When a glass production plant suffers from chronic energy losses and spiralling operating costs, the answer is not routine maintenance. It’s a radical technological transformation.
That is exactly what Glass Service Italy delivered in India.
Starting from a traditional air/gas heating system—outdated, energy-intensive and difficult to control—the Glass Service Italy team designed and executed the complete conversion of a Tandem Forehearth to oxy-gas technology, working on an existing, operational structure.
Nothing was left to chance. Every section of the fore-hearth channel was recalculated using advanced 3D simulations, which determined the optimal positioning of the burners at a constant pitch of 250 millimetres. This density level ensures precise temperature control along the entire path of the molten glass, a degree of accuracy that conventional systems simply cannot match.
The demolition and reconstruction phase was managed with millimetre-level precision: only the structurally necessary components were replaced, minimising plant downtime and keeping intervention costs under control.
Once commissioned and running under stable conditions, the data confirmed and exceeded the design projections:
- -60percent in Natural Gas consumption compared to the previous system
- Absolute thermal stability throughout the fore-hearth
- Measurable and visible improvement in glass quality
These are not theoretical projections. They are real figures, measured on a live production plant.
A project of this complexity is never achieved through technology alone. The success of this intervention is the result of the synergy between Glass Service Italy’s specialist engineers and the local Indian workforce, a collaboration that turned a demanding engineering challenge into a benchmark of industrial excellence.
Because behind every energy-saving figure, there is always a team.