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Digital Edition September 2018
COMPANY PROFILE: VERESCENCE COMPANY PROFILE: BASTÃœRK CAM DIGITAL GLASSMAKING: HEINZ GLAS COMPANY PROFILE: GUANGDONG HUAXING GLASS I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
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Welcome & Contents
Welcome to the Autumn digital issue In this issue we catch up with some of the highlights of the year so far. It’s been a busy year with the container glass sector in particular enjoying unprecedented levels of production. An increase in the disposable income of consumers in developing nations has led to an increase in demand for glass. This, combined with the attack on plastic and the harmful impact it has on the environment, has meant glass has become the material of choice for consumers. In this issue we highlight some of the key interviews that have taken place in Glass International so far this year. It’s a small issue to full the gap until our bumper glasstec issue, published later this month. Enjoy, and I hope to see you all at glasstec next month.
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Digital Issue September 2018
• Glass Melting Furnaces • Batch Plants • Engineering • Project Management • Turnkey Projects • Lehrs
Greg Morris, Editor gregmorris@quartzltd.com
For more than 70 years HFT has provided world class engineering, procurement and construction services to the global glass industry. Our leadership, experience, quality focus and attention to details have given HFT a highly respected reputation worldwide.
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2 Company profile: Verescence Verescence invests in its largest, greenest furnace 6 Company profile: Bastürk Cam A new player in Turkey’s container glass market 8 Digital glassmaking: Heinz-Glas A flacon for a digital world 10 Company profile: Guangdong Huaxing Glass Huaxing Glass continues to grow
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1 Glass International - Digital edition September 2018
Company profile: Verescence
Verescence invests in its largest, greenest furnace French luxury glass container manufacturer Verescence unveiled a £30 million investment at its flagship Mers-les-Bains plant, France shortly before Christmas. Greg Morris spoke to the company’s General Manager for France, Hélène Marchand, about the investment.
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ot only is Verescence’s new €11 million furnace at its Mers-les-Bains plant the facility’s largest, it is also its most environmentally friendly. The facility’s furnace number 6 has a capacity of 130t/day and is capable of producing 700,000 bottles a day. During the recent plant revamp, the company changed the design, shape and metallic structure of the furnace. It also reworked the installation of the feeder to obtain energy savings. The result was an energy reduction of 15% and 40% less CO2 emissions. The new furnace is gas instead of oil-fired. The majority of the furnace’s production will be a high quality glass named Xtra Flint, which is used in the high end perfumery and cosmetics sector and known for its brightness and transparency. While the majority of production will be flint glass, three of the furnace’s six production lines are capable of feeder colouration, should the need arise for coloured glass. Mrs Hélène Marchand, General Manager France for Verescence, is understandably pleased with the new investment.
2 Glass International - Digital edition September 2018
“A furnace is only rebuilt every 10-12 years so this is a very important moment in the life of our glass factory,” she said. “The environment is very important to us and our customers. When we rebuilt furnace number 1 in 2015 we achieved a target of 10% energy savings. “When we rebuilt number 6 part of the specification was to do even more energy savings, so we looked at a reduction of energy consumption and CO2 emission. The new furnace complies with regulations and makes us even more environmentally friendly.” Reducing its energy output and CO2 emissions is also good for its customers, who communicate a lot to consumers about their CSR. “By sourcing glass from Verescence the customer improves their environmental impact,” states Mrs Marchand.
Company Verescence has its headquarters in Paris, France and has seven plants around the world in France, Spain, USA and Brazil. Its French operations consist Continued>>
Company profile: Verescence
� The furnace will primarily produce Xtra Flint glass.
� Mrs Hélène Marchand is Verescence General Manager for France.
of the Mers-les-Bains manufacturing site and two decoration plants in Ecouche and Abbeville. The company makes glass for the perfumery and cosmetics industry and its customers include global names such as Chanel, Hermès and L’Oréal. It manufactures about 1 billion fragrance and cosmetic bottles a year globally. The Mers-les-Bains site employs 850 people and was originally built in 1896. The site has three furnaces – its two other furnaces have a capacity of 65t/day and has 13 production lines in total, in single and double gob. Once the glass is made, about 80% of its production is distributed to its French decoration plants, before being transported to its customers and shipped around the world.
Mers 2018 plan The recent investment was part of the Excellence 2018 plan and more specifically the Mers 2018 plan dedicated to the plant. A total budget of €30 million was allocated to renovate the facility, of which €11 million was for the reconstruction of furnace number 6. The investment included a complete modernisation of the production floor space. The factory was given a fresh lick of paint, new LED lighting installed, the canteen revamped, the offices renovated and the changing rooms modernised. Until 2016 the site also produced pharmaceutical glass, but this was moved to a new site in St Quentin, owned by SGD Pharma, while the Mersles-Bains site became under the ownership of Verescence and is dedicated solely to perfumery.
The decision was made to embark on the ambitious investment project in 2016. Mrs Marchand said: “We said to staff, we will stay in the factory and change it. Not only will they have competitive production tools to work with but we will change the aspect of the factory and make it a nice environment to work in. I think staff are satisfied with the jobs done so far but it is not finished yet, work is still ongoing.” Some of the production equipment Mrs Marchand refers to has been an investment in its forming technology. The cosmetics and perfumery industry is constantly asking for more differentiation of glass bottles to ensure their products stand out from competitors. As a result, glassmakers such as Verescence are requested to manufacture ever more complex shapes. Mrs Marchand said: “There is no limit to the imagination and we meet our customers’ requests as much as possible. We are asked by clients to go and find something new all the time in our forming techniques. The trends of a few years ago were for heavy bottles with lots of glass, but today the requests are for lighter bottles. “So today we have two types of requests: for very heavy bottles and for original shapes- for example, a shape inside the shape. Then we also have requests from clients for lighter bottles, so we are working in two directions. “For this we needed to change the forming process and make an investment.”
Continued>>
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“A furnace is only rebuilt every 10-12 years so this is a very important moment in the life of our glass factory,” said Hélène Marchand.
3 Glass International - Digital edition September 2018
Company profile: Verescence
� The furnace investment at Mers-le-Bains was €11 million.
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Inspection It has also invested in a new generation of inspection machines from fellow French company Tiama. “It is sometimes difficult to spot defects in perfumery and cosmetics bottles because they are so small,” states Mrs Marchand. “Automatic inspection machines on the market today have a good level of detection, and for us this is particularly important in terms of final quality. “But there are still some defects we are not able to see even with automatic machines and we need to make progress with our suppliers to be able to detect these defects with the machines.” The Mers-les-Bains site is situated in the heart of France’s famous Bresle Valley, which is a historic hub of glassmaking. Many local people are employed by the numerous glassmakers in the region and their knowledge of glassmaking goes back for generations. They take pride in their work because there is a rich culture of glassmaking in the area. Partly because of this, the Verescence site has a nice balance of older and younger workers, with a good configuration of experience and newer, fresher ideas. Also on site is an R&D centre and a school of glass. The company takes R&D seriously, with the majority of its 100 R&D staff based in Mers-lesBains. The Xtra Flint glass mentioned above was launched in 2015 and was the result of two years of R&D. The glass is regarded as brighter and more crystalline than perfumery flint glass. It has achieved a high luminance and light can now shine more brightly through the bottle. Its school of glass teaches people machinery training. Its production lines can have up to four job changes a day, so training for this is important. “We have short production runs compared to the rest of the hollow glass industry. Our average production run is around two to three days on one line,” states Mrs Marchand.
4 Glass International - Digital edition September 2018
� The investment included a complete revamp of the plant.
Industry 4.0 The next step for the factory is continued investment and to investigate the use of Industry 4.0 in its glassmaking process. It has invested in two 3-D printers on site for decoration purposes and envisages a lot of progress in decoration with Industry 4.0. The company has a technical director who recommends its technology suppliers for the group’s factories. For a company to be considered as an equipment supplier to Verescence, not only must it meet criteria in terms of quality and price, it also must be able to work with the company on innovation. “We need to be able to work together to develop new functionalities,” states Mrs Marchand. “It is important to be able to work with your suppliers to develop and innovate together and to be able to be better tomorrow, together.” �
Verescence, Mers-les-Bains, France www.verescence.com/
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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.
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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.
6 Glass International - Digital edition September 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).
7 Glass International - Digital edition September 2018
Digital glassmaking
A flacon for a digital world Virginia Elliott, CSO and Oliver Kober, Manager of Inspiration & Flacon Development at Heinz-Glas, discuss how a new perfume flacon meets the requirements of the digital world.
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ne of the most important and ubiquitous trends of recent years is digitalization. Our daily, private communication now runs on various social media channels such as WhatsApp, Facebook and Twitter. We stream movies, TV shows and Alexa makes our home smarter. Digitalization does not only play a major role in our private life but also at the Heinz-Glas Group. Digital communication via Skype and social media platforms connects us and our customers across all locations and makes it possible to exploit the full potential of our internationality and diversity worldwide. New creative and technical innovations are constantly being developed that change our life and social environment. This change is also noticeable in the cosmetics industry. This development is currently only limited to labels and cartons, which are lit with printed organic light-emitting diodes.
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Add value Digital cartons are one thing, but how could a perfume flacon look and add value in the digital world? We asked ourselves this question two years ago within HeinzGlas’s inspiration department. Customers had indicated a strong interest in this topic at previous inspiration workshops and how we could connect to the digital world, so it was finally time for the development of a perfume flacon with integrated electronic technology from Heinz-Glas. Since November 2015, Heinz-Glas, together with the company ds.Xpress Multimedia, developed a perfume flacon with a personalised display. The challenge was to combine the electronic components with our cosmetic requirements in such a way that the usual aesthetics of a flacon remained intact. We developed several design concepts with ds-Xpress and our tool development over a long but concentrated development
� Virginia Elliott, CSO, Heinz-Glas, alongside Heinrich Quintero, CEO, ds.Xpress Multimedia.
period until the actual final technical realisation in the second quarter of 2017. The result is a digital perfume flacon with the name of TimesSquare. It impresses with its simple, elegant and luxurious design and the extravagant, integrated high-tech. This allows the end user, by means of an app, to provide the flacon with a personal message and design. It can be played on the flacon using your own pictures, videos and music and can be used over and over again. The media can be provided with personal text and edited and changed using different filters. Through TimesSquare, the end user gets a perfume flacon with an added value that is absolutely unique. TimesSquare not only adds value to the end user but also to our direct customers. In order to use the personalisation of TimesSquare, the end user can download the free app and register to reuse the flacon. After the consumer registers on the app, the perfume and cosmetic industry can get an overview of the locations, volumes and consumer information worldwide and can thus plan targeted campaigns and marketing strategies by analysing the data. In October 2017, Virginia Elliott, HeinzGlas CSO presented TimesSquare at
8 Glass International - Digital edition September 2018
LuxePack Monaco. Virginia introduced TimesSquare at the FEVE panel where glass manufacturers could present their ‘novelties’ in regard to annually changing topics in front of customers. The topics that the panel could choose from to present at the FEVE panel were either 1. The Digital Big Bang, 2. Emotion or 3. Brand Awareness. Virginia chose to present TimesSquare, which addresses all of these topics in one product. The digitalization and emotion through the display and app and the brand awareness as the flacon is refillable. We are now presenting TimesSquare to our customers to develop and strategise
how their own flacon will be created with the TimesSquare technology. Generations two and three of TimesSquare are in progress, so stay tuned for more innovation. We can only say that no one has counted on this digital inspiration, neither our customers or our competition and we are so proud at Heinz-Glas to be the first to introduce this revolutionary product to the perfume and cosmetic industry. �
Heinz-Glas, Kleintettau, Germany www.heinz-glas.com
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9 Glass International - Digital edition September 2018
Company profile: Guangdong Huaxing Glass
Huaxing Glass continues to grow Li Shenhua, Chairman of Guangdong Huaxing Glass discusses the evolution of the company since its formation in 1987. He is also a member of the executive council of the China National Association for Glass Industry (CNAGI).
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uangdong Huaxing Glass operates 14 production facilities across China with an annual production capacity of more than 3 million tons, or about 16% of the total output in the country. The company was established in 1987 in Luocun village, Guangdong province. It was a small glass factory making bottles for customers in the local area. Its breakthrough came in 1996 when it built a new furnace and installed fully automatic IS machines. It received its ISO 9002 three years later. In 2002 it expanded its capacity by building a new factory in Wuzhou city in Guangxi province. In mid-2003, it began the construction of Daye factory in Hubei. Today, it has production facilities in Fujian, Jiangxu, Henan, Guangdong, Guangxi, Xinjiang, Hebei, Zhejiang, Guizhou, and Hubei.
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What makes you stand out from other Chinese glassmakers? We focus on areas where we have a clear competitive advantage. We have many distinctive capabilities. We develop our business of glassmaking around a model based on responsible growth, cleaner energy and the rational use of resources. We cannot accept the tag of product surplus, high-energy consumption and high pollution. What are the company’s strengths? We are a company powered by integrity, teamwork, excellence and caring. We have a proven track record in providing specialist solutions on complex, challenging, and quality products. In addition, we have a wide network of production facilities in major regions, to serve long term customers domestically and abroad. We always adhere to the principle of quality and maintain our own inspection centres in the central and southern region respectively to enhance the quality of our products.
What is your most popular product? We produce a variety of goods for the cosmetic, food and beverage industries. We believe that the demand is market oriented, and customer is the centric of change. With this belief, we have developed a harmonious relationship of cooperation among suppliers and customers. How many furnaces and how many production lines do you have? There are 34 glass furnaces and 167 glass bottles production lines today. Do you use modern machinery in your glassmaking process? We manage our production with highly efficient and innovative solutions largely based on: clean energy, efficiency, and state of the art technology. We installed dust and sulphur removing apparatus, where nitrogen and oxygen substances removal are necessary. We work with reputable and leading machinery and equipment suppliers. We also work closely with our suppliers to test out new production equipment for better production process, efficiency and product quality in glassmaking. Is the Chinese container glassmaking market a competitive market to be in? The Chinese market is going through a series of reforms to keep pace with development, innovation, and market conditions. It is transforming from extensive to intensive economy, and from simply getting bigger to getting better. It has the capacity and competency to sustain business for glassmaking across the country. Q: What challenges do you face as a glassmaker? Our main goals are the safety, environment protection and sustainable development. We apply science and innovation to
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find better, safer, cleaner and efficient ways to glassmaking. In the areas of production R&D, we have been cooperating with several organisations, such as Tsinghua University, Shaanxi University of Science and Technology, and South China University of Technology. We also conduct our own independent research and development for testing, design, installation, commissioning, operation guidance and personnel training. How would you like to see the company evolve in the next five years? We would like to continue to play a role in supporting the economy growth, technological advancement and the wellbeing of the communities. Our experience will enable us to go wherever clients go and respond to the challenges, minimise the risks and maximise the opportunities by setting up production facilities when necessary to support their businesses and markets. ďż˝
Guangdong Huaxing Glass, Foshan City, Guangdong, China www.h-xglass.com
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
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11/09/2018 13:20
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
WWW.GLASSMANEVENTS.COM/SOUTH-AMERICA Organised by:
Join the Glassman Group
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11/09/2018 13:28