19/03/2026
From theoretical efficiency to real savings: Glass Service's India success story
When a glass production plant suffers from chronic energy losses and spiralling operating costs, the answer is not routine maintenance. It's a radical technological transformation.
That is exactly what we delivered in India.
Starting from a traditional Air/Gas heating system — outdated, energy-intensive, and difficult to control — the Glass Service team designed and executed the complete conversion of a Tandem Forehearth to Oxy-Gas technology, working on an existing, operational structure.
How we got there
Nothing was left to chance. Every section of the forehearth channel was recalculated using advanced 3D simulations, which determined the optimal positioning of the burners at a constant pitch of 250 mm. This density level ensures precise temperature control along the entire path of the molten glass — a degree of accuracy that conventional systems simply cannot match.
The demolition and reconstruction phase was managed with millimeter-level precision: only the structurally necessary components were replaced, minimising plant downtime and keeping intervention costs under control.
The results, in numbers
Once commissioned and running under stable conditions, the data confirmed — and exceeded — the design projections:
• –60% in Natural Gas consumption compared to the previous system
• Absolute thermal stability throughout the forehearth
• Measurable and visible improvement in glass quality
These are not theoretical projections. They are real figures, measured on a live production plant.
Technology and people: the winning combination
A project of this complexity is never achieved through technology alone. The success of this intervention is the result of the synergy between our specialist engineers and the local Indian workforce — a collaboration that turned a demanding engineering challenge into a benchmark of industrial excellence.
Because behind every energy-saving figure, there is always a team.
📌 Watch the video to see the full technical details of the installation, from 3D design to commissioning.
Want to know whether Oxy-Gas technology is the right solution for your plant? Get in touch.
www.glassservice.it
