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AG16-4
GLASSTEC
20-23 SEPTEMBER DUESSELDORF, GERMANY
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Innovations for a better world.
WORLD OF
INTERLAYERS Sept. 20 − 23, 2016 Messe Duesseldorf Hall 10 • Booth E42 Special show glass technology live: Hall 11 • Booth D24
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Trosifol®, part of the Kuraray Group, is a leading global producer of PVB and ionoplast interlayers and is in the perfect position to become your preferred global partner for laminated safety glass applications. With the broadest product portfolio in the market, we at Trosifol® offer structural and functional interlayers for safety and security applications, sound insulation and UV control. For decorative applications, we supply colored interlayers, digitally printable films and other innovative products for interior design projects; and our ultraclear films exhibit the lowest yellowness index in the industry.
Contents: AG 16-4 Regulars
Features
12 Welcome
44 Container glass conundrums
Packaging markets remain resilient.
16 Headline News
Openings, closures and industry moves from across Asia.
30 Global View
Our eye on the international arena.
34 People and Places Movers and shakers, ups and downs.
38 Batch Raw material news and views.
40 Comment & Analysis Indonesia’s glass container boost.
44 Your favourite magazine is now available at the App Store… download today to see your first sample issue! Asian Glass: now for mobiles, ipads and androids 10
asianglass AG 16-4
AG reflects on some of the reasons that glass continues to struggle to isolate itself as the world’s premium packaging material, and questions what can be done to advance the argument.
58 Vietnam: too fast, too soon?
Jahir Ahmed looks at how Vietnam’s rapidly evolving glass industry is working to mature from an emerging market, to one with a more stable outlook.
72 High rise issues for India
Yogender Malik looks at how the subcontinent, despite continued objections from certain construction lobby groups, is about to boom as a façade construction destination.
80 Façade development
In part two of our façade focus in this issue, Michael Elstner discusses the challenges facing the construction of high-rise curtain walling.
72
Anaylsis 86 In Focus
AG looks at the thriving UK window industry.
88 Window
Analysis and insight into Malaysia.
94 Refractory Zone
In his latest exclusive offering to Asian Glass, Carlo Ratto discusses how refractory selection is increasingly a challenging task. www.asianglass.com
Why can‘t everything be this easy? Or what we like to call: the “Zippe-feeling” Every project presents new challenges – no two technical solutions are alike. And the more complex the task at hand, the greater our ambition to find a tailored and cost-effective solution that will satisfy your individual needs. This, combined with the reliability that our customers have come to trust, induces that special feeling. Contact us for all your requirements in terms of batch plants, cullet systems, preheating, chargers, automation and control systems, as well as engineering. ZIPPE – BECAUSE WE DO IT.
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Welcome
CONTACT DETAILS
AG16-4
T
he European Union’s (EU) food and beverage glass container packaging industry has grown to become “very stable” against other packaging sectors but must remain wary of a number of growing challenges, according to the latest forecast from Rabobank.
EDITORIAL
GLASSTEC
20-23 SEPTEMBE
DU ESSELDORF, GE
R
RM ANY
Demand for glass packaging for food and beverage products within the EU has remained stable in unit terms for many years, Rabobank said, in contrast to rigid metal, rigid plastics and flexible packaging materials, which have all experienced relatively high growth rates. This is partly due to growth in segments in which glass packaging is not traditionally used, such as meat and convenience food, but also due to changes in the competitive position of glass packaging. The glass packaging industry’s competitive environment has been forcing major industry players to adapt in order to remain competitive, Rabobank said. Many have consolidated significantly in the past 10–15 years, with the market share of the ten largest brewers increasing between 2015 and 2016 by almost 10%. And, in 2015, beverage bottles represented about 78% of demand for food and beverage glass containers in the EU. This share has slightly declined, while food containers have gained importance in the past ten years. As beer bottles represent the single-most important glass packaging category, changes in the beer sector can be felt across the entire industry, Rabobank said. It warned that falling beer consumption and pressure from rival packaging materials were restricting glass packaging’s growth. Glass bottle manufacturers could scale, innovate or consolidate to overcome the challenges of the industry, Rabobank added. One of the most surprising aspects of the glass packaging sector is its retention of relatively high profit margins. Rabobank global F&A supply chains strategist Susan Hansen said: “All in all, we believe that the outlook for the glass container industry will remain stable, yet challenging going forward. Focusing efforts on increasing flexibility and considering innovation as an ongoing process are key. Despite glass bottles/containers being a traditional or preferred packaging material for specific products like beer, spirits, wine or olive oil, there is no guarantee that this will not change in the future.” As the global container glass industry descends on Germany this month for Glasstec, such findings will doubtless make a few breathe a little more easily from the technology supply side. Happy reading…and enjoy Glasstec!
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HEADLINE NEWS ASIA Foreign boost for Viglacera share-sale Vietnam VGC, a construction materials company in which the Ministry of Construction (MoC) holds 91.49 per cent, auctioned 11.34 per cent of its shares and brought in VND418 billion ($19 million). Purchases for 82.33 million shares were registered, or 2.7fold higher than the amount on offer, by 178 investors, including 19 institutions and 159 individuals. The highest bid was VND14,300 ($0.65) per share. Five investors successfully bought all of the shares on offer, with foreign investors buying 15.5 million, or 52 per cent. The average bid price was VND13,923 ($0.63) against an initial price of VND11,700 ($0.53). VGC recorded impressive business results in the first half of 2016, a July 4 meeting heard. The pre-tax profit of VGC and its subsidiaries reached 129 per cent of the target and was up 53 per cent compared to the same period last year.
VGC itself reported pre-tax profit VND87 billion ($3.95 million) higher year-on-year and 43 per cent higher than the target and representing 55 per cent of the corporation’s total. VGC’s revenue increased 19 per cent compared to the target for the first half, which company directors described as impressive given the fierce competition. Despite being known for products such as sanitary ware, ceramic and granite tiles, terracotta, and non-fired materials, “glass is the most promising product of VGC in the current market circumstances,” CEO Nguyen Anh Tuan told VCG’s shareholders meeting in April. “With the current trend of real estate projects using box glass or at least double glazing along with the future trend of using ultra clear float glass and low-e glass, we believe the demand for glass products in general will rise significantly in the near term,” Mr. Tuan added.
Glass products like lowemitting, or low-e glass, have become a trend in other countries and not just Vietnam. Moreover, the number of glass and brick buildings has been increasing in recent years. “Low-e glass, ultra clear float glass and solar power glass are currently seeing buoyant demand around the world,” Mr. Tuan said. “Exports are therefore the top priority with VGC’s ultra clear float glass.” “Even though revenue from glass products only stood at VND150 billion ($6.8 million) out of total revenue of VND1 trillion ($45.5 million) in 2015, that was only the paper figure,” he explained. “VGC’s real profit from glass products last year was some VND200 billion ($9.1 million), representing a 20 per cent profit margin.” In 2015 the Prime Minister approved the construction of two VGC glass factory projects. The factory in southern Binh
Duong province, with a capacity of 2.3 million sq m per year, has begun operations while the factory in northern Bac Ninh province, with a capacity of 2.7 million sq m per year, is still under construction. Early this year the construction a low-e glass factory with an annual capacity of 2.3 million sq m began in Binh Duong province and operations are expected to begin in the third quarter. VGC will also be cooperating with the Urban and Industrial Zone Development Investment Corporation (IDICO) and a foreign partner to invest in an ultra clear float glass factory with a daily capacity of 600 tonnes in southern Ba Ria Vung Tau province. Foreign investors are also paying close attention to the glass market. According to VGC research, Chinese investors have been looking to build a glass factory in northern Bac Giang province. “This clearly illustrates the current trends,” Mr. Tuan said.
China/Pakistan j-v signed for glass production Pakistan The deal was signed at the Punjab Board of Investment and Trade (PBIT) headquarters, where Chief executive officer of the PBIT, Amena Cheema welcomed the CEOs of both the companies. Under the agreement, a manufacturing facility will be established near Lahore to manufacture and sell highquality USP Type-1 neutral glass tubing, vial in Pakistan using advanced technology and equipment. USP Type-1 neutral glass tubing is a new technology
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that has excellent chemical resistance and great mechanical strength. A new company will be formed which will be called Paidar Hong Glass. The new company will produce high-quality Borosilicate USP Type 1 and clear glass tubing under the supervision of highly-skilled Chinese glass technologists and engineers. Total capital commitment will be approximately $9 million. In addition, two furnaces with 24 tons per day capacity each will be installed along with glass tubing, glass
vials and glass ampoule manufacturing machines. These products are used by pharmaceutical companies for medical and research purposes. The joint venture is expected to help in import a substitution as well. According to a spokesman for the PBIT, the Board had been in close contact with both companies and played a major role in facilitating the agreement. The agreement will also lead to creation of 500 direct jobs and many indirect jobs.
Commercial operations are expected to begin by June 30, 2017. Speaking on the occasion, Ju Xin Hong, CEO, Globallink Glass, expressed his appreciation of the PBIT commitment to facilitating the agreement and said similar ventures should be pursued for the benefit of both Pakistan and China. Expressing her agreement, Ms Cheema praised the strong ties between China and Pakistan and said that such agreements bond well both the countries for the future.
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Haryana expansion drives Asahi India India Asahi India Glass has completed a major expansion exercise at its one of the four automotive manufacturing plants in India. The expansion exercise, which commenced in 2015 has been successfully completed at company’s Bawal ( Haryana plant. The expansion exercise has added a capacity of 700,000 windshields per annum and has taken the overall capacity of laminated glass from 1.5 million car sets to 2.2 million car sets per annum. Asahi India incurred a capital expenditure of INR 1.5 billion for this exercise. AIS Auto Glass, which started operations in 1987 with
manufacturing toughened glass for automobiles and windshields has four plants located at Bawal – Haryana, Roorkee – Uttarakhand (North), Chennai – Tamil Nadu (South) and Taloja - Maharashtra (West) and three sub-assembly units cum warehouses at Halol – Gujarat, Pune – Maharashtra (West) and Bangalore – Karnataka (South). The plants and sub assemblies are strategically located in proximity of India’s automotive glass manufacturing hubs and produce a complete range of automotive glasses. The OEM segment continues to be the prime driver of Asahi India’s automotive glass business
NEG expands pharma glass Malaysia Nippon Electric Glass (NEG), a leading Japanese manufacturer of specialty glass recently has invested RM80 million investments to expand its production facilities of pharmaceutical glass tunings in Malaysia. The expansion is expected to begin the commercial production by the last quarter of the year. The company has undertaken the expansion exercise after a detailed study and anticipated future growth in demand for highquality glass tubing in Malaysia and extended ASEAN region. The investment entails a new production line for melting and forming process. Nippon Electric Glass is a leading producer of glass for flat panel displays, electronic and optical devices and glass for solar cells in addition to pharmaceutical tubings. The Group achieved a total turnover of USD 2.075 billion in year 2015. The expansion will increase NEG’s production of glass tubing for pharmaceutical and medical
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use, such as ampoules and vials, as well as for applications in the manufacture of prefilled syringes and pen injections. Currently, NEG Malaysia is one of the leading producers of glass tubing for pharmaceutical and medical use in ASEAN region. Nippon Electric claims that glass tubing produced by the company has excellent chemical and acid resistance and high strength. With a high lead content and excellent radiation shielding properties, these products protects medical personnel against radiation exposure. Nippon Electric Glass has been operating in Malaysia for 20 years. Since its establishment, the company’s operations have grown manifold, expanding and diversifying its existing operations in Shah Alam. The company has completed its RM700 million investment to increase its production line for chopped strand glass fibre last year. So far, Nippon Electric has invested over RM6 billion in its Malaysian operations.
with the company having a dominant position in Indian car glass market. The company claims to have a market share of more than 76.57 % in the domestic passenger car glass market. According to Asahi Glass India, “ Our strong relationships with majority of leading OEMs in the domestic market that have been built over the years through strong performance in terms of quality, cost, delivery, and development (QCDD) of product will continue to drive key business growth for the company”. According to Asahi India’s CEO and MD, Sanjay Labroo, “ Auto SBU with revenue increasing
11.67% from ` 1208.07 crores in FY 2014-15 to ` 1349.10 crores in FY 2015-16 and segment profits by 14.58% from ` 161.48 crores in FY 2014-15 to ` 185.02 crores in FY 2015-16.” He further says, “ The auto industry is highly upbeat with renewed consumer confidence and slew of new high quality product launches. However, this growth will be skewed towards a few winners and involve high levels of volatility and complexity. Such an environment suits Asahi India well due to our extreme customer sensitivity and our readiness to equip ourselves for such positive ambiguity.”
Kyocera suffers as solar declines Japan Japanese PV module producer and project developer Kyocera has seen its solar operations decline in Q2 2016, returning sharply diminished profits. The company reported its consolidated financial results for the Q2 yesterday, in which revenues from its solar operations fell by more than 13% from the previous quarter. Kyocera's Applied Ceramic Products Group, of which its solar PV operations are a component, registered a JPY1.5 billion ($10 million) profit in Q2, down from JPY2.055 billion ($19.8 million) from Q1, or 57.4%. "Sales and Operating profit in this reporting segment decreased compared with the previous first quarter due to a decline in sales in the solar energy business mainly as a result of a decline in demand in Japan," Kyocera reports. Kyocera's Applied Ceramics division accounted for 14.3% of the company's total revenues
in Q2, down from 15..5% the previous quarter. The solar business brought in 3.3% of Kyocera's profits in the quarter, down from 6.8% the previous quarter. Despite the weakening performance of its solar business, Kyocera remains hopeful for a turnaround before the close of 2016. "Kyocera forecasts an increase in sales in the solar energy business in both the public and commercial sectors," the company stated in its Q2 consolidated results. BNEF forecasts the Japanese PV market will install slightly over 10 GW of PV in 2016, down from 12.65 GW in 2015. The appreciation of the yen against the euro and U.S. dollar featured prominently in Kyocera's Q2 performance, resulting in declining sales across various business units to a range of markets.
AG 16-4 asianglass
17
News
BJC aims for packaging top-spot Thailand BERLI JUCKER (BJC) aims to be the country’s leading provider of total packaging solutions, including glass, cans, paper and polyethylene terephthalate (PET) bottles, within five years. "To reach this milestone, we need to respond to increasing demand not only from future expansion of BJC and its affiliates such as Thai Beverage but also from outside clients, particularly those who are expanding overseas," Pattaphong Iamsuro, president of the company's packaging supply-chain business, said recently. "As we are in the packaging supply-chain industry, having a strong base in glass and can production appears not to be enough for future growth
and evolving demand in the market, particularly in food and beverage businesses." He said options would range from the company's own investment to joint ventures to mergers and acquisitions. He said several deals were under negotiation, with at least one expected to be sealed by the end of this year, but no further details could be revealed at this stage. Last year, the packaging industry was valued at Bt30 billion, posting single-digit annualised growth. Plastic packaging took the lead, followed by aluminium cans and glass containers. Euromonitor's latest research suggested that convenience remained a key factor in
the packaging business, while small pack sizes were gaining prominence. This week, BJC announced a Bt2-billion investment in the construction of a new furnace with production capacity of 300 tonnes of glass a day, to cater to rising demand for glass containers. The new plant in Saraburi province is scheduled to commence operations by the end of next year. The plant will be on a 95-rai (15.2-hectare) plot comprising three sites managed by BJC's subsidiary Thai Malaya Glass. It will be the second site where BJC manufactures glass containers for beer and other beverages, food, pharmaceuticals and other products.
When fully operational, the new furnace will give the group an overall daily glassproduction capacity of 3,800 tonnes, which is seen as sufficient to meet demand from domestic customers and those in Cambodia, Laos, Myanmar and Vietnam. In the first half of the year, sales from the group's packaging business were Bt5.356 billion, some 15.7 per cent higher than in the same period last year with small and medium-sized enterprises accounting for 20 per cent of the client portfolio. Buoyed by this performance, BJC is maintaining this year's revenue target at Bt11 billion, representing a 16-per-cent rise, Pattaphong said.
Taking a Stake in the commercial upturn New Zealand A new Christchurch glass supplier is catching the city's sparkling demand for new office blocks. Stake Glass opened a $10 million factory at the old Alliance meatworks site in Sockburn in July, sizing sheets to order for homes and light industrial buildings. The next step is cutting and framing glass for multi-storey commercial buildings, South Island sales manager Steve Ottley said. Stake Glass South Island sales manager Stephen Ottley says its $10 million factory is set to expand by the end of the year for more commercial glass production Stake should be ready to offer that service by the end of the year, Ottley said. Developers and architects were becoming more adventurous with glass and Stake expected more orders for office-grade toughened glass. Structural glass usually went up in sheets from three to four metres high and up to two metres wide. Ottley said the owners of large multi-storey buildings
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increasingly wanted large sheets of glass with minimal aluminium framing. That glass often had to be reinforced for safety under building code rules. Most customers wanted their residential glass between four and eight millimetres thick but it could range up to 15mm for commercial customers. Stake Glass started partly to take advantage of the Christchurch rebuild, Ottley said. Owners Jake Lane and Steve Spencer also moved into glass production as a fillip for an existing business, construction company Stake Consulting. Ottley said glass was getting to Stake's building sites too slowly, so the owners decided to build their own factory. The company imports bulk glass from China, India, Malaysia and Spain. All sheets are cut to size and some are reinforced, depending on a customer's order. While Christchurch was its main market, Queenstown was also promising. Stake Glass worked with float glass, a sheet made by floating molten glass on a bed of molten metal, and two-sided laminated safety glass.
The factory supplied glass for showers, mirrors and splashboards - as well as large panes for office buildings. One of the challenges for a glass fabricator was optimising the use of a sheet glass for as many customers as possible. Stake was using up to
20,000 square metres of glass a month. The factory was officially opened by Prime Minister John Key. Its main competitors in Christchurch were Metro Performance Glass and Veridian Glass, Ottley said.
Borosil buys stake in Klasspack India Borosil Glass Works (Borosil) has announced the acquisition of 60.3% stake in Klasspack for an undisclosed amount. While a majority of the funds were by way of primar y infusion into the company, there was a smaller secondar y purchase of shares as well. Borosil is a leading player in laborator y glassware and supplies to the countr y's top pharmaceutical companies, research laboratories, healthcare, science and educational institutes. Klasspack, a closely held company with manufacturing facilities in Nashik, Maharashtra, is a
leading manufacturer of glass ampoules and tubular glass vials used as primar y packaging materials by pharmaceutical companies. With compliance becoming increasingly stringent in the Indian pharmaceutical sector, Borosil said it plans to combine its technological expertise in specialty glass production with Klasspack's experience in world-class glass ampoule and tubular glass vial production to offer pharma majors a reliable partner to source their primar y glass packaging. Avendus, a leading investment bank, advised Borosil on the transaction.
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WHENEVER,
A
WHEREVER,
FENZI
IS THERE.
. SUSTAINABLE FUTURE DESIGNED TO LAST.
Solar mirror coatings must fully comply with the most diverse needs, even conflicting ones. On one hand, they must withstand enormous stresses; on the other, they must be as eco-friendly as possible. To meet this challenge, Fenzi created Fenzi Solar Coatings, a division specialized in researching innovative solar energy technologies. The result is Duralux Solar Coatings, a range of solar mirror coatings engineered to meet the highest standards of durability and resistance, in the most advanced solar heating systems. Duralux Solar Coatings have blazed an entirely new trail in the journey toward sustainability, rewriting the rules of the game from the ground up. New technological criteria, new guidelines and new objectives the positive impact of Duralux Solar Coatings on the industry is historic and the future ready to be enjoyed.
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News
ŞiŞecam orders 42 ATLAS systems from Tiama Turkey ŞiŞecam Glass Packaging, the fourth biggest glass packaging producer in Europe and the world continues its glass packaging control cooperation with Tiama through the order of 42 ATLAS systems. The ATLAS is a noncontact check detection system using cameras and detecting all checks appearing in the finish, heel, shoulder and bottom of bottles and jars. ŞiŞecam Glass Packaging which is affiliate to ŞiŞecam Group, global actor of the glass sector, has a total production capacity of 2.3 million tons a year. With its 80 years of corporate history, ŞiŞecam Glass Packaging continues its production in a total of ten plants in 4 countries. This environmentfriendly group is among the world’s most distinguished glass packaging manufacturers, due to its degree of specialization and it utilizes high-end technology and innovations. This explains why it extends its 10-plus year partnership with Tiama, a state-of-the-art player in real-time process and glass quality controls, which became, as one goes along, one of the main suppliers of the ŞiŞecam Glass Packaging plants, from the Greenfield projects to
the latest development of its production lines. This longstanding collaboration consists in a close support from Tiama’s team in all ŞiŞecam Glass Packaging hollow glass activities to solve
the fastest possible, the daily difficulties and subsequently improve quality and productivity. With this new installation, all the carousel machines in the three ŞiŞecam Glass Packaging Turkish factories will be
Textured glass to receiving duty protection? India The Government has started a probe into alleged dumping of a particular variety of glass from China to protect the domestic industry from cheap imports. The DGAD "prima facie finds sufficient evidence of dumping" of the glass from China. Gujarat Borosil Ltd has filed a petition before the Directorate General of Anti-Dumping and Allied Duties (DGAD) for imposition of anti-dumping duty on imports of "textured tempered glass whether coated or uncoated" from China. This glass is used as a component in solar photovoltaic panels and solar thermal
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applications. Other firms that make similar products include Asahi India Glass. DGAD, in a notification, said: "The authority hereby initiates an investigation into the alleged dumping, and consequent injury to the domestic industry... to determine the existence, degree and effect of alleged dumping and to recommend the amount of anti-dumping duty, which if levied, would be adequate to remove the injury to the domestic industry." The period of investigation covers entire 2015. The injury investigation period will also cover the period between 2012
and 2015. Countries start anti-dumping probes to determine whether their domestic industries have been hurt due to surge in belowcost imports. As a counter measure, they impose duties under the multilateral regime of WTO. The duty is aimed at ensuring fair trading practices and creating a level-playing field for domestic producers vis-a-vis foreign producers and exporters. India has already imposed anti-dumping duty on several products to tackle cheap imports from some countries including China.
equipped with Tiama’s ATLAS system by the end of 2016. ŞiŞecam Glass Packaging will therefore become the world’s biggest user of ATLAS with 92 machines installed. The main benefits of the Tiama ATLAS system are attested: adjustability, reduced job-change time, reduced human factor on the quality of settings and quick payback. ŞiŞecam Glass Packaging already benefited from the TIAMA’s after-sales international network with two local engineers available to ensure proximity and support of the Turkish customer’s needs. Now, it also takes advantage of the remote connection giving to Tiama’s engineers a direct access to the Turkish fleet of machines. This new collaboration enables TIAMA to reinforce its primary position in the coldend area in ŞiŞecam Glass Packaging plants. The partnership between TIAMA and SISECAM GLASS PACKAGING includes other trials and demonstrations are scheduled which demonstrates once again, the involvement of the Tiama’s teams in the success of its customers.
NEWS IN BRIEF Hong Kong-based Flat Group has won an investment licence to build a USD-200-million (EUR 180m) solar glass factory in Hai Phong, Vietnam, the Dau Tu newspaper reports. The group received the licence from the Hai Phong Industrial Zone Management Board to construct a plant with an annual production capacity of 580,000 tonnes of solar glass on an area of 21.8 ha (53.87 acres) within the Dinh Vu Industrial Park. The factory is expected to become operational in late 2017.
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EBRD acquires stake in recycling Turkey The European Bank for Reconstruction and Development (EBRD) has said it acquired a minority stake in the recycling arm of Turkish glass producer ŞiŞecam, in a move to help Turkey increase its glass recycling rate and boost its circular economy, in a written statement on June 28. ŞiŞecam is embarking on an ambitious 20-million-euro glass recycling operation, demonstrating its commitment to using more recycled glass than mined raw material, according to the statement. “To support these efforts and contribute to a more competitive, resource-efficient circular economy in Turkey, the EBRD is acquiring a minority stake in ŞiŞecam Çevre Sistemleri A.Ş.,
a newly established recycling arm of ŞiŞecam, and is extending a 40-million-euro loan to finance glass recycling equipment and energy efficiency investments,” said the bank. The EBRD has also mobilized an additional 2-million-euro loan from the Clean Technology Fund, a funding window of Climate Investment Funds, as well as EU grants, according to the statement. The investment is part of the EBRD’s overall strategy to help countries where it invests in tackling global challenges such as climate change, said the bank. With over 21,000 employees, production in 13 countries and sales in as many as 150 countries, the ŞiŞecam Group
Saint Gobain investments remain “on track”
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strengthening the entire glass recycling supply chain. Previously, the EBRD has helped ŞiŞecam to increase its glass collection rates. Under a pilot funded by the government of Spain in 2013, ŞiŞecam introduced thousands of bottle banks in several Turkish cities, including Istanbul, Ankara, Antalya, Edirne, Bursa, Konya, Aydın, Adana and Diyarbakır, and launched an awarenessraising campaign to encourage households to recycle glass. The success of this initiative paved the way for a 30-million-euro loan from the EBRD which financed the acquisition of new bottle banks, collection vehicles and glass bottle crushers, among other investments.
HNG plans “lightweight” bottles India
India Flat glass products and solutions major Saint Gobain India is in the process of investing around Rs 1,800 crore till next year. A senior official said that the company has fast-tracked some of its investments as the confidence levels are improving with the better business sentiments. Speaking to reporters in Chennai, B Santhanam, president and MD - Flat Glass South Asia, Egypt and Malaysia Saint-Gobain India (P) Ltd has said, "There are three major investments - the coater (Magnetron Coater line), float lines and we are investing in our gypsum ceilings business in Gujarat. Put together would be around Rs 1,800 crore, which will be completed next year." He was speaking at the sidelines at the First Convocation of Saint-Gobain – NTTF flagship Skill & Talent Development initiative Learn While Earn (LWE). He said that there has been an improvement in business confidence in the last six months across the industry. He added that the company is fast forwarding many of the of investment plans announced earlier.
is a global actor in business fields including all main areas of glass such as flat glass, glassware, glass packaging and glass fiber, as well as soda and chrome compounds. ŞiŞecam has been operating for more than 80 years and is the third largest glassware, fourth largest glass packaging and fifth largest flat glass manufacturer in the world in terms of production capacity. ŞiŞecam Cevre Sistemleri will provide its cullet suppliers with state-of-the-art equipment which they wouldn’t be able to invest in otherwise, according to data from the statement. This equipment will increase suppliers’ collection and treatment capacities as well as the quality of the cullet,
“For instance, the investments in our ceilings business in Baruch is on a fast track. The investment we are making in Chennai for the second Magnetron, will be ready in March end. The Float line we are hoping to come up by end of next year or early first quarter of 2018. Earlier we weren't as confident about these deadlines,” he added. The company is also targeting export opportunities in ASEAN countries. While it has been exporting to Middle East, the growth in demand in these markets is slowing down even as there are opportunities in the ASEAN countries. He said that the company believes in keeping its exports at 15-20 per cent, while the the rest of the production would be for the domestic market. The company has taken on board 53 students out of the 54 who were part of the LWE initiative, while one went on to become an entrepreneur. By 2020, the company’s aims to carry out all fresh Diploma Engineer recruitments through the LWE program.
Hindusthan National Glass and Industries (HNG), is planning to introduce light weight glass bottles under a brand for retail consumers, at about Rs 25 each. Hindusthan National Glass and Industries (HNG), bulk supplier of glass containers for food and beverage companies, is planning to introduce light weight glass bottles under a brand for retail consumers. "We are planning to come out with light weight glass bottles with a brand for retail consumers in the market during Diwali," HNG Vice-President Bharat Somany said. "Traditionally, we are supplying glass containers to food and beverages companies and this would be our first attempt to touch retail consumers directly," he said. HNG Vice-Chairman and Managing Director Sanjay Somany is directly involved in promoting glass bottles and has joined hands with Swachh Bharat Abhyian in pushing for its usage in offices and homes. Somany said with increase in health awareness, prospects are bright for wider acceptance of
these glass bottles for personal use instead of PET and other plastic bottles. The company, which hopes to price the bottles at around Rs 25 each, is also planning to create awareness for use of glass bottles. Somany, however, did not relate the retail foray as a strategy to counter slowdown which has hit the company's bottomline. In fact, on 16 March, the networth of the company had eroded to Rs 123 crore, which is more than 50 per cent lower than 2015's networth of Rs 313 crore.
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IDMA urges action over PET/glass rivalry India The Indian Drug Manufacturers' Association (IDMA) has urged the ministry of health and family welfare to consider the continued safe use of PET containers in pharma industry as the replacement of PET bottles with the glass bottles will increase the cost of medicine. The association has made a representation to the health ministry after the Drug Technical Advisory Board (DTAB)'s proposal to ban the PET containers in pharma packing. In the 71st meeting of DTAB the board has raised the issue of restricting the use PET containers for packing. The association has also submitted various scientific,
techno-commercial and logistic reasons for continued use of PET bottles, proving its safety and merits in pharma packing. The association explained that the use of glass container will add to the costs as there is 2-3 per cent loss in the glass bottles that occur due to breakage during transport. As per a study specific to pharma industry, 1.50 lakh of PET bottles can be transported in container vs 90 K glass bottles (100 ml), as weight of PET bottles case is 10 times lower than glass bottles case. Transportation costs and packing costs of corrugated boxes will drastically increase due to the increased weight of glass bottles.
The mono cartons will also be required for each glass bottle thus adding to the costs, all these leading to an estimated 25 to 30 per cent cost increase per bottle, which will in turn increase the cost of medicines that are supplied in glass bottles. Due to the increased demand for glass bottles, the prices of glass bottles will shoot up, as demand will be much more than supply, which will further lead to severe shortages as small and medium pharma companies may not be able to afford to purchase the glass bottles at the increased prices. The alternative to use of PET is glass as containers in pharma. The total pharma market of PET is
Coatings research to give boost to regional industry UAE Glass is specified by many architects for the exterior of new buildings. It makes for an attractive building façade and helps keep the cost of interior lighting low. However, it often allows too much heat from the sun to enter the interior of buildings in the day, which increases cooling costs. It also allows too much heat to escape from the interior at night, which increases heating costs. The challenge is finding innovative ways to improve glazing technologies so that manufacturing costs remain low while also ensuring that the natural colorless appearance of glass is not compromised. Some heat-blocking coatings give the glass a less than desirable brown or reddish appearance. Assistant Professor Dr. Adel Gougam and a team of researchers at the Masdar Institute in Abu Dhabi may have found a way to significantly reduce the cost and complexity of manufacturing energy efficient glass coatings. “Although recent advances in glazing technologies have helped reduce heat transfer in glass buildings, the complex, multi-layered coatings that have been developed are often expensive and difficult to manufacture, adding to the glass’
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economic and ecological costs,” explains professor Gougham. Conventional coatings achieve high selectivity – a measurement that indicates how effective a coating is at blocking heat but letting in sunlight – by stacking up to five layers of varying compositions and thicknesses on a glass pane. Most coatings use expensive silver nanolayers sandwiched between other layers of various materials. Creating these multi-layered coatings is a complex, expensive and rigorous process. Each layer is deposited sequentially over the pane of glass using a physical vapor deposition technique. Conventional coatings repeat this physical vapor deposition technique several times to create the multi-layered coatings. “In response to this, we have developed a glass coating made of a single layer of cheap, metallic oxide material that can block heat at nearly the same rate as the highest performing multi-layered coatings currently on the market, while minimizing manufacturing costs,” Gougham says. “By avoiding the need to repeat the vapor deposition technique several times, we have reduced the complexity and energy requirement of the
manufacturing process, as well as the manufacturing cost, contributing to a more sustainable production process and product,” Dr. Gougam said. The team’s innovative glazing technology may give the UAE’s glass manufacturing sector a considerable competitive advantage in the region, as building developers seek more sustainable building materials in response to the growing push for “green buildings” that are more environmentally friendly. Researchers estimate that optimized glazing can reduce a building’s cooling load by as much as 20%. That is significant in a country like the UAE, where air-conditioning accounts for up to 75% of peak electricity use in the summer months. The researchers plan to continue studying ways to optimize the metal oxide coating while keeping the manufacturing process as simple and cost effective as possible. The next step involves scaling up the coating to ensure that the same level of selectivity is achieved on a larger glass pane, then performing environmental tests to ensure its long term suitability and sustainability in the harsh climate of the United Arab Emirates.
1 lakh metric ton (MT) per year. To replace this will require 9 lakh MT of glass per year, due to the higher weight. This could lead to severe shortages of liquid medicines if one considers the entire pharma industry's requirements in glass. The pharma industry does use glass bottles in certain instances, where amber coloured containers are required to protect the medicine from being damaged by light. However, there is already drastic shortage of raw materials needed for glass and hence manufacturers of glass bottles may not be able to meet the requirements. New units or expansion of existing units would need a minimum of 2 to 3 years lead time, said IDMA.
Tariq expands tableware capacity Pakistan Pakistan’s Tariq Glass Industries has expanded its production capacity. The Lahore-based company has completed a maintenance programme on one of its tableware furnaces which has increased its capacity from 110 tonnes per day to 140 tonnes per day. The company also has fully automated printing machines, with the capability of printing six colours simultaneously, including gold and silver banding. TGL not only fulfils domestic demand but also exports its products to various countries across Europe, Middle East, Africa, Asia and the Far East. It also has a technical collaboration with Toyo Glass of Japan. The tableware furnace was re-fired in April 2016 and the company now anticipates to receive higher process for its tableware products. In financial year 2016 it will also focus on establishing power plants on its premises to have uninterrupted and cheaper electricity for manufacturing activities.
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PHP stays focused on doubling capacity Bangladesh PHP Float Glass Industries Ltd, a leading float glass maker, is set to double its production capacity to 300 tonnes a day in two years to meet the growing local demand. “It will take 12 months to manufacture and impor t the required machiner y,” Md Amir Hossain, managing director of PHP Group, said in a press meet in the por t city yesterday. “After that we will star t the conversion process, including installation of the additional facilities, which will take 12 more months.” It is a shor t-term expansion project of the factor y, Hossain
said as he hoped the Tk 300-crore conversion process would star t in the middle of 2017. The factor y now employs 800 people, including executives, engineers and workers, and will be able to employ 700 more after the expansion, he said. The factor y now manufactures float glass with thickness ranging from 2.5mm and 12mm, and the expansion will help the company produce up 15mm glass, he said. The factor y will also be equipped with European technology to automatically
detect and crush the defective goods unlike the earlier technology, which could only detect the un-melted par ticles, he said. The group also plans to star t manufacturing soundproof glass at the factor y by the time, the chief of the company said. As par t of its mid-term expansion plan, the group also plans to set up another plant in the next five years, which will be able to produce 600 tonnes of glass a day, Hossain said. The company aims to be the leader in the glass
manufacturing sector in 10 years, he said. A major por tion of the company's produce remained unsold when it star ted its commercial production in Sitakunda in 2005, he said. “But things have changed in the last 10 years with the rise in demand of float glass.” “We initially star ted expor ting glass to Nepal, Bhutan and India. But we could not give much concentration to the expor t due to the increase in local demand.” Ali Hossain and Jahirul Islam, directors of the company, also spoke.
ADVERTISER FEATURE
OCMI AND MT FORNI INTRODUCE THEIR TURN-KEY FACTORIES FOR PRODUCTION OF GLASS BRICKS In 1997 OCMI-OTG and MT Forni Industriali, established an industrial group capable of supplying a comprehensive range of equipment for the hollow glass industry as well as of performing projects plants on turn-key basis in both glass household ware and technical ware fields. This second is the case of production lines for glass insulators and glass bricks, which require a high accuracy with the preparation of raw materials, temperature setting for glass melting and final annealing, glass viscosity during pressing and glass item handling during the different operations. Such lines installed in Middle East, Northern Africa and Far East are examples of really prestigious achievements. Thanks to the experience acquired during the years, OCMI and MT Forni, with their trademark AMIG have been chosen by the main manufacturers of glass blocks in Italy and Middle East. The production capacity of glass bricks lines offered goes from 30 to 60 tons/day. After glass preparation equipments, from batch plant to gob feeder the brick forming is performed in the turntable pressing machine with index rotation driven by Geneva wheel mechanism or torque motor. The quality of press machine for glass bricks is guaranteed by the long experience of OCMI in the production of press and press-blow machines for several glass items. In this machine, working with hydraulic or pneumatic pressing mechanism, the halves of glass bricks are produced: the number of stations depends on the speed needed but the most suitable
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configurations for this production are 10 or 12 stations. The take-out of press machine unloads the semi-finished bricks on a conveyor going to the next working phase: the welding. OCMI can upgrade the traditional glass blocks forming line in order to double its capacity through two presses feeding the welding machine. Such a solution makes the new AMIG “high capacity” glass blocks line much more profitable in terms of both investment and operation costs. This double configuration can achieve a daily production of 25.000 finished glass bricks. Welding machine is available with 9 or 12 stations equipped with upper and lower ware holders for the handling of the two halves of glass brick to be welded. Welding process is made through pre-heating and melting of edges of each half-brick and consequent coupling of the two parts. After final cooling, the finished items are unloaded and transferred to the last annealing process through anthropomorphic robot purposely programmed by OCMI specialists. AMIG trademark joins the know-how about glass forming by OCMI and the deep knowledge about glass melting and thermal treatment by MT Forni. Equipments included in the supply of the production line are entirely developed in Italian factories of OCMI and MT Forni Industriali and the commissioning is carefully followed not only by skilled electrical and mechanical engineers but also by glass experts with specific knowledge in this product with high technical content.
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ADVERTISER FEATURE
Equipped for the future: thanks to 50 years of experience Bystronic glass Hall 14 Stand A38/E38
When the glasstec trade fair opens its doors in Düsseldorf on 20-23 September 2016, Bystronic glass will present more than 50 years of experience, innovations and trends in insulating glass manufacturing as well as automotive glass pre-processing at Stand A38/E38 in Hall 14 true to the motto “Mission next 50 years“. Two years after celebrating this anniversary milestone with the Swiss Bystronic glass subsidiary in Bützberg, it is now the turn of the subsidiary in NeuhausenHamberg (Baden-Württemberg, Germany): Here, machines and plants for the manufacturing of insulating glass have been developed, manufactured and shipped across the world since 1966. This landmark achievement is being celebrated during a daily Happy Hour on the trade fair stand, which will be held between 5.00 p.m. and 6.00 p.m. where regional specialities will be served. Bystronic glass will present innovative glass processing solutions for the architectural and automotive glass industries in over 1,200 square metres of exhibition space. A number of moderated, live machinery presentations will take place every day to provide the visitors with an in-depth view of the fascinating technologies. Cooperation partner Hegla will again be on the neighbouring stand, enabling the customers to easily enter into discussions with experts from both of the companies. Insulating glass manufacturing – the customers’ choice Not one, but two insulating glass lines will be in action on the Bystronic glass stand this year. The B’VARIO TPS and the B’COMFORT will be working back to back: Within the stand interior, the B’VARIO TPS will demonstrate the
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flexibility and possibilities of insulating glass manufacturing. The line that can be configured according to specifications will prove its unique diversity, offering a customised production solution for all types of orders. The use of the thermoplastic spacer TPS® further establishes how the production mix can be manufactured on a single line – without the need for external frame production or separating orders into standard and specialized batches. The insulating glass line is complemented by the newly developed finisher, which is an optional machine that makes the patented bevel joint invisible. In the tried and tested standard version, the bevel joint does not require any thermal-mechanical reworking – it is gastight. The use of the finisher allows customers the option of smoothing the TPS® bevel joint if desired, resulting in an aesthetically improved product. After processing, the thermoplastic spacer retains its form and density. The processing of shapes using the finisher is also possible. The newly developed machine can be easily integrated in existing insulating glass production lines without requiring additional space. The B’COMFORT on the edge of the stand is a start-up solution for use in automated insulating glass manufacturing processes. In addition to proven Bystronic glass quality and reliability, it is impressive due to low investment costs, a compact unit layout, individual expansion possibilities and high productivity capabilities. At the trade fair stand it will be presented together with the optional eco’sealer sealing robot. This is the economical solution for the automated insulated glass sealing, and is available in a number of options with numerous expansion possibilities.
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Glass handling –customers remain flexible In addition to the insulating glass lines, customers can also try out a selection of rational handling equipment for all flat glass processing fields. The sales hit Easy-Lift will also be exhibited. This handling device has been impressing glass processing industry customers with its rigid guidance and low dead weight since 1998. Recently, the Easy-Lift WINDOW has been well received in the window construction sector due to its flexibility in relation to frame design, and the special requirements needed for this market. Automotive glass pre-processing – novelties for the customers For many years Bystronic glass has been exceedingly successful with the champ’speed machine which is used for the pre-processing of automotive glass. Almost every second motor vehicle has been fitted with automotive glass that has been processed using a Bystronic glass unit. The champ’speed 2in1 version can break the automotive glass on one machine, with or without a template, and consequently has established itself within the sector. Bystronic glass will present further innovations and numerous developments at its trade fair stand: the linear drive has been improved even further, making it faster and smoother running yet more gentle in the process, making it suitable for processing thin glass <0.7 mm. This advanced piece of technology impresses,
providing easier methods to lay and remove shapes, improved repeat accuracy and reduced operating costs thanks to a reduced number of parts that wear. Furthermore, it is now possible to retrofit the 2in1 version of the champ‘speed into existing plants. Bystronic glass 4.0 –customers look to the future In the future everything will come closer together: machines, data, processes and applications. Bystronic glass connects all of these modules within the process chain by means of integrated data management – therefore providing customers with considerable competitive advantages. All of the measures, services, products and business models are aimed at securing quality in the final products, increasing the availability of the plants, and shortening process times, which ultimately result in reduced costs and increased revenues. At a separate stand area directly opposite the information counter at glasstec, customers can experience how this called “Bystronic glass 4.0” works. They can also look to the future in the Innovation Center. This is where Bystronic glass will be presenting innovations and new developments in the architectural and automotive glass industries. Website: www.bystronic-glass.com
About Bystronic glass Bystronic glass symbolizes innovation with machinery, systems and services for the processing of architectural and automotive glass focussed on tomorrow’s market. From basic requirements through to entire, customized installations Bystronic glass provides pioneering solutions – naturally, all in the highest quality. Bystronic glass is an international brand with globally operating companies that support their customers on site and through own sales and service companies. Since 1994, Bystronic glass is part of the Conzzeta AG, a renowned Swiss industrial holding company. Bystronic glass media contact: Iris Mittelstädt PR / Online Communications Bystronic glass c/o Bystronic Lenhardt GmbH Karl-Lenhardt-Str. 1-9 D-75242 Neuhausen-Hamberg Phone +49 (0)7234 601 120 Fax +49 (0)7234 601 114 iris.mittelstaedt@bystronic-glass.com www.bystronic-glass.com www.YouTube.com/Bystronicglass
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Bystronic glass sales contact: E-Mail: sales@bystronic-glass.com For the contact details of Bystronic glass global representatives please visit www.bystronic-glass.com
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News
Global View
Solar recycling to be mainstream business WORLD Glass and other materials recycled from decommissioned solar PV panels could be worth as much as $15bn to the global economy by 2050. According to a report released by Renewable Energy Agency (IRENA) and the International Energy Agency's Photovoltaic Power Systems Programme, recycling or repurposing solar PV panels at the end of their working life - around 30 years - can unlock a large stock of raw materials and other valuable components. Although solar PV recycling is still a relatively young industry, renewables targets and subsidies have seen capacity increase significantly in the UK and other EU countries, while the US, India and China are also now beginning to experience growth. Estimate are that PV panel waste, comprised mostly of glass,
could total 78 million tonnes globally by 2050 as more solar energy capacity comes online in the coming years. Of this waste tonnage, it is projected China could produce between 13.5 million and 20 million tonnes in volume by 2050, while the US could make up between 7.5 million and 10 million tonnes. The potential material influx from recycling solar panels could be used to produce another two billion new panels or be sold into global commodity markets, increasing the resource security of future solar PV. "Global installed PV capacity reached 222GW at the end of 2015 and is expected to further rise to 4,500 GW by 2050," IRENA director-general Adnan Amin said in a statement. "With this tremendous capacity
Hindustan sells European container arm EUROPE After suffering losses on a sustained basis, country's largest glass bottle maker Hindusthan National Glass has sold its 2011 acquisition Agenda Glass AG of Germany, fetching not even a half of what it paid for the buy. The Somany family has inked a deal with an undisclosed European glass container maker to sell its entire holdings in HNG Global GmbH, erstwhile Agenda Glass, for 23 million (Rs 176 crore), the company said on Thursday. HNG Global had a turnover of Rs 276 crore, which is about 12% of the consolidated earnings of the listed entity, HNGIL. In 2011, the bottle manufacturer paid 50 million to buy Agenda Glass AG, which has a 320-tonnes-a-day capacity plant at Gardelegen, making bottles for Jagermeister herbal liqueur and vodka Gorbachev among other brands. The Somany bothers, Sanjay and Mukul, were known for turning around sick companies. In fact, most of HNGIL's capacities have
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come via inorganic way, acquiring and converting sick glass bottling units of Owens Brockway in 2003, Larsen & Tubro in 2005 and Haryana Sheet Glass in 2007. Agenda Glass had become unviable ever since it started operations in February 2010, and the company went into bankruptcy exactly a year later. HNGIL then bought the facility through a short and quick insolvency proceedings, paying 50 million or close to Rs 320 crore at the exchange rate prevailing at that time. Considered to be experts in turning around ailing assets, the Somanys found out that the plant was not being run properly. Its pack-to-melt ratio, a benchmark for efficiency in the industry, was a low 71-72%, much below the industry break-even level of 83-84%. In comparison, Indian plants run at 89-90% ratio, Mukul Somany had then said. While technologies were upgraded and investments made to revive operations, the after effects of the economic
growth will come an increase in waste associated with the sector. This brings about new business opportunities to ‘close the loop' for solar PV panels at the end of their lifetime. To seize these opportunities, however, preparations for the surge in endof-life material should begin now." Amin said recycling and repurposing solar panels could offer considerable economic value to the global economy, but that this was dependent on continued transition to renewable energy as well as putting the "right policies and enabling frameworks in place". Specifically, there is a need for the adoption of effective, PV-specific waste regulation, the expansion of existing waste management infrastructure to include end-of-life recovery of PV panels and the promotion
of ongoing innovation in panel waste management. In most countries PV panels are classified as ‘general waste' but the EU was the first to adopt PVspecific waste regulations, IRENA said, which include PV-specific collection, recovery, and recycling targets. The EU directive requires all panel producers supplying the EU market to finance the costs of collecting and recycling end-of-life PV panels. Some panel makers are already preparing for a future where all panel parts are recycled. Earlier this year it was revealed that US firm First Solar is scoping the potential for mobile recycling units - trucks loaded with modular processing plants that could recycle panels at a solar site to provide a much cheaper way to turn panels back into their raw components.
slowdown post 2008 crisis were too much to get a sustained turnaround. To make things worse, consumption spending, a prime factor for the packaging industry, slowed down significantly in India. With Hindusthan National Glass itself struggling to survive the losses since FY12-13, it became increasingly difficult for the Somany family to keep sustaining its German operations whose
networth was at a negative Rs 15.3 crore as on March-end. HNGIL's own mounting losses have eroded half of its networth, the company informed the exchanges in May. The Joint Lender's Forum had earlier restructured its debt in March 2015, offering moratorium and a corrective action plan, giving lenders a right to convert into equity up to 20% of the term debt outstanding beyond seven years.
Vidrul to expand flat capacity ANGOLA Angolan glass company Vidrul – Vidreira of Angola will invest US$60 million in expanding production capacity with the installation of two new furnaces to ensure full glass supply in the country, announced the managing director. Carlos Martins said the plant currently produces 60,000 tons of glass, “and it is imperative to begin to produce more so that it can satisfy customers and have in stock about 10% of production.” Vidrul is the leading glass container supplier for the Angolan beverage industry, exporting some production to
several African countries, including Senegal, Madagascar, Benin, Ivory Coast, Mali, Senegal, Togo, Guinea, Gabon, Burkina Faso and Congo Brazzaville. Part of the raw materials for Vidrul’s production, more than 70%, comes from bottles collected at rubbish dumps, an activity that occupies a significant number of people in several Angolan cities. State newspaper Jornal de Angola reported in June that about 3 tonnes of bottles are transported every month from Luena to Luanda, making the container trade a profitable activity in the province.
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SEE DURST A T GL ASSTEC, HALL 12, S TA N D A 6 9
Digital glass printing and its new decoration possibilities by innovation leadership Glass is one of the most popular materials of modern times and the requests for decorative glass are becoming more and more. Growth forecasts for the glass industry in the coming years promise a lot. Durst has now successfully position itself as a quality leader and innovator of this niche market. The technology which was specially developed for decorating flat glass are currently producing successfully a few square meters decorated flat glass in countries like Germany, Austria, Italy, Czech Republic, USA, Mexico, Japan and Finland. In this field Durst offers a complete solution and guarantees a 24/7 operation by high-end components. This solution consists of a digital printer based on inkjet technology and frit-based ink. Under the brand "Rho Vetrocer" the premium-quality product is available by Durst.
Printer innovation:
The Rho Vetrocer series consists of 3 models with a max. printing width of 160 cm, 250 cm and 330 cm. The patented glass transport system, which is unique in the glass industry, guarantees incredible benefits. It consists of a sturdy steel frame that can carry heavy glass panes with more than 1 metric ton of weight without immigration level. The glass panes are thereby carried on to industrial ball rolls consisting of nylon balls and therefore the glass will be transported carefully without leaving scratches on the bottom of the glass. The transport through the printer of these heavy materials is done by using vacuum carriages which are driven on a precision rail system with magnetic drive inside the infeed and outfeed table. The positioning tolerance of this high-tech system amounts to less than 0.1 mm, and thus guarantees the highest print quality and low-maintenance operation. The glass is thereby accurately transported under the print heads and afterwards transported beneath a sensor-controlled dryer. The advantage of this sophisticated system is that the glass can be transported back to the beginning without loss of positioning point thus a further ink layer can be printed on the glass. This allows to print amazing Dual-Vision designs automatically. Dual-Vision print is the process of printing, for example, points spread over a glass surface, from one side you can see white dots and on the other side you can see black dots. Critical here is a perfect positioning accuracy: does not fit the position, a narrow white respectively black border is visible. The printer itself has a patented circulation concept. The ink circulates in the Rho Vetrocer from the main ink tank to the print heads, directly behind the nozzle plate back to the main ink tank. Therefore, there is a large ink circuit, which ensures a constant
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ink quality and a higher durability of the ink inside the system. Durst uses very hard and premium quality materials which are in constant contact with ink. For example, the sensitive nozzle plate, where just beyond the abrasive ink flows past, is made of hardened silicon. The hardened silicon corresponds to a hardness of 8 on the Mohs scale, the glass frit in the ink reaches a hardness of 7 according to Mohs scale. Furthermore, the specially developed print head electronics with its patented Durst VarioDrop System makes a perfect definition of fonts and fine lines on glass. The bionic print head carriage carrier, which also contributes significantly to the high print quality, consists of a milled aluminum-alloy and guarantees by its complex design an always constant defined by the operator print head distance from the medium. The directly to the printer built-on dryer, ensures a gentle drying of the ink layers. The dryer is sensor-controlled and dries the ink at max. 80° C. As a result, energy costs are reduced and a safe transport to the curing oven is ensured. The dryer is specially designed for the system (speeds, ink thicknesses and ink consistence) and is variable adjustable to different glass thicknesses.
Durstâ&#x20AC;&#x2122;s ink technology:
A substantial part which is also responsible for the best print quality is the ink itself. Durst develops and produces ceramic glass inks on its own thus the control over the quality and the sensitive production process of the ink is guaranteed. The sensitivity of the production process lies in the fine grinding of the pigments and frits. The close cooperation between the Durst Research Center in Lienz, Austria and the industr y-established production facility in India allows the development of own color pigments. With the new enhanced pigments (like yellow and green) Durst is able to expand the limit of the color gamut of a ceramic ink without the use of toxic metals such as lead and cadmium. The Rho Vetrocer ink is optimally adapted to the printing and the subsequent dr ying process and thereby a trickling on the glass sur face is significantly minimized. The Rho Vetrocer inks have been tested by the independent Fraunhofer Institute in Germany and certified for use on glass for industrial applications. All quality controls and the monitoring of all processes of the complete system guarantee optimal image quality and a reliable and low-maintenance production. Durst can guarantee this through its inkjet experience of decades in different market segments. Also, the constant attempt to improve already existing targeted solutions adds value for customers of Durst.
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AGR unveils Molson design UNITED STATES American Glass Research (AGR), in partnership with Molson Coors, has unveiled an innovative new beer bottle design for one of the brewing company’s popular brands in India, Thunderbolt. Featuring unique embossing and debossing, a fresh new color, and a ring-pull cap, the new bottle is designed to help Molson Coors distinguish Thunderbolt from other beers in the market. Thunderbolt, described as “India’s original strong beer,” had previously been packaged in a 650ml amber bottle, a common bottle type in India’s returnable glass market. In an effort to have Thunderbolt’s packaging match its one-of-a-kind bold taste, Molson Coors turned to AGR to create a bottle that was AGR, branded and uniquely
recognizable in the marketplace, while remaining easy to produce. “The collaboration with Molson Coors provided a unique challenge that we enthusiastically undertook,” said Bill Slusser, Manager of Research Services for AGR. “It is always gratifying when our customers provide such positive feedback regarding the introduction of a bottle design that is deemed a success both functionally and aesthetically.” Produced in emerald green glass, the new Thunderbolt bottle features an instantly iconic debossed, shield-shaped label panel adorned with the familiar silver and blue paper label. The angular and aggressive shoulder construction displays an embossed lettering wrap that spells out the Thunderbolt
brand name including a lightning emblem within the letter ‘O’. Two additional embossed lightning emblems bracket the back label panel, just above the lower sidewall pinch, which transitions into a prominent heel construction. A new ring-pull cap gives the bottle a modern and premium twist in both look and function. “We have received rave reviews from both customers and consumers about the new Thunderbolt bottle, which we believe reinforces the brand’s identity of always staying original,” said Mr. Ashish Kapoor, President of Molson Coors in India. “Nobody can lay claim to our distinctively different, signature bottle, which in turn will bring greater savings and
efficiencies to our business.” The bottle was created by Dr. Wenke Hu and Brad Salitrik of AGR, using a concept design provided by Molson Coors. Harnessing their experience and knowledge of glass bottle design, Hu and Salitrik created an enhanced design incorporating the specific bottle features and characteristics specified by Molson Coors along with appropriate bottle thickness and glass distribution. Using Finite Element Analysis (FEA) techniques, the team was able to evaluate the bottle’s ability to acceptably withstand the expected loading conditions (internal pressure, impact and vertical load) and to verify that the bottle would perform as desired once it was manufactured.
Aldora buys into Louisville Plate
from an Atlanta operation. Stone bought back the company, doubled revenues and grew the workforce from 25 to 40 people. The new owner expects to increase the payroll to 100 employees by 2020. While LPG's release noted that while Stone "could personally finance a new facility...it would not be prudent to
go it alone." Stone said in a brief interview that he had no one in the family interested in taking over, but he wanted to ensure the company remains in good hands. He was satisfied that Aldora's leaders shared a similar vision. "My employees are very dear to me," Stone said.
UNITED STATES Louisville Plate Glass, a centuryold homegrown company, has been purchased by Floridabased Aldora Aluminum and Glass Products. The price and terms of the acquisition were not disclosed. In an announcement released Monday morning, company officials said that the transaction was completed earlier this year and that they intend to add about 60 employees and expand into a 60,000-square-foot facility for tempering and glass fabrication off Produce Road on Chefs Way. LPG president Bill Stone, 80, said that the deal involved primarily an exchange of stock. Stone will remain as president and an Aldora shareholder. The shareholders have invested more than $5 million in the new facility previously occupied by Creation Gardens, a produce wholesalers for restaurants in the region. "We are really excited to partner with Aldora and to provide customers with added products and services," Stone said in the release. "Our business has grown substantially, so the timing of the transaction along with the new facility couldn't have been better." Aldora COE Leon Silverstein
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added that bringing LPG into his company's fold is a coup because the Louisville team and its products have "a great reputation in the industry...and we believe it will only get better with the capability that the new plant will provide." LPG, founded in 1911, provides tempered glass, laminated safety glass, shower enclosures and coated products distributed in Kentucky, Tennessee, Ohio and Indiana at 1401 W. Broadway. Aldora, with headquarters in Miramar, has five manufacturing locations and serves the East Coast from North Carolina to the Florida Keys and also export markets. The new Louisville facility will include a large tempering furnace, jumbo cutting table, glass polisher and a water jet. An upgraded residential insulated glass line will be relocated to the new manufacturing facility, according to the announcement. United Glass Corp., which owned Louisville Plate for 10 years starting in 1999, fell on hard time during the recession, and the board of directors, which included Stone, voted to shut down the facility in 2009. The plan was to serve customers
Clayton acquires Romag UNITED KINGDOM County Durham-based Clayton Glass has acquired a Consettbased manufacturer for an undisclosed sum. Romag, which also works in the glass industry, will continue to operate as a separate entity from Clayton Glass. The acquired business manufactures security glazing laminates, serving the security, architectural and transport sectors. Romag has annual sales of about £15m and employs a workforce of 150. While both companies have enjoyed success in their respective markets, the acquisition will bring additional opportunities for future collaboration. Ryan Green, managing director of Clayton Glass, said: "We are delighted to have completed the purchase of Romag and
look forward to helping both businesses grow and flourish in the years ahead. "Although there are many synergies between the two companies in terms of location, history and core glass manufacturing activities, they specialise in very different areas of the glass industry. "As a result, with both businesses having market leading reputations in their respective sectors, we will continue to operate each company completely independently so that both can focus entirely on continuing to grow their specialist market share. "However, the new arrangement also means that where there are opportunities to work more closely on specific future projects, then naturally we will do so."
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Vitro to purchase PPG flat unit MEXICO Mexican glass manufacturer Vitro has announced that it has agreed to purchase the flat glass unit of U.S. company PPG for around $750 million, giving it a foothold in the U.S. and Canadian markets. Under the deal, Monterreybased Vitro will acquire four plants with a total of five furnaces in the United States, a flat glass investigation unit and four glass processing centers in Canada, the company said in a statement. Vitro, which emerged from a lengthy debt restructuring process in 2013 and last year sold its glass container business to Owens-Illinois Inc for more than $2 billion, said the deal would make it a world leader in the flat glass business. "This investment will strengthen our glass business for construction and enable us to take part in the
U.S. and Canadian markets, as well as the high-tech solar control coatings sector, where we don't have a major presence," said Vitro Chief Executive Officer Adrian Sada Cueva in the statement. The deal is subject to normal regulatory approvals, the Mexican firm said. The companies began discussions in October 2014 at the glasstec show in Germany regarding the potential for a sale. The opportunity became more of a reality when Vitro sold its container business a year ago, which freed up capital to pursue an investment into the U.S. market. Meanwhile, PPG has put an emphasis on the coatings side of the company with a handful of big acquisitions in the past two years, namely the purchase of Comex. Coatings had already made up
more than 90 percent of PPG’s business when it announced the sale of its glass segment last week. With PPG’s focus on coatings and Vitro positioning itself for investment, the timing was right. PPG hadn’t received any other formal offers for the glass business, but there was interest from beyond, according to Beuke. “No one was beating the door down, but others were interested,” he said. He said the company “learned a lot” from selling its automotive business to private equity in 2008. “[Corporate] wanted a strategic partner, and one where there was not a lot of overlap,” he said. “[PPG] was looking for someone that would keep the business alive.” Vitro was especially interested
in the research aspect of PPG’s business. “When they toured our research center in the early stages … their CEO was really impressed, and they all thought it was a good fit,” said Beuke. Beuke said with the purchase, Vitro will retain all employees and that it will continue to operate as usual at its various facilities throughout the U.S. and Canada. “The people and the processes will be the same,” he said. “From a customer appearance, nothing should change.” Ultimately, he said the purchase will mean bigger and better things for the business. He said PPG recognized during the latest recession that it “wouldn’t be a leader anymore from a capacity standpoint” but that the business could be a good fit for another company.
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People and Places Electroglass Ltd appoints new agent Americas Electroglass Ltd has announced that Interglass S.A., based in Guadalajara, Mexico, has been appointed its agent for Mexico, Central and South America. With their established position and reputation as suppliers to the area’s glass industr y, Electroglass says it is cer tain Interglass will bring a valuable extra level of local suppor t to existing and new customers in the region. Contact details are available in the agents
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Glaston makes executive appointments Finland
section of the company’s website. Electroglass Ltd are an independent UK based company specialising in the development, design and manufacture of electric glass melting systems and equipment. Fur ther information is available by contacting: Grahame Stuar t. Project Sales Engineer. info@ electroglass.co.uk +44 (0)1268 565577 www. electroglass.co.uk
M.Sc.(Econ.) Päivi Lindqvist has been appointed Chief Financial Officer (CFO) and a member of the Executive Management Group at Glaston Corporation as of 19 September 2016. Päivi Lindqvist reports to President & CEO Arto Metsänen. Päivi Lindqvist joins Glaston from Basware Corporation where she held the position as Vice President, Business Control since 2014. Prior to that she has served in financial, communications and investor relations leadership roles
at Outokumpu Oyj and Tieto Corporation. As of 19 September 2016 Glaston’s Executive Management Group is the following: Arto Metsänen, President & CEO Päivi Lindqvist, CFO Sasu Koivumäki, SVP, Machines and Deputy to the CEO Artturi Mäki, SVP, Services Taina Tirkkonen, General Counsel and SVP, Human Resources Juha Liettyä, SVP, Americas Pekka Hytti, SVP, EMEA Frank Chengdong Zhang, SVP, Asia.
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People and Places Phoenix Award goes to Cho Tak Wong World In recognition of his outstanding contribution to the international automotive glass industry, Cho Tak Wong, Chairman of Fuyao Glass Industry Group, has been selected as the 46th recipient of the Phoenix Award ‘Glass Person of the Year 2016’. Born and raised in rural China, the life of Chairman Cho is a true rags-to- riches story. Having peddled cut tobacco and sold fruit on the streets of his hometown at the age of 16, he worked as a farmer and a chef, before joining Fuqing Gao Shan Special Glass Factory in 1976. Mr Cho was invited by the local authorities to take over the ailing flat glass processing business in 1983, a decision that soon led to the creation of a hugely successful Sino-foreign joint venture, manufacturing automotive safety and industrial technology glass throughout the world. In 1993, Fuyao Group became the first company in its sector in China to be listed on the Shanghai Stock Exchange. Today, the Fuyao Group is China’s largest exporter of automotive glass, with
business commitments, Mr Cho is one of China’s foremost philanthropists, his Heren Charity Foundation seeking to offer poverty relief, disease prevention and infrastructure projects. “I have always believed that an entrepreneur carries three responsibilities” he comments, “mightiness of the nation, advancement of the society and abundance of Cho Tak Wong: the latest Phoenix recipient
11 advanced production centres strategically located throughout the country, as well as international subsidiaries and business organisations in the USA, Japan, South Korea, Australia, Russia, Germany and Hong Kong. Customers include such global automotive producers as Audi, Bentley, BMW, Chrysler, Daimler, Fiat, Ford, General Motors, Honda, Hyundai, Jaguar Land Rover, Nissan, Volkswagen and Volvo. In 2009, Mr Cho became the first Chinese citizen to be named Ernst & Young World Entrepreneur of the Year. Alongside his extensive
the people. By achieving these three items, an entrepreneur can fully deserve his title.” The Phoenix Award Committee congratulates and acknowledges Mr Cho Tak Wong’s many achievements and looks forward to presenting him with the 46th Annual Phoenix Award at a specially arranged banquet in Dayton, Ohio, USA this October.
ABOUT THE PHOENIX AWARD® In May 1971, representatives of nineteen major suppliers to the glass industr y met in New York City to form an association for the express purpose of recognizing outstanding individuals who have made noteworthy contributions to the glass industr y. As a result of this meeting, the Phoenix Award Committee was born and soon adopted a code of by-laws with the following Preamble: “It is the purpose of the Phoenix Award Committee to select, each year, a person now living, who has been active in and has made contributions to any phase of the glass industr y. This may be in the field of science, production, or education relating to glass, and shall include glass containers, fiber glass, scientific glass, flat glass, tableware and electronic glass... As a symbol of this Award the recipients shall be presented with a glass sculpture representing the mythological Phoenix Bird.” Committee members ser ve for a period of four years, and six new members are elected each year to replace those whose terms have expired. Membership is on an individual, not on a corporate basis. Members must be employed by a company which is a supplier to the glass manufacturing industr y.
GIMAV unveils new president Italy The 2016 Ordinary General Meeting of GIMAV (Italian Association of manufacturers and suppliers of machiner y, equipment and special products for glass processing) took place on Wednesday, 15 June. Aldo Faccenda (Bottero SpA) was elected the new President and will take over from Cinzia Schiatti (Schiatti Angelo Of cina Meccanica srl). Michele Gusti (OCMI-OTG SpA), who was con rmed as President of the Hollow Glass Section and Dino Zandonella Necca (ADI SpA), who was confirmed President of the
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Accessories Section, were called to assist President Faccenda. Along with the new President, the Board of Directors was elected for a new term and is now composed of Barbara Antonini (Antonini srl), Federica Bovone (Elettromeccanica Bovone srl), Nicola Lattuada (Ade- lio Lattuada srl), Angelo Lovati (Lovati F.lli srl), Nancy Mammaro (Mappi International srl), Barbara Mazza (Cugher Glass srl), Michela Pezza (Fratelli Pezza srl), and Matteo Rolla (Neptun srl). “There was a ver y active par ticipation in the meeting
which led to the election of a Board of Directors that is widely representative of all the main areas of the sector: at glass, hollow glass and accessories” – stated Aldo Faccenda, HR Director at Bottero SpA and the new GIMAV President – “I am cer tain that this can be an excellent star ting point. Our aim is to continue with the development process that we star ted a few months ago, in terms of the association’s visibility and activities. GIMAV must continue to grow, by welcoming all of Italy’s star players in this sector, to strengthen its weight on the
domestic and international markets and to be universally recognized as a global player for all the glass trade worldwide.”
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Batch Duties have positive effect on local makers India // Soda Ash Lower import and anti-dumping duty (ADD) on imported soda ash helped Indian producers to improve their net profit margins in 2015-16. While domestic production rose, imports declined by 16 per cent. According to Alkali Manufacturers’ Association of India (AMAI) data, India had imported 705,600 tonnes in 2014-15, down to 591,990 tonnes in 2015-16. ‘’Indian manufacturers were able to satisfy the demand in the domestic market and China volumes were low, owing to availability issues there. As a result, import declined,’’ said Sunil Bhatnagar, president (marketing) at Gujarat Heavy Chemical Ltd (GHCL).This reflected on producer companies’ balance
sheet performance. GHCL’s profit after tax (PAT) was Rs 181.9 crore for the financial year ended March 2015 and rose to Rs 256.5 crore for the year ended March 2016. The net profit margin (NPM) increased to 10%, from the earlier 7.7%. Similarly, the PAT of Tata Chemicals rose to Rs 780.2 crore in 2015-16 from Rs 596.5 crore in 2014-15; the NPM increased to 4.4 per cent from 3.5 per cent in this time. DCW, in a loss during 201415 at Rs 5.9 crore, registered net profit of Rs 18.6 crore in 2015-16. ‘’Because of ADD, import of soda ash has been limited and this has helped Indian companies. If government will remove it, import will definitely increase, due to the
price factor. It might also force manufacturers to decrease their production,’’ said Mudit Jain, managing director of DCW. AMAI says the country requires 3.2 million tonnes a year, mainly consumed by the detergent and glass industries. Leading producers such as Tata Chemical, GHCL and Rohit Surfactants (RSPL) are raising their production capacity. Output rose to 2.69 million tonnes in FY16, from 2.5 mt earlier. The industry has been attempting to remain competitive with international prices, other than in the southern and eastern parts of the country where imports are more viable on account of cheaper logistic costs. However, China with
a capacity almost 10 times the Indian size and the US with their natural soda ash having a huge cost advantage, are a threat. In the first phase, GHCL, which at present has 850,000 tonnes production capacity, will raise it by 100,000 tonnes by FY’17, with an estimated investment of Rs 375 crore. In the next phase, likely to be completed by FY19, it plans to invest Rs 575 crore to increase capacity by 150,000 tonnes. ‘’Prices have always been an issue for the industry in India because of various factors such as raw material costs, power rates and higher interest rates. Other countries are offering the same products with lower cost,’’ said Jain.
of years ago. Oltchim was CET Govora’s biggest client. CET Govora recorded losses of EUR 74 million between 2012 and 2015. In 2015, the company’s losses were close to EUR 22 million at a turnover of EUR 90.5 million. The company increased its number of employees by about 800 last year, to 2,100, as it took over a coal mine that supplied the power plant, which only made its financial problems worse. Ciech is one of CET Govora’s biggest clients. However, Ciech is also dependent on CET because it can’t function without the steam from the power plant. Ciech Soda Romania, the company that owns the soda
ash factory, has also had big financial problems in recent years. The company went through insolvency and had to lay off 30% of its employees and restructure its activity. It recorded losses of EUR 65 million between 2010 and 2014. The results for 2015 haven’t been made public yet. Polish group Ciech claims it invested EUR 220 million in the Romanian factory after taking control, in 2006. The group’s representatives also say that this is the biggest Polish investment in Romania and the country’s only soda ash factory. Ciech Soda Romania had sales of EUR 63 million and 600 employees in 2014.
CET cuts power to soda plant Romania // Soda Ash Romanian power plant CET Govora in Ramnicu Valcea, which is currently in insolvency, has stopped delivering steam to the only soda ash producer in Romania, which is part of Polish group Ciech, thus forcing it to stop production. CET Govora’s judicial administrator, Remus Borza, claims that Ciech has been buying steam from CET Govora at very low prices, which didn’t even cover the production costs. He cancelled the contract between the two and asked Ciech to pay a higher price to restart the deliveries. Ciech representatives say they are trying to reach a compromise with CET Govora’s judicial administrator and that the price
he asked for steam is too high and would make the company unprofitable. The company’s Polish managers also claim that CET Govora actually makes profits from selling its steam to Ciech and that if CET decides to stop the deliveries this may push both companies to shut down their production, with negative consequences for the whole city. CET Govora is a thermal power plant that supplies electricity as well as heat to companies and the residents in Ramnicu Valcea. The company took a serious hit when the chemical plant Oltchim Ramnicu Valcea, the city’s biggest company, went into insolvency and reduced its production a couple
Altech upgrades resource for sapphire glass Australia // Kaolin Altech Chemicals Ltd has updated its kaolin resource following recently completed grade control drilling on its 100% owned high purity alumina (HPA) project in Meckering, Western Australia. The updated Resource measures 11m. tonnes of kaolin clay containing 45% minus 45 micron clay with a brightness of 82.7%. This resource will feed the proposed HPA plant in Malaysia for over 250 years.
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Iggy Tan, managing director, commented: “Altech can now progress to the next stage in preparation for mine development, the submission of what will be a relatively straightforward mining proposal and mine closure plan. “Upon approval of these items, the site at Meckering will be ready for the development of the campaign mining and container loading operation to supply feedstock for Altech’s proposed
Malaysian HPA plant.” HPA is a high-value, high margin and highly demanded product as it is the critical ingredient required for the production of artificial sapphire. Artificial sapphire is used in the manufacture of substrates for LED lights, semiconductor wafers used in the electronics industry and scratch-resistant artificial sapphire glass. Sapphire glass is used in the Apple watch. There is no substitute for HPA in the manufacture of
artificial sapphire. Altech was recently granted its mining lease at Meckering, where it is planning to mine 120,000 tonnes of kaolin every three years on a campaign basis, each mining campaign will last two months. The resultant raw kaolin will be stockpiled, then containerised into shipping containers at the rate of 40,000 tpa and transported to Johor, Malaysia for processing into HPA at the proposed plant.
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Indonesia plans glass packaging boost B
efore the end of 2016 the Indonesian government plans to have imposed a controversial excise on plastic packaging. Earlier this year the government had already suggested a IDR 200 (approx. USD $0.02) excise duty for food and beverage products wrapped in plastic packages. However, with all spotlights focused on Indonesia’s tax amnesty program this plastic wrapping excise tax has been off analysts’ radar. But why does the government of Southeast Asia’s largest economy want to implement it? According to preliminary information from Indonesia’s Finance Ministry, the excise will be imposed on all products wrapped in plastic, including bottles, bags and sachets. However, lower rates may apply for those companies that focus on recycling activities and therefore cause less damage to the environment. There are three reasons why the Indonesian government is eager to introduce a small additional charge on plastic packaging. Most likely it is the third reason (mentioned below) that is most appealing to the government. By making food and beverage products that are wrapped in plastic a little bit more expensive, the government slightly discourages consumption of these products. It is estimated that more than 80 percent of food and beverage products in Indonesia use plastic material for packaging. However, most of these items, such as snacks or soft drinks, are unhealthy. As such, the government tries to improve the overall health of the people through this excise tax on plastic packaging. Moreover, various studies indicate that plastic packaging has a negative impact on people’s health. When consuming drinks or food items that are wrapped in plastic material, there are certain chemicals that can migrate from the plastic packaging to the food products and beverages inside the package.
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Indonesia is the world’s second-largest plastic waste producer, after China. According to a report from Science, Indonesians use about 187.2 million tons of plastic, each year. Meanwhile, Greeneration Indonesia estimates each Indonesian individual consumes 700 plastic bags per year. Generally, Indonesians have a very low awareness of the importance of a clean environment and environmental sustainability. This is why rivers are usually clogged with plastic and other thrash, particularly in the bigger cities (moreover plastics take considerable time to break down naturally). The higher price of products packed in plastic materials will discourage consumption of these products and therefore there will be less thrash that is dumped in rivers or on streets. By imposing this additional excise tax, the government’s tax revenue will rise. Given that Indonesia’s tax revenue has been disappointing so far this year (and has been disappointing in recent years) the government is eager to find new sources that can deliver some additional state income (this is also the motive behind the tax amnesty program). The government collected a total of IDR 518.4 trillion (approx. USD $39.6 billion) worth of tax revenue (including customs and excise) in the first six months of 2016, down 3.3 percent (y/y) from tax revenue realization in the same period one year earlier, and only 33.7 percent of total targeted tax revenue this year. Having a population that numbers over 255 million people, most of whom have the habit of eating plastic-wrapped snacks and plastic-bottled drinks, this excise tax constitutes a great source of revenue. However, the excise tax on plastic packaging has also met fierce resistance. Firstly, stakeholders active in Indonesia’s food & beverage sector, packaging sector, and petrochemicals all objected to the new excise as it is considered to have a negative impact on sales. This could then even hinder development of Indonesia’s manufacturing industry (perhaps giving rise
to more food and beverage imports from abroad), while falling consumption of food and drinks may eventually actually lead to fewer tax revenue for the government. Business groups say the government should focus on the development of good waste management systems instead of using the excise as a tool to gain additional state revenue. Others claim that the new excise is not fair, or even goes against a basic human right. In Indonesia’s urban centers people cannot drink water from the tap, while river water is highly polluted. As such they are dependent on plastic-bottled water. Easy access to clean water (including a low sales price) is regarded a primary right of the people, and therefore some opponents of the excise request the government not to touch this segment in order to generate additional state income. Another problem is that plastic packaging has become a vital component in people’s lives. Plastic is a cheap, relatively safe and long-lasting form of packaging for food products and beverages. In recent decades plastic packaging has become very popular, undermining the market shares of glass or tin. Not only access to clean water, but food consumption is also one of the people’s basic rights. And given that there is no other (cheap, relatively safe and longlasting) material that can replace plastic packaging for food products and drinks, plastic-wrapped foods and drinks offer the key source of nutrition for the population. Affordable food and drinks is particularly important for those living below the poverty line as well as the huge group of Indonesians who live just above the poverty line. However, for the makers of glass packaging, such a move will come as a welcome boost. The quest will now be to provide affordable, lightweight alternatives to the existing packaging options, as well as beef up the country’s disparate recycling programme in order to capitalize on this sea-change in government policy.
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LiSEC hits at glasstec 2016 LiSEC shows its hits at glasstec 2016. Under the motto “best in glass processing”, which is also the new claim of the company, the plant manufacturer will present bestsellers which are hits in the fields of software, cutting, tempering, insulating glass manufacturing, glass processing, logistics & handling as well as service. Experience LiSEC and its hits in hall 17, stand A20! Best in Tempering: AEROFLAT The team achieved an almost 100% evenness by the still better design and the technically more sophisticated implementation of the ceramic air cushion bed in the furnace. This did not only lead to a processing result of the glass sheets with an even higher quality but also to an increased process reliability because the risk of damaged sheets is reduced. The convection current The convection current in the furnace was optimized by means of a computer-aided flow calculation tool, which simulates the convection. With the resulting lessons learned, the development team constructed a prototype as a model by means of which the team carried out the corresponding tests and again and again compared theoretical and practical values. Light-weight construction The team has revised the entire construction and, for this purpose, has used concepts from the light-weight construction. All in all, the developers were able to save approximately half of the weight without impairing the performance of the AEROFLAT. This weight reduction has advantages for the assembly (lighter engines and tools as well as simpler handling) but also for the customers due to lower transport costs and generally lower production costs. Spreitzer: „We have determined the optimum component strength and designed the construction so that we were able to save as much material as possible. Thus we were able to realize a reduction of the manufacturing costs of approximately 20%!“ An important aspect of the redesign was also the service and maintenance friendliness at the customer’s. Now, wear and maintenance parts can be removed and installed more easily due to the corresponding working height (ground level). Another plus factor which brings benefits already during assembly due to the simplicity
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and optimum set-up times. „The redesign project has gone extremely well along our meanwhile very well established development process: we had a perfect cooperation of the different departments in a small team at one location“, says Spreitzer. What is particularly pleasing is the fact that the first tests have already been very successful and that the engineers had to do only minimal retouching. Spreitzer: „The first AEROFLAT was installed at Internorm and has been running smoothly for more than one year! AEROFLAT: one technique – many advantages • No waiting time when the types of glass are changed • Wear-free ceramic components • Significantly shorter heating time • No cooling of the heating zone required in case of glass breakage • Identical cycle time for coated and uncoated glasses • Operators trained in only five days • 50% less staff required compared to conventional plants • No touching of the glass surface throughout the entire process • The tempering of double-sided coated and printed glass sheets is possible • Thermal tempering of glass is possible from 1 to 10 millimeters Best in software: Industry 4.1 à la LiSEC Industry 4.1 by LiSEC allows transparent and efficient production processes in the sector of the glass machining and processing industry. The integrated networking from the preparation of offers to the delivery supports the optimization of the production process and allows a seamless product tracking. Integrated quality checks along the production process beginning with the incoming goods inspection to the final check at the end of production allow a consistent quality report thanks to the networking which may act as a quality proof for a specific order. Learning and self-optimizing production machines and plants autonomously make decisions about the tools to be used and machine settings and thus increase the efficiency. Predictive and preventive maintenance is possible due to the permanent and consistent monitoring of the plants by means of integrated sensor and assistance systems. This maintenance helps to prevent unplanned downtimes and thus increases the availability
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of the plants. It is also possible to plan and organize service calls and required spare parts in an automated way. The evaluation of the collected data in real time results in receiveroriented reports which continuously provide the acting persons with relevant information and thus the basis for decisions. At the glasstec trade fair, LiSEC will present its concept Industry 4.1 on the TPA line. The centerpiece here will be the LiSEC Line Coordinator: all data of the line and its plants are collected and processed there. Best in Insulating Glass Manufacturing LiSEC will present another hit at the glasstec 2016: The leading manufacturer for plants and software for the flat-glass processing industry has developed an entirely new concept for the production of insulating glass units with thermoplastic spacers. The concept is designed with respect to cycle time, high quality and accuracy. Key features: • From the cutting to the completion of the insulating glass unit, no manual intervention will be required under normal circumstances, • The concept only provides for one applicator and achieves a cycle time of 35 seconds for standard triple-glazed insulating glass (size: 1m2) • High-Speed due to an innovative LiftOver system • Saving of investment-intensive core machines • New industrial design Core plants of the fast lane TPA line: Assembly press: The press used in this concept is a completely new development. The title AGP press (AGP stands for assembling, gas filling, pressing) ensconces a press which is, on the one hand, fast – we guarantee a cycle time von 35 seconds for triple-glazed elements in paired operation (basis: triple glazing – one sqm size) - and which features an extremely high pressing accuracy on the other hand. The tolerance for insulating glass up to a size of 2.5m2 amounts to a maximum of 0.5mm with reference to the element thickness. The press may be used in a very large range of applications due to the fact that the new AGP press can process elements of 350 kg/running meter (and up to 200 kg/running meter for the first two glass sheets). When producing step(ped) elements, the step bottom edge may be 150mm and the step upper edge may be up to 700mm. A particularly important feature of this press: up to triple-glazing insulating glass, all glass sheets are supported at any time during the assembly which prevents any sliding down. The AGP press also scores in terms of ease of servicing: an exchange of the press plates is possible without losing the accuracy. CleanSeal technology: the LiSEC sealing solution features a highly dynamic self-regulatory servo-controlled dosing system. It recognizes temperature variations and changes in the viscosity among other things caused by differences between batches and downtimes and it adjusts itself. The CleanSeal concept also includes an unwinding device which finishes off the corners instead of only correcting them. The overall system is so elaborate that one operator is able to cover all work steps. Especially the so-called “dabbing of the corners” is almost entirely obsolete. Thus, LiSEC does not use any prone to wear and therefore relatively expensive and inaccurate gear pump but a servo-controlled throttle valve: sealing material is applied with an open controller as long as possible, i.e. the material is optimized and controlled via an open discharge flow, the material feed is only throttled in the corner areas.
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Best in Glass Cutting LiSEC presents the fastest cutting technology worldwide! The revised RS cutting technology 2016 (grinding & cutting in one working operation) constitutes the worldwide fastest solution in terms of production runs with a high percentage of coating (>60%). For typical cutting patterns, our ESL-RS is by approx. 10% faster than the fastest cutting plants in the market. Combined with the new innovative glass storage solutions such as the package loading system and the revolutionary FlyOver glass loading, the glass storage costs and the cycle times are reduced to a minimum thanks to the highest storage density. Best in Glass Logistics The flat-glass-processing industry and the world of insulating glass manufacture are changing rapidly. Increasingly shorter delivery times combined with increasing quality requirements generate the pressure to produce free from defects. This is why LiSEC pays particular attention to quality in the production, downtime management and part tracking. LiSEC’s overall objective is a one hundred percent automated production which means that as few as possible manual handling is required in order to prevent production faults due to scratches, mixing ups or damaged and/or broken glasses. At the glasstec trade fair, LiSEC will present a logistics innovation: the new tilting shuttle SHL allows layout plans in even the most confined spaces which would not be possible otherwise. The tiltable glass shuttle covers standard inclination of 2-6° but it also tilts horizontally (90°) if required. The tilting shuttle uses the approved SHL system’s rail system and may therefore be operated highly dynamically with speeds of up to 300m/min and accelerations of up to 3m/s². Customer benefits: - It is now possible to realize customer wishes which have so far been impossible due to confined space conditions. - Saving of at least one tilting table including safety fencing per line Best in Glass Processing – no Compromises in Terms of Processing In the field of flat glass processing, LiSEC has been pursuing a clear objective for years: the best vertical processing quality at the lowest life cycle costs. Operators of glass processing plants benefit from many years of experience of the pioneer in the vertical processing in particular in terms of the edge processing with peripheral wheels. Sheets with dimensions exceeding the jumbo format as well as glass thicknesses of less than 3mm are already successfully processed on LiSEC plants. Needless to say that the high technical standards of the KBU plants are also reflected in the machined end product, the excellent quality of the polish – irrespective of the shape of the glass sheet – is still setting standards in the industry. With the integration of a drilling and milling station, the KBF, LiSEC provides a general-purpose tool for almost all applications and glass sizes. The production of bores as well as inside, edge and corner cutouts complete the processing of the glass sheet in only one clamping operation. In doing so, LiSEC is the only manufacturer who banks on only one processing spindle. This guarantees the customers a simple and stable system with minimal downtimes. The second processing spindle is replaced by an elaborate software and process control; this way it is in many cases even possible to realize the lowering on the back side of the sheet.
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ANALYSIS: Container Glass
PACKAGING PROBLEMS contradictions continue as glass fights its corner
AG reflects on some of the reasons that glass continues to struggle to isolate itself as the worldâ&#x20AC;&#x2122;s premium packaging material, and questions what can be done to advance the argument. We also include a focus on China, and the health of its own container sector.
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s a primary packaging material, glass continues to thrive. Global glass packaging market volume was estimated to be 47,000kt in 2013 and is expected to reach 60,847kt by 2020, growing at a CAGR of 4% from 2014 to 2020. Asia-Pacific is expected to maintain a leadership position in the glass market, and is estimated to account for close to 38% of the global glass packaging demand by 2020. Europe, the second largest market, is expected to play a key role in boosting the demand for glass packaging owing to the increased beer consumption from countries of Eastern Europe. Asia-Pacific is also expected to be the fastest growing regional market over the next six years, growing at an estimated CAGR of 4.2% in terms of volume from 2014 to 2020. The alcoholic beverages sector remains the highest consumer of the material. Brands in beer and wine continue to use glass as a brand differentiator, with a number of innovations that have the high shelf impact retailers are looking for. The pharma sector, too, has had a long and continued association with glass due to its sterile properties. However, plastics are encroaching on this market and others, and this development is only expected to accelerate in the long term. Plastic is also, as we have seen, increasingly being used in food packaging, but a number of brands in this sector will continue to use glass as their primary packaging material as it is a core component of their brand communication.
Usage trends
There is an appetite for more premium formats - sprayed and etched coatings, embossing, sleeving, screen printing and so on - as well as differently shaped and heavyweight bottles, to help premiumise high-end branded products. In contrast, environmental and price considerations combine to continue the drive towards lightweighting. Companies will continue to explore new solutions that meet this criteria.
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In the UK, for example, the weight of glass is constantly under consideration, as brands and their supply chain partners look to save costs with lightweighting initiatives. A major industry-wide initiative called Container Light, funded by the Waste and Resources Action Programme (WRAP) and managed by the Faraday Packaging Partnership, made practical moves towards lightweighting across glass packaging. The research discovered that participants were generally unable to detect a reduction in weight of 5-10%. Ten years later, lightweighting across the glass industry continues to be major area of product development. Generally, the aim is to create a more lightweight glass bottle for consumers that also reduces the amount of glass used in production. One such company, in 2014, reduced the weight of the 30cl Budweiser bottle by 10g as part of its environmental commitments. The benefit was that in 2015, the same company reduced energy consumption per hectolitre by 1% compared with 2014, and recycled nearly 100% of all waste and brewing byproducts. In the past several years, one of the biggest changes in the packaging market is the competition to attract the swell of millennials, which, by 2020, will account for a third of the adult population (about 83 million). The ripple effect has been a rise in local and craft brands, in nearly every beverage category, functional foods and beverages, and smaller formats, as well as an increased focus on health and sustainability. It is generally considered that the millennial consumer also has different expectations than previous generations. They are looking for transparency, sustainability, and local, smaller brands that offer new experiences and premiumisation. Glass containers are perfectly poised to meet these expectations, but there is a lot of competition in the packaging arena to win over consumers. The strengths that glass maintains as a premium packaging material continue to be felt right across the packaging industry. Glass isnâ&#x20AC;&#x2122;t perfect - its weight and
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ANALYSIS: Container Glass
fragility continue to be an issue for the supply chain, for instance. As consumers continue to favour this packaging material, innovation will no doubt continue.
Recycling remains an issue
There’s not enough recycled glass in the US to keep bottle manufacturers and beverage makers happy. Making a new bottle out of recycled glass uses less energy, compared to using virgin materials. For every 10 percent increase in recycled content in a new glass bottle, you reduce energy required to produce it by 3 percent to 5 percent. This means a reduced carbon footprint — as well as lower utility bills and bottle prices — for all companies involved. But glass, which is endlessly recyclable as opposed to other materials such as paper, has a miserable recovery and recycling rate in the US. “We don’t have high recycling rates for much of anything in the US but they are low for glass — about 25 to 30 percent,” said Roberta Barbieri, Diageo’s global environmental director, in an interview with Environmental Leader. Some European countries’ glass recycling rates, she says, reach 70 percent. “Glass is 100 percent recyclable,” said Katie Wallace, New Belgium Brewing’s assistant director of sustainability. “There are glass plants around the world making bottles with 96 percent recycled content and we would like the US to be one of those.” The supply-demand discrepancy is a major problem for the entire glass recycling value chain. And now more than 20 companies across this value chain are coming together to fix it. In an exclusive interview with Environmental Leader, sustainability executives from Diageo and New Belgium Brewing say the two beverage makers, along with the Glass Packaging Institute and the glass processing and recycling industry, have formed a coalition to make glass recycling a successful industry in the US. The US Glass Recycling Coalition’s members include consumer brands, glass manufacturers, waste haulers, recycling processors, and trade organizations. It’s the first time companies across the entire glass supply chain have worked together toward this common goal, the groups say. The impetus behind the coalition began a year ago at a Diageo workshop with representatives from companies across the glass recycling value chain. “A lot of time was being spent debating policy solutions to recycling in general in the US,” Barbieri said. “Everyone agrees recycling is not being done very well in the US but people don’t agree what the best policy solutions are at the federal, state and local level. Because of that debate, no progress was being made. We saw an opportunity to get people in a room, take policy off of the table and put solutions on the table and we wanted to talk with anyone with an interest in glass recycling about ways we could collaborate as a glass value chain to scale up best practices. A year later, that conversation turned into our official coalition.” The coalition met on April 21, 2016 for an inaugural session hosted by the Glass Packaging Institute in Washington DC. Members have each paid a $5,000 membership fee. The coalition includes: Allagash Brewing Company, Ardagh Group, Diageo (co-founder), Gallo Glass Company, Glass Packaging Institute (co-
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founder), Goose Island Beer Company, Heineken USA, NAIMA (North American Insulation Manufacturing Association, Inc.), New Belgium Brewing (co-founder), National Waste and Recycling Association (NWRA), O-I, Pratt Industries, The Recycling Partnership, Resource Recycling Systems (facilitator), Republic Services, Ripple Glass, Rocky Mountain Bottle Company, Sierra Nevada Brewing Co., Sims Municipal Recycling, Strategic Materials, Inc. and Waste Management. Glass recycling can pose challenges on the recycling infrastructure if not planned for and executed correctly. It can easily contaminate other recycling streams. It’s heavier, and thus cost more, to haul to recycling facilities. And it’s abrasive, and can be hard on recycling equipment. In addition, a few municipalities have decided to remove glass from their curbside recycling programs and send it to land fills instead. Coalition members will work on bringing best practices to the US glass recycling supply chain to increase the availability of “cullet,” the industry term for furnace-ready recycled glass that can become new bottles and jars, as well as fiberglass. Two North Carolina material recovery facilities, for example, are installing sorting equipment at the front-end of the recycling process instead of recovering glass at the end of the process, which is when it usually happens. “This saves the equipment from wear and tear and contamination that happens later in the process,” Wallace said. For companies like Diageo and New Belgium Brewing, glass is not being recycled at a high enough rate to meet the beverage makers’ needs for recycled glass to make new bottles. Using recycled glass will help companies lower their energy costs and also reduce risk, Wallace says. “In the future, with material shortages due to climate change issues and resource scarcity, using a finite resource that is endlessly recyclable is a smart, long-term business solution,” she explained. “And as energy becomes more expensive, if we can create products with less energy that will be a smart business move as well.”
The aluminium challenge
According to a newly-released study conducted by ICF International for the Aluminum Association, the amount of greenhouse gases (GHG) emitted in the course of transporting and refrigerating beverages in aluminium cans is lower than the amount of GHG’s released when the same quantity of beverages is transported in plastic or glass containers. Researchers determined that GHG emissions were between 7% and 21% lower per liter than for plastic bottles, and between 35% and 49% lower than for glass containers. The variance in results is due to the size of the bottles studied and the type of refrigerator used to cool the product prior to consumption. When comparing containers, GHG emissions for 12-oz aluminium cans was 45% lower than those for a 12-oz. glass container, and 49% lower than for a 20-oz plastic bottle when refrigerated and served in small markets and convenience stores. The size, shape, and weight of common single-serving beverage containers was studied as well. Researchers determined that aluminium containers consistently rated higher on packaging and cooling efficiency, which, in turn, required less
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ANALYSIS: Container Glass
energy to make and keep the containers cool. Lower energy requirements naturally lead to lower GHG emissions per unit. “As the world focuses on low-carbon solutions, it is important to understand where the opportunities are to make a real difference,” said President and CEO of the Aluminum Association Heidi Brock. “The study underscores the advantages of the aluminum can when it comes to sustainability.” Although prior studies examined GHG in aluminium production and recycling, the study in question was designed to understand the GHG related to the phase in between those events, when the product is serving the function for which it was designed, or the “use phase” of the product. “As more attention is paid to carbon emissions associated with the entire value chain of a product, the Aluminum Association asked ICF to look at the carbon footprint of a beverage container’s use phase,” explained ICF International’s Vice President Marian Van Pelt. “Across all scenarios studied, aluminum has lower associated use-phase emissions than comparable glass or plastic containers.”
Hardly a help?
However, as soon as the environmental side gains traction, you then get a situation where a government steps in with a piece of legislation that simply seems to fly in the face of the popular rhetoric. For example, thirsty residents of – and visitors to –Hong Kong may have to pay more for drinks sold in glass bottles after the imposition of a levy aimed at ending wholesale dumping of the c ontainers in landfills was given the legislative green light this year. The move – that will have a significant impact on bars and restaurants across anufacturers and importers. the city – targets m Lawmakers yesterday passed an amendment bill to start charging the levy from 2018. The amount has yet to be finalised, but the government has proposed charging HK$1 for every one-litre bottle. The money earned would be used to hire a contractor to collect and process glass bottles. ove, with only five opposing The majority of lawmakers supported the m it, including the Liberal Party’s Tommy Cheung Yu-yan, who represents the catering sector. According to official statistics, the city threw away 204 tonnes of glass containers a day in 2014, accounting for about 2 per cent of solid waste produced daily. Cheung said he supported protecting the environment, but questioned the effectiveness of the levy in reducing waste and increasing the number of bottles being recycled. “The government should think about giving tax rebates to caterers and retailers to encourage them to bring glass bottles back [for recycling],” he said. Cheung warned that the additional cost due to the levy could trickle down to restaurants and bars. The Liberal Party’s Vincent Fang Kang, who also voted against the proposal, said the levy alone would not solve the problem as there were not enough supporting services in place to deal with the waste. “Perhaps the government could give incentives, for example in terms of land, tax or loans, to attract foreign and local investors to put money into the glass recycling industry,” he said. Fang also accused the government of doing little to educate the public about recycling glass. Lawmaker Wu Chi-wai of the Democratic Party said while he supported the levy, the government should also come up with initiatives to encourage recycling at the community level. The food and beverage industry is worried about the impact on business. “If the levy is too high, the costs could be passed on to restaurants and supermarkets, which could in turn increase prices for customers. This could affect business,” Simon Wong Ka-wo, chairman of the Federation of Restaurant and Related Trades, said. “The HK$1 per one-litre bottle proposed earlier might not seem a lot for a bottle of wine, for example, but for a bottled drink that costs, say, HK$10, the levy would be 10 per cent the price of the drink.”
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But Wong said a lower levy could also be problematic. “If the revenue from the levy is not big enough to cover the costs of the recycling, this could lead to a possible future levy on restaurants and supermarkets,” he said. Wong said his group would seek discussions with the government on details of the scheme. A bar manager in Central said the levy would likely affect her bar’s profit level. “It could cost more for us to buy drinks [from d istributors] but we can’t charge the customers too much or they won’t come. So that means we will have to make less money,” she said. Despite the prospect of higher prices for bottled drinks, bar customers did not seem to be worried. One customer said possible price increases after the levy was enforced would not deter him. “A small bottle of beer is already HKD$50-$60; how much more can they charge [with the levy]? The levy won’t stop me from heading to the bars to enjoy myself,” he said. While various voluntary recycling schemes have been introduced over the years, there is no citywide, mandatory recycling scheme for glass bottles. Official figures show only 1,500 tonnes of glass waste was recovered from 55,000 tonnes generated in 2011. As of March this year, there were about 1,300 recycling points in residential areas and another 580 in public areas across the city. The government said it would expand the recycling network in the future.
The knock-on
Of course, every time there is a piece of negative news about glass packaging, and the arguments continue about effective collection of recycled products, the plastics fraternity just keeps ploughing on with its base message…replacement. Take the example of Plastipak, a global manufacturer of rigid plastic packaging, which has partnered with AriZona Beverages USA (Woodbury, NY) to commercialize the first ThermoShape system in the USA. The project came to fruition when AriZona challenged Plastipak to deliver a hot-fill PET package while preserving its iconic look and feel of its glass packaging. AriZona wanted the ability to be able to run on existing hot-fill lines, and offer barrier protection to maintain the great taste that the consumer has come to enjoy and expect. Utilizing Plastipak’s patented ThermoShape and DiamondClear barrier technologies, they were able to successfully deliver on all of these requests and create a smooth wall, hot-fill, extended shelf life, in a lightweight, recyclable PET container. It is able to maintain the product integrity while upholding the cost required to support AriZona’s marketing and supply chain needs. In the ThermoShape process, pasteurization renders the product microbiologically stable. The product is then filled hot to decontaminate the inner surface of the container and the closure. At this point, the container is cooled rapidly and immediately to maintain product taste and vitamin content integrity. As the result of this well-performing fill technology, hot fill products have a shelf life ranging from 6 to 12 months, similar to aseptic fill products. PET packages with DiamondClear feature a durable monolayer structure which eliminates potential aesthetic and performance issues. “Over the last several year Plastipak has devoted resources to broadening our hot-fill and barrier capabilities, so when AriZona came to us with this challenge, we were confident that we had the right combination of solutions to be successful,” said, Tim Eppinga, Global Vice President of Food & Beverage Category. Plastipak operates more than 37 sites in the United States, South America and Europe, with a total of over 5,000 employees. With global reach, such innovation continues to threaten glass container suppliers everywhere, who can only respond with lighter, more innovativelyshaped bottles, as well as an – often garbled – “green” message. The challenges remain, the battle continues, but there needs to be a more concerted move in the right direction.
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ANALYSIS: Container Glass
China in focus Chinaâ&#x20AC;&#x2122;s daily glass industry in 2015Q1-Q3 kept growing in general and the growth rate of output went down. The operation quality and economic efficiency kept stable.
Output
According to the monthly statistics from State Statistics Bureau on 867 scaled enterprises (with annual main business revenue up to and over RMB 20m, same as below) of daily glassware and glass container, the total output of daily glassware and glass container in 2015Q1-Q3 is 20,890.8kt with growth rate 4.71 (down by 3.11%) compared with previous year. The outputs of top five manufacturing provinces are: Sichuan 3,708.4kt, accounting for 17.8 of the China total, Shandong 3,453.7kt (16.5%), Hubei 1,735.6kt (8.3%), Henan 1,732.6kt (8.3%) and Hebei 1,324.7kt (6.3%). The output of the top five provinces accounts for 57.23% of the China total, down 1.32% (Figure 1). The output growth rates of the provinces with annual output of daily glassware and glass container over 1m.t are: Sichuan 9.20%, Shandong 0.87%, Hubei 7.79%, Henan -8.25%, Hebei 3.85% and Anhui 24.25%, Heilongjiang 1,210.1kt with growth rate 29.19%, Guangdong 1,181.8kt with growth rate 19.21%, Jiangsu 1,100kt with growth rate 3.71%. The total output of above mentioned nine provinces accounts for 74.1% of China total output.
Economic issues
According to the monthly statistics from State Statistics Bureau for 978 scaled enterprises of daily glassware and glass container, major economic indexes of daily glass industry for 2015Q1-Q3 are as follows: .In 2014, the main business revenue for daily glassware and glass container manufacturing is RMB 110,601m with growth rate 8.10%, down by 5.43 percentages. The main business cost is RMB 95,666m with growth rate 8.26%, down by 5.85 percentages. The total amount of profit and tax is RMB 10,247m with growth rate 11.59%. Of which, the profit is RMB 6,489m with growth rate 13.15%, down by 0.28 percentages. The profit rate of main business revenue is 5.87%, up by 0.34 percentages. In 2015Q1-Q3 the cumulative finished goods stock for daily glassware and glass container manufacturing industry is RMB 7,823m with growth rate 7.23%. The proportion of finished goods stock occupied the average balance amount of the circulating assets is 18.08%, down by 3.97 percentages. In 2015Q1-Q3 the number of losing enterprises engaged in daily glassware and glass container manufacturing is 94, 2 reduced. The total loss amount is RMB 306m, down by 58.17%.
Eco-trends
Output growth of daily glassware and glass container has been shrinking in four successive years. The reasons for the shrinking are as follows. Firstly, the insufficient effective demand curbs increase of production capacity. For example, Beer industry is the largest customer of glass container. The output of beer was 38.86 m. litres, down by 5.95%. Secondly, strict environmental protection policies eliminate part of the backward production capacity and reduce or delay part of the new production capacity. In regard to production of the industry, industrial concentration is low, although the decline in output growth, but the increase in inventory, the problem of structural overcapacity is still outstanding. The output will maintain medium and low growth trend. 3.2. The overall economic operation of the industry has been consolidated although the trend is even more marked slowdown in the growth and the competition among the enterprises has been becoming more and more intense. The enterprises give full play to their expertise in active mining potential and reducing costs and then the quality of overall economic operation of the industry tends to be stable
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Firstly, the growth of main business revenue has continuously experienced decline over the past five years. However, the oscillation amplitude narrowed and the growth is basically stable. The growth for 2015Q1-Q3 is down by 5.43 percentages. Secondly, the trend of profit growth is the same as the growth of main business revenue roughly. Moreover, profit growth is higher than growth of main business revenue and the growth rate difference between the two increased slightly. It shows that corporate profitability of the enterprises has increased Thirdly, growth of loss amount for losing enterprises decreased gradually and loss of losing enterprises has eased.
Trade considerations
According to the import and export statistics for 2015Q1-Q3 from China Customs, the total export value of 22 classes of daily glass products tracked by the Association is US$ 3,861m with growth rate -1.85%. Of which, export value of glass container is US$ 1,065m with growth rate 20.21%, up by 11.65 percentages. The export value of daily glassware is US$ 2,438m with growth rate -9.46%, up by 12.98 percentages. The export value of glass vacuum flask is US$ 240m with growth rate 0.39%, down by 4.99 percentages. The export value of glass apparatus is US$ 118m with growth rate 2.04%, down by 2.29 percentages. The export volume of glass container is 1,047.7kt with growth rate 6.40%. The export volume of daily glassware is 1,001.7kt with growth rate -11.40%. The export volume of glass vacuum flask is 94,943.6k.pcs with growth rate -6.21%. The export volume of glass apparatus is 50.2kt with growth rate 5.44%. The total import value is US$ 261m with growth rate 12.15%. Of which, export value of glass container is US$ 0.41m with growth rate -1.46%, the export value of daily glassware is US$ 147m with growth rate 13.73%, the export value of glass vacuum flask is US$ 5.2m with growth rate 6.42% and the export value of glass apparatus is US$ 68m with growth rate 19.02%. The import and export surplus is US$3,601m, decreasing by US$100. Export volume and value of glass container for 2015Q1-Q3 show positive growth and growth rate of export value is higher than export volume. That means that average unit export price was improved. The higher growth rate for February was caused by the low export volume and value for the Spring Festival in last February. The proportions of the export volume and value of all sizes of glass containers accounting for the total export of the glass containers industry are as follows. The export volume of ampoule accounts for 0.42% of the total containers export volume and the export value accounts for 0.72%. The export volume of containers with the size smaller than 150ml accounts for 29.31% of the total containers export volume and the export value accounts for 44.63%. The export volume of container with the size of 150ml ~ 330ml accounts for 11.34% of the total and the export value 9.62%. The export volume of container with the size of 330ml ~ 1,000ml accounts for 54.82% of the total and the export value 36.98%. The export volume of container being larger than 1,000ml accounts for 4.11% of the total and the export value 8.06%. The average unit export prices of all sizes of glass containers are as follows. The average unit export price for ampoule is US$1.77 per kg, down by 8.75% compared with the same period of last year. The average unit export price for container with the size smaller than 150ml is US$1.55 per kg, up by 14.54%. The average unit export price for container with the size of 150ml ~ 330ml is US$0.86 per kg, down by 12.90%. The average unit export price for container with the size of 330ml ~ 1,000ml is US$0.69 per kg, up by 14.29%. The average unit export price for container being larger than 1,000ml is US$1.99 per kg, up by 41.59%.
Daily glassware
In terms of the products of daily glassware, the top three export classes are as follows. Firstly, the export volume of other glassware used for table or kitchen were 362.6kt, down by 5.83% and export value is US$772 million, down by
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ANALYSIS: Container Glass
2.16%. Secondly, the export volume of other drinking glasses is 362.0kt, down by -6.73% and export value is US$710 million, up by 5.51%. Thirdly, the export volume of other glassware used for washroom, office or interior decoration is 197.3kt, down by -11.30% and export value is US$669 million, up by 0.26%. The export volume of the three classes of daily glassware mentioned above accounts for 92.03% of the total and the export value 88.23%. Export volume and value of glass container for 2015Q1-Q3 show negative Chinese exports of daily glass in 2015H1
Export of daily glass in 2015H1
Value
Volume
Growth Rate Product
growth, except for February. From March to September, the export volume and value of daily glassware show slow recoveries and growth rate of export value is higher than export volume, which shows average unit export price is flat or slightly increased compared with last year. Actually, the average export price is up by 2.18% in 2015Q1-Q3. This inhibits the continuous price decline over the past few years. However, the price increases still can’t make up the rise range in domestic labor and environmental protection costs.
US$m
Growth rate % Growth Rate %
Unit
Increasing by %*
%
Code
Commodity
Volume
Value
Average unit price
70023200
Other unworked heat resistant glass tube
56.65
8.65
-30.64
70023900
Other unworked glass tube
-24.78
-5.03
26.26
Daily glass total
2,525
-2.89
10.47
Glass container
694
22.75
17.88
Kt
712.4
7.70
70101000
Glass ampoules
1.69
-0.06
-1.71
Daily glassware
1,592
-11.84
7.51
Kt
656.6
-12.54
70109010
Glass container >1L
-0.93
48.21
49.60
161
6.25
4.27
k.pcs
62,865.9
-3.60
70109020
Glass container 0.33L - ≤1L
7.59
26.33
17.42
70109030
Glass container 0.15L - ≤0.33L
1.00
-8.78
-9.68
70109090
Glass container ≤0.15L
12.48
25.71
11.76
70131000
Glass ceramic ware
-70.60
-78.73
-27.66
70132200
Lead crystal stemware drinking glasses
-47.70
-29.02
35.74
70132800
Other stemware drinking glasses
-8.65
-5.94
2.97
70133300
Other lead crystal stemware drinking glasses
-16.99
4.79
26.23
70133700
Other drinking glasses
-8.30
2.39
11.66
70134100
Lead crystal glassware for table or kitchen
-38.20
-13.57
39.84
70134200
Other heat resistant glassware for table or kitchen
-6.66
-22.85
-17.34
70134900
Other glassware for table or kitchen
-4.81
-1.93
3.03
70139100
Lead crystal glassware for toilet, office & indoor decoration
-16.03
-11.62
5.25
70139900
Other glassware for toilet, office & indoor decoration
-9.49
8.45
19.82
70171000
Fused quartz glassware for laboratory etc.
32.11
21.87
-7.75
70172000
Other heat resistant glassware for laboratory etc.
43.22
31.54
-8.15
70179000
Other glassware for laboratory etc.
-5.86
-10.42
-4.85
70200091
Glass inner for vacuum flask
17.45
24.53
6.03
96170011
Vacuum flask with cases
-9.17
4.89
15.47
Glass container
7.70
22.75
13.97
Glass vacuum flask Glass apparatus
76
-0.10
-3.77
Kt
33.2
4.31
*compared with 2014H1
Import of daily glass in 2015H1 Product
Value US$m.
Growth rate (%)
Daily glass total
169
16.44
Glass container
27
2.64
Daily glassware
97
21.20
3
-1.34
43
17.44
Glass vacuum flask Glass apparatus
Export proportions of all sizes of glass containers in 2015H1 Product
Proportion (%) Export volume
Ampoule
Export value
0.40
0.74
Glass container <150ml
28.22
40.69
Glass container 150ml ~ 330ml
11.33
9.95
Glass container 330ml ~ 1,000ml
55.86
39.77
4.19
8.85
Glass container >1,000ml
Average export unit prices of all sizes of glass containers in 2015H1 Product
Unit price (US$/ kg)
Increasing by (%)
Ampoule
1.83
-1.71
Glass container <150ml
1.41
11.76
Glass container 150ml ~ 330ml
0.86
-9.68
Glass container 330ml ~ 1,000ml
0.70
17.42
Glass container >1,000ml
2.06
Glass container >1,000ml
4.19
50
asianglass AG 16-4
49.60
Sector total
Daily glassware
-12.54
-11.84
0.80
Glass vacuum flask
-3.60
6.25
10.22
Glass apparatus
4.31
-0.10
-4.22
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ANALYSIS: Container Glass
Export of daily glass in during January-April 2016
Export of daily glass during January-April 2016 Value
Volume
Growth Rate Product
US$m
Growth rate % Growth Rate %
Unit
Up or down (-) %*
%
Code
Commodity
Volume
Value
Average unit price
70023200
Other unworked heat resistant glass tube
22.21
9.25
-10.61
70023900
Other unworked glass tube
-8.81
-2.01
7.45
Glass ampoules
18.36
87.72
58.60
Daily glass total
1,621
-2.26
-0.30
Glass container
481
7.65
-17.53
kt
515.5
14.72
70101000
Daily glassware
988
-6.71
5.61
kt
424.7
-1.44
70109010
Glass container >1L
-9.10
-15.64
-7.19
17.21
-5.14
-19.07
Glass vacuum flask
102
-1.08
-9.64
k.pcs
43,005.2
4.91
70109020
Glass container 0.33L - ≤1L
Glass apparatus
50
0.98
-1.40
kt
22.7
3.81
70109030
Glass container 0.15L - ≤0.33L
20.28
4.17
-13.40
70109090
Glass container ≤0.15L
11.25
27.21
14.35
70131000
Glass ceramic ware
-2.93
-22.40
-20.05
70132200
Lead crystal stemware drinking glasses
73.38
6.95
-46.33
70132800
Other stemware drinking glasses
-25.51
-23.05
3.30
70133300
Other lead crystal stemware drinking glasses
89.44
52.30
-16.97
70133700
Other drinking glasses
-0.70
2.50
3.23
70134100
Lead crystal glassware for table or kitchen
73.77
2.34
-41.11
70134200
Other heat resistant glassware for table or kitchen
-1.96
-5.92
-4.04
70134900
Other glassware for table or kitchen
-0.41
-7.01
-6.62
70139100
Lead crystal glassware for toilet, office & indoor decoration
-52.25
-39.49
26.71
70139900
Other glassware for toilet, office & indoor decoration
-3.72
-11.97
-8.57
Growth rate %
70171000
Fused quartz glassware for laboratory etc.
-9.84
-13.43
-3.98
70172000
Other heat resistant glassware for laboratory etc.
-3.72
0.06
3.93
70179000
Other glassware for laboratory etc.
1.62
5.64
3.96
70200091
Glass inner for vacuum flask
4.45
-7.37
-11.31
96170011
Vacuum flask with cases
5.08
-0.47
-5.28
Glass container
14.72
7.65
-6.17
Daily glassware
-1.44
-6.71
-5.35
Glass vacuum flask
4.91
-1.08
-5.71
Glass apparatus
3.81
0.98
-2.73
*compared with the same period of 2016
Average export unit prices of all sizes of glass containers during January-April 2016 Unit price (US$/kg)
Product
Increasing by (%)
Ampoule
2.69
58.60
Glass container <150ml
1.56
14.35
Glass container 150ml ~ 330ml
0.76
-13.40
Glass container 330ml ~ 1,000ml
0.58
-19.07
Glass container >1,000ml
2.21
-7.19
Glass container >1,000ml
2.21
-7.19
Top three export categories of daily glassware on export value during January-April 2016 Export Volume Product
Export Value
Growth rate %
kt
US$ m
Other glassware for table or kitchen
157.1
-0.41
315
-7.01
Other drinking glasses
150.0
-0.70
297
2.50
82.9
-3.72
264
-11.97
Other glassware for toilet, office & indoor decoration
The export volume of the three categories of daily glassware mentioned above accounts for 91.82% of the total export volume of daily glassware and the export value accounts for 88.68% of the total. Export proportions of all sizes of glass containers during JanuaryApril 2016 Product
Proportion (%) Export volume
Ampoule
Export value
0.38
1.10
Glass container <150ml
27.00
45.24
Glass container 150ml ~ 330ml
12.11
9.90
Glass container 330ml ~ 1,000ml
56.92
35.28
3.59
8.48
Glass container >1,000ml
52
asianglass AG 16-4
Sector total
www.asianglass.com
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web: vertech.eu
ANALYSIS: Container Glass
Glass container 0.15L< ~ <0.33L
The export volume of the three categories of daily glassware mentioned above accounts for 91.82% of the total export volume of daily glassware and the export value accounts for 88.68% of the total. The export value of glass container during January-April 2016 was US$ 481m.,increasing by 7.65% compared to the same period of 2015. The proportions of the export volume and value for all sizes of glass containers taking up the total export of the glass containers are shown in Table 1. The average export unit prices of all sizes of glass containers are shown in Table 2.
Export volume of glass container 0.15L< ~ ≦0.33L was 62,446t, increasing by 20.12% and export value was US$ 47,643.3k, decreasing by 4.10%. The top five export destinations are shown in Table 5. Export destinations of container 0.15L< ~ ≦0.33L during January-April 2016 Destination
Export volume of glass ampoule was 1,970t, increasing by 19.36% and export value was US$ 5,299.6k, increasing by 87.72%. The top five export destinations are shown in Table 3. Export of daily glass in during January-April 2016 Export volume
Export value
Growth rate (%)
Tonne
US$’000
Growth rate (%)
Tajikistan
121.5
1,178.84
1,983
5,864.89
India
545.1
-4.16
632
-3.41
Russia
357.6
-38.33
523
-38.67
Turkey
158.9
-
347
-
Uzbekistan
178.8
-
254
-
Destination
Export volume
-9.93
9,063.8
0.46
Thailand
10,824.1
815.14
5,118.0
756.49
Hong Kong
5,883.5
76.39
4,509.0
87.23
Canada
5,223.8
10.46
3,173.6
6.02
Vietnam
2,670.1
59.63
2,644.3
89.17
Glass container 0.33L< ~ <1L
Export volume of glass container 0.33L< ~ <1L was 293,429t, increasing by 17.24% and export value was US$ 169,775.5k, decreasing by 5.13%. The top five export destinations are shown in Table 6. Export destinations of glass container 0.33L< ~ <1L during January-April 2016 Destination
Export volume
USA
US$’000
Growth rate (%)
USA
22,822.0
25.09
34,620.9
19.13
Indonesia
16,910.8
2.84
16,068.5
15.88
UAE
6,205.2
-6.88
11,657.2
5.55
Saudi Arabia
3,326.4
20.44
10,048.6
48.23
South Korea
2,635.9
-8.65
6,674.0
-1.48
Growth rate (%)
asianglass AG 16-4
US$’000
Growth rate (%)
110,535.9
-18.07
64,039
-17.61
Australia
32,110.9
619.15
15,330
365.03
Canada
17,578.7
16.05
9,789
17.80
South Korea
21,944.7
1,445.78
8,282
470.34
Thailand
19,457.6
483.87
8,101
235.06
Glass container >1L
Export volume of glass container >1L was 18,493t, decreasing by 9.10% and export value was US$ 40,813.3k, decreasing by 15.64%. The top five export destinations are shown in Table 7. Export destinations of glass container >1L during January-April 2016 Destination
Export volume
Export value
Growth rate (%)
Tonne
54
Export value
Export value
Growth rate (%)
Tonne
Growth rate (%)
11,915.8
Tonne
Export volume of glass container <0.15L
US$’000
USA
Glass container <0.15 L
Export volume of glass container <0.15L was 139,166t, increasing by 11.27% and export value was US$ 217,722.1k, increasing by 27.27%. The top five export destinations are shown in Table 4.
Export value
Growth rate (%)
Tonne
Glass ampoule
Destination
Export volume
US$’000
Growth rate (%)
Vietnam
3,470.5
30.41
18,335
-27.74
USA
8,862.1
-18.93
13,175
-7.51
Hong Kong
205.1
27.05
860
148.75
Indonesia
507.5
-4.74
718
4.54
South Korea
223.6
-17.45
709
87.05
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WE ARE GLASS PEOPLE
SWABBING ROBOT
AUTOMATIC SWABBING PROVIDES HIGHER PRODUCT QUALITY AND EFFICIENCY High precision and high repeatability Zero rejects from swabbing* No section stop necessary* Increased work safety Up to 75% savings on lubrication * depending on specific production process environment
www.heye-international.com
ADVERTISER FEATURE
SWABBING ROBOT ENHANCES PRODUCTIVITY AND OPERATOR SAFETY job changes, the factory All four high speed Tandem was considered an ideal IS machines at Ardagh’s location to test and prove Moerdijk glass container the effectiveness of robotplant near Rotterdam administered swabbing have been equipped lubricants. with specially developed Ardagh Glass had been robots to perform essential assessing the benefits mould swabbing duties. of using funnels with oil The Ardagh Glass project lubricants every third cycle, team responsible for this before the engineering team innovative technology has started to consider the use worked closely with Heye of robots. Furthermore, International and robotics the equipment’s potential specialist Socabalec to undertake other glass to create a system that forming-related tasks, provides significant Robot in Moerdijk plant including changing moulds productivity and cost and blanks was recognised saving benefits. as being worthy of detailed assessment. Dutch glassmakers have long been at the forefront of technological The project team led by Bernard Vorspel initially started to develop a developments that optimise production efficiencies and maximise robot that could handle the payloads required for these different duties. the industry’s profitability. And among the latest examples of the As Operational Excellence Manager for Ardagh Glass, Mr Vorspel innovative skills employed by Ardagh Glass personnel at the leads a team of people who are responsible for the identification company’s Moerdijk site is the development of a robotic solution to and implementation of process improvements at the glassmakers’ the previously manual task of mould swabbing. international production sites. He has been involved in the glass Since starting production in 1998, the plant in Moerdijk has focused industry for 10 years, including eight years in his current role. on the high volume manufacture of beer bottles. Today, the plant is A wide range of ideas were proposed and considered before the owned by Ardagh Glass and is one of two factories operated by the decision was taken to concentrate on the requirements for automated diversified international packaging group in the Netherlands. swabbing. On the recommendation of global automation solutions The original plant featured one melting furnace and two high speed expert FANUC, Belgian robotics specialist Socabalec SA was invited production lines. In 2009 a second furnace and two more lines were to join the Moerdijk development team. Based at Ham-sur-Sambre, added. Their combined manufacturing capacity is 640 tonnes/day. Socabelec was already closely associated with the hot and challenging NNPB beer bottles are produced in a green composition, in five glassworks environment, having previously developed robotic capacities from 207ml to 710ml. solutions for leading global suppliers of automotive windscreens. Just under 200 people are employed at Moerdijk, where production Now that the project has been successfully implemented, Socabalec efficiencies of better than 93% are standard. All four lines are continues to work closely with Heye International personnel, whose equipped with 10-section tandem double gob Heye IS machines job is to roll out the technology to other glass factories. Every new with 5in centre distances, involving 160 cavities in total. Apart from Heye IS machine is enabled with an option to include the swabbing minor differences in terms of take-outs employed etc, these are four robot. In essence, every machine is ‘robot-ready’, should the customer identical lines. All machines are equipped with Heye servo pushers decide to adopt the technology in the future. “The partnership with and two lines feature Heye servo take-outs. At the cold end, stateSocabalec is working extremely well” Mark Ziegler, Heye International of-the-art automated inspection and packing equipment is employed Marketing Manager confirmed, “helping us to provide an even more throughout. There is a constant flow of trucks to collect and deliver efficient service to customers.” palletised loads of bottles to the local customer, with comparatively limited stocks maintained at the factory’s warehouse. LONG-TERM OBJECTIVE It has been an objective of the international glass container industry OPERATIONAL EXCELLENCE to identify a workable automated solution for the mould swabbing The swabbing robot initiative became the subject of evaluation at process for more than three decades and the Ardagh Glass-led project Moerdijk in 2011. With its high production volumes and minimal
56
asianglass AG 16-4
www.asianglass.com
ADVERTISER ADVERTISERFEATURE FEATURE
has successfully developed and proved its equipment in operation at Moerdijk. “It took longer than originally anticipated because the project required financial investment, proving that the equipment worked effectively, both in longstanding trials and in production conditions” Bernard Vorspel recalls. “We wanted to prove that we could improve our production as well as our quality, in addition to providing personnel No loss after swabbing safety. It had to be shown that humans could work together with robots (symbiosis between man and machine) without increasing job change times.” Although others have attempted to resolve the automatic swabbing issue before, they had been unable to resolve spraying issues to the industry’s satisfaction. “Persuading the Board to support the project was not our most difficult challenge because of their history of supporting R&D projects” Mr Vorspel continues. “In terms of swabbing, we are confident that our goals have now been met, although there remain other opportunities to develop further, including those relating to temperature measurement, gob loading measurement etc. SUCCESSFUL INSTALLATION There are now four swabbing robots at Moerdijk, the last two installations having been completed in early 2016. The original 125kg prototype model is still running successfully at almost 99.9% uptime efficiency but the other three lines are equipped with the smaller, 25kg production version. Having successfully proved that the prototype worked as required, the robot has been optimised to include a series of weight saving measures and additional features, including a redesigned spraying arm. Not only is the robot significantly smaller but so is the beam that carries it, as well as the cage. A cleaner design has been created, incorporating a new design of flow sensor, several parking places, left and right swabbing configurations and the possibility to observe the process from the IS machine operator’s room. “We are now completely satisfied with this version and decided to install it on the other lines” says Bernard Vorspel. The robust design created is expected to operate at optimal efficiency for at least 10 years, the only equipment items likely to require replacement every five years or so being the cable and hoses. The spraying installation, linear track etc are described as being stateof-the-art and very hard wearing to accommodate the challenging conditions encountered at the hot end. Several commercially available swabbing compounds have been proved to operate successfully with the installation to accommodate the preferences of different glassworks. The robot has allowed the glassmaker to save more than 75% of lubricant when compared to conventional manual swabbing methods, as well as much faster application times, important environmental benefits via less airborne pollution and better health and safety conditions for machine operators thanks to the need for less interaction with the forming machine. There is also the benefit of consistent spraying of the same
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lubricant layer thickness on mould blanks, avoiding production losses during swabbing cycles and providing valuable material savings. Impressively, four mould halves can be sprayed in less than one second. Furthermore, the use of robots can provide important labour savings, enabling operators to concentrate on optimisation and defect correction. Apart from regular checks for hoses, cabling and bearings etc, no special maintenance routines are required. A test spray function is provided should any deviation in the spray pattern be noted and adjustments or replacement parts be required. During job changes, the robot’s operating parameters are reset off-line, repeating the settings created for previous runs and thereby ensuring further important savings can be realised. In addition, the equipment’s pre-programmed settings permit more than one job to be made on the same IS machine. “That’s the great flexibility provided by robots” says Bernard Vorspel. Furthermore, a short payback time has been realised. The glassmaker confirms the existence of zero rejects from swabbing, as well as the avoidance of section stops and improved operator safety. In addition, operators confirm the provision of stable and repeatable volume, thickness and location of swabbing agent in the process. CULTURAL CHANGE The project team’s goal is to install the same equipment throughout the international Ardagh Glass network, allowing each of the group’s glassworks to take advantage of this major robotic advance, as well as the accompanying cultural change to the subject of glass forming and in particular, swabbing. “Historically, swabbing has been used inappropriately by the industry to compensate for loading defects and to overcome problems associated with inadequately maintained sections etc” says Bernard Vorspel. “The robot is part of a complete quality management programme that needs to be put in place.” Within five years, Mr Vorspel believes all new IS machines purchased from Heye International will feature swabbing robots. This should lead to the production of more consistent, better quality glass containers. He also suggests that more advances in the deployment of robots for other aspects of the forming process will be the subject of further developments in the future. Heye International confirms that swabbing robot orders are currently being processed for customers in the USA and Australia, both of which are scheduled for installation during 2016. Heye International GmbH, Obernkirchen, Germany tel: +49 5724 26-0 email: marketing@heye-international.com web: www.heye-international.com
AG 16-4 asianglass
57
ANALYSIS: Vietnam
TOO FAST, TOO SOON ? VIETNAM CAUGHT IN A VALUE TRAP Jahir Ahmed looks at how Vietnam’s rapidly evolving glass industry is working to mature from an emerging market, to one with a more stable outlook.
I
n a clear sunny sky during the day time when a passenger glimpses Vietnamese towns and villages through the window of a landing aircraft, lots of houses and buildings with glass façades and glass windows appear on the view reflecting faster changes in last one decade. The landscape bears the testimony of using building glasses in large-scale, elevating from a different old style of living in the past decades. The change is a sharp contrast to the situation in which the Vietnamese glass manufacturers say their factories suffer from unsold stock, very often rising to the equivalent of over 30 percent of production. Since the mid 2000s it is suggested almost every year by the glass manufacturers, including Vietnam Glass Association (Vieglass) in a group, that Vietnam’s glass market is in the verge of collapse due to over capacity and the resulted unsold inventories that forced the operators, specially, flat and processed glass factories, to go for suspension of production to escape losses, if the government does not restrict new investment. They also sought restriction on imports. Nguyen Minh Khoa, managing director of 420 tons a day capacity Viglacera Float Glass Company (VIFG), alleged the duty on import of raw glass is 35 per cent, while on finished glass it is only 5 per cent, for which the fraudulent imports of finished products have increased affecting the flat glass operators. VIFG is a part of the parent and market leader Viglacera Corporation that owns some other float and processing glass units, including joint venture Vietnam Float Glass Co Ltd (VFG). Dong Nai based leading glass processor SADO GROUP’s general director Nguyen Cong Chinh said many of the high-rise projects have foreign consultants who recommend use of imported glass despite high price of some US$150-130 per square metre. Eventually, a restriction was imposed this year to continue until the stockpiling eases by 2020. Only world class units of advanced glass technology are permitted in flat glass sector. As a result, inefficient factories are now a little better protected, but the imports of efficiently produced alien glasses are still posing a threat. Some unofficial estimates show that Vietnam’s annual domestic demand for flat glass is already equivalent to 70-80 percent of the installed capacity of 180-200 million sq metres, while there exist some export markets for float glass.
Control causing problems?
The irony is that under protection the manufacturers hardly need capacity control, enhancement of cost-efficiency and productivity, according to the building material traders and real estate operators. Vietnam Association for Building Materials (VABM) believes that in present free market situation no curtail helps prevent new investors from competition as the past history proves. Rival products from new investors and imports will continue to arrive prompting the never ending outcry of the local manufacturers until they become competitive. Meanwhile, in a difficult inventory situation, the major affected victim is a 58
asianglass AG 16-4
non-construction glass plant, foreign investor NSG (Nippon Sheet Glass) GROUP subsidiary NSG Vietnam Glass Industries Limited (VGI) operated thin float display glass line that suspended production temporarily in last May impacting heavily on the US$123 million unit. Comparatively, the float lines for construction markets are running better in Vietnam. NSG’s joint venture float plant VFG is doing well at domestic and export markets. At 500 tons a day float glass production capacity VFG, NSG’s share is 55 percent, with Viglacera Corporation’s 30 percent and Japan’s Toyota Tsusho Corporation’s 15 percent. It substituted imports substantially and exported worldwide since commercial start up in 1999. According to Vietnam’s investment policy on building materials, the government is, in principle, in favour of promoting Vietnam to foreigners for investment in glass manufacturing. The Vietnam Ministry of Construction (MoC) earlier last year expected that flat glass would be a major export item, raising production for world market as well as for domestic consumption. MoC’s outlook for exports showed steady increase year on year rising to 100-110 million sq metres by 2020. A 40 percent drop in fuel prices and higher domestic demand have been a boon for the capacity expansion. In a forecast late last decade, the MoC projected the demand for construction glass in domestic market would increase to 131 to 140 million sq metres in 2015, rising further to 196-202 million sq metres in 2020. When there are lots of domestic buyers, the industry sources said, the issue of stockpiling always remains unresolved or unaddressed, and an outcry for protection goes on continuously since over a decade because of absence of capacity control and competitiveness. Historically, the manufacturers are demanding restriction on further investment, specially, in building glass, increase of tariff and technical barriers on imports and an end to the import at cheaper prices, to protect the domestic manufacturers when the glass market just started to pick up more than 10 years ago. Sources in MoC said their monitoring shows the market requires quality building material products at competitive prices to meet the demand of all types of consumers. To help pick up demand for new houses and commercial and noncommercial buildings the local manufacturers of construction materials should be highly efficient to market quality products at competitive prices, suggested Deputy Minister of Construction Do Duc Duy. Despite blockade, the production capacity continues to expand and imports rose year on year substantially. The demand increased manifolds as consumption of building glass increased with the higher growth of the country’s GDP and the consumers required a diverse range of products, mostly upgraded glass manufactured with latest technologies. Vietnam’s glass jumped in last 10 years with rise of consumption in all sectors, raw float glass, processed glass, glass containers, glass table and kitchenwares, special glasses for electronic and other industries, and various glasswares. Not all the domestic products are well attractive in price and www.asianglass.com
ANALYSIS: Vietnam
Upgraded safeguards Vietnam has recently upgraded the use of its technical standard for the restriction of heavy metals in glass, ceramic, porcelain and enamelled products that come into contact with food, with effect from May 1, this year. Earlier, in October last year, the Vietnamese Ministry of Health announced the promulgation stating: ‘National technical regulation on the safety and hygiene glass, ceramic, porcelain and enameled implements, containers, and packaging in direct contact with food’ to be upgraded with effect from May 1, 2016. This national technical regulation restricts the local and imported products’ migration of lead and cadmium, and includes a list of standards which can be utilized for demonstration of compliance. The Ministry of Health of Vietnam in a circular, no: 35/2015/TT-BYT [2] dated 28 October 2015, promulgated the use of QCVN 12-4:2015/BYT, which is: National technical regulation on the safety and hygiene glass, ceramic, porcelain and enameled implements, containers, and packaging in direct contact with food. Takes effect on May 1, 2016 Material
Type of food contact product
Heavy metals
Required limit
Flatware, including cooking wares
Cadmium
≤ 0.07mg/dm²
Hollowware Food containers
Glass
Lead
≤ 0.8 mg/dm²
Capacity < 600mL
Cadmium
≤ 0.5 mg/dm²
Lead
≤ 1.5 mg/L
Capacity of 600mL to less than 3L
Cadmium
≤ 0.25 mg/L
Lead
≤ 0.75 mg/L
Capacity ≥ 3L
Cadmium
≤ 0.25 mg/L
Lead
≤ 0.5 mg/L
Cookware
Cadmium
≤ 0.05 mg/L
Lead
≤ 0.05 mg/L
Cups and mugs
Cadmium
≤ 0.25 mg/L
Lead
≤ 0.5 mg/L
Cadmium
≤ 0.07mg/dm²
Flatware, including cooking wares Hollowware food container
Ceramics Glass-ceramics Porcelain
Lead
≤ 0.8 mg/dm²
Capacity < 1.1L
Cadmium
≤ 0.5 mg/L
Lead
≤ 2.0 mg/L
Capacity of 1.1L to less than 3L
Cadmium
≤ 0.25 mg/L
Lead
≤ 1.0 mg/L
Capacity ≥ 3L
Cadmium
≤ 0.25 mg/L
Lead
≤ 0.5 mg/L
Cookware
Cadmium
≤ 0.05 mg/L
Lead
≤ 0.5 mg/L
Cups and mugs
Cadmium
≤ 0.25 mg/L
Lead
≤ 0.5 mg/L
Cadmium
≤ 0.07 mg/dm²
Lead
≤ 0.8 mg/dm²
Cadmium
≤ 0.05 mg/ dm²
Flatware
Food containers Cookware
Enamel
Hollowware
Capacity ≥ 3L, including for cooking Capacity < 3L Food containers Capacity < 3L Cookware
Parameter Drinking rim
Lead
≤ 0.1 mg/dm²
Cadmium
≤ 0.05 mg/dm²
Lead
≤ 0.1 mg/dm²
Cadmium
≤ 0.07 mg/L
Lead
≤ 0.8 mg/L
Cadmium
≤ 0.07 mg/L
Lead
≤ 0.4 mg/L
Heavy metals
Required limit
Cadmium
≤ 0.2 mg/article
Lead
≤ 2.0 mg/article
Technical specification definitions: As the upgraded requirement defined the overflow, the flatware’s depth is not over 25mm, while hollowware’s depth is 25mm or greater from the deepest point to the point of horizontal surface passing overflow. Drinking rim is measured as 20mm below the rim on the outside of packaging, tools used for cooking and drinking. The food contact articles shall be labelled on labelling of goods and other provisions of relevant laws, in accordance with the circular. Data sources: The Ministry of Health, Vietnam
quality, yet were sold. Few of over half a dozen major flat glass plants and only some dozens of over 500 processing plants are manufacturing cost-efficiently, according to the industry sources. The boom time is expected to continue till next decade following a massive urbanization, according to the MoC. “Vietnam’s housing policies are under pressure from an increasing population, especially in urban areas. It is forecast that the urban population could reach 46 million by 2020, accounting for 45 per cent of the country’s total number,” Do Duc Duy said. He told a conference on Green
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Constructions for Low and Middle Income Housing held in Hanoi recently that the new housing demand could go up to 5.1 million apartments in the low and middleincome segments alone in the next 10 years.
New opportunities
To meet the growing demand, the Vietnamese manufacturers of raw and processed glasses have already marketed hundreds of new products in cooperation and collaboration with dozens of foreign companies, but the
AG 16-4 asianglass
59
ANALYSIS: Vietnam consumers still look for new products at best prices with after-sale services including replacement facilities. Companies are forced to market new or innovative products in face of stiff competition from imports, even from the ASEAN countries like Thailand and Indonesia, which enjoy easy access to the Vietnamese consumers under Asean Community. Vietnam’s industry sources believe that the property markets will pick up next year greatly. They said the market has seen a stable growth in the first half this year, in various sections from lower-segment to high-end and tourism. VABM said with recovery of the markets new projects are coming in stream with attractive offers by the developers to the apartment and condo buyers. According to the estimates of the MoC and building material traders, a substantial number of the households of the total population of nearly 100 million (2016) are buying or constructing new residential houses and a huge number of new institutional and commercial buildings are constructed every year. Those buyers are using quality construction glasses. MoC monitors a growing trend of urbanization and migration from the rural areas that ultimately creates opportunities for increased sales of construction glasses to be used in new houses. According to the estimates of the UN Department of Economic and Social Affairs, this year some 33.6 percent of the population in Vietnam is urban and the median age of the country’s population is 30.8 that has power for spending on improved living. Preferential loans in massive amounts are being provided for social housing development, according to Nguyễn Trần Nam, Chairman of the Việt Nam Real Estate Association. Nam said at an online business forum recently that commercial joint stock banks with controlling state stake-holdings would have to spend 3 percent, equivalent to some US$13.4-17.9 billion (VNĐ300-400 trillion), of their total outstanding loans for developers and buyers of social housing projects that can contribute significantly to the real estate transactions, which showed a good progress last year. “Vietnam’s real estate market began recovery from the end of 2013, with the number of successful transactions in 2015 doubling in Hanoi and a 1.8-fold increase in Ho Chi Minh City as compared to the previous year,” said Deputy Construction Minister Do Duc Duy. Official and other institutional forecasts indicate last year’s GDP growth of some six percent that stimulated Vietnam’s consumption will have a robust positive impact this year on the glass industry sector’s construction and packaging glasses both. According to MoC, housing and construction growth is further going up this year, despite affect of drought on agriculture that reduced GDP, significantly, in the first half of 2016 to some 5.52 percent, down from the 6.32 percent of first half of last year, as reported by the government’s General Statistics Office (GSO). “Vietnam has targeted GDP expansion of 6.7 percent this year, meaning growth in the second half will need to be around 7.6 percent if the target is to be met,” said Dao Quang Tuyen, director of the national accounts system department (NASD) at the GSO. “This may be difficult given the current state of the economy,” Tuyen added. Associations of building materials, constructors and real estate developers said the market has recovered considerably in last three years after a slump of a couple of years when the glass manufacturers were less concerned in controlling production capacity as a result of which there were unwanted inventories. However, industry sources monitoring shows, Vietnam’s real estate inventory had an estimated value of US$1.68 billion (VND37.49 trillion) as of the end of June, down 26 percent or US$603 million (VND13.4 trillion) from the end of December 2015, according to the Agency for Management of Housing and Real Estate Market under the MoC. Increasing consumption of beer and other beverages have helped packaging glass to stay in the market comfortably although imported beer continuously poses a threat. Current year’s demand for beer in the domestic market is expected to be around four billion litres, according to an estimate of the Vietnam beverage association VBA. Many foreign beer manufacturers, including Japanese and Thai, are planning to open plants in Vietnam to exploit the double digit growth, while existing foreign operators as well as domestic breweries, including market leader SABECO, have expanded production, said VBA. Beer and other beverages saw 10 per cent growth in the first quarter of this year, the highest increase for two years and mainly led by volume increases of 8.1 per
60
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PROFILE: CONTAINER GLASS PLANTS Malaya Vietnam Glass Limited (MVG) (O-I BJC Vietnam Glass Ltd) Location: Ba Ria-Vung Tau, My Xuan Industrial Estate, 80 km east of Ho Chi Minh City, Vietnam. Products: Beverage, drinks, food and medicine packaging glass Markets: Domestic and export markets Others: Malay Vietnam Glass Ltd is the leading beverage packaging glass manufacturer in Vietnam. The company has been taken over in 2010 and is now 70 percent owned by BJC and O-I. It is a manufacturer and distributor of glass containers serving producers of beer, beverages and foods, such as, PepsiCo Vietnam, CocaCola Vietnam, SABECO, Vietnam Brewery, Asia Pacific Brewery and SABMiller. Its production capacity of 280 tons per day is being expanded, following higher demands in the domestic market. It is well-equipped with world-class modern technology and natural gas is being used as a source of energy to reduce production costs. San Miguel Yamamura Haiphong Glass Co Ltd Location: Ngo Quyen District, Hai Phong City, Vietnam Products: Beverage, drinks, food and medicine packaging glass. Markets: Domestic and export markets Others: San Miguel Yamamura Haiphong Glass Co Ltd operates as a subsidiary of the Philippines based San Miguel Yamamura Packaging International Limited of San Miguel group. In Vietnam, its glass containers are used mainly for packaging beer, soft drinks, spirits and liquors, among others. It is a major manufacturer of packaging glass in Vietnam with international standard. Go Vap Glass Location: Vap Dist, Ho Chi Minh City Vietnam Products: Glass tablewares, glass containers, glass decorative wares and other glasswares. Markets: Domestic and export markets Others: Started as container glass factory in 1960, the Vietnamese state owned Go Vap Glass Joint Stock Co started production of color and clear glass tablewares, especially, drinkwares, in 1985. It has nearly 2,000 designs, and exporting to the world markets since 1993. Export serves mainly European Union and Scandinavian countries. In Vietnam’s large and deficit market, European and US companies are exploring markets for higher-middle and upper-end segments of consumers of glass tablewares. Chinese and other Southeast Asian glass tablewares are available in Vietnam to cater the increasing demand.
PROFILE: OPTICAL AND SPECIAL GLASS PLANTS Hoya Lens Vietnam Location: Binh Duong, Vietnam Products: Optical glass and other glass products. Markets: Domestic and export markets Others: Hoya Lens Vietnam is a subsidiary of Hoya Lens Corporation of Japan. Its optical glass products and lenses serve various industries including electronics, imaging, healthcare and others. Tamron Optical Vietnam Location: Hanoi, Vietnam Products: Optical glass and other glass products. Markets: Domestic and export markets Others: A subsidiary of Tamron optical glass and lens company of Japan Kishiro Vietnam Location: Hanoi Products: Optical glass and other glass products. Markets: Domestic and export markets Others: A subsidiary of Kishiro optical glass and lens company of Japan. Vietnam Special Glass Location: Ving Tau, Vietnam Products: Touch panel and solar glass Markets: Domestic and export markets Others: Vietnam Special Glass is a subsidiary of NSG (Nippon Sheet Glass) group of Japan. It is major manufacturer of solar glass and touch panel in Vietnam.
cent, according to US based researcher Nielsen’s FMCG Market Pulse report for the first quarter released in last June. Competition of alternative packaging is rising fast in Vietnam, but compared to flat glass, packaging glass is less concerned about capacity utilization as glass bottles are still most favoured packaging in major users, breweries. Domestic container glasses have stronger command on the local market compared to flat glass that suffers from capacity surplus.
Biting capacity
Industry sources predict that the annual demand for flat glass is likely to approach 220-250 million sq metres by 2020, against the country’s existing estimated annual production capacity of around 200 million sq metres. As all existing types of products meet only a part of the domestic demand of
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ANALYSIS: Vietnam diverse choices, the manufacturers are preferring enhanced exports. As a result, according to the Geneva based International Trade Centre (ITC), Vietnam’s annual glass exports have expanded many folds since the beginning of the current decade and rose to about US$800 million last year. The trend indicates the exports to exceed the billion dollar mark before the end of the decade, making a record for Vietnam of too fast growth in production and export of glass, in the region of Asia-Pacific. The manufacturers are under pressure to reduce uneconomic production and avoid wastage of rawmaterials and energy, and invest more on overhauling the total sector giving priority to product and market diversification as well as to drastically cut the environmental pollution, by modernizing the plants. The government advised the glass manufacturers and asked the Vietnam Glass Association (Vieglass) to go for manufacturing world class glasses both for domestic and export markets. The Prime Minister himself verifies the new investments. Also the Ministry of Industry and Trade (MoIT) made the manufacturers aware of the ever expanding glass imports, that reached well over US$700 million in 2015 and probably going to exceed US$800 million this year or approaching US$1 billion by the next year, if the country’s existing glass industry capacity is not reorganized to cater domestic demand and substitute imports. Most of the imported glasses are coming from a half dozen stable suppliers, China, Japan, Thailand, South Korea, Indonesia and Taiwan, in order of value of shipments every year during the current decade. Also these six countries and three others, Singapore, Malaysia and USA buy bulk of Vietnam’s exported glass products. Despite huge capacity expansion, Vietnam’s imports of flat and processed glass, container glass and fibre glass have steadily increased to around US$400 million in 2015, according to ITC. Interestingly, Vietnam’s float lines were the only sector that was able to reduce and substitute imports drastically and continuously. Compared to the import of float glass of worth US$120.78 million in 2012, it was down to US$42.49 million in 2015. During the year the container glass import figure doubled to nearly US$100 million, despite presence of the global leader in container glass, O-I of USA, and Southeast Asia’s largest packaging glass manufacturer, Berli Jucker Public Company (BJC) of Thailand, in Vietnam to manufacture beer and beverage glass bottles in partnership with Vietnam’s largest beer producer, SABECO. It is not a small wonder, Vietnam’s largest category of imports is glasswares, like table top items and kitchenwares, etc, under HS code 7013, with import shipments of worth about US$170 million in 2015, according to ITC. Investment in glasswares was neglected in spite of the highest demand. Packaging glass sector experiences bitter competition from the imported drinks and beverages and rival alternative packaging products, yet it offers opportunity of expansion due to high growth of packaging, observed VBA. Higher imports of bottled beer is now the major threat to the local manufacturers of glass bottles, according to Thang Pham, a senior official of Vieglass in Hanoi. BJC and O-I, partners with SABECO in the Vietnam’s major packaging glass manufacturing plant O-I BJC Vietnam Glass Ltd (Malaya Vietnam Glass (MVG), are studying the opportunities. BJC is more interested in buying stakes in SABECO, Vietnam’s biggest beer and beverage producer with about 50 share in the beer market. According to the VBA, Vietnam consumed 3.4 billion liters of beer in 2015, an increase of 10 percent over the year before and 41 percent if compared with 2010, making Vietnam a major beer drinker in Asia.
PROFILE: FLAT AND PROCESSED GLASS PLANTS
Troubled NSG
Indevco-Chu Lai Float Glass JSC (Chu Lai Glass) Location: North Chu Lai Ind. Zone, Tam Hiep, Nui Thanh, Quang Nam Province, Vietnam Products: Flat primary glass panels and various processed glass of thickness up to 25mm Markets: Domestic and export markets Others: Indevco-Chu Lai Float Glass’ float glass production capacity is 900 tons per day (annual production of 42 million sq metres). The products include, white glass, low-e glass, strong glass, laminated glass, double glazed glass, solar control glass, curved glass, ceramic glass, sandblasted glass, pattern glass, etc.
The suspension of thin float glass line at Vietnam Glass Industries Limited (VGI) is not affecting other operations of NSG in Vietnam said the parent company NSG GROUP that has interest in several others, in addition to VGI and VFG. The lone global major present in Vietnam’s flat glass production, NSG suffered badly from the unsold stocks of thin float display glass at the plant. It temporarily suspended production of the thin float line in last May in less than two years of its debut in June of 2014. NSG is a global major in production of architectural, automotive and technical glasses. As part of the technical glass business, it supplies ultra thin glass for small LCD applications. Its ultra-fine flat glass products are used in touch panel, computers and mobile devices. The Group’s US$123 million display glass production in Vietnam is operated by its wholly-owned subsidiary VGI in the southern province of Ba Ria-Vung Tau’s My Xuan A industrial park. NSG, which has another display line in Japan, is undecided
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Vietnam Float Glass Co Ltd (VFG) (Joint venture among Viglacera Corporation and Japan’s NSG Group and Toyota Tsusho Corp) Location: Phuong Lieu Commune, Que Vo District, Bac Ninh Province, Vietnam Total investment: US$126 million (commercial commencement in 1999) Products: Float and processed glass, a major caterer to local glass processing industries Markets: Domestic and export markets Others: In joint venture, the largest shareholder, Japan’s major glass manufacturer, NSG Group, owns 55 percent shares. Vietnamese state organization (now a joint-stock company) Viglacera Corporation’s ownership is 30 percent. The other partner Japan’s Toyota Tsusho Corporation’s stake is 15 percent. VFG is a leading manufacturer of quality float glass in Vietnam for processing its products for manufacturing safety, decorative, insulating and solar-control building glasses, autoglasses, glasswares and mirror glasses. The float glasses are clear, tinted and colour and are also being used directly for architecture and construction works. Its production capacity is 500 tons of float glass per day or about 30 million sq meters per year (based on 2mm thickness), equivalent to 145,000 tons of glass a year, having thickness range from 2mm to 15mm (tinted and colour up to 12mm) with different sizes (maximum size is 3658mm x 2438mm). The export markets include Japan, India, the Philippines, Saudi Arab, Hong Kong, Singapore, Thailand, Brazil, etc. Viglacera Corporation/Viglacera Float Glass Co (VIFG) Location: Tan Dong Hiep Production Area, Di An, Binh Duong, Vietnam Products: Float glass and glass processing Markets: Domestic and export markets Others: In addition to manufacturing normal float glass, Viglacera Corporation and its production unit Viglacera Float Glass (VIFG), started up in 2002 and now over 420 tons a day production capacity, operates glass processing utilizing processing plants in subsidiary units. The products include, decorative glass, mosaic glass, tinted glass, mirror glass (reflecting factor is more than 77 percent, clear view), grinding glass, rolled glass, insulating glass, tempered glass, opaque glass, laminated glass, etc. Viglacera’s newly installed energy saving glass will produce a total 5 million sq metres per year in two plants from this year, The plant located in southern Bình Dương Province will produce 2.3 million sq metres, while the other one in the northern Bắc Ninh Province is designed capacity of producing 2.3 million to 2.7 million sq meres. Viglacera DapCau Sheet Glass Joint-Stock Company (A unit of state-owned Glass and Ceramics for Construction Corporation (Viglacera) Established: 1990 Location: Ward Vu Ninh, Bac Ninh city, Bac Ninh province, Vietnam Products: Rolled glass, laminated glass, safety tempered glass, opaque glass, mirror, grinding glass, insulating glass and others. Markets: Domestic and export markets Others: Viglacera DapCau has joined with Facade Treatment Engineering (Malaysia) in 2008 for obtaining cooperation in producing and installing curtain wall systems, which gave the way for setting up of VinaFacade JSC in Vietnam. Malaysia based Facade Treatment Engineering provide the design while Viglacera DapCau provide glass and installation for any project under the name of VinaFacade. Available products include, stick system curtain wall, semi unitised system curtain wall, fully unitised system curtain wall and spider fittings glass wall. NSG Vietnam Special Glass Ltd. (VSG) (At building glass site of NSG Vietnam Glass Ltd) Location: My Xuan, Tan Thanh District, Ho Chi Minh City, Ba Ria-Vung Tau Province, Vietnam Products: Ultra thin float glass and display panels Markets: Domestic and export markets Others: NSG’s Vietnamese production unit VSG manufactures thin glass used for smartphone panels. The Japanese manufacturer is investing 13 billion yen (US$123 million) into the facility that started operation in 2014. The 0.5- to 1mm glass to be produced at the site is suited for the touch sensor substrates and protective screens of smartphones and tablet computers. The company has been making such ultrathin glass exclusively in Japan. The Japanese plant focuses on cutting-edge offerings of 0.5mm and slimmer. The setup is expected to improve production efficiency and double the company’s global capacity for ultrathin glass. NSG said with demand for mobile devices expanding rapidly in China and Southeast Asia, it aims to leverage its low-cost production in Vietnam to make inroads in the region.
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ANALYSIS: Vietnam
about its resumption of the Vietnamese display operation. The Japanese company with worldwide operation is already in trouble globally due to huge loss in the last financial year. To minimize the losses of the company it had no option other than eliminating the obstacle by suspending operation of loss making display glass. It has taken such actions worldwide this fiscal year. NSG said it would restart display only after improvement of the market situation and other factors related to making profit. In Vietnamese markets, the competition in display glass is already uncomfortable. Global major Samsung is reportedly going to add an additional capacity by injecting a huge investment of US$3 billion in the country to raise its total investment to US$4 billion to consolidate markets globally with cost effective production in Vietnam. NSG’s VGI is a major investor in Vietnam’s float and processed glass sectors. The subsidiary operates another float glass line for thin photovoltaic (PV) solar glass products. The line continues to operate, with no impact on production or sales.
First energy efficient
Several new plants for production of technologically latest types of glasses for different applications are coming up in Vietnam. One unit for manufacturing energy efficient glasses has already gone on stream recently by Viglacera Corporation. Viglacera said the production facility is the first of its kind in Southeast Asia and is capable of manufacturing 5 million sq metres of Low-E and solar control glasses annually in two plants located in the country’s south and north. The first phase plant with a production line of annual capacity of 2.3 million sq metres of glass was opened in last July at Tan Dong Hiep Industrial Park in Di An town of the southern province of Binh Duong, where the plant is installed at Viglacera’s Binh Duong factory, operated by its subsidiary, VIFG. To accommodate different decorative needs, the new low-e glass will have multiple colour options, said VIFG. In second phase, the company is building another facility in the northern province of Bac Ninh with a designed capacity of 2.3-2.7 million sq metres per year. This second plant is now under construction. The two-unit energy saving glass project, with an investment of US$22.3 million, uses technology and equipment provided by Von Ardenne GmbH of Germany, a globally leading manufacturer of industrial equipment for vacuum coatings on glass and other materials. Viglacera said its Low-E glass prevents transfer of heat from outside to inside and vice-versa, keeping room temperature stable and helping reduce energy for cooling in summer and heating in winter. Its solar control glass with coating Vietnam Glass Group Co Ltd Location: An Dong-An Duong District, Hai Phong, Vietnam Products: Float and processed building glass, including pattern glass. Markets: Domestic and export market Others: Vietnam Glass Group has have been producing, domestically selling and exporting the pattern glass and clear float glass. Its quality pattern glass meets the needs of different customers. The manufacturer has three pattern glass factories, including two sets of 240 tons production line with the available width of 2134mm, two sets of 120 tons production line with the available width of 2134mm, and one set of 80 ton production line with the available width of 1524mm. The manufacturer has a 350 ton capacity float glass production line with the available width of 3300mm to produce 2mm-12mm high-quality clear float glass. It also manufactures sliver mirror, aluminium mirror, reflective glass, insulating glass, laminated glass, and tempered glass. Sado Group JSC Location: Tam Phuoc Commune, Bien Hoa City, Dong Nai Province, Vietnam Commissioned: Started commercial operation in mid-2014 Products: Processed glass Markets: Domestic and export markets. Export markets include, USA, EU, Australia, Cuba, etc. Others: The new factory has an annual production capacity of 12 million square meters of several products including tempered glass, digital ceramic printed glass, laminated and insulated ones. It will also make aluminium windows and doors, to substitute the imported products. The processed glass products of sizes up to 3.3mx6.0m that meet European standards including those that apply to soundproofing and insulation. The Sado Group has invested nearlyUS$23.8 million in its first phase, deploying technologies from global industry leaders including LiSEC, Glaston and Benteler. The total cost of the project, implemented in two phases, is estimated at VND2 trillion ($95 million). Sado sources high quality materials from established sources, such as, float glass from Pilkington, Saint-Gobain, Viglacera, VFG, and AGC. Low-E glass from SaintGobain and Pilkington. Silicone sealant from Dow Corning.
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Vietnam’s major export destinations of glass and glass wares (US$’000) Major importers of Vietnamese glass products
Exported value in 2010
Exported value in 2011
Exported value in 2012
Exported value in 2013
Exported value in 2014
World (total exports of glass products by Vietnam to the world markets)
370,008
369,919
547,730
547,678
737,699
Singapore
97,846
138,293
264,779
192,626
214,946
Malaysia
52,706
37,041
78,652
100,926
133,945
Japan
65,166
53,635
56,930
77,953
101,180
Taipei, Chinese
7,372
22,594
13,235
32,585
76,855
China
62,772
37,796
19,616
44,605
75,326
United States of America
51,874
34,886
46,531
47,089
45,861
Korea, Republic of
2,867
13,865
12,787
7,993
16,214
Hong Kong, China
3,018
2,106
487
733
13,807
Philippines
5,319
6,697
14,764
10,724
9,486
Cambodia
4,349
4,199
5,506
2,882
5,800
29
486
29
2,175
5,713
Thailand
4,155
4,421
7,136
4,057
5,535
Canada
3,076
3,201
3,736
4,581
5,232
Indonesia
161
977
3,976
4,675
4,364
Germany
861
1,278
9,620
1,665
3,785
Bangladesh
75
256
1,191
2,859
3,010
Brazil
Myanmar
22
62
8
1,077
2,415
India
844
285
202
329
2,227
Lao People's Democratic Republic
377
449
909
675
1,721
United Kingdom
502
540
686
802
1,215
Australia
664
642
986
1,022
1,206
France
702
1,138
745
753
892
Netherlands
295
252
200
246
723
Sources: ITC calculations based on UN COMTRADE statistics. Data based on the partner reported data (Mirror data) are shown in orange
Eurowindow (The European Plastics Window JSC). Location: BCD Ly Nam De Str., Hoan Kiem, Hanoi, Vietnam Products: Safety glass, tempered glass, laminating glass, insulating glass, patterned glass (processor of Saint-Gobain glass). Markets: Domestic and export markets Others: Eurowidow has three glass processing center in Hanoi, Da Nang and Binh Duong. Eurowindow’s factories are equipped with modern automated production lines imported from leading suppliers of Germany, Italy, Finland and Spain. The factories produces mainly building products. The company also has four glass alternative factories for building products. Its pre-fabricated building materials, with thermal break combined with double glass, safety glass, tempered glass and solar control glass, create beautiful doors and façades with high long-life durability, thermal and sound insulation, the manufacturers claim. ThuanThanh Glass Joint Stock Company (TTG) Location: Dien Bien Phu, Hai Duong city, Vietnam Products: Processed construction glass, commercial building autodoor entrance systems, insulating glass, tempered safety glass, laminated safety glass, reflective glass, low-E glass, and various other processed colour and clear float glasses. Markets: Domestic and export markets Others: Uses float glass from Guardian (USA), Asahi (AGC) Belgium, VFG-NSG Group (Japan and Viet Nam). ThuanThanh Glass with its own produced glass and glass installations, contributed to high rise buildings in Vietnam.
www.asianglass.com
ANALYSIS: Vietnam
features prevent the amount of visual light from the sunlight from 5 percent to 95 percent; preventing up to almost absolute 99 percent of energy from sunlight and ultraviolet (UV) rays that are harmful to human health. The energy efficient glasses can save up to 45 per cent of electricity consumed by air-conditioners. Viglacera said, among others, the leading Vietnamese glass processors SADO GROUP and Eurowindow will use the glasses for manufacturing secondary products.
New solar glass
The Hai Phong Industrial Zone Management Board has recently granted an Hong Phuc Glass Location: Two plants in Phu Nghia and Nhu Quynh, in Van Lam, Hung Yen, near Hanoi, Vietnam Products: Toughened safety glass, laminated safety glass, insulating glass, decorative glass, etc. Markets: Domestic and export markets Others: Processes Pilkington, Guardian, AGC and Saint-Gobain glasses for various applications. Its annual production capacities of various types of glasses include, toughened (tempered safety glass) panel: 800,000 m2, with maximum width is 7.5m diameter; curved tempered glass: 300,000 m2; and laminated safety glass: 500,000 m2, and with laminated throughout, the thickness ranges from 6.38mm-12.38mm. Laminated color film types available. Reflective laminated safety glass thicknesses available are 8.38mm and 10.38mm, and others on demand. The yearly production capacity of soundproof heat insulating glass is 200,000 m2. Diamond Glass JSC Location: Hoa Khanh Industrial Zone, Da Nang city, Vietnam Products: Glass processing Markets: Domestic and export markets. Others: Diamond Glass manufactures construction glasses, including tempered safety glass, laminated glass, insulating glass, curbed glass, solar control glass and low-E glass. VinaFacade Joint Stock Company (VinaFacade) (Joint venture by Viglacera Corp, Facade Treatment Engineering (Malaysia) and Viglacera DapCau) Location: Hoang Hoa Tham Str, Ba Dinh Dist, Hanoi, Vietnam Products: Processed glass for building facades Markets: Projects in Vietnam, Malaysia, Singapore, UAE, Bahrain and other countries. Others: VinaFacade also offers design, customized fabrication, project management and installation of facade systems with processing of glass in its own facilities, including two of its owners Viglacera Corporation and Viglacera DapCau Sheet Glass JSC, and in Viglacera’s other major glass manufacturing/processing units and others, such as, Viglacera Float Glass, Phu Phong JSC, Thuan Thanh Glass JSC, Glasskote Vietnam JVC, etc. VinaFacade has many building glass installation projects in Malaysia, in cooperation with its Malaysia based, Facade Treatment Engineering Sdn Bhd. Some of them are showcasing the joint-venture’s capabilities. Glassworks Co Ltd Location: Nhon Trach Industrial Zone, Nhon Trach District, Dong Nai province, Vietnam Established: In 2010, as a subsidiary of Australia-based Professional Industry Diamond Pty Ltd (PIDIAMOND). Products: Processed glass. Markets: Domestic and export markets Others: Works done are processing of tempering, laminating, double-glazing and painting glass as well as, cutting, edging, beveling and drilling the at glass sheets precisely in various sizes according to customers’ requirements. Phu Phong JSC Location: Tan Tao Industrial Zone, Binh Tan Dist, Ho Chi Minh City, Vietnam Products: Processed glass Markets: Domestic and export markets Others: Phu Phong manufactures tempered glass, sheet glass, laminated safety glass, glass mirrors, insulating glass, curved glass, low-emissivity float glass, glass furniture, various glasswares including sanitarwares and giftwares. Thanh Dat Glass Location: P. Tra Noc, Binh Thuy, Can Tho City, Vietnam Products: Processed glass Markets: Domestic and export markets Others: Thanh Dat manufacturers various building glasses, including, toughened glass, laminated glass, reflective glass, glass mirrors, decorative glass, glass furniture, etc. Cao Trung Nghia Glass Co Ltd (Aluminum Glass Co) Location: Tan Binh District. Ho Chi Minh City, Vietnam Products: Processed safety glass for building exterior and interior and other use Markets: Domesti8c and export markets Others: Cao Trung Nghia manufactures toughened glass, insulating glass, transplant glass, laminated glass, toughened reflective glass, reflective glass box, glass mirrors, low-E glass, bent glass, patterned glass, cutting glass, etc.
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asianglass AG 16-4
investment license to Flat Group from Hong Kong (China) for a solar glass factory at Haiphong at US$200 million. The factory will cover 21.8 hectares in the Dinh Vu Industrial Park. It is expected to go into operation in late 2017 with a capacity of producing about 580,000 tonnes of solar glass per year. Currently, NSG owned Vietnam Glass Industries (VGI) is a major manufacturer of solar glass in Vietnam. VGI supplies the transparent conductive oxide (TCO) coated glass used in the manufacture of First Solar’s advanced technology thin film solar modules. VGI is First Solar’s primary source for TCO glass used at its module manufacturing facility in Kulim, Malaysia. Saigon Technology Glass Co Ltd Location: Vietnam-Singapore Ind. Park, Thuan An, Binh Duong, near HCM City, Vietnam Products: Processed architectural and furniture safety glass, and art glass Markets: Domestic and export markets Others: It manufacturers architectural safety tempered glass, safety laminated glass, tempered and laminated glass and silk printing glass. Its furniture glass processing are furniture glass and designing furniture use glass. Various other glass processing include, polishing, beveling, orge grinding, drilling, decorative EVA glass for interior use, bent glass, etc. Sunglass Safety & Energy-Saving Glass Industries Co Ltd (SUNGLASS) Location: B-10 Industry My Phuoc II, Binh Duong, Vietnam Products: Processed glass Markets: Domestic and export markets Others: SUNGLASS manufactures safety and energy-saving glasses for exterior and interior application in architectural and construction industries. The products include tempered glass, laminated glass, insulated glass and bended glass. Its flat and curved products include TEMPERMAX (tempered safety glass), PROSAFE (laminated safety glass) and PROCOMFORT (insulating glass). It also markets imported reflective glass, low-E glass, thick glass and jumbo-size glass. Hai Long Glass (Halon Glass brand) Location: Khu Cn Ha Binh Phuong, Thuong Tin, Hanoi, Vietnam Products: Safety glass, tempered glass, colour glass, insulating glass, reflective glass and car glass Markets: Domestic and export markets Quan Dat Location: Tan Thoi Hiep Industrial Park, District 12, Ho Chi Minh City, Viet Nam Products: Processed architectural glass, specially, façade glass Markets: Domestic and export markets Others: Quan Dat manufactures and installs curtain, partition, window and door glasses. It is a specialist on unitized façade. Thien Phu Glass Location: Ward Phuoc Vinh An, Dist. Cu Chi, Ho Chi Minh City, Vietnam Products: Safety tempered glass, laminated glass, IGU, painted glass and heat strengthened glass Markets: Domestic and export markets Viglacera Glasskote Limited Location: Cau Giay, HaNoi, Vietnam Products: Building exterior and interior colour glass and colour glass for other uses. Markets: Domestic and export markets Safety Glass Factory Location: Quang Minh Industrial Zone, MeLinh Distr., Vinh Phuc Province, Vietnam Products: Glass processing Markets: Domestic and export markets Dom Home Science Glass Mirr Co Ltd Location: Lot D-4B, My Phuoc 3 Industrial Park, Binh Duong, Vietnam Products: Glass processing Markets: Domestic and export markets Lien Chau Luc Technology Glass Corporation Location: Phan Van Hon, Tan Thoi Nhat ward, 12 District, HCMC, Vietnam Products: Glass processing Markets: Domestic and export markets Long Giang Glass Company Ltd Location: Tran Phu, Hai Chau District, Da Nang, Vietnam Products: Glass processing Markets: Domestic and export markets
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FURNACE TECHNOLOGY
CELEBRATED BY OUR CUSTOMERS AROUND THE WORLD
Our customer’s celebration dinner held inside a newly constructed TECO furnace
www.teco.com
®
TOTAL FURNACE CAPABILITY TOLEDO ENGINEERING / TECOGLAS / ZEDTEC / KTG ENGINEERING / KTG SYSTEMS / EAE TECH
ANALYSIS: Vietnam
List of glass products imported by Vietnam (US$â&#x20AC;&#x2122;000) Imports in value in thousand US dollars
List of glass products exported by Vietnam (US$â&#x20AC;&#x2122;000) HS Code
Product label of glass items exported by Vietnam
159,225
7006
33,671
140,143
72,192
112,520
HS Code
Product label of glass items imported by Vietnam
7013
Glassware used for table, kitchen, toilet office, etc
37,312
39,470
43,375
49,312
7007
Safety glass, consisting of toughened/laminated glass
27,684
19,351
30,099
7019
Glass fibres (incl glass wool) and articles thereof
62,501
73,196
69,540
7010
Carboy, bottle & other container of glass
34,787
36,783
39,739
48,299
96,699
7005
Float glass & surf grd/polished glass in sheet
31,456
120,785
111,197
91,533
42,493
7009
Glass mirrors
19,025
7003
Cast & rolled glass, sheets/profiles
7006
Glass of 70.03, 70.04, 70.05 bent, edge worked etc not framed etc
61,987
7020
Articles of glass, nes
31,599
64,699
67,081
107,266
22,275
7018
Glass bead, imitation pearl, glass eye, etc
2,450
1,867
3,736
6,587
9,990
Glass paving block for building/const, glass cube, etc
3,390
2,534
3,421
5,925
9,544
7002
Glass in balls, un worked
17,075
9,203
6,422
8,020
7,929
7017
Glassware for laboratory, hygenic/ pharm.
2,926
7014
Signalling glass ware & optical elements of glass nes, not optically work
11,985
7011
Glass env, open & pts, for electric lamps, cathode-ray tubes etc
1,323
7008
Multiple-walled insulating units of glass
13,677
4,217
5,829
6,354
3,750
7001
Cullet & other waste and scrap of glass
725
278
402
562
7004
Drawn or blown glass, in sheets
2,160
3,142
2,692
7015
Clock/watch glass for non-correc/correc spect, etc
579
376
7012
Glass inners for vacuum flasks
NA
NA
7016
Exported value in 2011
Exported value in 2012
Exported value in 2013
Exported value in 2014
Exported value in 2015
Glass of 70.03, 70.04, 70.05 bent, edge worked etc not framed etc
10,170
16,059
3,050
5,762
373,218
7005
Float glass & surf grd/polished glass in sheet
30,111
107,597
106,481
126,331
186,350
7020
Articles of glass, nes
262,803
338,170
335,757
493,825
104,023
7007
Safety glass, consisting of toughened/laminated glass
2,103
2,658
3,208
5,493
90,251
7009
Glass mirrors
41,923
50,764
52,068
58,214
36,536
7013
Glassware used for table, kitchen, toilet office, etc
6,134
12,839
23,618
23,962
25,212
7019
Glass fibres (incl glass wool) and articles thereof
4,353
4,561
6,928
7,525
13,015
7010
Carboy, bottle & other container of glass
2,584
5,651
10,245
9,657
6,697
7008
Multiple-walled insulating units of glass
492
167
104
377
2,940
7018
Glass bead, imitation pearl, glass eye, etc
683
713
2,372
1,731
1,925
7016
Glass paving block for building/const, glass cube, etc
262
565
315
174
1,035
7001
Cullet & other waste and scrap of glass
603
284
450
268
892
7003
Cast & rolled glass, sheets/ profiles
7,471
3,828
1,769
1,437
468
7011
Glass env, open & pts, for electric lamps, cathode-ray tubes etc
5
92
658
1,193
355
7015
Clock/watch glass for non-correc/ correc spect, etc
0
1
6
145
163
7002
Glass in balls, un worked
162
290
265
167
125
7014
Signalling glassware & optical elements of glass nes, not optically work
0
1
320
680
56
1,345
7017
Glassware for laboratory, hygenic/ pharm.
3
3,406
25
36
28
3,158
558
7004
Drawn or blown glass, in sheets
58
84
39
723
7
1,022
962
151
7004
Drawn or blown glass, in sheets
58
84
39
723
7
NA
NA
NA
7012
Glass inners for vacuum flasks
NA
NA
NA
NA
NA
Imported Imported Imported Imported Imported value in value in value in value in value in 2015 2014 2013 2012 2011
3,514
21,215 46,219
29,883
3,438
14,231
1,091
21,669 39,424
10,974
3,297
10,362
839
Sources: ITC calculations based on UN COMTRADE statistics. Data based on the partner reported data (Mirror data) are shown in orange
68
asianglass AG 16-4
28,801 40,797
13,409
3,364
6,924
1,431
37,309 25,978
22,376
6,305
6,113
4,889
Sources: ITC (Geneva) calculations based on UN COMTRADE statistics. Data based on the partner reported data (Mirror data) are shown in orange
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178x124_ING_GLASSTEC.qxp_Layout 1 29/08/16 18:10 Pagina 1
w w w . a d e l i o l a t t u a d a . c o m
ly Ita in de Ma
NEW
The widest range of edging and bevelling machines currently on the market
SEPTEMBER 20-23, 2016 Hall 16 Booth 16D40
ADELIO LATTUADA ® EVOLUTION OF GLASS WORKING
Via Abbondanza, 11/13 - 22070 Carbonate (CO) IT Tel. +39 0331.832713 - info@adeliolattuada.com
We are looking for NEW AGENTS for Far East and Southeast Asia
ADVERTISER FEATURE
Celebrating 40 Years of Visit Marrose at Glasstec Manufacturing Excellence Dusseldorf 2016 Stand 15G38 in Glass Polishing Wheel Technology Marrose Abrasives; based in the United Kingdom, is celebrating 40 Years of high quality abrasive polishing wheel manufacture and technology. Established in 1976; from 1979 Marrose began to specialise in the manufacture of rubber bonded abrasive products for polishing the edge of glass - for furniture, architectural and white goods such as refrigerator shelves and cooker control panels. Marrose Abrasives are leaders in glass polishing wheel technology, with a commitment to delivering the highest quality on all its product and services; and have focused on producing polishing wheels; for all flat glass grinding and polishing machines. With innovation in the design and manufacture of larger and more sophisticated (including CNC) grinding machines, Marrose Abrasives have added new abrasive wheel designs to its range of products for the glass processor, all produced to engineering tolerances, with consistent quality of product and performance. Tony Day Marrose Abrasives Managing Director said: We have a vision for manufacturing excellence - based on a solid foundation of technical knowledge, with leadership that guides - in a relentless drive to creates an efficient work flow; from raw materials to superior finished products, with the capability and manufacturing discipline that can respond quickly to any challenge.
“
”
Marrose Abrasives are currently looking for new distributors in Africa, Asia, Central & South America The key element of our 40 year celebration; is Marrose Abrasives market sector leadership, having developed into one of the most recognised, reliable and trustworthy brands, supplying high quality polishing wheels to the glass industry in 2016.
Contact details:
John Day (Global Sales Manager) Marrose Abrasives Ltd North Beck Mills, Becks Road, Keighley BD21 1SD, UK Tel: +44 (0) 1535 602634 Fax: +44 (0) 1535 610095 Email: sales@marrose.com Web: http://www.marrose.com
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asianglass AG 16-4
Glasstec 2016 will be Marrose Abrasives’ 19th consecutive attendance and this show plays an important role within our global sales marketing activity, in support of our European distributors, such as Diacon + Policon, W. Fritzsching GmbH & Co KG Germany, Schleiftechnik Neururer GmbH (Austria) and Lazurnoe based in St Petersburg. Within our strategic brand management program, Marrose operate a dedicated account manager support structure; demonstrating its commitment to high level sales, marketing and technical assistance to distributors; creating clear channels of communication; from order processing and manufacture, through to dispatch and on time delivery, ensuring our customers are receiving an outstanding level of service.
20 - 23 SEPTEMBER 2016
Marrose Abrasives export 80% of its manufactured products to countries such as: Australia, Canada, China, Europe, India, Indonesia, Malaysia, Middle Far East, Russia, South America, South Korea, Thailand, USA and Vietnam.
New Product Development At Glasstec 2016 Marrose will showcase a new range of POLYURETHANE CUP WHEELS for straight line and double edge grinding machines. This long awaited addition to our range of polishing wheels gives the glass processor a large choice of polishing wheels to achieve the best finish and lowest possible polishing cost on any grinding machine. Working on all thicknesses of glass, the new range of wheels can also be supplied bonded to an aluminium back plate giving stability in all conditions, ensuring maximum lifetime and ease of use from start to finish. This new product range comes after many years of product development and testing – including in house testing on our own 9 spindle upright edger. Marrose Abrasives are active members of the FEPA (Federation of European Producers of Abrasives), BAF (British Abrasives Federation) and working on EN safety standards, FEPA safety codes and ISO dimensional standards for abrasives.
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ANALYSIS: Facades
High achievers a golden chance for Indian processors
Yogender Malik looks at how the subcontinent, despite continued objections from certain construction lobby groups, is about to boom as a façade construction destination.
W
ith their high usage of glass, there is no doubt that high rises are one of the most important demand drivers of the flat and processed glass industry. In fact, in some of the Western countries, this subsegment is the most sought after by glass processors. However, the Indian glass industry, hasnâ&#x20AC;&#x2122;t had the opportunity to cater to this sub-segment until now in a big way due to the limited number of high rises is gearing to cater to this market as there are a large number of such constructions in various stages of completion. However, there is no dearth of stakeholders (mostly architects), who have voiced their concerns of suitability of glass as a building material in tropical climates such as India. These stakeholders have voiced their concern regarding suitability of glass particularly in the outer envelopes of such structures for this reason alone in fact.
72
asianglass AG 16-4
Thankfully, of course, there have been myriad advances in glass technology. Coatings, tinted products and insulating processes offers an unlimited range of glass varieties to the end users according to their needs and climatic conditions of every region.
Indian high-rise
As many as 106 skyscrapers rising 200 meters or above were completed across the world in the year 2015, setting a new global record for tall building construction, according to the latest report by Council on Tall Buildings and Urban Habitat ( CTBUH). The report says the 106 buildings of 2015 beat every record, including the previous high of 99 completions in 2014. The world now has 1040, 200 meters- and- taller buildings, which is almost four times the 265 that were there in 2000. Until recently, Mumbai was the only Indian city with high-rise buildings.
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WORLD’S MOST UP TO DATE HIGH SPEED TUMBLER AND STEM WARE LINE
FOTO
• •
capacity up to 75,000 tumbler/day capacity up to 60,000 stem ware/day
NEW GENERATION OF AUTOMATIC CRACK-OFF MACHINE WITH LASER
JOIN US AT GLASSTEC Booth 13E73 !!!
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capacity up to 75,000 glasses/day
•
single, double and triple loading system
ANALYSIS: Facades
The financial capital continues to see the highest demand for skyscrapers, as the only option to grow there is vertically. It now seems that in the coming decade, Maximum City will receive an even more cohesive skyline, with a host of projects in the race to touch the sky being constructed. The demand for high-rise buildings is certainly growing, and other cities are catching up. These constructions have been a boon for glass producers and processors. Besides, a huge quantity of glass, these structures have demanded intricate shapes and high value added glass, thus benefitting our industry immensely.
Glass usage
In India, the last few years have seen glass becoming the ‘hottest fashion statement’ in building construction. The skylines of all the Indian metro cities are dotted with highrise buildings clad in glimmering glass, spelling out affluence and style. Confined to tier I cities till a few years back, high rise glass buildings are becoming ubiquitous even in the tier II cities. Glass glazing, which has become a favored feature in buildings today, has numerous advantages apart from the attractive it gives to buildings. Glass reduces the weight on the foundations and makes for a lighter building. Use of glass creates space, brings the external environment, the skies and greenery outside into the spaces within the building. Glazing can also have a tremendous impact on the energy performance of buildings besides enhancing the visual and acoustic effects. Building energy consumption can significantly be lowered by opting for the right kind of glass and the right kind of glazing. Aside from that, glass does not require high levels of maintenance and the different types of glass available today carry an extra feature of safety and durability. With the continually evolving technology in glass, the demand and usage of glass has grown at a rapid rate in the high rise constructions in the country. Glass, if understood and used well, holds tremendous potential, especially owing to its many innovative features. For instance, Saint-Gobain Glass India, through its Saint-Gobain Vetrotech fire-resistant solutions, offers the Contraflam range, also known as the ´world´s toughest fire-resistant glass´. The company has supplied its products to many structures across the country, including Diamond Square, Mumbai; Suncourt, Noida; and The Leela Palace, Chennai. Focusing on safety, Asahi India Glass Ltd produces tempered, heat-soaked and laminated glass that provides structural integrity. The company´s products have been used in the new Reliance campus in Navi Mumbai and Reliance Twin Tower project, also in Navi Mumbai. Further, the development of high-powered glass has even led to it becoming Brick versus glass Brick Wall Density Thickness Weight/Square meter
2000Kg/m3 220mm 440 Kg/m2
Glass Density Thickness Weight/Square meter
2.51 g/c3 12mm 440 Kg/m2
(Taking into account, a double glazed unit 6mm outer glass - 12mm air gap 6mm inner glass) Weight/Square meter
30kg/m2
So, considering a typical high rise building - 50 stories high with 40,000m2 glass area Estimated weight reduction
74
asianglass AG 16-4
16,400 Tons
List of some of the high rises in Mumbai Name of Building
Location
Height
Floors
Imperial Tower- 1
Mumbai
254 meters
61
Imperial Tower 2
Mumbai
254 meters
61
Ahuja Towers
Mumbai
250 meters
53
Lodha Fiorenza 1
Mumbai
225 meters
62
Lodha Bellissimo
Mumbai
223 meters
52
Orchid Enclave 1
Mumbai
210 meters
52
Orchid Enclave 2
Mumbai
210 meters
52
Kohinoor Square
Mumbai
203 meters
52
The Ruby
Mumbai
191 meters
40
Urmi Estate
Mumbai
182 meters
45
Sunshine Tower
Mumbai
180 meters
40
World Trade Center
Mumbai
156 meters
35
Palladium Hotel
Mumbai
155 meters
40
Four Seasons Hotel
Mumbai
146 meters
35
Oberoi Hotel
Mumbai
144 meters
35
World One ( Under Construction)
Mumbai
442 meters
117
Queens Tower (Under Construction)
Mumbai
360 meters
90
Palais Royale (Under Construction)
Mumbai
320 meters
75
Omkar Tower 1 (Under Construction)
Mumbai
317 meters
78
Lokhandwala Minerva (Under Construction)
Mumbai
304 meters
82
a cost-effective option to be used in certain places against brick and mortar. One sq m of brick weighs around half a tonne, but a glass plane in its place weighs only one-seventh to one-fifth of the brick, making it lightweight. Thus, many structures are using glass in conjunction with steel to slash the weight of the entire structure, resulting in reduction of the foundation and duration required to complete construction. Also, with sustainable building gaining currency, there has been an increase in the use of high-performance glass in green-rated buildings along with a growing market in residential townships. There is a steady growth in the processed market segment, with more people leaning towards high value added glass.
Brick versus glass
Glass has a multitude of benefits for high rise structures, the chief advantages being structural, utility and maintenance. Also, glass is the preferred choice for its superiority in terms of attributes like visual appeal, lightness ease of installation and customization. Glass provides several advantages in structural glazing such as blending of interiors with exteriors. Unrestricted relaxed view, unhindered by building shape and improved productivity levels of the occupants by 10-15% Besides putting a huge weight load on the structure and foundations,
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cycle times < 28 s for Jumbo glass
ARC
V EL
HITE
CTU
RAL
HIGH PRODUCTIVITY + SMALL FOOTPRINT = LOW COST OF OWNERSHIP
THE
concepts
T LE
smart and fast pumping
NEX
ULTIMATE PRODUCTIVITY
GLA SS C
TY
TIVI
MINIMUM LOCK CHAMBER FOOTPRINT
CHE S
780 mm process compartment
REA
long target uptime for Ag WSM
ING
T-Series magnetrons
MINIMUM PROCESS FOOTPRINT
OAT
LONG CAMPAIGN TIME
DUC
PRO
COMPACT CONFIGURATION
TECHNOLOGY SUPPORT
VAprocos2
FAST PROCESS TUNING trimming & shimming software
EASY UNIFORMITY CONTROL
OGY
ADVANCED PROCESS STABILIZATION & HIGH RATE
> 25 years of process experience
NOL
optimized magnetic fields
TECH
EXCELLENT COATING UNIFORMITY
Our glass coating systems are perfect for producing high-quality architectural glass with Triple Low-E coatings everywhere in the world. Since 1975, we have delivered more than 50 large-area glass coaters to a global industy.
TRIPLE LOW-E WITH EXCELLENT COATING UNIFORMITY
integration of adjustable magnet systems
Glass Coating Systems
Learn more at the glasstec 2016 in hall 12, booth E41.
www.vonardenne.biz
ANALYSIS: Facades
conventionally used brick or concrete wall enclosures result in restricted vision or view, closed environment and sense of claustrophobia.
Processing opportunities
Demand of processed glass from 10 largest cities in high rise constructions City
Expected Tempered Glass Demand from high rises/ annum
Expected IG Glass Demand from high rises/ annum
Expected Low E Glass Demand from high rise/ annum
Expected Solar control Glass Demand from high rise/ annum
Downstream glass processors have been the largest beneficiary sub-segment of glass industry on account of rising number of high rises in the country. In fact, a number of new glass processing companies have emerged in and Mumbai 800,000 sqm 340,000 sqm 185,000 sqm 260,000 sqm around the areas of high rise cities such as Mumbai, Bangalore, Hyderabad 350,000 sqm 145,000 sqm 80,000 sqm 115,000 sqm and Noida to cash on the demand of high value added processed glass from Banaglore these buildings. Hyderabad 280,000 sqm 125,000 sqm 70,000 sqm 100,000 sqm Processed glass industry in India is approximately 2000 crores, comprising 210,000 sqm 90,000 sqm 55,000 sqm 65,000 sqm of 5 big , 15 mid scale and 200 small players (mostly unorganized and small) Kolkata across the country. Pune 200,000 sqm 80,000 sqm 45,000 sqm 60,000 sqm Mukesh Sharma, project manager at Micro Tuff Solution, a Noida based glass processor, which was glass façade and window supplier and installer at Gandhinagar 160,000 sqm 65,000 sqm 35,000 sqm 45,000 sqm Platinum Business Park, a 23 story commercial complex in Noida told, “ For 400,000 sqm 180,000 sqm 100,000 sqm 160,000 sqm this particular project, our company supplied 2800 double glazed units (a Delhi total of 5600 glass lites, with 6 mm and 8 mm glass lites separated by 10 mm Noida 260, 000 sqm 145,000 sqm 75,000 sqm 120,000 sqm of air. With each window using 0.70 sqm of IG glass, the total insulated glass 310, 000 sqm 165, 000 sqm 90,000 sqm 140,000 sqm used in the windows alone is 1960 square meters), about 3400 square meter Gurgaon of tempered low e glass and a further 1800 square meter of bent curved glass Chennai 260,000 sqm 120,000 sqm 80,000 sqm 130,000 sqm for the outer façade.” Vijay Reddy, Sales Head at Hyderabad based, Hyderabad Safety Glass says that a large part of the total processed glass demand for the six glass procesoors Vimal Rathi, MD, Glazing and Research, expounds on the virtues of glass in Hyderabad and vicinity comes from high rise buildings. According to Reddy, “ for construction: “Glass is light in weight, gives a beautiful appearance and is Few years back, when we entered into glass processing business, a large part of relatively maintenance free. Proper cleaning once a month or once a fortnight is the demand used to be from commercial projects like airport and hotels. But, in all you need to keep it in good condition and you won’t need to replace it for the last two- three years, the demand pattern of processed glass consumption has next 10-20 years. undergone a complete change.” He further says, “ Currently half of our demand is from the high rise commercial and residential constructions, while the other Glass for the tropics half from the commercial segments like hotels, metro and airport renovation.” The major complaint against the use of glass, especially in a tropical climate like that of India, is the heat trapping effect. The insulating quality of glass tends to trap in the heat along with letting in natural light, and using reflective coat at the Objections remain Glass in various form (processed, solar control glass and other options) are one of same time can heat up the surroundings. the most used materials in high rise constructions across the country. However, However, dubbing the effect and other misgivings about glass as outdated, some stakeholders in the construction industry continue to remain sceptical Saint Gobain India’s, Managing Director B. Santhanam says, ´With technological about its use in high rises. advancement, the new high-performance glass available has made it possible Citing an example of Southern city of Bangalore, Chandrashekhar Hariharan, to keep about 85 per cent of heat away while allowing unrestricted access to CEO, Biodiversity Conservation India Limited, says, Bangaluru is home to a vast natural light.´ number of buildings with glass facades. Widespread usage of glass has resulted in Chitra Vishwanath, an architect at Biome Environmental Solutions Pvt Ltd, rising of the temperature of the city by 2°C to 3°C when compared with outskirts. sees it differently. ´Investment in high-powered glass is too high, especially in the Hariharan said the city was already turning into an urban heat island as summers Indian context, if natural ventilation is provided as it is bound to be cheaper than were becoming hotter and winters colder. Glass facades increase the temperature any glass installation,´ she says not just outside the building but also inside it, as it traps heat. As a result of this, the temperature of the building rises. Safety issues? Even, some glass industry insiders accept that glass facades have some There have been raging debates about safety in the use of glass in general, and drawbacks. According to Harmit Singh, managing director, Global Facade in the case of fire in particular. Glass façades have often been held responsible Consultants,” To some extent glass facades on buildings increase the temperature for aggravating fire accidents in the buildings. However, glass companies and of the surrounding areas. In this backdrop, extensive usage of glass facades is processors don’t agree with these allegations. All of them unanimously state, “ counter-productive.” When proper norms and guidelines are followed in designing and constructing Krishna Chaitanya, zonal head, Asahi India Limited, says, “ In glass facades, glass buildings, and the right types of glasses are used for façades, the destructive there is a wide range of options to choose from, which can minimise urban heat effects of fire are greatly reduced.” island effect. Glasses are classified according to their solar reflective index and B. Santhanam of , Saint-Gobain India says,. ´If proper consideration is given to the ability to reflect heat; the right choice can minimise reflection of heat. The the safety aspect of a structure, incidents like fire will not require a scapegoat in heat-reflection phenomenon can be avoided if glass facades are used on the side the form of glass,´ he insists, saying that fire safety mechanisms must be in place. of the building that faces north.” KC Jain, President, HNG Float Glass says, ´One needs safety hatchets made of Daljeet Singh, owner cum Managing Director of Gurgaon based, Mico tempered glass that can be broken in case of an emergency, along with ventilated Industries says. “It is the usage of raw or cheap glass that causes problem to the openings at intervals. Including these systems right from the planning stage will environment. Now a days, a variety of glasses are available in the market and help reduce the risk of damage in case of any eventuality.´ Citing these as basic people in tropical countries, such as India, should go for darker shades with little precautions for every high-rise building, he says cutting corners is most often the reflecting coats, as it decreases heat emission.” reason for accidents. ´Globally, glass is being used much more extensively, yet any
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ANALYSIS: Facades
fallout is minimal owing to adequate safety measures.´ Senthil Kumar, Business Head - Projects, Asahi India Glass Limited says, “It would be unfair to blame glass for the destruction caused by fire in buildings. In most cases, it is negligence and poor-quality design and construction that result in loss of life and property. If proper norms and building safety codes are followed, and guidelines adhered to, glass façades only help in fire rescue and not make it worse.”
Another view
From an architect’s perspective glass has become one of the most important construction materials in high rise application. Christopher Benninger, Chairman, Christopher Charles Benninger Architects Pvt. Ltd. says “Glass is an easy material to install and finish the façade over large building masses. A low e glass specified by Saint Gobain is something we have used in many projects. In one of the projects, I invented the concept of ventilating the basements by creating glass chimneys that get hit by harsh sunlight sucking the hot air from the basement. Glass is also seen as material with less manufacturing errors to give that seamless finishing in building industry. After all, we as architects would like our buildings to be well crafted.” Jaspal Bhambra of Bhmbra Tuff Glass, a glass processors based at Faridabad, near New Delhi blames ignorance as the main reason for the less-than-stellar reputation of glass. He says, ´The ´misuse´ of glass is more prevalent than its use.´ It is certainly true that awareness of glass as a construction material on the whole is quite low. Incorrectly designed buildings, using inappropriate types of glass inaccurately and skimping on quality, coupled with ignorance on technological developments, set the stage for disaster.” Vivek Katju, a leading architect based in Chennai says, ´The embodied energy of glass is higher than any other construction material, so it is not prudent to use glass in excess amounts in high rises.´ The main benefit of glass, in his view, is that it provides security against harsh external conditions, especially in a chaotic urban environment filled with dust and noise pollution. So the usage of glass should be limited in areas where ventilated openings are not possible. “A knowledge-based approach towards glass applications, not relying on borrowed imagery from the West or the Far East for buildings incompatible with Indian climatic conditions, is necessary to stem the abuse of the material,” says Vinay Kataria of Rana Builders, who have used copious quantities of reflective glass in a new shopping mall at Saket in New Delhi. Glass represents modernity and a futuristic image, but systematic and standardized industry of coating façades with glass has ensured that as a construction material it is not exploited for its full potential.´
Regulatory issues
In order to remove the doubts attached to usage of glass in high rises, Indian glass industry producers and leading processors have been raising their voice for all stakeholders in the construction industry to come together and insist that the government put in place proper building codes with regard to glass, which includes fire safety and energy consumption among other issues to ensure proper implementation. Although the Energy Conservation Building Code (ECBC) has basic guidelines on the way, glass should be used in façades, as it is voluntary, it is also arbitrary in applications. The unorganized and erratic demand for glass without a single unified building code makes it difficult for the glass industry to understand the needs of the sector and undertake measures to address the same. According to Saint Gobain’s Santhanam, ´The problem lies with the nonimplementing of the proper building code, improper design and planning. For example, heat-soaked processed glass has to be used according to regulations globally but the situation is not the same in India where unchecked influx of low-quality glass shatters or breaks.´
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CASE STUDY: Ruby - Mumbai
The Ruby is one of the tallest office building in Mumbai. It is a 40-story 191m (627 feet) high modern and beautifully designed building with a full glass facade that is recognised as a landmark in Mumbai, a centre of finance and business in India. The glass that was used for the building's wall is high grade solar control glass that blocks sunlight and increases the efficiency of air conditioning.
CASE STUDY: World One Tower
When it’s completed next year, the 117-floor World One tower will be the tallest residential building on the planet and far and away the tallest building in Mumbai, nearly doubling the 61-floor Imperial Towers that currently hold the latter title. Llocated in Worli, Mumbai on the 7.1-hectare (17.5-acre) land, the project will cost INR 20 billion (US$320 million) and is expected to consume about 90,000 sqm of high value added glass till completion. .World One will be home to some of Mumbai’s wealthiest residents, with 300 luxury 3 and 4-bedroom units that start at $1.5 million, and feature designs by Giorgio Armani's Armani/Casa studio. Fancy, but World One might not hold the “Mumbai’s Tallest” title for long, considering the currently-on-hold IndiaTower is planned to reach 126 stories. Proposed and “under construction” high rises in India Building
Location
Height
Floors
Bengaluru Turf Tower
Bengaluru
660 meters
156
Lance Hills Towers
Hyderabad
604 meters
114
APIIC Towers
Hyderabad
450 meters
100
Wearesf Tower
Bengaluru
440 meters
109
GIFT Diamond
Gandhinagar
410 meters
86
Noida
400 meters
100
Bengaluru
390 meters
90
Gandhinagar
362 meters
70
Delhi
300 meters
80
Bangaluru
300 meters
94
Kolkata
300 meters
75
Golden Empire
Bangaluru
288 meters
68
Crystel Tower 1
Gandhinagar
276 meters
65
Clippers Tower
Gandhinagar
260 meters
65
Wave City Center Asta Vibrant Towers Gateway Towers Sikka dream Heights KRTE AFRD Tower Urban Twisted Tower
Signature Tower
Lukhnow
245 meters
65
World One ( Under Construction)
Mumbai
442 meters
117
Queens Tower (Under Construction)
Mumbai
360 meters
90
Mumbai
320 meters
75
Mumbai
317 meters
78
Mumbai
304 meters
82
Palais Royale (Under Construction) Omkar Tower 1 (Under Construction) Lokhandwala Minerva (Under Construction)
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ADVERTISER ADVERTISERFEATURE FEATURE
Towering technology
Kuraray solves a construction conundrum Designed with 20,589 wall panels with 7,000 unique shapes, the Laminated safety glass with SentryGlas® ionoplast interlayer has double skin glass façade is suspended from above on massive played a key role in enabling the design of a twisting, all-glass cantilevered trusses and stabilized by hoop rings and struts. The double skin façade on The Shanghai Tower in China — the world’s circular inner glass façade required 14% less glass than a square second tallest building after the Burj Khalifa in Dubai. SentryGlas® building of the same floor area. interlayer was chosen primarily for its visual clarity in combination The primary reasons for choosing SentryGlas® as the interlayer with low-iron glass, the enhanced strength it provided to the overall were the enhanced strength that it provided to the overall glass assembly, and because it eliminated edge delamination due glass assembly and the elimination of any edge delamination to the exposed edges of the glass. due to exposed glass edges in the structural silicone glazing. Completed in 2015, The Shanghai Tower is 632 metres (2,073 SentryGlas® also contributed to the overall sustainability of the ft.) high and has 128 stories, with a total floor area of 380,000 m2 tower by allowing a light coating to be used in conjunction with the (4,090,000 sq. ft.). The building’s tiered construction is designed interlayer for solar control. for high-energy efficiency and sustainability, providing multiple The choice of interlayer was also an important consideration separate zones for office, retail and leisure use. for the glass laminator, Shanghai Yaohua Pilkington (SYP) based The Tower takes the form of nine cylindrical buildings stacked in China and by the façade consultant. Initially, SentryGlas® was atop one another, all enclosed by the inner layer of the glass specified for the outer skin façade only, but the project scope façade, which completes a 120-degree twist as it rises. Between was later increased to include the inner façade, podium building the inner and outer layer of the façade are nine indoor zones that façade, glass fins and interior balustrades. In total, approximately provide public space for visitors. Both layers of the glass façade 200,000 square meters of SentryGlas® interlayer were used in are transparent, which is unique as most buildings have only a the building. single façade of highly reflective glass to lower heat absorption. The visual clarity of laminated glass was also an important factor. The double layer of glass eliminates the need for either layer Low-iron glass provides improved visual clarity by increasing to be opaque and reduces the need for indoor air conditioning light transmission and reducing the greenish tint in clear glass and heating. that is most apparent when viewed from the edge. Due to its high In recognition of the building’s sustainable design, the owners clarity, SentryGlas® ionoplast interlayers eliminate the undesirable of the building, Shanghai Tower Construction & Development, ‘yellow’ or ‘greenish’ tint that affects safety glass produced with received certifications from the China Green Building Committee conventional interlayers such as PVB, even at the outermost edge and the US Green Building Council. In addition, the China of weather-exposed laminates. International Exchange Committee for Tall Buildings Not only does SentryGlas® start clearer than (CITAB) and the Council on Tall Buildings and other safety glass interlayers, it also remains clearer Urban Habitat (CTBUH) recently awarded its throughout its life. Visual clarity is normally measured CITAB-CTBUH 2016 China Innovation Award using the Yellowness Index (YI), which is a measure to the Shanghai Tower for its suspended glass of the tendency of plastics to turn yellow upon longcurtain wall, which the judging panel recognized as term exposure to light. With a YI that starts at 1.5 “particularly novel”. or less (compared to 6-12 YI for PVB alternatives), The Tower’s architect, Gensler, identified three key SentryGlas® keeps its initial clarity after years design strategies — the tower’s asymmetrical form, of service. its tapering profile and its rounded corners – which For further information about SentryGlas®*, would allow the building to withstand the typhoon please visit force winds that are common in Shanghai. Using www.sentryglas.com wind tunnel tests conducted in a Canadian lab, * SentryGlas® is a registered trademark of E.I. du Pont Gensler and structural engineer Thornton Tomasetti, de Nemours refined the and Company t o w e r ’ s or its affiliates form, which for its brand of r e d u c e d interlayers. It building wind is used under loads by 24%. exclusive The result license by is a lighter Kuraray and its structure sub-licensees. that saved is $58 million More than 200,000 square meters of The Shanghai Tower takes the form of nine The Shanghai Tower is the tallest building in Trosifol® interlayer is used in the double cylindrical buildings stacked atop one another, China, standing at 632 meters (2,073 feet) registered in costly SentryGlas® all enclosed by the inner layer of the glass high, with a total floor area of 380,000 m2 a skin glass facades. façade, which completes a 120-degree twist as (4,090,000 sq. ft.). trademark construction it rises. This design reduces wind loads on the of Kuraray. materials. building by 24%.
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AG 16-4 asianglass
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ANALYSIS: Facades
Lofty aspirations the challenges of curtain walling
In part two of our façade focus in this issue, Michael Elstner* discusses the challenges facing the construction of high-rise curtain walling
T
he current design of high rise buildings is showing a tendency for the use of large and complex as well as multiple layer glass configurations. Glass is not any longer used as an infill element only, but it is also part of the supporting structure. This means, depending in the curtain wall design, the local building codes as well as the requirements of the building physics, the building climate requirements (e. g. thermal insulation, solar control as well sound insulation)., glass must fulfil any of those requirements. These challenges have to be fulfilled not only from a technical and functional point of view but also in terms of a durable product. Consequently, pre-sales and after-sales services in combination with an efficient technical communication during project development result of extreme importance.
Flat glass has been used for around 2000 years as a space-enclosing component and is, therefore, one of the oldest artificial building materials. Due to ongoing developments concerning manufacturing and finishing methods, it is now also one of the most advanced building materials that characterises modern architecture today. Since it can now fulfil nearly any requirement of modern building envelopes, the conflict between the fundamental human need for protection from the outside world, on the one hand, and the openness to light, on the other hand, has now been overcome. Providing glass for high rise buildings means not only mean to provide the chosen glass product in the agreed quality and with the chosen properties in the right time on the required location.
following considerations, which should be followed by Architects, Planners, Manufacturers, Executors for the building with glass are important: • Building Physics (Thermal Insulation, Acoustic Insulation etc.) • Installation & Replacement • Construction • Linear or Point fixing, SSG • Safety - Active & Passive Safety • Products (Single Glazing, IGU, strength of glass etc.) • Design of Glass (Construction, restraints, stability, serviceability etc.) • Add. Functions (Radar signal attenuation, Shielding glass for electromagnetic radiation etc.) • Standards & Regulation (Product and application standards or regulations national & international etc.) • Design (printing, films, coatings etc.) • Transport (truck, sea freight, air freight, one-way or returnable stillages etc..) As it can be seen from the topics above not only a good product is important. It is also necessary to have the support of a professional team in the glass manufacturing company which do takes care about production, QA/QC procedures, pre- and after sales service, engineering services and combined with a professional logistic and transport system. For logistic and transport the way of packing the glass so that it does not break or is damaged during transport is the most important consideration. For international projects glass is usually packed in wooden crates and transported with containers. This means that the logistic concept must consider the certain transport chain and consider the special properties of glass.
Building considerations
Designing with glass
A long history
Building with glass means that different requirements must be followed to finally have a functional and durable curtain wall and window system. The
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The application of glass as a part of curtain walls in high raise buildings as well as in windows must be designed very carefully. Part of this design process
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2015-4500-005_FUT_Anzeige_Glas_EN.indd 1
27.01.16 17:12
ANALYSIS: Facades
should be made by the glass processor and its supplier(s). This means that in advance, and during the pre-design process, an initial study of the project requirements must be made together with the architect and/or the building owner. And as a second step, a revision and monitoring of the planning phase of the curtain wall will be also necessary. This planning phase consists on many jobs and analysis which have to be precisely accounted for. According GANA Glazing Guideline [1] this does mean „[…] The design of a good glazing system incorporates experience, engineering principles and good judgment. […] The design professional(s) (architect, engineer, specifier) is responsible for selecting the glass suitable for its intended application. Amongst other design criteria, the following items should be considered during the design review”. • Loading requirements, glass strength and thickness, and thermal stress • Thermal performance requirements for glass and framing (U factor, condensation resistance factor (CFR), etc.) • Design of edge seal for structurally glazed IG units • Material Compatibility • Acoustical Considerations • Daylighting, glare and occupant- comfort considerations • Temperature extremes to which wall will be exposed • Locations and type of exterior shading and its effect on glass • Locations of interior shading devices, heating and cooling outlets, blind or drapery pockets, and ventilation grills that will affect thermal stress of the glass • Consideration of the surface of materials in spandrel areas and other locations where wash-off onto the glass may cause staining, tenacious residue or chemical attack • Locations of interior shading devices, heating and cooling outlets, blind or drapery pockets, and ventilation grills that will affect thermal stress of the glass • Weather tightness, including flashings, primary and secondary seals, and weep systems As it can be noticed on the considerations above and below, the design process is divided in a part which has to be analysed before and during the design of a curtain wall to chose the best fitting glass products. Some other requirements address topics which must be considered during installation and after the installation of the curtain wall elements or the glass products. The design process for a glazing system is very complex and needs to be properly developed hand in hand with the architect and the glazing system
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manufacturer. Further on it is described in [1] that the glass manufacturer or fabricator should do a shop drawing and material review which must cover as a minimum the following topics: • Review and comments on details • Evaluation of glass strength • Deflection and thermal stress resistance of the specified glass configurations • Indication of guidelines and recommendations for proper handling and installation as well as the protection of glass after installation • Revision of external shading, internal shading devices and certain glazing systems that may cause excessive thermal loading on the glass resulting in potential glass breakage • Analysis of the shop and / or architectural drawings to determine if glass requires heat-treatment. In addition to these points, the sealant, glazing tape and / or gasket manufacturer(s) should review details and evaluate the effect of adjacent glazing materials and framing sealants on the glazing elements, glazing tape and / or gasket adhesion and performance. They should also advise on the proper application and use of their products. The shop drawings and materials review consist also on additional topics, e.g.: • Glazing Operations • Anchors and Expansion Joints • Deflection of Framing • Erection Tolerances • Adjacent Work by Others • Drainage • Glass Clearance, Blocking and Bite All these topics are usually described in the glazing guidelines of each individual manufacturer. From the points above it can be considered again that not only a technical functional and durable product is important. Also a well organized and detailed design process results to be of critical importance. As already shown above the design of a glazed of curtain wall is a high demanding process. Being glass part of this process, it is very important for the intended application of the finished glass product that the necessary properties are very well described and hence, the correct product is chosen. The specifications are mainly focusing on product properties like, for example, requirements for allowable tolerances, visual quality criteria and building physics properties. A clear building-physics description of a glazing unit is very important and must therefore comprise, at the very least, the following information:
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ANALYSIS: Facades
• Thermal transmittance coefficient - Ug value • Total solar energy transmittance (solar heat gain coefficient) - g (SHGC) • Light transmittance - Tv • External light reflectance - P v • Colour rendering index in transmission- Ra • Selectivity Coefficient - S • Weighted sound-reduction index – RW Figure 2 shows these properties and their mutual influence. The key property is a very good (low) U value. As it can be easily noticed, none of the properties can be changed without influencing the others.
Fig. 4. Processing Glass Products [2]
Fig.2 Technical Properties
In order to achieve the best compromise between these related properties, it is usual to prescribe functional coatings. These are designed to reduce the Ug value and improve (which means normally to reduce) the solar factor to ensure thermal protection in summer. With at the same time a maximum light transmission as high as possible. Important particularly in the case of solar-control coatings are, besides the functional requirements, also the aesthetic ones. For this purpose the glass manufacturer should be consulted to assess the different possibilities in terms of technical values whilst still providing the desired aesthetic appearance. The next step is related to the production or processing of the glass products. Figure 3 shows the principle steps starting from the basic glass to the finished product as a result of the combination of multiple process types. This means that several steps are necessary to get the product with the required properties and consequently there are many possibilities to modify the product. Many variants can be configured to change and adjust a glass product in terms of the final technical and aesthetic properties. As it can be seen there is not only one product step from the basic glass product to the final product. The different processing steps are influencing each other And therefore it must be considered that the final quality is
also not a single topic. Quality represents always the sum out of different properties, e. g. As a conclusion from figure 5 it could be considered that glass manufacturers or processors must settle an efficient QA/QC procedure to
Fig. 5. Parameters defining the final Quality of Glass
assess their own production as well as the supply chain of the auxiliary materials of each individual product. 1. Regulations Apart from the product and services provided to their customers, it is very important to consider the knowledge of the regulations and standards applicable in the countries where the product is offered. On one hand the certifications for the products according to different product standards as well as the necessary or voluntary certifications for certain products, e. g. insulating glass units. On the other hand, also the regulations and standards for, e. g., thermal and structural analysis must be followed. In addition to codes and regulations a good engineering practice and the considerations of technical and physical principles is always a basic factor.
The future
Providing glass for international projects is always a challenge. Glass manufacturers and fabricators which are manufacturing and processing glass for such high demanding buildings must be very experienced and requested to offer high end and well developed services together with a high quality and durable product. In order to achieve a satisfactory result for all parties concerned, it is very important that all the different disciplines involved in manufacturing, the processing, and the application of these products cooperate with one another. This should occur already in the planning stage in a close collaboration between architects and specialist planners and glass manufacturers together, if necessary, with various specialized engineering enterprises. Fig. 3. Glass Products In addition Figure 4 provides a process categorization.
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State Certified Engineer, Master Glazier, official appointed and sworn expert for glass constructions (öbuv Sachverständiger) Head of the International Engineering Service at AGC Interpane.
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ADVERTISER FEATURE
HEGLA presents innovative, automated and cutting solutions live at the Glasstec On over 1600m² of floor space, HEGLA is exhibiting machines and entire systems in live operation. Glasstec visitors can once again see and experience technology at close hand. Among the innovations and developments presented at the HEGLA booth, there will be the new ProLam – a flexible combined solution for cutting float glass and laminated safety glass. Innovations include a modified cutting bridge and optimised processes. Additional features and equipment enhance the applications of ProLam, which is one of HEGLA’s best-selling systems. The infeed table now has low-maintenance electromagnetic linear drives that impress with high acceleration and accuracy of the cutting bridge when cutting float glass and during edge deletion. RapidLam Shape, a new addition to the product portfolio for cutting shapes in laminated safety glass, will also be shown for the first time. It was specially conceived for cutting shapes from smaller glass formats. Visitors of the HEGLA booth will also be impressed by the Galactic, which is equipped with electromagnetic linear drives to provide precision and agility in highperformance cutting of float glass. Installed just above the Galactic cutting system, the ReMaster remnant sheet storage system reduces wastage and handling costs to a minimum. It stores usable residual glass until it can be optimally used for further cutting. This also prevents damages from manual handling and eliminates the time required to find glass pieces that have been put aside. Even more automation is available through the implantation of the auto-sorting system SortJet, what is installed at the end of the cutting line. Whereby it fully automates the processes of sorting out, alignment and intermediate buffering of glass panes. The glass panes are picked up from the optimised cutting sequence of the cutting system and stored in the dynamic buffer of the SortJet, where they are either supplied directly to the IG line in the required production sequence or provided offline. Suitable software can provide further profound
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optimisation potential which goes far beyond the possibilities of manual handling and cutting plans. The two cutting lines, dominated by ProLam and Galactic, are supplied with glass from the Rapidstore shuttle storage by the Rapidloader floor loading system, which is also on display for the first time at the trade fair. The glass panes are initially kept as packets on space-saving storage racks. Following the specifications in the cutting plan, the shuttle then picks up a rack with unmixed types of glass and transports it to the direct pick-up location of the floor loading system. The shuttle then returns the remaining glass panes to the storage block. With Rapidstore, it is easy to extend current storage capacities at any stage to provide a floor or gantry loading system with direct access to a wider variety of glass. Since the storage system is purely floor-mounted, it is also suitable for shallow hall areas with no crane. If the racks are arranged across various buildings, they can be moved to an adjacent area suitable for loading. Thanks to a new paternoster, HEGLA fulfils customer wishes for a space-saving vertical storage solution which makes optimal usae of otherwise wasted space. This compact vertical compartment system enables material up to 6m long, such as spacers, to be stored horizontally. The object is either collected from the front face or from the front end. The handling process is significantly simplified and less time is required. HEGLA can be found at the Glasstec in hall 14, floor space 56. Our preferred partner Bystronic glass, with whom we maintain a long-term cooperative partnership, is located right in front of us. “Our booths are located side by side and goes on to show how well our cooperation really functions. Customers who wish to obtain comprehensive information on cutting and insulating glass solutions benefit from the combined expertise of both companies”, points out Managing Director Manfred Vollbracht.
AG 16-4 asianglass
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SPECIAL REPORT
In focus
THE UK GLASS & WINDOW INDUSTRY The situation within the UK Construction Industry gives a slightly different picture than that being experienced in the Glass and Window Industry. Output in the Construction Industry is forecast to continue its recovery in the next four years rising 17.9% by 2018. Growth of 5.5% is anticipated in 2015, more than double the rate of growth in the UK economy overall, as activity rises across the three key construction sectors of private housing, infrastructure and commercial. The increase in industry activity is expected to slow during 2016 and 2017 due to the impact of election uncertainties. The UK is facing its most uncertain election in over 40 years and any hiatus may hinder private and public investment this year. The housing market has slowed over the past six months, illustrated in house price inflation. However, house price growth still remains strong historically, in the year to January averaging 8.4% in the UK and 13% in London. As a result private house building continues to recover and starts in 2014 were estimated to be 13.3% higher than 2013. They are forecast to rise 10% in 2015 as major house builders continue to capitalise on high land values and margin, buoyed by strong house price growth and government policies such as Help to Buy. An expected further slowing of house price growth and policy uncertainty due to May’s election are anticipated to negatively impact upon private house building from next year. Starts are expected to rise only 5% in 2016 and 3% in 2017 as medium term growth will be more reliant on SME builders. Private housing repair, maintenance and improvement (RMI) output is forecast to rise 5% in 2015, reflecting strength in the housing market and growth in real wages. Output growth of 3% per year is then expected in each year between 2016 and 2018 as consumer led increases in activity are partly offset by lack of activity in government programmes to incentivise homeowners to undertaken energy efficient retrofit of the existing housing stock. The Green Deal has seen renewed activity since the reinstatement of the Green Deal Home Improvement Fund, nevertheless the majority of retrofit work occurs under ECO and the number of measures installed under this scheme has fallen 50.5% since a peak of 98,936 measures in March 2014 according to revised figures from DECC. The Green Deal is a UK Government initiative to improve energy efficiency in UK households. Various improvement works are offered to residents for no upfront costs and they will eventually be paid back through small payments taken out of energy bills. The money is not paid back directly to the lender, but added to the property’s energy bills. The person in charge of the energy bills is therefore responsible for the repayments, even if the property changes hands. The Energy Company Obligation (ECO) allows for energy saving improvements to your home if you are on certain benefits and own or privately rent your home. You will get all or part of the costs for loft or cavity wall insulation, solid wall insulation and boiler repair or replacements covered. Unfortunately, it does not support the glass and window industry. In an attempt to breathe life into the failing Green Deal Scheme, the Government introduced the Green Deal Home Improvement Fund (GDHIF). This allows home owners to claim back money from the Government if they make certain energy saving home improvements. You can get up to £1,250 toward the cost of installing any two measures from an approved list. At least replacement glazing got onto the approved listing but only to replace single glazing. It is felt that there may be in the
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region of 5 million properties in the UK, still single glazed. The difficulty is that nearly all of these are in the private rented sector and very few are in owner occupier properties. Green Deal has been widely criticised by the industry for not achieving the goals it set and a review is set to be undertaken by the Government’s Chief Construction Adviser after the election. Obvious a change of Government could scrap or change the Scheme totally. On windows specifically, since January 2013: • Only 23 window installations have taken place using Green Deal Finance up to March 2015 • 69 windows were installed with cashback up to the end of March 2015 in England and Wales. • The number of windows installed using ECO funding included: • 997 via the Carbon Saving Target element of ECO • 1,535 via the Caron Saving community element of ECO • 1 via the Affordable Warmth element of ECO This represents 0.2% of the measures installed via ECO funding. The GGF was approached by Government in 2001 and asked to consider the setting up of a Competent Person Scheme. With a proposed change to Building Regulations for thermal performance, the Government introduced the requirement that all replacement window and door contracts in England and Wales had to be registered with the Local Authority Building Control Department. There was concern that this huge increase in workload could not be managed by the Building Control Departments. One solution was a Competent Person Scheme, where the registered businesses were allowed to self-certify compliance to Building Regulations. FENSA was set up on 1 April 2002 and at its peak in 2004, it had nearly 9,000 Registered Businesses and registered 1.1 million installations. These figures decreased dramatically through the recession and at its lowest point in 2012 only 672,544 installations were undertaken. From April 2013 FENSA began to see an improvement and from then until May 2014 each month showed an improving number of installations compared to the same month, twelve months earlier. Never wanting to see a good thing working too well, the Government decided to bring in new rules for Competent Persons Schemes from June 2014. The thought process behind this was to ensure greater consumer protection by requiring mandatory Insurance Backed Guarantees and that each installer could show a minimum Technical Competence level. The new Conditions of Authorisation were introduced on 6 June 2014. There are 21 new conditions and the main condition to impact on the Competent Person Scheme Providers was the need to be accredited to BS EN 45011:1998 via the United Kingdom Accreditation Service (UKAS). As mentioned, the two main impacts on the Registered Businesses was the requirement to now provide an Insurance Backed Guarantee to cover the installation warranty rather than just offer one and the need for the Scheme Operator to assess existing businesses and applicants as technically competent against National Operational Standards (NOS) under a Minimum Technical Competence (MTC) assessment procedure, where one is in place for the relevant type of work. The assessment must include a knowledge test and an on-site inspection. One of the problems for the UK Window Industry is that it is a competent Industry not a qualified Industry, with the majority of the workforce without a formal qualification but with many years of experience. There was therefore an urgent need to move the vast majority of the Industry through the necessary
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SPECIAL REPORT
MTC assessments and to assist this process the Glass and Glazing Federation set up a Training Company within the Group, GGF Training Ltd, to assist with the task. The plan was that once the majority of the MTC task had been completed, then GGF Training would undertake the necessary packages of training as required by other elements of the glass and window industries. The introduction of these new conditions of Authorisation again slowed down the Industry as an element of the Registered Businesses in FENSA did not achieve the necessary levels of MTC or did not tie up with an approved insurer, so they were suspended from being allowed to self-certify compliance to Building Regulations. The number of installations that were undertaken in England and Wales over recent years are as follows: • 2012 - 672,544 installations which was -3.4% fewer than in 2011 • 2013 - 702,495 installations which was 4.5% better than 2012 • 2014 - January to May 297,999 which was 5.9% better than the same five months in 2013 • 2014 - June to December382,856 which was -9.2% fewer than the same seven months in 2013 • 2014 - Total of the year of 680,855 which was -2.8% fewer than in 2013 To date in 2015 (January to March) – 168,652 installations which are -4.9% fewer than the same three months in 2014. These changes to the Conditions of Authorisation have not only reduced the number of Registered Businesses in FENSA but also the same in the main has been seen across all Schemes in the Window and Door Industry. The two main Schemes are FENSA and CERTASS and their details are as follows:
ELECTROGLASS INTELLIGENT DESIGN FOR IMPROVED
FURNACE OUTPUT
See us at Glass tec stand no. 13-A8 , 3
Number of Registered Businesses 9/12
3/13
9/13
3/14
9/14
CERTASS
1850
1982
1908
1949
1691
FENSA
8712
8105
8193
7833
5365
98.7%
98.2%
97.8%
97.9%
96.7%
Joint Percentage Across Schemes
Number of Installations CERTASS FENSA Joint Percentage Across Schemes
9/12
3/13
9/13
3/14
9/14
30917
32571
39044
42457
43857
314588
349846
350317
364773
353595
98.5%
98.4%
97.0%
97.7%
97.2%
There are three other very small schemes operating in the replacement window and door market in England and Wales, but as was just highlighted, together this only represents a couple of percent of the Companies registered and the installations undertaken. In conclusion, the UK glass and window industries are still experiencing difficult times and although out of recession are not seeing the necessary increases to start to push figures back to those pre-recession. The outcome of the General Election could have an impact if we see the introduction of new incentives for home owners to improve the energy efficiency of their homes. FENSA is also working tirelessly with the suspended companies to try to assist them through transition to allow them to again self-certify their installations. There is still a lack of consumer confidence in spending larger sums of money on the home while the future is still so uncertain. The Industry is ready to undertake the work, we just need to hear the starting gun, to get everything moving.
HIGH EFFICIENCY ELECTRIC BOOSTING SOLUTIONS TO INCREASE FURNACE OUTPUT BY UP TO 65%
The Specialists in Electric Glass Melting and Conditioning
www.electroglass.co.uk BENFLEET, ENGLAND
Electroglass 2015 Ad.indd 6
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22/10/2015 11:31
AG 16-4 asianglass
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Window on
MALAYSIA
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Total float glass imports (sq metres)
Total float glass exports (sq metres)
Leading float glass export destinations (sq metres)
Leading float glass import sources (sq metres)
asianglass AG 16-4
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23 – 25 February 2017 The 5th Edition
SEE YOU
GREATER NOIDA DELHI, INDIA
www.glasspex.com
Supported by:
Held in conjunction with:
Messe Düsseldorf GmbH P.O. Box 10 10 06 _ 40001 Düsseldorf _ Germany Phone +49 (0) 2 11/45 60-77 62 _ Fax +49 (0) 2 11/45 60-77 40 SchreiberG@messe-duesseldorf.de
www.messe-duesseldorf.de
ADVERTISER FEATURE
Langendorf: a total logistics solution Langendorf is exhibiting a line-up of five key products at the IAA trade show in Hanover – split between its stand (E06) in Hall 27, together with an area (T13) within the outside display area. The German manufacturer, from Waltrop, has selected its exhibits to best showcase an extensive product range, which sees the company as a well-established supplier of rugged bodies and trailers to the building and construction sectors. Langendorf also offers specialist products for both dry freight and temperature controlled logistics companies. Langendorf’s range will be represented outside by a doubledeck Flexliner trailer from the firm’s well-established range of Inloaders. The trailer on show is mounted with temperature controlled equipment, and offers such significant loading capacity that two Flexliners in this specification can replace three conventional trailers – providing customers with a significant competitive advantage. A Flexliner can transport up to 55 Euro pallets or 87 roll containers per trip. This means up to 66% more freight per trip, resulting in about 30% less costs. The Flexliner can also be used with any standard tractor unit. An integrated tail-lift ensures loading and unloading can be carried out without requiring access to a loading bay or similar infrastructure. The Flexliner at the show is certified according to FNAFTP and has an unladen weight of approximately 11,500 kg, which results in a payload of about 20,000 kg. It features two decks - the upper deck is 13,410 mm long, and both compartments have an internal height of around 1,820 mm. The width between the axles is 1,610 mm, with the internal width 2,460 mm across the rest of the trailer. Langendorf’s exhibits inside Hall 27 include an Inloader, type SB, which is also known as the Flatliner and is used by customers all over the world. It can be operated in conjunction with two or three axle standard-specification tractor units, offering an unladen weight of just 9,500 kg. The independent Langendorf wheel suspension creates a loading area of 9,500 x 1,550 mm. Goods of 3,700 mm and with a length more than 9,000 mm can be transported under 4,000 mm total height. A hydraulic pump assembly provides the required hydraulic pressure for operating the trailer. It also provides the hydraulic function for the fixation arms on top of the trailer. They can be adjusted to any load and are operated from ground level,
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maximising safety for the driver. Sand and high-volume loads are particularly well suited for aluminium tippers. The model on display has an unladen weight of about 5,100 kg and offers a load capacity of 25 m³. The sidewalls are made of plank profiles in 200 x 50 mm sections; the thickness of the inner wall is 4 mm. The 5 mm floor is made of ultra-wear resistant aluminum with a hardness of HB110; making it about 50% harder than that usually specified in general tipper construction. Like all Langendorf tippers, there are many options to choose from, enabling customers to specify the trailer for their precise application. This includes a choice of axle configuration and tarpaulin systems, amongst many others. Another vehicle being displayed inside is the insulated steel half-pipe tipper, type SKS-HS 24-7,5. Offering a load capacity of approximately 24 m³, this trailer is equipped with disc brakes and has an unladen weight a little under 6,300 kg. It is equipped with insulation to meet the latest German regulations – this comprises a 50 mm thick layer of insulation between the inside and outside layers of the trailer body to provide excellent heat retention. Langendorf only uses Hardox HB 450 in these bodies. The front wall is made of 4 mm high quality steel on the inside and on the outside. The sides and rear wall are made of 4 mm Hardox HB450, the floor is 5 mm thick and made of the same material. The weight saving aluminum cover on the outside is 1 mm thick, and on the rear wall it is 3 mm. Steps on the front, both on the outside and on the inside allow easy access to the load space. Langendorf is once again offering the aluminum half pipe tipper within its range, and this trailer completes the line-up at IAA. It is represented on the stand by a SKA-HS 24-7,5, ensuring that the long tradition of aluminium half-pipe tippers is continued. The tipper on display, without chute, can transport loads of approximately 24 m³ in volume, with a height of just 1,500 mm. The unladen weight of this model is only 5,100 kg, even with a robust steel chassis, meaning it affords excellent payload potential. The front wall has a thickness of 6 mm, the sides are 7 mm and the floor is 10 mm thick, using quality HK34. The entire floor is covered with a 13 mm Quicksilver lining. Steps on the front, both on the outside and on the inside allow easy access to the load space.
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Total container glass imports (Kg)
Total container glass exports (Kg)
Leading container glass export destinations (Kg)
Leading container glass import sources (Kg)
Total cullet exports (Kg)
Total cullet imports (Kg)
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888 (-"445&$)"4*" $0. 4(
)BMM " 4BJHPO &YIJCJUJPO $POWFOUJPO $FOUFS )P $IJ .JOI $JUZ 7JFUOBN
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THE EXPO WHERE STRENGTH AND CLARITY COMES WITH A WORLD OF
Building on the foundation of transparency in technology and design, the 14th Zak Glass Technology Expo aims to set new role models of quality. The 2016 edition is set to be a conglomeration of the crème de la crop in the industry from around the world. This year, polish your definition of excellence and innovation in the world of glass processing..
Current Shows: Organised by: ZAK TRADE FAIRS & EXHIBITIONS PVT. LTD. 11, Murrays Gate Road, Alwarpet, Chennai - 600 018. Tel : +91 44 4295 9595 | www.zakgroup.com
For enquiries contact: Sulaiman Khan | +91 98999 52189 skhan@zakgroup.com www.zakglasstech.com
Anaylsis
Refractory Zone Mission Impossible: checking your fused cast refactories In the latest of his exclusive pieces for AG, refractories guru P.Carlo Ratto discusses the issues facing making an accurate, informed decision on product choice when going for a cold repair. In a couple of contributions published in this magazine earlier this year, I have debated about the nowadays complex scenario for any glassmaker needing to procure fused cast refractories for a given cold repair of a furnace. When comparing different profiles of fused cast manufacturers, I have also discussed around the several differences existing in the production technology and techniques, in the capability to control the process, tracking back single items to its production history and eventually to the intrinsic quality of the refractories produced, its ability to fulfill the specific requirements and to maintain the materials specifications within a given batch of production and between batches.
only way, is to run a complete audit of its way to manufacture and to control the process. The external support is generally requested since the knowledge relevant to the technological platform for fused cast production is typically not within the heritage of glassmaking companies. One could wonder: to understand the dependability of a given supplier of fused cast refractories, why it should be necessary to deeply understand its technological level? After all, to understand the quality and reliability of a silica brick or an insulating panel, is it not enough to run a number of physical, structural and chemical analysis on the product? Well, it all goes to the radical difference between a fused cast refractory and any other type of sinter refractory body, coming from whatever other shaping technique like dry/semi-dry pressing, isopress, vibro-press, vibro-cast and more.
The shape of things
In several occasions I did mention the fact that wise glassmakers will have to recur to (external) professional support in order to assess the above mentioned characteristics of a given prospect supplier and I will never reiterate enough the concept that to make a judgment about the opportunity to qualify a given supplier (of course in terms of risks/ benefits), the best way, or to say more clearly the
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All of the above traditional shaping methods have in common, with a limited range of variability, that the refractory body is homogeneous at medium scale. This means that a chemical analysis made on a proper sample from a brick can be considered representative of the general product chemistry. Similarly, a physical parameter (e.g. thermal expansion behavior) determined on a brick can be considered representative of the quality, and the same concept can refer to most technological parameters (like corrosion resistance), within the testing intrinsic variability and reproducibility. Under these conditions, variability of results attributable to samples can be related to the variability of product and process. Unfortunately, this is not the case for fused cast refractories, and particularly for AZS fused cast. The root reason is a remarkable degree of inhomogeneity of any fused cast body, directly descending from the intrinsic peculiarity of the forming process, including pouring the liquid ceramic at extremely high temperatures, and the subsequent stages of nucleation, crystallization and
P. Carlo Ratto segregation in a variable thermal field established during the passive liquid cooling process. This remarkable inhomogeneity applies to chemistry, texture, microstructure, porosity and several physical properties. From this single fact, therefore, descend a number of consequences that, together with a specific set of technological parameters, leads to an extreme difficulty to evaluate both product and process quality starting from product samples. Let us briefly go through the main aspects traditionally evaluated against specifications, in order to understand if a given refractory complies with specs and is fitting customers expectations, commercial warranties:
Chemistry conundrums
This is the first and most ordinary concept to which a buyer refer when procuring a refractory. Now, it must be stressed the fact that through chemical analysis of a fused cast block (and particularly for an AZS) you cannot absolutely understand if the product was indeed produced at the proper chemical composition! This concept is sometime very hard to be “digested” by glassmakers that must cope with the reality that there is no ways they can dispute the correspondence of the procured goods versus the “contractual” guaranteed chemistry. It is not by chance that in most case manufacturers provides “typical” or “reference” chemistries and only when requested to provide contractual chemical ranges for the main components, they often apply very large fork of variability, or a statement that the chemistry refers to the furnace sample (in other world to the relatively homogeneous liquid coming
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Anaylsis
The change is continuous… …but the high MOTIM-quality is permanent
www.motim.hu
all over the world
MOTIM
Fused Cast Refractories Ltd. H-9201 Mosonmagyaróvár, P.O.Box 29, Hungary, Tel: +36 96 574 100 Fax: +36 96 574 235 e-mail: fusedcast@motim.hu
Anaylsis
out of the furnace and before the segregation happening during cooling process) or to the average sample of a block. In other words, should you (as an example) take a sample drilling a small core out of a soldier block, the chemistry will strongly depend on where the core is taken, since different compositions will follow isothermal lines during cooling and the entity of segregation (typically more than 20% of the average) depends on shape, size, casting technique of the tested block. Purely in theoretical terms, the only way to understand the actual chemistry should be crushing an entire regular cast block, making a statistically valid sampling and then run the analysis on it. Not even this is viable when dealing with a reduced- or no- cavity block, since part of the casting is sawn away (header), with subsequent alteration of the average block’s chemistry. I believe it is now quite clear why nobody can say a given block is conform to the “guaranteed” chemical composition, by analyzing the block itself. So, what can be done? The only way to operate is to: 1 - Check if a given manufacturer has the capability (equipment, know-how, personnel and will to do) to control his own process chemistry. The appropriate method is taking a sample of liquid at the furnace (each pouring process), cool, crush and run XRF analysis on it. 2 - In case of the above point is a yes, check if the manufacturer really does it as a standard process. 3 - Acquire the process control records relevant to the period of production of the investigated goods, so as to be capable to run a statistical analysis telling you the level of confidence with which your product stays within the guaranteed chemistry parameters. It is clear that this is not corresponding to the simple procedure of requesting the chemistry data from the manufacturer, unless you will decide to totally rely on the supplier with an approach not different to simply requesting a unilateral certificate of conformity.
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Structural parameters
With the exception of weighing each block and comparing with the nominal and minimal weight (based on supplier’s specs), that is a routine operation in any acceptance inspection, there is really a few that can be done to double check the physical and structural quality of a fused cast block. The utilization of non-destructive means of investigation, like gamma-graphy (seldom used for obvious reasons), ultrasonic (now less used than in the past) and radar detection (now the latest fashion) have in common the fact that the problematical kernel of the technique stays within the stage of results interpretation (after acquisition of the raw data), in most cases developed by specific utilizers, generally the refractory makers. This is particularly true for the most recent radar techniques and it is therefore very difficult to take these non-destructive means of investigation as a tool to evaluate a prospect supplier. Microstructure depends a lot on the sampling position (skin to core), on the distance from head, on the overall size of the block and casting technique. Residual stress in the block is practically not measurable and yet this is one of the variables mostly related to the development of cracks when blocks are heat up in a furnace start process, for a given warm-up standard procedure. The residual stress depends on the manufacturing process quality and particularly from all stages between liquid casting and up to the cold extraction, when blocks have reached almostenvironmental temperature. The only way to evaluate the possibility to reach a valid physical and structural arrangement is to directly evaluate the quality and reproducibility of the manufacturing process and particularly the kernel of the applied technology.
Exudation tendency, Corrosion resistance, Blistering/cords potential:
These parameters are also those most
concerning for glassmakers, since they “should” represent the important characteristics pointing to the expected campaign life extent, and on the expected quality of glass produced from a furnace (at least for the fraction of defects coming from refractory interaction). Unfortunately, once more, the result of any test for these is also strongly dependant on the sampling within a block, on the casting technique and on the size/shape of the sampled block. In addition, and in spite of several attempts to establish norms for some testing like exudation and corrosion, a large difference still exists on the procedures followed by the few laboratories actually operating such tests (mostly fused cast manufacturers R&D structures), so that these are essentially comparative tests within a given lab; the variability inter-lab, even when following same procedure, is relatively large. We can say that the significance of these tests is acceptable only on a statistical basis when the “data population” is relatively high; this means, in practical terms, that very few glassmakers operate R&D structure capable of doing so, and that these operations are surely not suitable for evaluating a given new sourcing opportunity. As a final consideration, after evaluation of the a.m. points of discussion, we can surely confirm that the only way to evaluate a prospect supplier of fused cast refractories, cannot be analyzing the provided products (or even one or more provided-for-purpose samples!), but that it is indeed necessary to audit the technology and the techniques applied by such manufacturer, so as to ascertain if it has the capability and if it actually applies all those means necessary to produce an acceptable product, conforming the Customer’s expectations/needs and if it is capable to do so in a reliable and reproducible way, with all the actions on site to detect and discharge most possible non-conformities.
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INLOADER FOR SAFE AND EASY „MEIN LANGENDORF!“ GLASS TRANSPORT
Typical low cost alpha-beta alumina, showing light blue discoloration and surface contamination from moulding components”
D.K. Pek, Jet-Scan Pte Ltd, 510 THOMSON ROAD, #08-00 SLF BUILDING, 298138 Singapur, +65 6262 2463, +65 6262 2464,pek.chee.keong@tiongseng.com.sg, www.jetscan.com.sg Anz_Glass 178x124_(GB).indd 1
17.08.16 08:34
ADVERTISER FEATURE
Looking to the future of glass through CNUD EFCO eyes CNUD EFCO is world leader of lehrs for flat, hollow and foam glass. On top of that, it is a well-known manufacturer of tin bath accessories and roofs. According to CNUD EFCO, the glass world has to save on energy consumption and raw material use. Moreover, it has to contribute in an improvement of the overall thermal resistance of buildings without introducing extra fire risks by using the typical glass non-combustibility. Solutions based on polymers can never meet these targets. CNUD EFCO has a clear plan in mind to obtain the above goals, which is partially improving existing technology and developing new one. The forced convection zones of float glass lehrs are redesigned to work with a much smaller pressure drop, allowing (using) to use fans with a much lower pressure and energy consumption. On top of that, thermodynamics is pushed to the edge to recycle the low value extracted heat into high value electricity. Today, all the heat extracted during glass forming and annealing is simply not used. The ultimate goal is a float glass lehr, which does not consume but even produces electrical energy. To avoid that the heat of the glass is reflected during the cooling, EMISSHIELD nano-coating is used for the uppermost efficiency. Investors will find out that the lehr is completely paid in one campaign by this produced electrical energy, which is easily absorbed in a typical glass factory. Improvements on tin bath roof and accessories will increase
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the efficiency of the glass forming process resulting in less use of raw materials. But the major contribution will be the introduction of ultrathin glass into the architectural world. Chemical tempered thin glass is already introduced in the automotive world but has also several advantages in the architectural one. Indeed, by using multiple tempered ultra-thin glass panes with a low emissivity coating, extreme low U-values can be obtained with an acceptable weight. In this case, manufacturing efficiencies lower than 99% will no longer be acceptable. CNUD EFCO develops an annealing process which will meet these efficiencies. Combustible thermal insulations are foamed polymers, which are more and more replaced by a mineral equivalent. In a lot of cases, the fiber solution is not giving the necessary strength nor vapour tightness and cellular glass foam is needed. CNUD EFCO uses his tin bath and float glass lehr experience to deliver a foamingannealing furnace (lehr) for the efficient production of cellular glass. The combination of multi-pane ultra-thin window glass and cellular glass will become in a lot of cases the overall safe thermal resistance shell generating a comfortable healthy inner climate with minimal energy use. CNUD EFCO invested in a modern plant in Romania for the production and engineering of the above products together with R&D and prototyping. In that way, we contribute to a better and healthier world.
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ADVERTISER ADVERTISERFEATURE FEATURE
Automation, Optimization, Mobile Work: Exciting Solutions from A+W at Glasstec 2016
Since Glasstec 2014, the environment in which the flat glass industry works has rapidly changed. Catchphrases such as Industry 4.0 and Smart Factory indicate where increasing global competition is heading; they raise a lot of questions too: how do I deal with the new opportunities and challenges? The software company A+W has concrete answers to many of these questions – Glass Industry 4.0 / Production Automation will therefore be one of A+W’s most important trade fair themes. “We have,” says CEO Peter Dixen, “developed new and exciting solutions that optimize the processes of our customers and provide them with clear competitive advantages in day-to-day business. Our most important machine partners, with whom we are cooperating closely on the subject of Industry 4.0, are also included in the presentation of these solutions at glasstec.” A+W production worlds with real-time data exchange optimize the entire value-added chain – even beyond company boundaries. Machines and workpieces communicate via intelligent A+W interfaces – even if one machine is at the glass processor and the other is in the production area of its customer or supplier. A+W has increased the efficiency of its customers within integrated production environments, and has a great number
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of successfully completed projects behind it. “We have been doing much of what is demanded by Glass Industry 4.0 for years,” says Dixen. New and further developments in the field of Optimization have made an important contribution as well – from cutting with the money and material-saving A+W Defect Optimizer to optimized supply logistics with the A+W Logistics Optimizer. The visitors to the fair can also learn more about mobile solutions such as the web-based order entry software A+W iQuote for tablets and smartphones, which has successfully passed its pilot phase and in the meantime been successfully used by A+W customers in day-to-day business. Exciting for production managers, at the office or on the move with an iPad and other terminal devices, A+W Dashboard, the mobile control center software: A+W Dashboard works with the philosophy of Industry 4.0, with real-time machine data and results from the BDE, and as a result integrates seamlessly into the new generation of intelligent A+W control software. Come and visit A+W at glasstec in hall 14 / E 28 info@a-w.com | www.a-w.com
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