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End Port Furnace Typical TECO Side Port Furnace
As TECO works with its clients by taking a project from conception to production, questions may arise. This section is devoted to some frequently asked questions that may be of interest and benefit to you.
Why should I discuss my project needs with TECO?
TECO has more than 80 years of experience serving the world wide glass industry. We have designed and built over 1000 furnaces of all types. Secondly, TECO is involved with all aspects of a glass plant from the batch plant through the shipping dock. On major projects, TECO frequently gets involved with site selection and evaluation.

TECO is not a manufacturer of equipment, nor are we involved with supply of materials of construction. Thus, we can provide our clients with an unbiased solution that will optimize both capital and operating costs.
How is a glass melting furnace different from other pieces of plant equipment?
It is likely to be the biggest piece of equipment in the plant and because it is the source of molten glass, the plant cannot function without it. Because of size, furnaces are assembled and built on site. This is different from many other types of equipment that can be brought in completely assembled and set into place. Because of this, the integration of engineering and construction aspects demands excellence in project management.
How is purchasing a glass melting furnace different from other pieces of equipment?
In addition to cost, other services that are bundled with the furnace should be considered seriously. Technical service and project management are an important aspect of the delivery process that are often overlooked; however, their effect on the overall cost are significant. These services have important risk management implications in the buying and delivery process.
How should I begin the process of selecting a glass melting furnace provider?
Understand the fulfillment capability, financial strength and credit-worth of the potential vendors. The successful execution of glass melting furnace projects require technical strength in the following:
  • Thermal process design (i.e. the ability to design from basic engineering principles)
  • Refractory design
  • Structural steel design
  • Mechanical and electrical systems design
  • Industry regulatory issues
  • Construction
  • Project management
  • Field service
  • Operational troubleshooting
Financial strength of the vendor has inherent implications to the risk of any projects entrusted to that vendor. For projects that have large material procurement and construction components, credit-worth has implications to the underlying cost structure and ability to meet financial obligation.
How much of a project can TECO handle?
TECO can handle a complete glass manufacturing plant on a design/build basis, utilizing the client's forming technology and/or forming technology provided by others. Also, TECO can handle segments of a project such as a batch plant, furnace, forehearths, etc.
Can TECO really improve performance and percent pack of any type of glass manufacturing process?
TECO can maximize glass manufacturing performance in several ways.

    At the Batch Plant
    The mixed batch quality can be maximized with mass flow design of raw materials and the mixed batch handling. Batch system performance is also maximized by utilizing high resolution feeding devices and scales. The scale system is designed to be immune to air pressure and vibration.
    At the Furnace
    On new furnace applications, computer modeling and our many years of furnace design experience are utilized to determine ideal furnace parameters, firing practice, refractory selection and refining capability to maximize glass quality. Regarding the glass conditioning, prior to forming, this can be modeled to achieve the constant glass temperature required to suit the forming process. For highly volatile glasses, volatilization can be reduced to practically zero utilizing a muffled forehearth design.
TECO has the wherewithal to be able to deliver the necessary glass quality to achieve the maximum percent pack of any type of glass product.
What is the practical way to get started on improving performance?
For a new application, start working with TECO in the early planning phases so the necessary parameters and scope can be established and a program developed for accomplishing the task within budget and schedule constraints. For modernization of existing processes, a field audit is required to establish parameters and scope.
If the client has an existing glass manufacturing process, can performance be improved while in operation?
Batch plants can be modernized while maintaining glass production. Also, furnace systems can be improved while in operation by altering the combustion system, adding bubblers and/or electric boost. The improvement of the post forming operation can be improved on the run.
What can be done to minimize the cost of a project?
The TECO project management team utilizes over 80 years of project management experience on glass industry projects as a basis for controlling all activity and costs on a project. Essential materials and equipment are purchased while the engineering is in process and equipment and materials arrive at the site "just in time". The entire project is under tight control. TECO never misses a scheduled start up date.

Project scope should be clarified early and changed as little as possible. Scope changes are the prime reason most projects go over budget and schedule.
Does TECO continue to be interested in the project after start up?
TECO stays on site until the process is working to contract performance specifications and customer satisfaction. During the first year, TECO maintains contact with the client on a quarterly basis. For subsequent years, we suggest an audit on an annual basis so the campaign life of a furnace can be monitored and maximized. Planning for the rebuild should take place well in advance of the shut-down.
What about cost?
A TECO project will yield the lowest capital cost when including the longer campaign life, improved efficiency of operation and increased product pack resulting from the increased glass quality produced. TECO provides budget estimate information to enable our customers to make appropriate financial decisions.
Why is risk management an important consideration?
Every company differs in their ability and willingness to tolerate risk, particularly with large capital intensive projects. Because the design and building of a glass plant is a highly customized and service intensive undertaking, risk can manifest itself in many ways:
Financial risk
What would happen if someone in the supply chain (contractor or supplier) underestimates the cost of a critical component or is unable to perform? Can your company complete performance if a contractor is unable to do so? Do all the contractors and suppliers have the financial strength to meet their commitments?

Scope risk
Particularly on projects involving the rebuilding of or modifications to an existing furnace. What is the risk of overlooking an area that needs to be replaced or repaired? What could be the cost and schedule impact? Who will be able to make a sound assessment of the most cost effective approach? On a Greenfield, or new furnace, is it clear what the furnace supplier will provide?

Technical risk
What will happen if the furnace cannot perform as expected? What if the tonnage, glass quality or fuel efficiency are not as expected?

Understanding your company's perspective on these issues is critical to understanding the complete cost of the project. These risks are difficult to quantify, but they need to be factored into the decision making process if a well informed decision is to be made.
How can my company minimize its risk with respect to glass melting furnace projects?
  • Write a detailed scope of work or scope of supply. Studies have shown that there is an inverse correlation between the spread in pricing and the completeness of the scope of work/supply (i.e. the more detailed the scope, the narrower the range of pricing). The point of this scope document is to clearly indicate what you, as the customer, expect to be done and/or supplied with a special emphasis on responsibilities at critical areas of interface. A preferred supplier can be helpful in creating the scope of work/supply.
  • Select an experienced supplier.
  • Select a supplier that has "in-house" capability in the required areas of expertise, with a particular emphasis on project management. This is a way to ensure that you have committed and experienced people working with you.
  • Select a financially stable and credit-worthy supplier.
Should I have my project quoted on a cost-plus or firm price basis?
Projects that are well defined should be quoted on a firm price basis. TECO prefers to work on a firm price contract basis. Cost-plus type contracts are used for projects that cannot be adequately defined, such as a hot repair. On some applications, where a portion of the scope of work cannot be accurately defined, a combination of the two types of contracts is used.