BatchMaker - ilis gmbh
Contents
1. The Master Data window is divided into the following tab cards L1 On the Plants Furnaces amp Glass Types tab card you define the plants and the furnaces for which you want to produce glass recipes and batch recipes as well as the produced glass types e g amber glass green glass lead crystal or opal glass On the Raw Materials amp Cullet tab card you define the raw materials and types of cullet that you use for glass production On the Energy Sources tab card you define the available energy sources and the corresponding CO emission factors On the Chemical Components tab card you will find a list of all components that you can use for entering chemical analyses If you create a new configuration or master data file a list of all customary components is already predetermined However you can also extend or change this list as you require On the Options tab card you define the used currency and various other settings for the opened configuration User Manual Example of Application 24 4 2 2 Creating a New Raw Material To create a new raw material gt Activate the Raw Materials amp Cullet tab card in the Master Data window gt Place the cursor with the mouse or the cursor keys in the upper table in the first cell of the last still empty row marked with a 1 Plants Fumaces amp Glass Types Raw Materials amp Cullet hemical Components Options Redox Emission factor Comment fac2. NOTE The tolerances in the calculation of the batch recipe are always checked on the basis of the corrected nominal composition O You select from the Empty weights dropdown list box how raw materials that were Stated as carrier raw material but are not required in the batch recipe to achieve the required glass composition should be handled in the calculated batch recipe For instance with the Eliminate and notify setting raw materials without weights are removed from the batch recipe However you will be advised by a corresponding message which raw materials are affected in the calculation of the batch recipe O You can enter a comment in the Comment box which is also taken over in the batch recipe You can subsequently change this comment in the calculated batch recipe O You activate the Accept nominal values for components without carriers checkbox if you want to specify nominal values for components that are not brought into the batch by carrier raw materials User Manual Example of Application 31 4 3 2 Glass Components You define the wanted chemical composition of the glass to be produced on the Glass Components tab card cy Glass Recipe Flint glass General Glass Components Fixed Ingredients Melting Energy Nominal Glass Composition sum 99 501 Component Nominal Tolerance Saturation Evapor X abs abs X 72 0000 0 1000 Cad 10 5000 0 0500 MgO 2 5000 0 0100 ADO3 1 50
3. Viscosity login dPas 5 90 User Manual Example of Application 41 4 4 7 Displaying Report The report display for batch recipes can be configured so that for instance you can generate a reduced report without price information gt Click the Report button gt Select the elements that should be contained in the report from the Configure Report window You can show or hide all price information via the Include price information element By using the Pagebreak element you can insert a pagebreak before the glass property tables Pagebreak Glass Properties With diagram s gt After you click the OK button the report elements you have selected are displayed in a separate window I Save As g Print Q Print Preview Page Setup Batch Recipe 2015 07 24 13h06 Total cullet Foreign cullet Factory cullet 3000 00 4711 05 3982 729 0 3081 28 4774 16 4045 15 729 0 3 ry melting loss kg Batch costs a e e e APBIEEEIBEBE D mar ary m ABEIHEHEBHHE l a e Sisi T JAAA 2 lgzaigis IS le 2 8 s 2 9 3 s xS ce eo ojoj mj wmw IM O1S oa a ala ab om N e N io m N Co mr Batch Ingredients Glass s Dry weight Wet weight Glass Feldspar 145 5073 ssa 1485 5137 Calumte amp 40000 40000 39756 Phonolite 363793 36373 Sodium sulfate 15000 15000 Selenium pre
4. BatchMaker Standard Professional Enterprise User Manual Version 2015 2 9 ilis BatchMake File Edit Tools Window Help e e S ne c Hh WW ia Container Glass Cep Amber glass EE Fit lass Float glass Crystal class Glass Properties Viscosity E resistivity c UNS i Value Flint glass Float glass Crystal dass Ung 4 Doe Ee eet 73847 7352 70724 Clear Clear Clear n m 1460 12 1447214 1456 28 pne M ete 1204 11 1192 13 1195 25 a pa 1038410 1026211 1024223 1 5000 0 6000 1 0000 i 92229 909210 903320 0 0966 UN LH Littleton point 7 6 E EEE rer Littleton point 75 Annealing poi 13 56527 520 10 T 0 7250 0 1186 5 0000 _ FP e 105000 5000 5 0000 DENEN NNUNA 2 5000 3 7000 0 0455 0 0042 0 0008 Viscosity 0 0196 0 0088 0 0462 0 0342 0 1500 i 0 0032 0 0136 0 0185 0 0002 0 0039 0 0088 0 0013 0 0444 0 0020 0 0010 Se T Columns 3 wt mol Viscosity log n dPas Temperature T C Z Analyses d Flint glass ilis gmbh Konrad Zuse Str 22 D 91052 Erlangen Phone 49 91 31 9747790 Fax 49 9131 9747799 E Mail info ilis de Internet www ilis de Copyright 2003 2015 ilis gmbh All rights reserved Translation of the original operating instructions Valid for software version 2015 2 As at October 9 2015 The informat
5. o MnO 000126 a vc V205 Se oo tot E Repot Copy Data Rcs Rise Gose C Multiple analyses Single analysis You enter plant related the chemical analyses for the raw materials and types of cullet that you have defined in the master data in the Analyses amp Prices window The entry area consists here of a main table upper half of the window for the assignment of raw materials and cullet to the selected plant and for entry of the associated prices and humidities as well as a detail table lower half of the window in which a chemical analysis is assigned to each raw material or each type of cullet You will see in list form in each case on the right next to the tables all available raw materials and chemical components as they were defined in the master data in the Raw Materials amp Cullet and Chemical Components areas NOTE Alternatively to entering only single analyses multiple analyses for the same ingredient can be stored and averaged automatically Therefore select the Multiple analyses checkbox below the table Please refer to the Online Help for detailed information User Manual Example of Application 26 4 2 4 Entering Chemical Raw Material Analysis To enter a chemical analysis for the new raw material spodumene gt Mark in the right upper selection list the Spodumene entry and add it with the Ki button to the main table As an alternative you can transfer individual entries
6. 0001 0 00 amp Recalculate Synthesis There has been no warning in the recalculation since this time all tolerances could be complied with Correspondingly no component is highlighted in red NOTE The Change column appears only directly after the recalculation of the batch recipe If you save and reopen the batch recipe the Change column is no longer displayed gt Click on the Save button to save the batch recipe in the database 2 Enter a meaningful name for the batch recipe As standard the current date and time is suggested The new batch recipe is displayed in the File Manager below the corresponding glass recipe User Manual Example of Application 44 4 6 Creating Batch Recipe Manually As an alternative to calculating a batch recipe from a glass recipe you can also create a batch recipe directly from specified raw material weights e g if the chemical composition of the glass to be produced is not known and shall be calculated from existing raw material weights and raw material analyses To create a batch recipe from raw material weights 2 Select the New gt Batch Recipe command from the File menu or click the icon Jf New Batch Recipe in the toolbar The New Batch Recipe window opens gt Select the Plant for which the batch recipe shall be created The ingredients available in the plant are shown in the right selection list Plant gt Select the Furnace and the Glass type to be as
7. 14 1520 27 5400 43 4150 058640 LL m um semam oxide I e 0182 LL pee bh 00 28750 00 200 0 0800 26 5000 0 0700 ooo Oo p EIER i ce r e pm mE cullet 58 00 71 5400 12 8450 0 8156 10 0580 0 0132 0 0582 1 8400 0 3390 0 0578 0 0075 0 0028 0 0642 Amber Foreign cullet 195 45 00 71 2930 12 8398 0 8145 10 1689 0 0182 0 0322 1 8323 0 3574 0 1725 0 0117 0 0058 0 0623 Green de m 156 eso 71 9500 13 1003 0 6950 E 10 2840 2 0385 0 0225 0 0728 1 4584 0 0785 0 0063 0 o06s o an22 0 o4ss Factory Date Humidi Pri SiO2 Na20 K20 Li20 CaO MgO PbO BaO AI203 Fe203 Cr203 CoO NiO TiO2 V cullet e Humidity Price iy 1 t a a A a a 1 my 9 a PN T Cobalt re NW e eu NOTE You can print the report via the Print button or save it on your hard drive as an HTML file with Save As For instance you can send the report in HTML format by e mail Close the Report window Click the Save button to accept your changes 2 Close the Master Data and Analyses windows The master data and the analyses windows are closed but the associated data remain loaded User Manual Example of Application 28 4 3 Opening and Editing Glass Recipe To open the sample glass recipe for clear container glass 2 Select the Flint glass glass recipe in the File Manager and press the right mouse button 2 Select t
8. 2260 33982 0430 4D45 1473 723 0111 723 0111 MF Recalcuste Synthesis Repon User Manual Example of Application 38 4 4 4 Glass Components You see the calculated composition of the glass compared to the nominal composition on the Glass Components tab card Batch Recipe 2015 07 24 13h06 modified Batch Ingredients Glass Components Glass Properties Component Synthesis Nominal Tolerance Deviation Molar F x 4 4abs 4 abs eem E Carriers of SiO2 S02 72 0895 72 0895 0 1000 0 0000 71 6831 TE Na20 12 3145 11 8707 desit RE ES 10 5000 J 11 1868 Glass sand 209142 29 01 2 5000 00 305 Factory cul 7 2675 1008 0 0136 Aa Glass sand 22320 3 10 0 0444 Feldspar 1 4075 1 95 1 5000 87 Phonoite 0 2648 0 37 0 1148 04 Calumite 0 1856 0 26 0 0042 Selenium 0 1216 0 17 0 0039 003 Dolomite 0 0601 0 08 0 0013 Limestone 0 0211 0 03 0 0474 0355 Sodium sul 0 0001 0 00 0 0209 0 0010 00010 0 1500 The specifications from the glass recipe are listed once again in the Nominal and Tolerance columns The percentages of the components in the glass calculated from the raw material weights are listed in the Synthesis column The Deviation column states the absolute deviation of the calculated percentage from the nominal value The raw materials which according to chemical analysis contain the component marked in the left table in each case are listed in the detail table in the right part of t
9. Fa203 TiO2 MnO Multiple analyses Single analysis gt Apply your changes with the Save button gt Click on the batch recipe in the window bar to bring the corresponding window into the foreground Analyses x Ej Flint glass User Manual Example of Application 43 gt Click the Recalculate synthesis button in the Batch Recipe window The batch recipe is recalculated taking the new analysis into account without changing the raw material and cullet weights An additional Change column which displays the change of the synthesis compared with the originally calculated version of the batch recipe appears on the Glass Components tab card next to the Synthesis column ec fist fsa 7b Batch Recipe 2015 07 24 13h11 modified General Summary Batch Ingredients Glass Components Glass Properties Component Synthesis Change Nominal Tolerance Deviation 4 2 abs C abs abs sy SiO 72 1046 0 0151 72 0855 0 1000 0 0151 soz 72 1046 0 0151 72 0895 Ld UNE UU ME TIS i Na20 12 3145 1 s 50 Cao 10 5000 0 0500 0 0000 1 Glass san 20 9142 29 01 2 5000 E 0 0700 0 0000 Factory c 7 2675 10 08 0 0136 Glass sand 22320 3 10 Carriers of SiO 0 0444 1 5000 0 05338 0 0042 Feldspar Phonalite Calumite 1 4075 0 2739 0 1856 0 1216 1 95 0 39 0 26 0 17 0 0033 0 0013 0 0474 0 0203 0 0010 0 1500 0 0000 Dolomite 0 0601 0 08 Limestone 0 0211 0 03 Sodium s 0
10. Using Data in Previous Versions In order to use the data created with BATCHMAKER STANDARD PROFESSIONAL ENTERPRISE in a previous version version 2014 1 or older you can export single or all files from the database NOTE Potentially the previous version does not support all features of the current version So use the export function with caution 5 2 1 Exporting Database To export all files stored in the database to a ZIP archive gt Select the Database command from the File gt Export menu The Export Database window opens gt Change the proposed file name and the location if necessary 2 Click the Save button To use this data in a previous version of BATCHMAKER extract the ZIP archive into a folder of your file system 5 2 2 Exporting Configuration Master Data and Analyses To export the configuration from the database into a file 2 Select the Configuration command from the File Export menu The Export Configuration window opens 2 Change the proposed file name and the location if necessary 2 Click the Save button Proceed correspondingly to export the master data or the analyses 5 2 3 Exporting Glass Recipes Batch Recipes and Glass Compositions To export a single glass recipe from the database into a file 2 Select the Glass Recipe command from the File Export menu or the Export command from the File Manager context menu The Export Glass Recipe window opens gt Change the proposed file name and th
11. a function which makes it possible to display and compare data from multiple batch recipes gt Select the Batch Recipe Comparison command from the Tools menu or click the icon fe in the toolbar The Batch Recipe Comparison window opens Copy to Clipboard 2 Drag the three sample batch recipes Amber glass Flint glass and Green glass one after another from the File Manager into the Batch Recipe Comparison window The batch recipes are loaded and the data is displayed in tabular form Tii S102 0 1123 4 SiO2 0 1104 3 S102 1 0536 4 35 6337 41 275 12 3366 5113 08 kg 7 7123 kg 3522 44 kg 332 19 kg 6 5 X 477 3kg 6 19 2 183 1 kg 5 37 4780 83 kg 72352 kg 3333 33 kg 65 70 1100 kWh t glass 1100 kWh glass User Manual Example of Application 48 gt Under Compare select the desired data category you want to compare e g Batch Ingredients Dry weight kg 143 7136 kg 118 0566 kg 90 6815 kg 131 6453 kg kg 664 0845 kg 9 2959 kg You can also have the data displayed in report form here with the Report button The results are copied into the Windows clipboard with the Copy to Clipboard button so that you can process them further in other applications such as Microsoft Excel User Manual Example of Application 49 4 8 Calculating Glass Properties BATCHMAKER contains a glass property calculator with which you can calculate from their chemical composition and compare the glass properties of
12. application example New users in particular should work through the application example step by step whilst the program is running This manual is meant as an introduction only it does not describe all of the functions of BATCHMAKER For more detailed information please see the Online Help All the functions are fully explained there NOTE BATCHMAKER is constantly being developed and improved The illustrations in this documentation may therefore differ slightly in certain circumstances from how they will appear on the screen It is also possible that according to the ordered scope of functions Standard Professional or Enterprise some of the functions described here are not applicable in your version 1 1 Introduction The objective of batch calculation in glass production is compliance with a defined chemical glass composition which determines the properties of the final product e g thermal expansion and refractive index but also has a decisive influence on the melting properties and processability e g viscosity Thus batch calculation also has a substantial influence on another large cost factor in glass manufacture the energy costs Great economic importance is attached to the prediction of glass properties since this can drastically reduce the number of trial melts and thus the expense of time and costs in new and further developments of glasses In addition many glass properties such as viscosity can be determined physi
13. same time there is a warning that the tolerance value for Fe203 was exceeded in the calculation i Batch Recipe 2015 07 24 13h06 modified Component Synthesis Nominal Tolerance Deviation Molar F 4 4 4abs 4 abs vmm E i Ingredient Absolute Relative MEE onc 25522 5495 3142 23 01 0 0001 gt Acknowledge the warning with OK The row with the Fe203 entry is highlighted in red Thus you see directly the components for which tolerances were exceeded gt Activate one after the other the individual tab cards of the batch recipe you obtain detailed information about each tab card in the Online Help User Manual Example of Application 35 4 4 1 General The master data of the batch recipe are summarized on the General tab card i Batch Recipe 2015 07 24 13h06 modified General Baich Ingredients Glass Components E Fumace Fumace 2 Glass type Hint Fumace load 450 td Batches per day 62 2 Nominal value adjustment SiO2 0 0895 Redox number 4 2739 Dry weight 7711 05 kg Dry melting loss 478 73kg 6 21 X Glass amount 7232 32 kg Cullet percentage 65 4 Energy consumption 1150 kWh4 glass CO2 emission 0 2694 t CO2 t glass Batch costs 59 75 BA glass Energy costs 44 16 A glass CO emission costs 2 59 t glass Total costs 106 61 amp t glass Analyses as of 24 2015 1 01 45 PM I Protect batch recipe from changes d Recalculate Synthesis You see in the Analyse
14. significant amounts of SiO into the glass for example feldspar as the main carrier of Al203 and allows for this Only a tolerance but no nominal value is stated in this glass recipe for the oxide Fe203 If you mark the row with the mouse you also see that no carrier raw material was defined in the lower table In this way the percentage of Fe2O3 which is necessarily brought into the glass as impurity by the raw materials can be monitored If the percentage in this example exceeds 0 1 weight 9o there is a warning in the calculation of the batch recipe and you can correct the excess by using an alternative raw material for instance User Manual Example of Application 32 Only a saturation value is specified in this glass recipe for the oxide SO3 No carrier raw material is stated therefore SO3 is brought into the glass only indirectly by the other raw materials A maximum of 0 15 weight 9o SO in the glass is taken into account by the statement of the saturation value that which is brought in above this amount is considered to be evaporated You can also state only an evaporation value for a component for instance without defining a carrier raw material In the following we add a second main carrier for the oxide Al205 gt Mark the component AI203 in the Nominal Glass Composition table Feldspar is shown as sole carrier raw material of Al2035 in the lower table Add Phonolite as second carrier raw material from the ingredient list to
15. the table Enter a value of 20 in the Ratio column for phonolite Glass Recipe Flint glass modified Glass Components Fixed Ingredients L LIE MISLEUI Component Component iamen T m m SiO 0 1000 Li20 Cad 0 0500 des MgO 500 0 0100 Cr203 Fe203 0 1000 0 Co 0 0001 70 0000 a Tm 7 0500 gt NiO Tid Ingredient AlZO3 4 Spodumene 26 5000 jj g IE D Feldspar low iron 16 5400 Chromite 14 1520 User Manual Example of Application 33 4 3 3 Fixed Ingredients The Fixed Ingredients tab card is divided into the four Fixed Additives Glass Percentages Relative to Ingredients and Relative to Components subareas Sodium sulfate Fixed ingredients are amounts of raw materials or cullet that are not calculated through the nominal chemical composition of the glass but are added to the batch absolutely in kg or relatively in weight related to the glass amount a certain ingredient or a component As a rule raw materials are stated as fixed additives in kg cullet as glass percentage Save the glass recipe and leave the window open to calculate the associated batch recipe in the following step User Manual Example of Application 34 4 4 Calculating Batch Recipe To calculate the batch recipe from the sample glass recipe 2 Click on the Calculate button in the glass recipe window The calculated batch recipe is displayed in the Batch Recipe window At the
16. 00 0 0100 Fe203 0 1000 0 0010 0 0001 13 0000 0 0500 Main Carrier s of SiO sum 100 Ingredient SIOZ 4 Ingredient Ratio 2 64 9000 egilen atio 3 Glass sand low iron 90 a Phonolite 52 6500 Glass sand 10 n Feldspar 69 9560 Feldspar low iron 673400 a Calculate a Report mj Save Save As Close You see in the upper main table the components that should be contained in the glass They were transferred with the arrow buttons from the upper selection list into the table Nominal Tolerance Saturation and Evaporation can be entered for each component in the columns When the batch recipe is calculated the tolerances are checked automatically There is a corresponding warning if a tolerance is exceeded You can state one or several carrier raw materials for each component in the lower table If you have stated more than one carrier raw material for a component you define in the Ratio column the relative percentages for which the stated raw materials should be used related to the dry weights The sum of the percentages must always be 100 NOTE A carrier raw material is a raw material that introduces a chemical component expressed as a percentage of its total chemical composition For example glass sand is normally used as the carrier raw material for SiO When calculating a batch BATCHMAKER automatically takes into consideration other raw materials that also bring
17. 082 a n m tL S E em 2 T _ a oO r in gt 100 Lo VL T00 me Columns 3 wth mol Unit 7108 T 1419 218 C 1003 14 C 1000 1600 Temperature T C 1300 User Manual Example of Application 51 If you select a viscosity fixed point in the upper table the corresponding values are marked in the graphs By using the mouse wheel or the context menu you can enlarge or reduce the visible diagram area To pan the diagram hold down the right mouse button and move the mouse gt Select the Standard view command from the context menu to return to the original scale gt Click the Report button to display the data as a report IE Save As Ej Print Q Print Preview Page Setup Glass Properties Glass Property eoms 59 39 few ensi cm 7I i536 20 0008 fiser OO o reossos gt uemme 8 ew Hyoycass B dE LLL Shear modulus 3053 40 9 Possmsmis zi ze Specife neat 20 C meu jeu peci c heat 800 C uface tension 1300 C Viscosity Viscosity log n dPas 1000 Temperature T C FixedPoit Vawe Amber glass Sample Unit NOTE If you want to save the report including the viscosity curve select Web Archive single file mht as file type User Manual Example of Application 52 4 9 Ca
18. 20 1 1 360 786 8 963 513 2 720 284 5 53 32 308 56 7 8 33 622 258 7 1 684 660 6 You can also have the data displayed in report form here with the Report button The results are copied into the Windows clipboard with the Copy to Clipboard button so that you can process them further in other applications such as Microsoft Excel User Manual Data Exchange 54 5 Data Exchange 5 1 Importing Data from Previous Versions In contrast to previous versions up to BATCHMAKER SUITE EXPRESS 2014 1 data created with BATCHMAKER STANDARD PROFESSIONAL ENTERPRISE is no longer stored directly in folders of the file system but in database files However you can transfer data from older version of BATCHMAKER 5 1 1 Importing Master Data and Analyses If you have stored the master data and the analyses in a common configuration file file extension config gt Select the Configuration command from the File gt Import menu 5 ilis BatchMaker Ente Edit Tools Window Help T New 7 Open Close Analyses Glass Recipe Batch Recipe Glass composition gt Select the desired configuration file file extension config to be imported and click the Open Button 2 Enter a meaningful name for the new database in the New Database window The name of the imported configuration file without file extension is a good candidate for this purpose NOTE In BATCHMAKER STANDARD and PRO
19. ER and the driver of the license module gt Open the Windows Control Panel gt Select the Uninstall a program option gt Mark the ilis SoftwareManager entry in the list of installed programs 2 Click on Uninstall The program and driver files are removed from your computer User Manual Commissioning 9 2 5 Starting and Ending BatchMaker To start BATCHMAKER gt Open the Windows Start menu gt Open the tlis BatchMaker program folder in the Programs menu gt Select the BatchMaker entry NOTE The first program start of BATCHMAKER after booting your computer can take a few seconds depending upon the performance of the computer As an alternative you can double click the program icon F on your desktop to start BATCHMAKER Once you have completed your work with BATCHMAKER you exit the program in the File menu with Exit As an alternative you can click on the Close button of the main window 2 6 Demonstration Mode Without a license or when passing demo as a call parameter BATCHMAKER starts in demonstration mode In this case the addition DEMO appears in the title bar of the main window In demonstration mode any database can be loaded and edited but changes to the data are not stored permanently and will be lost when exiting BATCHMAKER or closing the database The demonstration mode is useful for training purposes or for users who are allowed to view data created with BATCHMAKER but not to change data persistently Us
20. FESSIONAL you cannot import configurations in which more than one plant is defined User Manual Data Exchange 55 The database is created and the plants and furnaces defined in the imported configuration are shown in the File Manager File tdt Took Widow Hep d Gy Se c WW Ef was If you have stored the master data and the analyses in separate files file extensions master and analyses 2 Select the Master Data command from the File Import menu Glass Recipe Batch Recipe Glass composition 2 Select the desired master data file file extension master to be imported and click the Open Button 2 Enter a meaningful name for the new database in the New Database window The name of the imported master data file without file extension is a good candidate for this purpose NOTE In BATCHMAKER STANDARD and PROFESSIONAL you cannot import master data in which more than one plant is defined User Manual Data Exchange 56 The database is created and the plants and furnaces defined in the imported master data are shown in the File Manager File Edit Tools Window Help ae amp wo E EF was gt Select the Analyses command from the File gt Import menu gt Select the desired analyses file file extension analyses to be imported and click the Open Button The analysis data is added to the database User Manual Data Exchange 57 5 1 2 Importing Gla
21. HMAKER your computer system must meet the following requirements E Oo OF OF OF OF 0 QO O 2 2 PC with Intel Pentium 4 processor or compatible Core i5 or better recommended 2 GB main memory 4 GB recommended 1 GB free hard disk storage Color monitor resolution min 1024 x 768 1280 x 1024 or higher recommended Mouse keyboard USB 2 0 interface Operating system Microsoft Windows 7 or higher with current update status Microsoft Internet Explorer Microsoft NET Framework Version 4 5 2 or higher Installing the Software The installation of BATCHMAKER is divided into the following steps O O O NOTE Installation of Microsoft NET framework Installation of BATCHMAKER Installation of the license module Reference is made several times below to file names with the file extension exe or msi These file extensions may not be visible according to the settings of your operating system You require administrator privileges to your computer for installing software and drivers If you are in doubt please contact your system administrator User Manual Commissioning 7 2 2 1 Installing the Microsoft NET Framework Before BATCHMAKER is installed it is necessary that the Microsoft NET Framework 4 5 2 or higher is installed on your computer otherwise BATCHMAKER cannot be used To install the supplied Microsoft NET Framework 4 6 2 Insert the installation medium gt Open the Microsoft folder gt Run t
22. T Chemical Components Energy Sources Options E Edit Analyses and Prices E Edit Glass Recipe E Qe Calculate Batch Recipe E Evaluate Batch Recipe Recalculate Batch Recipe e Compare Batch Recipes QM Calculate Raw Material Usage Calculate Glass Properties e Create Report E e Options Raw Materials and Cullet You define raw materials foreign and factory cullet that you want to use as ingredients in your Glass Recipe and Batch Recipes on the Raw Materials amp Cullet tab card in the Master Data window Note All purchased cullet is designated as foreign cullet in BatchMaker Factory cullet is as a rule cullet originating from the plant s own furnaces Define raw materials and types of cullet Complete at least the ID and Name fields for every raw material and for every type of cullet An entry is identified uniquely by the ID Provided no localized name has been defined the name is used for displaying the entry in other areas of BatchMaker e g when entering the raw materials and cullet used in the Glass Recipe Note By default IDs in BatchMaker are created automatically and are not shown in the table views The default behavior can be changed on the Options tab card Note As soon as you use a raw material or a type of cullet in other areas of BatchMaker you may no longer change its ID However the name can be changed later on without danger You can enter a localized name for the relevant raw material i
23. by double click with the mouse Enter a Humidity in weight if necessary Enter the Price if necessary o 08 O O button into the detail table Enter if necessary the analysis date or the date of delivery under Analysis date Now mark the SiO2 entry in the right lower selection list and move it with the Ki NOTE Alternatively you can double click the entry or use drag amp drop to move the entry to the left table 2 Enter as Percentage of SiO in the raw material spodumene 64 5 wt gt In the same way you can enter the other constituents of spodumen and their percentages in the lower table amp Analyses modified Raw Materials amp Cullet Energy Sources Options Ingredients for Plant Container Glass Ingredient Date Humidity Cobalt oxide Component Na20 K20 Fe203 TiO2 MnQ P205 3 Multiple analyses Single analysis Foreign cullet Amber 225 Chemical Composition of 5podumene sum 99 15 fe Plant Container Glass Price Ingredient EA Nepheline syenite Hematite 28790 00 Glass sand ultrapure 58 00 Selen pellets Percentage Component 0 1500 0 0800 7 5000 0 0500 26 5000 0 0700 0 0100 0 0200 Bad B203 Cr203 CoO CuO V205 5e Ce02 Er203 Md vt Check Iz Save Close NOTE You can mark several entries in the selection lists and add them to the
24. cally only by much experimentation and measurement BATCHMAKER assists you in the development and production of glasses by the automatic calculation and optimization of raw material weights for the glass composition you specify The work with BATCHMAKER can be broken down roughly into four steps O Definition of the master data such as the raw materials types of cullet and chemical components used O Entry and maintenance of the chemical analyses and prices for all raw materials used O Production of glass recipes with statement of the wanted chemical glass composition and if necessary definition of fixed ingredients such as cullet or refining agents O Calculation of batch recipes based upon the desired glass recipes in particular the computation of the raw material weights Moreover BATCHMAKER offers many useful and practical tools such as an integrated File Manager a glass property calculator for predicting and for comparing important glass properties such as viscosity and thermal expansion and a usage calculator for determining the monthly requirement of raw materials and cullet User Manual Introduction 5 1 2 Overview of Sections The Commissioning section contains instructions for installing BATCHMAKER You must work through this section if BATCHMAKER is not yet on your computer system or you want to install a more recent version of the software In Basic Operating Principles the most important operating and display elem
25. dialog file extension GlassProps dll and click the Open button The new library appears in the Registered glass property libraries list gt Activate the required glass properties in the Available glass properties list 2 7 3 Defining Fixed Points The fixed points for parameter dependent glass properties such as viscosity as function of temperature are defined on the Fixed Points tab card You see in the Glass property dropdown list box all functional glass properties that have been activated on the Glass Properties tab card 2 gt Select the required glass property from the Glass property dropdown list box The fixed points of the selected glass property are displayed in the table As a rule the predefined Default fixed points are sufficient for the calculation However if you want to define your own fixed points for example the gob temperature used in the production of hollow glass gt Activate the Enter custom fixed points option User Manual Commissioning 13 gt Place the cursor with the mouse or the cursor keys in the upper table in the first cell of the last still empty row marked with a Annealing point 13 Strain point 14 5 MEN Enter a meaningful Name for the fixed point e g Gob temperature Enter the desired viscosity value into the last column e g 3 gt Use the a and a buttons to move the new fixed point to the desired list position or click the Sort button to sort the list ascending
26. different glasses gt Select the Glass Properties command from the Tools menu or click the icon Es in the toolbar The Glass Properties window opens Ewe Glass Glass 2 Glass 3 Export Export Export Clear Cear Clear Ato att S02 Columns 3 wt mol gt Drag the sample batch recipe Amber glass from the File Manager into the Glass Properties window The calculated glass composition of the batch recipe is loaded into the first column on the table on the left hand side of the window 2 Enter a glass composition of 74 SiO2 16 Na20 and 10 CaO and manually into the second column of the table by default the SiO2 percentage is calculated automatically 2 Enter Sample in the heading of the second column as the name for this composition 2 Click the Calculate button User Manual Example of Application 3 02 30 35 2511 30 010 Minimum mol 0 0000 T Ato adus Columns 3 wt mol 50 Unit 1E 5 K g cm 3 89 40 36 2 493 30 008 Maximum Amber glass mol 4 The glass properties for the two compositions are displayed on the tab cards in the right hand area of the window You define in the Options of BATCHMAKER which properties are calculated here gt Switch to the Viscosity tab card Mame Amberglass Sample Glass 3 Save Save Save 100 0000 100 0000 71 2876 74 0000 12 2047 16 0000 0 7953 Value Amberglass Sample 7 60 7386 2 1461411 4 1038 10 10 5000 2 5000 0 0
27. e location if necessary gt Click the Save button Proceed correspondingly to export a single batch recipe or glass composition NOTE Batch recipes can also be exported using the Export button in the Batch Recipe window You can then exclude certain information e g prices from being exported
28. ents such as windows menus and buttons are described You also find out here how to obtain assistance for the individual program functions The Example of Application section deals with a typical application of BATCHMAKER by reference to sample files supplied with the software You are guided step by step through the program from editing the configuration file through producing a glass recipe up to calculating the corresponding batch recipe and thus you become acquainted with the most important functions of the program In Data Exchange you find information on the data transfer from previous versions of BATCHMAKER and how to use BATCHMAKER data in previous versions 1 3 Conventions To make distinctions clearer different fonts and icons are used in the text Labels and file names User input Cross references O Enumerations 2 User actions 1 4 Customer Support If you have questions on installing or operating BATCHMAKER please contact us at the following address We will be pleased to provide you with further assistance ilis gmbh Konrad Zuse Strabe 22 91052 Erlangen Germany Phone 49 9131 9747790 Fax 49 9131 9747799 E Mail support ilis de Internet www ilis de User Manual Commissioning 6 2 Commissioning In this section you will learn what the minimum requirements of BATCHMAKER are for your computer system and how to install the software on your computer 2 1 System Requirements In order to operate BATC
29. er File Edit Tools Window Help ang 5 m cO HF ED 18 Erlangen Before you complete the master data with furnaces glass types and raw materials and enter the raw material analyses please get familiar with the basic operating principles in section 3 Then learn the fundamental functions of BATCHMAKER with the aid of the application example in section 4 2 8 2 Opening Existing Database To open an existing database in BATCHMAKER 2 Select the Database command from the File Open menu 2 Select the desired database file extension bmdb and click the Open button User Manual Commissioning 16 NOTE You can also select a database from the recently opened databases list in the File gt Open menu The sample database Enterprise bmdb Professional bmdb or Standard bmdb depending on the BATCHMAKER edition is always listed so that you can easily switch back and forth between your own database and the sample data The database is opened and the name of the loaded database is shown in the title bar of the program window File Edit Tools Window Help e BATCHMAKER remembers the recently used database and reopens it automatically at the next program start IMPORTANT NOTE Use the supplied sample database only for training and test purposes but not as a basis for your own data Create a new database for your productive data as described in the previous section User Manual Basic Operating Princ
30. er Manual Commissioning 10 2 7 Setting up BatchMaker At the first start of BATCHMAKER you are requested by a message to check the preferences in the Options dialog and if necessary to adapt them to your requirements BatchMaker Enterprise di No option file could be found Please check your preferences and configure the desired glass properties and fixed points if available in the Options window The Options dialog is opened automatically after you confirm this message Only the most important settings are described in the following sections for a complete reference of the dialog please refer to the Online Help 2 7 1 Adapting Preferences You can make basic settings in BATCHMAKER on the Preferences tab card Preference Regional Settings Language Automatic Multilingual names for plants fumaces glass types and raw materials Range of Functions Edition Enterprise Upgrade Database The range of functions can only be changed if the database is closed File Options Stylesheet directory 2 Select the wanted language of the user interface from the Language dropdown list box If you select Automatic the language setting of your operating system is used User Manual Commissioning 11 gt With the Edition dropdown list you can reduce the functional range of your BATCHMAKER version This setting has an effect on newly created databases only gt In the Stylesheet directory box you can state a folder wit
31. for renaming or deleting and for adapting the display A small folder symbol opposite the relevant file symbol indicates that a file is open for processing in BATCHMAKER You can obtain further information on the File Manager in the Online Help User Manual 3 1 4 Window Bar At the lower edge of the program window you see in a bar which windows in BATCHMAKER are Basic Operating Principles currently open for processing and which window is active i Master Data As soon as you mark an entry in the window list the corresponding window is brought into the foreground E Analyses EJ EM Amber glass a Me Amber glass Using the popup menu you can close or minimize all windows or a selected window NOTE The window bar is only visible if at least two windows are opened 3 2 Obtaining Help You can obtain help on the program features for almost any situation in BATCHMAKER Pressing the F1 key causes a window to appear with a description of the program window in which you are currently located The Online Help of BATCHMAKER offers step by step explanations for all important operating processes Cross references also allow you to find related topics You also have access to the classified table of contents and the index through the Contents and Index menu items in the Help menu Hide Back Forward Print E QR General Operation Q amp File Manager py Edit Master Data Plants Fumaces and Glass
32. h XSL stylesheets which BATCHMAKER should use for displaying reports If you leave the box empty the standard templates provided with BATCHMAKER are used 2 7 2 Selecting Glass Properties On the Glass Properties tab card you can select the glass properties that should be calculated and displayed in the batch calculation and in the glass properties calculator and register additional glass property libraries alass Properties Fixed Points Registered glass property libraries Batch Maker GlassProps dll Remove Available glass properties Group Glass menir Parameter Author rm LITER NN CN r Thermal expansion 1E K er Themnoshock resistance AT K r Density p giem r Refractive index n tchMaker Dispersion d 1E 4 Maker Abbe number V r Chemical resistance ml 0 01 M HO ug Ma20 g Calculate even if the predicted eror is exceeding the model limits To adapt the list of calculated glass properties to your needs select or unselect the checkboxes of the desired glass properties Maximize the Options window to get a better overview NOTE You can adapt the display sequence of the glass properties to your requirements with the and buttons In doing so you can also mark and shift several glass properties simultaneously with SHIFT or CTRL User Manual Commissioning 12 To register a new glass property library 2 Click the Add button gt Select the required library in the Add Glass Property Library
33. h exemplary data for evaluation and training purposes is delivered with BATCHMAKER You can load this database at any time via the File gt Open menu NOTE Please note that the sample files in BATCHMAKER are only provided as examples and cannot be applied to the production unchanged 3 4 Working with Windows In BATCHMAKER several windows can be opened simultaneously e g the master data a glass recipe and a batch recipe You see which windows are currently opened in the window list of the File Manager and in the Window menu If you open several windows at one time note that only the topmost window is active If you select one of the entries the corresponding window is activated and brought into the foreground Please also note that the commands in the menu bar and in the toolbar always refer to the active window in each case For instance if you have opened several glass recipes then the Calculate command in the Edit menu acts only on the glass recipe in the currently active window User Manual Example of Application 22 4 Example of Application The objective of this section is the calculation of a batch recipe with reference to the sample data supplied with BATCHMAKER For this purpose the master data and analyses are opened and complemented with another raw material and its analysis An existing glass recipe is then adapted A batch recipe is then calculated from the glass recipe data and displayed as a report Finally you learn
34. he Open command from the popup menu File Edit Tools Window Help ae amp wo El c i Container Glass EHE Amber glass Ef ans Alternatively you can open the glass recipe by double clicking or by dragging it with the mouse from the File Manager into the workspace The file is loaded and displayed in the Glass Recipe window User Manual Example of Application 29 4 3 1 General The master data of the glass recipe are summarized on the first General tab card amp Glass Recipe Flint glass General Glass Components Fixed Ingredients Melting Energy Plant Container Glass Batch type Mixer batch Fumace Fumace 2 Batch size 3000 kg Glass type Hint Mominal adjustment s02 Fumace load Empty weights Eliminate and notify Comment Accept nominal values for components without carrier Protect glass recipe from changes af Calculate amp Repot Eis Swe Chose O Plant Furnace and Glass type describe for which furnace in which plant and for which glass type the glass recipe should be valid Here you can select the data that you have defined in the currently loaded master data under Plants Furnaces amp Glass Types NOTE So that you can enter the glass composition and the fixed ingredients the plant at least must be selected on the General tab card Otherwise the raw materials and cullet assigned to the plant are no
35. he file NDP46 KB3045557 x86 x64 AIIOS ENU exe by double clicking and follow the instructions of the setup program gt To install the German Language Pack for the Microsoft NET Framework 4 6 run the file NDP46 KB3045557 x86 x64 AIIOS DEU exe from the installation medium und follow the instructions of the setup program If required you can download language packs for other languages at http www microsoft com en US download details aspx id 48135 2 2 2 Installing BatchMaker NOTE You can install and use BATCHMAKER STANDARD PROFESSIONAL ENTERPRISE parallel to BATCHMAKER SUITE and BATCHMAKER EXPRESS versions 2008 1 to 2014 1 In case of BATCHMAKER 2007 or earlier you have to ensure that the installation path differs from the current version If necessary uninstall the old version and reinstall it a different folder than C Program Files x86 ilis BatchMaker before installing the new version To install BATCHMAKER on your computer gt Insert the installation medium gt Run the BatchMaker setup msi file and follow the instructions of the setup program 2 2 3 Installing the License Module BATCHMAKER is delivered with a license module dongle which is plugged into a USB port of the computer The license module contains your customer data and protects the software against unauthorized access NOTE If the license module is lost the license to use the software expires To install the ILIS SOFTWAREMANAGER and the driver of t
36. he glass to be produced e g the nominal chemical composition the raw materials used and the cullet added Several glass recipes can be opened simultaneously in BATCHMAKER Batch Recipes A batch recipe can be entered manually or calculated automatically from the data in a glass recipe and the current raw material analyses A batch recipe contains the weights of raw materials and cullet for production as well as the glass composition calculated from these Furthermore a batch recipe in BATCHMAKER contains additional data such as glass properties which are also calculated from the raw material weights As for glass recipes several batch recipes can be opened simultaneously in BATCHMAKER Glass Compositions A glass composition contains the chemical composition of a glass Glass compositions can be saved and loaded within the glass property calculator User Manual Basic Operating Principles 21 3 3 2 Storage Location of Databases As standard the C ProgramData ilis BatchMaker folder is suggested as storage location for BATCHMAKER database files that you create with BATCHMAKER You can and Should store your files also in a different folder e g on a network drive BATCHMAKER remembers the folder last used You can handle BATCHMAKER databases in Windows Explorer just like other files e g copying or renaming 3 3 3 Sample Data A database Enterprise bmdb Professional bmdb or Standard bmdb depending on the BATCHMAKER edition wit
37. he license module on your computer 2 Insert the installation medium 2 Run the SoftwareManager Setup exe file and follow the instructions of the installation program NOTE To ensure that the USB license module is correctly recognized you must be logged in with local administrator rights when it is plugged in Do not remove the license module as long as the computer is switched on User Manual Commissioning 8 2 3 Updating the License The license module is provided with an operating time limit on delivery The license module and thus the software can be used for an unlimited time only after importing a special activation file which will be sent to you by email To update the license gt Double click the license file made available to you file extension v2c The ilis SoftwareManager program opens 2 Click on Update License The license is updated 2 4 Uninstalling the Software 2 4 1 Uninstalling BatchMaker To uninstall BATCHMAKER 2 Open the Windows Control Panel 2 Select the Uninstall a program option gt Mark the BatchMaker entry in the list of installed programs 2 Click on Uninstall The program files are removed from your computer NOTE The data files you have created such as glass recipes batch recipes etc are not removed by the uninstall program and must be deleted manually if necessary by default C ProgramData ilis BatchMaker 2 4 2 Uninstalling the License Module To uninstall the ILIS SOFTWAREMANAG
38. he window User Manual Example of Application 39 4 4 5 Glass Properties The glass properties calculated from the glass composition are listed on the Glass Properties tab card You can configure in the Options window which glass properties are calculated here 5 01 0 35 1E 5 K 2502 0011 g cm Refractive index 1 5220 30 0022 Abe number SBME Chemical resistance 188 ug Na20 g Hydrotytic class 3 Young s modulus 74 18 1 70 GPa Minimum Maximum Value mol mol 5 C In this example the value for the Young s modulus is highlighted in yellow since the validity limits defined for this property have been exceeded If you mark the corresponding row with the mouse you will see in the lower table the violated validity limits for this property and the calculated value for these User Manual Example of Application 40 4 4 6 Functional Glass Properties If functional glass properties are activated in the options further tab cards e g for viscosity or electrical conductivity appear as appropriate For instance the temperatures calculated for the specified viscosity fixed points are listed and displayed graphically on the Viscosity tab card You can select arbitrary points on the viscosity curve The associated values are displayed in the boxes below the table carat m Viscosity 2 UJ 1460 1 16 00 pt TA put IU cris E IEEE i 4 00 1038 10 l al al pm EL z E tee Is 2 al ao o p Temperature T 922
39. ion and data included in this documentation is provided without guarantee and is subject to change at any time without prior notification The BatchMaker software and the corresponding hardware the license module may only be used on a single computer i e on the central unit in one location By purchasing this package the buyer acquires ownership of the data media and the hardware provided with the software but no rights to the software itself This applies in particular to all rights for duplication processing and rights of usage for commercial gain of the software The software as well as the documentation are protected by copyright law The license holder is permitted to make one reserve copy for backup purposes The copyright protection must be noted on this reserve copy The software and documentation may not in any way be modified duplicated or used to create derived products It is forbidden to decompile the software or to remove the copy protection Based on the current state of the art it is not possible to produce software that works free of errors in all application combinations ilis gmbh is therefore not liable for damages arising through the use of the software or the hardware delivered with it The names of products and companies cited in this documentation may be protected by trademarks of their respective proprietors User Manual Table of Contents 3 Table of Contents Eugene T IIS TIO UITIUM 4 Desh oisuoclleiue n N
40. iples 17 3 Basic Operating Principles This section explains the basic principles required to operate BATCHMAKER The user interface consists essentially of standard elements such as windows menus and buttons and you will be familiar with the way they are used from other Windows programs The following section assumes that you are familiar with basic information on how to work with the Windows operating system If you are not familiar with this information you should first consult the Windows documentation 3 1 User Interface The main window of BATCHMAKER is subdivided into four areas File Edit Tools Window Help O You can reach all program functions through the menu bar at the upper edge of the window O The most important program functions are accessible via large icons in the tool bar underneath the menu bar O The File Manager in the left margin of the window provides you fast access to your data O The remaining workspace is available for entry and evaluation windows Like most of the other windows the main window has buttons in the top right corner to maximize minimize or close the window You can move the window to any position on your screen and change the size of the window BATCHMAKER takes note of the position and size of the window and restores these the next time you open the program User Manual Basic Operating Principles 18 3 1 1 Menu Bar You can use the menu bar to reach all functions of the program T
41. lculating Raw Material Usage BATCHMAKER contains a usage calculator with which you can calculate from arbitrary batch recipes over selectable periods and tonnages the total consumption and the costs of raw materials and cullet gt Select the Raw Material Usage command from the Tools menu or click the icon n in the toolbar The Raw Material Usage window opens Prices As defined in batch recipes Remove E Calculate Copy to Clipboard 2 Drag the sample batch recipe Amber glass from the File Manager into the Raw Material Usage window The batch recipe is loaded and inserted in the Batches and furnace loads list 2 Enter the value 30 as Factor The batch recipe should therefore be used in production for thirty days with an average Load of 340 t 2 Insert in this way one after another the Flint glass sample batch recipe with a factor of 30 and Green glass with a factor of 20 2 Click the Calculate button The total usages and the batch costs of all raw materials and cullet used in these batch recipes appear in the right hand table User Manual Example of Application 4232 291 4 2 820 522 3 1 780 453 4 1 900 011 8 1 035 563 1 528 89 5 343 744 D 7 4 535 1 54 4411 20 079 2 17 2215 5 333 7 7432 9624 56722152 4 3293 711 6 1 360 786 8 963 513 2 7 20 284 5 2 993 426 5 1 780 453 4 1 500 011 8 1 035 563 1 528 89 5 343 744 0 4 635 1 54 441 20 079 2 17 2215 5 333 7 7 590 754 2 5 802 777 8 4 415 8
42. ly by value Glass property Use default fixed points Enter custom fixed points User Manual Commissioning 14 2 8 Creating or Opening Database When starting BATCHMAKER for the first time after the installation no database is initially loaded As a first step you have to create a new database or open an existing database for editing 2 8 1 Creating New Database To create a new empty database gt Select the Database command from the File gt New menu ise 2015 indow Help amp Glass Recipe Ww Batch Recipe Plant name Erlangen Quantity units Metric kg and t US b and ton Currency symbol E Energy unit amp kWh GJ ox tme 2 Enter a meaningful Plant name for the first plant of your organization e g the location 2 Check the Quantity units the Currency symbol and the Energy unit and adapt them to your needs if necessary NOTE You can change these settings later on the Options tab card of the Master Data window if becoming necessary gt Confirm your input with OK The Save New Database window is opened 2 Enter a meaningful file name for the new database e g the name of your company or organization 2 Click the Save button User Manual Commissioning 15 The database is created and the Master Data window is opened The new plant is shown in the Plants list of the Plants Furnaces amp Glass Types tab card and on the left in the File Manag
43. mE C Pd Ead 20 Su Working WIE WICIQGOWS seated eee e tear eb Ea y cate D e ee hp a ct ao ede a cfe ade 21 A Example OF Ap OllCaliOn scar cosutsaveesodearesduviacdasnianncereermednianvaiaaaetedaneeens 22 4 1 Opening the Sadample DatabasQ u uds aep VR bx EE Xn pA VEA UN REESE VUE VE ERVEX UE 22 42 Editing Master Data and Analyses uius voro perd vk RARE A VESSANAW VERE T EE EC ada aa 23 4 3 Opening and Editing Glass Recipe ssseseeeeeeeeee nennen 28 AA CalculatifiGu Balch RECIPES airna aed patina acta Sorel Ore aed pak inna ume DM P LDU DIPL 34 4 5 JRe calculaumdg Batch Reclpeostebata dm Su RENE Menu NUM MERO deena ea dune as Mane RE tenner ats 42 4 5 Creating Bateh Recipe Manually aisi vac nubit rav xd pre oU vex DU OVI UT EDU E pU RE 44 A J COMpPArING Bath RECIPES iriure irna prr ret th vis Sie deve er ER VEU Raf d ced th takes bn ex a 47 A B Calculating Glass Propertie S i ssetetibrd tatit toda baa qud b pe d LATIS EOS NN Dn CoD Uns 49 4 9 Calculating Raw Material Usage issssseeeeeeeee nennen 52 BD Pata Exelalideus tasted du tea aM A MMC CM A HM ME 54 5 1 Importing Data from Previous Versions cceeeeeen nme emen nnn nnn 54 5 2 Using Data in Previous Versions sassuasrsnsannnannsunansnnannunannunannunannnannnnannann 60 User Manual Introduction 4 1 Introduction This user manual describes the installation of BATCHMAKER and provides an introduction into the use of the software based on an
44. mix 92260 9 2260 88789 3977 776 Factory cullet Flint 7290114 729 0111 Close the Report window User Manual Example of Application 42 4 5 Recalculating Batch Recipe In the so called correction test the theoretical glass composition synthesis is recalculated and checked against the tolerances on the basis of the current chemical analyses and of the weights contained in the batch recipe Therefore with this function you can check quickly and simply whether a tolerance is exceeded by the change of the chemical analyses e g for a new raw material delivery and due to this a recalculation from the glass recipe is necessary In the following example the chemical analyses are changed so that the tolerance for Fe203 is complied with For instance in practice you have received a new raw material delivery with a changed analysis 2 Open the Analyses window via the Edit Analyses menu command or via the icon V Edit Analyses in the toolbar Mark the ingredient Phonolite in the upper table Change in the lower table the Percentage of Fe203 from 3 798 to 0 798 and the percentage of SiO from 52 65 to 55 65 Raw Materials amp Cullet Plant Container Glass Ingredient Date Humidity Price Ingredient Nepheline syenite M Hematite Dolomite low iron PE elie Selen pellets Coke powder Dolomite Component Percentage Component jor 5i02 556500 PbO J Na20 nm Ba K20 Cad MgO A203
45. n the Name lt language column The displayed language corresponds to the current Windows language setting To enter a name in several languages set the wanted language in your Windows interface and then enter a corresponding name in User Manual Basic Operating Principles 20 3 3 Working with Files 3 3 1 Data Types There are essentially the following types of data with which you work in BATCHMAKER O Master data O Analyses O Glass recipes O Batch recipes O Glass compositions All files created with BATCHMAKER are automatically stored in a database file extension bmdb Via the File gt New gt Database menu command you can create an arbitrary number of databases and load them into BATCHMAKER using the File gt Open menu or double clicking a database file However only one database can be loaded at a time BATCHMAKER remembers the currently used database and reopens it automatically at the next program start The name of the used database is shown in the title bar of the program window Master Data In the master data you define all basic elements which are referenced in other parts of BATCHMAKER e g plants furnaces glass types raw materials and chemical components Analyses In the analyses data you organize all chemical analyses and price information that you require for producing glass recipes and calculating batch recipes Glass Recipes A glass recipe in BATCHMAKER contains the specification for t
46. o PS 4 l2 OVERVIEW or Sectlolis vui sisenvitetie tine hduitun eecde tine sad tan pt rue PONE A pra LM cCR Ea RES DES 5 te CONVENON S are PCR 5 1 4 GUSCOMIEr SUDDORG cadi uosesubveex cactwe lien dateey dante vues e oer ur TvE da tad tisse tnu eu nae 5 2 COMMISSIONING esaa sed DT 6 2l System RequitemieliUS cacenesteni deua ps cale mr eti doni tee Decide goto EE 6 2 2 Installing the SOTtWaEGasebescebeekurrtwwkROtura wed u EE Vebepts beabur ruwvebosdra e odu EE Vebupsk apibus rs 6 2 59 Updating the BICelSeusdsvotu cR ERE aite Fred Eaton re pOlER E ER CERE ad FRE Catus LE BOSE PERDE 8 2 4 Uninstalling the SOT WOFe sssrseed sitse sa suykuas VERREREPPEFFEPELFKRERERTRFEEET VEREFEFEEPEFF RE FeiER 8 2 5b Starting and Ending BatchMaKker ssscssxessese d vex Ue A Es VOU EAE VC X PE US d EVO RE Ue D DEL int 9 2 0 Demonstratlol Mode ossis Ea uu add Rua EY Vea a veu va D Va at ew wa EY VD RR a 9 2 7 iSetuhg Up Balen Maker sse d tid bati Ped ote ta pce Eti dta A MD NES LEE 10 2 0 Creating or Opening Database u eee rr Ren en p e YER OUR CC UY C Ee C ET D Rn 14 3 Basic Operating Principles eeeeeeeeeeeeesee nennen rh nnn ann nn 17 Sob deer Interfaces curtain EDUC E RERO RP FRE DOE RUGERE PEE ELDER QUEUE ERE DUC R CGPRI VK EE KREIS 17 3 2 JObDEbalning Felbpvauasdosnaagtdbi PEDE EEREEOREES EAE RIA qao rm EE UREEFEORIES AUDIAT ER ar dE 19 93 NVOEKING WILD PINGS saris ace aiteiqid Races ide PI Ree EROR AE caer aa RE Pee Fea
47. o open a menu click on it with the mouse You can select a menu item within a menu by pointing and clicking in a Similar manner For a complete description of all menu commands please refer to the Online Help 3 1 2 Toolbar The most important menu items are combined in the toolbar For example you can create a new glass recipe by selecting the New gt Glass Recipe menu item in the File menu or simply by clicking on the icon c New Glass Recipe in the toolbar If you let the cursor rest on an icon for some time an information text on the function of the icon appears d X exo 3 1 3 File Manager You see in the File Manager all files stored in the currently used database organized by plants furnaces glass types and glass recipes File Edit Tools Window Help e v S Uc HW e E Container Glass DE Hint glass a fy Green glass E Float Glass ee Soda Lime Glas Ea Tableware elet Del Glass compositi E Amber glas Ej Clear float Show Folders Eq Crystal glass E Emerald float i fed Flint glass beeen Es Green gl FERI PA ead renstal You have several possibilities of opening a file from the File Manager For instance you can drag it by Drag amp Drop into the working area of BATCHMAKER use the Open command in the popup menu of the File Manager or double click the file Further commands for working with files are available to you in the popup menu of the File Manager for instance
48. s as of row the date and the time of the last saving of the associated analyses file The Valid from row states the time from which this batch recipe should be used in production You can change this value using the Valid From button The nominal value correction performed in the calculation is stated in the Nominal value adjustment row In this example the nominal value for SiO was increased by 0 0895 The Redox number of the batch was calculated from the weights on the basis of the Redox factors filed in the master data User Manual Example of Application 36 4 4 2 Summary The summed weights humidities melting losses glass percentages glass amounts and price percentages of raw materials factory cullet and foreign cullet are listed on the Summary tab card In addition information on the total amount of glass produced is displayed the total cullet percentage and the glass price percentages for the raw materials and cullet used User Manual Example of Application 37 4 4 3 Batch Ingredients The individual raw material and cullet weights dry and wet as well as the relevant melting losses glass cost and price percentages are listed on the Batch Ingredients tab card The oxide balance of the raw material marked in the left table in each case is shown in the detail table in the right part of the window 1516 8311 456 3377 380 4913 231 6806 168 5368 145 5173 40 0000 40 0000 36 3793 36 3733 15 0000 15 0000 9 2260 9
49. signed to batch recipe if applicable User Manual Example of Application 45 2 Mark the first desired ingredient in the selection list and press the button to add it to the left table Repeat this procedure until all desired ingredients are listed in the table 2 Enter the desired amount for each ingredient into the Dry weight or Wet weight column 2 Click the Calculate button to create the batch recipe from the input and display it in a new window User Manual Example of Application 46 gt Switch to the Glass Components tab card to view the calculated theoretical glass composition synthesis lass Components Component Synthesis Molar Raw material Culet Foreign cul X synthesis analysis analysis analy 5 i 71 409 70 4333 71 2683 l Ingredient Absolute Relative 12 6922 2 2 0 8113 Foreign cul 10 2717 Glass sand 20 1574 2823 20841 Fadoycu 64132 898 0 0172 Feldspar 1 8929 2 65 0 0310 Dolomite 0 0412 0 06 1 8568 EE j 2 0 0257 0 04 0 3804 Chromite 0 0058 0 01 0 1822 Sodit ie 0 0001 0 00 0 0111 0 0055 0 0628 0 0339 0 0772 nma gt Close the Batch Recipe window NOTE As an alternative to manual input you can also import the weights from an existing batch recipe and amend the values For this purpose drag the desired batch recipe from the File Manager into the New Batch Recipe window User Manual Example of Application 47 4 7 Comparing Batch Recipes BATCHMAKER contains
50. ss Recipes Following the master data and analyses you can import the existing glass recipes gt Select the Glass Recipe command from the File gt Import menu File Edit Tools Window Help 2 Select one or more glass recipes file extension recipe to be imported and click the Open button The selected glass recipes are added to the database and shown in the File Manager according to the corresponding plant furnace and glass type File Edit Edit Tools Window Help decd acne aa Container Glass gt Repeat this procedure until all desired glass recipes have been imported NOTE As an alternative to the menu command you can import glass recipes by dragging them from the Windows Explorer into the BATCHMAKER window User Manual Data Exchange 58 5 1 3 Importing Batch Recipes Following the glass recipes you can import the existing batch recipes gt Select the Batch Recipe command from the File gt Import menu is BatchMaker File Edit Tools Window Help gt Select one or more batch recipes file extension batch to be imported and click the Open button The selected batch recipes are added to the database and shown in the File Manager according to the corresponding plant furnace glass type and glass recipe is BatchMake File Edit Tools Window Help d e amp wm Ej WV E48 Container Glass OD Fumace EMES Amber Ef was NOTE BATCHMAKER attempts
51. t available in the glass recipe O Under Batch Type you can select whether the batch recipe should be calculated related to a mixer batch to the glass amount to be produced with or without cullet additives or to a certain raw material O You enter in the Batch size box according to selection in the Batch Type dropdown list box the amount in kg that should be used as basis for the calculation of the batch recipe O You enter in the Furnace Load box optionally the average glass amount produced per day The required batches per day are calculated from this in the batch recipe User Manual Example of Application 30 O You select from the Nominal adjustment dropdown list box a component that should be used for automatic nominal value adjustment Example You specify in the glass recipe a nominal composition that results in total in 99 in order to leave some play namely 1 for impurities that are necessarily brought into the glass by raw materials and cullet However in fact 1 25 impurities are brought in so that the total sum would be 100 25 In this case the nominal value of the component selected here is adjusted so that the sum of the nominal composition results in 98 75 therefore 100 including the 1 25 impurities If you do not want to perform an automatic nominal value adjustment select the None entry In this case the components are adjusted proportionately so that the sum of the calculated glass composition results in 100
52. table at the same time by holding the SHIFT or CTRL key down The entries that you have already added to the tables are no longer displayed in the corresponding selection list User Manual Example of Application 27 2 Click the Report button to have all analyses clearly displayed in a table IE Save As g Print Q Print Preview Page Setup Analyses for Plant Container Glass sa mY T aa eee material Glass sand 33 00 99 7200 0 0620 0 0284 0 0580 0 0168 0 0450 low iron Glasssand 550 ases vam vum va vora rep wien zm vous pum sess owe forootan forst owa Fomo L Limestone 1500 0 6582 0 0436 0 4523 553590 02805 0168501258 f 0 0180 Limestone 19 00 0 0520 0 4560 55 8534 0 2510 0 0850 0 0750 0 0085 a iron Dolomite 3200 1 1420 0 0956 04657 31 8750 20 1540 404215 04722 amp 0 0325 c NN NN 46 00 0 0230 0 0293 0 0002 30 8522 21 6030 mC 0 1520 0 0139 b 0 0032 Phonoite 3800526500 5 9430 4 0350 79500 0 5260 175680 37980 0315 Caumte 76 00 sa 620 03670 3750 Mason o2 mee o2egaf_ _ __ 0 3870 8100 69 9560 1 7560 11 1040 0 3850 0 0540 165400 0 1350 00645 EI Er Bis ome om ommo o em core coma oven om o o cS sn sol fo 31600 2 __
53. to assign the imported batch recipe to the corresponding glass recipe on the basis of the name This is possible if the name of the batch recipes starts with the name of the glass recipe Unassigned or falsely assigned batch recipes can be reassigned subsequently to a glass recipe using Drag amp Drop in the File Manager gt Repeat this procedure until all desired batch recipes have been imported User Manual Data Exchange 59 NOTE As an alternative to the menu command you can import batch recipes by dragging them from the Windows Explorer into the BATCHMAKER window 5 1 4 Importing Glass Compositions If you want to import a glass composition created with a previous version gt Select the Glass Composition command from the File gt Import menu gt Select one or more glass compositions file extension comp to be imported and click the Open button The selected glass compositions are added to the database and shown in the lower part of the File Manager File Edit Tools Window Help d e amp io c El Eu Container Glass EE Fumace 1 H Fumace 2 EMO Fumace 3 lah Float Glass EE Line 2 EM Line 3 Eig Soda Lime Glass Ef wna Ea Tableware EHE Day tank HES Pot fumace E1 f7 Glass compositions NOTE As an alternative to the menu command you can import glass compositions by dragging them from the Windows Explorer into the BATCHMAKER window User Manual Data Exchange 60 5 2
54. to compare batch recipes and to work with the glass property calculator and the raw material usage calculator NOTE All parts of the individual windows are not discussed in detail in this manual You will find a detailed description of all windows and functions in the Online Help 4 1 Opening the Sample Database A database must always be loaded to enable work to be done with BATCHMAKER To open the provided sample database gt Goto the File gt Open menu gt From the list select the Enterprise bmdb Professional bmdb or Standard bmdb entry depending on the BATCHMAKER edition The database is opened and its content is displayed in the File Manager The name of the loaded database is shown in the title bar of the program window File Edit Tools Window Help ay User Manual Example of Application 23 4 2 4 2 1 Editing Master Data and Analyses Opening Master Data Window To open the master data for display and or editing select the Edit gt Master Data menu command or click the icon Edit Master Data in the toolbar The Master Data window is opened Plants Fumaces amp Glass Types Raw Materials amp Cullet Energy Sources Chemical Components Options Plants Name Float Glass Green Soda Lime Glass Amber Tableware Supernwhite Lead crystal Crystal glass a E3 Sort Name Fumace 2 Fumace 3 J Le L9 OMe v sot Dee Repot Rre Rise Ge
55. tor t CO2A Name Meodymium oxide Foreign cullet Amber Foreign cullet Green Foreign cullet Flint Heat cullet Green Hat cullet White Float cullet Superwhite Factory cullet Amber j 0 0200 0 0050 0 0020 Hi i AH pere TI i 3b E E Fo rej gn 4 Factory il ERES Name Redox Emission factor Comment factor t CO2A Neodymium oxide Fin tb Fumcda r 0020 Foreign cullet Green Fore 0 0050 Foreign cullet Flint Fore 0 0020 Heat cullet Green Float cullet White Float cullet Superwhite Factory cullet Amber 2 Click the Save button to accept your changes User Manual Example of Application 25 4 2 3 Opening Analyses Window To open the analyses for display and or editing select the Edit gt Analyses amp Prices menu command or click the icon Edit Analyses in the toolbar The Analyses amp Prices window is opened co f Raw Materials amp Cullet Energy Sources Options Ingredients for Plant Container Glass Plant Container Glass Ingredient Date Humidity Ingredient 4 A 3 Nepheline syenite Glass sand low iron 450 33 00 Hematite 1 Glass sand 230 23 00 lt Glass sand ultrapure Soda ash 165 00 Selen pellets Limestone 15 00 e Potash Composition of Glass sand low iron sum 99 944 Component Percentage Component 2 am o CaO 0 0620 MgO 0 0284 AI203 0 0580 Fe203 0 0168 Cr203 0 0012 TiO2 00450 4
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