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May 2022—Vol.45 No.5

A GLOBAL REVIEW OF GLASSMAKING

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Contents

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Deputy Editor: Jess Mills Tel: +44 (0)1737 855154 Email: jessmills@quartzltd.com Designer: Annie Baker

May 2022 Vol.45 No 5

Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director Tony Crinion tonycrinion@quartzltd.com Chief Executive Ofﬁcer: Steve Diprose

Company proﬁle: Wiegand-Glas Wiegand-Glas ﬁres up Schleusingen furnace

Furnace: Horn Setting standards for the glass industry

Decarbonisation: BV Glas Promising applications for the use of hydrogen in the glass industry

Furnaces: FIC Hydrogen is not the answer for the glass industry

Furnaces: Fives A hybrid approach to the future

Decarbonisation: Sorg Sorg’s mission to net zero

Company proﬁle: futronic futronic celebrates 50th anniversary

Speciality glass: Schott How speciality glass enables health, energy and sustainability

Digital glassmaking: Siemens Innovating in unison

Events preview: ICG Industry and academia to gather at ICG 2022 in Berlin

Events review: Hotbels seminar 35th Hotbels Glass Industry Seminar

Glassman Latin America review Friends Reunited at Glassman Mexican event

Investment: HFT HFT to upgrade Owens Corning site

Recycling Close the Glass Loop online seminar

Palletising: Thimon Thimon: packaging since 1968

Chairman: Paul Michael

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Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2021 edition: UK £206, all other countries £217. Printed in UK by: Pensord 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

GREG MORRIS, EDITOR

Be first with the news! For breaking, up-to-date news

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VISIT: www.glass-international.com

for daily news updates.

Overcoming supply chain challenges

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It was great to meet so many members of the glass industry face to face after a two-year hiatus at the recent Glassman trade show in Mexico. The event was supported by the domestic glass manufacturing industry with visitor numbers very much higher than in previous years. People were keen to reconnect after such an absence and wanted to catch up on the latest news. The sector is in an unusual position. The container sector is flourishing, with unprecedented demand for glass bottles, primarily as a response to consumer kickback against plastic. But the sector is struggling to meet customer expectations due to supply chain issues. From components for glass equipment, chips for computer software, to ingredients for refractory materials, suppliers reported difficulties in sourcing these vital parts. Supply chains were already strained due to Brexit, pandemic-induced lockdowns and the Ukraine war but the recent shutdown in Shanghai in April added to the chaos. For the glass industry it is an added headache but one which can be overcome with planning and management to ensure the smooth flow of operations. Now is an incredible time to be in the glass industry with booming demand, increased use of digital technology and recent zerocarbon glassmaking. It is important not to let supply chain hiccups ruin what could be a pivotal moment for the sector.

Orora secures $12.5 million oxygen glass furnace grant

Australian glass manufacturer Orora has secured a grant to support the construction of an oxygen-fuelled furnace at its Gawler production facility. The $12.5 million grant was awarded from the federal government under the Modern Manufacturing Initiative to accelerate development and commercialisation of low

emissions technologies. Orora Beverage Group General Manager, Simon Bromell, said: “Our plan to introduce oxygen fuelled furnace technology to our site in Gawler, which would be a first for Australia, supports Orora’s ongoing commitment to reducing greenhouse gas emissions. Orora has a target of 60% re-

cycled content for glass bottles by 2025. The oxygen fuelled furnace, which would replace existing furnace technology, would contribute to this goal together with the construction of a $25M glass beneficiation plant at Gawler, which is expected to be commissioned in Q4 FY22.

Groupe Pochet plans electric furnace at French glassworks French luxury glass bottles manufacturer Groupe Pochet plans to invest in an electric furnace at its Guimerville plant in Normandy. The furnace will be opera-

tional by the end of 2024. “This electric furnace will be the very first French furnace dedicated to luxury bottles. It will enable us to drastically reduce our CO2

emissions by producing a largely carbon-free glass that will guarantee the beauty of tomorrow,” said Benoit Marszalek, Pochet du Courval’s Director of Operations.

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International News

Vetropack to cut 400 jobs at damaged Ukraine glass site

NEWS IN BRIEF

Forglass conference for glass producers

Forglass addressed critical challenges facing the glass industry in its latest conference for glass producers. The conference focused on Alternative Energy Sources for Melting Glass and Lowering Energy Consumption in Glass Furnaces. With the success of the conference, Forglass plans to continue the tradition and hopes that even more glass producers will participate in upcoming editions.

Wiegand-Glas returns to rail transport

the 600 staff will be lost. “We are aware of the impact this step will have on our employees in Ukraine – but we see no alternative at the moment,” said Johann Reiter, CEO of Vetropack Holding. The company has no plans to permanently close the site but wishes to reopen it after it has been repaired. A core team will continue to assess the situation on site. At the beginning of the Russian attack, Vetropack released all employees from work with continued payment of their full salaries. “This measure is only suitable as a temporary solution – not for the duration of a war that may extend over many months,”

said Mr Reiter. “Financing these jobs is directly related to the production and sale of glass packaging. Therefore, without production, we cannot sustain it.” Vetropack will be looking for possible solutions for the affected employees in cooperation with the plant management. As most of the workforce are men of military age, they are currently not allowed to leave the country or be deployed to other Vetropack plants. Nevertheless, 35 employees have already been able to relocate abroad, and some of them are already working at other Vetropack sites.

Ukraine glassworks issues urgent plea for raw materials A Ukraine glass manufacturer has issued an urgent appeal. The glassworks, which does not wish to be named for fear of a Russian missile attack, has continued to manufacture at full glass capacity despite the invasion of its country. It said it had obligations to its European customers,

which it aimed to fulfil despite the crisis. The company has started to run out of soda ash – a vital raw material in the glass manufacturing process. “If we do not find soda suppliers in the nearest future, then the entire glass industry may stop due to the lack of one

raw material component,” the company said. The group is ready to consider purchasing 10 to 20,000 tonnes or more. If you can help, please contact Greg Morris at GregMorris@quartzltd.com, who will pass your details onto the glassworks.

Recresco secures contracts for glass supply

UK based glass recycling company Recresco has signed two Welsh local council contracts for kerbside collected glass into its Cwmbran depot. The contracts will see Recresco reprocessing around 6,700 tonnes of commercial and residential collected bottle glass per annum. This will be sorted for end use at Knauf Insulation.

Solvay completes Green River acquisition

Solvay has completed the acquisition of a 20% minority stake of AGC in the Soda Ash joint venture in Green River, WY, USA for $120 million. The facility, operated by Solvay, produces soda ash and sodium bicarbonate from trona, a naturally occurring mineral to serve the glass, chemicals, detergents and food industries.

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Glass packager Vetropack is to cut 400 jobs at its Ukraine factory damaged by military fighting. It said damages at its Gostomel, Ukraine glass container manufacturing facility are so severe that resumption of operations is not possible for the time being. There is also still military activity in the region. Initial investigations into the situation have shown that only clean-up work as well as the protection and preservation of assets (including management of used glass and raw materials) are possible there in the medium term. Approximately two thirds of

Wiegand-Glas has begun work on the rehabilitation of its railway at its Steinbach am Wald site, Germany. The company has decided to return to rail transportation of its goods and raw materials to save in CO2 emissions. Every truckload of products transported by rail will save approx. 96 grams of CO2 per tkm compared to pure road transport.

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International News

Stoelzle begins €45 million Polish furnace rebuild Cleanfire® HRx™ Synchronized Boosting System All the boost you need, perfectly synchronized Need to boost energy input to your air-fuelfired regenerative glass melting furnace? Air Products’ Cleanfire® HRx™ Synchronized Boosting System is an innovative and costeffective solution. This patent pending, commercially-proven technology is added to your furnace and synchronized with air-fuel

Stoelzle Glass Group has invested €45 million in a furnace rebuild at its production site in Czestochowa, Poland. Earlier this month, the group started to empty its flint furnace at Stoelzle Czestochowa, the largest of seven plants belonging to the group. The furnace will be demolished and rebuilt within the next two and a half months.

The new flint furnace will reach a daily capacity of 480 t and will allow the installation of three more efficient production lines. Artur Wołoszyn, CEO Stoelzle Czestochowa, said: “This investment has been a huge challenge for Stoelzle, above all, the timing of the project, which has been planned in detail over the past two years. “Being 140 t larger than the old one, the new fur-

nace will allow more efficient and faster production lines. This investment will help increase the product portfolio for current customers, as well as to acquire new ones and meet their purchase expectations efficiently.” In the area of packaging glass production, the Czestochowa glass furnace will be one of the largest in Europe and the largest in the entire Stoelzle Glass Group.

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May news.indd 3

HSIL Limited changes name to AGI Greenpac Indian packaging company HSIL Limited has changed its name to AGI Greenpac. With the name change and completion of the divestment of the Building Products Division in March, the company has become a focused packaging player. The use of ‘green’ is to reflect the company’s commitment to offering sustainable packaging solutions that have a positive impact on the environment. It is the company’s promise to put sustainability at the core of day-to-day

business operations. AGI Greenpac will now lead the next phase of growth and the management team remains committed to capitalising on the growing market opportunities, expanding its packaging business, and unlocking value for its stakeholders. Mr. Rajesh Khosla, CEO, AGI Greenpac said: “We are now a complete packaging company, and a new shared purpose and identity will position AGI Greenpac to have a greater impact in the industry. Furthermore, we

remain fully committed to applying resources strategically and driving innovation within the packaging sector.” The company has recently started manufacturing speciality glass at a new greenfield facility in Bhongir, India. The facility spreads across 15 acres and has a manufacturing capacity of 154 tonnes per annum. The plant manufactures clear glass products are primarily used in the packaging of cosmetics among other industries.

Glass International May 2022

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International News

NEWS IN BRIEF

Libbey sells European glass operations

Libbey Glass is to sell its European operations to Dutch finance group Anders Invest. It said the sale would allow it to expand its business within its core markets, especially the Americas. Libbey’s European operations include a manufacturing and distribution facility in Leerdam, Netherlands and a manufacturing facility in Marinha Grande, Portugal. The sale also includes its Royal Leerdam and Crisal Glass brands. The the sale is expected to close within the coming weeks.

Bucher Emhart success

Bucher Emhart Glass reported a ‘very good’ start to the year thanks to strong demand in all its regions. In its latest financial note, the Swiss-based glass container technology supplier said the rapid upturn that had begun after the slump caused by the Covid-19 pandemic continued this year. Sales had doubled compared to the previous year and order intake increased by half. Strong demand continued in all regions, even Asia where there had been a certain amount of reticence last year. Bottlenecks in logistics continued to pose difficulties while the lockdown in China meant activities there were halted between mid-March and early April.

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Coca-Cola United partners with O-I

Coca-Cola Bottling Company United has partnered with O-I to capture more recycled glass from its production site in Georgia, USA. The recycled glass will be remade into glass bottles. Through the partnership, the company expects to recycle more than 700,000 out-of-date and damaged bottles annually.

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. � � � � � � � � � �

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Ukraine glassworks issues urgent plea for help Schott launches hydrogen pilot glass project Coca-Cola partners with O-I Indian company changes name Vetropack cuts jobs at Ukraine facility Ardagh completes Consol acquisition Saint-Gobain in zero carbon glass achievement Libbey Europe sold to finance group Sefpro acquires Monofrax Emharts reports strong demand

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Knauf Insulation starts build of US manufacturing facility Knauf Insulation North America has broken ground on a 56,000 m² glass mineral wool manufacturing facility in Texas, USA. The new plant in the city of McGregor, is the company’s largest greenfield investment and will create more than 150 new jobs. Work is scheduled to begin in the final quarter 2021 and

is expected to be completed in the third quarter of 2023. Once fully operational, the plant will manufacture 46 million m2 of glass mineral wool every year – enough to insulate 125,000 homes. Matt Parrish, CEO of Knauf Insulation North America, said the new Texas plant was “a natural next step for the company’s growth and aspi-

rations” filling a void in Knauf Insulation’s North American footprint. “This is a huge step for our customers,” he said. “This is one of the regions in North America where demand has been high for quite a while. “This plant will help our company grow and support our customers’ future growth. It is a perfect match for us.”

Encirc supports Britvic’s decarbonisation strategy Encirc has extended its beverages partnership with Britvic, the UK’s largest soft drinks company. Encirc will now fill Britvic’s Robinsons 500ml glass cordial bottles, which it already manufactures at its site in Elton, Cheshire. The move will prevent around a thousand lorry jour-

neys from Great Britain to Northern Ireland across the three years – resulting in carbon savings of up to 22,000 tonnes. This will support Britvic’s aim to reduce its carbon footprint by 50% by 2025. Encirc’s ability to bottle cordial is the result of direct investment in new equipment

and resources, such as its Effluent Treatment Plant in Elton, which can safely treat more waste materials without harming the environment. Parent company Vidrala has also invested £75 million in a national distribution hub for the UK and European beverages industry.

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International News

NEWS IN BRIEF

AFGM conference dates

The 44th ASEAN Glass Conference will take place between October 30 and November 3 in Pattaya, Thailand later this year. The conference will have the theme Glass: Sustainable World Solutions and be hosted by the Federation of Thai Industries (GMFTI) under the leadership of its organising chairman Mr Somporn Temudomsomboon, from Bangkok Glass. The event, organised by the Asean Federation of Glass Manufacturers (AFGM) will be the first since 2019 due to the Covid-19 pandemic. Mr Harris Hendraka, AFGM Chairman, said: “The ASEAN Glass Conference has always been the staple of glass industry events in the ASEAN region and this year will be no different.”

Ardagh plots South African investment after Consol acquisition

Ardagh Group is to invest in new furnaces after it completed the acquisition of Consol Glass. The Luxembourg-based glass packager received clearance from South African authorities to complete the $1 billion acquisition. The acquisition includes net debt assumed in Consol and includes a further $200 million investment in two furnaces. Ardagh said it was committed to a third furnace investment at Consol’s Nigel facility in Gauteng, South Africa which will add to the existing N2 expansion project.

Tiama appoints Director for hot-end division www.glass-international.com

Tiama has appointed Michel Carpentier as Director for its Hot-End Business Unit created earlier this year. The unit was formed to develop the company’s hot end operations; Tiama also plans to double the amount of employees in its hot end team. Mr Carpentier, who is also part of Tiama board, has years of experience as Production Manager and Plant Manager.

Indian investments boost global production at Gerresheimer Gerresheimer has boosted its global glass production capabilities with advanced facilities in India. The company installed the latest Type I Borosilicate melting furnace for flint and amber glass production using crossfired oxygen technology at its Kosamba site. The furnace is further

equipped with the latest production machines, including sensitive inspection equipment to comply with Gerresheimer’s moulded glass production standards. Stefan Rieder, Global Senior Vice President of Commercial Moulded Glass, said: “With this technology, we will substantially enhance our prod-

uct quality and address additional market segments.” By adding capacities in India, Gerresheimer intends to ensure consistent supply for critical pharmaceutical and healthcare facilities supporting increased packaging demand and public health.

Saint-Gobain secures zero-carbon flat glass achievement Saint-Gobain has become the first company in the world to achieve zero carbon production of flat glass. The technological feat was achieved last week by using 100% recycled glass (cullet) and 100% green energy, produced from biogas and decarbonised electricity. It was implemented for one week in Saint-Gobain’s flat

glass manufacturing plant in Aniche, northern France. By mobilising the network of partners developed by Saint-Gobain, the focus was placed on circularity, with the use of 100% cullet from endof-life glass from renovation or demolition sites and from production offcuts. The group’s industrial and research teams succeeded in

adjusting all of the furnace’s technical parameters to this dual challenge of operating with 100% recycled material and 100% biogas, while ensuring the right optical quality of the glass. This achievement is a clear demonstration of SaintGobain’s commitment to reach carbon neutrality by 2050.

Schott launches hydrogen glass production pilot project Schott has launched a hydrogen pilot project in its aim to manufacture climate neutral glass. The company launched the project at its headquarters in Mainz to test large-scale use of hydrogen in glass production. The largest share of Schott’s energy requirements and carbon emissions occur during the melting process. Glass melting requires temperatures of up to 1,700°C to produce speciality glass for vaccine vials, smartphone cover glass, or microchips.

Until now, Schott’s melting tanks have been heated with natural gas and in some cases with electricity. The company is working to change this as part of its initiative to become climate neutral by 2030. In order to develop climate-friendly glass melting processes, it has started several research projects. They are focused on electrification based on green electricity and on hydrogen combustion. In both approaches, electricity from renewable energies plays a decisive role.

Now, the company plans to test hydrogen-natural gasblends in large-scale melting trials at a furnace at its Mainz headquarters for the first time. Over the course of a month, the ratio of hydrogen in the natural gas/hydrogen mixture will be gradually increased to up to 35% by volume in three test phases lasting around 10 days each. The company will use these experiments to learn more about the effects of hydrogen in glass melting processes.

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Company profile: Wiegand-Glas

Wiegand-Glas started the second glass furnace at its Schleusingen plant in Thuringia, Germany after it was postponed at the end of 2021. Glass International spoke to Oliver Wiegand, who outlined the journey behind the decision.

fter a postponed start-up, Wiegand-Glas fired the second furnace at its plant in Schleusingen, which completed the second step of the site’s investment strategy. In addition to the furnace investment, the German container glass manufacturer has also invested in three new warehouses. These are for: finished goods, outdoor storage for cullet, and a new logistics centre to meet the requirements of higher capacity and the group’s sustainability strategy. Wiegand-Glas has built a greenfield container glass plant next to its existing facility in Schleusingen, which Mr Wiegand said emphasised the importance of the site for the group’s strategy. With the plant now fully operating, the glass manufacturer believes it can meet its goal of continuous and sustainable organic growth according to market needs, as well as a clear commitment to its regions.

Wiegand-Glas fires up Schleusingen furnace

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Rising demand Market figures by the European Glass Container federation (FEVE), among others, show an increased demand for glass containers in recent years, which is why the company decided to up its production capacity. Building the new plant was further accompanied by the decommissioning of the old furnaces at the existing Schleusingen site – where Wiegand-Glas operated a flint and an amber glass furnace. The manufacturer therefore decided to rebuild the plant in a large, high-tech and energy efficient manner to better meet the needs of new and existing customers. In addition, the new furnace will allow Wiegand-Glas to produce coloured glass as well as amber glass.

The right decision In times of war in Europe and with energy markets and the whole economy “playing crazy”, it is hard to say if there is the right time for any decision these days, but Mr Wiegand believes not making any decision is the worst one. Consequently, Wiegand-Glas recently began the start-up of its second furnace in March, which had been postponed since late 2021. The postponement caused the manufacturer,

and the market, to lose thousands of tons of amber glass. “We got in some trouble trying to satisfy customer needs in terms of time and quantity. But our production planning and sales team did their best to overcome the situation without critical damages,” said Mr Wiegand. “In the plant, we used the time for further training of our new stuff and technical optimisation of the production lines. But, in the end, it is also true that every postponement costs you a lot of money – every single day.” Personnel had already been hired and trained to operate the new furnace at the end of 2021. “For the motivation of our people, and with a few on structural costs, we had to make a decision.” The most important factor was the commitment of Wiegand-Glas customers and their willingness to overcome these difficult times. Mr Wiegand also highlighted the company’s existing contracts and the system-relevant character of container glass to the food and beverage industry. In addition, due to the war in Ukraine and European sanctions against Russia, there is a lack of glass supply from Eastern Europe and consequently more demand on central European

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Company profile: Wiegand-Glas

markets. The new end-fired furnace has a higher capacity than the previous one and will help to satisfy customer demand. The new glass plant will also create approximately 100 jobs.

Sustainability The new furnace runs on natural gas and electricity. By installing the latest technology and control systems Wiegand-Glas expects the furnace to become one of the most eco-friendly conventional container glass furnaces in the world, in terms of energy efficiency. The new production plant was an important step in Wiegand-Glas’ sustainability strategy. In addition, the new furnace allows the manufacturer to use up to 90% of cullet in its melting process – if the raw material is available on the market. Overall, this leads to 40% reduction in CO2 emissions per tonne of glass produced compared to the old furnace.

“No one knows what happens next. Especially the high

energy prices and the threat of a gas shortage. But there are Whilst the manufacturer is busy finishing the decommission and partial demolition of the old production site, there is some space left for further expansion at Schleusingen site. “We do have plans to replace an old furnace from another plant and build a large-scale, full electric furnace and invest in glass recycling there. This will meet the goals of our sustainability roadmap and contribute to the European Green Deal. But to present a precise timeline wouldn’t be practical in these uncertain times of war and economic problems.”

be a reliable partner in future years as well.” Wiegand-Glas is planning an open day in Q3 2022 to celebrate its heating up of the furnace, which it hopes to share with its customers, partners and employees, if the pandemic allows. �

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

challenging situations on every market, like the ones for raw materials or

”

freight.

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Key to success Mr Wiegand believes the key to a successful partnership is communication, particularly in these unpredictable times. “No one knows what happens next. Especially the high energy prices and the threat of a gas shortage. But there are challenging situations on every market, like the ones for raw materials or freight. “Together with our customers, partners, and employees we are taking short-term measures to overcome this critical situation together. At the same time, we will work on long-term strategies to

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Furnaces

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Setting standards for the glass industry Modern technologies, innovative spirit and technological leadership - all these attributes stand for both Horn Glass Industries and Wiegand-Glas. The two companies are led by a fascination for technology and driven by strength. Driven by this shared passion, the glass manufacturing process is optimised energetically, technically, technologically and continuously. Wiegand-Glas is the solution provider for glass bottles, jars, PET bottles as well as integrated services and has 450 years of glassmaking tradition. With plenty of experience in development and production, Wiegand-Glas has become one of the most successful container glass manufacturers in Europe. Horn’s expertise is based on more than 135 years of experience. Since the company was founded in 1884 as an artisan furnace construction company, it has developed into today’s international company for the planning and construction of most modern glass production plants. Horn received its fourth consecutive order from Wiegand-Glas in spring 2021. The furnace supplier was commissioned to optimise the new end fired furnace with three forehearth lines and

a melting capacity of 350 tonnes per day at the Großbreitenbach plant. After the successful commissioning last year, it turned out that the specific energy values were only slightly higher than the theoretically required energy demand of 3 GJ/t glass and thus the guaranteed values were already exceeded. For this reason, the two companies agreed to carry out further optimisation of the melting furnace. The aim was to reproducibly fall below the value of 3 GJ/t glass over a longer period of time. The melting furnace is characterised by the use of Horn’s e-Fusion boosting with an input of 15% electrical energy and the technological know-how from Horn’s R&D activities. During the production of olive green, the value was permanently below 3 GJ/t for the first time in the world over a period of one week with a cullet content greater than 85%. This 3 GJ/t furnace is another flagship of Horn’s technical ability. �

Horn Glass Industries, Ploessberg, Germany www.hornglass.com

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Decarbonisation

Promising applications for the use of hydrogen in the glass industry

ow can the European Union’s climate targets be reached? How could a significant reduction in fossil fuel use and associated carbon dioxide (CO2) emissions be achieved? For the energy intensive glass industry ,with its high temperature process an alternative to natural gas, could be the switch to hydrogen as energy carrier. With an energy demand of 68 PJ in Germany – 74% of which is provided by natural gas - the industrial glass manufacturing process is a significant CO2 emitter. But can a glass furnace just simply be fired with hydrogen instead of natural gas? To find out if and how hydrogen could be used in the glass production process was the aim of the German HyGlass project, based in North Rhine-Westphalia, one of the ‘hot spots’ in the German glass producing regions. The scientific project on a semi-industrial scale was initiated by the Federal Association of the German Glass Industry (BV Glas) and the GWI (Gas- und WärmeInstitut Essen), known for its expertise in thermal processes and gas usage. The HyGlass project was funded by the North Rhine-Westphalian Ministry for Economic Affairs - Innovation and the regional platform for energy transition “NRW.Energy4Climate”. It was also strongly supported by glass manufacturing companies in the region. In addition to the use of pure hydrogen and blends of hydrogen in the glass melting process, availability of hydrogen and aspects of logistics were considered, as well as technical feasibility along the value chain. The analysis of hydrogen’s impacts was focused on both combustion and glass quality. The project objective was to investigate the possibility of using hydrogen in regenerative glass furnaces

as a long-term replacement for gas. Both hydrogen-gas mixtures and pure hydrogen were examined. The possible applications of hydrogennatural gas mixtures as well as pure hydrogen in regenerative glass furnaces were the focus of the trials. Special attention was paid to the consequences on combustion and glass quality. On the other hand, challenges, such as logistics and availability of hydrogen, but also the technical feasibility of using hydrogen in the various processes along the glass production chain were discussed through cooperation with operators of glass melting furnaces. In this context, a site-based potential analysis for the production of hydrogen with wind and solar power at the glass production site was carried out.

The security of supply of fuels and electricity to provide the process heat is existential for the glass industry. In the light of the current energy crisis and the impending natural gas shortage due to the war in Ukraine, the issue of identifying alternative green energy carriers has become even more important. During the furnace running time, it is almost impossible to carry out major energy efficiency improvement measures that affect the actual melting process. These can only be carried out at the end of the furnace lifetime when a new furnace is being built, every approximately 10-20 years.

More than 80% of the energy used in the glass melting process consist of natural gas. The other main energy source is electric energy, often supporting the melting process in form of electrical boosting at the bottom of container glass furnaces. To reduce the use of fossil fuels, the electrification of various process steps with electricity from renewable sources is often the obvious approach. However, electrically heated glass tanks for the industrial production of mass-produced glass, such as container and flat glass, have not yet been developed and are therefore not available . Combustion will therefore continue to be necessary for many applications due to process-related reasons, especially in high-temperature processes. Established melting processes work with long, nonpremixed flames and a heat transfer that is mainly defined by the thermal gas radiation. Electrification of these existing processes would require considerable technical and economic effort and would not be feasible in the short and medium term.

Continued>>

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A recent project which investigated the potential use of hydrogen in the glass manufacturing process to reduce its CO2 emissions showed promising results suggests Christiane Nelles*.

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Decarbonisation

Not all natural gas is used in the glass furnace, a smaller share of it is also used in feeders and in the cooling lehr. Due to the low power densities in the lehr, there could be the possibility of electrifying these parts of the installation in future instead of substituting natural gas with hydrogen. Whereas in the feeder and in the regenerative glass furnaces, where the power densities are significantly higher and the preconditions for an electrification are difficult. Much better prospects are offered using hydrogen, even if the availability of it is still limited at present and legal framework conditions for green hydrogen are still unclear. In this case, security of supply, i.e. the development of a hydrogen infrastructure, will probably become more important in the future. The option of producing hydrogen locally with green electricity has shown that the available power generation capacities within a radius of 20km from the respective location are in many cases insufficient to produce the necessary quantities of hydrogen, even if it is assumed that the renewable power capacities can be utilised exclusively for glass industry’s hydrogen production. Despite these hurdles, the use of hydrogen in the glass industry is one of the options that are currently favoured . Both, the experimental results and the results generated by CFD, have shown that with hydrogen blends in natural gas up to the use of pure hydrogen, the burner capacity and the air flow rate must be kept constant by means of a suitable control concept so that the furnace chamber temperature and thus the approximately equal heat flow into the melt are maintained . If hydrogen is added to regenerative glass furnaces, less heat output is introduced into the system by means of the preheating air, since the calorific value of fuel and the minimum air requirement change. To compensate for this, the burner capacity must be increased slightly. Overall, from a combustion point of view, there are few concerns regarding the use of hydrogen in regenerative glass furnaces. Only the increased nitrogen oxide emissions, due to the higher local temperatures, pose a challenge, as the adiabatic combustion temperature of hydrogen is higher than that of methane. Experimental investigations have shown that NOX formation can be influenced, for example, by using a control lance. Experts at the GWI have found out that

the mixing intensity of fuel and air, and thus locally the temperature, peaks and ultimately the NOX formation can certainly be influenced by the burner angle. In addition to the effects of hydrogen on combustion, the influence of hydrogen on gas quality plays a central role. Basically, the results indicate an influence of the changing furnace chamber atmosphere on the glass discoloration. However, no simple correlation with the degree of hydrogen in the fuel gas mixture can be demonstrated. There are only indications of a correlation between glass quality/ glass coloration, glass quantity and the hydrogen admixture. The results show that the influence of hydrogen blends on glass colouration could possibly be avoided by adjusting the glass batch. This means that the hydrogen rate must not change permanently, as a continuous adjustment of the glass batch is not possible and a steady gas composition is also necessary in natural gas firing to achieve high product quality and reach a maximum of energy efficiency. In order to understand the effects of hydrogen on the glass quality more precisely, further in-depth investigations and analyses are necessary. The project results are very positive. “Hydrogen is one of the most promising candidates in the switch-over from conventional to regenerative energy sources,” said Dr Johann Overath, Director General of BV Glas. “BV Glas has been assessing the potential of hydrogen for a long time already in the framework of its decarbonisation strategy.” The experiments and simulations have shown that the use of hydrogen has only moderate impacts on combustion as long as the fuel-air ratio and burner output are maintained at a constant level with a control strategy. Both the furnace temperature and heat transmission remain more or less constant. The use of hydrogen can lead to higher NOx emissions. However, these can be compensated by technical measures at the furnaces. �

*Energy and climate policy advisor, BV Glas, Germany www.bvglas.de Gas- und Wärme-Institut Essen (GWI), www.gwi-essen.de

References 1

Energiebilanz Deutschland 1990 - 2017, Arbeitsgemeinschaft Energiebilanzen (AGEB), Berlin, 2018. 2 Fleischmann, B.: „Flexible use of (renewable/regenerative) electric power when melting container glass “, presented on Glass Trend seminar „How to face the technological challenges of the Paris climate agreement? “ Marktheidenfeld, Würzburg, 2018. 3 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass 4 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass (cf. Chapter 4.2 and Chapter 4.3). 5 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass (cf. chapter 5.2, chapter 5.3 and chapter 7.3). 6 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass (cf. Figure 7.7). 7 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass (cf. chapter 5.2). 8 Bledar Islami, Anne Giese, Marcel Biebl, Gas- und Wärme-Institut Essen e. V., Bernhard Fleischmann Hüttentechnische Vereinigung der deutschen Glasindustrie e. V., Johann Overath, Christiane Nelles Bundesverband Glasindustrie e. V., Abschlussbericht HyGlass (cf. chapter 6).

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Hydrogen is not the answer for the glass industry Stuart Hakes, CEO at FIC UK, suggests that the glass industry needs to look beyond the use of hydrogen in its bid to decarbonise.

on the glass because of heat transfer, but it is not a problem with electric furnaces because the foam holds the heat in. The other reason it is not an option is there are other industries that simply cannot electrify. Take the cement industry for example, you need a flame if you want to make cement, if you can’t use natural gas you will have to use something else and that will be hydrogen. In the transport sector, you cannot run an international cargo ship on electricity so they are going to use hydrogen. It is the same with lorries, I don’t believe batteries are an option. The hydrogen will have to be used elsewhere, there will simply not be Continued>>

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he glass industry has woken up to the fact that it needs to decarbonise. One of the things that struck me during meetings at the recent Glassman Latin America event in Mexico was how many people were asking questions about this subject and what they as manufacturers can do. The fact so many people were asking suggests there has been a drive, from younger people perhaps, to ask what is going on with the climate? Maybe children have been asking their parents what are they doing to reduce their carbon footprint? I think the pandemic has led to people to gaze at their navel and have decided now is the time to act. The biggest problem facing the industry at the moment is gas prices and the glass industry is a major user. It has been good for FIC because it means that people have woken up to the fact that decarbonisation has to happen, people recognise that although electricity is expensive it is the way forward. But I am convinced that hydrogen is not the option that people think, it is a stop gap and no more. Depending on where you make the hydrogen and which colour it is - and there are many colours - with current technology you can only mix hydrogen with natural gas to a maximum 40%, even if it is green hydrogen. Technology of more than 40% in the natural gas pipeline either does not exist or only exists in the laboratory, which is a problem. In the long term, hydrogen is not an option for a number of reasons. The first is, if you’re burning hydrogen, you have an issue with the amount of steam you’re making and there is not a single refractory currently available that can handle that steam. Secondly, it is well known that hydrogen flames increase the amount of foam. Foam is a problem

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enough for all the industries to use it. The glass industry needs to wake up to the fact that hydrogen is not the saviour and it is not the easy option that people think. There are issues with electric melting but we have proved conventional melting is an option with modelling. But the industry is risk averse, everybody wants to be second, and that is the advantage of the Glass Futures research centre in the UK. Glass Futures has an opportunity to show the industry what is possible, unfortunately it is not quite at the scale that they need convincing. The initial idea of Glass Futures was focused on alternative fuels and their original thinking was far reaching on what they had to do. But now I am seeing a conservatism starting to take place. Instead of recognising that we must now decarbonise, it is no good burning woodchips for a minute in a glass furnace and then spending 30 years replacing the tree, it does not compute. The realisation that the argument has shifted to decarbonisation should mean that we must finish at Glass Futures what we have been paid to do, and then move rapidly to the next stage. That means that this initial furnace, which initially had a lifespan of three to four years, now has four to five years of life. We should be saying finish alternative fuels, you can do that in two years, and then we want to do something dramatic. We want to do something to move forward. If we don’t take that opportunity, if we sit around for five years and not make radical changes, then we have missed an opportunity to lead the world as Glass Futures. It is an international consortium based in England and we must let that old guard of English conservatism get away with it, we want more drive. Other projects around the world need to be looked at seriously. One project looks at a 800t day furnace, which might have up to 14MW - a real example of somebody saying we have to do something. I have been vociferous about hybrid furnaces and decarbonisation going forward, that we are seen as one of the leaders of the discussion. Surprisingly here in Mexico, where we are close to oil and cheap gas from the USA, the continued use of fossil fuels is a concern. The conversations at the Glassman event were centred around electric furnaces, super boosting and moving the discussion further forward. Even with the US companies we are talking to, there is a wake up that something has to happen. America has cheap gas, it has gone up quite a lot recently but compared to Europe it is still cheap. There is that recognition that something has to be done and I think that has been driven by the war, partly because of increased legislation in more countries and I think people recognise we have to decarbonise for the sake of younger people. What young people perhaps don’t realise, and what politicians don’t tell them is that, if you are going to decarbonise the planet, the cost will be horrendous. It has to be done, but who will pay for it? Can the glass industry decarbonise? The industry is driven by accountants and senior managers who tend to only be in place for the short term, which is a problem. But I think young people and like-minded people are driving it, they have no choice, they have to go green. There is a groundswell from the public, and there is recognition from senior management that they have to be seen to be doing something. But is it enough? In my opinion I think the opportunity is there, the future is bright, there will be hotspots where it happens more quickly than others. �

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Furnaces

� Design of an advanced 400 tpd hybrid tank based on readily available constructive elements.

A hybrid approach to the future H

ybrid or fully electrical tanks present promising routes for the reduction of CO2 emissions from the melting process. Many countries progressively decarbonise their electricity production. In this article, we will focus on Scope 1 emissions i.e. those from the glass plant and therefore mainly determined by the melting tank design. Solely, CO2 emissions related to natural gas combustion with its 0.2t/MWh are considered. Emissions from raw material carbonates and production of electric power are not taken into account. Carbon capture or H2 combustion is not considered either as it is not readily available for the glass industry.

Electrically boosted (EB) glass tanks include with combined energy input between conventional combustion and electric heating by Joule effect. It is a concept already used in many furnaces: � In small proportions (< approx. 20% EB) to increase throughput or improve glass quality. � In average proportions (from 20% to approx. 60% EB) for specific glasses to overcome problems with high evaporation rates and foaming tendency. The need for drastic reductions in CO2 emissions creates a new application for boosted glass melters. The CO2 emission reduction implies a reduction of fossil

gas combustion in favour of an increase in electricity input approaching full electrical melting. In this article, hybrid melting is understood as a replacement of combustion power to reduce CO2emissions. Fully electric, cold top melters present, in principle, an ideal solution but have two constrains: � The operation must assure that full batch coverage is maintained – which is possible but requires a clever adjustment of pull, cullet, melt temperature – all adapted to the melt colour and heat transfer. Continued>>

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Hybrid and full electric furnaces could substantially reduce CO2 emissions through reduced the combustion power and thermal optimisation. Dr Wolf Kuhn* explores the advantages of this technology.

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Furnaces

� Fig 1. Specific energy consumption of regenerative, hybrid and fully electric furnaces compared to the theoretical melting energy (TMER) of a container glass batch with 50% cullet. Direct emissions from gas combustion led to CO2 emission per molten glass in the diagram on the right.

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� The thermal conditions in the conventional cold top melter design induce certain size restrictions1 that currently limit the capacities to approximately 300 tpd depending on glass type. Hybrid melters overcome these restrictions. The principle of hybrid melting allows good flexibility in terms of pull, cullet content and glass colour. The hybrid principle can be applied both to container glass, with melt extraction by a throat, and to float glass tanks with large fining areas, as well as melt extraction via waists with cooled skimmers. However, the design of hybrid melters is a hot topic of discussion. Right now, no container or flat glass furnace with a very high boosting input has been built on an industrial scale. Here, it is necessary to distinguish the term ‘hybrid’ glass tank from other electrification concepts. The use of high or super-boosting2 is mainly aimed at increasing production capacity – with almost unchanged furnace design and size. The energy input by combustion is barely reduced. Hybrid tank for reducing CO2 emissions aim to reduce combustion. This has consequences on the batch melting process and on the temperatures of melt and superstructure. The design of the upper furnace and the layout of the combustion system must be adapted. The proposals for this adaptation diverge.3

CO2 emissions

Fig 1 shows the specific consumptions of three containers glass furnaces with a capacity of >300 tpd and 50% cullet: 1. Efficient

end

fired

for

0-40%

boosting 2. Fully electric melter. It is worth mentioning that 300tpd is already at the limit of the technology established for fully electric tanks. 3. Hybrid melter of advanced design allowing for up to 80% electric power. The diagram is completed by the theoretical melting energy requirement (TMER) for a soda-lime silica batch with conventional carbonates. The release temperature of the CO2 resulting from the decomposition of carbonates influences slightly this TMER. Conventional tanks: Highly efficient end fired tank can reach about 3600-3700 kJ/kg. With fossil gas, specific CO2 emissions of 200 kg/t of glass result. Super boosting: End fired tank with a pull increase by boosting. The boosting reduces of course the fraction of combustion energy in the final melt. Super-boosting can therefore reduce CO2 combustion emissions to about 100 kg/t of molten glass. Hybrid melting A hybrid tank with a high boosting input approaches the specific consumption of a fully electrical tank. The drastic reduction of the combustion power allows CO2 emissions as low as 30 kg/t. Full electrical melting Cold top full electrical melting leads to low temperatures of the batch emissions and thus the lowest TMER. Only wall losses are added to the TMER leading to the lowest energy consumptions of

all melting tanks. For decarbonised electricity, the CO2 emissions by heating drop to zero. Melting rates and tank design The fundamental difference between conventional and hybrid melters and fully electrical melters resides in the drastic shift of the heat flux for batch melting from the upper to the lower batch face. This shift implies a change of the heat transfer mechanism with quite different temperatures: � A combustion space can reach over 1600°C in function of crown material. Even higher temperatures are achieved in flames. � The melt cannot exceed about 1450°C in the bulk volume under the batch to limit the wall temperatures and thus the corrosion. These temperatures lead to a difference in the radiation intensities that are emitted towards the upper or lower batch blanket faces. (Fig 2) The heat flux is here calculated with an emissivity of 0.9 – which is of course a simplification for the combustion space as well as for the melt space. Nevertheless, one can recognise the intense radiation of the combustion space with 1600°C reaching values of over 600kW/m² for incident radiation. The radiation density emitted by flames is even higher. On the other hand, the melt under the batch can barely exceed mean temperatures of 1450°C to limit the wall corrosion. This leads to a limitation of the emitted radiation to about 400 kW/m². Continued>>

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� Fig 3. Fives Stein shelf type cold top tank � Fig 2. Radiation emitted in the upper and lower batch blanket faces.

The flue gas is a transparent fluid that allows radiation from distant sources (flames, crown) to reach the batch surface without significant absorption (optically thin media). Glass melts are less transparent in function of their colour. The radiation emitted by hot bulk glass is reabsorbed by cooler melt near the melting interface of the batch. This mechanism slows the radiative transfer to the batch bottom significantly down. Of course, convective heat transfer can make some contribution to the heat flux from the melt. But this does not allow to compensate for the reduced heat flux densities by radiation from the glass melts. Specific melting rates of hybrid melters with low combustion input are lower compared to super-boosted melting tanks. Hybrid melters approach melting rates of cold top glass tanks with increased surface requirements for batch melting.

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Exhaust gas The shift of the heat flux from the upper to the lower batch side and the increase of the batch coverage in hybrid tanks offers a unique feature for the thermal optimisation of the remaining combustion input: a large ‘cold’ batch blanket surface is now available opening the way for a highly efficient thermal exchange between the blanket and the flow of exhaust gas from the combustion. However, it has been shown by thorough examination and CFD analysis that standard crown designs are inappropriate for an efficient thermal exchange between the batch layer and the exhaust gas. Parasitic radiation and recirculating, turbulent flow arise in high, conventional crown designs.

This can be overcome by the Fives Stein (FS) proprietary design with a lowered crown section (HRA).4 This design combined with hybrid melting allows an efficient thermal exchange and subsequent reduction of the exhaust gas temperature to record low values of about 400-600°C. The specific consumption of an optimised hybrid melter is low and comparable to that of fully electric melters. The low exit temperature of the exhaust gas allows us to avoid the investment in energy recovery by regenerators or recuperators. In the case of prolonged operation with low boosting/ high combustion input, two options exist to maintain the low consumption: � Oxy-combustion with its reduced flue flow leading to low flue heat losses. � Flue heat recovery and air preheating with a recuperator. Both options make it possible to limit the consumption of a hybrid melter to about 3000 kJ/kg under 50% cullet and 20% boosting conditions. Consumption then becomes comparable to conventional oxy-combustion furnaces with external preheating of the raw material and cullet.5

Hybrid design The principles of heat transfer to the batch blanket under hybrid melting lead to consequences for the tank design as outlined beforehand. FS applies these consequences in its proprietary design. The design presents a combination of an electrical melting section with a conventional combustion melter. To assure high reliability and availability, only well proven constructive elements are used that are readily

for 100-150 tpd.

available. Figs 3 and 4 show the FS hybrid melter compared to a cold top electrical melter with a flat, suspended roof.

Conclusions Significant reductions of CO2 emissions can readily be achieved by hybrid melters. However, the design of hybrid melters should be guided by some fundamental considerations leading to a sound design concept. FS has developed such a concept. Detailed design studies confirm the scalability of this tank design to very high production capacities. Detailed modelling studies confirm high flexibility in production (glass colour, cullet, pull changes, boosting input) under low specific consumptions. Low specific load of the electrical boosting and limited melt temperatures assure long campaign times for this hybrid melter design. On the other hand, for smaller melting capacities, full electric cold top melters often present a straight-forward solution for zero CO2 tank emissions, if operation control and production schedules adapted to full electrical melting are implemented. �

References: 1. W. Kuhn, A. Reynolds IGC Boston 2019. 2. Ross&Stewart, Glass Ind. 1978. 3. W. Kuhn et al. GPC 80 Ceram. Trans 2021; Muijsenberg et al. GPC 80, Ceram. Trans. 2021, R. Nebel GPC 81 GMIC symp. 2020, W. Kuhn GPC 81 GMIC symp. 2020. 4. W. Kuhn GPC 77, Ceram. Trans. 2018. 5. S. Chakravarti et al. GPC 81 Ceram. Trans. 2021.

* Chief Expert Glass Process, Maisons-Alfort, France www.fivesgroup.com

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Society of Glass Technology Join the worldwide network of interests centred on making glass great The Society of Glass Technology exists to serve people who are interested in the production, properties or uses of glasses, whether from a commercial, aesthetic, academic or technical viewpoint. It is a non-profit making organisation serving a worldwide membership publishing journals and text books, organising meetings and conferences on glass related topics. You can now join the SGT by going to www.sgt.org and selecting your journal choice and appropriate package. You will also be able to see the comprehensive history and activities of the society.

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Decarbonisation

Sorg’s mission to net zero Sorg’s environmental campaign ‘Mission’ will focus on providing sustainable melting technology to glassmakers and brand owners. The campaign aims to achieve net zero emissions for the industry by 2050.

Innovation In the last few decades, many companies

have introduced innovations in glass production processes to reduce energy consumption and emissions, as well as boost efficiency. With support from the private sector and International Finance Corporation (IFC) for example, the industry can continue to improve its energy efficiency while meeting increased demand for sustainable glass products. Sorg has long been a supporter of electric melting technology. Today, the business is already paving the way for sustainable melting, most recently launching a hybrid furnace – the Clean Melter – which can reduce energy consumption and carbon emissions by as much as 80%. The melter has a 400 tpd melting capacity and no restrictions regarding glass and raw materials. Another key industry focus is the digitalisation of the engineering, design and melting process. From raw materials to glass delivery, Sorg is developing innovations that will increase the predictability of melting glass across many applications, to provide greater security for the future.

Sustainable melting Sorg first introduced electric melting on an industrial scale over 50 years ago with the cold-top VSM furnace and has been innovating technology at every stage in the process ever since. These include the Batch Preheater, which together

with the EME-NEND Batch Charger and Increased Radiation Doghouse IRD, forms the Batch3 concept, reducing energy consumption and CO2 without affecting the furnace operation. Electric boosting has also helped to drive efficiencies for hundreds of furnaces worldwide. A future solution in development is a fully electric, hot-top horizontal melter for large volumes. Sorg has also used mathematic modelling for the past 20 years as an advanced tool to understand the glass melting process, analyse the effects of different components in glass production, and make precise predictions of the furnace’s design impacts on product quality.

Now or never The glass industry’s need of high energy is a challenge we simply cannot ignore. In the last few decades, many companies have introduced innovations in glass production processes to reduce energy consumption and emissions, as well as boost efficiency. The International Year of Glass and 150-year anniversary of Sorg both provide a perfect springboard for the German pioneer of glass melting and conditioning to launch its sustainable vision in in 2022. �

Campaign link: https://sustainablemelting.sorg.de

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ts versatility and affordability make glass an essential material for development in everything from containers and windows to data transfer and automotive. However, growing global concerns over climate change are putting unprecedented pressure on countries, companies, and consumers to adopt a new way of thinking. All over the world, supply chains are crying out for an answer to tackle carbon emissions. Brand owners are looking at alternative materials, while glassmakers are exploring alternative technologies and methods. Mission by Sorg is a commitment to develop the next generation of sustainable melting technologies that will slash emissions and help glassmakers to produce net zero glass at volume within the near future. To support this journey, Sorg will be investing heavily in its dedicated research and development facility over the coming decades, with the sole objective of working alongside glass plants to achieve large scale sustainable melting. More than just another sustainability campaign, Mission is a solid promise to empower the entire glass supply chain to ultimately stop and reverse climate change.

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Company profile: futronic

rom humble beginnings, futronic has grown and developed, and this year celebrates its 50th anniversary. Today a team of approximately 90 staff currently support 1000 installations globally in the glass industry, although futronic had nothing to do with glass production in the beginning; its first orders came from the food processing sector. It wasn’t until 1978 that the company got its first glass contract, six years after it was founded. Since then, it has become a specialist provider of complex automation solutions for plant and equipment manufacturers, with its strongest markets in Europe, Asia and Latin America. Its achievements in the past half a century include the development of its first ever control system for glass machines in 1979, and the MP-ST system, which paved the way for the company to grow and develop as a supplier of automated solutions. On futronic’s success, Mr Preuss referred to the company’s former Managing Director of Development and Technology, Wolfgang Lachmann, who played a key role in shaping futronic’s development for more than 30 years. “Lachmann once said that when you develop a new drive and control concept, it’s not just a question of staying one step ahead technologywise. You also must live up to your clients’ high expectations with regard to reliability, durability and efficiency. “Many of our systems have been running for 20 years or more. He was convinced that this mix of premium quality products, longstanding relationships, proximity to customers and firstclass service is the secret of futronic’s success – now and in the future.”

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Beginnings futronic was established in Tettnang, Germany in 1972 by General Manager Gerhard Funk, who named the company, and Production Manager Günther Scharpf. The two of them were soon joined by Horst Dieter Reinsch, who became Technical Manager. The trio at the helm were ambitious and it wasn’t long before projects also followed from customers in other industries, such as machine and plant manufacturing or medical, lab and process technology. In spring 1978 that futronic secured its first contract for a glass project. Oberland Glas in Bad Wurzach, now Verallia, requested the company to design a control system for glass machines.

futronic celebrates 50th anniversary

� futronic MD: Michael Preuss

This system, known as MP-ST, marked the entry of computer technology into glass production, displacing transistor logic and relays which were no longer up to the challenge. It was a groundbreaking invention that put futronic in front of the competition.

Ahead of the game The MP-ST paved the way for the company’s success as a top supplier of automation solutions for the container glass industry. The successor model was unveiled by futronic in 1987. The CIMOG (Computer Integrated Manufacturing of Glass) was the first control system anywhere in the world to facilitate freely programmable special cycles for the production process. The EPRO (Economic Production), a scaled-down version of the CIMOG, arrived on the scene a few years later. Finally, in 2004, futronic launched the FMT24S in the market. The FMT (Flexible Modular Timing System) is a distributed control system for IS machines with up to 24 sections that can be tailored to each customer’s individual specification. The company’s aim was to develop a control that was suited for any application. In 2004, Michael Preuss, who had been with the company since 1987, and Mr Lachmann, who was Technical Manager at the time, were appointed joint Managing Directors. futronic has been a subsidiary of Jetter of Ludwigsburg, Germany since 2006. In 2008 the company moved to a building complex in Tettnangs’s Bürgermoos Industrial Park, Germany where the firm still has its home

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Company profile: futronic

futronic celebrates its half century of supplying automation solutions to industry this year. Michael Preuss* outlines the secret of the technology company’s success.

Achievements Other than the MP-ST system, and the launch of the FMT24S in 2004, futronic has released many exciting and unusual projects over the years as its core business. Mr Preuss highlighted the significance of the company celebrating its 50th anniversary this year. “Steering the company in a dynamic environment through all the crises of the last five decades, through all the ups and downs – of which there have been more than a few – moving it forward, keeping it on course for growth, responding to new trends and realigning the business again and again has probably been the greatest achievement of all. “It hasn’t just been the achievement of just one person, because we’re not a family firm and we never have been. Credit is due to everyone here at futronic – to every single employee for their collective contribution to our success. We have every reason to be proud of that!” A large celebration was originally planned but the pandemic and the conflict in Ukraine meant the celebratory open day had to be postponed. A small celebration for the company’s employees and families may be held in the summer instead.

� futronic’s office building in Tettnang, Germany.

Core function futronic’s core competencies are in the fields of control technology, drive components and programmable controllers (PLC). As a system supplier, it offers customers automation solutions – from design, development, programming, production, testing and final acceptance right up to commissioning on site. When it comes to cost effectiveness, product quality, productivity and energy efficiency, customer expectations are rising continuously. That’s why more automation is required in the glassmaking industry. During the past five decades, futronic has gained a reputation for reliable controls and drives for container glass machinery and equipment.

1. Controls and drives Over the years, futronic has developed a series of controls and drives to meet the most varied requirements at the hot and cold ends. It’s pursued an open-source strategy from the outset. Its systems can be flexibly tailored to machines from different manufacturers and with different specifications. At the heart of its technology is the FMT24S (Flexible Modular Timing System), a distributed control system that can control all sequences and processes on an IS machine with up to 24 sections. The system is fully scalable. The spectrum ranges from low-budget for modernising foursection machines to high-end solutions with Continued>>

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today. It wasn’t long before the company needed more space and in 2013, invested €1 million in an extension. Five years later, it also acquired a flat-roofed building on an adjacent site, creating more shop floor capacity to house a harness manufacturing machine, equipment for making small devices and parts for development activities.

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Company profile: futronic

and engineers can meanwhile look back on several decades of experience with retrofit and refurbishment projects. Its specialists can draw on a huge knowledge base as well as rich experience with its various systems – the outcome of partnerships with leading producers, often over a period of many years. Minor, but decisive, refurbishments are often sufficient to boost the performance of an existing machine or system. Lower energy consumption, leading to lower costs and better productivity are other advantages.

3. Customised automation solutions

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24 sections. Maximum flexibility – essential for efficient production – and maximum investment security are guaranteed. The FMT24S can easily be implemented into a manufacturer’s existing IT and data structures. futronic’s portfolio also includes drive systems, components and controls for seamless integration into the FMT environment, or on request as a standalone solution. For instance, servo drives, reject systems or control systems for feeders and lehrs. The FMT24S treads new paths when it comes to controlling and visualising different machine cycles and mechanisms. futronic has simultaneously been active in the tableware field for several years. Industrial tableware production involves complex processes which must be reproduced reliably. Consistently high product quality can only be assured with the help of sophisticated and individually adapted control technology. That’s why the company developed a dual control solution combining the control and the synchronous drive based on a common hardware platform: � The Futronic Blow Machine Control System (FBC) for rotary blowing machines. � The Futronic Press Machine Control System (FPC) for rotary press machines.

futronic is in close contact with its customers and development partners. The company listens to what they say, sounds out their needs and takes up their suggestions. From there, it develops customised solutions and products tailored to their individual requirements. That’s how the company’s Swab Cycle Monitoring System (SCMS) came into being, for instance. Or its new Vacuum Process Control System (VPC), which makes sequences in the vacuum process visible and helps to avoid manufacturing and system problems before they have a chance to occur. Basically, futronic advises its customers regarding the feasibility of a particular system or a complete or partial solution, then develops a detailed automation concept optimally adapted to their ideas, visions and objectives. The company’s specialists analyse the project requirements, plan the electrics, design the necessary hardware and develop the control and visualisation software. futronic assists its customers with the selection and procurement of suitable components such as sensors, actuators and motors for controls and drives, which are precisely aligned to their wishes and specifications. It also formulates a suitable safety concept and puts together the necessary safety components.

This automation concept enables the company to cover the complete requirements profile from the feeder through the glass moulding equipment to the conveyor for the finished product.

2. Retrofits Nearly a thousand of futronic’s systems are currently in action around the globe. Of course, they have to be brought into line with the latest technology from time to time if existing production facilities are also to be used efficiently in the future. The company’s developers

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automation in a new dimension 50 years of futronic – At home in the heart of the glassmaking industry 1972 2022 the spirit of moving forward

www.futronic.de

Company profile: futronic

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Evolution Every company needs to evolve, of course, and futronic has done this successfully during the last few years. On the one hand, digital technology is continuing to make inroads into industrial manufacturing. This applies across all sectors and is an important issue for the glass industry. The ability to connect machines from different manufacturers together in a network is taken as a given. Rather than simply improving isolated machines or workflows, as has tended to be the case in the past, Industry 4.0 focuses on the value creation process as a whole and takes a holistic approach to optimising it. The advantages are undeniable: higher energy efficiency, productivity and operating reliability, not to mention the positive impact on company profitability. As an automation specialist futronic, too, has naturally devoted considerable attention to Industry 4.0 for some time. It has accumulated broad know-how and experience in this area over the last few years. Its aim is to secure a pole position when it comes to digital transformation and develop sustainable automation solutions. On the other hand, the container glass industry is not developing as fast as other sectors. Product lifecycles are long. Machines and equipment with a service life of 20 to 25 years or more are common. To make them fit for the future, they don’t necessarily have to be replaced but can instead be successively modernised with the help of retrofits. That way, they can continue providing reliable service for another 20 years. Despite all the innovations, the company wants to – and must – manage with this old technology as well. futronic offers 24/7 service with telephone and email support for this purpose if required; it also offers on-site repair and maintenance services.

Recent trends futronic has pursued a successful open-source strategy from the outset. On that basis, it has developed a series of controls and drives to meet the most varied requirements at the hot and cold ends. At the same time, those systems can be flexibly tailored to machines from different manufacturers and with different specifications. Flexibility has become an important factor for machine and plant manufacturers and their suppliers and will apply

� futronic founders, from left to right: Gerhard Funk, Güenther Scharpf and Horst Dieter Reinsch.

even more in future. Hardly anyone had digital transformation on their radar 10 to 15 years ago. Today, it’s clear glassmaking will become more energy efficient, productive and profitable because of digitalisation, Industry 4.0 and the technologies they give rise to. It will also be safer; safety is key here too. After all, these are the parameters all of us are driven by – machine and plant manufacturers, suppliers and of course the glass producers themselves. It is getting increasingly difficult for glassworks to find qualified personnel. That’s why, in this traditionally conservative environment, automation and closed loops are rapidly gaining ground. In terms of data from process or condition monitoring systems, so that manufacturing processes in all areas of container glass production can be optimised using machine learning methods and, on top of that, self-adaptively controlled in real time. Overall, it’s difficult to predict what the future holds, especially at a time like this. It’s crucial that we stay on the ball and don’t wait too long if we’re going to play an active part in shaping the future of automation, particularly in the container glass industry.

Recruitment The company is constantly on the lookout for good people – both talented young adults and experienced professionals. Skilled staff are required mainly on the technical side, for instance in hardware planning and software development, as well as quality assurance and control cabinet construction. We have a balanced mix of high-potentials who are either career entrants or still relatively inexperienced and ‘old hands’ who know the ropes. They are happy to pass on their knowledge to the next generation – because we also employ trainees. That way, we can be sure that valuable expertise remains on board. It’s a great way to ensure continuity. And our future too. It’s particularly noticeable in the Lake Constance area with its large industrial corporations and countless mid-market suppliers. But futronic’s Continued>>

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Data – the deciding factor

Company profile: futronic

Human Resources team do a fantastic job and invest a lot of effort in making the company increasingly attractive as an employer. It’s an investment that pays off. It may take a little longer than it did a few years ago, but in the end we do find the right people.

industry.” futronic devotes “considerable attention” to digitalisation issues; the technologies and the data that are the essence of it all. All the company’s R&D staff have this at the back of their minds whenever they develop a new control system. futronic also cooperates with various partners, exchanging ideas and experiences and reflecting together on which technologies, solutions and data can add genuine value for customers.

Automation When it comes to cost effectiveness, product quality, productivity and energy efficiency, customer expectations are rising. Whilst these aspects have always been relevant, they’re set to play a far bigger role in future. Sustainability, for example, is on everyone’s lips. It’s been futronic’s belief for many years that automation is just as crucial in the glass industry. It’s the company’s business to constantly increase the level of automation in this sector – to develop new technologies and solutions that help manufacturers move forward. To anticipate the evolving trends in automation, the key is to listen: “Anticipation means listening carefully: knowing what’s going on where, identifying needs and drawing the right conclusions. That’s always been important to us, and it will be in the future too. In short, we need to stay on the ball and not wait too long if we’re going to play an active part in shaping the future of automation, particularly in the container glass

Future It’s common knowledge that standing still means going backwards. futronic is confident it can continue its growth journey despite the difficult situation right now. The company also wants to evolve technologically, strategically and structurally. On the one hand, expanding and consolidating its position as one of the world’s leading providers of complex automation solutions for machines and equipment in the container glass industry. And on the other applying its knowledge and experience in industrial automation to other sectors too. futronic has set its sights high and we’re looking forward to the next ten years. �

*Managing Director, futronic, Tettnang, Germany https://www.futronic.de/en/home.html

Air Products is blazing a new trail for oxy-fuel burner technology . . . Boost your performance and productivity for better glass with the Cleanfire® HRx™ burner! Upgrading your oxy-fuel burners, adding burners to boost production, or converting your air-fuel furnace to oxy-fuel? The patent pending Cleanfire HRx burner offers you expanded functionality and flexibility with unmatched performance. It can deliver:

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• Increased flame radiation for high fuel efficiency • Ultra-low NOx emissions • Foam reduction capability for higher-quality glass • Enhanced productivity • Optional remote performance monitoring feature • Integrated high efficiency oxygen supply system This burner is the latest innovation in the long line of industry-leading Cleanfire® burners for the glass industry, which are now able to utilize hydrogen as a fuel, for a lower carbon footprint. To learn more or to schedule a demonstration in our state-of-the-art lab, call 800-654-4567 (code 10868) or visit airproducts.com/HRx.

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Company profile Futronic version 16.indd 5

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Henry Ford

ware handling

“If you always do what you’ve always done, you’ll always get what you’ve always got.”

Speciality glass

� Laserglas - Material and components.

How speciality glass enables health, energy, and sustainability By Dr. Matthias Müller, Head of Global Research and Development at Schott.

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hen we think about innovations in space exploration, electric vehicles, and vaccines for emerging infectious diseases, they all have a common thread: speciality glass. This remarkable material has aided pioneers since Otto Schott invented it in the 1880s. Without Schott optical glass in both the Westinghouse lunar TV camera and Hasselblad camera, Buzz Aldrin would have been the only person to witness Neil Armstrong set foot on the moon. One of mankind’s most extraordinary moments was made available to hundreds of millions of people because Schott’s speciality glass helped capture Armstrong’s first step, so the images could live on in history. Speciality glass has come a long way since it captivated an audience of 650 million on July 20, 1969, when Apollo 11 made its landing. It’s been bent, stretched, moulded, heated, and mixed with other elements and materials to create groundbreaking new possibilities. While it isn’t always the star of the show, speciality glass has enabled breakthroughs in health, energy, and sustainability through its versatility. Let’s take a deeper look at these applications.

Saving lives From diagnosis to treatment, speciality

glass plays a growing role in patients’ healthcare journey. The sooner you can diagnose patients, the sooner they can be treated, which is why point-of-care diagnostics have become so popular. According to MarketsandMarkets Research, the rapid diagnostics sector is projected to reach $72 billion by 2027 at a compound annual growth rate (CAGR) of 10.8%. This form of testing uses lab-on-a-chip devices to enable quick medical decisions from any location. These integrated microfluidic systems use technology that analyses a tiny amount of liquid without having to send the chips to a lab, vastly shortening the time it takes to reach a diagnosis. Speciality glass substrates are ideal for point-of-care diagnostics because glass is inert and a laser can create small channels on the substrate to guide the liquid where it needs to go. To meet the growing demand for diagnostics and bioscience capabilities, Schott plans to open a new, larger manufacturing facility in Arizona, USA this autumn. Beyond diagnostics, glass plays a role in the health industry. Borosilicate glass is considered a suitable material for storing medications such as vaccines. Due to its chemical resistance, it limits the interaction between the drug and the

container. This glass has been the gold standard for protecting medications since Otto Schott invented it. Over a century later, the company’s borosilicate glass tubing is being used to produce over 40 billion pharmaceutical containers per year.

New energy Let’s go back to the moon landing for another example of the large impact glass has had in solving societal challenges. Apollo 11 had three fuel cells that provided power and water to the astronauts. Fuel cells generate electricity through electrochemical reactions and the Apollo 11 cell stacks used hermetic glass sealing because it was the only material that could withstand extreme temperatures and conditions. We can stay in outer space for the next chapter of how glass empowers energy sources. Nuclear fusion is the source of solar energy, the fusing of atoms within the sun to create a single, larger atom and release an incredible amount of energy. Fusing atoms is happening here on Earth thanks to laser technology, which incorporates speciality glass. The National Ignition Facility (NIF) is the world’s highest-energy laser system, which uses a series of Schott glass Continued>>

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DÜSSELDORF | GERMANY

* latest swabbing-robot installed in July 2017 in Germany

Finally, you can get back into the spirit of this special world-leading trade fair. Meet everyone in the world of glass face to face. Discuss the latest developments in high-tech material glass with the best in the industry. From energy generation, reducing CO2, effective production and processing technologies to innovative glass products and applications. Make the most of the unique accompanying programme with many highlights and talks by leading experts from around the globe. Look into the future of glass today with pioneering exhibits. glasstec – let’s go!

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glasstec-online.com Messe Düsseldorf GmbH P.O. Box 10 10 06 – 40001 Düsseldorf – Germany Tel. +49 211 4560 01 – Fax +49 211 4560 668

www.messe-duesseldorf.de

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optics and large area laser glass slabs as essential enabling power amplifiers for its experiments. Last year it achieved a yield of more than 1.3 megajoules (MJ), putting it on the threshold of new fusion energy innovation. This has been of particular interest in the US where the White House announced a vision for clean, commercial fusion energy that moves the country closer to net-zero emissions by 2050. Our Duryea, Pennsylvania, facility is leading the development of laser glass to enable fusion energy for systems like the Laboratory for Laser Energetics at the University of Rochester.

Sustainable solutions In 2021, sales of electric vehicles hit 6.6 million, more than double the number in 2020. As more people turn to a greener alternative behind the wheel, glass plays an important role in solid-state batteries that power electric vehicles. Schott’s high-tech, glass-ceramic powder plays a key role in the next generation of batteries because it combines the functionality of separators and electrolytes within the battery. Compared to conventional lithiumion batteries, solid-state batteries enable higher energy density. Solid-state batteries expand an electric vehicle’s range by 30%, require only half

� Dr Matthias Mueller.

the charging time, age slower with higher operational reliability, can withstand higher temperatures, and are safer than the liquid electrolytes of lithium-ion batteries, which are flammable. Another application of glass that promotes sustainability is a protective covering for photovoltaic solar panels on satellites. The panels convert sunlight into electricity to power the satellites, where Schott’s 0787, an ultra-thin, ceriumdoped solar glass that acts as a protective cover, shields against the space radiation that poses a danger to the spacecraft. Glass’ durability makes it superior to other materials for these solar panels and protects against the solarisation that

could make the glass cloudy and therefore less optimal to absorb sunlight. Glass has unlocked many possibilities that advance humanity. Whether it’s allowing the world to view the moon landing or creating a more sustainable form of energy amid a climate crisis, glass has proven its versatility can improve lives. Glass will only continue to energise our future by enabling further breakthroughs and aiding the development of more sustainable solutions. �

Schott, Mainz, Germany www.schott.com

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25/05/2022 12:42:30 03.02.21 15:04

Digital glassmaking

� Waltec Maschinen is based in Bavaria, Germany.

Innovating in unison German machine builder Waltec’s partnership with Siemens has led to sustainable and increasingly digitalised concepts, such as fully electric e-servo presses. Dr Christian Reuss* discusses how these services have benefitted Polish manufacturer Trend Glass.

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he melting process is responsible for up to 85% of the energy consumption in the manufacturing process, depending on the type of glass and the production method. Waltec has been investigating potential savings in the remaining 15%. Based in Bavaria, Germany, Waltec specialises in sustainable process optimisations at the hot end with a focus on fully automated carousel-type machines for pressing tableware. Its innovations have been installed in more than 250 glass manufacturing plants around the world. Each carousel machine contains up to four press cylinders, each of which is supplied by its own plunger with a customised volume of gas. To understand the power of innovation in the field of press drives, it’s important to look at the past. Until ten years ago, Waltec was using conventional valve hydraulics. When servo pumps found their way into hydraulic glass presses at Waltec in 2012, there were several immediate benefits for customers: compared to the traditional setup, the servo hydraulic glass presses were much more compact and flexible and were superior in terms of output quantities. But most of all, they were more energy-efficient by up to a remarkable 50%. These savings were possible because the motor and servo pump operated

only while the ram was actuated, rather than running continuously like they did previously. There were also no valves in the entire drive train, and the large oil tank could be replaced with a compact pressure accumulator.

� Fig 1.The e-servo presses consume up to 85% less energy than the conventional method because they operate only when pressing force is needed.

Fully electric press drives The next meaningful leap occurred in 2020 when Waltec completely eliminated hydraulics and converted to electric cylinders. Herman Green, Global Sales Director at Waltec, said: “With our e-servo components, we’re able to offer clear proof of our company’s serious commitment to sustainable solutions at the hot end.” In addition to the glass presses, the conversion to entirely electrically driven machines has created even more tangible improvements for the glass manufacturers who rely on Waltec. Thanks to fully electric press cylinders, energy costs are reduced up to an additional 35% compared to servo hydraulics and up to 85% compared to conventional hydraulics. “This is an extremely important argument in this day and age when sustainable action and economic efficiency have to go hand-inhand,” said Mr Green. The absence of hydraulics means that oil is no longer needed – which in turn substantially improves occupational safety, because oil is notoriously flammable. Reduced emissions also benefit the health of the employees. It was also discovered that the e-servo presses required much less maintenance because they’re designed with fewer parts, and the e-presses consumed up to

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introduction of the TIA Portal, which will provide Waltec with full access to all of the digitalised automation, from digital planning and integrated engineering to transparent operation. 85% less energy than the conventional method because they also operate only when pressing force is needed (Fig 1). As for oil volume, Waltec was able to save up to 970 litres, again compared with traditional components.

Siemens For decades, all developments in the glass presses at Waltec have literally been ‘powered by Siemens.’ In other words, Siemens has always replaced all the carousel-type press lines’ automation and drive technology with new technologies and concepts (Fig 2). For example, in the case of the servo-hydraulic machines, the Sinamics S120 modular inverter system and Simotics servomotor were retrofitted to drive the pumps. Until that time, pressure and volume flow in the hydraulic system were controlled by valves. Process control for the presses continued to be performed by a Simatic S7-300 in conjunction with a Simatic HMI device. “We’re very happy to be using Siemens technology, because we can interact with our contacts on an equal footing, and they provide us with valuable insights into what technological direction we can go,” said Mr Green. “We see ourselves as a process consultant to our customers, which is why we want to be a frontrunner in terms of our technology.” When the switch was recently made to fully electric e-servo presses, it quickly became apparent that the typical Siemens drive technology environment would remain the same. “Programming is now even easier, because hydraulics are no longer involved,” explained Mr Green. Waltec is seeking to migrate to Simatic S7-1500 controllers. This will involve the

Data over experience Industry experts understand that sustainable technologies like e-servo are always coupled with data acquisition and evaluation so that measurable results can be obtained. Waltec customer Trend Glass, a Polish tableware company, had this experience. Michal Kaleta, Director of Operations at Trend Glass, said: “We’ve been working with Waltec for about 20 years, and in 2020/2021 we wholeheartedly decided to convert our glass press machines to fully electric operation.”

� Fig 2. Siemens has always replaced all the carousel-type press lines’ automation and drive technology with new technologies and concepts.

The family-owned company is represented in approx. 40 markets around the world and has dedicated itself to comprehensive environmental and climate measures, all of which are aimed at minimising power consumption, reducing CO2 emissions, and using renewable energy sources. The company initially tested electric

operation on one of its 15 lines, and the results were astounding. “Independent experts who took measurements after three months of test operation were actually able to conclude that e-servo was responsible for an 84% reduction in energy consumption compared with the conventional hydraulics previously used,” said Mr Kaleta. Considering this information, Trend Glass will be gradually retrofitting more glass presses. Mr Kaleta explained: “As a result, we chose the fully electric version for two of our new acquisitions, because Trend Glass has already been following a sustainability strategy for many years. The melting process also accounts for the highest energy requirements at our company, but the press area is the immediate second.” Trend Glass has relied on proven and globally available Siemens technology for many years, and its employees have been trained in a familiar technological environment. Since Trend Glass converted to the fully electric version, the process has also been more stable and employees have been working in a healthier environment, thanks to the absence of oil. The machines also have a lot fewer components, which means that Trend Glass deploys service much less frequently – which in turn simplifies spare part management. “And if service is necessary, most of it is now performed remotely or by employees on-site who are using visual aid systems,” said Green, referring to Waltec’s modular data management system WTRACK. �

*Business Development Manager, Siemens Digital Industries, Nuremberg, Germany, https://www.siemens.com/ global/en.html Waltec Maschinen, Kronacher, Germany, https://www.waltec.de/ Trend Glass, Radom, Poland, https:// www.trendglass.pl/en

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Digital glassmaking

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Glass experts Furnace support Process optimization Training and R&D Celsian’s aim is to minimize the cost of making glass for end users and the environment. We have an agile team of glass experts using proven methods like furnace modelling, laboratory measurements and practical furnace health checks to optimize glass melting processes. We also train operators and glass technologists through our standard course, dedicated programs and various e-learning modules. We strive to be the best partner for optimization of glass production worldwide.

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Over 1000 production lines are equipped with Graphoidal Shear Spray Systems. Contact us today to find out how our latest technology can help you. Graphoidal Developments Ltd, Broombank Road, Chesterfield S41 9QJ, England Tel: +44 (0) 1246 266000 Email: sales@graphoidal.com Fax: +44 (0) 1246 269269 Website: www.graphoidal.com

Events preview: ICG 2022

Industry and academia to gather at ICG 2022 in Berlin M

ore than 700 delegates have already signed up to attend the ICG 2022 congress on glass. The annual event, held for the first time in person since the pandemic, has been organised in Berlin by the German Society of Glass Technology’s (DGG’s). The Call for Papers with more than 600 abstract submissions from over 30 countries was successful and is promising a global get-together packed with experts from around the world. “The feedback has been very positive, everyone is looking forward to the Congress, after the pandemic abstinence. That is why the ICG 2022 will take place only in physical presence, no hybrid option. Our focus is to provide a high-quality Congress, offering many networking possibilities,” said Dr. Thomas Jüngling, Managing Director of the ICG 2022 hosting organisation Deutsche Glastechnische Gesellschaft. (German Society of Glass Technology; DGG). The ICG 2022 takes place in conjunction with the 95th annual meeting of the German Society of Glass Technology and includes the 13th International Congress on Advances in Fusion and Processing of Glass (AFPG2022). The congress is the meeting place for scientists, technologists, engineers, artist, as well as the industry and suppliers. As the DGG also wants to offer a platform for the next generation of glass scientists, students can purchase tickets at a subsidised price.

This year’s congress chair, Professor Dr Joachim Deubener, Clausthal University of Technology and programme chair, Professor Dr Lothar Wondraczek, University of Jena, have compiled over 470 lectures and 120 poster contributions for the ICG 2022. The lectures will be delivered throughout the congress, in eight symposia: � Symposium I: Chemistry and the Structure of Glasses � Symposium II: Glass Physics, Properties and Characterisation � Symposium III: Computational Glass Science � Symposium IV: Sustainable Glass Production � Symposium V: Glass Forming, PostProcessing and Quality Control � Symposium VI: Recycling and Raw Materials � Symposium VII: Emerging Glass Applications and Application-related Challenges � Symposium VIII: Culture, Heritage and Education The program and schedule are available on the congress website: https://www.hvg-dgg-events.com/ icg2022-program Next to lectures and a poster hall, an exhibition of suppliers from the glass industry will be staged. Moreover, a variety of social events have been arranged, including an opening ceremony, welcome

reception, excursions, and dinner banquet. At the opening ceremony the Otto Schott Research Awards will be presented as well as ICG and DGG Awards. At the welcome reception, the family-owned company Sorg will celebrate its 150th anniversary, inviting attendees to dinner and offering musical accompaniment. At the dinner banquet, the DGG will celebrate its 100 years anniversary and has booked a big band for this special occasion, as well as a DJ to end the evening with dance music. Berlin, the capital of Germany and congress venue, is probably the most interesting and diverse city within Germany. It has an eventful history, with many landmarks serving as reminders and outdoor museum spaces. The city is full of historic buildings, modern architecture, culinary delights and has a unique freespirited vibe to it, where everyone can be and come as they are. The DGG and the International Commission on Glass (ICG) look forward to welcoming the global glass community in Berlin, 3-8 July 2022. The conference language is English. �

Further Information: Deutsche Glastechnische Gesellschaft, Offenbach, Germany, tel: +49 69 97 58 61 0 email: gonzalez@hvg-dgg.de web: https://www.hvg-dgg-events.com/

www.glass-international.com

The 26th International Congress on Glass 2022 (ICG 2022) takes place between July 3 and 8 in Berlin, Germany and is hosted by the German Society of Glass Technology (DGG).

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Events review: Hotbels seminar

35th Hotbels Glass Industry Seminar

his year’s Hotbels conference attracted multiple representatives from 40 glass production facilities, in addition to delegates from 23 different organisations that supply essential services and products to the glass industry. The highlight of each Hotbels event is the presentation of the Business & Technology United (BTU) Award. This annual award was established in 2007, giving distinguished recognition to an individual or a group that has contributed significantly to the evolution of Hotbels and education in the glass industry. This year’s BTU Award was presented to Chuck Mace of Ardagh Glass Packaging. Chuck has worked in the glass industry for 31 years, beginning his career in Dunkirk, Indiana at Kerr Glass. He has a very broad range of experience in furnace operations and engineering. Chuck has a B.S. in management from Indiana Wesleyan University.

He has held many positions of increasing responsibility including Batch & Furnace Manager at Dunkirk, Lincoln, and Dolton, Furnace Design Engineer, Furnace Operations Engineer, Manager of Furnace Operations, and presently the

Director of Furnaces with responsibility for operations, maintenance, engineering support and process improvement of Ardagh Glass Packaging’s North American Glass container division. In addition to Chuck Mace’s contributions and discussion on Economics of Nano-Tec, attendees had the opportunity to learn from an array of important speakers from Cardinal FG, HarbisonWalker International, HotworkUSA, Fosbel, RHI Magnesita, TECO, CelSian Glass & Solar, Ametek Land & Simpson Combustion & Energy, and ERTL Combustion Products. �

� Pictured left to right are: Tom Graham (Hot-

Hotbels conference, www.hotbels.com Hotwork USA, Lexington, Kentucky, USA, www.hotwork.com Fosbel Ceramic Technologies, Cleveland, Ohio, USA, www.fosbel.com

work), Demetrius Rankin (Hotwork), Chuck Mace – BTU Award Recipient (Ardagh Glass Packaging), Bob Chambers (Fosbel) and Eric Yaszemski (Fosbel).

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Some solutions are clearer than others.

For 75 years, HFT has developed a reputation as a leading EPC contractor to the global glass industry. What you might not know is in that time, HFT has completed over 300 EPC projects in 47 countries for Float Glass, Container Glass, Fiberglass, and more. Whether it’s a greenfield glass factory in a far corner of the globe or a major facility reconfiguration just up the road, HFT has consistently delivered quality, efficient, and innovative project solutions. This performance, plus our commitment to customer satisfaction makes us the clear single-source choice to take your next project from concept to completion.

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5/24/22 10:33 AM

Friends reunited at Glassman Mexican event Glass suppliers and manufacturers were reunited for the ﬁrst time since the pandemic began at the recent Glassman Latin America event in Monterrey, Mexico. Greg Morris and Jess Mills spoke to delegates.

www.glass-international.com

1300 people attended the combined trade show and conference

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Glassman Latin America review

A key topic at the show was energy efficiency and decarbonisation. Stuart Hakes, of FIC UK said the industry had woken up to the fact that decarbonisation has to happen. “The biggest problem facing the industry at the moment is gas prices, and the glass industry is a major user. It has been good for FIC because it means that people have woken up to the fact that decarbonisation has to happen. People recognise that although electricity is expensive, it is the way forward. He continued: “We have had so many people here now talking about it, but before it was too expensive. The fact that they are asking suggests there has been a drive, from younger people perhaps, to ask what is going on? Maybe children have been asking their mums and dads what they are doing to help prevent climate change.

www.glass-international.com

hile subjects such as energy prices and supply chain issues were hot topics, the top priority for most was to reunite with professional contacts and old friends for the first time in years at the recent Glassman event. The trade show in Monterrey, Mexico was the first trade event for the glass manufacturing and processes sector since the pandemic began more than two years ago, and was an opportunity for industry professionals to finally catch up face to face. More than 1300 people attended the combined trade show and conference to discuss important topics such as decarbonisation, digitalisation and supply chain issues. A total of 87 exhibitor companies represented the glass manufacturing supply chain and highlighted everything from raw materials, to batch and furnaces, to forming, annealing, inspection, palletising and decoration. Alongside the show were tours to the nearby Crisa Libbey tableware glass factory, where guests were given a guided tour by Crisa Libbey staff of the hot and cold end of the manufacturing facility. There was also the opportunity to visit the nearby Museum of Glass, which highlighted the role of the Mexican glass production industry. The event also included a conference where nine glass technology suppliers presented papers on a variety of production processes. Visitors among the 1335 attendees came from Mexico, USA, Colombia and Paraguay, while exhibitors were from countries as varied as Germany, Turkey, Italy, Poland, France, Mexico and the UK. Visiting companies included international glass manufacturers such as O-I, IVC, AB-InBev, Crown and Saverglass as well as Mexican located factories such as Vitro, Glass&Glass, Vidrio Formas, Fusion Y Formas, Vidriera Santos and Vetro Cantabria. Hans Mehl, of Mexican company MGFS, said that talking to customers at the show had saved him a month’s worth of travel. He said: “I haven’t spoken so much in two days! It has been one of the best shows ever since we participated.” He said the Mexican glass industry was back on track after the pandemic and that the industry was growing again. “Projects which were stopped are now starting up again. The Mexican glass industry is becoming like it was before the pandemic with a straight upward curve. There is a lot of investment and in technology, Mexico is booming once again.” Pyrotek’s Sales Engineer- Glass, Fernando Jauregui, also reported a strong show. The group was exhibiting its technology for refractories, IS machines and ware handling and reported meetings with several Mexican glass manufacturers. He said: “The Mexican container glass industry is in a healthy phase. There are new lines starting in Mexico, and new companies opening. There is a lot of growth in the container sector while in the automotive, which had slowed due to the pandemic, is also starting to grow again.”

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Glassman Latin America review

Visitors came from Mexico, USA, Colombia, Paraguay, Germany, Turkey, Italy, Poland, France, Mexico and the UK

“Glassman has been a very good show for us, we saw some good quality customers and have had some very interesting discussions about potential new projects”

www.glass-international.com

Aleksander Pinda, LWN Lufttechnik

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Glassman Latin America review

“I haven’t spoken so much in two days! It has been one of the best shows ever since we

”

participated

Hans Mehl, MGFS

A total of 87 exhibitors

“I think the pandemic has led to people to gaze at their navel and decide that it is time to act.” Aleksander Pinda, of German-based company LWN Lufttechnik, was exhibiting the company’s cooling technology. The technology is used in the hot end to cool glass equipment such as IS machines and tubs. “Glassman has been a very good show for us, we saw some good quality customers and have had some very interesting discussions about potential new projects.” He added: “Energy efficiency has been a big talking point at this show. It is a hot topic in the industry, particularly from countries which do not have their own gas. “We can help companies decrease their energy consumption. With the rise in energy costs right now any way to reduce energy is a saving for a glass factory. For a new customer we are sure we can reduce their energy consumption by as much as 30%. “An efficiently selected fan means saving energy and also means less maintenance and less production losses. If a fan is selected properly then they are not causing overheating and different problems on the production line.” Andrea Cella, Area Sales manager at Antonini, said: “It was a very interesting fair, we noticed a large number of customers from Mexico and South America, with many visits to our stand, we are very satisfied. “The glass market in Central and South America is growing strongly, big groups are investing in new projects, let’s also say that the global glass market is growing positively and the glass demand is increasing day by day. “In my opinion, market growth is expected to be driven by the high demand for glass containers from the food and beverage industry, which will be helped by the banning of plastic in the coming years.” George Hall, Managing Director of Tiama Americas highlighted the company’s glass inspection technology. The company was focused on providing more advanced data to its customers from its full line of inspection machines. Its products, such as the Tiama Ecosystem, can pull data from its systems across the whole plant to be able to see images on any connected device, such as what’s being rejected by the equipment, and is able to respond quickly to what’s going on. Ultimately, with the accumulation of data, the plant will be able to build correlations in the data to help improve its production efficiency. Mr Hall said: “The show’s been fantastic. We’ve had a steady stream of visitors coming by to visit us, and it’s been great to be able to meet in person with them again after two years of not really being able to see a lot of our customers. It’s been a great experience for us.” A highlights video of Glassman Latin America is available via https://vimeo.com/708822734 The presentations from the conference are available via the Glass International website.

THE NEXT GLASSMAN EVENT WILL TAKE PLACE IN ISTANBUL, TURKEY, IN MARCH 2023.

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Investment

HFT to upgrade Owens Corning site HFT has secured a contract to upgrade Owens Corning’s 300,000ft2 fibreglass production plant in Nephi, UT, USA. The focus of the project is to expand the plant’s capabilities to be able to produce a broader range of fiberglass building insulation in the future, and will include modernisations and upgrades throughout the production line. It is set for completion in March 2023. HFT’s work on the Nephi facility will include furnace, forming, civil/ foundations, buildings, offices and utilities, as well as relocation of production equipment from another Owens Corning facility to the Nephi site. This project highlights HFT’s capabilities to execute complex, multidiscipline projects as a single-source solution. Bringing expertise in not only the fiberglass process line, but also the site/ civil, buildings and MEP, HFT will provide a single-source fully integrated project

solution, reducing risk and increasing project efficiency. The Owens Corning Nephi plant produces unbonded loosefill fibreglass insulation and employs about 40 workers. HFT President and CEO Mark Piedmonte said: “This alliance with a company of Owens Corning’s stature highlights the quality of work HFT is

known for throughout the industries we serve. “The range of plant upgrades we’re undertaking is broad. When we finish, Owens Corning’s production capabilities here will be significantly expanded.” �

HFT, McMurray, PA, USA www.hft.com

� Owens Corning’s Nephi fibreglass manufacturing facility in Utah, USA will be upgraded by HFT, with work set for completion in March next year.

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The new NX-VR-300 swabbing robot mounts on the valve blocks of all IS machines. Provides mould closed and neck ring automatic swabbing within the same section cycle. On the fly swabbing, no reject.

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Recycling

Close the Glass Loop online seminar T he European Close the Glass Loop (CGL) platform will celebrate its two-year anniversary with its annual online event on 30 June. The event will also mark the International Year of Glass, with a focus on the global dimension of glass collection and recycling. The keynote speaker, Dr Janez Potonik, Co-Chair of the UNEP Resource Panel, will open the event with a talk on the global circular economy. The programme includes case studies on glass collection and recycling from Kosovo, Kenya and Guatemala, as well as virtual booths of CGL partners from 11 European countries, showcasing their activities. The platform will also reveal the 2020 ﬁgures of glass collection for recycling in Europe at the event. CGL’s goal is to reach 90% average EU collection rate of used glass packaging by 2030 and improve the quality of collected glass.

Case studies

Kosovo Glass Recycling is a family-owned start-up developing the glass recycling potential of Kosovo in the region, especially through pool filters from recycled glass. In Kenya, Bottle-Logistics specialises in efficiently recovering industrial and postconsumer glass waste. The company then processes it into highly refined glass cullet, glass aggregate and clean reusable bottles for respective brand owners. Grupo Vical is a glass manufacturer with manufacturing plants in Guatemala and Costa Rica. The manufacturer has developed a network of waste pickers to bring back waste glass into their factories for a recycling rate of up to 90% in Guatemala. To register for the event visit https:// hopin.com/events/cgl-annual-event/ registration �

Close the Glass Loop, Brussels, Belgium https://closetheglassloop.eu/

13:30 – 13:35 Welcome by the moderator, JeanPaul Judson, NOWMORE 13:35 – 14:15 Conversation with Janez Potocnik, Co-Chair, UNEP Resource Panel 14:15 - 14:30 Visit to the National Booths to see what partners have been up to. 14:30 – 15:30 Closing the Loop around the World Example from Kosovo: Martin Berisha, Kosovo Glass Recycling Example from Kenya: Louisa Gathecha, Bottle Logistics Example from Guatemala: Eduardo Ordóñez,, Grupo Vical 15:30 - 15:45 Visit to the National Booths to see what partners have been up to. 15:45 – 16:00 Publication of the 2020 Glass Collection for Recycling Statistics Adeline Farrelly, FEVE

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The event format is a niche trade exhibition where people can arrange meetings with a number of suppliers and industry experts in one place. Visitors and exhibitors can attend the free conference sessions to hear from industry experts. These exhibitions bring together international experts, hollow and container manufacturers and businesses that use glass containers, to discover the latest innovations which include energy eﬃciency, quality control, packaging, logistics and decorative possibilities.

8-9 February 2023 | Seoul, South Korea

15-16 March 2023 | Istanbul, Turkey

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LATIN AMERICA 2024

15-16 May 2024 | Mexico City, Mexico

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BOOK YOUR STAND TODAY Ken Clark Sales Director +44 (0)1737 855117 kenclark@quartzltd.com

Manuel Martin Quereda International Sales Manager +44 (0)1737 855023 manuelm@quartzltd.com

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Palletising

The family company has manufactured palletised glass products packaging for over 50 years and continues to explore innovative solutions for glass industry. � COMBI-GLASS machine for a dark glass pallet.

Thimon: packaging since 1968 www.glass-international.com

ince 1968, Thimon has manufactured stretch and shrink-packaging machines. These include equipment for spiral wrapping, hooding, full-web wrapping, and handling systems. It was the first company to create a machine capable of wrapping palletised loads, which made Thimon pioneers in its sector. Today, Thimon is, above all, a team of 70 people dedicated to creating endof-line machines specially designed to meet its customers’ needs. The company believes that it has developed its expertise through accompanying its customers in their everyday activities and seeking out the best solution possible in every

situation. For the glass market, Thimon’s main concern is to provide customers with a solution that keeps sensitive products safe and intact throughout their transport or storage. The company said its teams are driven by innovation as they strive to find the best possible responses to customers’ market issues. Among all the packaging processes available, the company considers automated shrink hooding the best solution in terms of speed, robustness, total tightness, protection, and full respect of the glass products. Thimon’s shrink hooding processes are particularly safe for the glass industry

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Palletising

thanks to shrinking systems with hot air and gas supplies meeting the most severe standards of the market. Its solutions dedicated to the glass industry offer: � optimal throughput due to the non-stop working capacity of machines (more than 70 pallets per hour) � perfect seal on 5 to 6 sides and impermeability for products (against water, dust, UV rays, etc.) for an optimal preservation in case of long-time outside storage and severe weather conditions � perfect control of hot air while shrinking to ensure complete safety, � exceptional packaging result by eliminating folds, � savings on consumables and energy, due to the quality shrinking guaranteed for the thinnest and most demanding films on the market, � a capacity up to 9 film rolls depending on the machine, � simple and fast film feed path management, � the new user-friendly Thimon human-machine interface, � and its specific eight-point guidance system, allowing to cover the load without having to touch the products. The amount of packaging used is optimised, guaranteeing film savings of more than 10% compared to other pallet hooding machines on the market. Since its creation, Thimon has filed more than a hundred patents and continues to develop the solutions of tomorrow. �

� COMBI-GLASS, an ‘all in one’ shrink hooding system for the glass industry. This machine is for a white glass pallet.

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LIGHTENING THE IMPACT OF HEAVY INDUSTRY

BUILD BACK BETTER Brought to you by a coalition of industry experts, Sustainable Industrial Manufacturing (SIM) is a global series of regional exhibitions and conferences supporting and facilitating the transition towards cleaner manufacturing around the world. President Biden’s goal of a carbon-neutral economy by 2050 is dependent on the decarbonization of heavy industry. The 2021 Build Back Better Act, provides $4 billion for the deployment of technologies that can accelerate the emission reductions of industrial facilities. To support and facilitate the transition towards cleaner manufacturing in the USA, Sustainable Industrial Manufacturing will be staged in Cleveland, Ohio in September 2022. Hosting leaders from industry, innovation, science, government and investment, SIM USA will bring together those responsible for driving sustainability across hard-to-abate sectors.

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2024 |2024 MEXICO | MEXICO 2024 | MEXICO Mexico City, Mexico 15-16 May 2024

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DIGITAL SCREEN PRINTING HOT STAMPING FULLY AUTOMATIC UNIVERSAL DECORATING MACHINES

Bergkirchener Straße 228, 32549 Bad Oeynhausen, Germany kammann.de

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25/05/2022 13:45:53

53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce, 6 Tel +39 0577 304730 ifv@fonderievaldelsane.com

www.fonderievaldelsane.com

HORN® RAPID A DJ U S T B R AC K E T H-RAB The burner angle is a very important parameter, as it can have a strong influence on the melting process, furnace life and emission values. It further facilitates lower energy consumption. Therefore an accurate and rapid adjustment of the burner angle after burner replacement or cleaning is of utmost importance. The HORN® Rapid Adjust Bracket H-RAB offers a simplified adjustment of the correct burner angle to get replicable values. With two adjusting wheels the operator can easily adjust both the horizontal and vertical angle. The centre point of rotation is the nozzle tip itself. Thanks to an integrated scale, the angle can be read off easily. With regard to Industry 4.0 the holder is prepared for later installation of servo drives. With the input of additional information coming from NIR camera systems or other sensors the HORN® Rapid Adjust Bracket H-RAB bears the possibility of remote control.

HORN® GLASS INDUSTRIES AG BERGSTRASSE 2 D-95703 PLÖSSBERG/GERMANY LET‘S GO FULL CIRCLE. WWW.HORNGL ASS.COM

Glass International May 2022

Articles inside

Digital glassmaking: Siemens

Company profi le: Wiegand-Glas