The TECO Time Capsule
Introducing Toledo Engineering Co., Inc. and its Founding Fathers
George W. Batchell
Toledo Engineering was founded by G. W. Batchell, born in 1883, of Wellsburg, West Virginia. His illustrious career began in 1905 at the young age of twenty-two, where he was initially employed at the J. H. Mathews Company. After a decade of dedicated service, Batchell decided to part ways with the firm and venture into the glass plant construction industry under his own name in 1915.
George W. Batchell (G. W. Batchell) | Founder of Toledo Engineering Co., Inc.
One year after the founding of The George Batchell Company, E. E. McCamic, an original member of the J. H., Mathews Company who worked alongside Batchell, became a partner. Subsequently, the company was renamed The McCamic-Batchell Company.
The duo experienced rapid success and the opportunity to add an engineering and drafting department for designing and developing new ideas emerged. In 1918, the company not only moved into a new office building, located on Bassitt Street in Toledo, Ohio, and hired a new furnace design expert, W. G. Bergman, formerly in charge of furnace design at Owens Bottle Company. Following the hiring of Bergman, the company underwent a name change to McCamic-Batchell-Bergman Company, which lasted until 1925.
Upon McCamic's passing in 1925, the company reorganized into a partnership between Batchell and Bergman. At this time, it was named the Toledo Engineering Company, with its offices situated in the Nasby Building, 605 Madison Avenue in Toledo, Ohio. The company soon garnered a stellar reputation for designing and erecting glass plants, furnaces, and annealing lehrs across the United States, Canada, Mexico, and South America.
In 1929, Batchell acquired Bergman's interest, becoming the sole owner of Toledo Engineering Company until 1931. It was in this year that the Toledo Engineering Company was formally incorporated, and the stock was distributed to F. G. Schwalbe and C. W. Batchell, the brother of G. W. Batchell. G. W. Batchell maintained controlling interest in the company.
Franz G. Schwalbe
One of the original stockholders, F. G. Schwalbe, was instrumental in the growth and success of Toledo Engineering Co., Inc. (TECO). His engineering career began with exceptional promise, graduating at the top of his class from the College of Engineering at the University of Michigan in 1920.
Franz G. Schwalble (F. G. Schwable) | Original Stakeholder in Toledo Engineering Co., Inc.
Franz Schwalble then became a design engineer for the O'Neill Machine Company in Toledo before eventually joining the Toledo Engineering Company. Notably, he was a registered professional mechanical engineer in Ohio and authored numerous articles on glass-related topics. Franz’s expertise even extended to writing the section on "Glass Furnaces and Fuels" in the original "Handbook of Glass Manufacture".
In 1944, F. G. Schwalbe taught a groundbreaking class in glass technology at the University of Toledo, encompassing a comprehensive study of glass furnace fuels and their combustion. The course delved into the suitability and economics of various fuels in the context of glass melting, exploring different furnace designs based on the type of glass and required tonnage.
Charles W. Batchell
C. W. Batchell, also played a significant role in the company's history. He started his journey with G. W. Batchell in 1912 as a furnace designer and superintendent of construction, working at George Batchell Co., McCamic-Batchell Co., and McCamic-Batchell-Bergman Co.
Charles W. Batchell (C. W. Batchell) | Original Stakeholder of Toledo Engineering Co., Inc.
Upon his brother's death, C. W. Batchell assumed sole ownership of the firm, taking on the responsibilities of president, treasurer, and secretary. Through the passage of time TECO continued to grow and progress by appointing new officers, acquiring sister companies, and securing top talent that allowed the company to thrive and become the global leader that it is today
The company has remained a private entity and is currently operated by Scott Slater, Chairman/Chief Executive Officer, Todd Seifried, (related to CW Batchell on his mother’s side of the family) President/Chief Operating Officer, Douglas Burgoon, VP of Operations, Robert Gries, Chief Financial Officer and James Uhlik, VP of Technical Services.
Innovations are Illustrious and TECO has quite a few.
The narrative of the glass industry, especially in the realm of glass furnace engineering technology, is characterized by notable breakthroughs and advancements that have profoundly influenced the glass manufacturing process. TECO has played a pivotal role in driving the technological evolution that shapes the modern glass furnace industry. Let’s step through the decades within the time capsule and explore.
1900-1960s: The Dawn of Modern Glass Furnaces
At the turn of the 20th century, glass production was still largely reliant on manual labor and small-scale glassblowing techniques. In the late 1920s, TECO designed/built its first large furnace for sheet and plate glass for the Ford Motor Co., in Dearborn MI. Technological progress began to impact the industry and the invention of the regenerative furnace in the early 20th century marked a significant milestone.
In 1947 TECO Designed and project-managed it’s first turnkey glass container plant for Cerveceria Moctezuma S.A., Orizaba, Mexico, this was the first of many TECO container plants built worldwide.
Exterior of TECO Cerveceria Moctezuma S.A., Orizaba, Mexico glass bottling plant
Interior of TECO Designed Cerveceria Moctezuma S.A., Orizaba, Mexico glass bottling plant
Innovation has always been the heart of TECO. To broaden its offerings the company acquired The Arnold Weigel Co., in 1949. The Arnold Weigel Co. were pioneers in the field of lime plant design including lime kilns, rock crushing and screening plants and lime hydrators. This acquisition placed TECO in a more desirable position to handle all phases of glass and lime plant design and construction.
By the early 1950s, TECO was designing and building recuperative furnaces, which replaced direct-fired furnaces. This type of furnace allowed for the efficient use of heat, reducing energy consumption, and making mass production more feasible. Also, the Pilkington Process was created in 1952 and revolutionized the production of flat glass, enabling the mass production of high-quality sheet glass used in the construction and automotive industries. The ensuing demand paved the way for TECO to design and build float glass plants in the future.
To meet the increasing number of TECO clients, in 1954 TECO built a state-of-the-art office building located at 3001 Sylvania Ave., Toledo Ohio. The building was custom-planned by the noted Toledo Architects and Engineers Sanzenbacher, Morris, and Taylor, the new building was complete in every detail. It had year-round air conditioning, special lighting, and acoustical walls and ceilings along with the finest office and drafting equipment for the skilled and expanded TECO Staff.
Photos of the newly built ultra-modern offices of Toledo Engineering Co., Inc. published in the National Glass Budget Saturday, February 20, 1954 print edition
During the late 1950’s fiberglass production was also in full swing and TECO designed furnaces using the Escher patented recuperator. Advertisements promoting this new technology were seen in the National Glass Budget publication. Foundry work, specifically retrofitting heat exchangers also made for good business at this time.
A TECO Advertisement promoting the Austeel-Escher Recuperator from the National Glass Budget December 6, 1958 print edition.
1960-1980: Automation and Energy Efficiency
During the mid-20th century, there was a rapid shift towards automation in glass production. Continuous glass melting tanks allowed for the continuous production of molten glass. This reduced downtime and enhanced productivity. Moreover, this technology is still used in the industry today.
During the 1960s, the conversion of sheet glass vertical draw process furnaces to the new float glass furnace designs began.
- TECO’s first float glass furnace was designed and built for Ford Motor Co. in Nashville, TN.
- Now known as Carlex, the float glass forming technology allowed for larger furnaces (now capable of melting over 1000MTD) to be built with the ever-increasing demand for higher quality glass.
In the 1970s, advancements in refractory materials and combustion technology improved energy efficiency.
- Low NOx burners are first offered in TECO furnaces.
- Advancements in burner knowledge were made using flat flame technology, allowing TECO to expand its offering to include luminous glass flame burners.
A TECO description of the Luminous Flame Burner was published in a company-created capabilities brochure.
The development of electric melting technologies began to replace traditional gas-fired furnaces in some applications, reducing emissions and energy consumption.
- The design and completion of TECO’s first recuperative e-glass furnace partnering with Elemelt, Ltd. to provide electric melt furnaces in North America.
- The first Cold Top Electric Melter for insulation fiberglass at Owens Corning, Santa Clara, CA. was designed and built with specific accommodations for seismic conditions.
- Many fiberglass manufacturers converted their furnaces to efficient TECO electric melters, further reducing downtime and enhancing productivity.
In the late '70s, Dreicor Inc., a company that specializes in procurement, fabrication, and construction services was added to the TECO Group.
During the 1980s, TECO instituted the capability of designing and building batch plants. Further allowing the company to be a one-stop-shop for furnace plant production. A batch plant, in the glass industry, is a sophisticated and integral facility. It ensures the accurate preparation of raw materials, including sand, soda ash, limestone, and various additives are combined appropriately, leading to consistent, high-quality glass production. It combines advanced automation, precision, and quality control measures to meet the diverse needs of modern glass manufacturing while ensuring efficiency and cost-effectiveness.
Batch House TECO was designed and built for Johns Manville
TECO purchased its former partner Elemelt, Ltd., and formed TECO Europe. TECO Europe broadened its capabilities and scope and is now involved with glass furnace applications of all types, known industry-wide as Tecoglas Ltd.
The 80’s technology surge allowed TECO to partner with the University of Illinois and pioneered computational fluid dynamics (CFD) modeling, revolutionizing glass furnace design. This innovative approach created long-lasting furnaces that produced unparalleled glass quality. TECO's advanced technology blazed a trail for an improving era of glass production. TECO’s modeling capabilities are among the most respected in the world.
TECO Float Furnace CFD Math Model
1990-2000: Advanced Control Systems and Environmental Concerns
During this period, the glass industry started integrating sophisticated control systems to optimize production processes. Computerized control systems and sensors enhanced the precision of glass melting and forming. Environmental concerns led to the introduction of cleaner technologies and emission reduction measures.
To align with the environmentally conscious industry, after being approached by the U.S. Department of Energy, Fernald Area Office, TECO formed ENVITCO for the purpose of designing/building vitrification systems for encapsulating hazardous waste. Initially, TECO reviewed and declined the job but after discussions and negotiations, the project moved forward. Highlights during this period include:
- In 1994, TECO acquired the assets of KTG Glass Works Technology, now known as KTG Systems, Inc. (KTGSI) in the U.S.
- In 1996 KTG Engineering (KTGE) was acquired in the U.K. These acquisitions brought additional knowledge in several areas of glass melting technology specifically relating to container, tableware, and electric melting and boosting of soda lime and borosilicate applications.
- TECO designed/built its 43rd cold-top electric-melt furnace specifically tailored for the fiberglass insulation industry. The unit was installed at Knauf Fiber Glass, Shasta Lake, CA.
Additionally, in 2004 ZEDTEC joined the esteemed TECO Group of companies. With their expertise in the forehearth and conditioning segment of a furnace, ZEDTEC added valuable knowledge and insight to the group. Notably, ZEDTEC forehearth utilizes groundbreaking "Rapid-Cool" technology, which not only enhances flexibility but also allows for shorter lengths while maintaining optimal capacity in glass production.
ZEDTEC Forehearth Model | Toledo Engineering Co., Inc.
2000-Present: Sustainable Innovations and Specialized Glass
The glass industry is ever evolving and the 21st century has seen a remarkable shift towards sustainability and green technologies. With the implementation of advanced filtration and emission control systems, the environmental impact of glass production has been significantly reduced.
TECO’s commitment to innovation and growth is a constant and key business cornerstone philosophy. With a global presence, serving customers on every continent except Antarctica, the company’s drive to find new ways to excel never wavers.
In line with this mission, EAE Tech was established in 2014, specializing in industrial control solutions. The EAE Tech team brings decades of experience in the glass industry, ensuring expertise and proficiency in every aspect of the glassmaking process.
The challenges brought about by the pandemic affected companies worldwide, and TECO was no exception. However, the company weathered the storm and pandemic, and TECO remained “on-schedule” for the construction and completion of a greenfield glass plant despite the challenges of COVID-19.
Furthermore, TECO seized an opportunity for growth by becoming a majority shareholder in Glass Design Inc. (GDI), a company well-known in the industry for its excellence in hot and cold furnace repairs, among other capabilities.
TECO emerged from the unwavering drive and determination of a single individual who aspired to play a pivotal role in shaping and contributing to the success of the glass industry. Because of the company’s strategic business practices, loyal customers, and enterprise for success, TECO has emerged as a global leader in the glass industry.
Collaborating closely with prominent players in the glass production sector, TECO has not only elevated itself but has also significantly contributed to the industry’s continuing progress. Its achievements are underpinned by a collection of innovative patents, distinguished published articles, and the strategic acquisition of syngenetic companies, all of which collectively provide a comprehensive range of services encompassing furnace and glass plant construction, maintenance, and pioneering innovations. Today, TECO stands as an indispensable force in the glass furnace engineering landscape, driving advancements that continue to shape the industry.
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