Glass International July August 2018 by Quartz Business Media

B 47-5

HALL 13

July/August 2018—Vol.41 No.7

IPPE HALL 13/A31

INTERVIEW: EMHART’S TECHNOLOGY EXPERT COMPANY PROFILE: GUARDIAN GLASS PERSONALITY PROFILE: PENNINE CEO I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

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Contents

July/August 2018 Vol.41 No.7

B 47-5

July/August 2018—Vol.41 No.7

HALL 13

IPPE

Editor’s Comment

International news

Personality profile Philipp Zippe: Philipp guides Zippe into digital future

Forming Bucher Emhart Glass: Bringing new technology to life

HALL 13/A31

22 Company profile Wiegand-Glas: Wiegand-Glas embarks on major investment campaign.

INTERVIEW: EMHART’S TECHNOLOGY EXPERT COMPANY PROFILE: GUARDIAN GLASS PERSONALITY PROFILE: PENNINE CEO I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

27 Plant Utilities Sorg: Applying modern inventory techniques to plant repairs.

Glass International July/August 2018

31 Hot end Rondot: Rondot’s Smart Tong 32

GI Cover july aug 6.indd 1

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Front cover image www.teco.com

Company profile Pennine Industrial: Pennine celebrates 50th anniversary

36 Company profile Guardian Glass: Guardian set for largest investment year in its history.

42 Forming GTS: Using Virtual Reality in glassmaking 46 Furnaces Sivesa: Sivesa celebrates furnace start up 49

50 Industry 4.0 Siemens: Steklarna Hrastnik goes digital 52 Forming Emhart: Collaboration to improve BIS machines 54 Event review Furnace Solutions: International guests dominate at event

Plus find us on Linked-In and Twitter.

59 Inspection Marposs: Inspecting the container sector @Glass_Int

www.glass-international.com

62 Event review Mir Stekla: Celebrating 20th anniversary in style

www.glass-international.com

History Is red for stop?

1 Glass International July/August 2018

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Editor’s comment

Greg Morris

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Editorial Assistant: Sheena Adesilu Tel: +44 (0)1737 855154 Email: sheenaadesilu@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com

Is this the Golden Age of glassmaking?

www.glass-international.com

orgive the hyperbole but I’m convinced that the period we are in right now will be considered a golden age of glassmaking in years to come. This is obviously a bold statement to make, and I’m sure there are many of you who may disagree. True, there is pressure out there on glassmakers, such as competitor materials, increased legislation and higher quality regulations, but these are age old worries that will never disappear and have essentially been around since the dawn of glassmaking Today, everywhere I look, everyone I talk to appears to be in good spirits. Business is booming. Glass has never had it so good. Plastic is taking a hammering in the mainstream media, with more people objecting to its environmental impact. Glass, with its sustainable qualities, is perceived as the material of choice. Not only that, but the pockets of consumers in the gigantic markets of Asia are increasingly becoming deeper and people are choosing glass as their packaging material of choice. New connoseuiurs of whisky and other high end spirits want the best that money can buy. Liquor distilled and bottled in Europe is ﬁnding a home in far away Mumbai or Beijing. But it’s not only about the day to day business of glassmaking. The depth and rate of innovation in glassmaking is

ﬂourishing. Glass today is prevalent... everywhere! From modern-day communication to new futuristic concepts such as augmented reality, glass is the material with pizzazz. There have been huge advances in communication technology - and glass has been at the forefront of that, whether it be the bendable mobile phone screen or the touch screen tablet that has become a staple of our lives in recent years. Augmented Reality is becoming a more popular phrase now, with smartglasses and bionic contact lenses playing a substantial role in its use. There have also been advances in the way glass is made too. In this issue we review the Furnace Solutions conference where a member of the Prime Glass project was awarded best paper. The paper outlined how NOx abatements of 30 to 40% could be achieved. Importantly, it was delivered by one of the relatively few young people in the industry, addressing another challenge the industry faces. Smart manufacturing, Industry 4.0 and the use of digitalisation are set to play a role in the next chapter of efﬁcient, sustainable glassmaking. The use of technology will ensure that glassmaking is a safer experience than it is today. � Greg Morris, Editor gregmorris@quartzltd.com

Quartz Glass Portfolio ASIA 2019 Monthly journal for the industry worldwide

Directory 2017 Annual international reference source

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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director: Steve Diprose Chief Executive Ofﬁcer: Paul Michael Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com

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Member of British Glass Manufacturers’ Confederation

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United National Council of the glass industry (Steklosouz) Glass International annual subscription rates including Glass International Directory: For one year: UK £173, all other countries £242. For two years: UK £308, all other countries £432. Airmail prices on request. Single copies £47.

Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2017 edition: UK £206, all other countries £217. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ 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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Glass International July/August 2018

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International News

Verallia opens Zaragoza furnace ic sector, which has recovered strongly from the crisis, innovating and betting on new markets, with a clear exporting vocation.” Mr Pinto, wanted to “thank the entire team, for their commitment, daily improvement and pursuit of excellence, safety, quality and customer

satisfaction.” The site is dedicated to beer, wine, cava and liquor bottles production. It has two furnaces and the new one will reduce emissions by 9%. The speciality of the plant is its flexibility to be able to manufacture containers in 12 different glass colours.

Michele Gusti has been elected as president elect of Gimav, the Italian Association of Manufacturers of Machinery, Accessories and special products for glass processing. Mr. Gusti, who is also president of OCMI-OTG, replaces Aldo Faccenda of Bottero, who held the position for the 2016-2018 term, and was voted to serve as president of the Hollow Glass Division for the next two years. The president-elect of the Accessories Division is Dino Zandonella Necca of ADI.

SGT industry event

fortlessly in order to identify potentials for improvement. The software was installed at its Stölzle-Oberglas site (pictured) in Koflach, Austria and its Stölzle-Union site in the

Czech Republic. Stölzle-Oberglas manufactures 3.25 billion units of glass a year for the pharmaceutical, perfumery and cosmetics, spirits and tableware sectors.

Encirc’s €40 million furnace Encirc has opened a £40 million furnace at its glassmaking site in Elton, UK. The 206m2 sized furnace will increase the container glassmaker’s capacity by 100 tonnes a day and was opened by UK secretary of state for business, Greg Clark.

Michel Giannuzzi has been elected Vice-President and Laurent Zuber as Chairman of the European Container Glass Federation (FEVE). Mr Giannuzzi, Chairman and Chief Executive Officer (CEO) of the Verallia Group was elected Vice President of FEVE at the federation’s recent general meeting in Rotterdam.

GIMAV President

Stölzle digitises production Stölzle Glass Group has introduced smart software solutions for its Austrian and Czech Republic production facilities. The digitalisation project took one year to complete and allows users to access all relevant production parameters or machinery calibration data in real time through various mobile devices. It means employees and engineers no longer have to get the data from a desktop PC and save time. Also, production and efficiency analysis material can be generated ef-

FEVE leadership roles

Encirc Managing Director, Adrian Curry, said: “At a time when some are uncertain about the outlook of UK manufacturing, the investment in our new furnace represents a very strong commitment to our future by our Spanish-based parent company.

“We pride ourselves on using the latest technology which not only minimises our impact on the environment, but also helps increase efficiency in our supply chain. “This new furnace will increase our capacity to manufacture sustainable packaging.”

The Society of Glass Technology is to hold its Annual Conference in September in Cambridge at Murray Edwards College, UK. The conference includes an industry session where speakers will include Dave Dalton, CEO of British Glass, and Stuart Hakes, SGT President designate and FIC UK’s Managing Director. The Industry programme takes place on September 4 and will be focused on Energy.

Brazilian training course

A training course aims to prepare technicians to work in glass plants and associated manufacturing areas. The course takes place over three semesters and combines 1200 hours of theory and practical classes with 40 students maximum in theory classes and 20 in practical. It is organised by Certev, Abividro glass association and the Paula Souza Center in Sao Paulo, Brazil.

www.glass-international.com

Verallia Zaragoza has inaugurated a new furnace after a €21.5 million plant modernisation. The furnace can produce 1.5 million containers a day, or more than 190,000t/d of molten glass. It is mainly dedicated to the production of beer bottles. A ceremony took place in which Verallia President and General Director, Michel Giannuzi, General Director of Verallia Spain and Portugal, Paulo Pinto, and plant manager, Eulogio López, were among the 200 attendees. Mr Giannuzzi said: “Verallia is strongly committed to the beverage and food sector in Spain. “A competitive and dynam-

NEWS IN BRIEF

5 Glass International July/August 2018

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Beatson Clark bottle aims to ﬁght war on sugar Introducing the Cleanfire® ThruPorte™ burner A prescription for aging regenerators Undergoing regenerator repairs or having

A drinks company has turned to a UK glass bottle manufacturer to fight the war on sugar. Kolibri Drinks asked Beatson Clark to design and manufacture a bottle which allows consumers to control the amount of sugar in their drink. The sugar is stored in the cap of the bottle rather than in the liquid of the

drink. The idea is to allow the consumer to customise the amount of sugar and flavour in their drink, to suit their own taste and preference. The brief was to create an elegant bottle which would appeal to the premium retail and restaurant market. The bottle was designed and produced at Beatson glassworks in Rotherham,

UK and is a cone-shaped 300ml white flint flask made from 30% recycled glass on average. All the sugar has been removed from the botanical drink in the bottle and is stored instead in an elegant cap, so for the first time consumers can decide how much sweetness – if any – they wish to add to their drink.

Air Products reveals HQ plans

difficulty maintaining full production in an aging furnace? Turn to Air Products’ new Cleanfire® ThruPorte Oxy-fuel burner for an onthe-fly heating solution to avoid downtime or extend your furnace campaign. This patented and commercially-proven technology, installed from the underside of your port, allows you to add heat where and when its needed.

Air Products has unveiled the site for a headquarters. The 50-acre site will be built approximately one mile from its existing

headquarters in Pennsylvania’s Lehigh Valley, USA. Groundbreaking is expected in March 2019 with occupancy targeted by

Summer 2021. The new location will be the base for approximately 2000 Air Products employees with capacity for growth.

Vetri’s Ormelle inauguration

Key features: • Tandem water-cooled oxy-fuel burner and oxygen staging lance • Proven durable design that can be easily installed in an existing port, while the furnace is running • Adjustable flame length and angle for optimal heat distribution and surface coverage • Remote, wireless and continuous online monitoring of burner performance • Available for rapid deployment To make glass better, put Air Products in the mix.

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Italian container glassmaker Vetri Speciali has inaugurated a new furnace at its Ormelle plant. The furnace was inaugurated in a ribbon cutting ceremony at the site in Treviso, about 40km north of Venice.

Part of the funds for the €38 million investment were from the European Investment Bank. Vetri Speciali said: “This new plant that will bring a significant improvement in working comfort and an even greater attention

to the environment projecting the history of the plant and its territory in the global panorama of the great glass industry.” A total of 84 suppliers were involved in the project, many of them from the local area.

Nadir ends O-I acquisition plan Brazilian glass manufacturer Nadir Figueiredo has ended its plans to acquire O-I’s tableware unit. Nadir informed the Brazilian authorities it had decided to give up the planned acquisition. The company had announced the purchase of

O-I’s Rio tableware unit in May 2017. But the proposal was met with disapproval by Brazil’s Administrative Council of Economic Defense (Cade). It argued that the domestic market for glass utilities was highly concentrated.

The two companies were unable to reach an agreement with Cade and therefore decided to abandon the plan. Nadir is a leader in Brazil’s domestic glassware market and the owner of brands such as Marinex and Duralex.

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International News

NEWS IN BRIEF

IVC installs Vertech’s SIL

Mexican container glassmaker IVC has installed Vertech’s SIL equipment on its fourth furnace. Industria Vidriera de Coahuila (IVC) is a jointventure between Owens Illinois and Constellation Brands based in Nava, Mexico. French technology supplier Vertech has installed SILC on 13 production lines. In addition 14 decoration lines have been equipped with SILDeco, a SIL product dedicated to decoration.

Zippe’s Thai success

Zippe secured two orders from Thailand for a glass recycling plant and a batch plant. The contract with Siam Cullet includes a recycling plant for metal and nonmetal separation, organic separation, ceramic, stone, porcelain separation (KSP), as well as colour sorting. The capacity amounts to 30t/h whereby the plant can be extended up to 45t/h at a later date. Zippe has also received an order from Siam Glass in Ayutthaya for the extension of a batch plant.

www.glass-international.com

RHI Magnesita invests

Refractory supplier RHI Magnesita is to spend €20 million to expand its Chinese dolomite site. The investment in the Chizhou, Anhui Province, China, plant will help address global pressures in the supply of raw materials to the refractory industry and provide additional volumes to its customers worldwide. The Chizhou site includes a dolomite mine and raw material production as well as facilities for the production of dolomite-based finished products.

Waltersperger owner

French semi-automatic glassmaker Waltersperger has been taken over. The Blangy-sur-Bresle glassmaker has changed ownership and is in the hands of Stéphanie and Adrien Tourres who own 100% of the business.

Vidroporto chooses Xpar Vidroporto has chosen Xpar Vision as its new hot end inspection partner. The Porto Ferreira, Sao Paulo, Brazil-based glass manufacturer installed the latest generation XPAR IR-D double camera system. The system was recently installed, together with the inauguration of a new 12 section triple IS machine. After extensive staff training by Xpar consultants, it now provides a valuable tool in optimising the glass production process. With quality and perfor-

mance level mainly being determined in the Hot End, the IR-D is an objective analysis and measurement tool, capable to detect differences in these aspects of the forming process. The IR-D system is an invaluable tool for process moni-

toring, relating defects detected automatically to cavity of origin and using indicators or related trends at one or more zones in the bottle and ware spacing and positioning, resulting in effective machine monitoring.

Trend Glass chooses Forglass furnace Trend Glass has selected Forglass to perform a major overhaul of its W-2 furnace in its Radom, Poland plant. The regenerative end portfired furnace will melt ultra-white flint tableware glass, with melting capacity of 150 tpd. Forglass had to increase the height of the furnace superstructure, redesign the burner port necks and the top part of the regenerator chambers, change the checker lining (140×140 mm instead of

170×170 mm chimney blocks) and overhaul the oscillating batch charger with vibrating gutter. It also designed the side wall electric boost (1200 kVA) with required changes of melting tank. The performance parameters of the re-build exceeded the values guaranteed in the contract: - The pull was increased to 155tpd (without boost), - The specific melting capac-

ity is 1.95t/(m2·24h) for 30% of cullet, - The specific energy consumption was reduced by 300 kcal/kg; and - The glass quality index was below 10 bubbles Ø 0.5mm/100g of glass. Trend Glass said that the quality of the engineering and assembly works performed by Forglass were characterised by professionalism, accuracy and creativity in solving problems.

Corning invests in Chinese facility Corning will invest in an automotive manufacturing facility in Hefei, China. It plans to invest in the Hefei Xinzhan Hi-Tech Industrial Development Zone facility in Anhui Province for its automotive glass solutions.

Corning is planning for the facility to be fully operational by 2019. It will produce Corning Gorilla Glass for Automotive Interiors, a durable and optically advantaged cover glass solution specifically designed

for automotive interior applications. Retrofitting an existing facility will help Corning to bring on new capacity quickly to advance the growth of its automotive glass solutions business.

Schott buys Finnish bonding group Speciality glass manufacturer Schott is to buy Finnish micro bonding group Primoceler. Schott said the acquisition would enhance its core competence in the field of hermetic packaging.

The new company will be called Schott Primoceler and be based in Tampere, Finland, as part of Schott’s Electronic Packaging division. The deal will be completed by the end of the year.

Hermetic packaging refers to the sealing of electrical contacts with glass or ceramics. The inorganic and virtually non-ageing materials are used as insulators to prevent the intrusion of moisture.

8 Glass International July/August 2018

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International News

Top 10 stories in the news

NEWS IN BRIEF

Bastürk uses Heye

Bastürk Cam container glassmaker used Heye International’s expertise to start production. Basturk is located at the heart of the Malatya agricultural region of Eastern Anatolia. It has a 300 tonnes/day glass melting furnace, serving three Heye International 12-section SpeedLine IS machines.

Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1. Beatson Clark bottle aims to fight war on sugar � 2. Trend Glass chooses Forglass furnace � 3. Horn supplies technological line � 4. Corning to invest in manufacturing site � 5. Bresle Valley manufactures 70% of the world’s luxury bottles � 6. Glass Problems unveils conference schedule � 7. British Glass to host Glass Focus Awards 2018 � 8. Meeting of minds at SGT glass conference � 9. Brazil’s first Glass Technician Training Course � 10. Namibian manufacturer plans to build factories worth $750 million

Sisecam’s Italian job

Sisecam has completed its acquisition of Sangalli Vetro Manfredonia facility in Italy. Trakya Cam Sanayii, a Sisecam flat glass manufacturer, has invested €15.7 million in a second facility in Monte Sant’Angelo, Italy and doubled its production capacity in the country.

Steklarna investment

Slovenian packaging glass manufacturer Steklarna Hrastnik is to make investments of €12.7 million in 2018. The company has completed the first of these investments of €4.2 million to increase its production by 20%. It bought a new IS machine with a higher capacity for its Special production unit and moved an existing IS machines from its Special to its Vitrum unit. The investment had not only increased its capacities but also improved the working conditions, the company said.

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Bresle Valley boost

A French valley manufacturers the majority of the globe’s luxury bottles. The Bresle Valley, on the border of Normandy and Hauts-de-France, produces more than 70% of the world’s production of luxury bottles for perfumes, spirits and pharmacy, according to French manufacturers. “After a very sharp decline in activity for two years, we skyrocketed in 2010,” said William Varrall, director of the Glass Valley association, which represents 70 companies in the Valley.

Ian Martin Lindsay Fives Stein Limited (UK) has announced the death of Ian Lindsay, Sales Manager, who passed away in May following a short illness. Mr Lindsay joined the electric melting division of King Taudevin & Gregson Limited (formerly Penelectro) as a mechanical draftsman in 1978. He later moved into project engineering and contract management; working in both office and site roles he developed an extensive and broadbased expertise in the fields of electric melting, air-gas regenerative furnaces and electric boosting. After a short period with a different UK supply company,

Ian joined the newly establish Penelectro in 1997 and followed the company as it became part of the Fives Group in 1999. In later years under Fives Stein, Ian used his knowledge in sales, leading numerous projects in Europe and Asia, although his practical abilities meant he often retuned to spend time on site in engineering and troubleshooting roles. In his 40 years in the industry Ian gained the trust and respect of glass manufacturers throughout the world at both professional and personal level; he was the one they came to when they had problems,

the one they knew would take ownership of their difficulties and go that extra mile to help. Always good humoured, always willing, diligent and hard-working, Ian will be missed by his colleagues at Fives and by those he knew within the industry. Our sincere condolences go to his wife and family. Fives Stein.

O-I’s Helix bottle in the UK O-I’s ‘twist to open’ Helix bottle continues its conquest. It is now in the UK after establishing itself in France, Spain, Portugal, Benelux, South Africa, China, Japan and the US. The bottle has an original design with a floral decoration made in the O-I Innoval factory located in Chazelles

sur Lyon in the Loire, France. Helix allows the consumer to open a bottle of wine without a corkscrew, thanks to a simple ‘twist’, while preserving the distinctive ‘pop’ which is the hallmark of a cork closure. It was developed and marketed by O-I and Amorim, specialists, respectively, in glass packaging and corks. Glass and cork are recyclable, so Helix is also an answer to environmental challenges.

10 Glass International July/August 2018

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� 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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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

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>>

12 Glass International July/August 2018

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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 Continued>>

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� Site / Supervisors at work.

13 Glass International July/August 2018

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� Zippe batch plant.

Real-time Process & Quality Controls

and 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. “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.” �

When you need precise, cold facts… constantly

SELF-LEARNING, COLD-END INSPECTION SYSTEMS We don’t have our heads in the clouds when it comes to the quality of glass, we have real, practical solutions: self-learning inspection systems with sensors providing precise measurements even faster. Like everything else, our cold end inspection is backed by top service, support and training; and our constant research is working towards the Smart Factory – watch this space.

Zippe Industrieanlagen, Wertheim, Germany www.zippe.de Intelligence

Zippe profile.indd 3

Monitoring

Traceability

Support

31/07/2018 11:58:11

ENDTOEND Full-Process Excellence

Welcome to the digital age...

NIS and BIS cover the complete ware range with full servo technology. Future glassmaking is now complete. Emhart Glass SA - Hinterbergstr. 22 6330 Cham - Switzerland - Phone +41 41 749 42 00 - webmaster@bucheremhartglass.com - www.bucheremhartglass.com

Forming

Bringing new technology to life Dr Matthias Kümmerle has worked for Bucher Emhart Glass for 10 years. The company’s VP of Technology discusses his role and explains how innovation remains at the heart of the organisation. developments such as new sensor systems or mechanical modules represent the more frequent product launches. As glassmakers are under pressure to be more flexible, are facing increased competition from rival packaging materials, are confronted with environmental challenges as well as cost pressures Mr Kümmerle is convinced that the glass industry can remain successful only through continuous innovation. “The need for innovation has never been higher and we have to come up with safe, flexible and effective solutions,” continues Mr Kümmerle. Emhart invests up to €18 million a year on R&D and maintains its own research centre in Windsor, Connecticut, USA. The centre has its own fully functional glass plant with a 40t furnace and the full Emhart range of forming and inspection technologies. “This allows us to drive R&D, which would be difficult to do in parallel with on-going production at our customers.”

As a whole Emhart has about 80 people that work in the research and the development of new technologies.

End to End The company will be present once again at this year’s glasstec event, where it will highlight the achievements as well as the next steps of its End to End journey. End to End Technology is a unique set of solutions and automation technologies designed to make glass production easier, safer and more efficient. It takes a holistic view of the production process and unifies forming and inspection technology. Emhart launched its End to End concept at the previous glasstec in 2016. End to End also aims to address the problem of acquiring and retaining young talent to the glassmaking sector. Mr Kümmerle said: “This is probably one of the largest motivators for the Continued>>

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r Matthias Kümmerle’s role is to oversee all aspects of R&D and Product Management at Bucher Emhart Glass - from the feeder to the forming machine as well as ware handling and cold end inspection. “If you are in R&D in the glass industry you realise it’s extremely broad. “It is high in technical complexity and comprises a wide range of different engineering disciplines. At the same time it’s exactly the breadth of the technology which is fascinating and is a paradigm I enjoy a lot” says Matthias Kümmerle. Engineering disciplines include mechanical engineering, material science, thermodynamics or fluid dynamics, while in recent years software, controls, and data analysis have also become critical topics to the industry and to Emhart. While the introduction of a completely new type of IS machine is rare – once every 10 years – software products, such as new closed loop controls, and other

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Environment Forming

Mr Kümmerle outlines how a new item of technology is created at Emhart Glass

is a business case, we have a relatively conventional development process where we follow a stage-stage methodology, from concept to prototype and then go step by step. We have a strategic product platform in our organisation, where we act as a funnel, evaluating market needs and ranking development ideas and try to answer two questions: One, does a proposal fulfil a customer need and result in a favourable business case for it and two is our organisation capable of driving such development? The trick in product development is to make the right choices, to prioritise, since there arealways more ideas than available resources.”

“It all starts with a customer need and we try to understand what the customers want. Before we start doing anything we have meetings at the very early stages with our customers. We have a culture where we involve our customers in the R&D process from day one. In the past, R&D people were not comfortable to share early ideas with external customers. But we have changed this completely. Once we have confidence that a new solution addresses a market need and that there � Dr Matthias Kümmerle, the company’s VP of

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Technology

whole End to End development because we realised we had to develop technology in the direction where it is more effective, easier to use and safer to operate and is less dependent on experienced people. “We don’t believe it will ever be where you run a machine at the push of a button but we see a lot of areas where we can make the technology more effective and simpler. “End to End is a set of solutions and technologies particularly in the area of automation and process control that also makes better use of all the data than today.” One aspect of End to End focuses on automatically adjusting parameters of the forming machine by using measurement data from integrated sensors. As a result, the operators can spend much less time babysitting the machine and adjusting its parameters while at the same time the processes become more consistent, repeatable and thus resulting in better quality and higher output of the plant. End to End can also help glass operators manage the amount of data available to

them. Mr Kümmerle said: “If you look at the forming and inspection process there is a lot of data available. There is a multitude of control screens and monitors and the average plant engineer is overwhelmed. There’s a big push to make better sense of the data to help the operator in his task and to push automation to the next level.” Ongoing End to End developments aim at applying big data analysis to investigate correlations that a human could not pick up. The ultimate concept of End to End is that the hot end and cold end work hand in hand together. The cold end continuously ‘talks’ to the hot end. “We will feed information that is picked up in the cold end back to the hot end. Based on such information, the process will be adjusted automatically and eventually we will avoid defects being produced. “Today there are still too many losses and End to End tries to minimise those losses,” he added.

Customer Feedback Initial developments of the End to End journey have already been implemented in several glass plants in recent years and the response has been good. “We have been overwhelmed by the feedback we are getting on End to End. It seems we are hitting a nerve and the feedback from pretty much all our customers is that this is exactly what the industry needs.” End to End is a 10 year roadmap and is staged in a way where there are many intermediate steps and several product launches rather than a whole package which is completed in a couple of years. It combines several solutions on topics such as process control, safety and ergonomics. The company has also received positive feedback about the concept’s scalable approach, where customers can add on elements as they become available. Such feedback is one of the perks of Mr Kümmerle’s job. “One of the best things that can happen for somebody working in product

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To make glass better, put us in the mix. Improving combustion can enable you to increase glass production, reduce fuel consumption, enhance glass quality, and reduce emissions, such as NOx, SOx, CO₂, and

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Environment Forming

development is if there is positive feedback from the users and market. It confirms that your initiatives are going in the right direction and that you’re working on solutions that are recognised, that is very motivating.” More of the roadmap will be unveiled at this year’s glasstec, where Emhart will unveil more innovations towards its dream of a glass plant of the future. “In 10 years time it will be much more hands off and a very stable process. It will require less interaction of people and will be simpler for glass plants that struggle today with low efficiency rates to produce at a much higher rate.” �

� End to End incorporates the latest automation technology.

Bucher Emhart Glass, Cham, Switzerland www.bucheremhartglass.com

www.glass-international.com

ProductsCollage_GlassInt_HalfPage_Layout 1 6/28/2018 10:52 AM Page 1

Glass Conveying Innovations Only From Ramsey Working to improve glass conveying has been our goal for more than 50 years. Our commitment has produced more patented* silent chain conveying innovations than any other chain producer - from Lifeguard and R-Select to the RKO Ramsey Knock Out Tool . And there’s more to come with our newest products, Sentry and Ramsey All-Steel . We welcome the opportunity to discuss your needs. ®

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End of the road for ‘cat-scratch’ cord drains Almost 200 PSR Cord Dispersal Systems installed Money-back guarantee Pay-back time measured in weeks

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Company profile: Wiegand-Glas

Wiegand-Glas embarks on major investment plan Germany Großbreitenbach Schleusingen

Ernstthal Steinbach am Wald

� The Wiegand-Glas Group has four

� The Ernsthal plant is a speciality spirits bottle site.

glassmaking sites in Germany.

Wiegand-Glas is set to begin a €50 million investment plan at its glass plants in Thuringia, Germany. Greg Morris met owner Oliver Wiegand at the group’s Steinbach am Wald site to find out more.

www.glass-international.com

he first thing you notice about the Steinbach am Wald glass plant is its size. Emerging out of the trees just past the picturesque village, the site is the largest in Germany in terms of output. It contains four furnaces, nine production lines ranging from double to quadruple gob, a glass recycling plant, warehouses, an R&D lab and has a capacity of 1200/t, or 3.1 million items, a day. Wiegand-Glas is a container glass manufacturer which makes 8 million food containers and beverage bottles a day in its four glass plants – Steinbach am Wald, Ernstthal, Großbreitenbach and Schleusingen. It can provide colours and shapes to suit all tastes and its range of products includes all types of glass packaging as well as individual returnable and non-returnable bottles and jars. Wiegand-Glas can trace its roots back to the 16th century. Oliver Wiegand is the fourth generation of the family to work in the business. His greatgrandfather took-over the glass plant in Steinbach am Wald and owned seven plants at one stage. The Steinbach plant was the only one not to be appropriated by the East German government at the end of World War Two. With just one plant remaining the family had to work hard to re-start the business. In the years since the end of the

war Mr Wiegand’s grandfather and father also managed and grew the family company before Oliver and his cousin, Nikolaus Wiegand, took over in 1996. Bottles made at the site are transported all around the world. The Steinbach plant is located in the Franconian forest in Northern Bavaria and is a long way from the nearest big city. Frankfurt and Munich airports are both three and a half hours drive away for example. Its rural location is an advantage and a disadvantage, states Mr Wiegand. The unemployment rate in the region is extremely low, so attracting staff to the plant can be difficult. But, on the other hand, staff tend to remain at the plant once they are employed. “We are based in the countryside and the advantage of that means we don’t have a fluctuation of staff. People work here for a number of years - from the beginning of their career to retirement - so there are a number of experienced employees here. We have very good people in our plants and they make what we do possible.” Each of the company’s glassmaking sites are located within an hour’s drive of Steinbach. Ernstthal, located 25 minutes away, is a speciality spirits bottle plant. It was acquired by the WiegandGlas Group in 2016 and it is about to embark on a

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UK engineers working in Steinbach How did a group of UK apprentices end up working in rural Germany? The German container glassmaker made it possible for 14 apprentices from Wales to learn more about glassmaking at the Steinbach am Wald site. The trainees, aged from 17 up, got to know the corporate structure and production processes at Wiegand-Glas. They did not just receive a comprehensive overview of the production of container glass using state-of-the-art technology, but also practised on the machines and in quality assurance. The apprentices were hired as part of the EUContact scheme which aims to tackle youth unemployment by placing students in industrial plants. Wiegand-Glas hopes some of the young people will opt for a job in the group after completing their training. www.wiegand-glas.de

€50 million investment programme. Its 10-yearold furnace will be replaced with a new Sorg one, with a capacity of 360 tonnes a day of flint glass, up from the previous 250 tonnes. The furnace has three lines and on one line two more sections will be added to an IS machine. Inspection equipment will be replaced with the most modern technology in order for even better quality and for less bottles to be re-sorted. The inspection technology, from Tiama, has different types of High Definition cameras which can detect tiny defects impossible for the human eye to see. The technology will be combined with a new information system so all data from the inspection machines will be analysed and the operator can immediately see what kind of defect occurs on which bottle. “It means we can react much faster to bottle defects and also be able to detect defects that we are not able to detect today. We will reduce the visual inspection on the light screen wherever possible,” Mr Wiegand said.

The latest automatic packaging technology will also be installed as well as a new warehouse and a second, three-storey building. It will contain an inspection and packaging area on the ground floor, a first floor office building, and a canteen, changing area and meeting room on the second floor. The Ernstthal plant has three furnaces and nine lines. It produces spirits bottles in flint and super clear flint, as well as water and wine bottles. The site has the expertise to produce different shapes, customer specials, non-round and embossed bottles if required. It produces about 1200 different articles a year. Most of its customers are based in Europe but it exports internationally. Mr Wiegand said “While Wiegand-Glas mostly manufactures wine and beer bottles, the acquisition of the Ernstthal plant gave us the chance to expand the spirits market and enter the specialities bottles market, which was new for us.” He added: “Spirits bottles have to be very special. They are not easy to produce so you need a lot of know how and the right technology to produce these containers. “It’s a speciality plant, so we have to be flexible and still produce quality products while manufacturing at a high pack to melt ratio, so it requires high investment.” The project will mean the company will strengthen its market position and be able to react even more flexibly to customer requirements. Small series and individual containers in high quality flint colour in particular will be made there. The investment project will be completed in early 2019. The proximity of Ernstthal to Steinbach means there is a constant exchange of people, knowledge and parts between the sites. Regular training days are organised between each plants. The Steinbach site has a training centre so employees can train on an IS machine there before using the Emhart AIS machine in Ernstthal, for example.

Award Mr Wiegand is the 2018 Phoenix Award’s Glass Person of the Year. The awarding committee cited Continued>>

www.glass-international.com

Company profile: Wiegand-Glas

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Company profile: Wiegand-Glas

his willingness to embrace new technology and his environmental credentials (see interview with Mr Wiegand, June 2018 Glass International). In keeping with the company philosophy of using new technology, the Ernstthal site will use a LoNOx catalytic filter to reduce NOx emissions below 500 milligram per cubic metre. “The DeNOx technology with ceramic filter candles allows us to run the furnace more efficiently and in the secondary process eliminate the NOx,” Mr Wiegand said. This technology is already in place at the Steinbach plant and Mr Wiegand believes it is the first container glass site in Europe to use such technology to reduce waste gas emissions. It is a combined filter system that reduces SOx, NOx and dust and which works with ceramic candles. The filter went into operation at the beginning of the year and can eliminate all NOx emissions to nearly 0, while the dust emission is around 0.1 milligram per cubic metre. Mr Wiegand said: “It is positive news but on the other hand it adds cost to the production because the new filter investment is very high and the operational costs are also high.” Wiegand-Glas works with a number of suppliers that operate in all areas of a glass plant. It will commission a Zippe batch plant for its Steinbach site later this year, which will supply several furnaces. It has also worked with Sorg and EME to develop a batch and cullet pre heater at Steinbach, while its IS machines are a combination of Bottero, Bucher Emhart Glass and Heye International. “We have a good relationship with suppliers and carry out a lot of R&D work together where a lot of knowledge is exchanged.”

they want bottles. So there is more pressure and we have to be able to produce more rapidly and in smaller lot sizes. There are also more job changes and the job change planning has changed. You cannot plan four weeks away, sometimes you can only plan one day ahead.”

Familiar face

www.glass-international.com

Industry 4.0 Industry 4.0 has become a talking point in recent years and Mr Wiegand believes the industry has some way to go before it embraces the technology. “At the moment an experienced IS machine operator is still better than a computer. When there is a defect there are several ways to choose to remedy it. But more computers are being used in a glass plant now. “Today when you buy an IS machine you can buy so many sensors with the machine that you can measure a lot and then you need the software to analyse the data in order to change the settings of the machine. The software is getting better. “But I don’t think we can reduce staff. We have only one operator per machine and I cannot see us going to zero operators.” Like all other container manufacturers, Wiegand-Glas has seen the number of job changes increase in its plants. End consumer trends, driven by individualisation, mean customer requirements have changed. “There is more flexibility required now, we receive shorter notice from customers about when

� Wiegand-Glas can provide colours and shapes to suit all tastes.

Mr Wiegand is a familiar face within the container glass sector. He was Chairman of the International Partners in Glass Research (IPGR) organisation between 1998 and 2009 and is today its Vice Chairman. He represents the German glass industry on the board of the European Glass Container Federation (FEVE). He is also Vice President of the Bundesverband Glasindustrie (BV Glas) and is Chairman of the Fachgruppe Behälterglas (container glass trade section). He believes the glass industry will need to change ahead of ever-stringent environmental legislation. “By 2050 we will have to reduce emissions by 85% so that requires completely new technology. A huge step change is required. “The ETS will force us to reduce CO2 emissions and that means we need a new furnace type, which will require a new plant setup. “Maybe we will not have one furnace for a certain number of lines but have one furnace per line and that will be an electric furnace. “Electric furnaces are smaller than conventional furnaces and a smaller furnace for one line would be possible.” These are future challenges for all glassmakers, not just Wiegand-Glas. For now, the company will focus on its core markets and continue to invest in the latest new equipment to ensure it remains an efficient container glassmaker. Mr Wiegand states: “I think we are in a very good position both technically and also on the sales side. We offer a variety of bottles and we can supply whatever a customer requires in terms of shapes, colours and personalisation.” �

Wiegand-Glas, Steinbach am Wald, Germany www.wiegand-glas.de

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SORG offers more:

INNOVATION Because we canâ&#x20AC;&#x2122;t leave good enough alone VALUE BY DESIGN

At SORG, continuous innovation is in our DNA. Our mission is to provide customers with ever improving solutions and advantages. Reliable, flexible, environmentally friendly products that lower the total cost of ownership. That is why we took the best in class 340S forehearth and developed the new SORG 340S+.

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Plant utilities

Applying modern inventory techniques in plant repairs Clemens Eidmann* suggests how the use of 3D laser scanning in the inventory of a structure can help pinpoint a glass plantâ&#x20AC;&#x2122;s situation in rapid time.

Existing documentation You need to rely on existing documentation for the planning and integration of the new or to be modified plant parts or infrastructures. If these are still present, they are in paper format due to the age of the buildings. This makes the data transfer to the new plans difficult or impossible. Additions and adjustments

ďż˝ Fig 1. Measuring Points.

have often also been made over the years so that the existing documents are no longer up to date. In these cases, it was and is common for employees of the planning company to be on site for a longer period of time and to record the situation with conventional means, such as a paper drawing, folding rule and laser measuring device, depending on the size of the plant. Practice shows that these inventories contain inaccuracies and can also be incomplete.

Laser scanning A more than reasonable alternative to the classical inventory is the method of laser scanning, which has already been used in other areas. SORG has introduced laser scanning for the inventory of existing building structures and infrastructures in the glass industry. Laser scanning captures up to 1,000,000 points / second with the help of a laser beam rotating around two axes. Each detected point receives among other things two angles and a distance to the set up laser scanner. These polar coordinates are then converted into a Cartesian coordinates system. There is thus an x, y, and z coordinate for each point. The entire system can also be aligned in a 3-dimensional space as desired and so

positioned to newly planned system structures in CAD programmes. The Sorg laser scanning team is able to capture the complete plant situation in a short time. Therefore, the system is scanned across 400 or more installation sites of the laser scanner across all floors. Fig. 1 shows the measuring points (installation sites for the scanner). The entire system with all its details is subsequently calculated as a 3D point cloud and made available to the user. In this point cloud, which of course can also be available in colour, a simple measurement of the existing and required structures is possible. It is also possible to extract further measurements from the 3D representation, which did not seem superficially necessary (Fig. 2). The scanned system structure can be processed digitally, both with 2D CAD and 3D CAD programmes. In addition to the almost complete recording of the existing system with all its pipes, cable trays, stairs, stages, fans, other equipment and the associated ability to measure all these structures and their position to the millimetre, a clearer communication with the customer is possible (Fig. 3).

Continued>>

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xisting building structures and infrastructures and the demand for ever larger glass melting plants make the handling of so-called Brown Field projects increasingly complex. Existing structures are to be reused to a larger degree not only for cost reasons. The integration of new stages, entrances and plant components into existing systems requires a higher degree of coordination effort with the client than was necessary a few years ago. Extensive safety regulations and the positioning of new and also reusable equipment have to be considered now. Communication with and the involvement of the customer in the solution finding process, as well as coordination of the individual technical departments over the different project phases make it necessary to form a detailed visualisation of the existing plant complex.

ďż˝ Fig 2. Point cloud of complete glass furnace facility.

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Environment Plant utilities

Fig 3

Fig 6

Fig 4

Fig 7

Fig 3. Thanks to laser scanning measurements, the designer can gain missing information Fig 4. Collisions of new facility structure with existing equipment can be easily identified and communicated Fig 5. New equipment can be integrated in existing structures Fig 6 and 7. Determination of existing gob point location

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Fig 5 A picture is worth a thousand words. For example, the customer can be told very quickly if there are likely to be collisions with existing components and the system being planned (Fig . 4). Collision control is of course in the foreground of planning when using new components or those that are to be fitted to existing plant components (Fig. 5). In the example, a newly planned reversing unit is delivered to the existing structure. In the past, it only became apparent at the building site, whether the unit really fitted or needed to be adapted on site. As a basis for planning, it was well known that an oversize and possibly existing original planning documents were used. But it is not known whether these planning documents represent the real state.

Planning quality The planning quality at Sorg has been further improved by the introduction of the laser scanning process. With specially trained staff and its own equipment, you know exactly what is important when scanning. This ensures that you can reasonably construct with the data later on. A measurement of the entire system can be realised in a short time, without affecting the operation in any way. For example, the forehearth situation of a system can be scanned in one day and across all building floors. With the help of this data Sorg is then able, for example, to record the real gob point situation and consider it in the planning: All this saves adjustment work on

the building site and enables a smooth project process (Fig. 6 and 7).

Summary 3D laser scanning is a modern method which allows you to record existing structures quickly and accurately. The data can be used for further planning, so that accuracy is increased and possible collisions are already identifiable at the beginning of the planning phase. Sorg has successfully introduced 3D laser scanning into the glass industry. The company has the equipment and a team of experts to carry out the inventory in a timely manner, tailored to the customersâ&#x20AC;&#x2122; needs and the task. ďż˝

*Head of Design Department, Nikolaus Sorg, Lohr, Germany www.sorg.de

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Rondot introduces Smart Tong

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Hot end

Real-time Process & Quality Controls

ondot has launched Smart Tong, a new take-out insert that uses stainless steel braid. The carbon inserts are not always able to avoid the glazes and that is why Rondot developed Smart Tong: a new insert whose contact zone is equipped with a stainless-steel braid. The Smart Tong avoids thermal shocks, microcracks and lubricant marks on the glass thanks to its soft contact. A ﬂoating insert is also available for neck diameters from 26mm to 28.5mm. The company states that the advantages of the Smart Tong include reduced maintenance. Not only are they very durable about 4 to 5 times more than carbon inserts - but their braid can be changed directly at the factory (non-welded braid). �

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Working for a brighter future…

� � � The Smart Tong.

WITH TIAMA HOT-END MONITORING Receiving information faster is possible and easier with our Hot-End Monitoring Sensors. Our system is also more cost effective because it is modular: you choose only what you need. 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. So, watch this space if you are preparing for the Smart Factory.

Intelligence

Rondot.indd 1

Inspection

Traceability

Support

30/07/2018 09:50:15

Company proﬁle: Pennine Industrial

Pennine Industrial celebrates 50th 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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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.”

“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>>

32 Glass International July/August 2018

Company profile Pennine.indd 1

31/07/2018 11:59:59

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>>

www.glass-international.com

just under 70 staff today.

33 Glass International July/August 2018

Company profile Pennine.indd 2

31/07/2018 12:00:03

www.glass-international.com

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

�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

34 Glass International July/August 2018

Company profile Pennine.indd 3

31/07/2018 12:00:11

GLASS FURNACE DRAINING

GLASS FURNACE HEAT UP

THE SPECIALISTS Excelsius Global Services GmbH Bgm.-Dr.-Nebel-StraÃ&#x;e 14 97816 Lohr am Main Telefon 09352 6044-0 www.excelsius-global.com

Part of the

Group

“This will be the biggest investment year in Guardian history, outside of years where there were specific acquisitions. From an organic standpoint, our growth plans and reinvestment in the company - 2018 will be the biggest year.

”

� Kevin Baird, President and CEO of Guardian Glass.

Guardian set for biggest Guardian Glass President and CEO, Kevin Baird, outlined some of the trends that will define the company’s strategy in 2018 and beyond. Sheena Adesilu spoke with Mr Baird and senior Guardian executives to find out more.

www.glass-international.com

uardian has invested more than €50 million in the past five years to equip all of its float facilities in Europe with the best available technology and emission control systems. The aim was to reduce emissions by up to 80-90% for certain pollutants from the float glass process. But the spending won’t stop there. At a gathering in London, UK its President and CEO, Kevin Baird, stated: “This will be the biggest investment year in Guardian history, outside of years where there were specific acquisitions. From an organic standpoint, our growth plans and reinvestment in the company - 2018 will be the biggest year. He added: “Guardian has seen the industry turn and we are very strong today in Europe, especially central Europe. “We see growth in this business, around the

� Kevin Baird and guests.

world in most of our applications. Because of urbanisation, because of daylighting, because of trends, we also see more glass produced per application than in past years.” The largest investment will be in Poland, where it plans to create a new facility consisting of a 1000t/day furnace in Czestochowa, adjacent to its existing float glass facility. The plant is due to start up in the third quarter of 2019 and will create 50 new jobs. The group is also increasing the capacity of another furnace in Poland by 25%, which was due to be completed by June 2018. Guardian completed a cold-tank repair in its facility in Talheim, Germany last year where it Continued>>

36 Glass International July/August 2018

Company profile guardian glass.indd 1

31/07/2018 15:41:28

Company profile: Guardian Glass

increased the capacity by more than 20%. It is also currently building a laminating line in Oroshaza, Hungary, that will be able to laminate standard laminated glass and more special glass such as thick laminated glass. It is also upgrading its laminating capacity in Spain and Luxembourg. Its Vice President of Guardian Glass and General Manager of Guardian Glass in Europe, Guus Boekhoudt, said: “We believe that over the next five years glass will continue to grow around 4% a Euro every year. For me, it’s very important to understand what the growth rises are, besides economic profit. The underlying growth is that people want to have more daylight into residential and commercial buildings. I typically tell my staff, what we’re really selling is daylight to our customers. That involves bigger pieces of glass in residential and commercial buildings.” Globally, the company has 25 lines and competes two to three tank repairs every year. On average, every one or two furnace rebuilds tend to

be an expansion. The international investments include a new jumbo-coater that will launch in the US in a couple of months, as well as cold tank repairs Brazil and the USA.

Focus

� Kevin Baird, Guus Boekhoudt and guests

Guardian is focused on three segments: Commercial, Residential and Speciality. The Commercial segment is an important part of the company’s business in Europe. The Residential segment, from a volume point of view, is the largest segment it serves in terms of volume so it provides glass for a variety of applications. The Speciality segment involves selling glass and trying to position the company as specialists in the application. This also includes a specifier to help solve the most difficult problems. For example, Guardian Clarity glass will be showcased at glasstec in a different amount of applications. Mr Baird explained: “There has been strong

investment year in its history

“We believe that over the next five years glass will continue to grow around 4% a that people want to have more daylight into residential and commercial buildings... That involves bigger pieces of glass in residential and commercial buildings.

” Continued>>

� Guus Boekhoudt, Vice President of Guardian Glass & General Manager of Guardian Glass in Europe.

Company profile guardian glass.indd 2

www.glass-international.com

Euro every year. .. The underlying growth is

37 Glass International July/August 2018

31/07/2018 15:41:33

“Not only is Europe a place where business is good and markets are growing, but it’s a place where we really need to be

”

www.glass-international.com

in touch with our customers.

demand in the last several years, which is still increasing, for low iron glass. “The difference between UltraClear low-iron glass and glass with more or an ordinary amount of iron is pretty remarkable when they are side by side. “And [the demand is] also mostly for interiors; for textured and patterned glass. “So given our focus on product or process innovation, we do invest heavily in R&D. “I can’t stress enough the importance of taking product and reinvesting in the company’s capabilities, specifically in developing the new technologies of tomorrow.” Since 2016, Guardian has seen a healthy demand for glass and it believes that over the next five years, demand will continue to grow by 4% a year. The reason for this rise is that people want more daylight in residential and commercial buildings. Guardian is in the clear float business. This includes value adding, which often means converting clear float glass into something else, such as laminated or fabricated product and coatings or more use of low iron or heavy glass. The company is ‘excited’ to be investing in current trends. The glass manufacturer is in the global business more today then it ever has been and is moving its capabilities across country lines, continents and oceans to support its customers. It is keeping up with technology and making sure it remains competitive.

glasstec At this year’s glasstec exhibition in Düsseldorf, Germany, Guardian plans to include a multisensory experience so visitors can experience the benefits of glass. It also plans to present a new technology for the application of insulated glass. Mr Boekhoudt stated: “We are seeing a continued trend in conversion from double to triple glazing.

� Sheldon Davis, Vice President of Science, Technology & Innovation at Guardian Glass.

“This trend is not done yet. We believe that it will continue for the next three to five years and then it will reach a saturation level. “But that will also increase the use of laminated glass.” The company will present three products at glasstec. This includes vacuum insulated glass (VIG) products, a hybrid consisting of a monolithic piece of VIG that’s put into an IG configuration and Clarity, an anti-reflective glass product.

Skyscrapers Guardian has also collaborated with UK architectural firm SimpsonHaugh to create the building One Blackfriars in Bankside, London. It is 170 metres tall, 50 storeys high and consists of 5, 674 Guardian Glass panels. There are 274 flats and two penthouses at the top. The skyscraper can be purchased for £26 million. Mr Baird continued: “One of the interesting and fascinating parts of our industry is that it takes so much collaboration to finally come together to make a project like One Blackfriars. Of course, we’re very proud of our role there. “It sometimes amazes me to see all of these things come together to make such a beautiful building, the challenge with all of these different businesses and generally different companies and the ability to collaborate be absolutely critical. “We aim to create value for customers by a win-win transaction and by that I mean that we understand and expect mutual benefit. “We win and our customers win and we think it is important that the relationship is one of mutual benefit. “Using the fewest possible resources, creating and fully leveraging competitor damage focus on innovation and then a challenge process.

Continued>>

38 Glass International July/August 2018

Company profile guardian glass.indd 3

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Come to visit us

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Company profile: Guardian Glass

“Basically, that means being direct and intellectually honest with each other and all of our partners.” Another huge project includes the Jeddah Tower in Saudi Arabia, to be completed in 2019. The project will cost $1 billion and is 1.2 kilometres high. It will include 400,000m2 of Guardian Glass. It will exceed the Burj Khalifa in Dubai in size, which also has Guardian glass, and will be the tallest building in the world. “We’ll break new world records for tallest building, highest occupied floor, highest architectural top, highest tip and highest sky terrace,” stated Mr Baird.

Mr Davis explained: “So in general, when we design a product, we’re balancing these three features: aesthetics, its functional component – in this case, energy performance and efficiency – and how customers can take these products, process and install them in their buildings. “Regarding target value chains, we’re really thinking about the processors, cladders, architects, building owners and occupants. “We want to enable people’s lifestyles.” Guardian’s products are designed to satisfy and enable something that every group in the value chain is trying to do. It thinks about society and how it can create value for them. The glass manufacturer is trying to create products that are processors and effectively take, synthesize and make cladding into IGs that partners are able to put on walls in order to do great work. These products are more durable and easy to process. Mr Davis believes that daylight provides comfort and wellness, which is what the company’s product design is all about. Mr Davis concluded: “[What] Europe does for us, is it allows Guardian to understand global trends better. “I think there are many things that Europe are leading in with architecture and design. “And this is important to us because we want to be there to respond with our products, enable and support them. “If we move on beyond aesthetics, the other thing we have to do in our glass products is bring energy efficiency and sustainability. “And that boils down to two key factors: Selectivity and thermal performance.” The glass manufacturer has recently launched a website, www.guardian-possibilities.com. The website showcases possibilities for glass and smart design calculation tools to help companies with their application calculations. �

European research centre

� Sheldon Davis and guests.

Guardian Glass will be exhibiting at glasstec 2018 on 23rd26th October in Düsseldorf, Germany.

www.glass-international.com

Guardian Glass recently opened a second Science and Technology Center based in Luxembourg. The staff are a ‘very electric and powerful’ group of people who will provide resources and skills from all around the world. This includes physicists, glass ceramicists, architects, designers, business executives and engineers. Sheldon Davis, Vice President of Science, Technology and Innovation at Guardian Glass, said: “Not only is Europe a place where business is good and markets are growing, but it’s a place where we really need to be in touch with our customers. “So we have created a centre to satisfy the needs of customers, get to know the customers, and be able to take our global technology and bring it to the European context in a more effective and efficient way. “Innovation is really the life blood of everything every employee should be doing at Guardian.” Guardian hopes the team will help the global industry to develop new technologies and product capability. The overall vision for the Guardian Science and Technology Center is to create products with long-lasting value and process technology for customers’ target value chains. The team strives to create glass that is energy efficient and sustainable.

40 Glass International July/August 2018

Company profile guardian glass.indd 4

31/07/2018 15:41:36

Tableware

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Change between tall ware and standard fingers 8 finger spacing op�ons available as standard Designed for single, double and triple gob produc�on Handling containers from 30mm to 165mm diameter using one chain and inter-changable fingers. Special kit for small ware containers with 1 1/2” and 2 1/4” spacing (not standard) Halifax Way, Elvington, York, YO41 4AU, UK T: 0044 1904 608999 E: sales@sheppee.com W: www.sheppee.com

Environment Forming

Using virtual reality in glassmaking A UK company has launched a virtual reality system to train operators how to use forming equipment. The software even allows operators to step inside the IS machine. Greg Morris spoke to its director, Chris Sorsby*.

� Mr Sorsby in front of the virtual reality system.

www.glass-international.com

ne of the main challenges facing the glass sector is the lack of young talent entering the industry. The argument goes that there is not enough new digital technology used in glassmaking to appeal to young engineers, who are attracted by supposedly more glamorous sectors such as the aerospace or automotive industries. One UK company is aiming to change that perception. It has launched a virtual reality training software system that can be used to train IS machine operators but also provides extra razzmatazz to attract more youngsters. The company, Virtual Reality Machine

Training, has designed the system based around the operation of an IS machine and is used predominantly to train operators from a basic level. Company Director, Chris Sorsby, of Glass Technology Services, said the intention in the future was for use in R&D, to practice job changes and all the aspects ‘you would want an IS machine to do.’ “We’d like to do this in a virtual reality environment essentially because it is safer and cheaper to have this system rather than buy in a training session. “There’s no loss of production when you try new ideas in the virtual world and

you can try new things you would not be able to do in the real world.” The idea for the technology came from discussions between GTS and a coding developer, Mark Henshaw, who is an expert in VR. They decided specifically upon an IS machine because it is a critical part of glass manufacturing and it allows scope for further development in the glassmaking process. The technology is currently suited to new operators and those unfamiliar with an IS machine but the aim is to provide for all levels of experience. Continued>>

42 0 Glass International July/August 2018

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Mr Sorsby said: “At the moment we’re focusing on the UK apprenticeship standard approved by Government. “We’re making sure that all the functionality of the virtual reality environment allows it to be used as a training tool for that standard. “That standard has been developed by the glass manufacturers in the UK, so by doing that we will be able to give more experienced IS operators a better understanding of what they’re doing. “From a training perspective, it’s not there to replace the IS machine or training section, but is another aid to improve the level of training and to give IS operators a better and deeper understanding of the process and how you fix certain faults.” For users, the software starts in the changing room where they put on safety equipment and goggles. From there they walk to the IS machine where they can participate in a variety of functions. These include turning the machine on and off, performing an emergency stop and checks on the bottles. The technology allows operators to view the machine from the blow and the mould sides and they can climb above the machine to view it from the top. Users can also walk inside the machine and inspect the working parts of the equipment. “Even the best specialist has never been into the middle of a machine or seen a parison being made or a bottle being blown out,” stated Mr Sorsby. He added: “This technology can speed up the training process massively. Rather than showing diagrams you can get operators right in there learning the machine, so you can shorten that time. You can also trial training on that which is safer. From an environment point of view it is not hot and noisy and you don’t have to affect production at all. “The cost of the software is nothing like the cost of running an IS machine or a training section.” The technology took more than a year to develop and combines a mixture of videos, images and GTS training tools. The machine is based on a standard, generic IS machine and was developed in collaboration with a glass manufacturer. It is currently a three-section, single gob machine but if a customer requests a specific machine the company can modify it. “The aim is to be able to pick any IS machine that you want so you could use the machinery that you have in the factory.”

� A screen grab of the technology.

www.growth-group.com

Forming

Real-time Process & Quality Controls

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Monitoring

VTR GTS.indd 2

Inspection

Traceability

Support

31/07/2018 12:02:35

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Forming

Real-time Process & Quality Controls � Mr Sorsby enters the virtual world.

Find the one you’re looking for among the 1,000,000,000,000,000,000,000,000 others out there

The technology will be officially launched at the glasstec show but has been used by two glassmakers so far. One has been using it to train new personnel while the other regards it as a multi site training tool, where trainers and operators can talk to one another from different locations. “You can track every piece of training that is done and can standardise training globally. So if you’re a global manufacturer and want to make sure everybody that works for you knows how to use the emergency stop button, for example, you can have a visual record of everybody around the world doing that in exactly the same way so you know they all can do it. I think that’s a feature that nobody else has in the world.” The technology does not have a brand name yet but the package includes a Microsoft Oculus Rift headset, a bespoke water-cooled PC that allows customers to run the VR, sensors and the software itself. The price of the package will vary depending on how many items each customer purchases. The company’s future plans include the use of the technology for feeder tubes, forehearth, the annealing lehr furnace and cold end, as well as a flat glass plant. “There’s no reason why you couldn’t do a whole glass plant,” stated Mr Sorsby. Industry 4.0 has become a common theme in glassmaking in recent years and Mr Sorsby hopes that this technology will be part of that story. “All the high profile high tech industries are using virtual reality to develop their training and staff and I don’t see any reason why the glass industry couldn’t be doing the same. “I hope this technology helps move the industry forward. Industries where you think you’re going to see this are in automotive or in aviation. You can’t fly a plane before you fly it in a virtual reality scenario.” �

TRACEABILITY WITH UNIQUE BOTTLE IDENTIFICATION It’s like DNA for glass: an engraved data matrix code with which one can trace any bottle to its point of origin. The hot and cold-end data from all the sensors are assembled in this unique code making it a powerful tool, essential for “big” analysis. Backed by our service, support and training, it’s one of the many ways we’re helping you to get ready for Big Data in the Smart Factory.

*Commercial Director, Glass Technology Services (GTS), Shefﬁeld, UK www.glass-ts.com Intelligence

VTR GTS.indd 3

Monitoring

Inspection

Support

31/07/2018 12:02:41

Environment Furnaces

Sivesa celebrates furnace start-up Mexican container glass manufacturer Sivesa is celebrating a successful furnace rebuild project.

supplied a new, larger 165m2 recuperation furnace with a nominal capacity of 360 tonnes. The entire project was performed in 59 days, gob to gob, and production started exactly on time. A third line was installed due to the increase in capacity. Heye International provided a 10-section double gob IS Speedline, Italy’s Antonini supplied an annealing furnace, cold end equipment came from France’s Iris Inspection Machines and from Heye, while Italy’s Zecchettti provided the transportation and palletiser. Brazilian construction management company ak Engenharia e Projetos

supplied key personnel for the project involved in structural steel, installation of the recuperators, the combustion air piping as well as commissioning and start-up support at the furnace. This is now the second project for ak Engenharia e Projetos in Mexico after Vichisa in Meoqui, Chihuahua this year. The production to nominal capacity was ramped up in 24 hours and the entire project was implemented without any major issues. �

Sivesa, Orizaba, Veracruz, México www.crowncork.com

www.glass-international.com

he Furnace B rebuild was performed in the first quarter of 2018 and included the participation of more than 70 national and overseas contractors, with more than 800 additional staff at the plant working at the same time. Sivesa manufactures soda lime glass containers for the alcoholic and softdrinks beverage market. It has a total headcount of 750 employees and a team of 12 engineers were accountable for the entire replacement project. The project involved the exchange of its existing furnace B at its Orizaba plant in Veracruz. Germany’s Horn Glass

46 0 Glass International July/August 2018

sivesa furnaces.indd 1

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History

Prof. John Parker

Is red for stop?

admium metal was first recognised in 1817 and has been used to make coloured pigments since the 1840s. It was discovered as an impurity in zinc ores, being chemically similar. It combines with sulphur to form cadmium sulphide (CdS, melting point 1750˚C), a semiconductor with an electronic band gap of 2.4eV. This corresponds theoretically to a wavelength cut-off of 513nm – so it absorbs blue light strongly and makes an attractive yellow pigment. Selenium can replace the sulphur in CdS in proportions ranging from 0 to 100%. Pure cadmium selenide (melting point 1258˚C) has a smaller band gap. More of the visible spectrum is absorbed making it a rich red. Intermediate compositions are orange extending the colour palette available. Monet used these pigments to paint his sunflowers and they remain popular as they are not bleached by light. Art Glass factories in Murano rely on the precipitation of nanoparticles of these compounds in their glasses for the same colours. For many years glass optical filters with many different applications used the same colorants. For example, airports needed them for landing lights and strict standards controlled their light transmission and colour. Interestingly the band gaps of Cd(S,Se) decrease with temperature and so the filters change colour in a hot climate compared with a more temperate environment, a factor to be considered when fulfilling a purchase order. At home we had a teapot with a red CdSe glaze. This colour shift was visible when hot water was poured in. So this magic teapot indicated how full it was, whether it was freshly filled (still hot) or if it had been brewing for some time (colder). These colours are not easy to handle. Cadmium is readily reduced to the volatile metal (b.pt. 767˚C) when melting

under a reducing atmosphere; sulphur and selenium on the other hand require reducing conditions to form the required sulphide and selenide ions. Oxidising conditions reduce cadmium evaporation but create sulphate and selenate species that do not form the required colours. Both the raw elements sulphur and selenium and their oxides are also volatile. The Cd(S,Se) nanoparticles precipitate during forming and parts of an article that have cooled quickly (e.g. thin walls) can have smaller particles, giving a different shade, or may even be transparent. Re-working the glass can increase the average particle size and extend the size distribution, giving glasses with less bright colours than the artists want; they become instead brown rather than yellow or orange. The optical behaviour is more complex than described. Photons can excite free electrons into the semiconductor’s conduction band leaving holes in the valence band; electrons and holes can pair up to create so-called excitons with energies near the band edge. The energies of the electron-hole pairs are affected by particle size, complicating further the relationship between forming history and optical absorption. The current crisis has arisen because cadmium is volatile and is easily lost into the environment during melting in an open crucible, while REACH legislation (Registration, Evaluation, Authorisation and Restriction of Chemicals) sets low limits on permitted cadmium emissions. The waste gas scrubbers and electrostatic precipitators available to clean waste gases are too expensive for small familybased interests on Murano and glass artists cannot work with sealed systems. Finding an alternative is therefore a major concern, mirrored in the paint and pottery industries. The colours can be created by methods

that go back to Roman times, although much less easily and with a reduced colour palette. Then metallic nanoparticles were precipitated and coloured the glass by a different mechanism. Copper (and cuprous oxide) colloids gave particularly deep reds and were difficult to control, often producing an opaque product if the copper particles grew large enough to scatter light. Gold gave a cranberry colour with a hint of blue in the predominantly red transmitted light. Silver colloids gave a yellow colour. These colours were expensive and difficult to make, with the recipes often dying out for generations until they were re-created. Not until the 1300s was silver staining discovered and it gives only a superficial coloured layer suitable for stained glass windows, not a body colour. Selenium also gives a pale red and is still used for physical decolorising but is difficult to retain in solution and consequently is expensive. An organisation called InMurano has been created by local glassmakers to seek solutions to these problems and they have a presence on Facebook; they instigated a round table discussion by experts at the recent Glass Art Society meeting in Murano. Historical collections of glass making recipes are being scoured for alternatives and research projects are underway to find replacements. Semiconductors with the appropriate band gaps exist but must satisfy REACH, be cheap enough, with a capacity to be melted and precipitated as nanoparticles. We hope that an orange warning light is more appropriate than a red stop light. Or must we imagine a clown without a red nose? �

*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk

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Prof. John Parker discusses how REACH legislation is effecting glassmakers on the historic Italian island of Murano.

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Environment Industry 4.0

Steklarna Hrastnik gets digital with Siemens Siemens worked with Slovenian glassmaker Steklarna Hrastnik to develop a roadmap including its schedule, technology recommendations and return on investment data. By implementing the measures, the glassmaker aims to improve productivity, flexibility and sustainability.

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teklarna Hrastnik and Siemens developed a tailor-made strategy for the company’s digital transformation over the next five years. The Slovenian glassmaker has been laying the foundations for its digital transformation over the past eight years by investing in production automation and digitalisation. One of the aims behind the company’s transformation into a smart factory is to improve its niche position in the high-end sector. The company’s management is confident that by implementing the measures outlined in the roadmap, it will not only increase its production capacity and cut production time, but also improve its flexibility and so reduce its response rates to individual customer requests. Peter Cas, CEO of Steklarna Hrastnik, said: “By implementing Industry 4.0, we will upgrade our ability to produce the most technically complex bottle shapes and achieve even greater precision in our production. “This way, we’ll be able to further increase quality, productivity and efficiency, which will shorten the time from the order to its realisation. “As a consequence, we plan to increase our market share in special glass bottles in the highest quality class.”

� Slovenian glassmaker Steklarna Hrastnik was formed 157 years ago. Steklarna Hrastnik employees have been prepared for the impending changes and have acquired the new skills and competences required to guarantee a successful transition to the smart factory. By introducing advanced technologies, Steklarna Hrastnik also aims to achieve lower energy consumption, which will further improve its environmental footprint. Bernhard Saftig, Head of Vertical Glass at Siemens, explained: “Siemens is convinced that a comprehensive approach to digitalisation has the most sustained and positive impact. “It starts with a complete analysis that ensures that subsequent solutions will be optimally adapted to the specific needs and scope of companies such as Steklarna Hrastnik. A non-Siemensspecific, product-neutral, customeroriented strategy is a top priority.”

Digitalization consulting Industrial companies are facing challenges in terms of the flexibility, efficiency and quality of their production around the world. These challenges can only be tackled through digitalisation. Small and medium-sized enterprises in particular need to be sure that they are making the right long-term investment in digitalisation. Siemens is working

together with customers as part of its digitalization consulting service to develop a detailed roadmap which includes everything from a schedule and technical recommendations to return on investment data. The first projects to result from this consulting service have already been planned and implemented at Steklarna Hrastnik.

Digital transformation Bernhard Kienlein, Head of Process Industries and Drives Division at Siemens in Central and Eastern Europe (CEE), is confident that digitalisation consulting will be an important future market for Siemens. “The potential for improvement in terms of Industry 4.0 remains at the same high level in Europe – although the same applies to the associated challenges. So it’s good to plan digitalisation projects on a company-wide basis.” The benefit is obvious: The financial resources invested in a digitalization project can be used to the most efficient and optimum effect on the basis of the results and recommendations provided by Siemens Consulting. This provides companies with vital support in achieving and improving their economic goals. Continued>>

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Industry 4.0

Productivity gains A study recently carried out by Siemens Financial Services (SFS) entitled The Digitalisation Productivity Bonus: Sector Insights provides evidence that investing in digitalisation certainly pays off and that considerable productivity gains are possible. According to the study, by automating and digitalising their production systems with all the associated improvements to productivity, manufacturers can increase their manufacturing productivity by reducing their production costs relative to total sales by up to 9.8%. Companies can use the released liquidity in other areas such as investing in and successively financing new technologies. Further details of the SFS study are available at http://sieag.at/zj

About Steklarna Hrastnik Steklarna Hrastnik based in Slovenia has 157 years of history. It produces technically complex glass products using one of the clearest glass types in the world, and uses its expertise to manufacture a products from tableware to packaging glass. The packaging glass division produces sophisticated, specially shaped bottles

� Steklarna Hrastnik aims to improve its productivity, ﬂexibility and sustainability with its transformation into a smart factory.

for the spirits and perfume industries. Its technically optimised bottles made of brilliant clear glass visually enhance the end products of its clients. The company’s production plants are based on a sustainable model which enables it to produce top-quality glass products with motivated employees, as

well as reducing its environmental impact despite a steady increase in capacity. Steklarna Hrastnik employs around 700 people, generated annual revenue of €57.6 million in 2017 and exports 97% of its production to 55 counties around the world. �

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Glass International July/August 2018

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Environment Forming

How Emhart collaborates with customers to improve BIS machines UK-based Allied Glass is one of three plants that has adopted Bucher Emhart Glass’ (BEG) servo-driven BIS forming technology. After two years of collaboration between BEG and its customers, BIS is set to complete the firm’s portfolio of servo machines.

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ucher Emhart Glass (BEG) launched NIS, its first all-servo machine, in 1999. NIS is ideal for high-volume, high-speed production, but less suitable for smaller producers who need to manufacture in smaller volumes. So in 2010, BEG introduced BIS, which offers the same repeatable precision as NIS but can handle a wider variety of container designs, sizes and weights. Soon after its launch, the first BIS machines arrived in working glasscontainer plants. The first went to Nampak in South Africa, the second to Noelle von Campe in Germany and the third to Allied Glass in the UK. Since then, BEG’s engineers have worked with operators, other engineers and executives at the three plants to monitor performance, improve working processes and make BIS more stable and efficient. The four-way partnership has helped to improve BIS on a technical level, as well as capture a great deal of new learning on getting the most out of the technology. Allied Glass’ forming lines were 100% pneumatic before they got their BIS machine. Richard Summers, Group Operations Director, said: “It was a big decision for us, switching to servo. We’ve never previously seen ourselves as an R&D front-runner; we’ve always played things safe. But we wanted more sustainability and repeatability, so we took the decision to innovate.”

� The BIS machine was installed in three container glass plants.

� Richard Summers, Operations Director at Allied Glass

Best of both worlds Glass-container manufacturers are notoriously conservative, often preferring to stick with proven approaches rather than take an adventurous route. It’s a strategy that minimises risk, but can also mean missing out on the benefits of innovation. However, a partnership between an established technology provider and a forwardthinking manufacturer offers the best of both worlds: a shared goal to improve performance combined with solid technical expertise and commercial focus. Jarmo Kammonen took over as BIS Product Manager at BEG in 2014, following the first three BIS installations. Since then, he has monitored the machines and overseen developments and improvements.

Mr Kammonen said: “We know, from introducing NIS, that it takes a while to discover things. In co-operation with Allied and the others, we exchanged experiences of how BIS performed, and what it was like to operate. “After 18 months to a year, we started to see things that we wanted to improve.” BEG and its customers have grown far closer through the collaboration. Mr Summers said: “BEG were open and honest from the start. “They said, ‘Look, we want to know if there are any issues with the machine. If things don’t work, we’ll be there to support you.’ “And even though we’ve had some problems, I think the relationship Continued>>

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Forming

between BEG and Allied is stronger now than ever.”

Capturing best practices

New machine, new thinking As the Cookbook explains, it is essential to understand the BIS control and information systems in order to prevent production problems and downtime. This required a different approach from operators. Mr Kammonen said: “This is a new technology: all servo, and all digital too. “The way line supervisors run and monitor the machine is different from a traditional IS machine. “Instead of waiting for things to go wrong, you have the ability to spot problems before they happen – if you know what to look for.” Working with BIS has been a learning experience for everyone involved. Mr Summers added: “Your mentality has to be different. We only put operators with several years’ experience on BIS. Even then, we had to go back to basics and do some retraining to build up their confidence. “We were working through our own preconceptions as well as ironing out problems with the machine. “Our learning grew as the machine developed.”

� The BIS can handle a wider variety of container designs, sizes and weights.

From reluctance to enthusiasm Allied started out with 12 staff working on BIS, and now has 22 trained staff. Inevitably, not everyone warmed to the new technology right away. Jamie Kirton, IS Team Leader at Allied, said: “There was resistance from the team. “It was so new, so different. But after six to eight months, people started to adapt.” It showed that the more the team got involved, the better the machine performed. John Wray, Production Hot End Specialist at Allied, said: “Before, machine operators and shift supervisors would say, ‘I’m not going on there’, whereas now, people want to go on that machine. “And more people are coming forward and asking for training, which is good.” Mr Wray believed that firms needed to let people spend time on the training in order to get the true benefits from it. Paul Dickinson, Production Manager at Allied added: “We’re a little bit old-school here at Allied. But now we’ve got the new technology, people want to go on BIS.”

Cooperation and support Fortunately, BEG are always there with support. Mr Kirton said: “Our cooperation has been brilliant from day one. Our queries have been answered within hours. And when we can’t find the fault, an engineer has been on site the next day – if not the same day.” Darren Shelley, Engineering Manager, explained that Allied also has online support from BEG. He added: “If we have problems, the BEG technicians can dial into the machine remotely, make their own adjustments or just suggest remedies for us to do ourselves.” Mr Summers stated that no one has walked away from anything.

He explained: “We had issues that needed solving, BEG has put the resource in, and we’re in a much stronger place.” However, the learning flows both ways. BEG has two BIS sections running at its Research Center in Windsor in the USA, and has taken moulds from Allied there for analysis. Mr Kammonen said: “We can also try new mould designs to look at production speed, cooling and so on. That helps to get things right before plants invest in a lot of expensive mould equipment.”

Sharing knowledge In addition to working directly with BEG, all three BIS customers have collaborated, since they are too far away from each other – both geographically and commercially – to be competitors. The most recent example of this was the first BIS User Day, convened by BEG and hosted by Allied, where the insights generated through collaboration were shared with attendees. Mr Kammonen said: “Nampak sadly couldn’t join us, but Noelle von Campe and ourselves were both there. “The aim was to share the challenges and opportunities of working with BIS across a range of areas. “We also talked about future priorities, and how to improve BIS. “Sometimes, one manufacturer’s problem is another’s solution, and by discussing it around the table, you see that things can be solved.” As BIS comes into its own as a high-performing and glass-forming technology, it surely won’t be long before more manufacturers get involved and capitalise on the solid work that has been done by BEG and its pioneering customers. �

Bucher Emhart Glass, Cham Switzerland www.bucheremhartglass.com/

www.glass-international.com

With traditional IS machines, there is a huge body of operator ‘folk wisdom’, built up over decades and passed on from one generation to the next. But when a new technology appears, that knowledge base is not there. So, one of the first priorities for BEG and Allied was to capture the best practices to use BIS. Mr Kammonen said: “We realized that we needed standard operating procedures. “So, in January 2016, we worked with Allied to set up some additional training to get everyone confident, and compare how we at BEG felt it should be done and with what people were actually doing on the factory floor.” All the knowledge was recorded in writing to make sure every operator took the same approach. It was compiled into what is known as the Cookbook. “Then Allied developed the project further, and they now have a very nice training programme for their BIS operators. “They’ve also shared it with us, for which we’re very grateful.”

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Environment Furnace Solutions 2018

International guests dominate Furnace Solutions Glassmakers from around the world attended this year’s Furnace Solutions conference. Visitors attended from Japan, USA and Costa Rica as well as several European countries and included glassmakers, technology suppliers and associations at the two-day event. Greg Morris attended.

Stara Glass engineer wins best paper � Mr Minestrini (left) receives the Michael Garvey for best paper award from MTC Chairman, Nigel

� Sebastian

� Mattias Hagen of

Longshaw.

Bourdonnais of Sefpro.

Luft-und Thermotech-

www.glass-international.com

nik Bayreuth.

Stara Glass’s Giorgio Minestrini won the award for best presentation at this year’s Furnace Solutions event. Mr Minestrini won the Michael Garvey Award for his paper Primary Techniques for NOx containment for a More Sustainable Glass Industry. On receiving the award Mr Minestrini said: “I would like to dedicate this award to all of us in the glass scientiﬁc community

because I think that no one can work alone and thanks to the work of all of us the glass industry can achieve higher and higher results.” MTC Chairman Nigel Longshaw said: “It was a paper that stood out because it highlighted a problem and potential solutions but he was honest enough to say there are other solutions available.”

Continued>>

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Furnace Solutions 2018

his year’s Furnace Solutions event had a truly international feel to it wiith a number of overseas guests in attendance. Among the 87 delegates were glassmakers from Bormioli Luigi, O-I, Ardagh, Beatson Clark, Saint-Gobain and Stolzle in Europe, Guardian Glass from the USA, Japan’s Nippon Electric Glass and Vicesa from Costa Rica. The Training Day and Conference included 15 papers devoted to the melting process in glassmaking. The training day on day one featured papers from DSF Refractories, Ametek Land, Flammatec, Guardian Glass, Ardagh Glass, Eurotherm Schneider and CelSian. Sefpro’s Sebastian Bourdonnais started the Furnace Solutions conference proceedings on day two with a paper titled Refractory Material Challenges on a Sodalime Glass Furnace Feeder. He explained how the corrosion process and glass defect formation in a glass furnace feeder are critical issues because this area is the last conditioning area before the machine. He then proposed an overview of corrosion mechanism in this particular area and discussed a refractory optimised solution that has been adapted to glass

gave the excellent field results. His paper was awarded the Michael Garvey award for best conference paper of the day (see separate box). Glass Service’s Erik Muijsenberg discussed the Opportunities Industry 4.0 brings to the Glass Industry. Several parts of the glassmaking process have already have been converted to Industry 4.0, particularly in the cold end, but overall integration has not been done. He explained that Glass Services’s Expert System advanced software and hardware tools can help with the process. Air Products Jan Viduna spoke about performance Emissions and Quality Improvements in Oxy-Fuel glass Furnaces through Innovative Burner Technology. Recent progress in control of fuel and oxygen by Air Products’ combustion engineers has led to the development of a new burner technology, Cleanfire HRx. It is capable of staging nearly 100% of the burner oxygen while maintaining flame momentum and preserving optimal fuel/oxygen mixing. The results of several recent commercial installations of the HRx burner have verified the ability to attain higher melting efficiency, lower NOx emissions, and improved

conference floor to emphasise his paper. “If we want to reach some of these CO2 targets we have to look at electricity. And we have to look initially at why all electric furnaces are so efficient. It’s really quite simple – there’s no regenerator. “There’s very little superstructure because an all electric furnace has a cold top, it has an insulating blanket and the insulating blanket means we hold the heat where we need it, inside the melt. We also have a surface to volume ration much more efficient than any other kind of furnace.” The perception is that electric furnaces are expensive, have a short lifetime and lack flexibility. “But that is garbage, people haven’t opened their minds if they think like that,” stated Mr Hakes. Capital costs are low and while operating costs today are high due to electricity prices this will decrease in the future. Thermal efficieny is considerably better – between 70 and 80% compared to a maximum of at best 50% of a conventional furnace. In addition electric furnaces require cheaper raw materials, have less maintenance and have equipment rebuilds.

� Mark Bennett of

� Erik Muijsenberg

� Stuart Hakes of

� Neil Simpson of

� Fred Aker of Sorg

Ametek Land.

of Glass Sevice (Czech

FIC UK.

Ametek Land.

� Jan Viduna of Air Products.

quality constrains and feeder lifetimes. Stara Glass Engineer Giorgio Minestrini then discussed the achievements of the Prime Glass project when applied to furnace design. His paper, titled Primary techniques for NOx containment for a more sustainable industry, highlighted how the project had reduced NOx by approximately 35%. Stara Glass, together with the University of Genoa and Stazione Sperimentale del Vetro (SSV) developed and patented two techniques for the primary containment of NOx in regenerative end-port glass furnaces that

flame length control and stability than past designs. Additional HRx burner functionality has enabled substantial control of the gas atmosphere in contact with the glass surface, which has proven to be effective in reducing foam formation in the refining section of the melter. This, in turn, leads to higher melt temperatures and more efficient removal of glass defects in the refining section. FIC UK’s Stuart Hakes discussed The Future has to be Superboosting and All Electric Boosting. He spoke from the back of the

He also repeated the question, given during his 2016 award winning paper at Furnace Solutions, of furnace lifetime: “Why do we build furnaces for 20 years when we can’t predict the market with any certainty ﬁve years from now. What happens if like the plastics industry now, we are suddenly clobbered with an anti feeling and all seven-year forecasts are thrown out the window?

Continued>>

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Republic).

55 Glass International July/August 2018

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“So maybe there is an advantage of shorter life and maybe your perception of shorter life is not quite as you seem.” Sorg’s Fred Aker provided a paper titled Sorg 340S+ Forehearths, Improvements and Operational Data. He outlined the changes from the 340S to the 340S+ which includes the cover design has a simplified design one piece plate compared to the previous two pieces, the improved separation of direct and indirect cooling, the minimised use of fibres in the superstructure insulation, and less energy consumption. He outlined the history of the 340 forehearth system, which was transferred to Sorg in 2006 from Bucher Emhart Glass. At the time two forehearth products were sold separately: the 340 and Sorg’s STF system. But in 2009 they were merged to form the 340S, with the best features from each system adopted. The new 340S+ system was verified through Glass Service’s mathematical modelling. “If a customer has something difficult, like corners for example, we’ll do the glass modelling to verify it.” He added that the company designs all its forehearths for customer’s requirements, such as tonnage, space and colours. It is set up so its indirect cooling is sufficient alone to handle cooling needs. If need be it can have direct cooling as well and, if it absolutely has to be an option, bottom cooling can be added too The first customer to use the 340s+ melted 135t/d of UVAG green glass and achieved a homogenity of 97.4% without boosting. The final presentation was jointly delivered by Ametek Land’s Mark Bennett and Neil Simpson, who discussed Thermal Imaging using a NOx filter. The presentation was a follow-on from the 2017 presentation on the use of the near infrared thermal imaging borescope to profile furnaces and to increase capacity. This year’s presentation discussed the use of special filters that can make NOx ‘visible’ and therefore manageable. While the focus last year was on the superstructure with no flames present, this year the pair investigated the flames firing. By highlighting and identifying areas of peak flame intensity it is possible to identify which firing side has higher NOx and which port/burner is impacting the most. The Furnace Solutions event is organised by the UK Society of Glass Technology’s Melting Technical Committee (MTC). MTC Chairman Nigel Longshaw said:“It has been a stimulating two days. Everybody has enjoyed it and everybody has got something from it. “One of the things that was said was that the industry should be sending young engineers on these training courses and not people in their late 40s and older. Young people need to know the history of the technology but are not being exposed to it. “That can only be led from the top. Young people should be encouraged to learn from the people here who have had the experience of working in the glass industry for years.” After the event, Sorg’s Fred Aker, said: “This was my first Training Day and Furnace Solutions and I was very impressed with the format and quality of the visitors. The format allowed for a lot of networking and the breaks kept the presentations fresh. The organisation was perfect and things were kept moving on time. I don’t know if I personally can attend regularly but I will recommend that someone from SORG does take part.” The next Furnace Solutions event takes place June 5 and 6, 2019. �

Furnace Solutions 2018

Real-time Process & Quality Controls

When it comes to service, the sky is not the limit...

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Inspection

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EME GmbH Wockerather Weg 45, 41812 Erkelenz contact@eme.de www.eme.de

HALL 14/C22 Iris Inspection Machines Z.I. du chêne, 14 rie di 35eme Regiment d’Aviation, 69500 Bron, France www.iris-im.com

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KAMMANN GmbH

WALTEC Maschinen GmbH Kronacher Str. 2a 96352 Wilhelmsthal - Steinberg Germany Tel +49 9260 9901-0 info@waltec.de www.waltec.de

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CONDAT SA.104 Av. F. Mistral, 38670 Chasse-sur-Rhône. France. Tel +33(0)4 78 07 38 38 www.condat.fr

Don’t miss the next proﬁle page Contact Esme Horn esmehorn@quartzltd.com HALL 13/B62 Tecoglass Ltd, 60 Savile Street East, Shefﬁeld, S4 7UQ, UK Tel +44 (0) 114 275 9020 www.tecoglas.com

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58 Glass International July/August 2018

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Inspection

Inspecting the container sector Ahead of glasstec, Eleonora Bordini* of Italian company Marposs discusses the company and how Industry 4.0 is effecting the glass container market. 1) Can you briefly describe your business and tell me its strengths?

2) The glass containers inspection sector is a competitive one. What makes you stand out? Marposs has been in this market for a relatively short time, but has already gained a good reputation for quality, reliability and customer focus. The company has 66 years experience in metrology in demanding markets, such as the automotive one, and we know how to make a difference! We don’t provide just standard solutions. We listen to customers’ needs and propose solutions to their gauging problems. Our global presence allows us to provide rapid and effective answers to customers with sales and service engineers speaking the same language of the customer.

3) What type of inspection machinery do you provide? We provide measurement systems for the dimensional and geometric inspection of glass containers on a sample basis to be used in the laboratory or near the production line. Marposs offers

“The glass sector is currently a step behind in terms of automation and connectivity compared to other industries such as, the automotive one. solutions in contact and non-contact technology, in particular: Quick Set is a manually reconfigurable bench, using contact sensors, for the inspection of external diameters and straightness in the labelling area. It is widely used for the inspection of beer bottles, including those using ‘nolabel look’ labels, where the inspection of the external profile is particularly important. VisiQuick is mainly based on non-contact technology and is a fully flexible and modular machine, with automatic loading/unloading, that can include several measuring stations to carry out different controls such as: � External dimensions on body neck and finish, verticality, bent neck, mouth parallelism; � Internal mouth diameter and internal profile; � Weight;

”

� Push-up; � Glass thickness. VisiQuick can measure, without job change, any kind of container (any shape, any colour). VisiQuick is our flagship item and several VisiQuick units have been installed at glass container manufacturing plants.

4) How has Marposs approached the subject of Industry 4.0? The glass container industry is undergoing a rapid technological evolution. Only a few years ago, a limited number of customers had a fully equipped laboratory. Many of them used only gono go gauges and profile projectors for measuring containers, spending a lot of time and manpower. With these kinds Continued>>

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Marposs is worldwide leader in precision equipment for measurement and control in the production environment. We serve the Automotive, Aerospace, Glass, Medical and Consumer Electronics markets. Marposs products, irrespective of the target market sector, have the purpose to provide real-time, accurate information, in order to improve customers’ product quality and process efficiency. The Glass Containers market was approached and developed, in the last 10 years, with different products/technologies. Our strengths are our know how in metrology, global presence, and willingness to listen to customers’ needs, provide solutions and build long-term partnerships with them.

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Environment Inspection

7) Where geographically is Marposs strongest? Marposs is present in in 34 countries in five continents. There are 25 countries with companies belonging to the group (and a total of 3200 employees) and in nine countries with agents/distributors.

8) You spoke at the Glassman event in Mexico recently. Is Mexico an important region for Marposs? Mexico is a very important country for Marposs. Marposs S.A. de C.V. has 83 employees in total in Mexico City, Queretaro and Monterrey and one manufacturing plant in Queretaro. During Glassman we established very good contacts so it was definitely a successful event.

9) Are you unveiling any new technology at glasstec? � Labelling area profile inspection. of gauges and measurement results, accuracy and repeatability were poor and depended on the operator’s skill. Furthermore they could not collect data. There was no statistical analysis and no feedback to the production about process trends and deviations. This is not acceptable anymore. End users ask for higher quality and, in case of complaints, the manufacturers need to provide evidence on how they guarantee this quality. In case of problems, decisions must be taken quickly and this is possible only if all the necessary information is promptly available to the people who have to take these decisions.

market and related products, including optical contactless sensors, acquiring and consolidating the business with customers such as Saint-Gobain Sekurit, Fuyao, AGC, NSG, PGW and others. Marposs later expanded its business in other glass related markets such as containers and solar energy. Now I’m fully focused and committed, as Industry and Product Manager, to glass containers.

We will show a fully optional VisiQuick machine at glasstec with a new innovative (patent application filed), measuring station for the inspection of the labelling area profile. This system, based on optical technology, can accurately detect and measure bulges and sinks in the labelling area, which can produce defects, like bubbles and wrinkles, when the label is applied. Continued>>

www.glass-international.com

5) How do you foresee Industry 4.0 being implemented in the glass industry? The glass sector is currently a step behind in terms of automation and connectivity compared to other industries such as the automotive one. I believe that within the next five years this gap will have to be reduced. This industry will be required to improve on process efficiency and productivity. Big data collection and analytics is essential to achieve this target.

6) How long have you personally worked for the company and in the Glass Industry? I joined Marposs in 1996 and I was in charge of the glass industry in 2004. I initially developed the car glazing

� Glass thickness inspection with chromatic

� Internal diameter and internal profile inspection.

confocal sensor.

60 0 Glass International July/August 2018

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Inspection

Committed to your success

Welcome to Covia – formed in 2018 through the merger of two leading organizations: Fairmount Santrol and Unimin Corporation. We are a leading provider of minerals and material solutions for the Industrial market, with a broad array of high-quality products and distinctive technical capabilities. We have an extensive portfolio of � VisiQuick machine conveyors.

glass products and apply our solutions mindset to help you enhance your

10) How would you like Marposs to evolve over the next five years? I would like Marposs to enlarge its presence in this industry, introducing new products and technologies.

products and improve your glass melting processes. Learn more about our commitment to partnership at CoviaCorp.com/GIM8

We have installed a complete gauging line in VOA Albi (Verallia’s Albi plant), close to a manufacturing line, that was totally rebuilt with the additional purpose to increase flexibily (production of small batches of many different containers). The VisiQuick machine, thanks to its flexibility (no job change required when the article to be measured changes) is the right system to manage this variability. A few months ago we installed a VisiQuick machine in a Shandong Huapeng plant, one of China’s largest glass container manufacturers. The investment was made simultaneously with the furnace rebuilding. �

*Industry and Product Manager – Glass Containers, Marposs, Bentivoglio (BO), Italy www.marposs.com

www.glass-international.com

11) Are you able to tell me any interesting recent installations anywhere in the world, such as new plants or furnace rebuilds that have included new inspection lines?

For product information and local availability contact: EMAIL

Glass.Sands@CoviaCorp.com

CoviaCorp.com

61 Glass International July/August 2018

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Environment Events review: Mir Stekla 2018

Mir Stekla 2018 celebrates 20th anniversary in style This year’s Mir Stekla celebrated its 20th anniversary in Moscow in May. Exhibitors displayed the latest range of products, technologies and equipment in the glass industry. Alex Gurov reports.

www.glass-international.com

he annual trade show celebrated its 20th anniversary with 190 domestic and overseas companies from 20 countries. Glass industry professionals gathered at the eagerly anticipated event to showcase their products at the booths. Visitors comprised of builders, architects, designers, design engineers, furniture makers and representatives from sectors such as healthcare and food. Exhibitors came from Austria, Belarus, Belgium, China, Croatia, Czech Republic, Finland, France, Germany, Hungary, Israel, Italy, Netherlands, Russia, Spain, Switzerland, UK, Ukraine and USA. Vladimir Yakovlev, President of the Russian Union of Builders, said: “Mir Stekla put on display a full range of glass products, enabled builders to evaluate the possibilities of the glass industry and learn about new products and promising developments.” The products on display included; modern technology for glass production, machinery, equipment and tools for manufacturing a wide range of glass products, pioneering solutions for glass manufacturing, storage, transportation and processing, art and decorative glass, stained glass, testing and measuring

equipment, software and R&D. A new product sector was devoted to transparent and translucent materials in agriculture. Sergey Katyrin, President of the Russian Chamber of Commerce and Industry, said: “I am positive [that] Mir Stekla [has] enabled domestic and foreign manufacturers, customers of glass products, investors and representatives of sectoral science to share relevant information, generate business leads and showcase achievements in the glass industry that will ultimately facilitate the development of the Russian glass industry.” There were more than 70 Russian exhibitors and these included the KAMI Association, Yta, Adem, Caspian Flat Glass, Ferro Special Materials, Pikalevo Soda, Simvol Factory, Vremena Goda, Zenon Sign Supply, Karat, Steklocentr, Inmarket, Stanki Mira, Steklopack, Saratov Glass Institute, Steklo-Gaz, Sky Technology, Stanki-M, Komandor Trade House, MDM-Techno, Osborn Rus, Palina Coatings and TB Technologies. Overseas exhibitors included Glaston, Tiama, Grenzebach Maschinenbau, Hegla, RHI Glass, Bystronic Glass,

Heye International, Horn Glass Industries, Emhart Glass, Bottero, BDF Industries, Pneumofore, Mountain Glass Technology, Landglass Technology, Lahti Precision, Sklostroj Turnov, Saint Gobain Sefpro, Omco Croatia, Motim Kadko, Stara Glass, Hartmann & Bender Vertriebs & Produktionsgesellschaft, Henry F. Teichmann, Domanovo Production and Trade Plant.

Show Highlights � The ArtGlass Salon featured original ideas and cutting-edge trends in art and design works and interior design items. � The Novelties section gave companies the opportunities to demonstrate their products for the first time. � The Employment Centre was held for the first time. Visitors could receive and offer resumes, as well as get professional advice. � The Expocentre for the CounterfeitFree Exhibitions Project in order to minimise counterfeit products showcased at exhibitions and illegal copying of exhibited products online.

Continued>>

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� The Business Networking Zone was held to meet and establish business contacts with professionals working in glass and construction. � International Conference on Translucent Structures. The event showcased windows and facades.

It was organised by: the Russian Union of Designers, the Russian Union of Builders, the Russian Chamber of Commerce and Industry Committee on Entrepreneurship in the Construction Sector, the Union of Rural Builders of Russia, supported by the Russian Ministry of Industry and Trade, the Russian Ministry of Construction Industry, Housing and Utilities Sector, the Russian State Duma, and the Russian Union of Industrialists and Entrepreneurs. � The 16th Forum of Directors of Small and Medium Enterprises ‘Furniture as Business’ organised by Imperia Congress and Exhibition Company, Expocentre AO. � The 2nd World of Glass 2018 conference organised by Imperial Congress and Exhibition Company. Glass International distributed its Russian language and English magazines from its booth, as well as at the conferences. The first edition of Mir Stekla, a great success, was held at Expocentre on the initiative of the Union of Architects of Russia. Over the years, the participants have showcased the best achievements of Russian and overseas experts and opened new opportunities for glass manufacturing and application. Mir Stekla is Russia’s major glass show and one of the five largest in the world devoted to the achievements of the industry. It was recognised as Russia’s best trade show in the category ‘Glass products, manufacturing, processing and finishing technology’ in 2016. �

Mir Stekla 2019 will take place between April 2-5 , 2019 at Expocentre, Moscow. www.mirstekla-expo.ru

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CLASSIFIEDS.indd 1

ASIA 2019

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