Sheet glass is a widely used material, particularly in construction, home appliances and furniture, solar panels, and the automotive industry.  The processing of sheet glass can be significantly enhanced through the use of Infrared Thermal Imaging technology, and in this article, we look at the six ways that IR imaging helps to improve quality, sustainability and customer satisfaction whilst reducing cost and risk.

Sheet glass in windows, doors, shower screens, windscreens and other domestic uses must above all be safe  – meaning that it is strong and resilient, and that if it does break, it shatters into small pieces rather than forming deadly shards. The tempering process is used to give sheet glass these properties .Increasingly too, glass is playing its part in sustainability of the built environment – with Low E (low emissivity) glass used to help stop winter warmth escaping and summer heat entering through glass windows, doors and walls.  Low E glass is produced by applying a microscopic coating to the glass’ surface.

Temperature monitoring and management during the tempering and coating process is vital to ensure a high quality, safe product. It is essential to have a uniform temperature across the surface of the glass sheet as it comes out of the oven. Temperature variations across the surface can compromise the quality and therefore safety of the glass, even causing sheets to explode.

Traditionally,  inspection of the sheets as they come from the oven into the cooling area was done by the human eye, and skilled operators could, with the help of a zebra board, visually assess the plate glass for distortions that could indicate a quality issue. This method is still used in as many as 40-50% of glass processing facilities in Australia. But this approach is subjective, dependent on the skill level of the operator and leaves the facility dependent on key personnel who may not always be available. It takes relatively little distortion in the glass to cause it to be rejected, and if a flaw is missed by the human eye, the outcome could be costly.

1. Greater clarity and accuracy

Advanced thermal imaging technology, on the other hand, provides greater clarity and consistency than is achievable with the human eye alone. It uses infrared non-contact sensors and thermal mapping software to create a heat map image of the entire surface of each piece of glass as it exits the oven. The system will then identify temperature variations of any more than five degrees across different parts of the surface.

2. Always available

Thermal imaging technology, once installed,  is always available, so facilities reduce their reliance on a skilled inspection operator.

3. Integration with production control system for swift remediation

The information from the thermal imaging system is integrated with the production control system in order to swiftly troubleshoot and make adjustments if any variations are identified. For example, the issue may be caused by the temperature of the elements in the oven. Typically the elements that heat the outside edges of the glass need to be operating at a higher temperature than those in the middle, because the middle has the benefit of the heat from the surrounding parts of the surface. If the balance isn’t right, hotspots on the glass can occur – and a thermal imaging system will enable facilities to swiftly spot and rectify any issues.

4. Quality control

In sheet glass, a high quality product is indicated by uniformity of temperature. With a thermal imaging system operators can instantly see that the temperature is uniform, and be confident that the sheet will be of the highest quality.

5. Lower wastage, better environmental outcomes

With a manual checking system, any quality issues that get missed as the sheet comes out of the oven may lead to sheets having to be scrapped further along the production process, or even being rejected once they reach the construction site. Spotting issues early and remediating the production process leads to fewer faults and less scrapping. Whilst the aim is for scrapped sheets to be recycled, this is not always possible – and so reducing scrapping can also reduce environmental waste and enhance the facility’s environmental record.

6. Enhance customer reputation

Having your product rejected at site erodes customer trust and can ultimately harm sales and reduce revenue. Have a reliable, consistent quality control process significantly reduces the chance of rejection, and protects the facility’s valuable reputation.

Implementing thermal imaging technology in sheet glass processing transforms quality control, enhances safety, and reduces waste, creating a more sustainable and resilient product. By ensuring consistent temperature uniformity, thermal imaging reduces the risk of costly rejections, preserves the integrity of the glass, and strengthens customer trust. As the industry embraces more efficient and precise tools, glass processing facilities are positioned to meet increasing demands for quality, sustainability, and reliability, setting new standards for excellence in both product and production.