The HELANTEC fast-fill technology

RAPIDE gas filling systems

We deliver the highest-capacity manual gas filling systems for IG units.

The fast-fill technology is particularly well suited for the following requirements:
  • short cycle times

  • high capacity

  • filling in the production line – prior to the secondary sealing

  • large units, special formats and model IG units

  • universal implementation

  • reliable gas concentration / quality

  • documentation of the entire filling process

The emphasis is not on filling speed, but rather on highest efficiency. In addition to a short filling time, efficiency also includes low gas consumption, reproducible gas concentrations, easy adaptation to different tasks, as well as high availability at low maintenance costs.

Only these criteria enable fast and economical manufacturing of gas-filled IG units. Only the HELANTEC technology enables this efficiency.

With the fast-fill technology, during the filling process, in addition, the air is suctioned out of the IG unit. In this process filling capacity and suction capacity are precisely synchronised. Our proven gas analyser for concentration measurement is integrated in all of our gas filling systems. During the entire filling process, gas concentration is measured continuously and as soon as the desired gas concentration is reached the filling process is ended automatically. This is the only way to achieve uniform quality for each filling process.

The integrated process control (IPC) can be installed as an option. With this option the filling process is visualised and documented. Thus you have a verification of quality for each filling process, i.e. each IG unit. Automated and without additional effort.

HELANTEC is always a step ahead and only HELANTEC makes gas visible!

Turbofill

TURBOFILL has been developed exclusively for 1-hole gas fill technology whcich is dilution filling. A special triplex probe combines argon fill, air suction and pressure sensing. It guarrantees as much turbulences as possible to replace the air with argon. At the same time it removes the air so that the internal pressure stays at a very low level to prevent the IG unit from bending. As soon as the adjusted concentration is measured the machine stops autamtically.

Equipped with 4 stations TURBOFILL realises up to 2000 IG units per day1). As for all other products this type as manufactured with high quality product that assure long-lasting proven gas analysis. Thus TURBOFILL delivers constant gas fill quality for every IG unit.

1) at 8 hours/day and for IG units with 0.8m² / 14mm spacers / 11.2liters volume / argon / 90% concentration

RAPIDE L200

The RAPIDE L200 is based on the HELANTEC fast-fill technology and is the entry-level model of the RAPIDE L series. The capacity with one filling line is approximately 300 units1).

It is equipped with modern, progressive technology and enables efficient gas filling with reliable gas concentrations. This is measured continuously during the entire filling process via an integrated gas analyser. As soon as the set gas concentration is reached the filling process is ended automatically.

Synchronisation of the filling and suction process also enables trouble-free filling of large IG units. The handy device is well suited for changing implementation sites.

The HELANTEC RAPIDE L200 also convinces with its extremely favourable price-performance ratio.

Are you looking for higher capacity and shorter cycle times? If so, consider our gas filling systems, RAPIDE L500 and RAPIDE L900.

1) At 8 hours/day and for IG units with 0.8 m² / 14 mm spacers / 11.2 litre volume / argon / 90% gas concentration.

RAPIDE L500

The RAPIDE L500 is the top selling gas filling system with fast-fill technology!

This gas filling system has proven itself for many years and represents the state of the technology. The investment volume of the system is unrivalled in terms of capacity.

The RAPIDE L500 is more than "just" a manual gas filling system. With the integrated IPC the gas filling process is visualised and automatically documented. Only with this product do you have a verification of quality for all filling processes, i.e. for each IG unit – automated, without additional effort. Allocation of the IG unit is executed via barcode. Thus traceability in terms of gas filling is also ensured.

Only the HELANTEC technology makes these advanced possibilities available to you.

The capacity with 1 filling line is approximately 600 units1) And with 2 filling lines the capacity is approximately 1200 units1). Due to short cycle times, the RAPIDE L500 is excellently suited for integration in the insulated glass production line (on-line, i.e. downstream from pressing and upstream of sealing). Operation is intuitive thanks to the minimal number of operating elements. Nevertheless the RAPIDE L500 offers every conceivable convenience. Among other things this also means increased capacity through integrated intelligence. You will only find these features, in this quality and equipment at HELANTEC.

Additional highlights

  • The size of the IG unit is detected automatically during the filling process and the filling process is adapted accordingly.

  • For expensive gases (krypton) there is a gas saving program. A second gas inlet enables parallel connection of argon and krypton, for example. At the touch of a button you can change between the gas types, without additional calibration effort or loss of time when changing cylinders.

  • Adaptation and storing (depending on the requirement) of different filling parameters via the IPC (integrated production control).

To get started, the gas filling system can be equipped with one filling line. Thanks to the modular structure, retrofitting a second gas filling line at a later point in time is easily possible. For production of triple-glazed IG units, systems with 2 filling lines have proven to be very effective, because the two chambers can then be filled simultaneously. This is particularly advantageous for windows with an asymmetric structure. Because each filling line works autonomously, both chambers can be filled with different gases, without difficulty!

Through precise synchronisation of filling capacity and suction capacity, filling of large IG units is easily possible. In addition RAPIDE L500 can always manufacture pressureless and flat-positioned IG units.

If service is required, a diagnosis can be executed quickly and easily per remote maintenance via the modem integrated in the IPC. Through this measure service costs are reduced to a minimum. A routine manufacturer maintenance contract is not necessary!

With the HELANTEC RAPIDE L500 gas filling system you are ideally equipped for the challenges of your market and for future market developments. You will find more information on the high efficiency of the HELANTEC fast-fill technology and IPC under the respective headers.

Are you looking for even more sophisticated gas filling systems? If so, then our RAPIDE L900 gas filling system is the right choice for you.

1) At 8 hours/day and for IG units with 0.8 m² / 14 mm spacers / 11.2 litre volume / argon / 90% gas concentration.

RAPIDE L900

The RAPIDE L900 is the highest capacity gas filling system on the market and offers special advantages for the following applications:

  • fast filling and low gas losses - particularly with krypton
  • short filling times and extremely high capacity
  • economic filling of extremely large formats
  • fast filling of triple-glazed units in compliance with the cycle times of gas fill presses

For development, this meant precisely regulating even larger gas quantities in the millisecond range. At the same time the universal implementation possibilities, the two-hole technology and the proven closure system had to be retained. Nevertheless we were able to massively increase the efficiency. Here as well, and to an even more extreme degree, the same principle applies – namely that the maximum filling speed is not an expression of capacity. The crucial factor is efficient implementation.

However, due to the high capacity, in order to homogeneously fill the gas into the IG unit, even greater precision is required for synchronisation of filling and suction capacity. The filling process is a controlled process – it is not a purge process.

With due consideration of the cited boundary conditions – physical and fluidic – with the RAPIDE L 900, optimal performance has been realised. However this also demands considerably higher material requirements.

The capacity with 1 filling line is approximately 800 units1) and with 2 filling lines the capacity is approximately 1600 units1)

But this information does not really do justice to the capacity of the RAPIDE L900. Its real performance only becomes apparent with larger units and higher gas volumes. Through precise synchronisation of filling capacity and suction capacity, filling large IG units with gas is easily possible.

The RAPIDE L900 can always produce pressureless and flat-positioned IG units. Operation is intuitive thanks to the minimal number of control elements. Nevertheless the RAPIDE L900 offers every conceivable convenience. Among other things this also means increased capacity through integrated intelligence. You will only find these features, in this quality and equipment at HELANTEC.

Additional highlights

  • The size of the IG unit is detected automatically during the filling process and the filling process is adapted accordingly.

  • For expensive gases (krypton) there is a gas saving program. By the touch of a button you can change between 4 gas types, without additional calibration effort or loss of time changing cylinders.

  • Adaptation and storing (depending on the requirement) of different filling parameters via the IPC (integrated production control).

The RAPIDE L900 is more than "just" a manual gas filling system. With the integrated IPC the gas filling process is visualised and automatically documented. Only with this product you do have a verification of quality for all filling processes, i.e. for each IG unit – automated, without additional effort. Allocation of the IG unit is executed via barcode. Thus traceability in terms of gas filling is also ensured. Only the HELANTEC technology makes these advanced possibilities available to you.

To get started the system can be equipped with one filling line. Thanks to the modular structure, retrofitting a second gas filling line at a later point in time is easily possible. For production of triple-glazed IG units, systems with 2 filling lines have proven to be very effective, because the two chambers can then be filled simultaneously. This is particularly advantageous for windows with an asymmetric structure. Because each filling line works autonomously, both chambers can be filled with different gases, without difficulty!

If service is required, a diagnosis can be executed quickly and easily per remote maintenance via the modem integrated in the IPC. Through this measure service costs are reduced to a minimum. A routine manufacturer maintenance contract is not necessary!

HELANTEC also offers special solutions for specific applications – for example, additional filling cycles can be programmed individually with the Intelligent Fill Control Module. All devices are developed and produced in our facilities. All essential components for a custom solution are available. We offer our services in working together with you to implement special solutions tailored to your requirements.

1) At 8 hours/day and for IG units with 0.8 m² / 14 mm spacers / 11.2 litre volume / argon / 90% gas concentration / pure filling time

Intelligent Fill Control

The Intelligent Fill Control is an additional controller for the RAPIDE L900 gas filling system.

This development is the result of a customer-specific requirement: “Multiple gas filling cycles with different gas types must run automatically, with due consideration of the gas-specific characteristics.”

In other words, in order to ensure the required quality of the end product, each gas type must be filled via a different methodology. Simultaneously the integrated analytics for measuring the concentration must analyse the different gas types with reliable accuracy.

The Intelligent Fill Control module enables the user to autonomously define individual filling cycles. Operation is intuitive via touch display.

With simultaneous use of the IPC (integrated production control) it is possible to define different filling methods and shut-down values depending on gas type. Thus the user can even further optimise the gas filling process, autonomously – also for future requirements.

Our customer is excited about this solution! So are we...

Integrierte Prozesskontrolle (IPC)

Quality assurance and quality verification are of central significance for a company. In this regard, with the HELANTEC Integrated Process Control (IPC) you can sit back and relax.

The IPC visualises the filling process in real time. At a glance you know whether the filling process is being executed correctly and economically. In addition, all filling processes, i.e. each IG unit, is documented – in an automated procedure, without additional effort.

Versatile interfaces enable the connection of a label printer, barcode scanner or network integration. Thus all units can be uniquely identified and marked – traceability is easily possible.

The IPC can be integrated in the RAPIDE L500 and RAPIDE L900 gas filling systems, as an option. Various filling parameters can be set individually and changed at any time; this means that your gas filling system can be easily adapted to changing requirements.

An integrated gas analyser (type ISO-GAS-Control) is available for quality control, as an option. With the gas analyser the recorded measured values for quality control can be directly assigned to each IG unit, this means that the quality control results are directly compared with the production control results and documented. All recorded data can be analysed directly on the PC and compared with reference data as an evaluation aid.

With the integrated modem a diagnosis can be quickly and specifically executed via remote maintenance. There is nothing faster, easier, or more cost-effective.

This system is unique for manual gas filling systems. There is no comparable system on the market. And only HELANTEC makes gas visible.

The IPC is a worthwhile investment and is (almost) indispensable for companies with a rigorous quality-consciousness and proactive cost-consciousness.