COUNTRY FOCUS: RUSSIA IPGR: HOT END COATING FORMING
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EXCLUSIVE TO GLASS INTERNATIONAL: ARDAGH CEO NIALL WALL O-I GLOBAL CEO AL STROUCKEN
Glass International May 2014
WE ARE GLASS PEOPLE
EVOLUTION IN IS-MACHINES HEYE SPEEDLINE
HIGH SPEED AT HIGH QUALITY FOR MANY YEARS TO COME High safety and high usability to protect staff and equipment Clear interfaces for fast installation and exchange of parts Clean design to fulfil HACCP requirements Flexibility through modular design Same core – same variables
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Contents
May 2014
Vol. 37 No.5
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COUNTRY FOCUS: RUSSIA IPGR: HOT END COATING FORMING
2
Editor’s Comment
3
International News
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Front cover image courtesy of Sorg www.sorg.de
10 On the web:
Forming Heye International: Evolution in IS Machines Energy Efficiency International Innovative Technologies (IIT): Low energy grinding technology
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Technical topics
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History
20 22
Country focus: Russia Russia records upwards growth Russian industry reaps the benefits of modernisation
30 34
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Glassworks profile: O-I Alloa O-I celebrates â‚Ź30 million Alloa investment Hot end coating Hot-end coating: Strengths, risks and alternatives
25 28
www.glass-international.com/ features
Interview with Niall Wall Ardagh CEO: Verallia takeover is a good deal for customers
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Energy efficiency A fair exchange Cash from hot air Forming Nampak glass puts its faith in BIS SpeedLine ware handling for efficient production Forming solutions for the Narrow Neck Press and Blow process Glass machinery Smart monitoring tools
Plus find us on Linked-In and Twitter.
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@Glass_Int
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Environmental protection Eco-friendly benefits of digital ceramic printed glass Flat glass Triple glazing: A hot debate PVD coater for the latest energy challenges Glass International May 2014
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EXCLUSIVE TO GLASS INTERNATIONAL: ARDAGH CEO NIALL WALL O-I GLOBAL CEO AL STROUCKEN
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Editor’s comment
Greg Morris
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Editorial Assistant: Sally Roberts Tel: +44 (0)1737 855154 Email: sallyroberts@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com
Glass grabs the global media headlines
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I
’ve been told plenty of times since joining the glass industry that it is a fairly slow moving and conservative business to be in. Outside of the industry, it is an area that would not necessarily feature on most people’s radars. However, on a couple of occasions in the past month all that changed and glass was well and truly put in the public eye. While I was sitting in a small bed and breakfast in Alloa, Scotland and listening to the morning news on the radio, over the airwaves came the sound of Erik Bouts, Owens-Illinois (O-I’s) European President, announcing the news of a €30 million upgrade at the O-I plant in the small Scottish town. It was one of the lead stories of the day and was met with enthusiasm by the townspeople. The talk among hotel staff at breakfast was all about the investment and the implications it will have on the town. Everyone knows someone who works at the plant I was told. For the bed and breakfast, it meant potentially more business visitors and therefore more revenue. For the town, it is a lifeline. Later that day Mr Bouts stood alongside O-I’s global CEO, Al Stroucken to formally announce the investment, at which Glass
International was present. Later in the month came the next announcement, one of a truly global scale, that of Ardagh’s $1.69 bilion bid for Verallia North America being approved by the US Federal Trade Commission (FTC). Again, the news made headlines in the mainstream media and again got people talking. To ally FTC concerns Ardagh has agreed to sell six of the former Anchor Glass sites it only acquired in 2012. Once the deal has been completed Ardagh’s glass division will operate from 16 plants across the USA and employ some 5000 people – a huge company in glass industry terms. This month, Glass International is privileged to include discussions from the global CEOs of both Ardargh and O-I. First, Niall Wall, Ardagh CEO explains how the VNA acquisition will be a good deal for customers. He also explains why he is optimistic about the future of glass packaging. Mr Stroucken is similarly positive about the future of the Alloa plant, confirming its role as the heart of spirits packaging in Europe. Greg Morris Editor gregmorris@quartzltd.com
Directory 2013 Annual international reference source
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2 Glass International May 2014
Production Executive: Martin Lawrence Subscriptions Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034. Email: glass@quartzltd.com Website: www.glass-international.com
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International news
Ardagh completes Verallia North America acquisition Florida and plants located in Elmira, NY, Jacksonville, Fla., Warner Robins, Ga., Henryetta, Okla., Lawrenceburg, Ind. and Shakopee, Minn., according to the consent agreement. Ardagh previously acquired Anchor Glass in 2012 for €720 million. Once Ardagh has completed its acquisition of VNA and the sale of the six
former Anchor plants, its North America glass division will generate estimated annual revenues of US$2 billion (€1.4bn). The division will operate from 16 glass manufacturing facilities across the US, employing 5000 people. The transaction is set to reduce Saint-Gobain's net debt by €925 million (US$1.28 billion).
World cup bottle
Tiama partnership
from its UK plant. FIC designs and supplies electrical boosting systems for all glass types and manufacturing processes including TFT, LCD, float, fibre, holloware and borosilicate. FIC also supplies all-electric furnaces and forehearths, offering glass conditioning
options with the Isothermal unit to improve side to middle and top to bottom temperature gradients. Glass Service is a consultant in the field of glass melting, furnace modeling, advanced furnace control and operation, troubleshooting, and optimising furnace designs.
AGC restarts Teplice float line AGC Glass Europe has restarted one of its automotive glass float lines after a two-year upgrade. The upgrade at its Teplice, Czech Republic site was introduced due to a sustained
Glaston has agreed a deal to sell €2 million worth of equipment to a glass processor in Asia. The deal includes a special model of the Glaston RC350 toughening line, originally launched in 2012. The line is equipped with the Vortex Pro convection control system, which is designed with the aim of providing accurate heating control. The line will be delivered to the customer towards the end of 2014.
Frigoglass and Coca-Cola’s Dubai office have designed a limited edition football bottle ready for the 2014 world cup. The bottle will be distributed by Coca-Cola in the UAE, Kuwait, Iraq and Jordan. The Contour bottle reflects the shape of a football on one of the most distinguished bottles ever produced.
Glass Service acquires FIC UK The Czech Republic’s Glass Service Inc has acquired FIC (UK) Limited, based in Penzance, UK from its previous owner CNUD EFCO International. FIC will continue to operate as an independent supplier of electric glass melting equipment serving the worldwide glass industry
Glaston in €2m sale to Asian processor
increase in demand for automotive glass. The new line will create around 80 jobs to serve the Central European automotive market. First production of glass is
expected in the second half of April 2014. The Teplice plant has three float lines: One dedicated to building applications and two for automotive applications.
Stoelzle Czestochowa, which is part of Austria’s Stoelzle Glass Group, has formed a partnership with Tiama MSC & SGCC for the installation of four inspection machines dedicated to the inspection of premium spirit containers, such as the famous French Vodka Ciroc. The new equipment was approved by Stoelzle after several months of on-line benchmarks, allowing the Polish Glassworks to test new quality inspection systems from various manufacturers in the field of sidewall, base, finish and mould number reader. The concept that combines MULTI4, Kompass & MCAL4 allows a perfect control of special shapes, while orientating the containers with the help of software tools.
VISIT: www.glass-international.com – For daily news updates and regular features
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Saint-Gobain has completed its sale of Verallia North America (VNA) to Ardagh for US$1.69 billion (€1.27 billion). The proposed deal was first announced in January 2013, but was delayed due to competition concerns raised by the US Federal Trade Commission (FTC). The originally proposed agreement would have resulted in the newly combined Ardagh/SaintGobain and O-I controlling a majority share of the US glass beverage market. To satisfy the concerns of the FTC, Ardagh will sell six former Anchor Glass plants to an affiliate of KPS Capital Partners, a private equity fund manager. The six plants are its Anchor Glass’ former headquarters in Tampa,
NEWS IN BRIEF
3 Glass International May 2014
International news
NEWS IN BRIEF
Sigma Italy becomes Sigma Group
Wiegand places Zippe order
Sigma Italy has acquired an investment in Plovdiv, Bulgaria, and become Sigma Group. Sigma has more than 25 years of experience in the glass industry and specialises in the production of refractories for glass container manufacturers. Production of its new factory is oriented towards the Eastern Europe, Russia, CIS, Middle East, Asian and African markets.
Website tools Glass Technology Services (GTS) has launched two online calculators to help professionals across the flat glass supply chain work out the energy balance value – or ‘Effective U Value’ – and weight of their products. Designed to aid with specifications and highlight some of the important factors that should be taken into account when considering the options and benefits for different types of glazing products, the tools have been provided by GTS amidst growing debate over double and triple glazing. Available from www.glassts.com/
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Turkish printing centre Dip-Tech’s official representative in Turkey, KH Tasarim, has opened a Digital Glass Printing Center of Excellence. The site in Sancaktepe, Istanbul, is a professional centre for digital ceramic inglass printing and is the first of its kind worldwide. The centre offers a glass printing service solution to glass processors and provides consulting services to architects and designers. The centre is equipped with a fully automatic conveyer line, a washer and tilting table, Dip-Tech’s AR4000 Digital Ceramic In-Glass Printer with an inline dryer, and an unloading table – all necessary to secure a highquality product.
4 Glass International May 2014
Zippe has received an order for a cullet house and cullet transport system from Wiegand Glas. The order, which was received at the beginning of the year, is for the turnkey delivery of a cullet house and cullet transport system to supply all four furnaces at Wiegand Glas’s location in Steinbach am Wald,
Germany. The scope of supply comprises the complete plant technology as well as the complete control system including softwareprogramming, steelworks, installation and commissioning. The cullet house serves as storage facility for factory cullet, intermediate cullet,
special cullet and fine grain. Three independent transport systems guarantee a high flexibility, able to feed all four furnaces with cullet. Since Wiegand Glas operates with a very high cullet ratio, this plant section will be a crucial element in ensuring the melting material supply in Steinbach.
Euro beer sales boosts O-I Q1 results Strong beer sales in Europe helped boost Owens-Illinois (O-I’s) first quarter profits. Global volumes were up 2% year over year with European volumes up by 6% driven by strong beer performance as well as wine. Net sales in the first quarter of 2014 were $1.6 billion, on par with the prior year first quarter, although segment
operating profit was $218 million, down $8 million compared with the prior year first quarter. In South America, O-I’s Brazil operations also reported higher sales volumes, though those were offset by a weakness in sales in the Andean countries. Chairman and Chief Executive Officer Al
Stroucken said: “In Europe, we were especially pleased to see a positive volume impact coupled with the clear benefits from our restructuring efforts. “Record-setting snow and cold in North America dampened profitability in the quarter, despite modest volume growth.”
EME receives order from Brazil EME Maschinenfabrik Clasen and its sister company Shanghai Precision Dosing & Weighing System will jointly deliver a turnkey batch plant and cullet return system for IVN in Estancia, Brazil. Industria Vidreira do Nordeste (IVN) is a joint venture of local investors
(Grupo Ipiaram) and Verallia. The supply of the line is a milestone for EME and Shanghai Precision in the South American market. The batch plant is designed for two melting furnaces with a combined melting capacity of 740t/d in the final stage. In the first phase one tank
will be utilised, and at a later stage the line may be upgraded to the full performance. The installation and commissioning of all technological equipment and the control system is to be solely performed by EME and Shanghai Precision.
Be first with the news! Visit www.glass-international.com for daily news updates
SORG Forehearth Division
Over 2000 systems installed. + Operating on five continents + SORG 340S 190 forehearths sold since 2006 + 88 Boosting Systems + 117 All Electric Forehearths, also for special glasses =
35 Years Global Leadership
S56.14E
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At Home in the World of Glass
International news NEWS IN BRIEF
Owens-Illinois chooses BDF recovery plant Owens-Illinois (O-I) has chosen BDF Industries as the supplier of a heat recovery plant for the production of electricity via an Organic Rankine Cycle (ORC) turbine, at its Villota, Italy plant. The recovery of thermal energy via an ORC turbine allows efficient use of exhaust gases produced by the glassmelting furnace, with the aim of maximising energy recovery without affecting the glass production process. BDF Industries has been investing in the field of energy recovery since 1990 with the introduction of the Active Front End system (AFE), successfully applied to the controls of IS machines servo motors.
EME to build the world’s largest container glass batch plant EME Maschinenfabrik Clasen is undertaking a complex project to deliver the world´s largest container glass batch plant for production within a tight timeframe. The Modesto-based company, Gallo Glass, is continuously planning for the future. These plans not only include a Batch Plant upgrade but also include furnaces from Nikolaus Sorg. This has resulted in the need for building strategic partnerships with experienced and reliable suppliers.
EME has embraced this position of Gallo Glass and will deliver greater batching capacity and capabilities while ensuring that operational costs are reduced and plant availability is optimised. The first phase of the project will be commissioned in late 2014 with the final phases being operational in the Q2 2015. The scope of supply includes all key components for dosing, weighing and mixing to provide a precise and reliable solution. The control system for the
complete batch plant will be a PCS7 system featuring among others, redundant failsafe control systems, parallel batching and maintenance notifications.
glasstec 2014 on track Exhibitor registration numbers for glasstec are on par with the previous event in 2012, despite the economic situation in the sector. Last time, 1,175 companies representing glass engineering, manufacturing and crafts participated, 66% of which came to Düsseldorf from outside Germany. “We’re delighted by the great response to glasstec 2014, especially with the economic situation in the flatglass sector and partially in the mechanical-engineering sector,” said Hans Werner Reinhard, Deputy Managing Director of Messe Düsseldorf.
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Redwave Austria forms US subsidiary Redwave Austia has opened a subsidiary in the USA. Redwave Solutions US is based in New York. Both sales activities and after-sales service form the core business of the subsidiary. The ability to respond more quickly to sales inquiries, provision of services and supply of spare parts, as a result of being closer to the customer, should lead to increased sales and improved customer loyalty.
6 Glass International May 2014
Stölzle installs 3D printers Stölzle Glass Group has invested in 3D Printer kits at two of its production sites. After months of research, two different systems were acquired and installed in the Austrian headquarters Stölzle-Oberglas as well as in the British plant Stölzle Flaconnage. The UK site invested in a kit which can be customised to suit special needs. It prints by heating and extruding
plastic filament (ABS/PLA or T-glass) through a 0.5mm in diameter nozzle on a heated base, and builds layers on itself to create any shape required. The printer has a build platform of 280mm in diameter by 368mm in height. The Austrian headquarters invested in a more sophisticated type of 3D printer which is able to produce translucent UV
cured acrylate sample bottles. The 3D models are built in subtle layers (32μ) of acrylate around wax, which after the printing process will be melted away easily to achieve a sample bottle which can be filled and used for testing of closures by the customer. The 3D printer can create objects with a maximum size of 185mm in height by approximately 200mm in diameter.
AGC Europe chooses Air Products Air Products has recently installed an air separation unit (ASU) for AGC Glass Europe, the world’s largest producer of flat glass. The cryogenic PRISM ON300 plant, now operating at AGC’s Teplice factory in the Czech Republic, produces pure oxygen and nitrogen and represents a significant part of AGC’s rebuilt float glass production line. This is the first time in
Europe that the float glass production line has been equipped with a stand-alone ASU. The delivery is the result of a long-term gas supply contract between Air Products and AGC Glass Europe. The contract further strengthens the relationship between companies, which began almost 20 years ago in the Czech Republic. Pavel Kolouch, Air Products’ business manager,
said: “It is a great achievement for both parties and an opportunity to continue our growth with AGC. This is one of the largest investments of its kind in Europe.” The custom-built PRISM ON300 plant uses air separation technology by cryogenic distillation. The plant is capable of producing 300 tons of oxygen and 170 tons of nitrogen per day.
International News
StekloSouz of Russia and Expocentre have signed an agreement to merge the GlassExpo and Mir Stekla exhibitions. It means Russia will host one international event under the name Mir Stekla in 2014. The decision was made to enhance the credibility and successful development of the Russian glass industry. The National Joint Council of Russia’s glass industry created StekloSouz in 1999, the same year the first Mir Stekla exhibition was held. One of the key tasks of StekloSouz is the development of the glass market, and the coordination of information, marketing and educational programmes to address the challenges facing the industry. Mir Stekla, organised by Expocentre, is a platform for the presentation of the scientific achievements and developments of Russian
players in the industry, as well as a springboard for international companies that have decided to enter the Russian market. StekloSouz and Expocentre have decided to join forces to work on the development and strengthening of the Mir
Stekla brand, which has been well received both domestically and internationally. Glass International will be at this year’s Mir Stekla, which takes place in Moscow between 4th – 6th June.
Chairman of the Russian GlassUnion Association Mr Victor Osipov (left) and deputy General Director of the Expocenter Mr. Michail Tolkachev sign the agreement.
EU glass recycling rate passes 70% Latest glass recycling figures for the EU show there is far more glass recycled than ever before in Europe, increasing by 131% since the 1990s. Latest industry data confirms that average glass recycling rates in the European Union have passed the 70% mark. This means more than 25
billion bottles and jars were collected throughout the EU in 2012 to make new bottles. The savings in virgin resources could build two Egyptian pyramids. Recycling means that less virgin materials are needed despite market growth. Between 1990 and 2012, EU consumption of products
packed in glass increased by 39% in Europe. Glass recycling increased by 131%. As a result there is a large reduction of raw materials, CO2, and energy used to produce new bottles.
See national statistics available on www.feve.org
Caspian exports to Azerbaijan Caspian’s float glass plant has signed a letter of intent to provide provide 100,000 tons of glass per year to Azerbaijan. Caspian’s plant in Dagestan, Russia, became
operational in 2013 and produces 600 tons of glass per day. Azerbaijan is a priority partner for the company because it is a transit base,
through which products can go to Georgia and Turkey. Plant specialists are also studying the possibility of supplying flat glass to Kazakhstan and Georgia.
Tiama seals Thai deal Siam Glass Thailand has selected Tiama as its supplier for the upgrade of its cold end inspection machine in its Samutprakarn factory. Dedicated to the production of its M-150 health drink bottle, the five production lines will be equipped with Tiama Mcal Sidewall Inspection and Tiama Multi Top and Bottom Inspection. The Thailand energy drink company, along with its own container supplier, chose the inspection, which enhances its capacity to inspect mouth defects without any compromise. The contract awarded to Tiama includes the upgrade of several M machines with multi-head thickness measurement. After-sales support will be provided by Tiama’s Bangkok-based customer support team. Tiama is currently installing and commissioning the 15 inspection machines of Asia Pacific Glass’ three new production lines in Chacheongsao district.
Summer school The International Commission on Glass’ (ICG) 6th Workshop For New Researchers In Glass Science and Technology takes place in Montpellier, France between 7th-11th July, 2014. This year the Montpellier Summer School has been extended to include two streams, one following the traditional glass science format while the second strand is on the Technology of Glass Melting. Glass International May 2014
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GlassExpo and Mir Stekla combine forces
7
Interview: Niall Wall
Ardagh CEO: Verallia takeover is a good deal for customers
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As Ardagh expands its global presence with its recent takeover of Verallia North America, Greg Morris caught up with Niall Wall, CEO of Ardagh Group, to discuss this latest development and the company’s plans for the future.
continued Âť
8 Glass International May 2014
Interview: Niall Wall
T
he Ardagh Group has won US antitrust approval from the US Federal Trade Commission to buy Verallia North America, after agreeing to sell six of its nine glass container manufacturing plants to KPS Capital Partners. Following the US$1.7 billion acquisition and the divestment of these assets to KPS, Ardagh’s North American Glass Division will generate annual revenues of approximately $2 billion from 16 glass manufacturing facilities with a workforce of 5000. The Ardagh Group now has global sales of US$6.5 billion, (€4.8 billion), operating from more than 100 locations in 24 countries employing 20,000 people. Heading the new division as President of Ardagh Glass North America will be John Riordan, who has been Finance Director of the Ardagh Group since 1999.
financial crisis started in 2008, but are now littered with disaster. “Whilst we are very open to entering all markets, we remain to be convinced by the BRIC countries. We have no bias against these regions, but unless the criteria are right we will not invest in them. I’m not saying we will never do it but as yet a viable investment opportunity has not presented itself.” When asked whether China presented a challenge or an opportunity to Ardagh, Mr Wall said that China currently has too much capacity, has not consolidated, and has structural issues. “There is so much embedded capacity in every industry in China. If industry grew further the entire economy would suffer from unsustainable overcapacity. Under our business model we support our customers’ strategic requirements, but we would not put speculative capacity into any market, no matter how attractive it looked”.
Acquisitions
BRIC countries While much of the glass industry’s growth is in the developing BRIC countries, Mr Wall said Ardagh currently has no plans to invest in those countries. He said areas including Russia and Eastern Europe were regarded as a gold mine before the
“
Glass prevents waste so benefits the planet. It preserves food so plays a positive role in the reduction of food waste. It is also a permanent material that can be recycled and reused infinitely
”
Future of glass Unsurprisingly, Mr Wall is very optimistic about the future of glass packaging, which has many intrinsic benefits to withstand the challenge from competing materials. “The reality is that glass is still very relevant because it continues to be loved and trusted by consumers. We have seen a switch from PET into glass for some products, particularly in the health food and beverage categories. These sectors really understand the benefits as well as the inertness of glass. “Go into any bar, look at the spirits display, and you cannot fail to notice the innovation and creativity in bottle designs. This demonstrates the enormous flexibility of glass in terms of colour and shape. Glass packaging protects products, enhances brand equity and distinguishes a wide variety of products, yet it is not exclusive to luxury brands. For example, the wine and beer sectors, where many brands are packaged in glass, cover the whole spectrum of drinking occasions from special celebrations to socialising with family and friends.” Mr Wall had also championed glass’s environmental benefits: “Glass prevents waste, so benefits the planet. It preserves food so plays a positive role in the reduction of food waste. It is also a permanent material that can be recycled and reused infinitely.” Glass International May 2014
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Mr Wall said: “Our business model is essentially to acquire businesses in relatively mature markets and then create value with the extraction of synergies, a model which has worked well for us. We have completed 17 transactions since 1999 and have grown over a hundredfold by revenue in an industry which is relatively flat from an organic growth standpoint.” He believes that this latest acquisition is a good deal for US customers: “We already have strong relationships in North America with a number of our global customers and this acquisition means we will be much more relevant to them.” It also enables Ardagh to expand its R&D focus. Mr Wall explains: “R&D is a huge focus of ours. We work closely with our customers and we continue to invest in R&D, which we regard as a competitive advantage. “One of the benefits of this deal is for our Heye International business, (a global leader in glass making technology), to join forces with GPS America to become a strategically critical asset for the future development of our business”. He also commented on the appointment of John Riordan as President of Ardagh Glass North America: “John’s appointment reflects the importance of this market to the future growth of the Group. His replacement as Group CFO, David Matthews, brings considerable experience from his time at DS Smith plc and Bunzl plc to Ardagh, as we move to the next stage of our development.”
9
Glassworks profile: O-I Alloa
O-I is investing €30 million at Alloa to support the Scottish drinks industries.
O-I celebrates €30 million Alloa investment Greg Morris attended Owens-Illinois’s (O-I) official celebration of its €30 million investment programme at its Alloa, UK plant.
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O
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wens-Illinois (O-I) unveiled its €30 million investment in its Alloa, Scotland plant – and promised more is to come. Senior management including global CEO Al Stroucken and European President Erik Bouts attended the official celebration during a ceremony at the plant. They were joined by Scottish Government Ministers, who had helped secure a £3.9 million grant from Scottish Enterprise to assist in the upgrade. Mr Stroucken and Mr Bouts said the €30 million modernisation was part of a €140 million investment in its European plants that will take place throughout 2014. The investment will take place in the Alloa facility over three years and include upgrades of its product design and development capabilities. The result will be that it can create more packaging solutions to meet the drinks industry needs for segmentation, differentiation and premiumisation. The upgrade comprises new decoration and bottle printing facilities with increased capacity; on-site mould milling and a new Computer Aided Design (CAD) design suite for faster prototyping and quicker speed to market for NPD projects; more colours for premium products with a greater capacity to make black glass bottles; and facilities to produce extra flint bottles in more sizes and quantities. The spend also includes improved inspection equipment and inline, automatic inspection for black glass containers. Further investments in the next few months will see an upgrade to its 85 Furnace shop Glass International May 2014
ensuring it can produce a higher volume of containers.
Heart and soul
“
We would like to thank Scottish Enterprise for its support in strengthening our ability to service the developing needs of the spirits industry in Scotland.
”
Chairman and CEO Al Stroucken told Glass International that the investment in Alloa reflected what O-I is doing around the world. He said: “The challenge that we faced last year spurred us to step up our plans and to upgrade the plant, to add capabilities and attract new customers and to modernise in a way that demonstrates our commitment to quality and innovation.” He added: “This investment confirms this plant’s role as the heart and soul of spirits packaging in Europe. On a global basis we are investing in innovation and R&D to strengthen our capabilities and suite of services offered to our customers.” An example of this, he said, is its recentlyopened $35 million innovation centre near its headquarters in Ohio. The centre is at the same time a pilot plant where it runs sample bottles and sample bottle designs for its customers, as well as trying to implement new ideas and concepts with regards to the manufacturing of glass. More than 100 scientists and engineers from many disciplines work at the site investigating new ways to melt, process and form glass.
European operations O-I’s European operations account for 40% of its global business. It is the largest glass container continued »
Glassworks profile: O-I Alloa
Al Stroucken, Erik Bouts and Fergus Ewing, Minister for Enterprise, at O-I Alloa investment launch
The new Kamman silk screen printer at Alloa’s decoration plant is the first of its kind at a UK packaging plant.
“With the €30 million investment in Alloa we have installed cutting edge technologies to provide customers with best in plant glass packaging solutions.” “Europe is a critical region to our global business, the goal in Europe is to become the preferred strategic glass packaging partner for our customers for every country and every segment.” He added: “We are entirely focused on glass, there is no ambiguity on where the investments should go, it’s glass and glass only.” Its European division has recently implemented a new segment-specific organisational structure to better serve the market. The new structure allows it to be closer to its customers with increased speed and flexibility. It now has dedicated teams building specific strategies for the wine, food, beer soft drinks and spirits. Its new organisational structure is explained in more detail in the March 2014 edition of Glass International in an interview with Mr Bouts (Page 10).
Decoration The CAD suite allows O-I to design bottles alongside Scottish customers and their agencies.
Jim Rankine, O-I Operations Leader, said a new CAD design suite allows the company to design bottles alongside customers and their agencies. “We can now bring a new product to the market place in a shorter space of time. Before it was eight weeks, now it is 10 to 14 days.” A new Kamman silk screen printer has allowed the plant to produce new colours and new techniques. There is a market for different shapes now and in the past few months O-I has put 150 new products on-line, allowing it to attract new customers. “Even current customers are coming to us with new ideas because we have this new technology that we can deliver with now,” said Mr Rankine.
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producer in the world with 77 plants in 21 countries, employing 22,500 people. The Alloa plant is 260 years old and is the oldest glassworks in Europe still operating on its original site. It was established in 1750 by Lady Erskine of Mar. Today it produces more than 2 million bottles a day for the spirits, beer, wine and non-alchoholic beverages (NAB) segments and can produce white flint, extra flint, amber, black and green glass colours. Approximately 95% of its production is supplied and filled within Scotland. Mr Bouts said: “We have upgraded Alloa's design, new product development, glass colour and decoration facilities. ”We would like to thank Scottish Enterprise for its support in strengthening our ability to service the developing needs of the spirits industry in Scotland.” Mr Bouts said the plant was uniquely positioned to support its customers and the spirits industry in Scotland. “O-I has a strong commitment to Scotland, its thriving spirits industry and of course the many iconic global brands, which are created here. “We have a strong heritage in this country and we play an important role in the Scottish whiskey industry – an industry that generates £4 billion a year.”
11 Glass International May 2014
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because the bottom line counts
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Hot end coating
Hot-end coating: Strengths, risks and alternatives Recent investigations in the field of hot end coatings (HEC) for container glass have produced alternatives to traditional coatings, and a way of overcoming the present drawbacks of HEC. An alternative coating has been developed which can be used instead of tin-based coatings. Dr. Christian Roos*, Andreas Rosin**, Dr. Zahra Negahdari** and Dr. Thomas Struppert*** explain.
The effect of the HEC is firstly, and most importantly, it saturates the surface bonds on the juvenile glass and provides a certain roughness on the surface which enables a good adhesion of the subsequent cold-end coating (CEC). Secondly, it is said to increase the surface strength of the containers prior to the CEC application. Although this effect might be questionable (because of the thin and not fully closed layer that is deposited), undoubtedly the HEC has positive effects on the fresh surface of the hot container. The coating is deposited (depending on plant philosophy and customer requirements) in a thickness of 20 to 60 CTU (Coating Thickness Units, 1 CTU = 0.25nm for SnO2). Deposition efficiency is certainly a big issue in large-scale industrial processes. MBTC usually has a deposition efficiency of 20-25%, hence this process in general yields room for improvement.
So, the logical aim of a research task is to find a metal-(organic) precursor, halogen-free and 100% REACH compatible, which is suitable in an industrial CVD-based in-line HEC process at atmospheric pressure under air. Cost and efficiency at least needs to be comparable to the present MBTC process. Furthermore, the material and process performance has to be capable of coating up to 40,000 containers per hour and needs to withstand the harsh environment in a container glass production. A very robust process is necessary for that. Additionally, the process conditions, especially in terms of temperature are not always constant. The thermal load brought into such a
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1.60
1.52 1.47 1.42
1.40 1.20 1.00 0.80
1.25 1.18 1.11 1.08 1.05
1.13 1.11 1.03 0.96 0.89
0.79 0.73
0.74 0.73
0.60 0.40
0.43 0.36
0.20
0.15
0.00
0.13 550 Glass temperature
480 TOT DBU-Sn-DL
620
AA-105
EHTAA
DBu-Ti-AA
9000
DBu-Sn-DA
DBu-Sn-DA
DC
Bu-Sn-3EH
TPT
TNBT
Fig 1. Coating efficiency of different precursors as a function of temperature in [°C].
Glass International May 2014
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HEC effect
Furthermore, the process inevitably leads to the formation of HCl. HCl is first and foremost corrosive and can be a health issue to operation personnel. HCl can also react with uncoated containers and also (through the thin SnO2 surface coating) with the glass, causing surface defects due to sodium leaching and sodium-chloride formation. Hence, it is desirable to reduce or even avoid the generation of HCl in this process. Finally, besides health and efficiency, another important aspect remains: Tin, as the main functional component, is less abundant than one might think. The occurrence of tin in the earth’s crust is far less abundant than, for example, titanium. This relatively low abundance of tin, its need and use in many other applications such as sheet metal will certainly contribute to a cost-increase for MBTC.
Normalised coating efficiency
H
ot end coating (HEC) of glass containers is a standard process at every container glass manufacturer. Juvenile, hot containers are coated in a CVD-process with monobutyl-tin trichloride (MBTC, C4H9SnCl3) or in less frequent cases with tin tetrachloride (SnCl4) or titanium tetrachloride (TiCl4), possibly with additions of other additives. The coating process for MBTC itself is relatively simple and is capable of coating 40,000 or more containers per hour. MBTC is suitable for this type of process as it has a tendency to decompose on the hot glass surface causing a thin, but not fully closed, layer of SnO2 on the glass.
13
Hot end coating
Precursor (ad) R3
Heterogeneous thermolysis
Absorption/desorption R1 Precursor (g)
Hom. thermolysis
Particulate deposition?
TiO2 (p)
TiO2 (s) Coating
Airborne particles
= wanted path
Hydrolysis H2 O(g)
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Fig 2. Reaction paths at precursor deposition.
14
coating process differs with the type of container to be coated. A 1-litre sparkling wine blow & blow container, for instance, brings a much higher thermal input into the process than a 0.2-litre fruit juice container, produced by narrow-neck press & blow. And at a given container, the temperature loads on the process vary between, for example, a container coming from section 1 (hotter) and containers coming from section 12 (colder) of an IS machine. The surface temperature difference between containers from these sections can be 70K or more within the same job. Having these challenges in mind, the University of Bayreuth, Germany and IPGR, Switzerland had started to search for alternative materials that can be used as an HEC precursor in the containerglass industry. With an external partner (Agr International, USA), IPGR screened several substances that could have been promising candidates. Tin-containing precursors could only solve the problems if they could work at a high deposition efficiency, hence compensating a potential price increase of tin as raw-material. It was quickly understood that every tin-containing precursor would only partly solve the problem, even at high efficiency. Fig 1 shows several closely investigated precursors and their coating efficiency depending on temperature. The coating efficiency should not strongly vary over the temperatures that can occur on the surface of freshly produced glass-containers. Only a few materials can cope with the temperature differences encountered in the forming process, and therefore ensure a robust coating process. Coating efficiencies depending 30% or more on a narrow temperature window are undesirable.
Teamwork At this point, the University of Bayreuth Glass International May 2014
= unwanted path
R2
Coating thickness [CTU] 80 60 40
decomposes homogeneously in the atmosphere. This path – if it occurs – certainly limits the coating efficiency. Finally, if the precursor comes into contact with water a homogeneous hydrolysis R2 can occur. In both cases airborne Titanium-oxide particles are formed which are no longer available for the coating of containers. Several measures have to be made to avoid the above-mentioned unwanted reactions. With step-by-step improvements of an existing MBTC hood and aided by 2-D CFD modelling of the flow structures in coating hoods, the process was improved until it was capable of performing a long-term trial in a production line.
20
Testing
0
Height
30mm
80mm
Fig 3. Average coating distribution of a typical container.
and IPGR teamed up after realising that they were working in similar fields with similar intentions. After initial screening tests, in which also the spraying of the precursor was considered, it was decided to keep the process as close to the existing MBTC process as possible to avoid predominantly strong changes in the way the process is carried out. An AP-CVD process (atmospheric-pressure chemical vapour deposition) was therefore targeted. The selected Ti-precursor was closely investigated and special adaptions made to avoid several obstacles. The selected precursor shows a high coating efficiency with low temperature dependence. However, secondary reactions can take place which limit the deposition rate on the container (Fig 2). The reaction path R3 describes the desired decomposition of the precursor on the container. Starting with absorption of the precursor and the subsequent heterogeneous thermolysis of the precursor, resulting in a layer of TiO2 on the glass surface and non-toxic by-products plus water. An unwanted reaction path is the homogeneous thermolysis R1 which takes place when the precursor
The coating process was tested in-line with a several hour trial at WiegandGlas. The achieved coating thickness distribution was comparable to MBTC coatings, giving thicknesses of ca. 25CTU, depending on the process parameters. Fig 3 shows the average coating distribution of a typical container in that process (green area: MBTC standard). As a special condition, titanium-based coatings are prone to iridescent appearance if the coating thickness gets above a certain value. Under unstable process conditions (Fig 4) the coating thickness in the investigated process varies, leading to values of 50 CTU and more. If the value reaches above 60 CTU, an iridescent appearance on the containers occurs which renders the product unsellable. The trial at WiegandGlas proved the principal feasibility of this process being stable over a long period, producing sellable containers. Furthermore, containers coated with the alternative Ti-based precursor showed no differences in strength, coldend coating performance or label adhesion compared to standard MBTC coated containers. Also important to this trial was the coating efficiency. It can be considered as a good result that with a ‘justoptimised’, standard MBTC hood the coating efficiency was estimated to be 11%. Considering the potential of a coating hood especially designed and built for the respective precursor, a coating efficiency similar to MBTC or even better seems achievable.
continued »
Hot end coating
Risk of iridescent appearance due to too thick coatings
Coatings thickness [CTU]
60 50 40 Height 30mm
30 20
80mm
10 0 0
60
120
240 180 Time [min]
300
ELECTROGLASS POWER TO REDUCE YOUR ENERGY COSTS
Fig 4. Average coating distribution under unstable conditions over time.
After having filed patents in the respective field, the consortium will now identify further hood improvements and the best suitable hood design with the help of 3-D transient CFD modelling. Via this, flow conditions, deposition rates, temperatures and material concentrations can be calculated and hood improvements and their effects can be tested. In parallel, IPGR aims to team-up with an industrial hood supplier for an improved hood concept and commercial hood development. This is necessary as the next steps involve a strong commercial path. As we believe a pro-active approach is needed to drive the next step of HEC development, cooperation between RTD, industry and supplier should be targeted to enable commercialisation of the concept. The focus of this cooperation will be: a) Improving the process control (as Ti-based precursors need a precise process adjustment to avoid iridescent appearance); b) Improving the coating efficiency and homogeneity further due to optimised hood design; c) Improving the controllability of the process and making it robust for the harsh conditions in glass containers manufacturing; and d) Utilising the cost benefit of the base material. In summary, this development shows that alternative materials to MBTC are available, which can – if adapted and improved to industrial conditions – substitute MBTC in the near future. The next necessary development steps need to be carried out in a partnership of R&D partners, container glass producers and HEC hood and material suppliers. This is also vital for the suppliers of HEC material and equipment as, for example, REACH restrictions might require further actions and effort in the search for alternative HEC materials. If you are interested in joining us, then please use the contact information detailed below.
*Dr. Christian Roos, International Partners in Glass Research, Bülach, Switzerland. christian.roos@ipgr.ch **Andreas Rosin and Dr. Zahra Negahdari, University Bayreuth, Germany ***Dr. Thomas Struppert, Wiegand-Glas, Germany Glass International May 2014
EVERYTHING WE DO IS FOR IMPROVED... Energy Efficiency, Glass Quality, Furnace Output
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Technical topics
John Henderson Henderson Technology
It’s not ‘just’ glass!
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A
16
lthough I try to vary the topics in these columns the glass that predominates, whether the subject is quality, compressed air, toughening or another practical theme, is sodalime-silica glass. Some might not consider this unreasonable as, in one form or another, about 90% or more of the world’s glass (certainly by volume) is soda-lime. Most consumers’ interaction with glass is via a container or window and what are they made of? Soda-lime-glass, of course. However, no matter how important this glass is technically and economically it is only one part of one type in a huge array of different glasses that impact on our lives. Borosilicate glasses are a hugely important group that many do not recognise as being different. At the basic level most people’s interaction with borosilicates is in the form of ovenware, generally regarded as ‘Pyrex’ but how many of them would recognise that the glass screen on their smart phone or tablet was a borosilicate or even an alumino-silicate as the manufacturers of these thin flat glasses make astounding advances in glass technology to satisfy the demand for these products. Borosilicates also play a role in the pharmaceutical industry satisfying a demand for better durability than soda-lime can offer. Borosilicates are generally lower in expansion than soda-lime glasses and some will seal directly onto metals without intermediary steps. Much of the scientific instrumentation used both on earth and in space to study the cosmos contains a component that relies on a piece of borosilicate glass. I can well remember our team being asked to develop a high durability 47 expansion glass that would seal directly to ‘kovar’ type alloys and have a very low natural radioactive background signature. At first glance this might not sound too hard to a seasoned glass technologist but not many realise that potassium is naturally radioactive. All sources of potassium (carbonate, nitrate etc.) available to the glassmaker have potassium 39 as the dominant species, however, tiny amounts of potassium 40 are also found in these compounds and potassium 40 is radioactive. Now this is not as bad as it sounds because the amount of radioactivity is tiny compared to that normally experienced in everyday life, however it was
Glass International May 2014
“We should try to encourage everyone to think ‘It’s glass!’ not ‘It’s just glass.”
enough to mean that any glass formulated had to be potassium free. Not as easy as it sounds as several components used in glassmaking including soda ash and sand have traces of potassium as an impurity. The glass was made, was successful and is still in production as you read this column (albeit at a different manufacturer). Lead crystal for decorative purposes is still in production despite the negative press it has had (unjustly, many glassmakers would say) and there are many high lead glasses made for optical purposes where shielding from radioactivity is also a requirement. Many optical glasses are now based on lanthanum as a substitute for lead in giving the glass a high refractive index. I am sure I have mentioned before that all glasses are not silicates. Phosphates and borates have a part to play, the former predominantly in bioactive glasses as noted above and the later in specialised protective fields such as preservation of wood and alkali metal vapour barriers. Another abiding memory is of trying to melt a mixture of sodium borate and boric oxide and form it into rods. The melting was reasonably straightforward because it was relatively low temperature (in glassmaking terms) at 800oC. It was the fashioning into rods that was the problem as the viscosity of the melt was not much more than if we were working with water. We did get some pieces (it would be over generous to call them rods) which were sent for trials and the product was modestly successful as it did appear commercially in DIY outlets as a wood preservative. In a short column like this it is impossible to do justice to all the different types of glass that impact on our lives but just consider calcium phosphate based glasses for reconstructive surgery implants, calcium fluoride based glasses for dentistry, high silica glasses for optical communication fibres, lithium silicate based glasses for cooker tops and the many others that we may be unaware of. Not exactly a ‘technical topic’, I know, but glass is such a wonderful material we should celebrate its diversity and promote its understanding to as wide an audience as possible. We should encourage everyone to think ‘It’s glass! not ‘It’s just glass’.
John Henderson, Henderson Technology UK, Email info@hendersontechnology.com Website www.hendersontechnology.com
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History
Prof. John Parker Turner Museum of Glass In the first of a new series on the history of glass, Prof. John Parker, of both the International Commission on Glass (ICG) and the University of Sheffield, UK, discusses the evolution of mirrors, from their origin in 4000BC to the 19th century.
P
rof Parker writes: Uncovering the facts behind glass history means delving into a fascinating world where art, museums, theatre, literature, and archaeology can all provide pieces of the jigsaw. Generating a picture, even a little at a time and probably imperfectly, will be a challenge and privilege. So I have accepted this commission to create a series of brief cameos on Glass History. Some of you will certainly know more than me; if so, do send me your comments and help shape future articles.
the 1st century AD. The Roman author Pliny in 77AD mentions glass mirrors backed with gold leaf. In the 6th century the Chinese began making mirrors using silver-mercury amalgams, perhaps based on a similar technology for gilding metal objects using gold amalgams. By the 11th century, similar mirrors were being produced in Moorish Spain. European mirror development was slower, hampered partly by superstition. One Pope banned priests from owning mirrors because the devil can conceal himself in the mirror.
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Reflections on mirrors
18
The phrase seeing in a glass darkly comes from St Paul’s first letter to the Corinthians (13:12). But were glass mirrors really around so long ago? Paul was a Roman citizen and the Romans certainly used mirrors, but made from polished metal e.g. bronze or speculum metal. Corinth was allegedly a manufacturing centre for these luxury items, whose origins date to 4000BC. Polishing imperfections and susceptibility to scratches fit with poor image quality and Paul’s glass, the 1611 Bible translators interpretation of a Greek word for mirror, was probably metal, his comment a ‘dislike’ on a consumer preference form. Renaissance artists were also painting mirrors, often centrally, into their pictures. Art historians often explore the scientific, social and even psychological implications of the reflected images but that is not today’s topic. An early example (1434) is by Van Eyck. A rich merchant and his wife stand in front of a convex mirror. Carola Hicks in the Mail Online (2011) describes this as the only shape then available, the mirror having been cut from a blown glass sphere. Mirror makers had realised very early that a metal-coated flat glass sheet potentially offered reduced optical distortion and would suffer less damage. The earliest examples reported are from Sidon (modern-day Lebanon) in Glass International May 2014
Venice By the 13th century Venice had become a key centre for glass manufacture which allowed an evolution if not revolution in processing. They developed high quality, transparent Cristallo Glass (1450-1460), improved the crown and cylinder methods for making sheet glass, created cast glass, used grinding and polishing to achieve flat, accurately parallel surfaces and refined the tin/mercury amalgam process. Finally, the quality of their looking-glasses far exceeded those of their polished metal counterparts, but the labour-intensive processing and the dangers of mercury ensured that they remained expensive luxuries. They were given as gifts between the Royal Houses of Europe: Henry VIII’s 1547 inventory lists several looking-glasses, and the value of a Venetian mirror was said to equal that of a naval ship or an aristocrats’ country house; intricate, gilded frames were cheap in comparison and helped conceal imperfections in the glass. Their mirrors’ though were restricted to a maximum dimension of a metre. French royal ambitions demanded solutions, particularly for the Palace of Versailles. Within this architectural jewel is the Hall of Mirrors, 357 in total, built for Louis XIV in 1678-1684. He expected the best and wanted a waiting room for important
foreign guests that properly demonstrated his country’s technological prowess. It is no coincidence that the company set up by the French Minister of Finance to supply the palace, and which later was to become the firm Saint-Gobain, reported in 1687/88 its invention of a method for casting glass blocks suitable for larger mirrors than Venice could supply, their maximum dimension being 1.5m. The recruitment of emigrant workers from Venice by the French assisted the diffusion of mirror-making technology, and is underpinned by dark stories of assassins dispatched by the Venetians to protect their expertise and income. But such know-how had already spread. For example, the Duke of Buckingham’s (1628-1687) collection of glass-making patents gave him a near monopoly in UK mirror making. In the 1700s France displaced Venice as the European mirror centre. Subsequently, Bohemian, German and Belgian (Walloon) glass gained prominence. German chemist von Liebig invented a much safer silvering process for glass in 1835, allowing mass manufacture; ultimately the frame became the defining design and cost element. Earlier, I argued that St Paul would not have mentioned a glass mirror. Interestingly, polished obsidian, a natural volcanic glass, was used from 6000BC, predating metal mirrors. Its poor reflectivity though would have required ‘very’ before ‘darkly’.
References The Grove Encyclopedia of Decorative Arts, Gordon Campbell (2006), p110 Wikipedia on Mirrors. http://glassofvenice.com/murano_glass_history.p hp
Professor Emeritus John Parker, Curator of the Turner Museum of Glass at Sheffield University, j.m.parker@sheffield.ac.uk www.turnermuseum.group.shef.ac.uk
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Country focus: Russia
Russia records upward growth Site of this year’s winter Olympics and star of recent political debate, Russia has certainly got people talking lately. Sally Roberts looks at Russia’s glass market ahead of this year’s Mir Stekla exhibition.
W
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hatever the west currently thinks of Putin it is undeniable that he has done an incredible task with Russia’s economy. After the collapse of the Soviet Union in 1991, the nation’s first attempt at introducing a market state hit an all-time low with Russia’s financial crisis of 1998. However, following Putin’s ascension to power in 2000 the country’s economic reform has been astonishing, and its finances have rocketed. By 2007 real GDP had increased by the highest percentage since the fall of the USSR (8.1%), the World Bank had declared the Russian economy to have achieved “unprecedented macroeconomic stability”, and Russia had overtaken China in terms of capital investment. From 2009 the economy slowed, reflecting both the effect of the external global recession in countries that trade with Russia, and lower levels of domestic investment. In 2013 GDP growth slipped to 1.4%, an enviable figure to some countries but which, according to Russia’s Economic Development Minister Alexei Ulyukayev, “Cannot
20 Glass International May 2014
under any circumstance be considered satisfactory”. This is expected, perhaps subject to international relations, to increase to 2.6% in 2014 due to the effect of the Sochi Olympics, lower inflation, higher oil prices, increased residential construction, and improvements in the US and EU economies among other things. All this has, of course, affected the country’s glass industry – both container and flat. Pre-2009, the development of the glass food and beverage packaging market was consistently moving upwards. The growth
rate in 2006 was 126%, in 2007 it was 118%, and in 2008 it grew by 113%. In 2009, however, growth stalled, reflecting Russia’s own slowing economy and its effect on the production of products in glass packaging. In 2010-2011 there was an increase in the consumption of glass by 12% and 1% respectively, but the market has still not returned to pre-2009 levels. One of the primary reasons for foreign investment into Russia is the country’s growing consumer demand for glass. Putin recently announced that by 2020 Russia will need to have constructed 140 million m2 of housing, which will result in approximately 500 million m2 of flat glass needed for the project. The aim is that from 2016 Russia will produce 300 million m2 of flat glass The 2020 plan also decrees that by 2019 the production of medical glass will also have doubled its current rate. continued »
Country focus: Russia
Flat glass The Russian flat glass market has increased exponentially over the past few years. In 2000, Russian glass factories produced 86 million m2 of flat glass, a figure which more than doubled to 195 million m2 by 2010, and as of 2013 the amount of flat glass produced in Russia stood at 225 million m2. The entire volume of the Russian flat glass market stood at 250 million m2, meaning that the majority of the market can be satisfied using domestic produce. As for imported glass, approximately 12 million m2 came from Belarus, 10-12 million m2 was imported from China and Iran, with small amounts coming from the CIS countries. Russia’s major players in the flat glass sector tend to consist of international companies, for example AGC and Guardian are the largest producers on the Russian market. AGC has two factories, in Klin (near Moscow) and in Borisov (Belarus). Guardian also has two plants in Ryazan (approx. 120km south east of Moscow) and Rostov (200km north east of Moscow). Pilkington is also prominent in the Russian market, while Saint-Gobain produces much of Russia’s automotive glass. In 2013, Saint-Gobain entered into a joint venture with Sisecam’s Trakya Cam for an automotive glass manufacturing facility in the Republic of Tatarstan, Russia. In 2011, NSG Group merged with STiS Group of Companies to expand float production in Ramenskoye, Russia.
L
TEMPERING LINES On Belt & Spindles
Domestic Domestically, the largest Russian company in the clear float glass market is JSC Salavatsteklo, which also owns 100% shares of JSC Saratovstroysteklo, another large float glass manufacturer. Between them, these two companies produce about 70 million m2 of glass each year. Each company has two furnaces for float-glass production, 4 lines in total, including flat float-glass, low-E glass, solar glass, multifunctional glass, automotive glass, structural tempered and laminated glass, double glass panes, glassware, soluble sodium silicate and liquid sodium glass. The recently opened Caspian Flat Glass plant is another domestic producer. Caspian’s plant, located in Dagestan, Russia, became operational in 2013. The glass plant produces 600 tons of energy-saving glass per day, and has recently signed a letter of intent which provides for the delivery of approximately 100,000 tons of glass per year to the South Caucasus republic of Azerbaijan. According to Abakar Mudunov, the Executive Director, plant specialists are also studying the possibility of supplying flat glass to Kazakhstan and Georgia, as well as Iran and South Russia. Glass International May 2014
Conta Cont tact c us u : vidromeca ecanic niica@vid ca@viidromeca ecan aniica.c ca com o www. w.viid dr om meca ecan aniica.c ca com o Tel: T Te el +3 +351 35 51 24 44 4 55 555 55 060 0
Country focus: Russia
Russian industry reaps the benefits of modernisation The GUM shopping centre located in Red Square, Moscow.
Theresa Green* delves through the British Glass library to summarise recent developments in the Russian glass market.
www.glass-international.com
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22
he British Glass library holds a collection of information concerning all sectors of the glass industry spanning some 100 years of history. It’s an Aladdin’s Cave for anyone looking for glass-related information – from technological achievements in glass making, physics and chemistry, compositions, art work, recycling, company histories, mergers/acquisitions and much more. Members of British Glass can take advantage of the information in two ways – either a data search can be carried out electronically, with the results provided in a matter of minutes – or, the library can be booked by appointment. This article aims to provide you with an example of the kind of information that can be found in the library, focussing on a recent data search that was conducted using just two key words: ‘Russian markets.’ Industry statistics are important and, among other things, can help companies to stay ahead of their competitors. The information can be Glass International May 2014
rather sketchy, due simply to the fact that there are so many (conflicting) reports in circulation. However, for the purposes of this article I have rounded up the data in order to provide a best guess as to the situation today.
Russian glass industry The Russian glass industry began to modernise during the last 20 years as globalisation, climate change, demographic change and new technologies emerged. These trends have altered customer needs – with demand for flat and container glass increasing. However, this has led to challenges for glass manufacturers as they modernise production equipment in order to home in on market trends. The growth of the Russian glass industry has been above expectations both in terms of value and volume in the past five years. The latest market reports indicate that the glass industry in Russia is set to grow enormously, having hit a US$10 billion-revenue mark in 2013.
Between 2000 and 2011, the annual growth of domestic glass production (all sectors) was 11%.
Flat glass Demand trends in the flat glass market are shaped by the pace of economic development as well as the legislative and regulatory landscape. Bringing the Russian flat glass manufacturing sector into the modern world has led to challenges for some manufac-turers – the industry really did need to modernise in order to produce high quality float glass to enable it to adapt to market trends. Flat glass is produced using two manufacturing methods – float and rolled glass techniques. Float glass accounts for continued »
Country focus: Russia
Container Glass Compared to its flat glass counterpart, the Russian glass container industry is growing faster due to the rise in disposable incomes and increased consumption of beers and packaged foods. The container glass sector in Russia is a relatively modern industry. Many glass makers have successfully invested in new technology such as lightweighting and can provide sophisticated decoration techniques. Since 2007, 18 new factories have been built. The industry today comprises around 40 manufacturers in total, dominated by Ruscam (Anadolu Cam Sanayii parent) and Rusglass with ten sites between them. Total production is currently estimated to be around 8 million tonnes/pa, but this is expected to increase as new plants come on-stream. The latest newcomer to the industry is pharmaceutical glass manufacturer Voronezhmedsteklo. This project – which is still in the construction phase – is one of the largest pharma-glass enterprises to enter the market in the last few years. When complete, it is thought that it will top a massive 17.5 million tonnes per annum of vials, ampoules and bottles with an investment of 3,500 million rubles. Although return on this investment will take almost five years, the possibility for exponential growth beyond that is substantial, as long as sensible market pricing policies are adhered to. With the additional investment from JSC International Potash Company, it hopes to move to its own raw materials base eventually. However, although this looks like a recipe for success – wellfunded, and well-thought through - some partners at the Institute of Experimental Economics and Finance (MSU) believe that although the investors have chosen a ‘promising line of business,’ it is the scale of the investment that is of concern. Time will tell.
Summary I hope you have gained an insight into the unique collection of material that is available from UK trade federation British Glass. Glass industry information can be notoriously difficult to find. Our Library and Information Service is open for members to use freely, however, we welcome enquiries from anyone searching for that piece of glass-related information that is particularly difficult to find.
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the predominant share of overall demand. In contrast, rolled glass accounted for only around 8% flat glass demand during 2012. Library records indicate there are currently 24 float glass manufacturing facilities operating in Russia. We estimate that these 24 manufacturers produce some 4 million tonnes/pa. However, seven of these sites have been built since 2007 and are new, state-of-the-art factories, providing capacity of approximately 2 million tonnes. In addition, automotive glass demand is booming as Russia’s car sales increased by 11% to 2.9 million vehicles in 2012. Sales of value-added flat glass products, including solar control and coated glasses are also growing at a much faster rate than standard float glass products. The latest float glass factories all feature new coating plants.
23 Glass International May 2014
LESS EMISSION. BETTER PERFORMANCE. THE EME-NEND® BATCH CHARGER.
NEW GENERATION OF BATCH CHARGER INTRODUCED
The new EME-NEND® generation features chargers with one, two or three screws. Small melting furnaces can now enjoy all benefits of the world´s best charging technology. In addition the charging performance and lifetime was increased again.
• Completely sealed Doghouse • No uncontrolled entry of false air into the furnace • Reduction of NOx emissions and of energy consumption • Considerably less dust formation due to the transport by means of screw conveyors • Optimal batch distribution in the glass melting • Quick and easy exchange of the screws • Even huge melting furnaces can be operated with one charger and a single doghouse
EME Maschinenfabrik Clasen GmbH • E - M a i l : c o n t a c t @ e m e . d e • w e b s i t e : w w w . e m e . d e
Energy efficiency
A fair exchange Ardagh’s glass unit in Limmared.
Steffen Seehausen, Group Sustainability Manager for the Ardagh Group, describes how one of its plants is helping to heat neighbouring homes, and how this project forms part of the company’s ongoing sustainability programme.
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esidents of the small town of Fensmark (population 4,200) in the centre of the east Danish island of Zealand have more than one reason to feel proud of their largest employer, Ardagh Glass. In addition to providing jobs and creating wealth for its local community, our Holmegaard plant, which produces 160,000 tonnes of container glass each year, equivalent to nearly 700 million bottles and jars primarily for the beer spirit, wine, non- alcoholic beverage and food sectors, is contributing to reduced price heating for more than 1000 local homes. In a scheme run jointly with Danish energy provider SE Blue, surplus heat from our glass production is piped from the factory to an accumulation tank, able to store 100MWh of heat from where it is piped into the local district heating plant’s system and on to homes in Fensmark (Fig 1). It is one of a number of district heating projects that Ardagh Glass has engineered over the past few years. The first one was installed in the early 1990s at the company’s factory in Lünen in northwest Germany, where steam generated from the plant’s waste heat is still being used to produce heat for the municipality. A similar scheme has been running from 2010 at the company’s Limmared plant in Sweden.
Winning all over Europe All these local authorities are tapping into a valuable source of waste heat in what can only be described as a classic ‘win win’ opportunity. In Europe as a whole, with almost 50% of the final energy consumption being used for the heating needs of buildings and for domestic hot water production, the search has intensified to find alternatives to fossil fuels. Alongside energy efficiencies, such as increased insulation and improved building design, renewable heating sources are becoming an ever more useful means to enable countries to become less dependent on imported energy and contribute to the EU’s climate change objectives. The fundamental idea behind modern district heating is to recycle this surplus heat which otherwise would be wasted into an energy source for space heating and warm tap water. In situations such as glass manufacturing, the energy used to fire the furnaces is set free in the form of surplus heat.
Steffen Seehausen, Group Sustainability Manager for the Ardagh Group.
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25 Glass International May 2014
Energy efficiency
Fig 1. The heat exchange installation at the Ardagh Glass plant in Holmegaard.
Fig. 3. Quality cullet
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Sustainability is a journey rather than a destination, and it is one that Ardagh Group has been following for some time. Fig 2. Fensmark.
District heating means a system supplying heat produced centrally in one or several locations to a nonrestricted number of customers. It is distributed on a commercial basis by means of a distribution network using hot water or steam as a medium. District heating systems can vary substantially in size, from systems supported by local manufacturing operations supplying a few hundred or thousand buildings to systems that supply entire capital cities. In Europe, there are now more than 5,000 district heating systems, and the market share of district heat is about 10% of the heating market. More than 50% of the European district heating market can be found in the Northern & Eastern part of Europe (Germany, Denmark, Poland, Czech Republic, Finland, Russia and Romania).
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Holmegaard
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Although the use of recycled glass (cullet) in our furnaces has reduced the amount of energy required by the manufacturing process, the glass melting operation still generates a lot of heat that is discharged through the chimney. For some time Holmegaard’s management, as part of its corporate social responsibility target, has been considering how to put this heat to productive secondary use through a renewable energy programme. Now, thanks to an arrangement with Glass International May 2014
SE Big Blue, part of Danish energy group SE, a substantial part of this heat can be captured and used to heat homes in the neighbouring district. The waste heat, which is captured by indirect thermal energy exchange from our furnace flue gas, produces steam from water, which is then utilised in our internal process as well as being transferred to the local neighbourhood. New flue gas ducts were installed with bypass capabilities. The boiler and heat exchanger, placed after the E-filter, heat exchangers, pumps and pipeline installed between the Holmegaard plant and the heat district company, produce waste heat from the flue gasses that is converted into district heat (Fig 2). The heat-exchanger will be able to produce 18,000MWh/year. Approximately 14,000MWh of this energy will be sold to the heat district company, which constitutes 65% of the district heat requirements of Fensmark’s 5000 residents. The new system will also reduce CO2 emissions by 3300ton/year, due to a reduced use of gas for traditional gas boilers. Ardagh’s Henrik Bonné, Plant Director at Ardagh Glass Holmegaard, said: “The district will receive a secure supply of cheaper energy from one of its largest employers, a case of neighbour helping neighbours. It is good for the environment, as, against a traditional gas boiler heating process, it saves at least 3300 tonnes of CO2 a year, the
”
equivalent of taking 400 cars off the road. “In addition, the money we earn from the 18,000MWh we sell, helps to offset the cost of our investment. “Our aim with these energy-efficiency measures and utilisation of surplus heat internally and externally via Fensmark Fjernvarme (district heating provider) is an improved bottom line from the 18,000MWh we have to sell. “But we are also the biggest company in the area, with roots that go way back in time. That’s why it’s also a matter of protecting Danish jobs. SE Big Blue has really delivered the goods – not just in the form of consultancy, but also by taking responsibility for the total contract. The result is absolutely what we expected, and the future holds even more potential for further measures.”
Dongen and Limmared Holmegaard is the latest of a number of environmental projects and trials within Ardagh. Our facility in Dongen, The Netherlands, together with Coca-Cola Enterprises, recently launched a new heat exchange pilot programme. Residual heat from Ardagh’s glass furnaces is being captured and used to supply heat-driven processes at CocaCola’s neighbouring factory. The initiative is expected to provide a
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Energy efficiency
Sustainable The projects described above form part of Ardagh’s integrated and ongoing sustainability programme.
In an introduction to Ardagh’s latest Sustainability Report, which covers ongoing initiatives from all parts of the company’s worldwide glass and metal packaging operations, the approach was described as: “Sustainability is a journey rather than a destination, and it is one that Ardagh Group has been following for some time”. Ardagh Group, which has a turnover of €4.2 billion and employs more than 18,000 people, defines sustainability as “not only delivering a reduced environmental impact but also achieving sound economic performance and making a positive social contribution.” The emphasis has always been on “taking a proactive approach to identify and minimise any economic, environmental and social risks that may affect the business.” The company’s aim to be the leading supplier of inherently sustainable packaging is exemplified in the case studies that feature in the 2013 Report. The installation of heat exchange technology for district heating is one of several important projects that form part of this programme, which also includes improved cullet separation and improving the quality of recycled glass and recycling
education in schools (Fig 3). Another key measure that the company has taken to emphasise the importance of environmental sustainability from a business strategy point of view, includes the implementation of an environmental indicator – the GoGreen Index (GGI). “We use sustainability targets in our long term strategic planning to ensure that we reduce any negative environmental impact whilst remaining economically sustainable and socially responsible,” says Ardagh Glass Europe CEO Johan Gorter. He adds: “The manufacturing of products and creation of value to satisfy global demands are inherently linked with social and ethical as well as environmental impacts and challenges and will increase further unless we significantly change our culture and mindset.” The projects described in this article form part of a systematic and planned journey that is gradually changing both the culture and practices within the organisation as it strives to meet these challenges.
Ardagh Group, www.ardaghgroup.com/
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sizeable proportion of the energy required for Coca-Cola’s processes and thus reduces overall carbon emissions. This pilot project is currently ongoing, and on completion, the results will be analysed to give an accurate measure of the amount of energy and associated carbon emissions that can be saved on an annual basis. A small community of around 5,000 people in the municipality of Tranemo in Västra Götaland County in western Sweden, are benefitting from the waste heat generated by the furnaces at Ardagh’s Limmared facility as a result of another innovative energy-exchange installation on site. Since 2010, homes, businesses and schools now receive up to 100% of their hot water and heating requirements via the exchange, at a reduced price of approximately 50% (compared with alternative supplier E-ON). The heat exchanger also provides all the building heat requirements and hot water to the Limmared facility.
27 Glass International May 2014
Energy efficiency
Cash from hot air
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staggering amount of energy is required for the production of glass. Although the industry has now become relatively efficient in its primary production processes, there is still a great energy potential being lost through the chimney. Much better use could be made of this energy. “As an energy efficiency manager, the very thought of this is painful to me,” Michael Terhorst states, referring to his view on factory flue discharging unexploited waste heat into the atmosphere. The Key Account Manager from Spie Energy Solutions is responsible for helping glass industry clients around the globe save cash. His approach: “We take a huge volume of waste heat which leaves the factory virtually unused and turn it into usable energy.” The priority is always to reduce the client's existing natural gas or electricity consumption, while also making their energy requirement and energy costs more calculable. The technical principle behind all this is relatively simple. “We install waste heat recovery boilers before and after the exhaust gas purification systems. In Glass International May 2014
these boilers, the hot air is converted into usable energy such as hot water, steam or thermal oil”, Mr. Terhorst continues. To ensure that the pressure in the glass melting furnace remains constant, special components are installed, so that the production process is not adversely affected.
Public relations The top priority for utilisation of waste heat is to guarantee that the glass production process continues to run smoothly. The use of heat from the exhaust gases is of secondary importance. From countless discussions and visits with glass producers, Mr. Terhorst knows that: “In the primary processes, the branch already makes sophisticated use of the energy consumed. However, the secondary processes still pose a gigantic and generally untapped potential.” His experience from previous projects gives an air of optimism. Clients are generally open for technical innovation and, as a particularly energy-hungry sector, the glass industry is highly interested in employing sustainable
Michael Terhorst* discusses methods of utilising waste heat in the glass production industry. technology to limit its energy requirement. As Mr. Terhorst explains, “This not only saves money but has also become a key factor in public relations.”
Hot exhaust gas In principle, there are a wide range of uses for this hot exhaust gas: Power generation, feeding into heating systems, or the generation of chilled water. “These are individual modules which can be used alone or combined,” the energy expert explains. The variant which is most suitable for his client depends on a range of factors: “Each company has different requirements but there are two decisive questions: Can I use the energy acquired usefully, and is the investment worth it?” Profitability is the key to everything, and this depends not only on the size of the production site or on the direct environment. The profitability of investments such as these can also differ widely between countries. Before installation of the technical equipment to improve the energy-
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Energy efficiency
efficiency, Michael Terhorst and his team perform a detailed analysis, checking the processes and ambient production conditions for any untapped potential. The most important thing: “We guarantee our clients fixed energy savings.” The only question is in which area of the company these will be found, and how high they will be.
Huge savings The most logical source of potential savings and the cheapest is to feed the energy discharged by the waste heat boiler into the heating network of the company. “A neighbouring office block or adjacent production hall can be easily heated with the heat available.” As Mr. Terhorst explains, the exhaust gases are cooled so that condensation in the chimney can be still further excluded. This simple waste heat recovery model can of course be developed even further. One example of this is the integration of an absorption chiller for the production of chilled water. “In this case, we expect – assuming an average size of the glass melting furnace – that two to four megawatts of refrigerating capacity can be generated from the waste heat,” Mr. Terhorst calculates. “We can even feed the excess heat into a nearby district heating network,” Mr. Terhorst continues. With payment at normal market prices, the energy supplier receiving this service becomes another customer. The energy present could supply more than 250 households with heat: “If a housing estate is situated or planned locally, this provides a great opportunity for using the energy.” However, the hot air from the exhaust gases can also be used to generate power with the help of steam or thermal oil. As Mr. Terhorst explains, “This electricity can then be used on a ratio of 1:1 in the production process, and you can save the expensive procurement of this power on the market.” The outcome of this enhanced efficiency: Depending on their underlying conditions, companies can expect to save around €600,000 (US$827,000) a year in energy costs, and approximately 6,000 tonnes of CO2 per annum. “We also offer interesting financing models which, like the technical specifications, are tailored to the specific requirements of our clients”.
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Glass melting
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More use can be made of waste heat, saving companies money.
29 Glass International May 2014
Forming
Nampak Glass puts its faith in BIS South African glass manufacturer Nampak Glass recently invested in a second BIS machine from Bucher Emhart Glass. We find out why BIS is making so many waves in the container glass industry.
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ontainer glass manufacturing is a fantastic industry to be in, but most would agree that it’s also a fairly conservative one. New technologies don’t come along every day – and when they do, glass producers can be slow to adopt them, often preferring to stick with what they know. On top of that, the present economic conditions are hardly conducive to bold capital expenditure outlays. So when a leading glass plant buys two machines from a new line in quick succession, it’s time to sit up and take notice. And that’s exactly what has happened at Nampak Glass of Roodekop, Guateng, South Africa, where the second of two Bucher Emhart Glass BIS machines recently began production.
Quality demands Nampak Glass was founded in 1984 and produces glass for industries including beverages and food, serving customers throughout South Africa and Africa. “We’ve recorded growth over the last few years, despite a challenging economy and pressure from alternative packaging such as PET and aluminium cans,” stated Stoney Steenkamp, Nampak Glass’ Managing Director. Glass International May 2014
“As a growing business in a tough market, also dealing with an everdeclining skills base, we needed a machine that could meet our customers’ increasing requirements in terms of quality, while still remaining flexible. We’re a diversified firm, and we need to produce a range of glass containers across the industry.”
Enter BIS As Nampak reviewed the market, BIS soon emerged as the front-runner that could put a tick in all those boxes. It’s the latest addition to Bucher Emhart Glass’ range of IS machines, and the first new machine type since NIS was introduced in 2000. Like NIS, it offers the precision of a fully servo-controlled machine, but is designed to handle many container designs, sizes and weights, in smaller quantities and with quicker job changes. BIS is ideal for manufacturing containers for every industry, from beverages and baby food through to pharmaceuticals. BIS was originally announced in 2010 and successfully prototyped in 2011. It uses the parallel mould open/close technology pioneered on Bucher Emhart Glass’ AIS machines and is available in six-, eight-, 10- and 12-section configurations. The first machines
handled doubleand triple-gob production is now available. Going forward, a quad-gob version will follow.
Built for the modern world Throughout its long history, Bucher Emhart Glass has made it a priority to understand the needs of glassmakers, then create the machines and technologies that can meet them. BIS is no different – it’s a machine developed specifically for the demands of today’s industry and the economic climate in which it operates. The decision to invest in a new forming machine is one of the biggest and most difficult that a glass-plant manager will face. Internally, they need to be sure that the new machine will fit in the available floor space and interface with their existing furnace and inspection lines. The skills of the workforce are another factor. The key question is how to invest, based on the specific business case in order to deliver the maximum benefit. For glass-forming machines, the time horizon of that decision is as long as ten or even 15 years, making considerations of whole-life cost particularly important.
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Forming
Decisions taken now will have to sustain the business, both operationally and commercially, through whatever happens over the next decade or more. Meanwhile, the external pressures on plant managers continue to mount in every area: Cost, performance, flexibility, quality and safety. Brand owners want greater differentiation in terms of the packaging for their product, and they want their new products to reach the market more quickly than ever. But they’re naturally unwilling to compromise on quality – and are always looking for the most competitive cost per container too.
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Best way forward
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For Nampak Glass, BIS was the only way to solve this challenging equation. “We chose BIS not just because it could deliver everything we wanted, but also because the initial capital investment required was relatively affordable,” explained Stoney. “In fact, it’s not an exaggeration to say that BIS represents a revolution for us. Previously, this level of technology would have been beyond our reach because of the high capital cost, as well as the inflexibility in terms of options available. BIS has changed everything.” Having instantly seen the benefits of the new technology, Nampak was the first company in the world to purchase a BIS machine, and began operating its 0batch line in May 2013. “The installation went really well, with relatively few problems and a very smooth startup,” recalls Stoney. “That was the result of the careful planning carried out by Bucher Emhart Glass, as well as their detailed reviews prior to installation. The support from both operational and senior personnel was outstanding, and the training provided for our local people was fantastic too.” The machine was unveiled at an open house event last October, attended by more than 20 Bucher Emhart Glass customers interested in seeing the machine in production, inspect manufactured wares first-hand and hear from Nampak’s staff about their positive experiences with the technology so far. For those involved directly in production, the benefits include higher performance, a more stable production, faster and easier job changes, easier cleaning, ergonomic operation, improved operator safety and reduced noise. Owners and managers, meanwhile, are likely to appreciate BIS’ Glass International May 2014
improved speed and reliability, superior precision and process control, reduced energy intake and overall lower cost of ownership. For example, BIS’ faster job changes and workouts alone could deliver a saving of around €70,000 per year as compared with a similar IS line, while increased mould lifetime could save as much as €200,000 per year.
Real benefits Stoney is clear about the benefits delivered by Nampak’s new BIS machine. “It has brought us improved flexibility alongside a new level of product quality,” he stated. “It is now much easier for us to optimise our production process, and we’ve also reduced our energy consumption. Mould lifetime has improved substantially, and we’ve been able to de-skill our bottle-making to some degree too.” In March 2014, Stoney made the trip north to Bucher Emhart Glass’ Sundvall manufacturing plant, where the firm was hosting a ‘BIS Day’ dedicated to giving current and future customers more information about the young technology. The event was attended by a total of 41 guests, including delegates from leading names in the glasscontainer world such as Gerresheimer, O-I, Allied and Verallia. Guests were welcomed by Werner Gessner, Bucher Emhart Glass’s VP Sales, before Site Manager Catrin Forsberg introduced the Sundvall operation. Stoney then gave a presentation sharing his thoughts on Nampak’s first ten months of production using BIS. Over the rest of the day, delegates enjoyed a range of demonstrations as well as additional presentations on BIS and its benefits from Bucher Emhart Glass staff. The complete BIS 12 section DG 140mm running at 20 cycles, and the fully equipped prototype section in TG 95mm working at 24 cycles, demonstrated the impressive BIS capabilities.
The time has come “We feel very strongly that BIS is a technology whose time has come,” stated Leo Diehm, Director of Product Management. “If we look at the history of IS machines since 1925, development falls into three clear phases. First we had pneumatic motion controlled by a timing drum, which lasted a long time
but finally faded out, and was succeeded by electrically controlled pneumatic motion, which originated around 1980. The new servo IS standard has started to replace pneumatic IS machines, as happened in the past with the good old timing drum. Within a few years, servo IS machines will become the standard.” Servo control opens up levels of accuracy that couldn’t be achieved before. With pneumatic motion, each individual IS section was a ‘personality’ that had to be coaxed to peak performance by a skilled operator. With servo mechanisms controlled by modern technologies such as Bucher Emhart Glass’s FlexIS system, the motion of the IS line is repeatable, precise and controlled – and the benefits are clear. “BIS easily outperforms pneumatic IS machines built on 5” section frames,” stated Leo. “It allows glass-container BIS Technology
manufacturers to cut container cost without compromising on quality or ware range.” Based on the success of its first BIS purchase, Nampak quickly decided to purchase a second machine, which was delivered this Spring. As Stoney Steenkamp explains, the decision wasn’t difficult once the results of the first installation were clear. “BIS fully delivered on the original brief we gave Bucher Emhart Glass. On top of that, the ongoing support has been of a high standard. Even one year after installation, the after-sales support is still excellent. Overall, it was an easy decision to make!”
*Bucher Emhart Glass, Cham, Switzerland www.emhartglass.com Nampak Glass, Gauteng, South Africa www.nampak.com/glass
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Forming
SpeedLine ware handling for efficient production Wilfried Seidensticker* describes the importance of ware handling for ambitious productivity and quality results.
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o obtain high results in production you need good forming techniques, as well as a modern ware handling system to meet increasing speed and precision demands. Ware handling itself begins with the pusher system, which transports containers from the dead plate to the conveyor belt. The transport of hot containers benefits from an improved motion profile, which is one of the benefits of Heye International’s high-speed pusher type 2158. The optimised motion profile results in a parallel pusher movement to the conveyor belt. The new pusher type, replaces the former version 2155 and combines high speed with long-lifetime and less parts. Many parts are also used in the 2157 series with 2-axis for standard applications. The servo-direct drives reduce maintenance efforts, and for large plants with many production lines the modular design renders a quick conversion from right-hand to left-hand operations. A further advantage of the high-speed pusher is easy job change. Mechanical setting is no longer necessary, for example for the manual adjustment of cylinder stroke. Thus, a large part of possible disturbances and inaccuracies in the production process are essentially excluded. Conversant and approved parameters can be reproduced when running a job again which, in turn, ensures a smooth start-up after a job change. The geometry of the pusher mechanisms can be considered a ‘constant’. By setting defined parameters Glass International May 2014
controlling the motion profile, the system set-up almost becomes a constant when running a job again. Thus, incorrect settings can be excluded after a job has been successfully run once. The high-speed pusher can be implemented on machines with a large number of sections, in double, triple or quad gob operations.
High performance ware transfer The accurate ongoing transport of containers is assured once the highspeed pusher has precisely positioned them on the machine conveyor. Heye International’s high performance ware transfer type 4220 (with two parallel running conveyors) makes use of a simple but important principle that is also well known by motor sport racing drivers: Reduce speed when turning (direction change) and then speed up again. Centrifugal forces that also affect containers in ware handling processes and make them unstable are reduced. The containers perform direction changes in a smooth and even motion sequence. By reducing centrifugal forces and implementing a modern drive system (Simotion) with constant and reproducible parameters, the transport of containers at this critical point is managed successfully.
Accurate lehr loading Once containers reach the cross conveyor, it is critical to avoid negating the advantages achieved when pushing ware into the annealing lehr. Here too, lehr loaders driven by servo motors and equipped with up to three independently driven axes operate high-speed production lines. The modern and reliable Simotion
drive system provides parameters that can be reproduced precisely for each production run, once properly determined. In addition to these technical accomplishments, the question of how to pay off investments remains. This question can certainly be answered by model calculations. However, it makes no sense to implement the latest technologies from batch house to production machinery, before increasing rejects due to poor ware handling. Every high-class article produced properly but rejected during the ware handling process reduces turnover and profit.
*Hot End Product Manager, Heye International, Obernkirchen, Germany Tel: +49 5724 26 452 Email: marketing@heyeinternational.com Web: www.heye-international.com
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Forming
Forming solutions for the Narrow Neck Press and Blow process Adam Neupert* outlines a number of solutions to overcome the problems associated with the NNPB process.
determination, patience, and the right people and tools. Overcoming the blank side forming problems of the NNPB process is one of the foremost goals of Quantum Engineered Products, Inc. Its Forming System is innovative, proven, and reliable for producing NNPB containers. The forming equipment and techniques supplied by the company, remove the inconsistencies from NNPB blank side forming. The features of the system are designed to counteract the challenges production staff will be confronted with when operating the Narrow Neck Press and Blow Process.
Automatic gob weight control An important requirement of successfully producing NNPB containers is gob weight consistency. To achieve peak production efficiencies the glass temperature must be homogeneous and the gob weight accurate and consistent. An automatic gob weight control system should be considered for all production lines operating the NNPB process. Quantum meets this demand with its Total Forming Analysis (TFA). The system automatically controls gob weight through adjustments to the feeder tubes or individual needles by an increment dependent on the final position of the forming plunger. This
Fig 1. Quantum’s gob mechanism.
creates an accurate gob weight. The TFA holds average weights of +/0.5 grams on Narrow Neck containers. In many instances the TFA performs even more accurately. For example, it is currently achieving +/- 0.3 grams on a pharmaceutical production line in Europe. Although the performance of the TFA depends upon the final position of the plunger, it has the ability to visually display the entire stroke of the forming plunger. Currently, the user can see up to 8 ¼” (209.55mm) of the piston rod stroke. This opens up the possibility of blank side process control. The TFA can display many common NNPB production problems including required air pressure
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he Narrow Neck Press and Blow (NNPB) process was introduced to solve uneven glass distribution problems that are created using other methods of production. The NNPB process provides the greatest possibility for lightweighting narrow neck containers. By mechanically forming the parison, glass distribution is controlled and the result is a finished container with a more even wall thicknesses. Compared to the conventional Blow and Blow Process, manufacturers can achieve a final product that is around 30% lighter. Reducing container weight, while still keeping a high level of mechanical strength, offers incentives including higher energy efficiencies, raw material savings, and a decrease in logistics costs. There are many benefits to adopting the NNPB process, but there are also challenges associated with operating successful NNPB production. When running NNPB, a manufacturer must achieve tighter tolerances in all phases of operation. The word ‘narrow’ is used to refer to the finish dimensions of the containers being produced, but narrow may also be used to describe the required parameters of the NNPB process itself. From proper dosing and mixing of the batch, all the way to palletising, perfecting the NNPB process requires
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Forming
adjustments, machine alignment issues and forming equipment damage.
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Increased cooling efficiencies
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Once gob weight consistency and glass temperature homogeneity are achieved, the manufacturer can then focus on other criteria for a successful NNPB operation. There is a common feature within all Quantum cylinders that proves its value in all processes; Blow and Blow, Press and Blow, and especially Narrow Neck Press and Blow. That feature is an increased cylinder cooling capacity. One of the main principles in making container glass is ‘the controlled removal of heat from the glass.’ The NNPB plunger has a large surface area that contacts the glass. Keeping the plunger cool is important in maintaining high quality containers. A plunger that is not properly cooled becomes hot and disrupts the heat removal process, which causes container defects. Quantum’s individual cylinders are equipped with multiple design features that solve overheating issues. The cylinders have an air pathway that is free flowing, and it generates a uniform turbulence free air delivery system for plunger cooling. The pathway provides cooling air that has a higher velocity and volume compared to competitive systems. By increasing the plunger cooling air efficiencies, NNPB producers can eliminate overheated plungers which can directly cause ware defects such as split finishes, hollow necks and blisters. Improving plunger cooling can also extend the life of the mould equipment itself. Running hot plungers can cause the overlay material to chip and delaminate from the base material. These chips can be transferred to the parison which can create low bursting strengths in the finished ware. Hot plungers can also experience dimensional growth causing poor guide ring clearance that leads to stuck plungers and machine downtime. To take full advantage of an increased cooling capacity there becomes a need to also improve the exhaust system. It is important to exhaust the heated air from the cylinders as quickly and efficiently as possible. The faster the exhaust air is removed from the NNPB process the easier it is for the cylinder to ‘breathe’ and continue performing at a high level. The problem for some forming systems is that the exhaust systems are not optimised for Glass International May 2014
the best possible airflow. All of Quantum’s individual cylinders are equipped with dual upward exhaust. The exhaust system is designed around a chimney effect where the heated process air is evacuated out of the top the cylinders. This system is beneficial because the exhaust pathway is shorter and the heated air never contacts the critical parts of the lower cylinder.
Multistage cooling Quantum’s plunger mechanisms and process equipment rely on a principle of a completely sealed operating system. The cylinders are equipped with TubeWithin-A-Tube (TWT) technology and sealing features that enable plunger cooling to operate throughout the entire forming cycle. In traditional Press and Blow production the plunger cooling air operates in an On/Off sequence. The cooling air is stopped during gob loading and pressing to avoid problems associated with ‘blow-by’ reaching the
with the other mechanisms on the machine. The plunger foot, base plate and alignment plate are all designed to have float while aligning the mechanism. This float along with its alignment procedure gives the IS operator comfort in knowing that the blank side forming equipment is perfectly centred. It should also be mentioned that the Quantum Plunger Mechanism does not require realignment when changing jobs. The permanent alignment plate and base plate design ensures the mechanisms alignment stays true even when converting gob configurations. There is also a small amount of float in the preceding sleeve of Quantum’s Narrow Neck Positioner. This float compensates for any neck ring movement during revert. The sleeve extends over the top of the plunger positioner and it fits inside the neck ring making sure that a precise alignment of the blank/neck ring and
Fig 2. The Total Forming Analysis display screen.
glass. The sealing technology of Quantum Forming eliminates blow by and facilitates the ability to run 360 degree low pressure cooling. The plunger can be cooled during the maximum glass contact times of loading and pressing. The benefits of shifting from traditional cooling to multi stage cooling are numerous. For example, production obstacles of thermal shock to the plunger and cooler, increased air pressures and plunger sticking can be all eliminated.
Proper machine alignment Proper machine alignment is critical for producing quality containers in the NNPB process. Many common ware defects can be attributed to simple alignment issues. The Quantum Forming System provides operational alignment by design, not by installation or set up. From the plunger foot up to the blanks the Quantum alignment procedure ensures accurate alignment
plunger mechanism is provided during every cycle. During the pressing stroke the plunger runs entirely inside the sleeve and allows for a smooth ‘jerk’ free pressing action. Correct alignment of the plunger mechanism with the blank is essential for good operation. The list of challenges and obstacles that will confront NNPB producers is long. Perfecting the process takes time, hard work and dedication. In the future it will be up to a global coalition of researchers, suppliers and manufacturers to continue to advance the process. Quantum Engineered Products will focus its efforts on defining a reliable NNPB blank side forming system. Its success will be driven by the needs of the customer and its vision is to remove the challenges that hinder a successful NNPB production.
*Sales and Marketing Coordinator, Quantum Engineered Products, Inc. www.quantumforming.com
Glass technology
Smart monitoring tools Mobile technologies are re-shaping the way people track information and make decisions. While many of us already use this technology daily for things such as travel bookings, banking and car rental, this article argues that the same mobile, web-based technology can re-shape the way the glass industry conducts its daily business, tracks productivity, quality and service performance.
T
he trend towards ever greater mobility is unmistakable: Demand for mobile applications and mobile devices is exploding, outpacing demand for traditional ITsolutions. The trend is best demonstrated by the rapid rise of Google, Cisco, Apple and Samsung, outpacing traditional ITleaders such as Microsoft and Dell. Be it individuals, corporations or governments, all seek greater flexibility and efficiency in going about daily decisions, and decision making comes easier with access to the right information. LTE gateways enable every consumer electronic device with embedded WiFi capability to broadly access the internet. The rapid increase in internet density and access is expected to have major impact on industrial productivity.
Opportunity Here at Tiama, we believe that ITmobility offers a number of opportunities for the glass industry. Smart monitoring is already common place in the travel, logistics, learning and media sectors where order entry, order tracking, performance benchmarking and payments are tracked on-line, reducing layers of administration and delays. Similar practices, may apply to the glass industry. A good analogy is real-time information on free spaces in city car parks. With such information available on navigation dashboards, car drivers need less time to find a parking space, less fuel wasted on ‘driving around’ and less time wasted searching for a parking space. Similarly, information available on capacity and the performance of a plant or a certain job can help optimise order
planning with ever less downtime and administrative iterations. A manager may decide to access his factory’s data ahead of an important client meeting, for capacity availability or the assessment of latest service levels.
Solution Tiama supports access to decisional information through Tiama IQ Track. As a web-based, mobile software solution, Tiama IQ Track unlocks access to key performance metrics in a focused and timely manner – anywhere, anytime – the goal being to facilitate decisions that are fact-based and aligned with the company’s goals. Faster decision making is ever important in an industry where a few percentages of efficiency (Pack-tomelt) make the difference between profit and loss. Because of scarce resources, costlier raw materials, fewer defects and idle time permitted, Tiama IQ Track visualises and highlights performance by the minute, instantly. Instant visibility of metrics from the batch plant to the warehouse, including utilities, provides a comprehensive view of the opportunities and issues at hand. With over 50 years of experience in quality assurance, Tiama witnesses time and again the challenges faced by managers who
go about daily decision making. By tracking the company’s key metrics, Tiama IQ Track serves to focus and ease fact-based decision making.
Conclusion Management is about getting things done. Only what gets measured gets done. Access to key performance metrics facilitates decision making, making it easier, fact-based and focused. Tiama IQ Track is a solution that serves such a purpose. As a web-based, secure application, Tiama IQ Track applies mobile, internet communication towards leaner management i.e. better and faster decisions. Physical distance from clients and suppliers will always present challenges, however internet based mobility will help mitigate its effects substantially.
* Tiama msc & sgcc www.tiama-inspection. com/
The Tiama IQ Track as displayed on a tablet and smart phone.
39 Glass International May 2014
Environmental protection French Consulate in London.
that has the appearance of the original material without exploiting the earth’s limited natural resources. The ‘printed natural materials’ do not face the same risks of deterioration as the actual natural materials as the ceramic inks are baked into the glass, making the design extremely durable and resistant to scratching, chemicals and weathering.
Reduced external temperatures of buildings Increasing temperature in our cities is a form of pollution that urban populations face. Sun reflection from buildings is a contributing factor to the rise in temperatures. Digital ceramic glass reduces this phenomenon with the option of printing on the external side of the glass. The images or patterns that are printed on face one reduce reflection of the light from the building into the surrounding environment, thereby reducing its contribution to ambient temperatures in cities.
Reduced bird collision
Eco-friendly benefits of digital ceramic printed glass Architect Dan Schechter* shares the top eight ways that working with digital ceramic printed glass helps the environment.
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n the face of global warming and rising costs, architects, developers, and consultants are increasingly seeking sustainable and green materials. Digital ceramic printed glass is a material that is eco-friendly and also provides functionality and endless design possibilities, making it an ideal material to support sustainable architecture.
Optimised energy requirements Opacity, translucency and ink layer thickness can be precisely manipulated when digitally printing on glass. This provides an ability to control the shading coefficient, which controls flow Glass International May 2014
of natural light and heat. With this information in hand, and with the help of the latest software, it is possible to measure and predict the temperature of the interior of a building while still in the planning stages. This data allows architects, contractors, and developers to minimise the costs and size of air conditioning and lighting systems also reducing daily operating electrical costs.
Replication of natural materials Stone, marble, wood and other natural materials are easily replicated through digital printing. The final result is glass
An estimated 100 million birds die each year in North America alone due to collisions with glass. Digital ceramic glass printing can help our winged friends stay safe while still achieving aesthetically pleasing scalable and colourful designs. Printed patterns and images on glass make the glass visible to the birds, reducing the risk that they will be confused by the reflection of trees or open skies.
Recyclable building material Digital ceramic glass is treated like any other glass. The digital ceramic printed glass is handled and disposed of through standard recycling methods with no special considerations or arrangements.
Free of toxic heavy metals Digital ceramic glass can be printed using inks that are free of toxic heavy metals, eliminating the hazards associated with these elements. For example, Dip-Tech Digital Ceramic Inks are free of cadmium and lead, providing a safer and more eco-friendly option for decorated glass.
Support for urban renewal Printing a design on glass panels is suited to urban renewal projects where redesigning only part of a building is preferable to demolition and complete continued »
Environmental protection
Origami Building, France
Columbia College.
Mansueto Library, USA.
rebuilding. Digital ceramic glass can be designed to match the surrounding buildings, restore the look of the original structure, or create something new and exciting.
Environmental certification requirements
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The demand for environmental certification for building strategies and practices is increasing. Leadership in Energy & Environmental Design (LEED) and Building Research Establishment Environmental Assessment Method (BREEAM) are two well-known green building certification and assessment methods. Each programme evaluates a number of variables, such as energy requirements, water consumption, materials and resources, health and indoor environmental quality, and pollution, providing scores for each, and an overall achievement rating. As both the functionality and design of building glass touch impact many of the variables under consideration, digital ceramic glass can contribute significantly to a positive evaluation of a building’s environmental standing.
*Business Development Manager, Phoenicia Flat Glass Industries. Web www.phoenicia-ltd.com
41 Glass International May 2014
Flat glass
Triple glazing: A hot debate A number of recent articles and debate around triple glazing have highlighted the need for simple comparisons between the alternative glazing products and configurations possible for a site or location. Here, Garry Smith* discusses effective U values.
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here seems to be confusion amongst consumers regarding the Window Energy Rating (WER) scheme. We have discussed the need for important factors such as property location, aspect, heating and shading to be separately assessed in a number of articles and features in relevant trade press – this is not something a typical consumer can do, or would be aware of when looking at a WER Label. There are usually great benefits in replacing old windows with new, airtight, well-insulated, modern frames in any material. These benefits can mask the performance change derived from improving the glass alone. Two properties are key when considering the thermal performance of glazing: The thermal transmittance (U value), and the solar factor (g value), which define the amount of heat loss and the amount of energy gained by solar heating respectively. A little-used comparison tool is contained within the standard EN ISO 14438, ‘Glass in building Determination of energy balance value Calculation method’. This method combines the effect of solar factor, g value and thermal transmittance (U value) and takes into account the installation region and orientation of the glazing. The calculation allows any U and g values to be entered in order to calculate effective U values, or energy balance values, for Scotland, North UK and London, Thames Valley and the Midlands. The orientation options are, unsurprisingly, north, south and Glass International May 2014
east/west. The calculation applies to the period where heating is most used in the home and for the UK this is based on the months September through to May. As an example, we have taken northfacing glazing in Scotland and in the south of England. If we compare a typical unit that might be used in an A rated DGU (U=1.2, g =0.75 based on centre pane values) and a triple glazed unit (U=0.53, g =0.47) then the following results are obtained:
Example Effective U Values calculated for a North orientation, in Scotland (Table 1). Effective U Values calculated for a north orientation in London, Thames valley and Midlands (Table 2). A negative value means that the glass is calculated to let in more heat than it loses. In this example (Table 2) triple glazing is the best performer - providing that you can ventilate any excess heat out of the room. These figures are only based upon specific products variants used in this calculation, and different products, coatings or pane configurations will result in different results. The method
enables producers to compare the performance of their glazing products. The energy balance value should not be used for energy use or heating capacity calculations in buildings. Where windows do not naturally get the sun, due to aspect or shading, then products with a low U value will provide the greatest benefit, and in these locations this is typically a triple glazing configuration. The values of the calculation vary with location and orientation and you may find that a mixture of glass types in one building gives the best overall performance – therefore correct assessment and configuration of each installation is essential to provide optimal benefit and return on investment for the customer. Glass Technology Services has made a free ‘Effective U Value’ calculator available on their recently launched website, which can help specify the optimal glass depending on the location and aspect of each insulating glass unit. www.glass-ts.com/effective-u-valuecalculator
*Garry Smith, Principal Consultant, Glass Technology Services www.glass-ts.com
Example energy saving
Effective U value (EN ISO 14438)
A rated
0.38
Triple
0.01
Table 1. North Orientation in Scotland.
Example energy saving
Effective U value (EN ISO 14438)
A rated
0.09
Triple
-0.17
Table 2. North Orientation in London, Thames Valley and Midlands.
Flat glass
PVD coater for latest energy challenges Dr. Jens Ellrich discusses Grenzebach’s latest offerings for the flat glass market.
The lab coating machine at the Grenzebach headquarters in Hamlar, Germany.
Grenzebach, a supplier of cold end equipment for the flat glass industry, decided to add Physical Vapour Deposition (PVD) glass coating equipment to its product offering. Such completion of the overall portfolio enables the glass industry to purchase a complete coating system, from loading of the raw substrates towards unloading of the coated glass. System interfaces and spare part inventories are reduced to a minimum, and a common HMI surface for the coating plant not only raises the comfort level but also helps optimise operation costs and minimises downtime. The PVD coater is ready to produce thin film layer stacks according to latest energy conservation standards and is ready to be adapted for upcoming challenges. Grenzebach’s planar and rotary sputtering cathodes, in combination with process control and auxiliary equipment, guarantee a high accuracy when the materials are
disposed on the glass surface. The capacity of a typical coating system may reach up to 15 million m² per year, depending on individual product mix figures and the layout of the overall system. A lab coating system started operation in January 2014 at Grenzebach to underline its PVD coating activities. This coater, located at the headquarters in Hamlar, is ready to coat glass with sizes up to 2,600mm x 2,200mm and is currently equipped with five coating tools (sputter cathodes). The machine is designed for in-house layer stack development, as well as for individual client demands, training purposes and qualification of new hardware components.
*Grenzebach Maschinenbau, Germany www.grenzebach.com
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W
orldwide energy legislations and their enforcements as well as challenging architectural demands are driving more window and facade manufacturers to use glass which has been processed in a smart way to fulfil the requested performance data accordingly. As a result, the majority of today’s architectural glass used for commercial and residential buildings needs to be coated with thin film layers which finally control the energy flow through the finished window or facade element. Such thin film coatings are applied onto the raw glass surface between the float process and other successive processes (e.g. toughening, laminating, IG-unit assembly). Today, offline coatings (also known as soft coatings) are replacing the traditional online coatings (pyrolytic coatings) due to their outstanding performance characteristics, which are limited regarding the above mentioned criteria.
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ANNEALING ANNEALING & D DECORATING ECORATING LEHRS LEHRS ffor or Containers Containers aand nd Tableware Tableware
TTEMPERING EMPERING LLINES INES O ON NB BELT ELT / SSPINDLES PINDLES ffor or Tableware Tableware and and Stemware Stemware
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Manufacturers and suppliers of selas square port gas & air valves
GAS
Special cast irons and alloys for glass moulds
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