MAC-YUGONG Jumbo Glass Production Factory Automation Case From First to Fifth: Growing Stronger Together with BOYU

Boyu, the magic glass processor, after establishing 4000sqm automation factory in 2019, invested in a Jumbo glass-3300*7000mm automation factory in 2025.

This is the fifth automation projects we have completed for Boyu and once again our team has done a brilliant job.

In this Jumbo glass production factory which covering 5400sqm, MAC-YUGONG team designed a raw glass storage system, a 2-in-1 laser marking and cutting line, a double edger, a 35-layer sorting system, a tempering furnace, a vertical sorting system, a PVB laminated line and a TPS/4SG warm-edge IG line.

Their main products will be jumbo insulating glass units for premium windows.

Automation System Introduction

1. MAC warehouse management system (WMS)

The production starts with the handling of raw glass sheets. Workers use a handheld scanner (PDA) to scan each package, and all the relevant information is promptly uploaded to the ERP system. ERP always provides the latest warehouse inventory information for both offline and online raw glass storage. Subsequently, the ERP system conducts optimization based on the order structures and communicate with the MES system. This seamless integration of information systems lays the foundation for precise production planning.

Upon receiving instructions from MAC WMS, the raw glass sheets are transported to the warehouse for storage and unpacking. The storage area is equipped with 32 racks, providing enough capacity to meet the demands of daily production. Each rack can store 1 - 2 packages of raw glass sheets. When needed, the shuttle car will precisely be transferring the glass sheets to the loading table accordingly, ensuring a continuous flow of materials.

2. Precision Cutting and Identification

For cutting process, the MAC ERP will do the optimization based on superior algorithm, ensuring the best utilize of the raw glass sheets. Saving significant material cost in long-term.

At the cutting and laser marking table, advanced technology is employed. Every piece of glass is assigned a unique identity, which is crucial for traceability. It has the capability to print 3C markings, QR codes, and logos, etc. at any position as per the order requirements.

The laser marking imprints a 4mm * 4mm barcode on the glass sheets, significantly enhancing processing efficiency.

After cutting, a CCD device records detailed information about each glass sheet and feedback to ERP system, enabling real-time monitoring and quality control.

3. Edging Process and Special Handling

MAC MES system optimizes the production process to minimize the frequent opening and closing of the double edging line. All the information will be shared from MAC MES to double edger, so that the machine adjusts automatically as per the different sizes, thicknesses or edge deletion widths.

For example, If the glass requires Low-E edge deletion, double edger will automatically remove the coating film with the precise width based on the order information.

After edging, oversized glass sheets (exceeding 3000mm) and small-sized glass sheets that require drilling are unloaded from the side conveyor for further specialized processing.

4. Horizontal Storage and Sorting System

#1 rotary table connects the double edging line and the 35 - floor storage and sorting system. MES determines the rotation direction of the glass sheets based on the sophisticated MACsoft algorithm, ensuring efficient material transfer and quality control (especially for curtain wall productions).

Another CCD device captures all relevant information and feeds it back to MES system for continuous process optimization. The 35 - floor horizontal storage and sorting system, designed with space-saving consideration, features a combined cloud ladder. This innovative design comprises two layers, where the upper layer functions as an inlet conveyor for glass sheets entering the storage system, and the lower layer acts as an outlet conveyor and pre-batching layer - Lower layer with XYZ three-dimensional batching can make sure reach the maximum capacity of tempering furnace.

5. Advanced Batching and Tempering

MACsoft algorithm enables the pre - batching of multiple glasses of different sizes, maximizing the loading capacity of the sorting system.

#2 rotary table connects the 35 - floor storage and sorting system to the tempering furnace.

Glass sheets are then arranged on the final batching table in an X/Y/Z three - dimensional layout according to optimized patterns.

The MACsoft algorithm optimizes batching based on three key principles:

• Achieving the maximum loading capacity;
• Prioritizing orders;
• Ensuring the best quality control (especially crucial for curtain wall productions).

After tempering, the glass sheets pass through yet another CCD device. In case of any defective or self - exposure glass, MAC MES system can automatically initiate compensation procedures.

6. Shuttle Systems and Line Integration

The entire vertical sorting system includes two Jumbo 3300*7000mm shuttle cars, five sorting crates and slideways.

The sorting system will serve one PVB lamination line and one IG line, for laminated glass production, IGU production and even laminated-IGU production.

Shuttle #1 simultaneously transferring glass sheets from the tempering furnace. Plus, after laminated glasses exits the autoclave, they will be sent through the vertical conveyor and enter the sorting system via shuttle #1 as well.

The five crates are designed for different thickness and width of glasses with hundreds of slots, providing sufficient capacity for the demands of daily production.

Each slot in the sorting system is designed to store multiple glasses with different sizes, enhancing storage utilization.

MAC MES system further optimizes the pairing operation in different slots before the IG line and lamination line, based on the order structures, effectively reducing manpower requirements. As per MAC MES instructions, the paired glasses are directed into the IG line and lamination line respectively.

Shuttle #2 serves both the IG line and laminated line simultaneously, ensuring a seamless production flow.

Boyu Jumbo glass automation factory represents a remarkable achievement in glass manufacturing automation, showcasing the seamless integration of software and hardware , as well as innovative design. From raw material logistics to precision processing and final high-quality production, every step is integrated through MACsoft like MAC ERP, MES, and WMS. This factory not only for producing jumbo insulating glass units for premium windows but also sets a new standard for efficiency, quality, and sustainability in the glass industry.

MAC-YUGONG is proud to be a trusted partner in this journey, providing tailored automation solutions that have empowered Boyu to achieve its ambitious goals. We have built a legacy of success together, and we look forward to continuing this partnership as Boyu achieve new heights in the years to come.

To view the case, please click YouTube Link:

https://youtu.be/XHsYSeg07kY?si=Ns8XVY23JTVHYzi4