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Digital Edition December 2018
HIGHLIGHTS OF 2018
I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
ASIA 2019
WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS
REACHING THE ASIAN MARKET Glassman Asia will be the ideal opportunity to network with industry professionals from around the world whilst learning about the latest products and services on the market. The container glass industry is becoming more prevalent in Jakarta and surrounding areas in Indonesia. With
We are looking for producers, manufacturers and service providers within the following fields to exhibit their products and services: • Raw materials
• Processing machinery
• Batch Plants
• Laboratory services & analytical equipment
• Melting furnaces • Combustion equipment
companies such as O-I, AGC and Horn heavily investing in
• Refractories
sites around the country, there’s been an unprecedented
• Feeders & forehearths
boom in production over the last few years. This investment
• Hot end handling materials & systems
in technology and innovation in the region makes it an ideal meeting place for the regional industry, to gather, learn and
• Annealing & decorating lehrs • Cold end handling materials & systems
share ideas on the future of glass making.
• Decoration materials & equipment • Instrumentation/process control systems • Turnkey plant construction services & technical assistance & training • Software providers
• Tempering/laminating plants
TO FIND OUT MORE CONTACT: Ken Clark, Sales Director t: +44 (0)1737 855117 e: kenclark@quartzltd.com Manuel Martin Quereda, International Sales Executive t: +44 (0)1737 855 023 e: manuelm@quartzltd.com
CONTACT US TO BOOK YOUR STAND
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11/09/2018 13:20
Testing and research
American Glass Research opens European testing laboratory American Glass Research (AGR) officially opened its testing laboratory in Delft, The Netherlands last month. For its manager, Peter de Haan*, the building and opening of the facility was a career highlight. How pleased are you with the new research centre?
What products and services do you provide from this site? The research facility in Delft, in general, offers the same services to our European customers as our main research facility in Butler, PA. It is fully equipped with testing equipment and can conduct all types of testing and analysis of packaging glass. Specific examples include proof of design testing, coating evaluations and fracture analysis to name a few. Furthermore, the full array of our educational/training and consulting services is now also offered from our location in Delft.
Why did you choose Delft as a location? The strategy was mainly two-fold; the proximity of the Netherlands to a majority of our European customers makes it an ideal location. Specifically, the Netherlands has a very strong glass packaging industry and is also home to some significant brand owners that utilize packaging glass. Approximately 40% of the beer volume and 50% of the glass packaging volume in Europe originates from locations within a 500 km radius from the Netherlands. One of the major reasons to choose the City of Delft is its reputation as the premier research hub in The Netherlands. We have a partnership with the Technical University of Delft that grants us access to their research capabilities. This enables us to utilise a range of analysis methods and instruments to enhance the results for our customer.
Can you tell me more about the work you and your staff have put into it? Our goal was to create a workspace where we could easily move between our offices and various laboratories while promoting easy interaction among the team. The
space now occupied by the research facility was previously two separate businesses; one unit housed an art gallery and the other a children’s day care facility. Both units were required to realise our vison for the research facility; a combination of research areas, office areas and storage space. The two units were connected and the entire interior was restored to pristine condition. Substantial effort was invested into the infrastructure of the facility. The testing labs all needed to be rewired to accommodate a large number of power outlets for all our analysis equipment. Additional plumbing was required for our equipment utilising water or compressed air for operation.
How long has it taken to start this centre up? The initial operational and financial plan for our European research facility was presented to AGR’s Board of Directors in April 2017. We acquired the units in June 2017 and were operational by December 2017. In those five months we were able to fully build the research facility, send the staff for an extended training period Continued>>
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The research facility in Delft is a great addition to the capabilities of American Glass Research in total. The building that houses the research facility was chosen specifically to accommodate multiple laboratory areas, office spaces and a large storage space. There are separate labs for fracture analysis, dimensional testing and structural strength testing. All of the research areas are laid out in such a way that they fully accommodate an efficient workflow when working on multiple customer projects. The interior design of the research facility was built from the ground up by our Delft staff members. Needless to say, that everyone is pleased and proud with how it turned out.
1 Glass International Digital Edition December 2018
Testing and research
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to our main research facility in Butler, PA, and prepare to receive our first customer projects in December. However, learning and training is continuous at AGR. As a Senior Scientist, one of the most important tasks for me is to coach, facilitate and train our technical staff. Every year both technical staffs (in Butler, PA and now also in Delft) are recertified
Champagne bottles sabered to open facility The research facility was officially opened on February 8th, with a ribbon cutting by the Delft Official City Council Member, Ferrie Förster. The grand opening included two seminars and welcome speeches. There was also a unique opening of two champagne bottles by AGR’s CEO, Henry Dimmick, Jr. and AGR’s Director of Research, William (Bill) Slusser, who travelled from the United States to attend the event (pictured right). They used sabers to expertly cut off the top of the champagne bottles to open the site in front of local dignitaries, demonstrating a technique, which they would not normally endorse. However,
on all our testing and calibration procedures as part of our quality system. This guarantees that our reports always meet the highest quality standard of our customers. Presently, we are in the process of hiring a new scientist for the Delft location. This hire will free up more time for me to address the managerial side of running a research facility. However, I must admit that the blood of a researcher runs through my veins and that I will always feel the pull towards the actual research and science taking place in our laboratories. I feel blessed that my new responsibilities allow me to do both; managing the research facility and continuing to work on customer projects. Whether I am in front of our customers during our seminars or working on their projects I always enjoy the interaction.
food and even pharmaceutical fillers as these segments continue to grow.
Who do you anticipate will use this centre?
How will customers benefit from using this centre?
Our research facility in The Netherlands was specifically created to address the requirements of our European customers including Russia and the Middle East. Those customers have already started to access more of our services on a regular basis. We are also very pleased with the fact that new customers are becoming familiar with AGR now and the new research facility. The majority of our customers are the large brand owners and glass packaging manufacturers in Europe. Our plan is to attract smaller beverage,
Our new location will provide our European and adjacent region customers, with quicker response times, at reduced shipping costs. It will also allow us to deliver answers in the same time zone, currency and languages as the customers we are serving.
How long have you worked for AGR? After 18 years of combined experience in the flat glass and packaging glass industry, I joined AGR as a senior scientist in May
2 Glass International Digital Edition December 2018
in light of the festive occasion they made an exception. According to Mr Dimmick, Jr: “The new AGR testing laboratory in Delft will provide numerous benefits to our customers including shorter turnaround times which will save money. In addition, they will enjoy the added convenience of transacting business in the same language, time zone and currency.” More than 50 guests attended the opening, including Verallia, O-I, CanPack, Sisecam, Unilever, Campari and Celsian. The European glass manufacturers and brand owners were provided with a tour of the facility and assorted refreshments, along with the
2013. Joining AGR and ultimately building our European lab was the highlight of my professional career so far. One can say that our strength is essentially the combined knowledge that resides within our staff and the disciplined application of that knowledge to assist our customers. Everyone has their own area of expertise within AGR, but we are all bound by our common passion for glass. I specifically enjoy the ‘can do’ mentality of AGR which translates into being there for our customers whenever they need us. Furthermore, the direct interaction with our customers, either in front of a class or working on a project is something which I enjoy on a daily basis. �
Testing and research
opportunity to attend complimentary seminars entitled ‘The Do’s and Don’ts of Lightweighting’ and ‘Understanding and Establishing Impact Criteria’. AGR demonstrated its capabilities in regards to modern analysis and testing equipment for fracture diagnosis, performance testing and defect identification of glass packing while guests were provided with opportunities to get some hands on experience. The new testing lab is managed by AGR’s Senior Scientist, Peter de Haan, and his team, including; Office Manager Jennifer Hu-a-ng and Lab Technicians Laura van der Harg and Samantha Beijersbergen van Henegouwen (pictured first page). The Delft lab team is now fully supported by Commercial Representatives, Aleksander Broda and Ewa Prokulewicz. American Glass Research is a division of AGR International Inc. �
*Senior Scientist, AGR Europe, Delft, The Netherlands www.americanglassresearch.com
ASIA 2019 Jakarta, Indonesia
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3 Glass International Digital Edition December 2018
Company profile: Horn Glass
� It provides a variety of services for the hot end.
A flexible furnace maker
� Horn CEO Mr Stephan Meindl has worked there since 1994.
Horn has just successfully completed the largest project in its history which saw it oversee the completion of a container and float glass complex in Turkmenistan. Greg Morris travelled to the company’s headquarters in Ploessberg to meet its CEO, Stephan Meindl.
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H
orn Glass CEO and Managing Director, Stephan Meindl, is a proud man on the day Glass International visits. The German engineering company has successfully overseen the largest project in its history, which saw Horn in charge of supplying the technology for a container and a float line all on one site. Horn was entrusted with the delivery of all the process equipment, the installation, supervision and commissioning of the National Glass Complex in Turkmenistan. Mr Meindl is quick to acknowledge the role the team at Horn had played in the implementation of the project. He states: “I am extremely proud of this project. It was challenging at times but it could only be managed with a team like we have here at Horn. “I’m more than proud of our people and how they worked together to realise this. People of course work for money but at Horn there is more than that. There is a passion to do the job properly and to fulfil such an operation.”
4 Glass International Digital Edition December 2018
Turnkey Horn secured the contract with Turkish company TEPE Turkmen Insaat ve Ticaret for the delivery of a complete turnkey production plant for float and container glass. The float glass facility contained a 250t/day furnace and the container site a 50t/day recuperative furnace. The container site, located 20km outside the city of Ashgabat, was put into operation in October last year. Mr Meindl states: “It was a nice project for us because we relied on the thing we have done for 130 years, which is furnaces.” The project was two years in the making, with a one-year delivery time. Horn managed 35 suppliers, arranged to deliver 740 trucks, supplied refractories from elsewhere as well as provided its own equipment from its headquarters in Ploessberg, Bavaria. As well as delivering the equipment and supervising the installation, the Horn team will remain on site for a year to operate and train local glassmakers. A classroom was set up in
� Mrs Ekaterina Firsova and Mr Ulrich Imhof were recently appointed to leadership positions.
Company profile: Horn Glass � Horn is based in Ploessberg in northern Bavaria.
Turkmenistan for 20 glassmaking students every week. Delegations from the Turkmen glassmaker were also sent to suppliers around Europe for on the job training and to learn more about glass. Horn first visited the company eight years ago to pitch the project. It then took time to secure financing and decide upon the appropriate partners and contractors. “It was hard work!” jokes Mr Meindl. “It is unusual to have a glass facility which makes both container and float glass, but I have to say it is a fantastic complex.” “Our turnkey division often makes new plants in new countries and there has to be a period to make the decision to run a glass plant, and to take into account things such as budgets, land, organisation and energy availability. It all takes time.” Turnkey projects tend to be with newcomers to the industry so the evaluation and enquiries take longer. Many of the enquiries are more basic as opposed to technical questions such as those posed by an established glassmaker.
Background Horn is best known as a designer and supplier of melting technology for the global glass industry. It specialises in the area between where the batch is fed in, up to where the glass goes to the IS machine. The company serves all sectors of the glass industry, including container, float, tableware and technical glass. Less known, is it is also a tin bath furnace supplier. It started this six years ago and can provide a full tin bath from its site, apart from cameras and roof. Its customer list is a who’s who of glass manufacturers and includes the likes of Vetropack, Verallia, Piramal Glass and Crown Packaging. The company fabricates its own equipment.
All the highly critical technical parts such as burners, electrodes and batch chargers, are all manufactured in house. “This is particular to us and makes us very flexible. It is what the customer requests, that sometimes they don’t need a standard product, they need to change something on the product,” states Mr Meindl. “We are highly flexible because we are the manufacturer of the product itself, we don’t need to contract from the outside and tell the sub supplier to make it differently. “During a project execution, if something needs to be changed we can go to our workshop and change it, but to go outside takes time.” Such is its pride in its know how and manufacturing processes, it has not changed its Engineered in Germany slogan in 18 years. The company considers itself a technology leader and aims to bring the industry forward. “This is a challenge as we are a medium-size company,” states Mr Meindl. “But emissions and energy consumption have reduced over the past 20 years and I think Horn has played its part in that. With input from Horn, we feel we have brought an energy consuming industry forward. It used to be 1200 milligrams of NOx per kg of glass, now it is approximately 650 to 700, so it’s an enormous change. But we always want to do more.” R&D is also an important part of the business. It moves the company and the industry forward in terms of furnace optimisation and also gives Horn feedback on its daily operations allowing it to compare energy levels and optimise its calculations for customers.
Continued>>
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� The opening of the plant in Turkmenistan.
5 Glass International Digital Edition December 2018
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Company profile: Horn Glass
The company is currently going through a computer upgrade to make internal procedures more rapid and integrated. Its workshop has a Vision 2025 programme to become more automated. “Even we as a medium size company see opportunities to be more efficient, to have a fully integrated storage system, to transport things automatically to the machines, maybe building robots. In this regard we feel there is potential and we want to realise this.” The company employs 300 people in Ploessberg and a further 60 around the world. It has forged links with the likes of Bayreuth University in order to recruit future talent. It also has an apprenticeship scheme and last year took on 13 youngsters who worked across all aspects of the business. Although Ploessberg is a rural location it is located on the edge of the Bohemian forest and has a history of glassmaking. The location had the raw materials to make glass and companies such as Pilkington and Schott are based in the vicinity. This part of Germany has an unemployment rate of just 3.2% and is difficult to attract and retain talent. Despite this, when people are employed by Horn they tend to stay there for a number of years. About 80% of Horn’s business is international. Its partner agencies are located throughout Europe, Asia, America, Middle East and Africa - these partners allow Horn to offer its turnkey operation rapidly and reliably. “These daughter companies are our colleagues
6 Glass International Digital Edition December 2018
� It manufactures equipment in house.
and we transfer the same know how to them in order to effectively serve the market.” Its business spread is approximately 50/50 between container and float. Its strongest market is in Europe but it has customers around the world in places as varied as China, India and Mexico, and sees North America as an upcoming market again. It offers a range of furnaces from a 5t up to a 1000t for a float line. Its end-fired furnace comprises the largest proportion of its furnaces sold, but it also offers other types such as recuperative and oxy fuelled. End-fired furnaces are popular because of their energy efficiency. Oxy fuel consumes less energy but the high price of oxygen often curbs interest in them. Horn is focused on Industry 4.0 and believes that, step-by-step, the furnace will become more automised.
Philosophy Mr Miendl began his career at Horn in 1994. He worked there while studying as an electrical engineer at university in Munich. While combining his studies with employment he also developed the Optibeam glass level measuring device, still used by Horn today. Mr Meindl said: “After completing my studies the old Mr Horn said ‘you will remain with us’, and that’s how I started my career here.
Continued>>
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Company profile: Horn Glass
“I had no chance to ask my conditions, I was given my contract!” He worked in a variety of departments before being offered a place on the board in 2004 by former executive chairman, Max Sollfrank, who Mr Meindl credits as being hugely influential in his career development. When Mr Meindl took over as CEO he wanted to continue what had already been created by the board and he didn’t need to change the company philosophy. In the intervening time, the company has expanded by 100 staff and grown the turnkey business, which has secured larger contracts for the group. Mr Meindl has also reorganised the company’s leadership and appointed two new leaders of its main business units. Mr Ulrich Imhof is now in charge of the container and speciality glass business unit, while Ekaterina
8 Glass International Digital Edition December 2018
� More than 360 people are employed by the company around the world.
Firsova is responsible for the technological glass plant business unit. Mr Meindl said: “I have worked in many areas of the business and know a lot about the company. I’m very lucky to have had the opportunity to look everywhere from inside to understand and this benefits me today. “I really enjoy it here, to me it is not work, it is a hobby. Of course everyone has to work and take care of family and their private life but a lot of people like to work here. “I’m lucky to be a part of this and to be the head of this team in terms of this philosophy and manner. Out of this we have created what we have created, we have grown our position in the market and are a leading company in the industry.” �
Horn Glass Industries, Ploessberg, Germany www.hornglass.com
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Company profile: MGFS
Business is booming for MGFS
Business is booming in the Mexican container glass industry at the moment with a number of new investments and construction of a new plant. As Hans Mehl, Director of MGFS, states, the company has never been so busy.
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How is life in the Mexican glass container industry at the moment? It is very busy right now but also very exciting. There are a lot of new projects in the Mexican glass world. We are sometimes taking care of two projects at the same time. It gets undoubtedly busy in the container glass industry.
Hardly a week goes by without a new story about the Mexican glass industry, such as new investments and innovations. Has it kept you busy? Absolutely. We have never had so many projects as today. There are a lot of new investments made in the container glass industry. We deal with everything, from big, turn-key projects to heat up jobs and smaller maintenance jobs. We are fully booked throughout this year.
10 Glass International Digital Edition December 2018
ďż˝ A family business: Hans Mehl, (left) with his wife Isabel Gonzalez (centre) and nephew Luis Weller (right).
Why, in your opinion, is the Mexican glass industry going through such a boom period at the moment? Is glassmaking part of the culture in Mexico? I don’t think that it has to do with the culture in Mexico, but it has to do more with the strategic location of Mexico. There is our big brother, the USA, in the North and then there is a border with the Atlantic Ocean, one with the Pacific Ocean and one with the Caribbean. The US market is demanding a lot of bottles, mostly for beer and wine. Mexico is a low cost producer. Export is easy due to the vicinity to the oceans. As for the beer bottles, Mexico is not exporting so many beer bottles but mostly bottled beer. These bottles go into the export and do not return to the country. Continued>>
We last spoke at the Glassman event in Mexico in 2015. What has changed at MGFS? Are you closer to Hotwork International and Heat Up Latin America now? MGFS is still an independent company. Heat Up Latin America was established together with Hotwork International from Switzerland also as an independent company. MGFS is not part of Hotwork but we cooperate very closely. We share service personnel and I am also the CEO of Heat Up Latin America. MGFS has gone stronger into furnace and batch plant projects. MGFS has also increased the number of companies which we represent. Together with the companies we represent, we are present in nearly every project here in Mexico.
“The team I work with every day, show me their commitment, not only to the company, but also to me. Every day is a challenge and I
”
like that.
What services do the groups provide?
What markets do you serve? We serve every market in the glass industry. Hollow glass, float glass, C-Glass, pharmaceutical glass etc. We serve mostly the Mexican market but we also work in the US, Trinidad & Tobago, Guatemala, Costa Rica, Venezuela, Brazil, Peru, Chile and Argentina.
What benefits does this bring to customers in the region? We are very close to our customers. Reaction time in case of any emergency is very short. All of our employees speak Spanish and English. Communication is easy. The products of the companies we represent are very broad. Therefore the customer can contact us for various needs and the contact person is always the same. We have more than 25 years calling on the Latin American market. With Heat Up Latin America, we are also constantly improving our equipment and trying to implement solutions to well-known problems.
What, in your opinion, makes you stand out from your competitors? More than 30 years of experience in the glass industry. Strong links to other companies who
� Hans Mehl has been in the glass industry for more than 30 years.
can support us in case of need. Fast reaction time in emergency cases. First, we solve the problem, then we speak about invoicing. Dealing directly with customers’ problems and together with the customer solve these problems. Constant improvement of our equipment and technology.
You (Hans) have spent a number of years working in the glass industry. What motivates you to keep going? The team I work with. Every day, they show me their commitment, not only to the company, but also to me. Every day is a challenge and I like that. We have spread out our activities, and there is no time for boredom. Glass is my passion and I hope to “deal with heat” for a long time.
Do you anticipate more growth in the Mexican industry or is this the peak? I think we are far from the peak. We hear a lot about new projects and even if they are still not all confirmed, if only 50% of these rumours are realised, there is a lot of work to be done and there is a bright future for the Mexican glass industry.
Finally, how many staff do you have at the company? Does your nephew still work for you? In 2015, MGFS was a company consisting of 3 people and today we are a team of 10. Yes, Luis Weller, my nephew, still works with us and today he is our Operations Manager and also cooperates with Heat Up Latin America. My wife Isabel Gonzalez is also working with MGFS and she is our Financial Director and also takes care of Human Resources for both companies. Heat Up Latin America consists of a team of another 10 specialists who are full time employees and we can count on another 10 freelancers who cooperate with us. �
MGFS, Cuernavaca, Mexico mglassfactoryservices.com/en/
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MGFS provides: Supervision of furnace constructions (steel structure and refractory installation). Supervision of hot repairs, furnace operation and technical assistance, furnace audits including endoscope inspection. Furnace heat up including bolt control. Supervision of batch plant constructions. Audits of fused cast pre-assemblies. Heat Up Latin America provides: Furnace heat up and cool down. Expansion control, furnace drains, checker cleaning, all sorts of drilling, electrode exchange and electrode drilling in hot conditions. Combustion systems and burners. Oxy-fuel systems for emergency regenerator hot repair or checker exchange.
11 Glass International Digital Edition December 2018
� Philipp Zippe took over as CEO in 2016.
Philipp guides Zippe into digital future “In general the concept of the family company can be very strong. You have to understand each other, which is luckily the case with us. If you understand each other, the older generation gives responsibility to the next one while
”
at the same time the young generation respects the roots and heritage of the company.
It’s been two years since Philipp Zippe took over the running of the familyowned company from his father Dr Bernd-Holger Zippe. He spoke to Greg Morris about his enjoyment of the role.
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G
lass is in Philipp Zippe’s DNA. As a boy, conversations around the household dinner table would invariably turn to glass. Alongside his four sisters, he would regularly hear about the day-to-day life of the famil-run company and its contribution to the glassmaking industry. “My parents often shared their thoughts about the business with us and we talked about it together at home. Naturally glass was also spoken about a lot. We have a special attitude to glass, it was always clear to us to buy products made of glass. Buying plastic bottles was never thought of!” Philipp Zippe was appointed CEO of Zippe Industrieanlagen in April 2016, and is the latest in a line of family members to manage the company. He took over the role from his father Dr BerndHolger Zippe, who in turn inherited the position from Philipp’s grandfather. Zippe is an engineering and manufacturing company which specialises in batch house and recycling plants. It was originally formed in 1920 by Alfred Zippe Sr. in Haida, North Bohemia
12 Glass International Digital Edition December 2018
but moved to its current location in Wertheim, Germany in 1951. It has also been managed by Alfred Zippe Jr with his wife Edith, as well as Philipp’s father, who took over the management in 1991. Since Philipp’s appointment as CEO, time has passed in a flurry of activity. The company has been busy fulfilling orders around the globe as well as developing new products to keep up to date with changes in the market. “Success is never guaranteed and you have to fight for it every day, but all in all, it’s been an exciting first two years. I’ve enjoyed the teamwork with my colleagues and had many good conversations and projects with customers. We’ve also successfully realised many large-scale projects together. I’ve definitely enjoyed it, the time has passed incredibly quickly.” He has already made his mark: In May this year he helped organise the acquisition of Finnish competitor Lahti Precision’s glass unit. Continued>>
Personality profile: Philipp Zippe
“Today modern batch plants are fully automated and the risk of human error has considerably decreased in recent years and the
”
systems have become smarter.
Connection Philipp officially began working for the company 12 years ago in 2006 but had worked there during summer holidays while studying Economics with a specialisation in Process Engineering at the University of Aachen. He never felt pressured to work for Zippe, despite the company being a regular theme in his life. “My father always wished to have a successor but there was never any pressure on me – I could have done something different if I had wished. “But doing holiday work and internships
� Aerial image of the Zippe site in Wertheim.
and so on I learnt a lot about the company and the business and I had a different emotional connection to it. “Looking back, I became sure when I was at university where I learnt that I could have success and shape my working environment within an Small Medium Enterprise (SME) maybe more rapidly than in a huge multi-national company.” After he graduated, Philipp worked in a variety of departments within Zippe such as the mechanical, electronics and commercial departments to gain a wider overview of the business and what it offers to the market. “Sure, it gave me a deep insight into the processes of our company and how we develop solutions. But at the same time you always need to have an open-minded approach to the market. You need to go out and meet customers, attend exhibitions and always see where the market is going and where the demand is. “So you need both an internal as well as the external overview of the market. You’re always learning, you can never say you have got a complete overview, because the market never stops.”
Plan Philipp had a plan when he took over the reigns of the company, which he has already started to implement. “It’s important that every company does not stand still, it has to develop with the times. So it is my task, together with my colleagues, to shape the company for future challenges. “The first months were occupied with finishing projects and the acquisition of new orders, so it was daily or operative business in a challenging industry. I do have plans for the company - which we have started in terms of processes – and the changes we are facing in the industry is a long term one where you need commitment and breadth. “It’s important to always improve internal efficiencies but also we have to make the company fit for the digital age of which we are part of and that we want to shape in our area of the industry.” Industry 4.0, or digitalisation, has become a talking point in recent years and is a topic Zippe is up to date on. “We see rapid and accelerated speed of change which comes from the exponential performance of computers, the rapid development of the high speed internet and the accumulation of huge data which allows companies to build algorithms that make products smarter. “Today modern batch plants are fully automated and the risk of human error has considerably decreased in recent years and the systems have become smarter. “Our control systems incorporate modern technologies but we always want to bring new technologies to make the operation even easier and Continued>>
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� Site / Supervisors at work.
13 Glass International Digital Edition December 2018
Personality profile: Philipp Zippe
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more intuitive. We can provide communication interfaces to other systems like ERP systems monitor the operation status through mobile applications. Of course our products always orient themselves to the demand of customers to have the maximum benefit to them.” The company will provide a paper at the glasstec conference about Digital Glass Batch Production, on Wednesday October 24 at 10.35am. Zippe also plans to unveil developments related to Industry 4.0 from its booth. Philipp is quick to acknowledge the influence his father has had on him. Dr Bernd-Holger Zippe is well-known in the industry. He is a member of several organisations such as the Phoenix Committee and German Engineering Federation (VDMA) and remains chairman of Zippe today. He visits the office two or three times a week to stay up to date. “My father provided a good influence to me, he was always happy to talk to me about the industry and regularly took me to sites and customers. He explained about batch plants and what we do. “In general the concept of the family company can be very strong. You have to understand each other, which is luckily the case with us. If you understand each other, the older generation gives responsibility to the next one while at the same time the young generation respects the roots and heritage of the company.
� Zippe batch plant.
“This concept is strong and can provide stability and continuity not only for employees but for customers too.” Two of Philipp sister’s also work at the company: Susanne in Marketing, and Katharina Zippe-Sproll in Human Resources and Project Management. The aim for the next few years is to be a leading technology provider in the field of batch and cullet systems. Philipp plans to strengthen its development effort in dedicated technology fields and to continue to provide reliable products and solutions to customers. “We need to always try to improve ourselves, improve internal efficiency, be competitive cost wise and at the same time also question old solutions and try to bring technology further by adopting new technologies to the fields of batch and cullet plants so we are always up to date with offerings to the market. “You always have to be a reliable partner and be there with the customer when he has questions later on. “I’m proud to work here and proud we have a large team of skilled and talented engineers who dare to dream about how the technology may advance in the future.” �
Zippe Industrieanlagen, Wertheim, Germany www.zippe.de
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Company profile: Allied Glass Decoration
Allied Glass heralds the return of its decoration unit Allied Glass’s decoration facility has risen from the ashes after a catastrophic fire in autumn 2016. The company invested in the latest machinery to offer the most advanced decoration techniques from a new site. Greg Morris spoke to Michael Hogley about the facility’s transformation.
“To see everything wiped out like that was
”
T
he first thing you notice about Allied Glass’ new decoration and warehouse facility is how fresh it feels. Gleaming white walls, a high ceiling and a shiny floor greet you as you step in to the manufacturing area. The facility has only recently opened after a huge effort from company staff and management to get it up and running. The most eye-catching items are the modern pieces of decoration equipment situated in the centre of the shop floor. Pride of place is a KBA-Kammann K15 machine, while alongside it is a Tecno5 automatic machine and nine semi-automatic Dubuit machines. The company’s Head of Design and Decoration, Michael Hogley, (pictured above) is understandably proud of the new investment.
“The first time I walked in was the relief of how great this facility is, it is modern, clean and state of the art. The whole facility site had an extensive renovation prior to us so when we came in it was literally brand new. “We essentially opened the doors to a new factory and it gave us the opportunity to put our own mark on it. It was a blank canvas and we had the time to work on it and it has paid dividends today.” The idea was to create a one stop shop for glass packaging. The company wanted to take control of the entire pack so not only does it provide the glass packaging but also the secondary processing of the decoration as well. “There has been a drive in demand for decorative ware within the spirits market in recent years Continued>>
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heartbreaking
15 Glass International Digital Edition December 2018
Company profile: Allied Glass Decoration
because it adds luxury and value, so that was the driver to create a decorative facility,” he adds. The site is also equipped with two new Pennekamp lehrs as well as plenty of warehouse space. The site offers decorative options such as silk screen printing, ceramic inks, organic printing and precious metal printing, such as real gold and platinum. It is a remarkable turnaround from just over 18 months ago when on October 6, 2016 the decoration facility was completely destroyed. At the time it was located at Cross Green Way, situated a mile from Leeds city centre. The fire started accidentally on a Thursday night after most staff had gone home. A strong breeze meant
A few months later, in January 2017, the facility’s 30 staff were brought to the new site to help with the renovation work. Then just seven months after the blaze, in April 2017, the group moved into the £2.5 million facility at Wakefield Eurohub in Yorkshire, UK. “It was an unbelievable turn around, especially when you consider the lead times of such large pieces of machinery,” says Mr Hogley. “The whole team did really well, everybody from up at the top right the way down. Everybody was passionate about getting it back up and running. A lot of people had a lot of involvement throughout the years to get the department to where it was. “It was a stressful time but it also showed what
� The KBA-Kammann K15 machine takes priode of place in the new facility.
“The first time I walked in was the relief of how great
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this facility is, the small, isolated fire quickly spread, burning everything in its wake, including the site’s decoration machinery. “To see everything wiped out like that was heartbreaking,” recalls Mr Hogley. “But from that lowest point something amazing came out of it. Without that fire we would not have this brand new facility and state of the art equipment that we have here today. “The mentality was that we would come back bigger, better and stronger with new machinery and in a better position than we’d been in. But to do that we knew we would have to go through short term pain to get there.” A plan was formed to move to a new site conveniently situated between its two manufacturing plants in Yorkshire, UK. Negotiations took place with other glass manufacturers who offered to help by supplying bottles while Allied got back on its feet.
16 Glass International Digital Edition December 2018
Allied - and the industry - could do as a business state of the art. when faced with tough times.” The 196,000ft2 space is located half way between its Leeds and Knottingley manufacturing plants. The previoius Cross Green site had the Dubuit and Tecno machines but the machinery in the Wakefield site is more automated and, alongside the Kammann machine, can handle larger volumes. Most of the glass that requires screen printing comes from the Knottingley site, where the company’s premium coloured lines are based. The manufactured bottles, anything in size from
it is modern, clean and
”
Continued>>
Company profile: Allied Glass Decoration
From a manufacturing point of view, the new machinery allows more rapid job changes on the smaller machines. A job change will typically take 30 minutes on the Dubuit machine and four job changes a day are not unknown as a result. “We have the breadth of machinery to fit not just the high volumes but for the craft scene too. Those guys can be anything Customers who have between 2000 and 10,000 bottles a year so we still need that flexibility visited us have been and we do that with the semiautomatic Dubuit.” impressed. They’ve seen The new Pennekamp lehrs play a crucial role in the that we have great pieces decoration process. They are the same type of lehrs found at of kit, a fantastic facility any glass plant but operate at a different temperature. While in a and that we are back in glass factory they would typically start at 550°C, printing starts at a
“
”
business.
lower temperature. Depending on the job it can start at about 210°C, rise to 410°C and then to 550°C. It will then drop back down for a cooling off period. The temperature has to gradually rise to allow the bottle to adhere (cure). Work is still ongoing at the site, with the offices being refurbished and a training facility for 15 people set to be unveiled in the summer. The company has to keep on top of the latest decoration techniques and trends. One topic is Indutry 4.0, the ability for machines to talk to each other and its use in decoration. Another is the ability to decorate the entire surface of a bottle, which has become more commonplace. But for now, the organisation is proud of its new environment and keen to promote its latest developments. “No one has a facility as new and fresh as this. We’re evolving and we know that we can’t stand still. Customers who have visited us have been impressed. They’ve seen that we have great pieces of kit, a fantastic facility and that we are back in business,” concludes Mr Hogley. �
Allied Glass decoration unit, Wakefield, UK www.alliedglass.com
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50ml to 4.5 litres, are delivered to the site, where they are left for a couple of days while they adjust to the new temperature. They are then printed on and either put into storage at the warehouse or sent directly to customers. The majority of products decorated there are spirits bottles, and the glass can be sent around the globe when it leaves the Wakefield site (pictured above). “A lot of the precious metal and luxury goes into Asia where there is a requirement for it at the moment. On the other hand, in the UK in particular, we deal with a lot of craft, which is in much smaller volumes.” The balance between dealing with the much larger volumes of the mass market and the smaller runs of the craft movement means that the company believes it has addressed with the investment in the new machinery. While the Kammann machine can deal with runs of up to 100,000 bottles a day, the smaller Dubuit machines are suited for much smaller production output, such as a craft customer, which may only require 2000 bottles a year. The latest, six-colour print Tecno5 machine is suitable for smaller and mid-level ranges. “The new equipment gives us more flexibility and decoration options and allows us to push the boundaries of what we can do,” states Mr Hogley. The new equipment offers a range of options. The Kammann K15, for example, is an automatic printing machine, capable of doing up to six colours in one pass, can print round corners, shaped containers as well as squares, rectangles and flats. “The industry looks at the Kammann machine as the industry leader,” adds Mr Hogley. “It has brought immediate results and allows us to push the boundaries of innovations within print. There’s so much we can do with it and it allows us more scope. It’s a really good piece of kit!” Innovation remains key to the sector. Customers are constantly trying to differentiate. All of the brands try to tell a story and the entire pack, from glass to decoration, must reflect the values the brand is communicating. “We’re seeing more choice and a faster pace of innovation now. The investment in the machines allows us to offer more flexibility. We have the machinery and set up here to allow us to service that need in the industry.”
17 Glass International Digital Edition December 2018
Company profile: Bastürk Cam
Bastürk Cam: A new player in Turkey’s container glass market Muhammed Yalcinkaya, General Manager of Bastürk Cam, introduces the newest glass factory in the industry. The greenfield site was commissioned in February and will provide flint and green food and beverage bottles to Turkey’s eastern and central regions.
B
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astürk Cam is a family owned company with a business history of almost 50 years. The Bastürk Group has business activities in Turkey and Senegal. After successful completion of an expansion project for its textile plant in the past year, the group’s aim is now to enter the container glass market with a new container glass plant named Bastürk Cam in Malatya in the east of Turkey. All other container glass production plants in Turkey are concentrated in the Western or middle of Turkey. The new plant was built on a 145.000m2 plot of land. A total of 275 employees work there. The greenfield Bastürk Cam Sanayi ve Ticaret container glass plant was commissioned in early April this year, with the first bottle produced on April 15. The company intends to enter not only the Turkish market, particularly the middle and east of Turkey, but also the south as well as neighbouring countries. Many international equipment suppliers were selected to produce glass containers as well as many local equipment suppliers.
18 Glass International Digital Edition December 2018
� The company’s General Manager, Muhammed Yalcinkaya.
Company profile: Bastürk Cam
� EAE - Equipment for electrical busbar (Turkey).
� A number of international technology suppliers provided equipment to the plant.
Mr Yalcinkaya said: “EME, Sorg, Heye and MSK etc are well known and specialised companies in their fields. Because of this, we have a strong expectation to reach the target quality and efficiency during glass production in the shortest time.” Bastürk Cam will focus mainly on flint glass production but green glass can also be produced. The plant capacity for its Furnace A project is up to 300 tons of glass per day. Three production lines are connected to this furnace. All production machines are 12 section Speedlines from Heye International. Production in triple, double and single gob operation is planned. The site will produce jars for the food market and bottles for non-alcoholic beverage. In total about 480 million containers per year will be manufactured. “The company’s strategic goal is to realise, within a short time after successful commissioning of the present Furnace B project, which will have a planned capacity of about 500 tons of glass per day,” Mr Yalcinkaya added. �
Bastürk Cam Sanayi, Malatya, Turkey
www.basturkcam.com.tr info@basturkcam.com.tr
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The equipment suppliers for the project are: � EME MaschinenfabrikClasen - batch plant equipment and its cullet return system (Germany). � ARN Makina - equipment for raw material feeding and transport systems (Turkey). � WAM - equipment for dust filter systems. � Nikolaus Sorg - equipment for glass melting and glass conditioning systems (Germany). � Heye International supplied production, hot end handling and quality control machinery at the cold end (Germany). � Alfer MühendislikTaah – Fans for furnace cooling and production machinery (Turkey). � Antonini – Equipment for the glass annealing process and cold end coating equipment (Italy). � MSK Covertech – Equipment for cold end handling and packaging of glass containers (Germany). � Atlas Copco – Compressed air equipment (Belgium). � Pneumofore – Vacuum equipment (Italy). Iris Inspection Machines – Inspection machinery (France). � Agr Europa and Agr Intl Inc – Equipment for quality control of finished products (USA). � Pamuk Kardesler Makina – Furnace Steel and all other plant works (Turkey). � Formak Makina – Furnace and machine air cooling lines (Turkey). � MTM Makina – installation air, water and gas circuits (Turkey).
19 Glass International Digital Edition December 2018
Company profile: Pennine Industrial
Pennine Industrial celebrates th 50 anniversary Conveyor chain specialist Pennine Industrial Equipment is celebrating its 50th anniversary this year. The company supplies all around the world and has been at the forefront of improving conveyor chain speeds in glassmaking. Greg Morris spoke to its owner, Graham Hobbs.
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A
s Graham Hobbs reflects back on the 50 years of Pennine Industrial Equipment’s existence he does so with immense pride. The conveyor and sprocket specialist has grown from a one-man operation in its early days to a business that today employs 70 staff and operates all around the globe. Mr Hobbs said: “I’m definitely proud of what we have achieved here. But I’m also proud of what I think we will achieve as well and the legacy I think we will leave.” The company supplies conveyor chains, sprockets and drives to the glass industry as well as engineered plastics to the plastic industry. It remains at the forefront of conveyor chain technology in glassmaking and has invested £1 million in its products to reflect the speed of modern-day glassmaking. Eight-section, double- to-triple gob IS machines that double the speed of the conveyor are not uncommon today – a far cry from the 150 bottles a minute commonplace in glassmaking when Mr Hobbs started his career. The aim of the investment was to make a chain capable of handling 1000 bottles a minute. It worked with Sheffield Hallam University to design test rigs and had its own engineers model what it thought would be the best chain design in the world. It researched various materials, and different ways of manufacturing and assembling. After a successful 18-month trial at three glass plants it has started to sell the new product. Mr Hobbs cites the growth of the company and making Pennine a well-known and highly regarded name in the glass industry as one of his highlights. He is also proud of the fact the company has hired 70 apprentices since its formation. Many of them have forged successful careers of their own and Mr Hobbs said: “We’ve done right by them and they have done right by us and I think that in itself is an achievement.”
20 Glass International Digital Edition December 2018
“I’m definitely proud of what we have achieved here. But I’m also proud of what I think we will achieve as well and the legacy I think we will leave
”
History It was founded as Pennine Technical and Design Services by Graham’s father, Leonard, in 1968 but was left on the sidelines for five years as Leonard concentrated on other interests. Then, in 1973, when Graham was 17 and had completed his A-levels, he decided he wanted to work for himself but didn’t know what to do. So Leonard suggested that Graham should follow up on an idea Leonard had about conveyor chains.
�Graham Hobbs (left) with son Chris.
Continued>>
Company profile: Pennine Industrial
�The company employs
“He said I’ve got an idea to do with chains but I haven’t got time to do it, I’ve got my own business to run, do you want to have a go at running it? “There’s a desk, there’s a telephone, there’s the product. Now go and find some customers!” Graham didn’t know anything about sprockets or chains when he started so the next few months were a learning curve. But the breakthrough came after a meeting at the old United Glass site in St Helens, UK. Graham said: “The first time I went into the glass industry with this product, I told the client I honestly didn’t know what it could do for him. “He had heard it had been used somewhere and he heard that it was good and we talked about what he could do if he did a trial.”
Ecstatic After the chain had been on trial for six months, Mr Hobbs received a call to come and visit the site manager again. He was told that although the chain cost more, the glassmaker was manufacturing more bottles a day and that Pennine’s chain ran for five times longer than United’s previous product. “He then he handed me the order for their seven other machines. “He deliberately gave me the purchase order
in my hand because he knew it was important to me and knew I’d done him a good service. It was a nice moment!” Graham was ecstatic for what was, for then, a huge order of £40,000. But as he drove on the motorway home he was already thinking of his next move. “I knew straight away I could take it further. I thought why can’t I sell this chain into France, with all its wine bottles?” So a few days later he went to Manchester Library to find out where all the major global bottlemakers were located. He went through the yellow pages of every country they had and wrote down all the company names and private individuals that were listed as manager in the directories. “I started writing letters and some of them responded and wanted to try it. And it grew from there.” Among those early customers was the Danish glassware group Holmegaard, which still buys equipment from Pennine today.
Continued>>
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just under 70 staff today.
21 Glass International Digital Edition December 2018
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Father’s influence Pennine began to take off and Graham hired his first employee at 18. His father was there to provide technical advice, while still focusing on his own business. His father always knew though his own business would only last for 10 years and eventually he came to his son and asked him for a job. “In one sense I worked for my father, and in another sense he always said he worked for me. “He was always there behind me, whatever it was, I didn’t have the engineering experience that he had, I came up through a finances and selling route.” Such was Graham’s knowledge of the company’s finances that his father once asked him if he could afford to buy a new car. Leonard’s final job for Pennine came before his retirement in 1983 and was to find a new location for the company. It had been based in Saddleworth near Oldham but required a larger site due to its expansion. Graham asked his father to scour the UK for an appropriate site. “He looked from Scotland to Devon, I was prepared to move the family to anywhere in the UK if we had to. Pennine was my livelihood and if we had to move then we would move.” Graham wanted a site he could own and that had the space to expand if required. Leonard found the company’s current location, in Skelmanthorpe, near Huddersfield. The site was an old textile factory, which still had old looms in. It was renovated and after six months Pennine moved in. Since then it has expanded three times and plans to grow even further. Today approximately 60% of the company’s business comes from the container glass industry and the remaining 40% from the engineered plastics industry. “I never wanted to rely on one industry, I didn’t want to rely solely on one product. The world changes and I wanted to be able to adapt to a changing world,” said Mr Hobbs. Leonard passed away in 1989 and Graham said: “My dad was the best trouble shooter I ever met. He could make things work. He wasn’t the best
22 Glass International Digital Edition December 2018
�Pennine supplies its chain all around the world.
�The Len Hobbs testing facility was unveiled last year.
mathematical engineer, or aeronautical engineer, but if he told you that wouldn’t work and you said why, he would explain it later when he got round to thinking around it. When you got to talk to him during a quiet minute he would explain it. “He had a huge influence on me, he was one of life’s characters. I always turned to him for advice because you always got an honest answer. He wasn’t the kind of person who praised his children easily, he was quietly proud of what you had done.”
Anniversary
“I’m proud of the many people who have worked in one sense for me and in one sense with me. Some of the people have been with me for more than 30 years
”
The company recently celebrated its 50th anniversary with a birthday party for about 70 of its customers, suppliers and friends. During the birthday meal Mr Hobbs paid tribute to the company’s fellow directors, Martin Sykes and Graham Womersley, both long-term employees. He said: “I’m proud of the many people who have worked in one sense for me and in one sense with me. Some of the people have been with me for more than 30 years.” A future plan is in place for when Mr Hobbs retires that involves the company directors. Times have changed and decisions are no longer made by one person, such as in the days when Mr Hobbs formed the company. “It’s a sensible plan to keep everybody happy because you have to bring people on board who know what the plan is and why we are trying to achieve it so they can throw ideas into the hat.” The Hobbs family looks set to remain involved in the company for a while longer. Graham’s son Chris, a qualified accountant, was appointed as Finance Director in 2016. Just like Graham and Leonard in years gone by, the pair regularly exchange advice and information about the business. “Chris runs the money, so now I have to ask Chris if I can afford the car! The wheel has come full circle.” �
Pennine Industrial Equipment, Skelmanthorpe, UK www.pennine.org
WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS
THE EUROPEAN HUB FOR THE HOLLOW & CONTAINER GLASS MARKET Join us in Lyon for the biennial Glassman Europe event focusing on this important market for hollow and container glass manufacturers. This regular, popular event gathers together leading suppliers to demonstrate their latest innovation, products and services. In 2017, there were over 800 attendees from 25 countries, including representatives from O-I, Verallia and Ardagh. The press coverage from the event included a wide range of articles in national and regional business media.
TO FIND OUT MORE CONTACT:
We are looking for producers, manufacturers and service providers within the following fields to exhibit their products and services:
• Raw materials
• Processing machinery
• Batch Plants
• Laboratory services & analytical equipment
• Melting furnaces • Combustion equipment • Refractories • Feeders & forehearths • Hot end handling materials & systems • Annealing & decorating lehrs • Cold end handling materials & systems
• Decoration materials & equipment • Instrumentation/process control systems • Turnkey plant construction services & technical assistance & training • Software providers
• Tempering/laminating plants
Ken Clark, Sales Director t: +44 (0)1747 855117 e: kenclark@quartzltd.com Manuel Martin Quereda, International Sales Executive t: +44 (0)1737 855 023 e: manuelm@quartzltd.com
CONTACT US TO BOOK YOUR STAND
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WHERE THE HOLLOW GLASS INDUSTRY MEETS SOUTH AMERICA 2019 TO DO BUSINESS 14-15 May 2019, Sao Paulo Expo, Brazil
A RETURN TO BRAZIL South and Central America has been one of the most dynamic regions in the hollow glassmaking sector in recent years. There has been a host of new glassmaking facilities that have opened recently and there has been a renewed interest in the region thanks to its favourable economic and political conditions. This, coupled with an increased disposable income among the population’s consumers, has seen a surge of confidence in glass packaging. In short, there has never been a better time to expand your business within this region and we are delighted to be taking Glassman to Sao Paulo in 2019. Don’t miss out, reserve your exhibition stand now.
TO FIND OUT MORE CONTACT:
We are looking for producers, manufacturers and service providers within the following fields to exhibit their products and services: • Raw materials
• Processing machinery
• Batch Plants
• Laboratory services & analytical equipment
• Melting furnaces • Combustion equipment • Refractories • Feeders & forehearths • Hot end handling materials & systems • Annealing & decorating lehrs • Cold end handling materials & systems
• Decoration materials & equipment • Instrumentation/process control systems • Turnkey plant construction services & technical assistance & training • Software providers
• Tempering/laminating plants
Ken Clark, Sales Director t: +44 (0)1747 855117 e: kenclark@quartzltd.com Manuel Martin Quereda, International Sales Executive t: +44 (0)1737 855 023 e: manuelm@quartzltd.com
CONTACT US TO BOOK YOUR STAND
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