July/August 2015 | Vol. 38 No.7
O-I DISCUSSES VITRO MEXICO OVERVIEW HANDLING
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Glass International July/August 2015
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Contents
July/August 2015 Vol.38 No.7
July/August 2015 | Vol. 38 No.7
O-I DISCUSSES VITRO MEXICO OVERVIEW HANDLING
2
Editor’s Comment
5
International News
13 Mexican overview: Global spotlight shines on Mexican hollow glass industry
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21 Company profile: O-I COO discusses Vitro acquisition 22 Syrian glassmaker is ‘still alive’ 24 CTIEC aims to raise industry standard
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Glass International July/August 2015
26 Forming: Ardagh’s Flex Run enhances production flexibility 29 Furnaces: Reducing energy consumption at Vidrala 5
33 Glassman Latin America Catalogue
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Front cover image courtesy of 2015 www.pennine.org
Events World Glass Trend in Bilbao ICG TC09 Mir Stekla 2015 British Glass Focus conference and awards
Handling 60 Steel felt that reduces production contact faults 61 From invention to industry standard 62 History 63 Glass Technology Services 65 Batch The batch plant should not be the last piece in the puzzle 69 Regulations BV Glas discusses REACH regulations
Plus find us on Linked-In and Twitter.
@Glass_Int
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Furnaces 72 The role of high emissivity coatings in furnaces 75 Burning questions 78 Forming When less glass wall thickness is a solution 80 Lubrication Lubricants for all aspects of the industry 82 Inspection Visionary inspection 87 Automotive glass inspection fixtures 91 Diary
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1 Glass International July/August 2015
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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
All eyes turn to Mexico
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I
t’s the time of year when the glass industry takes a deep breath and a wellearned rest from the endeavours of business. For many it’s a time to relax and reflect on the year gone by and to plan ahead for the rest of 2015. As you lounge by the pool it’s worth reflecting that the wheels of the container glass industry have not stopped moving this year and the general feeling among the sector is a positive one. Bear in mind, though, that for some businesses, this summer will be an extremely busy one with staff working intensively to ensure they meet orders in time for September, when industry traditionally returns to work. This year has seen several acquisitions in the hollow glass arena with some of the largest the sector has ever known. The largest of these have been the capture of Mexican glassmakers. It cannot be a coincidence that some of the world’s major companies have focused on Mexican glass and secured some of the country’s most established glassmakers. February this year saw the conformation of Heineken’s sale of its Empaque Mexican packaging business to Crown Holdings. The deal, worth $1.225 billion, included Empaque’s glass bottlemaking business Sivesa which is based in Veracruz in the south of the country. Then, more recently, O-I announced its intention to buy Mexico’s largest container glassmaker, Vitro, for $2.15 billion. The deal includes its five food and bever-
age glass plants in Mexico as well as its Bolivian plant. O-I described the Mexican glass packaging market as ‘attractive and growing’ and it is not hard to see why. The influx of Mexican beers and spirits, namely tequila, into European bars and restaurants in recent years is testament to the success of the Mexican beverage market. All of which leads nicely to the Glassman Latin America exhibition and conference in Guadalajara on September 22 and 23. More than 75 of the world’s technology suppliers to the hollow glass industry will be exhibiting their latest developments, ranging from raw materials to furnace emission reduction technology. The parallel conference, which is free to attend, will include presentations from a mixture of glassmakers and equipment suppliers. The theme of this year’s conference is ‘Future solutions in the container and hollow glass industries’. The topics to be discussed vary and include preheating technology, environmental solutions and inspection methods. The event’s webpage will be updated shortly with the full conference programme ( w w w. g l a s s m a n e v e n t s . c o m / l a t i n -america/conference) We look forward to seeing you there.
Greg Morris Editor gregmorris@quartzltd.com
Quartz Glass Portfolio
Monthly journal for the industry worldwide
Directory 2015 Annual international reference source
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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com Production Executive: Martin Lawrence Subscriptions Tel: +44 (0)1737 855023 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
Over 75 companies exhibiting at Glassman Latin America
glass industry, with the recent acquisition of Vitro by Owens-Illinois (O-I) following on from Crown Holding’s acquisition of Empaque late last year and the joint venture agreement reached between Constellation and O-I.
Ardagh recognised for recycling partnership
Glassman Latin America 2015 hopes to take advantage of this activity, providing a platform for exhibitors and visitors to meet and do business. The Glassman conference will run alongside the event, which is held on the 22nd and 23rd September. This year’s theme is ‘Future solutions in the container and hollow glass industries’, and speakers so far include Grupo Modelo, Gerresheimer, BDF and Heye International, among plenty of others. There is still the opportunity to submit a paper for inclusion at the conference, and interested parties should contact gregmorris@quartzltd.com.
Vitro’s Guadalajara, Mexico site receives environmental award Vitro’s Guadalajara plant in Mexico has received an award for its environmental management at the site. The plant, named Vidriera Guadalajara, was recognised for how it deals with air pollution, noise, water, waste management, impacts on soil and subsoil, and environmental risks in general. It received the Clean Industry certificate from Mexico’s Federal Attorney for Environmental Protection (PROFEPA). “By obtaining this certifica-
tion as a Clean Industry, we maintain the record of compliance to environmental regulations of the authorities. “We therefore obtain benefits not only to the relationship between the company and its customers, but also with community and nature,” said Peter D. Magaña González, Manager of Human Resources at Vitro. A PROFEPA audit inspected common areas including internal roads, water treatment plants and storage of
waste and energy facilities. Some ideas for improvement were proposed that included adapting its processes to integrate eco-environmental technology and increase the use of sustainable energy. Vitro said the certification process began long before the audit, as employees received training on practical issues about reducing the environmental impact during the production process, and who also received environmental awareness lectures.
Ardagh Glass UK and recycler Reuse have received an award for their partnership to capture a higher portion of flint (clear) cullet. Judges at the UK’s National Recycling Award described the project as an excellent example of cradle to cradle packaging. Using cullet colour separation technology, the partnership increased the recycled content of glass packaging produced at Ardagh’s Doncaster, UK plant in 2014. Each glass bottle or jar had an average recycled content of 53% in the final six months of 2014, against an average recycling rate of 26% in the same period of 2013.
Steklarna to increase tableware capacity
Steklarna Hrastnik plans a series of investments to increase its tableware output to up to 90 tonnes per day. It will buy a new decorative machine, completely renovate its decorative area and buy a new machine for the production of miniature and perfume bottles and automatic control line, all within its tableware unit. It will also move its machines for the production of special bottles into the glass tableware unit. The investments will take place within the next year.
Gerresheimer boost
German pharmaceutical manufacturer Gerresheimer reported increased revenues of 6.3% in Q2 of this year, despite a drop in glass sales. It reported growth in medical and pharmaceutical plastic products but said, although business with its glass pharmaceutical primary packaging recovered as the year progressed, it still remained slightly down on the prior-year quarter. Revenues in its laboratory glassware business were slightly up, it reported.
VISIT: www.glass-international.com – For daily news updates and regular features
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Less than seven booths remain available for the Glassman Latin America exhibition in Guadalajara, Mexico this September, which will welcome exhibitors and visitors from all around the world. The event caters exclusively to the container glass manufacturing industry, and will house suppliers for every part of the hollow glass making process, from raw materials to decoration, under one roof. With an excess of 75 exhibitors booked so far, coming from Mexico, the USA, France, Italy, Germany, China and more, the event is proving to be an international affair. 2015 has been a busy year for the Mexican container
NEWS IN BRIEF
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International News
NEWS IN BRIEF
Dura Temp Europe appoints Sales Manager
Dura Temp Europe based in Bruges, Belgium has appointed Luc Lutters as its Area Sales Manager. Mr Lutters has joined the company in this role as Area Sales Manager (Technical Sales). Initially, he will provide support to glassmakers in France, The Netherlands and in Belgium. Mr Lutters was recently a Sales Manager in the automatic door and transportation industries. He holds degrees in elecromechanics and industrial engineering and is fluent in several languages including Dutch, French, English and German.
Jim Beam bottle
UK glass packaging manufacturer Beatson Clark believes it has captured the flavour of the American south in a bottle it has designed for Jim Beam bourbon sauce. The bottle has been designed to echo the shape of the replica 1940s American Stillhouse at the Jim Beam distillery in Kentucky. The bourbon sauce is described as a smoky and sweet sauce made using Kentucky Straight Bourbon Whiskey.
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Sentry conveying chain offers more protection
Ramsey has extended its line of wear-protected products to include the Sentry conveying chain. Sentry is an extended pitch two-pin chain that, according to the company, combines the best features of Ramsey’s Allguard FX, Two Pin, and Extended Pitch conveying chains with features developed for high speed power transmission chain. The company said Sentry customers would enjoy advantages including guard links with fully recessed pin heads, 100% hardened alloy steel construction – no sintered metal, two pin chain joints, extended pitch chain design, staked pin heads and pre-stressing for reduced chain elongation.
Vitro approves O-I $2.15 billion bid Mexico’s largest glass manufacturer, Vitro, has approved Owens-Illinois’ (O-I) $2.15 billion bid to buy its glass containers division. The transaction includes five plants for food and beverage containers located in Mexico, its Bolivian plant and distribution of products in the USA.
Not included in the deal are its assets associated with the cosmetics, fragrances and pharmaceuticals (“CFT”) segments, the equity interest in its companies Comegua in Central America companies as well as the company’s business involving chemicals and mould manufacturing, and machinery.
“We have long admired Vitro’s business and this transaction marks an important strategic step for O-I in that it allows us to establish a strong position in the attractive glass container segment in Mexico,” said Al Stroucken, chairman and CEO of O-I.
Jinzu bottle shortlisted for award The bottle needed to build an emotional connection with the creation of a brand the intricate print that covers three quarters of the bottle depicts a quirky bird carrying a black brolly. Cage birds were once typical in Japan, yet this one is holding a British umbrella. The image symbolises that Jinzu is a gin with its head in Britain and heart in Japan. The shortlisting follows on from Allied’s success in the 2014 Luxury Packaging Awards, when it won the category with the Tanqueray No Ten container.
Allied Glass has been shortlisted at the 2015 Luxury Packaging Awards in the Drinks Bottle category for its Jinzu bottle. Jinzu is a super- premium, hybrid spirit that blends British gin, botanicals and distilled sake. The packaging was created to symbolise the British and Japanese influences which inspired the creator. The pack needed to borrow the semiotics of premium gin with a twist. As a result the bottle shape is based upon a classic gin crock, yet the design also gives it a gently curving neck profile reminiscent of a sake decanter.
Verallia takeover receives approval The European Commission has approved, under the EU Merger Regulation, the acquisition of Verallia by Apollo Management L.P. of the USA. Verallia is a group of companies that manufactures and supplies glass bottles and jars for the food and beverage industries worldwide.
Before the transaction, Verallia belonged to France’s Compagnie de Saint-Gobain. Apollo Management is a private equity firm. The Commission concluded that the proposed acquisition would not raise competition concerns, in particular because there are no overlaps between
the activities of Apollo Management and its portfolio companies and those of Verallia. The transaction was examined under the simplified merger review procedure. Apollo is expected to buy Verallia for €2.945 billion ($2.819 billion).
Pneumofore supplies Sisecam Italian company Pneumofore has supplied two more UV50 vacuum pumps to Sisecam Eskisehir in Turkey. The installation follows three older UV50 pumps, all equipped with variable speed
drives that were put into operation in 2012. Pneumofore said the engineering collaboration on the project was excellent and the entire vacuum piping system was prepared exactly accord-
ing to the layout. The ambient is well ventilated at a temperature of only 20°C. Pneumofore first supplied Sisecam’s Eskisehir hollow glass factory in 2002.
6 Glass International July/August 2015
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International News
First Dutch beer launched in O-I black glass The first beer in O-I’s black glass container has been launched on the Dutch market. The Ouwe Hut craft beer is a project to mark the occasion of the town of Leerdam’s 250 years as a glassmaking hub. O-I provided the black bottle. Bier Atelier Vijfheerenlanden brewed the beer according to a centuries-old recipe and Libbey tableware manufacturer made the glass that emphasises the characteristics of the craft beer. Leerdam-based Bier Atelier Vijfheerenlanden brewed the beer to an 18th century recipe. The beer was drunk in those days because drinking the water supply made people ill. Antoine Jordans, Vice President and General Manager EMEA at Libbey, said: “For the Ouwe Hut beer, we opted for a champagne flute which contributes to the festive character of the anniversary, but above all, retains the foaming character of the beer”.
Ouwe Hut is limited in its availability and is the first Dutch beer that is sold in O-I’s black 33cl bottles. O-I’s Leerdam glass plant is located in the heart of the European brewing industry and produces more than 1.3 billion beer bot-
tles each year. The plant is one of the most modern glassmaking plants in Europe, thanks to a €21 million investment in 2013. An investment of €1.7 million in 2014 for the production of black glass emphasised that once again.
Gerresheimer to sell glass tubing operations to Corning for €196M Gerresheimer is to sell its borosilicate glass tubing business to Corning Inc. in a €196 million deal. Corning will assume ownership of Gerresheimer’s tubing plants in Vineland, New Jersey, USA and in Pisa, Italy, which employ 300 people. Gerresheimer described its tubing business as second in the global pharmaceutical tubing market
with FY 2014 revenues of €83m ($91.1 million). Gerresheimer and Corning said they will also enter into a 10-year-supply agreement for borosilicate glass tubes that will secure Gerresheimer’s demand for glass tubing. Glass tubing is an intermediate product that Gerresheimer manufactures mainly for its own plants, where the tubes are used
to manufacture ampoules, vials, cartridges and glass syringes. It also sells tubing to external customers but on a small scale. Both companies will also establish a joint venture to accelerate innovations for the pharmaceutical glass packaging market. The deal is expected to close before the end of this year.
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International News
NEWS IN BRIEF
Stoelzle’s French site to be centre of excellence
Stoelzle’s Masnieres, France site will become its new centre of excellence in terms of highend flacons for the perfumery and cosmetics markets. Stoelzle said major investment would be made to upgrade production and decoration equipment. The centre of excellence will focus on conception, production and decoration of luxury perfume bottles and high-end packaging glass for the cosmetics sector. The Masnieres glassworks site and a nearby decoration facility were bought by Stoelzle in December 2013.
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Heinz Glas in joint venture with Indian group
Guardian invests in UK site Guardian Industries’ Glass Group in Europe has invested more than £3 million to upgrade the production line at its Goole plant, UK. By completing the upgrade of its magnetron glass sputter coater, the facility is now able to make the more advanced coatings for its Guardian
through manufacturing,” explained Pablo Isasmendi, Plant Manager, Guardian Glass UK (pictured). The TPF applicator is the most advanced to date within the Guardian group and has the capacity to cover all glass sizes up to and including ‘jumbo’ size.
Libbey’s new process for glassware
The Board of Director’s of India’s Haldyn Glass has approved a joint venture with Heinz Glas. The deal involves the manufacture of perfume and cosmetic glass bottles for the export and domestic market. Germany’s Heinz Glas has 350 years experience in the manufacture of perfume and cosmetic bottles. It is present in 16 locations in 12 countries worldwide.
US tableware company Libbey has introduced a manufacturing process that enables a new range of soda lime glassware. Its ClearFire formula helped create what it described as the most brilliant and strongest soda lime glassware in the
Verallia Deutschland gas project takes shape
Bucher Emhart Glass has developed a 585 metering spout for pull rates between 110 and 160 mtpd. In 2002, Bucher Emhart Glass introduced the Metering Spout System designed to promote optimum gob forming conditions. The 585 metering spout series was designed for high tonnage operations pulling between 145 and 200 mtpd
A biogas project at Verallia Deutschland’s Bad Wurzach, Germany site is beginning to take shape. Various preliminary plans have been completed and there will now be a long-term test of biogas supply to the site. Verallia Deutschland Energy Manager Simone Spielmann said: “To the best of our knowledge, the site is still the first glass factory worldwide which will use unprocessed raw biogas in an industrial primary process.” She added that it is a fascinating project ‘with which the ecological sustainability of our company can be secured.’ The biogas supply will be tested for the next six months. So far about 50% of the site’s fossil fuel consumption has been replaced by biogas.
SunGuard SuperNeutral (SN) product series at the UK plant. An essential part of the upgrade was the addition of a Temporary Protective Film (TPF) applicator. “The TPF is used on all SunGuard SN products to protect the coating before and during processing, helping to secure higher yields
USA. The new stemware and tumbler collection, called Perfect Signature, will be available to retail markets later this year. The introduction of the collection represents the culmination of nearly two years of R&D, planning, installation
and testing. Libbey has invested $300 million since 2013 into its Shreveport, USA facility to develop and install new production equipment and furnace to produce glass.
Emhart develops 585 metering spout for lower pull rates in conjunction with Bucher’s servo driven NIS machine. In the past 13 years, a number of the large 585 feeders have been installed in glass plants around the world. However, market developments have recently pushed some of those glass plants to slow production, resulting in pull rates below what the 585 was originally designed for. Low pull rates can lead to
excessive wear on the spout and tube refractories, as well as poor weight and temperature control for the gobs. The Bucher Emhart Glass refractory plant in Owensville, Missouri, with assistance from the company’s engineering group in Connecticut, developed the spout, designed to operate at pull rates between 110 and 160 mtpd.
Horn secures furnace order Horn has secured an order for a 250 tonnes per day (tpd) float line and 50 tpd container line in Turkmenistan. Horn received the order in
April from TEPE Türkmen Insaat ve Ticaret for the National Glass Manufacturing Complex in Turkmenistan. The project will be realised
with TEPE Türkmen Insaat ve Ticaret as the EPC contractor and Horn as the technology supplier for the EPC.
Be first with the news! VISIT: www.glass-international.com for daily news updates
10 Glass International July/August 2015
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At Home in the World of Glass
Mexico overview
Global spotlight shines on Mexico’s container glass industry Mexico is famous for its beer and its tequila. Ahead of Glassman Latin America 2015 in Guadalajara, Greg Morris provides an overview of the flourishing Mexican hollow glass industry. The industry has been the subject of major investment projects in the past few months as domestic producers strive to keep pace with international demand. Mexico’s container industry is booming, mainly due to an explosion in international demand for Mexican beverages. The country is famous for its beers such as Corona, Modelo Especial and Desperado that are available in most Western bars and pubs. Mexico currently exports more than $1.5 billion dollars worth of beer annually, a figure that should rise as Anheuser-Busch owned Grupo Modelo and Heineken-owned Cervezas Moctezuma, continue to expand production.
There is a rapidly expanding market for Mexican beer in the USA, where Mexican beers now account for 15% of national sales. Mexico’s glass food and beverage packaging market is expected to grow to 25 billion units by 2018 from 23 billion units in 2014, according to market research firm Euromonitor. The market has been driven primarily by strong demand for beer. Continued>>
FEVISA Mexicali
O-I/CONSTELLATION Nava, Coahuila
VIDRIERA SANTOS CRISA LIBBEY VITRO Monterrey Monterrey Monterrey GLASS & GLASS Tamaulipas
INDUSTRIA Penjamo, VIDRIERA DEL BAJIO Guanajuoto VITRO Guadalajara
GRUPO MODELO San Luis Potosi
VITRO GERRESHEIMER Querétaro Querétaro
GRUPO MODELO PAVISA VITRO Mexico City Mexico City Mexico City
VIDRIOLerma FORMAS
VITRO Toluca
GRUPO MODELO Veracruz SIVESA
Orizaba, Veracruz
VETRONopaltepec, DE CANTABRIA Veracruz
www.glass-international.com
FEVISA San Luis Potosi
13 Glass International July/August 2015
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Mexico overview
Mexico’s most famous export, however, is tequila, which is exported internationally from several plants in Jalisco state. The annual volume of tequila consumed in Mexico is approximately 7.5 million nine-litre cases, equivalent to 35% of worldwide consumption. One in every three bottles consumed in Mexico is tequila and Mexicans have the highest per capita consumption in the world. There are 901 registered brands from 128 different tequila producers in Mexico and approximately 7% of them are regarded as ‘premium’ or ‘super premium’.
Acquisitions
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The Mexican glass container manufacturing industry has been the subject of much movement in recent months with several acquisitions and proposals. The most recent, and the largest, was earlier this year when Owens-Illinois (O-I) stated its intention to buy Vitro, Mexico’s largest glass container manufacturer, for $2.15 billion. O-I said the transaction provides it with a competitive position in Mexico’s glass packaging market. The agreement includes all of Vitro’s plants in Mexico and one in Bolivia, which together employ 4700 people. The acquired business is expected to generate estimated annual revenue of $945 million and adjusted EBITDA of $278 million. Furthermore, O-I expects to realise approximately $30 million in run-rate cost synergies by 2018 through a combination of procurement savings and operating efficiencies. “We have long admired Vitro’s business, and this transaction marks an important strategic step
z The Mexican Coca-Cola bottle is iconic in its design.
“We have a great deal in common with O-I and look forward to the expertise they bring to help meet the growing demand of our customers.
”
Vitro Chairman Adriàn Sada Gonzàlez
for O-I in that it allows us to establish a strong position in the attractive glass container segment in Mexico,” said Al Stroucken, chairman and CEO of O-I. “O-I is a clear leader in the global glass container market and is the ideal partner for Vitro’s food and beverage container business,” said Vitro chairman Adriàn Sada González. “We have a great deal in common with O-I and look forward to the expertise they bring to help meet the growing demands of our customers.” The deal is expected to be confirmed within a year. For more on the acquisition read our interview with O-I’s Chief Operating Officer, Andres Lopez, on p21. In another acquistion, US company Crown Holdings has bought Mexican packager Empaque in a transaction valued at $1.225 billion. Empaque is a manufacturer of glass bottles, bottle caps, and aluminium cans and ends. It is the packaging business of Heineken and the owner of the Sivesa business, which has a glass bottle production site and service plant in Veracruz, Mexico. Empaque had acquired the business in 2010 as part of the Femsa Cerveza acquisition. Crown Holdings announced its plan to buy Empaque in September last year and received regulatory approval in mid-February this year. The deal is expected to close shortly. Empaque employs approximately 1500 people and had projected sales in 2014 of $700 milion and EBITA of $150 million. The third major deal in the Mexican container market in recent months has been the partnership between O-I and Mexican brewer, Constellation. The Mexican brewer acquired a glass production plant in Nava, Mexico for $300 million from Anheuser-Busch InBev. It agreed with O-I to a 50/50 joint venture to own and operate the new glass plant and to use O-I as a secondary glass supplier. The glass plant is located next to Constellation’s brewery in Nava and will exclusively provide the bottles for the brewery. O-I will have primary responsibility for plant operations including purchasing, technical services and the plant expansion. Plans are in place to expand the capacity of the plant from one furnace to four furnaces over the next four years at a cost of approximately $350 million. O-I and Constellation each initially contributed approximately $100 million to the joint venture. The capacity expansion will be financed by equal contributions from both partners. When fully operational with four furnaces, the facility is expected to supply more than 50% of the glass needs for Constellation’s US beer business. The glass plant currently employs approximately 260 people but will rise to 800 once the four furnaces have been installed. Similarly, another of the country’s largest glass Continued>>
14 Glass International July/August 2015
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Forming - long time experience and proper technological knowhow to develop machineries and to meet the requirements of main glass containers’ producers.
Automation - competence in glass industry to supply processes and products for effective control and automation management for the glass plant.
Energy - the path of evolution brought the company to promote alternative energy solutions, to retrieve the dispersion of thermal energy and to produce energy respecting the environment.
Technical and engineering skills meet the enthusiasm and deep sense of belonging of BDF people: we supply to our Customers the extreme support in innovation, services and energy saving, assisting them in facing the Market.
Melting | Forming | Automation | Energy
All in one
BDF INDUSTRIES S.p.A. Vicenza - Italy - Phone +39 0444.286.100 - bdf@bdf.it - www.bdf.it
ADV_bdf istituzionale2014.indd 1
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Mexico overview
manufacturers and brewers is Grupo Modelo, which was taken over by global brewing giant Anheuser-Busch InBev. It brews and distributes 14 brands, including Corona Extra, the number one Mexican beer sold in the world, Modelo Especial, Victoria, Pacífico and Negra Modelo. Grupo Modelo’s glass manufacturing unit was previously run by Direccion de Fabricas SA de CV (DIFA). But when Anheuser-Busch InBev bought Grupo Modelo in June 2012 for $20.1 billion, DIFA was merged into the Grupo Modelo group as part of the transaction.
the world. Picture courtesy of Constellation Brands Beer Division, visit www.cbrands.com.
brands, particularly in the liquor and cosmetics sectors.
Vidrio Formas A manufacturer of containers for domestic and international liquor, food, industrial, cosmetic and pharmaceutical markets. Formed in 1990 it stocks containers ranging from 15ml to 2000ml.
Fevisa
Container glass manufacturers
Fevisa was formed in 1987 and is ISO 9000 certified. It is headquartered in Mexicali, right on the Mexican/US border. It is strategically located to serve the US packaging market.
Vitro
Sivesa
Vitro is Mexico’s largest container glass manufacturer. It is a major participant in containers, flat glass and glassware. Its subsidiaries serve many product markets including construction, automotive, liquor, cosmetics and pharmaceutical glass containers. It was founded in 1909 in Monterrey and now has joint ventures that gives it access to international markets. Its subsidiaries have facilities and distribution centres in eight countries located in North, Central and South America, and Europe. It exports to 70 countries.
Silices de Veracruz (Sivesa) is located in Veracruz in the south of the country. In September last year its owner Heineken said it was selling its Mexican packaging business, Empaque, to Crown Holdings for $1.225 billion. Empaque is a packager of a number of materials and Sivesa was its glass bottling unit.
Grupo Modelo
www.glass-international.com
z Mexican beers have become famous throughout
A company engaged in producing glass containers for the beer, food, wine and beverage industries. It was acquired for $20.1 billion in 2013 by AnheuserBusch InBev (AB InBev). The company is a brewer as well as a bottle maker and is responsible for producing some of Mexico’s most famous beers. It also runs a sand processing facility and a freight transportation operation.
Pavisa Pavisa is a hollow glass manufacturer in Mexico City producing containers for the liquor, cosmetics, food and pharmaceutical sectors. It has been in operation since the 1960s. Much of its output is geared to the needs of the premium
Pharmaceutical Pharmaceutical tubing manufacturer Gerresheimer is based in Querétaro. The plant was acquired by Germany’s Gerresheimer in 2002 from Ampolletas and was renamed Gerresheimer Queretaro. The plant only produced ampoules and vials for the domestic market initially, but now exports to the surrounding region, including the USA and Canada. It is a 63,000m2 site that includes four sub-factories. It also produces pre-fillable syringes and thin-wall weight tubes. German pharmaceutical manufacturer Schott has a subsidiary in Mexico. Schott Mexicana opened in Mexico City in 1989. It offers a full range of special glass products serving a spectrum of applications and markets. The company has a sales office in Mexico City and a pharmaceutical packaging plant in Veracruz.
Continued>>
16 Glass International July/August 2015
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FleXinspect M
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Mexico overview
Tableware Crisa Libbey
www.glass-international.com
Crisa has its roots in Monterrey, Nuevo León. It was founded in 1936 as part of Vidriera Monterrey, which is now Vitro. In 1938, Crisa opened its doors with its first manufacturing location known as Location C. Production was manual, there were only 200 workers and its line of products consisted of 50 different items. In 1956, Crisa acquired Cristales Mexicanos (Location M) and in 1987 Location I was built which as well as being a warehouse and packaging centre is also the main distribution hub. Products are decorated there and glassware and dinnerware are assembled. In 1975 its manufacturing location K2 was built to manufacturer crystal articles for the Kristaluxus brand. In 1988 Crisa started the automatic process to manufacture blender jar products while in 1991 it had its first Kamman decoation machines to decorate in six and eight colours. In 1997, the US group Libbey Inc. acquired 49% of Crisa and then obtained full ownership in 2006. The acquisition positioned Libbey as one of the world’s largest tableware manufacturer. Crisa has products such as glass, metalware and chinaware to serve markets such as retail, foodservice and B2B. The main processes are: press, blowing, manual and cold cut. Crisa has a strong national distributor network, 17 outlet stores stocked with the full product line, and exports to more than 70 countries around the globe. Today it manufactures 1000 different articles and employs about 3500 people.
z Grupo Modelo’s Tiera Blanca, Veracruz plant in the south of Mexico.
Lerma, about 45 minutes from Mexico City. Four smaller companies in operation are: r Industria Vidriera del Bajio (Corralejo) located in Penjamo, Guanajuato state. r Vetro de Cantabria in Nopaltepec, Veracruz. r Glass & Glass: Tamaulipas state. r Vidriera Santos: Monterrey. The total produced by the major companies is 3.111 million tonnes per year, amounting to 8525 tonnes a day.
Furnaces Fevisa has five furnaces at its Mexicali plant and two in its San Luis Potosi plant. Grupo Modelo has four furnaces at its Mexico City plant, four furnaces at its Vidriera del Potosí, San Luis Potosí, plant and two furnaces at the Tierra Blanca site. Pavisa has seven furnaces, melting a total of 350 tonnes/day. Sivesa has three furnaces, nine production lines, all double gob and four of those are tandem. Approximately 90% of Sivesa’s production is beer bottles but it also produces some soft drinks. In the past it produced soft drink bottles for Fanta and Coke. The O-I/Constellation plant currently has one furnace but plans to expand to four.
Tequila There are many plants from different groups that produce tequila bottles. The major producers for tequila bottles are Vidrio Formas (mainly high end tequila bottles), Pavisa (also high end), Vitro, from its Monterrey and Mexico City plants, and Industria Vidriera del Bajío. The company makes tequila as well as its own bottles and Corralejo is the commercial name for the beverage.
Glass container plants
Soft drinks
There are currently 18 container glass manufacturing plants in Mexico - 14 are owned by the ‘major’ producers and there are four smaller plants. r Vitro has five plants, located in Monterrey (1), Mexico City (1), Toluca (1), Guadalajara (1) and Querétaro (1). r Grupo Modelo has three container glass manufacturing plants located in Mexico City, San Luis Potosi and Tierra Blanca in Veracruz. r Fevisa has two plants located in Mexicali and San Luis Potosi. r O-I/Constellation has one plant located in Nava, Coahuila. r Sivesa has a plant located in Orizaba, Veracruz. r Pavisa has one plant located in Mexico City. r Vidro Formas has one plant located in
Most plants produce soft drinks bottles. Vitro currently produces most of the Coca-Cola bottles in Mexico while Fevisa also produces a small amount of Coca-Cola bottles.
Glassman Latin America takes place in Guadalajara, Mexico on September 22 and 23. Most of the world’s leading technology experts to the hollow glass industry are exhibiting at the event including BDF, Heye International, Sorg, Iris Inspection Machines, KBAKamman and All Glass. Confirmed speakers at the free-of-charge conference include Grupo Modelo, Gerresheimer, Fives Stein, UAS Messtecknik and BDF. r
www.glassmanevents.com/latin-america
18 Glass International July/August 2015
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O-I interview
The Vitro acquisition explained Following the recent acquisition of Vitro’s food and beverage business by Owens-Illinois (O-I), Sally Roberts spoke to Andres Lopez, Chief Operating Officer of O-I and former President of O-I Americas, to get his views on what this means for O-I and the Mexican market.
Vitro’s food and beverage business is very well-run, with strong management and well-run operations. We have long admired Vitro, which has a history nearly as long as O-I’s. It has the same kind of commitments to sustainability, high quality, safety and long-term customer relationships as we do. O-I has operations in North America and South America, but only a joint venture in Mexico. Vitro’s food and beverage operations are in Mexico and Bolivia, where we have practically no presence at all, so it fills a gap in our global footprint.
How important is the Mexican market? The macro trends in Mexico mirror many other economies in Latin America in that it has a growing middle class, which is attractive to many of our customers. As the middle class grows, it has more spending power, which food and beverage makers respond to by bringing new products on to the market. Glass has maintained a stable portion of the packaging market for years, so we see the potential for growth as the economy grows.
Why is O-I keen to have a presence in the country? O-I has virtually no operations in Mexico. We participate in a joint venture there with Constellation Brands Inc. (CBI), supplying only the CBI brewery adjacent to our plant. We have long wanted access to Mexico to fill a very large gap in our global footprint. Vitro has many longterm relationships with multinational customers who we do not work with, so this will expand our customer base. And it will help us better serve those customers that we have in common with Vitro. Also, we want to be able to service the needs of our customers as they expand globally and we were previously not able to do that for customers who were operating in Mexico.
Is the acquisition designed to increase O-I’s exports throughout the Americas? The aim will be to focus on Mexico’s domestic market. For the most part, glassmaking is a local business and in the ideal model, your plants are close to the ultimate destination of the containers.
“We have long admired Vitro, which has a history nearly as long as O-I’s. It has the same kind of commitments to sustainability, high quality, safety and long-term customer
”
relationships as we do.
We also want to be close to customers who are operating there.
Can you tell us if O-I has any plans to expand or invest in the region? We will continue with the expansion plans Vitro has already announced. Other than that, it is too early to speculate on any kind of other investment plans in Mexico.
How will the day-to-day running of ex-Vitro plants be affected? The Vitro food and beverage plants are well-run. As such, we are keeping the operational leadership team and the employees and we have no plans to change what they produce. We hope to benefit from synergies when we merge the know-how of the two companies, but that cannot come until the deal is closed.
Will this acquisition affect the IVC partnership between O-I and Constellation? As Vitro is already a supplier to Constellation, this agreement will broaden our relationship with CBI. The agreement does not have a direct impact on the IVC joint venture. It’s possible that we may realise some other synergies down the road once we bring Vitro’s food and beverage business into the O-I family, but it’s too early to see what those might be.
www.o-i.com www.vitro.com
www.glass-international.com
Why did O-I wish to acquire Vitro in particular?
21 Glass International July/August 2015
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Syria update
Syrian glassmaker is ‘still alive’
z Fig 1. Major European suppliers have installed equipment at the MCGI plant.
It’s been a year since Glass International reported on the plight of Syria’s only glass container manufacturer, Modern Company for Glass Industries. Despite continued sanctions, the company’s Chairman, Aiman Raslan, said the business is ‘still alive’.
www.glass-international.com
M
ost glassmakers’ perception of a bad day is when a piece of equipment breaks down or the discovery that their furnace is faulty. For the glassmaker it means production downtime and the resulting costs of missed work. However, these ‘everyday’ problems pale in comparison for Syrian hollow glassmaker Modern Company for Glass Industries (MCGI). The glassmaker, based just outside the city of Homs, Syria is caught in the middle of a civil war that has been waging for more than four years. Although the glassmaking site has not been damaged by the conflict, the resulting international sanctions against the country have hurt the company. Land borders have been closed to neighbouring countries Iraq, Jordan and Turkey so products have to be expensively freighted by ship. Crucial employees such as technicians and engineers, who fear for their safety, have also left the company and moved abroad.
The company’s Chairman, Aiman Raslan, admits that it has been tough for the company but said the crucial thing is that the company is still alive and open for business. The group, founded in 2009 shortly before the outbreak of the conflict, produces bottles and jars that meet international standards. Its products include olive oil bottles, glass gallons, edible oil and vinegar bottles, and soft drink bottles. Its customer base has increased yearon-year and its products are shipped to many parts of the Middle East. Mr Raslan said the company has international standard equipment from recognised global suppliers. The equipment includes an EME batch house, a Sorg furnace, Bucher Emhart Glass forming machines, Pennekamp lehrs, MSK cold end equipment, Tiama MSC – SGCC inspection machines and an Atlas Copco Compressor. Mr Raslan said that the equipment has
been kept in good condition and was well maintained by the MCGI team. The equipment was installed at the end of 2009 and beginning of 2010, just as the unrest began in Syria. There have been no technical site inspections from suppliers since the installation due to the conflict. Mr Raslan said: “We hope that our suppliers are proud because the equipment is still in excellent working order and still alive despite being unable to conduct any technical support or site visits from our suppliers due to the difficult situation in Syria. “MCGI would like to send a call to suppliers to ask them to support us and not leave us alone in this hard situation in order for us to stay alive. “MCGI has a challenge to keep the business running and stay alive, but we want the support from everybody in the glass community. We would like to ask them to support us technically and to lift Continued>>
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Syria update
z Fig 2. The company was formed in 2009 shortly before the conflict started.
Sanctions International economic sanctions have been imposed on Syria since the beginning of the conflict. Mr Raslan stated that this is unfair because the glassmaker is a private company and not affiliated to a political party. The factory employs close to 200 staff and, as Mr Raslan stated, these people could lose their livelihoods should the factory have to close as a result of the sanctions. He praised the efforts of General Manager Mr Aurobindo Roy Chowdhury, Plant Manager Mr Husein Berri, Production manager Mr Ahmad Hazani, Finance Manager Mr Imad Samman and Sales Manager Rami Khawaga. Mr Raslan remains positive about the future and the company has even launched new products. This includes 2800ml and 1500ml gallons for olive oil and the Damasco Bottle that has multiple uses. MCGI has also established a UK company, Raslan Enterprise Ltd, based in Twickenham, UK to promote its production to the UK and European markets. It has so far secured one contract and remains positive it will secure more for the remainder of 2015.
z Fig 3. It employs close to 200 people.
Company background
the industrial area has been unaffected. The manufacturing site is close to sand mines, a port and the Lebanon border. About 70% of production is exported Saudi Arabi, Iraq, Lebanon and other Middle East countries, while the remainder is for domestic use. The company has a €13 million expansion plan to build a second furnace at the site and extend its capacity to 230 tonnes per day. But this remains on hold while the conflict continues. r
The company capacity of 110 tonnes per day of flint glass has been unaffected by the dispute. The factory is based in the Hassiaa Industrial zone just outside Homs. Although Homs has been attacked
Modern Company for Glass Industries (MCGI), Homs, Syria. www.mcgiglass.com
z Fig 4. The new Damasco 750ml bottle.
z Fig 5. A 2500ml gallon for olive oil use.
www.glass-international.com
the international sanctions as we are the sole company in Syria in this field. “We are just a professional glass manufacturing company and we are not affiliated to any political party.”
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Company profile
z A CTIEC ultrathin substrate glass line.
Chinese flat glass group aims to raise industry standard Glass International spoke to Prof. Peng Shou, President of the International Commission on Glass and Chairman of China Triumph International Engineering Company, to find out more about the engineering group that is aiming to raise China’s industry standard.
www.glass-international.com
Can you explain the company’s history? With more than 60 years’ history, China Triumph International Engineering Co (CTIEC) has gradually developed from a glass designing unit engaged solely in flat glass engineering, to an international engineering group with three business strands: Glass, cement and new energy. We have a complete business chain from technical research and development, engineering designing, equipment manufacturing and general contracting engineering and more than 20 subsidiary companies. CTIEC is a national comprehensive grade-A designing, research and development unit – a national, high-tech enterprise. It is also the engineering technical platform of China National Building Materials Co listed on the Hong Kong Stock Exchange.
What is CTIEC’s role in the glass market? CTIEC’s flat glass production process technologies and equipment hold the leading role in China, and some of these process technologies and equipment have reached or even exceeded international advanced level. We can provide complete sets of production technologies and equipment of various glass products such as flat glass, light glass, speciality
glass and deep processing glass. We can also provide turnkey engineering for these glass factories.
What markets do you serve? Apart from the constantly growing domestic glass engineering business, CTIEC can now undertake general engineering contracting business for cement and new energy. In recent years the ratio of these three businesses in the foreign engineering market has grown constantly, covering regions from traditional markets such as Asia and Africa to America and Europe.
What other geographical areas does CTIEC cater to? CTIEC has expanded its market in developing countries such as Pakistan, Bangladesh, Egypt, and Ethiopia, to already well developed countries such as the USA, France, Japan and South Korea.
How important is R&D to the company? We all know the importance of technical research and development to an enterprise, and technical innovation has always been the inexhaustible driving force for the development of CTIEC. The leapfrog development of CTIEC in recent years Continued>>
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Company profile
derived from our high attention to technical research and development. We have won National and Shanghai Municipal Awards for Science and Technology Progress many times. The number of state authorised patents obtained over the past three years has exceeded the total awarded over the past ten years prior to 2011.
What is the link between China Triumph International Engineering and Bengbu Design and Research Institute?
z Prof. Peng Shou, who is CTIEC’s Chairman and is also President of the ICG.
Do you have any key partnerships with companies from overseas?
China is, of course, one of the so-called BRIC nations. What opportunities does being in one of the fastest developing nations in the world bring?
We have a close cooperation relationship with German companies Siemens and AEG, Japanese companies Mitsubishi and AGC, and the Italian company Bottero, among other renowned overseas companies. We have formed joint ventures with Bottero, Mitsubishi and Finnish company Elematic here in China. We also founded CTIEC-Teco Engineering Technology in the USA with the American company Teco. In addition, CTIEC conducted comprehensive cooperation with the New Jersey Institute of Technology in the areas of training emerging talent in industry, technical exchanges, and scientific research and development.
What makes China Triumph International Engineering stand out from its competitors? The reason CTIEC stands out from its competitors and stays in a leading position in the industry in terms of technology and management is that we have closely followed domestic and foreign market demands for many years, and also persevere with
technical research, development and innovation. At the same time, we constantly adjust our development strategy according to the constant changes of the domestic and foreign markets and adhere to transformational development.
CTIEC has secured contracts around the world, incuding here this Indonesian TG-2 900td float glass production line.
The rapid economic development of the other three BRIC countries brought new development opportunities for China and the business of CTIEC has successfully expanded to India and Russia. I think China could complement the other three BRIC countries in technology and work together to realise mutual promotion, cooperation and a win-win result. Just as the Chinese President Mr. Xi Jinping said at the colloquium of foreign experts in Shanghai on May 22nd, 2014: “China should be a powerful country in learning forever, always learn with an open mind from people all over the world no matter at what development stage, and strengthen the mutual tolerance, learning, and understanding with an inclusive posture to enhance our openingup to a new level.”
What does the future hold for China Triumph International Engineering? Our goal is to become a science-and-technologyoriented company with strong comprehensive capability and international competiveness, which focuses on building materials technology, integrating research and development, engineering designing, engineering contracting and manufacturing. I believe this goal could definitely be realised with the common efforts of the management and employees and the care and support of international colleagues in the building materials industry. r
China Triumph International Engineering, Shanghai, China www.ctiec.net
www.glass-international.com
CTIEC and Bengbu Design and Research Institute for Glass Industry are brother enterprises with profound historical origins. Both belong to the Fortune Top 500 China National Building Materials Group Co. We closely cooperate in the fields of building materials, technical research and development, and equipment manufacture. We also have complementary relationships in various businesses.
25 Glass International July/August 2015
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Forming
Fig 1. Flex Run is designed to help customers benefit from a production run for small or limited series items.
Flex Run enhances production flexibility
Ardagh Group’s North American Glass division developed the Flex Run service to allow for the production of two glass bottles on the same IS Machine simultaneously. It provides increased flexibility to run speciality bottles. Ken Towne* reports.
www.glass-international.com
P
roduction flexibility. In a world of heightened glass bottle innovation, it is something with which glass container manufacturers struggle. Whether adding a customised embossment to a stock bottle or creating an entirely new design with one-of-akind features, it has never been easier for brands to enhance their shelf impact through custom glass design using Ardagh Group’s Flex Run service. Ardagh Group’s North American Glass division developed the Flex Run service to allow for the production of two glass bottles on the same IS Machine simultaneously. Originally developed for the wine industry, the technology provides more flexibility to run speciality bottles with limited investment. Flex Run is designed to help customers benefit from a production run for small or limited series items, such as product launches, market tests, limited editions and commemorative bottles. It is ideal for customised embossments, unique bottle shapes, custom punt designs and different finish options. It also provides the opportunity to sample multiple products prior to completing a full production run. It is currently offered to wine customers in four colours – Antique Green, Champagne Green, Dead Leaf Green and
Flint – for orders as small as 1500 cases. According to Ardagh, the possibilities for individual designs are endless. Flex Run uses a ‘variable weight feeder,’ which allows for the automated delivery of variable weights of glass gobs to the individual forming sections. This service can produce containers at varying heights and weights, accommodating up to a 10% difference in bottle weights. In addition, this service gives the option of producing ware from just a single section up to the entire machine, as required. By optimising the number of sections required for a production run, the service can result in reduced mould equipment costs. Sampling capability is also enhanced, as it is no longer necessary to idle the entire machine to sample
ware on a single section. The remaining sections can remain in production while sample mould equipment is placed on the machine, allowing bottle makers to configure the sample job to their satisfaction. This helps ensure better start-ups on full production runs while improving the ware quality being sent to the packaging area.
Bottle manufacturing With Flex Run, it is required that the same bottle manufacturing process be used – either Narrow Neck Press and Blow (NNPB) or Blow and Blow (BNB), due to the type of moulds required. Although no specialised equipment is required, it is Continued>>
Fig 2. According to Ardagh, with Flex Run, production has never been easier.
26 Glass International July/August 2015
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Forming
important to ensure the entire line is able to handle the varying container sizes for inspection and packaging. The Flex Run service enables varying gob shapes to be produced, creating many possibilities for blank design. The Flex Run process can deliver a gob to the mould equipment as long as the weight remains within a given range. In a typical production run, the IS Machine must be stopped completely and reconfigured so the entire production line can be equipped for the next glass container, thus causing production efficiency to drop dramatically, resulting in costly downtime. A full set of mould equipment is required for the entire machine, even though the periodic volumes may be low. Running a ten-section machine produces a customer’s ware much faster, but for small orders the annual volume may be so low that the mould equipment costs cannot be adequately justified. If it is possible to order mould equipment for a smaller number of sections, then the cost to purchase custom mould equipment becomes more cost-effective.
Vision Inspection & Bottle Handling Equipment Independent Systems Finish Inspection • Bottle Handling Devices Star Wheel Separator • Base Inspection Mould Number Reader • Mould Fin Detector
Broader customer base Suddenly, custom bottles are within reach for a broader customer base and smaller-volume customers can develop designs that help differentiate their product on the shelf. With fewer sections in production for a particular item, the result is fewer job changes. A fixed volume order run on fewer sections will require more time to complete. In the meantime, the remaining sections continue to produce the matrix job, while the custom ware is stabilised and packed over a longer period. When the custom production is completed, those sections can be reset to run the matrix job or moved to the next set of custom moulds for another Flex Run job. Having the ability to meet customer needs for two different ware types certainly has its advantages. Historically, glass production has been focused on highvolume, high-speed production capability. As our customers respond to rapidly changing consumer demands, Ardagh has found a means to meet these needs with an affordable alternative to full machine scheduling. With Flex Run, production flexibility has never been easier, helping Ardagh to meet the growing innovation demands of its customers.
*Manager, Production Technology, Ardagh Group – Glass, North America. www.ardaghgroup.com/americas/glass
360° Servo Orientator User friendly high-speed Orientator with integrated bottle separation Upstream and downstream line control & automatic belt speed tracking. 200 bpm
PRO-SIGHT ONE & TWO One: Single Camera Universal Inspection System Two: Dual Camera Universal Inspection System
Glass Wall Thickness Hot or Cold
Single sensor used to measure either Hot or Cold Bottles
BESPOKE HANDLING AND INSPECTION SYSTEMS DESIGNED TO ORDER Fig 3. The Flex Run service enables varying gob shapes to be produced, creating many possibilities for blank design.
Glass International July/August 2015
For further information :
E-mail: info@pro-sight-vision.com www.pro-sight-vision.com Call: +44 1924 465 439
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The change is continuous… …but the high MOTIM-quality is permanent
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Furnaces
Reducing furnace energy consumption at Vidrala Vidrala’s Dr. Estela Alejandro* and Diego Ochoa** outline the company’s energy efficiency strategy, which in recent years has focused on its furnace operations and glass chemistry departments
Furnace Operation and Glass Chemistry were two separate departments within Vidrala until 2012, with their own targets and working procedures, and separate action plans in the case of problems. The Glass Chemistry department’s working procedure was based on adjusting the
Furnace operation Working procedures in furnace operation are generally based on experience and therefore submitted to subjective actions. This method is valid on a day-to-day basis but the results are unpredictable and lead to an instability that results in higher energy consumption. So an energy introduction model was developed, where all the input parameters were determined and the actions standardised. Continued>>
100 90
of blister issues at Vidrala in the 20122014 period.
% over total issues
80
Fig 1. Reduction
70 60 50 40 30 20 10 0
2012
2013
Type (a)
2014
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Department integration
colouring/reducing compounds to achieve colour specifications and/or modifying raw material proportions to keep the target oxide percentages. In the Furnace Operation department any blister or seed problems were solved by increasing energy consumption. So the first step was to integrate Furnace Operation and Glass Chemistry into the same department, together with the environmental area. Common targets were marked, action plans put together and a strategy coordinated.
Type (b)
Blisters/ton glass
O
ne of the main priorities in glass industry manufacturing is furnace efficiency. It is well known that large cost savings can be achieved by reducing energy consumption. Industrial experience shows that glass quality is often the constraining factor in the process of reducing energy. Gas emissions and other pollutants, closely linked to energy management in the furnace, have to be kept under the legal limit. So decreasing specific energy consumption by keeping the standard glass quality specifications and limiting pollutants has become a challenge for glassmakers. During the economic crisis that affected southern Europe three years ago, energy became a key factor for Vidrala, so the company took on the challenge and prepared its own strategy. The strategy was structured on four main blocks: (1) organisational changes by the integration of furnace operation and glass chemistry departments; (2) development of management and control procedures; (3) investigation of every issue in glass quality that may limit energy reduction (blisters, cords, stones); and (4) the roll-out of research & development projects.
70 71 72 73 74 75 76 77 78 79 80 81 82
66 67 68 69 70 71 72 73 74 75 76 77 78
Redox index
z Fig 2. Different behaviours observed in blister occurrence according to the redox index value.
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Furnaces
0,037 0,035 0,033 0,031 0,029 0,027 0,025 0,023 0,021 SO3<0,019% 0,019 0,017 0,015 0,013 0,011 0,009 0,007 63,0 % SO3 in glass
Fig 3. Sulphur solubility vs. redox index value for several reduced glasses in Vidrala. Arrows indicate the redox index value where sulphur is below 65,0 67,0
69,0
71,0
73,0 75,0
77,0
79,0
81,0
83,0 85,0
0.019% in glass.
Redox index
sensitive glasses without affecting quality and pull, it is essential to understand how optical and chemical glass parameters can influence during the melting and fining processes. Blisters are the main issue affecting olive green quality and are the main obstacle to energy reduction targets. The glass chemistry department strategy had to be re-defined: first, blister issues had to be reduced. For this, it was necessary to understand how glass chemistry works on blister formation mechanisms.
Blisters/ton glass
Control model
66 67 68 69 70 71 72 73 74 75 76 77 78
70 71 72 73 74 75 76 77 78 79 80 81
Threshold~70-71%
Threshold~75%
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z Fig 4. Examples of blister occurrence in type b furnaces at different redox value thresholds. This method is based on three pillars: (1) cost control, by balancing fossil and electrical energy depending on price; (2) definition of temperature and consumption targets; and (3) calculation of the energy portion directly applied to glass, taking into account the external effects. The method was standardised by corresponding working procedures and data registration forms, and implemented in every plant, as well as the formation of communication channels via reports. Energy consumption values stabilised as a result of the energy introduction model and high consumption peaks disappeared, which resulted in average lower values. Although the stabilisation of the process reduced energy it was still far from the targets sought by the department. A temperature decrease was regarded as the necessary next step to achieve the required reduction targets. Internal and external benchmarking was performed to identify the best practices to achieve a temperature reduction while still retaining glass quality. Targets took into account all the boundary conditions: type of furnace, colour, cullet percentage and pull. Best practices and defined targets, managed by the new standard energy introduction model, have led to a 2% reduction in energy consumption in two years (2012-2014). The method became insufficient as it was constrained by the appearance of
blisters, mainly in reduced glasses, and mostly in olive green – the main colour produced by Vidrala. It was necessary to carry out research to improve energy consumption reductions. Vidrala’s research projects continue today and these focus on process simulation by furnace and regenerator modelling, and on the optimisation of the energy introduction model with the help of commercial software.
Glass chemistry The optimisation and control of glass redox conditions during melting and fining are critical elements to achieve a good energy consumption/glass quality ratio, usually when the furnace operation has been optimised. Within industrial soda-lime container glasses, one the most redox sensitive colours is the so-called olive green (and its variations), that can produce, among others, colour deviations and blisters. This is a problem since it affects quality specifications and generates production losses. The narrow redox stability region of the glass requires accurate control of many elements. These include furnace operation parameters (as described above), cullet composition and its organic content, and the proportion of colouring, reducing and oxidising compounds in the batch that ensure glass quality specifications and that minimise production losses. To reduce energy consumption of these
A new reference glass control parameter was established in the definition of the management procedures: the ‘redox index’, expressed as Fe(II)/Fe total ratio. The redox index had always been measured but never used as a reference. The redox index target values were defined for each colour, as well as upper and lower limits. A glass chemistry control model was then developed and built to guarantee the following: r Colour specifications and viscosity properties, to be always between upper and lower limits; r Redox index between upper and lower limits; r Stone and blisters under maximum limit values; and r The cost of the batch. The operation is based on the corrections of deviations when parameters go over the upper and lower limits, parameterisation of the actions and, importantly, the preservation of cullet stability. This final issue is crucial because most of the cullet used at Vidrala for olive green production is mixed cullet. The method was standardised by corresponding working procedures and data registrations forms and then implemented in every plant. Communication channels via reports were also set-up. The result has been an increase of the stability of the reference parameters and quality specifications.
Cullet stability Cullet is the most important raw material used for olive green production so a method was developed to keep its stability. r Characterise the origin of the cullet, knowing that the origin is described Continued>>
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DECORATION TECHNOLOGIES
KBA-KAMMANN GmbH Bergkirchener Str. 228 路 D-32549 Bad Oeynhausen (Germany) Fon +49 (0) 5734 5140-0 路 Fax: +49 (0) 5734 5140-5130 mail@kba-kammann.com 路 www.kba-kammann.com
Flexible. Precise. Innovative.
Furnaces
by the following parameters: the type of cullet (mixed, flint, amber), colour proportions, grain size and organic content. This origin issue is even more critical in Vidralaâ&#x20AC;&#x2122;s case, where up to nine different cullet origins can be used at the same time. r Separation of cullet in plant by origin, the different origins are never mixed, both for storage and consumption. r Detailed planning of storage and consumption of each origin. These plans are done to reduce the number of changes, both changes in % and changes in origins. They also take into account the age of the cullet, that is to say, the organic content. This way the furnace with longer periods of stability can be provided. r Improving quality control procedures in plant. r Collaboration with the supplier and treatment plant.
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Blister issue reduction A so-called issue investigation procedure was set-up to undertake the blister reduction project. The aim of the procedure was to identify standard behaviours that could lead to established practical working protocols. During the issue investigation, the issue cause was identified, glass and furnace data analysed, production losses calculated and corrective and preventive action plans defined. All results and conclusions were registered in the issue report. Standard contingency protocols were created thanks to the issue investigation, both in glass and furnace operation, that have lead to a reduction of 53% of blister issues in two years (Fig. 1). In spite of this large reduction, some blister issues still remained that were not controlled rapidly enough. Therefore, a new project was formed to analyse and understand how glass chemistry influences blister formation mechanisms in Vidralaâ&#x20AC;&#x2122;s furnaces. To assess the influence of glass chemistry in blister formation, hundreds of industrial data were analysed, taken from everyday production, with the purpose of finding standard behaviours and relationships between them. Analysed industrial data consist mainly of glass data (redox index, SO3 content, iron oxide and chromium oxide content), furnace data (energy consumption, rising temperatures) and quality data-like blister concentration. These data belonged to 10 different colour campaigns in six furnaces, mostly olive green glass, but
also amber and antique, in a two- year period (2013-2014). When comparing the industrial data, two apparently contradictory behaviours were observed. There are some furnaces where blisters appear when glass is oxidised below a certain number of redox index (type a, Fig. 2). When the redox is higher, blisters become less. There are other furnaces that behave in exactly the opposite way; blisters appear over certain redox index, and they become less when glass is oxidised (type b, Fig. 2). For the (a) type furnaces, the observed effect was a consequence of sulphur solubility in glass. In Fig. 3, blisters appear when the sulphur solubility is below 0.019%. In some furnaces, this limit happens even at high redox values for olive green (>77 %). From an industrial data assessment, it was observed that, at a certain redox index value, the lower the solubility the more frequent the blister occurrence. Similarly, the larger the slope of sulphur solubility curve, the larger the risk of having blisters. At a certain redox value, the differences in sulphur solubility depend on several factors, such as chromium oxide content, glass temperature and possibly other parameters not yet identified. Research is underway to increase sulphur solubility in order to get more stability in a larger redox region while keeping colour specifications. Type b furnaces behave exactly the opposite. There is no blister problem at oxidation but at reduction, that is, over certain redox values bubbles start to appear. This effect has been observed not only in olive green glass but also in other reduced colours such as amber
and antique. For these types of furnaces, there are different redox thresholds for blister occurrence; blisters appear over different redox values depending on the furnaces (Fig. 4). It is certain that this effect is not a sulphur solubility question. Some hypotheses are under research and several laboratory and industrial scale tests are planned.
Conclusion Vidrala has done a lot of work in the past three years to reduce energy consumption in glass furnaces. The strategy has been defined not only in technological areas, but also in organisational and management aspects. The furnace operation and glass chemistry areas have to work interdependently and cannot leave out environmental management and furnace maintenance. Glass companies have plenty of knowledge based on experience and with subjective opinions. Improvements in energy reduction and glass quality can be achieved only by gathering and structuring this knowledge, with clear working procedures and well-defined targets based on internal and external benchmarking. It is important to understand the mechanisms that dominate glass melting and fining processes and to learn how the different input parameters (glass chemistry, energy sources, batch preparation) influence these processes. Data analysis and simple lab and industrial scale tests can be performed to assess the open hypotheses. r
*Physical Chemistry Laboratory Manager, **Furnace Production Manager, Vidrala, Bilbao, Spain. www.vidrala.com/en
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2015 www.glassmanevents.com/latin-america
22-23 September 2015 Expo Guadalajara, Guadalajara, Mexico
CATALOGUE
Ta ble wa re
Glass ainer
Cont
Floa t Gl ass Thin Glass
Fi br e
G las s
We have solutions for all types of glass production
EME Maschinenfabrik Clasen GmbH 路 E-Mail: contact@eme.de 路 www.eme.de
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From Glass People - For Glass People My creators made me so smooth and perfect, that`s why I made it around the world.
Thank you GPS
Competent through experience. Since 1923, in direct collaboration with colleagues from the neighbouring production facility, mechanics and engineers have been developing machines and installations for producing container glass.
Glasproduktions-Service GmbH
RuhrglasstraĂ&#x;e 50 45329 Essen Phone +49 (0) 201 36 00 771 Fax +49 (0) 201 36 00 737 info@gps-essen.de www.gps-essen.de
A company of Saint-Gobain Oberland AG
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22-23 September 2015 Expo Guadalajara, Guadalajara, Mexico
CATALOGUE
Ta ble wa re
Glass ainer
Cont
Floa t Gl ass Thin Glass
Fi br e
G las s
We have solutions for all types of glass production
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WELCOME
Glassman Latin America 2015 Catalogue
Glassman Latin America Welcome to Glassman Latin America 2015, and to Mexico - a country with a booming container glass industry that is currently at the centre of big changes and major investments. We hope that whether you are exhibiting at the show or just visiting, you will develop new relationships and reaffirm old ones, taking advantage of the fact that suppliers for the entire glassmaking process are housed under one roof. As always, we have organised a free-of-charge conference to run alongside the event, for an insight into industry trends and issues. This year’s conference theme is ‘Future solutions in the container and hollow glass industries’, and we are pleased to bring you speakers from Gerresheimer, BDF, AGR and Heye International, amongst others. Mexico is home to seven major glass container manufacturers, including Owens-Illinois (O-I), Fevisa, Pavisa and Grupo Modelo. The Mexican container glass industry has recently seen a joint venture between O-I and Constellation, as well as the ongoing acquisition of Vitro’s food and beverage division by O-I. The country has a world-renowned drinks industry, namely down to its Tequila and beer sectors, which ensures a high level of demand for glass bottles which is constantly expanding. Guadalajara is at the heart of the Tequila region, and we hope you take the oppportunity to sample some of the local produce while you are in town. Next year’s Glassman show will be held in Abu Dhabi, making a welcome return to the Middle East region. For further information get in touch with one of the Glassman team at this year’s event, or email Ken Clark (kenclark@quartzltd.com) or Jeremy Fordrey (jeremyfordrey@quartzltd.com).
VENUE: Expo Guadalajara, Mexico 10.30 - 19.00 10.00 - 16.00
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Opening hours: Tuesday 22nd September 2015 Wednesday 23rd September 2015
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ORGANISER: Quartz Business Media Ltd
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STAND No
COMPANY NAME
AGC Ceramics
E07
Agr International
E06
Magneco Metrel
C13
All Glass
B01
Merkad Makina Kalip
A24
BDF Industries
E03
Mersen Mexico Monterrey
E10
Beroa Novocos
B02
Messersi Packaging
A04
Car-Met
B13
Metavil
D12
Changshu Jianhua Mould Technology
A05
Metra
A14
Diter
A30
MGFS Glass Factory Services
E07
Dominion Industry
B02
Moldes Medellin
A03
Dura Temp Corporation
D01
Motim
A30
E.W. Bowman
A09
MSK Covertech Inc
D13
Electroglass
A28
Nikolaus Sorg
B03
EME Maschinenfabrik Clasen
B03
Olivotto Glass Technologies
E09
Ernst Pennekamp
A23
Parkinson Spencer Refractories
A15
Falorni Gianfranco
B16
PD Refractories
E13
Fermac
D09
Pennine Industrial
D01
FIK (UK)
C01
Pneumofore
C08
Fickert + Winterling Maschinebau
A10
Poco Graphite
D01
Fives Stein
D01
Polychem
A32
Flammatec
C01
Pyrotek
E01
Forma Glas
E12
Quantum Engineered Products
D10
Fosbel
A30
Ramsey Products
A09
Frazier-Simplex
A02
Reckmann
C11
futronic
E12
Refractarios Zedmex
B12
Glass International Magazine
High-Performance Material
STAND No B11
Rodatec
A01
Glass Service (Czech)
C01
S.I.G.Ma.
B10
Glass Service (Italy)
C09
Satinal
B09
Henry F Teichmann
C05
Sheppee International
D01
Heye International
A07
Special Shapes Refractory Co
A30
Horn Glass Industries
C10
Specialty Rondot
E16
Hotwork International
E07
Stara Glass
A12
ilis
B15
Strutz International
A09
Interglass
D01
System Res
B14
iProtec
A13
Tarkus Refractories
E07
Iris
C03
The Teco Group
C12
Thimon
A16
IWG Ingenieurb端ro D14
Tiama MSC & SGCC
C06
KBA-Kammann
Wagenbauer Glasofenbau
D11
Total Specialities USA
E16
Lahti Precision
A19
UAS Messtechnik
E07
Lattimer
D01
VMA
A23
Logistica Comercial Brigmadi
A11
Waltec Maschinen
D14
LSN Diffusion
E11
Zecchetti Srl
E15
Zippe Industrieanlagen
E07
Luoyang Dayang
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COMPANY NAME
EXHIBITOR LIST
Glassman Latin America 2015 Catalogue
Exhibitor information correct at time of going to press. Floorplan overleaf (page 36)
35 Glass International July/August 2015
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Exhibitor information correct at time of going to press.
M
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FLOOR PLAN
Glassman Latin America 2015 Catalogue
Hollow glass industry set for Guadalajara
ore than 85 of the world’s leading technology suppliers to the hollow glass industry are exhibiting at Glassman Latin America. Renowned companies will be exhibiting at the event which takes place in Guadalajara, Mexico on September 22 and 23. The event focuses on the hollow glassmaking industry and aims to bring together international experts, and glass manufacturers that use hollow glass to discover the latest innovations. The exhibiting companies will come from Europe, Asia, North and South America as well as Mexico. A free-to-attend conference will run parallel to the exhibition and so far has 14 confirmed speakers who
will each give a 20-minute presentation. The visitors that have registered to attend include representatives from Mexican hollow manufacturers Vitro, Pavisa, Fevisa, Grupo Modelo and Sivesa. The domestic industry has been in the news already this year with two huge acquisitions. Recently, the world’s largest container glass manufacturer, O-I, said it was to buy the food and beverage business of Mexico’s largest container glass manufacturer Vitro for $2.15 billion. In February this year, US company Crown Holdings bought Mexican packager Empaque for $1.225 billion. The deal included Empaque’s glass bottlemaking company Sivesa,
based in Veracruz, Mexico. A third acquisition, in 2012, saw global brewing giant Anheuser-Busch InBev acquire Mexico’s Grupo Modelo group, which makes glass bottles and brews beer.
About Glassman The Glassman series of events has been running for nearly 30 years and has brought thousands of hollow and container glass professionals together around the world. The event focuses on the hollow glass industry only and serves a particular niche in the glassmaking industry. This September’s event takes place in Guadalajara, in Jalisco state, which is Mexico’s official tequila state and home to a number of tequila distilleries.
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4-1-23, Shiba, Minato-ku, 108-0014 Tokyo, Japan Tel +81 3544291777 www.agcc.jp Booth: E07 AGC Ceramics Co., Ltd (also called “AGCC”) is a recognised refractory manufacturer and one of the proven suppliers in the world that can provide complete furnace engineering services together with complete refractory supplies and solutions. AGCC is a member of the world biggest glass manufacturer ‘Asahi Glass’. AGCC can propose an excellent furnace concept in terms of energy-saving and environmentally friendly technology with reasonable and economic refractory selection. This combination of material technology and engineering knowledge places AGCC in a unique position in the glass industry. AGCC has been appointed, by many customers in the world, as one of the best partners in terms of single responsibility on furnace projects.
AGR International
615 Whitestown Road, Butler, PA, 16001 USA Tel +1 724-482-2163 sales@agrintl.com www.agrintl.com Booth: E06 AGR International offers a variety of equipment and services specifically designed to meet the quality assurance needs of the global glass container manufacturing, filling and packaging industries. AGR’s products include high throughput, on-line inspection and process monitoring systems for containers and packaging products, automated laboratory products and a variety of manual gauges for use in the laboratory or on the production floor. AGR products play a significant role in the quality and safety of containers and packaging used around the world. AGR’s all-new Sampling Pressure Tester, the SPT2, pushes the boundaries of throughput, pressure generation, handling versatility and measurement precision to levels previously thought impossible. In this product, AGR has married the rugged and reliable performance of previous AGR pressure testing systems with the latest pressure and volume measurement
technology. This combination has resulted in a device that can perform highly accurate, hands-free pressure and volume tests on bottles at a rate of up to 270 bottles per hour. As an industry leader for over 85 years, AGR is committed to provide the glass container industry with the most technologically advanced products and services available for quality control and productivity improvement. AGR products can be found in over 120 countries.
All Glass Via Cesare Sarti, 20 - 43029 Traversetolo, Italy Tel +39 0521340810 Booth: B01
BDF Industries
Viale dell’industria 40, Vicenza, 36100 Italy +39 0444 286100 bdf@bdf.it www.bdf.it Booth: E03 BDF is a group of five leading companies in the hollow glass market, and one of the few OEM (Original Equipment Manufacturer) of melting furnaces, working-end, forehearths, feeders, IS machines and related control systems and equipment. Thanks to their companies, BDF Industries, BDF Servis, GT Glass Technologies, MCR Systems, TDE Macno, the group shares not only technological know-how and a big push for innovation, but also expertise, enthusiasm and a deep sense of belonging that makes it possible to understand and satisfy the requirements of the industrial sector worldwide. The path of evolution and the experience of more than a century has brought the group to promote alternative solutions, such as to retrieve the dispersion of thermal energy and produce energy respecting the environment. Our mission is to supply our customers with the maximum support in innovation, services and energy saving, and assist them in facing the market.
Car-Met
Via Cavour 9, 31013 Cimetta di Codogne’, Italy Tel +39 0438 794784 info@carmetspa.it www.carmetspa.it Booth: B13 For 45 years Car-Met has dedicated its activity to the hollow glass and decorating industry. The company has chosen to develop its own technology with the aim to improve the performance of its machines, always assuring a lower consumption. Strategic choices have been made to offer to customers the highest technology available in the market. Car-Met has the complete construction of its machines under its own control: design, structure, mechanical components, combustion installation, burners and the electrical installation are carried out inside the Italian plant. This system enables the company to control and assure the qualitative standard, makes it possible to respect delivery terms, allows for the guaranteed availability of spare parts and to be always in the condition to satisfy customers’ requests. Production: annealing lehrs; decorating lehrs; toughening lehrs; lehrs for special uses; mould pre-heating ovens; cross conveyors; stackers; hot glass scrapers.
Changshu Jianhua Mould Technology Shajiabang Town, Changshu City, Jiangsu Province Tel +86 51252509323 Booth: A05
Diter
Av. Del Parque 628, Col. Parque Industrial San Rafael, Guadalupe, Nuevo Leon, Mexico, 67710 Tel +52 (81) 8327-3079 bortiz@diter.com.mx www.diter.com.mx/ Booth: A30 Diter es tu mejor aliado en la industria del vidrio para soluciones de materiales refractarios y su mantenimiento. Representamos a Special Shapes Refractory Company, Minteq, y Motim, fabricantes líderes de refractarios para hornos de fundición de vidrio a nivel mundial. También, Continued>>
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AGC Ceramics
GUIDE TO EXHIBITORS
Glassman Latin America 2015 Catalogue
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Glassman Latin America 2015 Catalogue
somos representates de Fosbel, líder mundial en mantenimiento y reparación “en caliente” de material refractario en hornos de fundición de vidrio, por medio de métodos inovadores y propietarios. Nuestra experiencia como empresa familiar nos avala, con la confianza que nos han depositado clientes como: Guardian, Grupo Vitro, Grupo Fevisa, Sivesa, ABI Inveb (Grupo Modelo), Saint Gobain, Vidrioformas, Pavisa y Grupo Vical, entre otros. Diter is your best ally in the glass industry for furnace refractory solutions and their maintenance. We represent Special Shapes Refractory Company, Minteq and Motim, well established suppliers of refractory solutions for glass furnaces worldwide. We also represent Fosbel, a world leader for glass furnace refractory repair and maintenance solutions through proprietary and innovative methods. Our experience as a family business is clear, with the confidence from clients such as Guardian, Grupo Vitro, Grupo Fevisa, Sivesa, AB InBev (Grupo Modelo), Saint-Gobain, Vidrioformas, among others.
Dominion Industry
construction, maintenance and demolition. We also provide rope access expertise. We are also experts in hot repairs, while the plants is in operation, with technologies such as ceramic welding and robotic shotcreeting for the steel and glass industry. More than 100 years experience, in Mexico 30 years. Presence in 25 countries. For glass industry: Technical demolition refractory assembly mechanical & steel assembly hot repairs.
Dura Temp 949 S. McCord Road, Holland, Ohio, USA Tel +1-419-866-4348 Lori.Kennedy@duratemp.com www.duratemp.com Booth: D01 Dura Temp Corporation is an industryleading supplier of hot ware handling solutions for glassmakers worldwide. From the gob forming area through to the lehr loader, Dura Temp offers superior materials for standard parts and assemblies, as well as custom solutions. Dura Temp’s exceptional service enables glass manufacturers to achieve optimum results in the hot-end, supported by high-quality ware handling components, including: Sweepout pockets and assemblies, ware guides, transfer paddles, lehr stacker bars, lehr bar pockets and insulators, contact pads and fingers for container handling, and vacuum pads, platens and guides for tableware handling.
tonnes/day provide operating economy and glass quality assurance. High efficiency convection current control boost systems improve furnace pull and glass quality and enable significant tonnage increases with simultaneous reductions in electrical consumption. All electric forehearths for both volatile and non-volatile glasses offer substantial energy cost savings compared with other all-electric and gasfired designs. Electroglass high quality, insulated, water-cooled electrode holders are available for horizontal and vertical applications. Based in southeast England we offer worldwide service to our customers in all five continents with local representation in many regions.
EME Maschinenfabrik Clasen
Wockerather Weg 45, Erkelenz, Germany Tel +49 93525070 contact@eme.de www.eme.de Booth: B03 Leading worldwide supplier of batch and cullet handling technology, engineering, equipment and services for float, containers, display glass, fibres, special glasses, etc.
Ernst Pennekamp
www.glass-international.com
Electroglass Diagonal 27, Col del Valle, CP 03100, Mexico DF Tel + 52 55 16610923, 52 1 5526992994 adrian.lopez@beroa-mexico.com.mx www.beroa.group.com Booth: B02 Dominion Industry is an entity that adds together the historical experience of Karrena, Burwitz and CTP, the capacity in complex projects of CRI, Altac and Bierrum, the specialised technologies from Steelcon and Novocos and the leadership of Dominion and Beroa. A success history of knowledge, innovation and integration to serve our customers with a clear vocation of global leadership. World leaders in industrial services, especially in refractory, external insulation, acid resistant linning, fire proofing and painting. Dominion Industry is the premier chimney and tower builder worldwide. We specialise in concrete and steel chimneys, as well as in solar towers, cooling towers and silos. Our range of activities include, inspections, designs, new
4 Brunel Road, Manor Trading Estate, Benfleet, Essex SS7 4PS, UK Tel +44 (0)1268 565577 info@electroglass.co.uk www.electroglass.co.uk Booth: A28 Electroglass Ltd is an independent specialist in all-electric glass melting, conditioning, electric boosting and related systems. Based on decades of experience and ongoing technical development, Electroglass provides the most up to date technology for electric furnaces, forehearths and boost systems for all glass types, as well as precision control bubblers and ancillary equipment, such as glass level sensors, throat heating and drain systems. Our scope of supply includes design and specification, equipment supply and installation, plus commissioning of individual specialised equipment or complete system packages. All electric furnaces ranging from 200kg to over 250
Königsfelder Str. 38-42, Ennepetal, Germany Tel +49 2333 6050 Fax +49 2333 605200 info@pennekamp.de www.pennekamp.de Booth: A23 With its experience of more than 60 years, Pennekamp is a leading manufacturer of lehrs, hot end handling systems and container glass coating for the glass productions. This refers to glass industries such as container glass, table ware, float & display glass, solar glass and automotive glass processing. The scope covers design, engineering and manufacturing of quality equipment focusing on performance and low energy consumptions. In the area of hot glass handling as well as glass coating, the major aspects are performance and reliability. Pennekamp products include ware transfers, cross conveyors (segmented/water cooled), various types of
servo lehr stackers (speed related designs), energy-saving lehrs for the annealing of container glass, float & display glass, solar glass and table ware, as well as decorating and toughening lehrs. In addition, the company is involved in automotive glass processing (bending and toughening).
E.W. Bowman Richmond Street, Uniontown, PA, 15401 USA Tel +1 724 438 0503 sleaper@ewbowman.com www.ewbowman.com Booth: A09 E.W. Bowman Inc. has been a world leading supplier of annealing lehrs, decorating lehrs and mould pre-heating ovens to the container glass industry since 1959. Based in Uniontown, Pennsylvania, USA and with sales and service offices in York, UK and Bogota, Colombia it has supplied over 1200 lehrs to 56 countries. More information is available on our website www.ewbowman.com, or you could visit our International Sales Manager, Samuel Leaper at our booth. He can also be contacted via email at sleaper@ewbowman.com or phone at +1 724 438 0503.
Falorni Gianfranco V.le IV Novembre 15, Empoli (FI), Italy Tel +39 (0)571 922333 info@falorniglass.com www.falorniglass.com Booth: B16 Falorni has worked in glass since 1958 and is today a successful company focusing its activity on the design and installation of solutions for glass melting and conditioning. Our furnace technology ranges from conventional regenerative or recuperative air/gas heating systems, to oxygen/gas heating systems or hybrid gas and electric. Our glass range covers all the types: Soda-lime, crystalline, lead crystal, borosilicate and special glass. We deliver solutions from 30-50 ton/day suitable for automatic production of tableware up to 200-350 ton/day for high capacity container glass production. A feature of our furnaces and plants is maximum efficiency combined with high reliability. This is the result of experience, accurate modeling and the perfect combination of technological assets necessary to achieve the expected performance. Falorni uses first class refractory materials and integrates only high quality components, merging its Continued>>
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Fermac Via La Spezia, 162/A, Italy Tel +39.0521989056 sales@fermac.it www.fermac.it Booth: D09 Fermac is an Italian company based in Parma, Northern Italy, active in the screen printing market since 1993. Now it has reached a full and complete range of machines and is able to give its clients any sort of solution. From the small semiautomatic machines of Serie M, to bigger automatic and electronic Serie RUV, to CNC units as Serie F, CL and Flex-Num plus additional systems such as Uvitreat. Having said that, the companies newest focus is the development of its Jet Art range, digital printing CNC unit, suitable not only for the cosmetic industry but also for the long run container sector. From a commercial point of view, Fermac is concentrating its efforts on following up what our R&D department is doing, satisfying current customers demand whilst preempting future demand.
FIC (UK)
Longrock Industrial Estate, Penzance, Cornwall, TR20 8HX, UK Tel +44 (0)1736 366962 general@fic-uk.com www.fic-uk.com Booth: C01 F.I.C. (UK) Ltd designs and supplies all-electric furnaces as well as electrical boosting systems for a wide range of glass types and manufacturing processes including TFT, float, fibre, container, and borosilicate. We also have a wide range of electrode holders including our High ‘Q’ holder in which the cooling circuit is replaceable in under 10 minutes, and our Maxi ‘Q’ weld-free holder in which there is no weld inside the furnace refractory blocks making it ideal for more aggressive glasses. In addition, we specialise in a number of glass conditioning options such as our Isothermal unit for glass conditioning in the forehearth or distributor to eliminate
top-to-bottom and side-to-middle temperature differences. This system will significantly improve thermal homogeneity in coloured glasses and high productivity forehearths in flint glass. We also offer heat extraction systems to extract heat from the glass to aid glass conditioning and reduce gas consumption by the use of removable water-cooled tubes. In addition, these water-cooled tubes can be used to prevent premature shutdown of a furnace by rendering safe worn refractories. F.I.C. is a world leader in energy substitution systems and alternative technologies including nano-particle coating technology in partnership with Emisshield & Harbison Walker International.
Fickert + Maschinebau
Winterling
Wölsauer Str. 20, Marktredwitz, D - 95615, Germany Tel +49 (0)9231 / 502-57 www.fickertwinterling.de Booth: A10 Fickert + Winterling Maschinenbau GmbH is a leading manufacturer of high quality glass rolling machines and sheet glass cutting lines. We have our own ‘best proofed’ solutions. This is all completed by engineering and services. Since 1799 we are serving the glass industry as a partner of flexibility. Our engineering is individual and adjusted to the client’s interest for its best and improved glass production. Fickert + Winterling Maschinenbau GmbH is internationally well known with satisfied clients. The combination of flexible design and its own facilities for the production of machines, installation and commissioning, guarantees a high grade product with economical benefits for our clients. We specialise in rolled glass production starting from lowest to highest production volumes, up to 250tpd per production line including self-made cutting lines. Fickert + Winterling Maschinenbau GmbH is also a partner for glass foam production lines with a designed and proven technology for ‘fresh’ and recycled glass. With partner companies we can offer complete rolled glass plants, including solar glass productions with glass thicknesses down to 2mm. Fickert + Winterling Maschinenbau GmbH supports you with a group of well experienced experts to improve and extend your production. Solar, rolled and recycled glass productions.
Fives Stein
4A Churchward, Southmead Park, Didcot, Oxfordshire, OX11 7HB, UK Tel +44 (0)1235 811111 stephen.sherlock@fivesgroup.com www.fivesgroup.com Booth: D01 In glass, Fives is the glassmakers’ solution provider to enhance your plant performance, your competitiveness and to support you in the optimisation of your investment: We design, manufacture, install and commission glass equipment according to your needs. With 60 years of experience in a wide range of glass processes and applications all over the world, Fives is a demanding glassmakers’ partner in automotive, architectural, ultrathin, container, pharmaceutics, perfume, fibre, crystal and many other special glass processes. Fives offers a dedicated range of services, including the training of your teams on our equipment and assisting them for the full-scale glass production, which are offered to support you along your lines life cycle. Our understanding of the glass production processes and our intimacy with major glassmakers enables us to develop technologies and equipment answering our customers’ needs in terms of glass quality and operational performance. Our innovation aims to offer our customers: Low energy consumption; ultimate glass quality; easy operation and maintenance; optimised investment cost. Our wide range of expertise includes: Float, electric, end fired, oxy fired, and advanced melting furnaces, electric and oxy boosting, working end, forehearths, tin bath, annealing lehr.
FlammaTec
Rokytnice 60, Vsetin, Czech Republic Tel +42 0571498511 sales@flammatc.com www.flammatec.com Booth: C01 FlammaTec, Spol. s r.o (Czech Republic) and its daughter company FlammaTec GmbH (Germany) have become leading suppliers of advanced burner technology for glass furnaces. FlammaTec was founded by
two partner companies (STG Combustion Control GmbH & Co KG, and Glass Service, Inc) as a joint venture. The long-term knowhow of how to supply optimal and flexible heat into the glass can be found back in the advanced burner concepts. Six years since its inception in 2008, FlammaTec has already supplied well over 1500 burners to more than 90 projects on float, container, tableware and special glass furnaces. Such a strong reference clearly shows the benefit of this innovative combustion technology, which offers high performance solutions to FlammaTec customers. During Glassman Europe 2015 FlammaTec introduced its FlexOxy burner. FlammaTec burners improve heat transfer from combustion to the glass melt and thus also improve furnace efficiency and lower emission when replacing conventional burners. FlammaTec offers the following advanced LoNOx burner types: Underport gas injector, flex or freejet underport gas/oil dual injector, flex and freejet underport heavy oil injector (also can be used for backup solutions) sideport gas injector, flex new oxy’gas burner.
Forma Glas Salzburger Strasse 1, Neukirchen, Austria Tel +43 7729 20299 info@formaglass.com www.formaglass.com Booth: E12 Forma Glas machines + engineering is an innovative manufacturer of glass production machines for stemware, tumblers and press articles. Based in Austria and with more than 120 years of experience, we build individual machines and complete production plants. Production lines for: Stemware production; tumbler production; vases and bowls; ophthalmic lenses; car headlights; thermos flasks; laboratory glass articles; lamp bulbs; press glass lines glas processing machines; blowing machines lbs with 8 up to 32 stations for the production of stemware bowls, tumblers, laboratory articles, lamp bulbs, thermos flasks, vases and bowls etc. up to 60/pc. /min; presses type isp with 8 up to 20 stations hydraulic or servo for the production of stems for stemware (with bottom), ophthalmic lenses and smaller pressed glass articles; double station presses up to 14 double stations (isp 14/2); presses type rph, hydraulic or servo, with 6 up to 16 stations for the production of pressed table glassware; presses for the production of technical glass (car headlights); cold processing Continued>>
www.glass-international.com
experience with accurate calculation of performance based on theoretical modeling made with modern tools. The installation and commissioning of our plants is managed by skilled technical staff granting to the customers the respect of all specifications agreed.
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machines; automatic cracking-off, grinding and polishing machine type asa with 15, 30 or 45 stations for the finishing in standard cut-off process or laser cutting; washing and drying belt; fire polishing machine; tableware inspection machine.
Fosbel
20600 Sheldon Road, Brook Park, Ohio, 44142, USA Tel +1 (216) 362 3900 gortiz@diter.com.mx Fosbel.Inc@Fosbel.com www.fosbel.com Booth: A30 Fosbel es líder en reparación de material refractario en hornos de fundición de vidrio. La compañía ha conducido más de 2,500 reparaciones de hornos a todo alrededor del planeta. Los expertos ingenieros y técnicos de Fosbel están familiarizados con casi cualquier condición, y las reparaciones son conducidas de una manera efectiva y eficiente, reduciendo el tiempo muerto a un mínimo absoluto. Nuestros servicios incluyen inspecciones de hornos, soldadura cerámica, reparaciones ‘en caliente’, limpieza de checkers, restauración del piso de puertos, así como recubrimiento completo para bóvedas, entre otros. Fosbel is a leader in glass furnace refractory repairs. The company has conducted more than 2,500 glass furnace repairs of virtually every type around the world. Fosbel’s experienced engineers and technicians are familiar with almost any furnace condition, and repairs are conducted in an effective and efficient manner, reducing production downtime to an absolute minimum. Our services include furnace inspections, ceramic welding, hot repairs, checker cleaning, port floor restoration and dual crown overcoats, among others.
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Frazier-Simplex PO Box 493, 436 E. Beau Street, Washington, PA, USA Tel +1 7242251100 Booth: A02
futronic Tolnauerstr. 3-4, Tettnang, Germany Tel +49 (0) 7542 5307 0 info@futronic.de www.futronic.de
Booth: E12 The German company futronic GmbH, a subsidiary of the German Jetter AG, has obtained an exceptional reputation as a high-tech electronics engineering company worldwide. futronic has more than 40 years experience in developing, manufacturing and commissioning electronic control systems for the hollow glass manufacturing and tableware industry. For example: Electronic timing systems for a range of needs; synchronous drive systems; hot end reject systems for stuck and down ware; gateways to integrate components from other suppliers; cold end coating systems; controlling of proportional valves; automation of the lehr; training systems; and various, useful software packages. The new generation of timing system is called ‘FMT 24S’. This Flexible Modular Timing System for a maximum of 24 sections offers a high degree of flexibility and could be adapted to any type of I.S. machine. Customer satisfaction and constantly improved quality are the focus of futronic´s activities, which is reflected in fast delivery, comprehensive pre- and after-sales support, training and remote maintenance service.
Glass International Magazine
Quartz House, 20 Clarendon Road, Redhill, Surrey, RH1 1QX, UK Tel +44 (0)1737 855000 glass@quartzltd.com www.glass-international.com
Glass Service (Czech Republic)
Rokytnice 60, 755 01 Vsetin, Czech Republic Tel +42 0571498511 info@gsl.cz www.gsl.cz Booth: C01 Glass Service (GS) headquartered in the Czech Republic with offices in the Netherlands, USA, China and Slovakia is a leading consultant in the field of glass melting, furnace control, operation, troubleshooting and optimising furnace designs. GS programmers have developed in-house mathematical modeling software enabling the optimisation of glass melting
and combustion processes in glass furnaces and forehearths. More than 600 different projects have been completed using GS software. Presently a new version of furnace modelling software (GFM 5.0) is being developed. GFM 5.0 uses a new generation of non-orthogonal mesh, which provides proper representation of all geometric features and local refinement. GS has its own laboratory for glass defect analysis and analyses more than 2,000 defects yearly. Additional testing capabilities utilise basic and applied research in the field of glass melting. GS has invested considerable effort into developing a new technology called ‘Supervisory Advanced Control System’ using our proprietary software known as the Expert System - ESIII. More than 90 installations have been successfully deployed worldwide. GS supplies high quality selected raw materials to the glass industry. GS has registered lead silicate.
Glass Service (Italy) Via Cascina Lari, 56028 San Miniato, Pisa, Italy Tel +39 0571444235 Booth: C09
Henry F Teichmann 3009 Washington Road, McMurray, PA, Washington, 15317 USA Tel +1-724-941-9550 info@hft.com www.hft.com Booth: C05 Henry F. Teichmann, Inc. started servicing the glass industry in 1947. Our engineering, technical service, purchasing, construction and project management team is committed to providing turnkey services for batch plants, complete glass plants, electric furnaces, container glass furnaces, float glass furnaces, fiber glass furnaces, foam glass furnaces, sodium silicate furnaces, pressed glass melting services, TV glass furnaces, hand glass processes, tableware and lighting products. In our 68 years we have serviced over 1,000 projects worldwide. Our engineering staff has provided furnace designs utilising regenerative package furnace, crossfire furnace, end-fire furnace, electric furnace and oxy-fuel melter technologies. In addition to successfully converting to oxy-fuel firing for TV glass furnaces and fiberglass furnaces, HFT has worked with PPG in converting three PPG float furnaces into oxy-firing. Three new oxy-fuel float glass lines using HFT/PPG technology have
been successfully built in China. Henry F. Teichmann, Inc. has teamed up with PPG in providing turnkey solutions and up-to-date technologies to the float glass industry worldwide.
Heye International Lohplatz 1, Obernkirchen, Lower Saxony, 31683, Germany Tel +49 5724 26 452 sales@heye-international.com www.heye-international.com Booth: A07 We are Glass People - Being the One. Heye International sets standards as a global player in high performance solutions and customer-oriented services for the container glass industry. Thus, Heye International became a leader in the industry. What makes the difference is our passion for glass. We have got a mission: We are Glass People – with experience and passion heading for highest results. Our mission stands for customers’ satisfaction, our experience in glass and for the glass experts at Heye International. Our portfolio contains: HiPERFORM – IS-Machines and forming technology; HiSHIELD – Inspection technology & quality solutions; HiTRUST – Greenfield projects, modernisations or production optimising and technical assistance. Talk with our experts at this year’s Glassman and learn more about the latest innovation in hot end and cold end to boost your productivity.
Horn Glass Industries
Bergstrasse 2, Ploessberg, Germany Tel +49 96369204 info@hornglas.de www.hornglass.com Booth: C10 Horn Glass Industries is a leading international supplier of high quality glass melting solutions and services. As a competent partner, we strive to deliver the best product in order to allow our customers to benefit from an improved glass production process. Horn has vast expertise in engineering, design and manufacturing of different kind of glass melting furnace types, distributor and forehearth for container, tableware, glass fibre and special glass. Moreover Horn serves the glass Continued>>
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Hotwork International Calle Sonora #100, Col. Flores Magon, Cuernavaca, Morelos, 62370, Mexico Tel +52 17772676666 benjamin.koester@hotwork.ag www.hotwork.ag Booth: E07 Hotwork International, based near Mexico City, supplies services and products for the glass industry worldwide. Services: Furnace heat up; expansion control; cullet fill and furnace draining with complete water recycling; thermal regenerator cleaning; hot repairs. Products: Low NOx and highly energy efficient combustion technology; gas and oil burners for underport, sideport and throughport firing; oxygen burners for furnace and forehearths as well as oxygen roof burner. The Hotwork International team is always happy to assist you with our long term experience and expertise.
www.interglass.com.mx Booth: D01 Interglass SA de CV is a leading developer, manufacturer and supplier of speciality lubricants for the global glass industry. We are the only company focused on co-creating and tailoring solutions to each customer’s specific needs, in order to improve the packing rate, extend lubrication cycles and reduce the overall maintenance cost. Only specialised lubricants can cover the demanding requirements of the glass forming and finishing process. We have developed an extensive product line designed specifically for the most demanding applications: shear blade lubricants, delivery oils and coatings, the widest range of swabbing compounds, high performance IS machine oils and more. Interglass was founded in 1992 and belongs to Interlub Group, a leading speciality lubrication company that develops and manufactures tribological solutions for the most critical industrial applications.
iProtec
ilis Konrad-Zuse-Str. 22, Erlangen, Germany, 91052 Tel +49 9131 9747790 info@ilis.de www.ilis.de Booth: B15 ilis develops, produces and distributes software solutions, measuring systems and automated test equipment for quality assurance in the glass and optical industry. With the measuring and testing equipment of the StrainMatic and StrainScope series, the company develops imaging polarimeter systems for the automatic and objective measurement of residual stress in glass and plastics. BatchMaker and Chroma provide the glass industry standardised software solutions for simple and reliable calculation of batch recipes and glass properties, as well as for transmission and colour measurement
Dr.-Schott-Str. 35, Zwiesel, Germany Tel +49 (0)09922 98468 info@iprotec-gmbh.com www.iprotec-gmbh.com Booth: A13 Iprotec GmbH specialises in the development, construction, planning, manufacturing, installation and commissioning of glass machines and systems. The main area of expertise is in particular the construction and building of machines for hollow glass production. In our projects, we are focused on a good and permanent cooperation with customers and we offer you the following services: feeders; shears, blow moulding machines; press machines; sealing machines; casting machines; chains (handling equipment); lehr loading; lehr unloading; crack-off / melt-off; laser marking; automatic quality control; packing.
Interglass
Iris Inspection Machines
Lateral Sur Periférico Norte 559, Parque Industrial Belenes Norte, Zapopan, Jalisco, 45150 Mexico Tel +52 (33) 37 93 88 00 sales@interglass.com.mx
Parc du Chêne, 14 rue du 35ème Régiment d’Aviation, 69500 Bron, France +33 4 72 78 35 27 contact@iris-im.fr www.iris-im.com
Booth: C03 Iris Inspection Machines provides inspection solutions for glass containers of any shape or colour, including wine, beer, liquor and Champagne bottles, pharmaceuticals, perfumes and food containers. A team of dedicated Research and Development engineers has evolved a range of equipment to match the industry’s demanding requirements and satisfy the inspection needs of key international customers. The recent move to new premises in Lyon (France) represents an important step for Iris, who expects its new premises to be an important tool, helping the company to always better serve the industry. The company has based its development on a long-term partnership with glassmakers in the field of glass defects detection, as well as on an exceptional knowhow in the most innovative vision technologies. Iris was the first to develop and propose a 12 camera inspection machine. The success of Iris is due not only to the exceptional efficiency of its Evolution machines range but also to the excellent support provided by engineers worldwide. Thanks to a network of international agents and technical service centres, Iris is able to support customers throughout Asia, Europe, the Americas, Africa and Australia.
IWG Ingenieurbüro Wagenbauer Glasofenbau
KBA Kammann Bergkirchener Str. 228, 32549 Bad Oeynhausen, Germany Tel +49 573451400 Booth: D11
Lahti Precision
Ahjokatu 4A, Lahti, Finland Tel +358 3 829 21 Fax +358 3 829 4100 sales@lahtiprecision.com www.lahtiprecision.com Booth: A19 Companies of all sizes all over the world have selected Lahti Precision as their supplier of batch plants, cullet recycling systems, waste fiber glass recycling systems, engineering studies, and plant modernisations. With over 200 references, everyday more than 50,000 tons of raw materials are processed with the aid of Lahti Precision’s technology to be melted to the highest quality standards required for float glass, bottles, strong reinforcement fibers, warm insulation wool, flat TVs, LCD panels, bright tableware, and various other glass products.
Lattimer
Fürhaupten 35, Zwiesel, 94227 Bavaria, Germany Tel +49 99228448-0 info@iwg-online.com www.iwg-online.com Booth: D14 IWG designs, manufactures and supplies different glass melting furnaces, such as pot furnaces, day tanks, regenerative, recuperative and oxygen heated continuous tank furnaces as well as full electrical heated tank furnaces for domestic and lighting ware, tableware, containers, technical glassware, etc. IWG also offers pot arches, tempering furnaces, glory holes, all forehearth systems, supply stations for all medias, burner systems, combustion equipment, boosting and process controlling systems. IWG activities include engineering, services and consulting up to turnkey projects - Service worldwide.
79-83 Shakespeare St., Merseyside, UK Tel +44 (0)1704 535040 janice.aindow@lattimer.com www.latimer.com Booth: D01
Southport,
Logistica Comercial Brigmadi Tomillo 63, Victoria de las Democracias, Azcapotzalco, Distrito Federal, 02810, Mexico Tel +52 (55) 5556 2582 www.lcb.com.mx Booth: A11 We are specialists on refractory installation and thermic insulation, with several years of experience developing projects of construction and reparation of furnaces for national and international companies. Our strengths include quality assurance and occupational safety: All of our processes are certified according to the international norms ISO 9001 and OHSAS Continued>>
www.glass-international.com
industry with complete float glass projects. Internationally, more than 20,000 tons of glass is produced in furnaces manufactured by Horn each day.
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18001. This has allowed us to continuously increase the efficiency of our works, have zero claims during its accomplishment and meet the deadlines set in the planning. Also, because of our commitment to preserve the health and safety of our human value, we do our jobs with adequate operational discipline that allows us to reach our goal of zero lost time injuries. Experience and specialisation: We have engineers, technical service and highly qualified staff, in order to provide optimal services and engineering solutions to our customers in all of our construction projects and repairing of furnaces and other process equipment.
LSN Diffusion Cilyrychen Industrial Estate, Llandybie, Ammanford, Carmarthenshire, SA18 3GY, UK Tel +44 (0)8456800233 Booth: E11
Luoyang Dayang HighPerformance Material Songzhuang development zone, Mengjin, Luoyang, China, Tel +86 1082628985 dynh009@126.com www.refractory-dy.com Booth: B11
Magneco Metrel 223 W Interstate Road, Addison, Illinois 60101, USA Tel +1(630)5436660 Booth: C13
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Merkad Makina Kalip Maltepe Mah. Karacabey Sok. No.8/A, Istanbul, Zeytinburnu, 34010, Turkey Tel +90 212 4830710 msahin@merkad.com www.merkad.com Booth: A24 Best quality moulds and equipment for tableware glass industry. Glass moulds & machine spare parts supplier. Supplier of a wide variety of glass moulds for the tableware glass industry. Press, stemware lines, press & blow and spinning machines. Machine spare parts, neck ring baskets (holder or hanger), mould holders for 0-90 and h-28 type machines, two or three part press mould holders, crack off line mechanism gripping & loader & unloaders.
Mersen Mexico Monterrey Temis 703. Colonia Arbolledas de Santa Cruz, Guadalupe, Nuevo Leon, Mexico Tel +52(818)1272826 Booth: E10
Messersi Packaging Via I Maggio, 8, 60010 Barbara (AN), Italy Tel +39 071963861 mes@messersi.com www.messersi.com Booth: A04 Messersì Packaging, a leading company in the packaging market, established its position in the market with the production of PP and PET strapping band and with a complete range of packaging machines: Automatic and semi-automatic strapping machines, wrapping machines, hooding machines, thermo- shrinking system and complete packaging lines. With 35 years of product and service quality Messersì is the partner that comes up with new construction concepts for just the right, most effective, high-performance and sustainable solutions. Messersì is a byword for the conceptual and cultural innovation of industrial packaging, customised for any production line, any manufacturing and logistic sector, in all time zones, in all continents. Messersì presents itself to its customers as a single point of contact for the supply of machines and/ or automatic packing, handling, storage and logistics systems for palletised paper packs. The whole process is managed inhouse, from the offer to the design stage, from production to installation. The sales network and the Technical Assistance Service are able to operate worldwide ensuring customer’s success.
Metavil
Estrada da Maceira, 60, Picassinos, Marinha Grande 2430-444, Portugal Tel +351 244572960 comercial@metavil.pt www.metavil.pt Booth: D12 Metavil: Empresa Transformadora Metalo Vidreira, Lda. Founded in 1977 with the aim of developing and producing moulds and accessories for the glass industry, Metavil has been developing this area of work based on a philosophy of continuous
improvement of working methods and procedures ensuring the total satisfaction of our clients. Metavil has a set of resources capable of producing high quality moulds.
Motim
Metra Route d’Eu, BP2 76340 Blangy-sur-Bresle, France Tel +33 232974400 Booth: A14
MGFS Glass Factory Services Malaga 44 Norte, Col. Mixcoac Insurgentes, Del. Benito Juarez, Mexico, 03920 Tel + 52-777-3183972 mglassfactoryservices@hotmail.com Booth: E07 Our company offers worldwide supervision for: Furnace construction or cold repairs (steel & refractories), furnace inspections and evaluations, furnace maintenance, hot repairs, heatup & filling, thermal checker cleaning, drilling, overcoats, furnace operation, troubleshooting, construction of working ends and forehearths, fused cast preassembly inspections. Construction organisation and management, batch plants, project management for turn-key furnace and/or batch plants. We are official agents for: Zippe in Mexico, Costa Rica and Guatemala and for UAS-Messtechnik, Asahi Glass Ceramics Company, Hotwork AG-Switzerland for all of Latin-America. Together with these companies, we can offer individual solutions for the needs of the glass industry and complete turnkey projects. We offer more than 30 years of experience in the glass melting process, furnace construction, furnace comissioning, heat-up, batch preparation and handling. We offer 24/7 attention to our customers and direct comunication with all of the companies we represent. We speak German, Spanish, English, French, Italian and Portuguese. MGFS is a company proudly serving the glass industry.
Moldes Medellin Cra 49 #75 sur 133, Sabaneta, Antioqula, Colombia Tel +57 44039350 Booth: A03
9200 Mosonmagyaróvár, Timföldgyári utca 9-13, Mosonmagyaróvár, Hungary Tel +36 96 574 284 bortiz@diter.com.mx babos.zo@motim.hu www.motim.hu Booth: A30 Motim es reconocido como uno de los líderes mundiales en la producción de refractarios electrofundidos. Nuestros productos son utilizados principalmente en las industrias del vidrio y ceramica. La oferta de productos para la industria del vidrio incluyen los refractarios Korvisit A y Korvisit Ab de alumina electrofundida, así como los refractarios de AZS electrofundido Zirkosit S32, Zirkosit M36 y Zirkosit Y41. Motim is recognised as one of the world’s leading producers of fused cast refractories. Our products are mainly used in the glass and ceramic industry. The company’s speciality products for the glass industry include Korvisit A and Korvisit Ab fused cast alumina refractories, as well as Zirkosit S32, Zirkosit M36, Zirkosit Y41 fused cast AZS refractories.
MSK Covertech 4170 JVL Industrial Park Drive, Marietta, Georgia, 30066, USA Tel +1 770-928-1099 marcela.leano@msk.us www.mskcovertech.inc Booth: D13
Nikolaus Sorg
Stoltestrasse 23, Lohr am Main, Germany Tel +49 9352 507-0 nsorg@sorg.de www.sorg.de Booth: B03 The Sorg Group, along with their member companies, can supply turnkey installations and equipment from raw material delivery through the glass gob worldwide. This includes all aspects of the furnace lifetime cycle. From sustainable designs, construction, services, repairs, through Continued>>
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Olivotto Glass Technologies
V.Le Gandhi, 22, Avigliana, TO 10051, Italy Tel +39 011-9343511 info@olivotto.it www.olivotto.it Booth: E09 Olivotto Glass Technologies is a world leader in the supply of machinery and production technologies for hollow glass, from stemware line, to spinning machines, to tubing lines, to press machines for the production of any type of glass. Our supplies include: Feeders, press and blow m/c, presses-glass bricks and glass insulators lines, CRT presses, special presses for technical glass, twin table for pitchers m/c, blow-blow m/c, spinning m/c, stem welding m/c, burn-off m/c, stretching m/c, multifunction machines for stemware production, large containers m/c, glass tubing lines, fire-polishers, revamping and overhauling for all the above machines, engineering and services for turn-key projects technologies, products and services coming from the best know-how of Olivotto, Antas, Lynch And Lindner.
Parkinson-Spencer Refractories Holmfield, Halifax, West Yorkshire, HX3 6SX UK Tel +44 (0)1422-254472 admin@parkinson-spencer.co.uk www.parkinson-spencer.co.uk Booth: A15 Parkinson-Spencer Refractories Ltd manufactures refractories and engineered products for the glass industry. The product range is as follows: refractory division feeder expendables manufactured under licence to Bucher Emhart Glass; forehearth refractories for all types of forehearth; channel blocks in zircon-mullite and dense bonded alumina; working end and distributor glass contact blocks in dense bonded alumina; glass contact &
back-up blocks for the furnace; open & closed glass melting pots for the handmade glass industry; technical services division forehearth and distributor systems; forehearth and distributor combustion systems; forehearth and distributor control systems; cord dispersal stirrer systems.
the ever increasing demands of the glass industry and can significantly improve the handling of: bottles, jars, pharmaceutical and perfume ware, stemware, tableware and drinking glasses, pressed ware such as bowls, car lights and larger items such as glass bricks.
PD Refractories NA
Pneumofore
USA +1 502 241-5438 (U.S. East coast time) info@pdr-na.com www.pdr-na.com Booth: E13 PD Refractories is your powerful and competent partner for refractory products ranging from standard firebricks, to highalumina products manufactured from sillimanite, mullite, bauxite and corundum; super duty silica bricks, including our patent pending, energy saving Epsilon crown; zircon and zircon-mullite. And with our long term strategic alliance with Guangzhou Ling Nan Refractories Co., Ltd. we can provide you a complete refractory package with isostatically pressed products such as dense chromic oxide, dense zircon (zirconium-silicate), dense alumina, dense zirconia, dense tin oxide and chromium containing coarse grades, as well as electro-fused cast refractories based on AZS, alumina, and zirconia. We would welcome the opportunity to discuss where quality PD Refractories would fit within the scope of your next projects, and look forward to meeting with you soon, or at Glassman Latin America in Guadalajara!
Pennine Industrial Manor Croft Works, Skelmanthorpe, UK Tel +44 (0)1484 864733 sale@pennine.org www.pennine.org Booth: D01 Pennine Industrial Equipment Ltd has been involved in the manufacture and supply of ‘silent’ inverted tooth conveyor chains for the glass industry for over 30 years. During this time there have been ever increasing demands placed on the glass industry. Pennine has continued to improve its product range, ensuring that we remain a market leader within the glass container handling sector. Our range of patented HPLs (Head Protector Links) is a typical example of our willingness to work closely with hot end engineers, with a view to improving our customers overall efficiency. Pennine’s ‘PREMIUM’ Conveyor Chain has been especially developed to meet
Via N. Bruno, 34, Rivoli, TO, 10098, Italy +39 011 950 40 30 info@pneumofore.com www.pneumofore.com Booth: C08 Designer and manufacturer of rotary vane vacuum pumps, vacuum systems and air compressors to cover the pneumatic requirements of IS machines. Swiss engineering since 1923 for low operational cost, long durability and efficiency. Pneumofore rotary vane technology is gaining ground in the glass industry thanks to the numerous references with renowned reliability. Industrial vacuum systems based on rotary vane technology. Readyto-use, sliding vane, air-cooled vacuum pumps up to 6480 m3/h capacity and 0.5 mbar(a) residual pressure, with five years of efficiency guaranteed. Designed for 120,000 hours of operation without repair, and easy maintenance. Optional are variable speed, hot climate, central and remote control versions. Designed for continuous, heavyduty operation in glassworks worldwide. Vacuum system design and engineering for a low total ownership cost. Sliding vane, single-stage, lubricated, ready-to-use and air-cooled air compressors from 2.5 to 10 bar(g), up to 500kW, capacity up to 5120 m3/h, with the highest compressed air purity. As for all A-Series compressors, several options are available such as VS drive, remote control or connection to any PLC system, heat recovery and extraordinary air-cooling for tropical countries, up to 55°C environmental temperature.
Poco Graphite
300 Old Greenwood Rd, Decatur, Texas, 76234 USA Tel +1 940 393 4322 erin.adkins@entegris.com
www.poco.com Booth: D01 At Glassman, Poco Graphite will display precision ware handling solutions and unique Glassmate graphite materials that improve performance in container glass production, reduce machine downtime and increase yields. Poco is known for its designs, particularly precision holders and inserts that allow fast accurate machine setup and insert replacement. Standard steel holders are available in several types and sizes. Inserts are available as semi-finished blanks, or can be precision machined to a specific finish. Application specialists can assist in the selection of the optimum graphite grade based on pickup, application, and length of the production run. A featured product will be Poco’s new Glassmate-XL grade graphite. XL is an exceptionally strong and wear resistant 1-micron grade. It’s an ideal material for highly detailed thread finishes and long run, high wear conditions.
Polychem 6277 Heisley Road, Mentor, Ohio 44060 USA Tel +1 440-357-1500 mcojocaru@polychem.com www.polychem.com Booth: A32 Polychem/OMS Systems is a prime manufacturer of PET (polyester) strapping and strapping equipment for the glass container industry. Polychem offers top seal, side seal and horizontal unitiser/palletiser equipment for the lowest cost of ownership. All sales are backed with customer training and comprehensive service programmes. In addition to plastic strapping and strapping equipment Polychem/OMS Systems also produces hooding machines for glass bottles and containers. Contact Polychem/ OMS Systems for your glass securement and packaging needs.
Pyrotek Decada #5008, Parque Industrial Milenium, Apodaca, N.L. C.P., 66626, Mexico Tel +52 811-247-80-00 info@pyrotek-inc.com www.pyrotek.info/glass Booth: E01 Improve quality and performance, lower costs and narrow your vendor base with Pyrotek. A global company headquartered in North America, Pyrotek has experienced sales engineers around the world who Continued>>
www.glass-international.com
demolition at the end of the campaign. Sorg, through EME, Nikolaus Sorg GmbH, and SKS, delivers ‘Made In Germany’ solutions to all sectors of the glass industry. Our latest products include the LoM burners and the BATCH3 system. LoM burners are Low Momentum, Low Maintenance oxy-fuel burners. BATCH3 consists of IRD Doghouse, EME-NEND chargers and the proven Sorg Batch and Cullet Preheating systems.
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will work with you and your production team. Expendable refractory feeder parts/ shear blades/ I.S. machine parts/ take-out holders with DuPont Vespel inserts/ sweepouts/ transfer wheel parts/ stacker bars/ glass bending and tempering stainless steel fabrics, tapes, ropes and sleeving materials/ hot glass contact rollers/ insulation materials/ custom fabricated high temperature gaskets and seals.
Quantum Engineered Products 438 Saxonburg Boulevard, Saxonburg, Pennnsylvania, 16056 USA Tel +1-724-352-5100 info@quantumforming.com www.quantumforming.com Booth: D10 Advanced TWT plunger mechanisms and complete blankside forming systems, plus the Total Forming Analysis (TFA) and automatic gob weight control / process control system for IS machines. Quantum’s forming system can provide glassmakers with the ultimate combination of hardware across all forming processes, and we do it with fewer system parts and on any IS machine. We specialise in improving the critical process of blank side forming. At Quantum, we remain committed to the intelligent engineering of glass container forming systems. Solving your container forming problems is more than just a part of our business; it has been our only business for the past 40 years.
Ramsey Products PO Box 668827, Charlotte, NC, USA Tel +1 7043949134 Booth: A09
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Reckmann Werkzeugstarße 19/23, Hagen, 58093 Germany Tel +49 2331 3501-607 falero@reckmann.de www.reckmann.de Booth: C11 Quality ‘made in Germany’. Since 1970. We are one of the leading manufacturers of thermocouples and resistance thermometers. With more than 140 employees we produce crown, stack, bottom, spout and forehearths/feeder elements with platinum TC`s and platinum tip. We also offer recycling of old platinum and buying of your scrap of platinum and rhodium. Best quality for your satisfaction!
Refractarios Zedmex Galeana 415 OTE, Sta Catarina, NL 66376, Mexico Tel +52 8183363595 Booth: B12
Rodatec Campos Eliseos 188-1101, Col. Polanco, Deleg. Miguel Hidalgo, Mexico City, Distrito Federal 11560, Mexico Tel +52 55 5281 1172 rodatec@prodigy.net.mx www.rodatec.com Booth: A01 Rodatec, S.A. de C.V. has over 40 years of experience as the distributor and commercial representative for leading manufacturers of industrial decorating equipment for glass for the following processes: Screen printing (Machines Dubuit); digital printing (Dubuit Digital); pad printing (Teca-Print); hot stamping and heat transfer (CER). We distribute all the consumables related to the processes covered by our equipment range, with extensive inventories in Mexico, and we serve our customers with our side-by-side technical support, both on their new projects as well as on their current operations. Precisely this support has enabled us to become and maintain our position as leaders in the industrial decoration market.
S.I.G.MA. Group Via Delle Grigne, 12/A, Locate Varesino, Como, 22070 Italy Tel +39 0331-823195 sigmaref@tin.it www.sigmaref.it Booth: B10 S.I.G.MA. Group, specialised in the production of refractory materials for the glass industry since 1990, supplies the full high quality range of materials including sillimanite, mullite, zirconmullite, zircon, high alumina, fireclay, fused cast, insulating, magnesite, silica, special cements and concretes. S.I.G.MA. Italy produces 3,200 tons/year of special pieces and 6,500 tons/year of pressed material. Completing the range, about 5,000 tons/year are produced by our partners and controlled by our technicians both in production and auditing. S.I.G.MA. SRLU is the new facility located in Plovdiv, Bulgaria commissioned in March 2014 with a manufacturing capacity of 2,500 tons/year of vibrocast shaped pieces. Today, S.I.G.MA. Group is a
leader in Europe in terms of capacity, prices and lead times of shaped pieces.
Special Shapes Refractory Company
Satinal Via Rossini, 4, Molteno, Lecco, 23847 Italy Tel +39 031870573 info@satinal.it www.satinal.it Booth: B09 Satinal is an Italian company, specialising in the production of a chemical powder and equipment for the frosting/acid etching on the hollow glass (cosmetics, beverages, lighting) and flat glass. Satinal is present throughout the world, giving its customers quality, services and support, before sale, during the production/expedition, and after the sale. Satinal is a supplier to the most important glass manufacturers/decorators worldwide.
Sheppee International Halifax Way, Airfield Business Park, Elvington, York Y041 4AU, UK Tel +44 (0)1904 608999 kulliott@sheppee.com www.sheppee.com Booth: D01 Sheppee International Ltd is a world leader in hot glass ware handling for both the container and tableware industries, with over 50 years of experience. Sheppee supplies innovative and dependable solutions in the field of hot container conveying, lehr loading, glass contact materials and synchronous drive systems. Specific ware handling equipment has been developed including a range of servo driven lehr loaders suitable for all types of production. The Tri-Flex 3 axis servo loader offers maximum flexibility for the operator and provides a job storage facility. The MRS-9000 two axis servo loader is ideal for replacing existing mechanical machines. A full range of ware transfer units have been designed, suitable for handling the smallest pharmaceutical containers up to the largest champagne bottles. Dedicated transfer units are available suitable for flask and non-round containers. The recent development of the 6 axis ware handling system is proving to be very popular. Total synchronisation, handling and positioning of containers from the sweep out of the forming machine though to the loading of the lehr can now be controlled by a single windows based operator interface mounted at the rear of the lehr loader or remotely in an IEC standard control cabinet.
1100 Industrial Blvd, Bessemer, Alabama, 35022 USA Tel +1 205 424 5653 bortiz@diter.com.mx abarron@ssrco.com www.ssrco.com Booth: A30 Special Shapes Refractory Company (SSRCO) es una empresa familiar especializada en la ingeniería y manufactura de formas vaciadas de material refractario para la industria del vidrio, usando mezclas propietarias. Ofrecemos servicios de afilado y acabado, tiempos de respuesta excepcionales para reparaciones de emergencia, y a través de nuestros socios comerciales, podemos proveer soluciones en refractarios para asistir a nuestros clientes en reparaciones “en caliente” o “en frio”. Avanzando hacia nuestro segundo cuarto de siglo, SSRCO continua inovando con nuevos desarrollos en refractarios, tanto en materiales como en el diseño de formas, que en conjunto ayudan a nuestros clientes a competir en un mercado global. Special Shapes Refractory Company (SSRCO) is a family owned business that manufactures specialised, engineered pre-cast refractory shapes utilising SSRCO developed refractory mixes for use in the glass industry. We offer grinding and finishing services, quick turn-around times for emergency repairs, and with our co-op partners, we can provide refractory solutions that assist our customers for either ‘hot or cold’ repairs. As we move into our second quarter century, SSRCO is still continuing to work on refractory developments, both in refractory material and shape designs, that will continue to help our customers compete in the global market.
Specialty Rondot 30 Montgomery Street, Ste 240, Jersey City, Hudson, 07042 USA Tel +1 201-434-3600 info@specialtyrondot.com www.specialtyrondot.com Booth: E16 Specialty Rondot, a Groupe Rondot company, specialises in servicing the Continued>>
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can decorate larger bottles. The CLS-200 is a revolutionary design that has replaced the carrier conveyor chain or ‘link system’ with precision cams and can decorate a typical 12oz beverage bottle at speed of 200 BPM with ultra high precision. They are available in left to right, or right to left configurations, which can conserve floor space and manpower when multiple decorators are used. A typical CLS-200 has one extra station of which can be used for either seam registration or an additional decorating station! This provides customers with a simple and economical means for future expansion, something that our competitors do not offer. Both the CLS-200 and the CLS175 come standard with user-friendly touch screen control panels. Strutz International also manufactures and supplies ancillary equipment. Lehr loading stackers: push bar, pull bar, dual feed stacker systems. Strutz conveyors: single liners, lehr cross conveyors and dual cross conveyor systems automatic colour. Feeding systems: ECDDSL-1 and ECD-DSL-2 with dual single loop accurate temperature control.
TECO Group
Stara Glass
Piazza Rossetti, 3A/1, Genova, 16129 Italy Tel +39 010 576391 info@hydragroup.it www.staraglass.it Booth: A12 Turnkey jobs; furnace design; materials supply; furnace construction and demolition; plant start-up and running; maintenance at high temperature; research & development; other services.
Strutz International 440 Mars-Valencia Road, P.O. Box 509, Mars, Pennsylvania, 16046 USA Tel +1 724 625 1501 engineering@strutz.com www.strutz.com Booth: A09 Strutz International is a leading manufacturer of high speed, high quality bottle decorating equipment. Since the introduction of the CLS-200 chainless decorator, it has become the world’s top selling high-speed bottle decorator. Strutz now introduces the new CLS-175, which uses the same chainless technology but
3400 Executive Parkway, PO Box 2927, Toledo, Ohio, OH 43606-2927 USA Tel +1 419-537-9711 sales@teco.com www.teco.com Booth: C12 TECO is one group comprising five companies offering you total furnace capability. From electrode holders to turnkey plant construction, we have the inhouse expertise to meet your needs. Toledo Engineering, Tecoglas and KTG Systems can offer complete capabilities in glass furnaces of all types, with KTG Engineering supporting this activity as glass plant equipment manufacturers. Zedtec are the TECO Group specialists in forehearth and working end technology. The TECO Group has over 85 years’ experience serving the world’s primary glass manufacturing industry.
Thimon Savoie Hexapôle - 170 rue Louis Armand, Mery, France Tel +33 (0)4 79 61 00 44 m.mongellaz@thimon.com www.thimon.com
Booth: A16 Thimon is the only manufacturer with total expertise in every packaging technology for more than 40 years: Stretch/ shrink hooding, spiral wrapping, full web wrapping, bundling, conveyors.
Tiama MSC & SGCC ZA des Plattes,1 chemin des Plattes, Vourles, 69390, France Tel +33 4 37 20 15 00 marketing@tiama.com www.tiama.com Booth: C06 Tiama MSC & SGCC: On-line process and quality controls for glass packaging industry.
Total Specialities USA 5 North Stiles Street, Linden, New Jersey 07036 USA Tel +1 800 323 3198 dave.townsend@total.com www.totalspecialties.com/ Booth: E16 Total Specialties USA, Inc. – Glass Products Division, is the manufacturer and worldwide supplier of Kleenmold lubricants and coatings used in the glass container industry. Kleenmold Swabbing Compounds are recognised as the industry standard worldwide. In addition to Kleenmold, Total Specialties USA, Inc. manufactures a complete range of hot end lubricants and coatings. Our technical team is dedicated to formulating new products that are easier to use, environmentally friendly and improve the efficiency of the bottle making process. Total Specialties USA, Inc. is available to work with you and your company individually to solve any and all lubricant related concerns. Please stop by our stand E16 and we will be happy to discuss your needs.
UAS Messtechnik Prof.-Hermann-Staudinger-Straße 4, Viechtach, Germany Tel +49 (0) 99 42 / 94 86 - 0 info@uas.de www.uas.de Booth: E07 UAS Messtechnik is an innovative company of international reputation in the field of instrumentation engineering. Due to our broad know-how and conclusive complete solutions for all kind of process industry, we are the ideal partner to increase the efficiency of your plant. UAS provides
custom-made automation solutions. Our process management systems ensure a communication based on a highly intelligent structure utilising an open, freely definable architecture. With our 50 highly qualified employees UAS is able to realise turnkey projects. Worldwide service and after sales support are part of our basic services.
VMA
Gewerbegebiet 1 (OT Wümbch), Gräfinauer Straße 2, Wolfsberg, Germany Booth: A23 VMA specialises in manufacturing noncontact measuring and control equipment for the glass industry, such as thickness and stress measuring equipment for float glass, diameter and wall thickness measuring equipment for tubing lines and tube processing including control, regulation and visualisation systems as well as thickness measuring instruments for the on-line container glass inspection. VMA is able to integrate the thickness measuring systems in all kind of star wheel inspection machines at the cold end at container glass lines. Supply of turn-key systems including training and long-term service is guaranteed.
Waltec Maschinen
Kronacher Str. 2a, Wilhelmsthal, Germany Tel +49 92 60 99 01-0 info@waltec.de www.waltec.de Booth: D14 We design, construct, manufacture and supply machines for the glass industry. Production programme: Fully automatic production lines with PLC/CNC electronic control for tableware, spinning articles, stemware, press-blown articles, blowblow articles, toughening/tempering, microwave and technical articles, washing machine glasses, cold light reflectors, glass insulators, glass blocks. Quadruple gob lines/triple gob lines/double gob lines/ single gob lines. Spinning lines/stemware lines/press-blow lines/blow-blow lines/ toughening/tempering lines. Continued>>
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container glass industry through the supply of unique products and customised engineering solutions. The product range comprises products manufactured by Groupe Rondot companies such as Graphoidal, Rondot, Sheppee International, and Sonicam as well as complimentary products from external Principals such as Pennine Industrial Equipment and Heat-Up. Experienced sales engineers are available to visit customers and discuss regular requirements as well as potential efficiency and quality improvements within the container glass manufacturing process. CAD design services are offered for bespoke customer solutions or modifications to standard equipment. Products: Furnace/ inspection cameras; shear spray systems; spare parts and accessories for is machines; multi-zone is machine lubrication systems; stackers, transfers and cross conveyors; conveyor chains, lehr belts; cold end coating bridges and cold end coating dosing systems; mould gauges, reamers and calibers; mould polishing and plunger polishing machines; mould volume measuring equipment; temperature measuring equipment.
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Zecchetti
Via Galileo Galilei, 1-1/A, Montecchio Emilia (RE), Italy Tel +39 0522867411 info@zecchetti.it www.zecchetti.it Booth: E15 Zecchetti produces conveying/ palletising turnkey lines for empty glass containers, from lehr discharge up to finished pallet warehousing. The lines can cope with almost all kinds of articles and with a very wide range of speeds. Long experience and cooperation with the biggest glass factories has located Zecchetti among the worldwide leading manufacturers. The ability to propose, manufacture and supply the AS/RS Warehouse system allows Zecchetti to act as a unique supplier for the complete empty container cold end section. A particular feature of Zecchetti is to aim to make the customer’s life easier, namely by studying with them and then realising ‘made to order’ solutions.
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Zippe Industrieanlagen Alfred-Zippe-Str. 11, Wertheim, Germany Tel +49 9342 804-0 zippe@zippe.de www.zippe.de Booth: E07 Zippe has dedicated all its activities to the international glass industry. Acting as a partner in the area of melting material preparation, the design, manufacturing, installation and commissioning of plants, on turnkey basis if required, Zippe offers: Batch plants; engineering; control and automation technology; modernisation of existing plants, mechanical and electrical; modernisation of electronic control and weighing systems; recycling plants for factory cullet, post-consumer glass and special glass waste; batch chargers; glass level controllers; batch preheating; maintenance & service. Zippe is a competent and reliable partner not offering only delivery of equipment but also consulting and engineering. In-house educated engineers and supervisors install and commission the plants. Comprehensive documentation informs the customer about all plant functions and gives technological details, allowing easy problem solving by telecommunication dialogue.
PRODUCTS & SERVICES
Glassman Latin America 2015 Catalogue
Annealing lehrs/kilns Car-Met srl Dominion Industry Ernst Pennekamp GmbH & Co Kg E.W. Bowman Inc. futronic
Batch chargers BDF Industries SpA Electroglass Ltd EME Maschinenfabrik Clasen GmbH Falorni Gianfranco srl Horn Glass Industries AG IWG Ingenieurburo Wagenbauer Glasofenbau Lahti Precision Oy MGFS Glass Factory Services SA de CV Stara Glass SpA Zippe Industrieanlagen GmbH
Batch plant Dominion Industry EME Maschinenfabrik Clasen GmbH Falorni Gianfranco srl Lahti Precision Oy MGFS Glass Factory Services SA de CV Stara Glass SpA TECO Group Zippe Industrieanlagen GmbH
Batch/cullet preheaters EME Maschinenfabrik Clasen GmbH Logistica Comercial Brigmadi SA de CV MGFS Glass Factory Services SA de CV Zippe Industrieanlagen GmbH
Coatings, hot/cold end Fosbel Logistica Comercial Brigmadi SA de CV Total Specialities USA inc
Combustion equipment BDF Industries SpA Car-Met srl Dominion Industry Ernst Pennekamp GmbH & Co Kg E.W. Bowman Inc. Falorni Gianfranco srl Fives Stein ltd Flammatec ltd Horn Glass Industries AG Hotwork International AG MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Stara Glass SpA UAS Messtechnik GmbH
Container forming machinery/components BDF Industries SpA Lattimer Poco Graphite Pyrotek inc
Quantum Engineered Products inc
Control systems, cold end BDF Industries SpA futronic Heye International iProtek GmbH MSK Covertech Inc Stara Glass SpA Tiama MSC & SGCC VMA GmbH
Control systems, forming BDF Industries SpA futronic Heye International iProtek GmbH Olivotto Glass Technologies SpA Quantum Engineered Products inc Tiama MSC & SGCC VMA GmbH Waltec Maschinen GmbH
Control systems, hot end BDF Industries SpA futronic Glass Service Czech Republic Heye International iProtek GmbH IWG Ingenieurburo Wagenbauer Glasofenbau Nikolaus Sorg GmbH & Co. KG Tiama MSC & SGCC VMA GmbH
Control systems, melting BDF Industries SpA FIC (UK) ltd Fives Stein ltd Glass Service Czech Republic Horn Glass Industries AG IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG UAS Messtechnik GmbH
Cullet handling systems EME Maschinenfabrik Clasen GmbH Lahti Precision Oy MGFS Glass Factory Services SA de CV Zippe Industrieanlagen GmbH
Decorating equipment, flat Rodatec SA de CV
Decorating equipment, hollow Fermac Rodatec SA de CV Satinal SpA Strutz International
Continued>>
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Car-Met srl Ernst Pennekamp GmbH & Co Kg E.W. Bowman Inc.
Decorating materials Rodatec SA de CV
Engineering/plant design services AGC Ceramics co. ltd BDF Industries SpA Dominion Industry EME Maschinenfabrik Clasen GmbH FIC (UK) ltd Fives Stein ltd Glass Service Czech Republic Henry F. Teichmann Heye International Horn Glass Industries AG Lahti Precision Oy Logistica Comercial Brigmadi SA de CV MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Olivotto Glass Technologies SpA Stara Glass SpA TECO Group
Feeder mechanisms BDF Industries SpA Falorni Gianfranco srl Fives Stein ltd Glass Service Czech Republic Heye International Horn Glass Industries AG iProtek GmbH Nikolaus Sorg GmbH & Co. KG Olivotto Glass Technologies SpA Waltec Maschinen GmbH
Stara Glass SpA TECO Group
Handling & packaging equipment, cold end Ernst Pennekamp GmbH & Co Kg Messersi Packaging srl MSK Covertech Inc Polychem Zecchetti srl
Palletisers Messersi Packaging srl MSK Covertech Inc Polychem Zecchetti srl
BDF Industries SpA Dura Temp Corporation Heye International Olivotto Glass Technologies SpA Pennine Industrial Pyrotek inc Sheppee International Specialty Rondot inc
Inspection equipment, flat
Melting furnaces, day tanks
Presses
ilis GmbH VMA GmbH
Dominion Industry Falorni Gianfranco srl FIC (UK) ltd Fives Stein ltd Glass Service Czech Republic Henry F. Teichmann IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG
Olivotto Glass Technologies SpA Polychem Waltec Maschinen GmbH
Handling equipment, hot end
Inspection equipment, hollow AGR International Inc Falorni Gianfranco srl Heye International ilis GmbH iProtek GmbH Tiama MSC & SGCC VMA GmbH
Laboratory equipment AGR International Inc Glass Service Czech Republic ilis GmbH Tiama MSC & SGCC
Lehr belts/rollers
E.W. Bowman Inc. futronic iProtek GmbH Olivotto Glass Technologies SpA Waltec Maschinen GmbH
E.W. Bowman Inc. Pyrotek inc
AGC Ceramics co. ltd BDF Industries SpA Dominion Industry Electroglass Ltd Falorni Gianfranco srl Fives Stein ltd Glass Service Czech Republic Horn Glass Industries AG IWG Ingenieurburo Wagenbauer Glasofenbau Logistica Comercial Brigmadi SA de CV MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Parkinson Spencer Refractories Ltd Pyrotek inc
Melting furnaces, continuous
Stara Glass SpA UAS Messtechnik GmbH
AGC Ceramics co. ltd BDF Industries SpA Dominion Industry Electroglass Ltd Falorni Gianfranco srl FIC (UK) ltd Fives Stein ltd Glass Service Czech Republic Henry F. Teichmann Horn Glass Industries AG IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG TECO Group
Fire polishers
Forehearth assemblies
IWG Ingenieurburo Wagenbauer Glasofenbau Logistica Comercial Brigmadi SA de CV MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG
Lehr loaders/unloaders
Melting furnaces, pot Dominion Industry Falorni Gianfranco srl Fives Stein ltd Glass Service Czech Republic Henry F. Teichmann IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV
Moulds, glass forming Merkad Makina Kalip Metavil Pneumfore
Mould maintenance equipment
Lubricants
Oxy-fuel technology
Interglass SA de CV Total Specialities USA inc
BDF Industries SpA Dominion Industry Falorni Gianfranco srl Fives Stein ltd Flammatec ltd Henry F. Teichmann Horn Glass Industries AG Hotwork International AG IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG
BDF Industries SpA Dominion Industry Fives Stein ltd Glass Service Czech Republic Horn Glass Industries AG Hotwork International AG
BDF Industries SpA Dominion Industry Henry F. Teichmann Heye International Pneumofore
Pollution control systems BDF Industries SpA Flammatec ltd UAS Messtechnik GmbH
Process control equipment AGR International Inc BDF Industries SpA EME Maschinenfabrik Clasen GmbH Falorni Gianfranco srl Glass Service Czech Republic Heye International Horn Glass Industries AG ilis GmbH Lahti Precision Oy MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Quantum Engineered Products inc Reckmann GmbH Stara Glass SpA Tiama MSC & SGCC UAS Messtechnik GmbH VMA GmbH
Processing machinery, flat
Car-Met srl Pyrotek inc Sheppee International Strutz International
Melting furnace heat up/cool down
Plant utilities
Specialty Rondot inc
Processing machinery, hollow
BDF Industries SpA
BDF Industries SpA Falorni Gianfranco srl iProtek GmbH Olivotto Glass Technologies SpA Waltec Maschinen GmbH
Project management services Dominion Industry Fives Stein ltd Heye International Horn Glass Industries AG Continued>>
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Decorating lehrs
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Lahti Precision Oy MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Waltec Maschinen GmbH
Tableware forming machinery
Raw materials
MGFS Glass Factory Services SA de CV PD Refractories NA Pyrotek inc S.I.G.M.A. Group Special Shapes Refractory Company Stara Glass SpA
Glass Service Czech Republic Satinal SpA
Refractories, secondary
Technical assistance/training
AGC Ceramics co. ltd Dominion Industry Diter Fosbel Logistica Comercial Brigmadi SA de CV MGFS Glass Factory Services SA de CV Parkinson Spencer Refractories Ltd PD Refractories NA Pyrotek inc S.I.G.M.A. Group Special Shapes Refractory Company Stara Glass SpA
BDF Industries SpA Dominion Industry EME Maschinenfabrik Clasen GmbH Fives Stein ltd Fosbel Glass Service Czech Republic Heye International Horn Glass Industries AG ilis GmbH iProtek GmbH MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Olivotto Glass Technologies SpA Pyrotek inc Stara Glass SpA TECO Group Thimon Tiama MSC & SGCC UAS Messtechnik GmbH Zippe Industrieanlagen GmbH
Refractories, glass contact AGC Ceramics co. ltd Diter Dominion Industry Fosbel Logistica Comercial Brigmadi SA de CV Luoyang Dayang High Performance Material MGFS Glass Factory Services SA de CV Motim Parkinson Spencer Refractories Ltd PD Refractories NA Pyrotek inc S.I.G.M.A. Group Special Shapes Refractory Company Stara Glass SpA
Refractories, insulating
Shrinkwrapping equipment Messersi Packaging srl MSK Covertech Inc Polychem Thimon
AGC Ceramics co. ltd Spinning machines Diter Olivotto Dominion Industry ANTONINI 1_2 oriz 30/01/12 12.30 Pagina 2 Glass Technologies SpA Waltec Maschinen GmbH Logistica Comercial Brigmadi SA de CV
Forma Glas GmbH iProtek GmbH Merkad Makina Kalip Olivotto Glass Technologies SpA Waltec Maschinen GmbH
Temperature measurement equipment Dominion Industry FIC (UK) ltd Glass Service Czech Republic Horn Glass Industries AG Reckmann GmbH Tiama MSC & SGCC UAS Messtechnik GmbH
Trade publication Glass International
Tube drawing machinery Olivotto Glass Technologies SpA
Turnkey glass plant construction BDF Industries SpA Dominion Industry Falorni Gianfranco srl Henry F. Teichmann Heye International Horn Glass Industries AG IWG Ingenieurburo Wagenbauer Glasofenbau MGFS Glass Factory Services SA de CV Nikolaus Sorg GmbH & Co. KG Stara Glass SpA TECO Group
www.glass-international.com
Install Forget
ATS 250 - ANNEALING LEHRS - DECORATING LEHRS TEMPERING LINES - LEHRS UPGRADING
ANTONINI Srl • Via Medaglie d’Oro Resistenza, 2 • 50057 Ponte a Elsa (FI) • Italy | ANTONINI NORTH AMERICA - Pittsburg, U.S.A. Tel.: +39-0571-93221 • Fax: +39-0571-931828 • E-mail: antoninisrl@leonet.it • www.antoninisrl.com
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Events world
Experts gather in Bilbao for Glass Trend seminar
z More than 50 people attended the TC9 seminar in Bilbao.
Members of the ICG’s recently-formed TC9 group joined with Glass Trend in Bilbao, Spain for a two-day seminar aimed at investigating furnace heating technology. Glass International attended. It had its first two meetings in 2014 and each was attended by approximately 35 people The aims of the 2014 meetings were to define the different roles of its members and work out its programme for forthcoming years, including two annual meetings. The TC9 group also intends to contact other companies and trade groups from other geographic regions, and prepare an energy workshop with other energyintensive industries. Another target was to organise a combined seminar with the Glass Trend group. Titled ‘Furnace Heating Technologies and Energy Efficiency’, the event took place over two days in Bilbao, Spain in April this year. Its target audience were Glass Trend and TC9 members. A total of 73 people attended, visiting from 15 countries and representing 40 companies. They heard 17 presentations from a variety of glass professionals. The event was organised in partnership with Spanish container glassmaker
Vidrala who offered an evening dinner at the Guggenheim museum, in Bilbao.
Fossil fuel Among the speakers on the first day was Allied Glass’s John Naughton, who discussed ‘Advancing Furnace Performance and Energy Efficiency’. He talked about how to choose the right technologies when planning a furnace rebuild. Mr Naughton said that when planning the project, some technologies and melting strategies are compulsory while some are a strict either/or decision. For example, the installation of electrode blocks makes a retrofit of electric boosting easier. The installation of additional burner blocks allows for hot spot or crown boosting with air or oxy-fuel. The regenerator, port and combustion space design, once built, cannot be easily changed, so getting these right are critical to the efficiency of the furnace throughout its campaign. Continued>>
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T
he environment and ‘green’ technologies have become increasingly important in the glass industry in recent years. The energy intensive industry has demonstrated countless ways in which it has improved its environmental credentials, particularly in the use of heating technology. In 2013 the International Commission of Glass (ICG) launched Technical Committee 9 (TC9) to bring together experts to focus on energy-efficient glass production. Members of the committee regularly meet to discuss energy saving potential for all steps of the industrial glassmaking process. The committee encompasses all sectors of the industry including container, flat and speciality glass. Membership of the committee is comprised of people mainly from Europe but also from the USA and Japan. Members represent companies ranging from consultancy to equipment supply for the container, float, tableware and speciality sectors.
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Glass melting has to be cost efficient as well as energy efficient, he added, so fuel mix is a key consideration. Fossil fuel is the cheapest energy input but electrical boosting is essential for some glass melting such as coloured glass. Electric boosting also gives tonnage boosting. Oxy-fuel is the best for environmental impact but is expensive, he said. A partial oxy-fuel may have a part to play in future furnace designs. In conclusion he said that the next changes in glass melting are on the
saving measures. During the past 15 years this has helped achieve a 13% reduction in energy consumption over its four glass production sectors.
Batch and cullet preheater Vetropack’s Jan Kebisek described his experience with a new technology in use at a pilot installation for preheating batch and cullet – a method that works according to the fluid bed principle. He explained that different industrial systems for batch and cullet preheating
Delegates heard presentations from 17 people.
horizon. Electric melting is often discussed as the way to decarbonisation but is costly and perceived to be inflexible. Oxy-fuel is also expensive and has less decarbonisation potential. The question is, how will the transition from predominantly fossil fuel glass melting arise?
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Heat balance Turkish manufacturer Sisecam presented a paper titled ‘Heat Balance: A useful tool to create a better fuel economy.’ Presenter Neset Arzan, a Chief Senior Project Engineer of Energy and Combustion Systems at Sisecam’s Science and Technological Centre, discussed how heat balance studies offer a useful tool to understand the parameters that govern furnace performance and productivity. On-site heat balance measurements on existing furnaces help identify weaknesses in design in a retrospective manner. But, Mr Narzan said, model-based heat balance tools can be used to improve on the lessons learned on past designs to help realise increased efficiencies. He also highlighted how Sisecam has reduced its energy consumption during the glassmaking process and has implemented a combination of energy-
have been around for 25 years but require plenty of space and money to install the systems. He said it was difficult to justify the cost of these systems. Vetropack and Austria’s Binder +Co had developed a batch and cullet preheater based on the fluid bed principle. The fluid bed is widely used in various industrial applications mainly to dry materials. Binder +Co had applied the principle to cullet drying systems and had adopted it for preheating. Mr Kebisek said the pilot preheater had been in operation on a port-end furnace for more than a year at Vetropack’s container plant in Nemsova, Slovakia. The preheating effect is achieved by passing waste gas under controlled velocity through a layer of batch and cullet to create a fluidised state. The pilot preheater has a capacity of 40m tonnes a day. Mr Kebisek added that, based on test results, one can estimate how a full-scale preheater would function and with what degree of energy savings. He explained the details of the project with Binder+Co, which was installed in July 2013. The pilot installation processes approximately 10% of total batch flow. The fluidising bed is 2.5m in length and 0.6m wide. The only problems
the company encountered was the installation of regular cleaning processes and the fine-tuning of some parameters. Since then it has worked without any substantial interruption and because of this the company is now preparing a full-scale project based on the successful results of the pilot project.
Olive green glass Vidrala’s Estela Alejandro outlined a strategy to reduce furnace energy consumption in reduced glass (see feature on page 29, this issue). One of the most redox-sensitive colours within industrial soda-lime container glass is olive green and its variations. The narrow redox stability region of the glass requires accurate control of elements such as cullet composition and its organics, and proportion of colouring, reducing and oxidising compounds in the batch. This ensures glass quality specifications are met and production losses are minimised. Industrial experience has proved that glass quality has become a constraining factor in the process of reducing energy. It means the optimisation and control of glass redox conditions during melting and fining has become a critical element to achieve improved energy efficiency. For sensitive olive green glass, it is essential to understand how optical and chemical parameters influence the melting and fining processes. She explained how tests have been conducted on an industrial scale to assess the influence of redox on energy consumption on olive green glass. Her paper discussed some of the results of these tests. Redox control was also the theme of the opening presentation on day two by Ardagh’s Sven-Roger Kahl. His presentation highlighted the correlation between the redox state of the glass melt, the corresponding radiative properties of the glass and the resulting energy efficiency of a glass melting furnace based on data from several furnaces. It has shown how an improved redox control can contribute to improved glass quality and reduced melting cost. In his conclusion he said that by controlling the redox state it is possible to improve the heat exchange flame melt. As a result it is possible to reduce the amount of electrical boosting necessary for the melting process and possible savings are most significant for green glass. Continued>>
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Suppliers A number of glass equipment suppliers also presented papers at the event including FIC UK, Air Liquide, Celsian Glass and Solar, Fives Stein, Praxair and Glass Service. The latter’s Eric Muijsenberg discussed heat transfer optimisation performed by FlammaTec burners. He presented some practical results of the application of a flexible dual gas injector in several glass furnace projects from recent years. Glass manufacturers want options to reduce their existing burners and to help achieve an improved furnace operation. Mr Muijsenberg said the Flammatec Flex Burner uses two separate gas inlets and gas flows into the burner, which are controlled and measured independently.
SCRAPER CONVEYOR
z This year’s co-organiser was glassmaker Vidrala from host country Spain.
The burner tip can be optimised using computational fluid dynamic modelling to minimise turbulence at the burner tip. The burner nozzle was also designed to be fully adjustable, offering new technological advances. An abridged version of the Praxair paper was published in Glass International May 2015 issue (Thermochemical regenerator system proves itself at Pavisa, Page 29). A paper given by British Glass in Bilbao entitled ‘Roadmaps for improving energy efficiency’ was also published in the same issue (Glass Decarbonisation and energy efficiency roadmap to 2050, page 39). The next Glass Trend seminar is planned for 13/14th October this year and will be called ‘Sensors and Control’. It will be held in conjunction with TC21 and TC15 and be open to Glass Trend and TC21 and TC15 members only. TC9 is the 24th committee founded by the International Commission on Glass (ICG). The aim of the technical committees is to advance glass science and technologies. Each TC is formed of glass experts and each has a council, steering committee, chairman and members. The names of other TCs include Gases in Glass, Coatings on Glass, Waste Vitrification, and Glass Melting.
Glass Trend, organising office based at Celsian Glass and Solar, Eindhoven, The Netherlands. www.glasstrend.nl International Commission of Glass (ICG) www.icglass.org
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Glass International July/August 2015
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Environment
ICG’s TC09 focuses on energy Hans van Limpt*, chairman of the ICG’s Technical Committee TC09, outlines the role of the new group and how it will address energy efficiency in glassmaking.
I
n 2013 the International Commission on Glass (ICG) launched a new Technical Committee to focus on energy efficient glass production. It would help decrease greenhouse gas emissions and primary energy consumption in industrial glass production. Its name is TC09: Energy Efficiency in Glass Production. The aim is to bring experts together to discuss the energy saving potential and energy saving technologies available for all steps in the process of industrial manufacturing (from raw materials to glass product) and for all glass sectors. In cooperation with Glass Trend and Vidrala, TC09 recently organised the ‘Furnace Heating Technologies and Energy Efficiency’ workshop in Bilbao, Spain. The objective of the meeting was to bring together the glass industry (GlassTrend) and the ICG’s TC09 to exchange information, analyse further needs and driving forces in the field of furnace energy efficiency improvement by innovative heating technologies. During this workshop 15 oral presentations were given to an audience of about 80 participants.
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TC09 activities in 2014 In 2014 two TC09 meetings were organised: one in Aachen, Germany following on from the DGG - ACerS GOMD glass conference, and in Parma, Italy following on from the ESG-ATIV conference. The meetings were attended by 20 and 15 members respectively. Membership of TC09 is mainly from Europe but also from Japan and the US and several members represent global companies and sectors ranging from consultancy and equipment/material supply to float, fibre, container, tableware and speciality glass sectors.
The TC09 met in Bilbao in April and heard 15 presentations.
Members of TC09 explained about the different domestic situations with respect to energy efficiency regulations, carbon footprint and energy costs. Energy costs and energy-related regulations (CO2 trading) are high on the agenda of regulators as well as the industry, particularly in Europe. In Japan there has been a 20% yearover-year increase in electricity costs and a government initiative for CO2 reduction of about 26% until 2030 is under discussion. In the first instance, TC09 will focus on the glass melting furnace. The aims for 2014 were to define the different roles of the TC09 members and to define the working programme for the next few years. The first main activity is to define a uniform approach to energy efficiency or specific energy use within or across the various glass industry sectors. The existing non-uniformity is compounded by the fact that there is no common approach in the consideration of factors such as the effect of cullet, the efficiency of electric boosting, age and furnace design. TC09 will develop recommended Best Practices for defining energy use and efficiency so that companies within each glass sector can make useful comparisons. This approach will be used to explain some of the differences in performance between sectors and aid discussions with non-technical and/or external agencies. The committee also agreed to support the idea to seek the collaboration of other energy-intensive industries to develop energy workshops. TC09 will also support energy efficiency workshops specifically dedicated for the glass industry.
Future plans The future plans of TC09 are: r Organise TC09 meetings twice a year to exchange information between members. r Organise symposia related to energy efficiency in glass production. r Prepare a vision document of required future directions for R&D to develop technologies to improve the energy efficiency and CO2 footprint of industrial glass production. r Organise excursions. r Broadcast activities and results to the community. As well as these general activities a project will be formed to explain the energy balances of glass furnaces and to evaluate the methodology of applied energy balance models, measuring techniques and benchmark data. The project will be coordinated by a special working group within TC09.
Outlook TC09 will support the glass industry in its efforts to produce glass in an efficient and sustainable manner. For this the support and input such as data, reporting on new developments, and cooperation in projects from the glass industry is essential. r
For those interested in actively participating in Technical Committee 9 please contact: Hans van Limpt, hans.van.limpt@sibelco.com Richard Hulme, rhulme@guardian.com More information: www.icglass.org/technical_committees/
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Events world
An overview of the Mir Stekla exhibition.
Russian market shows signs of improvement at Mir Stekla Despite the Russian market’s recent setbacks there was an optimistic mood among those wanting to trade with companies from Russia and the CIS region. Sally Roberts attended this year’s Mir Stekla event in Moscow.
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M
ir Stekla 2015, the 17th international exhibition for glass products, manufacturing, processing and finishing technology was held at the Expocentre Fairgrounds in Moscow. As always the event was organised by StekloSouz (the united council of Russian glass industry enterprises) and was supported by the Russian Ministry of Industry and Trade. The organiser said that the show welcomed 8,000 visitors. Exhibitors who have already signed up to participate at next year’s event include Italy’s Bottero and Turkey’s Altinay.
Geographic breakdown More than 200 companies from 22 countries participated, with exhibitors coming from Europe and from as far away as the US and China, including companies such as Horn Glass, Heye International, Bucher Emhart Glass and Iris Inspection Machines. The
political situation in Russia in terms of EU sanctions was demonstrated by the absence of the German pavilion this year, with most German booths manned by domestic representatives. A spokesman from Heye International said of the show, which was attended by the company’s dedicated team for Russia and the CIS region: “The economies of the CIS countries continue to provide successful business opportunities… [we] are happy to have met so many customers during the Mir Stekla event”. There was a large number of Chinese exhibitors while, naturally, Russian exhibitors made up the majority with around 80 of the stands, among them Salavatsteklo, Saratovstroysteklo, Steklocentr and KAMI Machine Tool Trade Association. The Italians exhibited in force, with 14 glass companies gathered under the Italian pavilion including Pneumofore, Ocmi, Antonini and GIMAV, with other
Italian companies scattered throughout the exhibition hall. Alessandro Lamura of the Italian Trade Agency (ITA), which alongside GIMAV organised its pavilion, noted that although the Russian market is going through a difficult time, it’s important to stay involved: “To withdraw would be a mistake. The market is important for Italians”.
Domestic business The exhibition occupied 5,000m2 and covered areas such as modern means of glass production and processing; glass application; tools and auxiliary equipment; test and regulating equipment, software; transportation and storage of glass; design workshops, research institutes, schools and industry associations.
Continued>>
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z Mr Victor Osipov (right), President of StekloSouz, welcomed attendees to the event.
while the market recovers. This year the exhibition also had unusual consultants roaming the halls - Promorobots. These robots moved throughout the halls of the exhibition, talking with visitors and helping them with any navigational queries or general information.
Outstanding contribution A key part of Mir Stekla is its conference, which this year was titled ‘Glass and modern technologies – XXI century’. Organised by StekloSouz, the aim was to highlight the current state and development trends of the glass industry. The packed schedule featured more than 50 speakers and was attended by leaders and experts from 19 countries and 48 regions of Russia. This included industry
figureheads such as Pavel Bobosik, General Director of Zavod Ekran, who featured in the May issue of Glass International. Mr. Bobosik gave a report on the ‘Current State of Glass Container Production in Russia and Problems of Cooperation with Consumers of Glass Containers and Suppliers of Raw Materials’. Mr. Osipov also gave a few presentations, including a report on the current state of the Russian Glass industry and its future development. The conference language was Russian and it was well attended by the domestic visitors. In his welcome speech Mr Osipov said: "We believe that this forum is a major step towards the harmonious development of the glass industry. With the global glass community overcoming professional challenges by combining efforts on precise technological parameters, we believe we can keep its new-found position, despite the crisis.” Conference speakers discussed industry trends and challenges, for example, the need to solve problematic issues such as: the design of new plants, the construction of modern energy efficient glass furnaces, machinery and equipment. During the forum, Glass International was awarded a diploma from StekloSouz for its outstanding contribution to its regular and objective coverage of the Russian glass industry. Since 2010 Glass International has published a Russian edition for distribution throughout the region. Its Russian representative Alex Gurov was pleased to accept this award on behalf of the magazine. r
www.mirstekla-expo.ru
Russian companies made up the
z The Glass International team at the show were proud to receive an
majority of exhibitors with around 80
award for the magazine’s outstanding coverage of the Russian glass
taking a booth.
industry.
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The exhibition’s official opening featured speeches from various ministers of the Russian government whose sectors are intertwined with the glass manufacturing industry. These included Mikhail Men, Minister for the Construction Industry, Housing and Utilities and Alexander Rybakov, Vice President Chamber of Commerce and Industry. Sergey Bednov, Director General of the Expocentre and Viktor Osipov, President of StekloSouz, also welcomed attendees to the event, highlighting the importance of the show for the Russian market and their hope that it would be used as a forum for developing solutions for the glass industry while furthering business opportunities for those who take part. Mr Osipov said: “Economic conditions for holding this trade show are fairly good: the upgrade of manufacturing facilities is planned throughout the country, particularly furnace repairs and the replacement of equipment… Everything has been done for your participation in Mir Stekla 2015 to be commercially effective”. The event was held over four days, with many companies reporting a successful show. The resounding conclusion was that although it is a ‘local’ show, the sheer vastness of Russia and its environs means that it remains a good place to do business. Bob Hughes of Ramsey Products echoed these sentiments: “We already have a customer base in Russia and we are pleased with the level of interest we’ve had. The market is stable for us.” Most exhibitors seemed to be there to do business with existing contacts and customers, and to weather the storm
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Events world
British Glass focuses on the future
H
osted by British Glass and held in Manchester, UK the conference theme was ‘Innovation within glass and the supply chain’, which was reflected throughout the presentations given over the course of the day. The conference attracted more than 130 delegates from the UK and internationally with senior representatives from across the glass supply chain, including glass manufacturers, processors, brand owners, architects and raw material suppliers. In his welcome speech, Dave Dalton, British Glass CEO, (pictured above) said: “We cannot secure the future of the industry by continuing with the status quo. We must now, more than ever, collaborate and build a new vision for the future. The industry needs to invest in new technologies, new capabilities, and the necessary skills to thrive.”
Virtual reality The keynote speeches began with Alan Norbury, Chief Technology Officer of Siemens, who discussed the concept of Industry 4.0, or ‘the fourth industrial revolution’. His presentation focused on the idea of developing machines in virtual reality, and using the ‘industrial version of the internet of things’ to shorten a product’s time to market, increase flexibility and boost efficiency, resulting in better global competitiveness. Mr Norbury spoke of how the idea of ‘cyber physical machines’ and the concept of machines being able to ‘self heal’ is promoting an industry renaissance, which focuses not just
on energy efficiency, but on resource efficiency. He predicted that the engineers of tomorrow ‘will spend more time in the virtual world as reality’, and highlighted the benefits of this to industry, noting ‘if we use everything available today, use it with government investment, productivity would increase by 22%’. He concluded with the message that there is no reason why Britain shouldn’t be in the driving seat of this fourth industrial revolution. A keynote joint presentation was also given by Brian Waterfield, of Jaguar Land Rover and Andrew Brown, Strategy Director of Holovis. Mr Waterfield and Mr Brown echoed Alan Norbury’s earlier emphasis on the future importance of immersive, 3D virtual environments, demonstrating how using it for learning can increase staff’s speed to competency, improve the depth of learning, and reinforce compliance. Breakout presentations were held throughout the day, focusing on topics such as ‘Packaging developments’, ‘Capitalising on the future’, ‘Architecture and design’, and a glass recycling workshop, which saw key industry figures discuss ways in which the industry can address and improve issues surrounding the recycling of glass. Speakers including Sven-Roger Kahl of Ardagh, Fred Aker of Nikolaus Sorg, Marcello Osterero of Bottero Glass and Michael Hughes of the Canadean Group, were among the 14 presenters. Speaking in the Packaging Development breakout session, Mr
Hughes, Lead Analyst at Canadean, spoke about global consumer trends, and why these are so important to the glass industry. He emphasised how ‘putting the customer at the forefront, rather than an afterthought’ and promoting the benefits of glass, such as its environmental benefits, can allow the industry to make use of these consumer trends and market themselves to what consumers want. The current trend towards craft production was also discussed, along with the perceived benefits of ‘more value added’ and ‘extra care from the manufacturer’, which create more personal associations with the packaging. Mr Hughes concluded: “Consumer trends are relevant to everybody. “They are formed at the beginning of the supply chain, so are very relevant to glass packaging. “Focus should be on maximising value added, rather than cost reduction. You can make products feel more relevant, you can engage in more disruptive marketing techniques, you can enhance the indulgent aspect of it, you can enhance the transparency, and you can encourage consumers to slow down instead of facilitating their busy lifestyles, and differentiate from plastic in that way”. Following on from Mr Hughes, Marcello Ostorero of Bottero Glass Technologies delivered a presentation on ‘Simulations to improve IS machine performances and for lightweight container design’. Again placing the emphasis on virtual Continued>>
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This year’s British Glass Focus conference and industry awards highlighted the developments and innovations occurring throughout the flat and container sectors of the glass industry, giving a special emphasis to the ‘virtual environment’ that is emerging as a key facilitator to future industry success. Sally Roberts attended.
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Industry Awards: The winners r Glass Company of the Year Award r Lifetime Achievement Award: r Lifetime Achievement Award: r Outstanding Contribution Award: r Innovation Award: r Apprentice of the Year Award: r Leadership Excellence Award: r Supply Chain Initiative Award: r Marketing Award: r Corporate Social Responsibility Award
Owens-Illinois (O-I) Bernard Holt (Ardagh) Peter Fitzgerald (Encirc) Alan Minto (Allied Glass) Stoelzle Flaconnage Tom Cross (Encirc) Guardian Encirc Friends of Glass Encirc
z From left to right: O-I’s Paul McLavin, Marketing & New Business Development Lead, picked up the company’s award for Glass Company of the year, while Peter
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Fitzgerald (Encirc) and Bernard Holt (Ardagh) were awarded with Lifetime Achievement awards following their recent retirement.
simulations and virtual environments, Mr Ostorero demonstrated how Bottero uses virtual simulations to improve all aspects of the IS machine, from mechanics to process. Whereas in ‘real life’ it is almost impossible to see what is happening during the container forming process, the computer-aided visualisations allow experiments to deliver higher performance IS machines. Ardagh’s Sven-Roger Kahl gave an overview of the Dutch Glass Industry Roadmap until 2030 in his conference paper. He outlined how seven companies, two branch organisations, a glass research unit, a consultant and a government agency had put their efforts together to analyse the Dutch glassmaking sector and formulated a plan to improve its energy efficiency. They formed three working groups that focused on process improvement, sustainability in the process chain (such as making more glass available from recycling), and improving glass know-
how. The groups concluded that a 25% energy efficiency improvement could be made betwen 2009 and 2030 in the Dutch glassmaking sector. Key elements to work on included finding more alternative raw materials – each waste stream that contains glass is an important source. The groups will also follow trends in melting concepts and in improved furnace designs. Approximately 235,000 tonnes of glass ‘disappears’ in the country and Mr Kahl said one idea put forward was to demolish buildings in such a way that the float glass is rescued before it is mixed with other materials and contaminated. Most impressively the working groups, made up entirely of volunteers, have establised a Dutch glass website and formed a training course for young people. The glass technology training course is aimed at an intermediate level and the first group of students completed the course in academic year 2013/14. It is a step in reducing the glass industry’s
ageing population. The next aim, said Mr Kahl, is to encourage ways of ensuring that glass becomes a secondary school subject and is discussed by pupils. In the afternoon breakout session, Sorg’s Sales and Marketing Director, Fred Aker, discussed the particular challenges that smal scale pilot furnaces and test facilities pose. Examples of these challenges included the first all-electric vertical melter, furnaces for the melting of highly radioactive wastes, the Bucher Emhart Glass research centre, USA, and the O-I innovation centre in Ohio, USA that opened last year. Sorg supplied the small scale batch house and pilot furnace for the latter site. The equipment meant O-I could conduct trials at the site rather than using its own full-scale manufacturing facilities. Mr Aker said that anyone could build Continued>>
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Bernard Holt was also awarded with a Lifetime Achievement award, following his recent retirement from Ardagh. Owens-Illinois (O-I) picked up the award for Glass Company of the Year, after demonstrating both ‘exceptional operational success, as well as making a substantial effort to increase its staff’s safety’. A spokesman for British Glass noted how O-I’s effort to increase its safety culture has resulted in a 70% reduction in the company’s recordable injury rate from 2012-2014. Awards were also presented to Guardian, Stoelzle Flaconnage and Allied, who saw Production Manager Alan Minto awarded with the Outstanding Contribution award. Mr Minto started working in the glass container industry more than 40 years ago and throughout his career has been
z Alan Minto of Allied Glass picks up his award for
z Tom Cross of Encirc wins the Apprentice of the
Outstanding contribution.
Year award.
Industry awards
influential in the development of Allied’s manufacturing facility. Mr Minto was described by colleagues as ‘a glass industry stalwart with an outstanding knowledge of glass bottle manufacture, a true leader and innovator. Through his work, Alan has promoted the beauty and flexibility of glass as a packaging material.’ At the conclusion of the day-long event, Mr Dalton stated: “The future promises many exciting opportunities for the glass sector and for the possibilities of glass as a material. “It was once again fantastic to see the great and the good of the industry come together at our conference to discuss many of these issues and projects and celebrate their successes at our awards evening.” r
The British Glass Industry Awards were held during the evening dinner that followed the conference. Encirc won three of the awards on the night and also saw recently retired Strategic Development Director Peter Fitzgerald recognised with a lifetime achievement award. Mr Fitzgerald was presented with the award following his 17-year career with Encirc, and was praised for ‘his true interest in the people he has met over the years and of course his passion for glass and the business he helped develop at Encirc’. Encapsulating Mr Fitzgerald’s sense of humour, a spokesperson from Encirc said of him: “Peter is a true character and over the years has built many lasting friendships with customers, suppliers and of course with his colleagues. “Simply describing glass as a bit of beach, a bit of washing powder and a bit of mountain he has an innate ability to express himself.”
www.britglass.org.uk Dutch glass website: www.nederlandseglasfabrikanten.nl
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a small scale furnace but the trick is to simulate what happens in a large unit. Important things to consider are extensive modeling, high pull-up percentages, high turn-down rates, noise abatement and higher support needs due to the furnace being an R&D project and thus requiring tighter secrecy. Mr Aker added that modeling is an imoprtant part of Sorg’s business now and it now runs up to 16 models simultaneously all day for 365 days a year. It investigates customer problems and trys to solve them. Its modeling software is ‘off the shelf’ so anybody can buy it. He added though that the ‘driver’ – the human who operates the software – makes a vast difference. The results can vary depending on who ‘drives’ the software.
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Handling
A steel felt that reduces production contact faults î Ł Factory-ready assemblies
Garry Oldfield* outlines how a UK-based company has researched, developed and trialled the use of soft stainless steel material in contact with glass during the production process as an alternative to carbon-based materials.
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U
sing a soft and flexible 100% stainless steel felt as a glass contact material for high-speed production has resulted in the near-eradication of bottle contact faults at the hot end. The stainless steel felt takes the place of carbon on wipe-out fingers, ware transfer fingers and push bar pockets. The felt is supplied in three grades: a 6mm super soft felt suitable for delicate glassware; a 5mm heavy duty for general use and long life; and a super heavy duty 6.5mm material for aggressive applications. The heavy duty grade was developed three years ago when it was identified that a more durable and wear resistant heavy duty felt was needed, particularly on the wipe-out pusher fingers. At the same time the company had been engineering the metal work assemblies to be multi-fit components to function on its own ware handling systems and those of its competitors, including the IS machine pushers. This allowed glassworks around the world to experience the benefits of the stainless steel felt with a minimum down time, by exchanging the complete assembly. It led to an immediate reduction in the number of damaged ware. Other competitors, as the popularity of carbon waned, chose to use stainless steel wires, braided together in the form of a rope (usually fine welded onto shaped inserts) instead of carbon. Our observation of the use of this braid was
showing the 100% stainless steel felt in use.
that it worked well initially but over time the continuous wire strands compacted into a mass, in effect forming solid metal and consequently losing its contact characteristics, which caused damage to the glass. To avoid the drawbacks of braid and carbon as glass contact materials, we asked our material producers to go one step further, and to manufacture a heavier duty felt to withstand not only high temperatures but the continuous long time aggressive action of the pushers, as the glass was transferred from the machine onto the IS machine conveyor. A new product was offered that contained the same 100% stainless steel fibres as the 6mm felt but with a greater density of strands into the same volume. The specification was increased by a strand density of 20% and its thickness expanded from 5mm to 6.5mm. By using a 1.5mm longer felt strand the felt has more freedom to compact. This gave the product a longer life than the softer felt and upstaged the life of any other graphite/carbon products.
Tougher The tougher grade of felt, although a little more expensive to produce and slightly less soft to the touch compared to the original felt, was rated excellent by our customers for these specific assemblies. The main point is that the bottle contact faults remain at the same minimum levels
regardless of soft or heavy grade material used. Thus we offer the industry a choice of cushion density to meet its specific production needs. A customer who monitored the material in production for more than 12 months, reported that its 12-section double gob machine, running at 550 bottles per minute, showed no signs of wear or â&#x20AC;&#x2DC;bottle contact faultsâ&#x20AC;&#x2122; throughout this period. The material is produced in sheets 0.5m wide by 3m long. We use industrial cutting machines to shape the felt and in some cases we laser cut. This means the felt can be supplied to the customer with high temperature silicone glue in sheets or strips, or tailored to the individual metal work size. This gives customers, who wish, the facility to replace their contact material new for old, on site, on to existing assemblies. DA Oldfield supplies engineered spare parts complete with felt attached, for the IS machine wipe out pushers, transfer fingers and push bar pockets. It also offers to re-claim the used metal work to give an exchange service to recover old components with new felt in mind of customers working towards a greener environmental policy. r
*Engineering and Sales manager, D A Oldfield, York, UK. www.daoldfield.co.uk
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Glass handling
From invention to industry standard
I
n the 1980s, as the machinery used in container glass manufacturing grew in size and as the speed of the process increased, USA-based Liberty Glass developed its own solution to improve the process and ensure quality containers. Larger annealing lehrs and faster conveyors required a better way to transfer hot containers from the cross conveyor to the annealing lehr. This conveyor transfer happens shortly after the containers are moulded and while they are still hot and easily damaged, therefore any checks caused during this transfer could render the vulnerable containers unusable.
grow its hot ware handling product line for the container glass industry.
A global use While the basic mechanical parts of servo stackers have not changed much since its inception, electronics have. Today, Pyrotek’s servo stacker uses touchscreen controls with its proprietary software
The first servo stacker When Liberty Glass, which operated a plant in Oklahoma, installed several 15-foot lehrs and larger IS machines, it found the mechanical stackers in use at that time could not effectively transfer glass containers to lehrs of that size. The mechanical stackers were using cams and electric motors, limiting the ability to adjust movements to accommodate variations in container size, conveyor speed and other variables. This inflexibility was causing defects when transferring containers at high speeds. As there were no lehr loaders on the market capable of handling high-speed ware flow of glass containers, Liberty Glass developed a lehr loader capable of fulfilling this need. In 1991, Liberty Glass filed for and received a patent for the first servo stacker. The servo stacker’s 3-axis, smooth movement and electronic controls allowed for steadier transfer of bottles from the cross conveyor to the lehr, lessening contact and checking. Its electronics enabled operators to adjust the controls and speed of the machine. The servo stacker featured a sturdy framework and a belt drive of durable aramid-fibre material. In 2014, after several acquisitions, Pyrotek purchased the assets of Infinity Machine, which held the original patent technology. This gave Pyrotek the historic know-how and ability to expand and
zTop: Drawings from the first-generation servo stacker patent Liberty Glass Co. filed for in 1991. Middle: Pyrotek’s Servo 9000 Stacker. Bottom: Pyrotek’s custom-built control panel and touchscreen for the Servo 9000 Stacker.
that allows manufacturers to enter full job descriptions and hold more jobs in memory. The software also enables adjustments during production. If the stacker is contacting the bottles too hard, the speed can be slowed, and the servo stacker can be adjusted to match the speed of the lehr chain, for example. While the development of the servo stacker stemmed from Liberty Glass’s own needs, the company later sold the equipment to container glass manufacturers around the world, many of which are still in operation today. With proper maintenance and electronic upgrades, Pyrotek servo stackers can operate for many years, and some have been in operation for more than 20 years with an even longer expected service life. The servo stacker’s design also allows maintenance and repairs to be accomplished in-house during normal job changes. When the initial Liberty Glass patent expired in 2008, other equipment manufacturers introduced their own versions of the servo stacker to the market, making it an industry standard and a key piece of equipment in the container glass manufacturing process throughout the world. Pyrotek servo stackers remain an industry leader in strength, operator flexibility and longevity. Today, Pyrotek offers the Servo 9000 Stacker, which has recently been upgraded to feature a touchscreen and control panel, as well as upgraded software that yields smooth and efficient operation, improving production and melt-to-pack ratios. The equipment can optimally accommodate 10–20 foot lehr widths. Pyrotek also offers rebuilds, extending the service life of these machines. The company’s staff of field engineers provides training and support with machine installation and software. r
*Tulsa Plant Manager **Tulsa Engineering Manager ***Global Editor Pyrotek Inc., USA www.pyrotek.info/glass
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David Bridgewater*, Larry Page** and Sandra Hosking*** explain the history of the servo stacker, from its inception at Liberty Glass to its worldwide use today.
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History
Prof. John Parker Turner Museum of Glass and ICG
The fevered brow Prof. John Parker explores the history and science behind the thermometer, a glass instrument that is today taken for granted but which took centuries to perfect.
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round 1603 Galileo Galilei used air expansion to measure temperature. He inverted a partially-filled glass bulb with a long neck into a container of the same liquid as a seal. As the temperature rose the air inside expanded, causing the liquid level in the neck to fall. Unfortunately, pressure changes had the same effect. A moderate 3% pressure change has the same effect as a 3% change in absolute temperature from 300 to 309K, i.e. from 27 to 36°C! A few years later Galileo’s pupils in Florence created a thermometer unaffected by pressure, appropriately named a Galileo thermometer. It worked by using the changes with temperature of the net densities; i.e. the buoyancy of hollow glass floats immersed in a clear liquid of matching density. However, poor heat transfer rates in liquids made them relatively insensitive and slow to react and they consequently did not catch on. Fahrenheit’s announcement of the mercury-in-glass thermometer with a large mercury-filled bulb and just a little in the neck came in 1714. Similar devices using alcohol existed earlier and Schaeffer suggests that glass thermometer tubes were already being handmade in 1650. Older readers will recall being made to sit patiently as a child for at least a minute with the bulb in the armpit or uncomfortably under the tongue. After use the instrument had to be shaken violently to force the mercury past a narrow constriction back into the bulb. Such an instrument must give a reproducible and accurate reading. The first step is to make a narrow capillary tube with a uniform bore by stretching a thick hollow rod while blowing to maintain an open core. The next requirement is calibration. This was left to scientists with names that have become part of our vocabulary, particularly Fahrenheit and Celsius.
Fahrenheit’s reference points included the lowest temperature of a freezing waterice-salt mixture (0°F) and the human body (96°F). Celsius chose more reliable fixed points, namely the temperature of an ice-water mixture at equilibrium (freezing point) and the temperature of a water-steam mixture at equilibrium (boiling point). He demonstrated amazing attention to detail. By checking his fixed point over time he realised that the boiling point of water changed measurably with atmospheric pressure. He chose 100°C for ice and O°C for boiling, a choice that was overturned a year later. Now the ice-watervapour system triple point, which fixes both temperature and pressure, is used for calibration. Celsius also observed that when he removed his glass thermometer from its hot environment in steam, the mercury rose slightly. He correctly interpreted this as the cooling of the outer glass layers before the mercury inside noticed any difference, as a consequence of the low thermal conductivity of glass. The concomitant shrinkage slightly compressed the mercury inside the bulb, causing it to rise. Fortunately both glass and mercury expand uniformly over these temperature ranges. Thus between 0 and 100°C a linearly subdivided scale can be used. The same assumption of linearity would not apply nearer the glass transformation temperature (550°C). Careful measurement of thermometer behaviour led to an awareness of a phenomenon termed delayed elasticity. Normally we expect that a body resumes its initial shape/volume instantaneously on returning to its starting temperature (e.g. 0°C) after a thermal cycle (e.g. to 100°C). Glasses do not necessarily do that. The dimensions at the end of the cycle may differ from those initially and the subsequent rate of relaxation can be slow e.g. minutes. This does not make for
reproducible temperature measurements. The phenomenon was much investigated in the 1800s until it was finally related to the mixed alkali effect. Glasses predicated on a single alkali species were much more dimensionally stable. Of course the liquid used in the thermometer does not have to be mercury and indeed this element limits the operating range, the melting point being -39°C and boiling point 357°C. The health dangers linked to it plus its cost also mean that these thermometers are no longer used in medicine. As an alternative and for lower temperatures coloured, low freezing point organics such as alcohol are available. For higher temperatures gallium alloys have been used (m.pt 30°C and b.pt 2403°C). These require glasses with higher transformation temperatures; Schott sell thermometers measuring up to 1100°C using borosilicate glasses and even pure silica for the highest temperatures. Sprinkler valves often use a similar principle. They contain a liquid-filled glass bulb designed to break at a certain temperature as their content expands and in doing so, to activate the sprinklers. So, the glass that monitors the progress of a young child’s fever, also provides a cooling system to extinguish a fire. r
Bibliography Glastechnik, Vol 4, Spezialglas. H. Schaeffer & M Benz-Zauner, Deutsches Muzeum, Germany. http://en.wikipedia.org/wiki/Galileo_ thermometer 13/05/2015 http://en.wikipedia.org/wiki/Mercury-inglass_thermometer 13/05/2015
Prof Emeritus John Parker, Curator of the Turner Museum of Glass, Sheffield University, UK. www.turnermuseum.group.shef.ac.uk Email j.m.parker@sheffield.ac.uk
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Glass Technology Services
Glass Technology Services
Welcome news for testing standards Daniel Capon* explains how the latest revision to pharmacopoeia test methods for pharmaceutical glassware will help simplify requirements between the US and European standards and possibly bring cost savings for customers that regularly test to both standards.
Key changes include: Direct reference to the recommendation for delamination propensity or evaluation studies within both USP <660> and Ph. Eur 3.2.1 for the first time; Stricter autoclave programmes within respective glass grains and surface tests across both monographs, with additional requirements for the timetemperature profiles that must be achieved in both heating and cooling of samples and the required use of external thermocouples for temperature logging; and Mechanical sieve-shakers/sieving machines now allowed within glass and Ph. Eur. Daniel said: “This ongoing harmonisation is another positive step forward and builds upon unification between USP 37-NF32 and Ph. Eur 8.0 in 2014 that saw the USP adopt the Ph. Eur. glass grains and surface tests. “The key concern for many pharmaceutical and medical companies comes down to the growing need for
The latest revisions for pharmacopoeia standards emphasise recommendations for propensity and stability studies. Photo credit - Nixx Photography / Shutterstock.com
glass surface delamination evaluation, propensity and stability studies. “This has been a key area of support and development for us in recent years – with a range of services available and our direct involvement in research groups, including the International Commission on Glass’ Technical Committee 12 (TC12) for glass delamination.” GTS provides accredited testing services for pharmaceutical and medical companies as well as glass manufacturers and processors and participates in collaborative studies on glass containers for pharmaceutical and medical use. In addition to United States (USP) and European Pharmacopoeia (EP/Ph. Eur), GTS also tests to UK, Russian and Japanese Pharmacopoeia standards and provides a comprehensive range of chemical analyses, performance testing, quality assessment and consultancy services.
*Laboratory Manager, Glass Technology Services, Sheffield, UK www.glass-ts.com/pharmacopoeia, enquiries@glass-ts.com.
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he latest revisions to international pharmacopoeia standards for glass pharmaceutical packaging has seen further harmonisation for testing requirements and an increase in the necessity of delamination propensity studies across the pharmaceutical supplychain. The pharmacopoeia test methods relate to pharmaceutical glassware and include bottles, vials, ampoules, cartridges and syringes. GTS Laboratory Manager Daniel Capon, (pictured above) said: “The United States (USP) and European (Ph. Eur.) Pharmacopoeias remain the most widely used in the global market. “Recent revisions to both monographs continue to harmonise requirements between the two, bringing welcome simplification and, in some cases, savings for customers that regularly test to both the USP and Ph. Eur. Standards. “The latest revisions, USP 38-NF33 and Ph. Eur 8.3, further emphasise recommendations for propensity and stability studies, with direct references now being included within both USP <660> and Ph. Eur 3.2.1 for the first time. “This is a key concern for many drug manufacturers looking to approve their products within EU and US marketplaces and we have seen a dramatic increase in global companies coming to us for advice, consultancy and study programmes. “As such a specialist area it is understandable that there is so much concern and uncertainty in this area, we are one of only a few laboratories that hold the necessary specialist glass knowledge, experience and equipment.”
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Batch plant
î ś Choosing the most appropriate place for the batch plant minimises the investment and operating costs
The batch plant should not be the last piece in the puzzle Batch plant location is often decided at a late stage when planning to build a glass plant. But Metin GĂźnhos* explains that it should be an initial, decisive factor that will help save on costs.
Best location If trucks carry out the raw material delivery then access and a maneuver area should be considered. If a railway delivery is planned, the batch plant must be located close to the railroad. The location must be selected to obtain a shorter and straight batch transfer line to the furnace hoppers. Any obstacle between the furnace hopper and the
batch plant would increase the length and quantity of transfer equipments. If the land is not flat, it is recommended to install the batch plant on a higher appropriate area of the land to simplify the batch transfer system to the furnace.
Raw material delivery High volume raw materials are usually delivered either in trucks/wagons or in pressure trucks/tanks. Lower volume raw materials are usually delivered in large or small bags. All raw materials can be stored in batch plant storage silos, but if a large amount of raw materials are to be delivered, such as by ship to the plant, or if there is any potential risk which will stop delivery for more than four to seven days, such as heavy snow, an extra storage area must be considered. Designing a batch plant with a raw material storage capacity of more than seven to 10 days would result in huge silos and high construction costs. Allocating a storage rack space in the plant eliminates those problems. The batch plant should have the capability
to unload directly from trucks to the silos so that the required work force can be optimised. Thus, the raw materials traffic (except in emergency conditions) between batch plant and storage racks should be minimised. The raw materials delivered in big bags and bags can be stored in dry and closed idle spaces in the furnace building. Big bag emergency storage for the raw materials delivered in pressure trucks is recommended.
Transfer to silos Bulk raw materials are discharged into unloading hopper(s), and a discharge feeder, belt conveyor(s), and a bucket elevator is used to automatically transfer the raw materials to the silos. This system can also be used for big bag unloading. Due to the physical characteristics of raw materials, pneumatic transporters can also be used to unload to silos. The raw materials delivered in pressure trucks are transferred to the silos via pipes. The Continued>>
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hen planning green field glass facility investments, batch plant locations and specifications are often perceived as technical details and considered late in the design phase. But batch plant locations and specifications are directly related to the storage and logistics data of raw materials, which must be among the most important data in glass plant investment feasibility studies. It is hard to find the best place for the batch house if other systems are already placed. Choosing the most appropriate place for the batch plant minimises the investment and operating costs.
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Batch plant
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z Fig 1. A float glass horizontal batch plant (1850 tons/day capacity).
pressure truck unloading process takes 30-60 minutes so space for parking and maneuver of at least two trucks should be considered next to the batch plant. If the pressure trucks have an onboard compressor, they use the plantâ&#x20AC;&#x2122;s electric power. If they do not have an onboard compressor, they use the plantâ&#x20AC;&#x2122;s compressed air and consume a considerable amount of compressed air. So local pressure truck specifications should be investigated to determine glass plant electric power and compressed air capacities. The raw materials delivered/ stored in big bags or bags can be manually discharged directly into the storage silos. A truck unloading system or a pneumatic transporter can also be used for unloading to minimise work force requirements.
Determining silo capacities The volumes of raw material silos are determined proportionally to the daily consumption of each raw material. Depending on the availability, some raw material silos can be designed larger. Between two to 10 days storage capacity is usually preferred for each raw material. If you do not have a back-up storage, you should prefer bigger silo capacities
(five to 10 days) to prevent the risk of the production cut due to raw material shortage and this also gives extra time for system maintenance. But it should be remembered that an increased silo storage capacity means much higher construction cost for the batch building. If a backup storage (storage rack(s), and/or big bag storage) is considered, a two to five days storage capacity could be selected to reduce the batch building construction costs. The seismic condition of the terrain is a determining factor when selecting silo storage capacities.
Cullet storage silos Transporting internal cullet to the storage silos is another piece of the puzzle that should be taken into account in the early phase of the plant design. Cullet belt conveyor routes must be considered to collect waste cullet from the production line to silo. Depending on the glass production type (float, container) and the quantity of furnaces, cullet silos can be located in the batch house or close to the batch house or the furnace. The cullet equivalent to 5-80% of the batch can be delivered to the furnace together with the batch.
In case of higher consumption of cullet (>5%), external cullet is required in addition to internal cullet. In this case, external cullet delivery to the plant, external cullet silo location and capacity and the external cullet unloading system should also be considered.
Weighing system The weighing system includes binactivators for the raw material discharge from the silos, feeders, weighing hoppers, feeders to discharge weighing hoppers, and a transfer system (collecting belt conveyor, transfer belt conveyor(s), bucket elevator) to transfer raw materials to the mixers. Electromagnetic/electromechanical vibrating feeders, screw feeders and rotary feeders can be used, depending on the raw materialsâ&#x20AC;&#x2122; physical properties.
Horizontal vs vertical systems Theoretically, it is possible to weigh all the raw materials in a single weigh hopper. This may not be possible though due to technical reasons such as the limits of the feeder lengths, load-cell measuring accuracy limitations, building restrictions Continued>>
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Batch plant
zFig 2. The control system of a float glass batch plant
weighing system is named the Vertical (Tower type) System. If there are more than three to four weighing hoppers, a collecting belt conveyor is required to transfer the discharged raw materials to the mixers. If the mixer is placed at a higher level, a bucket elevator or a pneumatic transporter can also be used to elevate the batch to the mixer. If weighing hoppers discharge over the collecting belt conveyor, this type of weighing system is named as a Horizontal System. Although each of these two weighing systems has some pros and cons, each solution can be selected depending on the specific needs of each batch plant. However, the main differences between these two systems to consider are: For the same quantity of raw materials, and for the same silo capacity, the vertical system building height is taller, but the base area is less, compared to the horizontal system. It costs more to construct a Vertical System but the cost of the process equipment is a bit lower than a horizontal system. It is easier to maintain a horizontal system compared to a vertical system because there is more space between the equipment, which allows easier access for maintenance. As a rule of thumb, if the production capacity is less then 150-250 tons/day, and if there are land limitations, a vertical system design is preferred. The batch building and/or silos can be either concrete or steel, depending on
the local land conditions, construction costs, customerâ&#x20AC;&#x2122;s ability and preferences.
The mixer(s) Batch homogeneity is important to ensure best glass quality. Therefore, the mixers are considered among the most critical equipment in the batch plant. Since the maintenance time of a mixer is generally quite more than any other equipment in the batch plant, a backup mixer should be considered in the design, or a complete set of mixer spare parts (including a gearbox) should be kept in the plant. As a mixing cycle typically takes three to six minutes, the volume of the mixer is another key factor in terms of the production capacity of the batch system. If there is more than one furnace, each producing different glass colours, dedicated mixers for each furnace must be used. Since some raw materials are abrasive, abrasion resistance is another important factor in mixer selection, like all other equipment in the batch plant.
PROVEN SCIENCE
in Pressure Testing
Transfer to furnace After the mixing process is completed, the belt conveyors and the bucket elevators transfer the batch to the furnace hopper(s). The cullet is added to the batch during the transfer. The cullet can be weighed either in a weighing hopper or on a weigh belt conveyor. The furnace hopper size determines the maximum allowed maintenance time for the batch plant. Generally, the furnace hopper is designed with the capacity, which can feed the furnace continuously for about four to eight hours.
Conclusion These are general approaches to batch plant design excluding other special and exceptional cases and hybrid solutions, without going much into technical detail. Keep in mind that, furnace quantity/ capacity (now and in future), cullet ratio (min, max), batch recipe, raw material delivery types and frequencies, physical properties of raw materials (bulk density, humidity, particle size), seismic activities, and underground water level of the batch plant location are key determining factors for successful batch plant design. î ˛
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and access restrictions for maintenance. Another weighing system design extreme is to use dedicated weighing hoppers for each raw material. One weighing hopper for one to four silo(s) (or five to six silos in special cases) is usually preferred. If the number of weighing hoppers is less then three to four, it is possible to discharge weighing hoppers directly into the mixer. This type of
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Regulations
The impact of REACH on glass Reinhard Conradt* discusses the nature of industrially produced glass from a scientific point of view and contrasts this to the categories and definitions given in the REACH regulation.
units – and this cannot be transferred to inorganic glasses. Confusion is encountered with respect to clauses 1 and 2. Industrial glass might be mistaken as oxide mixtures. This article aims to refute this view and to demonstrate that industrial glass is a substance in the sense of REACH.
Scientific definitions Glass is fundamentally non-crystalline solids characterised by a lack of translational order of their atomic structure. Glass is also characterised by the absence of any microstructure. It is an essentially isotropic material without any internal phase boundaries. From a topological point of view, glass is a dense, non-fractal material. This is why the term ‘amorphous’ is an inadequate definition for glass. From a thermodynamic point of view, glass is an undercooled frozen-in liquid. To avoid confusion glass is distinctly rigid mechanically. Its stiffness is superior to many other materials. Nevertheless,
with respect to its atomic configuration, glass resembles a liquid rather than a crystalline solid. Fig 1 illustrates how the continuous loss of configurational degrees of freedom eventually yields a sudden transition from a fluid to a rigid condition. The glassy state is a fundamental state of matter in general, independent of chemical composition. From a chemical point of view, glass may be viewed as a class of materials that can be transferred into a glassy state. The scope of chemical composition is wider than the scope of industrial glasses. There is oxide glass (both silicate and non-silicate glass), other inorganic non-metallic glass (chalcogenides, halogenides and oxynitrides typical of special optical applications), organic glass, metallic glass and molecular glass. The scope of chemical composition is virtually unlimited.
Continued>> Traffic direction
Beginning of cooperative effects
Independent motion
Strictly correlated cooperative motion; loss of degree of freedom “velocity”
Loss of degree of freedom “change of lane”
Frozen-in state
z Fig 1. Illustration of the concept of freezing-in, i.e., of a sudden transition from fluid to non-crystalline rigid conditions upon a gradual loss of configurational degrees of freedom; example: traffic jam; in contrast to a parking lot, a traffic jam does not exhibit any translational order of arrangement of the individual cars.
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n chapter 2 ‘Definitions and general provision’, article 3 ‘Definitions’ of Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH)(1), Clause 1 states, substance: means a chemical element and its compounds in the natural state or obtained by any manufacturing process, including any additive necessary to preserve its stability and any impurity deriving from the process used, but excluding any solvent which may be separated without affecting the stability of the substance or changing its composition. Clause 2, mixture: means a mixture or solution composed of two or more substances. So the term mixture is used in a restricted sense, different from the conventions of the thermodynamic theory of mixed phases. It is used as a synonym of ‘heterogeneous mixture’, ‘mechanical mixture’, ‘mix’, or ‘blend’ and extends to a specific class of solutions with clearly separable molecular entities. Clause 3, article: means an object which during production is given a special shape, surface or design which determines its function to a greater degree than does its chemical composition. Most industrially-manufactured glass enters the market as an article. This is seen from the nomenclature of categories ‘holloware’, ‘flat glass’ and ‘fibre glass’, all of which refer to shape and geometry. Distinct ranges of chemical compositions may be attributed to each of these categories but their predominant features are shape and geometry. When considering the material related to REACH definitions with respect to industrial glass, the definition of ‘polymer’ (clause 5, not cited here) may be excluded. Although polymerisation plays a crucial role in the formation of inorganic glasses, the REACH definition rests on the concept of constituting monomer
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Regulations
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Industrial glass The industrial process of glass manufacturing starts with the preparation of a batch of raw materials. For demonstration purposes consider a simplified batch consisting of chemically pure raw material (in units of kg per 1000 kg of produced glass): 684.8 sand (SiO2), 51.4 feldspar 137.7 dolomite (NaAlSi3O8), (CaMg(CO3)2), 121.8 limestone (CaCO3) and 211.9 soda ash (Na2CO3). Minor batch additions such as fining agents or colourants are not taken into account. The raw materials are simplified as pure substances featuring the main phases of real raw materials only. The resulting glass has an oxide composition (by wt.) of 72 SiO2, 1 Al2O3, 3 MgO, 11 CaO, 13 Na2O, which is a realistic representative of a typical container glass. Each raw material in the batch is a real material with a specific chemical composition, atomic structure and specific properties. Some of the raw materials available may be classified as harmful. But during the melting process the raw materials lose their identities as individual substances and form a homogeneous melt. Their chemical properties are no longer reflected by the resulting glass. Fig 2 illustrates the short-range order structural entities present in the considered glass. The individual entities form building blocks (at the atomic scale) of a new non-crystalline matrix that chemically behaves in a way different from any of the raw materials. Chemically, the matrix as a whole behaves like a substance of its own. Confusion may arise from the fact that glass compositions are usually communicated in terms of wt. % of oxides. For the reader not familiar with the concept of thermodynamic components, this may give rise to misconceptions. Consider the term ‘components’. These are stoichiometric entities by which the chemical composition of a system may be expressed in an irredundant way. Any set of stoichiometric entities allowing this qualifies as a set of components. Among the virtually unlimited number of possibilities, the set of oxides is particularly simple and practical. This is because it allots one individual formula unit to each of the cations in the glass, with the common oxygen anion allotted to each of the cations so as to form charge-neutral entities. Although oxides also exist as real substances the oxide components of a glass do not
Fig 2. Illustration of the short-range order structural entities in a glass of composition
Na
+
(by wt.) 72 SiO2, 1 Al2O3, 3 MgO, 11 CaO,
Si4+
13 Na2O; grey circles feature cations, white
Al3+
circles oxygen atoms in the form of bridging oxygens (b.o., with two directed bonds)
Fully polymerised [SiO4] unit corresponding to SiO2
Fully polymerised Na[AlO4] unit corresponding to NaAlO2
and non-bridging oxygens (n.b.o., with one directed bond only.)
Bridging oxygen -0Si4+
Non-bridging oxygen -03fold polymerised Na[SiO4] unit corresponding 1/2 Na2Si2O5
Si4+
Si4+
C2+
Mg2+ 2fold polymerised units Mg[SiO4] and Ca[SIO4] corresponding to MgSiO3 and CaSIO3
have any significance exceeding their stoichiometric meaning. In other words, the oxides in a glass formula are entities by way of calculation only but no entities with a physical reality. An aqueous slurry of BaSO4 is an example. An oxide representation of this system would make use of the entities BaO, SO3, and H2O. The former two entities, if regarded as real substances, are rightfully classified as harmful substances. The BaSO4 slurry, by contrast, is inert and harmless; it can be injected without any concern into the human body as used in medical diagnostics. The example underlines the fact that stoichiometric oxide formulae may be totally misleading when conclusions on the harmfulness of a substance are drawn from the properties of the individual oxides taken as real substances. Some readers may now interject and point to the many tables in glass literature containing oxide specific factors that can calculate glass properties from oxide formulae [2]. Let b(j) be a specific factor of oxide j and p(j) the content of oxide j in the glass formula. Then a glass property P (e.g., the thermal expansion coefficient [3]) is readily calculated as P = Σ b(j)· p(j). Tables of oxide specific factors are typically generated by a numerical evaluation of a large number of experiments. But does the sheer existence of such tables defeat the above line of reasoning? This is not the case. First, the oxide factors are valid within narrow compositional bounds. Second, successful predictions are typically restricted to glass properties related to molar volumes. Molar volumes, in turn, result from cationanion distances and these are
similar in the individual oxides and in complex oxide glasses. By contrast, chemical properties usually cannot be predicted via oxide factors. So it can be concluded that it is not only raw materials, but also the oxides that upon glass melting, ‘forget’ the chemical features they possess as individual substances. Let us take into consideration the simplified container glass presented at the beginning of this section. It contains (in units of mol per kg of glass) 11.983 SiO2, 0.098 Al2O3, 0.744 MgO, 1.962 CaO, 2.097 Na2O. If normalised to 1 mol of a glass formula reading O2 Si0.825Al0.013Mg0.051Ca0.135Na0.289O2 can be obtained. The negative charges –4 from the O2cations are compensated by the sum of +3.300 from Si4+, +0.039 from Al3+, +0.102 from Mg2+, +0.270 from Ca2+ and +0.289 from Na+. The above formula is a representation of a substance newly formed during the melting process. It is true, the way of presentation is rather impractical. That is why technologists prefer the oxide formula. But there is no valid scientific reason to make a principal difference between such a complex substance with non-integer stoichiometric coefficients on the one side and simpler substances such as H2O or BaSO4 with integer coefficients on the other side. There is another way to represent the composition of a glass: analyse its position within a phase diagram. Then the glass composition is obtained in terms of crystalline phases that would Continued>>
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Regulations
appear upon complete crystallisation of the glass. For the above example, this yields a composition (by wt.) of 24.25 SiO2, 5.14 NaAlSi3O8, 7.47 MgSiO3, 38.62 Na2Ca3Si6O10, 24.51 Na2Si2O5. In the glass – as a homogeneous material – these phases do, of course, not exist as crystalline entities. But according to previous results[4-5], the nature of atomic short-range order in the glass is reflected by the local structure of the individual crystalline phases. This observation, substantiated by experiment[6], has been termed the ‘chemical structure’ of the glass. Again, with the exception of SiO2, the structural short-range order entities of the glass are far from being identical with the oxides. So, there is no scientific basis to view a glass as a mix of its constituting oxides by any means.
ElEctroglass PowEr to rEducE your EnErgy costs
Conclusion When taking the definitions of REACH seriously, there is no other way than classifying industrial glass as substances. This is true even if the glass occurs in a virtually unlimited variety of individual chemical compositions, and that each of them typically possesses non-integer stoichiometric coefficients. These latter facts are acknowledged under the REACH regulation where glass is considered as a so-called UVCB substance (substance of unknown or variable composition, complex reaction products or biological materials). This is taken into account by the EINECS inventory (listing glass under EC-number 266-046-0) and by Annex 5-11 of the REACH regulation. Here, the EINECS number 266-046-0 is described as encompassing the various chemical substances manufactured in the production of inorganic glasses. Eventually, in Annex 5-11, to which reference is made in Article 2-7b of the REACH regulation, the legislator acknowledges that glass is a substance. r
References [1] REACH regulation (EC) No. 1907/2006 of the European Parliament and the Council, 2006, version 2014. [2] H. Scholze: Glass – Nature, Structure, and Properties. Springer Verlag, Berlin 1991. [3] A.A. Appen: Chemie des Glases. Verlag Chemie, Leningrad 1974. [4] R. Conradt: Chemical structure, medium range order, and crystalline reference state of multicomponent oxide liquids and glasses. J. Non-Cryst. Solids 345 & 346 (2004), 16-23. [5] N.M. Vedishcheva, B.A. Shakhmatkin, A.C. Wright: Thermodynamic modelling of the structure of glasses and melts: single-component, binary and ternary systems. J. NonCryst. Solids 293 (1002), 312-317. [6] R.N. Sinclair, C.E. Stone, A.C. Wright, I.G. Polyakova, N.M. Vedishcheva, B.A. Shakhmatkin, S.A. Feller, B.C. Johanson, P. Verhuizen, R.B. Williams, A.C. Hanon: Inelastic neutron scattering studies of superstructural units in borate glasses and crystalline phases. Phys. Chem. Glasses 41 (2000), 286-289.
*Chair of Glass and Ceramic Composites, RWTH Aachen University, Aachen, Germany http://www.muw.rwth-aachen.de/cms/Materialwissenschaft-und-Werkstofftechnik/Forschung/Institute/Institute/ GHI/~buly/Lehrstuhl-fuer-Glas-und-keramische-Verbun/lidx/1/ Glass International July/August 2015
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EvErything wE do is for iMProvEd... Energy Efficiency, Glass Quality, Furnace Output
Specialists in electric glass melting and conditioning Electroglass Ltd, 4 Brunel Road, Manor Trading Estate, Benfleet, Essex SS7 4PS, England t: (44) 01268 565577 e: info@electroglass.co.uk w: www.electroglass.co.uk
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Furnaces
The role of high emissivity coatings in glass furnaces Thomas Kleeb* outlines the history of high emissivity coatings in glass furnaces and evaluates a coating with a versatile bonding system.
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he first use of a high emissivity coating in a glass melting furnace was in a wool furnace operated by a major North American fibreglass manufacturer in 2008. The 7.5% fuel savings realised was attributed to the use of the coating and provided a payback in less than six months. Since then, high emissivity coatings have been installed in 90 container, tableware, E-glass, lighting, borosilicate, alkali-silicate and electronic glass furnaces. These furnaces have been fired with gas/oxygen, gas/air, oil and coal gas. The refractory substrates coated include silica, alumina, mullite, zircon, bonded AZS, magnesite and fused-cast alumina. Fused-cast AZS cannot be coated due to its exudation, and the coating of lowexudation fused-cast AZS has not been attempted. In most furnaces, the high emissivity coating was applied to the superstructure above the tuckstones. In furnaces where the breastwalls were fusedcast AZS, only the crowns were coated. In the seven years since the first furnace was coated, five different high emissivity coatings have been evaluated. All of these coatings contained non-oxide, nano-sized high emissivity materials that maintain hemispherical emissivities (ASTM C83501) of at least 0.9 up to 1700°C. Emisshield high emissivity coatings** are preferred products due to their versatile bonding systems that result in adhesion to a variety of refractory substrates, whether new or those that have seen service.
High emissivity coatings High emissivity coatings are not insulators. They are not barriers to the conduction of thermal energy through a furnace wall. Insulating refractories are generally placed behind dense refractories at the cold face of refractory linings. While these reduce heat loss from a furnace, the amount of heat stored in the refractory is increased and the refractory
materials must withstand higher mean temperatures. Because the working lining acts as a heat sink, valuable process energy is absorbed by the refractories and lost by conduction to the cold face of the lining. Additional convective energy held by the furnace combustion gases is lost up the flue. When a high emissivity coating is applied to the hot face of the furnace refractory in the superstructure and crown, radiant and convective energy from the burners and hot furnace gases are absorbed on the surface of the coating and re-radiated to the cooler glass and batch. For high emissivity coatings to be effective, the temperature of the coating surface must be greater than the temperature of the glass, which is usually the case whether the glass batch is being melted or whether the molten glass is being refined. The amount of heat reradiated from the coating is predicted by the following equation: Q = Ew . Ď&#x192; . (TC4-TL4) Where: Q = re-radiated energy absorbed by the furnace load; Ew = emissivity of the coating; Ď&#x192; = Stefan-Boltzmann constant; TC = coating temperature; and TL = load (glass) temperature. Since the temperature of the coating and of the glass are raised to the fourth power, it is apparent that the coating absorbs and re-radiates the most energy when the temperature difference between it and the load is the greatest. Therefore, the greatest opportunities for energy savings are when a cold furnace is being commissioned and in the area where materials and cullet are being melted during operation. If the refractory and furnace conditions allow, the furnace heat-up schedule can be shortened to the degree that the fuel savings and earlier glass production value
can exceed the cost of the high emissivity coating. The application of Emisshield above the melt line increases the radiative component of heating glass at the expense of the convective component. The coating absorbs convective heat from the hot gases and re-radiates this energy to the glass. The result is less convective energy being lost up the flue and more radiant energy being used to heat the glass.
Glass tanks The benefits of using high emissivity coatings depend upon tank design and operating parameters. Uncoated refractories have emissivities (Ew), in the range of 0.4-0.6 at glass melting temperatures. The application of Emisshield to the refractory increases the emissivity of the refractory to about 0.9. This means about 90% of the energy absorbed by the coating is re-radiated to the cooler glass. Referring to the previously-referenced equation, it is easy to see that by increasing the Ew of the refractory, the heat absorbed by the glass, Q, will increase. This may not be desirable where over-heating can change the viscosity of the glass and alter the entire production process, so something else in the equation must be reduced to compensate for the increase of Ew, to maintain a constant Q. The factor that must be reduced is the temperature of the coating and the furnace gases and this is achieved by reducing the total energy input to the furnace. Of course, as total energy is reduced, fuel savings are gained. As the fuel use is reduced, the carbon footprint of the furnace and the NOX that it generates if it is gas/air-fired is also reduced. The combustion products of firing, carbon dioxide and water vapour, Continued>>
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Emisshield test panel
Special distribution of radiation, kw/m2
70 Full blackbody spectrum
60 50 40
CO2 absorbing band H2O absorbing band
30 20 10 0
z Fig 1. Wavelengths of energy absorbed by combustion gases compared to the
z Fig 2. Test panel of Emisshield on crown next to burner ports. Note the dark-
wavelengths radiated by high emissivity coatings.
er colour of the test panel compared to the uncoated crown.
Fuel usage vs. cullet content - C-Glass Historical data 2008 data
Furnace
Year 1
Year 2
Year 3
Year 4
Year 5
1 7-8% 7-8% 7-8% 7-8% 4-5% 6
7-8% 7-8% 7-8% 7-8%
24
7-8%
7-8%
7-8%
MMB BTU/Ton
47 7-8% 7-8% Uncoated
64 7-8%
z Fig 4. Fuel savings over time in five C-glass furnaces. Energy savings began decreasing after five years. Emisshield coated
î Ł Fig 3. First-year fuel usage per ton of glass in a C-glass furnace before and
absorb only the energy wavelengths characteristic of these gases (Fig. 1). When the specific wavelengths emitted by the gases are absorbed by the high emissivity coating, the energy is re-emitted from the coating as a full blackbody spectrum containing not only the characteristic wavelengths of the combustion gases, but all of the wavelengths in between. As the re-emitted energy passes through the furnace atmosphere, the combustion gases reabsorb the wavelengths characteristic of those gases, however the rest of the energy passes through the atmosphere and is absorbed by the batch and glass. Because of this, the glass surface is usually hotter than the temperature of the furnace atmosphere. It is essential, therefore, that the melting process be controlled by the temperature and behaviour of the glass batch rather than the temperature of the furnace atmosphere. While critical furnace parameters should always be monitored, the operation of the burners should be controlled by management of the furnace load. If a thermocouple drilled into the crown refractory or suspended through the crown is used as a furnace control, it will
after coating with Emisshield.
read the lower temperature of the coated crown and gases, causing the burners to be turned up and fuel use to increase. A test panel of Emisshield shown in Fig. 2 is visibly cooler than the uncoated crown. A parameter for determining appropriate burner settings might be the location of the point where the glass batch and cullet are 100% melted.
Burners If historic burner settings are used after the coating is applied, the glass and batch will be hotter and the 100% melt line will be closer to the doghouse than normal. The burners can be turned down until the 100% melt line returns to its pre-coating location. Another key glass temperature control point could be the entrance to the throat. Adjusting burner output so that the glass temperature at this location equals the pre-coating temperature will ensure that drawing and forming processes beyond the throat will not be affected by the use of the coating. This assumes, of course that the use of other energy sources, such as electric boosting, does not change. In using a high emissivity coating in a glass furnace, it is desired that no changes in temperature or
glass convection in the melt occur. The major furnace operating parameter changes should all be above the glass line, namely lower burner settings, lower furnace atmosphere temperature and lower flue temperature. After coating the breastwalls and crown of a glass tank, the furnace and crown behaviour during heat-up will be different than that experienced before the application of the coating. Early in the heat-up process, the bottom refractories or solidified glass will be the low temperature load that will absorb the energy radiated from the coated superstructure and crown. At this point in the heat-up schedule, the difference in temperature between the coating and the furnace load will be a maximum. Less heat will be conducted through the coating and absorbed by the refractories, so the degree of crown rise typically experienced at this point of the heatup in uncoated furnaces is not likely to occur. As the furnace contents get hotter, the Î&#x201D;T between the coating and the furnace load decreases and the crown will start rising. Continued>>
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% cullet 7-5% Lower fuel usage (superstructure)
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When cullet is introduced into an empty furnace, the ΔT will increase again and the crown will drop. The crown will begin rising again as the cullet heats and eventually melts. A drop and rise cycle will again occur as glass batch is introduced. The crown will stabilise when production stabilises and at that point it can be sealed. Furnaces with silica crowns will show less movement with raw material introduction above the quartz inversion temperature.
Measuring energy savings It can be difficult to quantify energy savings. High emissivity coatings can only be applied after a complete furnace rebuild or after a cold repair. In the former case, there may not be enough valid baseline data available to allow the performance of the coated furnace to be compared to the uncoated operation. During a cold repair, burner upgrades or regenerator repairs contribute efficiency improvements that complicate the evaluation of the coating applied at the same time. The first application of a high emissivity coating in the wool furnace mentioned in the opening paragraph presented an early opportunity to evaluate
the effectiveness of the coating, in this case Emisshield, under conditions where the coating was the only variable. The furnace had been idled for business reasons and when it was re-started, eight years of baseline operational data were available. No changes or repairs were made to the furnace, other than the coating of the entire superstructure, during the shutdown. Fig. 3 shows the fuel use % of cullet compared to the historical fuel usage. The actual axis values are proprietary, but the fuel savings value was 7.5%. Four similar furnaces were sprayed with the same coating in each of the next four years. The fuel savings of the furnaces were monitored annually. Fig. 4 shows that all of the furnaces showed nominally the same fuel reduction after the coating was applied. Furnace #1 maintained a 7-8% fuel saving for four years. After five years it dropped to 4-5% and in the sixth year it was not measureable. In tableware and container furnaces, a 3-4% fuel saving can be expected since the fused AZS breastwalls cannot be coated. In most circumstances, except those places with low energy costs, a payback of the coating price can be expected in less than a year.
Conclusion Emisshield and other high emissivity coatings have provided fuel savings, productivity gains and addressed certain environmental concerns. These coatings can reduce the carbon footprint of glass producers and, in gas/air-fired furnaces, reduce total NOx emissions. The effectiveness of these coatings can be compromised by operational and perhaps other technical conditions in the furnace. The location of the control thermocouple, thickness of surface foam, the percent coverage of the bath surface by luminous flames and operating practices can all have a diminished effect on the performance of the high emissivity coating. Communication between the glassmaker and the coating supplier is essential to insure optimum conditions exist to exploit the benefits.
* Manager - Product Technology, HarbisonWalker International, Pittsburgh, USA http://www.thinkhwi.com ** US Patent 6,921,431, EMISSHIELD® is a trademark of Emisshield, Inc., Blacksburg, VA, USA
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Burning questions Alain Grangeret* discusses the working principals of the dual gas burner design, which is widely used in many conventional firing furnaces.
How does the burner work? The gas tubes supply the natural gas, dividing it into two jets, an inner and outer jet.
Boundary of the jet
The inner jet discharges gas at high speed, a speed of a few hundred metres per second depending on the pressure supply. The outer jet discharges gas at a lower speed below 100 m/s and this is because of its larger cross section and lower pressure inlet. The manner in which the gas is injected results in the formation of a combustible mixture of air and ring-jet gas. The fully developed core of the gas flow mixes downstream with the furnace combustion air. With the same burner, it is possible to have different velocity profiles in the jet near field regions for the same gas flow rate (Fig 1). The single jet principles are similar for double concentric jet flames. There is a relationship between the injector design and the downstream flow profile up to the fully- developed region. Thereafter, little can influence the flame development and this is the end of the relationship with the physical injector design. Soot production occurs in a fuelrich flame and oxidation/destruction occurs in a fuel-lean region. The ring-jet gas boundary is the condition for the formation of soot and this happens at the root of the flame, which can be referred to as the initial and transitional regions. The heat emission of a flame is not only related in the formation of soot but
Fully developed turbulent Diffusion flame
Spot 546
Local reaction
Low pressure gas inlet
its action is combined with the mixing factor. It is easy to reduce the NOx level by operating the furnace with a higher CO content level at the furnace port exit. However, this is not always taken into consideration when producing low iron clear glass and also the lifespan of the regenerator materials.
Port design and the consequences with air/fuel mixing A turbulent diffusion flame is controlled by the mixing (or diffusion) processes of the fuel and its oxidant. Therefore, the furnace port design, the burner location and their respective distances between the glass surface to the crown have a major effect on the flame and furnace thermal behaviour.
Dual Impulse gas burner â&#x20AC;&#x201C; Is it a good burner? Yes â&#x20AC;&#x201C; the equivalent burner diameter based on the velocity profiles can be changed by varying the high pressure and low pressure gas supplies. This can influence the heat flux profile (rear and front crown temperature are important furnace indicators) and the visible flame length. This type of burner can offer flexibility to the furnace operators. Continued>>
°C 670
Soot creation
High pressure gas inlet
Initial & transitional gas regions
Fully developed region
z Fig 1. A gas injector design.
v Fig 2. Thermal image.
e 0.95 Refl. t. 60 Obj. d. 1m Rel.h. 30% Atm.t. 50
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ithin the glass industry there are only a few suppliers of gas burners. Therefore, prior to purchasing burner technology, the supplier market can be easily researched and assessed. Since the late 1990s, the general trend is to use dual impulse gas burners for conventional air-fuel regenerative furnaces. The related burner is commonly called a pipe in pipe burner and is a technology that originated from trials carried out in the 1970s. The claims for energy saving and NOx abatement by using this technology in the glass industry differs from one supplier to the other. These claims should be associated with the specific details of the operational furnaces, however, it is found this is not always the case. The current burner technology has many advantages including low momentum, good flame luminosity, flame control coverage and relatively good NOx results. When using this type of burner, it is important that the working principles of the dual impulse design are clearly understood.
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Does the outer and central jet arrangement influence NOX levels? As explained, the double concentric jet arrangement with the correct velocity profiles are the key factors for soot creation at the root of the flame. Beware of disappointment – the burner will not necessarily reduce the NOx level by much because the furnace combustion space design must be configured adequately. There is a combination with the inlet ports and the furnace design for optimising results, however other factors which intervene in the heat transfer to the glass have to be considered.
Are there any other requirements? The correct use of the dual impulse gas burner is based on implementing an adequate fuel gas control system. Attention must be given to adjusting the high and low gas pressure input combinations. This can be done mechanically with a specific burner design and/or with the help of additional pressure control valves. These control valves allow for
The burner block design must be appropriate if the burner face is sealing against the block. If the design is inappropriate, it causes internal recirculation of batch/hot gases products causing trouble to the flame development.
the implementation of burner control management, which adds a complementary function to the furnace supervision. This gives the advantage of changing the settings for various pull rates without adjusting the mechanical setup. The burner support should be light and versatile to use, however, many burner support designs are bulky and do not allow for the furnace operator to adjust the burner easily within a hot location. The burner refractory block should
be designed to limit the proportion of induced flow of furnace gases and dust back to the burner tips. The reason for this is that batch particles stick within the burner block and may compromise the dual impulse flame. The burner tips can be cooled with soft water (water jacket nozzle) or with external airflow. Both of these solutions should offer a design opportunity to seal the burner face against the burner block. The last consideration is to use the ‘cooling’ air for the internal burner parts when it is not firing. The purpose of this is not to cool the parts but to counteract the furnace pressure to avoid a hot reverse flow within the burner. Then it is not necessary to have a high flow rate of ‘cooling’ air (Fig 2). r
Reference Rogier, J. – Report GN 6 of Groupe d’Etudes des Flammes de Gaz Naturel, Toulouse, Oct. 1972
*Owner, freelance consultant and combustion expert at AG Gas, London. aggaslondon@gmail.com
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Forming
When less glass wall thickness becomes a solution Hélder Remédios* highlights an uncommon problem in a glass plant but one that can have serious cost implications.
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his article highlights a case where using the same mould design, different results were achieved in terms of glass distribution. It is not the most common issue to find in a glass plant. However, for niche markets where the same bottle or jar is produced in different colours, this is something to consider from a technical perspective. The results will be different and have implications when budgeting the costs of a production. Glass distribution is without doubt the most important contributor to the integrity of any glass container. The simulations shown here, as in Fig. 1, were made using Empakglass’s forming software. Glass colour in terms of physical properties influences the thermal transmission. This is common sense: we know how sunlight crosses more or less along a lighter or darker window. On an IS machine, the reheating time is directly influenced by the thermal conductivity of glass. The reheating is the period of time between the end of the parison transfer and the start of the final blow. During this time, the parison tends toward temperature equalisation (reheat) and gravity stretches it. Excessive reheating on the blank mould side allows the parison to sag and on the blow side to run so the two effects have to be counterbalanced. Stretching and cooling of the parison can be helped by the use of overhead cooling over the blow mould. The speed of invert affects the glass distribution of the finished bottle. If it is too slow, the parison will sag backward due to gravity; if too fast the parison is
Fig 1. (l-r) Glass thickness simulation, 3D Ren-
Fig 2. Wave shape defect and heel region not
dering, actual bottle.
completely formed.
Fig 3. Client’s flint glass thermal profile
Fig 4. Client’s black glass thermal profile
thrown forward by centrifugal force. The speed must be varied to suit the weight, viscosity and shape of parison. Referring to glass physical properties:. when comparing a darker glass versus a lighter colour glass, the time to equalise the parison temperature will take longer on the first case. Therefore the sag/run effects will be less for the same actual
time cycle comes to place. For this particular case study, the blank moulds were developed for an Empakglass client involved in flint glass. The consistency of the forming simulation results was confirmed during actual bottle production. Continued>>
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Forming
When the client decided to use the same mould set with ‘black’ colour glass, a visual defect appeared around the heel area. It was ‘wave’ shaped with a ‘cold’ appearance. The heel region was also not completely formed (Fig. 2). Another defect detected were ‘dropped bottoms’. These did not appear in the flint bottles produced with the same mould set. The defect is consistent with temperatures higher than the softening point. Curiously, although there might have been two different reasons for this (cold appearance and dropped bottoms), the root cause was just one – the thermal conductivity of black glass. By using Empakglass’s forming software, simulating in black and compared with flint: r The glass outside surface temperature at the moment where the final blow starts had an average of 40 degrees lower in black colour compared to flint => cold appearance on the out surface and ‘wave’ look; r The isothermal areas above 1080ºC in black glass are larger than in flint, mainly around the shoulder and mostly on the bottom, where the glass thickness is higher => longer to
Fig 5. Comparison between the glass distribution for flint (in blue), with a blank mould with 25% overcapacity and a
25%
40%
40% overcapacity blank
overcapacity
overcapacity
mould for black glass (in black) that keeps the same weight.
equalise temperature and therefore the occurrence of dropped bottoms already on the annealing lehr. This shows that the black glass reheat time is too slow when compared to flint (more difficult to have thermal transmission). In practice, this means that in ‘black’ when the final blow is applied, the glass is still cold on the outer surface and will not form completely on the blow side. This also confirms that the darker the colour and the higher the thickness, the worse it will be in terms of reheat time. The excessive glass thickness on the bottom combined with the reheat time difference between flint and black is too large (almost double). In black glass a deformation on the bottle heel could be seen, which did not appear in flint, after the bottles had entered the annealing lehr. In black, due to thermal conductivity when compared to flint glass (Figs. 3 & 4), it is necessary to reduce the bottle bottom thickness to get a faster reheat time on the glass. This can be achieved by developing a different parison design, with a higher overcapacity (Fig. 5). By doing so, both the ‘wave’ look on the heel and the dropped bottom effect are solved. Therefore, lower thickness on the bottom was achieved by retaining the same weight and increasing the blank mould overcapacity, which could solve the issues discussed above. r
*Partner, Empakglass, Santo António dos Cavaleiros, Portugal www.empakglass.com Glass International July/August 2015
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Lubrication
Lubrication for the glass industry With 160 years of experience in lubricants development, manufacturing and trading, French company Condat Lubrifiants offers chemical products and industrial lubricants for all aspects of the glass industry. Nathalie Vidal* discusses the company’s latest developments.
www.glass-international.com
U
sing its technical knowledge, Condat formulates lubricants with added value, adapted to most industrial applications. Condat has developed dedicated lubricants for the glass industry such as cutting oils, emulsions, and coolants. With more than 30 years’ experience and strong partnership with glass customers, Condat offers dedicated lubricants for all glass processes covering flat, packaging and optical glass operations. Condat’s objective is to recommend to its customers the best lubricating solution depending on their industrial processes, keeping in mind performance, costs and environmental constraints. Condat has taken into consideration environmental issues in the quality of its production and processes. It devotes 3% of its turnover and 53 employees to its research and development (R&D) department. Condat’s desire to respect the environment is shown in the development of new products such as ‘biodegradable lubricants’. These are lubricants based on vegetal raw materials and products that meet regulation constraints, such as REACH and GHS.
Packaging glass Condat has developed products and
An example of Condat’s glass cutting oils.
equipment to meet the requirements of the hollow glass process, including: r Soluble lubricants for shear spray and for the delivery system; r Neat oils for the delivery system; r Dual-component coating for the delivery system; r Swabbing compounds for moulds; r Oil and grease maintenance products, both mineral and synthetic, for IS machines. Thanks to its expertise in graphite dispersion solutions in other industrial markets, the company has launched a range of swabbing compounds for all glass container processes: r Blank mould lubricant: CondaGlass 370 This swabbing compound provides excellent uniform lubrication in the mould without transferring graphite to the glass part. r Ring mould lubricant: CondaGlass 397 This swabbing compound deposits a thin uniform graphite film on the ring. It eliminates defects on the neck ring and improves release. r Blow mould lubricant: CondaGlass 398 This swabbing compound provides a clean bright finish to the glass. Its
wetting agents and additives penetrate into tight surfaces. The CondaGlass swabbing compounds are designed to provide uniform lubrication and maximise production. Their viscosity is designed for the application; neither too fluid, nor too thick, thus allowing the right amount of lubricant to be applied to the mould. The final Condat development this year for the packaging glass industry is a dedicated synthetic oil ISO 220 for the maintenance of IS machines. Named Glass HTS 250, it lubricates the different parts of the machines with low evaporation and oxidation under high temperature conditions. As well as the range of lubricants, Condat also offers suitable equipment to optimise the use of its products. For example CondaMix, a specific dosing unit that delivers the accurate quantity of lubricants in the shear spray and delivery system. Dilution of the product is optimised and reliable; it allows substantial gains on lubricant consumption.
Flat glass Condat products and equipment that meet the requirements of the flat Continued>>
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Lubrication
Its CondaGlass FA are synthetic soluble coolants, designed for edge grinding operations. Their advantages are: r High resistance to mechanical foaming; r Keep the cutting properties of grinding wheel (less wear of tools); r Resistance to bacteria and fungi. The CondaGlass FA products are user-friendly: They are not classified as dangerous according to EU regulations, and are not classified as irritating or sensitising. They are not based on mineral oil, and do not include dangerous compounds such as DEA, formaldehyde or nitrites. Condat recently developed
Aerial view of Condat’s plant.
interleavant powders to avoid friction between the glass sheets. These products advance the Condat range for float glass. CondaGlass PF 1050, with an average size particle of 50µm, provides protection of the glass sheets during transport and facilitates separation. With a specific intrinsic viscosity, CondaGlass PF 1050 limits consumption of interleavant powder. Condat also offers analysis of products and water, environmental advice, and assistance concerning regulatory information. Condat also proposes suitable equipment such as dosing units or oil separators for flat glass applications. Located in Chasse-Sur-Rhône, France (30km south of Lyon) on a 84,500m² area, the Condat group produces technical chemical products. It employs 285 people in France and 100 more worldwide with production units based in North America, South America and Asia. r
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glass process (float, architectural or automotive), including: r Cutting oils; r Coolants for edge grinding and drilling; r Solutions for water treatment; r Interleavant powders; r Maintenance products.
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Inspection
Visionary inspection Esben Korre* outlines a tube end inspection system able to process 18,000 tubes an hour.
T
he increased demand for high quality glass tubes for pharmaceutical glass or solar heaters has led to higher inspection requirements. The tube ends in particular, where the tubes have been cut, formed and fused with a heat treatment, require high quality levels (Fig. 1). Defects such as chips, cracks, impurities or thin walls can have a huge impact on tube robustness and so thereby the lifetime of the final product. For pharmaceutical glass there are also strict requirements to end dimensions.
Vision
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JLI vision has developed many vision systems for the glass industry, particularly for online inspection of tubes. JLI recently developed its third generation tube end inspection system, which has been successfully installed at two tube factories. JLI vision was formed in 1985 and has been engaged in glass inspection since 1991. It offers systems for a variety of applications including hot end container glass trend analyser, number readers for containers, flat glass, stress detection, tableware inspection and on-line inspection systems for glass tubes. JLI also develops applications for
specialised production. One of these measures the inner diameter of a glass tube with an accuracy of 0.03µm. Measurements OD, ID, WT, out-of round and siding
>0.005mm
Chips & cracks
>0.5mm
Fuse dimension
>0.01mm
End shape irregularities
>0.02mm
Tube length
>0.1mm
Bow >0.02mm
Table of measurement accuracies.
System components The system consists of five high-speed 5-Megapixel cameras with telecentric lenses to avoid dimensional distortion. Two cameras look directly at the formed end, two look at the side of the formed end and the final camera is pointed at the centre of the tube to measure bow (Fig. 2). The tube end system is modular in its design and can be fitted to any existing conveyor – it only requires a ‘star wheel’ to be added or a similar mechanism to evenly space the tubes. After the inspection point a reject device is mounted to remove defective tubes.
Specifications and measurements The third generation tube end inspection system has improved its accuracy and
speed: it is now able to process 18,000 tubes an hour. The solution to achieve this speed is to analyse the tubes while in motion and thereby eliminate stop and go mechanics. The tubes are rotated while moving past the camera. The system measures outer diameter, inner diameter, wall thickness, out-ofround, siding, chips, cracks, end shape irregularities, bow and tube length. The systems are designed to handle tube diameters from 4 to 40mm. The key tube end dimensions are measured to an accuracy of 5µm. All accuracies can be seen in a table of measurement accuracies.
Algorithms The inner and outer diameter is calculated in the images taken at the tube end. The inner and outer edge is found and filtered to remove outliers. Outliers typically occur due to noise in the image or contamination on the lens. Removing outliers, before fitting all points to an ellipse, makes for a robust system. This method also provides trouble-free operation in a dusty glass manufacturing environment. The inner and outer ellipse (circle), Continued>>
z Fig 3. Overview of the mechanical design. Fusing z Fig 1. Fusing between dimensional measure-
z Fig 2. Picture from end camera (left) and from
takes place between the two horizontal cameras and
ments and the side cameras.
side camera (right).
the three vertical cameras (side and bow cameras).
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Inspection
are the basis to calculate the wall thickness, out-of-round and siding. Chips, cracks, shape irregularities and tube length are measured from the side cameras (Fig. 3). Each side camera takes 12 images of a single tube, while it is being rotated 360 degrees, giving a picture per 30 degrees. The fused edge is analysed intensively in every image to detect any shape irregularities. The glass surface between the two fused edges and the area below are inspected to detect chips and cracks. The area between the fused edges and below the edge is maximised in every image to get the best coverage. Tube length is calculated by using the end detection coordinates from the two side cameras – trigged at exactly the same time to avoid any tube movement between the images. The length of the tube seen in each image can be calculated to gauge the total tube length. The system can handle any tube length – it is only a matter of calibration. The bow is measured by the 5th camera, placed at the centre of the tube, lengthwise. This camera takes up to 100 images per tube. The displacement is measured and when plotted it takes the shape of a sine curve. All the measurements are filtered and fitted to a sine curve in the special algorithm developed by JLI. The amplitude of the sine curve corresponds to the bow of the tube. All tube end algorithms have been developed with the aim of being robust to noise and dirt, but also able to reject small defects. Fitting a cloud of points to ellipses (circles) or sine curves is part of the trick, but also filtering out single outliers and using sub pixels accuracy is part of the explanation.
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Benefits The obvious benefit is uniform sorting that gives high quality to the tubes approved by the system. But another major benefit is that no further manual handling is needed in the process, so a packaging system can be added to the line and a higher level of automation and efficiency achieved. The system provides statistics useful to monitor the handling process and to optimise production. All JLI systems connect to the internet and make it easy to service the equipment remotely.
The tube end inspection system was installed at Nipro Glass France, Aumale in December 2014, along with the existing JLI in-line SK-3020 tube defect detection systems. JLI used its knowledge and experience on tube inspection to provide the systems to Nipro as part of a total inspection strategy for tubing lines.
Future JLI vision expects to see an increased interest for tube end inspection, driven by the ever-expanding demands to the pharmaceutical business. Also, as a result of long tolerance chains pharmaceutical companies frequently request particularly high accuracy, which it said this system delivers.
*Senior Vision Engineer, JLI vision, Søborg Denmark www.jlivision.com
*Subject to technical specification, terms and conditions System 500 forehearths and distributors are offered with guarantees covering temperature stability, thermal homogeneity and fuel consumption. Are yours?
PARKINSON-SPENCER REFRACTORIES LTD Holmfield, Halifax, West Yorkshire, UK. HX3 6SX Tel: (44) (0) 1422 254472 • Fax: (44) (0) 1422 254473 Email: admin@parkinson-spencer.co.uk • www.parkinson-spencer.co.uk
www.glass-international.com
Customer reference
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Profile
Stand CO1
Stand CO3
F.I.C. (UK) Limited Long Rock Industrial Estate Penzance, Cornwall, TR20 8HX, UK Tel: +44 (0) 1736 366962 general@fic-uk.com www.fic-uk.com
Iris Inspection Machines ZI du Chêne 14 rue du 35ème Régiment d’Aviation 69500 Bron France Tel: +33/ (0) 4 72 78 35 27 sdevillard@iris-im.fr www.iris-im.com
Stand EO7
ZIPPE Industrieanlagen GmbH 1665 P.O. Box D-97866 Wertheim, Germany zippe@zippe.de www.zippe.de
- Stand D14 - WALTEC Maschinen GmbH Kronacher Str. 2a 96352 Wilhelmsthal - Steinberg Germany contact: Mr. Ulrich Zirfas, Managing Director Tel: +49 9260 9901-0 info@waltec.de www.waltec.de
STAND D01 300 Old Greenwood Road, Decatur, TX 76234 USA Telephone +1-940-627-2121 | www.poco.com
POCO’s hot glass handling materials offer excellent performance combined with reduced mechanical damage for increased pack rates.
Heye International Booth: A07 Lohplatz 1, Obernkirchen, Lower Saxony, 31683, Germany Tel +49 5724 26 452 sales@heye-international.com www.heye-international.com
Stand B15
ilis gmbh Konrad-Zuse-Str. 22 91052 Erlangen, Germany Tel: +49 9131 9747790 info@ilis.de www.ilis.de M-GLASS FACTORY SERVICES S.A. de C.V. Stand E07 Calle Sonora, #100, Interno 18-B Col. Flores Magon, CP 62370 Cuernavaca, Morelos. Tel. +52 777 3183972 Cel. +52 1 777 2676666 Cel. +52 1 777 2318910 mglassfactoryservices@hotmail.com
Fermac Booth: D09 Via La Spezia, 162/A, Italy Tel +39.0521989056 sales@fermac.it www.fermac.it
Stand A19
Stand EO6
www.glass-international.com
Quality Management Systems for Glass Containers Agr International, Inc Tel: +1 724-482-2163 Fax:+1 724-482-2767 sales@agrintl.com www.agrintl.com
Glass International Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QS, UK gregmorris@quartzltd.com www.glass-international.com
GLASSMAN MIDDLE EAST 2016 10TH-11TH MAY 2016, HALL 6, ADNEC, ABU DHABI, UAE Contact Ken Clark at kenclark@quartzltd.com www.glassmanevents.com
84 Glass International July/August 2015
PROFILE esme.indd 1
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Bright ideas. Better glass.
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Inspection
Automotive glass inspection fixtures Charles S. Voeltzel* discusses inspection in the automotive industry and the glass check fixtures that are used to verify the accuracy of bent glass.
Glass check fixtures In the early days of the bent glass industry, the glass shapes were relatively simple and could be defined by a drawing showing dimensions and radii. As the bend became more complex the OEMs would provide the glass supplier with a master tool cast from a model, with which to fabricate the parts. Check fixtures and other tooling were in turn cast from this master tool. A major improvement was the move to CAD design and machine cut master tools in the 1980s. Today, glass check fixtures (Fig. 1) for OEM glass are all machine cut to the master OEM digital data. For a glass checking fixture, a reasonable error for the fixture is 10% of the tolerance limit: if we have a size tolerance of +/1.0mm, our check fixture must be cut to at least +/- 0.10mm. That is a reasonable tolerance that most machine shops can achieve. Special measures must be taken for tolerances that are much less.
wood runners that are potted in epoxy on a surface table to provide stability during machining. The block is then milled to create a female mould for the fixture. The foam female mould surface is coated to seal the cells and then a release agent is applied. The blank for the fixture is built up on the female mould using casting resin mixed with hardener, chopped fibreglass and fine powdered glass. The glass gives strength and abrasion resistance to the material. An added benefit is that it reduces the coefficient of the expansion of the fixture to near that of the glass. The resin is allowed to cure and heat can be applied to speed up the curing process. A welded aluminium frame is attached to the fixture blank, using additional resin and glass cloth. The blank is then removed from the female mould. The feet of the frame are set in epoxy on a precision granite surface table and the fixture is leveled. Once the epoxy sets, the fixture is ready for the mill.
Fabrication of the fixture The starting point for the fixture is a foam block. The block is mounted on
Continued>>
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I
n the architectural glazing world, size and bend tolerances have not been a major source of concern. With most parts made up of flat rectangular shapes, little more than a good square, straight edge rule and caliper have been required to verify that a part is correct. A good CNC cutting line can turn out rectangular parts that are within a tenth of a millimetre, with ease. In the automotive glazing world, however, life is more complicated. Parts often have both horizontal and vertical bend. While the flat, unbent glass may start out precision cut to an exact size, the final bent size is a function of the bend, and the bend is a function of many other parameters leading to a substantial potential for variation in size. As well as size, we also need to verify that the surface has been formed to the correct shape, so that the fit and function will be as intended. Adding to the complication, as the automotive industry has embraced Lean, Six Sigma and other quality tools, suppliers have been hard-pressed to keep up with OEM expectations and specifications. What was a good part 20 years ago is todayâ&#x20AC;&#x2122;s reject and receipt of as little as one defective part by an OEM can lead to costly re-inspection and other corrective measures. At the same time, tolerances for bent glass parts are approaching those of sheet metal. In response, new processes have been developed by the glass industry that have tighter dimensional control and precision dedicated hard tooling is often required to verify the dimensional accuracy of these bent parts. This article examines the type of glass check fixture being used.
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Inspection
10mm
Design size Male inside surface of glass
Check ledge
12mm
Check ledge
Nets to fixture
3mm Pin
z Fig 1. Glass check fixture
Bracket
Profile edge
Profile edge
12mm 50mm
12mm min ~150mm
z Fig 2. Check ledge types
5-axis milling The type of fixture described in this paper is produced using a 5-axis mill. Similar fixtures can be made on a 3-axis mill with a 90-degree head, but multiple setups and more machining time and handwork are required. The first operation on the mill is to drill two holes into which bushings are inserted. These bushings serve as datums to establish the coordinate system. The surface (check ledge) of the fixture used to check the bend along the edges (form) is cut to match the inside surface of the glass (Fig. 2). On a windshield or rear window, this emulates the metal flange that the glass will be bonded to. This check ledge is typically 10mm wide. On parts that have a bi-lateral tolerance for bend, the check ledge will be undercut by 3mm and the glass supported on 3mm high pins inserted in the check ledge. Form is checked using a taper gauge or a go/no-go step pin. To check the size, the mill is used to cut a profile surface normal (perpendicular) to the inside surface of the glass, following the edge of the glass. This profile surface serves as a reference for size and other measurements and as a mounting surface for hard stops (datums). The profile surface can be cut to the nominal size of the glass or for a go/no-go type of check fixture, to the maximum size.
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Sweep bars Sweep bars (Fig. 3a & b) are used to check the bend along the vertical centre line. These are rectangles of 6mm aluminium plate cut to the contour of the outside surface of glass, plus an offset to allow for measurement on over-bent glass. A 6mm offset is typical. There are two types of sweep bars: those that mount to the fixture and those that rest on the glass. Sweeps that rest on the glass can either be mounted to the fixture, or hand applied to check the bend without a fixture. Sweep bars that only net to the fixture
z Fig 3a. Sweep bars
chemicals. A bar of Vespel can be quickly turned on a lathe to form precision datums. By boring a hole and mounting on a pin, the datum is free to rotate so that any relative motion between the glass and datums will not cause wear.
Nets to glass
Bracket
Holes Fixtures for parts that have holes will have holes drilled and bushings inserted. Step pins are used to check hole size and location.
z Fig 3b. Sweep bars
Calibration block Calibration surface
Plunger retract
z Fig 4. Dial indicators
give more accurate measurements, as they are not subject to any error in the bend of the glass at the edges, where the other type of bar rests.
Scribing The mill can be used to mark the fixture, using a scribe. These scribed lines are then used to make a visual check of the paint band, trademark and other features. They are also used to show where measurements are to be taken. Scribed lines are filled with paint to improve visibility.
Datums Glass, being hard and abrasive, is hard on all surfaces that come into contact with it during the cold end processes. Materials used for datums must not be as hard as glass, but at the same time cannot be soft enough to leave marks on the glass. Nylon and phenolic are frequently used. The datums are mounted to the profile surface. One of the best materials, and most expensive, is DuPont Vespel. Vespel is a sintered polyamide, which is tough and resistant to wear, temperature and
Dial indicators Dial indicators (Fig. 4) are used to measure a small number of points on a check fixture. The displays can be hard to read due to the location of the points being measured however many are equipped with a data port that can be used to transfer reading directly to a computer. Some indicators also have a threaded fitting that can be equipped with a remote retract cable that can be used to keep the tip retracted until needed. A reference surface must be cut on the fixture in order to be able to zero out (calibrate) the indicator.
Higher precision If a higher level of accuracy is needed or if the number of points or parts to be checked are high, an automated check fixture may be needed. In this case, probes are installed on the fixture which will automatically capture all of the measurements at once. A high precision, air activated spring return LVDT probe is typically used. Before use, each probe must be zeroed to a reference. The reference is measured using a coordinate measuring machine. The error is stored and used as an offset for each probe. In this way, the accuracy of the measurement can exceed the fabricated accuracy of the check fixture itself. r
*Principal Engineer, Creative Solutions Verre, Pittsburgh, PA, USA csvoeltzel@aol.com www.csvglass.com
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5 22 & 23 September 2015 Expo Guadalajara, Guadalajara, Mexico
Where the container 5 glass industry meets to do business 15 - 16 May 2012 World Trade Centre, Mexico City
NEW EVENT ANNOUNCED
2015 For more details contact: Ken Clark Sales Director Tel: +44(0)1737 855117 Email: kenclark@quartzltd.com Jeremy Fordrey Sales Manager Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com
See the website for more details
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04/03/2015 17:31
Trustee in bankruptsy of Huta Szkła Tur sp. z o.o. w upadłości likwidacyjnej (Tur Glassworks limited in liquidation bankruptsy) with headquarters in Poznaś, Poland (TIN: 7822311801, National Court Register of Businesses# 0000223114) calls for bids to purchase a BANKRUPT COMPANY located in Tur (the province of kujawsko-pomorskie), 40 Bydgoska Street for the amount no lesser than PLN 150,000,000.00 (write: one hundred and fifty million).
The assets of the company comprise among others: -
A plot of land located in Tur, registered under entry# 254/5, area 2.6813 ha (developed with a complex of buildings intended for production, storage and office purposes), registered with the land and mortgage register managed by the District Court in Szubin, Poland under entry# KW BY1U/00015177/4,
-
One oxygen and gas mixture-fired tank furnance with the capacity of 130 tonnes/day,
-
One cryogenic unit for oxygen production,
-
Three production lines with facilities.
Above-mentioned components constitute an operational plant - GLASSWORKS. The follwoing assets are not subject to sale: pecuniary assets (in cash and on bank accounts), liabilities, stocks, prepayments and accruals, securities and other receivables (owned by the bunkrupt company and managed by the trustee). In order to participate in negotiations and to carry out an audit or inspection of the subject hereof, interested parties shall pay a deposit in the amount of PLN 1,000,000.00 (write: one million) to bank account #60 1600 1462 1848 6570 4000 0001. Bids along with statements of deposits and confirmation of approval of terms and conditions of sale shall be submitted to the trustee, at the following address: Biuro syndyka, ul. Mickiewicza 5/9, 60-833 Poznań. Following a bid approval, the deposit shall be credited to the purchase price. Should your bid be rejected, the deposit shall be returned within 7 days of the selection of best bid (without interests). In the case of lack of bids, the trustee invites all interested parties to negotiate conditions of purchase. Regulations contain detailed terms and conditions of sale and are available at the trustee’s office at 5 Mickiewicza Street apt. 9 in Poznań, Poland. Please make an appointment by phone or by e-mail: biuro@kancelaria-bb.pl. Call +48 61 639 45 25 for further details. Please be advised that the bunkrupt company was leased to VENI S.A. with heaquarters in Warsaw, 81 Grzybowska Street. Said company made outlays in order to make the plant operational. A potential buyer may purchase said outlays from the lessee under a separate contract. Furthermore, the lessee shall have the right of first refusal pertaining to the purchase of the company registered with the land and mortgage register #BY1U/00015177/4 by the District Court in Szubin.
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r Glass Reflections September 7th-9th 2015 Cambridge, UK. CONTACT: www.sgt.org r Gulf Glass 2015 September 14th-16th 2015 Dubai International Convention and Exhibition Centre (DICEC). CONTACT: gulfglass@dmgeventsme.com www.glassinthegulf.com r ICG Annual Meeting The International Commission on Glass’s (ICG) Annual Meeting. September 20th-23rd 2015 Bangkok, Thailand. CONTACT: montana@optimum.co.th www.icgbangkok2015.com r Glassman Latin America Glassman will be returning to Mexico in 2015 and stands have almost sold out. September 22nd-23rd 2015 Expo Guadalajara, Guadalajara, Mexico. CONTACT: kenclark@quartzltd.com www.glassmanevents.com r IHS Chemical Soda Ash Business Outlook Conference The theme is ‘New Energy Paradigm and Soda Ash’. September 29th-30th 2015
Barcelona, Spain. www.ihs.com/events r Vitrum 2015 International trade show for flat, bent and hollow glass. October 6th-9th 2015 Fiera Milano exhibition complex, Milan, Italy. www.vitrum-milano.com/en r Luxe Pack Monaco Packaging exhibition for specialists luxury products. October 21st-23rd 2015 Grimaldi Forum, Monaco. www.luxepack.com/accueil.php r Glasstech Asia 2015 A platform for industry players to tap into the growing South-East Asian market. November 19th-21st 2015 Jakarta, Indonesia www.glasstechasia.com.sg r Glassman Middle East 2016 The Glassman exhibition and conference returns to the Middle East for the first time since 2009. May 10th-11th 2016 Abu Dhabi National Exhibition Centre, UAE. CONTACT: jeremyfordrey@quartzltd.com kenclark@quartzltd.com www.glassmanevents.com
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The glassmaker’s diary
Events world
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CLASSIFIEDS
ANNEALING LEHRS
HEAT-UP SERVICES
FURNACES
ANNEALING & DECORATING LEHRS for Containers and Tableware
TEMPERING LINES ON BELT / SPINDLES for Tableware and Stemware
contact us
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Glass International directory 2015 contact: Esme Horn to receive your copy
COMBUSTION SYSTEMS/BURNERS
GLASS LEVEL MEASUREMENT
RAW MATERIALS
Rio Tinto Minerals 2 Eastbourne Terrace London W2 6LG, UK Tel +44 (0) 207 781 1450 Fax +44 (0) 207 781 1851 Email: simon.cook@riotinto.com Web: www.riotintominerals.com
SCREEN PRINTING
DECORATING MACHINES KBA-KAMMANN GmbH Bergkirchener Str. 228 D-32549 Bad Oeynhausen (Germany) Fon +49 (0) 5734 5140-0 Fax: +49 (0) 5734 5140-5130 mail@kba-kammann.com www.kba-kammann.com
Global Combustion Systems
INSPECTION
Total Support
On-line Process & Quality Control
Unit 43, Evans Business Centre, Easter Inch, Bathgate EH48 2EH, Scotland, UK
TIAMA - msc & sgcc ZA des Plattes, 1 Chemin des Plattes, 69390 Vourles, France Tel +33 (0) 4 37 20 15 00, Fax +33 (0) 4 78 07 94 50 Email: marketing@msc-sgcc.com Website:www.tiama.eu
Tel+44 (0) 1506 657310 Fax +44 (0) 8704 799975 Email Sales@globalcombustion.com Web www.globalcombustion.com
FLEXIBLE. PRECISE. INNOVATIVE.
Glassman events visit: www.glassmanevents.com
COMBUSTION EQUIPMENT
Contact Esme Horn T+44 (0) 1737 855136 to book your space
INDUSTRIAL GAS ENGINEERS
I NDUST RIAL G AS E NGINEERS UNIT D2, BRO O KSID E BD2, U S Brookside I N E S S P ABusiness R K , G R EPark, E N G AGreengate, TE ,C H AD D ERTO N, M24 1G S, ENG LAND Unit Chadderton, T E L E P H O N E : 0 1 6 1 - 6M24 5 4 71GS, 7 0 0 UKF A X : 0 1 6 1 - 6 5 5 3 8 1 2 Tel +44 (0) 161 654 7700 Fax +44 (0) 161 655 3812 E-MAIL: S A L E S @ M O N T S E L A S . C O . U K WWW.MONTSELAS.CO.UK Email sales@montselas.co.uk www.montselas.co.uk
AIR
GAS
MANUFACTURERS AND SUPPLIERS OF SELAS SQUARE PORT GAS & AIR VALVES
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8/11/15 10:41 AM
53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce, 6 Tel +39 0577 304730 ifv@fonderievaldelsane.com
www.fonderievaldelsane.com