CASE STUDY
Glass Manufacturing / Container & Packaging Glass Coating
VarroTec, Netherlands
Optimizing Glass Production with Precision Dosing Pump Technology
Hot-End & Cold-End Coating • Netherlands, global operations • Equipment: Lutz-Jesco dosing pumps
Project Details
- Client: VarroTec
- Industry: Glass Manufacturing — Container & Packaging Glass Coating Equipment
- Location: Netherlands (global operations)
- Project Type: Hot-End & Cold-End Coating Chemical Dosing Optimization
- Equipment: Lutz-Jesco dosing pumps — industrial metering pump application for coating hood systems
- Key Metric: Coating layer thickness (CTU) accuracy
- Solution Partner: Water Treatment Supply
Project Overview
VarroTec is a globally recognised specialist in Hot-End Coating and Cold-End Coating equipment for container and packaging glass manufacturers. Known for its commitment to quality and innovation, VarroTec required a dosing system capable of delivering the level of precision its coating processes demand.
To meet this need, the company integrated a precision dosing pump system from Lutz-Jesco directly into its coating hood applications.
Glass surface treatment is one of the most chemically sensitive stages of the production process. Even minor inconsistencies in chemical application can compromise coating uniformity, increase material waste, and affect the final quality of the glass product. These challenges made it clear that VarroTec needed an industrial chemical dosing solution built specifically for high-precision, continuous-operation environments.
The Challenge
Inconsistent Chemical Application
Variability in dosing accuracy led to uneven coating layer thickness (CTU) across production lines.
Material Waste
Without a reliable automated chemical dosing mechanism, excess chemical usage drove up operating costs.
Contamination Risk
Imprecise dosing increased the likelihood of surface contamination during the coating phase.
Scalability Limitations
VarroTec needed a system that could be calibrated independently for each production line while maintaining consistent performance across all of them.
Our Solution
After testing and evaluating multiple dosing technologies, VarroTec selected Lutz-Jesco dosing pumps as the core of its coating hood chemical delivery system. The solution was built around three key components.
Three Key Components
Precision Dosing Pump System
Lutz-Jesco pumps were integrated into VarroTec’s coating equipment to provide accurate, repeatable chemical delivery at the per-production-line level, letting operators fine-tune dosing rates to the exact coating specifications required for different glass product types.
Dosing Pump Automation
Rather than relying on manual adjustment, VarroTec regulates chemical flow in real time. This reduced the margin for human error and ensured every coating cycle received the correct chemical volume, regardless of line speed or batch size.
Industrial Metering Pump Application
The system was configured to handle continuous, high-frequency dosing cycles without performance degradation — a critical requirement in a 24/7 manufacturing environment.
Process Chemical Dosing Control
This combination of process chemical dosing control and automated calibration gave VarroTec the flexibility to tailor coating layer thickness (CTU) to individual customer specifications while maintaining consistency across every production run.
Equipment Configuration
| Specification | Detail |
|---|---|
| Product | Lutz-Jesco dosing pumps configured as an industrial metering pump application |
| Application | Hot-End and Cold-End coating hood chemical delivery for container and packaging glass |
| Control | Real-time dosing pump automation replacing manual adjustment |
| Calibration | Independent per-production-line calibration to customer coating specifications |
| Duty Cycle | Continuous, high-frequency dosing in a 24/7 manufacturing environment |
| Key Output | Coating layer thickness (CTU) held to tight tolerance across all lines |
Results & Impact
Following the integration of Lutz-Jesco’s dosing pump automation technology, VarroTec reported measurable improvements across its coating operations — in product quality, chemical consumption, and the cost of keeping the lines running.
Improved Coating Consistency
Layer thickness (CTU) accuracy improved significantly across all production lines, enabling tighter tolerance to customer specifications.
Reduced Material Waste
More accurate automated chemical dosing minimised chemical overuse, lowering raw material consumption.
Lower Contamination Rates
Precise, controlled dosing reduced surface contamination incidents during the coating phase.
Reduced Maintenance Costs
The reliability of the industrial dosing technology decreased unplanned maintenance and downtime related to dosing equipment failure.
Scalable Per-Line Control
Each production line can be independently calibrated, allowing VarroTec to serve a broader range of customer requirements without compromising quality.
Before & After Comparison
| Parameter | Before Implementation | After Implementation |
|---|---|---|
| Coating Layer Consistency | Variable across lines | Precisely controlled per line |
| Chemical Usage | High, inconsistent | Reduced and optimised |
| Contamination Risk | Elevated | Significantly reduced |
| Dosing Method | Manual adjustment | Fully automated |
| Maintenance Costs | Higher, reactive | Lower, predictable |
| Production Flexibility | Limited | Customisable per product line |
Looking for Reliable Chemical Dosing Solutions?
Water Treatment Supply offers a full range of process chemical dosing equipment, precision metering pumps, and automation systems designed for industrial manufacturing, coating, and process water applications.
Tell us your chemical type, dosing frequency, and line requirements, and our technical team will specify a configuration that holds its accuracy under continuous duty.