Schneider Electric and manufacturer Saint-Gobain have joined forces to deploy a software-defined automation system for glass production.

Unveiled at last week’s Glasstec 2024 the project addresses the need for enhanced reliability in the lehr process.

This furnace, vital for annealing and cooling flat glass, usually lasts for 15 to 20 years.

Any downtime in the process halts production completely where even a one-minute power interruption can lead to up to six months of production loss, can often require equipment replacement, and can cost up to €200,000 per day.

Saint-Gobain together with Schneider Electric has developed the first open automation solution for the lehr process.

The proof of concept (POC) is powered by Schneider Electric’s open automation technology, EcoStruxure Automation Expert (EAE) which decouples hardware and software to allow devices and equipment to be freely connected across architecture layers, regardless of manufacturer.

The project also enhances safety and efficiency in glass manufacturing, with EAE enabling autonomous drive capabilities and representing a major advancement in distributed intelligence.

The ‘smart’ drives control the two glass-pulling motors, allowing autonomous operation and critical process decision-making at the equipment level, including deciding which motor will pull the glass, performing quality checks and paving the way for predictive maintenance.

Alex Richards, VP EMEA of Mining Minerals and Metals at Schneider Electric, said: "Our understanding of the float glass process has led to a solution that ensures dependability, safety, and productivity.

“Autonomous drive technology enables smart decision-making, and this solution, with its built-in modularisation and standardisation, provides immediate scalability, increased flexibility, and reliability.”

The solution’s modular design means it is easy to deploy internationally with its plug-and-play interoperability enabling up to 50% reduction in engineering, testing and commissioning times.

This scalability will enable Saint-Gobain to realise value at its sites and see exponential value globally.