Glass International December 2015 by Quartz

SPECIAL DIGITAL EDITION DECEMBER 2015

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Contents/Comment

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

Special Digital Edition December 2015 No.3

Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com

Contents/Editor’s Comment

International news

Ardagh’s £15 million furnace

39th ASEAN Glass Conference

Hanger inserts to eliminate seams

Chief Executive Officer: Paul Michael

Making the invisible visible

Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Email: subscriptions@quartzltd.com

SPECIAL DIGITAL EDITION DECEMBER 2015

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Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com Production Executive: Martin Lawrence Managing Director: Steve Diprose

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11 Diary

11 Heye’s speedline success 12 Toughening of glass by air methods

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

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

15 Feeling the pressue 17 Flexible forehearth systems 18 FEVE’s taste map results

Member of British Glass Manufacturers’ Confederation

Merry Christmas from Glass International

Greg Morris, Editor. gregmorris@quartzltd.com

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Greg Morris

Glass International annual subscription rates including Glass International Directory: For one year: UK £164, all other countries £231. For two years: UK £295, all other countries £416. Airmail prices on request. Single copies £45.

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One of the beautiful things about the glass industry is that it is a sector that never sleeps. Similar to the industry’s furnaces that remain open 24 hours a day to make glass,the sector has a steady stream of news and features worthy of publication to the wider world. Glass International has already increased its coverage of the industry with daily news updates on its website and a weekly newsletter emailed to the inbox of 25,000 glass executives. Here, for the third Christmas in a row, we are pleased to publish a free, bonus, digital-only issue that gives readers a taste of what the magazine has to offer. Inside is the usual mix of news, views and technical features. This includes a profile of Ardagh’s recent furnace investment at its Irvine, UK plant, a review of the recent AFGM conference in the Philippines and technical papers from the likes of AGR, Horn and Heye International.

Glass International Directory 2015 edition: UK £206, all other countries £217.

Plus find us on Linked-In and Twitter.

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

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International News

NEWS IN BRIEF

StekloSouz discusses technical challenges

Experts discussed the latest technical challenges facing the glass industry at a recent forum in Russia. Scientists and specialists in Russia spoke about a variety of issues including safety requirements and problems encountered in the design of plants at the recent Glass and Modern Technologies - XXI forum in Moscow. The event was organised by the United National Council of the Russian glass industry, StekloSouz, and had the theme ‘Problems that hinder the development of the Russian glass industry and their solutions’.

Guardian SunGuard wins award

Guardian SunGuard SNX 51/23 glass has been awarded a 2015 Product Innovation Award for its Science and Technology Center (STC) addition by Architectural Products Magazine. The STC’s 27,000ft2 addition features a curtain wall designed to achieve net zero energy results. It does this using building integrated and rooftop photovoltaic panels and Guardian’s latest commercial glass products for North America, the SunGuard SNX 51/23 glass and SunGuard Spandrel HT glass.

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Loadhog passes 20 million milestone

Loadhog has now cleaned more than 20 million Smartpads at its Sheffield, UK washplant, thanks to ongoing business from Encirc Glass. The Smartpad is a component of Loadhog’s Smartstak glass containment system, which has been used by Encirc to move its bottles more safely, cost-effectively and hygienically. Loadhog’s Sheffield washplant was the first not to use detergents and achieves its standards using environmentally friendly methodology.

UK container glass companies honoured for their flair -I, Ardagh and other memO bers of British Glass were honoured at the recent UK Packaging Awards. Several container glassmaking companies were commended for their innovation, quality and elegance – and for their ability to showcase a UK manufacturing industry creative flair. All the British Glass mem-

bers who entered were shortlisted for awards, resulting in winners and commendations. As in previous years, British Glass sponsored two awards – for everyday and premium glass packs. But it wasn’t just the glass-specific categories where its members were recognised. O-I’s £25million investment in its plant at Alloa has add-

ed value to Scotland’s spirit industry – bringing flexible manufacturing that will help Scottish brands in Scottish bottles compete in shifting global markets. The investment’s support of 600 direct, and 500 indirect jobs underlines the enduring role of modern glassmaking to the UK economy.

Middle East set for hollow glass show Hollow glass manufacturers from Iran, Saudi Arabia and other countries of the lucrative MENA region are all set for the forthcoming Glassman Middle East show. The free to attend exhibition and conference will be held in Abu Dhabi, UAE on May 10th and 11th May and will bring together suppliers and manufacturers from across the industry’s entire

supply chain. Abu Dhabi offers exhibitors access to the MENA region, situated within easy reach of the growing and dynamic markets of Saudi Arabia, Iran, Oman, India, Africa and, of course, the UAE itself. Companies that have booked stands so far include Pneumofore, F.I.C., Horn, Ilis and Reckmann. Several glass manufacturers and supplier

companies have expressed an interest in speaking at the conference, where they will discuss the latest opportunities and challenges facing the hollow glassmaking industry. The Middle East is a hub of glassmaking activity, and is conveniently located to benefit from lower energy costs. More information from http://www.glassmanevents. com/mid-east/

Germany’s BV Glas appoints Schott CEO as its President Germany’s BV Glas association has elected Schott CEO Dr. Frank Heinricht as president (pictured). Dr. Heinricht said: “The energy and environmental challenges are a major issue for the glass industry. We must not slacken our efforts to provide information about the production processes in glass production and to create an awareness of technical feasibility. Glass is the basic material for many products that contribute to achieving climate

protection targets.” BV Glas (The Federal Association of the Glass Industry) represents the economic interests of the glass manufacturing industry in Germany. These include the areas of flat, container, special and fibre glass. The industry includes 400 companies and approximately 53,000 employees. Total sales in 2014 amounted to around €9.1 billion.

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

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International News

Adnams and O-I create UK’s lightest branded beer bottle

when it worked with O-I to launch a 299g bottle in 2007. This style of long-neck, lightweight pack has helped regenerate the sector, which had grown to £490 million by the end of 2014. O-I’s designers and manufacturing personnel at Harlow, UK were able to shave weight off while retaining the shape and height of Adnams’ bespoke bottles. This meant that there was no impact on the filling equip-

O-I appoints John Haudrich as Chief Strategy officer

ment or tertiary packaging. The brewer is steadily moving production of all its bottled beers into the new container. Paul McLavin, marketing and business development manager for O-I in the UK, said: “We are aware that other glassmakers offer standard bottles at 280g but are excited to be able to offer customers an embossed bottle, with all the branding benefits that brings, which advances sustainability.”

Egypt’s Sphinx Glass set to expand IFC, a member of the World Bank Group, is investing in a 20% equity stake in Egypt’s Sphinx Glass. The investment aims to boost the glass manufacturing sector in the region, support the company’s expansion, and spur job creation and growth. The company is a key supplier of float glass to Egypt’s construction sector, and is a large regional and international exporter. The investment is part of World Bank Group strategy in Egypt to boost job creation through the manufacturing sector, and promote energy efficiency improvement initiatives.

Owens-Illinois (O-I) has named John Haudrich as Senior Vice President and Chief Strategy and Integration Officer, effective immediately. Haudrich is a member of O-I’s Global Leadership Team and will report to CEO-elect Andres Lopez. The new role of Chief Strategy and Integration Officer will be responsible for developing O-I’s strategy, executing key companywide activities and leading the global supply chain organisation.

Fives to supply Xinyi Group with Prium lehrs

Chinese glassmaker Xinyi Group has appointed Fives for the supply of one annealing lehr for float glass and four lehrs for photovoltaic glass. Two contracts have been agreed to supply annealing lehrs. Xinyi Group will construct a large glass plant in Malaysia as part of the ‘one belt and one road’ strategic plan pioneered by the Chinese government. Fives, with Fives Stein Metallurgical Technology Shanghai, is going to offer its Prium Lehr, which is a float glass lehr with maximum output of 1200 MT/D. It will also offer its Prium Lehr PVG, photovoltaic glass lehrs with a maximum output of 250 MT/D with a pull capacity and ribbon width which are the highest in the world for photovoltaic glass.

Heye appoints cold end service partner in USA

Nada Shousha, IFC Country Manager for Egypt, Libya and Yemen, said, “Creating new jobs and strengthening the manufacturing sector, particularly in an area that can boost exports, is vital in this period of transition for Egypt.

“We hope this investment will also help restore investor confidence in the country, and send a positive message to investors around the world”. Source: www.cpifinancial.net/ news/post/33811/ifc-invests-inegypt-based-sphinx-glass

Heye International has named Gen-In LLC as its exclusive service partner for cold end products in the USA. Based at Largo, Florida, Gen-In LLC offers a range of Cold End inspection solutions and services for the container glass industry specialising in upgrades and retrofits to existing inspection equipment.

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

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Adnams of Southwold, UK has partnered with glassmaker O-I to develop the UK’s lightest branded 500ml glass premium ale bottle. At 280g, the bottle shaves a further 19g off the brand’s lightweight bottle to create an additional annual carbon saving of 100 tonnes and removing 115 tonnes of glass from the waste stream. Adnams pioneered the use of lightweight glass in the premium packaged ale sector

NEWS IN BRIEF

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zLeft-right: Graeme Shepherd, Operations Director, Ardagh Group, Glass UK, Irvine; Rt Hon Nicola Sturgeon MSP, First Minister of Scotland; and John Passant, Operations Director, Ardagh Group Glass Europe NW & SE.

Ardagh unveils £15 million furnace investment Following a £15 million investment in its Irvine, UK facility, Ardagh Glass has a new flint furnace to cater to the Scottish drinks industry.

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rdagh Group has opened a £15 million furnace at its Irvine plant in Scotland, UK. The investment represents the latest chapter in the history of the Irvine plant, which began production in 1920 as Portland Glass. It will enable the plant, which produces bottles primarily for the Scottish drinks industry, to become one of the most efficient in Europe.

High quality standards The new flint furnace has been designed to increase production flexibility. It uses environmentally efficient, endfired technology updated from the cross-fired technology previously in use at the plant. The latest inspection equipment has also been installed, so as to obtain the high quality standards that are synonymous with much of the Scottish drinks industry.

The plant itself is one of the largest private employers in the area, and this investment, supported by a grant contribution from Scottish Enterprise’s Aid for Environmental Protection Scheme, secures the future of the 225 strong, skilled workforce. The scheme aims to “encourage investment in environmental protection measures by companies in Scotland, to secure both long term economic benefits to Scotland and to help achieve Scotland’s low carbon targets.” The investments are part of Ardagh’s plan to ensure the most efficient design and production processes, resulting in the delivery of high quality products.

Continued>>

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Company profile: Ardagh Irvine

of the company’s continued investment in its Irvine site, which is something to be commended. “I also welcome the news that Ardagh has made a commitment to the Scottish Business Pledge, making them one of first companies in the spirits supply chain to do so. “The Scottish Government will continue to work with Ardagh to ensure the continued success and growth of the business.” Addressing an audience of customers, local and national dignitaries, and colleagues, Graeme Shepherd, Director of Operations, Irvine, Ardagh Group, Glass, UK, said: “The Irvine plant is well regarded within the Ardagh Group for the quality of our output, the calibre of our management and workforce and the professionalism of our customer service, supported by on-going investment in technology and systems.”

“It will enable the plant to become one of the most advanced and efficient in Europe.” The new facility was officially opened by Scotland’s First Minister, Rt Hon Nicola Sturgeon MSP, who praised Ardagh’s commitment to local industry: “I am delighted to visit Ardagh to officially open their new furnace. This is evidence

Investment This investment is part of an overall sum of around £500 million that Ardagh Group has invested in its glass business over the past five years. Ardagh Glass has 35 glass factories around the world, which have a combined experience of more than 500 years of glass container making. r

Ardagh Glass, Irvine, Scotland www.ardaghgroup.com/

Laboratory/Technical Manager This challenging role is designed for an experience materials specialist with a proven technical/ managerial background.

Permanent position, full time.

Successful candidate will have overall responsibility for the safe and efficient operation of the laboratory, whilst heading up the research and development team and providing technical support for our sales activity.

Application to Mr Mike Jones, Group Managing Director, at jameskentcm@aol.com

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James Kent Group, A leading specialist ceramic materials company requires a Laboratory/ Technical Manager at their Stoke-on-Trent site.

Reporting directly to the Managing Director the candidate should: Hold a materials science or chemistry qualification to at least degree level Have a good practical knowledge of material properties Have the ability to both manager a team and work on own initiative Good working Knowledge of ISO quality and environmental standards and protocol Salary is competitive yet negotiable. Company offers a supported pension scheme, 25 days holiday per year and healthcare plan.

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39th ASEAN Glass Conference

“Technology and innovation are at the forefront of driving market

”

growth

39th ASEAN Glass Conference helps drive growth in the glass industry Nearly 300 international delegates attended the recent 39th ASEAN Glass Conference held in Cebu, Philippines and hosted by the Glass Manufacturers’ Association of the Philippines (GMAPI). Greg Morris attended.

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his year’s ASEAN Federation of Glass Manufacturers’ conference (AFGM) adopted the theme of ‘Glass Technology and Innovation: Driving Growth in Traditional and New Markets’. The four-day event included a combination of technical papers and networking events and was attended by nearly 300 people. Delegates attended from countries including the UK, the USA, France, Germany, Poland, Australia, Japan and China as well as the ASEAN countries of Thailand, Vietnam, Indonesia, Malaysia and the Philippines. Attendees were a mixture of glass manufacturers and suppliers to the industry. Manufacturers included O-I, Bangkok Glass, Siam Glass and Indonesia’s Muliaglass. The Philippines was well represented with delegates from San Miguel Yamamura Packaging Corporation, San Miguel Yamamura Asia Corporation, Asia Brewery, Arcya Glass Corporation and Anglo Watsons Glass. It was the first time the event had been held in the Philippines since 2010, when it was held on Boracay Island. It was last held in Cebu in 2002.

Mr Alcantara said the event was an opportunity for manufacturers and suppliers to combine their knowledge to produce the best glass possible, particularly in the face of fierce competition from rival materials. He said: “The glass industry in the Philippines consists of container, flat and tableware glass and has grown alongside the growth of the Philippines economy. It has been exceptionally better for the flat glass segment which grew by 38% in volume in 2014. This was due to a surge in construction of residential and commercial building projects, and this is expected to continue in the next several years.

Continued>> x Mr. David Fontes (far right) of Elster Thermal Solutions. Each conference speaker was presented with an award by the organising committee.

Opening ceremony After a golf day and a welcome evening on day one, the opening ceremony took place on day two. Among those to give welcome addresses were AFGM Chairman Chai Kung Fee, Conference Chairman Jonathan Aquino and GMAPI Chairman Emmanuel Alcantara.

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39th ASEAN Glass Conference

Technical conference Day three was devoted to the technical conference, which included seven presentations. These were: r Approaching Fuel Savings in the Container and Tableware Glass Melting Furnaces, presented by Masami Kitano, Senior Manager, AGC Ceramics; r Swabbing Robots Combines Productivity and Operator Safety, presented by Adam Omiczynski,

zx (above) The AFGM organising committee at the opening event in Cebu and (below) a total of seven papers were given to delegates at the conference.

Sales Manager, Heye International; r New Nox Removal Process from Exhaust Gas in a Glass Furnace, presented by Ryota Tsuji, Assistant Manager, Environmental Affairs Office, Nihon Yamamura Glass; r Glass Conditioning in Distributor and Forehearths – Solutions for Future Production Demands, presented by Ulrich Imhof, Business Unit Director, Horn Glass; r Electricity in Glassmaking – Often the Low Cost Option, presented by Richard Stormont, Managing Director, Electroglass; r Support to Glass Industry Grows with Elster Gas, presented by David Fontes, Glass Industry Manager, Elster Thermal Solutions; and r The Importance of Design and Specification for the Forehearth and Distributor, presented by David Parkinson, Managing Director, ParkinsonSpencer Refractories (PSR). The papers are available to download via the conference website, published below. Other activities included a Rampada beach dinner, heritage tour and a farewell dinner. Each of the events were sponsored by suppliers to the glass industry. Among the 43 companies to sponsor were Antonini, Sorg, Zippe, Bucher Emhart Glass, Iris Inspection Machines, Tiama, Electroglass, Heye International and AGC Ceramics. r

z Mr. Jonathon Aquino, Conference Chairman, speaking at the opening.

zx (above) Mr. David Parkinson of PSR and (below) Mr. Richard Stormont of Electroglass address the conference attendees.

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“Demand for container glass continues to grow despite intense competition from alternative packaging such as plastic, PET and aluminium cans. But while glass continues to grow, the trend in the use of alternatives has also become stronger, and we in the glass industry must be able to do better. The technology now offered by our equipment suppliers and partners, the innovation drawn from various Research and Development initiatives, and the access to and sharing of information: all of this combined can help glassmakers produce the best glass possible at present. “The bright minds that can make this happen are here, right now, at this conference. “Let us further our efforts to continuously create together, manufacturers, suppliers, new applications, and solutions that will bring more value to our customers.” He spoke of a recent initiative organised by GMAPI that has seen 16 domestic glass manufacturers, technology providers and material suppliers combine. The aim is for the organisation to be more rapid in response to the fast changing landscape of the glass market, he said. “Our aim is to represent manufacturers of glass products and other entities that directly complement and contribute to the Philippines glass business. We will work towards improved synergy and links, pursuing new products and markets. This is a new organisational model that we in GMAPI would like to propose to our colleagues in the AFGM, or other glass industry associations for that matter.” His thoughts were echoed by AFGM Chairman, Mr Kung Fee: “As we are all aware, this conference is an annual gathering of glass manufacturers, suppliers and stakeholders that aims to strengthen the interconnectedness, networking interdependency and collaboration among all the companies in the ASEAN industry. “This year’s conference theme reflects the needs of the glass industry to face constant changes and challenges.” Conference Chairman, Jonathan Aquino, said: “The conference theme basically emphasises that technology and innovation are at the forefront of driving market growth, which has a direct impact to the economics of doing business in the glass industry. “Technology and innovation appeals to all our stakeholders, particularly the glass manufacturers, material suppliers and technology providers, because it is the lifeline of the industry.”

The next ASEAN conference is scheduled to take place in autumn 2016. www.aseanglass.

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Moulds

Hanger inserts to help eliminate glass container seams Bill Roerig* reports that seams in glass containers are a defect that can affect the quality of a container. Several factors contribute to seam creation, including the way hangers close, as well as heat and cleanliness.

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ypes of seams include a neck-ring seam, which is a protruding seam of glass that runs vertically from the body of the container up to the finish. Baffle marks, meanwhile, can include a rough or damaged baffle seam on the bottom of a container. Pressure checks are cracks through a container’s wall that can appear at a seam. Blank and mould seams typically extend from a container’s shoulder to its base. They can appear on a container’s body, edge or side. The severity and quality impact of seams depend on the manufacturing process. Mould, blank, neck and heel seams are generally created when the hangers and inserts used in individual section (IS) machines fail to close precisely. Hangers, especially blank hangers, can warp over time, which further prevents the inserts from closing completely. One major glass container manufacturer using triple gobs wanted to remove those seams and any potential defects resulting from them. The hanger inserts were held in place

z Figs 1 a and b. IS machine hangers with inserts. with four pins, which required extensive machine downtime and effort to replace.

Finding the solution The solution was a modified hanger insert design that uses a single pin, allowing the inserts to ‘float’. As a result, the hangers were able to close completely with equal pressure,

z Figs 2 a and b. Left to right, glass containers with visible seams.

even if a hanger warped, thus removing seams. The single-pin design allowed the inserts to be replaced more quickly – within minutes – which decreases downtime. The hanger inserts that the container glass operation had been using would typically last for six months or less, while the new hanger inserts lasted for two or more years. Periodic cleaning is recommended to extend insert service life. The oil used to keep mould equipment lubricated can eventually harden, leading to crust buildup on inserts, that affects the smoothness of its movement. Pyrotek, which acquired the patented single-pin hanger insert modification technology earlier this year, is currently researching other applications for container glass manufacturers. r

*Founder of Roerig Glass Mold Insert Company, Jacksonville, Florida, USA. www.pyrotek.info/glass

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Glass stress

Making the invisible visible Aerne Analytic has acquired the sole distribution, service and production of the Saint-Gobain Oberland laboratory equipment range. Alexander Thalhofer* highlights the uses of both the density and strain testers for the glass industry.

ollowing the take over of Oberland’s Bad Wurzach’s product range, Aerne Analytic’s specialists will produce and distribute the new equipment as well as service the older devices already on the marketplace. The company’s portfolio has, therefore, expanded to encompass not only the new products, but also the spare parts for existing equipment and consumables for Oberland devices. Two of the products developed for the glass industry are discussed below.

 Polariscope: Production monitoring by qualitative and quantitative measuring of stress in glass.

Strain Tester

For a qualitative analysis of stress, the specimen, e.g. a glass rod or a bottle bottom, is held in the upper half of the viewing field (full-wave plate). A change in colour indicates if tensile or compressive stress exists, and the strength of the stress can be estimated by the intensity and extension of the coloured range. To determine stress quantitatively, the stress centre is tested in the lower half of the viewing field (green colour filter). The degree of stress is determined by rotating

 Automatic glass density tester: Fully automatic measurement of the density of transparent and opaque glass samples according to the Settlling Method.

the analyser until the darkening of the range and the reading of the angle from the scale correspond. The Polariscope is available in two models: r With a rotating analyser for qualitative and quantitative measurements (standard version); and r With a fixed analyser for qualitative measuring to compare with standard samples. The device can be installed on an optional available tripod. For direct integration into the production line, the strain tester is also available with a separate lighting case.

Density Tester The density of glass is dependent on its chemical composition and is therefore an important indicator for the stability of glass production. With the Automatic Density Tester, the physical density of up to six glass samples can be determined at the same time. The measurement is carried out automatically and can be performed within hours, making it a simple and compact instrument for quality assurance and production monitoring. Up to four glass samples are inserted into each test tube together with an Continued>>

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With the Polariscope, the annealing process of glass can be controlled quickly and easily directly on the production line. Thermal or mechanical stress caused by temper faults or inclusions can be recognised quickly and evaluated qualitatively and quantitatively. The Polariscope comprises the following stress measuring procedures in one device: r light-dark method (qualitative measuring); r colour change method (semiquantitative measuring); and r compensation method according to Sénarmont (quantitative measuring).

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The glassmaker’s diary

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Glass stress

r Celsian NCNG Glass Technology Course As part of the Society of Glass Technology’s centenary calendar of events, Celsian has opted to host its glass technology course in the UK for 2016. February 29th - March 4th British Glass/SGT building, Chapeltown, Sheffield. CONTACT: neilsimpsonfsgt@btinternet.com r Baku Glass The first time the event has been held in Baku, Azerbaijan, held in partnership with the GPD glass processing conference. March 1st - 2nd Baku, Azerbaijan CONTACT: www.glassonline.com/site/bakuglass/ r International Congress on Glass 2016 A platform for the dissemination of glass science and technology information. April 7th - 11th Shanghai International Convention Center (SHICC), Shanghai, China. CONTACT: icg2016@vip.sina.com www.icg2016shanghai.com r China Glass 2016 Annual Chinese exhibition returns to Shanghai. April 11th-14th Shanghai New International Exhibition Centre, China. CONTACT: ceramsoc@163.com www.chinaglass-expo.com r Glassman Middle East 2016 The Glassman exhibition and conference returns to the Middle East for the first time since 2009. May 10th - 11th Abu Dhabi National Exhibition Centre, UAE. CONTACT: jeremyfordrey@quartzltd.com kenclark@quartzltd.com www.glassmanevents.com r Mir Stekla 2016 Annual Russian exhibition. June 6th-9th Moscow Expo Centre, Pavilion Number 2, Russia. CONTACT:re@expocentr.ru www.mirstekla-expo.ru r Furnace Solutions 11 Annual furnaces-themed conference. June 9th Lucideon, Stoke on Trent, UK CONTACT: christine@sgt.org www.furnacesolutions.co.uk

Strain tester technical data Housing PVC, white Lighting source round fluorescent lamp, 32 W Optical system two polarising filters, quarter-wave plate (140 nm), full-wave plate (560 nm), green colour filter (546 nm) Viewing field size 235 nm Magnification lens 3-fold, 250 mm Power supply 230 V/50 Hz or 115 V/60 Hz (optional) Dimensions 600mm depth, 360mm width, 380mm height Weight approx. 22 kg Automatic density tester technical data Housing PVC, white Heating max. 100W Circulating pump 35 W Tempering medium distilled water Density liquid Mixture of 1-bromnaphtaline and 1, 1, 2, 2-tetrabromethane Measuring range approx. 1,5 bis 2,9d g/cm3 Measuring accuracy ± 0,0002 g/cm3 Measuring time typical 2 h, min. 1 h Sample size approx. 5 bis 10 mm edge length Power supply 230 V/50 Hz or 115 V/60 Hz (optional) Ambient temperature approx. 20 to 30°C Dimensions 365mm depth, 630mm width, 300mm height Weight approx. 25kg

additional reference sample, the density of which has already been determined. The test tubes are filled with a liquid, whose density is adjusted at normal temperature, so that the samples swim on the liquid at the start of the test. During the measuring, the temperature in the water bath is increased slowly and continuously at approximately 3K/h. The density of the liquid in the test tubes decreases as the temperature increases, so that samples sink according to their actual density and activate the light barrier. Through the light barrier alarm the actual temperature is registered and is related to the samples. The density of the glass samples is determined by a temperature comparison with the reference sample, and is recorded either as an ‘absolute density’ or as a ‘density difference’. The actual measuring data in each test tube can also be read during the measuring, without disturbing the measuring procedure. After reaching the final temperature, the heating is switched off and the water bath is cooled. Initial and final temperature as well as heating speed can be adjusted individually. The regular darkening of the density liquid is compensated for by an automatic adjusting of the light density. r

*Product manager, Aerne Analytic, Weißenhorn, Germany http://www.aerne-analytic.de

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Forming

Heye’s success in Netherlands The production of 660ml beer bottles at a plant in the Netherlands now runs 15% faster at a high pack-to-time, thanks to a SpeedLine IS-Machine.

PRESSURE AND VOLUME TESTING IN ONE MACHINE.

Agr’s SPT2 is the most advanced volume and pressure measurement system available today. Additional features include: • Fast throughput • No job change • Lab-precision volume measurement at the line

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ombining speed and quality is down to two things: a competent, well-organised and ambitious team in the plant, and the equipment they use. The highest quality materials and precise manufacturing processes combine speed with minimum wear-out, resulting in a machine lifetime of up to 15 years. Powerful cooling techniques have also been developed to manage temperature challenges. SpeedLine IS machines are flexible and permit an assortment of production (different container weights) to be undertaken on the same machine with Heye servo plungers and servo shears. Changeover times from DG to TG and back have been shortened with the assistance of a flexible loadmaster delivery system, with rapid changeovers provided between production processes (BB, PB and NNPB). Short, scheduled downtimes are delivered via the use of sensors and monitoring techniques, helping to minimise downtime costs. In addition, the optional use of the Heye Robot for swabbing blank moulds avoids the loss of containers and increases productivity. The SpeedLine IS machine fulfills Hazard Analysis and Critical Control Point (HACCP) regulations and increases work safety. With many safety-related features already incorporated in the basic machine, optional safety elements include a patented dead plate control that avoids glass accumulation and section downtime. Intelligent, temperature-controlled central lubrication also reduces oil consumption and improves cleanliness.

AG R I N T L . C O M • +1.724.482.2163

Heye International, Obernkirchen, Germany www.heye-international.com

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Glass toughening

Toughening of glass surfaces by air and contact methods Taras Zheplynskyy*, Oksana Serkiz*, Myroslav Golovchuk** and Marella Õis*** outline a research project which compared toughened glass using both the contact and the air method.

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oughened glass is widely used today as a glazing on buildings[1]. Its disadvantage is its large energy use in the actual toughening process because it is necessary to use highpowered ventilators for the cooling and transporting of glass sheets along the toughening furnace. A new energy saving, thermal toughening method is the contact method where a glass sheet is fixed between the heat conductive plates and in such a form is heated to the toughened temperature before being cooled by water[2,3]. This method eliminates the need to use the high-power ventilators for cooling and transporting glass sheets. In addition, there is the possibility of toughening various sized glass samples without any change to the parameters of the technological cycle. A number of works are dedicated to the study of the properties and structure of toughened glass[4-7]. In the new method,

SiO2 Al2O3 Fe2O3 CaO MgO SO3 Na2O 71.8 0.7 0.1 8.6 4.4 0.3 14.1

z Table 1. Composition of float glass, mass % the cooling process differs from the traditional one, so there is the need to investigate the properties and structural features of this glass. The quality of sheet glass is determined by its surface condition[6], so one of the main questions is the research of surface properties of the glass, including microhardness, density and surface chemical resistance. The investigation of these values makes it possible to study the structure of materials, density of structural units packing, their stability and chemical inertness.

Experiment To study the process of toughening, sheet float glass samples of 50×25×6 mm were used. The oxide composition of float

glass is shown in Table 1. Glass toughening was carried out by the air and by the contact methods. Air toughening was performed by heating the glass samples to a temperature of 680°C, the isothermal holding was three minutes, the duration of cooling was 1.5 minutes. Toughening by the contact method was carried out by heating the glass fixed between the heat conductive plates to the temperature of 680°C. The isothermal holding was three mins. Cooling was carried out by water, the consumption was 0.06 l/s, the duration of spraying was 30s. The value of the stress was measured by SCALP – 04. Continued>>

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Glass toughening

Results The results show (Table 2) that after toughening by the air and by the contact methods the glass density decreased from 2501kg/m3 to 2495kg/m3 (for air toughening) and to 2496kg/m3 (for contact toughening). The phenomenon of the density reduction of toughened glass is described in[4, 5], where authors explain this change by the feature of structural rearrangement during toughening. In the surface layer of the toughened glass there are the uniformly distributed compressive stresses and in the central layer the tension ones, which reduce the density of glass. However, this explanation is not complete because the reduction of the middle layer density of glass would lead only to an increase in glass thickness. The research of the sample size change shows that after toughening, not only the thickness increases (to 0.01mm), but the width (to 0.05mm) and the length (to 0.11-0.12mm) as well. This can be

Glass sample

Residual stresses, Increase of glass size, mm

Density,

MPa thickness width length

Initial

- -

kg/m3

2501

Toughened by air

0.01

0.05

0.12

2495

Toughened by contact method

0.01

0.05

0.11

2496

z Table 2. Change of size and density of glass after toughening. Glass sample

Residual stresses,

Micro hardness,

Density of surface

MPa

MIIa

layer of 0.01mm, kg/m3

Initial

- 5600 2501

Toughened by air

5300

2438

Toughened by contact method

5400

2461

z Table 3. Microhardness and density of float glass surface. Glass sample

Residual stresses,

Initial

Acid resistance,

MPa mg/dm2

Reduction of mass after thermal treatment at 500C, mg/dm2

- 2.1

0.2

Toughened by air

2.6

0.7

Toughened by contact method

2.4

0.4

z Table 4. Acid resistance of glass. explained by the fixation of the hightemperature glass structure as a result of rapid cooling. However, the relative increase of thickness (6/0.01 = 600) as a result of the formation of the tensile zone in the middle layer is larger than the relative increase of width (25/0.05 = 500) and length (50/0.12 = 417). The microhardness of glass samples before and after toughening was measured. The results show (Table 3), that as mentioned earlier[4, 7], the microhardness of toughened glass is less than of the initial one. But using the same values as residual stresses, the microhardness of glass, toughened by the air method, is 100 MPa larger than of the glass toughened by air. In work[4] the decrease in the microhardness of glass after toughening was explained by the increased fictive temperature Tf as a result of the intensive air cooling, which leads to a decrease in density. In addition, K. Keze[7] has shown that the presence of a compressive stress on the glass surface does not lead to an increase in microhardness. For a more thorough study of the causes of the decreased microhardness, the density of the glass surface layer was measured. Glass samples were etched in a mixture of hydrofluoric and sulphuric acids and the density of the glass measured by the deposition method. The results show that after toughening on the glass surface there is a layer of small value of density (Table 3). The density of the layer of 0.01mm of glass, toughened by air is 2438kg/m3, which is 63kg/m3 less than in the initial. For the sample,

toughened by the contact method, the difference of density is smaller and it is only 40kg/m3. The microhardness value of glass strongly depends on the density of the surface, so the value of toughened glass is lower than of the initial one. The density of the surface layer of glass, toughened by the contact method, is larger than of glass toughened by air, so respectively, the microhardness is higher.

Acid resistance The influence of density reduction on the value of acid resistance was investigated. The results show (Table 4), that after toughening the resistance to HCl acid decreases. However, as in the previous case, the glass sample, toughened by the contact method, is more stable than the sample toughened by air. The glass samples after testing to acid resistance were heated to 500°C and held for two hours before being slow cooled. The results show (Table 4), that thermal treatment leads to a decrease in the glass mass. This can be explained by the water release as a result of polycondensation of silanol groups (Si - OH) formed by the interaction of glass and acid. This reaction can be described as: 2 ≡ Si - OH = ≡Si - O - Si≡ + H2O The additional thermal treatment of toughened glass samples under the regime of toughening (three min at 680°C) following by slow cooling was carried out. Continued>>

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The linear dimensions of the glass samples were measured by an optical Cathetometer with an accuracy of 0.01mm. Microhardness was determined by measuring the length of a pattern obtained on the surface of samples after the penetration of a pyramidal diamond indenter under the load of 0.98 N. The results are the mean of 20 injections placed in different parts of the glass surface. The length of the diagonal was measured using an Axio-vision. The error of measurement was 50 MPa. Glass density was determined by the deposition method. Glass samples were dipped in a flask with a mixture of heavy liquids. The flask was placed in a thermostat temperature that was gradually increased at a speed of 0.25 degree/min. The density of glass was determined by the temperatures at which the sample was lowered into the liquid mixture and crossed the definite mark. Measurement error was 0.5 kg/m3. To study the density of the surface layer the glass samples were etched in a mixture of concentrated acids and water in a volume ratio of HF: H2SO4: H2O = 1:1.5:2.5 for two minutes. They were then dried in an oven at 100°C followed by holding in a desiccator for 30 min. Acid resistance of glass was determined by the mass loss per surface unit after boiling for 3 h in 6 N solution of HCl acid. Measurement error was 0.2mg/dm2.

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Glass toughening

After thermal treatment the relaxation of residual stresses occurred and the value of the residual stresses decreased from 80 MPa to 0 MPa, Table 5 shows that the glass structure becomes more dense, and the density increases both in the initial and the toughened samples and equals to 2505kg/ m3. Moreover, there is a corresponding decrease of the size of all glass samples.

Conclusions The contact method of glass toughening saves more energy than the air method because glass cooling is carried out by water spraying. The density of glass samples decreases after toughening and on the glass surface there is a layer of even smaller value of density. Accordingly, the microhardness and the acid resistance of toughened glass is less than in the initial sample. However, these properties are better in the glass toughened by the contact method, than in the glass toughened by air. After thermal treatment of glass samples tested against resistance to HCl acid it was found that their mass decreased because of the polycondensation of silanol groups. Further thermal treatment of toughened

Glass sample

Density of glass,

Decrease of glass size,

kg/m3 Before

After Thickness Width

Initial

2501 2505 0.01 0.03

0.08

Toughened by air

2495

2505

0.02

0.09

0.21

Toughened by contact method

2496

2505

0.02

0.10

0.20

z Table 5. Change of density after additional thermal treatment by toughening. glass samples by toughening followed by slow cooling, revealed that due to the stress relaxation the glass density increased. This method of toughening requires further improvement and we are looking for partners for cooperation. r

physically and chemically tempered glasses. 2012;358, 3438–7. 5) R. Gardon. Thermal tempering of glass, Glass.- Science and Technology. 1980, 145-71. 6)

J. Schneider, S. Schula, W. Weinhold.

Characterisation of the scratch resistance of annealed and tempered architectural glass.

References

Thin Solid Films. 2012;520,4190-9.

1) J. Schneider, S. Schula, W. Weinhold.

7) K. Kese, Z. Li, B. Bergman. Influence of residual

Characterisation of the scratch resistance of

stress on elastic modulus and hardness of soda-

annealed and tempered architectural glass.

lime glass measured by nanoindentation. J.

Thin Solid Films. 2012;520, 4190-9.

Mater. Res. 2004;19, 3109-21

2) T. B. Zheplynskyy, Z. I. Borovetz, M.Y. Golovchuk. Method of glass tempering. Patent of Ukraine No 84517, 27.10.2008. 3) T. Zheplynskyy, O. Serkiz. Contact method of glass toughening Glass International. 2013;36, 42-3. 4) A. Koikea, S. Akibaa, T. Sakagamia, K. Hayashia, S. Itoa. Difference of cracking behavior due to Vickers indentation between

*Faculty of Silicates, National University Lviv Polytechnic, Lviv, 79000, Ukraine **Karpenko Physico-Mechanical Institute NAS of Ukraine, Lviv, 79601, Ukraine ***Institute of Cybernetics, Tallinn University of Technology, Tallinn, 12618, Estonia Website www.lp.edu.ua/en

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Testing

Feeling the pressure According to the company, Agr International’s new pressure testing system offers accurate results for managing pressure performance and volume in glass containers, with the capability of testing up to 270 bottles per hour.

 Agr SPT2 is designed for efficiency, offering precision volume measurement and pressure testing for glass containers in a single, compact system.

feed a set of bottles as required, without the need to reconfigure the system. With the increased throughput and the ability to accept bottles from multiple lines, the SPT2 provides users with greater flexibility and savings in their testing programme. The increased throughput of the SPT2 also offers glass bottle makers a way to sample ware on a more frequent basis and as a result proactively detect and correct pressure and volume-related problems before they become issues.

Automatic pressure testing The Agr SPT2 is designed to provide a viable alternative to the hand selection and manual testing of bottles for volume and pressure performance. When integrated into the production line, the SPT2 can be configured to receive bottles selected for sampling on a regular basis, throughout the production cycle. Once bottles are received in the Continued>>

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gr International’s Sampling Pressure Tester, the SPT2, offers a level of testing capability for the glass container industry. The SPT2 is the culmination of more than 40 years of experience in manufacturing pressure testers that are designed to help improve and protect packaging performance. In addition to measuring and testing precision, the SPT2 can test up to 270 bottles per hour; a 35% throughput improvement compared to existing industry offerings. This is a key advantage of this system and can result in savings in testing and production efficiencies. To achieve throughput at this rate, the SPT2 employs a two-station design with concurrent volume measurement and pressure testing operations. A robotic handling system allows for optimal bottle travel and placement through the system. Closed-loop controls are in place to manage bottles throughout the system and monitor the testing process, to maintain efficient bottle processing and throughput. Multiple line compatibility is another added feature of this system. The SPT2’s intelligent management system and universal bottle holders can automatically adjust for bottles of different sizes and finishes. This capability, combined with the high throughput rate, makes it possible to test different bottles from multiple manufacturing lines, or hand-

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Testing

technology would provide the accuracy and repeatability necessary for the type of measurements that are needed for the glass container industry. “With this technology we have been able to achieve the necessary accuracy, yet overcome the problems and inaccuracies associated with flow-meter based systems and the complexity and variability of gravimetric methods. Furthermore, measurement precision is not affected by water quality or density of water.”

Easy integration

z Agr SPT2 incorporates volume measurement that performs simultaneously with pressure testing with

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laboratory accuracy, on the plant floor.

SPT2 station, they are automatically tested for pressure strength and volume performance. Data from tests can be uploaded in real-time to plant-wide data collection and process management systems. Because the SPT2 can operate on a 24/7 basis without the need for operator intervention, testing can be performed on a defined schedule regardless of time of day or the availability of personnel. At the heart of the SPT2 is an advanced pressure generation system that makes it possible to precisely pressurise containers at a constant ramp rate of up to 69 bars (1 minute equivalent). In addition to testing capabilities for high-strength containers, the SPT2 also tests low-pressure ware with a high level of confidence. The pressure control of the SPT2 facilitates the detection of low pressure leaks and can distinguish them from low pressure breaks. This design provides accurate and controlled pressurisation throughout the testing process, which meets the rigid testing

requirements defined in ASTM C-147, Standard Test Method for Internal Pressure Strength of Glass Containers, and ISO 7458, where a constant-rate of increasing pressure must be applied to the bottle in a precise and defined manner. The SPT2 offers the choice of pressurising bottles to a pre-defined pressure point (proof testing), or to destruction. The optional volume measurement system on the SPT2 offers manufacturers an alternative to the time consuming and labour intensive work required for laboratory volume measurements. With the SPT2, volume measurements can be performed simultaneously with pressure tests capturing data for volume fill point, fill point at a given volume and overflow. “The volume measurement system on the SPT2 is more precise and repeatable than any volume measurement product on the market,” cited Senior Process Leader, Sudha Christy. “After extensive testing and research we determined that positive-displacement

The SPT2 can be configured on a sampling line to provide a protocol to integrate easily with commercial process management systems. The SPT2 is also designed to operate with Agr’s OmniLab automated measurement system. When integrated with the OmniLab system, pressure and volume as well as dimension, weight and thickness data can be correlated into one report. The SPT2 is the latest generation of automated pressure testing systems supplied by Agr for the glass container manufacturing industry. Agr’s automated pressure testing stations date back to 1979 when Agr first pioneered the concept of automatically sampling containers from the production line and testing them for pressure strength on a regularly scheduled basis. This development made it possible to continuously monitor the pressure strength of bottles being produced, and provide a statistically significant level of sampling that is not cost-effective or practical with laboratory-based testing. Over the past 40 years Agr has supplied 2100 pressure testing units to the global glass container industry. The SPT2 takes this a step further with its high throughput and its ability to provide precision volume measurements. Agr’s Chief Operating Officer, Bob Cowden, said: “Our product development team accepted and fulfilled a challenging product specification relative to pressure range, universal handling, volume measurement and precise on-board diagnostics. ” The SPT2 and OmniLab are part of Agr’s broad line of on-line, laboratory testing and quality control devices for the glass container and filling industries. r

Agr International, Butler, PA, USA www.agrintl.com

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Forehearths

Flexible forehearth systems Horn Glass Industries discusses its latest furnace, and how its design aims to aid the lightweighting of bottles and improve flexible production performance.

 Fig 1. Horn’s GCS301 furnace, the company’s latest addition.

Superstructure design Going back to basics, the GCS301 forehearth now has concave-shaped cover blocks (Fig. 2). There is a strict separation between the centre part and the outer part of the forehearth. The volume above the colder glass at the boundary area of the channel block is concaved, as is the inner part, to guide cooling air via the centre. The working principle is completed with lateral aligned chimney’s and a central radiation opening. With these lateral and central openings, the waste gas patterns can be distributed over the entire glass surface or guided to only the required areas (centre or border) in each single section of the forehearth – except the equalising zone, which is flat roofed.

Insulation and heating Reduced insulation layers lead to rapid temperature changes, required for job changes. Contrary to the general belief that reduced insulation increases energy consumption, the glass industry experienced lower consumption, due to precise energy input where it is required. The colder glass in the outer sections of the forehearth channel requires energy input in order to balance the temperature difference between the outside and inside. For this purpose the forehearth is equipped with the above mentioned cover blocks, to separate the left and right outer portions physically and to heat selectively.

The central section of this cover block is deeper and thus closer to the glass surface than the outer section. This results in a slope of the cover block from the outside to the inside. Regular pencil burners fire along the entire forehearth length. Heat transfer from the flame gases is affected by both convection and radiation. From the sloped cover block, the radiation of the flame gases is reflected towards the outer sections at the glass surface. At the slope of the superstructure the waste gases move in geared turbulences, so the heat is transmitted by convection from the flue gases to the glass surface in the colder outer section at an increased rate.

Cooling The GCS system works with different cooling systems to cool the hotter glass in the forehearth centre. It uses radiation cooling for this purpose, indirect and also direct superstructure cooling by means of cooling air. While radiation cooling is used in each section of forehearth, indirect cooling is only used for short forehearths with considerable high tonnage output. At forehearths with frequent job changes and quick temperature adaptation the direct cooling can optionally be installed in the superstructure. The system enables the direct cooling air to be led via the centre part or to spread over the entire surface by chimney Continued>>

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lass bottles compete with plastic packaging PET bottles in the beverage and spirit packaging sector. The main t advantage of PET bottles is their weight and so the glass industry has counteracted this by producing lightweight bottles as an alternative to PET bottles. The production of these bottles requires a fully understood narrow neck press and blow (NNPB) forming process at high machine speeds. The viscosity of the liquid gob has to be as homogenous as possible in order to obtain uniform wall thickness when the container is formed. This target is attained by only minimal temperature variations of the glass gob. At the end of the forehearth, before the glass enters the spout bowl, thermal homogeneity is measured and calculated by various, customer specific, formulas. This so called ‘K-Factor’ needs to be more than 98% over the entire production profile and different glass colours. A second trend, caused by ‘just in time’ production which itself aims to save on storage costs, shows that plants due to be rebuilt or green fielded have enhanced requirements on forehearth performance regarding pull ranges. This shows that nominal minimum and maximum loads spread. This is accompanied by a wider field in gob temperatures. The newly designed forehearth ‘GCS301’ is Horn’s answer to increased demands regarding forehearth flexibility and performance (Fig. 1). Channel widths from 26” up to 54” are available.

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Forehearths

adjustment, in the same way as waste gases can be guided. The afore-mentioned cooling systems are used in the function of forehearth tonnage, inlet temperature and required gob temperature in various sizes and numbers. Each forehearth concept is therefore adapted exactly to the specific requirements of the glass producer. Horn Glass Industries has installed more than 30 GCS301 forehearth units for several customers in Europe and abroad. All of them have indicated satisfaction regarding control and function of the systems, and also reported a reduced energy consumption of about 25-30% compared to the previous Horn systems. A thermal homogeneity index beyond 99% was also realised in several plants.

z Fig 2. The concave-designed cover blocks, to guide cooling air via the centre.

This suggests that the GCS301 forehearth is the ideal solution to comply with the high demand of the glass industry in terms of flexibility and performance. r

Horn Glass, Plossberg, Germany www.hornglass.com

FEVE’s European taste map results K More than 29,000 people from 30 EuroBland: A taste of bold flavour The culinary definition of bland is ‘a taste found in diets rich in grains, beans, and tomatoes.’ Meanwhile, beer reminds Brits of home, yet they prefer sparkling wine for a Friday night, while the French like a cocktail to start their weekend. Germans will typically have their spices next to them in the kitchen, whereas Italians love fresh herbs. The quiz explored character traits of EU citizens. While the continent as a whole

would describe itself as fun, the Germans say they are quiet and the Swiss reserved.

The land of olive oil

A majority of Europeans choose olive oil over any other oil when given a choice. The continent produces 73% of the world’s olive oil and consumes 66% of it.

The caffeinated continent A huge majority of Europeans have a preference for coffee as part of their breakfast ritual, but, unsurprisingly, the UK prefers tea. 13 European countries are included in the top 15 coffee consuming nations worldwide. r

www.friendsofglass.com/ tastemap/?lang=gb

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pean countries recently took part in a quiz organised by Friends of Glass, which set out to explore various European taste preferences.

ey findings were that European taste as a whole tends towards ‘bland’ foods, while there are regional differences in alcohol preferences, herbs versus spices and character traits.

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