GS-MR PRO:Load Automates LiSEC Flexible Spacer Insulated Glass Lines
GS-MR Robotics explore how their patented PRO:Load robotic glass loading system is automating the industry leading IGU manufacturing lines which continue to come with manual loading as standard.
Most of us have IGU double glazing at home but are we aware of the manufacturing techniques employed to make our windows? We can leave the manufacturing details to the experts because glass is a dangerous commodity, right?
Is it a revelation to discover with the level of technology available throughout the manufacturing world, the glass processing machinery manufacturers latest automated high specification IGU production lines still utilise manual loading and unloading as standard? Operators set to load glass panes of all sizes and weights, including patio door sized, through their shift for ‘Living Wage’?
And it’s the same at the end of the ‘automated’ processing line, although unfortunately the IGU is now 2 or 3 times heavier than at the loading end.
A fully automated manufacturing IGU line dependent upon manual labour in two key production areas is indicative of where the glass processing industry is placed regarding meaningful automation.
It should be no surprise then the glass industry has labour issues – loading tonnes of glass every day for the living wage and not much more.
Only long standing IGU machinery manufacturers can explain why they have failed to produce a proactive automated IG loading system within reach of SMEs budgets. The continuing reliance on a manual handling process which contributes to producing significant amounts of waste is questionable, although having been adopted in excess of 50 years ago, you will struggle to find a video demonstrating the process to any degree.
Manufacturers maintaining their insistence that modern IG processing lines continue to rely on manual loading enables the industry acceptance of that creation of waste, with social media posts proudly showing tonnages of cullet returned for recycling as though cullet glass isn’t waste.
Whilst other industries have accepted automation the glass industry has remained hesitant to acknowledge it could be the necessary avenue securing its future commercial competitiveness.
In 2018 GS-MR Robotics were busy designing automated systems with glass industry issues in mind, solutions that would challenge the continuing heavy reliance on manual processes, reviewing issues from the recruitment and retention of labour, to increasing costs and stabilisation of production quality.
Feedback from the industry towards robotic automation was anticipated, with a firm reluctance to accept automation could handle glass in its raw state and on its edge, regardless of the already multiple proven automated systems successfully handling other complex commodities throughout global industries – interesting to note the emphasis being placed upon a robot possibly breaking glass when operators had to regularly deal with the impacts of broken glass.
In comparison to other manufacturer’s loading solutions incorporating substantial footprints and major capital investment whilst loading unverified glass, GS-MR Robotics took the proactive and ergonomic route, manufacturing their patented PRO:Load solution loading verified glass automatically via its edge, removing any damage to glass special coatings – the only worldwide solution not to incorporate vacuum cups and operating within a substantially reduced footprint.
Designed and manufactured in house by GS-MR Robotics, the PRO:Load performs multiple verifications on the glass with capabilities to measure to a 0.2mm variance, only loading the glass if it completes verification. It is GS-MR’s patented process that, for the first time within the global glass industry, keeps problems away from the loading area, eliminating avoidable production stoppages. The GS-MR PRO:Load has the capability to load any manufacturer’s vertical processing IG line with any manufacturer’s software platform – manual loading operators are then upskilled in its operation, significantly reducing rework costs, increasing Health and Safety benefits and employee well-being.
Fast forward to 2025, it’s encouraging how the industry has shed its hesitance of robotic automation, not least in terms of looking to achieve improved production quality, reduced materials wastage and reductions in CO2 emissions – essential industry goals which are met head on by GS-MR Robotics automation solutions, with the next two PRO:Load installations set to load the latest LiSEC Flexible Spacer IGU Lines at Press Glass UK’s new high-tech UK site (part of the global Press Glass group).
The global glass industry is changing. With continuing consolidation of the UK market competition is clear. Overheads though, regardless of business size, are overheads and the only smart approach is streamlining processes to eliminate obvious waste.
Challenges spawn innovation bringing progress where none was considered possible. Anyone investing in manufacturing today would lean towards well designed, sustainable and meaningful automation – that would not include an historical manual process which knowingly produced waste.
GS-MR Robotics
Based in Telford, UK. GS-MR Robotics design and build customer driven bespoke and production patented, ‘Industrial Innovation’ Award winning robotic automation solutions for the glass industry.
