Production

This clear borosilicate glass belongs to a group of glasses that excel in high temperature and chemical resistance and low thermal expansion. They are defined by the international standard ISO 3585. They are used in the most demanding fields, in chemistry, pharmacy, healthcare, biology and food industry.
ISO 3585 CERTIFICATE

Raw materials, prepared and mixed in a modern automated batch plant, are melted in all-electric resistance furnaces with vertical melt flow and a continuous production process. Electric glass melting has a 50-year tradition in Kavalierglass glassworks and is unique in the world in terms of its scope of application.

Rotary blow molding machines shape thin-walled containers (such as beakers, flasks, glasses, kettles) from a drop falling from an automatic dispenser. The drop, placed in the machine on an annular base, falls through its opening and stretches partly under its own weight, but mainly under the air pressure from the blow head, and rotates around a vertical axis. Two parts of the mold, which have the shape of the final product, are clamped around the hot flask. By increasing the air pressure, the product in the mold is shaped and after the mold is opened, the remover transfers the product to a conveyor. On blow molding machines, a technological edge called a hump is created during molding, which is removed in the next machine by melting. The production line is automatically connected to automatic nozzle molding machines and machines for decorative or functional printing and those types of products where this is required.

We produce a wide range of baby feeding bottles, as well as laboratory, blood and special bottles for laboratories using a modern automatic machine from a Czech manufacturer. We are among the world leaders in the production of baby and reagent bottles.

The hot glass forms a drop in the dispenser at a temperature of approximately 1300 °C, which is automatically cut off and falls into the press mold and is then pressed out by hydraulic pressure. The pressing is cooled in other positions of the press, and smoothed and polished by a system of burners. It is then transported by a conveyor belt to a tunnel hardening furnace, where it is rapidly cooled by a stream of air after reheating and surface hardened. Its temperature resistance is thus increased by 50% and the product acquires the necessary properties for all usual thermal manipulations in the laboratory and in the home.

Technically demanding modern automatic production of borosilicate tubes as semi-finished products for further processing is a basic prerequisite for the successful production of the entire range of laboratory instruments and glass industrial apparatus. Kavalierglass glassworks uses a modern Vello system drawing line for the production of tubes up to 50 mm in diameter, and tubes of larger diameters, up to 170 mm in diameter, are drawn automatically on equipment of their own design.

The range of laboratory and technical glass produced in the Kavalierglass glassworks includes thousands of types of products. Therefore, there are still hundreds of types of products that must be produced by hand, either due to the complexity of the shape or for small production runs. However, the plant employs highly qualified and skilled glassmakers who are able to handle every problem of hand-forming glass, whether it is a modern roasting pan for dietary roasting of chicken or a 200-liter reactor vessel. The use of manually operated mechanical and hydraulic presses and the final blowing of the largest and most complex products with compressed air eliminates physical effort and makes the work of glassmakers easier. The finishing operations of hand-formed products are also carried out on modern machines, usually of our own design and production.

Glass processing over a furnace remains the basic technology of every manufacturer of laboratory equipment. In the Kavalierglass glassworks, dozens of qualified glassblowers produce even the most complex laboratory equipment and instruments daily, exactly according to drawings and standards. They mostly use machine-shaped glass semi-finished products and only weld the final assembly of the instrument over a furnace. Many operations in glassblowing technology are also mechanized. Machines mainly produce semi-finished products such as standardized ground glass, taps and others. The production of measuring cylinders is fully mechanized. Some laboratory vessels must be precisely measured and the volume marked on the product in the prescribed manner. Marking is usually done with durable enamel printing, but for a smaller part of the production, a more conservative marking process by etching is also used at the customer’s request.

The finishing of large glass containers, reactor vessels and heat exchangers of the glass industrial apparatus program is extremely demanding. Flanges with a diameter of up to 600 mm are welded onto the vessels for final cold assembly, and inlet and outlet extensions, taps and bushings for thermometers and stirrers are welded onto a defined location on the vessel. Multiple helices of heating or cooling coils are welded into the cylindrical shells of the heat exchangers.

The final stage of the industrial equipment manufacturing process is assembly, during which the entire equipment is assembled and functionally tested using non-glass accessories and connecting parts, metal flanges, screws and seals. At the customer’s request, the manufacturer also carries out final assembly and testing, or commissioning, of the equipment in the customer’s facility.

Mass-produced household glass is sold in sets and assemblies, which are rationally formed during product packaging. Assembly also includes the assembly of non-glass elements and accessories. The conclusion of the assembly operation is the palletization of packaged products and the wrapping of pallet assemblies with shrink film. A transport pallet covered with film as a modern, maximally safe and economical packaging of products is then the basic sales and shipping unit.