Glass International May 2018 by Quartz Business Media

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May 2018—Vol.41 No.5

COMPANY PROFILE: BASTÜRK CAM FURNACES FORMING

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I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International May 2018

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Contents

May 2018 Vol.41 No.5

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May 2018—Vol.41 No.5

Editor’s Comment

International news

COMPANY PROFILE: BASTÜRK CAM

FURNACES FORMING

Good Good v bes

I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International May 2018

EME-NEND VL/VR charger ®

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EME-NEND® VL/VR charger

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14 Furnaces Sorg: Sorg’s approach to environmental limits 22 Future of Furnaces Sorg

24 Furnaces Horn: What are the future requirements for glass conditioning systems?

Modular Concept Redundant

EME GmbH · E-Mail: contact@eme.de · www.eme.de

25 Industry 4.0 Heye: Smart container glass plant today and tomorrow

EME GmbH · E-Mail: contact@eme.de · www.eme.de

Front cover image www.eme.de

Company profile Bastürk Cam: A new player in Turkey’s container glass market

29 Ware handling Sheppee: The increasing demands of high speed ware handling 32 Forming Emhart: Manual mode increases safety levels

Plus find us on Linked-In and Twitter.

@Glass_Int

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Pyrotek: Blank linkage design for bottle quality

Forehearth Services: Good gob, bad gob

Quantum: Challenges in Parison forming

BDF Industries: Multi Direct Drive Gob Distributor

Diary

History

Events preview: DGG 92nd meeting

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Furnace Solutions 2018

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Editor’s comment

Greg Morris

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

Risk taking can provide huge beneﬁts to the sector

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ongratulations to Oliver Wiegand, owner of German container glass manufacturer Wiegand-Glas. Mr Wiegand is the Phoenix Award’s 2018 Glass Person of the Year, and was nominated for his commitment to innovation in glassmaking. The Phoenix committee of suppliers and technologists to the industry recognised Mr Wiegand for his forward-thinking and willingness to embrace new technology. He has worked with suppliers in the development of new technology and, importantly, allowed them to test new innovations in real time glass production at his four plants in Germany. Mr Wiegand is to be applauded for this. When a new innovation works it is a step forward not only for a company but also, eventually, for the entire industry. Wiegand-Glas will reap the initial beneﬁts but other glassmakers will inevitably follow and embrace the technology as well. But while they may be on the same terms on a technology level, Wiegand-Glas will always be the thought leader, the company setting the example, or - to put it in social media terminology - the ‘Trending’ company. Being a trendsetter isn’t without its risks. How many times have supposedly fantastic new ideas gone wrong? In the case of Wiegand-Glas, how much production time was lost as a result of an effort that failed? How many times have they, in collaboration with suppliers,

suffered disappointment and had to go back to the drawing board? We will never know. But the glassmaking industry has to continue taking these risks and to be prepared for failure in order to continue to innovate. It has to. Both customer and public pressure will ensure it. The plastic industry may be on the end of plenty of negative coverage at the moment thanks to the publicity surrounding how it is discarded as waste, but this will not last. It has ﬁnancial resources far beyond those of the glass sector and the ﬁghtback to promote it in the public arena will begin soon. Glass has to continuously publicise itself as the material of choice to consumers and promote itself as the greenest, healthiest item to choose on the supermarket shelf. The industry has made fantastic progress in lightweighting, in limiting emissions and in recycling. Every container made at Wiegand-Glas, for example, contains 80-95% of cullet generated at its facilities. There are risks involved, but the glass industry has much to gain by following the example of Mr Wiegand’s open approach to glassmaking. �

Greg Morris, Editor gregmorris@quartzltd.com

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

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

Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2017 edition: UK £206, all other countries £217. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.

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International News

NEWS IN BRIEF

Consol abandons IPO

Oliver Wiegand, owner of Germany’s Wiegand-Glas, will be the 48th recipient of the Phoenix Award and Glass Person of the Year for 2018. Mr Wiegand has glass in his blood, the history of the Wiegand family and its glass roots can be traced back 450 years. Oliver has grown up in the family business surrounded by glass production throughout his whole life, supported, guided and influenced by three generations of leading European glassmakers who understood the values of using modern technology, while keeping family values and traditions over the many years of growth within the Wiegand-Glas Group. Mr Wiegand (pictured)

forms the 4th generation and is the joint CEO of Wiegand-Glas along with his cousin, Nikolaus Wiegand. The Committee selected Oliver Wiegand to receive this year’s award in recognition of his forward-thinking and drive to embrace new technology that allow his four modern glass container plants to increase production, while at the same time manufacturing cleaner, more environmentally friendly glass. His openness to work with suppliers in developing and, all importantly, testing new technology in real time glass production is one of the reasons why he is so well respected within the glass industry. “His vision not only to

improve his own glass production plants through new technologies, but also to share these developments through his commitment to IPGR (International Partners in Glass Research), of which he has been Chairman for many years and still holds the position of Vice Chairman, makes him a driver and a leader for the whole Container Glass Industry,” said Phoenix Chairman Graham Womersley. He represents the German glass industry at the board of FEVE (The European Glass Container Federation). In BV Glas (The Bundesverband Glasindustrie) he is vice president and Chariman of the Fachgruppe Behälterglas (container glass trade section).

Bucher Emhart Glass supplies IS machines to IVC in Mexico Bucher Emhart Glass has recently supplied three NIS machines to the Industria Vidriera de Coahuila (IVC) plant in Nava, Mexico. The IVC plant in Nava, Coahuila, Mexico is a joint venture between O-I and Constellation Brands. The NIS machines (pictured) are all 12-section and all 5” triple gob (TG) for IVC’s furnace number four. This was the latest project that takes the plant to a total of 13 NIS machines, all TG, 11

of which are 12-section and two are 10-section. The speed of the machine varies but they are about 470bpm, or 13 cycles per minute on the 12 section machines and 390bpm or 13 cycles per minute on the 10 section machines. All of the bottles formed by the machines are flint and are either 12 ounce Corona or 12 ounce Modelo Especial. Emhart has worked with IVC for five years starting with Furnace 2, then Furnace 1,

Furnace 3 and concluded with Furnace 4. Mr Scott Neubert, Project Manager Bucher Emhart Glass, said: “I think that they purchased these machines because of the technological advances and advantages that the NIS presents over more ‘traditional’ pneumatic or semi-pneumatic machines. He concluded that IVC was happy to work with Emhart ‘and the feeling that we have in working with them is quite mutual.’

Verallia sells its Algerian operations

Verallia Italia has sold its Algerian operations, Alver, to the Algerian company Condor Electronics. Alver is located in Oran and has operated as a Verallia subsidiary since 2011. It employs 360 people. Its two continuous-fire furnaces produce glass bottles and jars for Algeria’s food and beverages market. Condor Electronics operates on the electronics, automotive and renewables sector.

Heye appoints Iberian sales specialist

José María García-Lomas de Lanuza has joined Heye International as the new local Sales Partner for Portugal and Spain. Mr García-Lomas aims to help local glassmakers to continuously improve manufacturing, inspection and production efficiency, as well as build strong business relationships. He is dedicated to increasing customer satisfaction, which makes him ideal to take on the role of Heye International’s local sales support in the Iberian Peninsula. After his academic studies, he worked as a key account manager and sales director, focusing on inspection technology. Mr García-Lomas gained his glass industry expertise by managing and increasing sales for international technology suppliers to the container glass industry in several countries.

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Oliver Wiegand is 2018 Phoenix Award recipient

South African container glassmaker Consol has pulled out of a planned $240 million Johannesburg stock market flotation, citing challenging market conditions. “The prevailing environment is not conducive to the offer achieving valuation objectives,” the company said in a statement. “It would not be in the best interests of the company to proceed with the offer at the current time.”

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International News

NEWS IN BRIEF

Anchor to close US plant

Anchor Glass is to close its Zanesville, Ohio mould fabrication plant, and its Streator, Illinois machine repair shop in the USA. The Zanesville facility employs 69 people. Mould production is projected to cease by the end of November 2018. A mould engineering office will be maintained in the area. The site manufactures moulds for glass bottles that are distributed to the company’s six glass manufacturing plants.

Sisecam purchases former Sangalli Vetro plant

Turkey’s Sisecam has won the auction of the former Sangalli Vetro plant in Italy with an offer of more than €15 million. Sisecam won the auction with an offer of €15,715,000 for the Macchia plant, better known as Manfredonia Vetro.

Ametek appoints Reckmann as sales partner

Ametek Land has appointed Reckmann as its new sales partner for Germany. Reckmann is based in Hagen and is an all-round supplier of temperature sensors and components for industrial applications. It will be responsible for developing sales of Ametek Land’s infrared non-contact temperature measurement instruments across all industrial markets including glass, steel, aluminium and industrial processing.

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Euroglass Polska begins float plant construction

Euroglas Polska has held a ceremony in Ujazd, Poland to place a cornerstone for the construction of its second float glass production line. The new line is set to begin production during the first quarter of 2019. The ceremony was attended by Euroglas Polska representatives, the Swiss holding Glas Trösch, Press Glass and local authorities.

Costa Rica’s Vicesa orders FAMA 12 section IS machine Mexican glass engineering company FAMA has received an order for a 12-section triple gob IS machine. Costa Rican container glass manufacturer Vicesa (Vidriera Costa Rica) ordered the machine along with a 2G Kit conversion and a K54 feeder. Fama will also be responsible for optimising the lay-out in order to increase the glass pull from their furnace. The machine is designed to run at 475 BPM. FAMA’s Sales and Marketing Director Luis Zertuche said the company was extremely pleased to be working with

Vicesa. He said: “We have worked with Vicesa for the last year and a half visiting them and reviewing their potential necessities in order to be present when the opportunity arose.

“This is a very robust and flexible machine that includes a high efficiency mould cooling system.” FAMA will deliver the machine in Costa Rica by the second week of October.

Xpar extends hot and cold end quality control connection Xpar Vision has added a new functionality to its Hot End sensor technology. Its IR-D system has been extended with a ‘Crucial Rejects’ feature, to achieve a higher level of quality control for bottles and jars and is available now. An increasing amount of bottling companies demand products with higher standards in terms of quality (zero-defect) against lower cost.

At the same time container glass manufacturers are forced by their customers to implement internal auditing procedures and standards to guarantee quality of deliveries. Quality Assurance (QA) therefore is becoming more crucial. Xpar Vision has supported this need with the integration of a direct connection between the IR-D system and QA

systems in the Cold End. This integration enables container glass manufacturers to reduce the risk of recalls and claims and to minimise blocked pallets (quarantined or held ware) for critical defects. The new functionality is called ‘Crucial Rejects’. It is available with the release of v7.10 IR-software and can be retrofitted to the latest generation IR-D systems.

Fermac in Russian commissioning Russia’s Glass Décor has commissioned a direct silk screen printing machine produced by Italy’s Fermac at its decoration factory in Orekhovo-Zuevo, Moscow Region. This CNS (computer numerical control) machine is designed to decorate glass bottles with complicated shapes,

as well as apply decoration on glass bottles’ edges. This new purchase is the only machine with a real CNS electronic package which syncs five numerical axes during decoration cycle, also including vertical movement and rotation of the object, screen holder carriage transla-

tion, flood bar translation. This control allows Glass Decor operators to control decoration at each stage, as well as decorate bottles of any shape or of any complicated architecture. A processor controls the technology line, considering the size and shape of the decorated bottle.

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International News

NEWS IN BRIEF

O-I appoints Sales and Marketing Vice President O-I has appointed Raymond Palmen to the post of Vice President of Sales and Marketing for Europe. It follows the promotion of Arnaud Aujouannet to Chief Sales and Marketing Officer. Vitaliano Torno, President of O-I Europe, said: “Raymond is a highly experienced sales and marketing professional with a strong background in B2B and B2C markets. “We look forward to Raymond’s support and leadership as he helps drive both customer-centricity and our ability to position ourselves as the preferred supplier for glass packaging.”

MAVSA’s Mexican order

Argentina’s MAVSA has secured the order of a new press machine to a Mexican glass manufacturer. Maquinas Argentinas del Vidrio (Mavsa) will supply one MDP 24-34 press to the Mexican tableware manufacturer at the end of May. MAVSA is an Argentinian producer of complete production lines for containers and tableware glass, including mould equipment, and has 40 years of experience on the international glass market.

Forglass float success

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Polish glass engineering company Forglass recently completed three major hot repairs of float furnaces for Saint-Gobain in Germany, UK and Romania. The main task facing the Forglass team was a hot overcoating of the furnace Melting Tank, including Dog house, Tank sides, Exit wall and Waist. The preheated tiles were placed and the steel structure was adapted accordingly. Some minor repairs were also performed at the Melting End superstructure. Following the completion at each of the locations, Forglass received a letter from Saint-Gobain emphasising that all work was performed in a safe manner, and there were no accidents or injuries.

Top 10 stories in the news 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. Vicesa orders FAMA 12 section IS machine � 2. Qixia Changyu Glass orders Sorg glass melting furnace � 3. Stoelzle Masnières appoints Etienne Gruyez as CEO � 4. Sisecam purchases former Sangalli Vetro plant � 5. Saint-Gobain buys stake in Chinese flat glass company � 6. Emhart supplies IS machines to IVC in Mexico � 7. Verallia sells its Algerian operations � 9. Consol constructing Ethiopian glass plant � 10. Xpar Vision extends hot and cold end quality control connection

FEVE: Glass recycling at 74% The average glass recycling rate in the EU28 is steady at 74%, states FEVE. More than 11.6 million tons of glass bottles are collected and recycled into food grade quality material for the production of new containers. Countries such as Belgium,

Slovenia and Sweden, with excellent separate collection systems, continue to outperform beyond 95%. While glass stands alone as the most circular packaging solution, maintaining permanent quality even when recycled, the reality is that there

is still an important collection gap to fill in many EU countries. “Our industry is mobilised to fill the gap to 100% EU glass recycling because recycled glass is a most important raw material,” said Adeline Farrelly, FEVE Secretary General.

Ardagh’s Irvine plant uses first sustainable battery storage system Ardagh Group has implemented a sustainable battery storage system to increase resilience and energy security at its glass container plant in Irvine, Scotland. It is the largest behind-the-meter storage system in Europe and the first to be used in the glass industry. The Irvine plant needs a reliable energy supply to support its continuous manufacture of glass containers throughout the year. The sustainable battery, provided by ESB Smart Energy Services, provides the plant with a reliable back-up during peak energy consumption and sends energy back to the grid when demand is low. The solution is a combination of a Tesla battery and a

grid-optimising platform. The Tesla battery is designed to efficiently store energy during periods of lower demand and to support demand during intermittent power failures. The grid-optimising platform enables Ardagh to par-

ticipate in the National Grid’s Firm Frequency Response service. In practice, the battery reduces the plant’s reliance on the grid and when excess energy stored by the battery is not required, it can be delivered back to the National Grid.

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International News

Sorg in double Chinese success

dering the new Furnace 7 was the efficient design with regard to energy consumption, low emissions and glass quality requirements. Qixia Changyu is the largest producer of wine bottles in China. It produces high quality packaging in various glass colours. Furnace 7 is planned to produce flint glass. The furnace is a gas-heated end-fired furnace with melting booster and the melting capacity is 350 tpd. The glass conditioning system consists of a Sorg STW working end and three Sorg 340S forehearths. As well as the design and engineering package Sorg will supply the complete equipment, including the gas and electric heating system, combustion air supply and waste gas system, batch charger type EME-NEND S3, measuring and control system, forehearth equipment and the SCADA (Supervisory Control and Data Acquisition) System. The new Sorg fixed transformer system will be supplied for the melting booster. All forehearths are equipped with the Sorg OMT (Oxygen Measuring and Trim) System. Pictured: the contract signing at Huifeng Glass Products.

GLASS UNLIMITED Experience pure glass. Innovations, technologies, applications, products, trends and know-how. The global glass value creation chain is concentrated in one place – live and tangible. Nowhere else, only here at the world’s leading trade fair glasstec. Be part of it!

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Chinese manufacturers Jiangxi Province Huifeng Glass Products and Qixia Changyu Glass of Shandong Province selected Sorg to build their new furnaces. Jiangxi Province Huifeng Glass Products is a cosmetic packaging and flacon manufacturer. Its furnace number 2 will be a 60tpd modern gas-heated regenerative end-fired furnace and be 35m² in size. It will be built alongside the existing furnace number 1. The working end and five forehearths as well as all necessary equipment will also be supplied by the German glass furnace maker. The furnace needs to fulfil high quality criteria, but at the same time has to be highly energy efficient and low in emissions. As well as the manufacture of high-quality glass products, Jiangxi Huifeng also produces packaging for added value of the articles in-house. This includes various kinds of painting and print processes as well as caps and packages. Qixia Changyu Glass in Shandong Province, China has ordered a glass melting furnace and three forehearths for its planned new production line. An important factor for or-

23 – 26 OCTOBER 2018

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2 wind turbines helped us improve our green credentials. With a potential 50% energy saving a System 500 forehearth conversion could improve yours.

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International News

Real-time Process & Quality Controls

Forglass supplies to Trend Group Poland’s Forglass has designed, fabricated and installed a 120/150 TPD regenerative end-fired furnace to Trend Group. Trend Group is a major Polish producer of tableware glass. The furnace order for its Szydłowiec plant included electric boosting to melt ultra-white flint tableware glass. Following a successful startup, many performance parameters exceeded the values guaranteed in the contract. Chiefly, the glass quality index is below 10 bubbles with

the specific energy consumption below 1020 kcal/kg. Forglass furnace design takes into account the specific characteristics of oxidised, ultra-white flint tableware glass with low iron content – mainly high values of effective thermal conductivity coefficient and higher saturation of SO3 in the molten glass. Trend Group expressed its satisfaction with the furnace by placing subsequent orders – the modernisation of three additional furnaces for its other plants.

When you need precise, cold facts… constantly

Stölzle Masnières CEO Glassmaker Stölzle Masnières has promoted its current general manager, Etienne Gruyez, to the position of Chief Executive Officer in charge of the Perfumery and Cosmetics Business Unit. Mr Gruyez will oversee the upcoming innovation and growth phase of the Hauts de France site, Stölzle Masnières Stölzle Parfumerie and Masnières Décoration. Thanks to its closer integration as part of the Stölzle Glass Group, Stölzle Masnières Parfumerie is able to meet any and all of its clients’ desires. In 2017, it launched a totally integrated product development process, assisted by 3D

printing and with reliable production equipment and quality management. As a result, it can now present new products to its clients in less than four weeks. This new process will allow the company to innovate rapidly in design and decoration.

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

Intelligence

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Monitoring

Traceability

Support

10/05/2018 08:28:11

Company profile: Bastürk Cam

Bastürk Cam: A new player in Turkey’s container glass market Muhammed Yalcinkaya, General Manager of Bastürk Cam, introduces the newest glass factory in the industry. The greenfield site was commissioned in February and will provide flint and green food and beverage bottles to Turkey’s eastern and central regions.

� The company’s General Manager, Muhammed Yalcinkaya.

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astürk Cam is a family owned company with a business history of almost 50 years. The Bastürk Group has business activities in Turkey and Senegal. After successful completion of an expansion project for its textile plant in the past year, the group’s aim is now to enter the container glass market with a new container glass plant named Bastürk Cam in Malatya in the east of Turkey. All other container glass production plants in Turkey are concentrated in the Western or middle of Turkey. The new plant was built on a 145.000m2 plot of land. A total of 275 employees work there. The greenfield Bastürk Cam Sanayi ve Ticaret container glass plant was commissioned in early April this year, with the first bottle produced on April 15. The company intends to enter not only the Turkish market, particularly the middle and east of Turkey, but also the south as well as neighbouring countries. Many international equipment suppliers were selected to produce glass containers as well as many local equipment suppliers.

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Company profile: Bastürk Cam

� EAE - Equipment for electrical busbar (Turkey).

� A number of international technology suppliers provided equipment to the plant.

Mr Yalcinkaya said: “EME, Sorg, Heye and MSK etc are well known and specialised companies in their fields. Because of this, we have a strong expectation to reach the target quality and efficiency during glass production in the shortest time.” Bastürk Cam will focus mainly on flint glass production but green glass can also be produced. The plant capacity for its Furnace A project is up to 300 tons of glass per day. Three production lines are connected to this furnace. All production machines are 12 section Speedlines from Heye International. Production in triple, double and single gob operation is planned. The site will produce jars for the food market and bottles for non-alcoholic beverage. In total about 480 million containers per year will be manufactured. “The company’s strategic goal is to realise, within a short time after successful commissioning of the present Furnace B project, which will have a planned capacity of about 500 tons of glass per day,” Mr Yalcinkaya added. �

Bastürk Cam Sanayi, Malatya, Turkey

www.basturkcam.com.tr info@basturkcam.com.tr

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The equipment suppliers for the project are: � EME MaschinenfabrikClasen - batch plant equipment and its cullet return system (Germany). � ARN Makina - equipment for raw material feeding and transport systems (Turkey). � WAM - equipment for dust filter systems. � Nikolaus Sorg - equipment for glass melting and glass conditioning systems (Germany). � Heye International supplied production, hot end handling and quality control machinery at the cold end (Germany). � Alfer MühendislikTaah – Fans for furnace cooling and production machinery (Turkey). � Antonini – Equipment for the glass annealing process and cold end coating equipment (Italy). � MSK Covertech – Equipment for cold end handling and packaging of glass containers (Germany). � Atlas Copco – Compressed air equipment (Belgium). � Pneumofore – Vacuum equipment (Italy). Iris Inspection Machines – Inspection machinery (France). � Agr Europa and Agr Intl Inc – Equipment for quality control of finished products (USA). � Pamuk Kardesler Makina – Furnace Steel and all other plant works (Turkey). � Formak Makina – Furnace and machine air cooling lines (Turkey). � MTM Makina – installation air, water and gas circuits (Turkey).

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Environment Furnaces

Future challenges and Sorg’s approach to environmental limits Dr Matthias Lindig* highlights some of the future challenges facing furnace makers and Sorg’s approach to forthcoming EU environmental legislation. Here he expands on some of the answers given in last month’s Future of Furnaces feature, which is re-published after this article. Sorg will provide a paper at the Furnace Solutions event, previewed on page 53.

eside statutory emission limits other tools have been introduced to encourage the industry to invest in new waste gas cleaning systems, the reuse of waste heat or in new processing from renewable energy sources. One of these tools is the so-called emission trading system (ETS), which is addressed to all European countries. It is a long term measure with different time intervals associated with intermediate goals. Every year we have to face about 1.9 billion tons of CO2 per year emissions or more correct CO2 equivalents (called EUA) EU-wide. Among the EU partners, Germany is the one with the highest share in emission. From 2005 to 2007 it was almost 500 million tons. During the so-called first and second trading period from 2005 to 2012 emission sources were allocated and the total amount of emissions was ‘capped’ i.e. limited EU-wide. Each country committed to continuously reduce these emissions. The first complimentary emission allowances were granted to the industry based on average values received during the allocation period. For the third

0,9

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mineral industry other combustions

trading period from 2013 to 2020 these complimentary allowances were cut annually by 1.74%. For all emissions exceeding this number of complimentary allowances company sites need to purchase allowances by auctions. What is the glass industry’s contribution to CO2 emissions and what is it in comparison to the entire national emissions? Glass production emissions in Germany are about 0.9% of the total emissions. Two thirds are emitted by power plants. The entire industry and power plants are causing in total 45%

� Fig 2 Endport furnace for container glass:

QF +94 QRL Qflue gas -23

� Fig 1. Annual

85m2, 250t/d, 65% cullet, heat balance (energy inlet 100%).

-7

QL +47

emissions in kT/year

QB +6

CO2 equivalent of all industrial fields in Germany 2015. Source: Emissionen in Zahlen, DEHSt Germany 2015

QC-7

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QWall-21,5

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paper + pulp

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non metal industry

of the national emissions in Germany. Over 50% is traffic and buildings’ heating (Literature - DEHSt Report 2015) (Fig 1). For the next trading period the policy is searching for new options to shorten the available allowances in the market. An increase in an annual cut by more than 1.74%, maybe 2.2%, is very likely to be established. The excess number of available allowance will be withdrawn for a certain time period (backloading). In consequence the market price for the EUA will rise.

3,9

chem. industry iron + steel refinery

7,9 5,4

power plants

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Fuel Boosting Chem. heat demand Glass delivery Total wall losses Combustion air Waste gas behind regenerator Wall losses regenerator

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www.growth-group.com

Furnaces

Real-time Process & Quality Controls

CO2 emissions in kg/t glass

225

200

175

150

125

100 0,00

5,00

10,00

15,00

20,00

25,00

Boosting of total energy input in %

� Fig 3. 90m2 endport furnace with 60% cullet – CO2 emissions versus boosting share.

National emission limits and laws The overall mass of greenhouse gases (CO2 and equivalent gas species) will definitely be restricted in the near future. But the specific emissions, the concentration of flue gas species in particular, are restricted by law as well. In Germany the first technical instruction for emission reductions was established in 1974. The decree has undergone several updates with tighter emission limits. The emission limits are now harmonised EUwide. The limitations are based on investigations of the so-called Best Available Technology (Literature - Industrial Emission Directive 2010/75 EU). As a consequence, there are two driving forces (the self-commitment and the legal emission limits) pushing the industry towards more efficiency and prevention of emissions. What are the expectations for the near future? A new draft of emission directive will come into force within a short time. The new emission limits for NOx concentration cannot be observed only with primary measures. Additional flue gas cleaning facilities will be necessary and raise the overall production costs for one ton of glass. New dust limitations might also require an exchange of the existing filter systems.

Working for a brighter future…

Conclusions for the glass industry The European Countries have contracted in achieving a significant reduction of CO2 emission within the next decades. The German policy agreed on a CO2 reduction by 90% until 2050. As a consequence of this goal, an industrial production, which implies thermal processing steps in this country, will only be feasible in future by using either electric power or hydrogen also generated by electric power. A number of projects have been established by the government but also industrial associations are promoting and supporting technical solutions and striving to achieve these ambitious goals. The SORG company was invited to some of these activities and has given technical support. Sorg has offered solutions applicable for the near future demands as well as solutions for the distant future. Before explaining these solutions it might be necessary to illustrate the present glass furnace performances and pinpoint opportunities of improvement without significant changes in processing.

WITH TIAMA HOT-END MONITORING Receiving information faster is possible and easier with our Hot-End Monitoring Sensors. Our system is also more cost effective because it is modular: you choose only what you need. Whatever your choice, it will improve your knowledge of the process and it is backed by our service, support and training, along with constant research. So, watch this space if you are preparing for the Smart Factory.

Continued>> Glass International May 2018

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09/05/2018 11:55:52

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40,0

CO2 batch 250

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200 20,0 150 15,0 100

10,0

5,0

CO2 batch/(batah + combustion)

CO2

300 Total CO2 emissions in kg/t glass

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Furnaces

0,0

0 30

70 Cullet content in %

110

� Fig 4. 90m2 endport furnace with 260 t/d pull – CO2 emissions versus cullet share

Glass melting furnaces today Today’s furnaces are strongly insulated. The outside wall has less than 150°C. Nevertheless, there are still sections which need to be free from insulation like metal lines or scewbacks. This minor share, about 10% of the total wall surface, contributes to more than 30% of the entire furnace heat loss. Minor improvements might be still possible and it is a matter of reconsideration during each present furnace project (Fig 2). Other drawbacks in efficiency are leakages and trapped false air. An open doghouse or open joints might cause about 3% of the entire energy used for melting. A sealed doghouse, sensitive furnace pressure control, continuous inspection and hot sealing could help to reduce these heat losses. With the EME-NEND batch charger and the IRD Doghouse, Sorg supplies a completely sealed charging area for the furnace. After furnace heat-up, a ceramic welding and sealing to close joints between the side wall and crown from outside might be highly recommended (cold face welding). Hot face welding to close joints with lances from inside the furnace is also a proven technology. By now, this technology is state-of-the-art and successfully carried out by the Sorg subsidiary Fuse Tech. The implementation of additional sensors for CO2 measurement or gas quality is required when the combustion efficiency needs more control. More unpredictable gas quality and variations in the public net are caused by feeding low LCV bio gases and hydrogen. Sorg has developed a control loop using natural gas analyses, calorific value and air demand calculation. With this loop system the total energy input into the furnace will be kept constant. It is a pre-set control system and not a re-adjustment. In conclusion all of these issues are relevant for energy savings and minor CO2- emission reductions.

Sorg approach - facts Looking at CO2 reduction one may not forget all the operation parameters influencing the energy consumption. The replacement of natural gas input by electric heating is a large contribution to CO2-reduction. Looking at the public traffic, the conversion to electric power is a measure without any alternatives. This is justified by the increasing share of electric power generated with renewable sources. In Germany 2014 more than

Yes, there is intelligence out there... lots of it

REAL-TIME INTELLIGENT DATA ACCESS By receiving open information from one single, smart database in real-time, you’re even more in touch with all your processes – no matter where you are – which means greater efficiency and productivity, less defects and losses. In fact, it’s like having your own personal satellite backed by our service, support and training. So, watch this space if you are gearing up for Manufacturing Intelligence.

Continued>> Glass International May 2018

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Environment Furnaces

4,00

240

Spec. energy

220

� Fig 6. Sorg’s end-fired furnace with an

3,90

CO2

230

3,80 3,70

210

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200 190

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enlarged pre-melting system EPMS.

3,20 2,5

3,0

3,5 Specific pull in t/m2*d

4,0

� Fig 5. 70m2 endport furnace with 60% cullet – pull increase versus spec. CO2 emissions and specific energy consumption.

25% of the total power was generated using renewable sources and with a progressive trend. In case of glass melting furnaces the use of about 15% electric power instead of fuel can save more than 15% of CO2 in the flue gas. The use of boosting is directly correlated to the CO2-emissions (Fig 3). The energy input and CO2 emissions can be reduced by using recycled cullet. An increase in the use of recycled cullet by 20% equates to more than 5% CO2 reduction (Fig 4). Also a pull increase, increase of pull compared to melting area, results in a specific decrease in CO2 emissions. The higher the pull, the lower are the emissions related to one ton of produced glass. An increase in melting performance together with the reuse of flue gas heat for batch preheating can result in more than 20% of CO2 reduction (related to the ton of produced glass) (Fig 5).

Sorg approach - concept In summary there are still various measures available to improve the emissions of existing furnaces.

The next cold repair of a furnace would allow for the implementation of new design features to increase specific pull, apply flue gas reuse and batch preheating as well as implement more capacity for electric boosting. The increase in use of renewable sources for electric power generation also implies changes in availability or temporary shortage in supply which has to be balanced EU-wide with neighbouring countries. Consumers will be asked in the near future to be more flexible in using the various heat sources. Melting furnaces should run with more or less electric boosting depending on short term changes in availability in the public power net. In conclusion a new furnace concept is required for flexible boosting and high specific pull. Sorg has made a proposal based on the well-known end-fired furnace concept. The charging section should be enlarged and equipped with boosting. In this section a pre-melting of the batch will be performed. The high crown in this section allows radiation heat transfer with the batch surface. The melter itself needs special features to

control the flow pattern regardless of the heat flow ratio from inside the melt with boosting or from the combustion space. The feasibility of the concept is proven by modeling calculations. A large number of end-fired furnaces built by Sorg are already equipped with an enlarged doghouse proving the feasibility and the advantage of such a concept. The risk of further increase of this charging section is controllable (Fig 6). It seems to be inevitable that electrically boosted or all-electric glass melting furnaces will be the most suitable technology in future. On the other hand it is unlikely that large end-fired furnaces will be replaced by all-electric melters. The limitation in capacity of those furnaces is well known. In the past, Sorg has built all-electric melters with capacities up to 180t/d for container glass and up to 250t/d for C-glass. The limitation in capacity is accounted for the cold top and vertically orientated melting processing. The batch has to insulate the melt surface. The melting of the batch Continued>>

� Fig 7. Calculation example for one line conveted to all electric heating – Impact on CO2 emissions and in case for purchasing EUA allowances.

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Endport furnace with 3 lines pull 280 tpd and cullet content 75% CO2 from combustion 5130 t/a Difference in CO2 emission Cost of 1 EUA Cost of allowances

1476t/a 9,37€ 13.746€/a

Endport furnace with 2 lines pull 200 tpd All electric furnace with 1 line pull 80 tpd and cullet content 75% CO2 from combustion 3663 t/a

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layer is only from underneath with no support from top with fossil firing. Due to this the specific pull is limited up to about 2.5 to 3.0t/m2/d depending on glass type. The critical path proceeds directly from top batch layer down to the throat. The fining, blister release has to be performed just below batch in the hottest section. The minimum residence time depends strongly on the basin depth. Melting larger quantities all-electrically requires substantial changes in the furnace design. Since the official schedules for emission limitation are almost for the long term, it might be a feasible solution to perform the change from fossil to all-electric or highly boosted in several steps. The next CO2 trading period starts from 2020. The runtime might last for about eight years. The costs for emission allowances will definitely rise. The complementary allowances will drop for each manufacturer. Sorg has calculated the benefit of one production line of a three lines fossil-fired furnace to all-electric. From the technological point of view this change does not imply any risk. The use of electric power instead of fossil fuel needs to be mirrored with increasing costs for emission allowances. An increase in costs for 1EUA up to €40 justifies the decision in running on line all-electric. The CO2 emission of the fossil-fired furnace with reduced pull is reduced and does not require emission purchases. In a calculation example a 100m2 furnace for 280t/d pull with three production lines is used. One of the lines, preferentially the one with long run production items, is converted to an all-electric melter with one line. The fossil fired furnace continues with reduced capacity. The savings in CO2- emission equates to almost 28% of the previous emissions (Fig 7). The emission savings might be in the range of what manufacturers can anticipate looking the requested overall reduction rate during the next CO2 trading period. The decision is based on proven technology and without any risk. A stepwise change in melting technology might be the most appropriate approach. As mentioned above increasing demand in flexibility raises expectations to operate a furnace within a large range of boosting between 10 and 90%. Sorg has done extensive studies to investigate the thermal conditions and melting conditions resulting from these very diverging boundaries. The crown temperature might vary in a range of 200°C. The glass temperature charge end might change by more than 100°C. For those changes in temperature, a suitable refractory still needs to be invented. For today’s refractory availability, boosting rate changes between 10 to 35% might be feasible. Semi-cold top melters would allow running between 70 to 90% boosting rate. For these operation conditions the melter design needs changes to ensure suitable fining conditions as already mentioned above. Various solutions have been considered and published in the path. In practice only a few have been realised, mostly for smaller capacities and for special coloured glasses. Today, the mathematical simulation allows investigating the melting, fining and refining conditions in detail. The former furnace solutions for all-electric melters are based on the model of large cross-fired furnaces, which were recalculated and severe disadvantages in fining performance were identified.

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

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

Continued>> Glass International May 2018

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Completely new approaches in design features inside the basin are required. Sorg is presently developing a large all-electric melter using mathematical modeling. One of the key criteria for evaluation is the bubble tracing. Typically about 12,000 blisters with 0.1mm in diameter and with typical gas content are placed under the batch layer in the charge end of the model. Experimental growth functions are derived from laboratory tests. The path, growth and release at the surface or in the glass exit flow is calculated and compared with similar gas-air-fired furnaces well-known regarding their fining performance. It will depend on several criteria in the future whether we need this kind of special melting furnace solution. Availability of electric power, cost conditions, and cost increase for emission allowances might have a strong influence in the decision making.

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Summary The obvious changes in climate and the impact on environment need a response from the energy - intensive industry. Climate and resources are compulsory reasons for inventing new ways of production with less greenhouse gas emissions. Sorg is trying to find new approaches with increase in productivity and in substitution of fuel by electric power. New furnace concepts are required and Sorg is preparing solutions for larger furnaces for containers but also for float furnaces using high fraction of electric power. �

*Research and Development Manager, SORG, Lohr am Main, Germany. www.sorg.de

Sorg completes Gopal Glass project Sorg has successfully completed the project for an ornamental glass manufacturing plant in India and handed it over to production. The project was started in March 2017. The customer, Gopal Glass, is a specialist in ornamental glass production in India and intends to expand its capacity with additional production units. The furnace has a melting capacity of 150 tonnes per day. Two forehearths are connected to the working end, both of them producing ornamental glass plates with a width of 1.2m. The Sorg team planned the furnace system with the corresponding supply units. The special feature of the melting furnace is the heating with gas and oil. Therefore, Sorg developed the appropriate control concept and equipment setup and implemented them on site. The customer bought the refractory material as well as the steel domestically in India. The most important equipment parts such as the batch charger (EME CPO-500 D) were delivered by Sorg. The complete system was installed in an existing production hall. The former manufacturing plant was demolished beforehand.

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

GLOBAL SUPPORT TO MAKE THE MOST OF YOUR INVESTMENT We’re not in space (yet) but the Tiama team is there for you with more than 70 international experts, offering the best in service, support and training backup. We offer local customer support, on-line spare-parts catalogs, a 24/7 hotline and remote troubleshooting. Our team also provides excellent training programs which help you make the most of your investment and help you identify problems before they happen. So, watch this space to see how our service will help you prepare for Manufacturing Intelligence.

Intelligence

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Future of furnaces: Sorg

Dr Matthias Lindig, Research and Development Manager, Sorg 1. What is your company’s involvement in the furnace industry for glassmaking? Sorg has been involved with glass furnaces and installations for the production of all types of glass for decades and has earned a reputation for driving innovation throughout the industry. An example of the innovative attitude of the company is the development of a batch preheating system for lower cullet percentages which has been operating successfully for years reducing energy consumption and CO2 emissions as well as making it possible to melt more glass using the existing furnace area.

2. In your opinion, is the glass furnaces sector evolving quickly enough with new ideas to address the new wave of environmental thinking and meet current climate legislation? And can you indicate what your company has done to address this?

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The short answer is that Sorg is moving quickly enough and that some of the future solutions lie in the past. One Sorg customer has been employing cullet preheating continuously for three decades. Sorg is a pioneer in all-electric melting which eliminates CO2 from combustion and NOx emissions. If you ask me if the industry is adopting these measures as quickly as Sorg would like, then the answer is probably no. Current energy prices and CO2 certiﬁcates are at low prices that do not drive innovations. On the other hand, lower costs are good for the industry and the competitiveness of glass as a whole. Other measures from Sorg include allelectric melting, batch preheating as well as extremely efﬁcient oxy-fuel melters such as our OxEcon.

will clearly require additional ﬂue gas cleaning equipment. The second issue will be the trading of emission allowances. This trading was established in order to allow the manufacturers to improve their processing in steps. The value of the European allowances will become signiﬁcantly higher in the near future. Without changes in existing melting technology the operational cost per ton of glass will rise for manufacturers in the common market. This will give manufacturers outside of the EU with less stringent emissions limits a competitive advantage.

4. How do you foresee furnaces evolving over the next say, ﬁve to 10 years? The key issue for the next ten years will be the continuously decreasing amount of free emission allowances for the glass manufacturers. Our crystal ball sees partial substitution of fossil fuels with electricity. Hopefully generated from clean renewable sources. This will lead to more boosting, more interest in all-electric melting and possibly new interest in an old Sorg concept, the EMDR. This is a hybrid furnace that is largely all-electric with enough fossil fuel to allow the melting of problem glass.

5. Do you think it possible furnaces will have shorter lifetimes in future? Or can you see their lifetimes increasing? Higher speciﬁc pull of melting furnaces is connected with reduced emissions per ton of glass. And higher speciﬁc pull is also linked with shorter lifetimes. This can be partially compensated through best practice maintenance and furnace audits including radar such as being developed by PaneraTech. Please pose this question to the refractory suppliers as well. Hopefully (for our customers) advances in materials will lead to even longer campaigns.

6. What will the furnace of the future look like? Will it be run entirely on renewable fuels or a hybrid of energy sources? The hybrid furnace is already state of the art and quite common. Most container glass furnaces are operated with a mix of fossil ﬁring and electric boosting up to 15%. This boosting rate may very well increase in the near future. Employing electricity from renewable sources is not an obstacle for glassmakers. The concern is: will we be able to generate enough renewable energy for all of the new demands including public transportation and electric cars? �

Sorg, Lohr am Main, Germany www.sorg.de

3. What are the technological challenges facing the furnaces sector in terms of meeting environmental legislation? Is the legislation realistic? When we talk about legislation, we have to address the emission limits harmonised in the European Union and periodically reviewed and updated based on bench mark studies. The anticipated new target values

Continued>>

SORG interview to repeat.indd 1

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Environment Furnaces

What are the future requirements for glass conditioning systems? During the Glassman exhibition in Lyon last September Joachim Gesslein* presented a paper about the future requirements of glass conditioning systems. Here is an abridged version of his presentation.

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ithin the last decades of glass production the demands on glass conditioning systems have increased drastically. For example, the pull has increased to 200 tpd, pull range and forehearth flexibility is much higher and multi gob production for light weight articles is widespread, with high thermal homogeneity requirements. In addition there is a high job change frequency and colour changes in the furnace, increasing changes in the heating gas composition and at the same time customers expect lower energy consumption and maintenance. To meet market demands, forehearth suppliers have worked hard on the improvement of efficient distributor and forehearth systems as well as on the equipment and additional tools, such as stirrer systems and drains, to improve glass quality. But now a state has been reached which does not allow any further large steps forward. A complete change of the existing solutions is pretty much excluded because the investment budget is limited. However, in this context, glass manufacturers should also consider that the investment in a glass conditioning system is in most cases less than 1% of the later production value.

Intelligent control systems Some additional tools such as intelligent control systems speed up the systems and make it more stable to avoid operating errors and save energy. In some cases, it is also possible to effect some advantages with additional or full electrical heating systems. But the most important factor is still good engineering of the glass conditioning systems with right

dimensions of glass bath, heating and cooling systems. This is the most important precondition to achieve successful production results and low operation costs as the outcome. For this reason, a glass producer should define realistic production conditions to put the forehearth designer in a position that allows him to use the available know how and technical solutions in the right way. There is also potential to improve the glass conditioning systems because the conditioning does not end at the front of the spout. Strictly speaking, the conditioning only ends when the glass has reached the forming process in a mould. The spout area and gob distribution systems are also parts of the glass condition system because the temperature and viscosity profile is changing here again. The knowledge about the optimal temperature and glass viscosity, optimal gob shape and location when the gobs enter the forming process is an important precondition to achieve an optimal forming result.

Most customers have no exact information about the real conditions in this area and what is the necessary optimum before the forming process starts. With the new high speed camera systems of today it is possible to measure and partially control the conditions exactly at this point. One of the next steps is to link all the available information within the forehearth and spout together and to grapple actively in the conditioning process to control not only solely the temperature in the equalising section. The gob weight, viscosity and shape also need to be regulated before the forming process starts. However, this task cannot be resolved by the forehearth supplier alone. He can only contribute his knowledge, technical skills and tools in a team of glass producers and machine suppliers to elaborate new control systems for the glass conditioning. ďż˝

*Glass Conditioning specialist, Horn, Ploessberg, Germany www.hornglass.com

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Industry 4.0

Smart container glass plant of today and tomorrow Axel Schroeter discusses how Industry 4.0 can be maximised to design the Smart Plant of the future. This paper is an abridged version of a presentation to be given by Mr Schroeter at the forthcoming 92nd DGG conference in Bayreuth, Germany, previewed on page 48.

oday, everybody, including the container glass industry, is discussing Industry 4.0. But everybody has different ideas about what Industry 4.0 really means. The challenges of today will become more important in the future. Decision makers need to know ‘what’s going on’ to take the right measures in the shortest possible time. Their managers want to get a quick overview of their plants. On the other hand, the number of experienced glassmaking specialists will decrease significantly in the future.

Major daily challenges Who needs to know what? Depending on the function in the glass plant, different employees have different requirements for information, for example: Operator: Which wheels do I have to turn and which knobs to push to improve the production quality of my machine? Department Manager: How do I get more and faster information about

container defects detected by the cold end inspection machines? Plant Manager: Where in my plant do the losses occur? Group Director: How efficient is each of my plants and how can I increase customer satisfaction?

The Solution: Heye PlantPilot The PlantPilot is a management system that collects data from the relevant plant systems, cold end as well as hot end, analyses them and makes them available to all persons who need them (See Figs 1 and 2). How can smart Cold End Inspection Technology of today support the Smart Plant Concept? An example: Cold End Check Detection with ‘Intelligent Cloud Masking’

Why Masking? A camera-based check detection system for container glass makes use of the fact that a check in the glass causes a significant reflection.

Unfortunately, reflections are not only produced by checks. Other causes, such as stray light or edges of the container, can be the reason for ‘continuous reflections’ (Fig 3). The system needs to decide whether the observed reflection is a continuous reflection or caused by a check. A good way to help the system to achieve this is masking the continuous reflections so that they can be ignored by the image analysis system.

Masking by ‘Teaching’ A well known, simple method of masking, is called ‘Teaching’. After each job change, up to 500 ‘good’ reference containers, free from checks of any kind and only showing continuous reflections, are needed. The system records all reflections and creates a mask for this type of article by adding up the continuous reflections of each individual reference container. Continued>>

Raw material preparation

PlantPilot Server with Database

• Graphs/Charts • Messages • Reports

TERMINALS

Glass melting

Inbound delivery

Annealing lehr

Ware handling

INSPECTION MACHINES • Defect data ARTICLE COUNTING • Counted values DEVICES

Forming

• Rejected mould numbers • Clear counter

INSPECTION MACHINES

Final stage: All systems communicate with each other in a closed loop mode!

Server with Database

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TERMINALS

• Operator Inputs (HE/CE/Mould Shop

Laboratory

PRODUCTION • Production data MACHINES LABORATORY (OPTION • Statistical data

� Fig 1. PlantPilot Architecture.

• Management

EXTERNAL ACCESS

Outbound logistics

Packing

Quality inspection

Cold end conveyor

� Fig 2. Glass plant final stage.

25 Glass International May 2018

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ICM

Teaching

ICM

� Fig 4. Resulting masks for the 1st bottle.

Database with hitlist

� Fig 3. Good or bad reflections?

Major disadvantages: 1. Time consuming 2. Up to 500 reference containers need to be absolutely free from any checks. 3. The resulting mask is much larger than necessary for one specific container, increasing the chance that checks are not detected.

Update hitlist

Teaching

� Fig 5. Resulting masks for the 7th bottle.

Inspection machines report a glass defect.

Remedy #1 from hitlist

Yes

Input manually or from inspection machines

Success? No

Next remedy from hitlist (#2,#3,...)

� Fig 6: A self learning system

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Intelligent Cloud Masking (ICM) An intelligent and smart system creates the mask individually for each container. This avoids any influence of the previous containers on the actual one and keeps the mask as small as possible. Heye’s Intelligent Cloud Masking (ICM) does exactly this. ICM uses the fact that continuous reflections and reflections caused by checks show a different behaviour when the container is rotating. The continuous reflection does not follow the rotation and stays in a constant position. The check and its reflection move with the rotation. The process works as follows: A series of pictures is taken while the container rotates. By comparing the images, the system can decide which reflections follow the rotation and which ones do not. The latter ones are continuous reflections and can be masked accordingly. When the next container arrives at the inspection station of the machine, the mask of the predecessor will be deleted and the process starts again. So the mask is created specifically for the actual container.

Which method is better? Figs 4 and 5 show the masks created

for the first and the seventh of the same series of good reference bottles. The left part of the picture shows the results for Intelligent Cloud Masking (ICM), the right side for teaching. For the first bottle (Article 1), both masks (white area) look the same. For the seventh reference bottle (Article 7), the mask created by ICM (violet area) is still of similar size as before. The mask created by teaching is already much larger because teaching creates the mask by summing up the results of each reference container. After several hundred reference containers, the mask becomes so large that the probability of overseeing checks increases significantly. ICM: A smart Masking Technology � It is a self learning system. � It creates the mask from each container individually. So each container is a reference for itself. � It does not need hundreds of good reference containers. � It saves time compared to a simple teaching procedure. � The mask is only as large as necessary for the specific actual container. This reduces the probability of overseeing checks significantly.

Future challenge In all glass plants the major portion of the production know-how is in the heads of experienced specialists. But the number of such specialists will decrease in the future. So we have to find a way to overcome this trend with technology.

The Solution: A self-learning system A smart plant management system will help to establish a system based on production know-how. The system will have a self-learning data base containing all possible glass container defects and all possible remedy measures. The remedy measures will be prioritised by a hitlist, based on their success history. The flow diagram in Fig 6 shows how this process will work. As a result, the production know-how of the system will get better with every recorded successful remedy. This will be a true Industry 4.0 Smart Plant system. �

*Axel Schroeter, Product Manager, Heye International, Obernkirchen, Germany www.heye-international.com

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Moscow - Russia Hall 2 - Booth 21D10

Take a look inside. Discover perfection. Designed, made and tested totally by us. 8-10-12 GOB SECTIONS AND TANDEM DELIVERY IS-P: DG 6 ¼”-TG 4 ¼” SYSTEM IS PARALLEL The final8000 glass container ADV quality depends on a good HSS gob distributor and delivery

• • • • • • • • •

between scoop-trough and deflector-mould. We have improved the actual technology to deliver the gob to the machine with the fastest and uniform flow and grant a high thermal homogeneity for final glass container’s high quality.

30°MULTI ConstantDIRECT trough angle CONSTANT New deflector profile longer on trough side DRIVE X2-X3-X4 ANGLE New deflector design and profile GOB DISTIBUTOR GOB DELIVERY Higher gob speed Shorter contact time between gob and trough Withsoft Electronic position More centrifugal force variation 30° constant trough angle control for each scoop thanks to new deflector profile Less deformation of the with gob the Strongly decreased the impact forcelonger between gob and trough possibility to align individually on trough side, this Nullify atfor the end point of the deflector profile everycentrifugal scoop withforce trough ensure higher gob speed with great improvement of gobs shorter contact time between delivery on high production gob and trough for less machines. deformation of the gob.

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LESS IMPACT

SOFT VARIATION

CENTRIFUGAL FORCE ON NEW DEFLECTOR DESIGN 0,0035 0,003 0,0025 0,002 0,0015

2 TRADITIONAL DEFLECTOR PROFILE

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All industrial processes involve, at one stage or another, the usage of contained heat, whether to produce the paper we use on a day-to-day basis, a simple steel screw, the glass windshield for a car, or the cement that supports the foundations of our houses. Being present in so many different industries makes us proud of the service we offer and gives us a sense of belonging, with active and responsible participation in the world around us.

With a a network of more than 30 subsidiaries and partners, from America to Japan, the Lizmontagens Thermal Technologies Group expanded its industrial services worldwide for the past decades, becoming the global leader in glass furnace construction and one of the leading references in heat containment for industry.

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40 yearsâ&#x20AC;&#x2122; service to the industry

anniversary edition Av. Almirante Gago Coutinho, n. 56 - 10th, 1749-041 Lisbon / Portugal Tel. + 351 218 429 270 / Fax. +351 218 409 412 / marketing@lizmon.com / www.lizmongroup.com

Ware handling The focus on achieving precise hot end ware handling has never been more critical.

The increasing demands of high speed ware handling

s the drive to light weight glass containers continues, combined with the introduction of larger and faster production lines, the focus on achieving precise hot end ware handling has never been more critical as modern production speeds push ware handling to the limit. The speed and the efficiency of an entire production line is reliant on good quality ware handling and on todayâ&#x20AC;&#x2122;s quad gob 12 section and tandem forming machines the production of glass containers is rapidly approaching the 800 bottles per minute mark. Critically it is the hot end ware handling where good quality containers can be lost. Therefore, the question is becoming less of how many containers can be formed per minute, but how glass container producers can handle so many containers. With such a reliance on ware handling for the progression of glass container production, the glass industry is looking to ware handling experts for the solutions to make the seemingly impossible achievable. Such rapid growth within the industry and the expansion of new

facilities inevitably leads to large-scale recruitment drives with talent shortages presenting a significant problem for glass manufacturers. The production process requires operatives to have a good insight in to this complex process to achieve the efficiencies demanded on the manufacturer. Therefore, the importance of removing human error from a process is elevated further when designers look at new innovations and the way we do things. For more than 60 years Sheppee International has been at the forefront of ware handling innovation and design, working closely with industry partners to achieve new alternatives that will enhance glass container production and future proof our process. As a company specialised purely in the science that is ware handling, Sheppee takes a more holistic approach to ware handling. While physically hot end ware handling includes several individual processes, there is no isolation between each stage. What happens at point A, influences the quality of point B and so on. Ware handling is not fragmented, the

sweepouts, machine conveyor, transfer unit, cross conveyor, lehr loader and push bar collectively are the ware handling process, integrated together and Sheppee International embraces this philosophy. At the glasstec trade show in 2016, Sheppee launched the â&#x20AC;&#x2DC;ITS-1000â&#x20AC;&#x2122; an Integrated Transfer System designed to enhance and increase glass container production speeds, and also to reduce human error in the functionality and the setup of the equipment (Fig 1). Since the introduction of the ITS ware handling system, production facilities have reported increases in production efficiencies without the need for intense training of personnel. To optimise ware handling correctly it is essential that the equipment is set up correctly. It can take the same amount of time to set up a machine correctly as it does to set it up incorrectly. If a good procedure is adopted for setting up the transportation of containers into the lehr, it is often quicker to attain maximum transport efficiency. With high transport efficiency many benefits can be realised quickly. Continued>>

www.glass-international.com

Roy Clarkson* discusses the importance of ware handling in an era of larger and faster production lines. The question today, he states is less of how many containers can be formed per minute, but how glass container producers can handle so many containers.

29 Glass International May 2018

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Environment Ware handling

� Fig 1. The ‘ITS-1000’ an Integrated Transfer System

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With the increasing number of high speed production lines, Sheppee International has sought to eliminate poor set up from the equation and developed a totally integrated ware handling system that incorporates all the elements of ware handling machinery. The ITS-1000 is the combination of the latest VFT-2000 transfer unit and transfer drive, IS machine conveyor drive with dual belt and an integrated cross conveyor idle end. Already in production on a 12-section quad gob machine, this system has immediately increased the pack rate in to the lehr by a staggering 5.4% by ensuring the containers successfully transfer on to the cross conveyor and are positioned exactly. With the increase and investment in production lines across the industry, this system offers the glass

container producer the ability to realise high-end production speeds. The system is engineered to enhance the stability of containers as they make the transition through ninety degrees. There are several defining factors that are critical to successful transferring of containers: 1. Position of containers on the IS machine conveyor 2. Stability of the container in the transfer pocket 3. Stability of container entering the cross conveyor 4. Position of container on the cross conveyor The synchronisation between the incoming containers on the machine conveyor and the transfer pockets is

critical and with poor set up of the sweep-outs and un-compensated belt stretch, misalignment of containers is detrimental to ware handling. To compensate for unequal positioning the VFT-2000 has an elongated lead in to an already enlarged transfer curve, ensuring that the misaligned containers are collected, guided and stabilised prior to entering the transfer curve. Once in to the transfer pocket, the changing direction of the container subjects it to varying adverse forces, decreasing its stability. The role of the dual belt is to provide consistent momentum in one single direction, which holds the container firmly in to the transfer pocket. This secondary belt has adjustable speed, which can be controlled independently or from the software of the Sheppee TriFlex lehr loader. As the container is transited through the transfer curve, the design of the VFT-2000 reduces the container spacing by 18%. By reducing the container spacing in the transfer, the necessity of decreasing the cross-conveyor speed to reduce spacing is also removed, helping to sustain stability and therefore high production speeds. Entering the cross conveyor is once again, a highly over looked cause of container instability. As the silent tooth chain rolls over the idle sprocket, the toothed chain often sags causing a dip in the transferring surface. This creates instability in the container and can contribute to container misalignment on

� Fig 2. To compensate for unequal positioning the VFT-2000 features an elongated lead in to an already enlarged transfer curve.

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Ware handling

the cross conveyor. To counter this, the integrated cross conveyor idle end encompasses an adjustable lower wear plate positioned beneath the silent tooth chain at the point it disengages from the idle sprocket. This ensures that the transfer surface of the chain remains 100% level. Instability leaving the transfer can be caused by the transfer finger conflicting with the container as it enters the cross conveyor. The VFT-2000 transfer incorporates a finger retract design, ensuring that as it leaves, contact with the container it does not move or reposition it in any way. These disparate elements combined ensure that perfectly synchronised and positioned containers arrive in front of the lehr push-bar ready to be loaded. The ITS-1000 can be integrated with either the Sheppee CCA/1200 cross conveyor or the customers’ existing cross conveyor. This means that the end user can benefit from the advantages of totally integrated ware handling without the expense of replacing existing equipment, likewise the system can be controlled from the Triflex lehr loader providing the ultimate ware handling system on the market today.

Case Study O-I in Melbourne, Australia has kindly given permission for the following information to be shared. In June 2017 O-I Melbourne installed the ITS-1000 / VFT-2000 ware handling solution, specifically to improve the production performance of a lightweight long neck beer bottle. Historically this container has performed under target, driven by losses from hot end handling instability. As a consequence this has increased production downtime and impacted the quality and productivity of the production run.

LAB-PRECISION VOLUME MEASUREMENT

SPT2 ON THE PLANT FLOOR

Precision volume measurement is no longer confined to the lab. SPT2 delivers consistent, high-accuracy volume measurements and pressure testing on the plant floor, with rapid throughput.

Prior to the installation of the Integrated Transfer System, the following production data was recorded: � Container losses at the lehr – 5.9% � Production down time – 7% � Maximum production speed – 469 bpm � PTPS – 83.8% � Tonnes per day – 105.8 Following the installation of the Integrated Transfer System, the following production data was recorded: � Container losses at the lehr – 0.57% � Production down time – 1.2% � Maximum production speed – 490 bpm � PTPS – 89.2% � Tonnes per day – 118.3 Increasing production speed by 21 bottles per minute 30,240 per day, a reduction in down time by 5.8% and reduction of losses by 5.33% and increasing quality and productivity by 5.4%.

Conclusion Many glass manufacturers look at ware handling as fragmented and isolated processes, without considering the cause and affect each process has on the next. It is our philosophy that an inclusive and holistic approach to ware handling is implemented. �

*Regional Sales Director, Sheppee International, UK http://www.sheppee.com/

ware handling sheppee.indd 3

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09/05/2018 14:14:26

Environment Forming

Manual mode increases safety levels � Fig 1. The manual mode is designed for safer job changes

Inge Friberg* discusses how a manual safety mode within Emhart Glass’s news FlexIS 3 control system reduces risk and simplifies the job change procedure.

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job change on a glass-forming machine is always a challenge. Each minute without glass has an economic impact on the plant. Therefore, diminishing the downtime is a key goal. To optimise the machine shutdown, there is a high level of co-activity on the machine, with operators working simultaneously on both sides of the machine. Numerous parts of the section equipment have to be changed and adjusted. These adjustments are done manually by using electrical override commands to run each section mechanism individually. During manual operation of the mechanisms with these commands, the operator should not interact with the section mechanisms to avoid any risk of injury. During a job change procedure, there are numerous occasions where a manipulation of blank and blow side mechanisms is required, thus increasing the risks of hazard inherent to the interaction between the operator on the blank side and the operator on the blow side. This can only be reduced by

an intricate cooperation between the operators on each side of the machine.

Manual mode operation With the release of the next generation of its forming control system FlexIS 3, Bucher Emhart Glass (BEG) has launched a new safety concept for manual interaction with the sections of a glass forming machine. The safety control development is based on three principles: � Separation of the Blank side and Blow side mechanisms (patented); � Two-hand Operation of the mechanisms; and � Speed Supervision for Servo Electric Invert (SEI) and Servo Electric Take-out (SETO) mechanisms.

The separation of Blank and Blow Sides, the Two-hand Operation, and the speed supervision are based on the JetSafe technology introduced with the FlexIS 3 controls (pictured overleaf). When interacting with a section during accessory exchange or job change, the operator will now activate the Manual Mode operation by a switch located at his working side (Blank and/or Blow side).

The combination of these three principles with the use of the Manual Mode reduces the risk and simplifies the job change procedure. The Manual Mode safety controls are certified in accordance with ISO EN 13849 requirements.

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Forming

The activation of Manual Mode initiates the Two-hand Operation mode and the Speed Supervision. By activating the Manual Mode on the blank side, the operation of the mechanisms on the blank side is only possible (Blank Moulds, Baffle, Funnel, Invert, Plunger) by simultaneously pressing and holding the Enable button and activating the override switch for a mechanism. Similarly, the activation of the Manual Mode operation on the blow side allows for manual operation of the blow side mechanisms (Invert, Blow Moulds, Blowhead, SETO) by the same Two-hand Operation mode. The Two-hand Operation mode eliminates the risk of having any human interaction in the section while a mechanism is moving. As soon as the Enable button is released, the mechanism stops immediately and the section remains in a safe stop condition. The separation of the blank and blow sides for the mechanisms reduces the need for the operators to coordinate operation between both sides of the machine and herewith reduces risks. The operator on the blow side takes the ownership of the blow side mechanisms only, and the operator on the blank side takes the ownership of the blank side mechanisms only. The operation of the SEI mechanism in Manual Mode can be done from both sides of the machine but the operator who initiates the movement is the one who controls the SEI mechanism. In this condition, the SEI cannot be activated simultaneously from the other side of the machine. During Manual Mode operation, the speed of both the SEI and SETO mechanisms is considerably reduced and safely supervised. Should the speed exceed the specified limits for any reason; the section immediately stops in safe mode. The Two-hand Operation of the SEI and SETO mechanisms with Speed Supervision simplifies the adjustment of the neck rings and the take-out arm. The Manual Mode is fully operational with all the servo mechanisms of the NIS and BIS machines. All BEG IS and AIS machines equipped with SEI mechanisms and SETO mechanisms can benefit from the Safety Controls and Manual Mode operation, to take advantage of the Twohand Operation with Speed Supervision for servo mechanism adjustment. The Safety Controls and Manual Mode Operation is part of the BEG strategy to develop a simple and safe glass forming machine operation. ďż˝

*Compliance Engineer, Bucher Emhart Glass, Cham, Switzerland. www.bucheremhartglass.com

forming Emart.indd 2

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Environment Forming

Blank linkage design balances closing and improves bottle quality David Cole* discusses how Pyrotek’s blank linkage design in type F IS machines has improved the production efficiency at glass container manufacturers.

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forces. Using less air pressure also reduces wear on equipment mechanisms and mould equipment, potentially increasing production throughput.

Customer trials “In customer trials, once we install a first section and they see the benefits of it, the design sells itself,” says Bridgewater, who has been providing dozens of customers with this design for 25 years. “Customers are able to achieve longer service life of their equipment, and they create better quality bottles. The trials turn into longterm customers.” Some Pyrotek customers are seeing seven-year production campaigns before replacing their linkage system.

That compares with three to five years for customers using alternative linkage systems. “We’ve basically doubled the life-cycle of the linkage,” Bridgewater says. Combined with a balanced insert design, the balanced set-back post linkage design can both optimise melt-to-pack ratios and help manufacture better bottles. “We have service engineers located regionally around the world to be in-plant and service the needs of customers,” he says. �

*Global Marketing Writer, Pyrotek, Spokane, Washington State, USA. www.pyrotek.com/glass

Closing force test averages 2500

2000

Pounds

lass container manufacturers who have converted to Pyrotek’s balanced set-back post linkage design in type-F individual section (I.S.) machines have enhanced their production efficiency, reduced stress on machine parts, and helped improve product quality. Machine operators who are not using this linkage design sometimes experience product quality issues such as ‘thin shoulders’ on the seam, which can be caused by the misalignment of blank mould cavities, or one arm standing open. Engineering studies of these alternative designs show that when they close at the centre line one side can often overpower the other, causing the weaker side to lose strength and the contact point to move further away from the centreline. Pyrotek’s linkage design is structured to stay centred, maintain ideal closing angles, and ensure one side’s clamping force doesn’t overpower the other. “With this linkage you get stronger closing forces and you get stronger resistance to opening,” says David Bridgewater, Pyrotek’s plant manager in Tulsa, Oklahoma, where the linkage system is manufactured. Comparison tests between Pyrotek’s design and the industry standard show Pyrotek’s version has minimal variation in closing pressure from cavity to cavity (Fig 1). Pyrotek’s design allows the hangar inserts to float, while with the industry standard design the inserts are fixed in place. Using the industry standard design, with air pressure of 172,369 Pascals (25 pounds per square inch), the force on the individual blank can be 173 kilograms (381 pounds). With Pyrotek’s design, at the same air pressure, the force on the individual blank will be 499 kilograms (1100 pounds). Allowing machine operators to use less air pressure reduces operating costs, while maintaining the necessary closing

1500

1000

500 0

20psi

25psi

30psi Industry standard

35psi

40psi

Pyrotek

� Fig 1. Comparison tests between Pyrotek’s linkage design and the industry standard.

� Fig 2 Rendering of Pyrotek’s linkage design.

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03.04.18 12:14

Environment Forming

Good gob, bad gob John McMinn* highlights the importance of the forehearth in gob formation and glass distribution within the container.

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hermal gradients within the gob and temperature differences between gobs produced from adjacent orifices are a significant factor in container faults and ware rejection. It is crucial to have knowledge of the factors that determine good gobs and bad gobs and how to eliminate or mitigate the production of bad gobs. The quality of the gob is essentially determined by the forehearth design, the skill level of the forehearth operator and the resultant achievable thermal homogeneity of the forehearth exit plane at the spout entrance. Some years ago I was fortunate to work with Matt Hyre at a time when he pioneered mathematical modeling of the entire forming process. Among the models Matt produced was a study of the causes of thermal inhomogeneity in the gob produced by the operation of the forehearth. Matt used numerical simulation to model the flow of glass through the forehearth and spout and its subsequent passage through the forming process and into the final container. This allowed a study of the influence of forehearth performance on container quality. The results of this study proved the old adage that a good bottle is made in the forehearth; or more precisely, consistent gob and container quality is dependent on control and consistency of the forehearth exit plane temperature profile. Prior to the equalising zone the flow pattern of the glass within the forehearth is laminar. As the glass nears the spout entrance the flow is influenced by both the tube rotation, the downward flow of the glass and the plunger action. Within the spout the orientation of the orifices has a large influence on the glass flow pattern. The glass delivered to the different orifices originates from different areas of the spout entrance plane. For example, if the forehearth is operating with straight line shearing, the glass entering the spout at the bottom right hand side exits mainly through the inner orifice whereas

the glass entering the spout at the bottom left hand side hand exits mainly through the outer orifice. The glass in the bottom central area will exit mainly through the outer orifice. Since cord-rich glass will concentrate at the bottom central area this explains why it is common for one gob to contain greater quantities of cat scratch cord than the other gob.

Parison forming Temperature gradients within the forehearth exit plane can produce an uneven temperature distribution in the spout that affects the temperature distribution within the plungers and the orifice ring. This results in gobs with different weights and temperatures. Due to the lower viscosity the hotter gob will be longer than the colder gob. The mould receiving the higher temperature gob will have a higher surface temperature than that receiving the colder gob. This has a negative impact on the forming of the

parison since the hotter gob will produce a longer parison before invert due to the lower viscosity. As a consequence of this the region of the parison that will form the heel of the container will be thicker for the hotter gob. As a result of the differences in parison length the final blow will occur too early for the shorter parision resulting in a thinner bottom and a thicker neck. The differences in glass thickness distribution are significant, the smaller gob will produce a thinner heel and base, the larger gob will produce less thickness variations that will make the container less likely to fail under pressure. As discussed above different areas of the forehearth exit plane exhibit preferential flow patterns dependent on orifice orientation but thermal gradients at the spout entrance also produce thermal gradients in the gob irrespective of orifice orientation. It is common practice Continued>>

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Forming

to define the exit plane with a ninethermocouple point grid defining the exit plane into three horizontal levels and three vertical columns. However studies have found that not all nine points are of equal importance in the formation of the gob. The area defined by the three vertical central thermocouples and the bottom RHS and LHS have much more influence than the areas defined by the top RHS and LHS thermocouples. Forehearth operation should concentrate therefore on achieving minimal temperature gradients between the central vertical column and the side bottom glass streams. Forehearth control strategies, such as cascade and bias control, that aim to control the forehearth exit plane temperature profile, have been available for many years, but individual zone setpoint manipulation remains the most widely used means of controlling the glass temperature profile at the spout entrance. The effectiveness of this is determined firstly by the expertise and experience of the operator but crucially by the reaction of the forehearth to the changes in operational parameters.

Forehearth Services specialises in determining what factors prevent the forehearth from achieving a thermally consistent forehearth exit plane.

Performance audits Now in its 10th year Forehearth Services has conducted forehearth performance audits around the world on all major forehearth designs (and several, shall we say, less conventional designs). This has allowed us to acquire a unique insight into the efficacy of the various designs and the level of performance achieved by the users in various glass plants. Within the container and tableware sectors of the industry there exists a wide discrepancy between the theoretical performance of the forehearths and the actual operational performance. This observation is based on Forehearth Services’ forehearth performance audits that have consistently identified large variations in both design efficacy and performance. Surprisingly, and disturbingly, not one single forehearth audited within the past 10 years was found to be operating correctly with

the result that the consistency of the forehearth exit plane temperature profile was compromised – and as a result production and container quality were correspondingly affected. There are many reasons why a forehearth fails to deliver the theoretical performance level but operator skill levels and inappropriate maintenance schedules are often to blame. Often poor forehearth performance is due to combinational elements that not only compromise the forehearth exit plane thermal profile but manifest in slow response and excessive fuel consumption. Using analytical techniques developed by Forehearth Services it is possible to identify and rectify all factors that prevent optimal forehearth performance and compromise the forehearth exit plane thermal profile. �

*Managing Director, Forehearth Services, UK Email enquiries@forehearthservices. co.uk. Web www.forehearthservices.co.uk

Increase Productivity Improve hollow glass production with Pyrotek solutions for IS machines.

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• Consolidate your supplier base • Profit from global expertise • Partner with local technical specialists

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Environment Forming

Challenges in parison forming Steven Kozora* discusses some of the challenges related to process changes that occur on a daily basis and how Quantum process equipment makes every single job change easier.

ne of Quantumâ&#x20AC;&#x2122;s main objectives is to help its customers reduce machine downtime. The company focuses on supplying a forming system that is designed to facilitate the daily operation. In addition, our mechanisms are mechanically sound and dependable. This is achieved through the innovative design of the equipment and the quality of materials used. A principle of Quantum and a keystone of its equipment is the material used in the manufacturing process. Quantum manufactures its glass forming equipment from hardened steel alloys, which last much longer than softer, more fragile materials used in other systems. Through the use of innovative manufacturing techniques, the company has been able to use the highest quality materials and remain cost-competitive.

Challenge #1:

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Job conversions to different number of cavities Some job changes are simple and only require different Finish Equipment. Some job changes are more elaborate and require a change in the number of cavities/gobs per section. For example, your machine is running a wine bottle on double gob and needs to change to a beer bottle in triple gob. Changing a job from triple gob to double gob, or vice versa, is usually a big struggle and time consuming (Fig 1).

Solution: Universal Individual Cylinder With the Quantum Universal Individual Cylinder this job is fast and easier. As you can see in the conversion diagram, we utilise the same cylinders and only change to the number of cavities desired. This makes the process easier and faster. There is no need to realign the equipment and cylinders can be pre-configured. You

ďż˝ Fig 1. Conversion Graphic.

can even change from Blow & Blow to Wide Mouth Press & Blow or whatever process you will run next. Patented innovations, such as the flat

bottom cylinders with manifold, have provided the industry with a forming Continued>>

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Environment Forming

issues is the extreme heat of the plunger. When the plunger is overheated, it creates spike defects during retraction.

Solution: 360° Continuous Cooling Air flow management is a key feature of our design for the NNPB process. We designed the positioners to be air leak free. This key feature in the Quantum Cylinder from TWT technology combined with leak free positioners work together to allow the Forming Plunger to be cooled throughout the entire forming cycle. Quantum is able to provide superior Plunger cooling using lower air pressure during the entire cycle (Fig 2).

� Fig 2. 360° continuous cooling.

Challenge #4:

system that can cost-effectively adapt to the frequent job changes that production departments demand. Quantum’s forming system has been pivotal in delivering flexibility to the industry and providing customers with a competitive edge in their respective markets.

Job change within the WMPB and NNPB process Another frequent job change requirement is for different parison heights. For short parisons, like beer bottles, to tall parisons for wine. To perform this task the glassmaker uses different size spacers. To change the spacer seems simple but requires 10 steps from removing split clamp rings and locking stud to installing a new spacer and reassembling the cartridge.

Challenge #2: Chasing Cartridge to change thimble and plunger in the Blow & Blow process Changing the Blow & Blow thimble and plunger is one of the most common operations in the glass container factory. Little attention is given to this operation as it is simple and performed many times per week. This challenge is what we call an un-surfaced need, the operator is chasing the cartridge to try and lock the thimble in place but the cartridge keeps moving.

Solution: Quick Change spacer for WMPB and NNPB

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Solution: Quantum Non-Rotating Cartridges This process equipment fits all Quantum plunger mechanisms and as the name says, it locks in position to receive the thimble. The cartridge is designed to stay in position so the operator doesn’t need to keep chasing it for every single job change. Another advantage of this cartridge is that all parts are assembled together making it easier to change from one process to another. You don’t have to deal with lose parts and components as all the springs are captured inside the cartridge. Another important benefit for using non-rotating cartridges, is it allows the possibility of running non-round finishes in Blow and Blow. Registered finishes can be difficult to produce, especially in BB. This is why we at Quantum have

� Fig 3. Quick Change spacer for WMPB and NNPB.

Loading positions can be changed quickly and easily with Quantum’s quick change spacer. The company designed a spacer that sits over the adaptor and is able to be removed by hand, when the positioner is in the full up position. This design speeds and simplifies the process. Now, only six steps are enough to get back up and running. There is no need to remove the locking stud and adaptor to change Loading Spacers (Fig 3).

Conclusion integrated such a feature into our core product. In addition, our Tube-Within-a-Tube (TWT) has allowed glassmakers to benefit from increased inlet airflow for plunger cooling and counterblow, increased exhaust capacities to expel the heated process air and a dirt-free air delivery system that can increase the quality and strength of the containers produced.

Challenge #3: Overheating of Plunger in Narrow Neck Press & Blow process In the NNPB process one of the main

The process of making a perfect bottle or container is complex from start to finish. Quantum’s goal is to allow production teams to turn their attention towards improving the efficiency of other processes, knowing their forming equipment will be the reliable backbone of the manufacturing system. �

*President, Quantum Engineered Products, Saxonburg, PA, USA www.quantumforming.com

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Forming

A Multi Direct Drive gob distributor to reduce defects A distributor system for all gob configurations has been designed and developed by BDF Industries to offer glass producers high speed and superior quality performances.

This is particularly true in outer sections of the machine where eventual positioning errors due to non-independent scoop motion has a more significant impact, in relative terms, as compared to inner sections. Years of experience in the hollow glass market has allowed us to affirm that scoop-trough misalignment is often the cause of compromised solutions, which subsequently lead to less than optimal gob delivery. In many cases, the gob collides and impacts with the trough as it exits the scoop, consequently slowing down and deforming in an anomalous manner, thus resulting in defective or low-quality products. There are difficulties associated with gob delivery in outer sections of machines with 10 or more sections, subsequently resulting in defective products. The Multi Direct Drive gob distributor guarantees perfect and repetitive alignment between every single scoop and relative trough, for both central and

outer sections. The transfer of gobs on to relative troughs is fluid and repetitive, thus eliminating energy losses due to impact and allowing a higher gob speed in the trough.

Motor and drive system BDFâ&#x20AC;&#x2122;s Multi Direct Drive gob distributor is distinguished from those currently available in the market insofar as every single scoop is controlled by its own motor and direct drive system, without intermediate elastic elements: this means every single scoop and its relative positioning is totally independent of the others. Other defining and particularly appreciated features include entirely independent programming and the absolute repeatability of individual positions based on the selected and Continued>>

www.glass-international.com

he end quality of a glass container depends on the efficiency of the gob distributor and delivery system, consisting in a scoop-trough and deflector. That is why BDF Industries has sought to improve its current technology, working to develop a faster and more consistent flow to improve gob delivery to the machine and guarantee high thermal consistency, all determining factors in ensuring the high quality of finished glass containers. The Multi Direct Drive gob distributor constitutes one of the most important components in the BDF Industriesâ&#x20AC;&#x2122; Forming range of products. It has been patented directly by the internal Technical Department in single, double, triple and quadruple gob configurations for all known machine types and has been carefully designed and developed to offer glass producers high speed and superior quality performances. The innovation was inspired by the desire to introduce a more reliable, highperforming system into the market with respect to those currently available. Traditional gob distributors are renowned for presenting a number of difficulties when it comes to perfectly aligning the scoop and trough.

43 Glass International May 2018

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Environment Forming

� Multi Direct Drive Gob Distributor SG-DG.

The glassmaker’s diary

www.glass-international.com

active recipe, guaranteed by each scoop’s direct drive and control system. The set-up and self-learning functions in ‘jog’ mode, on the other hand, allow each scoop position to be redefined every time the gob delivery position needs to be modified on the relative trough. The mechanical rigidity of each single drive and the choice of components with optimal structural and dynamic characteristics, make this gob distributor one of the highest performing mechanisms for speeds up to 240 cuts/ min. The mechanism is able to guarantee operational reliability and dynamic solutions even at the highest performance levels thanks to its mechanical sturdiness, the rigidity of the drive and low vibrations.

� Multi Direct Drive Gob Distributor.

Another important element is the improved durability of components and therefore the reduced need for scheduled maintenance, due to the transmission of motion by way of pinion-racks in oil baths. Thanks to the proximity switch on the other hand, it is possible to monitor the

correct working position of the gob distributor, which can be controlled either by electronics incorporated into the electrical panel of the IS machines or by stand-alone electronics, which offer additional flexibility. These technical features of the system not only make the process more fluid, but above all translate into important advantages for glass producers. First, a higher production speed and increased productivity and, also, thanks to a reduced number of defects, improved efficiency and reliability. �

BDF Industries’ Forming Technical Dept, Vicenza, Italy. www.bdf.it

Mir Stekla 2018 May 28-31st Moscow, Russia. CONTACT: www.mirstekla-expo.ru/en/

ICG Annual Meeting 2018 September 23-26th, 2018 Yokohama, Japan. CONTACT: www.icg2018yokohama.com/index.html

DGG’s 92nd Annual Meeting May 28-30th, 2018 Arvena Kongress Hotel, Bayreuth, Germany. CONTACT: https://dgg.converia.de/?sub=37

42nd ASEAN Glass Conference September 24-27th, 2018 Yogyakarta, Indonesia. CONTACT: www.aseanglass42.id

Furnace Solutions 13 June 6 and 7, 2018 Lucideon, Stoke-on-Trent, UK. CONTACT: www.furnacesolutions.co.uk/Index.html

World Soda Ash Conference 2018 September 25-27th, 2018 Gran Melia Hotel, Xi’An, China. CONTACT: www.chinasoda.com.cn/2018WSAC

10th ICG Montpellier Summer School July 4-8th, 2018 Montpellier, France. CONTACT: www.icglass.org

glasstec 2018 October 23-26th, 2018 Düsseldorf, Germany CONTACT: www.glasstec-online.com

14th European Society of Glass conference July 9-13th, 2018 St Malo, France. CONTACT: https://pncs-esg-2018.sciencesconf.org

79th Glass Problems conference November 5-8th, 2018 Columbus, Ohio, USA CONTACT: http://glassproblemsconference.org

SGT Annual meeting September 2-5th, 2018 Cambridge, UK. CONTACT: http://cambridge2018.sgt.org

Glassman Asia 2019 January 30 - 31st, 2019 Jakarta, Indonesia CONTACT: www.glassmanevents.com/asia

44 0 Glass International May 2018

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History

Prof. John Parker

Let them eat cake Prof John Parker* provides a historical perspective on the use of sodium sulphate in glass melting.

www.glass-international.com

n July 2016 I wrote about the sources of sodium and potassium carbonates (soda ash and potash) as glass melting fluxes. By the 18th century in Europe plant ashes had replaced soda from natural deposits and typically contained both soda ash and potash; barilla plants (aka glasswort) from Spain were one popular source while in Britain kelp from Scotland’s beaches was harvested for burning. Potash came from burning wood but deforestation in Europe had long since shifted its sources further afield to North America, Scandinavia and Russia. But by 1775 Spanish barilla ash had become so costly that the French Academy offered a prize for making soda ash from common salt, interestingly not long after chemistry had matured sufficiently for the possibility of such a transformation to be envisaged. Leblanc was the first to solve the riddle in 1791. His process reacted sea salt with sulphuric acid to give sodium sulphate (salt cake). Hydrogen chloride gas was a by-product with no commercial value and so was vented to the atmosphere with a dramatic negative impact on the environment. Next the salt cake was reacted with chalk and charcoal to give calcium sulphide and sodium carbonate; indeed, natural sodium sulphate had already been used in Russia for glass melting by first reducing it with coal – their sulphate had been discovered in the 18th century in the salt lakes of Siberia. The final stage of the Leblanc process involved leaching with water followed by evaporation to extract the sodium carbonate but the considerable volume of toxic black waste left behind was simply dumped; some of these sites in the UK are now designated SSSIs (Sites of Special Scientific Interest) having become a habitat for unusual calcareous plants including orchids. Leblanc sadly never received the French

Academy prize; worse still his plant was annexed by French revolutionaries in 1794 and his technology was widely disseminated. He committed suicide in 1806 having disastrously failed to profit from his efforts. The process was subsequently widely developed in NE England and by the 1870s the British soda output reached 200 000 tons p.a., more than produced in the rest of the world. The Leblanc method was used by glassmakers for several decades; Douglas and Frank illustrate the enormous production facility used by the Chance Brothers at their Plate Glass works in Oldbury, Worcestershire. Inevitably there were attempts to bypass the second lengthy step in the soda ash production process and during the 1830s and 1840s, salt cake from the first stage of the Leblanc process increasingly displaced the more expensive soda ash for glassmaking. Higher melting temperatures were required though with consequences for furnace operation. In 1863 Solvay in Belgium successfully produced sodium carbonate (from salt) using a much more efficient and less polluting approach that gave a much cheaper product; soda ash again became the major source of alkali. Now, salt cake occurs naturally as the decahydrate and had been known since 1625 when a scientist/apothecary Johann Rudolf Glauber found it was a general purpose and effective laxative, known as Glauber’s salt (sal mirabilis). Mirabilis means miraculous and glassmakers too must have realised its advantages. Reaction between sodium sulphate and silica sand proceeds slowly below 1350°C but a small quantity added to the batch in a modern furnace acts as a surfactant, encouraging quicker solution of the last sand grains. In low temperature pot melts two centuries ago, it probably helped reduce silica scum, a problem that typically

needed a refractory ring floating on the melt surface to give an impurity-free working area. Sulphur exists in a glass melt in different oxidation states – as the sulphate radical, sulphite or sulphide. Each has its own solubility with different dependencies on temperature and oxygen partial pressure. This redox behaviour means that small additions of salt cake in the batch act as a non-toxic refining agent and can assist with chemical decolourising – very useful roles when arsenic was the competitor. Because of sulphur’s complex chemistry, its solubility curve has a deep minimum at a redox value that varies with temperature. Sodium sulphate itself is poorly soluble and easily separates out. Changing redox/temperature can also lower its solubility, resulting in the formation of foams that are difficult to disperse. Such behaviour must have mystified the glassmakers of an earlier era. Salt cake is still produced in large quantities: 4 million tons p.a. comes from natural sources while less than 2 million tons is produced chemically. The glass industry uses 110 000 tons p.a., an amount which has plateaued since 1970. Its other uses include: detergents, currently taking 50% of the total production just to add bulk to the product; making wood pulp; and textile dyeing. Perhaps a surprising application is for thermal heat storage; this uses the latent heat of melting the decahydrate at 32°C to store low grade thermal energy. �

Bibliography https://en.wikipedia.org/wiki/Leblanc_ process. R W Douglas and S Frank, A History of Glassmaking, Foulis *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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DGG’s 92nd meeting includes Czech and Slovak associations

www.glass-international.com

Mr Ulrich Roger, Managing Director of the German Society of Glass Technology (DGG), discusses the group’s forthcoming 92nd meeting, which has been expanded to be held in conjunction with the Annual Meetings of the Czech Society of Glass Technology (CSS) and the Slovak Society of Glass Technology (SSS). 1. Congratulations to you and your colleagues for organising the conference programme for the forthcoming DGG/ CSS/SSS event. How pleased are you with such a large programme? Such a large programme caused a lot of work in advance but the goal is to create an interesting event. The participants are wide scattered like students, scientists, engineers and technicians.

� Last year’s DGG meeting took place in Weimar, Germany.

� Mr Ulrich Roger.

2. Has it taken a long time to organise both this programme and the event as a whole? To organise such a varied conference you have to start with the ﬁrst preparations more than two years in advance. It is difﬁcult to specify an exact number of working days. We have a team of about three persons who invest more or less part of their working labour in the preparation of such a conference.

3. Have you noticed a particular ‘trend’ within the conference papers this year? There is no clear trend visible. Not only the number of papers and posters are varying year by year also the subjects are sometimes more technical or more scientiﬁc orientated.

Continued>>

48 0 Glass International May 2018

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Events preview:DGG 92nd meeting Environment

4. This year is being held with partners from the Czech Republic and Slovakia. Why did you decide to partner?

8. The conference location is in Bayreuth. Why did you choose this location?

It is the ﬁrst time to cooperate in a congress with these two societies. Both societies are relative small and it would be nearly impossible for them to organise a bigger conference on their own. It is a win-win option for all partners. The smaller societies can improve the attractiveness of their annual conference for their members and the DGG enlarges its annual congress from a national to a more international event.

First: At the university in Bayreuth the department of ‘Werkstoffverarbeitung’ a group of scientists are working on glass research projects. The reason is to promote this glass research location. Second: The geographical location of Bayreuth is near to Czech Republic and to Slovakia.

5. How pleased are you with the partnership so far? Up to now all three partners seemed to be happy about this cooperation and it works well.

6. What is the aim of the conference? The goal of our annual conferences is to join technology and science with glass.

7. Who is the target audience for this conference?

9. How many years have you been involved with both the DGG and this conference? What do you enjoy about the conference? For more than 35 years I have been involved with the DGG and its annual conferences. First, as a student, than as a scientist, then as an engineer and for more than 14 years as the managing director of the DGG. I have enjoyed and still enjoy the high scientiﬁc and technological level and the possibility of networking at each annual conference combined with changing locations.

Basically, everyone who is in touch with glass. Not only technicians and scientists also students, artists, pensioners, …

88%

10. The DGG is approaching its centenary in 2022. Is it too early to ask if any plans have been made yet to celebrate this anniversary? At the 2022 conference combined with its 100th anniversary, the DGG will host the 26th ICG Conference and several steps are already completed. The location will be Berlin at the Maritim Conference Hotel near the Tiergarten. Further steps are the planning of the conference programme. The main point over the years may be that we try to bring technologists and scientists together and at the experience and professionalism of the conference teams. The joint conference takes place from 28th to 30th May, 2018 in Bayreuth, Germany. The event includes 104 oral and poster contributions that cover topics reaching from the fundamentals of the glassy state and amorphous materials to energy applications of glass topics related to health, medical, and biological applications as well as optical materials and devices, and ﬁnally to glass production technology. �

More information www.hvg-dgg.de/en/home.html

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Events preview: Furnace Solutions

Optimisation is the theme for Furnace Solutions this year Nigel Longshaw, chairman of the SGT’s Melting Technical Committee that organises the annual Furnace Solutions event, discusses this year’s conference and training day.

he Melting Technical Committee (MTC) are very pleased with this year’s programme. Each year the MTC aim to put together papers that are relevant to glass producers and to achieve this every year we look for new first-time presenters to the conference. The theme of this year’s conference is Furnace Optimisation and we have pulled together speakers with technologies that efficiently control the operation of the furnace, environmental emissions and how furnaces will be controlled in the future. Very experienced glass producers also pass on their knowledge and experience during the Training Day. Organising the conference never stops. We are continually looking for interesting papers and already have offers for papers for next year’s conference.

young and experienced glass producers in a relaxed and informal environment. To keep the conference relaxed there are extended breakout periods for delegates to meet old and new friends, to review papers and learn from each other. The Geoff Evans Dinner on the Wednesday

industrial glassmaking issues. Very quickly this initial idea quickly exploded and we now have delegates visiting from Europe, the USA, Turkey and Israel. What was thought would be a small UK conference is now firmly in the diary of international glass producers.

Have you noticed a particular ‘trend’ within the conference papers this year?

What is the aim of the conference? The aim of the conference is to pass on knowledge and experience to both

� Last year’s winner of the Michael Garvey award was Sisecam’s Tunc Goruney, pictured being handed the award by Nigel Longshaw on the right.

evening is another great opportunity for the industry to get together to talk about their passion - glass - in a friendly environment.

Who is the target audience for this conference? The target audience is practical glass producers. The initial intention of the conference was to get UK glass producers together once a year to talk about practical

What can delegates typically expect when they visit the event? Firstly, a very warm welcome from the SGT as they enrol. The papers are always interesting and delivered by people who are passionate about their subject and very importantly delegates have plenty of time to network with other guests and presenters. Continued>>

www.glass-international.com

The industry has three goals: to make quality glass efficiently, to prolong the life of the furnace as long as possible and to satisfy environmental issues. This year’s conference focusing on optimisation is looking at control aims to give delegates the tools to manage their furnaces efficiently. The key to prolonging the life of the furnace has been the correct selection of refractories, how to extend life with hot repairs and unobtrusive monitoring of refractory wear. The environment is always a concern to the industry, delegates are always interested in novel ways to reduce CO2, SOx / NOx and particulates emissions into the atmosphere.

53 Glass International May 2018

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Environment Events preview: Furnace Solutions

� Delegates at last year’s event

www.glass-international.com

The conference location has always been Lucideon, in Stoke On Trent. What are the beneﬁts of this location? Lucideon was chosen because it had a long association with the glass industry evaluating raw materials and refractories for the suppliers and the glass industry. It is centrally located and close to the M6 making it easy for UK delegates to travel by car. For international visitors it is well serviced by Manchester, Birmingham, Liverpool and East Midlands airports.

How many years have you been involved with both the SGT and the MTC that organises this event? Before joining DSF I worked for Lucideon (Ceram as it was then). At the time of the first conference Sarah Baxendale

� This year’s programme includes papers from Stara Glass and Sorg.

(the then Ceram refractory specialist) and Geoff Evans asked me to help with the organising of the conference on the day. I’ve now been involved in all the conferences taking on bigger roles over the years.

How pleased are you to have seen the event grow so much over the years? Very pleased. Initially it was organised to be a small UK conference. Now it is established with delegates putting the date of the next conference in their diaries as they leave that year’s conference

One presentation will be given the Michael Garvey award for best paper. Can you tell me a little about the background of this award?

Michael died in a climbing accident in 2008 aged just 27 years old. The Guardian Glass employee was a key member of the Goole process team. He presented a paper at FS-3 and made a good impression on the audience and members of the MTC. The award is sponsored by Guardian and came about thanks to Chris Windle, Geoff Evans and the other members of the MTC. It shows the ‘people matter’ side of the SGT. �

Furnace Solutions 13 takes place on June 6 and 7 at Lucideon, Stoke-on-Trent, UK. More information from www.furnacesolutions.co.uk

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