Mirror Manufacturing Production from glass to mirror

Mirror Manufacturing Mirrors made by Deknudt Mirror Works : 1. Quality of the glass: Usage of “fresh” glass coming out of the ovens of the best European glass manufacturers 2. Silvering on own silver conveyor 3. Specialised in mirror (double sided, silk-screen printing, edge finishing,…) 4. Respect for the environment (no lead, purification installations,…) 5. Completely conform all strict EU-norms (ISO 9001)

Mirror Manufacturing Technical info about maximum dimensions : Thickness of the glass :maximum 8 mm dikte Silver conveyor : maximum 1120 mm wide Printing :glass size :max x 1150 mm plain printing :max x 1065 mm sandblasting :max x 965 mm quadri :max. 666 x 400 mm Durorolls :maximum 1900 x 685 mm

Mirror Manufacturing Supply of fresh glass by glass manufacturers

Mirror Manufacturing Glass warehouse Deknudt Mirror Works Fresh DLF glass plates of 1 e quality (321 x 255 cm)

Mirror Manufacturing Glass warehouse Deknudt Mirror Works Also coloured glass is processed

Mirror Manufacturing Glass cutting machine Deknudt Mirror Works Cutting of DLF glass plates (321 x 255 cm) to optimal working size

Mirror Manufacturing Waiting trolley of cut glass to silver conveyor

Mirror Manufacturing 2 e lacquer layer/glue layer 1 e lacquer layer passifation silvering activation sensibilisation glass watching direction in mirror Silvering : Different layers of a mirror

Mirror Manufacturing DLF glass (321 x 255 cm)  cut to starting size (optimalisation) Glass silvering Mirror 1st protection Drying Mirror 2nd protection Drying Final cutting to size Edge finishing : bevel, F- or C-edge Normal mirrorDouble sided mirror Glass silvering Mirror 1st protection Drying Glue layer on mirror Drying Final cutting to size Durorolls (back to back) Edge finishing : bevelt, F- or C-edge

Mirror Manufacturing DLF glass (321 x 255 cm)  cut to starting size (optimalisation) Glass silvering Mirror 1st protection Drying Mirror 2nd protection Drying Printing front side Final cutting to size Edge finishing : bevel, F- or C-edge Printing back side of the glass Silver printed glass Glass silvering Mirror 1st protection Drying Mirror 2nd protection Drying Final cutting to size Edge finishing : bevel, F- or C-edge Print front sidePrint back side

Mirror Manufacturing DLF glass (321 x 255 cm)  cut to starting size (optimalisation) Cover glass with tape (= transparent parts) Silvering glass double protection of mirror Drying Remove tape (= transparent again) Possibly print again (sand blasting effect) Final cutting to size Edge finishing Glass silvering (no protecting lacquer) Mirror partially covered on the back side (= printing what has to remain mirror) Remove uncovered silver (= transparent again) Possibly print again (sand blasting effect) Final cutting to size Edge finishing Transparent / Sandblasted Via silk-screen printing Transparent / Sandblasted Via covering with tape

Mirror Manufacturing Step 1. Glass preparation : Clean with water Thorough rinsing and polishing with Cerium oxide 9 Batteries with 12 turning brushes each Drying and heating up to about 30 °C

Mirror Manufacturing Step 2. Sensibilisation and activation : For a good attachment of the liquid silver on the glass surface. Sensibilisation :A tin oxide solution is sprayed on A little further, it is rinsed off as well Activation : Palladium Chloride solution on the surface a little further the surplus is sprayed off

Mirror Manufacturing Step 3. Silvering : Liquid silver is equally divided over the glass surface by means of a spraying curtain. (1 micron = 1/1000 of 1 mm)

Mirror Manufacturing Step 4. End of precipitation reaction : After 30 seconds the precipitation reacton of the liquid silver is finished. The surplus is sprayed off and the chemical reaction is stopped.

Mirror Manufacturing Step 5. Passification : Silver layer is treated with a layer of tin chloride soluiton. Also that one is rinsed of a little further In this way, the use of an environmentally unfriendly cupper layer can be avoided. = Green Mirror Deknudt !

Mirror Manufacturing Step 6. 1 e pouring curtain of protection lacquer : 1 st layer of protection lacquer on the silver layer (20 micron)

Mirror Manufacturing Step 7. 1 e Drying oven : Mirror runs through a 1st drying oven to let the protection lacquer slowly dry Temperature : 90°C - Duration: 4 minuten.

Mirror Manufacturing Step 8. 2nd pouring curtain of protecting or glueing layers : 2nd lacquer layer on top of 1st protection layer: Regular mirror : 2 x^protecting layer Double sided mirror : glue lacquer (thermoplastic glue)

Mirror Manufacturing Step 9. 2nd drying oven : The protected mirror runs through a 2nd drying oven to let the 2nd layer slowly dry. Temperature: 180°C - Duration : 4 minuten

Mirror Manufacturing Waiting trolleys in the production After drying and quality control, the mirrors are put on waiting trolleys, in expectation of the next process and in the mean time cooling down

Mirror Manufacturing Silk screen printing : Step 1 : Preparation : Glass is put on the machine, thoroughly rinsed and dried

Mirror Manufacturing Silk screen printing : Step 2 : Printing : Glass goes under screen Paint is spread over the the sieve. Paint only goes through tiny holes in the sieve.

Mirror Manufacturing Silk screen printing: Step 3 : Oven : Printed mirror goes through drying oven: 3 min. à 120°C

Mirror Manufacturing Silk screen printing : Step 4 : Quality control printing quality : Final check of the printing quality. Mirror put on waiting trolley for further processing.

Mirror Manufacturing Durorolls / Double sided mirror : Step 1 : Preparation : Mirrors with thermoplastic glue in the upper lacquer layer are layed down back to back

Mirror Manufacturing Durorolls / Double sided mirror : Step 2 : Through oven : Mirrors go through an oven of 110°C : both glue layers become plastic and get fixed to each other

Mirror Manufacturing Durorolls / Double sided mirror : Step 3 : Pressing and cooling : Mirror plates are pressed together by 12 consequent pressing rolls. Cold water is poured through the rolls, which makes the mirrors cool down slowly and hardens the glue.

Mirror Manufacturing Durorolls / Double sided mirror : Step 4 : End control : Mirrors are now permanently glued to each other. Quality control and putting them on a waiting trolly for further processing.

Mirror Manufacturing Cutting to final correct sizeDrilling holes

Mirror Manufacturing Edge finishes : Chamfer Grinding the sharp corners C-grinding mat of polished Classic bevel e.g. 25 mm on 7° F-grinding mat of polished Modern bevel e.g. 7 mm on 30°

Mirror Manufacturing Edge finishes : Chamfer Sharp corners removed Unprocessed cut glass edge

Mirror Manufacturing Edge finishes : C-grinding mat or polished F-grinding mat or polished

Mirror Manufacturing Edge finishes : Classic bevel e.g. 25 mm on 7° Modern bevel e.g. 7 mm on 30°

Mirror Manufacturing Edge finishing machine (linear = 1 side at a time)

Mirror Manufacturing Edge finishing machine (double sided linear = 2 sides at a time) 2 sides horizontally and in the middle 90° turn for vertical sides == > 4 x quicker than linear edge finishing

Mirror Manufacturing Edge finishing machine (CNC)