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April 2022 —Vol.45 No.4
STOELZLE DECORATION FACILITY FORMING HEYE DIGITAL SPECIALIST INTERVIEW I N T E R N A T I O N A L
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www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Deputy Editor: Jess Mills Tel: +44 (0)1737 855154 Email: jessmills@quartzltd.com Designer: Annie Baker
April 2022
Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
Vol.45 No 4
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Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director Tony Crinion tonycrinion@quartzltd.com Chief Executive Officer: Steve Diprose
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Chairman: Paul Michael
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Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2021 edition: UK £206, all other countries £217. Printed in UK by: Pensord Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.
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Decoration: Stoelzle High-speed spraying line brings immediate benefits at Czestochowa
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Decarbonisation: ZeroCO2-Glas Aiming for sustainable container production
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Forming: Sklostroj Coolings power for cavity rate 20
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Digital glassmaking: Heye All set for a digital future
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Forming: Pneumfore Grupo Modelo installs vacuum pumps at Mexican beer glass bottle facility
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Forming: Novaxion Swabbing robots reinforced with experience
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Sustainability: Sisecam Creating glass for the future
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Women in Glassmaking: Courtney Calahoo An Indigenous woman in glass
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Country Overview: Vietnam The container glass industry in Vitenam
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IYOG: Glass Futures Glass industry lunch at the House of Lords
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International News
GREG MORRIS, EDITOR
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Facing up to some huge challenges
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The last two years has seen some colossal news stories impact the glass industry. Starting with the Covid-19 pandemic, the past 24 months has been a rollercoaster journey for those involved in the sector. From the apocalyptical start of the pandemic and the closure of the hospitality sector, to glass’s status as an essential industry and the gradual recovery in demand for glass from end consumers, there has never been a dull moment. Its latest headwind lies in the challenge of rising energy costs, exacerbated by the conflict in Ukraine. Not only has this increased energy costs but added to the shortfall in raw materials for the sector. All the while, the industry has also faced up to the ongoing challenge of sustainability and innnovation in order to decarbonise. The twin pillars of decarbonisation and the energy crisis are linked: why depend on overseas energy from an unpredictable source when it is possible to channel ‘green’ energy from closer to home? Thanks to innovation and inspiration, more glass manufacturers are moving forward. A glimpse of our news pages this month reveals agreements between a number of companies intensifying their efforts to go green. While energy prices will continue to rise across the supply chain in the short term, the effort to decarbonise must remain a long-standing priority.
AGC and E.ON sign first green PPA in France
AGC and E.ON signed the first green Power Purchase Agreement (PPA) in France to improve energy efficiency and decarbonisation. The joint project will tackle waste heat recovery and production of green power at AGC‘s float glass plant in Seingbouse, France. The project will be developed, implemented, financed and operated by E.ON and supported by the French Government as part of the ‘France Relance’ plan set up by ADEME (French Environment and Energy Management Agency). Both parties have agreed to structure the project as PPA where E.ON will produce and sell electricity to AGC on a long-term basis at fixed price. This will allow AGC’s site to become largely independent
of volatile energy markets. At AGC’s Seingbouse site, heat will be recovered to generate CO2-neutral electricity by implementing an innovative Organic Rankine Cycle (ORC) plant with a capacity of 1.3 megawatts (MW). To further decarbonise, E.ON is also installing a photovoltaic power plant with a capacity of 2.7 MW on the factory’s premises. It will generate renewable electricity on a total of 27 000 m2. By combining the photovoltaic panels with the ORC power plant, E.ON will annually provide AGC with around 10 gigawatt hours (GWh) of decarbonised electricity from 2023 onwards. This electricity is fully produced and consumed on AGC’s site and covers a large
part of the electricity needs. On this basis, around 595 tons of CO2 are annually avoided. Marc Bartheld, Plant Manager AGC Seingbouse, said: “Our plant is one of AGC’s larger production lines for the building sector with a yearly production of 240,000 tons of float glass. Our goal is to reduce our greenhouse gas emissions by 30% and our energy consumption by 20% by 2030. “To achieve this, we are constantly working to improve the environmental performance of our production sites. “The project in Seingbouse here in France is a perfect example of how E.ON can help us to not only achieve our sustainability goals, but also to secure the site’s long-term competitiveness.”
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International News
NEWS IN BRIEF
Monofrax acquisition
Saint-Gobain Performance Ceramics has acquired the US refractory producer Monofrax, from the German fund Callista. Saint-Gobain said the acquisition would help accelerate its growth in the refractory industry. SaintGobain Ceramics Business Unit is led by Nicolas Miegeville. Both SEFPRO and PCR (Performance Ceramic Materials) belong to this BU.
Nippon Electric Glass (NEG) has succeeded in melting glass with combustion technology using a hydrogen-oxygen burner. The company has demonstrated the melting of glass using hydrogen fuel from a hydrogen-oxygen combustion burner, developed in collaboration with Taiyo Nippon Sanso Corporation. The newly developed hydrogen-oxygen combustion burner can change the mixing ratio of natural gas and hydrogen as appropriate. In the demonstration, it was confirmed that in either combustion method used, only hydrogen or a mixture of hydrogen and natural gas, a melting capacity equivalent
to that from natural gas combustion could be obtained by adjusting the flow rate of fuel according to the mixing ratio. This enabled oxygen combustion technology and hydrogen combustion technology to be combined, thereby resulting in zero CO2 emissions from combustion. Oxygen combustion technology removes more excess nitrogen than air combustion, thereby reducing the amount of exhaust gas/ heat. It has been introduced in almost all melting furnaces of the company. For glass melting, NEG promoted the switching of fuel from heavy oil to LPG and natural gas, which generate less CO2, and completed the
conversion to natural gas in 2010. The company has set the “promotion of carbon neutrality” as a priority measure and is working on the technological development of CO2-free fuels, such as hydrogen, to achieve carbon neutrality by 2050. Hydrogen-oxygen combustion technology is expected to contribute significantly to carbon neutrality through its combination with the power ratio of melting energy, which the company has been working on for some time. The company will continue to develop the technology toward application as a mass production process.
Nosotros releases 100% recycled glass bottles Nosotros Tequila & Mezcal will produce 100% recycled glass bottles for all products. The shift to 100% recycled glass bottles aids Nosotros’s sustainability goals by
removing millions of pounds of glass waste from landfills, emitting lower CO2 levels, and reducing production resources. Crafted in Jalisco and
Oaxaca, Mexico, Nosotros Tequila and Mezcal products are sustainable, small-batch, 100% agave, gluten-free and Kosher.
Vidrala’s CO2 reduction targets have been validated by the Science-Based Targets initiative (SBTi)*. The manufacturer aims to reduce its Scope 1 and 2 greenhouse gas emissions by 47%, and its Scope 3 emissions by 28% by 2030. The Science-Based Targets (SBTs) will aid in the prevention of rising the planet’s temperature more than 1.5°C compared to preindustrial levels.
Glaston receives €4 million order
Glaston has received an order for an advanced flat tempering line from a North American glass manufacturer. A North American glass manufacturer required additional capacity with a quality end product. The tailored line, with automation and flexibility for high capacity thin and thick glass production, met the customer’s needs.
Gerresheimer growth
Pharmaceutical and cosmetics glass manufacturer Gerresheimer has reported record revenue growth. In its latest financial note, the German headquartered group reported revenue of €1,497 million last year, an increase of 7.6%. Dietmar Siemssen, CEO, said: “The results show our strategy is paying off: We are turning Gerresheimer into the leading provider of solutions and systems for the healthcare and beauty industry.”
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Nippon Electric Glass melts glass with hydrogen
Vidrala’s CO2 success
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International News
NEWS IN BRIEF
Sisecam launches GlassTool
Sisecam has renewed its Performance Calculator under the name of Sisecam GlassTool. The Performance Calculator, in which performances such as light transmittance, solar factor, and U value of the combinations created by changing the thickness and properties of Sisecam’s flat glass products can be achieved, has been renewed under the name of Sisecam GlassTool.
Schott plots Turkish factory opening
Schott has been present in Turkey since 1988 and currently has around 700 employees at its two sites in Çerkezköy and Bolu. A new factory will be starting operations in Bolu in spring 2022, which will increase the manufacturing volume at the site by 50%.
Sibelco plots acquisition of Polish glass recycler
Sibelco has announced offered a tender offer for 100% of Polish glass recycler Krynicki Recykling’s shares Krynicki Recykling is the largest glass recycler in Poland, and Sibelco has offered PLN23 per share.
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O-I receives $3.5 million funding boost
O-I Canada will receive $3.5 million in government funding to modernise its Montréal plant. The Canada Economic Development for Quebec Regions (CED) will provide the repayable contribution as part of a nearly $40M investment from the Government of Canada for green projects. The company plans to acquire digital production equipment to increase the amount of recycled glass introduced into the production line at its Montréal plant. The expansion project will enable up to 75,000 tonnes a year of cullet and glass to be diverted from landfill sites.
Pilkington fires float glass furnace on 100% biofuels Pilkington UK has become the world’s first flat glass manufacturer to fire its furnace on 100% biofuel, as part of an industry trial to find sustainable alternatives to natural gas. A sustainable biofuel made from organic waste materials powered the St Helens furnace entirely for four days, creating 165,000ft2 of the lowest carbon float glass ever made. The fuel emits circa 80% less CO2 than traditional natural gas used in the sector. The trial forms part of a £7.1 million project led by industry research and technology organisation Glass Futures, working under the Department for Business, Energy and Industrial Strategy’s Energy Innovation Programme. It aims to demonstrate that the furnace could run safely at full production on the lowcarbon fuel without impacting product quality. Neil Syder, managing director at Pilkington UK, said: “Our world-first trial with Glass Futures proves how biofuel presents a realistic
low-carbon alternative to natural gas, which will allow manufacturers to cut thousands of tonnes of CO2 from their production years ahead of alternative zerocarbon options becoming more readily available. “Last Summer, we became the first glass manufacturer in the world to fire a furnace with hydrogen, which represented a major step forward towards our future as a net-zero industry. But a significant body of work remains before hydrogen and electrification become feasible alternatives to natural gas for glassmakers, making biofuels an important transitionary fuel. “The success of this trial is also important for the many sectors that rely on glass as an integral supply chain material. We’re now far closer to glass with less embodied carbon being accessible, which will help developers to create a more sustainable built environment.” Aston Fuller, General Manager at Glass Futures, said: “It is great to see a technology demonstrated on a container
furnace one year ago be adopted onto a float line just one year later. “Biofuel represents a real short-term opportunity for the UK glass sector to lead the way in sustainability among energy intensive industries, and this trial is another great example of what can be achieved when industry, academia and public partners work together to tackle the major challenges and opportunities of the future.” In a glass furnace, burning gas is pumped into a 20-metrelong chamber to heat it to 1,600 degrees celsius, causing raw materials including sand and recycled glass to melt to the consistency of treacle. This is then floated on top of a bath of molten tin, making the glass perfectly flat before being cooled. Pilkington UK fired hydrogen on its glass furnace in August 2021 in a worldfirst trial as part of the HyNet Industrial Fuel Switching project to decarbonise industrial processes across the North West of England.
Ciner submits plans for UK plant Ciner Glass has submitted its planning proposal for a glass plant in Wales, UK. Ciner Glass has lodged plans with the local council to build a glass bottle factory at the Rassau Industrial Estate on the outskirts of Ebbw Vale, Wales for its UK market. Ciner is one of the largest producers of natural soda ash, a key material in the production of glass bottles.
The site’s location will help reduce the company’s carbon footprint in association with its transportation. Arup, the agent for the project, said: “The proposed development seeks to construct the glass manufacturing facility within Rassau Industrial Estate, utilising two vacant employment land allocations and an undeveloped land parcel within the site, making
effective use of the A465 strategic road network to facilitate distribution.” There could be as many as 670 jobs associated with the running of the facility and at the peak of the construction period 450 jobs. Arup also said the factory would provide apprenticeship and training opportunities for the local labour market.
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NEWS IN BRIEF
Wiegand-Glas starts furnace heat up
Wiegand-Glas has started the second amber glass furnace at its Schleusingen plant in Thuringia, Germany. Wiegand-Glas said it was “happy and proud” of its colleagues who made the successful start of production possible. The furnace start-up was postponed in January due to Covid sickness among staff as well as the risings costs of energy and raw materials.
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Ambev invests in Brazilian glass bottle production plant Allied Glass to source hydroelectricity from Drax Pilkington fires float glass furnace on 100% biofuels NEG successfully melts glass with hydrogen Decarbonisation & Public Funding: What’s in it for the Glass Industry? Vidrala CO2 reduction targets validated by SBTi Ciner submits plans for UK glass plant Crisa Libbey to host tour of Monterrey Plant for Glassman attendees Wiegand-Glas starts furnace heat up Forglass prepares for GLA 2022
Knauf Insulation opens recycling facility
Knauf Insulation has opened a €15 million Glass Mineral Wool recycling facility in Visé, Belgium. It said the facility will pave the way for an exciting new recycling service for the construction and deconstruction industry.
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Allied Glass in hydroelectricity plan
Drax Energy Solutions has signed an agreement with Allied Glass to provide 66 gigawatt hours (GWh) of electricity annually from a river hydroelectric scheme in Scotland. With a bespoke Corporate Power Purchase Agreement (CPPA), 100% of the electricity used by Allied Glass is certified with Renewable Energy Guarantees of Origin (REGOs) from the Drax Group Galloway Hydro Scheme. This allows Allied Glass to match its energy use with the renewable electricity generated to support its carbon reduction goals. Alan Henderson, CEO at Allied Glass, said “We chose to source our renewable power from Drax’s Galloway Hydro Scheme, as knowing exactly where our electricity comes from helps us continue towards our 2025 sustainability targets. “We work closely with our suppliers to ensure that the materials and resources we use are sustainable. Renewable electricity is very much part of that process.”
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BDF tallest ISmachine installation BDF has installed one of its tallest IS glass manufacturing machines in the world at a production facility in Western Europe. The 12-section machine has been raised 3” because the customer needed to produce tall products. The delivery constant angle increases the height of the machine in relation to the delivery and ease of alignment. The machine is already in operation and the installation was completely managed by its mechanical and electrical team.
Glass Futures invites IS machine collaboration Glass Futures has invited IS machine suppliers to partner with it in the development of technologies for the glass sector. The UK research and
development, and training hub said it was a great opportunity to support the industry, showcase machinery and demonstrate the latest glass container forming
technology at its pilot facility in St Helens, UK. If you are interested and would like to find out more information please contact: peterjfirth@gmail.com
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FIC and SSRC enter refractory agreement
F.I.C. has entered into an agreement with SSRC to supply the refractories for a small all-electric furnace to melt a very special glass composition. SSRC (Special Shapes Refractory Co.) is based in Bessemer, Alabama, USA and provides special solutions to the entire glass market. F.I.C. (UK) Ltd and its German based subsidiary F.I.C. Germany supply the global market with boosting systems up to 12MW for Superboost-Systems and also for both small and special AEM (All-Electric-Melter) and Hybrid-Melters. Hybrid-Melters are the final step in the decarbonisation process as the furnace should first be converted to an Oxy-fired-System with a large percentage of boosting initially. Therefore, a part of the SSRC´s scope of supply includes a ceramic bonded AZS for the superstructure which is important for this application. Burner equipment will be supplied by FlammaTec Germany, which is also a division of Glass Service Czech Republic.
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Bastürk Cam orders Horn furnace
Horn is to build 560t/day end fired furnace for Turkish glass container manufacturer Bastürk Cam. The furnace will have a melting surface of 185.4 m² in the Malatya, Turkey facility and designed for six forehearths for the production of container glass. The contract also includes two new Horn batch chargers HVR 600F batch chargers. The two batch chargers were recently subjected to a test with regard to conveyor capacity. Each batch charger must have a conveyor capacity of 700 tonnes per day, so that each machine itself can handle the entire capacity of the furnace.
Stoelzle celebrates a year of US glass manufacturing Stoelzle Glass Group has celebrated a year of container glass production in the USA. It said since its acquisition of the Monaca plant in March 2021, continuous investment in Stoelzle USA has proven an impactful first year breaking into the North American market. It serves diverse clientele ranging from North American Spirit partners such as Bulleit Bourbon to local distillers such as Middle West Spirits. In the past year, Stoelzle has modernised the Monaca facility and said it will continue to enhance the plant production lines. Nate Smith will become President of Stoelzle Glass USA. August Grupp will continue as a director of the board
and will take over the role of chairman of the board from Georg Feith, the company’s CEO. Smith brings more than two decades of experience to the appointed role of President, with previous positions in operations, manufacturing and most recently as Vice President of Operations. In addition to Stoelzle, Smith has held roles with Anchor Hocking, Corning and Osram Sylvania. In recognition of the refurbishments and plant success, CEO Georg Feith and President August Grupp, along with other local Stoelzle leaders commemorated the anniversary with a ribbon-cutting event last week, joined by the
Beaver County Chamber of Commerce and local officials. Since acquiring the Monaca, Pennsylvania plant, Stoelzle has found success with important customers such as Bulleit Burbon, while also focusing on the local market, with distilleries such as Middle West Spirits, taking the company to new heights in the local and prestige spirts niche markets. Stoelzle has also modernised and refurbished plant facilities, while simultaneously improving employee safety measures and morale. Within the upcoming year, Stoelzle will completely relaunch a new production line, in order to advance bottle manufacturing.
Verallia reports revenue growth Global glass bottle packager Verallia has reported a revenue growth of 24% for the first quarter of 2022. In the first quarter of the year, Verallia recorded revenue of €750 million, compared to €605 million in the first quarter of 2021. This represents a 24.0% increase in reported revenue and 23.9% organic growth. Adjusted EBITDA also in-
creased and stood at €183 million. However, the adjusted EBITDA margin decreased slightly (-72 bps) due to an increase in sales prices. This amounted to 24.4% over the quarter. Verallia continued to reduce its net debt during the quarter. Net debt stood at €1,222 million at the end of March 2022. This corresponds to a net debt ratio of 1.7x, down from 2.1x
in March 2021. Sales prices have also been increased to mitigate the impact of the cost inflation. In Latin America, sales volumes in Brazil and Chile posted strong growth, while in Argentina production was limited due to a furnace repair. Moreover, a dynamic approach to managing sales prices has continued in order to offset local inflation.
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Decoration
� Stoelzle Czestochowa plant
High-speed spraying line brings immediate benefits at Czestochowa
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A recent investment in a high-speed spraying line at Stoelzle’s Czestochowa, Poland glass decoration site has reaped immediate benefits as the company responds to an increase in demand for glass. Andreas Herzog* describes the spraying line while, inset, Maciej Lubas**, describes some of the proudest creations crafted at the site.
W
e started decoration operation at our production site in Czestochowa, Poland in 2007, with three second-hand machines and 35 people. Since then we have grown constantly in terms of machinery and staff. Step by step, we introduced new decoration processes and machinery. In the past 15 years our group has invested more than €35 million into the
growth of our decoration department. We are now working on 16 modern and automatic lines, including all common decoration processes. More than 250 million bottles are decorated per year in Czestochowa. Some of the techniques offered by Stoelzle are screen printing, spraying, frosting, decals, Quali Glass Coat 2.0, digital printing, hot foil stamping, and accessory application.
At Stoelzle Czestochowa we decorate all kind of glass containers. We serve the Prestige Spirits market as well as the Perfumery & Cosmetics sector and pharmaceutical products. Tableware articles such as the 1lt mug for the Octoberfest in Munich complete the portfolio. Practically we are brightening up our high quality glass from 5 ml miniatures up to 1.75 litre bottles on automatic machines.
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A proud heritage Maciej Lubas (right): Product and Sales Deco Development Manager at Stoelzle Czestochowa has more than 12 years expertise in the decoration department. He describes some of hs favourite bottles he has helped create in that time.
� Andreas Herzog
a) Ciroc bottles – a range of bottle sizes and different flavours, all with a special decoration, in various decoration steps (pictured below). We can proudly say that the Ciroc range was one of our initial projects in decoration, so the basis of further growth. STC started with a standard decoration (spraying, badging) for four-five flavours in 2011. Every flavour has been characterised by a certain basis colour (green = apple). Year after year, more standard decorations were successfully developed, reaching a total of 10-11 flavours so far. We also developed the demanding decoration for at least seven special editions, such as the Ciroc Blue Steel featured in the movie Zoolander, which were even more demanding. b) 30ml Make-up bottle Double Ware by Estee Lauder: this bottle was decorated in three steps, which are frosting, screen printing on the front and back, and gold hot foil stamping.
This was one of the first items we decorated via hot foil stamping. We invested in a hot foil stamping machine and started to learn this completely new decoration process fast. It took us just a couple of weeks to overcome all technical difficulties and decorate this demanding bottle technically perfectly. Nowadays, we still decorate this item at a very high level of efficiency and quality, reaching an output of 10-12 million pieces per year. c) 50-100ml Paco Rabanne Pure XS bottle: this item combines two decoration processes, gradient spray and gold hot foil stamping on the sharp edge of the facetted body. It took us almost six months to develop the automated decoration process for this demanding bottle. Other suppliers failed to successfully reach the target within a two year development time.
Our new high-speed spraying line (figures 1, 2 and 3) offers outstanding performance, efficiency and automation to our customers. It is equipped with an automatic loading and unloading system and also takes advantage of fast curing by infrared lamps, which further enhances the production capacity. As the demand for decorated glass containers has grown over the past few
years, Stoelzle will now be able to offer increased capacities and shorter leadtimes. It can do all kind of spraying effects such as multicolour and vignette even faster. For the opening of the new line we have invited our owner and our board to see the new machine running as we believe an investment of this size is always a big sign of trust from our owner. In my opinion, decoration is incredibly
important to a glass container. A bottle is a bottle, but a decorated bottle is outstanding! With decoration you can tell a story and perfectly convey the emotions and ideas promised by the precious content. Decoration adds value to the bottles. Choosing standard bottles and making them unique by decoration is also a Continued>>
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Fig 1
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Decoration
� Perfumery & cosmetics bottle frosted and hot foil stamped.
Fig 2
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� Figure 2 above and figure 3 below. convenient choice to reduce costs of glass packaging. The main current customer trends in glass decoration is sustainability. All processes and all operations are being evaluated for their environmental footprint. So, we constantly strive to develop more sustainable techniques and processes. For example: the powder coating technique Quali Glass Coat 2.0 saves 77% of CO2 emissions compared to standard lacquering (liquid paints). The latest innovation is the recycled ink, which is developed exclusively for Stoelzle, from rubber waste. The carbon black used in colour pigmentations derives from end-of-life tyres, which now have a sustainable purpose. Based on its CSR strategy Stoelzle has committed themselves to use only eco-friendly, water-based inks and to withdraw from solvent-based colours, in all of its three decoration sites. In addition to this we are developing with our partners the use of new ink generations, such as low curing inks, or inks made out of waste. Our new line is equipped with fast curing Infrared lamps. This results
in a much higher energy efficiency and a considerable reduction of gas consumption. In the whole Stoelzle Group we have recently implemented a process and energy data management system where the decoration sites and their production lines are also included. More than 5000 check points have been implemented throughout the Stoelzle Glass Group to collect and evaluate energy data to further improve all processes.
In terms of digital technology, Industry 4.0 is standard and absolutely necessary in all manufacturing processes such as decoration. We measure and analyse performances, downtimes and several other important production parameters automatically. Two years ago we started a group-wide digitalisation initiative based upon an internally developed software. The goal is to improve the manufacturing process by tracing and recording data. All manufacturing machines and quality inspection machines are connected to the same network and forward information to a centralised database. The main target is to boost reaction time and gain flexibility by maximising knowledge about processes. For this new line we worked with our supplier for the first time. To do so, a mutual partnership and trust must be created from the beginning. Every line is a tailor-made machine, a symbiosis between the supplier’s technology and the customer’s expectations and requirements. �
*Head of Group Decoration , **Product and Sales Deco Development Manager Stoelzle Czestochowa, Poland www.stoelzle.com
Fig 3
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Decarbonisation
Aiming for sustainable container production
The ZeroCO2-Glas project aims to develop a hydrogen-fired glass melting tank for CO2-neutral container production. Christian Roos* discusses the work so far and its plans for the future.
A
emissions and substantial energy savings. Saving energy and CO2 emissions is one of, if not the, major challenge for future generations. The consortium aims to continue the glass industry’s long history in striving for emission reduction and energy savings. To achieve these goals, several
companies decided to form the ZeroCO2Glas project. These are: RWTH University, furnace technology group Horn Glass Industries, and the International Partners in Glass Research (IPGR). The IPGR consists of 10 glass-related companies: Continued>>
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specialist group of glass-focused organisations has forged a partnership in a bid to help make the glass manufacturing process more sustainable using renewable energy. The bold aims of the ZeroCO2-Glas group are to manufacture glass for container production with net zero
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Decarbonisation
Emhart, Sisecam, Orora, Nihon Yamamura, Fevisa, Gallo, Vetropack, Wiegand-Glas, Stoelzle and Vidrala. The goal of the project is to use an allencompassing approach to develop a revolutionary glass melting process. This includes a new type of glass melting tank, which can melt glass for container production with net zero CO2 emissions and energy savings. The project is funded by the German Ministry for Economy and Climate, BMWK, with a maximum of €8.4 million with a total project volume of approximately €15 million. The funding is in aid of increasing energy efficiency, expanding renewable energies and reducing greenhouse gases significantly.
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ZeroCO2-Glas
Pre-work on the project actually started over four years ago, when various melting concepts and hydrogen combustion was evaluated. Mr Roos said the consortium explored heat recovery technology such as a thermo-chemical regenerator (TCR) on the basis of methane or methanol. But the partners chose hydrogen for the following reasons: both TCR approaches had been examined with more expertise by other institutions, TCR had never been a main focus for them and hydrogen enables a true CO2-free process if generated with renewable resources. The consortium also explored different furnace designs and firing techniques, as well as multiple investigations on glass combustion interaction. All this helped to finalise the furnace design.
The upscaling stage of the project started January 1 this year and is planned to run for the next three years. The aim is to achieve a glass melting furnace with a lower energy consumption compared to conventional furnaces, which would be in the range of 15%, as well as CO2-free glass melting. This will be achieved through using alternative, CO2-free raw materials for batch melts that have a lower reaction enthalpy. This will result in energy savings due to avoiding unnecessary humidification of the batch and an additional increase in process efficiency. The latter is due to a special melting process that will reduce the dwell time of glass in the furnace as well as an improved furnace design. The furnace will be set up in Aachen, Germany, as a hybrid furnace with hydrogen-oxy and natural gas-oxy firing. Additional electrical heating, together with the corresponding peripherals, will represent a fully-fledged container glass site with an IS machine. The melting tank has high flexibility in using both hydrogen and electricity with a broad mixing ratio. In addition, new glass compositions are being tested within the project, which allow advantages in terms of their emissions and properties of the finished glass. All approaches have already been tested on a laboratory scale.
Partnership Mr Roos said that each of the partners in the project brought a unique skill to the project. With the departments for Glass and Glass-Ceramics as well as Industrial
Furnaces and Heat Engineering, RWTH University has strong scientific knowledge as its basis. IPGR has the perfect network and melting technology know-how. As a renowned furnace manufacturer, Horn Glass brings its high expertise in furnace technology and design. Wiegand-Glas supports forming and quality evaluation of glass as an industry-partner and an end-user of technology. Glass container manufacturer Stoelzle has also made significant investments in areas such as R&D to achieve targets in the field of energy reduction and boost ecofriendly processes and technologies. Mr Roos said the project was different to other collaborations, as the consortium is not focusing on generating renewable fuels. The project concerns the glassmelting process and “takes it as a precondition” that hydrogen supplies are available. He believed that anything else would “enlarge the project to an extent that is not manageable” for the consortium.
Conclusion Mr Roos said the consortium was “very positive” that they could produce a CO2free manufactured container by the end of the project. Despite the project being high-risk, he believes that the partners’ commitment, both financially and in their work force, to the project will ensure it succeeds. �
*General Manager of International Partners in Glass Research (IPGR), Aachen, Germany www.ipgr.com
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FIC GREEN ad 2022_Layout 1 16/12/2021 09:26 Page 1
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Forming
Coolings power for cavity rate 20 Combining production speed and energy saving in glass forming is a key success factor today. Sklostroj’s servo IS machine, type ISS, is able to cover an article portfolio from large containers in double gob up to triple gob wine and quad gob beer productions*.
� ISS in 12 section triple gob (TG).
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T
he IS machine is the core of the forming process. More than a decade ago Sklostroj in Turnov launched the ‘ISS’ full servo IS machine. Meanwhile the machine has become a reliable standard in many glass plants all over the world. The first machines of the ISS series ran for nine years without a major overhaul. When it comes to decision making criteria about large investments, flexibility is a major subject. For IS machines this means the possibility to cover a wide article range, of course at low unit costs. Starting with 6 ¼’’ double gob, the ISS is producing wine bottles in 5’’ triple gob, as well as baby food or standard beer bottles in quad gob (95mm). Of course, NNPB, PB and BB are available. In BB productions, the unique LPBB technology is often used, saving weight and improving wall thickness distribution.
Powerful cooling High speeds are based on cooling performance. On a baby food line, the ISS
proves a cavity rate of 20 cycles over a long period. The main reason is the design of the parallel MOC mechanisms, allowing a precise guiding of the mould halves combined with high performance 360° cooling. Compared to other IS machines, the design of the ISS allows a larger flow of cooling air for the neckrings, for blank and blow moulds, reports the deputy CEO for production.
Energy saving Compressed air is costly and should be avoided. By using servo-technology for most of the IS mechanisms, Sklostroj reduces dramatically compressed
air consumption. Even the plunger mechanism in NNPB productions is available as servo version. Jan Koren, COO and head of R&D, is proud to say this patented servo plunger mechanism runs stable and precisely in NNPB productions for many years. Coming back to the energy management of the servo axis: the brake energy recovery, based on the Siemens Active Line module is standard. An IS machine with many servo axes following a precise timing and consuming energy in planned sequences, is the ideal application for this concept. A 12-section full servo IS machine, including feeder and ware handling, has an electric consumption of only 30kW for all actuators. This value cannot be reached by pneumatic driven machines.
Downtime reduction to safe energy Often underestimated is the importance of downtime reduction of the IS machine.
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Forming
If the forming process is interrupted, the furnace still consumes a large amount of energy. Sklostroj sees two ways to tackle this challenge. First, preventive maintenance needs to be implemented without compromise. The Siemens-based control platform provides all necessary tools for the machine operator to avoid unexpected maintenance stops. Modern servo drives give clear feedback about deviations in the mechanisms, like a torque increase due to higher friction. Data analysis is on everyone’s lips these days and the Siemens MindSphere platform as an industrial IoT solution evolves quickly.
Lightweight production Leading brand owners are ambitious to decarbonise their own production. Sklostroj sees lightweight production for the mass markets as a crucial lever. For NNPB productions, the process control with closed-loop options for gob weight and press duration control the tool of choice. To reduce weight in BB processes, Sklostroj sees two solutions. First, the Sklostroj gob watch closed-loop allows a precise determination of the gob weight including an automatic control of the feeder settings. The gob watch works with single weight or multi weight feeders. Second, the patented LPBB solution (Light Production BB) for the blank side is a robust vacuum system to decrease on the one hand the container weight by approximately 10% through an improved glass distribution. On the other hand, the production speed can be increased by up to 3.5%, states Lenka Drahanovska, Sales Manager at Sklostroj.
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Technology is important but not the only success factor. Team spirit and motivation is at least on the same level. As a family-owned company, Sklostroj is able to pursue a long-term innovation strategy, combined with a dedicated HR strategy. Skill management and diversity plays an important role, leading to a mixture of senior design engineers with younger, digitalnative technicians. The team spirit and its diversity, combined with an open communication has led to quite positive customer feedback. Perhaps the most important factor, states Mr Koren with a smile. �
*Mark Ziegler, Global Business Development and Marketing Manager, Sklostroj, Prepere, Czech Republic https://www.sklostroj.cz/en
� Parallel mould opening
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and closing mechanism (MOC) with large air-flow for coolings.
Contact us: +44 (0)20 8332 2519
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Digital glassmaking
All set for a digital future
� Smart Plant.
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Dr. Michael Kellner* discusses digitisation, emissions and artificial intelligence in glass manufacturing. Dr. Michael Kellner was born in Jena and had already come into contact with glass as a student through an internship at Schott Glas. “Glass - that’s what it exactly should be” he says in retrospect, having studied building materials and process engineering with a focus on glass in Weimar. As early as 1986, he was involved with the first image processing cameras and their use for inspecting glass. “The theory was there, but the technology was not yet powerful enough
for the glass industry,” he says. During his doctorate on automation and image processing technology in glass production, Dr Kellner began working at Schott Glas. After the doctorate, he started as a trainee at the former company HeyeGlas, an innovative, medium-sized enterprise. Initially, he was the link between production and development for introducing automation solutions in glass production. In 1992, he was responsible for testing the first image processing applications based on image processors
at Heye, and shortly afterwards he began to develop PC-based image processing solutions. “Experts at the time thought that image processing could never work with a PC,” says Kellner. “What a mistake”. The ‘process engineer’ with a doctorate left the company in 2000, but returned to Heye in 2006 as head of development. Since 2019, he has been responsible for the development of digital systems, a field in which Heye has been involved since the 1990s. It introduced a PCparameterisable, electronic timing system
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Digital glassmaking
for controlling the IS-machines and the hot end reject system, including the evaluation of pushing glass containers from the dead plate on to the machine conveyor by means of pushers. The complete hot end process was converted to servo technology, i.e. from gob forming to ware handling. “This was a huge step into the future, as the motion sequences were now matched and followed by the feedback generators according to the given motion curves,” he states. Shortly afterwards, the first servo motors were also used in the IS-machine to make critical process sequences reproducible and to avoid container defects. An important component in light glass production is certainly the introduction of the Heye Process Control, which digitally
records and visualises the pressing process by recording the plunger positions.
Hot end gob camera In 1998, Heye worked on a hot end gob camera for recording the cut of gobs. But the resolution of the cameras and the performance of the PCs was not sufficient enough. The experiences gained were important to build up the skills for the following years. When the first grabber cards were available, the new Terra computers were bought and a camera-based mould number reader and a camera-based sealing surface tester developed. The company has converted complete machine platforms because the market has tended to triple and quadruple gob operation. “Consequently, we made all the
hot end equipment ‘fit for the future’. Today we offer the complete technology platform for all applications. The further development of sensors and actuators has created new opportunities. Since the introduction of industry 4.0, we are raising the bar higher.” For example, the new IS-machine, the Heye SpeedLine is the first machine that is fully bus capable. The next development goal was to create areas in the IS-machine where sensors, actuators, the necessary cables and the processor technology could be installed safely and reliably. Safe and reliable means, in this context, protection against heat, oils, oil vapours, water, water vapour, dirt and glass. “We have succeeded with the Continued>>
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� Dr. Michael Kellner.
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Digital glassmaking
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� Smartline2 Cold end inspection machine.
SpeedLine because we have conceived the design differently. The cable routing was first designed and tested where the sensors must be mounted and how we can technically protect them to ensure longterm stability. “Operating sensors without failure in a 1000°C hot environment is not so easy. Thanks to the bus system, all systems in the machine are networked together and a large number of sensors can be managed. “This naturally brings with it new possibilities and products, for example the intelligent lubrication interval control - the Heye Multi-Circuit Central Lubrication - which saves oil and increases the lifetime of the components. Also the inline measurement of pressures and temperatures of the equipment should only be mentioned here. “With this machine, we have taken a giant step into digitisation. There is now a ‘Communication Tower’ that combines all network components, computers and servers in one cabinet. “The components are interconnected and communicate with each other. SpeedLine is a platform technology in which components such as robots or measuring and control systems can be easily integrated.” Via the Communication Tower there is also a gateway to the outside, i.e. to the customer. The Application Programmable Interface Heye SmartLink provides the customer with the data of the manufacturing process for individual data analysis.
“Most of the software is developed by us, especially in the key technical areas. “The hollow glass industry is a relatively small and special market segment. It is difficult to explain the processes to external companies. There are a few components that we buy, such as sensors. However, the suppliers then work for the glass industry in the long term and are therefore aware of the requirements.”
Decarbonisation The most topical issue at the moment is the CO2 footprint or decarbonisation. If you took energy consumption and leave the compensation models aside, then it is essentially about the sensible use of energy and the avoidance of energy waste. “For us as a machine manufacturer, two different directions are relevant when it comes to emissions. “On the one hand, it is a matter of minimising losses, which means producing as much as 100% of the glass bottles possibly without defects. Then you don’t have to throw away glass bottles, don’t waste the energy needed to make them and have a better CO2 footprint. “On the other hand, the focus is on equipment availability. It is best to operate the machine 24/7 and produce glass bottles without any defects. This also includes minimised job change times. “To avoid emissions, it is important that errors are found and eliminated as soon as possible. This is why it is important to reduce the gap between cold end information gathering and hot end information processing. To
increase efficiency, we use the PlantPilot information system, which records the efficiency situation and messages deviations to those points where corrections need to be made.” This results in an improvement in equipment availability and an increase in yield by reducing transport and quality losses. Efficiency increase and CO2 reduction are therefore closely related. Then, ideally, the measurements would have to take place at the Hot End. “This is not easy, however, because many of these measurements are contacting measurements. And when I contact a hot bottle with a measuring tool, it deforms and becomes unusable. “We still do not have a solution to how it might work to turn a hot bottle and, for example, to measure the wall thickness. That is not realistic at the moment. Today, we want to measure the parameters of the forming process directly and keep them constant within narrow limits. “We use infrared cameras at the hot end to identify deviations in the process more quickly and, above all, not to exceed or fall below the limits and to take countermeasures immediately.” This technology is called Hot End Closed Loop. Ideally, non-contact sensors control and regulate the process.
Control loops Different sensors are also used at different locations for the different process sections. They are then used to influence Continued>>
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WE ARE GLASS PEOPLE
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Digital glassmaking
parameters of the gob, the parison or the bottle. If you start with the gob forming, you use a gob camera to adjust and control the gob shape and gob weight. Also, the gob temperatures can be measured to influence the spout temperature in the feeder. On the blank side, the gob delivery into the blank mould can be detected and adjusted. The tool temperatures on the blank side (blank mould, neck ring and plunger) can also be measured and controlled. Infrared cameras on the machine conveyor are already frequently used today to measure wall thickness distribution and detect global errors. Optical cameras are planned on the machine conveyor for measuring and controlling the container geometry and for detecting glass defects. The manufacturing process is completed when the glass container passes the annealing lehr. The cold end does not deal with controlling the process. However, what should be mentioned, is to check automatically whether the inspection machines are set correctly by using sample containers. However, downstream processes, such as printing or surface treatments for increasing the strength, can also be measured and controlled.
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Weight and shape In the 1990s, a price war broke out for disposable packaging. To save on raw material, energy and transport costs and also to reduce the charges to the dual system for disposable bulk items, projects were launched to reduce the weight of glass containers – that means, to produce with thinner wall thickness. Heye has an advantage with its experience from H1-2 technology and was able to transfer this to IS-machine technology. A relic of these times is the famous Paderborner beer bottle. It was shown that the shape has an immense influence on the weight of the container while maintaining its strength. Today, a compromise is sought between an individual bottle shape, volume and weight with sufficient strength. “If we want to become more ecological, then we will have to compromise on the individual bottle shape in favour of the container weight,” he states. Many machine components and HI products, which were already developed for light glass technology at the time, are now standard in industry. Starting with the Process Control, through axial
cooling and hot end transport – all of them components that can be used with know-how for the production of lightweight containers.
Lightweight glass challenges The characteristic of simple light glass is that it breaks quickly. You can fix this problem with thermal or chemical postprocessing, but it will increase unit costs. No one would probably pay a deposit of several Euros for a gorilla milk glass bottle. For the future, a technology must be developed that is based on the current hollow glass production and is efficient. “Anyone who manages to increase and maintain the glass surface strength in the production of lightweight glass will be at the forefront in the future. “I see the big emission savings in the glass industry globally in the recycling of cullet from the market (waste glass collection and processing), because for a glass bottle production from cullet, much less energy is needed than for a production from raw materials. “Energy savings through heat recovery from the forming processes and in the annealing lehr have further potential. The ecological approach follows the economic approach: If you save energy, you also save money. This is a strong incentive. The biggest cost factor in glass production is energy.”
Remote maintenance For remote access via the Internet, it is essential to consider security. Cyber criminals are lurking everywhere, and so companies are increasingly sealing themselves off. This means service providers cannot get into the company
networks to connect to the machine and provide support from there without considerable effort. Solutions must be found in consultation with the IT departments of the customers.
Artificial intelligence “AI is currently high on the agenda. I am now in the third wave: The first was in the 1980s, the second in the 1990s and the third is rolling now. You can certainly do a lot with artificial intelligence. “But, you have to keep the boundaries in mind: Artificial intelligence is determined on the basis of learned information from the past. “To learn a corresponding neural network, a large number of good and bad example objects are needed – we talk about 500 to 5,000 information. Gaining and learning these examples is a huge effort. And when new objects appear, the neural network cannot begin with them.” There are AI applications, the decision is already working very well. In the glass industry, on the other hand, this only works for simple applications, such as reading mould numbers in the sevensegment code. Glass defects, on the other hand, become more difficult because they always look different. If new information is added that the trained system does not know, AI will not get any further. There are basically no two exactly the same checks. “Perhaps a combination of imaging processes and neural networks can help, but that is still a dream for the future.” �
*Development Engineer, Heye International, Obernkirchen, Germany www.heye-international.com
Heye SpeedLine IS machine
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tc273_TECO_A4_Advert_2020_Style_v11.qxp_Layout 1 14/05/2020 15:30 Page 5
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Forming
Grupo Modelo installs vacuum pumps at Mexican beer glass bottle facility As part of its new furnace installation, Mexican beer brewer and glass manufacturer Grupo Modelo has installed a third Pneumofore UV100 Rotary Vane vacuum pump in its Tierra Blanca glass production plant.
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T
o keep up with customer demand, Grupo Modelo took decisions to improve production outcomes through the use of reliable and efficient equipment. Following the latest moulding trends with IS machines to achieve higher precision, minimal waste and high-speed productivity, Modelo Group invested in vacuum technology. As the added value of vacuum in the hollow glass moulding process is sometimes difficult to define, Pneumofore made a ‘vacuum-only’ test on the IS machine in another Mexican plant to evaluate the effective contribution of the vacuum capacity to the glass moulding process. The test was performed with a Pneumofore UV16 VS30 vacuum pump which was enough to supply vacuum to one IS machine with 10 double sections. The demonstration was successfully conducted by the company’s glass moulding engineers. Then the vacuum was combined with low pressure to get even better results in terms of reduced rejection rate at the cold-end quality inspection and quantity of bottles per minute on each IS line. In 2020, the company installed a Pneumofore UV100 vacuum pump equipped with Variable Speed drive in the Tierra Blanca plant. The air-cooled machine, with nominal installed power of 220 kW and up to 6.610 m3/h in capacity, was installed along with the existing vacuum systems. The vacuum setpoint is 280 mbar(a) connected to the IS machine at furnace no. 2. One additional furnace is being prepared and gradually all the IS lines will be connected to the new vacuum system that has now being upgraded with three Pneumofore UV100’S in total.
During the commissioning of the two additional vacuum pumps, Pneumofore engineers checked the entire system, which was properly installed according to the recommendations for the long-term efficiency. The three vacuum pumps, based on the Rotary Vane technology of Pneumofore, are capable of supplying up to 20.000 m3/h as total capacity in the vacuum level range of 50 to 450 mbar(a). The Variable Speed drives guarantee the constant vacuum level by adapting the machine’s rotation speed to the production requirements and ensure high power savings. This practice increases the glasswork
productivity, by using all the highperformance potential available on the IS moulding lines of the latest generation. Grupo Modelo has 11 breweries plus 10 vertical plants where it produces bottles, caps, and other operations. It makes glass bottles in three of them. With nearly 100 years of experience in producing hollow glass containers for the manufacturing, distribution and sale of beer in Mexico, Grupo Modelo boasts 17 famous beer brands, including the popular Corona Extra beer in transparent glass. �
Pneumofore, Rivoli, Italy www.pneumofore.com
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EXTERNAL DIMENSION
INSIDE DIAMETER AND PROFILE
WEIGHT
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Forming
Swabbing robots reinforced with experience
� Novaxion swabbing robot.
Over the past 15 years, Novaxion France has successfully installed 100 swabbing robots around the world. Frédéric Nio* explains the company’s recent changes made in partnership with the Rondot group.
Swabbing smartly Novaxion specialises in robotics technologies for the glass industry, offering solutions for the automatic swabbing of blank moulds and neck rings on IS machines. Innovative developments, an individual approach to each customer, along with professional engineering and management, are among the qualities that have positioned the company as a specialist in the industry over the last 15 years. In 2005, Novaxion decided to integrate a reliable industrial model of robot from Fanuc, a global manufacturer of factory automation, thereby adding an important example of automation to the production of glass containers. Initially, the company offered gathering robots for the handcraft and semiautomatic production of glassware but in 2008, a high-performance swabbing robot was introduced to apply a specially engineered swabbing spray to the moulds. The decision was taken to ‘smartly’ spray the lubricant on to the cavity of the mould, an approach recognised as
the ultimate solution to offer both neck ring and mould swabbing. All other existing carbon sooting or swabbing tool management solutions required a manual swab to the neck ring. Novaxion’s solution provides effective and independent lubrication of the blank moulds and neck rings using a dedicated arm and nozzle. Under air pressure, the swabbing lubricant (oil) is sprayed inside the mould while it’s closed, ensuring the even distribution of a thin film of lubricant. This solution results from an extensive and focused development of the spraying tool, specific nozzle studies and spraying profiles, combined with lubricants and their behaviour. As a result, the pattern of lubrication during automatic mould swabbing can be customised specifically to each production or cavity design.
Automation and lubrication The swab motion is fully controlled and monitored by the robot control unit, in terms of position and speed. Motion synchronisation is triggered by the IS
forming control system. The swabbing robot is fully automated and all parameters can be configured for each section individually. This means that each section can have a different swabbing profile, depending on the ware produced (e.g. multi gob feature). The robot is quickly and easily set for a production type and does not use a learning sequence.
Swabbing cycles There are several swabbing modes that can be combined and selected by the operator, including normal and on-thefly. In the normal swabbing process, the blank mould and neck ring lubrication mode, when combined, will require one ‘section cycle’ and consequently, Continued>>
� Typical spraying pattern, equally
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R
ecent integration with the Rondot group has provided expanded manufacturing facilities for Novaxion. In addition, several management changes have been implemented to better serve and respond to the demand of customers. In April 2021, Mr Nio was named the company’s Managing Director. Having worked as a Senior Manager at Rondot for six years, his association with the glass industry extends over two decades. Mr Nio’s experience will facilitate the company’s integration within the group and its development of sales.
distributed on the mould walls.
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Forming
�The spaying nozzle extension uses a hollow cone spray.
one section reject. This combined mode provides both swabbing moulds and swabbing ‘on’ and ‘inside’ the neck ring. The special design of the spray nozzle produces a hollow shape cone so the oil doesn’t contaminate the plunger. With the on-the-fly swabbing process, it is important to highlight that the Novaxion robot alone can provide moulds close ‘on-the-fly’ lubrication. This method improves the process, its efficiency and the end result. The thin layer of lubricant applied to the moulds will deliver no reject and will not require a section to be stopped during swabbing. This reduces the number of defects and oil consumption, as well as extending the mould’s lifetime and allows for a better pack-to-melt ratio.
and knowledge are important, including the determination of bottle shape and dimensions, weight, calibration, cooling capacities and fine tuning of the IS machines. The swabbing robot is not intended to completely replace the operator; it makes the working environment safer and more effective for the glass plant. A close link between the machine and human helps to achieve and maintain higher production rates.
User benefits Thanks
to
the
technical
solutions
implemented in the Novaxion robot concept, it is now possible to significantly improve plant performance, reduce lubricant consumption (>75%), provide a more efficient and high quality lubrication process, reduce rejects, product defects and losses, and contribute to a cleaner and safer working environment, while removing the operator from the contaminated area, thereby protecting their health. The smart robot also has XNcontrol software, as well as section temperature measurement and cooling management. Automation should be applied where the disruptions in the process are revealed. Swabbing is a process where variations exist by shift, by operator or by the product being used (lubricant type and quantity). A constant quality of production with high output is achievable with automatic swabbing. With extensive experience, Novaxion is ahead of this technology and can offer a comprehensive solution to an automatic swabbing project: � Using a spray for smarter and more precise application of lubricant inside the moulds and neck rings. � The special nozzle provides smart swabbing to the neck rings, without Continued>>
Health and safety A multi-level safety system covers the operation of the robot along the IS machine, thus considerably reducing the risk of injury to operators. Virtual safety barriers offer three safety zones with different safety behaviours of the robot. The robot complies with the CE Machine Directive.
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Human impact The swabbing robot uses much less lubricant than traditional methods (approx. 75% less). Less lubricant and automatic swabbing generates less fumes, thus keeping the operator away from the area of swabbing, preserving health and improving the local working environment. The swabbing robot will free the operator from repetitive and dangerous tasks, allowing more time to focus on bottle making supervision and action. This is where the operator’s added value
� Swabbing mould closed.
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Prepare for the future it’s less expensive than you think.
Monitoring
Smart Factory is approaching and, thanks to the YOUniverse, it has become far easier to prepare for. It’s also cost effective because the Tiama Hot-End Monitoring System is modular: you choose what you need and when you need it, building the YOUniverse that suits you.
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TIAMA HOT MASS For gob weight control, gob shape and temperature monitoring
TIAMA HOT MOVE Article positioning management with early warning to avoid jam
TIAMA HOT EYE For critical defects detection and recognition, dimensional measurements
TIAMA HOT FORM For infrared radiation monitoring and real time statistics
… and they can take action autonimously – now that’s Smart! So, whatever your choice, it will improve your knowledge of the process and it is backed by our service, support and training, along with constant research. For more information visit youniverse.tiama.com.
Data – the deciding factor
Forming
The new NX-VR-300 swabbing robot mounts on the valve blocks of all IS machines. Provides mould closed and neck ring automatic swabbing within the same section cycle. On the fly swabbing, no reject. � Frederic Nio, Managing Director at Novaxion
polluting the plunger equipment. � A patented solution for mould-closed swabbing. � On-the-fly mould closed swabbing with no rejects. As a proof of the equipment’s success, more than 100 swabbing robots are successfully running on four continents, with projects in Europe, Asia, Africa and the Americas. �
*Managing Director, Novaxion, Saint Rémy de Provence, France www.novaxion.fr
W NE
� Triple gob Novaxion spraying tool and nozzle extension.
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THE UNIQUE PATENTED SOLUTION FOR MOULD CLOSED SWABBING WITH 15 YEARS EXPERIENCE administration@novaxion.f r Check for your local contact on website www.novaxion.f r
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For humans, it’s obvious. For NEO too.
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Sustainability
Creating glass for the future
� Sisecam headquarters in Istanbul’s Tuzla disctrict.
Dr Ilkay Sökmen* provides an overview of Sisecam’s recent developments in areas such as medicine, agriculture, automotive and antibacterial glassware, with a focus on sustainability. colour was developed with R&D studies and transferred to production. We introduced the transparent and bubblefree recycled glassware to the market (Aware Collection) for the first time.” Dr Sökmen pointed out that glass is an ideal substrate to add many different functions to its surface without sacrificing its unique properties and explained V-Block antimicrobial coating technology: “V-Block Technology, which was developed with the aim of preventing the growth and spread of microorganisms on glassware, neutralises virus and bacteria. “Combining the purity of glass with hygiene, V-Block puts health first without sacrificing the transparency of glass and has the feature of being the world’s first antimicrobial glassware product. “The coating is a nanoscale, optically transparent thin film with a noniridescent appearance and holds the most effective form of copper in a matrix to reduce harmful microorganisms. The copper substance in the formulation is an ECHA registered active substance. It is applied to the hot glass surface with chemical vapour deposition technology and the surface has a nanoscale roughness that prevents microorganisms from adhering to the surface. It also does not
� Dr Sökmen at the IYOG Opening Ceremony at the Palace of Nations in Geneva.
require any light activation and is a nonleaching antimicrobial coating.” She outlined that glass is a key element used primarily as a facade material for architecture, and has become an important insulation material in buildings, not only in terms of transparency and aesthetic appearance, but also in terms of energy savings. She emphasised that by using the modern technologies, Sisecam can offer various coated glass products with different and high optical performances, which provide effective energy savings with heat and solar control features. “Glass has an important place in all transportation vehicles with applications such as heat and solar-controlled windshields with defrosting feature, heatable rear windows, and roof windows that can change colour with electric current and so on. Continued>>
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he International Year of Glass 2022, declared by the United Nations, was launched on February 9th with the opening event held at the United Nations building in Geneva. Sisecam was among the main sponsors of the three-day long opening event. During the conference Dr Sökmen gave a speech in which she stated that Sisecam considers sustainability as the focal point of its activities. The company attaches great importance to developing products, with the vision of leaving a better world to future generations in line with its Care For Next sustainability approach. Dr Sökmen also discussed products developed by Sisecam scientists. Dr Sökmen started her speech by stressing that glass is distinguished from other materials with its complete and infinite recyclability without compromising its quality and purity. She said: “Sisecam produces 100% recycled glassware from glass that has been used at least once, resulting in 38% reduction in CO2 emissions and 31% energy savings compared to the production using 25% cullet. A change in consumer perception was achieved in both the glass colour and appearance of this product. The Bosphorus Turquoise
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Sustainability
* latest swabbing-robot installed in July 2017 in Germany
*
Ilkay sokmen.indd 2
“Unlike these, I would like to give you an example of a different use of glass in automotive applications, which is taking over one of the markets where plastic is used. “Sisecam has commercialised the Exterior Glass B Pillar Cover products, which are preferred as a replacement for the plastic part between the front and rear side windows of the vehicles, and thus obtains a more aesthetic product that does not fade or scratch.” Dr Sökmen drew attention to the use of glass in two important fields such as agriculture and medicine. She explained Sisecam’s R&D projects in the related areas as follows: “In the field of agriculture, Sisecam released patented technology on controlled glass fertiliser with its eco-friendly behaviour, rich nutrient content through a wide range of compositions, controllable dissolution rate and suitability for high scale production. In addition, in the field of medicine, we have started R&D works on innovative approaches for the healing effect of glass which is used especially for the in-situ irradiation of tumours in the body.” In her speech, she stated that glass is an indispensable component of tableware and that the most important approaches in this field are about lightweight designs and strengthening. In this context, she mentioned that by developing a special glass composition and strengthening this glass with an ion shielding technology, Sisecam produces strong and dishwasher safe thin glass products which have complex shapes. She continued her speech on the efforts at Sisecam to reduce product weight: “Sisecam attaches great importance to this issue and allocates substantial resources to realise the reduction in energy and raw materials consumption as well as the carbon footprint that the lightweight products promise. “While making lightweight glass packaging, we start with analysis-aided design studies by using advanced tools. We see glass not only as a material suitable for R&D, but also as one the focal point of art with creative, original and usable new designs that emerge with our forming and design abilities.” She stated Sisecam’s Design Studio prepares 500 creative designs for various brands each year using modelling techniques and transforms these designs into glass art with automatic and handmade productions. Sisecam has also implemented the 7Cbasalia bio-cycle technology to create a green and circular economy, which creates the opportunity to transform waste into useful outputs at the end of a sequential chain of reactions. Sisecam has taken a strong step in the field of environmental microbiology with this technology. Hydrogen gas was obtained during the disposal of inorganic wastes, which is the first of its kind, there is no other solution that can produce hydrogen gas from wastes. This new biotechnology collaboration will support Sisecam to reach 2050 carbon neutral future, she added. With the message ‘Glass is Future’, she concluded her presentation by emphasising that since glass is one of the materials that changed the history of humanity from past to present, it will continue to be among the products of the future and produce sustainable solutions for many industries. �
*Glass Technologies Director of R&D, Sisecam, Istanbul, Turkey www.sisecam.com Glass International April 2022
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Women in Glassmaking
An Indigenous woman in glass
� Dr Calahoo pouring glass in her current laboratory at Genics Inc.
W
hile in academia, Dr Calahoo was surprised to discover that glass helped her to bridge the gap between science and Indigenous communities. Outreach programmes with a focus of glassmaking allowed her to speak with Indigenous students on their experiences in a neutral, low-stress environment. She therefore believes glass science and technology could be an ‘objective way’ to interact with Indigenous communities.
There is still a lot of mistrust between Indigenous communities and wider society, not to mention the scientific community. In worst cases, anthropologists have taken sacred artefacts and not returned them, disregarding their cultural significance. Dr Calahoo believes the relationship can be healed, but it will require organisations to be patient and listen to the people within Indigenous communities on what needs to be done.
“It’s great that the Canadian government is trying to form a strategy and is acknowledging these communities. But it’s not going to be easy to overcome that sort of history.” Dr Calahoo, who is of Mohawk and Cree descent, grew up in Alberta, Canada. Like many Indigenous families, her family was forced onto a reserve; they needed permission to leave and sell Continued>>
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The study of glass not only helped Indigenous scientist Dr Courtney Calahoo* interact with Indigenous communities, she believes it could also aid in bringing these communities and wider society closer together. Jess Mills met with Dr Calahoo to discuss further.
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Women in Glassmaking
Genics � Fig 2 . A residential school in Canada – eight of Dr Calahoo’s family members are in this photo.
� Fig 3 (below left). A dissolvable glass rod is inserted into wood to prevent rot.
� Fig 4 (below right). Boron and copper distribution in – 100mm section after two months.
crops. Children were often taken away to residential schools (Fig 2), where they were forced to speak English or French, and siblings were separated.
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Getting into glass As a child, Dr Calahoo said she could often be found out in the country or in the woods playing with frogs. Much to her mother’s frustration, she also had a fascination with combining all the liquids in the house, hoping something would happen. This led to her childhood nickname of ‘messmaker’ and ignited her interest in science and chemistry. After completing her Bachelors of Science at McGill University, Dr Calahoo was unsure of where she wanted to go next. As she was interviewing for PhD positions in 2010, she met with Professor Joseph Zwanziger, a glass scientist. Prof Zwanziger discussed the many unique uses of glass, such as encasing material for solar cells, and how using different glass formers with lower melting points, specifically phosphate glasses, could contribute to a reduction in greenhouse emissions and energy usage. Coming from a province where oil and gas “are king”, Dr Calahoo said she couldn’t help but be intriguied: “I was
allured by a project that had clear green impacts and environmental sustainability. Up to that point, I definitely thought glass was just for windows and screens, so it was eye-opening to hear about this whole industry.” From there, Dr Calahoo uncovered the wonders of the industry, and hasn’t looked back since. She said she has found the scientific glass community extremely welcoming, which was highlighted for her at the recent International Year of Glass (IYOG) Opening Ceremony. “I think we’re really lucky that we have this option to be scientists in a university and to be researchers in the glass industry. We all go to the same conferences and we really talk to each other […] I have found that people are really welcoming and just want to talk about glass.” In her work, Dr Calahoo said she enjoys exploring whether glass could be a solution for long-standing issues within other industries, such as preserving construction materials. “I think people think that we’ve made glass. We’ve made float glass and windowpanes and now we’re done. But they don’t realise that even a small company like Genics is innovating and coming out with new glass products.”
The majority of Dr Calahoo’s research has focused on uncommon glass formers, such as ionic glasses, metalorganic frameworks and inorganic glass composites. She is currently working with Canadian manufacturer Genics as part of her postdoctoral fellowship at the University of Alberta. The company works with forestry and utility organisations to preserve the lifespan of wood, and is also planning to expand into agriculture and construction. At Genics, Dr Calahoo has been working on a dissolvable glass technology that preserves wooden structures such as telephone poles. Currently, the process involves drilling a hole into the wood and inserting a glass rod (Fig 3), which then takes the water from the ground, as well as fresh rainwater. Dr Calahoo described the process as follows: “[The water] slowly dissolves the glass over about two months. And when the dissolution products, like the chemicals, go into the wood, they actually stay there.” The chemicals, copper and borate, become a biocide (chemical mixture) when they are dissolved into the water (Fig 4). This mixture is antibacterial and prevents rot. Further advantages include the controlled rate in which the glass dissolves: “You don’t need to worry about one mineral suddenly becoming more soluble and overwhelming its surroundings.” Future applications of the technology could see the glass being applied to wood as a wrap, “like a Band-Aid”, to avoid the time-consuming drilling process. However, Dr Calahoo said that the dissolvable nature of the glass can be frustrating to study, which is perhaps why it hasn’t been investigated much outside of the medical field. “If you have something that you know is going from a nice hard glass to something that is gelling overnight, then you’re always concerned that your measurements are wrong because it’s taking on water.” She further commented that the soluble nature of the technology goes against the traditional attributes of glass staying “clear and beautiful”. She believes most companies wouldn’t want glass that’s going to dissolve or leak chemicals when it encounters water. Although, for the forestry industry, the technology has Continued>>
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Air Products is blazing a new trail for oxy-fuel burner technology . . . Boost your performance and productivity for better glass with the Cleanfire® HRx™ burner! Upgrading your oxy-fuel burners, adding burners to boost production, or converting your air-fuel furnace to oxy-fuel? The patent pending Cleanfire HRx burner offers you expanded functionality and flexibility with unmatched performance. It can deliver: • Increased flame radiation for high fuel efficiency • Ultra-low NOx emissions • Foam reduction capability for higher-quality glass • Enhanced productivity • Optional remote performance monitoring feature • Integrated high efficiency oxygen supply system This burner is the latest innovation in the long line of industry-leading Cleanfire® burners for the glass industry, which are now able to utilize hydrogen as a fuel, for a lower carbon footprint. To learn more or to schedule a demonstration in our state-of-the-art lab, call 800-654-4567 (code 10868) or visit airproducts.com/HRx.
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Women in Glassmaking
� Fig 5. Fishing spear (or kokiwog): John Tyman, Copyright Pitt Rivers Museum, Oxford University, 2010. saved countless hours and dollars: “Even if you extend the lifetime of the wood by 50%, it’s still millions and millions of dollars being saved.”
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Sustainability Dr Calahoo believes that Genics has ‘ended up’ as a sustainable company: “When you triple the lifetime of wood you’re helping to create a carbon sink. You are reducing the amount of trees, reducing the energy it takes to install the wood. A lot of these telephone poles are in the middle of nowhere, especially in Canada, so it’s a big amount of effort to go out there and replace them every 20 years.” However, Canada’s dependency on oil and gas can complicate matters. In Alberta, the oil and gas sectors are the main sources of power for most industries; nine percent of Canada’s GDP is from oil, which all comes from the province. Dr Calahoo said: “I do think that we’re trying to be sustainable in many fields and industries, but it’s hard with oil and gas.” She has also discovered that introducing more sustainable technologies to new industries can be challenging, as no one wants to be the first to try a product. “One of the bigger issues we have is getting anybody, like a construction industry, to take on innovation […] Let’s say they’re using a product that they know works. They don’t want to go and test the new product. They don’t want to be the ones to try it, because if it doesn’t work, then it’s their problem.” Dr Calahoo said a solution could be to create more associations between
the glass industry and scientists to fund sustainable technology. She suggested that having an impartial organisation between the two would provide a safety net for initial collaborations before a trusting business relationship is built.
Indigenous glassmaking At the IYOG Opening Ceremony, Dr Calahoo discussed the similarities between Indigenous techniques for sculpting natural glasses, like horn and antler, and the skills for traditional glassmaking from Egypt and Mesopotamia. She believed the straightening procedure used by the Inuit to shape musk ox horn, an animal native to the Arctic, was equivalent to the skills needed for lamp working and glass blowing: “There is quite a bit of overlap because the horn material is made out of keratin, which does have a glass transition in exactly the same way that an amorphous material does.” Dr Calahoo said the horn shares a similar molecular structure to other glasses that she’s worked on, although the substance is not as ‘pure’ as glass; natural glasses often contain more than one material. Despite this, she thought the procedure used to shape the horn was still similar to the techniques used in a traditional glass working shop. (Fig 5) Dr Calahoo said she would like to see anthropologists explore Indigenous glassmaking, to learn how and why they created natural glass products and how their techniques differed from more studied communities. She believed Indigenous glassmaking techniques
should be held in the same regard as old world methods. “Why can we not look at the shaping of this natural type glass like horn and antler with the same fascination, and see what differences and traditions were passed down?” Dr Calahoo also thought that studying these methods could teach modernday glassmakers the value of energy and the conservation of materials, due to the scarce resources many of these communities had. Not to mention, the importance of investing in the members of a community. “Often, the reason that women or Indigenous people are not at higher levels is because no one has taken the time to show them. No one has seen that they are valuable and that they could be good at that position because they normally are not in that position.”
Indigenous glass scientist Dr Calahoo believes that being Indigenous has made her more aware of the challenges that people face when entering an industry, particularly young and/or Indigenous women. She said it has made her more determined to try and help those joining the industry, as well as breaking the Indigenous stereotype. “In Canada, we definitely have the stereotype of a drunk Indian, let’s say. And even if you don’t realise it, you do have this sort of image in your mind. […] I would say that from school and throughout my career, it has been satisfying to surprise people.” Continued>>
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Women in Glassmaking
� Fig 6. The Indigenous population
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in the US and Canada.
In Canada, 5% of the population is Indigenous (Fig 6), but Indigenous students only make up 2.7% of federally funded scholarships and fellowships at the undergraduate level.1 In higher education, the numbers fall off drastically – 1.9% at Master’s and Doctoral Awards and 0.4% of Postdoctoral Fellowships.1 “A lot of these Indigenous students come from poor backgrounds, so the tuition of university is quite expensive. Money is a barrier, so they can’t really imagine seeing themselves at university. No one in their family has gone to school before, so they just sort of stop thinking about it.” To address the educational gap, Dr Calahoo has been a part of several outreach programmes for Indigenous communities. During her PhD, she was part of project that brought in highschool aged children to create sugar glass and conduct experiments on it, such as measuring its refractive index. Whilst the objective focus was glass, the experience allowed Dr Calahoo to discuss wider issues with the students, such as university funding available for Indigenous people. “I have considered that being a higher level in science and industry means that I could implement different initiatives or have outreaches. I can be the person that goes into Indigenous communities and
talks to younger people. I can be the person that initiates some sort of programme for affirmative action. But I never really thought about that connection with glass technology, like the glass science itself, until more recently.” Dr Calahoo believes that having an objective focus, such as glass, could help to repair the fraught relationship between science and Indigenous communities, as well as wider society. “If we could demonstrate that the knowledge and the technology [of Indigenous communities] were equal with Romans, I think that that could go a long way to changing people’s perception of Indigenous people. There are negative stereotypes. We have negative stereotypes of ourselves as well. That’s part of the reason why being able to highlight positive things, that people can be proud of, becomes extremely important.”
Hopes Dr Calahoo believes the glass industry is recognising change, although there is still much more to be done to ‘level the playing field’ for young women and/or ethnic minorities entering the industry. She advised that companies should invest in their employees to see them thrive in their roles, but acknowledged this could be time consuming and difficult. “It takes so much effort to be the
one that provides the resources to give everyone a level playing field. I hope that somehow industry and academia can begin to recognise that and somehow encourage their leaders to be able to give the resources to help people individually.” Multiple studies have shown that more diverse teams lead to greater innovation and profit. Businesses run by culturally diverse leadership teams are more likely to develop new products than those with homogenous leadership,2 and companies with more women are more likely to introduce radical new innovations into the market over a two-year period.3 Unsurprisingly, those in the top quartile for ethnic and racial diversity in management are 35% more likely to have financial returns above their industry mean, and those in the top quartile for gender diversity are 15% more likely to have returns above the industry mean.4 With an industry focused on achieving net zero carbon emissions by 2050, solutions for sustainable glass production are more crucial than ever. In Dr Calahoo own words, the industry is only going to grow: “We ourselves don’t even realise the breadth of compositions, properties and applications glass can have.” Therefore, why not encourage diversity to discover new minds and new ways of thinking for next chapter of the glass industry? Dr Calahoo’s full talk is available via UN Web TV, please see the link below. �
References 1. Figures from the Natural Sciences and Engineering Research Council of Canada (NSERC),
https://www.nserc-crsng.gc.ca/
index_eng.asp 2. Max Nathan & Neil Lee (2013) Cultural Diversity, Innovation, and Entrepreneurship: Firm-level Evidence from London, Economic Geography,
89:4,
367-394,
DOI:
10.1111/
ecge.12016 3. Cristina Díaz-García, Angela GonzálezMoreno & Francisco Jose Sáez-Martínez (2013) Gender diversity within R&D teams: Its impact on radicalness of innovation, Innovation, 15:2, 149-160, DOI: 10.5172/impp.2013.15.2.149 4. Vivian Hunt, Dennis Layton & Sara Prince (2015) Diversity matters. McKinsey & Company, 1(1), pp.15-29.
*Genics Inc. and University of Alberta, Edmonton, Canada https://genicsinc.com/ https://www.ualberta.ca/index.html UN Web TV: https://media.un.org/en/asset/ k13/k13xelnyhx
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Country overview: Vietnam
The container glass industry in Vietnam
Vietnam has registered the fastest economic growth among the ASEAN countries over the last five years. The country has been called “the next Asian miracle” by various international financial institutions with healthy economic growth forecasts, which will result in the steady growth of the country’s glass industry. billion litres, equal to nearly 93% of the previous year’s volume (4.35 billion litres). However, the consumption reduced 20% on a year-on-year basis. In the economically dynamic Southeast Asian region, Vietnam stands out as a development success story. Over the last ten years, the country has recorded an average annual growth rate of 6%, which compares favourably with other countries in Southeast Asia. With a population of over 98 million and a median age of 32.7 years, Vietnam has several dynamic trends, which augurs well for the further development of the glass industry in both the major sub-segments. Rising incomes, favourable demographics, and urbanisation are three of the key factors, which will keep the momentum of the current phase of the rapid growth of the glass industry.
Demand analysis Alcoholic beverages account for more than 53% of the total container glass consumption in Vietnam. Non-alcoholic beverages, foods, and pharmaceuticals segments account for 12%, 18%, and 12% respectively, while the rest 5% goes to the miscellaneous segments. Beer is the largest consumer of container glass bottles in the country. With a total consumption of 4,650 thousand kilolitres of beer (in 2019), Vietnam is the 9th highest consumer of beers globally. The importance of container glass in the domestic beer industry is evident from the Continued>>
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he Vietnamese container glass industry comprises of two large scale and a small scale container glass producer. Alcoholic beverages accounts for the lion’s share of total container glass consumption in the country. Nearly 20% of the total container glass demand is met through imports from the other ASEAN countries and China. Covid-19 didn’t have much impact on the container glass industry in 2020 but the industry felt the impact of the pandemic last year. After a subdued 2021, domestic container glass production and consumption are expected to clock a growth of nearly 8% in the current year. According to the World Bank country report on Vietnam: “Vietnam had a turbulent year in 2021. Despite a strong start in the first semester, the Covid-19 outbreak in April derailed recovery and led to extensive economic costs. Vietnam’s economy grew by 2.58% in 2021. Looking ahead, GDP is expected to rebound to 5.5% growth in 2022 in a scenario where the pandemic is under relative control both at home and abroad.” Nguyen Van Viet, Chairman of the Vietnam BeerAlcohol-Beverage Association said: “Vietnam’s beverage sector is looking for a kickstart after a turbulent couple of years. In 2021, we faced huge challenges related to logistics and shipping activities due to strict movement curbs in the southern provinces. Tough pandemic prevention regulations have caused many difficulties for businesses to transport their products and organise production activities. In 2021, the production volume of beer in Vietnam reached around 4.05
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Country overview: Vietnam
fact that two of the major brewers (Saigon BeerAlcohol-Beverage Corporation and the Hanoi Beer Alcohol and Beverage Joint Stock Company) have a stake in both the major container glass producers in the country. Until about a decade back, nearly 90% of the beer was packaged in the container glass, but, during the last few years, the competition in the Vietnamese beer segment has intensified. Beer packaging in aluminium cans has also increased rapidly due to the government’s policy to completely ban non-recyclable packaging materials by the end of 2025. Currently, there are six manufacturers of aluminium cans for beer in Vietnam, who are giving stiff competition to the glass industry. The Vietnamese beer industry is dominated by four brewers, namely Saigon Beer-AlcoholBeverage Corporation (Sabeco), The Hanoi Beer Alcohol and Beverage JSC (Habeco), Carlsbergowned Hue Brewery (Carlsberg owns 100% in this operation), and Heineken NV. These four companies hold 90% of the market on the basis of volume, while the remaining 10% is divided among Masan Brewery, Sapporo, AB InBev, and Carlsberg-owned Southeast Asia Brewery. The packaged food segment is the secondlargest consumer of glass containers. Penetration of modern retail in the country during the last decade has increased the share of container glass in the food segment.
Raw materials
O-I BJC Vietnam Glass O-I BJC Vietnam Glass has one furnace and four production lines; the company produces 300 million glass containers per year for beer, soft drinks, food, wine, spirits, and pharmaceutical industries. The company’s 8.4-hectare production plant is located in My Xuan A Industrial Zone in Ba Ria - Vung Tau province. It has a designed capacity to produce up to 100,000 tons of amber, flint, and, emerald green glass containers per year. The company has adopted NNPB (Narrow Neck Press & Blow) in the 4th production line, which allows thinner and more equal wall thickness of glass containers. Weight is reduced and consequently, energy and raw material consumption are minimised, which helps the company to achieve a more sustainable and environmentally-friendly manufacturing process. The company has a long and transformational journey as a container glass producer in the country. Established in 1967 as Khanh Hoi Glassware Factory owned by SABECO, the company joined Fraser and Neave to become Malaya Glass Vietnam in 1993. Joint Venture O-I BJC acquired 100% shares from F&N in 2010, renaming the company as O-I BJC Vietnam Glass. A year later, the company relocated its manufacturing to the current site in My Xuan A Industrial Zone, Ba Ria - Vung Tau. Located around 60 kilometers (37 miles) southeast of Ho Chi Minh City, the plant was built between September 2009 and November 2011. The current plant replaced OI-BJC’s existing facility
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Vietnam is endowed with a rich supply of silica sand, one of the key raw materials in the container glass industry. The country’s 2,560 km-long, mainly flat coastline is host to many large alluvial silica sand deposits. The central coast region – from Quang Binh to Khanh Hoa – which skirts the western side of the South China Sea is abundantly rich in silica sand resources. Van Hai in Quang Ninh province, Nam O near Da Nang City, and Thuy Trieu in Khanh Hoa province – are being mined to supply silica sand for Vietnamese glass industry. The largest of the country’s silica sand deposits is the 36.5 million tonnes in Thuy Trieu deposit in Khanh Hoa
province. Thuy Trieu consists of a combination of special grade and grade I sand, which have high silicon dioxide (SiO2) content, making Thuy Trieu the most valuable silica sand deposit in the country. Vietnam’s other deposits contain mostly grade I (Van Hai, Quang Ninh province) and grade II sand (Thon Bung, Bac Giang province and Nam O in Da Nang City). Soda ash, the other major component in container glass production is largely imported from China and US. Solvay, one of the largest global soda ash producers, has an office in the country.
48
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Country overview: Vietnam
in District 4 of Ho Chi Minh City which was vacated by O-I BJC to facilitate the city’s urban development plans. “In Vietnam, the packaged beer market, in particular, has always been predominantly in glass. Customers and consumers are seeking quality, taste, and purity of contents and glass are the best package to deliver that. “The Vietnamese market is a dynamic one and quality demands and specifications from our customers are increasingly stricter. This new plant puts us in a wonderful position to meet and exceed those high standards now and in the future,” the then CEO of OI had commented on the occasion of the commercial start of this plant. Parent company Owens-Illinois, Bowman, Pneumofore, Vertech, and Lubisol Engineering are some of the technology suppliers to the company.
San Miguel Yamamura Hai Phong Glass Company Located in the northern port city of Haiphong, San Miguel Yamamura Hai Phong Glass is the country’s second largest container glass producer. With a designed capacity of 380 tonnes per day of glass containers, the company caters to beverages (both alcoholic and non-alcoholic) and food segments of the industry. San Miguel Yamamura Hai Phong Glass (SMYHG) is a joint venture between Philippines’
packaging company San Miguel Yamamura Packaging Corporation (SMYPC) and Hanoi Beer Alcohol and Beverages J.S Corporation (Habeco). San Miguel Yamamura Packaging Corporation (SMYPC) - a joint venture between two famous Asian groups, San Miguel from the Philippines and Nihon Yamamura from Japan. San Miguel is known as the Philippines’ largest group specialising in producing beverage, food and container glass packaging. Nihon Yamamura is a large container glass manufacturer in Japan. Inheriting the advantages of these two groups in terms of technology and human resources, SMYGH has become one of the two leading container glass suppliers in the Vietnamese market. Japanese company Yamamura Glass and Strutz International are two technology suppliers to the San Miguel Yamamura Hai Phong manufacturing plant.
Go Vap Glass A container glass cum tableware glass producer, Go Vap Glass supplies container glass products to the cosmetics and perfumery industries, niche food companies, and pharmaceutical industries. Located at Vap District in Ho Chi Minh City, the company has a designed capacity to produce 110 tonnes per day of container glass through one furnace. �
Glassman Latin America
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Don’t miss the next profile page in May.
Nikolaus Sorg GmbH & Co. KG Stoltestrasse 23, 97816 Lohr am Main Germany www.sorg.de
These exhibitions bring together internati onal experts, hollow and container manufacturers These exhibiti ons bring These together exhibiti internati ons bring onal together experts,internati hollow and onalcontainer experts, hollow manufacturers and container manufacturers esmehorn@quartzltd.com glasstec stand no: and businesses that use glass containers, discover the latest ons which include and businesses thatto use and glass businesses containers, that innovati use to discover glass containers, the latest to innovati discover ons the which latest include innovations which include energy efficiency, quality control, packaging, logisti cs and decorati ve possibiliti es. energy efficiency, quality energy control, effi ciency, packaging, quality logisti control, cs and packaging, decorati3/A81 logisti ve possibiliti cs and es. decorative possibilities. Hall1
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The event format is a niche tradeformat exhibitiison where people canisarrange meeti ngs with a wheremeeti The event aThe niche event trade format exhibiti on a niche where trade people exhibiti can on arrange people ngscan with arrange a meetings with a number of suppliers and industry experts inand oneindustry place. Visitors exhibitors can attend number of suppliers number of suppliers expertsand and in one industry place. experts Visitors in and one exhibitors place. Visitors can attand endexhibitors can attend Contact Esme the free conference sessions toconference hear Horn. from industry the free sessions the freeexperts. to conference hear fromsessions industryto experts. hear from industry experts.
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2023 | TURKEY 2023 | TURKEY2023 | TURKEY 2023 | KOREA 2023 | KOREA 2023 | KOREA 2024 | MEXICO 2024 | MEXICO2024 | MEXICO 49 Glass International April 2022
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Glass Futures
Parliamentarians and dignitaries gather at the House of Lords to promote glass’s past and future impact A glass industry and supply chain centric lunch was held at the House of Lords on Wednesday 23rd March 2022. It was sponsored by Lord David Prior, Chairman of NHS England, with principal guests Lord Karan Bilimoria, CBI President and Lee Rowley MP, Industry Minister at The Department for Business, Energy and Industrial Strategy (BEIS).
www.glass-international.com
T
he lunch, orchestrated by Glass Futures and British Glass in support of the Worshipful Company of Glass Sellers Charity Fund, set out to celebrate the United Nation’s International Year of Glass 2022. The year seeks to promote the past significance and positive future of glass. The dinner was attended by over 80 delegates including a number of international senior representative of multi-national glass manufacturers. The Age of Glass initiative demonstrates how the glass community is supporting UN Sustainable Developmental Goals (UNSDG 2030 agenda), (1) responsible production and sustainability; (2) innovation and infrastructure; (3) affordable and clean energy; (4) climate action; (5) education and gender equality. Over lunch, a number of prestigious
speakers, introduced by Richard Katz, Glass Futures’ CEO, spoke about their passion for the future of glass: � The Lord David Prior of Brampton, Chairman of NHS England, celebrated the ambitious vision of the glass sector which brought about Glass Futures. � Lee Rowley MP spoke in support of the industry, understanding of the difficulties currently faced around energy security and pricing, and invited further engagement. � Lord Karan Bilimoria, president of the CBI and Founder of Cobra Beer, spoke about his experiences of glass and about coming together to overcome challenges. � Leigh Baildham, Chairman of the Worshipful Company of Glass Sellers’ Charity Fund, outlined the importance of the Charity’s ‘Glass in Society’ Project
reaching out to education to encourage a life-long interest in STEM subjects, particularly science with specific reference to glass. � Dave Dalton, CEO of The British Glass Manufacturers’ Confederation called for further action to keep the UKs domestic glass industry on a positive financial footing and called on continued investment in innovation Richard Katz said: “At this time of extreme energy prices, we were delighted BEIS Industry Minister, Lee Rowley MP, and CBI President, Lord Karan Bilimoria, together with a number of MPs, BEIS and UKRI officers, could join senior representatives from regional authorities and the glass industrys at the House of Lords lunch. It was a fantastic opportunity
50 0 Glass International April 2022
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� Alicia Durán, IYOG Chair.
� Richard Katz, Nick Kirk and Dave Dalton.
� Richard Katz
� Allen Norris, Matthew Demmon, Paul McLavinand and Andrew Pea. � Dave Dalton House of Lords reception celebrating glass in the 2022 International Year of Glass programme and in celebration of the achievements the industry has made on carbon reduction and process technology efficiency improvements. “Parliamentarians and dignitaries gathered to celebrate both what has been done already, but more importantly the continuing work of the sector through British Glass, Glass Futures and Glass Technology Services, driving the agenda for all foundation sector industries and for UK manufacturing excellence.” �
� Lord Karan Bilimoria
www.glass-international.com
to bring the glass industry together in the same room as key decision makers, whilst raising funds for the Glass Sellers Charity Fund in celebrating the United Nations International Year of Glass 2022. “Glass Futures aims to accelerate collaboration across the global glass supply chain to support the industry’s sustainability journey, demonstrate and deliver disruptive technologies and generate new ideas with a positive impact all the way through to the consumer.” Dave Dalton said: “It was an honour and a privilege to both attend and speak at the
� Left: Lynn Sidebottom (Beatson Clark) and Barbara Beadman (Master Glass Seller).
51 Glass International April 2022
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CLASSIFIEDS.indd 1
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