Glassware Manufacturing Crane Configuration Solution
Glass manufacturing (quartz sand 200–500 kg/m³, melting furnace 500–2,000 t, forming machines 5–20 t per unit, annealing lehr 100–300 t) is a high-temperature heavy industry. Furnace cold repairs every 8–15 years require full-plant crane coordination. Recommended configuration: QD double-girder 30–80 t high-temperature-rated + LD single-girder 5–10 t + KBK. Kelude's glass industry solutions feature heat-resistant design across the entire lineup.
Glassware manufacturing (tableware, containers, bottles and jars) starts with quartz sand, soda ash, and dolomite, melted in a furnace at 1,550°C, then formed on individual-section (IS) machines. The furnace runs continuously for 8–15 years between cold repairs — and a cold repair is the single largest crane-intensive operation the plant will ever undertake. This article focuses on crane configurations for both daily production and cold-repair scenarios.
Raw Material Batching — Weighing, Mixing & Conveyor Installation
The raw material system comprises: weighing cars in the storage yard (electronic scales accurate to ±0.5%), mixers (5–15 t per unit), belt conveyors, and the furnace hopper. Quartz sand (SiO₂) dust causes severe equipment wear. Weighing car track accuracy is ±2 mm. Full system installation typically takes 2–3 months.
Recommended model: LD-type single-girder electric overhead crane, 3–5 t capacity with a 10–15 m span, covering equipment installation and maintenance areas in the raw material workshop. Fitted with a dustproof electric hoist (IP55-sealed with positive pressure control box). A jib crane assists with mixer liner plate replacement (each plate 50–100 kg).
Price reference: LD single-girder 3 t/12 m — approx. $4,500–$9,000 per unit (dustproof version +10%). Kelude's glass raw material solution includes a dustproof hoist and a weighing car maintenance platform.
2. Furnace Cold Repair – Full-Process Crane Operations for Overhaul
Glass furnaces (500–2,000 t/d) undergo a cold repair every 8–15 years, requiring a 2–4 month shutdown for complete dismantling and rebuild. The removal and re-laying of refractory bricks (fused cast AZS bricks, 50–200 kg each, 5,000–20,000 bricks per furnace) must proceed without interruption. Even after cooling, temperatures above the furnace remain at 60–80°C. During cold repair, the QD bridge crane operates at a continuous duty rating of ≥80%.
Recommended model: QD Type double-girder bridge crane, 30–80 t / 20–30 m span, high-temperature resistant configuration (Class H insulated motor rated for 180°C+, refractory cable, and forced cooling fan). Equipped with a masonry platform (3 t capacity, electric hoist, full furnace width coverage) and a dedicated refractory brick lifting spreader (clamp-type or vacuum lifter).
Price reference: QD double-girder 50 t / 24 m: approx. $44,500–$74,200 per unit. High-temperature package and masonry platform add roughly 25%. Kelude Heavy Industry's furnace cold repair solution includes full-cycle crane planning and backup equipment support.
3. Section Forming – Mold Quick-Change and Equipment Maintenance
Section forming machines (5–20 t each, 8–12 sections per machine) are the core equipment for glass container forming. Molds (blank molds / blow molds, 50–200 kg per set) require frequent changes based on product specifications—typically 2–6 times per day. Maintenance work involves lifting out the carriage (2–5 t) and cam box (1–3 t). Workshop temperatures range from 35–50°C due to furnace radiant heat.
Recommended model: LD Type single-girder electric overhead crane, 5–10 t / 15–20 m span, covering the section forming area. Paired with a hydraulic mold changing trolley (500 kg capacity, electric lift) to minimize crane occupancy time. A jib crane (250 kg) on the die rack enables rapid mold retrieval and storage.
Price reference: LD single-girder 5 t / 18 m: approx. $7,400–$14,800 per unit. Kelude Heavy Industry's section forming solution combines the hydraulic mold changing trolley, die rack, and jib crane as an integrated package.
Crane Configuration Guide for the Glass Industry
| Process | Machine Model | tonnage | special requirements | reference price |
|---|---|---|---|---|
| Raw Material | LDDustproof | 3~5t | IP55/Positive Pressure Box | 3~610,000 |
| Furnace Cold Repair | QDHigh Temperature Resistant | 30~80t | HGradeinsulation/Fan | 30~5010,000 |
| I.S. Machine | LD+Mold Change Cart | 5~10t | Temperature Resistance35~50°C | 5~1010,000 |
Kelude Service Advantages for the Glass Industry
Kelude Heavy Industry specializes in the glass manufacturing sector, covering the full process from raw materials and melting to forming. With extensive experience in furnace cold repairs, we have completed crane support systems for over 30 glass furnace overhauls.
Cold Repair Lifting Support
Complete package featuring high-temperature-resistant QD overhead cranes, masonry platforms, and refractory brick lifting spreaders — ensuring uninterrupted operation for 2 to 4 months during cold repairs.
Quick Mold Change System
Configured with hydraulic mold changing trolleys for I.S. machines, die racks, and jib cranes — improving mold change efficiency by 50% and minimizing downtime losses.
FAQ
Q: How should the crane duty classification be selected for glass furnace cold repairs?
A: During cold repairs, cranes operate continuously (16–20 hours per day), requiring a heavy-duty classification (A7/A8). Motors should be rated for S1 duty (continuous operation) with Insulation Class H (temperature resistant up to 180°C). Kelude's cold repair solutions include A7 QD overhead cranes with forced cooling fans and standby motors for maximum reliability.
Q: How can frequent mold changes on I.S. machines reduce crane occupancy?
A: If mold changes (2–6 times per day) rely entirely on the LD overhead crane above the I.S. machines, other work areas lose crane access. Improved approach: a hydraulic mold changing trolley (500 kg load capacity) moves along floor rails between I.S. machines. Molds are pushed/pulled from the machine side during changes, and the crane is only used for transport between the die rack and the machines. With Kelude's hydraulic trolley system, crane occupancy is reduced by over 70%.
Q: What is the recommended handling and masonry approach for refractory bricks in glass furnaces?
A: For refractory bricks (fused cast AZS, 50–200 kg each, 5,000–20,000 bricks per furnace): ① Forklift trucks deliver brick stacks to the furnace side, where the QD overhead crane lifts them onto the masonry platform (electric lifting, 3 t capacity, full furnace width coverage); ② Masonry workers stand on the platform to place bricks (the platform moves up level by level as work progresses); ③ Special-shaped bricks (curved/corner bricks) are positioned using adjustable brick clamps (50–200 kg gripping force) assisted by the crane. Kelude's cold repair package includes the masonry platform, brick clamps, and brick stack transfer solution.
Q: How should the rails for the hydraulic mold changing trolley be laid out?
A: The trolley rails run parallel to the I.S. machine line (double track, 600–800 mm rail gauge), passing in front of the machine group. The trolley travels along the rails to any I.S. machine for mold loading/unloading. Rails must avoid machine foundations (lowering the track or routing around conflicts where necessary). The hydraulic power unit is located at the end of the workshop, with hoses routed through a cable drag chain along the rails. Kelude provides rail layout drawings and foundation interference checks for the trolley system.
