Optical labs are always striving for the highest level of efficiency. In the past, traditional alloy systems, while still providing exceptional lens manufacturing capabilities, did not offer some of the environmental benefits and yields that lab operators demand today. Alloy Replacement Technology, also known as ART or the ART System, was developed by Satisloh, a global leader in ophthalmic and precision optics manufacturing technology, based in Germantown, Wis.



Kyle Crawford



The company said it recently shifted the direction of lens manufacturing away from alloy to a non-alloy solution, offering an environmentally friendly alternative to traditional alloy blocking. The process eliminates some risks associated with lens manufacturing, such as handling dangerous metals. Instead, the method utilizes a universal, reusable plastic block piece and a UV-curable adhesive.

With the ART system, tape for front-side protection is no longer required. Additionally, the system uses a synthetic material combination to eliminate hazardous substances like heavy metals and their discharge into the water cycle. As a result, labs can offer a safer manufacturing process for their staff and customers.


Increasing Productivity
“Labs are always looking to increase productivity without growing their existing footprint,” said Kyle Crawford, vice president of sales at Satisloh North America, Inc. “ART streamlines the blocking process without adding equipment or process steps because ART does not need tape or a 39-minute cold downtime.”




Satisloh’s Art Blocker A.


The ART system is integrated into five of the company’s manufacturing units including the Art Blocker A, a fully automated, alloy-free lens surface blocker; ART-Deblocker-2, a fully automated, alloy-free lens surface deblocker; ART-Blocker-M, a manual, an alloy-free lens surface blocker; ART-Deblocker-M, Manual, an alloy-free lens surface deblocker; and ART-Glue-Detector, an optional peripheral machine that detects glue residues after deblocking.



Satisloh’s Art Blocker A (lens blocking with glue).



Crawford said that ART blocks provide more enhanced lens support and stability than alloy blocking, which means a more precise surface cut and reduced chatter marks.

Measurements have also been improved with the addition of spatial blocking, which gives more accurate lens positioning for an improved prism and thickness accuracy.

Crawford said ART offers a clean blocking process that uses UV-curable glue instead of alloy which contains toxic metals. This, he said, has challenged the traditional way of manufacturing lenses and has been one of the key reasons why labs are adopting the process. “I invite anyone to visit one of our 200 plus ART customers. You will be quickly impressed by the cleanliness of the lab and efficiencies that are gained when special alloy handling is eliminated,” he said.


Adopting the ART System in Stages



Satisloh’s Art Blocker M (right view).


Transforming the manufacturing process within an existing lab structure can be daunting. For labs that are still on the fence about adopting ART, or prefer to adopt the system in stages, Crawford said this process can be done over time. The system is designed to work on both manufacturing systems, so a full changeover can be done more gradually.



Satisloh’s Art Blocker A (UV curing glue lens blockpiece).



“We have several ART customers that have run both alloy and ART together, which allowed them to transition at a speed that was comfortable for them,” he said, adding it can be integrated into existing alloy and ART blocked systems. So far, the company has installed more than 200 systems worldwide.

The lens manufacturing process has been slow to adopt sustainability practices in the past due to a lack of technology available that supports clean manufacturing. The transition to ART is more than just a move to improve efficiency, according to Crawford, but it takes lens manufacturing in a new sustainable direction. Additionally, the safety benefits are forcing many labs to evaluate their current processes and make the move toward alternatives in the interest of employee safety.

In the past, handling the materials created during the production process could be dangerous because heavy metals posed a safety risk for production staff and the overall workspace. The ART system has made the lens production process safer by removing toxic lead and cadmium, eliminating the risk of water contamination.


Saving Both Time and Money
“Alloy handling is an expensive labor-intensive, dangerous process. When comparing ART versus the compliance needed to handle Alloy properly, ART is a significant savings of both money and time,” Crawford said, noting the ecological benefits are also an attractive feature of the system. “Customers who have made the transition from Alloy to ART have found their labs run much simpler by eliminating the tidiness processes that are involved in handling alloy.”

Crawford said the time saved during the manufacturing process means faster production times. The ART system has no cold downtime, saving up to an hour in processing time. This also means a smaller lab footprint with no stackers, destackers, or cooling conveyors required for holding trays during the cool-down period.

Water consumption has also been lowered by 50 percent since this method of manufacturing requires two machines with ART, rather than four alloy machines. There is also no alloy tank heater or cooling plate, streamlining production even further. The system also reduces mineral consumption, including bismuth and indium, offering a more sustainable manufacturing solution with a 35 percent reduction in climate change impact.

Changing to any system can be time-consuming and expensive. To counteract these effects, Crawford said the Satisloh Consulting and Project management team works with lab staff to ensure they make a smooth transition and feel comfortable using the new technology.

“When our team leaves, you still have the benefit of the industry’s largest support team. They can further hone their skills by attending one of our hands-on ART training courses at the Satisloh Academy in Germantown, Wis.,” he said.

Making the Shift to the ART System




ART block pieces.


Best Price Digital Lenses Inc., a full-service digital wholesale and AR coating lab located in Pensacola, Fla., recently made the shift to the ART system. General manager Rolando Domingo said the company was looking to become more automated and reduce breakage in the lab.

He said the ART systems’ move away from traditional metal alloy piqued the interest of his team. “Alloy particles are one of the most common causes of scratching lenses and the ART system eliminated that for us,” he said, adding that the system helped fill several production gaps on his line. “The largest gap filled for our lab was no longer being limited in surfacing due to staffing issues. It can be quite challenging to train new staff about surfacing and keep the department staffed for multiple shifts. That all went away with the ART system.”



ART-Deblocker-M.



Domingo said the system did offer the lab the opportunity to reduce production costs, particularly in the area of salaries. He noted that instead, the company repurposed the majority of their surfacing staff, a move that kept people employed and preserved valuable knowledge on the production line.

Overall, Domingo said that the improvement to the finished product was noticeable, but one area of finishing stood out above the others.




ART-Deblocker-2.


“There was a very big difference in knife edges. With the ART systems, our knife edges significantly came down, which was very beneficial for our polishers,” he said.

The change also resulted in improvements to efficiency and production time, as a result of the automation component of ART. Domingo added that scratches were cut in half within the first two months of installation.

As new and existing labs grapple with the range of production choices available on the market, Domingo said the ART system has applications that are best suited to larger labs.

“I would highly recommend any lab processing more than 600 to 700 jobs per day to switch to ART, but in my opinion, if a lab is processing less, it wouldn’t be as beneficial,” he said. “I would definitely recommend for a lab to do their homework and if possible, visit a lab currently using the ART systems before switching.”