Maintaining and Sustaining

More Information

As mentioned, the level of clean glass processed on the washer should be recorded soon after installation, post-startup, and validated at regular intervals (see Cleaning Process Verification), to determine potential issues before they cause production downtime or failed assemblies. The following lists several inline checks and preventative maintenance of the machine:

Test and Verify the Cleaning Level - Knowing what cleaning level your washer can achieve is important. You will need this as a baseline in order to ensure a sustainable cleaning level throughout the life of the machine. Such testing is best recorded after the burn-in process time of the washer, immediately following the installation. Observations concerning observable molecular and particulate contamination should be recorded, even if below the acceptable post-process cleaning threshold. Record also any known machine process values, such as temperatures, chemistries and concentration, static air pressure at each air knife, water conductivity/resistivity of the rinse zones, etc.

Preventative Maintenance schedule – Every washer should have one; a periodic check list displaying the intervals of component checking and machine cleaning. This includes check intervals for the rolls, brushes, drive mechanics, etc. as well as cleaning of the brushes, tanks, and internal baffling.

Implement a Maintenance Schedule - The schedule implemented should be based on the equipment supplier’s PM documentation, with method to verify cleaning and maintenance checks have been completed.

Periodically Perform Water Quality Checks – This includes the ion levels (most important in the rinse zones), TOC (if possible), and suspended solids within the zones. [In a washer configuration with a re-circulated tank, it is important to verify proper filtration is included within the associated re-circulation zone, as well as a clean filter – Contaminates can be deposited on the glass, from the washer.]

Maintenance Contracts – Please contact the Billco service team to discuss maintenance contracts

Cleaning Process Verification

It is important to first and foremost know the optimum performance of your glass washer to use as a baseline. To verify cleaning levels you will need to monitor when the surface energy begins to decrease or the presence or size of particles begins to increase. We have listed some common methods used to document surface energy and particle counts for IG and Laminating. These methods insure good adhesion strength of spacer and laminate and eliminate or reduce visual particles in assembly.

Direct Methods (Macroscopic) – DIAGRAMS SHOWN BELOW

· Visual Inspection: Back Illumination (Transmission)

· Visual Inspection: Front Illumination (Reflection)

· Water-Break Test

· Dyne Testing (Use of known fluid tensions)

· Contact Angle

· Steam (Fog) Test

Direct Methods (Microscopic)

· Magnified Visual Inspection (Back and Reflective Illumination)

· Dark Field and Bright Field

Indirect Methods

· Methods include solvent chemistry analysis


Common Inspection using Visual Methods

Front Illumination (Reflection):

- Inline Inspection - where operator present for inspection (contaminate detection)  illumination from  above the glass lite, observation from above

-Observation of glass surface, with reflected light angled to eye/camera

- Offline Inspection - Observation typically within a dark and uniform colored environment (inspection box for small samples, or dark room for large samples)

-Control of the illumination intensity (amplitude of light source)

-Control of the wavelength (visual color or lighting hue)

-Control of beam width (spot diameter)on the front surface of the glass lite

-Method applied in Microscopic and Macroscopic observation


Back Illunination (Transmission): 

- Inline Inspection - where operator present for inspection (contaminate detection) Illumination from below the glass lite, observation from above

- Offline Inspection - Observation typically against a dark and uniform color background (inspection box for small samples, or dark room for large samples)

-Observation of glass surface, at angle to beam (indirect observation)

-Control of the illumination intensity (amplitude of light source)

-Control of the wavelength (visual color or lighting hue)

-Control of beam width (spot diameter) on the back surface of the glass lite

-Method applied in Microscopic and Macroscopic (typical) observation