Unveiling a Legacy: GF Piping Systems' Journey with Infrared Fusion Technology

From its inception to the cutting-edge solutions of today, discover how GF? Piping Systems continues to lead the way in harnessing the power of infrared fusion technology. In the early 1990, GF Piping Systems introduced Infrared (IR) fusion technology, a contact-free butt fusion process aimed to facilitate fast and reproducible joining of plastic pipes and fittings, positioning the world's first to utilize in a wide range infrared fusion technology.??

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Since when has Georg Fischer Piping Systems applied itself to the IR fusion technology???

In April 1990, we began developing the contact-free fusion technology. Our aim was to successfully launch the new butt fusion fittings to the market. To achieve this, we wanted to provide a fusion process that could enable the fast and reproducible joining of our PP and PVDF plastic pipes and fittings. This additional benefit was strategically designed to encourage customers to make the switch to Georg Fischer.??

The contact-free approach, involving the melting of pipe faces through infrared radiation, presented a significant advantage, especially for materials like PVDF, known for its highly adhesive melt. This method proved to be considerably more efficient and sterile compared to conventional methods used to date. We were very happy being the world's first to utilize infrared fusion technology in the area of plastic piping systems across a broad spectrum of dimensions (d20-225 mm).??

The development spanned two years, where we also applied patents to secured the sizeable development costs in the project. Both IR and BCF (bead and crevice free) are considered radical innovation steps, milestones in plastics technology.??

In July 1992 we supplied the first machines of both types, IR-63 and IR-225. This occurred at a time when the semiconductor industry started to boom. The industry, then mainly domiciled in the USA, gladly availed itself of this technology. One could even say that the semiconductor industry wouldn’t be what it is today without the IR fusion technology. Nowadays, this fusion process is used in many other industries as well. We were, at that time, nearly two years ahead of the competition and were thus able to set the industrial benchmark which we have held until today with continual further developments.???

What is behind the IR technology and where is it utilized???

In the infrared (IR) fusion process, the material within the fusion zone is brought over the melting point without contact via heat radiation. Subsequently, both of the parts to be fused, the pipe and/or fitting, are joined exactly via the (jointing path) overlap distance. This jointing path control makes it possible to achieve the reproduction accuracy of an automatic process with the IR fusion machine, which is controlled manually. The advanced IR Plus, an evolution of the original machine, incorporates an infrared sensor to measure the fusion bead temperature, determining the conclusion of the fusion process. Due to this monitoring, the IR Plus fusion machines could be equipped with an extra cooling ventilator. Both the monitoring and the use of a cooling ventilator, enabled to reduce the cooling time by up to 60%.??

This represents a huge time savings, so that the customer benefits from much shorter installation time without losing jointing quality. Thanks to this high reproducibility approach the result is that similar to BCF, the 80,000th fusion is equally good as the first.??????

This technology is mainly used in clean room environments. In the manufacture of computer processors, where measurements are made in ppb, particles per billion reference particles, contact-free fusion offers the cleanest method of jointing. With so many fusion welds in a piping system, quality assurance is a very important aspect. Visual inspection of the fusion beads, as well as automatic logging of the fusion data and fusion weld identification on labels.??

The application areas for both IR and BCF are therefore mainly to be found in the high-end area. In other words, in the semiconductor industry, in life science and the chemical process industry. Besides the above-mentioned qualities, such as purity and reproducibility, the IR fusion technology features has the already mentioned advantage of short fusion times, which has been cut in half, on average, compared to conventional ?butt fusion processes?. It is therefore the fastest butt fusion process in industrial plastic piping systems construction today. That explains why other industries are also interested in using the IR fusion technology.??

Where does innovation for new products come from and how can these be established in the market???

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The market doesn't consistently forecast future needs. Radical innovations typically originate from R&D efforts, necessitating even additional effort to convince customers of their utility and validity. However, this proactive approach proves more effective, as demonstrated in our case, where we gained over two-year advantage over competitors. Consequently, staying ahead requires vigilance to avoid falling behind. This has led us to investigate in ?Strategic Innovation Projects?.??

When introducing products to the market, quality and service are important factors. Both are instrumental in the success of a product, particularly when dealing with tools like IR or BCF fusion machines for manufacturing piping systems. We are dedicated to consistently delivering top-notch quality and responding promptly to any issues that may arise. Our service team can swiftly address concerns on-site when necessary.??

Besides after-sales service, we also offer service in the form of training courses, which we have specific developed for our customers. For example, we offer welder training courses, but also quality control courses for the fusion process. QC, in this case it refers to users learning how to check the quality of the fusion weld. Customers are thereby able to benefit optimally from the technology supplied by us. This generates customer loyalty and – even more importantly – trust in the Georg Fischer technology.??

In addition to technology, quality, and service, the design of a machine plays a major role. Here we act consistently according to the maxim ?Form follows function?. Although for the fusion machines the function is without a doubt the main priority, we consulted an agency for the machine design. The ergonomics and appearance of the machine must be appealing, so that working with the machine is also appealing. The rationale is simple: when you enjoy using a tool, the quality of your work naturally improves, and identify better with the machine. Ultimately, the recognition of the GF brand is pivotal for us, and design and appearance serve as critical influencers in this regard.??

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What sets Georg Fischer apart from its competitors???

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We offer complete packages, encompassing products, jointing technology, and training for installation personnel. Additionally, we prioritize accommodating specific customer requirements through application support. We carry out in- company training and continuing education, which foster such quality support.??

Our extensive product range is coordinated to meet market needs. With extensive experience in pipe, fitting and valve construction and manufacturing, we guarantee maximum quality and safety, recognizing their paramount importance for various media flowing through piping systems. Moreover, our offerings extend to valve actuators, measurement and control technology, specialized parts, pre-assembled modules, and specific jointing techniques like IR fusion technologies.??

Our standout feature lies in customer training, project and localized after-sales service. We offer our customers training for fusion, maintenance, installation and quality assurance. Our welder certificates are highly sought after and serve as a mark of quality.??

Furthermore, our machines, along with service packages, are available for worldwide rental. Our distinct competitive edge is bolstered by comprehensive logistics services, including transportation to and from installation sites, thorough machine verification, and maintenance before each rental, all supported by our well-trained local teams.??

Whenever a problem arises globally, our experts swiftly provide solutions to ensure complete customer satisfaction. This approach has proven highly successful for both us and our customers and it will be continues adopted to follow the changing requirement of our customers.??

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Where do we stand today after the groundbreaking invention of IR???

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Since pioneering contact-free IR fusion technology in 1992, we want to remained at the forefront of innovation. The IR-63 M builds upon this legacy, ushering in a new era of precision and efficiency in infrared welding. With the experience of 32 years successful use of infrared (IR) fusion technology, GF Piping Systems introduces the IR-63 M, a new IR welding machine that maintains established technology while integrating new hardware and software features for faster, more convenient, and so more efficient welding.??

This latest innovation combines established features with new hardware and software enhancements, enabling faster, more convenient, and efficient welding. The machine-controlled process ensures high-quality welds, particularly beneficial for sectors like chemical processing, microelectronics, and water treatment. With the IR-63 M, GF Piping Systems we want to simplify and expedite the welding process for various materials such as PVDF, ECTFE, PP-H, PP-n, PE100, PFA? or PVC-U, resulting in even shorter preparation times, fewer installation steps and additional up to 50% shorter cooling time. Our goal is to redefine tomorrow by seamlessly merging state-of-the-art technology with unparalleled accessibility. With the IR-63 M, we preserve the simplicity, durability, and compactness of our current machine while seamlessly integrating the latest advancements to offer an elevated customer benefit.??

#infrared #innovation #connectionsforlife ??

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