Glass International July/August 2019 by Quartz Business Media

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July/August 2019â&#x20AC;&#x201D;Vol.42 No.7

EMHART AND ICG CONFERENCE REVIEWS FURNACE SOLUTIONS WINNER INTERVIEW RAW MATERIALS FOCUS I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

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Contents

Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: George Lewis Tel: +44 (0)1737 855154 Email: georgelewis@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com

July/August Vol.42 No.7

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

Ofﬁcial publication of Abividro the Brazilian Technical Association of Automatic Glass Industries

Member of British Glass Manufacturers’ Confederation

China National Association for Glass Industry

Market Trends Is the container glass industry aligned to customer expectations?

Lubrication: Linde Transitioning to automated mould lubrication

Review: Bucher Emhart Summit A review of the summit in Zurich

Review: ICG Conference More than 900 people from 45 countries attended the Boston, USA event

Soda Ash in the glass industry An overview of the soda ash industry

Raw Materials: Sibelco How minerals can support a more sustainable glass industry

Raw Materials: University of Shefﬁeld How an ancient technology could help deliver decarbonisation

Furnace Solutions Burcin Gul discusses award win

Forming: Xpar Vision How hot end forming technology can help container glassmakers

Inspection: Tiama The quest for the perfect container for cold-end inspection

Automation: Bucher Emhart Glass Making the vision of End to End automation come true

Industry 4.0: MSK Is Industry 4.0 for the cold end a dream or reality?

Quality Control: Marposs How to bring QC lab technology to a production environment?

Moulds: Heye International Transitioning to automated mould lubrication

Recycling: Gx Glass The Environmental Beneﬁts of Recycling Glass

Moulds: Sonicam Empowering mould shops

International Trade: DIT Exporting opportunity for UK glass industry is clear

GLASSMAN EUROPE CATALOGUE

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Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2018 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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Editor’s Comment + International news

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International News

2019 DIARY

GREG MORRIS, EDITOR

September

FRONT COVER IMAGE: www.pennine.org

17-18 Glassman Europe Biennial trade show and conference focused on hollow and container glass. Lyon, France www.glassmanevents.com/ europe

www.glass-international.com

A daunting task ahead

Much of the news in recent weeks has been about the 50th anniversary of the Apollo moon landings. The achievement of Neil Armstrong and his two colleagues was a tremendous feat in engineering, overcoming insurmountable obstacles using a combination of human ingenuity, technology and a drive to succeed. Watching the footage on TV reminded me that glassmakers face their own variety of challenges in the next few years. It is a daunting task. Not only are customer expectations changing, such as more varied bottle styles, but end consumer tastes are changing too with a requirement for lighter bottles that have been manufactured with fewer emissions. While the container glass industry has benefitted from the backlash against plastics, it must now prove its environmental credentials or risk alienating a generation on consumers. On top of these worries is the requirement for a glassmaker to adopt digital or Industry 4.0 production technology to become a more efficient manufacturer. There is a lot for a glassmaker to juggle in the future. A forthcoming conference aims to address some of these issues. The Glassman event in Lyon, France aims to provide answers to the sustainability and the digital challenges that lie ahead. While it has made tremendous steps already, the industry risks being left behind other materials if it doesn’t act rapidly.

01-04 SGT Annual Meeting Conference focused on raw materials in glassmaking. Cambridge, UK www.sgt.org

Be first with the news!

VISIT: www.glass-international.com for daily news updates

Heinz-Glas Poland starts Sorg furnace Heinz-Glas has started operation of a Sorg end-fired furnace at its Dzialdowo, Poland plant. The furnace replaced the previous oven, as it no longer met the necessary standard. The new furnace has a melting capacity of 150 tpd, and with use of electricity is expandable up to 180 tpd. The furnace, with a Sorg third generation working end (STW) is connected to six Sorg Third generation Forehearth (STF) production lines, two of which are equipped with Sorg colouring forehearths. The equipment for melting end and forehearths is industry standard, and includes integrated cooling systems

designed by Sorg. The safety technology is said to be at the highest level of DIN/EN 746-2 and was implemented with redundant Sorg gas supply and safety control for melting end and forehearths. Sorg’s burner holders WSH, modular stirrers as well as the Sorg Conti-Drain were also used. The different furnace concept required extensive construction measures as well as an intervention in the existing structure and was challenging for everyone involved. The project was completed successfully on time, the glass was high quality and energy consumption was lower than specified.

24-26 World Soda Ash Conference Conference focused on the glassmaking raw material. Cannes, France https://ihsmarkit.com/ events/World-Soda-AshConference-2019/speakers. html 24-26 Gulf Glass Biennial flat glass-focused trade show for the Middle East market. Dubai, UAE www.gulf.glass

October

01-04 Vitrum Trade show specialised in machinery, equipment and systems for flat glass. Milan, Italy www.vitrum-milano.com 10-12 glasspex India Exhibition focused on the nation’s glass production. Mumbai, India www.glasspex.com 14-17 AFGM Five day conference devoted to the region’s glassmaking. Cebu, Philippines www.aseanglass.org

November

21 Glass Focus A daytime conference followed by an awards evening over dinner. Sheffield, UK www.britglass.org.uk/glassfocus-2019

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International News

NEWS IN BRIEF

Stoelzle Masnieres plots expansion

Sisecam has fired up a €42 million flat glass furnace in Targovishte, Bulgaria. It held an inauguration ceremony attended by 300 people. These included Sisecam’s European flat glass customers, architects, sector professionals and government dignatories

as well as company employees. Vice Chairman and CEO Professor Ahmet Kirman stated that the group had made its first investment in Bulgaria under Sisecam Chemicals since 1997. He said: “We took our first step for new investments in

Bulgaria in 2004. “Our group laid the foundation for the flat glass, automotive glass and glassware production facilities in 2004. “With this investment, we were bestowed with the title of the ‘Largest Greenfield Investor in Bulgaria’.”

Nadir Figueiredo sold to US investment company Brazilian tableware manufacturer Nadir Figueiredo has been sold to a subsidiary of US financial company HIG Capital for R$836,265 million ($222.98 million). The glassmaking company said 97.67% of its shareholders had approved the sale to

Flamengo Participacoes, a subsidiary of HIG. Nadir said: “The transfer of share control will not cause disruption or change in our strategy or business model. “All our Nadir Figueiredo product lines will continue to be available to the market.”

HIG Capital is a global private equity investment company, which seeks to generate positive economic impact and long-term value for its investors. The objective of the acquisition is to diversify its business portfolio in Latin America.

O-I completes Mexican acquisition O-I has completed the acquisition of Nueva Fábrica Nacional de Vidrio, (Nueva Fanal) from Grupo Modelo. Grupo Modelo is a wholly owned affiliate of Anheuser-Busch InBev. O-I paid $188 million for the group.

The Nueva Fanal facility is located near Mexico City and has four furnaces. The furnaces produce 300,000 tonnes of glass containers annually for Grupo Modelo for the domestic and global markets. O-I expects the business to

contribute $140 million of revenue and $40 million EBITDA on an annual basis, with incremental synergies anticipated. O-I has also entered into a long-term agreement to continue to supply glass to Grupo Modelo.

Vidrala in €500 million investment Spanish container glassmaker Vidrala plans to invest €500 million over the next five years to modernise its plants. It has launched an investment plan that will involve the disbursement €500 million which will be used to

modernise its facilities by introducing new technologies and environmental improvements, and expanding production capacity. The group’s president, Carlos Delclaux, announced the measure at a recent sharehold-

ers meeting in Llodio, Álava, Spain. The investments will give priority to the most profitable plants: the two in Portugal and the two in the UK of its British subsidiary Encirc.

Durobor glassmaker faces bleak future

Belgian tableware glassmaker Durobor is to shut down its furnace unless an investor is found. The company went into receivership at the beginning of May. Three potential buyers of the glassware company from Europe, Israel and the Middle East - came forward after a subsequent appeal for investment. But Sogepa, the financial arm of the Walloon region in which Durobor is based, announced that two potential buyers of the factory had withdrawn and that it would now proceed to a shutdown of the oven.

Forglass completes Krosno Glass project

Polish engineering company Forglass has completed a project for compatriot Krosno Glass, a manufacturer of exclusive glassware and decorative crystal. Despite many unexpected challenges, Forglass completed the work on time and to a high standard, both professionally and from a health and safety perspective. Krosno has awarded Forglass further work on its next furnace.

www.glass-international.com

Sisecam fires Bulgarian oven

Stoelzle Masnieres Parfumerie, based in northern France, plans to increase its production capacity. The perfume glassmaker will replace its existing furnace with a new, larger one in the summer of next year. It means the group can also develop a fifth production line. Etienne Gruyez, the facility’s CEO, said the investment would increase production capacity by 30% and create jobs in the Hauts de France region. Meanwhile, Austrian hollow glassmaker StölzleOberglas has increased its capacity. The plant, in Koflach, Austria, implemented an additional flint glass line with a 10 section triple gob Bottero IS machine, which produces food jars.

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International News

AGC Glass chooses Zippe

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Zippe Industrieanlagen has received an order for the turnkey supply of a second float line at AGC Glass in Guaratingueta, Brazil. The supply also included a batch plant, cullet return as well as the steelworks. The concrete works were customer sided responsibilities. Zippe also secured the supply of the charging technology. This was a float charger type EO

2525 TH with a charging capacity of 280t/day per machine. Four machines are installed in total at the furnace which have a total charging capacity of 1120 t/day. The furnace capacity is 850t/day. The plant control system is affected by a modern automisation technology with reliable architecture. A redundant SPS control system and two SCA-

DA-servers safe plant.

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Zippe partners with HFT Batch Plant specialists Zippe Industrieanlagen and Lahti Glass Technology have appointed Henry F. Teichmann, Inc. (HFT) as exclusive sales agents and construction partners for the USA and Canadian markets. The partnership aims to

add value to US and Canadian glassmakers, providing them with the best of both worlds: world-renowned technology, from two experienced and well known raw material handling companies coupled with the in-country expertise, experience and sup-

port of HFT. This collaboration provides clients with one point of contact and responsibility for the turnkey supply of Zippe and Lahti equipment, improving communication and removing risk from the project.

Applied Vision in expansion US inspection company Applied Vision has completed a building expansion at its US site. The expansion is an addition to Applied Vision’s existing facility in Akron, Ohio, increasing its capacity to more than 100,000ft2. The project is said to significantly enhance its abil-

ity to serve a rapidly growing global customer base. The new space allows Applied Vision to expand its R&D and manufacturing capabilities while continuing to focus on sustainability by maintaining surrounding vibrant green space. Manijeh Novini, Applied Vision’s Chief Finan-

cial Officer, said: “Following our record-breaking fiscal year in 2018, we want to continue to invest back into our business. “This is by providing the best products and service possible to our customers while also providing our employees with the very best facilities and work environment.”

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If it’s in your glass, we’ll inspect it.

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International News

Top 10 stories in the news

NEWS IN BRIEF

Tiama and Ermi

Tiama and Ermi have entered into a cooperation agreement. The decision was made after Ermi encountered financial difficulties in the past couple of years. The two French companies said the cooperation would bring together their complementary skills and would allow them to guarantee adequate support to all customers with a perfect continuity. Tiama will take over sales activities with all customers and Ermi will become a Tiama entity.

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. Ardagh installs solar power plant at US glass site � 2. Nadir Figueiredo sold to US investment company � 3. Glassman Europe: Is glass the answer to increased opposition to plastic? � 4. Verallia Chairman and CEO Michel Giannuzzi elected President of FEVE � 5. Sisecam’s Burcin Gul talks about Furnace Solutions award win � 6. O-I completes acquisition of Mexican glass packaging facility � 7. A Year of Glass plan put forward to UN � 8. AGC Glass relies on Zippe technology � 9. GTS develops glass-specific periodic table to celebrate 150 years � 10. Heinz-Glas’s end-fired furnace starts operation

FEVE president

FEVE – the European Container Glass Federation - has elected Verallia Group Chairman and CEO Michel Giannuzzi as its President for the 2019-2021 term of office. Mr Giannuzzi succeeds Johan Gorter, CEO of Ardagh Glass Europe. Mr Giannuzzi said: “Our industry has an opportunity right now: as packaging is under scrutiny by consumers for its sustainability and healthy credentials. “The glass industry is perfectly positioned to respond to customer and regulatory requirements leveraging the benefits of the Circular Economy.”

www.glass-international.com

Fermac US appointment

Fermac has appointed a Sales Manager for North America. Mr Thomas Molfese will be responsible for all sales efforts throughout the USA and Canada and will be based in Buffalo, New York. Prior to joining Fermac, Mr Molfese worked for ITW’s Industrial Decorating Solutions Group for 12 years.

Fred joins PaneraTech

PaneraTech SmartMelter has appointed Fred Aker as Vice President of Sales and Marketing. Fred joined PaneraTech on July 1 after 34 years working at German engineering company Sorg. He progressed from an original IT role to a Sales Director.

Glass Service hosts successful furnace seminar Glass Service (GS) held a successful 15th International Seminar on Furnace Design – Operation and Process Simulation in the Czech Republic. The event was attended by 150 glass experts from 25 countries including USA, Mexico, Japan, India, Saudi

Arabia, Russia, New Zealand and several European nations including UK. Feedback from participants was positive. In conjunction with the Seminar, the ICG’s Technical Committees 15 and 21 held their meetings, while a User Meeting of the GS Glass Fur-

nace Model (GFM) also took place, which was attended by 40 glass specialists. The Seminar highlighted the latest developments in furnace optimisation and CO2 reduction with support from simulations and advanced control.

O-I Australia agrees energy deal O-I Australia has agreed a domestic gas sales agreement with Senex Energy. Under the five-year agreement, Senex will supply O-I Australia with 1 PJ of gas a year commencing 1 January 2021 (5 PJ in total). O-I can also elect to increase

the total contract volume by up to an additional 1.1 PJ of gas a year over a five-year term (up to 5.5 PJ in total) commencing no earlier than 1 January 2022 thereby providing O-I’s Australian East Coast manufacturing plants with additional gas supply certainty.

O-I operates four plants across the east coast of Australia and employs 1050 people. Gas will be supplied at the Wallumbilla Gas Hub in Queensland at a fixed price in line with current market levels, indexed annually.

6 Glass International July/August 2019

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International News

NEWS IN BRIEF

Johns Manville to build US production line

Johns Manville (JM) plans to build a Climate Problowing wool production line in McPherson, Kansas, USA. JM will begin construction on the expansion project later this year, pending various governmental approvals, and anticipates the completion in early 2021. The Berkshire Hathaway company will employ more than 330 people in McPherson once completed.

Encirc in Industry 4.0 ‘world first’

UK glass container manufacturer and bottler, Encirc, is set to boost glass production capacity at its site in Elton, by building a worldfirst ‘Industry 4.0-ready’ glass production line. The new line will have technology installed which will see the plant’s hot end (where bottles are produced) digitally connected to the cold end (where bottles are inspected). Once operational in Q2 2020, the line will make use of in-built intelligent swabbing, laser identification marking and inspection machines, which will be fully integrated to work alongside humans.

www.glass-international.com

Ardagh signs Absolut Vodka agreement

Ardagh Group has signed a 10-year agreement with The Absolut Company. The agreement will see Ardagh supply The Absolut Company with glass bottles for its Absolut Vodka brand. Ardagh’s production facility in Limmared has been the largest supplier of the Absolut Vodka bottle since the brand’s launch 40 years ago. Ardagh produces more than 100 million of the vodka bottles every year from its Limmared plant, Sweden. The site is the country’s oldest operating glassworks and was founded in 1740. It employs 480 people today. The Absolut Vodka bottles are produced using more than 40% recycled glass.

A UN Year of Glass? The year 2022 could be designated the Year of Glass under proposals put forward to the United Nations. Glass industry leaders are drafting a plan to submit to the UN in New York which outlines why glass is such an important material. Alicia Duran, President of the International Congress of Glass (ICG) outlined the plan at the Convention of Glass Associations in Venice, Italy. The convention was organised by Italian glass manufacturers and machinery association, GIMAV, Vitrum trade show and the Italian Trade Association. She told delegates: “The idea

is to tell the whole planet about the world of glass. Every sector of glass will be covered and the aim is to have a high impact on the global community.” The proposal will be submitted to the UN in February 2020 with a decision expected in July next year. Ms Duran said they had already received support from 50 countries but aimed to have a total of 100 nations behind the idea. It was important to get support from universities and R&D centres from African and Pacific Ocean nations. The year 2022 was chosen because it coincided with the ICG’s international Congress on Glass in Berlin, Germany

during the 100th anniversary of the German Society of Glass Technology. A 2022 UN Year of Glass would allow societies, universities, museums and artists enough time to plan events throughout the year. All of the national associations linked to the ICG have approved of the idea. Ms Duran said: “A UN Year of Glass in 2022 would underline the technological, scientific and economic role of glass and the importance of a year of glass for improving the performance and development of key technologies that contribute to meet the challenges of a sustainable society.”

Ardagh installs solar power plant Ardagh Group has installed a 20-acre solar power plant at its Bridgeton, NJ glass manufacturing facility. It worked with its partner KDC Solar to install the plant. The solar plant will supply renewable energy to the glass

manufacturing site and contribute to a reduction in the glassmakers carbon footprint. Key features of the solar project include: � 5.5 MW DC; � 15,930 PV modules supported by 1,283 racking posts;

� 61 pieces of electrical equipment; � 60 miles of wire installed; � 20 acre solar facility; � two separate arrays connected via directional drilling under a roadway and under wetlands.

Pilkington UK invests £3 million in structural glazing machinery Pilkington United Kingdom has invested more than £3 million in new technology to increase its capacity to manufacture Pilkington Planar. The glass manufacturer, part of NSG Group, has invested in a toughening furnace, an in-

creased capability heat soak oven and a glass-measuring device. The new toughening furnace is expected to help increase volumes of the structural glazing system. It is due to be operational by

August, and will be located at the Pilkington Architectural site in St Helens, UK. The investment also increases the size capability of the toughening furnace and heat soak oven to 6000mm x 3000mm.

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Market trends

Is the container glass industry aligned to customer expectations?

� Emma Bowers.

� Richard van Breda.

lass has traditionally been the preferred packaging format for food and beverages. It has robust characteristics that are well understood and respected. But alternative packing options are available. So, what does glass need to do, for its customers, to retain its preferred packaging status? Glass customers come in multiple forms. There is the brand owner and the filler – in some cases these are not the same. Then there are the retailers and

distributors. Finally there is the consumer - the final End Customer. Each have their own requirements, differing priorities and multiple expectations of the packaging. A solution for one may not be the same for the other. Some of the preferred status dimensions include, but are not limited to the following: The primary role of packaging is to contain and provide protection to the product. In this area glass performs

exceptionally well when compared to its competitors. Glass provides superior O2 and CO2 barriers and other product protection. Another expectation of the packaging is to complement the product contained within it. As a vehicle for carrying the brand – glass has inherent premium attributes that have developed over its long legacy. The premium status of glass, Continued>>

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In the first of a series of articles, former SAB Miller and Coca-Cola executives Richard Van Breda and Emma Bowers, discuss what glass needs to do to ensure it retains its appeal to consumers and its preferred packaging status. This is an abridged version of a presentation due to be given at the Glassman Europe event in Lyon, France on September 17.

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Market trends

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to date, has not been challenged. This looks to continue – as it is unlikely a vintage bottle of whiskey or wine will not be sold in a glass bottle! But, how does it maintain this position given the rapid development of alternative technologies? Glass needs to find a way to complement its traditional characteristics and premium-ness with a heavy dosage of innovation. This demand of innovation ensures that brand owners will want to select glass ahead of other choices. Brand owners will select glass because their consumers choose it. Closely linked with Innovation demands, is the need for marketing – packaging carries the brand and the brand message. Glass has made strides in furthering the marketing offerings, think of the classic Coke contour glass bottle. The plethora of embossing capabilities has been a significant marketing breakthrough. But the question is what comes next? Does glass have anything further to offer from a marketing perspective, or does it need to rely on the labelling industry to move this aspect forward? It remains to be seen if the glass industry has any influence here. With premiumisation, comes the need for individualisation and flexibility. From an operational perspective glass needs to become more flexible in its manufacturing capability. Allowing speed to market but also different package options, including labelling, decoration and other value added features. The recent spotlight of NGO, media and increased consumer awareness upon the packaging industry to address many of societal over-consumption behaviours has put increased pressure on plastic above other packaging materials. This is rightly so given that plastic holds the largest share of the packaging material mix for food and non-alcoholic beverage. However,

the container glass industry faces its own headwinds that need to be addressed if it is able to continue to compete for the packaging mix alternatives. One of those expectations - now well documented - is to reduce the environmental impact of the package. This is the biggest topic in the industry and everyone is debating this. Brand owners are making commitments to reduce, reuse and recycle their packaging. This is helping to educate each of us consumers about our role that we can play in that cycle. Glass presents a dichotomy – on the one hand a single use non-returnable bottle has a high carbon footprint. On the other, a returnable bottle has the lowest packaging carbon footprint. How does glass address the challenge of a carbon neutral glass bottle? One must also keep the perspective of price – irrespective of the brand position and premium position – the cost of packaging is vital in determining the preferred status. Cost is less of a factor on a $100 bottle of wine versus a single serve of mainstream beer. Nevertheless cost plays a big factor in the packaging choice. This aspect plays to other packaging substrates. Glass containers, as a value chain, need to continuously adapt and innovate to remain relevant and retain its preferred status. �

Richard Van Breda, IS Engineering, Cham, Switzerland Vanbreda@isengineering.com, richard@richardvanbreda.com www.isengineering.com Emma Bowers, Managing Partner, Green Puffin Consulting Limited, London, UK emma@greenpuffinconsulting.com, www.greenpuffinconsulting.com

About the Authors Emma Bowers and Richard van Breda both have extensive experience in packaging and glass particularly. Their specific experience in large global FMCG businesses allows them to provide a fresh perspective to glass manufacturing from both sides of the supply relationship. In a future series of articles, a number of industry relevant topics will be discussed and unpacked. The topics will provide another perspective the industry often reflecting the opinion of the glass customer or consumer. In doing so, we will discuss some opportunities we see for the industry and hope to spark some debate in the process. We also look forward to broadening the discussion on this topic on 17th September 2019 at Glassman in Lyon. In the meantime, we’d love to hear from you with any comments, questions or other topics you would like us to cover in upcoming publications.

Glass International July/August 2019

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Glass Recycling | Batch Charging | Glass Level Controlling | Preheating | Maintenance & Service

Lubrication

� Flame-based carbon coating with Linde’s Carboflam technology is said to be more advantageous than oil-based systems.

Transitioning to automated mould lubrication

www.glass-international.com

Rainer Mieth*, Matthias Görisch** and Stephanie Englert***, explain why glass producers have adopted Linde’s Carboﬂam technology.

lass manufacturers today are exploring ways of transitioning from manual lubrication to automated systems with a view to increasing process efficiencies and productivity. Many producers of container as well as art and tableware glass use Linde’s Carboflam technology. This solution is not only highly automated but also offers further advantages compared with oilbased systems. The key drivers for converting from manual lubrication to a highly automated process are:

� The main reason is that repeatable lubrication results are difficult to realise during continuous manual production. � Manual swabbing is a timeintensive and highly repetitive task, tying up operators who are no longer free to perform other value-adding tasks. � There is a general desire to minimise workplace pollution – in other words, organic compounds and steam. � Customers are keen to reduce the effort required to clean machines and components of oil-based lubricants. � Safety legislation within the EU is increasingly strict, accentuating the need

for alternatives to manual lubrication. The answer to these manual lubrication challenges can be found in solutions originating from industrial automation and electrification. Other industries such as automotive have also redefined and optimised manufacturing processes. These automation solutions are reshaping the glass industry, especially the container glass segment – which typically relies on production lines with individual section (IS) machines.

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Lubrication

Automated lubrication solutions � Fig. 1 Temperature profile of the blank mould surface during glass forming. (Forming of container glass. The blue and green lines represent two measurement points on the surface of the blank mould)

Benchmarking technologies How effectively do the different automated lubrication technologies address the manual lubrication challenges that glass manufacturers face – as outlined above? Looking at the repeatability of lubrication results, one can say that, in general, all automatic lubrication solutions provide superior results to those achievable with manual lubrication and thus minimise the reject rate related to lubrication repeatability. Furthermore, an automated solution eliminates the time-intensive and highly repetitive task of manual lubrication, leaving the operator free to focus on more valuable tasks. Automation also reduces operator interaction with running machines and this mitigates the risk of crushing and other hazards. There is an important difference between Carboflam and both the manual lubrication approach and the two automated lubrication technologies outlined above, namely product quality. This quality gain is attributable to the absence of oil with the Carboflam process. Swabbing robots and fixed oil-spraying systems use a special oil-based lubrication agent for the glass forming process. Manual lubrication is also based on oil. Carboflam applies a pure, thin carbon layer and is totally free of oil. This key feature ensures that the temperature of the blank mould surface remains more stable and homogeneous during glass forming compared with oil lubrication (Fig 1). A stable temperature profile is important. It leads to a more homogeneous – and thus higher-quality – glass surface and reduces the reject rate attributable to variations in the mould temperature profile to zero. The automatic design in combination with an oil-free process increases the pack-to-melt ratio of industrial-scale installations by 1 to 2% and even more in some instances. Reaching beyond the quality and

productivity gains outlined above, one can also note distinct differences in cost between the different approaches to automation. Looking at the up-front investment costs, Carboflam Capex is similar to that of fixed oil-spraying systems but much lower than that of swabbing robots. Over time, it also offers potential to optimise operating costs and total cost of ownership. The higher packto-melt ratio, for example, has a positive impact on the operator’s bottom line. Gas consumption can be further reduced by switching from a pilot flame to electric ignition as the ignition source. In addition, the lack of oil and optimal adjustment of process parameters with Carboflam extend the lifetime of moulds and reduce cleaning effort – also of adjacent components. Carboflam can also help to avoid the costs associated with unnecessary downtime. Because each section of an IS line is operated independently, the operator is free to access individual sections. So if the operator needs to handle a specific mould, the moulds in the other sections remain operational. Finally, it can enhance productivity through ease of operation. Its new and advanced features keep glass manufacturers abreast of the latest industry automation trends. One such feature is the touch panel with an integrated database of all parameter settings per product program. The operator can easily select the desired product via touch panel and it automatically adjusts the process parameters and thus the thickness of the carbon coating. �

*Senior Application Engineer, Application Technology, Linde Gas **Market Development Metallurgy & Glass Central Europe, Linde Gas ***Global Marketing Manager, Commercial Management – Primary Industries, Application Technology, Linde Gas www.linde-gas.com

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There are three main automated lubrication systems on the market with the ability to replace manual lubrication. The first is a swabbing robot. With this method, an oil-based lubricant is sprayed or brushed into the blank mould by a robot. The robot works with precision and uses a spray nozzle or brush to repeatedly apply only a small amount of the special lubrication oil to the surface of the mould of each section in the production line. Nearly 100% of the lubrication oil is then deposited as an even, thin layer on the blank mould surface. This solution can be fully integrated into the glass forming process flow without interrupting production (depending on the speed of the IS line). The swabbing robot moves fully automatically to the required section of the production line. The second option is a fixed installation on every section of the production line. This automatic lubrication system uses a nozzle to automatically spray a special lubrication oil into the mould of each section. The fixed spraying unit/system precisely applies only a small amount of lubricant oil, depositing nearly 100% of the oil in an even, thin layer on the blank mould surface. This solution can also be fully integrated into the glass forming process without stopping production (again depending on the speed of the IS line). The third option is Carboflam technology, a flame-based carbon coating solution. With Carboflam, acetylene is combusted under precise and reproducible conditions and thus separated into hydrogen and carbon. Nearly 100% of the carbon created is then deposited as an even, thin layer on the blank mould surface. This coating step is fully integrated into the glass production process and does not require any stoppages (depending on the speed of the IS line). The acetylene is combusted with a post-mixing burner based on an under-stoichiometric acetylene/oxygen flame mixture. When the magnetic valves in the Carboflam burner gas supply line are opened, the gas streams out to the burner head. The acetylene stream is shielded by an oxygen stream. A pilot flame or electric ignition mechanism at each burner head automatically ignites the gas stream. The carbon coating process for a blank mould takes just 0.1 seconds per coating.

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COVERING THE WHOLE SPECTRUM FROM BATCH TO HOT END

www.sorg.de

www.eme.de

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Events review: Emhart Summit 19

GLOBAL GLASSMAKERS ATTEND EMHART SUMMIT Glassmakers from more than 36 countries attended a summit which explored the future of glass packaging.

were in attendance at the event in Zurich, Switzerland, close to Emhart’s headquarters.

Summit19, organised by Bucher Emhart Glass, investigated the themes that will make a difference to the container glassmaking industry in forthcoming years. The three-day event included 15 conference presentations, opening and closing talks from Bucher Emhart Glass President Martin Jetter, as well as networking opportunities.

These included Allied, BA Glass, Bangkok Glass, Encirc, Ekran, FEVE glass association, Heineken, HNG, O-I, San Miguel Yamamura, Takestan Packaging Glass, Toyo Glass, Vetropack, Vidroporto, Wiegand-Glas and more. Glass International was also in attendance.

Approximately

100

glassmakers

Heineken, Croxsons, Zero Waste, the Food Packaging Forum Foundation, FEVE, Wellershoff and Partners and the Institute for Future Policy.

Conference presentations were given by cm.project.ing, Emhart Glass, Gallo Glass, IS Engineering, Sorg,

hat is the future potential of robots in a glass plant? Can they take on ever more complex tasks and help the human operator by replacing mundane jobs? This was the focus of Dr Matthias Kummerle’s presentation at the Summit 19 event with an hour-long talk titled The Future of Forming: How new technologies will impact the operation of glass plants. The talk encompassed some of the evolutionary developments in a glass plant, the technology used in IS forming machines today and some of the remaining challenges that face a glass plant, despite the introduction of modern technology. These include improving average efficiency rates, increasing quality requirements and regaining flexibility. Bucher Emhart Glass’s approach to new technology has been the consequent pursuit of its End to End technology roadmap, which focuses on forming and inspection technology. Dr Kummerle, who is Vice President of Technology at Bucher Emhart Glass, said technology has matured to a level that more people are using robots on the blank side to swab the blanks. This is safer than manually swabbing and brings consistency benefits. But there are still reservations from the glass industry about using more robots. “The reservations we continue to hear

are it is still a learning curve on certain processes, it still requires know how of people and not everybody is willing to move to that learning curve yet. “The other is it is not free of charge, there is CAPEX involved obviously. “Some people ask themselves, as long as there are no other applications for this robot, is the swabbing part sufficient to justify this CAPEX? “So the discussion is what else can the robot do? Is the robot key to having a dark plant?” Bucher Emhart Glass is exploring what else can a robot do at the moment, besides swabbing. Customers have suggested they would like robots to start changing the mechanical parts of the machine, changing the moulds or even the delivery system if an IS machine went from double to triple gob. But Dr Kummerle said: “Look at the effort it takes to implement these developments and the value you would expect. You can see that the further you go down and the more mechanical the tasks you want robot to do then the more difficult it gets.” He suggested that robots were suitable for lubrication tasks with several further applications expected. Measuring tasks with the use of robots were technically possible but the question is without the sensors we have today how big is the additional value? For adjustments, it will be possible

to use robots in some cases, such as deflector adjustment, which is expected to happen soon. But after that it is tricky, said Dr Kummerle. “One of the reasons is that even if it is technically possible one of the fundamental challenges we currently have is the current machine concept is not well suited for these type of things. “If you try to use a robot to substitute what an operator is doing today you will run into challenges. “The assumption for the time being is that robots will be standard for certain tasks and there will be some applications that will be offered but then I believe it will take quite a while to take the next step.” He believes though that the combination of recent developments means there will come a point when a machine will be set up mechanically and running ‘hands off’, in parallel with people doing certain tasks such as job changes or mechanical maintenance tasks.

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The role of robots in forming technology

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Events review: Emhart Summit 19

Preparing for the future Futuristic technology such as the Internet of Things, virtual reality, AI and robotics will bring huge change to the world – and the glass industry should be prepared for it. Werner Gessner, VP Sales at Bucher Emhart Glass discussed the future of the sector at the Emhart Summit 19 with a presentation titled The New World – a challenge and an opportunity for the industry. During a 30-minute opening speech on the second day of the conference, he outlined some of the mega trends impacting the globe. He then focused on the glass sector and how these changes and disruptions could affect it. Disruption is mainstream and business needs to respond to it, he stated. Political events and climate change can create disruption, such as plastic polluting the oceans. But no matter where they come from, these trends are disruptive for

businesses and governments. They can shift market power among competitors, challenge existing business models and approaches, realign trade patterns, reorient supply chains, drive business relocations and influence work forces and consumers. It is easy for businesses to underestimate the pace of change but responding to disruption is critical. Previous strategies adopted by a successful business may need to be changed in future. Some of today’s megatrends include connected consumers, an ethical living experience and more healthy living. In the food industry sustainability efforts have been increased with more lightweight, environmentally friendly products and packaging. Some of the questions facing industry relate to the future of work and how smart technology will be integrated into a factory. What intelligence will be

needed to create a smart future and what will happen to humans when machines become workers, for example? But in an ageing, resource-constrained world, there is a requirement for smart solutions such as those brought about by the digital revolution. “We are at the start of a smart revolution that could fundamentally change the way the world works,” said Mr Gessner. Smart technology can increase accuracy, efficiency, remove mundane tasks and save time. Emhart’s End to End technology is a smart factory enabler, Mr Gessner said. It focuses on equipment, automation, care, empowerment and training. It can help

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How will EU legislation impact the glass industry? A legislative tsunami is approaching the glass packaging industry but is the sector prepared for it? Fabrice Rivet, Technical Director at the European Glass Container Federation (FEVE) discussed Decarbonisation and the Circular Economy during a 45-minute presentation at the Emhart Summit 19. The two tsunamis are that of the circular economy and the decarbonisation challenge. In 2015, the EU set targets which aim to modify production and consumption patterns as well as waste management. As a consequence, new recycling targets have been set. It means that by the end of 2025 70% weight of glass has to be recycled and by the end of 2030 75% weight must be recycled. There will be a move from ‘collected for recycling’ to genuinely recycled and there will be a new measurement point for recycling. In addition Extended producer

Responsibility schemes will become the cornerstone of EU waste management policy and will be mandatory for packaging. The EU Commission, in its Single Use Plastics documents from May 2018, had proposed a mandatory 90% collection rate for plastic beverage bottles and that some plastics would be banned in the EU. These include plastic straws, cutlery and food containers. Mr Rivet warned that if plastics can claim a 90% collection rate that FEVE would be fully committed to increasing the glass recycling rate. But this should not come at the expense of the existing bottle bank system, in place since more than 40 years. Introducing a DRS on glass packaging would divert a large proportion of glass from bottle banks and could make the current system not economically viable. Big brands will also have a part to play in helping increase recycling rates in the

future. Many of them, such as AB InBev, Coca Cola and Danone have already stated they want more recycled content in their packaging. The second challenge facing the industry is decarbonisation. While the industry has made dramatic inroads in reducing its energy consumption - since 2008, it emits 5% less CO2 for every tonne of glass on average - more must be done. It produces CO2 emissions from the natural gas/heavy fuel used

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Events review: Emhart Summit 19

bridge the knowledge gap and set of solutions and automation technologies designed to make glass production easier, safer and more efficient. It unifies forming and inspection technology. Some of the future challenges of a glass plant include increased quality requirements, price pressure, higher safety levels, loss of know-how and the requirement for more flexibility. “These influence us quite heavily,” said Mr Gessner. “We have to keep these in mind when we go forward and define our development programmes. Part of this is already taken into consideration with our current developments but there are still a lot of things to do and we are not at the end of the line. “From forming to inspection and integrated working together we have to be ready and prepared. More importantly we have be open to new technologies. “I think this ought to be via a common approach. We cannot develop something without the connection to a glass plant, we can both help each other.”

furnaces, process emissions from decomposition of carbonates (~1/4 of total CO2emissions) and from indirect emissions for the production of electricity used. Mr Rivet discussed the Emission Trading Scheme, which takes place in four stages between 2005 and 2030. The scheme aims to reduce carbon emissions on stationary installations across the EU. It wants to reduce the greenhouse gas emissions in the sectors covered by 43% between 2005 and 2030. He then highlighted an EU Clean Planet for all communication from November 2018. The Commission is proposing to go for a net zero emission by 2050, but without touching the 2030 reduction target. If this was to happen, the year 2050 is only two furnace lifetimes away. Any new factory built at this time would have to be carbon free. The incentive is there for the glass industry to achieve this. If glass manufacturing was to be carbon free there would no longer be any worries under the Emission Trading Scheme, it would give it a competitive advantage against materials that are not CO free and the main angle of attack against glass would become irrelevant.

Furnace builders’ challenges Revised environmental rules will mean alternative furnace technology should be considered to make glass in future. Delegates at the Emhart Summit 19 were told that forthcoming EU legislation means European glass furnaces are likely to have to embrace new technology to reduce emissions. Alexander Sorg, Managing Partner of Sorg, provided an hour-long presentation titled The Future of Glass Melting: Caught in the Crossfire of Environmental Policy and economics. The presentation was divided into two parts. The first half focused on legislation and the impact of the European Emissions Trading scheme. The second half investigated alternative technologies to reduce CO2 emissions. He told delegates that while European carbon emissions had remained constant over the past 10 to 15 years those of China’s were multiples of 10 years ago. He added that India’s emissions are currently low but are expected to rise substantially. The decarbonisation initiative began with the Kyoto protocol of 1997 with limited goals. But the Paris 2015 Treaty set ambitious reduction targets, with the aim of becoming carbon neutral by 2050. Mr Sorg said: “When I see the only serious plans are developed in Europe and how difficult it will be to change industry and to change the behaviour of society, I question if this is a serious plan?” He highlighted the European Emissions Trading Scheme and how it will affect the glass industry. It is currently in the third trading period with the fourth period due to start in December 2020. He stated that politicians are concerned about the competiveness of European industry so measures have been taken to safeguard it. They are worried industrial production could shift to outside the EU and the products then re-imported, which contradicts EU policy. While the ETS could reduce emissions and ban fossil fuels, there is a threat of what the consequence will be on the power supply if coal is phased out. Melting glass electrically today is more costly than using fossil fuels, he stated in the second half of his

presentation. “The price of electricity today is still much too high and is something politicians need to solve,” he stated. To meet the requirements of EU legislation and to reduce CO2 emissions, furnace builders will have to make changes to their ovens. Minor changes can be made, such as changes to insulation, avoiding leakage and false air, optimising furnace and regenerator dimensions, but these will still not meet legislation goals. Glassmakers often request increased use of cullet but this is hampered by limited availability. One option is a batch pre heater which has reduced both CO2 emissions and energy consumption by 15%. “The beauty of it is it reduces energy consumption but also provides more glass because you can pull the furnace higher.” While it costs more than a cullet pre heater and has the same payback time of four years, a batch pre heater has higher potential gains. Another technology option includes synthetic gas (syngas) under the brand name Optimelt. Two furnaces have been realised so far but the potential for energy reduction is in the same range as a batch pre heater, he said. A hydrogen or biogas-fired furnace is feasible but it requires an adjustment in burner design. A feasibility study by Germany’s HVG and GWi groups concluded it is possible to convert conventional furnaces. But, stated Mr Sorg, will there ever be enough biogas to operate a glass furnace? He concluded with an investigation into hybrid furnaces. Hybrid furnaces will be more economical than fossil furnaces by the 2030, he suggested. But they will come with increased operation costs and, unless conditions completely change, the markets will become more expensive.

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Events review: Emhart Summit 19

Global brewer challenges glass sector Heineken and its consumers want sustainable glass production and packaging solutions. Ruben Griffoen, the Dutch brewer’s Sustainability Manager for Global Packaging, told the Emhart Summit 19 the company was under increased pressure from consumers to provide environmentally friendly solutions. As a result it has launched the Drop the C in Packaging campaign, which aims to lower its CO2 emissions. The company has made substantial progress to become greener. It has urged glassmakers to follow its example and to reduce their environmental footprint. The glass industry should adopt more renewable energy in its furnaces, use more cullet in its glass production and make further lightweighting of bottles in order to make the CO2 neutral bottle. During his presentation Mr Griffoen provided examples of brands that had failed to innovate, such as Nokia, Kodak

and Atari. The glass industry needs to move faster. He warned that plastic was in the public eye at the moment, but would glass be next? “Will consumers ban high CO2 packaging? I have to say this could be the next big thing. When we talk about furnace lifetimes I want you to start working on it now and not just talk about sustainability at events like this but make it part of your agendas.” During questions afterwards, he was asked by Emhart CEO Martin Jetter if Heineken would be prepared to contribute towards new furnace technologies to ensure carbon neutral bottles. He answered there are places in the world where renewable energy was ‘cheaper than from the grid’. These places will become increasingly more common. He suggested that governments were thinking of increasing tax on natural

gas and lowering it on renewables. Heineken is able to offer help in regards to these solutions, he added. He suggested that the glass industry could look to government subsidies for help in transforming to renewable energy.

Embracing the needs of boutique brands

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The glass industry needs to embrace the challenges that smaller, boutique brands offer, the Emhart Summit 19 was told. Tim Croxson, Chief Operating Officer at Croxsons, said the smaller brands present their own unique problems – and often the glass industry does not rise to the challenge. During a 20-minute presentation he said today’s customers want choice and smaller orders of glass but are told this is not always possible. “I often hear the accusation that as an industry we are lagging behind and not doing enough to keep pace with

the future consumers and what they are looking for.” He gave examples of where customers were told that glass may not be supplied to them, sometimes for up to a year. He described how in 2008 there was a glass shortage similar to today. Many brands were lost to plastic and have never returned. “There is a danger of that happening again today. We are forcing brands to use other materials because glass is in short supply.” While there is no easy fix to that in 12 months the industry should think up to 15 years ahead to prevent capacity constraints and stop brands being unable to trust glass. Much of the industry’s output is catered towards the baby boom generation yet their purchasing influence is slowly waning. Younger generations are buying less and that is a challenge the glass industry needs to respond to. Millennials and Generation Z were moving away from large, mass produced goods to something more local, embracing variety, differentiation,

individualisation and often nonalcoholic. Rather than offering customers two or three standard bottles, the sector should consider offering them between six and nine. To help customers stand out the sector should offer customers more bottles at a similar commercial level rather than the standard two or three. “I believe that when customers can compete on a greater level it’s good for their industry and is good for us as well.” He suggested many of the younger brands do not have the wealth of experience that the glass industry has. The industry could pool its resources and offer online training to operators and packaging people for example to help increase their knowledge. It would help prevent panicked phone calls from customers worried about their glass and would also build meaningful long term relationships. “What if we as an industry were able to train brands, to train their teams to a higher level on all things glass so that further down the line they can help us?”

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Consistent, end-to-end digitalization ensures lasting success

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Events review: Emhart Summit 19

The key to a successful company Bucher Industries CEO Jacques Sanche investigated the elements that make companies successful. He highlighted a McKinsey and Company book, Beyond the Hockey Stick, which had investigated thousands of businesses over a 10-year period and compared their financial performance. The most successful companies had displayed 10 key elements, one of which was past investment in R&D. He said: “There was a clear correlation between those companies that had been investing in R&D and those that made a better race during these 10 years. “It obviously paid off to have a higher

R&D budget than the ones who didn’t.” He focused on industry trends and stated the negative perception towards plastic was a huge opportunity for glass. “The plastic discussion is going on and people are becoming aware there aren’t many alternatives to glass. I think that is a huge opportunity. There is an increasing perception that the right way is to go along the glass path.” In conclusion he said that three topics should prevail in the industry: reusability, productivity and the beauty of glass. The notion that glass is good should be promoted more and should help

increase demand for glass. More cullet should be made available via discussions with local authorities. This in turn would re-emphasise glass’s sustainable qualities. Glass plants still have potential to improve their productivity, he said. “The pack to melt must be better. We have to make glass production less magical and more industrial, it has to be a more predictable process. “It is our job and we are working hard to get it into that direction. Job changes have to become more routine rather than an experiment.”

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A delegate’s view.... Attendee and speaker Richard van Breda of IS Engineering gives his thoughts on the summit. “There were two key themes to come out of Summit 19. First, that of the mega trends of sustainability and decarbonisation. Secondly, the need for the industry to adapt to the digital era and to develop associated technology. Neither of these themes were discussed at the previous Summit, six years before. Speakers made it clear that despite some pockets of excellence in the industry, there was a need for a pan glass industry combined initiative to move glass as packaging industry forward, to ensure its long term success. Decarbonisation and sustainability was the overwhelming mega trend discussed. The scene was set by Heineken, which shared its expectations of glass as a future sustainable packing substrate. They demand carbon neutral glass packaging as an industry standard in the near future. FEVE reinforced Heineken’s view,

confirming that all the big multinational FMCG companies have similar demands. FEVE reflected on the good progress in European glass recycling. However, the same cannot be said about the rest of the world. Plastic packaging is under pressure for its burden on the environment. The forum was told it was only a matter of time before the glass container sector will feel this prerssure too. Sorg made a call to action for technology development. The future of glass melting was caught in the crossfire of environmental policy and economics. The furnace is the biggest contribution to the glass carbon footprint. With current technology, the industry is approaching the limits of CO2 reduction and energy efficiency. To achieve the customer demanded step change reductions requires joint technology development and funding. Is the industry ready to tackle this? Emhart reinforced the need for increased use of technology, specifically, big data to drive automation. It discussed

increasing the use of sensors to manage and control machines digitally and scientifically. The focus on automation and robotics to replace repetitive human dependent tasks. Additionally, the collection and application of big data from the process is a key enabler for its closed loop End to End technology. These digital technology developments have spin offs, which provide value to the glass value chain. This was discussed by IS Engineering, with the adoption of glass traceability. Is the glass industry doing enough to be successful long-term? Are the investment and speed of adoption of new technology and skills sufficient? Is the industry’s response to the mega-trend of decarbonisation and sustainability sufficient? Is the glass industry positioned to attract the people skills sets that emerging technologies will require? Delegates were left with important points to reflect upon.

Martin Jetter, Bucher Emhart Glass, CEO, opened and closed the conference.

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Events review: ICG 2019

International Congress of Glass is a global event More than 900 people from 45 countries attended the International Congress on Glass (ICG) held in Boston, USA recently. Greg Morris was one of them.

1. Manoj Choudhary 2. Adria Biosca Mecias 3. Mark Bennett 4. Mr Nakamura 5. Saint-Gobain 6. Stefano Ceola 7. William Johnson 8. Wolf Kuhn

he five-day event was organised by the International Commission on Glass and The American Ceramic Society Glass and Optical Materials Division (GOMD). Glass International was among those in attendance. The event marked several milestones. This included the 25th edition of the Congress, the 100th anniversary of the ACerS Glass and Optical Materials Division, and the Society of Glass Technology’s first Michael Cable Award and lecture. A total of 866 presentations were given at the event within 43 technical sessions. There were also two poster sessions, a Festschrift, eight award lectures,

networking receptions, and working committee meetings. Dutch group GlassTrend organised a Sustainability in Glassmaking debate as well as a technical session titled Towards Carbon Free Glass Production. Other events included a Women in Science Reception and an award for the best young scholar. There were 200 students among the delegates. GOMD chair Liping Huang presided over the 100th anniversary segment of the opening ceremony, receiving congratulations and recognition from ICG, SGT and the Deutsche Glastechnische Gesellschaft (German Glass Society, which will celebrate its centenary at the 2022 ICG in Berlin).

The congress included the Morey and Stookey lectures, as well as the first awarding of the new L. David Pye Lifetime Achievement Award to Charles Kurkjian and John Douglas Mackenzie. A Festschrift in honour of Alfred University professor emeritus Arun Varshneya also took place throughout the event. Programme chair John Mauro said: “This was such a wonderful opportunity to bring together the global glass community to exchange technical ideas and deepen our sense of camaraderie in the world of glass.” ICG president Alicia Durán said: “This Congress is part of our scientific work and, like science, is a collective effort.” �

THE NEXT ICG WILL BE IN 2022 IN BERLIN, GERMANY.

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Events review: ICG 2019

“Glass has been silent or at best reluctant to tell our story. But now is the time to change. Our numbers are nothing to be ashamed of.

” O-I Vice President for Sustainability, Jim Nordmeyer.

Glass needs to tell its story T “We are the most sustainable packaging material in the world and it’s time to have our voices heard.” In a 30 minute opening presentation of the Glass Recycling and Sustainability session, Mr Nordmeyer described the glass recycling value chain, and the challenges and opportunities of glass recycling. He highlighted how glass can be collected from the kerbside and be back on the shelf as a product in just 30 days – no other material can do that. He described the EU as a pioneer of the circular economy, with an average container glass recycling rate of 74% across its 28 countries. Some, such as Sweden have a 90% glass container recycling rate. He described the US glass recycling market. While the nation disposes of about 10 million tonnes of container glass a year only about 33% of that is recycled. “What happens to the other 67%”? he asked.

While some of it is downcycled and used in applications such as construction material, the remainder is landfilled. He debunked some myths about glass recycling. Statements such as recycling uses more energy than making something new, items must be meticulously sorted for recycling, and products made from recycled content are lower quality, are all false he said. He suggested six points that need to be done to help improve recycling rates. These are promoting best practices in glass recycling, strengthening glass markets and the value chain, providing solutions oriented resources for local and state governments, collaborating to build a strong foundation for success of glass recycling, and partnering with glass champions to seek solutions that increase glass recycling. “We have to advocate and encourage change. It’s hard but we have to really push.” �

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he glass industry needs to speak up and promote its environmental credentials, a conference heard. While other materials have been telling their recycling and sustainable stories, glass has remained silent for too long said O-I Vice President for Sustainability, Jim Nordmeyer. He told the ICG Congress 2019 in Boston, USA: “Metal, plastics and fibre packaging are out in the market telling their recyclability and sustainability stories. They’re doing it every day. “Glass has been silent or at best reluctant to tell our story. But now is the time to change. Our numbers are nothing to be ashamed of.” Some countries in Europe have an up to 90% recycling rate for glass containers but the industry has been afraid to tell its story, said Mr Nordmeyer. “That’s about to change because O-I is going to take the lead and start telling that story and I encourage you to do the same.

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GlassTrend:

Is carbon free glassmaking possible? The GlassTrend seminar at the recent ICG focused on the environment and ‘greener’ glassmaking processes. Greg Morris was in attendance.

seminar discussed Carbon-free Glass Production during the 25th International Congress on Glass in Boston. The seminar, organised by Dutch association GlassTrend, focused on topics such as is carbon free glass production possible, which technologies are available to achieve this goal and how far is the path to carbon free glass production?. The seminar included 14 papers related to the subject. The presentations varied from papers related to general themes and trends in glass production, to more technical, detailed papers. The event was chaired by GlassTrend chairman AnneJans Faber and fellow CelSian colleague Oscar Verheijen. Among the companies that spoke were O-I, China Triumph International Engineering Company, CelSian Glass, AGC, Fives, TECO, Eurotherm by Schneider Electric and FIC UK.

Climate change O-I’s Vice President for Sustainability, Jim Nordmeyer, opened the session with a paper titled The Challenges and opportunities of glass manufacturing towards Carbon Neutrality. It was Mr Nordmeyer’s second presentation at the ICG event, after his paper 24 hours previously. He opened the speech with a startling graph about major weather events in his native United States. There had been 14 major weather events each exceeding 1 billion of damages in 2018 alone – ‘not an insignificant amount,’ he stated. He warned that the global temperature is predicted to rise by 1.5˚C in the next 20 years and that extreme weather events and their severity and frequency will continue to increase. He then discussed some of the reasons why the glass industry needs to reduce its own carbon footprint.

Many famous brands and customers have made carbon neutrality a priority and have set public and demanding targets to reduce the carbon footprint of the supply chain of their products. “They have thrown out the challenge to the glass industry and it is up to us to accept it,” said Mr Nordmeyer. A quick pathway, such as improving recycling and decarbonising the grid would lead to a 36% emission improvement in 2050 compared to 2012 he suggested. But a more aggressive approach, using renewable energy, could lead to a 77% emission reduction. “But there is a lot of work to be done and the glass industry could be at the leading edge of that work or we can be late adopters. I propose we be at the leading edge.” Continued>>

O-I’s Vice President for Sustainability,

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Jim Nordmeyer

AnneJans Faber, of CelSian Glass and GlassTrend Chairman.

Daniel Backhouse, Sheffield Hallam University.

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Environment Events review: ICG 2019

He suggested bold action which requires innovation, to look at alternative fuels and renewable energy and different ways of melting. There are risks to this approach though, he warned. On the policy side consumers, businesses and policymakers are all disjointed. There is a lack of support from some governments in respect of climate change, particularly in the US. “But industry has not given up in the United States in respect of this challenge. It will continue to address it.” He said that, in the future, everyone needs to play their part in addressing the issue. “We need to start today, with everyone’s commitment. And it is not just individual glass companies, we need to look upstream and downstream to our suppliers, to adjacent industries for ideas to change the footprint of the glass industry.” He suggested decarbonisation would require a lot of effort, with the next generation of consumers the one that will drive the agenda. He said: “We need to look at lower zero carbon energy prices, we need to look at keeping nuclear alive – and I know that is a controversial subject depending on the region you live - and we need technology breakthroughs. I believe they will come over the next decade.” He concluded: “Glass has been around

for 3000 years perhaps longer but will we be around for another 3000 years? “I think we will but it will take the efforts of the entire industry to do so.”

Chinese viewpoint He was followed by a representative from China Triumph International Engineering Company, who discussed The Transition of the Chinese Glass Industry towards Zero Emissions. Original speaker Peng Shou was unable to attend. He said the Chinese glass industry was focused on becoming a greener industry and had worked with companies, universities and institutions from countries such as Germany, USA and Japan to improve its environmental credentials. In its latest five year plan, published in 2015, the Chinese government set out goals to support the development of the glass industry. These included five projects such as the construction of a national manufacturing innovation centre and more use of high-end manufacturing equipment. It stated that the use of more robots, AI and other intelligent manufacturing methods would improve production efficiency as well as reduce emissions. China issued a commercial licence for 5G on June 6 this year and its use would help accelerate the smart plant, he said. Within its energy reduction and environmental policy the

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China Triumph International Engineering Co

Chinese government has stated that environmental standards would be strictly upheld. Another of its environmental focus is on the photovoltaic market. In 2018 China increased its PV capacity by 44.1GW to 174.63GW, marking it the largest in the world. It expects to reach 800GW capacity by 2030.

Alternative fueling Dominik Orzol, of the International Partners in Glass Research (IPGR), gave a presentation titled An all encompassing and radical view on carbon free glass production. He discussed the pros and cons of alternative fueling methods. While fully electric furnaces are emision free, safe, and contain advanced melting systems, there are significant infrastructure challenges. In addition, storage needs are very high and unclear - would it be backed up by the power grid for example. The pros of Methanol TCR as a fuel are that it is partly emission free, is relatively easy to store and only requires moderate adaptations to existing furnaces at the port and burner. But, the infrastructure of a TCR system needs to be implemented and large amounts of methanol and oxygen would need to be stored. Hydrogen firing is emission free and a higher adiabatic flame temperature is possible. But a storage system would be Continued>>

Edwin Ferreira, TECO.

Dominik Orzol, IPGR

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Events review: ICG 2019

Hans van Limpt, Sibelco

Andy Reynolds, Fives

required and an infrastructure system would need to be implemented. A number of adaptations to existing furnaces would also be required. In summary he said that the evolution of existing technology is only an intermediate step to achieving a 100% carbon free glass bottle and that process technologies for new approaches need to be developed.

Biomass ash A talk from the University of Sheffieldâ&#x20AC;&#x2122;s Dr Daniel Backhouse highlighted the use of a potential new technology in raw materials . The University has been studying the use of biomass ash for use as a raw material in glass melting. Its alkali and alkaline earth content means it could be used as a partial replacement for high value limestone, soda ash and/or dolomite. It has the potential to offer reduced CO2 batches, reduced melting temperatures and lower energy demand. The use of biomass has increased as an energy source in recent years, particularly in Europe and the USA/Canada. There has subsequently been an increased availability of a range of different biomass ashes. Some UK projects have focused on using biomass ash as a raw material for

use in the glass industry. These include the Enviroglass 2 and BiomAsh projects. The Enviroglass 2 project focused on clear container glass, float and glass wool while the BiomAsh looked at green and amber container glass. They analysed the ash from 11 power plants across the UK and found 23 different types of ash. In his conclusion Dr Backhouse suggested that the presence of transition metals, particularly iron, causes coloration in clear glass. However, loading of at least 5 wt.% are possible with a little colouration. The next steps will be to work on float and mineral wool glass. An abridged version of this presentation is available to read as a feature article in this issue, page 47.

All electric The remainder of the presentations then focused on electric glass melting. These were given by Edwin Ferreira of TECO, Andy Reynolds of Fives Stein, Rene Meuleman of Eurothem by Schneider Electric and Stuart Hakes of FIC UK. Many large brands, such as Heineken and Ab Inbev (ABI) have called on their glass industry suppliers to help them reduce their carbon footprint. Rene Meulemen told the conference that ABI for example has set a goal that by 2025 100% of all its purchased energy will be

from renewable sources and it will have a 25% reduction in CO2 emissions across its value chain. Big brands will identify both the energy efficiency and cost reduction opportunities in their supply chain. They will engage with suppliers and assist them to implement their sustainability initiatives. They will identify those suppliers which are leaders and which are laggards in terms of sustainability performance, said Mr Meuleman. Electrical melting has many advantages. These include high efficiency, lower capital costs, CO2 recovery, avoidance of air pollution and smaller footprint. But its disadvantages include it costs more, electrical furnaces tend to be smaller and there are questions about power supply reliability. But the sector is addressing these challenges. While cold top vertical melting is not a fix all solution it certainly has a place in the future of glass melting, particularly in large scale production. A 300 tonnes per day container glass furnace is already a viable solution where the glass type and output are relatively stable. The sector is on the road to finding a solution to using electric melting in float glass and a 600 tonnes per day furnace has been mooted, although there are challenges to achieve the required quality. ďż˝

ICG 2019, HTTPS://CERAMICS.ORG/EVENT/ICG2019 INTERNATIONAL COMMISSION ON GLASS, WWW.ICGLASS.ORG

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Rene Meuleman, Eurotherm by Schneider Electric

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Environment Events review: ICG 2019

Sustainability gets green card during GlassTrend debate G lass manufacturing professionals attended a sustainability debate about the future of glassmaking at the 25th International Congress on Glass. About 45 industry experts from glass manufacturers, technology suppliers and associations took part in the hourlong debate within the Congress held in Boston, USA. Glass International also attended. Rather than a traditional panel discussion, each attendee was invited to sit in a particular group, discuss a slightly provocative subject, and at the end, after consideration of both sets of arguments, did participants give their personal opinion with a green (pro) or red (con) card. The debate was organised by the GlassTrend group, which aims to improve the competitive strength of the entire glass industry. The debate was chaired by GlassTrend chairman AnneJans Faber and its advisory member Oscar Verheijen. Mr Faber said: “The main goal of this debate was to collect valid arguments pro and con the statements, with an open mind, rather than pushing personal opinions upon other participants.” He added: “As organisers of this first GlassTrend debate, we received many positive reactions on this debate format and we will surely repeat this type of interactive session in future GlassTrend events. So be prepared to have your arguments ready next time!”

Debate

Oscar Verheijen

combustion was more realistic. They also questioned the safety aspect of storing and transporting hydrogen. The final ‘score’ for this discussion was Con 27 and pro 11. The final debate was In 20 years the cullet percentage for flint, container, flat, fibre and tableware will exceed 80% (similar to coloured container glass at the moment.) The cons suggested this would be fine from a cost perspective and means less use of natural resources, mining and transport. But the con side said that high quality cullet would not be available and that alternative raw materials would also reduce CO2. The final score for this debate was pro 5 and con 33. �

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The debate discussed three subjects and attendees were split into three groups: the pros, the cons and the neutral

observers. For each subject, each group was asked to give either the for or against argument to each topic while the neutral observers watched the proceedings. After each 20-minute debate attendees then switched position to ensure everyone took part in proceedings. Attendees then voted at the end of each debate to see if they agreed or disagreed with the statement. The first topic was: A CO2 tax of at least $50/tonne of CO2 is required to stimulate the glass industry to invest in CO2 reducing technologies (to reach a 50% reduction by 2030). Those in the Pro camp suggested this would support a Return on Investment (ROI) and would encourage companies towards more renewable energy, thus helping save the planet. Those in the cons side said glass was suffering economically already and that this tax would squeeze already limited resources. They suggested that the tax could become lost in government bureaucracy and administration rather than being used efficiently in the glass industry. The vote saw 23 people vote for the Pro side and 15 for the Con side. The second statement discussed was: In 20 years, all glass furnaces will be operated with more than 80% of the energy provided by hydrogen combustion. The statement sparked a lively debate with the Pros team stating that hydrogen storage is effective and that the natural gas infrastructure system could be used for hydrogen. But the Cons suggested that the 80% figure was too much and that 30%

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Environment Events review: ICG 2019

Dr Richard Hulme was presented with an award by sponsor AGC at the end of the lecture.

Dr Hulme, (left) with SGT president and memorial lecture chairman, Stuart Hakes.

Michael Cable Memorial Lecture: Tribute to a glass great

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senior glass technologist gave a touching tribute to his former tutor during a memorial lecture. Guardian Glass’s Dr Richard Hulme spoke movingly during the inaugural Michael Cable Memorial Lecture held at the International Congress of Glass 2019. He discussed Emeritus Professor Cable’s many achievements in the glass industry and his research which has helped move the industry forward. The 50-minute lecture was titled after a Professor Cable phrase, You Ought to Go Away and Think Again. Dr Hulme said: “This is a great honour for me and I’m humbled at being selected to do this. I know that ‘Prof’ is looking down on me from somewhere.” Professor Cable was respected globally. As well as an Emeritus Professor at the University of Sheffield he was a Fellow of the Society of Glass Technology (SGT). He received the Otto Schott Medallion in 2006 by the Deutsche Glastechnische Gesellschaft (DGG) for his research and received the ICG President’s Award in

1998. He was an Honorary Doctorate of Technology at the Abo Akademi, Finland. He was highly respected for his work in CFD Modeling, as well as in melting and refining, work still relevant today, said Dr Hulme. CFD modelling has developed into a useful tool for the glass industry and is extensively used for the furnace. “Given the complexity of the melting process, CFD models do a remarkably good job,” said Dr Hulme. Modeling can predict performance depending on furnace design, is possible to run ‘what if’ scenarios before applying them in practice and is useful for troubleshooting – it can trace the origin of defects back to operation or refractory sources. But Dr Hulme warned: “Like Cable I think that CFD modelling is extremely useful but anyone who thinks they are 100% accurate ought to go away and think again.” Dr Hulme first worked with the then Dr Cable between 1973 and 1977. At first

he didn’t like his tutor. He was direct, had a fearsome reputation and had high expectations of his research students. He thought Dr Hulme was at Sheffield to do his Masters and to get to back to his then employer Redfearn Glass, as soon as possible. But Dr Hulme soon grew to respect and like his tutor: “He had a sense of humour and could raise your spirits for knowing him.” Prof Cable was meticulous in his approach and acknowledged the Yorkshire glassmaking industry, where both Prof Cable and Dr Hulme are from. He also had excellent handwriting and later wrote on the front of one of Dr Hulme’s books: ‘To Richard, a genuine glass technologist,’. “This is particularly valuable piece of my library,” said Dr Hulme. Prof Cable passed away in 2016 leaving behind his wife Peggy. Dr Hulme said: “I didn’t like Prof Emeritus Michael Cable, I loved him dearly and I miss him.” �

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Erik Muijsenberg, Vice President of Glass Service (Czech Republic)

Is hydrogen a viable future energy source?

ydrogen could be a viable future furnace energy source to help reduce glassmaking emissions, a conference speaker told the ICG Congress in Boston. Erik Muijsenberg, Vice President of Glass Service (Czech Republic) presented a 20-minute paper titled Glass Melting Furnace Design with a lower CO2 footprint using renewable resources. He told delegates that the paper had been prepared by both Glass Service and its daughter company FIC UK. He said the EU requires a 45% reduction in CO2 by 2030 compared to 2005 and an 80% reduction by 2050. Glass companies need to plan now for 2030 when a furnace lifetime of approximately 12 years is considered. He pointed out that it took Earth 2.4 billion years to generate fossil fuels, which are derived from solar energy, and it has taken humans just 170 years to burn them out. It would take 100 million years to generate enough fossil fuels for what is burnt in one year at present energy consumption. He highlighted that since the Fukushiima Daiichi nuclear accident in Japan in 2012, Germany had increased its use of renewable energy. It has 50GW of capacity, mainly as a result of expanding its solar and onshore wind capacity. Forthcoming offshore wind plans are huge, one park planned in the UK alone would generate 50GW with each windmill generating 10-15 MW. A 350 tonnes per day furnace requires about 10MW of energy, so just one windmill is sufficient. He warned that renewable energy availability is currently fluctuating and the price of electricity is sometimes even a negative, when there is overproduction. But renewable energy is the way forward and it will become cheaper. In Germany renewable generated electricity and other renewable energy is now cheaper than fossil fuels generation (before taxes), he said. He believes that hydrogen will be an alternative in the future. While the infrastructure is not yet available it is easy to convert. It is also easier to store hydrogen compared to electric energy in batteries. Global company Shell, for example, plans to store it in special salt caves (offshore). In the meantime, steps to reduce a furnaceâ&#x20AC;&#x2122;s CO2 output include installing electric super boosting (depending on electricity price and source) and installing model predictive control (MPC) to balance fluctuating energy prices and availability. ďż˝ Glass International July/August 2019

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Soda Ash

Soda ash in the glass industry Ahead of the SGT’s raw materials conference in Cambridge, UK in September we provide a selection of raw material articles over the following pages. We start with Seema Gahlaut’s overview of the soda ash industry.

Industry

Percentage of global soda ash

consumption (%)

Flat Glass

Container Glass

Speciality and other glasses

Soap & detergents

7 15

Chemicals

Mining

Pulp & Paper

Others

� Table 1. Soda ash consumption by different industries.

Rank

Company

Installed capacity

(in million tonnes)

Country

% of global capacity

10.3

Solvay

7.32

Belgium

Ciner

4.60

Turkey

6.5

Tata

3.73

India

5.2

Genesis Alkali

3.68

USA

5.17

Shandong Haihua

2.85

China

4.0

India

3.8

Poland

3.4

Nirma

2.73

Ciech

2.43

Sanyuu Group

2.20

China

3.1

Hubei Yuhua

2.10

China

2.9

Sisecam

1.93

Turkey

2.7

� Table 2. Top 10 global soda ash producers. for soda ash in South East Asia and India, the trend for global prices is likely to remain a mixed bag.

China retains pole position The largest producer of flat and container glass makes China the largest consumer of soda ash. The country has also become the largest producer of soda ash in the past two decades. Despite a clampdown on a

number of soda ash production facilities in last two years, China continues to be the largest soda ash producer in the world, having an installed capacity of around 31 million tonnes per annum, which is roughly 45% of the global installed capacity.

Continued>>

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oda ash is the 10th most commonly used chemical in the world. It is perhaps the most significant raw material in the glass industry. In addition to the glass industry it is used as a raw material in the production of detergents, cleaning products and as an additive in food, pharmaceuticals, chemicals and metallurgical applications. Soda ash makes up about 15-17% of the total batch volume, accounts for nearly 60–65% of the total batch cost and is the most keenly observed raw material for glass producers. Availability of soda ash in the domestic market and cost often decides the price competitiveness of a glass producer. There are two grades of soda ash; ‘light’ and ‘dense’ They are identical in terms of chemical composition, where the only difference is their granule size. Light-grade is a fine powder form of soda ash, mainly used to manufacture other chemicals, where dense-grade is widely used for glass production. The glass industry is the largest consumer of soda ash by a considerable margin. Consumption of soda ash by the glass industry differs regionally, but globally the glass industry accounts for about 53% of soda ash consumption. Table 1. Flat glass accounts for about 26% of global soda ash demand, while container glass 20% of the total output, followed by all the remaining categories of glass products which account for 7% of the total soda ash consumption. USA is the largest natural soda ash producer. The country is also the largest exporter of soda ash. Until 2017, China was the second largest exporter. However, Turkey replaced China in 2018 as the second largest exporter. Table 2. With environmental checks finally completed in China, and most plants resuming normal production, addition of capacity in Turkey, a tight supply situation in the global and Asian soda ash market is gradually easing. However, as a result of strong demand

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Soda Ash

Company

Installed capacity

(in million tonnes)

Location

Shandong Haihua Group Company

2.85

Tangshan Sanyou Group

2.20

Shandong Hebei

Henan JinshanHuagong

1.70

Henan

Liangyungang Soda ash plant

1.20

Jiangsu

Shandong Haitian ( Jinjing Group)

1.20

Shandong

Qinghai Soda ash development

1.20

Qinghai

Sichuan Hebang Company Limited

1.20

Sichuan

CNSG Kunkun soda ash

1.10

Qinghai

Qinghai Wucai Mining

1.10

Qinghai

Hubei Shuanghuan Chemical

1.10

Hubei

� Table 3. Top ten soda ash producers in China.

Company

Installed capacity

Location

(in million tonnes)

Nirma

1.450

Mehsana

GHCL Limited

0.975

Sutrapada

Tata Chemicals

0.850

Mithapur

Rohit Surfactants Private Limited

0.500

Jamnagar

Table 4. Indian soda ash producers.

of synthetic capacity, is the second largest in China and eighth largest globally. China had an installed capacity of 14 million tonnes in 2004, which grew to 31 million tonnes by the end of 2018. The main export markets for Chinese soda ash producers are South-East Asia, South Asia and East Asia market.

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India Post environmental restrictions, production in 2018 was lower than previous year by 5%. In 2018, China produced 25.8 million tonnes of soda ash (down 5% over last year level of 27 million tonnes), with a capacity utilisation rate of 83%. Domestic consumption in the year was at 24.7 million tonnes (down 4% against last year), with 1.4 million tonnes exported. Domestic demand slowed due to a closure of a number of float glass plants. Chinese soda ash supply is expected to remain balanced. New capacity addition and production growth are expected to remain in line with demand growth and exports may remain at current low levels of 1.2 to 1.5 million tonnes. Table 3. Shandong Haihua is the largest Chinese producer and the fifth-largest worldwide, with 2.85 million tonnes per year of synthetic soda ash capacity. Sanyou Chemical, with 2.2 million tonnes/year

India’s total installed capacity of soda ash is slightly above 4 million tonnes, with an estimated production of about 3.2 million tonnes in the financial year 2018-19. The total demand of soda ash in the country is about 4.1 million tonnes. Four major soda ash producers in India account for the majority of production. Domestic companies Nirma, GHCL, RSPL and Tata Chemicals dominate the country’s industry. Table 4. Despite the sizable installed capacity and output, the Indian glass producers import a large amount of soda ash for their production needs. The Indian government’s antidumping duty on soda ash imports from seven countries has increased the cost for Indian glass producers. The Indian soda ash industry also suffers from a weaknesses of concentration of 97% production capacity in the western state of Gujarat. The cost of transportation to glass producers in the south and north India, which constitutes about 40% of

the installed capacity of glass industry, is high when compared to the ocean freights of imported soda ash from US/ China/Kenya and Europe. Around 25% of Indian demand is met by imports. Indian glass producers import soda ash from China, Turkey, USA, Pakistan, Iran and Kenya. India’s largest soda ash producer, Nirma has an installed capacity of 1.45 million tonnes of soda ash. The company’s production facilities are located at Mehsana in the state of Gujarat. In 2008, Nirma acquired the California-based natural soda ash producer, Searles Valley Minerals, which has manufacturing facilities at Argus, Trona and West End. Tata Chemicals, which is the third largest producer globally, has an installed capacity of 850,000 tonnes of soda ash at its Mithapur, Gujarat plant. Soda ash capacity in the country is also rising. Tata Chemicals is planning a 150,000 tonnes per annum expansion of its soda ash capacity in the next two years. Another, GHCL, is increasing its total capacity to 1.2 million tonnes per annum by 2021 with a 125,000 tonnes per year capacity expansion slated for completion by the end of current year. This would be followed by two further 50,000 tonnes per annum expansions during the next three years. Supply of soda ash to the Indian market is further expected to ease as nearly 400,000 tonnes of soda ash capacity is expected to come back on-stream in China after the environmental issues forced the closure of some facilities.

Iran and Pakistan Iran and Pakistan have enough installed capacity to meet the demand from glass producers in their respective countries. In addition to the domestic market, these countries are able to export some soda ash to other neighbouring countries. In Iran, two of the largest soda ash producers are subsidiaries of flat glass producers Kaveh Glass and Sahand Industrial. Semnan Soda Ash Company (SSACO), a subsidiary of Iranian flat glass producer Sahand Industrial Group (SIG), is a producer for the group’s glass business and other glass producers in Iran. The company began commercial production of soda ash in 2006 and has an installed capacity of 700,000 tonnes per annum. Table 5. Continued>>

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Soda Ash

Pakisatn’s ICI expanded its soda ash production by 50,000 tonnes per annum in early 2018. The company is able to meet about 80% of demand from the country’s glass producers. However, with the recent capacity expansions by two float producers, Pakistani glass producers will have to import a proportion of soda ash if fresh capacity doesn’t start in the country in the next two years.

USA Though discussing the availability of soda ash in Asian countries in this article, it is important to understand the dynamics of US soda ash production and exports as it has been one of the major soda ash exporters to the Asian glass industry. The installed soda ash production capacity in the United States was 13 million tonnes per annum in 2018. It produced around 12 million tonnes of soda ash. US production was down by 1% compared to 2017. The total domestic consumption was around 5 million tonnes, the remainer, 7 million tonnes, was exported. US exports are supported by large

Company

Installed capacity (in tonnes)

Location

Country

Semnan Soda Ash Company

700,000

Semanan province

Iran

Kaveh Glass Group

300,000

Firuzabad, Fars

Iran

ICI Pakistan

4,25,000

Khewra

Pakistan

Table 5. Iran and Pakistan’s soda ash producers.

demand from South America, South East Asia, Australia and parts of Europe. The US continues to face competition from Turkey in their traditional markets of South East Asia and the Asia Pacific region due to the natural freight advantage Turkey has over US-based producers.

Emergent Turkey Turkey has emerged as one of the most important producers and exporters of soda ash recently. The domestic glass industry has benefited immensely due to the availability of soda ash in the domestic market at competitive prices. Turkey’s strategic location enables it to serve European, Asian and African glass markets. At the end of 2018 it had a total installed capacity of 5.35 million tonnes of soda ash. Domestic consumption was a little over

1.0 million tonnes. Considerable trona resources in Turkey make it one of the most important soda ash producing countries for future demand. Trona is found in the Kazan and Sincan district borders of Ankara. The country has around 900 million tonnes of exploitable trona reserves, and is in second place behind United States. Asian glass producers are expected to benefit from the recent addition of soda ash capacity in Turkey, as the country has the potential to replace USA imports in these countries. Asian producers will be able to cut import costs as freight costs from Turkey are substantially less compared to the United States. South East Asian glass producers in particular will benefited most from this move. �

WSA2019 WORLD SODA ASH CONFERENCE 24-26 September 2019 | Cannes, France An intensifying focus on sustainability in the move towards a circular economy boosts soda ash demand and opens up new opportunities. Amid these shifting dynamics, how will the soda ash market balance evolve? How will your business ensure supply security? Where do the new opportunities for the industry lie?

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Join us in Cannes for the World Soda Ash Conference 2019, bringing together all the stars of the soda ash industry for indepth discussion and exciting networking opportunities.

See you on the French Riviera!

For more information visit ihsmarkit.com/WSA2019 LYNN URBAN | DELEGATE SALES T +1 303 397 2801 E Lynn.Urban@ihsmarkit.com BEN KINBERG | PARTNERSHIP OPPORTUNITIES T (212) 425 8116 M (917) 399 3911 E Ben.Kinberg@ihsmarkit.com 309031511-0119-SK-CHE Copyright © 2019 IHS Markit. All Rights Reserved

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Raw Materials

� Sibelco’s plant in Dessel, Belgium, where three wind turbines generate more than 21,000 MWh of clean energy per year.

How minerals can support a more sustainable glass industry

he glass industry has made good progress in reducing its environmental footprint over the years through improved energy efficiency, waste reduction, increased recycling and new product development. But the high-temperature, energyintensive nature of glassmaking, combined with growing demand for high-quality raw materials, means that manufacturers still face big challenges if the industry is to maintain a competitive edge in a low-carbon economy. Sibelco has been looking at new material solutions to help customers achieve more sustainable manufacturing processes. Its approach can be broadly divided into three areas: � availability of materials to ensure long-term supply; � optimisation of materials to reduce energy usage, improve quality and minimise waste; and � increased use of recycled materials.

Ensuring access to responsibly-mined materials Access to consistent, high-quality raw materials is a common challenge for glass manufacturers. For example, global demand for industrial silica (quartz) sand is estimated at approximately 300 million tonnes per year, of which 34% (102 million tonnes) is consumed by the glass industry. While silica sand is abundant, gaining access to the right deposits is not straightforward. The sand must be of the right (low iron) quality and the deposit must be of a sufficient size. Another big factor is the deposit’s proximity to customers - a silica sand quarry tends to be no more than 300km from its main customer base to limit transport costs and emissions. Most importantly, a mining permit will only be granted if any impact on the local environment can be minimised. Sibelco is committed to the responsible

management of all of its mineral deposits, ensuring a sustainable supply of highquality materials for customers based on long-term resource management. Its mining activities involve three key phases: preparation, operation and rehabilitation. The preparation phase can last up to ten years and includes geological surveys, environmental impact assessments and permit applications. The operation phase focuses on responsible management practices during the lifetime of the deposit, involving detailed quarry planning to ensure that materials meet customer specification, environmental management, permit renewals and local stakeholder engagement. When mining finishes, the quarry is safely decommissioned and the land rehabilitated in a way that brings maximum benefit to the local environment and community. Continued>>

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With carbon emissions the biggest talking point right around the world, Ruud Dorscheidt* explains how the glass industry can become more environmentallyfriendly.

43 Glass International July/August 2019

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� Research & development at Sibelco’s Centre of Excellence for Glass.

Thanks to this commitment to sustainable mineral extraction, Sibelco has permitted access to some 20 years of silica sand reserves globally, together with long-term supplies of other glass minerals including dolomite, nepheline and feldspar. Its aim is to continuously maintain this level of reserves, creating certainty for customers and their future strategies.

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Optimisation of materials The materials used in a glass batch can reduce or increase melting temperatures, as well as affecting reject levels and end-glass quality. Optimisation of these materials requires in-depth understanding and expertise. Sibelco has established a Centre of Excellence for Glass with a dedicated team of glass industry experts. In collaboration with external partners, Sibelco has been conducting research and development focused on existing and new materials and techniques to create new solutions and optimise customers’ results. Work is focused on solutions. Looking ahead, the glass industry’s inevitable switch to all-electric, hybrid or other furnaces carries potentially big implications for raw materials. The melting behaviour of minerals, cullet and other batch materials may be very different in the new furnaces and Sibelco is undertaking research to understand how.

Recycled materials The use of cullet in glass manufacturing has been developing positively over the years. Recycling means that less glass waste goes to landfill, while reducing the amount of primary raw materials needed to make new glass. It takes up to 30% less energy to melt pure cullet than it takes to melt a batch made up of 100% primary raw materials -

every 1,000 tonnes of cullet saves around 314 tonnes of CO2. Sibelco sources and transforms more than one million tonnes of glass waste into high-quality cullet each year. At its plant in Antwerp, it is able to treat waste streams that other recyclers cannot, thanks to a combination of innovative new optical sourcing technology and process know-how. Its process removes metals, plastics, paper and card from the waste batch, before filtering the remaining glass by size and purity. Optical sorting technology then separates the cullet into four distinct colours which is sent to customers to re-enter the manufacturing process, hence completing a valuable closed-loop recycling process. Beyond cullet, Sibelco is exploring further possibilities for secondary raw materials, such as slags, ashes and other by-products. Secondary materials will only be feasible for use in glass manufacturing if they meet strict criteria for consistency, quality and availability. Raw materials have a major role to play in building a more sustainable, competitive glass industry. Access to responsibly-mined materials, how they perform in the furnaces of today and tomorrow, and advances in recycling to reduce the use of primary materials are all considerations. Sibelco’s approach goes beyond the supply of materials – its solutions incorporate technical support, logistics

expertise and access to research and development facilities. It works in partnership with customers to find the optimal combination of batch materials in order to achieve desired quality levels with the least amount of energy consumption/carbon emissions. This partnership extends to solving

� Sibelco produces more than one million tonnes of cullet a year.

day-to-day production issues, optimising manufacturing processes and exploring new possibilities for future solutions. By working together in this way, glass manufacturers and materials providers can achieve new breakthroughs and overcome technological barriers to reduce energy consumption, improve quality and eliminate waste. �

*Technical Support Manager Glass, Sibelco, Maastricht, The Netherlands www.sibelco.com

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Raw Materials

An ancient technology could help deliver decarbonisation W. Deng, D. J. Backhouse, F. Kabir, R. Janani, M. Bigharaz, P. A. Bingham* A. Wardlow, M. Marshall and R. Ireson** discuss how biomass ash could help deliver decarbonisation to the glass industry.

Recycled wood Virgin wood Straw MBM poultry

ďż˝ Location of UK Biomass energy facilities in operation or under construction.

Continued>>

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urrent glass manufacturing practices use a combination of manmade and mined raw materials with minimal variability in composition, and commercial glass compositions have remained largely unchanged for the past 50 years. However, as an energy-intensive industry, global commercial glass manufacture is a key sector that consumes 220TWh/yr of energy and emits 5060MT/yr of CO2. In 2015, the Paris Agreement set a target to reduce greenhouse gas emissions by at least 40% by 2030 and 80% by 2050 compared to 1990 levels, which places enormous commitments on the so-called Foundation Industries, which includes the glass sector. The UK is already playing its part in delivering the Paris Agreement through its domestic climate framework. In 2015 the UK Government and British Glass published their Glass Decarbonisation Roadmaps to 2050 to help coordinate and support achievement of decarbonisation goals within the glass sector. Both Roadmaps highlight glass batch reformulation as one enabler for the glass industry to reduce its energy consumption and CO2 emissions. Low cost, energy-saving, emissionsreducing, recycled and alternative raw materials are all considered to be materials that could help to achieve this in an economically viable way. In contrast to the burdens and challenges of achieving decarbonisation, these changes in the industrial environment also provide new opportunities to explore and establish new approaches and new technologies, with the potential for symbiotic winwin relationships with other sectors. For example, the energy generation sector is in the process of switching fuel from

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Raw Materials

coal to biomass to generate electricity in response to the UK’s decarbonisation policies. According to the Ofgem 201617 Biomass Sustainability report adjusted to reflect specific data omissions and other data sources, in 2016-17 the total consumption of biomass by dedicated biomass facilities and cement kilns in the UK (excluding imports) was 5.8 MT. The UK now has >20 biomass power plants (fuels include recycled wood, virgin wood, straw, poultry litter and sewage sludge) and the urgent need to replace fossil fuels with renewable energy sources has led to proposals for a further 37 UK biomass power plants (Fig. 1), which will generate >2 MT / year of biomass ash. The majority of this biomass ash is currently sent to landfill or used in low-value applications such as construction filler materials. Biomass ash management and valorisation is thus an escalating issue.

Component 1 2 3 4 5 6 7 8 Na2O

0.73 1.82 0.90 0.92 1.54 0.52 0.64 0.97

MgO

13.41 6.21 5.90 11.79 4.40 1.59 9.88 5.44

Al2O3

1.92 0.68 1.59 6.43 0.93 0.88 1.40 10.60

SiO2

7.51 3.34 40.98 22.05 3.16 58.88 6.07 28.01

P2O5

7.17 6.99 7.05 8.24 4.38 1.62 17.83 3.32

SO3

1.40 7.08 1.39 1.16 2.53 1.28 0.95 1.98

K2O

21.56 18.55 7.52 8.46 27.43 6.74 13.64 5.73

CaO

18.72 31.35 11.39 17.95 30.55 4.16 21.93 11.21

TiO2

0.76 0.17 0.36 1.58 0.22 0.27 0.45 2.00

MnO

0.13 0.05 0.08 0.18 0.11 0.06 0.11 0.25

Fe2O3

5.47 1.42 2.64 10.86 1.51 2.36 3.81 14.63

CuO

0.02 0.01 0.01 0.03 0.02 0.01 0.04 0.04

Rb2O

0.01 0.03 0.01 0.01 0.01 0.01 0.82 0.01

SrO

0.06 0.06 0.02 0.04 0.04 0.01 0.06 0.03

0.03 2.72 1.34 0.03 4.56 1.85 0.14 0.13

Cr2O3

NiO

0 0 0 0.01 0 0.01 0 0.01

ZnO

0 0 0 0.02 0 0 0 0.01

ZrO2 LOI

0 0.01 0.01 0.01 0.01

0.02 0.03

0 0 0 0.02 0 0 0 0.01 21.11 19.52 18.81 10.21 18.60 19.75 22.21 15.59

� Table 1 shows analysed chemical compositions (weight %) of 8 different biomass ashes.

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Decarbonisation In this article we describe how, from the perspective of the glass industry, biomass ash could represent an excellent opportunity for introducing a new raw material capable of delivering stepchanges towards decarbonising the glass industry. Yet this approach is actually a reboot of ancient technology. At the turn of the 1st millenium A.D., the Roman Empire produced large amounts of worked glass through a two-stage system. Primary glass centres close to sites of valuable raw materials were used to produce large amounts of ‘raw glass’, i.e. glass cullet. This raw glass was then transported to local glass production centres, which remelted and worked the raw glass to produce glassware for local consumption. The raw glass was produced from lime-rich sand and natron, an evaporite which is a mixture of Na2CO3·10H2O and NaHCO3, accompanied by smaller amounts of NaCl and Na2SO4. The main sources of natron were at Wadi Natrun and al-Barnuj, Egypt. However, from the 7th to the 9th century A.D., the availability of Egyptian natron declined. This was partly due to increased demand for natron, not only for glass production but also for the production of medicines and detergents. Political upheaval arose in the natron-producing region, with multiple invasions by foreign powers and a prolonged civil war (811 832 A.D.). The volatility of the natron supply necessitated a change in flux material by glass producers. The choice of flux was governed by the availability

� Fig 2 Laboratory-manufactured amber, green and colourless glass samples produced from reformulated commercial container glass batches with biomass ash.

of local materials. In the Levant and Near East, ashes from halophytic plants from the Salicornia and Salsola genera were used, whereas in northern Europe wood ashes were used, primarily beech (Fagus) ash. These wood ash glasses are known as ‘Waldglas’, (‘Forest Glass’). Wood ash glasses were found in the Carolingian Empire from as early as 800 A.D, and their industrial manufacture continued into the 18th Century. Production declined after this time due to a combination of factors: (i) increased demand for glass products (one tonne of glass requires 250 tonnes of wood to produce); (ii) the move from wood-fired to coal-fired furnaces, which drastically reduced the availability of wood ash; and (iii) increasingly strict quality and consistency requirements for glass products, which was difficult to achieve given the variability of the wood ash. A further cause of this change is also put forward: as the industry became increasingly mechanised, the composition of the glass needed to be controlled more tightly due to the

inability of machines to match the adaptability of human glassblowers to changes in glass viscosity.

Alternative raw material In 2016, a primary study of alternative raw materials for soda-lime-silica container and float glass manufacture (funded by Innovate UK) was successfully delivered by some of the present authors, and biomass ash was identified as a promising alternative raw material for energy and emissions reduction in the glass industry. Following this achievement, further successful funding bids to Innovate UK and BEIS in 2018 have enabled two parallel 2-year projects to go forward. The main purpose of these projects is to explore and develop the use of a broad range of biomass ashes as raw materials to reduce energy consumption and environmental impact of several different types of glass and ceramic product including amber, green and colourless container glasses, float glass, mineral Continued>>

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wool and heavy clay ceramics. Two classifications of ash (bottom ash and fly ash) are typically generated during the combustion of biomass fuels. Bottom ashes are produced in the combustion chamber and are composed of sand particles, mainly quartz, often mixed with mineral impurities contained in the biomass. Biomass fly ashes (BFA) are the finest fraction of the ashes. They are separated from the stream of gases outside the combustion chamber by specially designed systems to avoid their emission. Overall, the quantity and quality of ashes produced during biomass combustion are strongly influenced by the characteristics of the biomass fuel source as well as the combustion technology and operating conditions of the process.

TEMPERING LINES on belt Opal - Borosilicate - Soda-lime

Chemical composition In terms of chemical composition, biomass ashes represent a number of means to help decarbonise the glass industry, including: (i) substantial contents of glassmaking ‘fluxes’ such as alkali and alkaline earth elements; (ii) low carbonate contents – unlike the carbonate raw materials currently used, some biomass ashes contain little carbon, reducing raw material CO2 emissions; and (iii) biomass ash has substantial amorphous content unlike crystalline raw materials such as sand or carbonates, and thereby melting energies could be reduced as the energy input to drive fusion reactions will be reduced. It has previously been concluded that glass furnace power could be reduced by 40kW for every 1°C in furnace temperature reduction. Table 1 shows chemical compositions and Loss-on-Ignition (LOI) values for several different types of biomass ash, retrieved from. The major components vary from ash to ash, but in general, CaO, K2O, SiO2 are the major oxides, in addition to moderate levels of MgO, P2O5 and Fe2O3. CaO and SiO2 are two of the three primary constituents of container glass and float glass (along with Na2O), which means that biomass ashes could be used in replacement for sand and limestone in industrial glasses. In addition, the introduction of K2O in replacement for Na2O could have a two-fold benefit: reduction in the amount of highvalue soda ash required for each batch; and the exploitation of the mixed-alkali effect which could lead to reduced glass melting temperatures and hence, lower energy demands. Fe2O3 is used in the production of green and amber container glasses as a colourant. Overall, biomass ashes contain a variety of components with value for the production of commercial glasses. Another issue that must be overcome is the effects of impurities from ashes on the glass properties and quality, as some impurities, such as transition metal colourants or volatile elements may cause difficulties in glass production practice. Sheffield Hallam University and Glass Technology Services, together with partners from across the supply chain, are working to solve or mitigate such issues. By overcoming them, considerable amounts of biomass ash (2 MT/yr) could be diverted from low-value applications and valorised as raw materials in glass manufacture (Fig. 2). This exciting development will enable an ancient technology to be ‘rebooted’ in the present, thereby helping to solve some of the most pressing environmental and societal problems facing the modern world. �

TABLEWARE Toughening Lines on spindles

RIM TEMPERING

CHEMICAL TEMPERING

*Materials and Engineering Research Institute, Faculty of Science, Technology and Arts, Shefﬁeld Hallam University, UK. **Glass Technology Services, Shefﬁeld, UK. Glass International July/August 2019

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Furnace Solutions 2019

Furnace Solutions focuses on quality

his year’s Furnace Solutions and Training Day were again a great success for delegates, speakers, sponsors and the organisers, the Melting Technical Committee (MTC), of the Society of Glass Technology (SGT). Delegates came from places such as the USA, Israel, Turkey and Western Europe. The MTC were extremely pleased that over a third of delegates represented 15 glass producers. The Training Day ‘Guilty as Charged’ focused on the importance of the Batch House to produce consistent glass quality. The day started with lively presentations from Dr Richard White of Lucideon, Martin Marshall of GTS and Dr Richard Hulme of Guardian Glass. Mr White and Mr Marshall’s presentations focused on how to test raw materials and how different raw materials create glass formulations. This was followed by Mr Hulme who brought together elements of the inherent difficulties in analysis and measurement as well as the need to understand the physical and chemical properties of glass and how these may be affected – for good or ill – by making batch changes. Ardagh’s Peter West focused on the actual mechanics of batch house

operations. Sorg then presented its thoughts on the basics of glass melting and colour forehearth conditioning. Of great value to those attending the training day were the panel sessions where the conference and trainers debated lively and topical questions of the day. Continuing the theme of the training day was Trevor Wilson of DSF Refractories, who concluded the Training Day by giving the Mellor Memorial Lecture for the IOM3. The theme of his lecture was the effects of Carry Over on Regenerator Refractories. The Mellor Memorial Lecture honoured 150 years since the birth of renowned ceramicist Joseph Mellor, who was instrumental in developing refractory and ceramic understanding into a science and the beginning of the Iron and Steel Institute, which evolved and merged with other Institutes to become what is now known as IOM3. At the start of the Furnace Solution Conference first time speaker Sebastian Woltz of EME presented his thoughts on the challenges of upgrading the Batch Plant. Continuing the SGT’s commitment to keep the conference relevant and interesting this year was no exception

when, Tony Pawinski of VRTM demonstrated his virtual reality training package for IS operators. During a breakout period delegates enjoyed experiencing first hand, living in a virtual IS world. In a departure from the normal subject category presenters, Andrew Bowker from the Health and Safety Executive (HSE) was invited to brief the conference on the HSE’s strategy and manufacturing priorities, Welding Fumes and how it works with stakeholders through its CHARGE initiative. HSE, Glass, Mineral, Ceramic, Stone, and Concrete industries and Trade Unions are all part of the CHARGE stakeholders. The UK has an impressive health and safety record and Andrew outlined how this impressive record will be improved. Refractories are always an important topic at Furnace Solutions. Michel Gaubil of Sefpro discussed the thermomechanical stresses induced by the glass corrosion process of fusion cast AZS Soldier Blocks. Benjamin Köster of Hotwork continued the refractory theme demonstrating how regenerators can be repaired using oxygen to hot hold the furnace. Continued>>

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Nigel Longshaw* discusses the Society of Glass Technology’s 14th annual conference and training day and the future of the glass industry.

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Furnace Solutions 2019

The environment is never far from our minds. Andy Reynolds and Fives Stein are working to develop all electric furnaces to meet future zero CO2 emission targets. Andy’s paper looked at the work understanding refractory corrosion in an all-electric furnace. For a successful conference the SGT always encourages glass producers to pass on their experience to their peers, 2019 was no exception. In 2017 Libbey installed Optimelt technology at its Leerdam site. Frank Schuurmans, Leerdam’s Project Manager reported how the Optimelt heat recovery technology was installed and how well the technology is working. He reported Optimelt is now operating at 99% of the time. The winner of this year’s coveted Michael Garvey Award for the best paper of the day was Burçin Gul of Sisecam. On winning the Michael Garvey Award Burcin Gul said: “I truly appreciate the SGT and the MTC for providing such a great platform and recognising my efforts.”

Burcin Gul is a young research engineer who gave her first conference paper in English. Her paper clearly demonstrated her knowledge and understanding of computer modelling and glass making to model the effects of the combustion space in an end-fired furnace, improving energy and cullet consumption. The conference concluded with Andy Reynolds and Nigel Longshaw signing the Fellows Book to formally become Fellows of the SGT and Neil Simpson was presented a special award for his outstanding commitment to further the goals of the SGT. The SGT has always aimed and prided itself on making the Conference a social event. This year more than 40 delegates had dinner at the Totally Delicious Bistro on the eve of the Furnace Solutions Conference and after the Training Day. Old and new friends came together for an evening of laughter. After the Training Day, first time presenter Richard White said: “It was a pleasure to partake in the meeting.” Sam Leaper, from first time sponsor

Best paper ‘knocked us out’ Nigel Longshaw discusses why Sisecam’s Burcin Gul won the award for the conference’s best paper. Sisecam’s Burcin Gul won the award for conference best paper. Mrs Gul won the Michael Garvey award for her paper, Improving Furnace Performance by Design and Operation. Her paper investigated the role of design parameters in combustion space on energy consumption and better management of the temperature profile in glass container furnaces.

Furnace Solutions conference Chairman Nigel Longshaw said Mrs Gul’s enthusiasm for the subject gave her paper an added extra. He told Glass International: “It was a difficult decision because there were some very strong papers. Her enthusiasm and the detail she was able to give in 30 minutes knocked people out. She was so knowledgeable about her subject. She

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� SGT chairman Stuart Hakes with Mrs Gul.

Henry F. Teichmann said: “Thanks to everyone connected with the event for setting it up and taking care of everything. I enjoyed the conference very much and will look forward to next year’s event.” The theme for next year’s training day and conference is ‘Know your Furnace’. The Training Day will concentrate of how and why it is important to monitor your furnace and operation. The Conference takes that theme further with papers from experts who audit and monitor the furnace. The SGT is looking for contributions from experts who can pass on their experience and demonstrate new technologies. Potential contributors are invited to send a title and short abstract of their paper to Christine Brown at christine@sgt.org by the end of the year. Next year’s conference will again be held at Lucideon, Stoke-on-Trent, UK on June 3 and 4. �

*Furnace Solutions Chairman, SGT, Sheffield, UK www.furnacesolutions.co.uk

is a young engineer and was talking in a second language but had the audience transfixed by her presentation.” The two-day Furnace Solutions event comprised of a training day and a conference day and took place at Lucideon, Stoke-on-Trent, UK. Approximately 80 people from 10 countries attended each day. The training day comprised of five presentations and had the theme: The Batch: guilty as charged. The conference day comprised of eight presentations from EME, VRMT, Fives Stein, Libbey, the UK Health and Safety Executive, Hotwork and Sefpro as well as Sisecam. Mr Longshaw said: “It was very good event and I am pleased. There were really high quality papers on both days and very good speakers to the extent that during the questions and answer sessions there was a lot of two way conversations around the room, particularly during the training day. “One of the great things about Furnace Solutions is the opportunity to debate relevant topics and those conversations rolled out to the breakout periods.” �

Continued>>

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Furnace Solutions 2019

Burcin Gul discusses award win Fresh from receiving an award at the Furnace Solutions conference in June, George Lewis spoke to Sisecamâ&#x20AC;&#x2122;s Burcin Gul* about her winning paper. Tell us about yourself and how you came to work in this industry and for Sisecam. I received a Master of Engineering (M.Eng). degree within the Energy and Environment programme in Chemical Engineering from the University of Manchester, UK in July 2014. Subsequently, I joined the modelling and simulation group of Sisecam Science, Technology and Design Centre. During the final year of my engineering education, I became very interested in subjects of heat transfer and fluid dynamics. Given that these subjects were easily applicable to the glass industry, I was naturally attracted towards scientific positions in glass industry with inhouse scientific innovation. As a chemical engineer, Sisecam was the perfect fit for me. With mathematical modelling, today, I advanced my understanding of features of flow and heat transfer in the furnace and was able to identify key areas requiring research and development to further enhance the furnace design and operation.

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Why did you write the paper on improving furnace by design and operation? Since the melting process consumes substantial amounts of energy, specific fuel consumption reduction through improving furnace design is a high priority need. In this study, I focused on improving thermal performance by enhancing combustion space design and operating parameters of a container furnace as the flame form has an effect on spatial variation and the amount of heat transferred to glass. So that it regulates the convection currents in the melting tank. After conducting extensive computations by Sisecam Furnace Model and obtaining feedback from and operational sites, it was well understood that the role of design and operating parameters in furnace performance. I would also like to point out that

this is a collaborative work of Sisecam Research and Technological Development Presidency. Therefore, I express my sincere appreciation to my colleagues for bringing their expertise and experience around the table.

How did you feel winning the Furnace Solutions award? I feel honoured that the research work on mathematical modelling has been recognised as worthy of such an award. I am deeply honoured to receive this important award and to join past recipients who are experts in their fields.

Did it come as a surprise for you to win the award? This award was certainly unexpected for me as there were many outstanding presentations by very talented and experienced speakers in the conference. I feel humbled and invigorated by the recognition, and will direct this energy into my next research.

Do you feel your award was even more special considering the industry is a very male dominated one? The number of the female scientists in Sisecam is quite high and I have met so many talented women in Sisecam. Therefore, I was not really aware of that I have entered a male-dominated field until I attended conferences abroad. I realised the challenges in having your work recognised as a woman in maledominated industries. In that sense, as the first female winner this award marks a great professional attainment for me.

provided a great platform to succeed in the fields of glass science. For the past few years, I have had the opportunities to discuss the agenda items in the glass industry with highly respected experts in this community. Our discussions served to motivate me to think about designing more efficient furnaces. Therefore, I truly believe the SGT has an important role to inspire new generation, especially women, to think about glassâ&#x20AC;&#x2122;s future applications and take action.

You are already starting new research. Can we know what will it be based on? Recently, I have been working on optimisation of design and operating parameters of float furnaces for low iron production. My research focuses on application of developments in glass production to new furnace design and improving the operating conditions of glass melting furnaces. I have been also improving myself in area mathematical modelling and combustion technology development for the glass industry. ďż˝

*Researcher, Sisecam Group, Turkey www.sisecam.com.tr

As the first female winner of this award do you think you can help bring a new generation of women into the industry. Absolutely! I think, these kinds of awards have big impact on closing the gender gap in female representation and can be very inspirational to encourage more women to pursue a career in our field. Years of experience in the Society of Glass Technology (SGT) community

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Forming

Lighter and stronger... Paul Schreuders* highlights how hot end forming technology can help container glassmakers produce lighter and stronger bottles with no defects. such things as cullet quality, viscosity, temperature, glass homogeneity, ambient temperature, deterioration and wear of material, swabbing, job change, stop/ start sections or bottle design. Any glassmaker aims to minimise the effect of these sometimes unpredictable disturbances on gob condition (weight, temperature, shape), gob loading (speed, length, time of arrival, position), temperatures (parison, moulds, plunger, neck ring) and consequent quality of bottles. Timely, consistent and accurate information about gob condition, gob loading, temperatures and quality of bottles is the starting point to realise the ambition of lighter and stronger bottles produced with zero defects at higher speed. For the past 15 years numerous (hot end) sensors have become available. Using sensor information as a starting point creates a world in which facts prevail over opinions. Effectively this means that less valuable time is lost on opinions and more valuable time spent on solutions.

Hot end forming: quality focus

Inspection versus process monitoring

For years, hot end forming was steered towards putting as many bottles as possible into the lehr, without attention to their quality. Quality was a concern of the cold end. The hot and cold end was naturally divided by the lehr and the lehr time, like two different worlds. Consequently and in case of quality issues, there was hardly any communication or feedback from cold end to hot end, and if there was any communication or feedback, the time delay due to lehr time made ineffective. Quality is made in the hot end. Today good tools are available to support a proper quality focus in the hot end.

Use of sensors Sensors see more and deliver constantly consistent information compared to humans. Consistency of information is highly important. If the forming process is examined, many disturbances affect the glassmaking process. These can be

With todayâ&#x20AC;&#x2122;s hot end sensors for bottle monitoring, critical defects can be eliminated at the hot end. Logically implementing these devices are of help in improving the quality to customers. Nevertheless, a hot end sensor for bottle monitoring should not be used for inspection only. The reasons are obvious. First, all existing hot end sensors for bottle monitoring are able to inspect

many but not all types of defects. Moreover, like any inspection machine (in hot end or cold end) no sensor will be able to be 100% effective for inspection. As every rejected bottle or jar is a direct loss of production time and energy (CO2), the focus should be on preventing defects to be produced. The main purpose of having a hot end sensor for bottle monitoring is that inspection of single bottles, according to customer specifications, despite not being 100% effective, eliminates critical defects. It also allows the collection of signals which give a strong indication of cavity-, section-, front or back gob- or machine-performance. Eliminating critical defects, including stuck and fallen ware in the hot end, ensures a smooth flow through the coating hood and cold end inspection equipment. The indication for cavity-, section-, front or back gob- or machineperformance allows for effective root cause analysies (learning, preventing) and fast remedial action in case of problems. Rapid remedial action in the hot end on the basis of in real time information directly leads to efficiency improvements, and is the starting point for stabilising the forming process (Fig 1).

Lowering disturbances As mentioned above, many disturbances (cullet quality, viscosity, temperature, glass homogeneity) can affect the glassmaking process. Basically these Continued>>

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par Vision from The Netherlands entered the global container glass industry 20 years ago. It was the first to introduce Infrared sensor technology for hot end inspection and process monitoring. Since then the company has grown into a specialist and technology leader for hot end sensor and robot technology. Its overall ambition is to assist the global container glass industry to make bottles and jars lighter and stronger, produced with zero defects at higher speed. This ambition has recently been supported by a mega trend against plastics and environmental pollution, and by clear requests from major breweries and other glass packaging users to drastically reduce the carbon footprint of the packaging materials. Importantly for individual glassmakers, it follows the ambition for lighter and stronger produced with zero defects at higher speed simply pays off. In this article the ingredients are given, step by step, to realise this ambition.

ďż˝ Fig 1. Bird swing detected and rejected. Root cause in swabbing. Improving swabbing leads to preventing this defect from being produced.

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Forming

�Fig 3. Vertical (left) and horizontal (right) glass distribution. � Fig 2. Swabbing is a main disturbance in the glassmaking process and creates

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defects.

disturbances are the root cause for forming process variations, and the higher the level of forming process variations the more defects are produced. It speaks for itself that lowering the level and frequency of disturbances will be of great help in realising the ambition of lighter and stronger produced bottles with zero defects and higher speed. For example, there is currently an emphasis on swabbing. It is true swabbing is one of the main disturbances in the glassmaking process (Fig 2). It is a remedy as well as an enemy. In reducing the disturbances due to swabbing one could take different routes: a. Organising manual swabbing; strongly implemented SOP’s while monitoring the effect of each swabbing cycle. b. Automating manual swabbing by use of automated lubrication systems; automated swabbing in comparison to manual. Swabbing ensures consistency in frequency and impact. c. Minimising swabbing by use of an automated lubrication system; minimising swabbing compared to automated swabbing with a focus on reducing frequency and impact. The reduction of the disturbances due to swabbing goes from a to b to c. Option C has the lowest disturbance. Xpar Vision’s latest BlankRobot fits this option, which through ultra-precise swabbing of special lubricant can lower swabbing frequency to once per 2 to 3 hours, which, due to the

focus on reduced frequency and impact, allows for other functions to be executed by the BlankRobot. Logically it is up to the glassmaker to make choices here.

Managing process variations To compensate for the relatively high level of process variations due to the aforementioned disturbances, we simply use more glass. To meet the customer’s specification of 1mm while achieving a reasonable level of efficiency, a design specification will range from around 1.7mm narrow neck press & blow process (NNPB) up to sometimes more than 2.5mm blow blow (BB). This oversizing is performed on purpose to avoid the risk of producing faulty bottles. In earlier days, when they were unable to make strength calculations, this was the way to construct buildings that would last for centuries. This oversizing compensates for a high level of process variations (or the low level of forming process control) and is generally accepted by glass container manufacturers and their customers. As a result no single bottle is the same. Monitored by an infrared sensor at the hot end it can be clearly seen that forming process variation leads to bottle variation in terms of wall thickness variation (glass distribution). This glass distribution basically has two components: vertical glass distribution and horizontal glass distribution. Fig 3 shows an example of

vertical and horizontal glass distribution. Reviewing many bottles produced we can see a continuous shift in glass distribution, both vertically and horizontally. To reduce the weight of bottles and to prevent defects from being produced, we should prevent these shifts from happening. Controlling glass distribution is the key to lighter and stronger bottles and jars, produced with (almost) zero defects at higher speed. Logically controlling the glass distribution does require continuous monitoring of bottles and jars produced, and measuring everything we do against changes in glass distribution. To effectively manage the forming process glass distribution is THE reference.

Combining and analysing data The use of more sensors leads to more data. Smartly combining and analysing these data potentially gives more and better information for the sake of effectively managing process variations. Ultimately we have a dream: one big database with all data available, automatically combined in a machine learning type of environment, creating most effective closed loop algorithms, etc. Let that remain a dream. In our view we need to be more practical.

Continued>>

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Web: www.deryaas.com / www.glassymould.com

E-mail: info@deryaas.com Phone:+90 216 592 3234 Fax: 90 216 592 3235

Gullu Baglar mh. Kahramanlar Cad. No, 27/1 Pendik / Istanbul / Turkey

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* latest swabbing-robot installed in July 2017 in Germany

Forming

� Fig 4a. Gob length decreased due to increased friction in deflector. � Fig 4b. Decreased gob length causes increase of parison neck temperature… process and vertical glass distribution. More control loops are expected to become available soon. Experience shows that all different control loops, once applied, basically have the same positive effect: the process variation is reduced, bottles show less shift in glass distribution and have fewer defects. It is important to understand and acknowledge that in regards to control loops, the sensor measurement accuracy is of utmost importance. It is unfortunate that sensors with a low measurement accuracy have also entered the market today.

Pay off � Fig 4c …which results in shift of glass distribution and finally a thin neck defect (hollow neck). For example, loading data or temperature data related to bottle data: once we know the relation we will be able to control loading and temperatures in such a way that we produce bottles with less shift in glass distribution and thus less defects. And also, some cold end data (like blisters, cracks, etc.) are a clear indication of a process variation. Even if not noticed in the hot end, using these data helps reduce process variations (Fig 4a, 4b and 4c).

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Strong organisation Once sensors are applied, we should organise ourselves around the information provided by the sensor. It does not make sense to have sensors and in the meantime have operators and/or specialist not using the sensor information. As mentioned, sensors see more. The foremost sensors deliver more consistent information than humans. Consistency of information is important. Sensors continuously monitor the status

of gob condition (weight, temperature, shape), gob loading (speed, length, time of arrival, position), temperatures (parison, moulds, plunger, neck ring) and consequent quality of bottles. Any change has a cause. Once this cause is known, a Standard Operating Procedure (SOP) can be set up and applied. Applying SOP’s makes life easier for all. From customer feedback we have learnt that integrating new employees in the hot end is easier due to the use of sensors and SOP’s. Ideally, particularly when machines are larger (which operator can control 48 cavities?), automation should be applied. The sensor observes, analyses and, through feedback to the IS timing, the necessary adjustments are made. Adjustments can be made within milliseconds as the feedback is via a computer. The best operator/specialist could never do this. In the past five years, (hot end) automated control loops have become available for controlling gob weight, ware spacing, mould temperature, plunger

The ingredients are given in this article to realise the ambition of lighter and stronger produced bottles with zero defects at higher speed. As container glass industry members, we need to embrace this ambition now, utilising the mega trend against plastics and environmental pollution and follow the requests from major breweries and other glass packaging users to drastically reduce the carbon footprint of packaging materials. Importantly for individual glassmakers, following the ambition of lighter and stronger, (almost) zero defects at higher speed simply pays off. Personally I am convinced that we as a container glass industry can do up to 25% better than today. This 25% relates to less weight, less defects and higher speed. In addition, following the ingredients as mentioned in this article, it will help us to cope with a workforce which is ageing, the difficulty of hiring, integrating and retaining new employees and health and safety issues which will become more relevant for all of us. �

*CEO, Xpar Vision, Groningen, The Netherlands www.xparvision.com

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Environment Inspection

The quest for the perfect container for cold-end inspection Damien Defenouillère*, explains why Tiama’s MX4 carousel machine is the trend leading machine for cold-end inspection on hollow glass and why it needs to be a step ahead to enhance defect recognition.

he time has come to reinvigorate the Neck or Heel Camera Inspection type (NCI/HCI), 10 years after its ﬁrst release into the market. But before getting into the substance of this new batch, it might be useful to recall the original aim of the NCI/HCI. The purpose is to detect any possible defect located in those two speciﬁc areas. But imaging a defect and getting rid of the shadows generated by the glass itself is extremely strenuous on in-line machines. This is even harder when the diameter is small (in the neck of a container for instance) or when the article shape produces dark areas (push-ups). The objective of the NCI/HCI is to eliminate all these shadows by using line-scan cameras when rotating the container in a carousel machine. The main hardware evolutions are

the switch to homemade high-performance cameras, Tiama advanced electronics (Calia 3 CXP board integrated in the main frame computer) and a powerful and sharp LED lighting. All these hardware enhancements make it possible for the software to integrate all the latest developments of Tiama machines. Therefore, the N C I / H C I inspection is based on the proven MCAL4 software, beneﬁting from its experience and powerful algorithms to search and identify the tiniest deﬁciency.

� � These hardware components make it easier for software to integrate the latest developments.

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Masking to reveal intruders

� CI user interface dynamic masking (yellow) to detect small defects (red) such as drawn or compact next to the ring.

The new updated architecture will allow the integration of advanced image processing to learn patterns. Any engraved logo or trademark could be identiﬁed and learnt to generate the appropriate mask. Enhanced data treatment will recognise this pattern on the current unrolled image and will relocate the mask to exclude them from the treatment. Therefore, extremely high sensitivity can be applied even in engraved areas. In such perturbated areas, a proﬁcient object recognition makes it possible to detect any intruder in a crowd of potential defects.

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Object recognition In its quest for perfection, the advanced software aim is not anymore limited anymore to a basic ‘detect & reject’ task. The classiﬁer provides the operator with the power of identifying and categorising the object found. Therefore, the worker has the capability to set different sensibilities and thresholds depending on the quality level target. Effective design, inherited from the MCAL4, can recognise normal objects such as shadows or mould seams from real defects. The remaining detected objects, that do not match the recognition parameters are then compared to all the rejection parameters to classify them. As a result, any pixel out of the acceptable value is tracked and categorised. This tool represents an incalculable worth for the operator eager to reach the highest product quality.

Eliminate the stress The inspection can also easily be converted to stress analysis, to eliminate any tense container from the production line. To accomplish this task, polarising ﬁlters are integrated on the camera lens and on the light source. Consequently, the light generated through the LED light source is perfectly directed. Any tension in the glass inspected will deviate the light from normal direction and will thus generate a light level increase on the camera instead of a normally dark image. This speciﬁc function is called NSI/HSI (Neck or Heel Stress Inspection).

High value data provider Thanks to its advanced tools, this neck and wheel inspection delivers high value data. The defect classification allows to distinguish the different deficiencies and get the proper actions started to eliminate the different root causes. Furthermore, it can also be used for statistical analysis to reveal the pain points more accurately than just pointing the area. Indeed, once detected, identified and classified, the inspection increments the objects in specific counters. By a simple request, any connected device might collect the number of defects of any kind in any of the inspected areas. This knowledge is a gift for any production manager to carry out the appropriated operations.

YOUniverse, the smart factory concept

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An active component of the Tiama YOUniverse data providing philosophy, the Tiama NCI participates to the development of the Smart Factory. The different exchange protocols gather and send high-value data, for every single container inspected. Fully integrated in the MX4 machine, the data produced by the NCI can be linked to a speciﬁc single ID thanks to a Data Matrix Reader, or more simply associated to the original mould through a Mould Number Reader. The information is sent into Tiama Intelligent supervision systems such as Tiama IQ scan or Tiama ECO-system. Instead of releasing a binary verdict, Tiama intelligent systems make it possible to follow production drifts and react with immediate actions at the hot end even before the real defect appears. Therefore, glassmakers can prevent any container rejection and consequently improve their pack-to-melt ratio. This closer regulation loop improves the global production line efﬁciency. �

*Carousel Product Engineer, Tiama, Vourles, France. www.tiama.com

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Automation

Making the vision of End to End automation come true With its End to End vision, Bucher Emhart Glass (BEG) is aiming to bring true automation and closed-loop control to glass container production. Martin Grönblad* and Thomas Bewer** explain how. � Main picture. End manufacturing is seen by BEG as a way to deal with growing competition and price pressure.

� The Flex Control Centre is the brain of the End to End solution, gathering data to be used by apps using the central hub.

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ven though the core process for producing glass containers has not radically changed over the last 100 years, new technologies were gradually brought into the picture, such as servo controls and sensors. Over the past 15 years, the data gathered about the production process has become far deeper and more detailed, with sensors measuring everything from mould temperature, plunger position and gob weight through to the inspection results of finished wares. This flood of new data opens up new possibilities for automation that the industry’s founding fathers could never have imagined.

The End to End vision End to End is much more than a commercial target or a technical project; it’s a direct response to the challenges that glass plants face. While demands for quality are increasing, glass plants must also deal with growing competition and

price pressure, along with a loss of knowhow. Additionally, legislation toughens around work place safety as well as environmental aspects. BEG estimates that over the next few years, know-how will decline even further and as this knowledge gap grows wider, technology and support must expand to bridge it. End to End is BEG’s answer. It’s a set of solutions and automation technologies designed to make glass production easier, safer, more consistent and more efficient, backed up by unrivalled support expertise. Crucially, as its name suggests, End to End unifies both forming and inspection technology – the Forming and Cold End Inspection of a plant’s production line. Some solutions are available today while many others are in the pipeline for the next release.

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Automation

Closing the loop One of the foundations of End to End is closed-loop control. Process control systems gave operators data on the wares being produced, but left them to make their own adjustments. This made plants reliant on a few expert operators with the technical knowledge and experience to optimise production. Once the experts clocked off, quality levels fell. With a closed loop, process data is used to make automatic, real-time

control. For example, in terms of glass distribution, the system will measure loading, gob shape, blank and plunger temperature and glass distribution in the formed wares, and use its findings to control temperature (through blank contact/cooling times and plunger contact time), final blow timing and deflector adjustments. Future possibilities under development will include controlling gob weight and length independently of each other, or controlling blank cooling by monitoring

line. With wares taking one or two hours to travel from the Hot End to the Cold End, there is a time lag between spotting defects and making adjustments to address them. Additionally, there is no real traceability to match up the defects seen in a container with the settings at the time that it was formed. With true closed-loop control, data will be gathered from both the forming line and inspection, brought together in a single control system and used to adjust processes completely automatically.

� BEG’s FlexRadar is able to accept and reject newly formed containers at the Hot End.

The future of closed loop These existing Closed Loops are undoubtedly valuable and cost-saving while only focused on single parameters linked to single settings. The next stage will be intelligent, multi-variable process

As more production data is gathered over time, machine learning will allow the system to become ever more sophisticated. The overall benefit is to reduce variations in the process for increased quality and performance. But, it also means more hands-off production, with operators free to focus on tasks other than adjusting parameters. It also allows the plant to reach steady-state conditions much faster following a job change.

Flex Control Centre the temperature of parisons, moulds, plungers and formed containers all at the same time. No human operator could monitor and balance so many variables at once – but an automated system will be able to. The ultimate goal is a system that can understand what adjustments need to be made across the entire production

BEG’s forthcoming Flex Control Centre will play a central role in making HE/ CE closed loop a reality, by acting as the central hub or ‘brain’ of the End to End solution. It gathers data from the forming machine, inspection machines and other sensors. Applications running on the Flex Control Centre use this data Continued>>

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adjustments to process parameters, keeping production on track without the need for expert human input. Today’s closed-loop systems from BEG cover specific areas such as Plunger Up Control, Blank Cooling Control, Plunger Cooling Control and Bottle Spacing Control. For example, the FlexRadar monitors newly formed containers in the Hot End, acting as a pre-filter for Cold End inspection and allowing for immediate corrective action and rejects. Meanwhile, the FlexIS Bottle Spacing Control Closed Loop uses FlexRadar data to maintain equal ware spacing on the conveyor to prevent jams and breakages.

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Automation

to give operators valuable information on safe operation, maintenance, process stabilisation and defect rectification. The data correlation from hot end and cold end data relies on BEGs traceability products. The BEG laser marker ID Mark marks a unique data-matrix identifier on each container which is then read by the ID Read within the Cold End Inspection equipment. These results allow the Flex Control Centre to trace the container’s entire ‘history’ through the production line and link it to sensor readings and settings at the IS machine. As a result, quality (as reflected in inspection results) can be correlated with process settings for each individual bottle and, finally, settings can be automatically adjusted to avoid defects. BEG has created the first End to End installation, including the Flex Control Centre and traceability equipment, at its research centre in the USA. Having the correlated data available researchers move on with big data analysis and hope to discover as-yet-unknown correlations for improved container quality. Each of these correlations could potentially lead to a different application on the Flex Control Centre leading to increased pack rates.

FlexRobot When we think of a robot, we usually imagine a machine doing a heavy, dirty

� BEG’s FlexRobot will automatically stop if someone approaches the machine, meaning the risk of accidents is greatly reduced.

or repetitive job that people would prefer to avoid. And that’s exactly what BEG’s FlexRobot does. FlexRobot takes on the job of manually swabbing blank moulds and neckrings. This task exposes the operator to hazards, fumes and heat, time after time – once an hour for each neckring, and every 20 minutes for blank moulds. For a 36-cavity machine, that adds up to over 1500 interventions over the course of an eight-hour shift – all done at a consistent frequency, intervention time and amount of lubricant. FlexRobot does all this automatically, carrying out rapid, precise and consistent swabbing by spraying lubrication from a nozzle inside the closed blank moulds and neckrings. A system of three safety zones ensures that FlexRobot moves more slowly, or stops completely, if someone approaches the machine. The risk of accidents and strain injuries is reduced and the operator gains time for other tasks. By eliminating swab rejects, the plant can improve pack rate. In the future it will take over even more swabbing tasks (e.g. baffle), measurements (e.g. temperatures of blow moulds) as well as adjustments (e.g. deflectors).

The dream BEG has a dream for the future that it hopes to realise through automation. First, it hopes to achieve a pack-to-melt ratio of at least 90%, by sharply reducing the number of containers rejected at the Cold End. That might not sound like a major improvement over 85%, but it would deliver savings of more than €1 billion across the industry. Each furnace and shift will have just one IS machine operator, and they will never have to get ‘into’ the machine to make adjustments. When they need advice, they will go to the control centre, which will act as their ‘best consultant’. It is a long-term plan with developments being introduced into the market gradually. “Once, our job was to sell a machine, then maintain it,” says Martin Jetter, President of BEG. “Now, we see our job as helping a glass plant run as efficiently and profitably as possible. That’s why End to End is our future, and we trust it’s a future our customers will share.” �

*Product Manager Process Products & Automation and **Senior Project Manager, Bucher Emhart Glass, Steinhausen, Switzerland www.bucheremhartglass.com

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Industry 4.0

Is Industry 4.0 for the cold end a dream or reality? MSK is specialist supplier of Cold End equipment to a glass factory. To this day, it is still the only supplier that develops and produces all of its components in house, including software The subject of digitisation and Industry 4.0 is an integral part of product development for MSK, and the group has worked on these topics continuously for several years. As a Cold End expert, MSK has tasked itself with defining Industry 4.0 for the Cold End, and determining the impact digitisation will have on the Cold End. The use of digital technologies and sensor technology, the automation of processes and increased networking will make the Cold End future-proof. The effectiveness and efficiency of MSK’s lines are being increased through the optimisation of recipes and predictive maintenance management. Complete traceability of individual bottles – from the production phase via warehousing to final sale – will enable better supervision and facilitate self-learning processes. MSK’s machinery and software concepts are logically tailored to this requirement and are constantly being improved upon. Even now, the visualisation software EMSY 6.0 is based on an intuitive Touch Surface level, which enables the

seamless management of formulas. Job changes are already being simplified by means of automation, and statistics on runtimes, waiting times, downtimes and consumption statistics (film, gas, air, electricity, etc.) are also available. The data from the HMI machines are interlinked,

facilitating analysis. The data management software EMSY analytics was launched at glasstec 2018. EMSY analytics combines the data of all EMSY-controlled machines at the Continued>>

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Environment Industry 4.0

Job changes and maintenance can also be controlled through centralised time management. MSK is currently developing an app to enable the mobile status monitoring of MSK systems. The launch is planned for the end of 2019, and the deployment of virtual reality and augmented reality is

planned for 2020. ‘Savings through technology’ has been the driving principle behind MSK Covertech Group’s innovation and progress for 40 years. �

MSK Covertech, Kleve, Germany www.mskcovertech.com/

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Cold End in terms of Industry 4.0. This allows the entire Cold End to be centrally monitored using real-time data. This means that efficiency at the Cold End can be analysed, and data from the cooling furnace to the pallet warehouse can be viewed easily. Thanks to the self-learning system, efficiency can also be increased.

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Quality control

How to bring QC lab technology to a production environment? Eleonora Bordini* discusses the VisiQuick mini, a compact, flexible, semiautomatic bench introduced by Marposs for glass container measurement on a sample basis.

lass container manufacturers can keep production under control, at the cold-end, in various ways: � Periodically bring a batch of containers taken from the line in the quality control laboratory for an accurate measurement with a sampling gauging machine; � Install, near each manufacturing line, after the annealing lehr, a gauging table with go-no go gauges for periodic manual control of a production batch. The second approach, allows the timely detection of production problems, without the need to bring containers to the laboratory and wait for gauging machine availability.

A control carried out with hard gauges has drawbacks: � Results depend on the operator’s skill. � The necessity to buy, manage and periodically calibrate a large number of go-no go, with related costs. � Controls by attributes can highlight a problem (for example a too small inside diameter), but not provide any quantitative indication. � Does not allow data collection, and therefore statistical analysis and the possibility to promptly detect process trends and deviations. Controls carried out with go nogo gauges typically include: Height, verticality, inside diameter, a few parameters on the finish (for example thread diameter and ring diameter), and body diameter. Usually a scale is also present on the gauging table to measure the containers’ weight. The control of a production batch, including one container per mould present in the forming machine, takes between 10 to 30 minutes, according to the number of containers and number of

gauges involved. Marposs has designed and is ready to deliver a flexible and compact (1.000mm x 700mm x 1.000mm) measuring system, based on optical technology, to replace all hard gauges for external dimensions measurement. VisiQuick mini can measure, without any job change, and with laboratory quality level, glass containers that, regardless of their colour and shape, have the following overall dimensions: � height ≤ 410 mm. � external body diameter (or diagonal for non-round containers) = 30 - 120mm. The container to be measured is manually placed on a rotating plate, that can also travel along a vertical axis, to bring the portion to be measured in front of a high resolution camera with compact telecentric lens and backlight illuminator. An optional industrial scale can be integrated in the mechanics of the plate, to measure the container’s weight. Measurable characteristics include most of the measurements already available on the external dimensions measuring station of the VisiQuick machine, i.e height, verticality, bent neck, mouth parallelism, body parameters (e.g. diameter, long/short sides and diagonals on non-round containers, height of a given diameter, etc…), finished parameters on any finish type (e.g. diameters, heights, angles, radiuses, etc…). After selecting the recipe of the article to be measured and entering the mould numbers sequence, the operator manually loads the first container on the rotating plate and starts the measuring cycle. The plates travel, in a vertical direction, to bring the portions of the container to be measured in the camera range. In each position, the back-illuminated container rotates and its images are focused on the camera’s sensor and measurements are

acquired. When the measuring cycle is finished, a light warning device informs the operator that the measured container can be removed. The same measuring cycle is repeated for the second and next containers of the batch. Cycle time depends on the container height, the number of characteristics to be measured and their position. Average cycle time is in the range 30 60 sec. VisiQuick mini allows the collection of data that can be integrated with production monitoring systems, such as Vertech SIL. VisiQuick mini can of course be also installed in the laboratory. This option is convenient for customers with a limited budget or plants located in countries with low labour costs. �

*Product Manager, Glass Containers, Marposs, Bentivoglio, Italy www.marposs.com Ms Bordini will be presenting at the Glassman Europe conference in Lyon, France on September 18 a paper titled ‘How to use QC Lab technology in a production environment’.

� The Visiquick Mini.

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Moulds

Sophisticated mould design

part from access to the necessary knowhow, glass container quality is only as good as the quality of equipment and materials employed. Optimal production conditions need detailed attention to mould equipment design and materials. When the production of a new bottle or jar is planned, besides the mould design itself, attention should be focused on the container design. It depends on the type of container and whether empirical data such as weight analysis and deformation studies are already available or comparable. Heye International specialises in the knowhow necessary to handle new designs. In the case of traditional and lightweight container designs alike, Heye uses the Finite Element Method (FEM), deriving values relating to the internal pressure situation, head load and impact stress test. This FEM is a simulation software that ultimately reveals if the container

with the stipulated weight and wall thickness data meets the filler’s requirements. As an alternative, for ultralightweight containers, Heye offers customers the support of a pre-test under real production conditions, either at the customer’s production site or at a glass plant within the Ardagh Group.

Co-operation benefits When it comes to the design of moulds and plungers for new containers, Heye works with sister company UniMould, which has considerable experience in the manufacture of NNPB/PB plungers, plugs and cooling tubes. UniMould developed a special and well-proven plunger coating several years ago.

� Knut Prasuhn. � Heye works with sister company UniMould on many products.

Together with the mould and plunger material, this coating optimises the impact and internal pressure condition of the container. Damage to a container’s internal surface is avoided by this plunger material and coating combination. “This co-operation has resulted in a market leadership position with regard to the performance and stability of glass containers”, said Knut Prasuhn, Head of the Service Department at Heye International. “Our customers benefit from this ‘one-stop’ service and co-operation, generating a diversity of valuable experience.” �

*Head of Service Department, Heye International, Obernkirchen, Germany www.heye-international.com

CCMS

TWO HEADS ARE BETTER THAN ONE

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One system. One operator. One touch performance. High-precision coating measurement for the ﬁnish and body of glass containers.

OUR BRAND

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Recycling glass

The Environmental Benefits of Recycling Glass

x Glass, is an interior flat glass processor and manufacturer. Its best-selling products for use in commercial projects are manufactured using glass with recycled content, such as its magnetic glass, printed and back painted glass. Every day, consumers throw away tonnes of rubbish that ends up in landfill sites, rivers, and oceans. Glass products are a significant part of this waste – and are estimated to take over one million years to decompose. Glass bottles, containers and jars are found in almost every home, and many of us fail to make sure they’re recycled correctly. Recycling a single glass bottle would save enough energy to power a light bulb for four hours, so imagine the energy we could save if we recycled all of our glass.

into the manufacturing process reduce the need for raw materials, but it also substantially reduces the energy required to melt and process it. Cullet melts at a lower temperature than raw materials, like silica, which would otherwise be used in the production. Each tonne of cullet added saves 1.2 tonnes of raw materials.

The Process of Recycling Glass Glass is one of the only materials that can be repeatedly recycled without losing its strength or quality. When you send your waste container glass for recycling, it is taken to a plant to be processed. It is broken up into smaller pieces, known as ‘cullet’, and separated into different colours by a machine, colours such as green, brown/amber, and clear. The sorted broken pieces are then crushed, cleaned and mixed with raw materials like sand and sodium carbonate. Using recycled glass in the process of making glass reduces the amount of raw materials needed – sometimes by up to 90%. Recycled glass can be used to make a range of products, including tiles, fibreglass insulation, AstroTurf, cladding and other building materials. Once other chemicals have been added, they require specialist recycling and cannot be recycled in the same way as pure container glass.

Environmental Benefits Not only does adding recycled glass

� For every one tonne of glass recycled, more than 300kg of carbon dioxide is saved from being released into the atmosphere.

It also reduces air pollution by 20% and water pollution by 50%. For every one tonne of glass recycled, over 300kg of carbon dioxide is saved from being released into the atmosphere, which would have been produced in the manufacturing process of pure glass.

Longevity Flat glass products such as splashbacks, cladding and whiteboards have a long lifecycle, and only need to be replaced in the event of an accidental breakage making it a sustainable product. Businesses and organisations across

the world can do their part for the environment, not only by recycling but by purchasing products made from recycled material. This could be in their products and packaging – but also materials used in offices and kitchens. Gx Glass allow its specialist component glass products, such as its magnetic glass, to be returned to it for specialist recycling; a perfect example of how businesses can do their bit to tackle environmental destruction. Throwing glass bottles away with your normal household rubbish will mean it ends up in a landfill and cannot be made into something new. Put glass in the recycling bin, or if you don’t have one – put it to one side and then dispose of your glass at your local bottle bank; you are usually able to separate them by colours here, too. Find out where to take your waste glass by Googling your nearest glass collection centre. Recycling efforts should not be limited to glass; tin cans, foil trays, cosmetic bottles, milk cartons, plastics, food packaging, cardboard, magazines and newspapers are just some other household products which can be given a new life. In your workplace; batteries, old documents, plastic bottles, delivery boxes and junk mail can all be remade into something else, rather than ending up at a landfill site. With increased recycling efforts, we can save energy, reduce greenhouse gas emissions, minimise pollution caused by waste, reduce the use of natural resources, and lighten landfills. Think about what you’re buying before you do so, make sure that what you buy can be recycled. If it can’t, speak to the manufacturer or retailer about it. If we change our habits and how we think about what we buy, we might have a chance to lessen the impact we’re having on the planet – before it’s too late. �

*Marketing Executive, Gx Glass, Ashford, UK https://gxglass.com/

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Gx Glass looks at how recycling is just one of the things we can all do to help lessen our impact on environment. Beth Meakin* reports.

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Screen printing and full colour inkjet printing on glass bottles (from 5 until 500 bpm)

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Moulds

Empowering mould shops S9 – Soniscan is a major step forward in the mould shop machine field as moulds or plungers out of tolerance can be perfectly spotted, reports Sophie Major*.

roducing bottles damages moulds that need to be maintained and controlled regularly. These operations modify the internal volume, shape and dimensions of mould cavities that can significantly affect the containers’ sizes that can be produced out of the requested tolerances. In addition, a mould which produces a bottle out of tolerance is traced most of the time when the bottle has been produced and inspected after its travel through the cold end controls or at the laboratory. Sonicam therefore developed its latest mould scanning machine called S9Soniscan (Fig 1). It allows a dimensional control of used or new moulds and bottles with a comparison to the original CAD drawing. Out of tolerance moulds, non-conformed shapes of bottles will be trapped before leaving the mould shop area.

Operating principle The purpose of S9-Soniscan is to provide automatic 3D scanning measurements of blank, finish moulds, bottom plate, neck ring moulds, etc. On top of that, all mould shapes can be operated as well as glass containers to control shapes and other dimensions. S9 – Soniscan has displayed, in a short time with an optimised precision, all requested dimensional parameters. For instance, mould volume, dimensions, roundness of the inside cavities, flatness of surface such as the hollow profile of the mould joint surfaces and wear and tear areas with a 3D coloured mapping can be measured and controlled thanks to the Sonicam scanner engineering (Fig 2). As for a mould set, the two mould cavities and the bottom plate are scanned separately in S9-Soniscan. It operates with a superposition of the result of the scan (cloud of points) with the associated CAD drawing that can be imported

through different formats. The definition of the dimensions and data that need to be controlled as well as the selected tolerances are set at the beginning of the process and done once as they are stored in the software memory. One of the major aims of S9-Soniscan is to increase the lifetime of the moulds. Worn areas or dimensions outside tolerances are perfectly known today. Human errors in polishing or repair operations are consequently reduced (Fig 3). The operator will be then able to focus on its real added value and easily work on the moulds thanks to the report given by the touch screen interface.

Industry 4.0 compatible Industry 4.0 standards have been implemented in S9-Soniscan, including the remote access for maintenance, trouble shooting, repair and supervision. These also include CSV added outputs, XML and TCP/IP connectivity, as well as

XML tags on all data points to export the production data from the machine. Wear and tear areas provided by S9Soniscan on moulds or plungers are important information for optimising polishing programmes on our existing polishing, grinding and plunger polishing machines. Sonicam is now going further and offers the possibility to link S9-Soniscan with these machines. S9-Soniscan has not only been designed to answer customers’ needs but also to ease the operator’s life in his daily work. S9-Soniscan can be proposed either manually where operators load and unload the moulds, or semi automised with conveyors, or fully automised with our expertise in robotics.

Creating a smart future Factories equipped with the Industry 4.0 standards can create a progressively smarter future, where our automations and robotics can play a crucial role in the Continued>>

� Fig 1. S9 – Soniscan.

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Moulds

performance of the mould shops. For instance, S9-Soniscan can be equipped with a robot to load moulds automatically from a mould shop trolley. The same robot will unload the scanned cavities and separate the moulds with inside tolerances that can go straight back to production from the others that need special maintenance which are conveyed to specific repair stations. Clever markings such as engraved data matrix on moulds can also be foreseen for a perfect mould traceability in and outside the mould shops.

*Sales & Marketing Manager, Sonicam, Lyon, France Email: mail@sonicam.com www.sonicam.com.

� Fig 2. Mould scan processed without adding a 3D spray including a cross section inside engravings

� Fig 3. Wear & Tear areas

Further growth expected Sonicam has been supplying the hollow glass industry for more than 40 years. Its machines have been developed according to the requirements of the glass container industry throughout the world.. Sonicam is an ideal perfect partner to design greenfield mould shops by providing efficient mould machineries, abrasives and equipment, work benches together with the entire mould shop lay out. Its engineering in automation allows a less painful job for operators that currently carry tonnes of heavy mould cavities per day. �

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International trade

Exporting opportunity for UK glass industry is clear Thinley Topden* discusses how UK glass firms can take advantage of opportunities overseas.

advantage of the robust global demand for high-quality products that can meet the world’s most stringent standards. The UK’s reputation for specialist glass, and glassmaking equipment, puts it at an advantage when approaching certain international markets. A study on the matter suggests that promoting the ‘Made in the UK’ or the ‘Britishness’ of a product can make buyers willing to pay a premium, and there’s no reason this national brand advantage shouldn’t be translated to the glass industry. Global glass consumption varies by country and region, however certain markets remain net glass importers – which presents an opportunity for the UK, particularly in specialist glass and industrial equipment design. The biggest area of opportunity for the UK glass industry lies within the research and development side of the industry. There’s also room for British producers

to move into the international flat glass and fibre glass markets. Additionally, there are some ways that British companies can get into the international market while still operating at home. For example, a number of wine producers from Australia and South Africa are shipping their wine to the UK to be bottled and sold domestically. International Trade Advisers from the Department for International Trade are on hand to support our manufacturers and the related industry to make the most of this global market. With support available ranging from monetary assistance to attend trade shows, to introducing companies to contacts in new markets, DIT is helping British companies capitalise on global demand. For example, a Southend-on-Sea manufacturer of furnaces for making Continued>>

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he UK’s glass industry is changing as the country adapts to stricter environmental regulations and innovation stemming from Industry 4.0 – the ‘fourth industrial revolution’ that integrates and leverages computerised, interconnected and automated production processes in manufacturing – into our factories. Preparing for change requires investing in the future, and while innovation is crucial for a company’s future, it amounts to nothing if you haven’t sourced the customer base to match. An opportunity that is often missed is to source new customers from overseas. Through expanding to new markets and new customer bases, new revenue streams can help to diversify business and make it more resilient to fluctuations in the domestic business climate. Additionally, exposure to new markets can attract new skills and innovation, having an impact on long-term competitive advantage and stability. High-volume glass manufacturing contributes around £1.3 billion to the UK economy each year, and specialist glass manufacturers on British shores are developing innovative glass for use in medical, communications, navigational and power generation technology. Our specialist glass industry is an essential part of Britain’s advanced manufacturing potential and industry. Beyond that, companies that supply glassmakers with furnaces, equipment and specialist refining chemicals to make products mean that glass production stretches into other facets of our industrial economy. The UK’s glass industry is renowned for its high quality – making it trusted and respected in the global marketplace. Additionally, as our environmental standards for glass production are amongst the world’s most rigorous, UK companies are well positioned to take

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Environment trade International

� As part of his work with the DIT, Mr Topden helps create opportunities for UKbased companies to work abroad

crystal glass recently secured a £4.2-million contract to supply a custommade furnace to a new Portuguese customer. Glasstronics, based in Great Wakering, designs furnaces that melt glass using electric current. Its latest contract is with Vista Alegre, a Portuguese business that sells crystal glass tableware, gifts and lamps directly to consumers across Portugal and Spain. The multi-million-pound deal will see Glasstronics build and supply a furnace

for Vista Alegre to make its own crystal glass. The furnace will give the business the capacity to produce 12,000 tonnes of crystal glass every 24 hours – equal in weight to the Eiffel Tower and enough to make 60 million drinking glasses per year. ITAs at DIT helped the company to secure a bond to cover production costs for the furnace, a requirement of the contract with Vista Alegre, by linking them with UK Export Finance to facilitate the process. This is Glasstronics’ biggest contract in more than 20 years and has the potential to increase the business’ £1million annual turnover by as much as 400% to £4million within the next 12 months. Research shows that companies that export are more profitable and resilient than those that do not. However, many SMEs may approach exporting with caution. With 64% of UK manufacturing firms being SMEs with a turnover smaller than £40m per year, there may be a lot of British glass companies missing out on the global demand for our product. Exporting can, of course, present certain challenges. But with the right knowledge and support, these can be addressed and overcome.

Whether it is working with experts from across government, including the diplomatic teams based in our embassy and consulates, or leveraging our existing relationships with regulatory stakeholders on behalf of British companies, DIT teams will be there every step of the way. In addition to offering support through trade missions and export funding, DIT also has expert ITAs across the UK to help companies of all sizes with going overseas, on everything from legal issues to tax and logistics. Tapping into the growing opportunities abroad can help British glass manufacturers and the related industry to diversify their income and create more sustainable businesses. I encourage any interested firms to get in touch with our team via their local DIT office or great. gov.uk, and see how we can help them start or grow their export activity. The support is out there, and your glass could be too. �

*Head of Region for East of England at the Department for International Trade (DIT), London, UK https://www.gov.uk/government/ organisations/department-forinternational-trade

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History

Prof. John Parker

Widening refractory options Prof John Parker* discusses the choice of refractories for regenerators.

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year ago (June & October 2018) I wrote two articles on refractories for glass melting furnaces. I explained how a developing understanding of the chemistry of the silica-alumina system, particularly based on studies by the geological community, catalysed improvements during the 19th and early 20th century. The introduction of electric melting a century ago then caused a step change, with the birth of the so-called fusion cast refractories, often rich in zirconia. The focus of those articles was the glass contact materials needed for building tanks. The bricks used in the combustion system, particularly the regenerators used for heat recovery from hot exhaust gases, didn’t feature. Given that regenerator temperatures are mostly lower than in the melting chamber, except perhaps at the very top, the choice of refractories should be more straightforward. This was not the case though. In the early years of regenerative heat recovery in the mid 1800s the only choice on offer was the same aluminosilicates used elsewhere in the furnace. While such bricks were moderately resistant to sand carryover from the batch, the waste gases passing around them were rich in volatile fluxing agents, strongly basic sodium salts such as NaOH that reacted strongly with the bricks reducing their life expectancy. Over the decades rising temperatures in the furnaces to intensify melting rates increased volatilisation rates and exacerbated the problem. The aluminasilica-soda phase diagram highlights the issue, showing how even a few % of soda can produce a high proportion of liquid phase, albeit with a high viscosity. The consequence is a loss of the mechanical integrity of the brick. In the main furnace chamber the answer was fusion cast blocks containing high melting point zirconia to reduce

attack. A similar solution was developed in 1973 for the regenerators in the form of AZS fusion cast bricks with a cruciform profile. The brick shape promoted stable stacking with appropriately sized channels for gas flow. Another imaginative solution was identified at a similar time. This was the use of bricks whose main component was MgO, magnesite, a material used by the steel industry to resist attack by basic slags. MgO, like soda itself, is classified as a basic material as opposed to the more acidic oxides, silica and alumina. Generally, basic compounds like magnesite and soda do not react with each other to form stable compounds while they will react with more acidic oxides like silica and alumina. This meant that basic magnesite bricks were also unusually stable in regenerator chambers. The high melting point (2852˚C) contributed to the brick’s chemical resistance but its manufacture did not require energy intensive electro-melting. Inevitably life is never straightforward. MgO does react with the sulphur oxides present in waste gases from the decomposition of sulphate refining agents. Magnesium sulphate is formed leading rapidly to the destruction of the brick. Fortunately magnesium sulphate breaks down to its oxide components above 1100˚C in an inert atmosphere. So magnesite materials were not attacked by oxides of sulphur in the hotter regions of the regenerator – only a cooler zone midway down the chambers was at risk. So, two solutions were available for the same problem, fusion cast and basic materials. An argument used to promote AZS bricks was its higher thermal conductivity. Being fusion-cast it was low porosity materials; and had a significantly higher thermal conductivity than the higher porosity basic materials. Because temperatures are cycling in regenerators and the bricks alternately store and release

energy, conductivity is a more significant issue than elsewhere in the structure. Temperature changes propagate more slowly in the more insulating material; if the bricks are too thick – its cores do not participate in heat transfer. Now the more conducting AZS was easily cast into cruciform shapes where the arms were only 30mm thick. Magnesite materials had to compete and shapes were created based on square chimneys which could be easily stacked like the cruciform materials and yet were thin enough to be effective for heat transfer, given its slightly lower thermal conductivities. Mathematical modellers had a field day. Understanding the factors involved led to other innovative changes such as the corrugation of the surfaces of cast AZS materials to improve convective heat transfer. Convection is the dominant heat transfer mechanism on the air cycle because of the absence of radiating molecules such as CO2 and water – the socalled greenhouse gases. Subsequent compositions have continued to develop as corrosion mechanisms are better understood and now bricks can be matched to the different zones in the chambers and different melting conditions. Brick shapes have evolved too so that different thicknesses and various flue dimensions can be created. This has also allowed regenerators packing to be designed to fit the available space while optimising for the changing conditions throughout the chambers. So basically you pays your money and you takes your choice. Or like fusion cuisine, different products can be combined to optimise the results. �

*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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Glassman Europe Catalogue

CONFERENCE PROGRAMME TUESDAY 17 SEPTEMBER 2019

SUSTAINABLE GLASSMAKING/TRENDS IN GLASSMAKING 10.15 The future of plastic packaging in a (more) circular economy Susan Hansen, Global Strategist for F&A Supply Chains, Rabobank 10:45 Is the container glass industry aligned to customers’ expectations? Emma Bowers, Global Procurement & Supply Chain FMCG Executive, Green Puffin Consulting Richard van Breda, former SAB Director, now Independent Consultant 11:05 The container glass industry and its role in the circular economy Sheryl Webersberger, Product Policy Advisor, BV Glas COFFEE & EXHIBITION TIME 11:45 Circular Packaging at ABI Aline Casagrande, Circular Packaging Global Manager, AB InBev

WEDNESDAY 18 SEPTEMBER 2019

FUTURE GLASS FORUM 10:15 How glass manufacturers can successfully manage their digital transformation Pascal Huguet, Head of Siemens, Siemens 10:45 Steklarna Hrastnik’s journey toward industry 4.0 Jaša Polutnik, Head of Projects, Steklarna Hrastnik 11:05 Using software to improve maintenance Kevin Fiedler, Local Project Manager, SGD Pharma COFFEE & EXHIBITION TIME 11:45 Combining high resolution NIR furnace vision with Expert System III model based furnace control Thierry Barriant, Project Manager, Glass Service 12:05 Digitalisation in Glass Melting Philippe Kerbois, Regional Sales Manager EMEA, AMETEK Land

12:05 CO2 step wise emission reduction is necessary and possible Erik Muijsenberg, Vice President, Glass Service

12:25 How to use QC Lab technology in a production environment Eleonora Bordini, International Industry Manager, Marposs

12:25 Decarbonisation and the Circular Economy Fabrice Rivet, Director, Health, Environment, and Safety, FEVE

12:45 Machine Learning and Artificial Intelligence: the future of Glass manufacturing. Juan S. Farias, MD of FAMA.

LUNCH & EXHIBITION TIME

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14:00 O-I and Chovet-Db2i set for success on Gironcourt partnership Jean-Pierre François, O-I Manufacturing Nicolas Lelorrain, Gironcourt Project Manager, ChovetDb2i 14.20 A new world of glassmaking Paul Schreuders, Xpar Vision 14.40 The swabbing robot Mathieu Dumesny, Technical Manager, Novaxion

83 Glass International Catalogue - July/August 2019

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EXHIBITOR LIST + floor plan - 1.indd 1

B10

B09

A02

Conference

B01

B04

B13

C01

C05

C03

D01

D05

D11

D10

D06

D14

D15

ENTRANCE

C04

C02

C11

C10

B11

B03

C12

C13

B12

D04

D12

D13

E04

E07

E02

E05

E06

E13

F01

F05

F10

F15

F04

F02

F11

F14

F06

F03

F12

F13

G01

G04

G10

G15

Catering

G03

G14

G02

G12

G13

Glassman Europe Catalogue

Exhibitor information correct at time of going to press.

08/08/2019 14:22:15

Glassman Europe Catalogue

EXHIBITOR LIST COMPANY NAME

STAND

A151 SRL GLASS MACHINERY PLANTS & ACCESSORIES

COMPANY NAME

STAND

ELIMKO ELEKTRONIK IMALAT VE KONTROL F06

TIC. LTD. STI.

D14

AGR INTERNATIONAL INC

D15

EME GMBH

E05

ALL GLASS S.R.L.

E13

EMMETI SPA

C11

AMETEK LAND (LAND INSTRUMENTS INTERNATIONAL)

FAMA E07 F10

F.I.C. (UK) LTD

ANTONINI SRL

D10

FLAMMATEC C04

C04

BDF INDUSTRIES S.P.A

B13

FLUORITAL C12

BELREF SA

D05

FOREHEARTH SERVICES LTD

BERNARD BONNEFOND SAS

C03

FUSIONTEC SRL

F11

CAR-MET SRL

E02

GLASS INTERNATIONAL

B10

CARRIER EUROPE, SCA

F15

GLASS SERVICE

C04

CHOVET-DB2II E04

HENRY F. TEICHMANN INC.,

C10

DELTEC SAS SKO FRANCE, HKO FRANCE DELTEC

C13

C02

HEYE INTERNATIONAL GMBH

F01

DIVERRE F13

HORN GLASS INDUSTRIES AG

C01

E. W. BOWMAN INC

IRIS INSPECTION MACHINES

D01

ISIMAT GMBH SIEBDRUCKMASCHINEN

D11

MARPOSS SAS

B03

C10

ELECTROGLASS B01

MIMSAN KONVEYOR SISTEMLERI VE EKIPMANLARI SANAYI VE TICARET ANONIM SIRKETI NIKOLAUS SORG GMBH & CO KG

D06 E05

PROTEIS B12 RAMSEY PRODUCTS

F12

RECKMANN GMBH

B04

RENOLD GMBH TOOTH CHAIN

F04

REVIMAC F11 RONDOT SA

SIPAC S.P.A.

C11

SOCABELEC SA

F03

SOCIETY OF GLASS TECHNOLOGY (SGT)

G04

SOMEX C05 D12

TECNO5 C12 VIDROMECÃ&#x201A;NICA F05 VMA GMBH

F14

WBT SRL

D13

XPAR VISION

B09

ZECCHETTI SRL ZIPPE INDUSTRIEANLAGEN GMBH

B11 D04

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SVA INDUSTRIE FERNSEH GMBH

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GUIDE TO EXHIBITORS

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AGR INTERNATIONAL INC Stand D15 615 Whitestown Road, Butler, PA 16001 United States Phone: +1 724 482 2163 Email: kmarcelus@agrintl.com Website: www.agrintl.com Agr International, Inc. offers a variety of equipment and services specifically designed to meet the quality assurance needs of the global container manufacturing, filling and packaging industries. Agr’s products include high throughput, on-line testing and process monitoring systems for containers and packaging products, automated laboratory products and a variety of manual gauges for use in the laboratory or on the production floor. Agr products play a significant role in the quality and safety of containers and packaging used around the world. Agr products can be found in over 120 countries.

ALL GLASS SRL Stand E13 Mr. Marco Ballerini Via Cesare Sarti, 20 43029 - Traversetolo, Parma, Italy Phone: +390521340810 Email: m.donarini@allglass.it Website: www.allglass.it All Glass of Italy is a leader in cold-end conveyors and palletisers. Nowadays All Glass is recognised as a leading supplier of conveying lines and palletizers in the coldend area of a glassworks. The numerous references in such installations for the most important international glassworks allowed All Glass to make a name for itself as a reference partner in this sector. In recent years all the important glassworks who have chosen All Glass have gained full satisfaction in terms of excellent performance, efficiency and service. Considering that the production of a glass furnace never stops, in its machinery All Glass uses first-class components and long-term tested elements only. All Glass’ technical structure is organised to guarantee constant assistance during all the steps of design, assembling and start-up and to assure a prompt after-sales support during the maintenance periods. Making use of consolidate synergies, All Glass is the ideal partner to entrust the service of complete engineering for turnkey new solutions and for retrofits or relocations of existing installations. The keys of All Glass team’s success are the

constant research in direct symbiosis with clients to develop tailor-made customised solutions, and the natural bent to aftersales assistance and support, which makes All Glass the ideal partner in terms of performance.

AMETEK LAND Stand F10

Mark Bennett Stubley Lane, Dronfield Derbyshire S18 1DJ United Kingdom Phone: +44 (0)1246417691 Email: land.enquiry@ametek.com Website: www.ametek-land.com AMETEK Land is a specialist in the design and manufacture of monitors and analysers for industrial infrared non-contact temperature measurement, combustion efficiency and environmental pollutant emissions. AMETEK Land has supported

the global industrial community for over 70 years with innovative and reliable products and solutions. AMETEK Land will showcase the benefits of its NIR-B Glass, a new thermal imaging Near Infrared Borescope, designed specifically for use in glass-melt tanks with an optional auto-retract version for additional instrument protection. It will show how the NIR-B Glass provides continuous real-time temperature data, combined with a crystal clear thermal video image, allowing a single solution to replace the traditional approaches of visual cameras and periodic hand-held pyrometry. AMETEK Land will also showcase: Cyclops, high-quality portable non-contact thermometer, providing precision spot temperature measurement with unmatched accuracy and reliability. - LSP-HD, infrared linescanner, for detection of small temperature differences across the width of the glass product providing optimum product quality through improved process control. - Lancom 4, portable combustion and stack emissions gas analyser, offering the best accuracy available from a portable gas analyser, achieved by using an advanced sample conditioning system.

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BELREF SA

Stand D10

Stand D05 Ariane Dosi Rue de la Rivierette 100 7330 Saint-Ghislain, Belgium Phone: +32473831004 Email: ariane.dosi@belref.com Website: www.belref.com Belref SA was founded in 1834 and has more than 150 years of experience. Belref specialises in the manufacturing of high quality refractory products consisting of bricks, concretes and precast shapes. Thanks to a team rich in knowledge and know-how, Belref is able to provide high quality products and services. The engineering department allows Belref to propose tailored and suitable solutions for its customers. Belref’s main fields are : Glassmaking - Steelmaking - Coke making - Incinerators - Cement plant - Non-ferrous industry.

Via Medaglie d’Oro della Resistenza, 2 50053 Empoli - Florence, Italy Phone: +39 0571 93221 Email: com@antoninisrl.com Website: www.antoninisrl.com Antonini srl is an Italian company working since 1946 in the branch of hollow glass. Antonini supplies annealing and decorating lehrs, tempering lines, mould prehating kilns, thermal shock lehrs, cold end coating spray and dosing unit. The company is very active also in upgrading and reparation of second hand lehrs of all brands. Low consumption and zero maintenance are the strong qualities of Antonini’s equipment, together with the post sales service, made by highly specialised technicians. All equipment is made in Italy and all materials are high quality, to keep the standard in a top level. Up to today more than 1600 new lehrs have been installed.

BDF INDUSTRIES Stand B13 Claudia Vedovato via dell’industria, 40 Italy Phone: +390444286100 Email: c.vedovato@bdf.it Website: www.bdf.it BDF Industries is a company with headquarter based in Vicenza and has 112 years of history and tradition of mechanical and automation competence. Serving glass manufacturers all over the world for more than 60 years. Thanks to its own internal division competences of Melting - Forming - Automation - Energy, is the sole player in the hollow glass market, able to offer turn key plants from the engineering to the maintenance service with advanced technological products and solutions. Our mission is to serve customers with competitive plant and process technology and automation to produce quality and offer skilled after-sales service involving top-specialized engineers. BDF Industries production range includes: IS Machine, Gob Forming and Delivery Timing System, Forehearts, Batch Chargers, Glass Level, Control Systems and Energy Recovery Systems.

BERNARD BONNEFOND Stand C03 Philippe Bernard 7 Allée Mathieu Murgue - Terrenoire 42100 Saint-Etienne, France Phone: +33477953000 Email: bernardbonnefond@wanadoo.fr Website:www.bernardbonnefond.com Bernard Bonnefond was established in 1925. The main product is The Varivolt: An on load stepless voltage variation transformer, from 30 to 30.000 kVA, particularly used in the glass industry, for electric furnace and boosting. Turnover €13.5 million - Export sales more than 80%. Other products : I.V.R. (induction voltage regulators) – from 30 to 1.000 kVA Subsidiaries: Bernard Engineering: Industrial installation and commissioning services of Bernard Bonnefond equipment, expertise in electric boosting for glass furnaces AMPPELEC : Special Bus-Bars for high current (1.000 to 50.000 A).

CAR-MET SRL Stand E02 Mr Mario Zanin Via Cavour 9 31013 Cimetta Di Codogne - TrevisoI, Italy Phone: +39 0438 794784 Email: info@carmetspa.it Website: www.carmetspa.it Car-Met dedicates its activity to the hollow glass, decorating and tempering industry. The company has chosen to develop its own technology with the aim to improve

the performances of its machines assuring always a lower consumption and offering to customers the highest technology available in the market. Car-Met has the complete construction of its machines under its own control: design, structure, mechanical components, combustion installation, burners and the electrical installation are carried out inside the Italian plant. This system enables to control and assure the qualitative standard, makes possible the respect of the delivery terms, allows to have spare parts always available. Production: Annealing and decorating lehrs, toughening lines, mould pre-heating ovens, cross conveyors, stackers, hot glass scrapers.

CARRIER EUROPE SCA Stand F15 David Petit rue Joseph Luns 52, Belgium Phone: +3267400159 Email: dpetit@carriereurope.be Website:www.carriervibrating.com/about/ carrier-europe/ Carrier’s unique vibration technology gives you the power to perform varieties of processing functions while conveying, feeding or elevating bulk materials. From the most delicate grains to the bulkiest ores, our patented drive systems apply harmonic motion to handle your materials without degradation. Product Lines Vibrating Conveyors Carrier, Posi-Flow Fluid Bed Dryers and Coolers Carrier, FluidFlow - Vibrating Feeders Carrier Ampli-Flow - Float glass: Stream quenchers, Conveyors at the ejection points, Conveyors at the edge cuttings, Bottles: Gob quenchers, Rejects conveyors, Wind shields: Conveyors at the edge cuttings, Fibre glass: Strands dryers, Fiber scrap dewaterers and conveyors, Research & Development Carrier Equipment are constantly improved to offer more process capabilities and less maintenance work. New applications are developed in collaboration with a customer’s engineering team. Comprehensive product testing allows the exploration of various processing methods and new technologies before investment. Each piece of equipment is tailored for a precise fit into the processing operation. References include Glaverbel, Isover, Saint-Gobain, SaintRoch, Pilkington, Owens Corning, Vetrotex, Splintex, Sediver, Glashüttenwerrk Müller, Glenshaw Glass, Las Tunas, GTE Sylvania, Miller Brewing and Oschatz.

CHOVET-db2i. Stand E04 51 ter rue de Saint Cry, 69009 Lyon, France Phone: +33 4 78 66 06 10 Email: contact@chovet-db2i.com Website: www.chovet-db21.com Chovet DB2i is a specialist industrial engineering company with an international presence, structured to carry out EPCM (Engineering, Procurement and Construction Management) and EPC (Engineering Procurement and Construction) projects in the fields of glass, cement, and industrial minerals. Glass Industry: Chovet DB2i has built a team of complementary and jointly responsible specialists with 30 years’ experience in designing and building glass production plants. Our engineers have successfully completed projects around the world in the fields of containers, tableware, flat glass, glass wool, rock wool, fiberglass, television tube glass, and ceramic glass, as well as insulation and reinforcement. Batch plant – Furnace (with regenerators, recuperator, electrical) – Forming – Cold end – Civil and building works – Fluids and energies – Environmental control We have significant experience of working within operating constraints and of the challenges associated with modifying installations that are part of operating units. Chovet DB2i monitors all trades intervening in the various phases of construction, and our expertise in working on existing facilities enables us to complete even the most complex of projects.

DIVERRE GROUP Stand F13 Pascal Bandelier Avenue de Champlevert, ZI du Recou 69520 Grigny France Phone: +33 047 224 2240 Email: contact@diverre.eu Website: www.diverre.eu/?lang=en The Diverre group specialises in the glassware industry, we take action on the whole mould life cycle from the design, to the manufacture and repair. We position ourselves on the high end and appreciate working with luxury industry. We master the whole chain, from the design to the manufacture, until the installation of conveyors line of bottles. Diverre’s strength is also a special machines design office coupled with our sheet metal workshops, mechanised welding for all types of industry. We improve continually our industrial Continued>>

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ANTONINI S.R.L.

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process to ensure our competitiveness and our sustainability. Le Groupe Diverre est spécialisé dans la verrerie, nous intervenons sur l’ensemble du cycle de vie du moule avec sa conception, sa fabrication et sa réparation. Nous sommes positionnés sur le haut de gamme et apprécions de travailler pour l’industrie du luxe. Nous maitrisons l’ensemble de la chaine de la conception à la fabrication jusqu’à l’installation de lignes de convoyage de bouteilles. La force du groupe Diverrec’est aussi un bureau d’études de machines spéciales couplé à nos ateliers de tôlerie, mécano-soudure pour tout type d’industrie. Nous améliorons de manière continue nos process industriels pour assurer notre compétitivité et notre durabilité.

E.W. BOWMAN Stand C10 Sam Leaper 3009 Washington Rd, McMurray PA, 15317 United States Phone: +17244389550 Email: info@hft.com Website: www.hft.com Global Lehr supplier E.W. Bowman is now part of the HFT team. EWB specialises in the supply of container glass annealing lehrs, decorating lehrs, mould pre-heating ovens, belt cleaning brushes annealing, lehr process consultation & lehr overhauls.

Electroglass Ltd

www.glass-international.com

Stand B01

Mr Richard A Stormont 4 Brunel Road, Manor Trading Estate, Benfleet, Essex, SS7 4PS, United Kingdom Phone: +44 1268 565577 Email: info@electroglass.co.uk Website: www.electroglass.co.uk Electroglass is an independent specialist in all-electric glass melting, conditioning, electric boosting and related systems. Based on decades of experience and ongoing technical development, Electroglass provides the most up to date technology for Electric Furnaces, Forehearths and Boost Systems for all glass types, as well as Precision Control Bubblers and ancillary equipment, such as Glass Level Sensors, Throat Heating and Drain Systems. Our scope of supply includes design and specification, equipment supply

and installation, plus commissioning of individual specialised equipment or complete system packages. All Electric Furnaces ranging from 200kg to over 250 Tonnes/day provide operating economy and glass quality assurance. High efficiency Convection Current Control Boost systems improve furnace pull and glass quality and enable significant tonnage increases with simultaneous reductions in electrical consumption. All Electric Forehearths for both volatile and non-volatile glasses offer substantial energy cost savings compared with other all-electric and gas-fired designs. Electroglass high quality, insulated, water-cooled electrode holders are available for horizontal and vertical applications. Based in South East England we offer worldwide service to our customers in all five continents with local representation in many regions.

Elimko Elektronik Imalat ve Kontrol Tic Ltd Sti Stand D14

Malik Aviral 8.Cadde 21.Sokak No:16 Emek Ankara Turkey Phone: +903122126450 Email: malik.aviral@elimko.com.tr Website: www.elimko.com.tr Elimko is a leader company in raw material preparation and storage plants with numerous references, also building Automatic Control Systems including mechanical parts since 1976. These activities made Elimko a reliable name in batch houses and automation.

EME GmbH Stand E05 Jens Rosenthal, Managing Director Wockerather Weg 45, 41812 Erkelenz Germany Phone: +49 2431 9618-0 Email: contact@eme.de Website: www.eme.de EME GmbH is a leading global supplier of batch preparation plants, cullet handling equipment and batch charging technology to the glass industry. Customised solutions ranging from single component supply to complex turnkey batch plants. The EME batch-charging technology provides for a completely sealed doghouse, reduced dust,

lower energy consumption, fewer emissions and less rouge air entering the furnace. All benefits of the EME-NEND batch-charging family are available with a screw or a vibratory tube transport system.

F.I.C UK Limited Stand C04

EMMETI S.p.A. Stand C11 Corrado Avvanzini Via G. Galilei, 29 42027 Montecchio Emilia (RE), Italy Phone: +39 0522 861911 Email: emmeti@gruppoems.it Website: www.gruppoems.it Emmeti is now part of the EMS GROUP EMS Group is the result of the merger of Emmeti, the international benchmark in palletizing and depalletizing systems for the bottling and glassmaking industries (hollow glass), and its affiliates Mectra, specialised in the food, pet food and can-making fields, SIPAC Spa (conveyor lines) and Logik. EMS Group is at your disposal for full-service engineering, manufacturing and commissioning of new production lines, as well as for any type of refurbishing and upgrade of existing lines. Emmeti designs and manufactures complete cold-end lines for the glass industry, as well as packaging lines for the plastic container industry and beverage industries (wine, beer, distilled spirits, soft drinks, water, juices and other beverages).

FAMA Stand E07 Keramos 225 pte, Colonia del Prado, Monterrey, Mexico Phone: +52 (81) 8863 2822 Email: ventasfama@vitro.com Website: www.fama.com.mx FAMA has more than 70 years of experience serving the glass industry. Now we expand our products and services worldwide offering integral solutions for glass manufacturers. We have a specialised workforce and high quality standards and services that will bring solutions to enhance our customers’ success into their operations. Our wide range of products and services can be classified into five categories: Moulds, Machinery, Special Equipment, Automation and Engineering Services.

Mr S C Hakes Longrock Industrial Estate, Penzance, Cornwall, TR20 8HX, United Kingdom Phone: +44(0)1736366962 Email: general@fic-uk.com Website: www.fic-uk.com F.I.C. (UK) Limited design and supply allelectric furnaces as well as electrical boosting systems for a wide range of glass types and manufacturing processes including float, fibre, container, and borosilicate. In addition we offer a number of glass conditioning options such as our Isothermal unit for glass conditioning in the forehearth or distributor to eliminate topto-bottom and side-to-middle temperature differences. This system will significantly improve thermal homogeneity in coloured glasses and high productivity forehearths in flint glass. We also offer heat extraction systems to extract heat out of the glass to aid glass conditioning and reduce gas consumption by the use of removable water-cooled tubes. These tubes can be placed anywhere from the throat through to the back of the forehearth. Within the range of electrode holders manufactured by F.I.C is our unique High ‘Q’ holder in which the cooling circuit is replaceable in under 10 minutes. Our Maxi ‘Q’ holder is a weld-free type with no critical welds within the furnace refractory structure. We can supply all-electric forehearths offering major energy savings as well as other glass conditioning options.

FLAMMATEC Stand C04 Petr Vojtech Rokytnice 60, 755 01 Vsetin, Czech Republic Phone: +420 571 498 566 Email: info@flammatec.com Website: www.flammatec.com FlammaTec, spol. s r.o. (Czech Republic) and its daughter company FlammaTec GmbH (Germany) have become leading suppliers of advanced burner technology for glass furnaces. FlammaTec was founded by two partner companies (STG Combustion Control GmbH & Co KG, and Glass Service) as a joint venture. The long term know how of how to supply optimal and flexible heat into the glass can be found back in the advanced burner concepts. 11 years after its start

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FLUORITAL Stand C12

17 Avenue Du Superbe Orénoque Village d’Entreprises Jules Verne II 80440 Boves France Phone: +39 0422.919203-04 Email: info@fluorital.com Website: www.fluorital.com Fluorital is a dynamic, family owned company with its main plant located in Italy near Venice. With more than 30 years of experience in the research and production of organic paints and silkscreen inks for glass decoration, Fluorital produces different types of spray paints, roller varnishes, and screen printing inks, UV-curable and solvent-based inks. The application fields of its products include perfume and cosmetic packaging, wine and spirit bottles, tableware, flat glass for furniture and interiors, and lighting glass. All products are heavy metal free, and can be applied directly onto glass, as they do not require any primer. All products are curable at low temperature or with UV lamps, enabling important energy savings. The resistance of Fluorital’s products to the most severe tests required in the different market fields makes them the top reference on the market. Fluorital invests considerable resources in Research and in its laboratories; beside the continuous update of more consolidated products, research is aimed at developing new finishings and products with even more

efficient resistance, and environmentally friendly characteristics. Currently, as an alternative to vacuum metallisation, Fluorital is introducing a simple, low temperature spray metallisation process that can be run on most standard decoration lines.

FOREHEARTH SERVICES LTD Stand C13

John McMinn Wath Wood, Rotherham,S. Yorks United Kingdom Phone: 44 (0) 7850 328299 Email: forehearthservices@gmail.com Website: www.forehearthservices.co.uk Forehearth Services Ltd is a UK based company specialising in increasing plant productivity through the optimisation of forehearth performance. Forehearth Services have conducted forehearth audits and troubleshooting on a wide variety of forehearth systems in over 20 countries across four continents. Using techniques devised by Forehearth Services, the audits establish the current operational status of the complete forehearth system. Using the results obtained by the audit a detailed procedure is established to eliminate any operational faults that may be responsible for problems with homogeneity, excessive fuel usage, blister formation etc. Forehearth performance is strongly influenced by the skill of the forehearth operators and engineers. Forehearth Services training program offers the most comprehensive instruction into all aspects of forehearth technology, and has been embraced by many of the world’s major container and tableware glass plants. Spread over five days, the course provides both theoretical and hands-on instruction to equip operators and engineers with the knowledge required to operate and maintain the forehearth systems at maximum performance. The training modules used in the course cover, Glass Conditioning, Forehearth Development and Operation, Forehearth Combustion, Forehearth Control, Container Defects and Forehearth Trouble Shooting.

FUSIONTEC SRL Stand F11 Mr.Gianfranco Tempesta - Export Manager Via Mario Carraro, 9/11 Montecchio Maggiore (VI), 30675 Italy Phone: +39 342 3942907 Email: g.tempesta@fusiontec.eu Website: www.fusiontec.eu Fusiontec is a Revimac company founded with the purpose to integrate under one roof all activities related to the industrial manufacturing of refractory materials for furnace/working end, forehearths and feeder expendables. Revimac and Fusiontec may offer a complete package including high quality material refractories and equipment for the full control of the glass melting & conditioning process.

for glass manufacturing, and is targeted at glassworks involved in the production and processing of hollowware and special glass (bottles, containers, household, lighting, technical, scientific, industrial and medical glassware). GMP&A is a bimonthly periodical with about 100 pages of product news, current world news, technical articles and dossiers, worldwide exhibitions, glassworks in the world, Yellow Pages, etc. GMP&A is supported by GlassOnLine.com, the most visited international website for the glass industry and by the Glass Industry Directory, an annual guide which gives a complete overview of international glassworks and suppliers involved in hollowware and special glass manufacturing.

GLASSMAN EVENTS

GLASS INTERNATIONAL MAGAZINE

Stand TBC Stand TBC

Quartz House, 20 Clarendon Road Redhill, Surrey RH1 1QX, United Kingdom Phone: +44 (0) 1737 855000 Email: glass@quartzltd.com Website:www.glass-international.com Glass International offers readers the latest news from across the hollow, container, flat, and speciality glassmaking industry and is the official media partner for the global Glassman events. The magazine focuses on industrial, economic and environmental issues affecting the industry and includes articles discussing the latest developments and challenges in glass manufacturing. Regular features comprise of global news and events, company and country profiles, and previews and reviews of important industry conferences and exhibitions.

GLASS MACHINERY PLANTS & ACCESSORIES Stand A01 Luciano Molina via A. Gramsci 57 20032 Cormano (Milano), Italy Phone: +39 0266306866 Email: luciano.molina@glassonline.com Website: www.glassonline.com/site/ Glass Machinery Plants and Accessories is one of the leading international magazines

Quartz House, 20 Clarendon Road Redhill, Surrey RH1 1QX, United Kingdom Phone: +44 (0)1737 855000 Website: www.glassmanevents.com The Glassman Events portfolio focuses on the glass manufacturing sector, specifically the hollow glass sector of the industry. With three events a year, these exhibitions bring together international experts, hollow and container manufacturers and businesses that use glass containers, to discover the latest innovations which include energy efficiency, quality control, packaging, logistics and decorative possibilities.

GLASS SERVICE Stand C04 Erik Muijsenberg Rokytnice 60, 755 01 Vsetin, Czech Republic Phone: +420 571 498 511 Email: info@gsl.cz Website: www.gsl.cz Glass Service (GS), headquartered in the Czech Republic with offices in the Netherlands, USA, China and Slovakia, is a leading consultant in the field of glass melting, furnace control, operation, troubleshooting, and optimising furnace Continued>>

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in 2008, FlammaTec has already supplied well over 4000 burners to over 180 projects on float, container, tableware and special glass furnaces. Such a strong reference clearly shows the benefit of this innovative combustion technology that offers high performance solutions to the FlammaTec customers. FlammateTec burners improve heat transfer from combustion to the glass melt and thus also improve furnace efficiency and lower emission when replacing conventional burners. FlammaTec offers the following advanced LoNOx burner types: • Underport Gas Injector, Flex or Freejet • Underport Gas/Oil Dual Injector, Flex of Freejet • Underport Heavy Oil Injector (also can be used for backup solutions) • Sideport Gas Injector, Flex • New Oxy/Gas Burner.

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designs. GS programmers have developed in-house mathematical modeling software enabling the optimisation of glass melting and combustion processes in glass furnaces and forehearths. More than 700 different projects have been completed using GS software. Presently a new version of furnace modeling software (GFM 5.0) is being developed. GFM 5.0 uses a new generation of non-orthogonal mesh which enables proper representation of all geometric features and local refinement. GS has its own laboratory for glass defect analysis and analyses more than 2,000 defects yearly. Additional testing capabilities utilise basic and applied research in the field of glass melting, GS has invested considerable effort into developing a new technology called a ‘Supervisory Advanced Control System’ using our proprietary software known as the Expert System - ESIIITM. More than 240 installations have been successfully deployed worldwide. GS supplies high quality selected raw materials to the glass industry.

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HENRY F. TEICHMANN, INC Stand C10 Samuel Leaper 3009 Washington Road, McMurray PA 15317 United States Phone: +1 724 941 9550 Email: info@hft.com Website: www.hft.com Since 1947 Henry F. Teichmann, Inc’s engineering, technical service, purchasing, construction and project management teams have been committed to providing turnkey services for batch plants, complete glass plants, container glass furnaces, float glass furnaces, fiberglass furnaces, foam glass furnaces, sodium silicate furnaces, pressed glass melting services, hand glass processes, tableware & lighting products. In its 70 plus years the engineering staff have provided furnace designs utilising regenerative package furnace, cross-fire furnace, end-fire furnace, electric furnace and oxy-fuel melting technologies, and have serviced over 1,000 projects worldwide. HFT’s vast construction experience has led to it gaining a formidable reputation throughout the world for its outstanding record of safe, on-time and under budget performance for the construction of glass manufacturing plants and furnaces. HFT’s highly trained and experienced project managers and supervisors, having a diverse range of experience and skills are among the most respected in the industry. Global Lehr supplier E.W. Bowman is now part of HFT. Bowman specialises in the supply of

container glass Annealing Lehrs, Decorating Lehrs, Mould Pre-Heating Kilns, Belt Cleaning rushes, Lehr process consultation & Lehr overhauls.

HEYE INTERNATIONAL GMBH Stand F01

Jens Langer Lohplatz 1, 31683 Obernkirchen, Germany Phone: +49 5724 26 452 Email: sales@heye-international.com Website:www.heye-international.com Heye International – Being the One – for project management, production optimising and high performance equipment. Being the One stands for market leadership and complete solutions. We are Glass People – with experience and passion heading for highest results. Our mission stands for customers’ satisfaction, our experience in glass and for the glass experts at Heye International.

HKO FRANCE DELTEC Stand C02 24 Rue Du Mont De Templemars, ZI De Seclin, 59139 Wattignies France Phone: +33 6844 73334 Email: christophe.joucla@deltec.fr Website: www.hko.de

HORN Glass Industries AG Stand C01

Sebastian Hecht Bergstrasse 2, 95703 Ploessberg, Germany Phone: +4996369204142 Email: sebastian.hecht@hornglas.de Website: www.hornglass.com With more than 130 years of expertise in the construction of glass melting furnaces Horn is well known as specialist and expert in the glass industry. However, over many years Horn has continued to extend its capabilities and has grown from being a glass melting furnace builder into one of the leaders of the industry in technological plants. Subsidiary

companies in China, Malaysia, India, Croatia, Ukraine and the Czech Republic add value to global customers. Almost 80% of the products are exported from Plößberg, located in Upper Palatinate Bavaria, to more than 61 countries worldwide. Horn offers its customers full support and a helping hand at all times. Due to a very high level of vertical integration of all products Horn is able to propose tailor-made solutions and at the same time has ventured into unknown areas, e.g. in the construction of their own tin baths and associated equipment. Horn manufactures a large number of products in its own workshop in Plößberg and is the service provider for the realisation of customer visions and projects in the field of glass and supports its customers from the first draft through the implementation process, to permanent production support on site.

IRIS INSPECTION MACHINES Stand D01 Jean-Luc Logel Z.I. du Chêne, 14 rue du 35ème Régiment d’Aviation, 69500 Bron, France Phone: +33 (0)4 72 78 35 27 Email: contact@iris-im.com Website: www.iris-im.com Iris Inspection Machines is a leading provider of turnkey sorting solutions for glass containers of any shape or colour, including wine, beer, jars, liquor and Champagne bottles, pharmaceuticals, perfumes and food containers. A team of dedicated Research and Development engineers has evolved a performing range of equipment to match the industry’s demanding requirements and satisfy the quality needs of key international brands. Iris Inspection Machines is known for its Evolution 12 sidewall and sidewall stress inspection equipment, for its Evolution 5 base, base stress, finish and mould reader machine. But Iris has recently introduced two new equipments dedicated to the perfume, high value liquors and flaconnage industry, Evolution Ultimate for transparent defects and Evolution Dim for precise dimensional on line. The company has based its development on a long-term partnership with glassmakers in the field of glass defects detection, as well as on an exceptional know-how in the most innovative vision technologies. Iris was the first to develop and propose a 12 camera inspection machine. The success of Iris is due to the efficiency of its Evolution machines range and also to the excellent support provided by engineers worldwide.

ISIMAT GMBH SIEBDRUCKMASCHINEN Stand D11 Rindelbacherstrasse 36-40

74379 Ellwangen (Jagst), Germany Phone: +49 7961 886 0 Email: info@isimat.de Website: www.isimat.com Isimat excels in designing and manufacturing advanced printing machines for direct printing onto packaging containers. Print quality, reliability and productivity make Isimat’s printing machines the preferred choice in the global market of direct container printing.

MARPOSS SAS Stand B03 3,5,7 Rue de la Tuilerie 77500 Chelles, France Website: www.marposs.com Marposs is a world leader in the supply of gauging systems for dimensional and geometric inspection for industrial environment. Thanks to its 65 years of experience, metrology know-how and its wide range of products, Marposs is able to give an answer to any gauging necessity by providing measurement components, benches or measuring machines up to fully automated lines. Marposs is headquartered in Bentivoglio (BO) and is present in 34 countries, in 25 countries with its own sales and service network and in nine countries with agents/distributors. The group has about 3,100 employees.

MIMSAN CONVEYOR SYSTEMS & EQUIPMENT INDUSTRY AND TRADING JOINT STOCK COMPANY Stand D06 Dr. Sertan Erkanlı Omerli Mah. Uzuncayir Cad No:15 Arnavutkoy /Istanbul 34555, Turkey Phone: +90 (212) 771 13 30 - (136) Email: sertan.erkanli@mimsan.com.tr Website: www.mimsan.com.tr Continued>>

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CONNECTING THE GLASS MANUFACTURING INDUSTRY MAGAZINE

October

2017—Vol.40

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SMA CONTAINER GLAS QING TONGCHAN PROFILE: ZHAO REVIEW CONFERENCE INDUSTRY 4.0 DECORATION

Glass International

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offers readers the

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Packed with information on the glass

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manufacturing industry and continually updated with news for glass professionals,

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container, flat, and speciality glassmaking

www.glass-international.com

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also features special articles

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industry and is the official media partner for

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across the hollow,

Glass Intern