Targeted batch house modernization and equipment upgrades to improve reliability and reduce material loss
A glass manufacturing plant in California, originally constructed in the 1950s, had been operating continuously for more than six decades. Over time, critical batch house equipment reached the end of its service life, resulting in frequent mechanical failures, unplanned downtime, and increasing maintenance costs. Leaks throughout the system caused raw materials and mixed batch material to escape the process stream, leading to product loss and additional disposal costs. To improve reliability and reduce waste, the client partnered with Re:Build Optimation to assess the full batch operation and recommend targeted equipment replacements.
Re:Build Optimation began the project with a comprehensive batch house audit and system assessment. The audit covered the full process, from raw material receiving and unloading through to batch delivery at the day bins.
Each piece of equipment was evaluated and categorized using a red, yellow, and green system:
By combining the assessment results with risk, cost, and operational impact analysis, Re:Build Optimation worked in close partnership with the plant team to prioritize upgrades that delivered the greatest reliability and waste-reduction benefits first. Together, the teams sequenced work by plant area and phased implementation to maximize return on investment while aligning upgrades with the plant’s operating schedule and minimizing production disruption.
Re:Build Optimation implemented a wide range of equipment replacements and improvements across the batch house. Key upgrades included:
In addition, many components exposed to high levels of cullet were upgraded with chromium carbide wear liners to increase durability and reduce future maintenance requirements.
Re:Build Optimation completed a large-scale modernization program across a 12-month period while maintaining production continuity through phased field installation. The project enhanced equipment reliability, reduced material loss, and improved worker safety, allowing the plant to sustain higher operational efficiency with less unplanned downtime. The $2.9 million investment provided the client with a more robust and maintainable batch system that will continue to perform reliably for years to come.
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