MAIN PRODUCTION LINES

1. Cutting line

The cutting line is one of the most modern lines of LiSEC Corporation. The system is automatically operated and allows cutting different shapes of glass. The cutting line consists of following components:


- The storage racks were normalized and numbered so that the system can recognize when taking the glass;
- The mobile overhead crane with rotating suction frame helps to pick up glass easily and safely in the exact position;



- Compartmental storage for glass remnants from optimized glass cutting is automatically moved in and out;



- The tiltable loading and unloading table;
- Cutting tables consist of:
+ Fully automated cutting table: cuts different types of glass such as float, coated, Low – E and laminated glasses;
+ Semi–automated cutting table: cuts small or special shapes of glass.

Thanks to advanced software, the production process can combine different batches of glass in a particular cutting process, thus reducing glass waste. The software also supervises and updates materials and output in order to carry out effective production strategies.


Technical data
Maximal glass size 3300 x 6000 mm
Glass thickness Float glass: 2 - 19 mm
Laminated glass: 2x3 – 2x10mm
Maximal cutting length (Laminated glass) 4600 mm
Maximal cutting speed 120 m/ minute
Capacity 18.000.000 m2/year

2. The automated edge grinding, washing and drying line

This modern synchronous line manufactured by LiSEC Corporation undertakes edge grinding, washing and drying of glass sheets on all four sides in a fully automatic cycle. The grinding process achieves optimal and gentle planning of glass edges within the shortest cycle times and minimizes the quantity of required abrasive materials. The grinding machine uses diamond-equipped wet grinding belts which is able to grind the front and rear side of a glass edges simultaneously.



Technical data
Glass thickness 2 - 19 mm
Minimal glass size 180 x 350 mm
Maximal glass size 3300 x 6000 mm

3. Automatic Bending Machine - Butyl Coating Machine - Desiccant Filling Machine

The machines are responsible for bending, coating butyl and filling desiccants for profile bars to prepare for processing insulated glass:
- Fully automatic bending machine for spacer bars:
This machine is a perfect solution for insulating glass line because of its shorter and simultaneous bending cycles. In the first step, the profiles are automatically fed in, connected and cut to length. The sequential feed device ensures maximum measurement precision in bending. The profile storage magazine provides storage capacity for a large number of profile bars.


Technical data
Minimal glass size 100 mm x 250mm
Maximal glass size 2900 mm x 5200mm
Profile types aluminum, steel, stainless steel, plastic
Profile height 6 - 8,5 mm
Profile width 6 - 24 mm, 8-24mm

In addition, the machine has an adapting equipment which allows bending small frames with the size of 190 x 60 mm.


- Automated butyl coating machine for spacer frames:
+ Butyl extruder for precision butyl coating on both sides of spacers;
+ Sensor-controlled guide rollers ensure optimal stabilization of the frame and thus protect even coating;
+ Opening and closing of the coating nozzles for each frame side are controlled automatically;
+ The coating speed can be set individually.


Technical data
Minimal glass size 100 mm x 120mm
Profile height 6 - 8,5 mm
Profile width 4 - 22 mm, 5 - 23mm, 6 - 24 mm
optional 22 - 40mm, 23 – 41mm, 24 - 42 mm
Butyl nozzle 3 x 2,2mm, 4,2 x 1,5mm

- Automated desiccant filling machine for bent spacer frames
+ The machine fills desiccants automatically for bent spacer frames;
+ The desiccant filling process is simply and automatically carried out for aluminium, steel and plastic frames with different thickness.


Technical data
Profile types aluminum, steel, stainless steel, plastic
Profile height 6 - 8,5 mm
Profile width 6 - 24 mm
Profile length 50 -2500mm

4. The insulating glass line

The insulating glass line of SADO GROUP is one of the most modern productions line provided by LiSEC Corporation. This is a perfect line for manufacturing high-quality double and triple glazings and special insulating glass units with up to 3 steps and gas-filled units (stepped units). SADO GROUP also uses one or more tempered or laminated glass sheets for superior insulating glass. Moreover, the advanced insulating line enables to use special materials to manufacture fire-resistant glass.
The line consists of following components:

+ The automatic and manual bending machines ;
+ The automatic and manual desiccant filling machines;
+ The butyl coating machine;
+ The fully automated washing and drying system
+ The pressing and gas-filling machines
+ The automated and manual sealing system for applying silicone, polysulfide to glass
+ The system of cranes for loading glass maintain the originally geometric structure of the glass and avoid glass deflecting by the relative movement between the glass sheets.


Outstanding features
- The glass sheets are mechanically washed by distilled water treated by Eurowater’s system. As a result, the glass reaches the highest standards of cleanness and transparency;

- The gas-filling machine can carry out an unrivaled gas-filling rate up to 95%, hence minimizing gas losses;
- Fully automated silicone and polysulfide sealing machines ensure the exact calculation of material volume;
- The high-quality materials for processing insulating glass such as silicone, polysulfide, butyl, profile bars and desiccants were imported from the USA and European countries. They are suitable for different weather conditions; therefore, the insulated glass always maintains higher thermal insulation, sound reduction and long-term durability.





Technical data
Maximal glass size 2900 x 5200mm
Minimal glass size 180 x 350 mm
Thickness
(thickness of glass sheet/ frame/ glass sheet)
12-60mm
Gas types Argon, or Crypton, Xenon

5. The tempering glass line and Heat-Soak-Test-Oven

a. The tempering glass line
The tempering glass line consists of a modern furnace and loading and unloading conveyors.
+ The furnace can temper the maximal glass size (2900 x 5200 mm).
+ The glass is heated by High air volume Glaston Chinook™ convection system which leads to optimise heat uniformity and help to avoid hot spots in the glass. Consequently, the tempered glass has higher strength and durability than other normally annealed glass.


b. The Heat-Soak-Test-Oven

The oven of SADO GROUP uses the most advanced technology and it is manufactured by Torganuer Maschinenbau company. The oven stringently tests tempered glass and destructs all unqualified glass in order to prevent glass from a spontaneous breakage. (In fact, the tempered glass can break spontaneously if it is not soaked, hence causing damage to humans and buildings). The destructive test method will secure that glasses having overcome the test are suitable for architectural and structural applications.



Technical data
Maximal glass size 2900 x 5200 mm
Thickness 4 - 19 mm

6. The laminating glass line

This synchronous line is a high tech solution for processing laminated glass. The system consists of following components:
+ Laminated glass pressing machine (LISEC);
+ The Autoclave (Scholz);
+ The air filtering and compressing system (Kaeser).

Outstanding features

- The autoclave enables to laminate glass sheet using all the types of PVB and provide optimum ratio output. The equipment makes the PVB film bond tightly to glass sheets and help to remove bubbles. Consequently, laminated glass of SADO GROUP maintains the highest clearness.
- The production line can process two to twenty-layer-laminated glass in which each glass layer can be 12mm thick.



Technical data
Maximal glass size 2900 x 6000 mm
Minimal glass size 200 x 400 mm
Thickness of single glass sheet 4 - 19 mm
Maximal thickness of laminated glass 120mm

7. Digital ceramic printed glass line

- SADO GROUP imported the ceramic printed glass line from Dip-Tech Company, the world’s leader in ceramic digital glass printing.
- The system consists of state-of-the-art digital printer, image processing software and special ceramic inks.

Outstanding features
- Printing up to 6 colors simultaneously
- Assuring the accuracy of dot placement and edge to edge printing
- Wet layer thickness is up to 80 micrometer
- Multi-Job printing (prints up to 5 pieces simultaneously)
- Printing more layers on one side of the glass but creating different images when seeing from two sides of the glass
- Fully automated operation from printing to drying glass.
- Dropfix technology in combination with moveable print heads improve quality of printed glass.


Technical data
Minimal glass size 400 x 400m
(Using adapting plate enables to print smaller glass)
Maximal glass size 2900 x 4200mm
Glass thickness 2 – 19 mm
Capacity 30m2/h for one color
Resolution 720 DPI

8. The grinding, polishing, drilling and milling line

This is the most advanced line manufactured and installed by Benteler Group. The machines automatically load the glass, grind and polish glass edge. Then the glass is loaded to washing and drying system.
The line consists of following components:
- Grinding machine: provides optimal grinding results basing on precision, speed and process reliability.
- Drilling machine: includes twin-driller with multiple augers which can be change automatically. The machine is capable of executing multiple drilling applications with a reliable process and easy operation; the miller carries out milling shapes of glass programmed in CNC controlled machine.

Technical data
Minimal glass size 250mm x 450mm
Maximal glass size 2900 x 5200mm
Glass thickness 3-19 mm

9. Production lines for machining aluminium windows, doors and facades

a. Fully automated machine (ALUSTAR)

SADO GROUP invested in the most advanced production line from RAPID for manufacturing Aluminium products as windows, doors, and facades. With the components sub bench saw optima ALU and profile machining centre 3-Axis-Module ALU in a noise protection cabin, we realise a further production lines for our program of products in the range of Aluminium profiles machining. The process of cutting and machining works in parallel, according to the position of the operation on the bar.

Standard equipment:

In feed magazine, up to 7 profiles.
Transport axis with a gripping pliers, turnable 90°.
CNC-control on a PC with windows XP (embedded)
To operate via Touch-Screen-TFT display.
Milling and drilling module with up to 16 units.

Outstanding features:

Highly flexible and universally applicable for cutting and machining of Aluminium profiles. Proven RAPID machine building quality in connection with modern and sophisticated control technology sets new standards regarding:

- Performance: Modern CNC control engineering allows fast operational sequences. All operations are automated.
- User-friendliness: The intuitive and logical user interface enables a user-friendly operation with this machine. The actual true values and machining operations are shown on the operating screens of the machine. Machining operations are graphically supported (touch screen).

b. Semi-automated machines

The system consists of semi-automated machines which are well-equipped for machining special shaped products or small quantity of products.
The system with high customization enables to support CNC system which ensures high speed and specialization for each profile type.

SUPPORTING EQUIPMENTS

1. Fine Water Filtration System

SADO GROUP installed Fine Water Filtration System of EUROWATER (Germany) to provide high purity water for processing glass. Filtration process comprises water softening and Reverse Osmosis (RO – without using chemicals). This is the most modern water treatment system which is capable of removing pyrogenic substances as well as microorganisms. Washing glass with filtered water provides the best output. Therefore, physical features, colors and clearness of the glass are not changed when tempering. The system which consists of technical know-how and selected high-quality components complies with the highest industrial standards.


2. The system of recirculated water treatment

In order to protect the environment and provide clean water for processing glass, SADO GROUP installed a system of recirculated water treatment manufactured by LiSEC Corporation. Before dirty water is conveyed into the cleaning system, a flocculant is added continuously and automatically which is then mixed with dirty water using an integrated mixer. The lamellar package integrated in the cleaning system ensures a short reaction time with minimum water losses. The system filters all of glass particles in dirty water. The glass particles are solid and harmless waste which is kept in safe tanks. Then they are reused as the raw material for float glass manufacturers to save natural resources. SADO GROUP always pays special attention to saving materials and reusing natural resources. For this reason, we can prove that our factory is friendly to environment and contributes to develop "green architecture".

3. Argon gas supply system for insulating glass line

- SADO GROUP set up a modern system of Argon gas supply which manufactured by Vietnam – Japan Gas JSC to ensure production schedules and product quality. Equipments of the system including bearings, gas cylinders, safety valves, fittings, wiring and pressurization system were imported from Japan and passed the safety inspection.

- The system comprises a line of gas cylinders maintaining a continuous supply of Argon gas for insulating glass line. Filling insulated glass with the 99.999% (5.0) high purity Argon gas ensures the perfect quality of insulated glass and an excellent barrier to prevent heat transfer.

4. The system of cranes, fork-lift trucks and hand pallet trucks

SADO GROUP equipped a range of cranes, fork-lift trucks and hand pallet trucks so that materials and finished products are safely and quickly loaded to meet the production schedules. The system of 12 highly efficient cranes and special glass storage racks imported from Europe enables to load materials as well as products safely.

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