Forehearth and Distributor Audits

How can an operator tell how well a forehearth is performing? The normal method is to consider the thermal efficiency value provided via the equalising zone 9 thermocouple points. As anyone who has attended a Forehearth Services forehearth training course knows, the efficiency value is a very coarse and unsatisfactory measure of operational efficiency.

Different forehearth designs with different cooling, combustion and control subsystem technologies provide different levels of performance – thermal homogeneity, thermal stability, speed of response, fuel efficiencies, zones interactions etc. Each design provides a different maximum operational efficiency. If the operator looks at a particular forehearth how does he know whether as a system it is operating at 90% of optimal efficiency or 70%? Such an assessment is subjective. But subjective assessments do not produce forehearth performance optimisation, increased pack-rates or fuel savings.

What is needed therefore is a methodical analysis of all aspects of the forehearth and its subsystem operation to obtain a meaningful measure of the current operational status of the system as a whole. Based on this analysis any factors adversely affecting forehearth performance can be rectified ensuring the forehearths and distributors are operating at optimum performance, delivering the highest possible pack rates at maximum energy efficiency and container quality - and ensuring the forehearths and associated equipment are operated without danger to plant or personnel.

Based on over 40 years experience of forehearth design and operation Forehearth Services have developed a suite of performance assessment testing procedures that allow the degree of forehearth performance to be quantified.

Typically involving the analysis of over 1000 readings and measurements per forehearth the audit provides the plant manager with a written report providing the precise status of the forehearth and its cooling, control and combustion systems. It also provides an analysis of how well the forehearth is being operated and identifies any hardware faults and operational functions that are adversely affecting the performance. Using this data a plan is produced to configure the forehearth to produce optimal operation. The audit procedures are specifically designed to identify the source of common forehearth problems, poor thermal homogeneity, blister and other container defects, fuel efficiency etc.