Glass int june 2014

O-I INTERVIEW: R&D VICE PRESIDENT

SAB MILLER FOREHEARTHS

www.glass-international.com

Glass International June 2014

EXCLUSIVE TO GLASS INTERNATIONAL: PROFILE OF GERRESHEIMER’S NEW SYRINGE FACILITY AT ITS BüNDE PLANT

growth-group.com

Reducing energy and emissions Here’s some tasty news for glass producers looking for ways to make their furnace more economical and ecological: The HVR 700F-2P charger, part of HORN´s ECOfurbishing program.

HORN's innovative doghouse design combined with the HVR 700F-2P charger result in a tightly sealed doghouse, greatly reducing energy and emission values. The advantages are: s preglazing of the batch inside the doghouse – for furnaces with or without batch preheating s reduced carry-over of raw materials s reduced energy consumption s reduced NOx emissions s adjustment of batch layer through individually controlled paddles s reduced wear and tear compared to screw chargers, for example The HORN doghouse and the HVR 700F-2P: further examples of how to improve furnace efficiency, thereby saving money – and our planet. the HORN optimisation program visit www.hornglass.com for more

I N N O VAT I O N E N G I N E E R E D I N G E R M A N Y

C O N TA INER G LA SS s COSM E T IC GLAS S s F I B R E GL AS S s F L AT GL AS S s F L O AT G L A S S LI G H T ING s PH A R M ACE UTICAL GLASS s S O DI UM-S I L I C AT E GL AS S s TAB L E WAR E s T U B I N G

Contents

June 2014

Vol. 37 No.6

10

O-I INTERVIEW: R&D VICE PRESIDENT

SAB MILLER FOREHEARTHS

2

Editor’s Comment

3

International News

www.glass-international.com

10

Company profile: Gerresheimer The syringe: Small but sophisticated

14

Interview with Ludovic Valette Glass profile

16

Glass recycling Returnable beer bottles scheme boosts sustainability drive

19

British glass

22

History

24

Russian overview Chinese glass producers eye Russian expansion

EXCLUSIVE TO GLASS INTERNATIONAL: PROFILE OF GERRESHEIMER’S NEW SYRINGE FACILITY AT ITS BüNDE PLANT

Front cover image courtesy of Gerresheimer www.gerresheimer.com

14

25 29 32

Forehearth Concepts for insulating wool (C-glass) forehearths How much energy savings can be expected on air-fuel forehearths?

Forehearth control - Infra-red pyrometers or thermocouples?

Toughened glass 36 Unexplained glass failure - Don’t jump to inclusion conclusions

38

Forming 39 Practical container forming simulation Plus find us on Linked-In and Twitter.

41

@Glass_Int

www.glass-international.com

46

43 46

Flat glass Façades: Optimum efficiency Events world British Glass Focus Conference discusses latest trends A successful China Glass 2014

www.glass-international.com

Company profile: Pennine 38 The Pennine way

1 Glass International June 2014

Editor’s comment

Greg Morris

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Editorial Assistant: Sally Roberts Tel: +44 (0)1737 855154 Email: sallyroberts@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com

All hail the humble syringe

www.glass-international.com

L

ike many things on Earth the syringe is one of those objects that, once used, is discarded and quickly forgotten about by its user.

It is likely that each end user does not put too much thought into the production process of this humble thing. Yet, it might be small in stature, but it provides a lifeline to hundreds of thousands, if not millions, of people every day. Not only does it improve the quality of life for some people, it saves the lives of others.

Due to the rise of ‘Western’ conditions such as diabetes, the use of glass syringes is increasing. Similarly, as the developing world increases its disposable income, the use of syringes is on the rise.

The good news for our industry is that glass is considered the ‘gold standard’ for syringes. It is inert and has better barrier properties than plastic, so is impermeable to gases such as water vapour or oxygen.

So, it was fascinating to visit the production site of such an important object to the industry. Gerresheimer’s Vice President of Global Syringe Systems, Carlo Reato, and his team very kindly gave a tour of the company’s Bünde, Germany site.

As you would expect of something that comes into contact with humans on

such a regular basis there are a number of regulations to overcome before a company can start production.

Once production starts there are audits to meet and continuous safety checks. If one syringe is faulty it can lead to a recall of thousands of others – a very costly event.

Some companies might crumble under such a headache but Gerresheimer has thrived. It is about to start its fourth glass syringes line at Bünde. A remarkable achievement considering the first line was only commissioned 12 years ago in 2002.

F

urther congratulations are due to Owens-Illinois (O-I), which is due to officially open its new R&D centre in Perrysburg, Ohio, USA. We spoke to O-I’s R&D Vice President Ludovic Valette, who states the centre will be ‘instrumental to advancing breakthrough innovations in glassmaking’. It will also be used to help train workers on new processes and technologies. It is an exciting time for the company and industry.

Greg Morris Editor gregmorris@quartzltd.com

Directory 2014

www.glass-international.com Glass International June 2014

Subscriptions Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.

Email: glass@quartzltd.com Website: www.glass-international.com

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

Member of British Glass Manufacturers’ Confederation

China National Association for Glass Industry Glass International annual subscription rates including Glass International Directory: For one year: UK £154, all other countries £217.

For two years: UK £277, all other countries £391.

Airmail prices on request. Single copies £43.

Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK.

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.

Annual international reference source

2

Production Executive: Martin Lawrence

Glass International Directory 2014 edition: UK £206, all other countries £217, post free.

Quartz Glass Portfolio

Monthly journal for the industry worldwide

Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com

Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2014 ISSN 0143-7838

International news

Turkey’s largest glassmaker i ecam has said its Pa abahçe tableware unit has started talks to acquire shares in Arc International, a French household goods maker.

In a filing to the Istanbul Stock Exchange, Sisecam stated that Pasabahçe had signed a non-disclosure agreement regarding the non-binding talks.

Pasabahçe’s share in the global glass household goods market is currently 12%, putting it third in the market,

while Arc International is the leader with 13%.

If the talks between the companies finalise with an acquisition, Pasabahçe will rise to become market leader, ahead of US company Libbey.

The French company, which has an annual turnover of around €1 billion produces around 4.3 million pieces of glass household goods every day.

The company earns 47% of its income from Europe, but outside France it has production activities in

China, Russia and the United Arab Emirates.

Pasabahçe and Arc International co-operated to enter the North America hotel and restaurant sector jointly in 2006.

Arc International is privately held and has been owned by members of the Durand family since 1916.

Brands under the Arc group include its own Luminarc, Arcoroc, Cristal d’Arques, Longchamps, Pyrex and the crystal brand J. G. Durand.

Quinn Glass now called Encirc Quinn Glass and Cobevco are rebranding under the name Encirc.

The name Encirc was designed to describe the company’s offering: From the manufacturing of container

glass, to modern filling facilities, warehousing and logistics, the company aims to completely encircle a customer’s needs.

Adrian Curry, Managing Director, said: “We are the

only company in the world that can offer a range of supply chain services, reducing environmental impact, shortening lead time to retail, and reducing cost.”

O-I to spend €30 million in Harlow Owens-Illinois (O-I) is to invest €30 million in its Harlow plant to focus on the UK beer market.

The company proposes to build a new furnace with latest technology in Harlow, replacing the plant’s two existing furnaces, which are

reaching their end of life.

In addition, O-I intends to install quality equipment.

Up to 47 employees will be affected by the planned changes.

O-I is in consultation with employee representatives and will collaborate to minimise the

impact on employees, including job relocation to other O-I facilities and outplacement service support.

On completion of the investment, the plant will continue to employ around 120 people.

Ardagh award Ardagh has received recognition for its involvement with one of the most successful packaging launches over the past 12 months.

It won taken silver in the annual World Packaging Organisation (WPO) Marketing Awards for Absolut Unique. This is an award nominated independently by the judging panel in recognition of true marketing excellence.

The bottle made history as the world’s first limited edition spirit bottle, where every single bottle is unique.

Otto Schott Research Award winner Professor Donald Bruce Dingwell is the winner of the 13th Otto Schott Research Award.

The Canadian experimental volcanologist has headed the Department of Mineralogy and Petrology at the Ludwig Maximilian University (LMU) in Munich since 2000 and is Director of the Department of Earth and Environmental Sciences.

Dingwell received the award for his many years of research in the field of physical and chemical properties of volcanic glasses.

AGR launches marketing campaign American Glass Research has launched a new marketing campaign to build awareness of its full range of consulting, testing, training, and analytical services for the glass container industry.

Markets served include glass manufacturers, fillers of glass, and the pharmaceutical industry.

Using the mantra ‘We Know Glass’, the new campaign includes the development of a new logo that will appear on all customer touch points.

VISIT: www.glass-international.com – For daily news updates and regular features

www.glass-international.com

Sisecam plots move for France’s Arc International

NEWS IN BRIEF

3 Glass International June 2014

International news

NEWS IN BRIEF

Rumpke upgrades Ohio recycling facility Rumpke Recycling is upgrading its Dayton, Ohio, recycling facility at a cost of $2.5 million.

The unit of Cincinnatibased Rumpke Consolidated Companies Inc is adding a new sorting system to replace old equipment and improve the plant’s efficiency.

The facility sorts glass and cardboard from the more than 500 tons of recycling the unit receives daily.

GTS secures audit success The UK’s Glass Technology Services (GTS) has further expanded its product testing and chemical analysis services for the glass supply chain after securing independent audit success.

Scoring highly across technical (ISO 17025), administrative (ISO 9001) and environmental (ISO 14001) performance audits, the company has also successfully achieved Notified Testing Laboratory status and has made seven extensions of scope to its comprehensive technical UKAS accreditations.

Anchor Hocking halts production at US plants EveryWare Global said it is temporarily halting production at its two US plants, including the Anchor Hocking plant in Monaca, in order to preserve cash while the Lancaster, Ohio, company negotiates with creditors over a loan default.

The company did not disclose the number of hourly and salaried employees who will be idled for three to four weeks. It said certain employees are being furloughed without pay.

The company blamed the loss on a number of factors including a $20.7 million tax-related impairment charge and severe winter weather, which resulted in higher utility costs.

It also cited higher severance expenses and fees paid to consultants who are developing cost savings initiatives.

EveryWare said it is expanding the role of Alvarzez & Marsel, a turnaround consultant that is

Friends of Glass looks beyond the label

www.glass-international.com

Beatson Clark produces craft beer bottle Beatson Clark has been chosen to produce a unique beer bottle for craft-brewers Thornbridge Brewery, based in Derbyshire, UK. The bespoke 500ml amber glass bottle with a standard crown neck finish will feature the Thornbridge Brewery crest around the shoulder and the strapline ‘Innovation Passion Knowledge’ around the base.

Charlotte Taylor, Marketing Manager at Beatson Clark, said the partnership with Thornbridge Brewery strengthens the glass manufacturer’s growing reputation in the brewing sector.

Beatson has previously produced bottles for breweries such as Meantime Brewery in London.

4 Glass International June 2014

advising the company on cost reduction and efficiency measures.

The company said it is in default on a $250 million loan and has until May 30 to convince lenders to either waive the default or agree to new terms.

Cash generated by operations and other available credit ‘are not expected to be sufficient to fund our operations in the near future,’ the company said in a press release.

Friends of Glass has launched a campaign to encourage consumers to ‘look beyond the label’ at the packaging role played by glass.

Independent research conducted with 8,000

consumers reveals that Europeans are more worried about health and food safety than environmental problems, international terrorism or public safety.

The findings unveil a

concern among European consumers linked to the potential health risks of chemical compounds leaching into food from packaging.

Two thirds of consumers admit they are worried about food contamination, as well as the risk of chemicals leaching from food packaging into its content.

Eight out of ten consumers surveyed believe these chemical interactions could be a risk to human health.

The findings reveal European consumers are most worried about plastic containers.

EME secures Algerian contract German batch plant and cullet return system supplier EME Maschinenfabrik Clasen has won the bidding with the Algerian-based glass producer Africaver.

Societe Africain du Verre (Africaver) belongs to the state owned Enava Group

and is modernising its patterned glass line in Jijel, Algeria and has put its faith in EME technology.

The production line at Africaver has a melting capacity of 130 t per day.

EME is upgrading major parts of the raw material

transport, dosing and weighing as well as parts of the batch transport.

In addition a new control and visualisation system will be delivered and EME will be in charge of the supervison of installation and commissioning.

Be first with the news! Visit www.glass-international.com for daily news updates

SORG GROUP

we make glass possible Everything you need from one partner: raw material delivery through conditioned glass. And we have the services you need to keep everything running 24-7-365. The SORG Group. We make glass possible.

SORG GROUP Stoltestraße 23 97816 Lohr am Main Germany Tel.: +49 9352 / 507- 0 www.wemakeglasspossible.com

International news NEWS IN BRIEF

Bystronic wins Chinese glass award The Chinese Glass Association celebrated its 50th anniversary with a twoday event focused on furthering the technology and development of insulating glass machines.

500 guests were invited to the gala event in Hangzhou, where Bystronic glass was presented with an award for technological leadership within the field of insulating glass.

“Our technologies have helped to make significant headway and further the advancement of insulating glass production standards across China,” Hans Ulrich Schick, Head of Bystronic glass China, said.

www.glass-international.com

Schott to upgrade Brazil plant Schott is to modernise its Vitrofarma, Rio de Janeiro plant in 2015 with a $15 million upgrade.

The investment co-incides with the 60th anniversary of the plant. The plant was not just the company’s first production line in Brazil, but also its first production facility outside of Germany.

As a way of celebrating the anniversary and to increase productivity, further modernisation of the plant is planned for 2015, with a budget of R$15 million. More than R$100 million has been invested in the plant over the past 10 years.

The refurbishment will enhance product quality.

Today, some 180 employees work at the plant, which covers an area of 23,000m2.

Since 1999, it has focused its growth strategy on making neutral glass tubes, specifically for the pharmaceutical industry, and its products are now familiar as packaging for medicines and vaccines.

Previously, Schott Vitrofarma produced material for fluorescent and incandescent bulbs and glass items for laboratories.

6 Glass International June 2014

Turkey’s Gürallar orders Horn Glass end-fired furnace Turkish table glass manufacturer Gürallar has placed an order with Horn Glass for an end-fired furnace.

The 300tpd furnace with three forehearth lines for container glass production is

for Gürallar’s new company, Gürallar Cam Ambalaj, based on a 300,000m2 site in Kütaya.

The Gürallar Group decided to form the new company earlier in the year to produce container glass.

The group, established in 1948, has also changed the Artcraft brand to LAV, which it said reflected the young and dynamic spirit of the group. It said it had renewed its identity to become a global brand.

Dismatec wins Royal award UK glass plant engineering group Dismatec has been awarded the Queen’s Award for Enterprise in International Trade 2014.

The Sheffield-based company received the award for its growth in international trade in the

past three years.

Managing Director Michael Horsfield said: “It’s a tremendous accolade for us and is reward for the hard work and professionalism of the team. We are extremely customer focused and staff have the correct attitude

towards customers. The award is a reflection of that.”

The company of five staff has focused on the USA, Middle East and Eastern Europe in recent years.

Mr Horsfield said: “We offer a unique, specialist service.”

Gimav appoints Deputy Director Laura Biason has been confirmed as Deputy Director for Gimav, the Italian Manufacturers’ Association of Machinery, Accessories and Special Products for Glass

Processing.

Laura Biason will promote member companies, working alongside Gimav Director Renata Gaffo.

Her task will be to attend

international glass meetings, interact with the main Italian and overseas institutes, and strengthen initiatives aimed at increasing the association’s prestige.

Ramsey’s tool is a knock out

The Ramsey RKO tool is used to connect and disconnect conveying chains.

The process can be particularly tedious and time consuming with wear protected chains like Ramsey Allguard FX and Lifeguard, where pin heads are recessed below chain link surfaces.

The RKO tool, or ‘Ramsey

Knock Out’ tool, is designed to quickly and easily remove pins wherever a chain must be disconnected.

The same tool can be used to simply install chain connecting pins wherever chain sections are to be

joined. The RKO tool also maintains chain link and spacer alignment during chain connection.

RKO knockout tools are equipped with modular guide plates that allow the tool to be adapted to almost any Ramsey Allguard FX or Lifeguard chain.

Just specify which type of chain you are using and the RKO tool will be delivered already setup to fit your chain. Alternatively, you can order the modular guide plates individually, and configure the tool for any chains that you wish.

, Tomorrow s Technology Today

The World’s leading glass companies come to FIC with their Electric Boost/Heating projects E-Glass

Installations up to 3,500kW in oxyfired furnaces for extra tonnage and improving glass quality to eliminate strand breakages.

Container Glass

Various installations in flint and coloured glasses, up to 2,500kW for increased output and quality.

Float Glass

Boosting installations from single zone 1,000kW designs to 3 zone 6,000kW installations, for increasing clear output, maintaining output on tinted glass, energy substitution and reducing emissions. Multiple bubbler installations.

Display Glass Numerous installations of up to 1000kW installed power for TFT/LCD glasses using tin oxide electrode blocks to achieve exceptional glass quality.

Electric Furnaces

Developing new furnace designs for most glass types, including opal. Complete technical back-up for melting quality improvement from raw materials though to forehearth, including all operational problems.

Trouble shooting service on all types of existing furnace designs.

www.fic-uk.com Tel +44 (0) 1736 366 962 Fax +44 (0) 1736 351 198 Email general@fic-uk.com

FIC (UK) Limited Long Rock Industrial Estate, Penzance Cornwall TR20 8HX, United Kingdom

, The World s Number One in Furnace Technology

International News

Tableware producers in Italy and Brazil are among the latest glassmakers to benefit from the automated inspection solutions delivered by Iris Inspection Machines.

It is now two years since the Bron-based specialist developed the necessary know-how for the inspection of drinking glasses, refining its container inspection technology to meet the demands of the international tableware sector.

Today, Iris Evolution 12 and Evolution 5 machines are successfully operating at several international factories, including those of Italy’s Vetreria di Borgonovo and Nadir Figueiredo of Brazil.

Piacenza-based Vetreria di Borgonova produces 500 different pressed and blown glassware designs, while Nadir Figueiredo has been the reference point for

International tableware producers choose French inspection group quality glass tableware production in Brazil for more than 100 years, operating from new production facilities in Sao Paulo.

Thanks to the flexibility and universal hardware of Evolution 12 and Evolution 5 machines, intelligent software allows users to inspect surface and geometric defects in hollow glassware.

The combination of 12 cameras and sophisticated inspection tools and algorithms permits the inspection of numerous defects, including breaks, broken edges, scratches, bubbles, stones, tears and chipped cups.

In addition, the technology plays an important dimensional inspection role,

www.glass-international.com

Recycling company credits success to Teesside University

8

A UK recycling company has credited its success to its partnership with Teesside University.

WRL Glass Media, in Middlesbrough, UK takes unwanted glass and then processes it into granulated form for applications such as water filtration and shot blasting.

Since it was taken over by parent firm Ward Recycling in 2012, the business has seen its sales steadily increase and its sales in foreign markets were recently recognised with the New Exporter prize at the North East Process Industry Cluster (Nepic) annual dinner.

The company has recently opened a new office in Prague to service the Czech Republic and has exported to France, Germany, Portugal, Glass International June 2014

Spain, Belgium, The Netherlands, Greece, Cyprus, Israel, Italy, Iceland, Denmark and Ireland.

It has credited a lot of this success to its ongoing work with Teesside University.

Ward Recycling decided to take over WRL Glass Media when its previous owners, who were in partnership with Ward Recycling, went into administration.

The glass recycling market was new to Ward Recycling and so the firm turned to Teesside University for help to get the PAS102 accreditation which reclassifies waste to a secondary product.

Manager Gareth Godwin said: “When our partner went into administration, we were left with a choice to either cut our losses or to take

on the glass recycling plant and remain in the industry and learn about how we could reconfigure the business.

“That was when we contacted Teesside University who supplied us with all the information we needed to do to get the PAS102 accreditation.”

Once that accreditation was achieved, WRL Glass Media was helped to obtain a Regulation 31 certificate which allows the granulated glass to be used for filtration for human consumption – one of only two companies in the UK to achieve that standard.

The University has also worked with the company on other projects including a corporate video for the company website.

controlling verticality, planeity and diameters.

An important advantage for tableware manufacturers is that Evolution 12 machines can be used to inspect different articles on the conveyor simultaneously, thanks to the equipment’s intelligent software recognising and identifying the different items.

Vitro award Mexican container manufacturer Vitro won a World Packaging Organization prize during the Worldstar Awards 2014.

Its glass container for True Passion by Mary Kay was presented with the World Packaging Organisation’s (WPO) prize for Health and Beauty. The event was held in Düsseldorf, Germany and acknowledges the containers’ industry.

Shlomo Frymerman, Director of Vitro’s Perfume and Pharmaceutical Business, said: “True Passion 60ml. was awarded from a total of 316 containers presented by companies during 2013.”

True Passion is the first fragrance that Mary Kay has designed exclusively for the Latin-American market. The red glass container was inspired by the region’s flora, specifically the Passion Flower of Brazil.

www grow www. o th-g ow -grou roup up.com .

If you can‘t wait 90 minutes for results...

...it‘s time for It’s hot news in every sense: the hot end monitoring concept by Tiama, designed to put you ahead of the game.

Inspired by your needs and by applying our know-how, we have developed technology that works – to make your life easier.

Tiama Hot Systems already gives you information at the hot end that complements the data you receive at the cold end. A modular concept that is highly efficient and, above all, easy to use: that’s Tiama HOT Systems. Contact HOTsystems@tiama.eu for more about the versatile hot monitoring range that helps your team win.

tiama –advanced knowledge

Company profile: Gerresheimer

Ahead of the unveiling of its new Ready-to-Fill syringe production line, pharmaceutical manufacturer Gerresheimer invited Glass International to its Bünde, Germany site where its senior staff chatted about the plant’s exciting new operations.

Greg Morris reports.

The syringe: Small but sophisticated

www.glass-international.com

T

10

hey may look small and simple but syringes play a vital role in the well being of thousands of people everyday. The rise of ‘Western’ diseases such as diabetes or high blood pressure has seen increased demand for injections. To ensure syringes are safe to use by the public, a glassmaker has to meet plenty of regulatory and safety requirements, including ISO certification and regular audit checks. All components inside the syringe must work properly. If there is even a microscratch on the glass ‘barrel’, a glass plant could be closed.

Syringes come into direct contact with the medication so utmost care must be taken to manufacture them. The syringe has to be perfectly clean because even the tiniest contamination could alter the medication.

Gerresheimer’s Bünde plant in the Ostwestfalen-Lippe region Germany specialises in Ready To Fill (RTF) syringes. RTF means Gerresheimer takes responsibility for the washing, siliconising, pre-assembling with cap and sterilising of the syringe. A customer, usually a pharma company, still has the option of buying unwashed and unsteralised syringes from the Bünde plant, known as bulk syringes, but there is a move today Every single syringe is a towards the RTF process.

Carlo Reato, Gerresheimer’s Vice patient. They help extend a life, President Global Syringe Systems, said: “Every single syringe is a make a life easier or even save a patient. They help extend a life, make a life easier or even save a life. life. Each syringe could be you, Each syringe could be you, me, a child or a brother. me, a child or a brother..

“We have to make sure that what we deliver is 100% and that is the biggest challenge.

We have quality control to Carlo Reato, Gerresheimer’s Vice ensure a faulty syringe does not go out onto the President, Global Syringe Systems market.

“

”

Glass International June 2014

continued »

Company profile: Gerresheimer Visual inspection after assembly.

“When syringes are manufactured, each one is inspected several times – by cameras, sensors computers and the human eye. Our employees have responsibility for ensuring no patient suffers harm as a result of defective syringes.”

A syringe has to work in any climate, in any part of the world and in a number of years time.

Some syringes may not be used for three to five years after they are made, so quality control is allimportant. The plant operates 24 hours a day, seven days a week and quality control has to remain constant, whether it be a summer holiday, Christmas or a weekend.

Three-stage process

Autoinjectors As demand increases on healthcare providers worldwide it has become common for patients to inject drugs at home. Administering drugs for problems such as diabetes, rheumatism or multiple sclerosis at medical centres puts a strain on budgets. Pre-filled syringes which administer drugs through an autoinjector device are becoming more important.

Autoinjectors help prevent needle injury. They are usually made of plastic and integrate the glass syringe within them. However the force of the plunger when administering a drug can cause the glass to break.

In the past this has led to product recalls. In response Gerresheimer has developed its Gx G-Fix standard adapter, which it says reduces the risk

Put simplistically, there is a three-stage process to making a glass syringe: Syringe glass barrel production, needle assembly inside a clean room and then the RTF processing inside a clean room.

The Bünde site receives 1.4 metre length glass tubes from its sites in Vineland, NJ, USA and Pisa, Italy, which are then cut to length.

All Gerresheimer’s syringes are made of Type 1 borosilicate glass. All glass supplied from its Vineland and Pisa sites has to be scratch free and be of the correct dimension and size.

Once the barrel is produced a needle is inserted, which has to be glued precisely. The needle cannot be bent and there cannot be a hole otherwise the medication may spill out between the needle and the glass. It also has to be perfectly glued to ensure that, when injected, the needle does not stay in the skin when the patient pulls the syringe back out.

The RTF final process clean room is similar to a pharma environment. Syringes are washed and siliconised, and testing takes place with cameras to make sure settings are correct and rubber components within the syringe have been prepared precisely. Each barrel and cannula is siliconised to ensure the plunger works.

of glass breakage and permits the precise and reliable positioning of the syringe.

The Bünde site.

www.glass-international.com

continued »

11 Glass International June 2014

Company profile: Gerresheimer

Fast facts

The wall thickness of a glass syringe is around 1mm Their diameter varies between 4 and 9mm, depending on their shape.

Vaccines and other medications are filled into glass syringes because glass is inert – perfect for long-term storage of medications.

Needles are 2cm long but not all of it is visible Needles have an internal diameter of 0.2 to 0.3mm and an external diameter of 0.3 to 0.5mm.

The outside of a needle is siliconised so it hurts less when in contact with skin.

Substances injected from a glass syringe include antithrombosis medicines, vaccines, medicines for multiple

RTF assembly.

When they are made, each syringe goes into a ‘nest’ of either 100 or 160 other syringes. The nests are then boxed, palletised and sent to a customer, usually a pharmaceutical company. If the customer finds just one syringe out of spec they can order an entire batch of 1 million syringes to be destroyed. They can also ask for production at the plant to be halted.

www.glass-international.com

RTF 4

12

Line RTF 1 started production in 2002 at Bunde and in the intervening years the company added lines two and three. Line RTF 4 is due to start production in Q3 of this year with a number of validation tests currently taking place on the line to ensure it meets regulatory standards.

By the time RFT line 4 is up and running the site will have the capacity to manufacture 400 million RTF syringes a year. Mr Reato stated that each introduction of a new line has seen an improvement over the years in terms of speed and flexibility as well as more cameras to ensure needles are straight, capping is perfect and each length is precise.

Other improvements include the avoidance of glass-glass and glass-metal contact through the use of pick and place robots and segment transport systems. There is no glass-to-glass or glass-metal contact for fear of causing microcracks or scratches. Anything out of spec is thrown out and destroyed.

“If we don’t destroy it the customer may find out, and that is much more expensive,” stated Mr Reato.

Why glass?

“Glass will stay the main material for syringe use,” stated Claudia Petersen, Gerresheimer’s Global Director Marketing and Development, Tubular Glass Syringes. “It is a well-known material and is the gold standard for primary packaging of injectables.”

“Glass is inert – it is less reactive and has better Glass International June 2014

sclerosis and rheumatoid arthritis.

barrier properties than most plastics – glass is impermeable to gases such as water vapour or oxygen.

“Medications in glass syringes are suitable for long-term storage over several years, meaning the medication is in contact with the glass for longer.” The advantage of glass syringes is there is no need for the laborious step of taking the medication from a bottle prior to application.

In addition, glass has been used for hundreds of years to store drugs so is well known and people have plenty of experience in handling it. From a pharmaceutical side, an advantage is it is transparent and so key for visual inspection for any discolouration of liquids. Its inertness is useful as well. Many drugs have a PH7 so therefore do not interact with the glass.

Gerresheimer and Bünde Gerresheimer is a German manufacturer of pharmaceutical and healthcare glass with operations in Europe, North America, South America and Asia. It has 40 plants and revenue in 2013 of €1.3 billion. Its 11,000 employees are spread out in countries including Mexico, China, India and Italy. It specialises in primary packaging and drug delivery devices for the pharma industry.

Its Bünde plant employs 800 people and was founded in 1947 as Bunder Glass by the Hennings and Zimmermann families. It was taken over by Gerresheimer in 1987. Since then it has developed the site into a specialist for RTF syringes, which are marketed under its Gx RTF (Gerresheimer Ready to Fill) brand name.

The site is Gerresheimer’s competence centre for RTF glass syringes, which are used for applications such as the long-term storage of pharmaceuticals such as vaccines.

Gerresheimer, Düsseldorf, Germany www.gerresheimer.com

FleXinspect M

FleXinspect T

FleXinspect BC

FleXinspect B

FleXinspect C

FleXinspect - A full line of configurable inspection systems to ensure your product quality FleXinspect inspection systems deliver optimum accuracy to guarantee your glass quality and safeguard your reputation. These efficient machines offer a full spectrum of inspections, with simple operation, plant control integration, and small footprints for easy installation. FleXinspect brings the technology, quality, and service of the world’s leading glass machinery company to your glassmaking process to protect your products and your brand.

FleXinspect. The future of glass inspection technology, delivered today.

www.bucheremhartglass.com

Glass profile: Owens-Illinois R&D

Glass profile: Ludovic Valette Ludovic Valette, Global Vice President, Research and Development, Owens-Illinois (O-I) was appointed in September 2013 and joined just as construction of the company’s Innovation Center was completed.

R&D team and position us as a strong partner across O-I’s multi-disciplinary organization, for example products innovation and manufacturing.

How is O-I’s Research and Development team structured? Is it just based in North America or are there centres globally too?

Ludovic Valette, Global Vice President, Research and Development.

Can you tell us a little bit about your personal history and your industry experience? Have you worked in the glass industry before?

I joined O-I in August 2013. Prior to that, I served as the research and development director of the global Epoxy business for The Dow Chemical Company. For more than 13 years, I had the opportunity to work on three continents and oversee multi-cultural teams across Europe, North America, Latin America, Asia Pacific and India.

While I have not worked in the glass industry, the chemical industry is similar in many respects.

Both are usually a couple of steps upstream from consumers in the product value chain. Many areas of innovation rely on the ability to partner with brand owners and to develop solutions with a strong value proposition for both them and consumers. Continuously upgrading our production capabilities and assets is also critical, both industries being capital intensive.

www.glass-international.com

What does your new role at O-I entail?

14

One of O-I’s strategies is to increase its competitive advantage in the glass container business by investing in innovation and R&D. I am responsible for leading O-I’s research and development activities to create new technology concepts focused on glass science and process innovation that will guide O-I, and glass manufacturing, into the future. To achieve this, I am working to help grow the expertise of the

We believe that “each challenge represents an opportunity for glass to maintain or regain its leadership position against alternative materials in the food and beverages packaging

”

industry.

The majority of our R&D activities take place at our Perrysburg, Ohio headquarters in North America. We collaborate closely with our colleagues in other regions who have expertise in manufacturing, technology and customer insights that feeds our R&D work. To effectively reach out to 77 facilities in 21 countries, we rely on our network and communication “hubs” such as regional engineering, manufacturing, and business teams.

Once these 2-way communication channels are established, we conduct “voice of the customer” surveys to identify unmet needs and pain points. These surveys also help us prioritise sites where new technologies should be implemented. Moreover we are developing tighter collaborations with academia, industrial partners, and customers.

You joined O-I just as construction of its Innovation Center was nearing completion. You must be very excited by this. What has the opening of this centre meant for both O-I and the industry as a whole?

I am happy to share that we officially started production in the Innovation Center in September 2013. The team did a phenomenal job of safely completing this unique facility at our Perrysburg, Ohio headquarters in only eight months. The facility is instrumental to advancing breakthrough innovations in glassmaking. It includes a combination of state-of-the-art, conventional, and new-to-the-world technologies to further advance our competitive position. It allows us to pilot and validate novel concepts and technologies; to sample new containers to accelerate product development; and to train our workforce on new processes and technologies.

Will there be any areas that the centre will focus on in particular, such as improving energy efficiency and reducing emission from the glassmaking process?

O-I is committed to reducing our energy use and emissions, and increasing recycled content across our global footprint. The Innovation Center provides an iterative learning environment to build upon our sustainability efforts. continued »

Glass profile: Owens-Illinois R&D

In particular, much of our research is focused on ways to make glass using less energy and minimising emissions which includes enhancing our manufacturing processes and developing new technologies to melt glass and form containers.

From your experience working in other industries is there any advice you can give the glass industry to improve its position?

Very similar to what happened for other so-called mature industries, the time is ripe for the glass industry to initiate a new maturity cycle. Glass should not be considered an old material, but as a material with a long history. Consider a parallel with the recent discoveries in steel, engineered wood, or polyolefins. We are working on the next generation of glass processes and disruptive material properties. We combine knowledge developed in our own portfolio, in adjacent fields, and in totally different application areas.

We keep expanding the capabilities of glass while building on its inherent values described by the Glass Is Life™ movement.

in the food and beverages packaging industry.

The glass industry faces challenges related to large capital investment and energy intensity.

Consequently the existing assets footprint does not perfectly match the market needs. The breakthrough technologies in glass processing and glass forming will break this paradigm to better aligned with the current requirements of our customers, and to be more responsive to their emerging needs. We must also constantly upgrade the skill set of our workforce as technology evolves.

Can you tell us of any plans for the future of R&D at O-I?

We believe that each challenge represents an opportunity for glass to maintain or regain its leadership position against alternative materials

Owens-Illinois (O-I), Perrysburg, Ohio www.o-i.com

www.glass-international.com

In your view, what are the current glass industry challenges and opportunities?

R&D is the change factor that the industry needs to re-establish glass as the packaging material of choice for food and beverage containers, and highlight the benefits of glass for the modern world. O-I’s R&D roadmap was designed with these outcomes in mind. The advances in glass science and the breakthrough technologies to process and form glass that are being developed and validated in our computer models, in our laboratories, and in our Innovation Center will be the keystone of the glass container industry in a decade or two.

15 Glass International June 2014

Glass recycling

Returnable beer bottles scheme boosts sustainability drive SABMiller’s Stedrick Saayman* explains how the company is committed to sustainability activities throughout its supply chain, production processes and the way in which it adds value to local communities. Returnable beer bottles have a much lower carbon footprint than glass used only once, and help reduce cost for consumers.

www.glass-international.com

M

16

ost companies today are looking to strengthen their supply chain sustainability initiatives. Many fast Moving Consumer Goods (FMCG) companies, including SABMiller, have publically declared water and energy reduction targets.

Around the world, many industryspecific collaboration structures have been established to measure and report key sustainability indicators such as energy usage, waste recovery rates, resource efficiencies and carbon emissions.

These efforts generally drive broad improvement towards better transparency, sustainability and accountability. The idea of a ‘circular economy’ is increasingly gaining ground, and the beer industry is well positioned in this regard.

Depending on the supply chain makeup and the type of container used, packaging accounts for as much as 35% of a beverage product’s carbon footprint, mostly owing to the primary packaging.

A portion of beverage containers and other packaging waste invariably enters municipal waste streams and becomes landfill, although these packaging challenges are not limited to beverages.

Product developers are therefore turning to sustainable packaging design to find novel opportunities within the complete product lifecycle. In many ways, sustainable design efforts challenge the single-use paradigm in today’s age of convenience and ease of disposal.

In the beer industry, reusable bottles and kegs are excellent examples of sustainable multi-use packaging Assuring the quality of out-going returnable bottles in Cervecería Bavaria, Colombia

solutions that have been in use for decades. Returnable glass bottles in particular play a commendable part in sustainable beer supply chains and now more than ever provide tangible packaging opportunities in relation to packaging design, manufacturing technologies, sustainability initiatives and regulatory environments.

Global Scale The many environmental benefits of returnable bottles have arguably not received enough recognition in the beverage industry. Beer is the only category where returnable bottles currently dominate.

About half of all beer brewed globally is sold in returnable glass bottles. In 2010 in Europe, 24.5% of all beer sold was in returnable glass bottles. The proportion of beer sales in returnable bottles differs by market, even in the same region. In Western Europe, for example, 62% of sales in the Netherlands are in returnable bottles, while in the UK it is close to zero.

SABMiller has more than 3.5 billion

returnable bottles in circulation.

That number is equivalent to half of the world’s population and, if stacked side-by-side, would wrap around the earth six times.

It operates large returnable bottle fleets across Africa, Asia and Latin America and within its business in Europe it has about 700 million returnable glass bottles in circulation.

Sustainability remains a key driver of future directions in the glass industry and beer industry in terms of achieving water, energy and emissions reduction targets, and to reduce reliance on virgin resources.

The beer category accounts for 74% unit volume share of glass packaging, and as such strategic packaging choices will shape both these industries.

Apart from reusable kegs for on-tap dispense, returnable beer bottles have the lowest carbon footprint when compared to other packaging options and deserve a closer look.

continued »

LESS EMISSION. BETTER PERFORMANCE. THE EME-NEND® BATCH CHARGER.

NEW GENERATION OF BATCH CHARGER INTRODUCED

The new EME-NEND® generation features chargers with one, two or three screws.

Small melting furnaces can now enjoy all benefits of the world´s best charging technology. In addition the charging performance and lifetime was increased again.

• Completely sealed Doghouse • No uncontrolled entry of false air into the furnace • Reduction of NOx emissions and of energy consumption • Considerably less dust formation due to the transport by means of screw conveyors • Optimal batch distribution in the glass melting • Quick and easy exchange of the screws • Even huge melting furnaces can be operated with one charger and a single doghouse

EME Maschinenfabrik Clasen GmbH • E - M a i l : c o n t a c t @ e m e . d e • w e b s i t e : w w w . e m e . d e

Glass recycling

Reduce, reuse and recycle Glass bottles offer excellent opportunities to ‘reduce, reuse and recycle’, which has long been the acknowledged hierarchy for minimising packaging waste.

To reduce resource consumption and ensure sustainable continuity of glass packaging, a detailed understanding at country level of trends and consumer choices, the needs of all stakeholders along the value chain, and the sustainability considerations that apply to the entire packaging life-cycle is required.

The glass industry has collectively done a lot to educate consumers and influence purchase decisions in favour of glass packaging, and has achieved tremendous improvements in glass recycling in some territories.

Noticeably, Europe has steadily increased the average glass recycling rate to recently surpass the 70% level.

Reusable bottles are heavier for durability, but through meticulous glass bottle design processes we are able to scientifically optimise the design weight of bottles.

When one considers this process of reducing the amount of glass required to produce a bottle, returnable bottles score extremely well on environmental assessments scales for its opportunities to ‘reduce, reuse and recycle’.

Beyond the refillable bottle itself, the secondary bulk packaging such as crates in this supply chain are also reusable.

Resource efficiency While many sustainable design initiatives come at a cost to the end consumer, refillable beer bottles do not.

This unpretentious and well-tested package has the green credentials of being reusable and recyclable and, at the same time, offers consumers a lower price due to a number of inherent

www.glass-international.com

Pallets of returnable bottles in South African Breweries.

18

Glass recycling makes good sense because less virgin materials and energy are required, based on a closed-loop packaging cycle. Returnable bottles are also recyclable at the end of their useful life, either as post-consumer cullet or through being discarded in the brewery refilling process.

When compared to post-consumer recycled cullet, the circular refilling arrangement improves the quality of cullet fed back into the glass producer’s melting process.

Recycling alone will not be enough to secure a sustainable future. Ultimately, the planet benefits when glass containers are designed that can be efficiently produced, reused and recycled in a closed loop system.

This further decouples resource demand and direct environmental impacts from consumption for improved resource efficiency.

Glass International June 2014

efficiencies in the supply chain.

The repeated use of the bottle has an obvious lower cost per serving effect, decoupled from virgin resource demand.

Empty bottles returned for cleaning and refilling through existing infrastructure and distribution channels provide further reverse logistics synergies as return transport legs are efficiently utilised.

In most markets, returnable bottles tend to be larger. These larger packaging formats intended for pouring and sharing fits well with the jovial nature of beer and social drinking occasions and improves the affordability per serving.

Breweries are able to reliably and efficiently refill glass bottles thanks to the technology advances in bottle washing, inspection and filling and wellestablished operating practices.

Bottle coating chemistries for returnable bottles have also evolved to

reduce scuffing.

SABMiller is working internally and with partners in industry to reduce the amount of water and energy used in the cleaning and refilling process.

Looking ahead Industries survive when they are able to sustainably meet particular consumer needs at an affordable price.

As users and producers of glass bottles and policy makers, we should promote and preserve industry models which make environmental sense. SABMiller is committed to actively pursuing sustainability ambitions in collaboration with our suppliers, peers, partners, governments and rule makers.

The benefits of glass packaging are considerable. It is inert, transparent, and infinitely recyclable and it offers great design flexibility. It is also reusable. The role that refillable beer bottles play within broader lifecycle analysis and industry analysis should not be ignored as this is one opportunity to improve energy efficiency and minimise packaging’s effect on the environment.

In most of the world there are no regulated post-consumer recycling mandates, yet efficient circular economies exist through returnable beer bottle systems globally.

Legislation and other incentives in favour of recycling have a positive and direct impact on environmental sustainability, but should not detract from earth-friendly reuse practices.

Media forecasts generally predict the global share of beer sold in returnable bottles to remain flat, based on a slight expected increase in emerging markets and offset by an annual decline of around 1% in Europe.

Before disposable alternatives became part of our busy lives it was the norm to refill pens with ink and to return milk bottles and soft-drink bottles to the store. Beer is sold in a variety of packages to be enjoyed at various consumption occasions. Returnable beer bottles are sustainable efficient stalwarts of the industry.

Through industry collaboration, strategic partnerships, consumer education and other initiatives, we can preserve a tradition which serves a common purpose in both reducing our impact on the planet and bolstering sustainability efforts.

*Stedrick Saayman, Head of Technical Procurement – Packaging, SABMiller

British Glass

The team Glass Technology Services

Technology leader at the forefront of glass research Robert Ireson* of Glass Technology Services (GTS) outlines some of the groundbreaking projects the organisation is involved in, in partnership with industry and academia.

G

Partnership Through funding a Knowledge Transfer Partnership (KTP) with the University of Leeds, we’re also further developing our high quality glass melting infrastructure, expanding the range of glasses we can supply to the photonics industry. Funding a separate part-time post-doc secondment from the University of Leeds is enabling us to support other research developments and grant funded projects within the organisation – particularly focusing on specialist glasses for near infrared (NIR) and midinfrared (MIR) applications. And when it comes to product innovation, we’re working in partnership with manufacturers and universities across Europe, developing new glass compositions, coatings and processing – in many cases helping to take innovations from concept through to product commercialisation.

Project grants

GTS has been “awarded nine project grants over the past two years, having a value in excess of

”

£1.6 million.

GTS has been awarded nine project grants over the past two years, having a value in excess of £1.6 million, with seven of those from the UK’s innovation agency, the Technology Strategy Board and two funded under the EU’s FP7 framework and Marie Curie IAPP programme.

We’re keen to develop and participate in new projects and partnerships. With a grant application success rate of more than 90%, we can offer advice on the variety of funding sources available, from commercial organisations, government bodies and institutions and can assist in the writing of grant proposals.

GTS has an established reputation and global network of academic and commercial partners across many sectors and is in an ideal position to help pull together world-class consortia of experts to help with any glass-related development.

International clients in many markets – including architectural, automotive, food and drink, pharmaceutical, technical, defence, photonics and biomedical – enable us to work on exciting, world-class developments, demonstrating the incredible strength and versatility of glass and to continually push the boundaries of what can be achieved.

A number of our current projects are included below and the first of these demonstrates how technology developments made in specialist areas are helping us bring new technologies, developments and transfer knowledge into the mainstream glass industry.

continued » Glass International June 2014

www.glass-international.com

lobal demand for our knowledge in glass continues to grow and has led to continued expansion at GTS across our product testing, consultancy, innovation, research and development and chemical analysis services for the glass supply chain.

Making extensions of scope to our technical UKAS accreditations and undertaking major investment in new plant equipment, people and training, our testing remit has been extended to include various methods of ICP-OES (inductively coupled plasma optical emission spectroscopy) and FTIR (fourier transform infrared spectroscopy).

GTS is also now a Notified Body for glass construction products under the Construction Products Regulation, following recommendation to the EU by the UK government.

19

British Glass

Cutting edge GTS, with support from the University of Leeds, is involved in two new projects which are developing high speed laser processing techniques for the cutting and shaping of flat glass. If successful the technology will provide a fast, cost effective route to cutting challenging glass substrates. The technologies under development will also look to customise optical properties of glass components at the same time.

Using our new laser facility, the project will investigate non-contact laser processing and look to demonstrate the technology as both feasible and a step-change in processing – enabling highspeed, low-cost, cutting, shaping and engraving.

If successful, this technology could translate from the flat glass industry into other sectors – such as tableware, optical components and specialist processing.

3D-BioGLAM.

Bone trauma

www.glass-international.com

Joint treatments

20

We’re working with an international consortium of academic and business partners to create a new generation of joint and bone treatments, using specialised bioceramic polymer composites, which minimise invasive surgery and improve patient recovery, addressing needs such as osteoarthritis, vertebral and maxillofacial bone fractures.

The Restoration project demonstrates the benefits of glass in the treatment of degenerative joint disease and broken bones.

Bioceramic polymer composites can conform to a patient’s anatomy, protect and support the fractured bone and resorb non-toxically within 24 months of placement.

New injectable composites are also stimulating bone regeneration and delivering specific drugs to the target site. In the treatment of osteoarthritis, bioceramic composite plugs are being developed, which minimise invasive surgery and could delay or completely remove the need for a total joint replacement. GTS is working in partnership on the project, with the University of Newcastle upon Tyne, Sagetis Biotech, Bionica Tech, Orla Protein Technologies, Karolinska Institutet, Acondicionamiento Tarrasense Associacion, Universidade de Eura, Institut Quimic de Sarria, Fondazione del Piemonte per l’Oncologia and JRI Orthopaedics. (http://restoration-project.eu)

Phosphate Fibres.

Glass International June 2014

Our specialists are leading a project in which we have developed a working prototype fibre drawing production facility to pave the way for industrial manufacture of bioresorbable phosphate glass fibre glass tows.

These are specialist fibres which can be used for a multitude of biomedical applications, including the treatment of serious bone trauma.

The production facility aims to produce bioactive phosphate-based glass fibres in a form that can be used to produce fabrics and reinforced plastics allowing clinical uses.

The materials produced from the glass fibres stimulate cell growth and are gradually replaced by cells such as bone or skin due to the unique ability of the material to dissolve in body fluid in a controlled manner. Other partners in the project include The University of Nottingham, Controls Interface Ltd, Invensys-Eurotherm and P-D Interglas Technologies.

Revolutionising orthopaedic surgery

Light MiLES.

Laser technology In another project, led by Thales UK’s Optronics business in Glasgow, UK, we’re providing photonics and material science expertise to develop and demonstrate a compact, low cost and eye-safe laser-illuminated imaging sensor, capable of long-range operation.

Light-MiLES (Miniature Laser-illuminated Eyesafe Sensors) will see the development of

customised, ultra-high quality glass materials for use within the laser cavity of the sensor, which will enable reduction in the energy requirement and weight of the final product while offering improvements in device performance.

The ‘eye-safe’ laser technology has far reaching applications, especially where human exposure is unavoidable – and could include applications such as optical communications, medical diagnostic use, remote sensing (LIDAR), range finding and targeting across defence, medical, construction, domestic and commercial markets.

Other partners in the specialist consortium include Gooch & Housego Ltd and the University of Leeds.

The FASTIC.

In partnership with specialists in ultra-fast lasers, materials and orthopaedic implants, we’re developing a new technology which will allow surgeons to customise joint replacements during surgery, when there is bone loss due to bone cancer, dissatisfactory implants or other situations where bone loss cannot be quantified prior to operating.

The FASTIC (Femtosecond-pulsed-laser Augment/bioglass Sintering Technique for Implant Customisation) project is set to revolutionise joint replacement surgery thanks to the development of new lasers and orthopaedic biomaterials.

The bench-top laser systems will be used alongside newly-developed orthopaedic bioactive glass materials, which surgeons will be able to sinter together without raising the temperature of surrounding bone or tissue.

continued »

British Glass

The technology has the potential to revolutionise complex joint replacement surgery and to be applied in other fields that require rapid manufacture on heat sensitive substrates.

Our partners in the project include project leaders JRI Orthopaedics Ltd as well as M Squared Lasers Ltd, the University of Leeds and the University of St Andrews.

In a separate project, also led by JRI, GTS is working to develop a novel additive manufacturing technique which will utilise selective laser sintering of bioactive glass materials to create customised three dimensional structures for use in biomedical implants. The project is also looking to translate the technology for use in other applications, including sensors for use in the photovoltaic industry. Other partners in the project include the Manufacturing Technology Centre Catapult, 3T RPD Ltd., Sheffield University based Mercury Centre and Delta T Device LTd.

the glass supply industry both in “GTS workstheacross UK and internationally. �

Knowledge transfer While many of the above projects are associated with specialist glass applications we are particularly excited about a number of processing technologies from these areas that we can see potential for in the mainstream glass industry. We also have a number of commercially funded projects running closer to market in the mainstream industry which unfortunately we can’t discuss due to commercial confidentiality.

Our specialist teams are delighted to be part of these and other, groundbreaking projects. Exploiting technologies in material science, advanced materials and photonics, enables the glass industry to be at the forefront of innovation and to demonstrate the true worth of glass in many applications.

See our portfolio of disclosable projects and studies online at www.glass-ts.com/projects or sign-up to our newsletter for regular updates on projects, news and other developments.

If you have a product idea, require a novel glass solution, or have research in mind why not contact us to discuss your ideas.

Our specialist knowledge in glass, combined with experience and expertise in EU funding opportunities, mean that we can assess a variety of project funding, delivery and exploitation options.

GTS works across the glass supply industry both in the UK and internationally, providing analysis, consultancy, testing and research and development support across the glass, food and drink, architecture and construction, retail, medical, pharmaceutical, defence and biotech sectors.

*GTS Innovation Team Leader, website www.glass-ts.com Email enquiries@glass-ts.com.

Glass International June 2014

History

Prof. John Parker Turner Museum of Glass and ICG

It’s all done with mirrors

www.glass-international.com

L

22

ast month we considered the history of mirrors.

Both steady improvement and step changes in technology led finally to cheap mirrors, with seismic consequences.

By the 19th century the population at large could view their own image. They no longer had to rely on someone else’s description. This stimulated the industries of cosmetics, fashion and design. In architecture, mirrors brought light to dark corners and enlarged rooms. Now partially reflective external glazing in office blocks helps to control solar gain.

Dentists and mechanics use mirrors to repair our cavities and our cars.

The military have also appreciated the possibilities. Simple periscopes were used as early as ‘the 30 years war’ for spying (1618-1648), while submarines use highly sophisticated systems to navigate unseen.

Another early application of mirrors still used by schoolboys today was the coding and decoding of messages. Leonardo da Vinci was a keen exponent of mirror writing but perhaps because of his lefthandedness – it avoids smudging wet ink – rather than a desire for secrecy.

Good quality mirrors led Greek and later Arab philosophers to investigate the mathematics of reflection. Of course they worked with metal mirrors as did Newton when making reflecting telescopes.

Apocryphal stories abound of Greeks, inspired by Archimedes, using shore based mirrors to ignite the wooden boats of approaching Roman enemies but these have been discounted e.g. in a recent TV documentary that attempted to duplicate the experiment. Such stories may have their origins in the dazzling of potential attackers so they were unable to navigate.

Now glass underpins the development of reflecting telescopes because the best image quality requires a surface figured to an unbelievably high accuracy. And the shape over several metres must not change significantly with temperature.

Glass International June 2014

Zero expansion glass ceramics have been created for this purpose. The European Extremely Large Telescope (E-ELT) project will use a 39m mirror, in segments which are positioned dynamically by computer.

Such mirrors are usually ‘silvered’ on the front to avoid the distortions and heating caused when light travels through the glass. In reality silver is avoided because it oxidises.

Typically aluminium is deposited instead.

We normally link mirrors to the visible wavelengths in the spectrum and silver is valued for its high and constant reflectivity throughout this range. Gold though is a particularly efficient IR reflector, while aluminium is ideal for the UV. Car mirrors sometimes use the less reflective chromium to avoid dazzling the driver. Tailored multilayer coatings of transparent materials can also generate excellent reflectors at specific wavelengths.

Today the focusing of the sun’s energy using mirrors is part of the drive for new energy sources. Solar furnaces can achieve temperatures up to 4000°C, able to melt steel, manufacture fuels using high temperature chemistry, or create nanoparticles by sublimation. Indian scientists are considering their use for cremation, which otherwise requires 200300kg of wood.

Two-way mirror A one-way mirror (aka a two-way mirror) is an intriguing application, often at the heart of television crime dramas. It has a partially reflecting coating.

An interviewee sees a mirror while the TV audience watch, apparently through a normal window. In reality light travelling in either direction behaves the same, a limitation imposed by thermodynamics.

Otherwise identical heat sources on each side would be out of equilibrium; one would heat up while the other cools by transferring radiation unequally. The key

is the differing light levels on each side.

On the brighter side the reflection is seen while on the darker side the transmitted image dominates. Magicians also use this effect. An uncoated glass sheet slanted at 45° to the audience will reflect 7% of incident light. It shows the rear of the stage but can also reveal hidden objects behind the curtains, depending on lighting. This effect has the stage name Pepper’s Ghost although the original patent was Dircks’.

The first demonstration was on Christmas Eve, 1862 at a performance of Dicken’s ‘The Haunted Man’. Many theatregoers, including allegedly the physicist Michael Faraday, puzzled over the effect, returning time and again to uncover its secret.

A kaleidoscope uses three glass sheets set at 60° to produce a triangular prism. At the far end a hollow transparent disc contains coloured chips. The objects themselves can be seen through the eyepiece but also an hexagonal arrangement of identical images created by the high reflectivity of the glass to light incident at glancing angles.

A mirror maze is a fairground novelty consisting of large partially reflecting sheets set to give a number of confusing images for the victim attempting to negotiate a safe path.

Fairgrounds also complete the circle of development by using mirrors with profiles that are far from flat to create comically distorted images of any who dare to look.

Bibliography Wikipedia: John Henry Pepper, Solar Furnaces

*Prof Emeritus John Parker, Curator of the Turner Museum of Glass at Sheffield University.

Email j.m.parker@sheffield.ac.uk Website www.tunermueseum.group.shef.ac.uk

FIVES, Unparalelled experience with innovative technologies for special glasses Visit us at Mir Stekla

4 - 6 June, Mo scow, Russia Booth No 21A 32

The supply of working ends, forehearths and feeder + furnace melting technology, electric heating and boosting =

TOTAL SOLUTIONS to glass melting and conditioning SERVICES

EQUIPMENT Penelectro Melting Technology Penelectro Electric Boosting Technology Batch Charging & Level Control BH-F 400 & 4000 series Working End BH-F 400 & 4000 series Forehearth BH-F Colourant Forehearth Electric Forehearths, Gathering Bays & Delivery Systems

Penelectro C-Type Electrode Holders Penelectro Ancillary Equipment BH-F Oxy-Gas Firing System BH-F ESG Feeder & BH-F 50 Series Feeder BH-F 1000 Servo Feeder BH-F 900 Series Mechanical Feeder BH-F Cascade Bowl

Project evaluation and feasibility study Project Management Equipment Specification and Design Manufacture and Supply of Specialist Parts Installation and Commissioning Service Technical Support, Advice and Training

glass.fivesgroup.com Fives Stein Ltd. - 4A Churchward - Southmead Park, Didcot - Oxfordshire OX11 7HB ,UK Phone: +44 (0)1235 811111 - Fax: +44 (0)1235 817676 Web: www.fivesgroup.com/fivesstein/uk - E-mail: fivesstein-uk@fivesgroup.com

Russian overview

Chinese glass producers eye Russian expansion Eugene Gerden* reports that recent sanctions on Russia may have a detrimental impact on Western glass manufacturers with sites in the country.

www.glass-international.com

T

24

he Russian glass market is on the verge of big changes, due to a forthcoming expansion of Chinese producers and the reduction of activities of western producers, caused by sanctions recently imposed on Russia by the EU and the USA. The deterioration of relations with western countries, as well as recent threats of nationalisation to the assets of western companies operating in Russia made by top Russian officials, has led to the deterioration of the business environment in the Russian glass market.

Many western manufacturers have not ruled out the possibility of revising their investment projects in Russia.

The situation may further deteriorate further if a provocative law is adopted.

The “Confiscation of property, assets and accounts of European and US companies, operating in Russia” is under discussion in the Russian Parliament.

The design of the law is currently underway and there is a possibility that its adoption may take place in forthcoming weeks.

The adoption of the law is expected to become Russia’s response to the latest package of sanctions on the country.

The sanctions were approved by the US Congress on Russia several weeks ago and are considered by some analysts as the toughest since the Cold War. It is difficult to say which foreign assets may be confiscated. Theoretically, the Russian government can seize foreign company assets operating in Russia.

Another response to the imposed sanctions may be new duties on the import of raw materials, supplied by western producers to their Russian plants.

Glass International June 2014

Chinese expansion Meanwhile, there is a possibility that the decline of investment by western producers in Russia may result in the expansion of Chinese glass producers within Russia.

The Russian government has already promised to create favorable conditions for Chinese investors doing business in Russia during the recent visit of Russia’s president Vladimir Putin to China, where a number of bilateral contracts were signed.

As part of the visit, the Russian government has already promised Fuyao Glass Industry Group, China’s flagship glass producer, to provide assistance in its further expansion into the Russian auto glass market.

In September last year, the Chinese company announced the opening of a plant for the production of automotive glass in the Kaluga region. The declared volume of investment reached USD$300 million. The annual capacity of the plant is 1 million glass sets.

As part of the recent talks between Russia and China, the Russian government has supported the idea of tripling the capacity of Fuyao’s plant up to 3 million tonnes and to establish a full-cycle of production.

The plant specialises in finishing operations of production heat treatment and bonding. At the same time glass itself is supplied from Fuyao’s Chinese factories.

Japan The increase of capacities and the establishment of a full cycle of production is expected to allow Fuyao to compete with Asahi Glass, the current market leader. It owns the domestic Bor Glassworks and has 60% of the Russian automotive glass market.

In the case of Asahi Glass, the deterioration of relations between Japan and Russia may result in the suspension of some of its projects in Russia, the most important of which involves building a glass plant in the Tomsk region, Siberia, construction of which should start this year.

According to the Russian Ministry of Industry and Commerce, which oversees the project, the project might be suspended indefinitely.

According to Asahi’s initial plans, the plant should be commissioned by 2015 with a capacity of 800-1000 tons per day.

Investment in the project is €180 million. Some of the funds are expected to be invested in the development of a local quartz sand plant.

The plant would specialise in the production of float-glass, while its major sale markets would be Siberia and the Far East. Some production would also be supplied to the Asian market.

Representatives of the company declined to comment.

At the same time, there is a chance the Ukrainian crisis and sanctions against Russia may also have a negative effect on Guardian Industries’ Russian business.

Guardian is another western glass major, which has had success in Russia in recent years.

Last year the company opened Guardian Glass Rostov, the company’s 10th European plant and the largest in its history. The plant cost RUS8 billion (USD$240 million) with a capacity of 900 tons per day.

According to the company’s initial plans, the site should be expanded in the next few years, but these plans may be revised due to the recent events in Ukraine.

*Freelance reporter, Russia.

Forehearth technology

Concepts for insulating wool (C-glass) forehearths

Jürgen Grössler* outlines how electric heated conditioning systems have a number of technical advantages over gas systems, as demonstrated by Sorg’s STF/E forehearths.

Design criteria and dimensioning The design of fibre glass conditioning

Indirect air cooling (if necessary) Zircon mullite superstructure

Open glass surface

Electrical heating - molybdenum electrodes

Fused cast AZS channel blocks

Fig 1.Structure of a forehearth for C-Glass production

forehearths is determined by the operating parameters of the production process. The type of melting furnace; full-electric or fossil fired is important for the estimation of the riser temperature of the glass.

The temperature gradient of the glass from the forehearth entrance up to the bushings must be calculated using the corresponding tonnages to anticipate the critical operating conditions at the design stage.

The required heating and cooling systems are then included into the technological layout. If cooling systems are necessary, they are ideally arranged near the forehearth entrance to use the remaining channel for homogenisation.

For C-Glass indirect air cooling systems are normally used to keep the forehearths closed because of the volatile glass components (boron). Some parameters, which are important for other glass types like residence or cooling rates are secondary considerations. It is more important to find the right balance between the dimensioning of the heating systems and the degree of insulation of the forehearth refractories.

Often the layout of the forehearths is restricted, especially for production lines in existing buildings. This often makes

continued » Glass International June 2014

www.glass-international.com

R

ecently a number of publications have heralded several glass technology anniversaries.

Examples include the Owens Bottle Machine 1904, the first IS-Machine 1924 and the Emhart K-Type forehearth in 1944. There is an anniversary to celebrate in the area of fibre glass too.

Since 1904 insulating material has been produced from so called C-Glass.

C-Glass is an alkali lime silicate glass with a boron content of 4.5-6.5%.

Initially C-Glass was used as a thermal insulating material, later for sound proofing and fire protection.

In the beginning a 2-step production process was employed with glass rods as an intermediate product. This made the production process complex since the fibres needed to be produced from an intermediate product.

Fibreglass was not widely adopted until it was possible to produce fibres directly from the glass melt.

Today C-Glass insulating wool is almost solely produced using the TEL process.

The German Friedrich Rosengarth developed and patented centrifugal technology after being inspired at a parish fair watching cotton candy being made.

25

Forehearth technology

an angled design necessary. For green field sites it is advantageous to arrange the forehearths in a straight layout. This makes it easy to achieve the required thermal homogeneities. For suboptimal angled designs electric auxiliary heating systems are foreseen to influence the different thermal layers and left- to right-differences directly.

Structure of a forehearth for C-Glass production The channel blocks rest on the insulating material in steel casings. The fused cast or chrome oxide containing ceramic bonded channel blocks are

Fig 2. Water cooled plugs into the electrode holes.

tightly assembled. However, expansion joints are foreseen at certain locations.

During heat-up, these expansion joints allow the expansion of the refractories and will close during the heating up process.

The superstructure of the forehearth consists of specially shaped refractories which are covered by insulating bricks.

The refractories are fixed by means of a steel bracing structure bolted to the steel casings. The superstructure is used as a combustion chamber for gas heated forehearths, but also for the heating-up and emergency combustion in case of electrically heated forehearths (Fig 1).

www.glass-international.com

Heating systems

26

It is estimated, that 90% of all forehearths use fossil heating systems, while only about 10% are electrically heated.

Our combustion systems consist mainly of a gas-air-mixing skid supplying burner manifolds. This system is simple and reliable. The disadvantage is that fossile heating systems produce waste gases, which usually exit into the factory. These waste gases consist mainly of carbon dioxide, water vapour and volatile boron and alkali compounds Glass International June 2014

from the glass. This makes the waste gasses aggressive towards refractories in the temperature range of 750°C to 950°C. The design of the chimneys has to especially take the waste gas velocity under consideration. Poorly designed or incorrect chimney placement leads to high maintenance efforts and possibly premature failure and replacement.

Gas heating systems especially influence the temperatures of the glass surface while it is difficult to influence the bottom glass. Furthermore, gas combustion systems always require a certain minimum output to prevent back firing which restricts their operating range. An electric heating system does not have this restriction and does not produce any waste gases. The forehearth superstructure can be completely closed and no waste gasses are emitted into the surroundings. A small number of chimneys will still be necessary for the initial heat-up and emergency heating, but they are closed during normal operation.

This is why electrically heating systems by means of molybdenum electrodes are seen as the ideal solution for C-Glass forehearths.

seal the electrode holes are not necessary.

Using normal uncoated electrodes which are less expensive requires the protection of the molybdenum against oxidization at high temperatures. This requires the installation of water cooled plugs into the electrode holes (Fig 2).

The molybdenum electrodes are only then inserted when the glass level is achieved. This insures that the molybdenum is always immersed in glass and has no atmosphere contact at high temperatures. The sealing of the electrode is again done by creating a protective layer of glass around the electrode. Air cooling of the electrodes aims above all to protect this protection layer and should be installed for forehearths running at very high temperatures (Fig 3).

The cooling air should be applied directly towards the connection bar as shown in the picture. The cooling air generates an overpressure in the hole and prevents cakings or accumulation of dirt particles and minimises the temperature of the connection bar.

The second electrode type is watercooled electrodes similar to those found in furnaces. These electrodes act as a

Forehearth electrodes We use two types of forehearth electrodes: water cooled and dry electrodes without cooling.

Dry electrodes are most common.

These electrodes consist of two parts, a molybdenum rod and a temperature resistant connection bar.

The molybdenum rod is inserted into the glass while the connection bar is used for the fixation of the electrode and the connection to the power supply. All current carrying parts of the electrode are protected by means of protective shielding.

Molybdenum oxidizes at high temperatures when in contact with oxygen. Because of this molybdenum needs to be protected against air contact at temperatures above 600°C. This protection is realized using two possible methods. The preferred method is to use coated electrodes. The advantage is, that the electrodes can be installed prior to or during the heat up process. The forehearths are heated up and filled with glass while the electrodes are in place.

After the filling of the furnace the electrodes need to be sealed properly.

This method requires much less attention and effort during heating up and filling. Temporary water plugs to

Electrode head Sealing plug (molybdenum) Connector Glass seal

Light air cooling

Fig 3. Air cooling of the electrodes aims to cool the protective around the glass.

heat sink compared to uncooled electrodes. This is no obstacle in the area of the forehearth entry, especially in forehearths with high tonnages, but can be a problem near the bushings especially for production lines requiring good thermal homogeneity. Further disadvantages are the necessity to observe the holder temperature and water flow as well as having to provide a cooling water loop with clean and treated water.

continued »

Install Forget

ATS 250 - ANNEALING LEHRS - DECORATING LEHRS TEMPERING LINES - LEHRS UPGRADING

ANTONINI Srl • Via Medaglie d’Oro Resistenza, 2 • 50057 Ponte a Elsa (FI) • Italy | ANTONINI NORTH AMERICA - Pittsburg, U.S.A. Tel.: +39-0571-93221 • Fax: +39-0571-931828 • E-mail: antoninisrl@leonet.it • www.antoninisrl.com

Forehearth technology

The electrodes are staggered for each heating zone. This results in consecutive longitudinal heating circuits. Each heating zone is equipped with single phase dry transformers. The power regulation is done by means of thyristors which enables a stepless power variation.

Heating up equipment To commission the forehearths they have to be heated up to the operational temperatures by gas heating, for which three methods are used (Fig 4):

glass melt. All relevant standards and regulations are taken into consideration for our systems.

Energy cost and payback Energy costs together with the initial investment is a very important factor.

Electricity is more expensive compared to gas in most countries. Even though the energy efficiency is much better for electrically heated systems, the total energy cost is higher than gas. The gasheated forehearth is the cheaper option.

Increased requirements

Fig 4. Heating up equipment.

Burners with ignition and flame surveillance Advantages are automatic operation and a high safety level achieved by the ignition and flame surveillance.

Disadvantgeous are higher control efforts and the higher price.

Burners with separate air and gas supply Advantage is easy use and setup. The disadvantage is the need for experienced personnel and the necessity of continuous monitoring.

www.glass-international.com

Burners with gas connection and natural air aspiration

28

These burners are cheap but have high personnel costs. They are susceptible to disturbances and need to be watched continuously by experienced personnel.

Safety Electric heating systems as well as gas heating systems require high safety awareness and safety measures. The direct electric heating of the glass bath puts it under an electrical load.

Especially for service and maintenance work it is important to consider that even with partly deactivated heating systems current can be conducted by the Glass International June 2014

Forehearths 30 years ago typically had three or four bushings and were pulling 30-50 t/24h. These forehearths were typically 8m long, 0.6m wide, with an installed heating capacity of around 160kVA. Operational life averaged three to four years.

Approximately 15 years ago we built a conditioning system with 10 bushings for 160 t/24h. The total length of the two forehearths was 74m with channel widths of 0.6-1.1m and had a combined heating capacity of 1500kVA. The lifetime of the system was approximately six years.

Today we design and build systems for more than 200t/24h with up to 16 bushings and a design life of seven to eight years (Fig 5).

advantages over gas systems, which are demonstrated by Sorg STF/E forehearths.

Only three of the past 39 newly built Sorg systems for C-Glass were gas fired.

Advantages include the higher energy efficiency, the reduction of volatiles escaping from the melt as well as the avoidance of waste gases. The reaction time of the control loops are faster compared to gas heated systems. The thermal homogeneity is excellent. While gas heating systems cannot be used over the whole range, electrically heated systems can be operated from 0%-100%, which makes them more flexible. Direct electric heating allows, if necessary, the fast unfreezing of the bushings.

The optimal forehearth design incorporates an exact analysis of the requirements of the production system to ensure the achievement of the best operational results with the lowest investment and operational costs.

Even after 35 years of experience with the design, construction and operation of conditioning systems the correct operational design is the most important sucess criterion. This includes the increased use of CFD modelling as an important design tool.

6 Bushings

Three steps to full production A special challenge for Sorg was the design and construction of a C-Glass conditioning system for 220 t/24h. This system consists of two forehearths: One forehearth is angled directly after the riser, the second forehearth is a tandem forehearth in a T-layout.

This system was not commissioned all at once due to production requirements of the customer, but in three phases. At first only the angled forehearth was commissioned. A special design of the insulation material ensured, that the forehearth worked correctly initially as well as during the final full capacity of 220 t/24h. Secondly, one leg of the Ttandem forehearth was commissioned and some months later, the second leg was commissioned. All three phases of the commissioning were coordinated and executed by Sorg.

Shutoff

Shutoff

5 Bushings

5 Bushings

Fig 5. Sorg can design and build systems for more than 200t/24h with up to 16 bushings and a design life of 7-8 years.

References: -

Schott Glaslexikon –MVG-Verlag Allgemeine Technologie des Glases von Prof. Dr. H. A. Schaeffer

-

http://www.Saint-Gobain.com

-

http://www.wikipedia.de

-

Helmut A. Schaeffer; Margareta BenzZauner: Spezialglas-Glastechnik, Deutsches

Conclusions Gas heated conditioning systems for fibre glass are an economical alternative to full-electric systems. Electric systems, however, have a number of technical

Museum.

*Glass Conditioning Manager, Sorg, Germany www.sorg.de

Forehearth technology

How much energy can be saved with air-fuel forehearths?

People often have a hazy idea when they deal with energy on conventional air-fuel heated forehearths. They claim that these equipments are deep pits of energy which is almost the truth. Some also say that glassmakers could easily make huge fuel savings.

François Deblock* explains that the reality is much more complex.

everyone can notice that the fuel range is important. As a consequence, the fuel skid must be designed by the supplier to be flexible enough, so that it will be able to face extreme heating expectations.

We can also point out that the heat released by the cooling glass is not as important, especially when the pull is low or when the glass gob needs to be hot.

The large amount of heat in the fumes is the consequence of two physical phenomena. On one hand, the combustion of cold air with fuel does not deliver a powerful radiative flame due to the large and useless amount of

Fig 1. Order of magnitude of a forehearth thermal balance.

nitrogen and also due to the small temperature difference between the core of the flame and the glass surface. On the other hand, the glass transparency does not facilitate the heat transfer from the combustion along the forehearth.

Finally, glassmakers should not be surprised by so much heat into the fumes: All of them have already noticed high streams of flames coming out from the superstructure in evidence! (Fig 2) Thermal losses through the walls are different if the substructure or the

continued Âť

Substructure: 10%

Thermal leaks: 15% Thermal losses Superstructure: 30%

Fumes: 45%

Hot glass: 0 to 15% Thermal sources Fuel: 85 to 100%

Comment Such data requires some comment. First

www.glass-international.com

I

t is interesting to have a look at a typical thermal balance of a forehearth.

When we audit production lines of flint glass containers whose pulls do not pass over 50tpd, fuel consumptions usually stagger between 15 and 60kW per meter. Of course such a large range is surprising. It is dependent on factories, production standards or distances of the spout from the furnace. This fuel amount represents most of the forehearth thermal sources, whereas the hot glass cooling along the forehearth forms the minor part. The balance between fuel and glass can typically be 85/15%. In the worst cases, when the thermal gradient along the forehearth is nearly flat or when the production line is off, this balance can even reach 100% only for fuel. On the other side, looking at thermal losses repartition, fumes constitute the largest energy pit (roughly 45%), then thermal losses through the superstructure for 3035%, then miscellaneous thermal leaks for 10-20%, then substructure heat losses for 5-10% (Fig 1). All these figures have been taken out from our glassmaking experience. They may be not fully representative of the whole glass container industry, but they give us some relevant orders of magnitude.

29 Glass International June 2014

www.glass-international.com

Forehearth technology

30

Fig 2. Flames reveal the bad heat transfer of the air-fuel combustion.

Fig 3. Functionality of each refractory block makes efficient insulation of the superstructure difficult.

superstructure of the channel are considered. There are usually less losses all around the glass channel than around the combustion chamber.

Such differences can be explained by the design of the insulating sublayers which are continuously put together between the refractory channels and the steel casing, without any thermal bridge, except for the necessary non-insulated expansion zones.

Building an efficient insulation for the superstructure is more complex due to the installation of all the special blocks: Burners, thermocouples, dampers, chimneys or openings for direct cooling.

All these pieces create non-direct radiative thermal losses which are usually difficult to eliminate (Fig 3).

The function of the fuel is to mainly balance thermal losses, but is also the price to pay to keep glass cooling under control and finally achieve good glass homogeneity. Do not forget that the thermal equilibrium of the forehearth is sensitive and could turn upside-down shortly. Bad combustion settings may lead to fuel increase without additional heating. A non-suitable thermal gradient along the channel may start reboiling and glass defects. And generally speaking, producing out of the specifications may cause forehearth troubles.

solutions with highly improved efficiencies. But they also cause other troubles which compromise their development: Possible electrochemical effects, expensive oxygen cost, additional cost for converting an existing forehearth rather than for a basic refurbishment, the need for skilled forehearth operators, scheduled maintenance.

These are the reasons why glassmakers still prefer the conventional premix airfuel heated forehearth, fully validated for its reliability, flexibility and simplicity, despite its high energy consumption and its high level of emissions.

Another option for minimising energy cost is to provide the forehearth with some hotter glass, coming from the throat at the entrance of the channel. As cooling glass can easily release energy by radiation, the outcome is direct savings on fuel consumption.

A third interesting possibility is to reduce thermal losses. It makes sense for energy savings, but it is also often justified by the following statement: The more insulated the forehearth will be, the more homogeneous the glass should be. If the steel casing is large enough, it is possible to design an efficient thermal insulation all around the refractory channel, but taking care of the refractory corrosion at the glass surface.

Microporous insulating panels are known as reliable materials, but they are also very fragile. In any case, one must take care of the design to fulfil all the specifications of the future forehearth: Pull range, min-max thermal gradients, expected colours, job changes waiting time. If the forehearth is expected to be flexible, some obvious engineering

Energy As energy is a key issue for container forehearths, suppliers and glassmakers must carry on with innovation and improve the efficiency of the process.

The most profitable option is to change the heating device. Full-electrical and oxyfuel forehearths, as they are currently designed, offer interesting Glass International June 2014

solutions have been developed to speed up transient periods and to achieve suitable thermal conditions for conditioning the glass properly.

Also keep in mind that some insulating materials have limited service temperatures and that the forehearth will have to produce for the next 10 years!

Minimal energy consumption All in all, there are relevant engineering solutions for minimising the energy consumption on forehearths. Based on our industrial glassmaking experience, we know that we can target between 15 and 20kW of fuel per meter of a conventional flint glass forehearth.

However, such consumption cannot be reached everywhere. It also depends on forehearth layout and production facilities.

To get such results, the design phase is crucial. A customer specification must be accurate and detailed, based on a faithful vision of the future. Unfortunately, it is more difficult to have a clear vision over a few years.

Finally, the selected design will not only depend on technical factors. It will also depend on external parameters that impinge on industrial profitability. Local energy costs, security on energy supplies, greenfield or refurbishing project, political and economical stability of the country or currency exchange rates are some factors.

AGMS will be exhibiting at glasstec Dusseldorf in Germany in October 21st to October 24th, 2014.

Managing Director, AGMS, Blaringhem, France www.agms-intl.com

Forehearth technology

Forehearth control – Infra-red pyrometers or thermocouples?

John McMinn* describes how to measure forehearth performance and optimise performance.

www.glass-international.com

I

32

have been privileged enough to have spent 38 years in the glass industry and to have met and worked with glass plants in 74 countries.

Apart from 12 years as a research physicist studying heat transfer in glass, I have spent the majority of my career designing a variety of new shiny forehearths including the PSR500 and the Emhart/Sorg 340.

As managing director of Forehearth Services I have spent the past six years looking at – well, shall we say less shiny forehearths.

Unfortunately forehearths don’t remain shiny for long. They operate in a challenging environment hotter than the Sahara desert at noon and rained on by condensing mould dope. No surprise therefore that even the dedicated few pay infrequent visits to the forehearth platform.

Not wanton neglect exactly, but operating more on the basis of ‘as needs must’. It is no surprise therefore that forehearth performance deteriorates with time. The problem is how does one measure forehearth performance? It can be hard to quantify and even more difficult to quantify and recognise deteriorating performance.

Forehearth Services has performed forehearth audits on more than 100 forehearths in more than 20 countries, and quite simply we measure forehearth Glass International June 2014

performance. More importantly we identify the steps that need to be taken to return the forehearth and its combustion and control systems back to optimum performance.

Audits Lack of performance is due to a combination of factors ranging from mechanical de-calibration to inappropriate forehearth operation – with quite a few stops in refractories, cooling systems and control equipment in between.

An audit comprises a holistic system of tests, analyses, and measurements of all functions relevant to forehearth performance including forehearth operation. When the audit data is analysed it provides a map of what needs to be done to optimise the forehearth performance.

The principal objectives of an audit are to increase pack rates, decrease energy wastage, protect plant equipment from improper operation and decrease the likelihood of a catastrophic, unscheduled shutdown.

Unsurprisingly, the overwhelming majority of clients that commission an audit do so because one or more of their forehearths is compromising production. Sometimes the reasons for poor performance are multi-causal and complex. In others the cause may be

down to lack of training of forehearth personnel.

Blister is a common reason for commissioning a forehearth audit. The audit can, by a system of elimination tests, identify the origin and cause of the blister. The inability of the forehearth to maintain a stable gob weight is also high on the list of reasons for commissioning an audit. But, frankly, the problems associated with operating a forehearth optimally are abundant.

Infra-red pyrometers vs thermocouples As an example, Forehearth Services has for a long time been advising customers operating with dark amber or green glass to avoid using infra-red pyrometers as zone control sensors. The advice is based on a great many forehearth audits where it has been shown conclusively that using an infra-red pyrometer, rather than a thermocouple, greatly compromises the control and performance of the forehearth.

Consider the two charts below that show control reactions of forehearths operating with dark amber glass. Fig 1 shows the response of a forehearth zone combustion loop to a 5°C set point increase, shown in blue. Control of the

continued »

Forehearth technology

70

1156 1155

60 50

1153

Output %

Temperature: °C

1154

40

1152 1151

30

1150

SP PV OP

20

1149 10

1148

0

1147 1

3

5

7

9 11 13 15 17 19 21 23 25 27 29 31

surface, an increase in combustion can affect the glass surface within a short timescale. Consequently, a pyrometer reading the glass surface will quickly assume the set point has been achieved.

The problem is that the signal from the pyrometer tells the controller that the zone is at the required set point temperature where, in reality, it is only the glass surface that has achieved the required temperature increase. The temperature of the bulk of the glass remains unaltered.

Time: mins

Case study

34

Glass International June 2014

glass colour. A pyrometer operating over the above waveband can typically ‘see’ up to 35mm into the glass. For dark glasses however this distance is reduced to as little as 0.5mm.

From a glass control perspective the situation is made worse by the fact that the first 50% of the glass depth accounts for 80% of the signal delivered by the fibre-optic to the detector. For flint glasses this is tolerable but for dark glasses this results in 80% of the signal being derived from the top 0.25mm of the glass depth – i.e. effectively the glass surface.

By contrast the thermocouple measures some form of averaged glass temperature at a depth of 25mm – which is why the sensor took almost three minutes to react to the increase in combustion output and a further 12 minutes to achieve set point. The pyrometer however responds within one minute and achieves set point after a further two minutes.

While an increase in the combustion output takes time to affect the glass temperature 25mm below the glass

A recent audit was conducted on a forehearth where each zone was controlled by a pyrometer. In addition, each zone was equipped with a tri-level thermocouple approximately 650mm downstream from the pyrometer and used for glass temperature monitoring only. The set point was increased by 5°C and within a few minutes the pyrometer registered that set point had been achieved and consequently the combustion output was reduced.

However, the tri-level thermocouple registered no increase in glass temperature at any level in the glass.

This is a strong argument to suggest that pyrometers are inappropriate for control of dark coloured glasses.

Indeed, audits conducted on forehearths operating with dark glasses invariably identify the pyrometer as a source of control problems. That is not to say that thermocouples do not have potential for forehearth control problems. But that will have to be the topic of a future paper.

*Managing Director, Forehearth Services UK. www.forehearthservices.co.uk

70

1168 1167

60

1166 50 1165 1164

40

1163

30

1162

20

1161 10

1160 1159

0 0

5

10

15 Time: mins

Fig 2. Pyrometer Response to 5oC SP Increase.

20

25

30

Output %

loop is by a thermocouple positioned at the front of the zone at the standard depth of 25mm below the glass surface.

The reaction of the controller output, shown in green, shows the set point increase caused a 35% increase in combustion output. This increase in output resulted in the glass temperature, shown in red, achieving the new set in 14 minutes.

By contrast, Fig 2 shows the combustion loop response to the same set point increase. In this case, control of the zone is provided via a fibre-optic pyrometer positioned at the front of the zone. The 5°C set point increase results in a much smaller 4% increase in combustion output. Despite this modest increase in combustion the set point was achieved in three minutes.

It is tempting to conclude that, if you require fast, efficient forehearth control, then you should choose pyrometers in preference to the apparently slow reacting control offered by thermocouples. Unless, in addition to the forehearth combustion system, the pyrometer is mysteriously providing its own heat input there is something seriously wrong with this comparison.

The discrepancy between forehearth control and pyrometer control is due to differences in glass measurement methodology between the two instruments. The standard pyrometer used in forehearth control utilises a silicon cell operating within a narrow waveband of 0.7 to 1.1 m. This is the essence of the problem when using this type of temperature sensor in forehearths operating with dark coloured glass.

The glass depth from which the detector can receive radiation is dependent on both the wavelength over which the detector operates and the

Temperature: °C

www.glass-international.com

Fig 1. Thermocouple response to 5oC SP Increase.

SP PV OP

VETRIGLASS S.r.l.

Via 1° Maggio n. 35 48010 CASOLA VALSENIO (RA) - ITALY Reception +39 0546 76711 Fax +39 0546 76065 Customer Service Fax +39 0546 73082 Procurement office Fax +39 0546 76799 mail. info@vetriglass.org

OmniLab

Ne New w things are are coming. coming. See us at: at:

TEL+1.724.482.2163 +1.724.482.2163 WEBAGRINTL.COM E-MAILSALES@AGRINTL.COM E-MAIL

Toughened glass

Unexplained glass failure Don’t jump to inclusion conclusions Glass Technology Services (GTS) is urging property owners and insurers not to assume that an NiS inclusion is the cause of an unexplained breakage in toughened glass.

A

B

C

Fig 1. Competition: Which of the butterfly failure patterns in Fig 1 is caused by NiS?

www.glass-international.com

N

36

ickel Sulphide (NiS) inclusions are a known issue for toughened glass, resulting from the presence of nickel contaminants in the glass melt reacting with sulphur, most likely from the furnace fuel.

During thermal toughening, these inclusions undergo a crystalline phase change to a smaller form and are fixed in place within the glass upon cooling.

Over time the inclusions grow and can eventually impart enough stress in the glass to cause spontaneous failure.

When toughened glass panels fail, Nickel Sulphide (NiS) inclusions are the ‘go to’ culprit. Independent research and development, consultancy and testing specialist, Glass Technology Services (GTS) is urging property owners and insurers not to assume that a NiS inclusion is the cause of an unexplained breakage.

Cave, said: “It should never be assumed that the seemingly spontaneous failure of a toughened glass panel is due to a NiS inclusion. Numerous other factors could be involved, such as non-NiS inclusions, vandalism, design flaws, poor toughening, edge damage and damage due to contact with fittings and fixtures. Any unexplained failures of toughened panels should undergo analysis to determine the true cause of failure.”

Even where a ‘butterfly’ failure pattern is observed – something commonly associated with a ‘spontaneous’ NiS failure – a NiS inclusion cannot be assumed. The three images in Fig 1 depict this same failure pattern, however, whilst one is due to a NiS inclusion the other two have resulted from a glassy inclusion within the glass and an impact.

October? Simply tell us which of the butterfly failure patterns in Fig 1 is caused by NiS for the chance to win. For more information follow us on twitter @GlassTesting and look out for our #ButterflyCompetition announcement, alternatively subscribe to our newsletter at www.glass-ts.com to receive details in our next bulletin.

Supply chain The GTS team works throughout the glass supply chain - from manufacturers, processors and installers through to architects, consulting engineers, property owners insurers and lossadjusters - to analyse glazing failures.

This service can be provided both on-site or in the laboratory.

When a fully toughened panel fails, the failure origin must be analysed to determine the cause of failure – therefore

Competition Other factors GTS Glass Technologist, Dr Richard Glass International June 2014

Fancy winning an iPad Mini or a place on our Glass Appreciation Course this

continued »

Toughened glass

it is essential that the broken remains are retained for investigation. Once the origin is identified this is analysed using optical microscopy, scanning electron microcopy and energy dispersive x-ray spectroscopy, to identify the presence and nature of inclusions (NiS or otherwise) or physical damage.

Where inclusions aren’t to blame, physical damage and residual material can be analysed to determine likely contacting objects, whether it be from an outside source or from interactions with fixtures and fittings in the framing system.

These analytical capabilities and experience in glass enable the team to provide expert reports concerning a whole range of failures - ranging from external influences, such as vandalism and impacts, through to incorrect specification, interaction with components, material processing and fabrication or the presence of manufacturing defects.

“The industry knows that thermally toughened glass has numerous benefits over annealed and heat-strengthened glass, including better resistance to thermal changes, increased strength and safe breakage characteristics,” said Dr Cave.

“Steps have been taken to eliminate NiS from the production of float glass, with changes in raw materials, manufacturing methods and processing techniques. The heat soaking process, introduced into manufacture by Pilkington in the late 1960s, is also now recommended for all glazing installed in critical locations such as barriers or overhead glazing.

“While it is not guaranteed to eliminate NiS inclusions altogether, the likelihood of spontaneous failure due to NiS is reduced when heat soaking has been carried out.

“But NiS inclusion should never be assumed. Of the failed toughened panels examined by GTS in 2013, two thirds had failed due to the presence of NiS inclusions, with the remaining third a combination of impact damage, poor toughening, detrimental interaction with fixtures and nonNiS inclusions.

“To highlight this, a property management firm recently sent several failed toughened units to GTS for analysis after spontaneous failures had occurred throughout the building.

While analysis of the majority of the units identified the presence of NiS inclusions, other units featured impact damage at the failure origin.

“Ultimately, architects, engineers and specifiers should consider the benefits and drawbacks of all types of glazing before installation and ensure that they adhere to all relevant building regulations and codes of practice. Installers should adhere to the specifications and follow best practice to avoid unnecessary breakages.”

GTS is accredited to ISO 9001, ISO 14001 and ISO 17025 standards and is a Notified Body (number 2461) for the Initial Type Testing (ITT) of glass products under the European Union’s Construction Products Regulation (EU) No 305/2011 (CPR) in order to CE mark products for the European marketplace.

The team provides analysis, consultancy, testing, research and development support to glass manufacturers, processors, tougheners, designers, architects, consulting engineers and specifiers across the UK and internationally.

ELECTROGLASS YOUR LINK TO ENERGY EFFICIENCY

EVERYTHING WE DO IS FOR IMPROVED...

Energy Efficiency, Glass Quality, Furnace Output

Specialists in electric glass melting and conditioning www.glass-ts.com/architecture-and-glazing; Email enquiries@glass-ts.com or Tel +44 (0) 114 290 1801

Glass International June 2014

Electroglass Ltd, 4 Brunel Road, Manor Trading Estate, Benfleet, Essex SS7 4PS, England t: (44) 01268 565577 e: info@electroglass.co.uk w: www.electroglass.co.uk

Company profile: Pennine

The Pennine way Managing Director Graham Hobbs (third from left) welcomed various dignitaries and customers to the official opening.

Following our report in the Dec/Jan issue of Pennine’s new extension, Glass International was invited to its site to celebrate the completion of its facility.

F

ollowing on from our company profile in Dec/Jan which featured an interview with Managing Director Graham Hobbs, we were pleased to be able to take part in the official opening of Pennine’s extension.

The day-long event was attended by approximately 30 people and included a champagne reception, plant tour, and a lunch. It included speeches by Mr Hobbs, the local mayor and MP. The opening was attended by all members of Pennine’s staff, as well as the Mayor of Kirklees and Simon Reevell MP, and was a great example of a successful British manufacturing company that is exporting its products worldwide.

www.glass-international.com

The extension

38

The factory tour showcased the original building and the new extension, as well as both the classic and ultra-modern machinery that is used on site.

The £400,000 two storey building was built by local firm Radcliffe Construction, and is part of a £2 million expansion project that the company hopes will help to double its exports over the next four years.

Pennine specialises in supplying silent inverted tooth conveyor chains for the container glass industry, and plastic components for the food industry.

Although the plastics division pulls in a larger quantity of orders the glass division is by far the most profitable, Glass International June 2014

and so the extension has been designed to help the company speed up and expand present production, as well as allow more storage facilities so large orders can be instantly fulfilled.

The first floor of the extension leads directly on from the existing premises, and is used for assembling the conveyor chains themselves. The ground floor is used solely for storage, and both zones are already being put to use and benefitting the company.

Chris Marshall, who has worked with the company for 26 years, noted that due to the extra storage space available Pennine now has a great advantage over its competitors, as it is able to instantly fulfil large orders to companies such as Pepsi. In an industry where time is of the essence, this can often be the deciding factor when a manufacturer chooses a supplier.

The future Discussing the future of the company, Graham Hobbs certainly seems to have a clear vision for the company his father created over 45 years ago. Having been MD since the age of 21, Hobbs has 38 years of experience at the helm and no plans to slow down anytime soon.

Toasting to the next 30 years, Hobbs expects the business to keep increasing its orders, revenue and staff, and continue to be an important employer to the region. Having been based in Skelmanthorpe since its inception, Pennine has close ties to the community and no plans to leave.

Hobbs also highlighted Pennine’s pride in its apprenticeship record, which has seen the company employ a new apprentice across various departments each year – prior to any government incentives or initiatives.

The official opening with the local MP and mayor.

Forming

Practical container forming simulation

I

n order to use simulation in the manufacturing environment, it is important to integrate the simulation tools within the production workflow. Usually, companies use a professional CAD system and therefore all simulation tools must be able to interact easily with these systems.

Furthermore the forming simulation must be able to compute the containers in 2D (axis-symmetric), 3D-part and full 3D depending on the geometrical properties. Switching the geometrical dimension should not be an issue.

Nogrid provides forming simulation software developed especially for the container glass industry. Nogrid software computes glass forming processes in 2D (axis-symmetric), 3D-part (cut 3D model) and full 3D, and allows the simulation of all kinds of glass forming processes for container glass such as: BB (Blow and Blow) PB (Press and Blow or Wide Mouth PB) NNPB (Narrow Neck Press and Blow) PB tableware (Press and Blow for the tableware industry).

Nogrid pointsBlow solves the complete Navier-Stokes equations (continuity equation; velocity equations; energy equation) within the fluid. The glass viscosity depends on temperature, as shown in Fig 1. Three

standard viscosity curves are implemented and further curves can be added by the user.

In the container glass industry the glass composition and therefore the glass properties can vary, but usually soda lime silica glass is used. We used the standard container glass for the computations in this paper, and the blank mould, the blow mould and the plug are replaced by an approximate heat flux boundary condition: . .

Q = HTC . A(T – Tmould) HTC is the heat transfer coefficient, T is the glass temperature at the interface glass-mould and Tmould is the temperature of the mould. The heat transfer coefficient h used is constant over time, but if better experimental data is available this can be modified.

The container geometry is created in a Computer-Aided Design (CAD) system.

The market for CAD software is huge, and in most cases CAD vendors use their own format for saving and interchanging the data. Providing and maintaining all these formats turns out to be profitable, but fortunately all CAD packages support the STEP or ACIS formats to enable the exchange of data between different CAD systems. The ACIS format supports faces and the STEP format supports in addition volumes.

5.5 long (weak) standard short (stiff)

log viscosity pascal seconds

5 4.5

Fig 1. Viscosity depends on temperature.

4 3.5 3 2.5 2 1.5 800

850

900

950

1000

1050

1100

1150

Due to the fact Nogrid software needs only faces in 3D and edged in 2D, the ACIS interface would be fine, but the STEP format provides the additional possibility of giving the faces a name which is already within the CAD system.

The Nogrid software can import the STEP file including all face names (Fig 2).

This is important, because in that case the software can connect all faces with the corresponding initial and boundary conditions and can run the simulation without any additional user interaction.

So, within the Nogrid pointsBlow software all kinds of container wall types are predefined using a unique name. For instance, there is a wall type using the name PLUG. This PLUG type is connected with a set process data, which defines the initial position and temperature, the thermal conditions, the movement and the times for activating and deactivating.

If Nogrid pointsBlow imports the STEP file and it finds faces carrying the name PLUG, all the PLUG simulation data are connected to these faces (Fig 3).

Later during the computation, the PLUG faces will exactly do what is defined in the PLUG settings data. The PLUG settings data itself can be modified in the Nogrid pointsBlow Graphical User Interface (GUI). Fig 4 shows schematically the process steps that occur during the BB process, and it is clear that the PLUG must be in its final position when the gob enters the blank mould and should be removed shortly before the counter blow is switched on.

The user can set the IS machine data easily within the GUI for all wall types and all thermal conditions as well.

When the user decides to investigate a modified geometry, only the geometry has to be replaced. The simulation data can be reused (or simply copied to a new case, which is done in the software

1200

Temperature degree celsius

continued Âť Glass International June 2014

www.glass-international.com

Alfons MĂśller* discusses the use of 2D and 3D simulation in the forming process used by the container glass industry.

39

Forming

Fig 2. Container imported using STEP interface.

Fig 3. View on the PLUG faces.

Fig 4. Steps during BB process.

Fig 5. Geometry 2-D (axissymmetric).

Fig 6. Geometry full 3-D.

www.glass-international.com

a

40

Fig 7. Geometry 3-D clip using angle of 72°. b

c

Fig 8. A Results 2-D (axis-symmetric). B Results 3-D-clip. C Results 3-D.

automatically).

Seperating the geometrical data from the simulation data is a huge advantage.

Once the 3D CAD geometry is imported the user can easily select the geometrical dimension of the model.

That means the user is able to run the simulation in 2D (axis-symmetric), 3D part or full 3D. 2D (axis-symmetric) means the object Glass International June 2014

remains unchanged when it is rotated around an axis. Because the 3D problem reduces to a 2D problem in that case (Fig 5), the computation time is reduced significantly. In Fig 6 the computation time for full 3D is about one to two hours, whereas for 2D it is about three to five minutes. Internally the software cuts the 3D model (which are 3D faces) by a plane and as a result edges are

generated. The edges will inherit all properties from the corresponding face, and will now construct the geometrical border for the 2D simulation.

Without changing the CAD geometry or modifiying the simulation conditions the user can easily switch between the different dimensions. In case of the 3Dpart model only part of the 3D container is computed. In a combo-box it is possible to select different rotating angles form 180° (half model) to the smallest angle of 60° (1/5 model). The full 3D geometry is cut automatically and the cut faces will inherit all properties from the full 3D faces. Fig 7 shows the 3D-part using a cutting angle of 72° and Fig 8 shows the related results.

A further advantage of separating the geometrical data from the simulation data is that it makes it easy to add additional wall types to the simulation.

For instance, in reality a funnel is always used to ensure that the gob falls into the blank mould and not beside. In simulation the funnel walls are usually not required, because the gob position is well defined. But in cases where it is important that the gob is deformed and decelerated by the funnel, the funnel should be added to the CAD geometry. If the name ‘FUNNEL’ appears in the STEP file Nogrid pointsBlow will activate the funnel wall type otherwise the type will be ignored.

Additional faces for the gob are automatically included. These faces represent the shape of the initial gob geometry and the user can modify the shape and its position individually within the GUI. For instance, if the user changes the gob weight, the length of the gob will change. Thereby the gob diameter is increased by the user and the gob length will decrease correspondingly as well. Bottles with a handle can also be computed, thus there are no limits regarding bottle design and the user can test and evaluate a certain container without restrictions.

Nogrid software allows glass container forming processes to be simulated in full 3D, in a 3D part or in 2D (axissymmetric) in a practical time for all real container shapes.

The user can easily switch between the dimensions without taking care of the underlaying geometry.

*Managing Director, Nogrid, Germany Email: info@nogrid.de Web: www.nogrid.com

Flat glass

Façades: Optimum efficiency

‘Ice Q’ restaurant, Austria.

The 900m2 glass façade was built using highperformance triple-pane insulation glass.

Finding ways to improve energy efficiency is one of the greatest challenges facing contemporary architecture. Sebastian Pflügge discusses how using highly functional glass products and integrating energy-relevant products are effective ways to achieve optimum efficiency, even in large-format glass façades.

expectations, façade technology has been systematically improved in years past. One target pursued in this development process is the multifunctional adaptive façade, a shell that’s able to respond dynamically to changing environmental conditions.

Glass façades hold great potential in this area. Decentralised controls for ventilation, heating and cooling via the building envelope enable significant building technology reductions. At the same time, integration with building automation systems ensures that individual components can work together in perfect unison to achieve maximum energy efficiency.

Efficient combination The components needed for the multifunctional façade of the future are already widely available. The challenge, then, lies in the optimisation of existing systems and in the combination of available technologies and products.

Ambitious targets have been set. In Europe, for example, the ‘Energy

Performance of Buildings Directive’ (EPBD 2010) stipulates that all new buildings in EU member states must be constructed as “nearly zero-energy buildings” from 2020 onwards.

This high bar can only be cleared by using highly efficient façades that provide excellent insulation and smart indoor climate control – all while harnessing the power of the sun.

Optimised technology Despite significant progress, largeformat glass façades continue to be left behind when it comes to heat transfer properties, by classic perforated façades with insulation. At the same time, however, they also offer numerous advantages over solid construction.

Thanks to copious amounts of glass used, they allow for visual contact with the outside world. What’s more, they create enhanced lighting possibilities and ideal conditions for solar gain.

The E2 façade by Schuco (Fig 1)

continued » Glass International June 2014

www.glass-international.com

F

açades have moved beyond being just static shells providing weather protection at the interface of building interior and exterior. They’re often compared to human skin, which has a protective role to play but also adjusts dynamically to external conditions and thus maintains the body’s ‘ideal temperature’.

Modern glass façades are tasked with exactly this function – except in relation to indoor climatic conditions. In light of significantly tightened energy efficiency standards for buildings, the building envelope must play yet another crucial role in achieving a reduced primary energy demand: Heating, airconditioning and lighting are among the most power-hungry systems in office buildings, and the façade can directly influence these consumption factors.

The goal must be to optimise thermal insulation, protect interior spaces from overheating, ventilate rooms in a controlled manner, use daylight to the fullest extent possible, and minimise the use of supplementary air-conditioning.

Keeping pace with ever higher

41

Flat glass

illustrates an energy efficient system complete with a revolutionary combination of façade and system technology, that both saves and generates energy. It has four function modules: Decentralised ventilation; façade-integrated photovoltaics; façade-integrated solar shading; and integrated opening units.

www.glass-international.com

Functional glass

42

The use of safety glass brings to the fore the extensive structural possibilities and design advantages offered by glass (curved glass, screen printing, digital printing, enamelling etc.) and thus provides considerable flexibility in the design of customised high-performance glass façades.

However, large glass surfaces also allow for outside conditions to strongly impact the indoor climate.

Excellent results are possible nowadays with high-performance thermal- and solar-control glass. For example, double-pane insulating glass filled with the noble gas argon and used with warm-edge spacer systems currently achieves a thermal transmittance value of around 1.0 W/m2K. This value drops to 0.6 W/m2K for triple-pane insulating glass used in standard configurations, and 0.5 W/m2K is possible if the space between panes is increased.

Even lower thermal transmittance values are possible in today’s standard glass configurations by using the ultraexpensive noble gas krypton.

To further reduce the thermal transmittance coefficient while using argon, quad-pane insulating glass can be used. Even though these products achieve a U-value of 0.3 W/m2K, they’re not any heavier than conventional triple-pane glass because they’re made using hardened thin glass.

Another option is vacuum insulated glass (VIG), which would make stacking window panes an easier-to-manage task for window and façade manufacturers.

Glass of this kind is already available in Asian markets, but Europe is still waiting to see equivalent products become ready for mass production.

Solar control Besides heat insulation, large-format façades must also master the challenge of providing reliable solar and glare protection. Solar control glass alone – while efficient and easy to integrate – is Glass International June 2014

often not sufficient to reliably prevent undesirable heat gain in interior spaces during the summer.

Alternatives to shading systems installed on the inside or outside of the façade are available, including special solar control glass featuring electric voltage- based automatic tinting to minimise the impact of sunlight.

In autumn of 2013, the University of Giessen presented an intriguing development in this area. Led by Prof.

Bruno Meyer, the Physical Institute developed and filed a patent application for an energy-efficient glass coating that allows for temperature- dependent thermal transmittance.

Using this passive (i.e. non- voltage), transparent glass coating allows for the straightforward control of sun-induced heat gain in interior spaces. At 20˚C the

Fig 1. The Schüco E² Façade is an energyefficient complete system that unites façade and system technology.

material autonomously switches from semiconductor (permeable to light) to metal (reflective).

Insulation glass with integrated solar and/or light directing control is another frequently used alternative. These systems are integrated into the glass and can be controlled manually or electronically to align with individual insulation and light conditions.

Thanks to integrated slats with variable adjustment angles, daylight can be directed into the interior of the room. For example, the Austrian company Eckelt Glass offers DLS Ecklite Evolution, an insulation glass product with two separate, electrically driven louvre blinds integrated into the glass, featuring a concave section for active light directing in the upper part of the

glass and a convex section for efficient solar and glare control in the vision area.

Depending on exterior lighting conditions, users can choose to open either the vision area only or both the vision area and the upper area for an unobstructed view.

Energy from the façade Photovoltaic modules can be incorporated in nearly any kind of glass installation. Solutions with integrated PV can easily be implemented even with multi-pane insulating glass with thermal and acoustic protection properties and with overhead and walkable glass.

Set up correctly, the solar control functionality of a PV façade can even make additional shading systems obsolete. Moreover, solar energy from collector systems integrated into the façade can be used for heat production. glasstec 2014 in Düsseldorf will show just how innovative the glass industry really is, including what product solutions this sector has in store to help make glass façades more energy efficient, and how architects and façade builders envision the future.

From 21 to 24 October, the international trade fair will present the latest developments revolving around the energy-efficient building envelope at the trade fair stands, the ‘glass technology live’ show, and the façade centre.

This range of offerings is further enhanced by the scientific conference ‘Engineered Transparency’, from 21-22 October 2014, and by the International Architecture Congress, entitled ‘Glass 5.0 – Design, Function, Emotion’, on 22 October 2014.

The building envelope Thanks to continuous construction, technology and product advancements, plenty of development potential remains for large-format glass façades.

Regardless of any temporary façade design trends, topics such as energy efficiency and improvement of indoor climatic conditions will dominate architecture and façade construction in future, with additional attention paid to the sustainability of materials and products used.

Stronger multi-disciplinary cooperation will be critical on the path to energy-optimised glass façades and buildings.

* Sebastian Pflügge, glasstec 2014

Events world

British Glass Focus Conference discusses latest trends More than 130 people attended the annual British Glass conference in London, UK to hear about the latest industry trends. Greg Morris was among them. design and fashion trends.

For the first time the event, held at Grange St Paul’s Hotel, London also included an industry awards evening, where Ardagh Group won both Company of the Year and the People and Skills award.

Food packaging Perhaps the most powerful presentation of the day was given by Dr Muncke who discussed some of the plastics involved in food packaging. The Food Packaging Foundation is a charity formed in 2012 and based in Zurich, Switzerland. It is an independent foundation making scientific facts and expert opinions related to food packaging health accessible and understandable..

A recent study in Portugal found that 60% of people’s food packaging was made up of plastics, such as PET and PPP. Small monomers in the plastic can get out of the packaging and into the food.

There is evidence of chemicals in packaging now being found in people’s bodies. An example is Bisphenol A, which until three years ago was used to

make hard plastic and found inside beverage and food cans as well as infant bottles. According to Dr Muncke it is now found in everyone’s bodies as a result of daily exposure to it.

Research into statistics of diseases has found that certain chronic diseases seem to be increasing in humans, such as allergies hormone-related cancer and diabetes. These diseases are complex so there is no single cause.

In the past it was considered that genes cause disease and ‘the dose makes the poison’. But today’s thinking is that while faulty genes will play a part it is now known that lifestyle factors are also a factor and that chemicals can help cause these diseases – animal studies have proved this.

British Glass In his opening address Mr Dalton said that the British Glass association had to ensure that glass remained on the UK government’s agenda.

continued »

a platform upon which those vested with the “Wepowerneedto todobuild the right thing can do so with our material. ”

British Glass CEO Dave Dalton said glass had to remain on the UK Government’s agenda.

Glass International June 2014

www.glass-international.com

T

he day-long conference included three keynote presentations, 11 breakout session papers and an opening address from British Glass CEO Dave Dalton.

The overall message of the day was that the future of the industry cannot be secured by persisting with the status quo. Collaboration, investment in the latest technologies, new capabilities, improved productivity and a trained workforce are required to ensure they have the necessary skills for the future.

Speakers included Dr Jane Muncke, Managing Director of the Food Packaging Forum, James O’Callaghan, Partner at architect’s firm Eckersely O’Callaghan, and Ruth Miller, Senior Economist at the Confederation of British Industry (CBI).

Among the speakers at the breakout sessions were Sheffield University’s Prof John Parker, who spoke about Innovations in Glass and Bottero’s Paulo Mazzone who discussed Innovations in The Glass Manufacture Process.

Joe Walmsley, Director at Daedalian Glass Studios discussed the latest glass

43

Events world

Ardagh win Company of the Year.

To do that it had forged relationships at a high level, corralled its capabilities, challenged the way it does things and created an environment where ideas can prosper.

He said: “We need to build a platform upon which those vested with the power to do the right thing can do so with our material.”

He added: “It gives us a status and an understanding with the powers that be.

We are talking to decision makers about how they can change the world in which we operate in.”

One of its innovations is the Glass Academy, which is aimed at attracting new talent to the industry. Mr Dalton said that the association was punching above its weight at the moment but had to use that platform to continue its good work. It has given examples of its work to the UK Government, which in return has offered to fund the development of high quality materials.

www.glass-international.com

UK Government

44

In a supporting statement Dr Vince Cable, the UK’s Secretary of State for Business, Innovation and Skills, said: “The Glass Focus Conference is an important opportunity to reflect on the vital role that glass plays in just about every facet of our daily lives, from packaging and tableware to medical technology and fibre-optics.

“Glass is a vital part of the hi-tech manufacturing supply chain. Last month I announced a further £100m of support under our Advanced Manufacturing Supply Chain Initiative to strengthen supply chains and to support the reshoring trend.

“We share your commitment to developing a skilled workforce. As well as co-funding the Glass Academy Project with industry, earlier this month we launched ‘Your Life’ - a campaign to drive up the number of young people, Glass International June 2014

Dave Dalton CEO of British Glass opens the Conference.

James O'Callaghan.

Jane Muncke, Food Packaging Forum.

partners and is open to the idea of codeveloping and funding.

Paul Earnshaw, Packaging Manager at Tesco, gave an overview of the company’s packaging sector. The group, which employs 530,000 people worldwide, is changing its packaging approach and wants to engage with the packaging chain and wants to know the benefits packaging can bring.

With thanks

especially women, studying science, technology, engineering and mathematics (STEM) subjects.

“With so much forward thinking and innovation in the glass industry, there is a wealth of promise and potential. I can assure you that in turn, Government will continue to build on its strong partnerships with UK industry to achieve our ambitions for growth, and ensure this potential is crystallised.”

Breakout sessions Other breakout session subjects included an Industry Roadmap which included speakers from British Glass, and Packaging Developments, which included a talk from worldwide brewer SAB Miller and a speaker from UK supermarket, Tesco.

SAB Miller’s Richard Corker discussed the group’s packaging strategy and said beer and glass are still a good fit, with about 60% of SAB’s beer sold in glass.

About 76% of the company’s Ebita comes from developing markets and its biggest beer sold in terms of volume is Snow, mainly sold in China.

The company recently changed the way it works and has created an industrial and academic network. It has a small R&D team that works with industry partners, academics and

In a closing statement Mr Dalton said: “We would like to thank everyone who attended the conference and supported us in bringing together the glass industry and promoting glass as a material.

“We cannot secure the future of the industry by persisting with the status quo. We must collaborate and build a new vision for the future by investing in new technologies, new capabilities, improving productivity and training the workforce to ensure they have the necessary skills.”

“We were also delighted to hold our inaugural Glass Focus Industry Awards at this year’s conference, recognising some of the companies who are already striving towards this vision, congratulations to all of the winners.”

The British Glass Industry Award results were: People and Skills (sponsored by The Glass Academy) – Ardagh Group Innovation of the Year (sponsored

by Siemens) – Eckersley O’Callaghan.

Special mention to Allied Glass for its investment in 3D printing Glass Company of the Year (sponsored by British Glass) – Ardagh Group

British Glass, www.britglass.org.uk/ glass-focus-conference

Events world

A successful China Glass 2014

T

he event, at the New International Expo Centre, Shanghai, took up seven halls with an exhibition area of 80,000m2.

Exhibitors came from 27 countries, including China, Italy, Germany, USA, France, Finland, the UK, The Netherlands, South Korea, Japan and India.

The four-day glass show attracted more than 23,000 professional visitors from nearly 80 countries in the world.

Around 3000 people from outside China including visiting groups comprising about 400 members from industrial, trading and press sectors of India, Vietnam, Japan, Malaysia and South Korea. Prof Peng Shou (pictured above, second from left), President of the International Commission on Glass, was among those to visit the event.

International Standing Many giants of the industry exhibited at the event including Glaston, Lisec, Bystronic, Benteler, CNUD-EFCO, Grenzebach, Fives Stein, Bottero, Teichmann, PPG, Sorg and AGC. There were also German, Italian and US pavilions.

The Italian exhibiting group had more than 1200m2 for 24 companies; the German group, supported by its Government departments and organised by had a booth area of 600m2 with 30 companies. More than 20 companies had booths of 400m2 in the US pavilion.

A number of companies including

rented even larger booths compared to the previous year.

There were about 50 newcomers at this year’s exhibition from the USA, Germany, France, the UK, Czech Republic, Malaysia, Estonia, as well as China.

Glaston presented glass pre-processing technology and diamond and polishing tools. Its exhibits include heat treatment technology such as flat toughening, bending and toughening, flat laminating, as well as Low-E and ultraLow-E glass products.

Lisec showcased glass-processing equipment, mainly machinery for photovoltaic glass, production/quality management software system and spacer bars; DIN standard laboratory for glass products quality control; European standard full range of architectural glass products and glass transport technology for public road.

Bystronic displayed its products and laser cutting technology. It specialises in conveying, cutting, drilling and bevelling of shape glass, particularly vehicle windscreens Belgium’s CNUD-EFCO supplies technology for annealing lehrs and tin bath roofs, designed to cover glass production capacities from 50MTD to 1000MTD with ribbon widths varying from 0.7m up to 5m, and to anneal clear, coloured, coated, PDP and TFT glass ranging from 0.3 to 25.0mm in thickness.

The Fives Stein Group provides thermal equipment and production lines for float glass furnaces and annealing lehrs, including melting furnaces with either gas, electric or oil combustion systems, electric boost and bubbler systems, working ends and forehearths with combustion systems, as well as oxy-gas forehearths for various types of fibre glass or solar glass.

Grenzebach displayed the latest float glass production lines and cold-end test techniques.

PPG partner, Henry Teichmann provides turnkey projects including engineering, procurement, technical service, and project management for float, fibreglass, container and other speciality glass plants, complete float glass solutions, oxy-fuel firing and CVD coating technologies.

Corning showcased its machinable glass ceramic, high purity fused silica and zero expansion glass technologies.

Japan’s AGC provides solutions related to glass melting furnaces, in addition to high-rank float glass, on-line Low-E glass and TCO glass.

Israel’s ceramic in-glass printer DipTech had a popular stand with plenty of visitors on the first two days. The company presented its decorative and functional requirements for interior and exterior printed glass applications.

continued » Glass International June 2014

www.glass-international.com

More than 800 exhibitors from 185 companies took part in this year’s China Glass event.

45

www.glass-international.com

Events world

46

Chinese companies at the fair included Jinjing Group, China Luoyang Float Glass Group, China Triumph, Zhejiang Topglass, Ruitai, Xinyi, AVIC, Taiwan Glass Group, CSG, Shunde Golive, Liaoning Lewei, Shanghai, Yaohua Pilkington, Shabo Glass Group, Luoyang Northglass, Mingte, Guangdong IVACO, Guangdong Fushan, Landglass and Tenon.

Rewarding On the exhibition’s second day, Guangdong IVACO received a number of order forms from Iran, Turkey, South Korea and Poland. Seven of Guangdong Fushan’s eight machines worth RMB3,000,000 ($500k) were sold out and export orders of more than RMB10 Glass International June 2014

million ($1.6 million) were clinched.

Luoyang Northglass was delighted after its 18m x 3.3m numerically printed glass was sold to the headquarters of Apple Inc.

Activities during the Show A number of technical and academic activities were arranged, including the International Symposium on Advanced Glass Melting Technology, which had energy efficiency, low carbon and new technology for recycling material as its theme. It discussed topics such as melting and oxy-fuel combustion technologies.

Another conference, GPD China 2014, addressed energy efficiency and sustainability in buildings with a focus

on intelligent glazing and energy management. There was also two technical seminars with about 400 attendees, who had lively discussions on several topics.

The Consulate General of Germany in Shanghai held a Night of German Pavilion to help enhance the relationship between Chinese glass businesses and German companies.

There were also news briefings and workshops given by exhibitors to promote their brands, products and R&D results.

China Glass, organised by the Chinese Ceramic Society and Beijing Zhonggui Exhibition. www.chinaexhibition.com

Glass International is pleased to announce that it publishes two Chinese language issues per year. (April & September) The Chinese editions are distributed by China National Association for Glass Industry (CNAG) and at international events including China Glass.

Contact us: Advertising: Ken Clark T: +44 1737 855117 E: kenclark@quartzltd.com Editorial: Greg Morris T: +44 1737 855132 E: gregmorris@quartzltd.com

www.glass-international.com

CLASSIFIEDS ANNEALING LEHRS

HEAT-UP SERVICES

FURNACES

ANNEALING ANNEALING & D DECORATING ECORATING LEHRS LEHRS ffor or Containers Containers aand nd Tableware Tableware

TTEMPERING EMPERING LLINES INES O ON NB BELT ELT / SSPINDLES PINDLES ffor or Tableware Tableware and and Stemware Stemware

contact contact us us

vidromecanica@vidromecanica.com vidromecanica@vidromecanica.com www.vidromecanica.com www.vidromecanica.com

Glass International Directory 2014 contact: Esme Horn to receive your copy COMBUSTION

SYSTEMS/BURNERS

GLASS LEVEL MEASUREMENT

RAW MATERIALS

SCREEN PRINTING

Rio Tinto Minerals 2 Eastbourne Terrace, London W2 6 LG, UK Tel +44 207 781 1450 Fax +44 207 781 1851 Email: simon.cook@riotinto.com Web: www.riotintominerals.com

DECORATING MACHINES KBA-KAMMANN GmbH Bergkirchener Str. 228 D-32549 Bad Oeynhausen (Germany) Fon +49 (0) 5734 5140-0 Fax: +49 (0) 5734 5140-5130 mail@kba-kammann.com www.kba-kammann.com

Global Combustion Systems

FLEXIBLE. PRECISE. INNOVATIVE.

INSPECTION On-line Process & Quality Control

Total Support TIAMA - msc & sgcc

Unit 43, Evans Business Centre, Easter Inch, Bathgate EH48 2EH, Scotland, UK.

ZA des Plattes, 1 Chemin des Plattes, 69390 Vourles, France.

Tel +33 (0) 4 37 20 15 00 Fax +33 (0) 4 78 07 94 50 Email: marketing@msc-sgcc.com Website: www.tiama.eu

Tel +44 (0) 1506 657310, Fax +44 (0) 8704 799975 Email Sales@globalcombustion.com Web www.globalcombustion.com

GLASSMAN EVENTS VISIT: www.glassmanevents.com

COMBUSTION EQUIPMENT

CONTACT ESME HORN +44 (0) 1737 855136 TO BOOK YOUR SPACE

INDUSTRIAL GAS ENGINEERS UNIT D2, BROOKSIDE BUSINESS PARK, GREENGATE, CHADDERTON, M24 1GS, UK TEL +44 (0) 161 654 7700 FAX +44 (0) 161 655 3812 EMAIL SALES@MONTSELAS.CO.UK WWW.MONTSELAS.CO.UK

AIR

Manufacturers and suppliers of selas square port gas & air valves

GAS

Special cast irons and alloys for glass moulds

53035 MONTERIGGIONI (Siena) ITALY Strada di Gabbricce, 6 • P.O.Box 30 Tel. +39 - 0577 - 304730 Fax +39 - 0577 - 304755 E-mail: ifv@fonderievaldelsane.com • Website: http://www.fonderievaldelsane.com

Fonderie Valdelsane S.p.A.