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April 2017—Vol.40 No.4
SCHOTT CHAIRMAN INTERVIEW DARTINGTON CRYSTAL COMPANY PROFILE RECYCLING I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
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Contents
April 2017 Vol.40 No.4
2 Editor’s Comment WWW.GLASS-INTERNATIONAL.COM
5 International news
April 2017—Vol.40 No.4
12 Company profile: Schott Schott Chairman ensures company retains its competitive edge
SCHOTT CHAIRMAN INTERVIEW DARTINGTON CRYSTAL COMPANY PROFILE RECYCLING I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
16 Company profile: Dartington Crystal 50 years of hand-crafted quality Glass International April 2017
12
21 Company profile: Marpak Extrusions Investing in the film industry 24 Recycling FEVE ‘Ambitious though ambiguous’: EU stance on Circular Economy 26 Glass Packaging Institute US Glass Recycling Coalition gains momentum 30 Richard van Breda Can cullet ensure glass remains key?
Front cover image www.pennine.org
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1 4 6 8 12
CHINESE SUPPLEMENT Company interview: Bottero Bucher Emhart Glass Stewart Engineers Vertech Phoenix Award winner
33 Alex Gurov Spotlight on Russian recycling 37 GRConsultant Alternative uses for recycled glass 40 Uusioaines Foam glass aggregates boosts Finnish recycler
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Energy efficiency 46 Glass Service A self-driving glass melting process 48 Heatcatcher Choosing the best techniques for waste heat recovery 50 Moulds Commersald Impianti. Reducing costs and downtime in mould making
Plus find us on Linked-In and Twitter.
@Glass_Int
44 History
30
52 Forming Bucher Emhart Glass. A reliable high tech solution
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1 Glass International April 2017
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Editor’s comment
Greg Morris
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: Sally Love Tel: +44 (0)1737 855154 Email: sallylove@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com
Industry’s upbeat mood prevails in Argentina
Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855133 Email: manuelmartinquereda@quartzltd.com Production Executive: Martin Lawrence Managing Director: Steve Diprose
T
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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
here is an upbeat air within the industry at the moment, with plenty of business taking place and people happy as to how the sector is progressing. A quick read through our news pages and our website reveals just how much investment has taken place recently. A few examples include Verallia in Oiry and Albi in France, Shandong Jingyao in China, a contract for Horn Glass in Algeria and even in Moldova, where GCC has recently placed an order for a bypass conveyor with the UK’s Talos Packaging. I’ve just returned from the Glassman South America event in Buenos Aires where this positive atmosphere was prevalent among international exhibitors and visitors alike. The event provided a meeting place for global members of the glass industry to meet, share ideas about new methods of glassmaking and hopefully build future relationships. I’d like to say a public thank you to the Argentinian container glassmakers who attended the event in such strong numbers, particularly Buenos Aires-based manufacturers Cattorini and Rigolleau. Their staff – alongside employees from fellow Argentinian packaging glass manufacturers O-I, Verallia and Coop de Trabajo Cristal Avellaneda – attended in their droves and visited many of the booths. Hopefully they had beneficial and fruitful discussions with exhibitors.
The show now moves to Lyon in September and work is already underway to ensure European glassmakers attend the event in the similar numbers as the Argentinian and South American manufacturers did. Several of the Glassman exhibitors were promoting the latest technology and innovations for use in container glassmaking. New ideas will ensure glass remains the material of choice among customers ahead of competitor items, such as PVC and plastics. Forward-thinking and innovation are two terms that apply to the company featured in our lead article in this issue. I spent a fascinating afternoon at the Schott headquarters in Germany where I had the honour of interviewing its chairman Dr Frank Heinricht, as well as touring one of its manufacturing plants and visiting its own company museum. There is a huge focus on R&D within the company and the benefits of this are clear to see. Its glass is used in a variety of applications, both on Earth and in space! Importantly, and encouragingly, it reports glass is either replacing or being combined with plastics in applications. Great news and enough to make me feel even more upbeat! �
Chief Executive Officer: Paul Michael Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com
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Quartz Glass Portfolio SOUTH AMERICA 2017
Glass International Directory 2016 edition: UK £206, all other countries £217. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.
29-30 March 2017, Buenos Aires, Argentina
Monthly journal for the industry worldwide
Directory 2016 Annual international reference source
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Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2017 ISSN 0143-7838
Glass International April 2017
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International News
NEWS IN BRIEF
O-I staff cuts
Verallia invests €20m to modernise Oiry plant Jean-Pierre Floris, Chairman and CEO of the Verallia group, inaugurated the Oiry plant’s, France new installations. Over €20m has been invested in modernising the production capabilities for this industrial site, which makes bottles for the Champagne and sparkling wine market. The plant’s furnace has been
completely rebuilt and its five production lines modernised. The Oiry site celebrated its 40th anniversary in 2015 and employs 160 people. It produces 550,000 bottles a day. Since it was founded in 1975, Verallia’s Oiry plant has specialised in carbonated products such as Champagne, sparkling wines and ciders, and
large-capacity containers (3L – 15L). The installations also improve the working conditions for the plant’s teams. More than 15% of the total investment package was earmarked to meet this objective with a focus on work station ergonomics. Photo credit: Feng Shang.
Iris wins second order from Tsingtao beer bottle producer
Owens-Illinois (O-I) has eliminated 28 jobs in its information technology department at its Perrysburg, USA campus, with some of the work set to move to its IT centre in Poznan, Poland. The world’s largest container glass manufacturer said the job cuts are in IT security and collaborative services. Some workers have already been made redundant while others will be phased out between now and June.
Moldova Glass orders Talos bypass conveyor
Moldova’s Glass Container Company (GCC), a glass bottle and jar manufacturer, has commissioned a bypass conveyor from the UK’s Talos Packaging Systems. Designed to interface with its existing line, the bespoke bypass conveyor also interfaces with the Iris Inspection camera system, which provides GCC with a cohesive solution. GCC manufactures green, brown and flint bottles and jars with a capacity of between 10-500cl.
Sisecam’s sales boost
Sisecam Group reported consolidated net sales of TL 8.4 billion (roughly US$2.3 billion) and a net profit of more than TL 1 billion (US$2.8 million) for the full-year 2016.
Chinese glass container producer, Shandong Jingyao has purchased more of the latest cold end inspection solutions from Iris Inspection machines. The recent order involves three new Evolution 16 sidewall and sidewall stress inspection machines, together with three Evolution 5 machines for base, finish and stress inspection + spacer technology. Finish inspection is critical for NNPB process operations, where overpressed, unfilled
and line over finish are critical defects, as well as inclusions with tension in beer bottles. Shandong Jingyao is an established supplier of glass packaging for China’s iconic Tsingtao beer and has been the subject of investment in recent years to keep pace with growing demand. The glassmaker’s modernisation strategy has included installing the first NarrowNeck-Press-and-Blow (NNPB) production lines in China to
make the Tsingtao bottles. These high-speed 10-section Heye International IS machines are successfully operating with advanced cold end inspection equipment from Lyon, France-based Iris Inspection machines. This follows an equipment order placed by the glassmaker with Iris in 2015 and is confirmation of the customer’s satisfaction with the service and support provided by Iris in a competitive environment.
Zippe’s Vibrotube batch charger has been officially patented by European Patent no. EP2894131. The patent was filed on 25.09.2014 and is already valid for 38 states. The features of the patent are the conveying of glass batch by vibratory tubes that counteract abrasion, a sealed doghouse and the creation of small batch piles by servo driven and sealed linear pusher elements. First installations show a substantial reduction of energy consumption and high reliability.
www.glass-international.com
Zippe’s Vibrotube patent
5 Glass International April 2017
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International News
NEWS IN BRIEF
Horn Algerian order
Horn Glass Industries will supply the engineering and equipment for a 70tpd recuperative cross fired furnace for a project near Oran, Algeria. Horn’s services include the entire supervision for the furnace construction, installation and commissioning. Horn will also provide the equipment for the furnace, distributor and forehearth, such as refractories, steel structure, combustion system, electric measuring and control equipment.
Ruscam standardises on Heye Rotor Mechanism
Guardian Glass Brazil
Guardian Glass will begin a major capital project to repair the float glass furnace and expand production at its Porto Real, Brazil plant. The project will increase the plant’s production capacity and enhance products and services to support its customers. Ricardo Knecht, general manager, Guardian Glass South America, said: “This project demonstrates our confidence in Brazil, and it is aligned with our long-term growth strategy.” The Porto Real plant started operations in 1998 and in 2010 added a magnetron sputter coater, allowing production of Guardian Residence and Guardian SunGuard low-E glass products. The plant services window customers and commercial fabricators in Brazil.
Russian container producer Ruscam has standardised the Heye Rotor Mechanism (pictured), equipping every feeder channel on all production lines with the technology. As part of the international Sisecam Group, Ruscam produces approximately one million tonnes of glass packaging
annually from five manufacturing plants in Russia. The rotating movement of rotor segments within the Heye Rotor Mechanism provides homogeneity of the glass mass and optimal weight consistency. The servo-driven design gives reliable functionality,
South American container industry attends Glassman event
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Glass Service seminar
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The registration website for the Glass Service (GS) 14th International Seminar on Furnace Design (June 2122, Velke Karlovice, Czech Republic) is open. Papers will be given by glassmakers and institutes such as: Corning, Charles University Prague, Johns Manville, Praxair, Saint Gobain, Schneider Electric and Sisecam. For more info and registration visit: seminar. gsl.cz .
long lifetime and is suitable for mounting on various feeder types. Via a rotating movement of the toothed ring, three paddles provide a stirring movement in the glass mass to keep it homogenous. Variable speeds and a change of rotation direction are possible, together with manual height adjustment. The motion of the servo motor is controlled by Heye Simotion Servodrive. At the five Ruscam plants, mechanisms have been fitted to production lines. “We standardised the Heye Rotor Mechanism in all our glassworks, as this mechanism is an excellent solution with regard to weight consistency and homogeneity,” said Ruscam’s Forming Department.
Nearly 1000 visitors from South America’s glass industry attended the recent Glassman South America event. The free-to-attend exhibition and conference devoted to the container glass industry attracted visitors from throughout the continent. The majority of visitors to the Buenos Aires show were
from Argentina, with domestic manufacturers Cattorini, Rigolleau, O-I, Verallia Argentina and Coop de Trabajo Cristal Avellaneda all sending delegations of staff to the show. There were also visitors from Verallia, CristalChile and CristalToro of Chile; O-I, Heinz Glass, Envisac and Compañía Peruana de Vidrio of Peru; as
well as a number of Brazilan glassmakers in attendance. Exhibitor Luis Zertuche, Sales and Marketing Director of Mexican group Fama, said: “It has been a very enriching experience for the entire FAMA team and we are sure very good things will happen for our business from this fair.” Stuart Hakes, Managing Director of FIC UK, said: “Its been important to be in Argentina and see old customers that perhaps we’ve lost touch with, such as Rigolleau, Cattorini, and CristalChile, all of whom have visited our stand, plus a few new companies. “It’s been the best South American show we’ve had. All credit to the organisers.”
Glass International April 2017
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, Tomorrow s Technology Today
E L E C T R H I G I C D H F U S H V Q H R R N P F O L A C O R D E T E I B U E H R L B B E A N E L E R T E S R S H C Y S M O M T T E D E A R M L L O E N I N U G G B I N O E E I R O I N T S G T 1
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Why bother scrabbling around for a solution?
International News
BDF Industries visits site of Bolivian glass factory Italy’s BDF Industries visited the site of the new Envibol glass factory in Zudañez, Bolivia. The BDF team coordinated the activities related to the supply of the furnace, forehearths, equipment
and automation with the Envibol Operations Department. The BDF team comprised of the Technical Manager Eng. Finarelli, Project Supervisor Eng. Sola and the Area Manager Eng. Vital-
iano Gregori. They checked the progress and attended a twoday coordination meeting, confirming its planning for the turnkey supply of the different parties.
SmartMelter validated in furnace bottom blind trial PaneraTech has successfully demonstrated measurement of a furnace bottom in a blind trial on a float line furnace. A US-based float glass manufacturer approached PaneraTech to use its SmartMelter solution to measure and monitor the residual thickness of the furnace bottom on a float line furnace that was near the end of its campaign. Eight months before the
planned shutdown date, PaneraTech performed an initial assessment of the furnace bottom. The company continued to monitor the progress of glass infiltration at the furnace bottom over the next several months. Prior to the furnace drain for rebuild, PaneraTech performed a final survey of and submitted a report indicating the final thicknesses of the furnace
bottom. After the drain, the float glass team selected several spots and measured the actual physical thicknesses of the furnace bottom. This was compared with the SmartMelter measurements. The SmartMelter sensors had measured residual bottom thickness within 0 - 5mm (0.2 inch) of the actual bottom thickness.
Simon Holmes appointed MD of Sheppee International Simon Holmes has been appointed Managing Director of UK ware handling company, Sheppee International. Mr Holmes first joined the company 22 years ago in July 1995 as an apprentice, shortly after his 18th birthday. Since then he has worked in several roles in both production and in
sales at Sheppee, as well as stints working elsewhere in the industry. Mr Holmes said: “I am emotionally proud. It’s been a rollercoaster ride for me. I’ve worked here man and boy and to be appointed MD means an awful lot to me. “My focus is obviously on developing the business
and developing new equipment but also the security and well-being of all the people here is of major importance to me.” Sheppee is based near York, UK and is part of the Rondot group. Sheppee employs 44 people and is devoted exclusively to hot glass container ware handling equipment.
Glass International April 2017
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E L E C T R H I G I C D H F U S H V Q H R R N P F O L A C O R D E T E I B U E H R L B B E A N E L E R T E S R S H C Y S M O M T T E D E A R M L L O E N I N U G G B I N I C O E E U K I R O L T I N S D G T 1
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When FIC can supply all of your glass needs
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International News
NEWS IN BRIEF
Samuel Leaper joins Henry F. Teichmann
Samuel Leaper has joined Henry F. Teichmann, Inc as Sales Manager. Sam has more than 15 years experience in the glass industry, during which time he has held a variety of technical and sales roles. Henry F. Teichmann provides engineering and contracting services to the glass industry worldwide, and is headquartered in Pittsburgh, USA.
Furnace Solutions 12
This year’s conference Furnace Solutions conference is truly international. Dr. Yakup Bayram, of PaneraTech and Fosbel’s Joe McKintosh, both from the USA, are first time visitors as is Tunc Goruney from Sisecam, Turkey. Richard Stormont from the UK’s Electroglass will also present a paper for the first time at the event. Furnace Solutions and Training Day takes place at Lucideon in Stoke-on-Trent, UK on June 7 and 8. www.furnacesolutions. co.uk
MAVSA’s O-I Rosario job
Argentina’s MAVSA has installed a 503 Type Feeder at Owens-Illinois (O-I) Rosario plant in Argentina. The feeder for new Line 33 will supply the glass gob for a Bucher Emhart Glass IS10 - 5 1/2” DG Machine.
www.glass-international.com
Falorni Tech website
Falorni Tech has launched its new website, www.falornitech. com, after two months of hard work and dedication. The website aims to be a practical tool to connect with customers and investors by showing them who the company is and what can be achieved by working together.
Libbey appoints CFO
Libbey has appointed James C. (Jim) Burmeister as Chief Financial Officer. He will have accountability for Libbey’s worldwide finance organisation.
Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1 BA Vidro buyout of Drujba Glassworks is suspended � 2 Verallia invests €20m modernising Oiry plant � 3 Horn Glass receives Algerian order � 4 BDF Industries visits site of new Bolivian glass factory � 5 Sheppee names Simon Holmes as MD � 6 SmartMelter successfully manages risk at Cardinal Float Glass � 7 Gerresheimer’s Kosamba, India plant comes on stream � 8 O-I cuts 28 staff at Perrysburg site � 9 Ruscam standardises on the Heye Rotor Mechanism � 10 Zippe secures European patent for Vibrotube batch charger
Verallia’s Everglass invests €7m in Rozet-Saint-Albin site Everglass, a subsidiary of the Verallia group and a recycler of glass containers, has invested €7m to modernise its RozetSaint-Albin, France site. Emmanuel Auberger, CEO of Verallia France and chairman of Everglass, inaugurated the new installations at the site which specialises in the treatment of domestic glass. The site is now equipped with technologies to better sort collected glass, thus enabling greater cullet recycling in glassmaking furnaces. The €7m invested has enabled the existing flint
glass sorting machine to be equipped with laser technology, ensuring a higher recovery of optically-separated waste. An additional optical sorting unit has also been installed to optimise the sorting of infusible solids and separate flint from coloured glass. In addition, the installation of an exchanger now makes it possible to recover the calories consumed by the waste compressors to preheat the dryer, the most energy-intensive stage in the process. Lastly, load-weighing automation thanks to a storage silo
improves both circulation and safety on the site. Everglass treats more than 20% of domestic glass collected in France at its two sites in Rozet-Saint-Albin and Châteaubernard. The Rozet-Saint-Albin site annually produces around 230 kilotons of cullet and has 30 employees. Everglass’s Rozet-Saint-Albin site supplies cullet to Verallia’s plants in Vauxrot, near Soissons in the Aisne department, 30km away, and Oiry in the Marne, 80km from RozetSaint-Albin.
Gerresheimer’s Kosamba, India plant comes on stream Gerresheimer’s factory making glass vials and ampoules recently went on stream in Kosamba, India. Jens Heymann, Senior Vice President Europe & Asia Tubular Glass said: “With our new plant in India and its counterparts in China, we will be able to fully meet demand from the Asian pharma industry for high-quality primary packag-
ing made from tubular glass.” Having a uniform global standard for its machinery and employees who are trained in the production process ensures that all the workflows in all the plants meet the same standards. “Our zero-defect strategy is based on a ‘product-by-process’ approach. We want our customers to get the same
high-quality products from us wherever they are in the world. Which factory they were made in cannot be allowed to have an influence.” Gerresheimer manufactures its primary packaging for the Asian market in Shuangfeng in China and at Kosamba. The Chinese factory has 30 years’ experience in manufacturing vials.
10 Glass International April 2017
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Company profile: Schott
Schott Chairman ensures company retains its competitive edge Dr Frank Heinricht has been Chairman of the Management Board at Schott for nearly four years. He oversees a business that produces a huge variety of glass, ranging from pharmaceutical tubing, to household items, to glass used in telescopes looking out to space. He invited Greg Morris to a tour of the company’s headquarters in Mainz, Germany, and to discuss the pharmaceutical business.
www.glass-international.com
I
t’s not hard to see why Dr Frank Heinricht remains as enthusiastic as ever about Schott. The company produces a huge variety of glass and its products can be found at home, in modern smartphones and even in space. He was appointed Chairman of the Schott Management Board in 2013 after spending 10 years at management level with Heraeus. Now, nearly four years into the role at Schott, his passion remains undimmed. “I absolutely enjoy it here, it is such a diverse company. I like the close contact with our customers and I like our applications and how fascinating they can be. “We have applications in pharmaceuticals, astronomy, home appliances, automotive, electronics. It is such a widespread variety and makes the job so interesting. “I like our variety of ideas, we have an
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Company profile: Schott
opportunity lab where people bring in their ideas and what people think they can do with glass. We evaluate the ideas and if it’s a good one we put the resources in and start new ventures in speciality glass.”
Trends
� Schott’s headquarters in Mainz, Germany.
Miller and Electrolux, and they confirm that they use more glass because of the good feeling it produces.”
Industry 4.0 and pharmaceutical To retain its competitive edge the company constantly has to not only innovate but also maintain high standards. The pharmaceutical sector understandably has high hygiene and safety standards and Schott has used Industry 4.0 principles to deliver what Mr Heinricht says is a quantum leap in monitoring its manufacturing process. It has developed a method, called perfeXion, where it can measure online, with extremely high precision, whether there are any inclusions, bubbles, or objects within the glass that might cause an issue later on. In parallel, it can also measure online, at high speed, the thickness (both inner and outer diameters) of the pharmaceutical tubes. � Schott Chairman, Frank Heinricht.
Continued>>
www.glass-international.com
As can be expected from such a hightech, forward thinking company, there is a huge emphasis on R&D and innovation at Schott. Approximately 4% of its sales are spent on R&D, with 300 staff working in its R&D centre. Encouragingly, it reports that glass is either replacing competitor materials or is being combined with other materials. Dr Heinricht states: “We see clear trends where glass is replacing plastics. For example, in automotive, people are moving away from plastic dashboards to glass. People with phones are used to the nice feel of glass phones and want to reproduce this feeling in other areas of living, such as in their cars and in home appliances. So it is a trend that glass is regaining importance. “Then there is the combination of materials, where you can do laminates, combining plastics and glass, offering advantages from both worlds. Schott has received good feedback from home appliance customers such as Bosch,
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Company profile: Schott
www.glass-international.com
“I can proudly say we are the only company who can do this. Just a few weeks ago we promoted this to the public that this is a new step. We can measure every mm of every tube. Industry 4.0 means we can collect all the data from this measurement, store it in a data file, give it to a customer and let them know the quality level of this. Our customer can feed this data into his machine to enable a more stable process. We can offer a more stable diameter to the customer, so they know they will get quality-controlled tubes from Schott. “We do this to improve quality, to improve the traceability for the customer and to keep our leading edge in front of competitors.” The ideal, final vision would be for feedback from its pharmaceutical customers. Feedback about the yield or any problems means Schott can determine what needs to change in its process and improve its performance. “This is one example of where we are pretty advanced, it is one of our flagships and is attached to our pharmaceuticals. It is a new step for us and the customer, but we are convinced they will quickly recognise that we will have more stability and we can drive our process more precisely than in the past. Before it was an average outgoing quality, that gave you a limit and within the limit you allowed for some fluctuations. But if you only have small fluctuations you have a much more stable process.” The pharmaceutical sector has particularly stringent standards so the composition of the material has to be precise or it could impact on a syringe plunger when used by a patient, for example. Such are the strict requirements regarding cleanliness and training in its pharmaceutical business that Schott applies those principles to other sectors of its glassmaking. “It’s a good training camp for us – we take it seriously and apply those principles to other areas of Schott.”
� The perfeXion process enables product-quality data of each individual glass tube to be collected online and in real-time.
Continued>>
14 Glass International April 2017
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Company profile: Schott
The sole shareholder of Schott is the Carl Zeiss Foundation. Originally formed to ensure employee rights, the aim of the foundation
states of Baden-Wuerttemberg, RhinelandPalatinate and Thuringia by paying out dividends. The main focus is on supporting universities and support is rendered for the natural sciences, engineering, mathematics and � There is an emphasis on R&D and
computer science.
innovation at Schott.
Its pharmaceutical customers include the large household names in the industry such as GSK and Novartis. The opportunities for pharmaceutical glass appear good. An ageing population requires more medicine and therefore more glass. A second trend is the rise of diabetes globally because people are eating more. Growth in this sector is anticipated at 3-4% globally, while Asia is forecast for a double-digit rise due to the demand for more syringes and glass containers. Glass still remains the favoured material in the pharmaceutical sector due to its inertness and stability – some plastics can dissolve the ingredients in the tube if they are stored for a long time.
Evolution While Schott can be considered a trendsetter due to its innovations and quality of glass, it does not rest on its laurels. Mr Heinricht believes there is still room for improvement in its speed and flexibility. “Sometimes we rely on being an innovation and quality leader, but on the other hand, we could be more speedy and flexible in front of our customers. This will change in the future.
� � (above and below) Its pharmaceutical customers include the large household names of the industry, such as GSK and Novartis.
“I want us to be innovative but also fast when it comes to changing and modifying things. If there is a request from a customer or a reaction in the market I want to be faster to react, and faster in saying yes or no in development projects.” As the company evolves over the next five years Mr Heinricht does not rule out the possibility of potential acquisitions. Its innovation pipeline is filled with new products, with ideas such as putting two drugs into one syringe or container and mixing it later on to get a final composition. A new launch can take several years with plenty of testing and analysing before a product is ready for market. “It hasn’t been hard for me to adapt to Schott. I have three fantastic colleagues on the Board of Management, then 20 people on the executive so we have a very good team. When I started at Schott I said it is a journey and we will have to change in terms of speed and so on. But the general set up of Schott is a very good one, which makes life more easier.” �
Schott, Mainz, Germany www.schott.com
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today is to promote science in the three German
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Company profile: Dartington Crystal
50 years of hand-crafted quality Dartington Crystal is celebrating its 50th anniversary this year. From humble beginnings the company is now the UK’s only remaining handmade crystal glassmaker. Commercial Director Richard Halliday discusses how the company’s pioneering spirit has ensured its longevity. By Greg Morris.
D
www.glass-international.com
artington Crystal was formed 50 years ago in June 1967 by the Dartington Hall Trust, a philanthropic group with the remit of creating employment and starting a craft industry. When they formed the factory there were no glassmakers in the UK county of Devon. The trust employed a Swedish glassmaking team who were decamped to the rural location in the west of England. The Swedes trained a number of local workers in glassmaking and the business grew from there. What had started as an employment creation exercise quickly grew into a commercial operation that thrived. Today the company employs 120 staff at its 8000m2 site and has expanded into other sectors. It receives 200,000 visitors a year at its restaurant and retail outlet as well as tour its production factory. The company has made several acquisitions in recent years and its portfolio includes Caithness Glass, Royal Brierley and John Beswick. Its Commercial Director, Richard Halliday, has worked for the company for 16 years and states: “We are the UK’s only remaining handmade lead crystal factory. We’re very much the go-to place for somebody in the market for our type of product. “I think we’re the last man standing possibly because of our West Country independent state of mind and creativity, partly because we’ve always been a bit different. Maybe that’s kept us ahead. “The business started with a slightly counter culture side to it in the late 1960s and early 1970s. It was swimming against the tide and I think we still have that pioneering spirit. “When the business first started the product was new and innovative. The design style is timeless and is very relevant today. It is a clear simple style. “The brand has been a real strength to us. People grew up with it, trust it and recommend it.”
Skill and flexibility
� It has developed its colour capability to reflect customer requirements.
Continued>>
The company makes premium glass products using craft techniques that require a high level of skill and flexibility, all from its factory in Devon. It makes approximately 165,000 items a year, the majority of which are hand blown. This varies from standard products to bespoke designs. Its product range includes drinking glasses, household items and giftware such as bowls and vases.
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Company profile: Dartington Crystal
About 90% of its products are sold in the UK and it sells into several market segments such as the John Lewis store, glass shops, factory outlets and its own shop and website. Another big chunk is its promotional, corporate and bespoke range, such as big companies requesting business gifts. “We have quite a spread of customers, and that has been part of our strategy of recent years, the diversification of the product and the spread of risk. When I joined we were reliant on a few big customers. If one caught a cold we’d come down with flu,” states Mr Halliday.
Hurdles
� Dartington increasingly serves the bespoke and corporate markets.
� Dartington Crystal makes more than 165, 000 items of glass a year.
� The majority of its products are hand-crafted.
By serving the retail sector the company has to be close to customer trends. It capitalised on the recent resurgence in gin drinking and the emerging craze for Prosecco, for example, by changing its style and shape of its drinking glasses. The company is constantly in touch with customers, attends the major design fairs and is as close as possible to people and what is going on in their lives. “There are a lot of different influences in terms of how a new product is developed. It’s a neverending evolving process, in terms of it can be a request from a customer or it can be a sales idea. Our designers have got their finger on the pulse in terms of trends and styles that are emerging but it can also be capitalising on a trend,” says Mr Halliday.
Focus In future it will focus on growing its export market. It currently sells products to Australia, the USA and the Middle East but sees growth in pockets of Eastern Europe, where there is a demand for authentic UK brands. Continued>>
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Despite the positive outlook, the company has had to overcome hurdles, particularly in the early-2000s. The business didn’t react to a changing market and had to reduce its scale, making redundancies along the way. In 2006 the group changed owners and management team. This included promoting Mr Halliday as well as employing a new Managing Director, Neil Hughes. The new Chairman, John Hammond, allowed more experimentation and free-thinking and gave the management flexibility in its business and product development. Mr Halliday states: “We found that just because things or a style didn’t work say 10 years ago, doesn’t mean it won’t work now. There are current trends, or customers and sectors, that we didn’t get into before that we are in now.” The production site has three large furnaces and four smaller ones. It melts about 1.5 tonnes of glass a day and uses a batch of 24% lead, 54% sand and 17% soda ash. The company has developed colour capability in recent years to reflect customer requirements in, for example, the luxury spirits market. It gives the company the ability to produce gift and home accessories in colours that otherwise would have to be sourced from suppliers.
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Company profile: Dartington Crystal
ANNEALING LEHRS
� The site comprises a production factory, restaurant and retail store.
HOT-END COATING
It will continue to focus on high value custom and bespoke products as well as grow its online business. While it does not foresee a production capacity increase, these things should secure the security of the factory. Another growth area is in its decoration and engraving output, particularly online. Customers increasingly want their bespoke products to have a badge or personalised message, whether it’s hand engraved, sand blasted or laser engraved. Encouragingly, Dartington is looking to the future. It has a number of glass blowers who will retire in future years and so has employed a number of trainee glassmakers in its in-house apprentice scheme. Mr Halliday says: “We see ourselves as the home of British craft glassmaking and it is important that the craft is continued. “There has to be a succession of the skills for our business to keep on making glass. So we have employed a handful of younger lads, trainee glassmakers, in the glassmaking process and we will continue to build up their skills. “It is a great craft to see carry on, the skills and the passion here are unique.” Dartington will celebrate its 50th anniversary throughout the year at trade shows and with customers, as well as a more formal celebration later in the year. It has also adapted its branding to carry the 50th anniversary logo. “We’re delighted to reach this milestone, we overcame adversity to survive our early years then rebuilt ourselves in recent years to be very much alive and kicking. “There are employees and ex-employees still around who can remember all of the 50 years. I think it’s a great story, and there are not many businesses in the UK that have got that track record. We are a small business punching well above our weight. We’re very proud to be 50 years old and hope to be around in 50 years time,” he concludes. �
Dartington Crystal, Torrington, UK www.dartington.co.uk Glass International April 2017
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Company profile: Marpak Extrusions
� The company produces blown film on extrusion lines at its locations in Leeds.
Investing in the film industry
What does Marpak Extrusions produce? Marpak produces flexible polyethylene based packaging, specialising in the field of pallet protection, and has over 30 years combined experience in the blown film extrusion and conversion market. We make the shrink-wrapping as well as the palletisers, in conjunction with the Danish company Lachenmeier. Basically we offer cold-end packaging solutions – there are a number of solutions that we’ve provided for the glass container industry, such as bottle diverters.
Can you give me a brief history of the company? Marpak was started in 1979 by Richard Gibson. He was working for a Swedish company and decided
to start on his own – he was already in packaging so it made sense to continue in that field. He built the business up, moved premises, kept scaling, then moved to Westland Square in 1990. He had four or five extrusion lines and started working with Rockware, who became our biggest customer. One thing led to another, and we progressed within the glass industry. In 1999 or 2000 he sold the company, and we subsequently restarted circa 2003. Initially we started up with a single extruder in Barnsley and started to supply Ardagh again, which built the business up. We then bought a facility in Leeds and started producing there, then moved back Continued>>
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Marpak Extrusions recently expanded with a new factory site in Leeds, investing around £2 million in its infrastructure and equipment. Its sister company Talos has also unveiled its Transport Simulator, which allows companies to gain first-hand knowledge of how palletised goods react during transportation prior to putting them on the road, and is used by companies such as Ardagh. Sally Love visited the company and spoke with Commercial Director Jamie Gibson, to discuss the recent investments and the company’s plans for the future.
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Company profile: Marpak Extrusions
What drove you to invest recently?
into our former premises at Westland Square. We gradually put more lines in and got bigger with the support of a number of blue chip companies such as Ardagh. I joined the business when it restarted. There was only a few of us and we’ve gone from around three of us to over 40 employees now – it’s just grown and grown. We supply the majority of the container glass manufacturers in UK, but we also supply some sites in Sweden, Denmark and the Netherlands. We’re currently in negotiations with other European manufacturers as well. As the business evolved we realised there was a market for second hand shrink-wrap machines so we formed Talos, essentially buying and selling this equipment. From the early days Talos has evolved and we now manufacture our own endof-line packaging solutions as well as various additional solutions.
What industries do you cater to? It’s mainly the glass industry, plastic containers, the furniture industry and the building industry. The glass industry accounts for a significant proportion of business for both Talos and Marpak.
Increased demand from our customers meant we inevitably had to invest in a new facility as we ran out of space at Westland Square. As such we built the new factory and put in a co-extrusion line, which together was about £2million worth of investment, and has created around 10 jobs. So, we now have four sites in total. We needed the co-extrusion line because quite a lot of packaging is now moving towards coex, on which we produce stretch hood film. It’s not applicable to the glass industry, though, it’s mainly used within industries such as building and white goods etc. It secures the pallet without using gas or heat. The new factory is for that and for the wide-width line, which again caters more to the furniture and bedding industry. � The Transport Simulator, designed by Marpak’s sister company Talos, allows manufacturers to test-run their pallets before leaving the factory.
Has the glass market grown recently? It’s grown for us, or it is growing, which is why we’re in talks with manufacturers in Europe. There’s certainly space for it to grow, because our products are probably the best on the market. Between 2011 and 2014 we saved Ardagh UK a significant amount of money by downgauging, which is where you make the film thinner but keep the same strength characteristics. So, you’re not downgauging for the sake of it, you’re improving the blend of your material and then keeping the same strength qualities with a thinner gauge. If you downgauge from 100 micron to 80 micron, which is what we did, you save 20% of the cost of the packaging. If you think about it, in the glass industry there aren’t many areas where you can make those kind of savings, however we managed that at Marpak.
Was that driven by customers asking for it, or from in-house efforts?
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It was driven by both Ardagh and ourselves with technical assistance from Total Petrochemicals as well as a number of our other key suppliers, in order to achieve the best blend and to save these costs. It’s good for the companies financially, but there’s also the positive environmental impact attained by using less heat in the packaging process, as well as using less material in the packaging.
Is environmental sustainability important to you as a business?
“We built the new factory and put in a co-extrusion line, which together was about £2 million worth of
”
investment, and has created around 10 jobs
Downgauging is important in regards to reducing our footprint and that of our customers, but we also have Marpak Green, which is a polymer produced in Brazil from sugar cane as opposed to oil. Using this, we can produce the same film we make for everybody else but using sugar canebased instead of oil-based polymers, and so it’s massively beneficial to the environment.
Continued>>
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Company profile: Marpak Extrusions
The only drawback is that it’s expensive, but if you use 51% of this product then you’re carbon neutral so we’re trying to make as many of our customers as possible aware that this is an option; that it’s the way forward.
Where does the Transport Simulator come in to things? We were approached by one of our customers in the container glass industry who wanted something that would allow them to test the pallets, especially when downgauging and reducing the thickness of the film. When they test the film at their plants they want to be able to see how the pallets react when they’re on the move. You could always put them on a wagon, drive them 100 miles and bring them back, but you still can’t actually see what they’re doing on the pallet – whereas the transport simulator that we’ve designed at Talos allows you to do that. You can see how the pallets are reacting. We’ve sold a number of these transport simulators within the glass industry, as well as to other sectors including the paint and fertilizer industries due to issues they have transporting their products. Obviously, if a load of glass smashes, or paint, it’s an expensive clean up. The impact of a damaged load arriving at a customer is more than just the damaged product; it’s also their confidence in the supplier’s ability to deliver a quality product. It’s about the buyer’s confidence, and the investment in the simulator allows our customers to have confidence that their product will arrive undamaged, and that they will maintain a good working relationship with their customer.
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Do you have plan to expand into new regions? We have agents operating within a number of European countries, and we’re presently looking into the Portuguese and Spanish markets, that’s our primary focus. Outside of Europe, from a Talos point of view we’re in the middle of developing training software and we’ll be looking to sell that globally. We sold a Transport Simulator to India recently, although that wasn’t for the glass industry. The idea is, when you have something like the Transport Simulator in a market such as India then you can look at other markets in that region as you have a point of reference.
Are you nervous about Brexit? A little bit. I think the uncertainty surrounding when we’re going and how we’re going, membership in the single market; it’s a bit worrying. It depends how people perceive us, when we leave the EU. Obviously from a currency point of view it makes us quite competitive at the moment, but we still have to buy our raw materials from Europe so it’s a double-edged sword. Around 40% of our raw materials come from Europe, so when the exchange rate is low it has made the polymer very expensive.
Waltec Maschinen GmbH
What are your immediate plans for the future?
Kronacher Straße 2a 96352 Wilhelmsthal / Steinberg Germany
At the moment, because we’ve just had all the investment, it’s probably to consolidate in terms of improving Talos’s profile and getting all our staff up to speed and investing in them. There will be a big push for Talos in the next year. �
Phone +49 9260 9901-0 Fax +49 9260 9901-99 E-Mail info@waltec.de
Marpak Extrusions, Leeds, UK www.marpak.co.uk www.talospackagingsystems.co.uk/index.php Glass International April 2017
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Recycling
‘Ambitious though ambiguous’: EU stance on Circular Economy Jean-Paul Judson* discusses FEVE’s response to the recent European Parliament vote on the Circular Economy package. sufficient quantities of feedstock entering the loop. For glass, separate collection is the single most critical step to ensure quality recycling, because the material – once collected – is cleaned, crushed and prepared for use in glass furnaces. There is no further transformation required and, as an inert and permanent material that can be endlessly recycled without loss of its properties, the material when recycled remains safe to be used for, inter alia, food contact packaging applications. A lot of attention is also paid to waste prevention and the importance of the waste hierarchy, i.e. how to promote the re-use of packaging. There are some initiatives on a national level to promote the share of reusable packaging placed on the market, but as of yet, there has not been a proven policy that supports re-use, and the legislators are currently facing this dilemma at EU level. But again, the real challenge is not Why should permanent materials be recognised in legislation? Raw material
Pr
Re
cy cli ng
od
To boost the circular economy Collection
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A
little over a year ago, the European Commission presented its Circular Economy Package, including a revision of the EU waste legislation. In the next few months, the European Commission, Member States and the European Parliament will battle out a final text that will become legislation to be transposed into national laws. Tackling waste on an EU level is definitely a complex matter. The ambition of finding a single harmonised method to channel waste streams into the most resource-efficient activities runs against market realities and the deployment of infrastructure and technology. In addition, against the backdrop of Brexit, some Member States could be tempted to ensure waste and resource management remains a matter of national, and sometimes even local, sovereignty. In a recent report entitled ‘Going Round in Circles’, Policy Exchange estimates that British businesses would lose more than €2bn over the next 20 years through the EU’s Circular Economy Package**. On the other side of the EU spectrum, the European Parliament is doing its utmost to keep the EU on an ambitious course to achieve the Circular Economy. The key to its commitment is to raise the recycling targets and make separate collection of glass mandatory across the EU. This is the only policy that should be at the heart of any legislative action on waste at European level: to consolidate the collection of waste, and progressively introduce and support sorting and treatment techniques that will increase the quality of recycled material so that it can effectively replace virgin raw materials. Yet collection remains the centrepiece of any waste management strategy. Promoting separate collection is the only realistic policy to combat littering, especially in the context of packaging. It is unthinkable to develop recycling infrastructure and technology without
Consumption: use and reuse
uc
tio
n
being addressed. Rather than clearly setting out a path to promote re-use, the discussion is rather about how to allow certain Member States to credit their reuse efforts towards the overall recycling target. This turns the Circular Economy Package into an accounting exercise, and not necessarily into an endeavour to encourage step changes in the ways to use, re-use and recycle waste materials.
Final stages As the final stages of negotiations approach, the fear is that recycling targets become the object of political bargaining, disconnected from the realities of the waste sector and the intricacies of each national or regional context in terms of waste collection. For the container glass industry, the challenge is to continuously increase collection rates for glass, and ensure that cullet is of the highest quality to enter the furnace. The recycling targets in EU legislation, backed up by separate collection of glass, have definitely underpinned the deployment of separate collection of glass across the European Union. Some Member States have surpassed their objectives, while others are still lagging behind, but the collection rates have been steadily increasing. Targets must remain focused on recycling and not confused or combined with re-use or preparation for re-use targets, as was initially proposed by the European Commission. Any watering down of the recycling objectives will be detrimental to the closed loop recycling model of the glass industry.�
*Public Affairs Manager, FEVE (the European Container Glass Federation), Brussels, Belgium. **https://policyexchange.org.uk/wp-content/uploads/2017/02/Going-Round-inCircles-FULL-REPORT.pdf
24 Glass International April 2017
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Recycling
US Glass Recycling Coalition gains momentum One year on from its formation, Lynn Bragg* reports on the US Glass Recycling Coalition’s activities and the challenges it is overcoming to improve glass recycling rates in the USA.
O
ver the past year, the US Glass Recycling Coalition (GRC) has made substantial progress towards collaborating across the supply chain to offer resources, best practices and the knowledge of local glass champions to help community glass recycling programmes in the USA succeed. The GRC is a non-competitive coalition that brings together representatives from across the US value chain with the vision of recycling all glass containers to the highest and best use, while maximising economic, environmental and social benefits. Since its inception, the GRC has grown to over 35 members, including glass manufacturers, fibreglass insulation producers, waste haulers and processors, material recovery facilities, brands that use glass to showcase their products and capital investors. The GRC also has non-voting advisory members as part of a Government
Advisory team, which currently includes five representatives from three cities and two states. The GRC members receive direct advice and input through this Governmental Advisory team to help develop and improve effective glass container recycling on-the-ground. The coalition also encourages collaboration through the supply chain to support the most accessible and viable glass recovery and recycling options for consumers, who overwhelmingly support glass container recycling. To do this, the GRC encourages financially sustainable mechanisms that can generate quality recycled glass to strengthen bottle-to-bottle, as well as fibreglass insulation, markets. While the GRC day-to-day operations are managed by a consulting firm, GRC members address specific strategic tasks Continued>>
Glass Recycling Coalition members: O-I Ardagh Gallo Glass Owens Corning Glass Packaging Institute Heineken Diageo Pernod Ricard Constellation Brands Sierra Nevada Brewers Association Strategic Materials The Recycling Partnership Rocky Mountain Bottle Company Allagash Brewing Company Fetzer New Belgium Brewing
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91% of consumers say that recycling is an important part of conserving natural resources
Ripple Glass Goose Island Beer
Americans want to recycle glass
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90%
say that it is important to recycle materials rather than sending them to the landfill
95%
of those who live in a community which recycles glass say glass should continue to be collected by recyclers
91% Glass is made from natural resources
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say finding ways to avoid wasting our natural resources is important
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Recycling
through a committee or ‘work stream’ structure. This has been effective for tackling a number of tasks quickly. The GRC member-led work streams within the Coalition have now completed the development of a website and content (GlassRecycles.org), a glass decision matrix for state and local governments (final review pending), a network of glass champions, and a ‘heat map’ of locations where glass recycling may be in jeopardy.
Consumers want to recycle; industries want to reuse The GRC is encouraged and hopes to build on consumer desire to recycle their glass bottles and jars. A March 2016 SurveyUSA poll showed that 95% of Americans who live in a community that recycles glass say glass should continue to be collected for recycling. 90% say that it is important to recycle materials rather than send them to landfill. Fortunately, most consumers have access to glass recycling. An August 2016 study by the Sustainable Packaging Coalition showed that 81% of residents with access to recycling programmes in the US are able to recycle glass through either curbside or drop-off collection. For the majority of communities, the market demand for quality recycled glass is strong. The glass container and fibreglass industries combined purchase about 3.2 million tonnes of recycled glass annually to supply more than 70 US manufacturing plants. More robust glass recycling in some communities, however, has been hampered by recent long-term market forces and the potential for contamination that comes from singlestream curbside collection of recyclables in an increasingly diverse materials mix.
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Glass recycling challenges Over the past few years, the recycling industry has witnessed a shift in the composition or ‘mix’ of material types and packaging heading into the material recovery facilities (MRFs). On average, by weight, glass now makes up about 25%, paper has decreased overall and lighter, multi-material packaging has increased its share of the incoming mix. Adjusting for this new stream, known in the industry as ‘the evolving tonne’, has posed a challenge to haulers, recyclers and processors, as they try to reclaim and resell as much material as possible. Placing additional pressure on recycling is the overall prices paid for the
AMERICANS SAY “YES” TO GLASS RECYCLING
81%
Of the U.S. population have recycling programmes available for glass beverage bottles
32.5%
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40%
32%
Beer and soft drink bottles
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Food and other glass jars
FACT 90% of consumers say it is important to recycle materials rather than landfill them
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collected commodities. Since reaching a commodity revenue high of $140 per tonne in 2010, the average commodity revenue has decreased to roughly $94 per tonne. As revenue sharing agreements between haulers, recyclers and cities decrease, costs to provide recycling services to residents go up. In an effort to reduce labour costs, most communities have chosen single stream collection to gather as many recyclables as possible in one truck trip. Unfortunately, this has created sorting challenges at the MRFs, with as much as half of the recycled glass collected lost to landfill disposal as a result of contamination.
GRC recommendations Given that glass makes up one quarter of the incoming recycling stream, the GRC has begun to provide recommendations on best practices (sorting equipment and technology to improve recovery glass recovery) to MRFs, guiding them to operational models that are cost effective and have proven results. For local decision makers, the GRC also reviews common
collection practices, emphasising the benefits of each for glass recycling. Through these resources, the GRC is helping to educate and provide information to recycling coordinators and other stakeholders so they can make necessary changes that can help capture a higher percentage of glass heading through the recycling system. As part of this effort, the GRC hosted its first webinar in December, which attracted more than 150 industry stakeholders and municipality representatives to hear directly from MRFs about best practices for effective glass recovery and processing. In March a webinar will be held on financing and partnerships to demonstrate how entities allied around glass recycling can take advantage of available grants and other local and state resources. These grants often complement significant company investments. GRC members and technical staff are also in the process of finalising an interactive decision matrix for communities and will work with them to find solutions for glass recycling, including demonstration projects, alternative collections options, and MRF and collection best practice models. When finalised, this user-friendly tool will guide a decision-maker through the process of identifying the best glass recycling option for their community, using a series of multiple choice, decisiontree questions. Every community needs a glass recycling programme that works best for their residents and the glass recycling supply chain. For rural areas of the country, drop-off for glass may be most efficient. More populated regions may look to invest in sorting technology at the MRFs to capture and recover more glass. Identifying which programme is a good fit, and assisting with resources, should help to increase glass recovery rates overall. The Glass Packaging Institute and packaging stakeholders will continue to work together in 2017 to enhance and strengthen glass recycling programmes. The work of the GRC and its broad coalition of members is critical to identify problem spots, collaborate, and then assist the flow of quality recycled glass through the supply chain. �
*President, Glass Packaging Institute, Arlington, VA, USA. www.GlassRecycles.org
28 Glass International April 2017
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I see all 2586 spots in a split second. I see more, faster... I am SCOUT, the new intelligent inspection technology from Bucher Emhart Glass. My automatic synchronization across multiple cameras provides faster and enhanced inspection performance. Emhart Glass SA - Hinterbergstr. 22 - 6330 Cham - Switzerland Phone +41 41 749 42 00 - webmaster@bucheremhartglass.com - www.scoutbyemhart.com
Recycling
Can cullet ensure glass remains key? Richard van Breda* highlights how cullet is critical to the future of container glass but that its use in global container glassmaking today is relatively low.
www.glass-international.com
G
lass has traditionally been the favoured packaging format for beverages and processed foods. It is well understood and revered for its stability, inertness and protective capabilities that it provides. Glass exudes premium qualities, which makes it the package of choice for top-end products. One is unlikely to sell a £1000 bottle of whiskey in PET. For the mass market, glass has come under pressure from PET and cans as both offer a lower cost packaging solution. Glass needs to evolve and make itself more relevant and competitive in the mass market to ensure its survival in the mainstream, one-way packaging sector. Cullet may provide the solution, but the entire container glass value chain needs to buy in and promote glass collection and recycling. Cullet is a vital enabler in the container glass industry, and the benefits of using increased amounts of cullet are well understood by the glass industry. However, when one analyses the amount of cullet actually used in glass manufacturing one is surprised to see that its use is, globally, relatively low. This paradox needs to be rectified if glass is to remain as an attractive packaging material, relevant to the demands of modern times. More cullet use has advantages for the container glassmaker: 1. Decreased energy usage – between 2.5 to 3.3% energy reduction per 10% cullet usage in the batch composition. 2. Reduction in fusion losses - typically between 17% to 18.2% of the virgin input batch is lost to fusion losses and lost moisture. Increased use of cullet reduces the consumption of virgin raw material.
3. Increased furnace life: Increasing the amount of cullet used reduces the heat burden on the glass furnace. This can result in a prolongation of the furnace life through reduced operating temperatures. 4. Decreased carbon footprint: Reduction of 5.5% less CO2 per 10% cullet increase. 5. Increase in the furnace draw as a result of decreased energy requirement for melting. 6. Enhanced melting stability and quality of the glass. 7. Leverage on raw material supplier prices – cullet offers an alternative to virgin batch. With all these benefits, one would expect that globally glassmakers would be chasing cullet as the main raw material input into their processes. There are many examples, predominantly in Europe, where one sees glass plants using cullet levels in the 80% to 90% range. But unfortunately, these are the minority when one views this from a global perspective.
Intense Global glassmakers say they are working intensely to increase the amount of cullet that they use in their processes. In its 2014 sustainability report, O-I states that: “In 2009, we set a goal of using a global average of 60% post- consumer cullet in our manufacturing process by 2017”. This ambitious target was established from a 2007 base of 34%. In 2014, it had progressed to 38%, leaving a very long way to get to 60% in three years. It further states that in 2014 it purchased 4.7 million tonnes of cullet for its global
operations. Based on its numbers, it needs to source a further 2 to 3 million tonnes of cullet a year globally to achieve the stated targets. So the obvious question is, why are they not able to make better progress? Why are they simply not just buying more cullet and achieving all their targets? After all, they are already spending the money on virgin batch materials. They are also missing out on the many virtues of increased cullet levels. Perhaps the answer lies in the cost and availability of cullet. Cullet is a relatively low valued commodity - valued by the industry at circa $100/MT delivered. Transportation is expensive and quickly consumes a large portion of the value. The cost factor quickly becomes an obstacle to increasing cullet levels. Will the supply chain accept increased costs for increased levels of recycling? From an availability perspective, is the lack of cullet available a result of consumer behaviour? People are simply not separating used glass and making it available for recycling. Perhaps legislation is the answer? When considering the availability of cullet, one needs to consider how waste is collected and recycled in the local markets. FEVE’s “Container Glass – 2013 - Collection for Recycling Rates in Europe Report”, contains recycling rates for the EU28 countries at an impressive 73%. Clearly, the culture of recycling and collection is providing the required availability. The O-I Sustainability Report notes Continued>>
30 Glass International April 2017
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Recycling
Pressure Brand owners have also made big statements about reducing their carbon footprints. Packaging normally accounts for the biggest single contribution to the carbon foot print. Coke stated it would reduce its footprint by 25% between 2010 and 2020. SABMiller also targeted a similar reduction. Diageo has set a target to reduce by 2020 its own carbon emissions by 50% and those from across its supply chain by 30%. Carlsberg states packaging currently accounts for approximately 45% of its total CO2 footprint and a major proportion of its product costs. This means that a CO2 saving on packaging can often be translated into a cost saving. Packaging being the biggest single contribution to the carbon foot print means that reducing packaging CO2 emission is the obvious place to start. Looking at the various packaging substrates, non-returnable glass was by far the biggest contributor – (based on the brewing industry point of view, which differs from the glassmakers point of view). What better way to reduce the
carbon footprint than by increasing the amount of cullet used and lightweighting the containers.
Returnable glass It is not uncommon to see a returnable glass bottle refilled and reused more than 50 times. One is familiar with the distinctive white wear rings on the contact surfaces of well-used glass bottles. Returnable glass bottles offer some of the lowest cost beverage packaging combined with a much lower carbon footprint. Many of these returnable glass fleets operate with less than 3% loss rate per trip – truly amazing. Why then, are these returnable glass systems so successful? Clearly the monetary value of the deposit system appears to drive the system.
4.7
million metric tonnes of cullet purchased globally in 2014
Average post-consumer content used in production GLOBAL
38%
EUROPE
49%
N. AMERICA
26%
L. AMERICA
28%
ASIA PACIFIC
36%
� O-I global cullet ratios. Source 2014 sustainability report
Where there is legislation, returnable bottles with deposits, or simple container legislation, the rate of glass collection increases dramatically. Knowing this, should the glass and beverage supply chain lobby for deposits to increase the recycling rates? Big beverage owners tend to answer no. One needs to view this from the big beverage brand owners’ perspective. They generally oppose the implementation of deposit legislation. Coke has recently been in the media in the UK, discussing the implementation of deposit legislation. In fact, they suggested other collection mechanisms worked better. The brewers understand the effect of price elasticity on beers sales and they are wary of deposit legislation as this could result in decreased sales. The big end retailers also have
accountability for reduced returnable glass. They are notoriously anti-returnable packaging. As a rule, they steer clear of any returnable packing that requires deposits to be collected, and even worse, having to deal with the return of used glass bottles and deposit repayments – there simply is no opportunity to make a margin on this activity.
Economical separation Consumers need to recycle, rather than simply dumping glass into the household refuse. In many countries in Europe, consumers are meticulous about delivering colour separated, cleaned used glass containers to the recycling depot – as part of their civil duty. Other countries, like Australia, have curb side collection of separated recyclable materials is in place. In co-mingle packing recycled collections, glass has become the most difficult material to successfully separate. Typically, glass containers have got lighter and thinner over time and get broken during the compaction in the collection process. The broken glass is difficult to separate and then further requires colour separation before it can be routed back into the recycling process. Further compounding factors are the relatively low value of cullet on a per tonne basis and also relative to the yield of bottles per tonne of cullet. Additionally, cullet is not an easy material to handle in the waste stream. Cullet cuts and it is abrasive on equipment. Increased cullet solves many issues for glassmakers, reduces costs and improves the process. Brand owners get to continue to use glass as a mainstream packaging solution, while addressing the carbon foot print issues. Returnable glass may offer a solution but this requires retailers to be willing participants in the recycling network. Adversely, glassmakers will make and sell less glass. Consumer discipline is also paramount to prevent glass ending in landfill. Cullet is critical to the future of container glass. All players in the value chain need to play their part and it cannot be done in isolation. The issue remains to align all players’ interests and expectations. To achieve this, legislation may be the only solution. �
Richard van Breda, Independent Consultant, Switzerland Richard@richardvanbreda.com Tel+41 78 858 0488
www.glass-international.com
that North America is its lowest cullet usage region, with only 26% in 2014. It goes on to note that the 10 states that had container deposit schemes in place produced 80% of the cullet that they used. Does this imply that container deposit legislation is the solution? In Australia, there is deposit legislation in place in some states and others are scheduled to follow in the near future. There appears to be a common view that the amount of glass collected and ultimately recycled back in glass bottles increases with the advent of deposit legislation. So does the solution to increase the collection of post-consumer cullet lie in the implementation of container deposit schemes? Many see the deposit legislation as an additional tax and hindrance. However, one can certainly argue that it drives increased cullet availability. When the funds raised are channelled back into glass recycling and cullet beneficiation capacity, the result is increased use of cullet by glassmakers.
31 Glass International April 2017
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II II
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BOTTERO CEO BUCHER EMHART GLASS PHOENIX AWARD WINNER - CHO TAK WONG I N T E R N A T I O N A L
C H I N E S E
S U P P L E M E N T
Welcome to Glass International’s mini supplement in Chinese language
China Glass is here!
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05/04/2017 09:46:58
公司访谈：Bottero CEO
Bottero CEO拥抱 数字时代
意
大利中空和平板玻璃解决方案供应 商 Bottero于 2015年 3月 委 任 Marco Tecchio（左侧照片）为其集团CEO。
据悉，他在管理金属加工、纺织、汽车和电子设备 等不同市场领域下的高科技公司时卓有成效，因而 获得了公司的信任。 在过去的工作中，他直接参与了高科技企业孵化 器的开发，对可进一步提升企业竞争力的产品和流 程创新有个人的独到见解。 对于加入Bottero，他说，Bottero吸引他的众多因 素中，综合全面的技术知识是其中重要的一点。 “Bottero的优势在于，它是一家科技公司，在产品 制造的技术应用上有很强的优势。 “它在其他领域优势略稍弱，例如，市场营销等 等，但在处理中空和平板玻璃的工艺方面，它是全 球领先的。 “Bottero是一家优质企业，全球化公司，并且在不 断的发展和进步之中。我们已经开发出一系列产品 和技术，上市后将多年处于领先地位。” 对于这一类以技术为驱动力的公司，研发始终是 重中之重，且属于集团最大的固定成本支出。 “奠定我们工艺设计优势的一大因素是：科技解 决方案高于一切。您需要在技术上具备绝对的可靠 性。玻璃制造是一个24小时不间断的工艺流程，因 此，显而易见的是，技术可靠性非常关键。”
公司 Bottero成立于1957年，创始人是Pasquale Bottero， 最初是一家平板玻璃制造厂的服务公司。随着公司 的不断壮大，业务有了多样化发展，开始涉足中空 玻璃、零配件和工艺设计。现在，公司已成 为全球化的大型企业，总部设于意大利 库内奥，并在美国、巴西、中国、法 国、德国和英国成立了制造工厂和分 公司。其中空玻璃领域的解决方案包 括玻璃纤维调整加工、玻璃成型、玻 璃制品存放和管理系统等等，在平板 玻璃领域则提供了一系列浮法玻璃 和夹胶玻璃的切割设备。公司还提 供了综合全面的产品支持和培训， 包括在现场或其意大利工厂的支 持。Bottero的产品出口至欧洲、 北非和南非、北美、拉丁美洲、 中东、远东和大洋洲的50多个 国家。
继续>>
www.glass-international.com
在Bottero 60周年庆前夕， Greg Morris与公司CEO Tecchio就 其对公司的发展规划展开交 流。虽然集团已走在行业技 术尖端，但自动化和模拟是 企业将继续投资的两大关键 领域，他告诉Greg Morris。
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公司简介
◄ Bottero总部位于意大利库内奥，成立于1957年。
三大关键领域 他认为，传感器、自动化和闭环这三大领域对玻璃行 业实现全自动化起着关键作用。 进一步对业内技术知识进行投入，研究在玻璃瓶成 型期间工艺如何操作，对整个行业至关重要，也正如 Tecchio先生所说，这是真正影响玻璃分布和玻璃瓶 稳定性的一个重要参数。
近来，玻璃制造行业中越来越受到广泛关注的一个术 语是工业4.0，也称作物联网、厂际自动化、数字时 代、工艺控制，或者自动化。 Tecchio先生来自拥抱这一新技术潮流的高科技公 司。他致力于确保Bottero未来数十年内始终处于科 技前沿。 “我们制定了一项战略，旨在努力实现中空玻璃制 造和IS机器的全自动化。和我们一样，每一家公司， 甚至是我们的竞争对手，离实现公司投入的全自动化 流程还有很长的一段距离。 “我个人具备全自动化流程的背景，我对全自动化 保有强大信心，但实现它还有很长的路要走。为此， 我们需要进一步提升机械的自动化程度，需要建立对 机器管理的更为密封化的闭环，并要利用自动化实现 工艺流程的稳定。 “这是我们必须努力实现的变革，对未来10年的中 空玻璃机械化是理想化的结果。 “我们十分关注工业4.0。我们已投入一定资金， 并对内部进行了改革，因为我们开始对一切内部信息 系统进行审核。这使得我们可以使用物联网和其他工 业4.0带来的新科技，这些技术都将融入我们向市场 推出的产品和整合服务。 “我期望这一科技能够在未来5-10年内在整个行业 中扩展开来。该科技在起步时发展速度通常很缓慢， 但到了一定的阶段，将会带来指数式的增长，我们所 有人都应为这一阶段的到来做好准备。 “平板玻璃行业的全自动化程度较高，但中空玻璃 行业还有很大的差距。这不仅仅是Bottero的情况， 业内其他公司也是如此。操作人员和IS机器在机器正 常运转过程中仍需要产生互动。 “从客户角度来看，我们的市场是相对保守的，各 家企业，不论规模大小，推进革新的动力都不够，因 此变革的速度也很慢。” Tecchio先生承认，相较他以往的职业经历，例
另一个要点是，Bottero对玻璃成型模拟投入的大 量资金。目前，已形成一个对工艺流程的时间、温度 和机械特性实现完整可靠的模拟。投入的资金还完成 了对成型工艺。按毫秒记的全面模拟。 公司已实现了模具设计和重量降低的模拟，但现在 还能够提供一整套模拟服务，以便其客户能够对流程 有完全的掌控。 “对于全自动化，您需要确切了解工艺方方面面的 情况。每个元素如何更改玻璃瓶的形状和特征，如何 改进工艺和改进玻璃瓶。” 吸引Tecchio先生接受这一职位的一点是，这是投 资科技和通过解决方案发展公司的一大良机。他是自 动化的支持者，相信自动化可发挥的巨大优势，而非 仅从成本的角度去考虑。 一个全自动化的系统可以减少油和润滑液的消耗， 因此也是有利于环境保护的高效解决方案。 “自动化过去被视作一个昂贵的解决方案，但现在 的情况刚好相反，这样的观点已经过时。自动化成本 更低，而且非常高效。 “玻璃是一种很好的材料，但是制造玻璃的工艺先 进性低于其他材料。我们必须努力弥补这一差距。 从技术的角度看，如何做很容易理解，但不容易 实施。” 在未来五年里，Bottero将继续投入自动化的发 展，并维持其在模拟工艺上的灵活性。 从地域上看，意大利和西欧仍然是公司在中空玻璃 领域业务最好的市场，占销售额的40%，但在主要销 售替代型机械的地区，市场相当萧条。在发展中地区 和国家，例如，中国、东南亚和墨西哥，我们预见到 了市场发展潜力。 总体情况是，在未来几年，Bottero将投入更多。 “每一天我都收到来自员工的大量信息，我们不断 地交流新想法、新科技和潜在的新应用，全都是与玻 璃相关的信息。 “当我展望未来时，我相信Bottero的玻璃业务一定 会有光明的前途，”他总结到。■
如，在Elettronica Santerno、Santex Rimar Group等意 大利集团任职，以及担任M31的创始人，他发现玻璃 行业的自动化程度较低。
意大利库内奥Bottero www.bottero.com
www.glass-international.com
工业4.0
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Company profile Bottero_Chinese.indd 2
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检测
科威特集团安装FleXinspect 科威特集团旗下的海湾玻璃制造公司于2016 年对其日均产量达300公吨的工厂实施 现代化改造。它为其冷端生产线选择了 Bucher Emhart Glass的检测机械设备， 对简单顺利的安装流程感到很满意。
海
湾玻璃制造公司(GGMC)为
可在现场作业，根
其 冷 端 生 产 线 选 定 Bucher
据 GGMC和 BEG自
Emhart Glass机械设备。
身的要求对硬件和软
科 威 特 集 团 的 玻 璃 容 器 制 造 商 于 2016
件进行定制升级。测试安装还有助于
年升级了其生产线和检测线，并选定了使
操作人员在成批生产开始之前开展培
用Bucher Emhart(BEG)的FleXinspect C和
训。
FleXinspect M组合，该组合采用BEG最新发 布的Scout技术。 工厂设有两个熔炉，日均总熔化能力达 300公吨，可制造各种形状和尺寸的玻璃容 器。GGMC主要为软饮行业的一些知名品牌 服务，包括百事、可口可乐、吉百利史威
Martin
Frieg说。“从一开始，两家公
司间展开了积极和正面的合作。 培训从一开始就已规划好，有助于增强客 户的信心，促进起步。”
安装
立操作这些设备。 与更为精确的检测和随之而来的品质上 的改进一样，作业转换速度也大幅度得以提 升，特别是FleXinspect C，其转换可在数分 钟内完成。
FleXinspect是 Emhart主 打 的 检 测 产 品
9月，三部FleXinspect设备中的第一部，即
“在双方所有团队的参与协作之下，我见
系 列 。 该 系 列 包 括 旗 舰 产 品 FleXinspect
FleXinspect C已在GGMC的车间1.1中完成安
证了全新技术最流畅的安装，”BEG维修工
T、 FleXinspect M， 以 及 模 块 化 的
装和试车。此时，GGMC和BEG已建立起稳
程师Mick Simmons说。“更为重要的是，客
固的工作关系，这一阶段的作业开展得十分
户向我们反馈，他们对这项技术以及技术
顺利。几天后，FleXinspect C已准备继续，
实现的品质非常满意。我在此对GGMC在本
可开始作业，一旦生产启动，只需要一些调
项目实施过程中提供的一切帮助表达由衷的
整即可。
感谢。”
FleXinspect B和C，这两个模块可组合成一 个装置，即FleXinspect BC。 去 年 推 出 的 Scout， 是 BEG为 控 制 其 FleXinspect机器打造的系统平台。BEG宣称
www.glass-international.com
Bucher Emhart Glass制造。
满意，信心满满，”BEG的项目经理
士、喜那滋和威拓(Vimto)，以及食品行业 的一些客户。
▲ FleXinspect C设备由
“该项目起步很成功，每个人都很
其不只是软件，更在检测性能方面存在很多
与此同时，两部FleXinspect M设备也已顺
“我 们 对 项 目 的 顺 利 实 施 感 到 很 满
具体的优势，包括照明更佳、光学元件分辨
利安装完成，未出现任何问题。依靠BEG提
意，”GGMC的工厂经理François Laenen说，
率更高、处理器更快功能更强大，以及检测
供的全面培训，GGMC的操作人员能够从第
巧合的是，他也是BEG的前员工。“它有着‘
算法更先进。
一天起就完全上手，熟练操作所有设备。
即插即用’式的简单易用设计，这很特别，
到11月，GGMC已准备好实施第二阶段的
您可能只会在传输机或推动器上看到这样的
Scout，且所有新型FleXinspect机器均标配
安装，车间2.4和2.5收到一部FleXinspect C
特点，而现在如此复杂的检测设备也做到
该技术，意味着基本所有客户都可利用该技
设备和两部FleXinspect M设备。
了。现在，我们期待着FleXinspect和Scout
现 有 的 大 多 数 BEG检 测 设 备 科 升 级 至
术的性能。
安装设置再一次顺利地在短时间内完成。
在未来为我们带来长久的品质优势。”■
试车后直接开展了验收测试。客户没有任
测试和培训
何投诉，对作业十分满意。
GGMC项目从2016年夏季开始，FleXinspect
即插即用
www.bucheremhartglass.com
C和FleXinspect M机器的组合可由GGMC自
安装之后，GGMC能够立即接手对设备的管
科威特，萨法特，海湾玻璃制造公司。
行安装到测试回路上。BEG现场销售工程师
理，只需BEG提供少量的场外支持，即可独
www.ggmc.com.kw
瑞士，卡姆，Bucher Emhart Glass
4 Glass International
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·
contact@eme.de ·
:www.eme.de
涂层
选择最佳的浮法玻璃 涂层技术
Ron Hunt*和Chris Cording**讨论 浮法玻璃镀膜 技术的优劣势。
有
多种技术可用于浮法玻璃镀 膜。用于制造高质量功能性 涂层的应用最广泛的镀膜技
术可分为两类：物理蒸镀(PVD)和化学蒸镀 (CVD)。 PVD工艺包括一系列操作方法，溅镀是其 中一种，也是在玻璃材料上应用最广泛的一 种。溅镀涂层一般也称作软镀，通过PVD工 艺完成涂覆。高温分解涂层通过CVD方法完 成涂覆，一般也称作硬镀。 两种方法各有优劣。在评估玻璃制造厂
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该采用哪种系统时，必须要考虑系统的哪些 性能和处理因素最能满足产品和制造需求。
磁控溅射技术
▲ 内涂层机。
金属和氧化薄膜沉积至玻璃表面上而成形。
2. 由 于 材 料 、 能 量 、 维 护 和 折 旧 的 原
银是低辐射溅镀涂层的活性层。其他涂层包
因，制造成本较高（通常是CVD涂层价格的
括挡层、颜色修正氧化层和金属牺牲层。
两到三倍），因而利润较低。
相比高温分解膜制造商，溅镀膜制造商可 利用这些额外的涂层提供更多的产品。 线下批量溅镀的软涂层具有以下一些 优势： ■ 溅 镀 可 由 未 参 与 玻 璃 制 造 的 公 司 完成； ■ 溅 镀 是 使 用 一 系 列 目 标 材 料 确 定 的 流程； ■ 可缩短交付时间，从而减少每种产品 的库存； ■ 通过沉积更多涂层，溅镀涂层可为部 分应用提供更优的属性。
溅镀涂层的操作独立于浮法玻璃制造流程，
基于上述优势，很多公司选择使用溅镀工
在线下完成。薄膜通过加速高能量离子在低
艺。玻璃分销商选择有限，但是，安装溅镀
温条件下从目标朝玻璃表面的移动而成形。
系统有利于他们的业务增长，由此也证明溅
离子大量投放至玻璃表面，形成均匀的薄膜
镀系统的流行。但是，玻璃制造商有其他选
层。离子之间的连接比较弱，因此该工艺也
择，也应考虑到溅镀涂层的不足之处：
称作“软镀”。 商业溅镀涂层通过在真空室内将6至12层
3. 随着沉积的层数增多，产出会下降。 4. 溅镀涂层为软镀层，在正常处理和制 作过程中容易划伤。 5. 溅镀涂层对湿度很敏感，需要使用带 干燥剂的密封袋。 6. 使用密封包装后，贮存寿命有限，而 在打开包装后，使用寿命将进一步缩短。 7. 溅镀涂层的黏附力较弱，可导致绝缘 玻璃装置的密封胶失效。建议去除溅镀涂层 的边框，这会增加制造成本。不需要去除边 框的溅镀涂层可能会因为某些清洁剂和砖墙 清洗活动导致密封剂快速失效。 8. 溅 镀 涂 层 一 般 不 能 用 于 单 片 玻 璃 应用. 9. 增韧后的软涂层需要特殊技巧进行处 理，通常会导致增韧损耗的增加。
1. 在同等生产能力下，溅镀设备的投入 成本较高。 继续>>
6 Glass International
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涂层
高温分解CVD技术 化学蒸镀(CVD)用于制造美学涂层和功能性涂层。在玻璃制造流 程中，专业化镀膜机通过将金属氧化物在半熔融玻璃（600°C至 700°C）表面分散开，生产CVD涂层。蒸汽与玻璃表面接触时会产 生化学反应，产生永久性的牢固共价结合键，进而形成一层坚固的 涂层，增强玻璃的韧性和耐腐蚀性。 这类硬化的涂层比柔软脆弱的溅镀涂层更耐用，因为在正常搬运 过程中可能会不小心抹掉溅镀涂层。制造商和生产商采用与标准浮 法玻璃相同的程序和设备来处理CVD涂层，从而提升产量和利润， 优化交货期并改善客户服务。高温分解CVD涂层具有以下优点： ■
投入资金少；
■
产量高；
■
制 造 成 本 低 ： C V D 涂 层 成 本 ~ $ 1 / m 2， 而 溅 镀 涂 层 成 本
~$4/m ； ■ CVD是线上流程，因而具有不可比拟的高吞吐量； 2
■
CVD涂层通过共价结合键与玻璃粘结到一起，从而延长使用
寿命，防刮伤并耐腐蚀； ■
CVD涂层可用于专业应用中，例如，整体式玻璃、触摸屏和
抗微生物材料。导电涂层应用，例如，太阳能电池板和家电玻璃， 5皮爾金頓公司的玻璃工廠正在受益於能源消耗和使用的減少。 使用CVD涂层更为实用；
■
不需要特殊搬运设备和程序；玻璃采用与基本玻璃一样的设 系統由可編程控制器（PLC）、控制器、驅動器、輸入輸出接
口(I/O)、數據採集與監視控制系統(SCADA)、馬達以及攝像頭 备进行搬运和货运；
■
所組成，可以為玻璃生產線提供整套控制系統，為玻璃生產的 各個工序提升效率。
CVD涂层不会因空气中湿气而造成脱层，因而突破了使用寿
命的限制； ■
準確的分析 CVD玻璃与标准浮法玻璃产品的增韧方式类似，因而提升了
■
退火或回火CVD产品之间没有任何视觉差异。要求综合硬化 宣稱對其日常運營和操作帶來了好處。
這個項目在完成過程之中沒有給英國皮爾金頓公司現有的工作 产出，节约了成本； 安排造成任何擾亂。該項目完成之後，英國皮爾金頓公司已經
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量性能發生變化報告的時候，能夠獲取到重要的生產數據，從 而可以讓經營和管理團隊在出現問題的時候，能夠更加有效地 从生产的角度看，虽然拥有多项优势，但CVD的应用范围小于溅 查詢出發生這些問題的可能原因。 镀，原因入戏： 另外，新的控制系統所提供的這些信息也可以為生產線進行 預知性維護提供信息和支撐，以確保不會降低生產過程的可靠性。 1. 线上使用的CVD技术，直到现在才具备商业吸引力。 現在，生產線所生產和製造的產品質量，也滿足並超過了 2. CVD系统必须在浮法玻璃制造厂的生产线上安装。 市場要求方面。通過成本分析和透視、測量和計算生產線所生 3. 一些制造商误以为CVD存在空间上的制约，无法安装。 產的廢品，生產線所生產的廢品也有了減少，這有助於提高生 4. 一些制造商误以为CVD仅可在冷修复过程中安装。 產工藝的運行效率，節省資金和費用。 Derren Gittins是英國皮爾金頓公司玻璃生產下游工藝運營 總監，他對這次控制系統升級所產生的效果非常滿意。他 哪一种最好？ 說：“我們真的很珍視與西門子公司以及IconSys公司的合作伙 对于玻璃制造商来说，哪一种涂层玻璃最好，具体取决于多个因 伴關係。” 素，其中包括客户的位置、操作的规模和类型、库存周转和预期使 “他們不僅具有玻璃方面的專業知識和經驗，同時也能夠 用寿命等。提供高質量的幫助和支持，從而確保了項目實施和進展得十分 順利，沒有對我們的生產任務造成任何損害和干擾。在項目完 但是，在大多数玻璃制造商看来，高温分解CVD技术因其低投入 成之後，整個工廠的控制技術被集成為一個整體，在獲取重要 成本和操作成本，以及高产出的特点，优势非常明显。 的實時數據方面為我們帶來了好處，可以幫助我們根據這些信 对于下游客户来说，溅镀涂层和高温分解涂层的玻璃被视作高性 息做出決策。” 通過實施控制系統的集成項目，英國皮爾金頓公司在這個 能的玻璃产品。建筑商和业主一般都能接受这两种产品，他们主要 充滿競爭的玻璃行業之中獲得了更好的競爭優勢，不僅滿足了 的关注点在美观性上，因而稍稍倾向于使用CVD。■ 其優化生產線性能、績效和效率的目標，而且還可以使其更好 地滿足全球客戶的需要。 █ 西門子英國公司位於英國Frimley
*工艺工程师，**技术总监Stewart Engineers， 網頁地址：www.siemens.co.uk/entry/en/ 美国北卡罗莱纳州，威克森林 info@stewartengineers.com. www.stewartengineers.com
31 《國際玻璃》中文版特刊 2016年四月
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和退火玻璃的项目进而获得了更为协调统一的色调。 由於在新的控制系統上線之後，在生產線出現故障或者質
7 Glass International
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流程控制
工业4.0：玻璃制造商的 重要挑战 Ulas Topal*和Marie-Claude Cens**讨论最新软件对玻璃制造商在应对 智能工业挑战时提供的支持。
随
着无数新技术的应用，数字 革命已融入我们的日常工作 和生活，例如，在线信息平
台、移动性、物联网、人工智能、云应用、 大数据和社交媒体等。 制造商致力于在工厂内融入这些技术革 新，以企步入通常被称作第四代工业革命的 时代。 要纳入智能工业，工厂货系统都必须满足 四大要求： ■
■
直接信息：经理不必寻找信息，但信
息必须直接传递到经理处； ■
经理需要在移动设备上实时了解各种
业绩；
备也将进行通讯。数据传输不再通过需要掌
必须具备线上灵活性和移动性。需要定期执
握PLC编程知识的现场总线完成，而是借助
行细致的分析，提升品质和性能。更强大的
从web2.0和XML标记进化而来的Web服务，
分析可大幅提升产品开发。
此类服务既可能实现全球标准化也可以由制
但是，分析需要从工厂内的设备和装置上 获取数据，并长期存储数据。
线效率、质量标准和成本。
信息互换
技术支持：包括系统支持人制定决策 控制系统
高或存在危险性的任务的能力； ▲ 图1：制造执行系统。
www.glass-international.com
出简单决策，尽可能自动化的能力。
8
从工厂设备处收集到的信息有助于操作人 应、能量管理、设备综合效率(OEE)、生产
信息透明度：系统通过传感器数据创
去中心化决策：信息物理系统自行作
造商定义。 员和经理采取纠正和预防措施，从而改善供
互操作性：机器、设备、传感器和人
和解决问题的能力，以及协助人执行难度过
■
因的操作警报。
操作人员在使用生产线信息系统时，
■
建实体世界的虚拟副本，创建信息化背景。 ■
货状态、功耗，以及附加持续时间和停机原 在不了解信息使用对象是谁的前提下，设
连接在一起，相互之间能够建立通讯； ■
度、当前托盘参考、木质托盘和中间层的存
数字革命的核心是制造执行系统(MES)，这 是一个控制系统，用于管理和监控工厂地板 上的在制品。制造执行系统的目标是提高生 产率，减少周期时间，即生产订单所需的总 时间。在工厂金字塔中，MES是ERP系统和
客户请求 与行业的革新同步的是，客户的要求也越来 越高。他们要求更高品质、更优惠的价格、 更快速和定期的交付、定制化产品、产品数 据的可追溯性，以及供应商提供的高等级 支持。 因此，制造商面临着如下多种全新挑战： ■
灵活性和移动性；
机器及已联网设备中间的一层。
联网的设备
MES为数据收集（从设备和装置中获取信
工厂内已联网的装置可以发送和接收信息，
息）、提取数据进行分析、数据展示（在监
提供更多附加值。
控器、平板电脑、智能手机上），以及数据
所有设备都可以联网：批处理、熔炉、馈 送机、玻璃瓶自动成型机、玻璃韧化炉、检
互换（与ERP系统和外部报告系统） 图1 提 供了保障。
测设备、传感器等等。 例如，托盘装运机器人可能发送有关其速
继续>>
Glass International
Vertech_Chinese.indd 1
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FIC ads 2015 Chinese_Layout 1 21/03/2017 09:41 Page 1
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
GLASS SERVICE
A Division of Glass Service
流程控制
▲ 图2：工厂信息控制面板。
▲ 图3：数据提取解决方案。
新技术也对MES供应商和软件开发人员有 影响。软件创新通过协作式创新实现，这一
程序已完成实现在线，可以在平板电脑和智 能手机上显示。
协作方式是将MES供应商、移动应用开发人
使您能够直接访问关键信息。 SIL控制面板是完整生产监控解决方案的 入口，用于实时监控玻璃制造人员的表现，
员、检测设备供应商的专长知识和客户体验
针对工厂管理的个人化控制面板
结合到一起。
为帮助玻璃制造商增强其竞争能力，实习前
并确保生产数据长期可追溯。■
对于软件开发人员，必须将玻璃制造商作
进的关键一步，即工业4.0，针对工厂业绩
*这是Topal先生于2016年10月在泰国华
为讨论中心点、倾听他们的要求，通过主动
管理的SIL解决方案提供了个性化的控制面
欣召开的第40届AFGM会议上提供的演讲稿
合作完成相关开发。
板，可实时监控生产信息（图2和图3）。
节略本。
灵活性很有必要，即使是对工厂管理系统
经理、监督人员、质量控制人员、生产
等工业应用来说。应用过去在工厂的PC上
线操作人员等，可对自己的控制面板进行个
* CEO **营销总监，Vertech，
显示，然后是在经理的笔记本电脑上。
性化定制，选择满足各自特定需求的实用指
法国夏隆市，www.vertech.eu/
现在，生产、检查和质量控制管理的应用
标。一整套50多个带通知的可配置小工具
数字思维 数码打印
梦想照进现实。 JETARTSERIES Fermac china.indd 1 Vertech_Chinese.indd 2
中空玻璃项目的全数字化打印工作流程 2017/4/3 21:45:44 05/04/2017 09:27:50
WE ARE GLASS PEOPLE
MAXIMISE YOUR PROFIT 生产效益最大化
COMBINE SPEED AND FLEXIBILITY 高速度与灵活性兼备 WITH SUPERIOR LIFETIME 超长耐用 High production speed 高速生产 Fast job changes 快速换产 Reduced downtimes 节省停机时间 Robot option 机器人可供选用(涂油) Clean design 清洁设计 中国联络处： 阿达国际-玻璃工程事业部 电话：010 64637797 网址：www.cgeglass.com.cn
传真： 010 64639114 email: mail@cgeglass.com.cn
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凤凰奖获得者
Fuyao Glass主席被授予 凤凰奖 曹德旺，福耀玻璃集团 （Fuyao Glass Industry Group） 主席，被评选为第46届 凤凰奖2016年度“玻璃行 业年度风云人物”的获奖 者。该奖项表彰其对国际 汽车玻璃工业的杰出贡 献。他向Glass International讲 述了自己步入玻璃行业以 来的辉煌职业生涯。
曹
主席是真正白手起家的人。他出生和成长 在中国农村，16岁时在家乡的街道上叫卖 烟草和水果。
在1976年加入福清高山特种玻璃厂以前，他还在 当农民和厨师。曹先生接受当地有关当局的邀请， 于1983年接手了处境艰难的平板玻璃加工业务，很 快，他作出决定，成立了中外合资企业，在全球制造 汽车安全玻璃和工业技术玻璃，获得巨大成功。 1993年，福耀集团成为业内中国首家在上海证券 交易所上市的公司。
www.glass-international.com
现在，福耀集团是中国最大的汽车玻璃出口商， 在全国拥有11个生产中心，同时在美国、日本、韩 国、澳大利亚、俄罗斯、德国和香港特区成立了多个 国际子公司和业务组织。 客户包括众多全球知名汽车制造商，例如，奥迪、 宾利、宝马、克莱斯勒、戴姆勒、菲亚特、福特、 通用汽车、本田、现代、捷豹路虎、尼桑、大众和沃
除了取得大量的商业荣誉外，曹先生还是中国最 著名的慈善家之一，他成立的河仁慈善基金会(Heren Charity Foundation)，旨在支持扶贫、疾病预防和基 础设施建设项目。 “我始终坚信，企业家要肩负三大责任：国家的强 大、社会的进步和人民的富裕。只有实现这三大目 标，企业家才能对得起自己的头衔，”他说。
祝贺他荣获凤凰奖本年度“玻璃行业年 度风云人物”称号。从众多优秀的玻璃 供应商中脱颖而出，获得这一奖项，您 有何感想？ 首先，我想感想行业对我的欣赏和帮助。我过去的工 作获得肯定，我感到非常自豪。 然而，对我而言，这个奖项也反映了行业对我的殷 殷期望和鼓励，推动我更上一层楼。因此，能够获此 殊荣，我感到无比的喜悦。
尔沃。 2009年，曹先生成为首位被授予年度安永全球青 年企业家称号的中国公民。
继续>>
12 Glass International
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凤凰奖获得者
您在玻璃行业取得了巨大的成功，也亲 自见证了自己的企业怎样蜕变成国际集 团。这一路肯定有很多值得称赞的故 事，但让您感到最骄傲的成就是？
这是一个很大的市场，有着高素质的劳动力。此
去40年里，我全身心投入到一件事上，即玻璃行业
外，美国还希望重新获得全球制造业领导者的地位，
的发展，从未为了名声或财富而分心。
这对像我这样的企业提供了非常好的机会。
地政府，以及各行各业的人，都向我提供了极大的支
使命。
持。这让我感到我的投入很值得。
在开始投入玻璃行业之前，您在做什么 工作？
您在2011年成立了自己的慈善基金会， 河仁慈善基金会，并且据报道您已成为 中国最大的慈善家。能简单介绍一下您 的基金会以及成立它的原因吗？
我还养过牛。
您是怎样踏入玻璃行业的？ 我想要离开农村。在朋友们的建议下，我说服村政府 成立了一家工厂，然后在那里上班。工厂制造水表使 用的钢化玻璃。那是一家非常小的企业，只有大约
“过去40年
10名员工。投资大概在5万元。
里，我全身心
您对玻璃最大的兴趣点在哪里？
我捐赠了价值3亿的福耀股份来成立了河仁慈善基金 会。根据目前的市值，股份价值大约为7亿。基金会 受到了国务院的特别肯定，是中国最大的以资产为基 础的基金会。 我设立基金会是想为所有企业家树立榜样，以身作 则去关怀贫困和弱势群体，帮助国家和谐发展。
玻璃清洁透明。它为世界带来舒适。当人们开车去工
您为哪些类别的项目提供支持？
作或是出去玩时，玻璃为他们阻挡了风暴。
救灾、脱贫和教育助学。
您的事业曾经经历过低谷吗，如果有， 您是怎么克服的？
您是否希望福耀将来扩展到世界的其他 地区？
创业存在极高的风险。企业家每时每刻都在应对风险
当然，每天都想。目前，除美国外，福耀已经在西
带来的挑战。
欧、俄罗斯、韩国和日本发展了业务。■
只有了解风险存在可能性的人才可能想出各种规 避风险的方法。对我而言，没有所谓的低谷或高峰。
对于现在想要投身玻璃事业的人，您有 什么建议吗？ 忠诚。每个行业都很艰难，因此必须要保持强大。永 不放弃，这样您才能克服困难。
www.phoenixawardcommittee.org/index.htm
www.glass-international.com
”
业的发展
我在当地社区中声望不错。我的客户、供应商、当
自信，以及责任感。为社会福利做贡献，始终是我的
很多不同的事情。我曾经是农民、工人、小生意人，
上，即玻璃行
我喜欢美国，而且我相信这里有巨大的投资价值。
我最骄傲的是我对汽车玻璃行业始终如一的热情。过
是什么给了您成功的动力？
投入到一件事
近几年，福耀玻璃的业务已扩展到美 国，这背后有怎样的动力，截止目前反 响如何？
13
Glass International
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书到用时 方恨少？ 只有TIAMA能做到知无不言， 助您掌控全局 我们不仅对冷、热端的生产流程和产品质量提供实 时监控，我们还能让您了解到更多信息。 如果您像我们一样相信技术可以推动发展，不妨 看看TIAMA的检验方案，我们愿意助您一臂之力。 正确的选择是成功的一半。
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Recycling
Spotlight on Russian recycling 2017 is officially the Year of Ecology in Russia. Our correspondent in Moscow, Alex Gurov, discusses Russia’s recent ecological progress.
Waste management According to an estimate by the Ministry of Natural Resources and Environment, the Russian Federation annually produces a few billon tonnes of waste, including around 50-60 million tonnes of Municipal Solid Waste (MSW), mainly produced by the inhabitants of cities (around 400 kg per inhabitant annually). More than 90% of all MSW in Russia is sent to landfill, while in the EU it is less than 40%. Russia's landfill covers an area equal to the size of Switzerland. Russia’s Accounts Chamber recently carried out an audit of existing landfills. It turned out that under the dumps there are four million hectares occupied, where nine billion tonnes of MSW is buried. Up to 90% of waste can be recycled today but only around 10% of MSW is used again (7% by recycling and 3% by incineration). According to an expert estimate by the Academy of Municipal Economy, the
solid waste average is composed of 35% wastepaper; 7-15% of polymers; 5-8% of glass and 3-6% of ferrous and non-ferrous metals. Before today, in Russia it was rare to have a separate garbage collection. Today MSW annual recycling potential is estimated to be up to 15 million tonnes per year, but throughout the entire country only around 300 MSW processing plants and a dozen incinerators are in operation. Separate waste collection and recycling is slowly catching on in Russia but still generates less revenue than conventional landfills. New amendments to the federal law ‘On Production and Consumption Waste’ took effect from 2016. At present, each region will have to decide how to deal with waste - to sort and recycle it, send it to a landfill, or incinerate it. Federal funding will depend on the implementation of such programmes. According to Russia’s Ministry of Natural Resources and Environment a new project called ‘Clean Country’ started in Russia from 2017. This project will create an effective model for recycling of the municipal solid waste, and form a
new MSW incineration industry. This will not only help clean up the country's towns from household waste, but also create electricity and jobs. The project involves the construction of four MSW incinerators in the Moscow region and one in Tatarstan with a total processing capacity of 3.35 million tonnes of MSW per year. This will reduce the amount of waste disposal in the Moscow region and increase the utilisation rate to 12%. Moscow has a population of around 12.3 million but there are only a few hundred locations in urban centres with special bins where one can drop off recyclable rubbish. Usually they are situated in public places where consumers take their empty glass bottles and jars for recycling. Moscow annually produces about 5.5 million tonnes of MSW that covers about 1/5 of Russia’s total MSW. Almost 80% of Moscow's garbage goes to 20 regional landfills, about 15% is incinerated by three Continued>>
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2
017 is the year of ecology in Russia. It is also the 100th anniversary of the October revolution that ended the reign of the tsars and created the Soviet Union. In January 1917, Tsar Nicholas II officially set aside land near Siberia’s Lake Baikal for the Russian Empire’s first nature reserve (pictured). To commemorate the anniversary, 2017 is the Year of Ecology and Protected Areas. The aim is to draw attention to the ecological problems of Russia, the conservation of biological diversity and maintenance of ecological safety. The total expense for events dedicated to the Year of Ecology is estimated at 194 billion Rubles (€3 billion), of which 84% of the budget is funded by private companies, 12% from municipal budgets and 4% from the federal budget. Many amendments to environmental laws will come into force in 2017.
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Recycling
regional incinerators and 5% is processed. According to the Moscow Government the landfills’ structure is composed of up to 19% of wastepaper; 14% of polymers; 12% of glass and 4% of ferrous and nonferrous metals. The average Russian family of four throws out around 1,000 used bottles a year. Annually it may return around 3 million tonnes of glass in just Moscow.
Glass recycling in Russia According to Rosstat, in 2016 Russia’s flat glass production was 250 million m2, while container glass production was 12 billion units. Of this, 85% were bottles and 15% were wide-neck jars. The domestic glass container market is worth more than 55 billion rubles (€900 million). Of its total bottle production, more than 60% are beer containers. Domestic breweries use around 4 billion glass bottle a year. The current Russian
Designer of the dosing and mixing line
A new approach As mentioned earlier, the Russian Government has introduced recycling rates and special ecological fees. For glass products the Ministry of Natural Resources has introduced a disposal rate at 15% and ecological fees at the rate of 2858/2564 rubles per tonne for flat and glassware. This corresponds with payment for glass packaging in EU at €45/t. The Russian glass industry produces about 4.7 million tonnes of flat and container glass a year, from which one third is glassware. Total fees from the glass industry can achieve - at Ministry of Natural Resources rates and regulations – a few billion rubles in the near future. The volume of landfilled glass disposal in Russia exceeds 3 million tonnes per year, which is 10,000 hectares of land annually. All Russian glass container waste is collected in two ways. The first method is to reuse entire empty glass bottles and jars made by beverage producers. The second is to add some cullet into the furnace to be melted back down to molten glass for processing into new bottles and jars. The latter process is known as closed loop recycling and gives the most
StromI (Russia) Glass Establishment (Italy)
-
ZAO “Stekloavtomatika” (Russia)
AMC Glass (Italy)
Glass Technologies (Italy)
Teco Glass (Great Britain)
Glass Technologies (Italy)
Horn Glass Industries AG (Germany)
Estimated capacity, ton/day
290
450
220
400
Melting area, m2
110
145
80
140
Designer of the furnace equipment
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According to Mr Osipov, in EU countries the proportion of cullet in the production of coloured bottles is on average 65%, and white bottles up to 80%. In Russia, the average cullet use does not exceed 30-35% of raw material use. Less than 20% cullet in the glass furnace cannot be used. It is a question of energy efficient and environmentally friendly operation of the glass melting furnace, as well as strength and quality of making glass.
structure of beer packaging is estimated by RBK company to be 45% beer pack to PET-ware, 25% to glass packaging, 25% to aluminium can and 5% to beer kegs. According to StekloSouz, the United National Council of the glass industry enterprises of Russia, the domestic glass industry has more than 100 glass ware plants, 22 flat glass plants and about 80 others producing different types of glass products. StekloSouz CEO Victor Osipov said: “Glass is a unique material; it is inert and is highly resistant to the influence of other substances. In Europe, the glass bottle turnover is six to eight times, but in Russia each bottle is reused just two to three. “In the USSR reusable containers in overall consumption was about 85% but we collect about 40-45% of the bottles and 65-70% of cans presently. In Russia today we only recycle 1015% of glass into cullet. But we know the benefits of cullet for the glass industry, which results in a reduction in the amount of virgin raw materials. “One tonne of cullet replaces 1.2 tonnes of virgin material ingredients, which includes about 600kg of sand and 350kg of soda and limestone. At the glass factory the replacement of some raw materials by cullet in the batch reduces the energy consumed when melting the batch, it reduces CO2-emissions, increases pull rate, as well as reduces the need to landfill empty glass bottles.” Russia’s largest breweries such as Baltika and Heineken don’t use secondary glass bottles and try to use more NNPB light glass bottles to decrease glass waste.
Refractory materials
KPOK CRRC (China) SEPR (France, India)
Start-up year
2014
2012
2014
Lines quantity
5
4
4
5
8/6
8/10/12
6/8
8/12 BDF 51/2
Sections quantity Glass-forming machine Annealing lehr
BDF 51/2, Bottero 61/4
Bottero 61/4
Bottero 51/2
Antonini (Italy)
CAR-MET (Italy)
Antonini (Italy)
Control measurement devices
2010
Bush&Spreen (Germany), AGR (USA), IRIS (France), MCAL (France), MULTI (France), M1 (SGCC), FLEXT (Emhart Glass)
Conveyor lines, palletizer
All Glass (Italy)
Gemco (Holland), CAR-MET (Italy)
Steklopack (Russia)
All Glass (Italy)
Termal shrinking machine
MSK (Germany)
Emmeti Sipac (Italy)
Steklopack (Russia)
MSK (Germany)
Table 1: A breakdown of Rus-Steklo’s four plants.
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Recycling
environmental benefit. Street stalls for collection of glass containers for payment are popular in Russian but have declined in recent years. There is a network of small stalls in large towns whose role is to collect empty glass bottles for refilling. These are cleaned, disinfected and processed for the next cycle. Beverage producing plants and local breweries could benefit from a ban on the secondary use of glass containers. The Russian glass waste market is formed mostly through the domestic collection of glass, while glass waste exports/imports from/to Russia is only occasional and insignificant. According to the research company Techart, between 2014-2016 the total volume of waste glass collection remained at about 1.1 to 1.2 million tonnes per year. The structure of the total volume of glass processed is as follows: 90% - of whole glass (bottles and jars) and about 10% - of flat glass (excluding inside plants turn-round cullet). According to Techart, the glass recovery rate in Russia is currently about 21%. This low level of glass recycling is associated mainly with the absence in Russia of
separate waste collection. In the next few years with the introduction of a system of separate waste collection and processing this figure may exceed 30%. Mr. Pavel Boboshik, Chairman of glass container manufacturer Ecran from Novosibirsk noted that the ideal composition of the glass bath and cullet for the production of glass bottles is 60/40. His plant requires around 5,000 tonnes of cullet a month. Ecran recorded a record level of glass production in 2016 of 421.3 million glass bottles, of which 57.6 million were by Narrow Neck Press and Blow (NNPB) technology. Each bottle weighed 280g, a reduction of 25%. In 2017 the company plans to produce 471 million units of glass. Russia’s glass industry plans to modernise but the lack of domestic glass producing and processing equipment remains a challenge. Most Russian glass plants (both flat and container glass) are modern with the latest technology and equipment. For example Rus–Steklo has a 22% share of the Russian market and makes glassware at four factories: in Sergiev Posad (SPSZ), Omsk (OSZ), Kingisepp (KSZ) and
Velikodvorsk (VSZ) with a total capacity of 1 billion units a year, including more than 300 types of flint glassware (See Table 1). The Nikolsky lighting glass plant (NZSS) stated in January this year that all glass products would be made from 100% recycled glass. About 20% of its glass is exported to the EU.
Mir Stekla 2017 Anyone interested in the current state of the Russian glass industry, including the potential development of the glass recycling sector, as well as wishing to develop their business in the field of recycling cullet, are invited to visit Mir Stekla 2017 International Exhibition between 5-8 June 2017 at Expocentre Fairgrounds in Moscow. Mir Stekla (World of Glass) is the largest show for the flat and hollow glass industries in Russia and Eastern Europe, alongside the International Forum on Glass and Modern Technology. It is a joint project between the AO Expocentre and StekloSouz. �
www.mirstekla-expo.ru
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Recycling
Alternative uses for recycled glass Jean-Pierre Delande* gives a review of alternative outlets for recycled cullet, outside of the normal re-use in the container glass industry. fraction contains a higher proportion of CSP (infusible materials, in particular stones, ceramic and porcelain). These fine particles are richer in organic matter, mainly from food residues in the containers. This organic contamination mostly concerns colourless glass, where pots and jars are more frequent. The fraction for which an alternative outlet is sought is proportionately divided as shown in Fig. 1. For every 100 parts of glass collected, about 10 parts should find an outlet in an alternative product outside the glass sector, including insulation fibreglass and foam glass. The development of alternative outlets for the worst fraction of the collected glass opens the door to recycling economies. The valorisation of the finest fraction and glass dust outside the glass industry permits a reduction of investment in optical sorting machines that can treat the finest fraction, despite the difficulties this entails in the feeding of furnaces. UK context Production 2011
2.311.000 tonnes
Consumption 2011
2.428.000 tonnes
Collection
1.481.000 tonnes
Incorporation capacity
984.000 tonnes
The possibility of valorising the fine fragments in an alternative sector permits the sorting process to proceed with screening to a larger particle size (>10 to 12mm), which results in a superior quality of purified cullet.
Alternative uses British Glass has studied the environmental impact of different scenarios of alternative recycling. The method used consists of establishing a comparison of the amount of CO2 saved following various applications inside and outside the glass industry. The chosen reference is a hypothetical case where the glass would be developed with 100% of virgin raw materials and 100% of the waste would go to landfill. These two extremes are purely arbitrary and unrealistic. The conclusions of the study are clear-cut and underline that outlets outside the glass sector represent a lower environmental benefit. The study underlines how glass recycling within the sector, including fiberglass, remains the primary objective. The environmental impact is limited for incorporation into bricks and for blasting (shot blast).
� Table 1: UK consumption leads to coloured glass waste
Continued>>
greater than the needs of British glass manufacturers.
Collected glass = 100
Manual sorting rejection =+/- 7
Manual sorting Magnetic sorting
Land filling
Grinding
Metals recycling = 1
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G
lass recycling is considered from a complete ‘cradle to cradle’ life cycle perspective. The recycling of waste material back to its original use is the best option for economic and environmental reasons. Recycling saves on fossil fuels used for powering furnaces and, as a consequence, reduces greenhouse gases. To the direct combustion of solid fuel or gas must be added the saving of CO2 resulting from the decarbonisation of the raw materials replaced by cullet. Every 10% of cullet used in the batch saves 2.5% in energy consumption. This saving varies according to the type of production (coloured or clear glass), the age of the furnace and the cost of raw materials. The collection of glass containers is necessarily a local activity, whereas the supply of cullet is a function of consumption – and consumption is not related to the production of nearby glass manufacturers. A good example is the UK: Consumption in the UK leads to an amount of coloured glass waste greater than the needs of UK glass manufacturers, who are mainly producers of colourless, flint glass. This imbalance results in a need for alternative outlets. Given the imbalance in the ratio of colourless to coloured glass, the UK is the champion of alternative outlets (Table 1). Glass is a material suited to 100% recycling into a new form, as theoretically there is no reduction in quality when recycled. However, there is a loss in quality of the collected waste and the processed cullet. There is thus a residual waste from the sorting/purification process, which is incompatible with the furnace feeding. Automatic optical sorting does not permit the profitable processing of glass fragments under 7mm: 7mm is the smallest size currently possible, although recent developments of optical sorting machines tend towards reducing this limit (up to 3mm), at a cost of subsequent investments. This fraction of recycled glass, smaller than 7mm (or less), is eliminated by screening after crushing. In principle this
Magnetic sorting Rejection <3mm = 4
Screening+drying
Dust (3% organic) =5
From grinding > 3mm Rejection optical sorting = 4
Optical sorting From optical sorting
Global rejection KSP =+/- 4 other = +/- 4
Clean cullet Efficiency +/- 85%
Land filling
Glass factory
Potentially recoverable
� Fig. 1: The fraction for which an alternative outlet is sought is proportionately divided.
37 Glass International April 2017
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Recycling
� Fig 2: The process of foam glass production.
Heat recuperation
Foaming furnace Output foam glass
Burners*
Mixing
Foaming agent
* Electrical heating is also possible
Feeding cullet Fine grinding
Coarse grinding
It is negative for aggregate and the filtration substrate, mainly on account of transport costs.
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Fiberglass insulation The use of cullet in fiberglass insulation production is the alternative outlet that absorbs the greatest volume. The technical conditions required for the production of fiberglass remain constrained. The viscosity of glass before being processed into fiber influences fiber length and the infrared emissivity influences the speed of cooling. As a consequence, the quality of useable cullet should meet certain criteria: � The presence of certain oxides such as CO2 (blue glass), Cr2O and FeO (green glass) are disadvantageous to the transfer of IR heat and thus to the cooling speed. These conditions determine the control of fiber thickness and length. � The colour mix should also be under control. � Colourless glass is highly oxidized (as is sheet glass), green glass varies between being slightly oxidized and slightly reduced, and brown glass is highly reduced. The treated mixture should maintain maximum stability (avoiding brown glass). � The fusion process may be achieved with a wide range of degrees of oxidation, but maximum stability is required. If this is not the case, then undesirable effects are possible such as the formation of foam (SO2) and increased energy consumption. For these reasons, fiber producers prefer to use cullet from sheet glass. The use of container glass is not necessarily excluded, subject to strict quality control and the guarantee of a stable supply. CSP particles can block the fiber-forming holes. The CSP must be eliminated as much as possible (or at least finely ground).
Drying
The required quality criteria can be summarised as: no metals, no ceramics (porcelain, vitro ceramics, refractories); good chemical stability of the cullet (colour mix); and a stable, and lowest possible loss, of fire (humidity and organics content). The required quality criteria is not fundamentally different from the quality criteria intended for the production of container glass.
Foam glass Foam glass or cellular glass is a vitreous material which looks like a glass sponge formed of closed pores of homogenous size. The density of the pores may rise to 1,000,000 pores per cm3. The closed character of the porosity assures the thermal insulating quality as well as its impermeability. As it comes from a vitreous material, cellular glass offers good chemical inertness, a total absence of toxicity and adequate heat resistance. The process has the advantage of permitting the valorisation of recycled glass, which is more contaminated than the portion destined for glassware production. The fine particles normally sent to landfill are suitable for inclusion in foam glass manufacture. The process is not affected by the presence of CSP and vitro-ceramics. As the glass is intended for grinding, the apparent density does not matter. The characteristics of suitable glass are thus much less critical than for glass destined for glassware. The minimum sorting process necessary consists of eliminating metals and paper, and to control the content of organic matter. The outlet into cellular glass allows for a saving in the sorting process in comparison with the solution ‘everything goes to glassware’ which
makes optical sorting necessary. The production of cellular glass has been developed in Sweden and Norway (and is now in full expansion in Germany, Italy and Russia) where production units are close to the cullet refineries and take from them the least valuable part. The production of foam glass uses the following sequence of processes: 1) Coarse grinding The portion >5mm is ground to obtain particle dimensions <10mm. 2) Drying The ground material is dried using gas from the foam oven chimneys. 3) Fine grinding-micronisation After drying the material is finely ground in a compressive crusher and reduced to a particle size of <100um. 4) Addition of foaming agents A foaming agent is mixed with the ground cullet. The nature of this reagent and its dosage represents the main knowhow of the operation. 5) Foam oven The foam oven is in the form of a tunnel +/- 20 metres long. The material to be treated is spread out evenly on a conveyor belt set in motion by two drums. The material is approximately 2cm thick. The upper vault of the oven contains the burners. The reaction is classic for the formation of cellular glass. The glass brought up to temperature softens while conserving a sufficient viscosity to determine the size of the cells. The foaming agent oxidises by forming carbonic acid. The viscosity of the melted glass must be such that the gas formed remains captured in the material without being able to aggregate into bubbles of too great a size. It is thus the sufficiency of these two parameters, viscosity and gasification of the foaming agent, which constitutes the key to the formation of foam glass. At the exit of the oven, the foam solidifies and is broken up by gravity on the exit drum. Fig. 2 illustrates the process of foam glass production. Foam glass has many applications. As aggregate in concrete, cellular glass permits the creation of partitions with good thermal insulation. The lightness of the material facilitates the improvement of structural support on unstable ground. It may be used as a material for embankments and road underlay, as well as decorative Continued>>
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Recycling
applications with a coloured polymeric binder.
The valorisation of glass The use of waste glass – and container glass in particular – in the form of ‘sand’ grinded in a comparable particle size, in place of natural sand, has always been considered an alternative outlet of economic interest. This outlet could involve the scrapping of optical sorting machines, given the inertia of the infusible substances (CSP) in this type of application. The characteristics of ‘glass sand’ are advantageous with regards to chemical inertness and the filtration capacity of this material. However, the compaction and bearing capacity of glass sand is insufficient. The grinding of glass in different particle proportions and the calibrated mixture of these grounds could be satisfactory. The cost of natural sand is economically sustainable. The more difficult use of ground glass in concrete is the object of studies and research. Some results shine a favourable light on the future of such uses.
Chemical treatments Scientific literature has highlighted ways to enable the purification of recycled glass by new chemical routes. The different procedures studied have one thing in common: the analysed processes cause the dissolution of cullet in highly alkaline solutions. Experimental conditions, although demonstrating specific particularities, respond to the following conditions: � The pounded cullet of container glass is treated in a watertight reactor; � The environment is alkaline (NaOH or KOH) at temperatures of 65oC to 360oC; � Atmospheric or weak pressure; � Length of treatment from 1 to 6 hours. The obtained product is a synthetic tobermorite (calcium silicate hydrate) in powder or granules. This product displays an interesting property. One notices a capacity to absorb and stabilise heavy metal ions in a water solution and in particular cadmium and lead. This mineral may be used as a means of in-situ improvement of polluted surface water, but equally as a means of filtering industrial effluents. It is used as a reactive barrier product to prevent the spread of pollution to surface waters. No industrial application has been established so far.
Conclusion The alternative outlets represent a weaker economic interest than incorporation in the original glassware channels: it is the poor relation of glass recycling. There are several reasons, such as limited volume, geographical dispersal of resources, presence of specific contaminants (CSP, vitro-ceramics, organic substances, metals, PVB) and transport costs. Recycled glass is in competition with other cheap materials. The portion unsuitable to glassware production, which represents a considerable quantity, deserves continued attention. The outlets present an economic and environmental interest and merits more research and increased development. �
*GRConsult, Recycling Solutions, Belgium info@grconsult.be Glass International April 2017
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Recycling
U
usioaines Oy is Finland’s largest glass recycling company, with a capacity to treat up to 120,000 MT of raw cullet annually. Uusioaines doubled its production capacity of Foamit foam glass aggregates (FGA) during 2016 and now has the highest level of production capacity at any single location within the EU. Uusioaines is a member of Ferver, the European Federation of Glass Recyclers that supports and promotes glass recycling at institutional, public and professional levels. Its members are located in 18 different countries and are responsible for recycling 70% of all glass waste in Europe.
History
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Glass collection had been part of the Stenberg Corporation’s operations from the early 1980s onwards. Initially only float glass was used in the production of glass wool and the float glass was crushed and screened with the company’s stonecrushing and screening equipment. Subsequently container glass was also processed. Soon there were problems with impurities, and it became necessary to build a specialised, more efficient glass recycling line where the glass was crushed, cleaned, and sorted according to colour and delivered for industrial use as cullet. In 2009 the company name was shortened to Uusioaines Oy. In 2010 a new treatment plant opened, complete with x-ray colour sorting and CSP sorting equipment. The installation of a computerised automatic sampling system followed to guarantee consistent quality and to pass on reports from this system to customers as a matter of course. Construction of the Foamit factory was completed that same
Foam glass aggregates bo Finnish glass recycler Uusioaines has joined Cleantech Finland, doubled its foam glass capacity and reduced its carbon footprint reports Henry Rawstorne, Export Manager.
year and Foamit FGA production started that December. The small particles, or fines, are now milled on site for the manufacture of Foamit. Today the capacity of the glass treatment plant is sufficient to meet Finland’s foreseeable future needs, while the production capacity of the Foamit factory has been doubled since its original construction.
Lightweight aggregate Foamit is a foamed glass lightweight
aggregate for civil engineering applications such as motorways, bridges and approach embankments, and in housebuilding. It is ideal for sub floors and for preventing cold bridging in well-insulated new builds. It can play an important role by insulating old buildings while retaining breathability. In commercial new-builds it can also be used in green roofs, roof terraces and rooftop parking areas. What sets Foamit apart from its competitors is that it is manufactured from carefully selected raw cullet that is treated and milled on site. Its properties include: high compression strengths, a closed cell structure, high insulation values, the ability to form a free-draining layer, breathability and excellent environmental credentials. Major applications are as light weight fills for domestic, industrial and civil engineering uses. It is easy to use and handle with standard equipment such as excavators and front-loaders. Foamit foam glass aggregates are suited for applications in housebuilding in a variety of structures. Foamit as a bulk fill material is one of the lightest on the market. Benefits of this low density
� Foamit furnace. Continued>>
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Recycling
es boosts Finnish recycler � Foamit factory stock yard.
process of Foamit foam glass, there is no organic matter contained in any of these finished products.
Compliance In 2016 Foamit FGA achieved the one-off certification process proving compliance with building regulations and standards across England, Wales and Scotland, which ensures acceptance by all local authorities across these countries as well as increasing industry confidence in its the performance and suitability. It is also designed to make the building control process faster, easier and cheaper by simplifying the submission route. It is currently in the process of gaining the LABC Warranty status, which will ensure easier structural warranty approval for UK customers.
Key markets Clean cullet is used as raw material for the glass container and glass fibre insulation industry. Foamit FGA is produced onsite for sale to construction and civil engineering companies, for use in infrastructure projects, commercial construction and housebuilding. While the domestic Finnish market remains important for both Foamit and cullet, processed cullet is also exported to numerous countries within the EU. Important export markets include the Nordic countries and the UK.
� Retrofit light fill. include the ease of compaction of the material and transport efficiency. Foam glass’s cell structure gives the product low thermal conductivity (dry about 0.1W/ mK), making it an excellent insulator. Its easy compaction and angle of friction ensure a stable substructure on site. It is non-combustible and has low capillarity, meaning it can be effective as a moisturebarrier. Foamit is made up of 99% purified recycled glass which has been milled, mixed with a foaming agent and then
passed through a furnace at around 900oC. The resulting sheet of foam glass is lightly scored and allowed to break up into approximately 60mm pieces as it cools and falls off the conveyor. This material, Foamit 60, is a standard size for infrastructure projects. This material can then be crushed and screened, producing the specialist sizes for commercial and domestic construction, including Foamit 30 (20-30mm), Foamit 20 (10-20mm) and Foamit 10 (3-10mm). Thanks to the nature of the manufacturing
Uusioaines Oy became a member of Cleantech Finland in 2017. Cleantech Finland is a hub of Finnish cleantech expertise and sustainable innovations, bringing together fresh ideas and solutions for advanced cleantech business. Cleantech is key to the Finnish economy and is one of four focal points of the Finnish government, while the Finnish cleantech business employs around 50,000 people. 40,000 new jobs are expected by 2020. Uusioaines Oy is audited and operates according to the quality management standard ISO 9001 and the environmental management standard ISO 14 001. Foamit is CE-certified according to EN 13055-2: 2004 and due to the manufacturing process, it does not contain organic substances and is nonflammable. It is odourless, inert and does not leach harmful substances in conventional applications. Continued>>
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Cleantech Finland
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GLASS HAS A GREAT PAST.
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End-of-waste criteria Since the end of 2015 Uusioaines has worked in accordance with Article 6 (1) and (2) of the Waste Framework Directive 2008/98/ EC, where certain specified waste shall cease to be waste when it has undergone a recovery (including recycling) operation and complies with specific criteria. Uusioaines’ processed glass cullet comes under Commission Regulation (EU) No 1179/2012 and all overseas shipments include a statement of conformity with the end -of-waste criteria referred to in Article 4 (1) of the former regulation.
24/7 automated testing Simple operation Versatile bottle management supports a wide range of ware No job change 25% faster throughput than other industry offerings
Carbon footprint
Future trends Innovation has been at the heart of Uusioaines’s structural development programme over the past decades. Foamit FGA production in tandem with the technology contained within its glass treatment plant has enabled the company to achieve close to a 100% recycling rate of incoming raw cullet in 2016. Increasingly environmental standards and factors, such as carbon emissions, will be a driving force, while political challenges, such as those posed by Brexit, can cause changes to markets as well as providing opportunities. �
OUR BRAND
PROTECTS YOUR BRAND
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During 2016 and 2017 Uusioaines carried out a study of its carbon footprint, with regards to recycled cullet and Foamit products. Underlying the calculation of the carbon footprint are Uusioaines’ aims to find out the carbon footprint caused by its operations, and on the other hand emissions of carbon dioxide generated by the manufacture of foam glass aggregate in relation to glass wool and glass packaging carbon dioxide emissions. In addition to the impact on the carbon footprint of the use of glass cullet, the aim was to also determine the effects on the carbon footprint of the delivery of glass cullet for the above uses. The calculation also studied cullet as a raw material and the impact on the carbon footprint of any change in the ratio of the mixture of virgin materials to cullet to be used as raw material. As a result of the survey, Uusioaines has been able to instigate a carbon reduction of a decrease of 280 tonnes for 2017. This will be achieved partly through the usage of biogas for the furnace stage of Foamit production.
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History
Prof. John Parker
Weighty matters Prof. John Parker discusses how the ability to measure density accurately offers a powerful means of monitoring production quality.
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I
n the third century BC Archimedes allegedly jumped from his bath and ran naked down the street having had the first eureka moment ever, one which defined the bare essentials of density measurements. It helped him demonstrate the dishonesty of a goldsmith who had made a golden crown fit for a king but adulterated it with silver (which was wholly inappropriate). He realised that the volume of water displaced on immersion measured the volume of an irregular object allowing its density to be determined. Subsequently he realised that the mass change of the object on immersion gave an even more accurate value. For glassmakers the ability to measure density accurately offers a powerful means of monitoring production quality. Knowing how it varies with temperature is also important for modellers of furnace convection currents. The density of any glass can be estimated using the molar masses and molar volumes of its constituent oxides. A better approximation is achieved using phase diagram information and representing the glass by the crystalline phases that would form an equilibrium mixture of that composition. Estimates are, of course, what they say on the tin. While comparisons between actual and predicted values offer rich fodder for scientists aiming to use deviations to unravel structure, of more interest to the practising technologist is the precise effect of small changes/errors in composition. Fortunately careful measurement by early 20th century technologists has given us factors quantifying the density change caused by a small increase in the proportion of one component in the batch. Published data based on linear relationships allow predictions for changes up to 2wt%. Thus for a typical soda lime silica glass, a 0.1% increase
of CaO (for example owing to excess limestone in the batch) will cause a density rise of 0.0011 g/cm3. Now this change is insignificant compared with an actual density near 2.5g/cm3 and too small for measurement by techniques based on volume displaced. Thus a density bottle is only accurate to 0.01g/cm3 unless great care is taken. But Preston proposed a comparative method based on sink-float principles; a glass sample, which can be small but must be durable, is floated on a slightly more dense liquid and the liquid is heated gradually until its density falls below that of the glass, at which point the fragment sinks. This approach is extremely sensitive and capable with proper calibration of determining densities to 0.0001g/ cm3, so long as the liquid temperature can be controlled and measured to 0.1oC. As a result density can be used for quality control of glass composition/ homogeneity and is more sensitive to small compositional fluctuations than standard chemical analysis techniques. Of course a change in density can have several origins and full analysis requires measurement of other properties with a different compositional dependence. Importantly density is influenced by its thermal history and so for quality control, standardisation is required by re-annealing the fragment or at least consistently taking the sample from the same position across the lehr. The variation of density with thermal history mystified early glass technologists who associated annealing only with stress release. Now the link to viscoelastic behaviour is better understood and is important for modelling forming processes. Such behaviour also allows forensic scientists to differentiate glass fragments which have been toughened, while density values after careful annealing can isolate glasses from many different sources.
As a property in its own right, density is rarely important. Collectors may appreciate the extra mass of hand cut lead crystal glass but there is little potential to lightweight an article simply by reducing glass density. Interestingly in the 18th century the introduction of twist stem wine glasses with hollow spirals was said to help circumvent a glass tax based on the weight of the article. Recently ultradense scintillating glasses were tested as potential detectors in the Large Hadron Collider experiment only finally losing out to lead tungstate single crystals that weighed in at 8g/cm3. For accurate modelling of glass furnaces at high temperatures melt densities and thermal expansion coefficients are needed since density changes drive convection flows. Good quality data are difficult to find although a very rough guide is that expansion increases approximately 4 fold above TG. Thus at 1500oC the density may be >10% lower than at room temperature. Extensive international studies have been undertaken to obtain improved data and the ICG has coordinated inter-laboratory comparisons of results. One method was the application of Archimedes principle with a platinum bob whose expansion behaviour was well defined; this uses a really hot bath. Alternatively hot molten globules of known weight are photographed and the digital images analysed to determine their volume. Archimedes would probably have appreciated seeing glass float on water. Large hollow glass spheres are sometimes used as buoyancy aids for fishermenâ&#x20AC;&#x2122;s nets. Since he also evaluated pi he would have been able to determine their volume, and hence density, while avoiding any embarrassing exposure. ďż˝
*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk
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Energy efficiency
A self-driving glass melting process Erik Muijsenberg* and Menno Eisenga** outline how intelligent furnace design systems can improve the efficiency of a glass furnace, focusing on how electricity use can best be monitored and managed. This is an abridged version of a paper given at the recent SGT Centenary Conference.
T
he car industry is one example of an industry that is quickly changing, and using more sensors such as radar, sonar and visual cameraâ&#x20AC;&#x2122;s , for example, in self-driving cars. Most cars today use partial or already fully electric engines to put the car into motion. This revolution is also possible for a glass-melting furnace. This advancement is possible thanks to cheaper sensors and a change in electricity costs thanks to resources such as renewable energy. Even in the Middle East, where oil is cheap, the sun powers oil pump jacks (Fig. 1). Renewable resources in the EU today generate around 30% on average of the required electricity. On some windy and sunny days this can rise to around 80%, making electricity price negative at some points during the day (Fig. 2). The glass industry and glass furnaces can also make use of this advantage, but to do this they need an intelligent, fully automatic control system that can use the dynamic change in the availability and
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Import balance Solar Intraday continuous 15 minutes average price (right axis)
ďż˝ A solar-powered oilfield pump jack.
pricing of electricity, and even plan ahead to anticipate these changes. The electricity market itself can provide future predictions that can be fed into a smart control such as Expert System III. This can also be seen in Fig. 2, as the light grey and yellow area at the end of the diagram. This paper will demonstrate how intelligent furnace design and operating practices can increase overall glass furnace efficiency, by using advanced furnace modeling to help select the most-optimal furnace design for a certain type of glass
Conventional > 100MW Solar forecast Intraday continuous 15 minutes low price (right axis)
Conventional > 100MW planned Load Intraday continuous 15 minutes high price (right axis)
and pull. This can be achieved by installing (more) electric heating in unique ways. The average residence time of a common glass furnace can be, for example, 30 hours, while the minimum residence time is sometimes only three hours, so the whole available space volume is poorly used. Furthermore, flexible top-firing energy input is optimised in conjunction with Continued>>
Wind Load forecast
Wind forecast Intraday continuous 15 minute call (right axis)
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ďż˝ Fig 1. Electricity production and pricing including prediction in Germany (snapshot in May 2016 from Fraunhofer ISE website).
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Energy efficiency
ďż˝ Fig 2. End fired furnace with melter and barrier electric boosting.
the electric boost, in the most optimal combination (Fig. 3). Altogether this can significantly save energy, increase furnace pull-rate and reduce emissions. A flexible furnace using natural gas and electric heating can be operated at higher pulls per square metre and cubic metre when necessary, and at the same time reduce energy costs at a given pull rate. A furnace designed in this way can also be economically optimised, using advanced Model Based Predictive Control (MBPC). MBPC can decide better than a human operator when to use which energy input in the most optimal way, keeping the balance between temperature stability, glass quality, furnace lifetime and actual, to-the-minute costs of the used energy source (especially electricity). Operating the optimal furnace design (with gas firing and electric heating/boosting) with fully automatic Model Based Predictive Control allows the glass producer to operate the furnace in the most cost-effective way with the minimum use of operators. Fig. 4 shows an example of fully automatic furnace control. As well as the energy costs savings, the system also delivers temperature stability to the melting process resulting in higher glass quality and production rates. The technology can often also offer a pull increase and emission reduction, while energy cost reduction can be 2-6%. This leads to payback times of only three to six months. ďż˝
*Vice President, **Technical Consultant, Glass Service, Czech republic, www.gsl.cz/en/glass-service.html
Plant electric energy Electric boostling F#1 & F#2
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Fluctuations in gas heat value can be compensated by rapid corrections in gas setpoint, if CV-meter is installed
ďż˝ Fig 3. Flexible use of electricity versus gas heating depending on availability and costs, while maintaining automatic glass bottom, throat or riser temperature.
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Energy efficiency
� Fig 1. 0.5 MWe ORC Electricity generating system, installed after the electrostatic precipitator at Lhoist.
Choosing the best techniques for waste heat recovery Darren Bryant, CEO of Heatcatcher UK, discusses best available waste heat recovery techniques for the glass industry and outlines UK government initiatives to help manufacturers with funding.
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H
eatcatcher started designing, building and operating Waste Heat Recovery (WHR) systems in the lime and cement industry, commissioning its first plant using Organic Rankine Cycle (ORC) technology in 2013 by recovering the exhaust gases from a rotary kiln to generate 0.5MW of electricity for the UK Lhoist site near Durham (Fig. 1). The opportunities and challenges of integrating the best available waste heat recovery techniques into the float and container glass furnaces are similar to the lime and cement industry, except the return on investments are improved because the annual operating hours of the glass furnaces are higher. All energy intensive industry sectors face increased energy prices and the Heatcatcher team of engineers have applied their knowledge and experience to match the best available ORC and steam expander technologies to recover the heat energy from glass furnace exhausts. With increased environmental legislation to limit exhaust gas emissions, plants anticipate higher capital costs of additional flue gas treatment (FGT) equipment. These are often required to operate with lower exhaust gas temperatures and so additional cooling is required. The
cost of new FGT equipment and cooling equipment to lower the temperature can be mitigated by a WHR system, removing the heat and converting to low carbon electricity prior to the FGT equipment.
WHR integration Selecting the Best Available Techniques (BAT) for heat exchanger integration and matching it to the best commercially available ORC or Steam Expander is an area of expertise crucial to meeting the technical and economic conditions of a WHR integration project. Technical considerations include: � How variable is the temperature and mass flow rate of the exhaust gas? � What is the exhaust gas chemical composition limiting the minimum operating temperature? � Plant space constraints determining heat exchanger location and ductwork integration. � Ductwork changes if combining exhaust streams of more than one furnace. � Heat exchanger cleaning method and pressure system pressure drop. � Additional WHR system pressure drop effect on process and induced draft fan. � Variation in exhaust stack efflux
velocity from lowering the temperature. � Future demands on reduced emissions limits and flue gas treatment.
WHR economic value Once the technical aspects of integration are assessed then the economic considerations of how to gain the greatest value for the typical 15 to 20 year life of a WHR system. Is the value in producing large quantities of hot water, with a small amount for site usage and the rest to be sold over the fence to a neighbouring plant or a district heating system? Finding a neighbouring host to consume large quantities of hot water is commercially challenging and the connection to a planned District Heating Network may receive local government incentives but can be a lengthy process. Converting the recovered heat to all low carbon electricity or a combination of electricity and a small amount of heat for site usage has been the preferred choice of glass plants that operate WHR systems. WHR systems in operation include the 1.3MWe ORC generator installed in 2013 at the AGC flat glass plant in Cuneo, Italy; the 0.5MWe ORC generator at the Continued>>
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Energy efficiency
� Fig 2. Exhaust Gas Heat Exchanger Vetrobalsalamo, Milan.
� Fig 3. Heliex Power 400kWe Steam Screw Expander electricity generator
Picture courtesy of Heliex Power Ltd.
installed at Vetrobalsalamo, Milan. Picture courtesy of Heliex Power Ltd.
O-I Glass container plant in Villotta di Chions, Italy; the Guardian Glass steam cycle generator being installed at the Goole float glass plant in the UK; the 5.5MWe ORC generator at the Sisecam plant in Bulgaria; and the 0.4MWe steam screw expander installed at the Vetrobalsalamo plant in Milan, Italy (Figs. 2 and 3). Figs. 4 and 5 show some integration arrangements of these projects and how electrical power only is generated or a Combination of Heat and Power (CHP) is produced.
The department for Business Energy and Industrial Strategy is expected to launch the first phase of the ‘Industrial Heat Support Programme’ later this year, offering up to 40% funding support for these feasibility studies. The second phase of the IHSP in 2018 could fund up to 30% of the capital costs of
implementing the best projects identified from the feasibility studies. �
Heatcatcher, Brighton, UK email info@heatcatcher.com www.heatcatcher.com.
Dry air cooler
400V/50HZ Thermal oil loop
ORC
Summary 420°C
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Stack Exhaust treatment
HiT WHR HEX Furnace
ID fan
� Fig 4. Power Only - Single furnace with heat exchanger before the Exhaust Gas Treatment, supplying the ORC generator with hot thermal oil to generate electricity only and condensing with a dry air cooler. 80°C Thermal loads 90°C Thermal oil loop
420°C
400V/50HZ ORC
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WHR HEX Furnace
65°C
Stack Exhaust treatment ID fan
� Fig 5. Combined Heat & Power - Single furnace with heat exchanger before the Exhaust Gas Treatment, supplying the ORC generator with hot thermal oil to generate electricity and using the condensing hot water temperature from the ORC to provide hot water at 80°C for use by the site or to sell over the fence.
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With an increased need to mitigate against rising energy costs of glass manufacturing and stakeholder pressure to decarbonise the sector there is a growing interest in WHR solutions. For example, in November the British Glass Manufacturing Confederation hosted a Knowledge Transfer workshop on WHR that was attended by many company senior representatives, keen to understand about WHR systems. While many of the technical integration aspects must be satisfied with a feasibility study before a business case can be presented to the board, an investment grade document is needed for the board to decide if the project is to be directly funded from their capital expenditure budget or externally funded under a Power Purchase Agreement (PPA) or Energy Services Contract (ESCo). The UK government has recognised through its ‘Industrial Decarbonisation and Energy Efficiency Roadmap to 2050’ that the cost for Energy Intensive Industries to prepare the feasibility study are substantial.
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Moulds
Reducing costs and downtime in mould making Commersald Impianti has completed three Research and Development glass mould projects. Massimo Trigari, General Manager, discusses.
T
echnological research by Commersald Impianti concerning machines and equipment for P.T.A. hard-facing glass moulds continues to produce innovation. The group, based in Modena, Italy, has completed three development activities this year, which were long awaited by its customers.
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Plasma Microwelding The first project was its research into Plasma Microwelding (Fig. 1). It consists of the development of a technology that responds to a request to contain the hard-facing dimensions to the area of the contact glass of moulds and accessories. The innovation has an aesthetic value of the finished product and it represents a drastic reduction of costs for the lower volume of the coating material, which results in a higher operating speed and a lower consumption of filler metal. From a metallurgical point of view a thin, fast and uniform thickness coating determines: � Reduced dimension of the heat affected zone. � Minor defects for the lower amount of base metal melted in the welding deposit.
� Regular transition area, straight and perfectly defined. To obtain these aesthetics and economic advantages, care must be taken in groove preparation and the precision of fixtures. The welding equipment must have a good control of the current and voltage to obtain a stable arc at low amperage to be able to make a ‘cold’ welding with all alloying elements in the matrix perfectly fused. The filler powder flow must be constant and regular and injected with precision in the plasma arc centre, to obtain a thin and regular bead with dispersion contained within 10%. The tungsten electrode must be sharpened with care at a 40° vertex angle. Commersald Impianti working stations – even the oldest ones – with the new Microwelding nozzle are perfectly suitable for the purpose and have all the characteristics to obtain perfect microwelded beads.
Business continuity The second innovation is aimed at business continuity by limiting downtime due to programming errors or
misinterpretation of the welding process. Commersald Impianti has activated an advanced remote assistance service of its last generation, integrated to a Koy Vision system on favourable terms for buyers of PTA welding equipment. The system mounted on the machine by the customer allows Commersald Impianti technicians to interact with the operator viewing the welding programmes remotely, advising and if necessary intervening from office via the internet. Integrating the remote assistance with a Koy Vision system, our technician from the office may participate in real time exactly as if they were on site, at minimal costs and with maximum efficiency. Koy Vision gives an amazing overview: you can see the welding pool and nearby area in detail with a high-definition camera through an external monitor. By recording the images the customer has the opportunity to make a considered post-process survey. The movie will be provided to the customer with the certification documents.
Continued>>
50 Glass International April 2017
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Moulds
Fig 1. Plasma microwelding.
CAD Designed Projects that Feature a
360°
“Walk-Through” Capability
It should also be highlighted that when in automatic, the welding deposition cannot be controlled for security reasons by an operator within the work area. This may cause defects and rejects in production. The perfect pool vision through the external monitor connected to the camera will be useful to understand why porosities or creaks appear, giving the possibility to intervene on the welding and moving parameters in real time, avoiding the waste to the benefit of cost containment. Koy Vision operates in conditions of maximum safety with closed barriers by improving the efficiency of suction of the fumes, protecting the interior of the workshop by the flashes of light and observes the weld pool through the monitor.
HFT also provides . . . • Procurement Services • Construction Services • Project Management
The third innovation concerns the robot servo systems. To move the pieces from the loading tray to the preheating induction system and from this to the welding machine, Commersald Impianti has developed robotic equipment inclusive of robot manipulator. Thanks to the use of a camera positioned above the loading tray, the robot is able to identify and accurately grab the workpiece while a load positioned on the base of the powder feeder detects changes in weight and identifies potential scrap pieces. It is a complete equipment able to work for a full shift without operator intervention, an innovation that reduces labour costs in mass production of moulds, neck-rings and all the other glassware accessories. �
Engineers and Contractors to the Glass Industry 3009 Washington Road • McMurray, PA 15317-3202 • USA
www.hft.com +1 724 941 9550 Fax: +1 724 941 3479
dchen@hft.com
cyoest@hft.com
Commersald Impianti, Modena, Italy www.commersald.com
www.glass-international.com
Robot servo systems
51 Glass International April 2017
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Forming
A reliable high tech solution Martin Grönblad, Product Manager of Process Products at Bucher Emhart Glass, outlines the group’s Flexible Pressure System (FPS) and how it has evolved since it was introduced 18 years ago. Pressing pressure = Operational air pressure * A1 A2 A1 A2
www.glass-international.com
S
ince the Flexible Pressure System (FPS) was first introduced almost 18 years ago, the system has evolved into a standard in the industry. In the Bucher Emhart Glass machine portfolio it is the standard for Plunger Up actuation on all machine types and is a must for customers producing containers in NNPB. The success of FPS for Plunger Up is based on the dynamics that are required to successfully form a parison. Once the plunger has penetrated the glass and is approaching the end position, the control of the plunger operating air pressure becomes vital to avoid unfilled finishes and over presses. Blank seams can be caused by the pressing pressure inside the blank moulds, which is a product of the ratio difference between the projected area of the plunger piston and the projected area of the plunger (the opening on the finish). Since the area for the finish is smaller than the piston area, the pressure inside the blank mould will be amplified, and it therefore creates an increased pressing pressure. This pressure is projected onto the walls of the blank mould and can potentially push the mould equipment apart and consequentially create blank seams. Not only does the operating air pressure need to be kept low, the pressure oscillation must also be kept to a minimum to ensure repeatability in the forming process (Fig. 1). To further complicate the forming process, when the plunger is exposed to stick slip at standstill, the friction coefficient is higher than during movement (µStatic>µKinetic). The required low pressure during pressing is therefore not ideal at the beginning of the plunger motion. In addition, the plunger movement is also related to the mechanical condition of the mechanism, where factors such as lubrication and dirt also contribute to variations in the movement. For this reason there is a need for multiple pressure steps with an actuator
� Fig 1. Pressure on inside a blank mould. that offers a quick response to set point changes. With this background it is clear that a directional valve (On/Off) with one defined operational pressure cannot perform this task successfully.
� Fig 2. FPS valves.
The heart of it The heart of the FPS technology is the direct proportional solenoid valve (Fig. 2). This proportional valve acts on an analogue set point signal coming from the FlexIS control system and outputs the corresponding operational pressure. However, if we look under the hood of the proportional valve we understand that it is actually packed with intelligence. Depending on which function the proportional valve is used for, the characteristics of the underlying control algorithm is tailor-made to suit the intended function and therefore gives optimum functionality in the forming process. Bucher Emhart Glass’s proportional valves are produced in Hannover, Germany. In this production facility the valves are assembled in a lab environment with each individual valve calibrated against its own mechanical characteristics for optimum performance. Going from the lab coats and ESD protected environment in Hannover to being mounted on a glass production line may seem from the outside as a big step, but this is a misconception. Over the years, these valves have built a good reputation in the industry due to their long service lifetime. Nearly 100% of the annually produced IS machines are equipped with FPS Plunger Up, but this technology is not limited to use for the Plunger Up. A high
percentage of the machines are equipped with FPS for Plunger Cooling/Counter Blow as the industry sees the advantage of precise parison forming during B&B, as well as the increased cooling capacity during NNPB and PB due to the valves high flow rate. The popularity of FPS for Final Blow has also increased over the past few years, with better shaping control being achieved during the final stage of forming. Today, Bucher Emhart Glass promotes new innovations such as the Plunger Up Control, which offers further enhancements and control features for the forming of the parison. With this control, a defined dwell time can be set and kept at a narrow band through the parison forming process. During recent years, the availability of a repair kit for the valves, repair services as well as an FPS tester has been added to complement the portfolio. In conjunction with the FlexIS control system, the actual output pressure can be displayed on the User Console by utilising the integrated feedback signal from the valves. �
*Bucher Emhart Glass, Cham, Switzerland http://www.emhartglass.com
52 Glass International April 2017
EMHART TO USE.indd 1
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Cold End Solutions for the Glass Industry Cold End Lines Palletizers
Pallets Conveying
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CHINA GLASS PROFILE
Stand: E1/O46
Photo credit: Quais de Saône - Lyon - Marie Perrin
Stand: E1/393 F.I.C. (UK) Limited Long Rock Industrial Estate Penzance, Cornwall, TR20 8HX, UK Tel: +44 (0) 1736 366962 general@fic-uk.com www.fic-uk.com
Stand: E1/025
Stand: E1/291 HORN Glass Industries AG Bergstrasse 2 95703 Ploessberg Germany www.hornglass.com
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Serving the glass industry Stand: E1/277
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ZIPPE Industrieanlagen GmbH P.O. Box 1665, D-97866 Wertheim, Germany zippe@zippe.de www.zippe.de
glass.fivesgroup.com
Encart media planner 2015 Asian glass.indd 1
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After the success of 2015, Glassman Europe is returning to Lyon,
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Glass International April 2017
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Defects no longer know where to hide
Intelligent engraving inspection The Evolution 12 engraving identification and inspection module is a software innovation that allows the machine to identify engravings in a containerâ&#x20AC;&#x2122;s body or base. Because it is very difficult to predict how an engraving will look, this module dramatically improves inspection in these areas. By calculating the position of the engraving, the machine identifies the pixels related to the engraving, as well as those that relate to a defect. This algorithm has been improved and tested over recent months on several production lines, including those devoted to beers, carbonated beverages, wine and high value spirits.
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