cooling sections will be driven by AC electric motors, which compared to the more obsolete DC motors are subject to significantly less wear and tear (such as for the brushes and the rotor) and require much faster and less frequent maintenance checks.
EUROQUALITY – A/C motors and all the best European equipment
EUROPEAN QUALITY MATERIALS
AC electric motors (more modern and less problematic)
Maintenance free gearboxes, motors and bevel gearboxes
Design assembly to minimize downtime.
UNIQUE REMOTE CONTROL REAL TIME ASSISTANCE
Moreover, all our machines are connected via internet, through an innovative virtual assistant system, to our operations center where a team of engineers is constantly at the service of our customers to solve any problems remotely, being able to connect in real time to the plant and having the possibility, in agreement with the customer, to intervene promptly.
USER FRIENDLY FURNACE, NO SPECIALIST NEEDED
Mazzaroppi’s plants are governed by the intelligent software 4.0, a system of the latest generation created in order to increase the performance and the efficiency of the machinery without the use of highly specialized personnel. After noting over the last decade that one of the problems encountered by our customers was that of finding specialized operators who were able to use the plant at its best, we decided to create a software 4.0, which automatically makes many of the adjustments and tricks to perform the hardening process at its best, and which previously would have fallen on the skills and experience of the operator.
All this series of automatic operations makes easier the work of the operators at the machine, who will not be busy to manage the process parameters but they will simply have to carry out the recipes change and supervise the correct operation of the plant, checking few but important parameters
AUTOMATIC AND REAL TIME REPORTS OF EACH PROCESS
At the end of each glass load, the system will generate a report that will connect the temperature of the chambers at the end of the heat treatment, the exposure times at these temperatures, the positions of the conveyors and the air pressure in each cooling section. All this will allow us to keep the plant under control from the point of view of functionality, but above all it will be possible to keep track of the process repeatability.
40% VALUE GUARANTEED AFTER 10 YEARS
The machinery is durable over time thanks to the care of all the elements that make up its accurate construction. We use only CE certified materials and, normally, after 10 years of use, our machinery has on the market a residual value of about 40%. An excellent investment for those who choose us.
ROLLER WAVE INTELLIGENT SETTING
Thanks to the intelligent software 4.0 we have developed an accurate movement of the glass with continuous variation that adjusts itself automatically, moreover the use of special servomotors allows us to manage acceleration and speed of the glass plates that vary automatically depending on the type and thickness of the same ensuring a significant decrease in the phenomenon of roller wave.