explitia for the glass and ceramics industry
The digitalization of the glass and ceramics industry takes glass manufacturing to a higher level. explitia’s solutions address the needs of glass production plants facing challenges such as high energy costs, the need for strict quality monitoring, and the efficiency of glass manufacturing and forming processes.
Discover how we can optimize your production facility and experience the power of Industry 4.0.
Production Portal – the path to digitization of the glass and ceramics industry
Production based on furnaces, precise ingredient dosing, and forming parameter control require modern digital tools.
That is why we have created the Production Portal. It is a solution that supports the digital transformation of glass manufacturing plants, providing full support in:
- monitoring,
- process optimization,
- product traceability.
The system is modular and scalable. This allows for the gradual implementation of explitia’s Production Portal and the ability to adapt it to the specifics of glass production.
The biggest challenges in glass production – explitia’s solutions
1. Efficiency of production and energy processes
Energy costs are one of the main challenges in glass production, where key processes – melting, forming, and tempering – require significant energy consumption. With the efficiency module in the Production Portal, we offer:
- real-time monitoring of energy consumption at each stage of the production process,
- measurement of furnace efficiency, forming lines, and tempering machines,
- analysis of OEE indicators (availability, performance, quality) for entire technological lines,
- identification and elimination of causes of downtimes and heat losses.
2. Traceability – full traceability of the production process
In glass production, traceability of materials and parameters is crucial to ensuring quality. With the traceability module, we provide:
- detailed recording of melting and forming parameters (temperature, pressure, batch composition),
- identification of raw material batches (sand, soda, dolomite) and their impact on final quality,
- monitoring of operator work, machines, and production lines responsible for glass forming,
- full reporting for audit and quality compliance purposes.
3. Quality maintenance through SPC (Statistical Process Control)
In the glass manufacturing process, the quality of the final product is directly related to controlling technological parameters at every stage. Our SPC module allows for:
- automatic monitoring of key parameters such as glass thickness, strength, dimensions, and stress levels,
- sending alerts in case of deviations from quality standards,
- reducing losses caused by defective products and rejected batches,
- predicting anomalies based on historical data and current statistical analyses.
4. Flexibility in production planning and execution
Dynamic management of production orders and optimization of forming lines and melting furnaces is key to reducing costs and ensuring timely delivery. With the planning module, we offer:
- optimization of production schedules, considering furnace efficiency, forming lines, and maintenance downtimes,
- monitoring of material and energy consumption per production batch,
- dynamic order planning for various types of glass (architectural, packaging, specialized),
- the ability to immediately respond to priority changes from the sales or logistics department.
Why implement the production portal?
Energy cost optimization
Precise monitoring of energy consumption and support in identifying areas for savings.
Full traceability
The ability to track technological parameters for each glass batch.
Scalability
The possibility of starting implementation with a single furnace or production line and gradually expanding to the entire plant.
Improved quality and efficiency
Automatic SPC analysis and the OEE module allow for quick identification and elimination of issues in the production process.
Fast results
The first benefits are visible within the first few weeks of system use.
Examples of implementations and our experience in the digitization of the glass and ceramics industry
The Production Portal has been successfully implemented in industrial enterprises requiring full process control, material traceability, and energy consumption optimization. Our experience in process manufacturing allows us to deliver a tool perfectly tailored to the specifics of glass production.