Inline gas measurement verifies the gas fill rate of sealed units directly after the gas press, without breaking the glass structure. This page brings together what IG manufacturers need to evaluate automated measurement: a glass compatibility check, an ROI calculator, an integration checklist and results from production lines already using it.
| Factor | Detail |
|---|---|
| Measurement point | Directly after the gas press |
| Technology | TDLAS: the device measures oxygen and converts the result to argon, krypton or other insulating gas concentration |
| Glass types | Double and triple glazing, including most coated and laminated glass |
| Space needed | 700 mm of free space in the IG line (Laser Integrated) |
| Measurement time | Double glazing approx. 9 to 22 s, triple glazing approx. 13 to 26 s, when unit dimensions are received from the line |
| Data | Every result stored per unit and transferable to the IG line or ERP system |
The gas press is the point where the gas fill rate of an insulating glass unit is decided, and the result cannot be checked visually. Filling accuracy varies with glass type, unit size and flatness. Manual spot checks cover only a sample of production, so underfilled units can reach customers undetected.
Measuring every unit inline changes this:
Laser measurement works through most coatings and laminations, but compatibility depends on the unit structure. The Sparklike Laser Compatibility Checker lets you select a double or triple configuration, choose the glass type for each pane from a list and see the result immediately.
Sparklike offers two ways to bring TDLAS gas measurement into an IG line. Both use the same measurement technology. The difference is who builds the mechanical integration.
| Sparklike Laser Integrated™ | Sparklike Laser Components™ | |
|---|---|---|
| Suited for | IG manufacturers who want a complete measuring station | IG manufacturers with in-house automation, IG line builders, system integrators and OEM partners |
| Sparklike delivers | Measuring station including device, mechanical integration and movement system | Measuring head, electrical cabinet, user interface software, cabling and data analysis software |
| Buyer provides | Installation site preparation (see Step 4) | Mechanical movement system, fastening, IG line communication, integration engineering and argon flushing supply |
| Additional | Turnkey, adaptable to most line configurations | Lower investment cost; also measures cavity and glass thickness |
The ROI calculator compares your current gas quality control costs with the investment in Sparklike Laser Integrated. It works in four steps: current QC labour and sampling costs, optional warranty and defect costs, device investment and gas savings, and a summary with payback period and five-year comparison.
The conservative estimate uses QC cost savings only. Warranty, defect and gas optimisation savings are shown separately as additional justification.
Laser Integrated is installed next to the IG line after the gas press, on a flat floor, touching only the units. Glass types and line specifics are mapped during the purchasing process, so the device limitations and features are known before installation. Contact persons from the customer and the IG line producer coordinate settings and stay available during installation.
On site, the customer arranges a 240 V power supply, an electrician for high voltage coupling, floor anchoring for the station, access equipment, and an internet and IG line connection that meets data security requirements. Minor production interruptions should be expected during integration.
Isophon Glas in Germany installed Sparklike Laser Integrated to verify the gas fill rate of the majority of its production. After two years of operation, the company is installing a second system on its new IG line. Isophon uses Sparklike Laser Portable alongside the inline system to double-check results that fall outside target.
Laser Integrated is also in use at for example MI Windows and Doors, Glaseksperten, Q4Glass and EDL Glass.
All positive – the system works reliably and delivers values that can be verified with the portable system – within the scope of the measurement accuracy.
Directly after the gas press. Measuring at this point shows the gas fill rate before secondary sealing and further processing, so deviations can be corrected immediately.
With Sparklike Laser Integrated, approx. 9 to 22 seconds for double glazing and 13 to 26 seconds for triple glazing when unit dimensions are received from the IG line.
Without line data, approx. 25 to 38 seconds and 31 to 44 seconds.
Yes. TDLAS measurement works for double and triple glazing, including most coated and laminated glass. Use the Laser Compatibility Checker to confirm your specific structure.
Both use the same TDLAS measurement technology. Laser Integrated is a complete measuring station including the mechanical integration. With Laser Components, the buyer builds the movement system and line communication.
Each result is stored per unit and can be sent to the IG line or ERP system. The data supports quality documentation, customer reporting and gas press adjustment.
Book a free online product presentation to review your glass types, line layout and integration route with a Sparklike specialist.
