When Latvian company VALMIERAS STIKLA ŠĶIEDRA, AS  approached Lahti Glass Technology, the challenge was clear: their 25-year-old control system had reached the end of its life. Spare parts availability was uncertain, the user interface was cumbersome, and the risk of production interruptions was already high. At the same time, the customer needed to modernize the process and ensure room for future expansion.

“The old system was outdated – both software and hardware wise. Support and further system modifications were no longer available, and it was becoming quite a risk to rely on this system to run such an important part of production,” says Eglis Krüzenbergs, Investments Project Manager at VALMIERAS STIKLA ŠĶIEDRA, AS.

One factor made the project exceptionally demanding: the plant had to stay in full operation throughout the upgrade. The VALMIERAS STIKLA ŠĶIEDRA, AS furnace runs 24/7, and shutting it down would have caused significant production losses. The renewal therefore had to be carried out on the fly – like a heart transplant, where the old heart is removed and the new one installed in its place. There is no turning back, and the patient must immediately survive with the new heart.

Control system modernization while keeping furnaces running

LGT prepared the project with meticulous care. Already in the pre-engineering phase, detailed steps and schedules were defined to guide the implementation. In practice, the work progressed in 8-hour windows during which the customer’s furnaces were filled and the control could be temporarily switched to the new system. Every actuator was reviewed, tested, and fine-tuned.

“This was a unique operation – not everything could be tested at a desk in advance. Experience, a calm approach, and strict sequencing were essential,” says Jukka Karppinen, Senior Control Systems Engineer from LGT.

From a technical perspective, the solution included new PLCs, user interfaces, weighing electronics, and frequency converters. A new cabinet was also delivered to enable future expansions. As mechanics and cabling did not require changes, implementation was smoother.

Modern control system brings flexibility and reliability

The project was completed without production downtime – the result is a modern and flexible control system that brings clarity and reliability to VALMIERAS STIKLA ŠĶIEDRA, AS operations. The new user interface is visually clear, with two process screens providing an overall view. The system also allows actuators to be switched into manual and maintenance modes, giving the customer more flexibility and faster response in exceptional situations.

In addition, the system opens opportunities for expansion – for example, adding new raw material silos and related equipment can now be done with ease.

“The patient lives and is doing well – the new heart is working,” summarizes Jamshid Shidfar, Sales Manager at LGT.

Why did VALMIERAS STIKLA ŠĶIEDRA, AS choose LGT?

“We had previous experience with LGT’s system in our USA, Dublin plant – a totally new batch production plant built by LGT. The system was working flawlessly, so when the next project came up, we already had LGT on our radar. Although, we considered multiple companies, LGT stood out with their communication, experience and reasonable pricing,” continues Eglis Krüzenbergs.

Valmiera Glass and LGT share a long history of collaboration in multiple projects. The customer had already seen LGT’s control solutions in action and knew this was a highly demanding task that “not just anyone could handle.”

LGT´s experience, expertise in similar projects in Italy and Indonesia, together with mutual trust were decisive factors. LGT was able to do what the previous supplier would not: replace the control system on the fly, without shutting the plant down.

Looking ahead

The upgraded system has been in operation since February 2025 and has run steadily.
With the modernization, production risks have been reduced, usability improved, and the path opened for future expansions.

This project is a prime example of LGT’s strengths: experience, precision, and a deep understanding of the customer’s business – and above all, a team that values communication and thrives on solving challenges together. The control system renewal was not just a technical upgrade but a vital investment in securing VALMIERAS STIKLA ŠĶIEDRA, AS production continuity.

Want to learn more about similar modernizations and what options might be possible for your plant? Explore our Solutions Clinic service.