FalorniTech - Industrial Division of Falorni Gianfranco Srl

V.le IV Novembre, 15, 50053 Empoli (FI)
Italy

Contact

ANDREA ZUCCONI

Commercial Director

Phone
00390571922333
00393387143323

Email
info@falornitech.com

SIMONE SCARSELLI

Deputy to the General Manager

Phone
00390571922333

Email
info@falornitech.com

Our range of products

Product categories

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.01  Batch charging technology

Batch charging technology

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.02  Forehearth technology
  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.03  Melting technology for tank furnaces

Melting technology for tank furnaces

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.04  Melting technology for pot furnaces

Melting technology for pot furnaces

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.06  Regenerative systems

Regenerative systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.07  Recuperative systems

Recuperative systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.09  Combustion technology
  • 01.04.09.01  Combustion technology for oil and gas fired melting furnaces

Combustion technology for oil and gas fired melting furnaces

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.09  Combustion technology
  • 01.04.09.02  Combustion technology for oxy-fired systems

Combustion technology for oxy-fired systems

  • 01  Glass production/Production Technology
  • 01.04  Glass melting technology
  • 01.04.10  Feeder colouring

Feeder colouring

  • 01  Glass production/Production Technology
  • 01.08  Equipment for glass fibre production
  • 01.08.01  Glass wool technology

Glass wool technology

  • 02  Glass processing and finishing
  • 02.12  Environmental protection/Recycling
  • 02.12.02  Glass Melting / Waste gas technologies
  • 02.12.02.02  NOx reduction technology, emission reduction technology

NOx reduction technology, emission reduction technology

  • 06  Contracting, consulting, engineering, services

Contracting, consulting, engineering, services

Our products

Product category: Forehearth technology

FLEX- COND, the flexible glass conditionin system developed by Falorni Tech to boost the NNPB production

The NNPB production process demand more rigorous requirements of the process variables and general setup. However, it should be emphasized that despite the relevance of a cutting-edge IS machine, the key issue in NNPB production is the thermal homogeneity of the melted glass achieved in the conditioning forehearth. Only by the proper combination of technologies that involve the whole forehearth, the achievement of the suitable thermal homogeneity can be possible. The Flexible Glass Conditioning System by Falorni Tech has been developed to serve this objective: before all, the glassmaker who wants to turn its production in NNPB must be sure of the performance of its glass conditioning system. And the FLEX-COND system represents the optimal combination of technologies, properly upgraded since 2010, that works for reaching the highest level of Thermal Homogeneity Index (THI) with values beyond 98% with flint glass.
The FLEX-COND system represents the optimal combination of technologies, properly upgraded since 2010, that works for reaching the highest level of Thermal Homogeneity Index (THI) with values beyond 98% with flint glass.
In the FLEX-COND forehearths the channel zones superstructure is designed with a winged roof profile that creates independent and separated areas acress the channel width. This means the possibility to manage separately the cooling and heating effect not only within the channel length but within every single zone (two-dimension control of heating/cooling distribution). The superstructure is then provided with a composite ducting system in which hot gases and/or cold air are managed to flow by the action of dampers and forced air. The FLEX-COND superstructure has a modular design and can be used both in distributor and forehearths. The standard design size is for channel width from 26” to 48”. Tailored and bigger dimensions can be designed as well up to 54” (tandem massive production). The geometry of the forehearth (width, length) is calculated considering the required range of pull rate, glass color, inlet conditions, and layout so that there’s normally not a straight and unique solution possible.  The capacity of production required for one single forehearth can range from 30 tons/day (smallest unites) up to more than 200 tons/day, for the biggest and massive production of containers.
The right concept and a rigorous design path are the cornerstones of FLEX-COND, which embeds integrated solutions that contribute to the overall performance of the glass conditioning system.
The channel heating is supported by a combustion system based on Falorni Tech AQRatio (Accurate Air/Gas Ratio Control System). This system is designed to guarantee constant and stable Air/Gas ratio at any heating range. The airflow is controlled by a servo linear flow valve which provides repeatable and exact flow value within the entire range of action. The gas flow is controlled through a servo-mechanical actuator by which the gas flow amount is linearly proportional to the airflow at any flow range. The Air/gas ratio is kept constant during the regulation fluctuations driven by the temperature profile demand and is independent from the pressure losses in the air/gas mixture line downstream the regulation skid due to fouling in the pipe or in the burners.   FLEX-COND is supported by Falorni Tech ICS (Interactive Control System) a controller based on a unique technology that supports the whole conditioning phase.  A new controller philosophy, which provides the standard control capabilities but with additional features as the systematization of logical decisions for the operator’s risk reduction, support to the operator on process status and data reading, an automatic control of a set of working parameters to reduce to the occurrence of damages/shutdowns. Falorni Tech ICS is conceived as concrete support for the operator who will be able to increase the efficiency and efficacy of the system in terms of glass quality, energy efficiency, thermal homogeneity and boost the producton output.  Last but not least is Falorni Tech COR-DIS (Cords Dissolution System): it is a stirring device designed to be used in all forehearths. it can be equipped from 2  to 4 stirrers and allows easy operation and maintenance. The system performs the dispersion by mixing of the impurities present in the bottom of the forehearth and allows to set the stirrer with an inclination, boosting the bottom glass mixing.

 

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Company news

Date

Topic

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Jul 31, 2020

Recovering heat from the furnace with the customization of the heat recuperator

Our workshop is carrying out the construction of a Metallic Heat Recuperator System for a new Recuperative Furnace of medium capacity to be installed in Turkey.
Although this type of furnace cannot achieve the same efficiency in terms of fuel consumption compared to a regenerative furnace, specialists know that they still are the “workhorse” in manual and semi-automatic glass plants with low/medium scale production. The recuperative furnace requires low CAPEX and provides high operating flexibility, easy operation, and low maintenance.
This Recuperator System is configured in a double stage (hot stage and cold stage). Each recuperator is a double shell type designed specifically and exclusively for the Turkish Customer, being tailored to the furnace design supplied by Falorni Tech to produce high-quality clear glass with a highly flexible rate. Structurally, the inner shell (hot) and outer shell (cold) difference of dilation is compensated by an integrated expansion joint which guarantees perfect air sealing. The whole structure is completely insulated by rock wool and lined with aluminum sheet cladding which allows minimizing the parasite heat losses. The system is designed and built to make self-cleaning in case of fouling and is provided of safety devices to prevent structural failure in case of accidental shut-off of electric power (combustion fans not in operation). This type of Recuperator System is installed on top of the chimney and supported by an external holding structure which enables fast installation and replacement. Our recuperators are designed using 3D modeling and exploiting the long experience gathered in building and operating this kind of furnace in the past 30 years (more than 100 units installed).
Falorni Tech provides a complete range of metallic recuperators with different technologies: double shell for hot air temperature up to 500 – 550 ° or tube bundle for hot air temperature up to 650-750°.
The main benefits of our recuperator are:

  • Safe and easy operation
  • Low CAPEX
  • Available in double-shell or tube bundle type
  • Possibility to install in single or double stage
  • Easy installation
  • Easy withdrawal and maintenance
  • Extended lifespan

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About us

Company details

FALORNI TECH- GLASS MELTING TECHNOLOGY 

Officially branded in 2015, Falorni Tech has quickly built a reputation for its professionalism, quality of service and flexible approach to meeting its customer’s needs. The expertise available from Falorni Tech embraces glass melting furnaces of any kind (regenerative, recuperative and oxy-fuel), together with complete distributors and forehearths, including colouring solutions. The scope is completed by a full range of ancillary furnace equipment which includes combustion systems, burners, reversal valves, exhaust systems, batch charging solutions, glass level controllers, recuperator, boosting systems and many others. High efficiency plants and Low-NOx solutions are provided to meet environmental restrictions, while entire glass container or tableware facilities can be engineered, with complete production lines and auxiliary equipment. 
To preserve the tradition and the excellence of artistic glass making, the Company has kept in operation the art glass division: Falorni Glass Furnaces is dedicated to niche products of melting furnaces for the production of art glass and crystal. 
                                              RANGE OF  PRODUCTS

MELTING FURNACES
(REGENERATIVE, RECUPERATIVE, OXY- FUEL) 

 CONDITIONING SYSTEM ( DISTRIBUTORS, FOREHEARTHS, COLOURING FOREHEARTHS) 

 ANCILLARY EQUIPMENT
COMBUSTION SYSTEMS,  FURNACE AUTOMATION AND CONTROL,  PROCESS SUPERVISION , WASTE GAS MANAGEMENTS SYSTEMS  METALLIC RECUPERATORS (DOUBLE SHELL AND TUBE BUNDLE TYPE), BATCH CHARGERS,  AUTOMATIC GLASS LEVEL SYSTEMS,  BUBBLING SYSTEMS, ELECTRIC BOOSTER, FRIT DOSING EQUIPMENT, STIRRERS, GLASS GATHERING ROBOTS

HOLLOW GLASS SPECIAL PRODUCTION  (BY FALORNI GLASS FURNACES)  
  •  MINI CONTINUOUS FURNACES FOR SPECIAL AND COLORED GLASS
  •  DAY TANKS
  •  POT FURNACES
  •  MINIGLASS DAYS TANKS AND POT
  •  LABORATORY FURNACES

 RANGE OF SERVICES
  • ENGINEERING
  • TURNKEY SOLUTIONS
  • EPC PROJECTS
  • BASIC AND DETAILED ENGINEERING
  • PROCESS ENGINEERING
  •  PROJECT MANAGEMENT
  • TRAINING
PRE-FEASIBILITY ANALYSIS 

ASSISTANCE
  • AUDITING
  • TECHNICAL SURVEYS
  • SUPERVISION DURING CONSTRUCTION
  • STARTUP AND COMMISSIONING
  • LONG TERM ASSISTANCE

 

 

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Company data

Export content

> 75%

Number of employees

11-30

Foundation

1958

Area of business

Glass manufacture/production technology