Operational Support
Support operators. Diagnose problems. Improve performance.
How operational support helps
Every furnace faces moments of instability, from temperature fluctuations and energy losses to unplanned downtime, quality issues or slow color changes.
When challenges arise in your batch house or glass furnace, our specialists visit your plant to measure, observe, and analyze your furnace in operation. Backed up with many years of experience, we translate complex data into clear, actionable insights.
Whether it’s improving energy efficiency, extending furnace lifetime, or improving glass quality, we provide an expert set of eyes to recommend practical improvements that make an immediate impact on your process.
Challenges we solve
Measurable Benefits
Remote support
Not every operational challenge requires on-site presence. With decades of hands-on expertise in the glass industry, CelSian’s highly experienced professionals are uniquely positioned to support plants across a wide range of operational areas and technical challenges through applying advanced simulation tools, data analysis, and laboratory expertise to diagnose issues and identify improvement opportunities from a distance. The CelSian lab and CFD tool GTM-X help to understand furnace conditions and improve furnace performance.
On-site support
Every furnace behaves differently, and sometimes on-site support is needed only to resolve immediate production issues quickly. When your furnace doesn’t behave as expected, data is your best guide. On-site support brings CelSian’s expertise directly to your plant, collecting precise process data to pinpoint inefficiencies, validate performance, and guide targeted improvements in real time.
Color change performance
Color changes can be seamless or pose significant production challenges. Even with well-designed color change programs, some production losses are unavoidable. Our role is to help you minimize these losses. By assessing your furnace condition and target glass composition, our experts develop a tailored color change program that protects the furnace campaign and ensures quality. Color change support can be further enhanced through online or on-site training, empowering your team to execute changes efficiently and confidently.
Operational support in action
A flat glass producer aimed to reduce energy consumption and production costs. Through on-site evaluation and targeted analysis, opportunities were identified to improve thermal efficiency and reduce edge losses at the ribbon. Practical adjustments were implemented to improve overall performance without disrupting production, and the following impact was achieved:
Impact:
- 4% reduction in energy consumption through improved insulation
- 0.72% increase in yield by reducing edge losses
- Lower operating costs with improved process efficiency
A container glass producer experienced a significant, sudden decline in glass quality, with rising blister and seed levels that impacted production stability and yield. Through ongoing operational support, the furnace setup and burner configuration were reviewed and adjusted to restore stable melting conditions and improve glass quality.
Impact:
- 30% reduction in blister and seed levels
- 1% increase in pack rate
- Improved process stability and production consistency
A container glass producer increased raw material usage to improve yield and reduce internal cullet, but the change led to excessive foaming and instability during melting. Through a combination of on-site support and laboratory studies, the batch composition was refined to address the root cause of the issue.
Impact:
- Reduced foaming during melting
- Stable glass color throughout production
- Glass quality maintained through formula changes
From knowledge to lasting impact
From classroom training to on-site furnace support, CelSian works directly with teams in real operational environments. Academy courses, workshops, and furnace support sessions are closely connected to daily practice, ensuring that learning is immediately applicable. The result is stronger internal capability, more confident decision-making, and sustained improvements in performance, energy use, and glass quality.
Technical Manager, Glass Manufacturing
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