Glass july:august 2014

July/August 2014 Vol. 37 No.7

O-I R&D CENTRE BENNU GLASS HANDLING

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Glass International July/August 2014

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Contents

July/August 2014

Vol. 37 No.7

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July/August 2014 Vol. 37 No.7

O-I R&D CENTRE BENNU GLASS HANDLING

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Editor’s Comment

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International News

www.glass-international.com

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Front cover image courtesy of Bucher Emhart glass www.emhartglass.com

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Glass profile: Bennu Glass Bennu is born Glass profile: O-I R&D Centre Owens-Illinois celebrates the opening of its Innovation Center The UK’s Society of Glass Technology (SGT)

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Company profile: Thor International Colombian group makes inroads into glass industry

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British glass

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History

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Hollow glass Hollow glass industry overview

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Glass machinery German glass machinery ready for glasstec

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Handling Dry lubrication helps improve glass package stability Protective clothing for the glass industry Inspecting thin glass Quad gob ware handling Robotic glass handling

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Events world Mir Stekla at its best

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Fibres An overview of basalt fibres

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Diary

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Plus find us on Linked-In and Twitter.

@Glass_Int

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Abividro 24 The importance of retaining talent in the glass industry

1 Glass International July/August 2014

Editor’s comment

Greg Morris

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

The calm before the rush

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W

elcome to the summer edition of Glass International. Many of you will be taking a well-earned break over this period and is a time to sit back, relax and soak up the sunshine.

This year is a glasstec year, so for many of us the summer break will be a last chance to recuperate before preparations begin for the big October event.

Here at Glass International we have already begun accepting submissions for our September (glasstec) issue, so please feel free to send me any articles that you feel could be relevant to this issue.

As we all know, glass is an industry that never sleeps so, even while we are away on our summer holiday, the industry continues to function.

This is particularly true of our featured glassworks this issue, Bennu Glass, based in Washington state, USA. There has been much talk recently of the Ardagh takeover of Verallia North America in the USA and the ramifications it will have on the US glass manufacturing industry. Critics say it will give Ardagh and Owens-Illinois too much power and they will control a huge percentage of the market.

Well, Bennu is one of the glassworks that make up the remaining percentage of the market and they are undaunted by the takeover.

Its CEO Jerry Lemieux states its new technology and its quality will ensure it is successful. So much so that much of its production of wind bottles and craft beer bottles, mostly for the Pacific Northwest region in North America, is sold out.

A

nother busy man is the new Society of Glass Technology (SGT) President, Russell Hand.

He recently took over the top spot at the Society and one of the main roles during his three-year tenure is to oversee the society’s 100-year-anniversary in 2016. Plans are already well under way with a number of celebrations planned.

On top of this Mr Hand wants to make sure the centenary is a time when the SGT looks forward instead of backward.

He states the society needs to embrace the 21st century and the new technologies in communication and publishing this has brought. By doing so, it will ensure the society remains relevant to both today and tomorrow’s generation of glassmakers.

Enjoy the summer!

Greg Morris Editor gregmorris@quartzltd.com

Directory 2014

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International news

UK trade association British Glass has secured funding for a new academy building.

Local leaders from the public and private sector secured £320 million for the Sheffield City Region.

Some of the funding will be used to build new training

facilities, including a brand new British Glass Academy.

Dave Dalton, CEO of British Glass and The Glass Academy, said: “This is fantastic news for the city of Sheffield and for us as the trade association representing the UK glass

industry.

“We are delighted to hear Government is investing in skills and training projects, business investment programmes and the infrastructure needed to boost the local economy and create new jobs.

“The glass industry is rooted in the work of a Sheffield University department 100 years ago so it’s fitting that the creation of the British Glass Academy as a world class centre of excellence and hub of glass training in the UK will be based in Sheffield.”

FTC approves Ardagh’s acquisition The USA’s Federal Trade Commission (FTC) has officially approved a final order of Ardagh Group’s $1.7 billion acquisition of SaintGobain Containers, after the company sold off six glass plants and related assets.

The FTC’s administrative complaint alleged that the proposed acquisition would concentrate most of the $5

billion US glass container industry in two companies – Ardagh/Saint-Gobain and Owens-Illinois (O-I).

But in settling the FTC’s complaint, Ardagh agreed to sell six of the manufacturing plants it acquired through its acquisition of Anchor Glass Container Corporation, along with Anchor’s former corporate headquarters in

Tampa, Fla. The six plants are located in Elmira, NY; Jacksonville, Fla; Warner Robins, Ga; Henryetta, Okla; Lawrenceburg, Ind; and Shakopee, Minn.

Ardagh’s sold the six manufacturing plants and related assets to Glass Container Acquisition LLC, an affiliate of KPS Capital Partners LP.

O-I chooses BDF recovery plant O-I has chosen BDF Industries as the supplier of a heat recovery plant for the production of electricity via an Organic Rankine Cycle (ORC) turbine, at its Villota, Italy plant.

The recovery of thermal energy via an ORC turbine allows efficient use of exhaust gases produced by the glass-melting furnace,

with the aim of maximising energy recovery without affecting the glass production process.

BDF Industries has been investing in the field of energy recovery since 1990 with the introduction of the Active Front End system (AFE), successfully applied to the controls of IS machines servo motors.

This has allowed BDF Industries to complete its offer of furnaces, forehearths, IS machines and exhaust gas control systems.

Thanks to this project BDF Industries reaffirms its role of ideal partner for the glass industry, with the complete knowledge and know-how required by each part of the glass factory.

Gimav President Cinzia Schiatti has been appointed to her fourth term as President of the Association of Italian Manufacturers of machinery, accessories and special products for glass processing (GIMAV).

Guardian appointment Guardian Industries has named Rick Zoulek as Vice President of Flat Glass for the Americas.

Zoulek will oversee all aspects of Guardian’s North and South American flat glass business and position the company for continued long-term profitable growth.

Zoulek joined Guardian in August 2013 as Vice President of Flat Glass for North America.

AGC Mexican ceremony AGC Automotive Mexico has held a groundbreaking ceremony for a new automotive glass plant at Villa de Reyes, San Luis Potosí, Mexico.

AGC said the plant would contribute to the growth of the city of Villa de Reyes, as well as the automotive industry in Mexico.

Slovenian funding Steklarna Hrastnik Glassworks has secured funding for the modernisation of its container glass plant.

The investment is worth €8 million, 75% of which will be loaned by NLB financial group, while the glassworks will provide €2 million of its own funds.

The funds will be used for the renovation of furnaces and the purchase of new machines in the Special Unit, where the glassworks produces bottles.

After the reconstruction, the life of furnaces will be extended by 10 years.

Work will commence on 15 September 2014 and last until 3 November 2014, when production starts.

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

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British Glass secures funding for new academy building

NEWS IN BRIEF

3 Glass International July/August 2014

International news

NEWS IN BRIEF

GPI changes address The Glass Packaging Institute (GPI) in the USA has changed address.

Its offices are now located at 1220 N. Fillmore St., Suite 400, Arlington, Va. 22201 USA. The telephone number has remained the same.

Muijsenberg wins award Glass Service’s Erik Muijsenberg has won the Michael Garvey Award for the best paper at the Furnace Solutions 9 conference.

Mr Muijsenberg presented a 30-minute paper titled ‘Complete model-based control of glass production’ to more than 90 conference delegates.

Gary Smay to retire from AGR Gary Smay has retired from full time duties after a 44 year career at American Glass Research (AGR).

Gary started at American Glass Research in 1970 after completing his studies at the University of Pennsylvania.

He is recognised as an expert in the areas of surface protection of glass containers and glass coatings. He also is established as a world class educator in the subject areas of coatings, cord and annealing stresses and fracture diagnosis for the glass container industry.

Gary will continue to provide training to the industry as a lecturer (emeritus) in the American Glass Research Glass Technology Seminars.

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HyGear in Russia HyGear has shipped three more Hydrogen Generation Systems (HGS) to Russia during the last quarter, for use at a large glass production company.

HyGear’s HGS is highly suitable to supply glass plants with the right quantity and quality of hydrogen while saving costs and emissions.

Furthermore, the on-site reforming system overcomes the dependency of hydrogen supply by tube trailers.

AGC to close Belgian plant Asahi Glass Co (AGC) is to terminate production of photovoltaic cover glass (patterned glass) at its Roux facility, Belgium, and shut the plant.

The decision was taken following due information and consultation with the Works Council and the union

organisations which started on February 10, 2014.

There are 190 employees working at the plant.

The photovoltaic cover glass market has seen continuous price decline due to oversupply, which resulted in deteriorating profitability of the group’s business.

Since operating losses at the site are unavoidable, the AGC Group said it had to urgently revise the group’s production to meet the market requirement, and it would be impossible to convert the plant to another type of production.

Motim celebrates 80 years Motim Fused Cast Refractories, the privately owned Hungarian company, celebrated its 80th anniversary in June.

Hundreds of guests, including local dignitaries, customers, suppliers and global agents as well as key Motim personnel gathered to celebrate the occasion.

Following her father’s brief history of the company, Szilvia Gerezdes, Motim’s Managing Director gave an introduction to the occasion, recognising some of the countries that were represented such as the USA, Japan, South Africa and the majority of Europe.

The event included traditional dancing, violin performances, a magic show, a falconry display, beer and

A handmade, hand cut lead crystal vase produced by O'Rourke Cut Glass of Mt Pleasant, PA, USA. It was cut by Peter O'Rourke himself, and jointly presented

by Ron D. Argent (Argent Enterprises, USA) and Paulo de Botton (Tecinde, Portugal), both parties being agents for Motim.

wine tasting and a selection of food throughout the day, as well as fireworks.

Many of the guests presented gifts to Motim as a

remembrance of the day, and the global interaction between the guests and Motim was continuous.

Poco Graphite celebrates 50 years Poco Graphite is celebrating its 50th anniversary in business this year Man’s desire to explore space and safely return led to the development of speciality materials that could withstand high temperatures during reentry.

One of these materials was speciality graphite developed by a Texas-based aerospace

company. This material breakthrough was so unique that technology was acquired

by Pure Oil Company in 1964 for further commercialisation.

The graphite division became known as Poco, an acronym for the new owner.

Poco’s graphites have subsequently been used in a variety of applications and

markets and its materials portfolio has increased to include a family of graphites, silicon carbides, high temperature materials and a variety of post processes and machining capabilities.

Poco’s main facility is in Decatur, Texas. The location has expanded over the years to 350,000ft2 and employs more than 250 people.

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

4 Glass International July/August 2014

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International news

New President of FEVE Erik Bouts, President of OI Europe, has been elected President of FEVE, the European Container Glass federation.

Collectively, the European container glass manufacturing industry is the largest glass producer

in the world, with more than 160 plants operating across Europe.

It is also an important sector of the EU economy, creating jobs and wealth in local regions.

Mr. Bouts succeeds Stefan Jaenecke, CEO of

Verallia Deutschland, who led the association for the previous two years.

The container glass industry employs some 50,000 people in Europe, and FEVE members have plants in 23 European Member States.

Schott Ibérica to close Spanish manufacturing site Schott Ibérica has reached an agreement with workers about the closure of its manufacturing site in Sant Adrià de Besòs, Spain.

The company decided to close the factory because investments would be needed to renew and update the

production equipment in order to remain competitive.

Schott said that it would not have been possible to operate the plant in an economical way in the future. The plant will reduce its activities in two steps beginning this summer

and stop production at the end of 2014.

Employees will gradually cease their work in the plant.

The company said 30 of the 112 affected employees will be able relocate and work at its facilities in Germany and Switzerland.

www.glass-international.com

Dura Temp double appointment

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Dura Temp has appointed a Vice President of Sales and Marketing and a Technical Director.

Erica Jaspers (above left) has been promoted to the position of Vice President of Sales & Marketing, and Wesley Weaver (above right) to Technical Director.

Ms. Jaspers started with the company in 2004 and

was previously Manager of Global Sales and Marketing.

Her leadership in growing the sales and marketing efforts for Dura Temp and knowledge of the glass industry will serve Ms. Jaspers well in this new role.

Mr. Weaver has been with the company since 2008 and his

Glass International July/August 2014

responsibilities at Dura Temp have included providing technical support to clients.

Mr. Weaver will continue to support clients, provide leadership to Dura Temp’s technical department and contribute to the research and development of new products.

21–24 October 2014

CRAFTS LIVE! // NEW! Applications and products up close on the activity area in Hall 9 // Profitable business fields with glass in interior design: Functional and processed glass, e.g. for showers, walls, floors or furniture // Effective know-how: Seminars, lectures and tips for new fields of activity // Automotive glass: Current trends, products and tips for use

www.glasstec.de/crafts

International News

Bystronic celebrates 50 years Bystronic Maschinen based in Buetzberg, Switzerland celebrated half a century of processing technology for the glass industry.

The management board celebrated this anniversary with all employees and their families at an evening event held in a circus tent, alongside a company open day in June.

The evening programme of corporate entertainment was accompanied by culinary specialities as well as speeches from management speakers.

For the visitors, it was also an opportunity to view the fully-automatic “champ’speed” automotive glass production line in production conditions.

Bystronic Maschinen was founded in Buetzberg in 1964 and, as part of the Bystronic

glass group, has been part of Zurich based Conzzeta since 1994.

Since the company was founded, Bystronic Maschinen has been active in the development and manufacture of processing systems for the fullyautomatic cutting, breaking, grinding, drilling and handling of flat glass.

Following reorganisation

in 2012, the location has concentrated exclusively on automotive glass.

Almost half of all passenger cars worldwide are equipped with glass produced using production units from Buetzberg.

The 50-year anniversary celebrations are continuing and will conclude at glasstec 2014 in Duesseldorf.

Beatson Clark’s machine caps it all

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Beatson Clark can now supply pharmaceutical bottles pre-capped thanks to an £80,000 investment.

A new Groninger six-head capping machine is now in operation at the company’s Rotherham, UK site.

The equipment will allow Beatson Clark to fulfil a contract with a major high

8 Glass International July/August 2014

street chemist to supply precapped alpha sirops, continental winchesters and bespoke round bottles.

The machine applies a 28mm Mediloc cap to glass bottles and can process up to 180 containers per minute.

“Safety is a paramount concern for pharmacists and it’s essential that the correct

cap is applied to the bottle,” said Lynn Sidebottom, Marketing Director..

“Certain pharmaceutical products need to be childsafe and ensuring the correct cap is used also reduces the risk of contamination during storage.”

Beatson Clark’s new capping machine has an associated UV ink jet coding system which applies a date/time stamp code on both the cap and the container for traceability.

The capping machine is part of a £12 million investment, which includes an amber furnace to be installed in September 2014, new automatic inspection equipment, a new production machine and an updated computer-aided design (CAD) system.

NEWS IN BRIEF

Solar partnership Asahi Glass Europe and Obeikan Glass plan to produce and market solar control glass together in the Middle East.

AGC Glass Europe has signed a letter of intent with Obeikan Glass Company, a Saudi Arabian glass manufacturer, to establish a solar control glass coating joint venture.

The processing line for solar control glass coating will be built in Yanbu, Saudi Arabia, where Obeikan Glass already operates the largest float glass plant in the Gulf.

Operations are scheduled to start in early 2016.

Black glass booms O-I’s black glass portfolio has increased to 19 products as more beer, wine, and distilled spiritsmakers opt for the product’s stand-out effect.

In 2010, O-I started to investigate ways to better protect the contents of a bottle and black scored highly on two main factors: Aesthetics, and a high UV protection.

O-I currently produces black glass at six of its facilities, in Brazil, Australia, New York, Atlanta, Ottawa and Scotland, although in theory the practice could be carried out at any of its sites.

Press Glass boost Press Glass, the largest independent glass manufacturer in Europe, is to invest €12 million in its plant in Radomsko, Poland.

The area of the production halls will be doubled and 200 new employees are to be hired.

The plant was established in 2008 and is the company’s newest factory (the remaining ones are also located in Poland, at Nowa Wie, Tczew and Tychy).

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Glass profile: Bennu Glass

Bennu is born Bennu Glass is the new player on the block in the US container glass market. It recently celebrated the second anniversary of its furnace being lit. Despite being in a market dominated by global giants it is not daunted by the competition. CEO Jerry Lemieux spoke to Glass International.

- Can you briefly explain the history of the company?

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Bennu Glass was formed by Medley Capital, a private investment firm, when the latter bought substantially all of the assets of the former Cameron Family Glass Packaging (CFGP) through a bankruptcy foreclosure sale in March 2010.

Bennu immediately began the long process of contracting with Nikolaus Sorg & Co. to design, engineer and install a new oxy-fuel furnace to replace the failed electric melter that led to the CFGP bankruptcy. This process included the necessary local and state permits for the facility, and most importantly the air emission permit from the State of Washington’s Southwest Clean Air Agency.

Bennu had to hire a complete new workforce for the factory as there were no employees left from CFGP. Every piece of existing equipment had to be recommissioned and the employees trained.

The new furnace was lit on July 4, 2012, and production began later that month.

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- How is the company structured and how many employees are there?

Bennu has 95 employees, all located in Kalama, Washington. The corporate staff is comprised of the CEO, CFO, Sales Manager and Human Resource Manager; all other employees are in factory operations.

- What markets does the company serve, and what geographical areas are covered?

Bennu makes wine bottles for California, Oregon, Glass International July/August 2014

Washington and Western Canada. It also makes 22oz. beer bottles for the vibrant craft brewing industry in the Pacific Northwest.

- What is your most popular product?

Bennu has a family of stock bottles that are popular with our distributor customers, who purchase bottles from Bennu to supply the thousands of small wineries on the West Coast.

The highest volume bottles are a pair of 467g bottles, one Bordeaux and one Burgundy. Each bottle is manufactured with either a standard cork finish or a screw-top Stelvin finish.

- It’s been just over two years since the grand re-opening ceremony of the company. What has the time been like?

It has been two years of great great successes. The factory has preformed beyond our initial expectations. Bennu’s quality and efficiency rival any in the industry.

- Did you have an overall business plan when you took over, and is this now beginning to take shape?

While the sales ramp-up period took longer than we forecast, Bennu is now completely sold out.

Prices are slightly lower than we expected, primarily as a result of the influence of imported Chinese glass.

- You are a newcomer in a market which includes global giants OwensIllinois and Ardagh. continued »

Glass profile: Bennu Glass

No. The Bennu factory is state-of-the-art, and I’m confident our quality, productivity and cost structure are all extremely competitive.

- The site has a notable history as a result of the 2009 leak. Did you have any second thoughts about basing yourselves on the site in terms of extra costs in repairing the site, and time taken to repair the site?

No. The CFGP site was like finding a new car on the side of the road, only with an inoperable engine! A new furnace needed to be installed, but the rest of the factory was basically brand new, and the bottle machines, inspection kit, and loadbuilding equipment were all high quality.

- Similarly, the company was formed in 2010, a period when the world economy was in a fragile state due to the recession. Did this play on your mind?

No. Despite the economic downturn, wine production and consumption (in volume terms) actually grew through this period. We were comfortable that the long-term demographic and economic trends in the wine business supported what is, by its nature, a long-term investment strategy.

- Sustainability is the current buzz word within industry at the moment.

What ‘green’ credentials do you have?.

Bennu may be the ‘greenest’ glass container factory in the USA, if not anywhere in the world.

Approximately 25% of the melting energy comes

from electric boosting; electricity in Washington comes heavily from hydro and wind power generating facilities. The Sorg oxy-fuel furnace is extremely efficient. We are using liquid oxygen in the combustion process, which lowers NOx emissions. We have a bag filter system (from Luehr in Germany) that removes virtually all SOx and particulate matter. Recycled glass makes up 50-70% of our batch formula.

- How much of a challenge is there from manufacturers in developing nations, such as China and elsewhere?

China has made a big push in wine bottles in the USA over the past six or seven years. However, there remains a preference among the wineries and the distributors for a reliable, high-quality domestic supplier.

- What does the future hold for Bennu Glass?

Bennu has a great future ahead of it. With capacity sold out, we can focus our attention on continuous improvement opportunities in our operation, such as pack-to-melt, quality, and cost. The acceptance of Bennu in the market has been great.

Bennu is blessed with a dedicated, talented and committed team of employees focused on safety, productivity and the quality needs of our customers. We are definitely here to stay.

Bennu Glass, Kalama, USA, http://bennuglass.com/ Glass International July/August 2014

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Does this daunt you?

11

Glass profile: O-I R&D Centre

Owens-Illinois celebrates the opening of its Innovation Center

Collecting a glass sample

The Innovation “ Center has exceeded

Furnace and forehearth

our expectations in

O

www.glass-international.com

wens-Illinois (O-I) has celebrated the official opening of its Innovation Center, a combined R&D and pilot plant

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facility.

Based at the company’s global headquarters in Perrysburg, Ohio, the centre has already established itself as a valuable asset to the company.

Through the Innovation Center, O-I seeks to advance new concepts in glass production and qualify emerging technologies that could revolutionise the process of melting and forming glass.

“The Innovation Center has exceeded our expectations in its first few months of operation,” said Ludovic Valette, Global Vice President of R&D. “Through extensive collaboration among the Glass International July/August 2014

its first few months of

”

operation.

said Ludovic Valette, Global Vice President of R&D

R&D teams, others in the global technology organisation, the product innovation team and manufacturing, we have significantly accelerated the pace by which we produce sample bottles for our customers and test changes in the production process.”

The 24,000ft2 facility, which is approximately one-tenth the size of a typical manufacturing plant, houses a 20 metric tonne oxy-fuelled furnace manufactured by Sorg which is 12.1m2 (5.5 x 2.2 x1). The furnace can use electricity to melt glass as a suplment to natural gas.

The centre also includes two production lines and inspection equipment.

On one line sample bottles and trials for new products are made, significantly reducing the continued »

Glass profile: O-I R&D Centre

Thehe bbest Th es Techn hnolo nollogy og and n Pe Perfor erforrma maannce Fast facts

Construction of the site was completed in 12 months.

The centre operates 24/7.

Zero discharge facility; all process wastewater is recycled.

It can use between 10 to 95% recycled glass in its process, with the goal to use 95%.

The other 5% is sand, soda ash and limestone.

All glass not sent to customers for sample evaluations is recycled back into the process.

L

H Visual inspection in cold end

C time needed to produce exactly the right bottle and minimising disruption to the manufacturing plants.

The other line is dedicated to research and development, and is being used to develop new technologies and processes for melting and forming glass.

In its first eight months of operation, the centre’s team has already produced more than 40 sample bottles for customers and internal development purposes. In 2013/14 the centre produced four different colours.

“Innovation is a key component of our long term strategy,” said Al Stroucken, chairman and CEO. “This Innovation Center demonstrates our belief in glass as the optimal packaging solution and our confidence that we can shift some of the paradigms around glass manufacturing.”

Website www.o-i.com Glass International July/August 2014

Conttact Conta ac us now: vidro rome ecani c ica@ c @vidro rome ecanica.com c c c www w ww.vidro rome ecanica c ca.com c Tel: +3 Te 351 244 555 06 060

Glass profile: SGT President

SGT President with an eye on the future The UK’s Society of Glass Technology (SGT) recently named Prof Russell Hand as its new President. He spoke to Greg Morris about his plans for the role and about the Society’s forthcoming centenary in 2016.

www.glass-international.com

P

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rof Russell Hand was named President of the Society of Glass Technology at the beginning of the summer. His three-year term will have him overseeing the Society’s 100year anniversary in 2016, for which the Society already has plans.

For Prof Hand (pictured), the centenary represents an opportunity for the group to move forward and embrace new technology and cultures.

He has been involved with the SGT for 20 years, and has been Senior Editor of the SGT publications ‘Glass Technology’ and ‘Physics and Chemistry of Glasses’, as well as being a UK representative on the International Commission of Glass (ICG) council.

Now as President, the general plan is to move the SGT forward.

He states: “One of the focuses is that we have a centenary in 2016. This will be a time of celebration. There is always a tendency of centenaries to look back. But if that’s all we do with the centenary then we will have failed and Glass International July/August 2014

it will be to the long-term detriment to the Society.

“I want to look at how we move forward, how we make the society responsive to the needs of the 21st century, dealing with the changes that have come about in communication and publication – some of which are of benefit to us.

“People from a different continent can now be involved in committee meetings and that was unthinkable a few years ago. But equally, this creates its own challenges in terms of delivery of publication, open access models and things that are out there that provide competition.

“So there are a range of things that we have to look at and I see that as one of my major roles, but also making sure that the Society doesn’t lose what it has but is suited to moving into the next 100 years.

“I’m very much looking ahead while recognising what we have done in the past and

continued »

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Glass profile: SGT President

do not want to belittle that in any sense whatsoever. “But the world is changing, and we will have to change to make ourselves relevant to the next generation of glass engineers and scientists.”

Celebrations To celebrate its centenary in 2016 the SGT’s annual meeting that year will be held in conjunction with the European Society’s of Glass’s own meeting, which will be held in Sheffield, UK. Other plans in the pipeline include a centenary banquet, and events held in conjunction with the University of Sheffield’s Turner Museum of Glass, such as a Turner lecture.

www.glass-international.com

Professional career

16

Prof Hand has been involved in the glass industry for 25 years and is a Professor of Glass Science & Engineering at the University of Sheffield, UK. He readily admits he is an academic rather than an industrialist. He joined the University’s Department of Materials Science and Engineering in 1989 from Cambridge University. He was appointed to a Lectureship in 1990 (Senior Lecturer 2001; Reader 2010; Professor 2012) and in 1999 obtained an MEd in Teaching and Learning for University Lecturers.

His two main areas of interest relate to glass strength and to nuclear waste vitrification. He is interested in consistently stronger bulk glass, particularly at bulk scale but at an affordable cost.

Nuclear vitrification, he states, is a very real and practical application of glass.

His research areas include Radioactive Waste Vitrification where research is focused on glass composition development for the immobilisation of ‘difficult’ anionic species and legacy wastes into vitreous wasteforms.

Another area is Durability of Nuclear Waste Glass where research is focused on understanding the effects of high pH environments on the durability of nuclear waste glass using laboratorybased durability test methods.

Prof Hand is also responsible for a field based long-term glass burial site at Ballidon, UK (a limestone environment), an experiment now in its 44th year, and which involves collaboration with the Pacific North-West National Laboratory, USA. He states: “I’m fascinated by glass because it is a very interesting material that we do not fully understand. Structurally speaking the amorphous nature of it means you have no simple way of describing the structure across space. If you’ve got a crystalline material, once you’ve worked out what’s in the unit cell and the positions of the atoms in the unit cell you know the positions across space.

“You can’t do that with glass and that then gives rise to a whole range of interesting properties.

Glass International July/August 2014

I want to look “at how we move forward, how we make the society responsive to the needs of the 21st

”

century

Origins of the SGT In 1916 Dr W. E. S. Turner, a chemistry lecturer at Sheffield University, United Kingdom, recognised the importance of drawing together in one organisation the various groups of people interested in glass, and so the SGT was formed.

From this beginning, the Society has responded to the needs of industry and academia, and remains a model for other glass societies. The Society continues to grow in stature with members in more than 50 countries.

“Particularly on the mechanical property side, it’s almost your archetypal brittle material and that raises its own interesting set of challenges of how do we improve the properties while at the same time recognising the reasons it has got some of the other properties that we want, such as transparency.

“This is precisely one of the reasons why it is not particularly good from a mechanical property point of view. So there’s a whole range of interesting fundamental science but also interesting engineering and practical glass issues.

The two together have kept me very busy.

“The nuclear waste side has got me into compositional development because there you start saying ‘ah, lets throw in this range of elements from the periodic table which is much wider than you would normally throw in’ and that raises a set of its own challenges and problems, to produce something you want to be extremely durable.

“Glass is ideal for it, because you can’t quite call it a universal solvent but it will accommodate many species from the periodic table.”

Achievements His proudest achievements so far in his career are specific projects that raise more questions.

He states: “A good project always raises more questions. I’m interested in things that will hopefully have a long-term application but by being an academic I’ve always been at the lower TRL levels, well away from the production environment, not because I’m against it but because it’s the area I work in.”

He is also proud of the work of the SGT and what it has achieved in the past 100 years.

He states: “The SGT brings academics and industrialists together through technical committees and the various groups that run the SGT, such as its council. Meetings such as Furnace Solutions, which is more industry focused, brings industrialists together to discuss very real practical problems.

“The event also includes a training day to fill in some of the gaps that currently exist in glass education. These sorts of activities are fundamentally important.

“Our annual meeting tends to be more scientific, although there is an industrial element to it. It brings together academics from outside the UK, mainly Europe but we are global and have members in North America, Australia and India.

“Everyone receives one of two journals as part of their fee, which they can get electronically or hard-copy. So the SGT is worthwhile for a mixture of networking and for useful technical information.”

Society of Glass Technology, Sheffield, UK www.sgt.org

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Company profile: Thor International

Colombian group makes inroads into glass industry Sally Roberts met with Colombia’s Thor International, to discuss the company’s foray into the container glass industry.

Can you give a brief overview of the company’s history?

How many employees does the company have?

Thor International is a designer, manufacturer and marketing company of high-tech elements that provides integrated solutions in each of its divisions.

We have been in the market for 10 years performing high-precision manufacturing in sectors such as Defense and Aeronautical for the Colombian government.

Thor international just recently started its new division, Thor Glass, with a concept dedicated to mould design for glass container manufacturers.

We are offering our customers throughout the world engineering created in top of the line software, with the best technical team and customer support.

Having a reliable and outsourced engineering supplier means that container manufacturers have the option to quote mould equipment from any manufacturer worldwide, choosing the best option either in price or delivery times. This creates huge savings (up to 30% in price and 50% in time) for their companies without being tied down by mould manufacturers that own the engineering.

30, of which almost 70% are engineering and technical.

What markets does Thor serve?

Latin America and Colombia, but a project like this has the advantage of being able to work for any customer in the world: The customer requirements as well as the finished product are handled via the internet, making the geographical location irrelevant. Our aim in Thor Glass is to serve customers in all of the five continents.

What areas of the glass industry is Thor involved in?

Container and hollow glass.

What prompted the company to move into the container glass industry?

Some of our employees have worked in the glass industry for several years with some of the leading companies in the world; this experience

www.glass-international.com

continued »

18 Glass International May 2014

gave us a global vision about the big opportunity of this market.

From our previous work experience, we witnessed firsthand the lockdown that mould manufacturers have on the glass container manufacturers, tying down the engineering to the manufacturing. We offer to break this chain!

The glass container companies are clear about their core business, which is making containers.

Having large engineering departments implies huge costs during short engineering periods, whereas with our option they only pay for what they really need. It is in our best interest to have a fast turnaround; we make a profit by being efficient.

All of the mould manufacturers tell their customers that the engineering is free with the price of the equipment; this of course should fool no one! We believe that the only real argument is to tie the glass plants down. We are looking to change this.

We believe the mould engineering belongs to the container manufacturer, not the mould manufacturer, and we supply our customers with all of the information they need to decide who to go to in the future.

What percentage of Thor’s business is with the glass industry?

25%, but this project is just getting started and we intend to grow by leaps and bounds within the next year.

What geographical regions are currently most important to Thor?

Our customers in the US and Europe will probably benefit most from our rates, but customers in Asia, Africa and Latin America will surely benefit most with our engineering level.

Thor Glass has a concept dedicated to mould design for glass container manufacturers

are targeting customers all around the world; our solution is as relevant for customers from Australia to Portugal and from Russia to Chile.

Looking ahead to the next five years, where will the company’s efforts will be focused, in terms of technical or strategic developments?

We will stay at the cutting edge of software, materials and manufacturing processes for the industry. Our engineers will be constantly up to date, so as to offer our customers the most reliable and efficient designs for their mould equipment.

What is the greatest challenge faced

by Thor?

Changing a paradigm is never easy, and convincing companies that have operated the same way for decades can be difficult – but the logic is irrefutable and the benefits in time and money are just too great for any company to ignore. Starting a new business takes a lot of perseverance, but when you have a good product and a game plan it is just a matter of time.

What does the future hold for Thor?

Any expansion plans?

Our easiest market is probably Latin America, but as we are offering a knowledge-based product we

Thor International, Colombia. www.thorint.com

The Thor plant in Colombia

www.glass-international.com

Looking ahead to the next five years, where will the company’s efforts will be focused, geographically?

We aim to continuously grow while offering our customers and community constant improvement and benefits. In the near future we will offer our customers more and improved products that will make their processes easier, more reliable and efficient.

continued » Glass International May 2014

19

British Glass

Gareth Jones British Glass

Developing a glass industry roadmap to 2050 What is an industry roadmap, and why do we need one? Gareth Jones* answers these questions, and outlines the aim to capture the high level ambitions of the glass industry, and develop strategies to make them happen.

B

www.glass-international.com

ritish Glass (BG) has recently undertaken a strategic roadmapping process with two specific objectives: To produce a decarbonisation roadmap as well as a wider strategic industry roadmap.

The process of creating the roadmaps has been, and still is, just as important as the production of the document itself. The process has involved the industry communicating and working together in partnership towards a common goal, in this case the sustainability and growth of the UK glass manufacturing industry.

The aim of these roadmaps is to answer important questions for both the wider glass industry and BG as the representative body of the glass manufacturing industry, such as which direction do we want or need to go in and how do we get there?

The roadmap concept was originally developed

by Motorola in the 1970’s with the then CEO, Bob Galvin, defining it as ‘an extended look at the future of a chosen field of inquiry composed from the collective knowledge and imagination of the brightest drivers of change in that field’.

This explanation has stood the test of time and is still relevant to our roadmap activity today.

20

Workshops There have been a number of workshops held to date with a wide range of senior executives from across the industry and key members of the supply chain. This activity has brought together stakeholders with different perspectives to build agreement on key challenges, opportunities and actions and has facilitated ongoing dialogue.

The added benefits of the process have included networking and relationship building, idea generation, collaboration, knowledge sharing and learning. Within the workshops sessions, open Glass International July/August 2014

“do weWhichwantdirection or need to go in and how do

”

we get there.

discussions were held around the challenges, potential innovations, developments, threats, opportunities and trends that may affect the glass industry. Key themes identified included: Skills shortages along with an ageing workforce and a lack of succession planning.

Problems with attracting and retaining talent and the need to change the perception of the industry at a school, college and university level to encourage talent to enter the industry and see it as a viable career option.

A need for further innovation and creativity within the industry.

Resource issues concerning materials and energy.

Legislation in terms of raising awareness in Government and among policy makers.

Marketing of glass as a material to the supply chain and end-users and the need to better promote the benefits of glass to the supply chain, Government and consumers.

Collaboration within the industry and with partners such as academia and other industries.

Key actions and outcomes The lack of skill levels both within the industry and in recruiting appropriately skilled employees was seen as a priority by the group, and through The Glass Academy project and Women in Manufacturing, British Glass has already started to address these challenges by engaging with the existing and next generation workforce.

Through the ‘Employer Ownership of Skills Pilot’, a part-Government funded initiative, The Glass Academy has been busy building links with education, industry and key political departments,

continued »

British Glass

Above and below: A number of workshops have already been held with many senior executives from the industry taking part

funding a range of training interventions, facilitating the employment of young people and designing industry specific training programmes.

Another of the key actions that British Glass is now driving as a result of the strategic roadmap process is the celebration and promotion of glass as a material. As Dave Dalton, British Glass CEO, likes to say, it is ‘a material that has its technological horizon still ahead of it’.

The concept of ‘Brand Glass’ has been launched to start to highlight the innovative work that is being undertaken within the glass industry and reflect the positive messages surrounding glass across the sector.

This consumer-led and Government focused initiative will engage with these target audiences to encourage their support and promote the progressive nature of the industry, emphasise the R&D and technological developments across the sector and ensure the benefits of glass are communicated so it becomes the material of choice.

The industry must come together to collaborate and build a new vision for the future by investing in new technologies, improved capabilities and the necessary skills to thrive, and through the roadmaps, this is developing into a reality.

This is an ongoing interactive process and further workshops will be held over the next few months. Please contact Gareth Jones at British Glass for further details, if you have any questions or would like to get involved.

*Project Manager, The Glass Academy and British Glass Email g.jones@britglass.co.uk Website: www.britglass.co.uk Glass International July/August 2014

History

Prof. John Parker Turner Museum of Glass and ICG

One shade of blue

B

lue glaze for me is indelibly linked to fine tableware and cucumber sandwiches. I still recall the exotic images decorating my elderly aunt’s willow pattern plates and how they offered an escape from adult conversation.

www.glass-international.com

Colour

22

The Chinese were using cobalt-rich ores to create their evocative images 5000 years ago. These ores occurred naturally, but elementary cobalt was first isolated and characterised only in 1735. Its name derives from the German ‘Kobold’ meaning goblin, which itself originates from the Greek ‘cobalos’ meaning ‘mine’.

This sobriquet was given to cobalt ores by silver miners, who recognised a link between them and the quality of the silver extracted. But then, one man’s meat is another’s poison.

Egyptian Glass makers also realised cobalt’s colouring qualities. Early stained glass windows incorporated both cobalt for deeper and copper for lighter blues.

400 years ago an English chemist (Cookworthy) held the rights to sell in England industrial quality cobalt minerals from Saxony, importing them into Bristol.

They dissolved easily in glass and low concentrations conferred an intense and stable blue hue.

Simultaneously, Ravencroft’s lead crystal glasses, noted for easy hand-working and lack of iron discolouration, were successfully competing with Venetian Cristallo. The rich blue glass created by adding cobalt to lead crystal carried additional overtones of wealth and status.

Cookworthy allocated the rights to purchase his ores liberally. The local glass industry expanded rapidly, producing ‘Bristol Blue’ ware. At its height 17 separate glassworks were melting this composition, although production ceased in the early 20th century. Now Bristol Blue has again become highly collectable and Glass International July/August 2014

currently two glassworks in Bristol make it.

Others also appreciated the opportunities that blue glass production presented. One market was to alchemists, keen to display their lotions and potions to maximum effect. Several colours were used (blue, amber, green, red and yellow).

Certain colours became associated with poisons, including blue, while surface profiling allowed identification in the dark. Such features were not initially controlled by legislation but were adopted by custom and practice, and certain products dispensed in blue glass such as castor oil were only regarded as poisons by the young, forced to imbibe them.

Protection & illumination Colour offered more benefits than branding alone. Another was to protect the contents. Strong sunlight caused heating and could spoil the contents.

Initially there was little appreciation that the blue end of the spectrum was particularly deleterious, that the more energetic blue, violet and ultraviolet light could initiate reactions which spoiled taste and reduced the medicine’s efficacy.

Even by the 19th century though, experimentalists realised that the best protection was offered by yellow and amber glasses, whose colour arises from their strong absorption of blue light. Blue glasses were less effective, as they transmitted damaging blue light, and pharmacists slowly abandoned them.

Now glass collectors seek out hand-made, blue glass medical containers, and prices can reach hundreds of pounds.

Glasses used for illumination have also benefitted from cobalt. Incandescent lamps are too red and a little cobalt in the glass envelope can improve colour, although reduce efficiency. One patent proposes its addition to mirror glass.

Because silver reflects less blue than red, cobalt doped glasses, which absorb red, can balance the image colour. Cobalt blue

glasses were commonly used as eye protectors when examining hot furnaces, the colour seen also being a sensitive indicator of temperature.

Only low cobalt concentrations are needed for colouring so efficient batch mixing is an issue; two-step dilution is needed either by using a pre-prepared cobalt-rich glass concentrate (smalt) or by premixing the minerals with sand.

Another approach was to case a partially blown clear glass with a thin, strongly coloured, blue glass; selectively removing this layer gives the glass artist flexibility.

Because cobalt concentrations are low, physical properties change little. Stresses caused by contraction mismatches during cooling of joined coloured and clear glass pieces should be negligible. Often though the glass makers’ experience was different and Turner, English & Winks, at Sheffield University, investigated this. Critically, cobalt absorbs infrared light at wavelengths where the glass would normally be transparent. Glass baths had steeper temperature gradients and early blue glass furnaces were necessarily shallower than those for clear glass. But equally hot blue glass emitted more heat and so cooled more quickly, causing the unexpected stresses in the glassware.

Similarly machines making blue rather than clear glass containers could be run 10% faster.

Cobalt is still added to glass because iron impurities give it a greenish tinge.

Decolourisation requires traces of cobalt plus selenium pink. Red, blue and green balance each other and the glass appears colourless, although with a reduced transmission. Our cobalt blue makes at least one of the many shades of grey.

Bibliography W.A. Weyl, Coloured Glasses, Society of Glass Technology, 1951 Handbook of Chemistry and Physics, CRC Press, 1974

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Abividro

Abividro

The importance of retaining talent in the glass industry Edison Toporcov* highlights the importance of training and continuous dialogue, and how this ensures the glassmaking tradition stays up to date in a world of rapidly changing technology.

D

espite the rapid evolution of technology (especially in the areas of mechanics and electronics), alongside the ease of communication and information via the internet, the glass industry still encounters difficulties preparing the necessary manpower.

Specialised manufacturing of products increasingly requires quality, cost reduction, competitiveness, sustainability and to remain on the market in the face of fierce competition from other types of packaging.

This article highlights what the possible options are within the industry, so its skilled labour may have continuity and the ability to keep up with new technology.

www.glass-international.com

Glassmaking tradition

24

We know that traditionally glassmaking has always been carried out internally, with employees trained to keep the methods and processes secret and to not promote the dissemination of this knowledge.

The experience and knowledge of ancient glassmakers, therefore, often ends when they retire.

Furthermore, with the absence of vocational courses in the glass sector, we continue to train professionals ‘in-house’ because current technology requires them to have a broader knowledge of the process.

There is a special need to prepare the workforce that, as part of their job, must discuss the process from the raw material to the final product with the client.

This is undoubtedly a challenge, because as we prepare these professionals, how do we create communication channels between them and how do we train them?

Amazingly, the speed of data Glass International July/August 2014

communication seems to have led to a difficulty in terms of interaction between people. The result is an information overload and lack of knowledge in this specialised workforce.

They need to touch, to see what happens, talk, exchange ideas, see the results, and disseminate knowledge. In fact, this approach needs to be instigated and managed by stakeholders, including the guidance and exchange of information from experienced professionals in the areas involved.

Two-pronged approach It is a difficult task because it requires a two-pronged approach to be effective: The expert that teaches also needs to listen to the expert that learns, and both must come to an equal position.

The professional on the shop floor needs constant training, and updated guidance on the overall knowledge of the process. Professionals who have this knowledge should be encouraged to transfer this baggage acquired during years of work, via teaching and training programmes.

The glass industry, knowing the difficulty in training skilled labour, needs to promote the training of future professionals through the knowledge and experience of those considered ‘older’, and recognise that they can contribute, even after retirement.

Our experience has shown that this programme gives results when the demands of training originate exactly from the base of the pyramid, i.e. from the needs of shop floor and their immediate superiors.

Mutual respect between experts and those being trained leads to a synergy that allows participants to create, design,

study, help and not be absorbed by the day-to-day problems of a company.

We've had amazing results when our professionals realise that the company is giving an opportunity to open a direct dialogue between those who produce and those who take our products to customers.

This means that we must show them the entire production chain and the responsibility of each within the organisation.

The professional on the shop floor is eager for information and does not always receive it in a proper way.

Experts are a fundamental part in this training and dissemination of knowledge, since having the experience of actual cases helps prevent a repetition of the problems usually caused by the lack of information available to young professionals.

An important point to note is the retention of talent in the glass industry can survive and is effective if you have the full support of the company.

This is not only a strategic plan for continuity and improvement of technology in industry, but is also recognition of the value of training.

We must remember that today's professionals must be prepared to be future teachers and thereby leave a legacy that will allow the continuity of glassmaking expertise necessary to maintaining the nobility of the glass.

*Technical Committee Member, Brazilian Technical Association of Automatic Glass Industries (Abividro) São Paulo, Brazil. www.abividro.org.br

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Hollow glass

Hollow glass industry overview

The hollow glass industry is faced with intense international competition. To secure their future, manufacturing companies are developing products and building energy-saving production facilities.

Two success factors One of the most important developments in hollow glass over the past few years has been the development of lightweight glass.

Without sacrificing strength, the industry has gradually succeeded in

reducing the weight of different glass packages by up to 60%.

This has produced benefits in the handling and transportation of products, while also leading to substantial savings in raw materials and energy.

Apart from the weight, another increasingly important element is product design. Anyone wanting to stand out among the crowd of competitors must produce high-quality products that appeal to the consumer.

It is therefore worthwhile investing in the development of packaging and suitable production facilities.

According to the Glass Packaging Action Forum, an initiative of the German container glass industry, there has been a 39% European-wide increase in the consumption of products packaged in glass.

This upward trend is partly due to a reduction in weight and partly to the positioning of glass as an environmentally friendly and trendy form of packaging.

sustainability.

Glass is essentially made from raw materials that are available in abundance and which occur naturally, i.e. quartz sand, soda, lime and dolomite. It is 100% recyclable and can be turned into new products. This makes glass products resource-efficient, ecofriendly and sustainable.

Recycled glass has in fact come to be the most important input material for glass packaging. Its share in newly made packaging is 60% on average throughout Europe.

Another important benefit is its reusability: Within a reusable glass system a glass bottle, for instance, can be used up to 50 times before being recycled.

Energy as a cost driver Despite the benefits of its products, the container glass industry is in competition with alternative packaging materials, such as metal and, above all, plastic. But even within the glass industry the market is highly competitive.

Ecologically sustainable One factor that is providing the hollow glass industry with a positive outlook is the increasingly important aspect of

continued » Glass International July/August 2014

www.glass-international.com

H

ollow glass for the storage of oils and ointments has been in use for a long time, with evidence dating back 3500 years. The properties of the material were valued greatly at the time and are still among its major quality characteristics today.

Glass is made of natural raw materials, can be moulded into an infinite number of shapes and is inert, i.e. the material does not react with its content.

This means there is virtually no interaction between the container and the product, and is therefore an excellent packaging material – not just for food and drinks, but for cosmetics, pharmaceuticals and numerous chemical products.

Bottles, jars and flacons are produced by the container glass industry, which forms the ‘hollow glass’ market segment together with the domestic glass sector (drinking glasses, tableware glass, gift items.)

27

Hollow glass

Companies face fierce international competition and increasing pressure from imported goods, so the situation in national markets is often difficult.

Within the EU in particular, glass manufacturers are subject to strict legal requirements concerning environmental protection, safety at work, compliance with legal regulations and, above all, rising energy costs – competitive factors which are more difficult than in countries with lower standards.

This applies especially to German

much lower price per kilowatt hour of electricity.

After the EU Commission had classified this practice as an illegitimate subsidy, the German Government now wants to either reduce the number of energy-intensive companies exempt from the levy or restructure the system of discount ratios.

When the agreement with the EU Commission was announced on 8 April 2014, it was still difficult to see how this might impact glass manufacturers.

Glass manufacturers have substantially reduced their energy consumption and their emission of pollutants over the last few years.

Photo: Schott

emphasises that in this context, however, ‘for free’ does not mean that it ‘incurs no costs’: “Thanks to extremely high benchmark figures and the cross correction factor, it is estimated that 65% of certificates will be given to German glass manufacturers for free. However, as there will be an upper limit to allocation, all glass manufacturers – including those of container glass – will still need to purchase emission rights”.1 Moreover, Brussels will be adding further complications as the EU Parliament has now agreed to the practice of backloading, whereby carbon certificates are removed from emissions trading in order to create an artificial scarcity on the market and to increase prices.

The increase in cost pressure is intended to promote environmental protection. BV Glas, however, believes that this is sending out the wrong signals. The association maintains that backloading misses the mark, as it is precisely the energy-intensive glass industry that has massively invested into technology with greater efficiency over the last few years, so that its potential has now largely reached its limits.1 Not only has the industry achieved substantial reductions in carbon emissions, but it has also made considerable progress in minimising NOX (nitrogen oxide) emissions, particularly through measures that interfere directly with the combustion process in a melting furnace (primary measures).

www.glass-international.com

Energy-saving measures

28

container glass manufacturers, because they must also bear the burden of Germany’s renewable energy levy (under the German Renewable Energies Act), a measure introduced to help usher in the energy turnaround, as envisaged by the country’s political decision- makers.

According to Dr. Hans-Joachim Konz, President of the German Association of the Glass Industry (BV Glas), only 13%1 of all companies in the German glass industry (about 400 in total) were exempt from this charge – an exemption that was granted to safeguard the economic future of an area and which was intended for energy-intensive enterprises, so that they could pay a Glass International July/August 2014

Carbon emission certificates Another burden for the container glass industry is the cost of carbon emission certificates. The decision as to whether Europe’s glass industry is to be put back on the so-called Carbon Leakage List will not be available until the end of 2014.

Carbon leakage means that greenhouse emissions are outsourced to non-EU countries in cases where manufacturers are no longer able to operate competitively in their own region and where they would otherwise have to cease production.

Sectors that are included on the list are given the relevant certificates for free.

Dr. Johann Overath, CEO of BV Glas,

According to cost structure statistics published by the German Federal Statistical Office in 2013, the share of energy costs in the gross output value of hollow glass production was 14.9% in 2011, while this value was on average 8.6% for the entire industry, i.e. comprising glass and glass product manufacturers.2 In view of high energy costs, hollow glass manufacturers can only remain competitive if they use innovative, energy-saving production methods.

This is another area where the industry has made great progress recently: According to the Glass Packaging Action Forum, the use of

continued »

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Hollow glass

energy in melting equipment went down 77% between 1970 and 2006. The biggest share of these savings was due to greater efficiency in production facilities (-32%).

Other savings were achieved through weight reductions of glass products (25%) and the addition of recycled glass (-20%). The required melting energy is reduced by 3% for every 10% of broken glass that is used in this process.

The European hollow glass industry therefore benefits substantially from its high recycling rate, which – according to latest reports from the Glass Packaging Action Forum – was 83% in Germany in 2012. The European Container Glass Federation, FEVE, reported an EU-wide average of 70% for the same period.

Two important partners of Germany’s container and industrial glass manufacturers in the implementation of the latest technologies are the Research Association of the German Glass Industry (HVG) and the German Glass Engineering Society (DGG).

Both organisations have supported developments in the glass industry for many years.

HVG and DGG promote research at the interface between academia and industry, maintain laboratories, offer a wide range of advisory services to answer comprehensive questions on glass technology, and provide information through publications and training events on the latest developments and findings in research.

frequent changes in glass types, and Dr. Dispan anticipates another significant increase in retooling over the next few years.3 He describes the glass industry as investment-driven: Unless there is sufficient investment, he says, companies are likely to suffer greatly in their future viability.

According to Dr. Dispan, as well as having to conduct the necessary cold repairs to optimise melting tanks, the glass industry is engaged in a competition for innovation to secure Efficient production engineering is indispensable for container glass manufacturers wanting to maintain their competitive positions on the international market.

Photo: Messe Düsseldorf

www.glass-international.com

Greater production efficiency

30

To combat high energy costs and the influx of cheap imported products, the industry has to use highly efficient technology. This is especially true for Germany as a country with high wages.

“What it means is that companies in the glass industry must have the best available technology, energy-efficient and largely automated facilities and machinery as well as a suitably efficient and motivating organisation of work routines,” says Dr. Jürgen Dispan from the IMU Institute in Stuttgart in his analysis ‘Glass Industry in Germany’, published in January 2014.3 It is apparently not a matter of process speeds but also of ensuring a high level of flexibility. One major operational issue, particularly in the container glass industry, has been the question of conversion flexibility due to Glass International July/August 2014

machine and plant manufacturers, who can provide the industry with more breathing space through forwardlooking technologies.

Dr. Bernd Holger Zippe, Chairman of the Glass Engineering Forum within the German Engineering Federation (VDMA), said in a press release published in November 2013: “There is a good level of demand from the speciality and hollow glass industry. Many German companies have therefore opted for special applications and for the solution of technically demanding challenges.

“Other business sectors with good prospects are apparently the engineering of customised plants and machinery and the provision of services. In 2014 the industry is mainly expecting new investments in the hollow glass sector.” glasstec 2014 will be showing forwardlooking production and handling solutions provided by glass machine and plant manufacturers – solutions that can help towards further improvements to the performance of the hollow glass industry.

The leading global trade fair for the glass industry will be held in Düsseldorf from the 21st to the 24th October.

As on previous occasions, a symposium will be held, accompanying the special exhibition glass technology live. At this symposium information about the latest developments will be provided by Hüttentechnische Vereinigung der Deutschen Glasindustrie (HVG), Deutsche Glastechnische Gesellschaft (DGG) and the Glass Technology Forum within the VDMA.

Bibliography

unique selling propositions and technology leadership.

The strategy towards this goal, he says, involves not only the development of innovative products but also, among other things, innovative methods and processes to improve the efficiency of operational routines.3

1. GlasNews, newsletter of the German Association of the Glass Industry (BV Glas), December issue 2013.

2. Statistisches Bundesamt (Federal German Statistical Office), Produzierendes Gewerbe, Kostenstruktur der Unternehmen des Verarbeitenden Gewerbes sowie des Bergbaus und der Gewinnung von Steinen und Erden, Wiesbaden 4 June 2013, p. 308.

3. Dispan, Dr. Jürgen, Glasindustrie in Deutschland – Eine Branchenanalyse, Industriegewerkschaft Bergbau, Chemie, Energie (ed.), Hanover Jan. 2014.

glasstec 2014 The extent to which any existing potential can be realised largely depends on the innovative strength of glass

Sebastian Pflügge, PflueggeS@messe-duesseldorf.de www.glasstec.de

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Glass machinery

German glass machinery ready for glasstec German glass machinery manufacturers continue to expand their global market leadership position. Their efforts are backed by the German Engineering Federation (VDMA), home to more than 90% of German manufacturers.

T

hanks to new products, services and strategies, German glass machinery manufacturers continue to expand their global market position.

Take, for instance, glass machinery manufacturer Grenzebach, which has worked feverishly on developing itself from a conventional automation provider into a solutions provider of complete manufacturing plants.

Robert Luxenhofer, Sales Director for the display segment, says: “Our goal is to invest in new technologies and gain a deeper understanding of factory processes.”

The company has successfully tackled the first steps on this path. For example, it has marketed and sold systems for loading and unloading display coaters for thin film transistor (TFT) displays since 2009. About 50 such systems are deployed globally today.

The future, however, belongs to

organic light-emitting diodes (OLEDs).

Displays manufactured with this technology offer advantages over TFTs, which are still common today, including a sharper picture, wider viewing angle and reduced energy consumption.

That was reason enough for Grenzebach to explore the topic further, resulting in equipment for loading and unloading display coaters for OLED displays. Its functions parallel those of the TFT display system, but the technology used in its implementation is fundamentally different: In contrast to TFTs, which are produced using the cleanroom procedure, the OLED manufacturing process takes place in an ultra-high vacuum and thus in an airless space.

The requirements, says Luxenhofer, “are decidedly more stringent.”

Among other things, neither the usual way of transporting the panels by

gripping and suctioning them nor current drives can be used in a high vacuum environment.

But Grenzebach technicians have found practical solutions based on the existing system for loading and unloading TFT display coaters. “We modified the line accordingly,” says Luxenhofer, as he tries not to reveal too much information. Just this: The screws alone, made of silver, are worth about €30,000 per line.

A holistic strategy Grenzebach’s work in the architectural glass segment offers further evidence of the company’s holistic strategy.

In September last year, the manufacturer started offering complete turnkey packages, which include the

continued » Glass International July/August 2014

www.glass-international.com

Grenzebach robot technology being used to load and unload a vertical coater.

33

Glass machinery

necessary equipment for coating. In fact, says Dr. Jens Ellrich, who heads the coating technology department, they come ‘with everything that goes along with that, including process engineering.’ The aim is to use glasstec to introduce the topic to a broader trade audience for the first time.

Moreover, says Ellrich, the company is able to service not just its own equipment but also machinery and plants from virtually any other manufacturer, especially those made by manufacturers that have since disappeared from the market.

Insulating glass Grenzebach isn’t the only German glass machinery manufacturer with a lot to offer to glasstec visitors.

Another is Bystronic glass, which will present speed'line at the trade fair, currently the world’s fastest production line for triple-pane insulating glass.

According to Peter Nischwitz, who’s in charge of corporate communications, the line can be used to produce triplepane insulating glass in the same time as double-pane insulating glass on any other line, including the company’s own and competitor products.

www.glass-international.com

Simulation software

34

Triple-pane insulating glass has been on the market for quite some time, but socalled total cost of ownership (TCO) software – which the manufacturer will also present at the trade fair – is new.

It lets users quickly and easily simulate the entire production process for any insulating-glass line supplied by Bystronic glass.

Among other things, the software calculates exact cycle times, material quantities and the cost per unit of insulating glass. Even logistics expenses, including labour costs, can be calculated with extreme precision – if necessary, down to the last euro. What really turns the tool into a show-stopper, though, is its ability to simulate any change whatsoever in the plant’s configuration.

The various components can also be exchanged freely.

Moreover, simulations for various warm-edge spacer materials can be run.

Not only does data collected in this way facilitate the rapid and uncomplicated optimisation of production processes on existing lines, it can also be used for high-precision alignments of the way the lines function and the needs of customers. Even exact ROI calculations Glass International July/August 2014

Grenzebach’s offerings include turnkey PVD glass coating lines able to process glass measuring up to 2600 mm x 2200mm

are possible to figure out the time it takes to amortise expenses for new lines or newly installed components.

The same is true for side-by-side comparisons of complete production lines in various configurations.

However, a prerequisite for all this is that the complete set of parameters and data points necessary for the calculation is available – and only the customer can provide that. All in all, says Tobias Neff, the Production Manager in charge of solar technology at Bystronic glass and the creator of the software, the tool allows for cost reductions, depending on the configuration of the equipment.

And as if that wasn’t enough, companies – at least those based in Europe – receive another benefit: The software helps them to secure EU grant money available to businesses when they introduce new production technologies with reduced emissions of harmful CO2 that are more eco-friendly than the ones they replace.

The software makes it easy to generate the required proof demanded by the authorities.

The tool, says communications manager Nischwitz, has been ‘extremely well received’ by customers. He added that Bystronic glass wants to be more than a mere provider of manufacturing equipment, aiming instead at becoming a solutions provider in a more general sense. “We want customers to know that we don’t just understand this process from a technological but also from a business standpoint.”

Even though every company that deploys Bystronic glass software receives a PDF file with the data calculated for their plant, they don’t get the software itself. “We’re guarding it like gold,” says Neff. No wonder – it’s based on experiences collected, often painstakingly, over the course of years.

VDMA, Germany www.vdma.org

Bystronic’s speed'line machine can produce triple-pane insulating glass just as fast as double-pane insulating glass on other lines.

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Handling

Dry lubrication helps improve glass package stability In a crowded and competitive marketplace, packaging can help brands create an advantage at point of sale. Unusually shaped bottles can, however, cause problems on the manufacturing line – a problem Dry Lube believes it can help with.

A

s well as offering lighter and more environmentally friendly packaging, interesting bottle shapes are becoming more readily available.

There are a number of drivers that can influence the decision to change bottle design. The most common reasons are: Recouping market share; entering a new market; increasing point of sale

engagement; conveying brand attributes; and commemorating a milestone with a limited edition.

The decision is often made in the marketing department based on market insight and marketing objectives.

Production headache All too often a new bottle design is signed off without consulting the production department about its filling capabilities and experience in filling non-standard bottle shapes. Surprising the production department with a new bottle design can create a production headache.

For example, bottles with an inverse taper (its shoulders are broader than its base) can be especially tricky.

The design of the bottle creates a

www.glass-international.com

continued Âť

Fig 1. Bottle Design

Fig 2. Bottles with an inverse taper can destabilise and fall over during production

36 Glass International July/August 2014

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Handling

Fig 3. A close up of a tapered bottle that has de-stabilised

single point of contact high up the bottle and no stabilising point at the bottom.

When the bottles line up together, the centre of gravity in the bottle moves beyond the balance point and the bottles can de-stabilise and fall over.

The result is a high volume of wasted expensive premium packages and dramatic drops in efficiency: OEE can drop to 30% and packaging losses can amount to tens of thousands of dollars each month.

Fig 4. It is important to accurately control the CoF to manage the drive pressure of the bottles

Protecting the bottle integrity Finally, a typical lubrication system uses spray nozzles which can cause excess lubricant to be sprayed onto the package which damages labels.

Dry Lube’s distribution system applies a thin layer of lubricant on to the top and underside of the conveyor belt using Section of the conveyor

www.glass-international.com 38

Glass International July/August 2014

Dry Lube, Edinburgh, UK www.drylube.co.uk

CoF

Reason

De-palletiser

0.08 – 0.1

Low CoF required as crates provide stability.

De-crater

0.09 – 0.1

Empty bottles are more unstable requiring tight control on CoF range. < 0.09 Too much slippage, bottles will not align. > 0.12 Packages could fall from too much pressure.

Bottle inspector

0.1 – 0.12

If outside this range the package will not move at the expected speed meaning that the rejector could miss the package that it intends to reject.

Infeeds and outfeeds of the rinser, filler, pasteuriser, labeller

0.1 – 0.12

Single conveyors, bottle pressure required to ensure no gaps on entry to starwheels and scrolls feeding process equipment.

Filler outfeed

0.1 – 0.12

<0.08 Low traction on belt means that package is not carried out of filler machinery as expected and could lead to a jam.

How Dry Lube can help Dry Lube provides a technical solution for unstable packages by managing the coefficient of friction (CoF) using its lubricants. The lubricants have been formulated for filling line conditions and can be used with cans, PET, carton and keg containers as well as one-way glass and returnable glass.

It is important to accurately control the CoF to manage the drive pressure of the bottles: Too high and the bottles will drive into guides and other bottles causing damage and fallen bottles, too light and the drive will cause bottle slippage, slow running and low production efficiencies.

Dry Lube’s zonal distribution system provides the capability to control different CoF values as packages travel along the filling line, depending on the characteristics of each conveyor section.

Table 1 is based on a returnable glass bottle line in beer packaging. It shows the tolerance range for each zone and the reason for it.

Managing CoF with conveyor lubrication technology can make a substantial improvement to package stability which also improves levels of safety in the production area by reducing the volume of broken glass. But what is its impact on final package quality?

brushes and conveyor inserts.

This ensures specific dosage volumes are dispersed with zero excess ensuring the final package quality is not jeopardised.

>0.14 Product coming out of filler at high speeds will stick on the belt and could topple over.

Glideliners

0.1 – 0.13

Require forward drive on the bottles to single file on the rail. Needs to be low enough to enable bottles to single file easily.

Deceleration

0.06 – 0.10

Product speed will be brought down abruptly and could lead to fallen packages without consistent CoF control.

Inliners

0.09 -0.12

Less side pressure on bottle than glideliners and usually much longer.

Pressure Combiners

0.11 – 0.13

Higher COF required ensuring pressure is achieved to push the container through combiner and achieve single file.

Inclines

0.12 – 0.15

Bottle size is a factor here. Need a slight increase in CoF to stop the container slipping back down the slope.

Declines

0.1 – 0.12

Necessary to stop bottles accelerating downhill, then crashing and falling or breaking.

Packer

0.09 – 0.11

A little pressure is required to drive the filled containers into the packers however lateral movement in this area should also be taken into consideration.

Table 1. The tolerance range for each zone of the conveyor and why

protatherm copy_00_GI_0909 7/30/14 12:26 PM Page 1

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Handling

Protective clothing for the glass industry Glass manufacturing and processing are potentially some of the most dangerous working environments in the world. David Bennett* provides an overview of the protective clothing available to industry staff.

T

he glass industry is a global business employing millions of people worldwide, with around 100,000 people in the UK alone.

Due to the manufacturing techniques and the materials used and produced, glass manufacturing and processing is one of the most potentially dangerous working environments.

However, health and safety legislation and initiatives within the industry (for example, The Glass Charter in the UK) and by individual employers, combined with the existence of suitable personal protective equipment (PPE) which is often designed and developed specifically for the glass industry, means that the industry enjoys, in most countries, an enviable safety record.

Although both glass manufacturing and processing inevitably share a range of common hazards and PPE solutions, there are distinctly different risks faced in the two main types of working environment.

www.glass-international.com

Hot end

40

At the hot end, the principal needs are to provide protection against ignition while working in the general proximity of heat and flame, and against extreme heat (both radiant and convective). This is not only during the manufacturing process itself, but also during furnace repair work and plant maintenance, where temperatures can reach several hundred degrees C and with a potentially naked flame.

In these circumstances it is important that garments (often a separate jacket and trousers) provide adequate insulation and flame-protection, are of a loose fit to allow heat dissipation, and Glass International July/August 2014

continued Âť

Heat-resistant hot-end woollen â&#x20AC;&#x2DC;Gladdingâ&#x20AC;&#x2122; jacket

Handling

Cold end The hazards encountered in glass processing can be equally severe and potentially life-threatening.

Armatex Bodyguard cut-resistant sweater Armatex Bodyguard cut-resistant sweater with puncture-resistant reinforcement patches (on shoulders, sleeves and stomach)

Traditionally the prime areas of exposure to the risk of injury, principally from broken glass, have been regarded as the arms, wrists and hands, although employers are now increasingly giving consideration to other areas including the legs and stomach.

Arms and wrists can be protected by sleeves and cuffs/wristguards respectively. Originally manufactured from leather, these are now commonly manufactured from aramid composite materials, usually covered or reinforced with polycotton for a comfort and additional protection.

Due to the many high performance fabrics now available, ideally these should be certified to Level 5 cutresistance and Level 4 punctureresistance (the maximum obtainable) according to EN 388:2003. In the UK cuffs/wristguards should be a minimum of 20cm long according to the GGF guidelines.

Hand protection for handling and cutting glass is now usually provided by a knitted aramid or UHMW polyethylene composite glove with a palm (or sometimes, full) coating appropriate to the particular application.

Latex and nitrile are the most common coatings.

Latex provides good grip in dry, wet and oily conditions, although nitrile is sometimes preferred for soft coat, its better resistance to cutting oils and to avoid latex allergies. Leather may be used for increased durability and also to avoid damage to soft coat.

Fingerless gloves are no longer considered appropriate for any glass handling activities. All products should be certified to EN 388:2003, with gloves offering Level 5 cut-resistance (the maximum obtainable), often with Level

4 puncture-resistance, now widely available.

Recent developments in yarn and knitting technology have brought a new dimension to torso protection.

The traditional leather jacket, sometimes reinforced with metal rivets, gave way initially to polycotton jackets and sweatshirts lined with or made from aramid fabric and, most recently, to lightweight seamless knitted garments usually manufactured from a blend of high performance fibres and combining comfort with maximum cut protection.

In the absence of any specific international standard for this type of protection, garments should instead be certified to the relevant glove standard (EN 388). Reinforcements in key areas (shoulders, arms and stomach) can provide enhanced puncture-resistance.

Aprons, now usually manufactured from aramid fabrics, but sometimes reinforced with leather, continue to be used to provide cut and puncture protection to the lower torso and/or thigh/groin areas.

Leg protection, total or partial, can be provided by polycotton trousers lined with a soft aramid composite fabric.

Aprons and trousers should be certified in the same manner as other garments.

Other items of PPE such as footwear, eyewear and respiratory protection, which are critical in both hot and cold end applications, are subject to their own regulatory regimes and are outside the scope of this article.

(With thanks to Andy Reid and Ken Ward)

*Managing Director, Bennett Safetywear, Liverpool, UK www.bennettsafetywear.co.uk Glass International July/August 2014

www.glass-international.com

are ergonomically designed for comfort, mobility and quick removal if necessary; forced cooling may be necessary in some circumstances.

Despite the number of flame-retardant man-made fabrics available, a number of multinational companies continue to use garments (including hats) manufactured from a treated heavyweight wool due to its excellent insulation properties.

These may be reinforced with either an aramid fabric for additional insulation and to prevent singeing in the case of accidental contact with heat or an aluminised fabric to protect against extreme radiant heat. Alternatively, a full aramid or aluminised garment with a wool or other lining can be worn.

Head protection, usually for furnace repairs, is provided in the form of a balaclava hood manufactured from multiple layers of a knitted flameretardant fabric, often Nomex, sometimes with a nose-piece for maximum facial protection. All clothing should be certified to EN ISO 11612:2008, the relevant European/international standard for protective clothing against heat and flames, although products certified to EN 531 (an earlier standard) continue to be in use.

The same principles apply to hand protection in so far as it must provide flame-retardancy with adequate insulation, dexterity and grip. Aramid continues to be the most suitable fabric for this purpose, having supplanted leather and asbestos some time ago.

In extreme conditions a mitt, rather than a five-fingered glove, may be more suitable as its construction permits additional insulating layers and improves air circulation and heat dispersion, and can be discarded more quickly in an emergency.

Where dexterity and grip are paramount and the heat is less severe, a seamless knitted aramid gauntlet with a cotton lining will provide adequate protection, in some cases up to 500째C. Gloves should be certified to EN 407:2004, the European standard for gloves giving protection from thermal hazards, and ideally also to EN 388:2003, the equivalent standard for protection against mechanical risks.

41

Handling Typical inside view of a defect scanner

Inspecting thin glass Dr. Ulrich Neuhäusler* discusses advancements in thin glass production, and new trends in optical metrology and camera-based defect inspection.

www.glass-international.com

T

42

hanks to its excellent optical properties, resistance to scratches, chemicals, UV light and diffusion barrier properties, glass is the material of choice for applications such as solar panels, the encapsulation of OLED display or lighting devices and CMOS/CCD image sensors as well as touch screens in smart phones and tablets.

‘Miniaturisation’ has been – and still is – a general trend in microelectronics.

When looking at the evolution of electronic devices, they have become more compact from generation to generation. For this reason, the glass used in such devices has continuously shrunk in thickness, and the amount of thin glass production with thicknesses in the low mm range (even entering the range well below 1mm down to 100μm) has increased. Fortunately, optical inspection technology is able to keep pace with these advancements in thin glass production.

Glass International July/August 2014

Thin glass inspection tools The production of thin glass poses challenges to glassmakers: Making glass thinner is intrinsically connected to an increasing glass band speed at the cold end. Because thin glass is largely used in microelectronics, more stringent criteria for glass defects in terms of smaller defect sizes and new defect types have to be addressed at a high detection speed.

At the same time, the product has become more sensitive and is susceptible to breakage due to its reduced thickness.

Handling becomes difficult, and the product conditions unstable in terms of shape and position deviations due to the ability of thin glass to flex. Robust and reliable inspection technology has to adapt to these new boundary conditions.

automated classification into different types requires several detection channels such as bright field, reflection and (near) dark field. Only the combination of the information acquired from all channels allows the unambiguous identification of the correct defect type.

Unambiguously identifying glass defects helps to minimise the number of misclassified defects, and keep fake detection and defect misses low.

The increasing speed of the glass band (when reducing glass thickness) coupled with the high spatial resolutions required and up to five detection channels calls for new parallel concepts of detection. Conventional inspection technology mostly uses a serial data acquisition approach, where all channels are read in a serial fashion one after the other.

Defect inspection The detection of different glass defects (such as top and bottom tins in float, bubbles, knots, stones), and their correct

continued »

Handling

This approach is easily limited by the maximum scan frequency of the camera used, because the effective scan frequency is the actual maximum camera scan frequency divided by the number of channels.

Our approach uses an RGB detector system, where channel separation is accomplished by illumination with light of different wavelengths.

The wavelength-selective sensitivity of the RGB-sensor CCD line detector has almost no cross talk between channels. The maximum scan frequency is no longer limited by the number of channels, but only by the camera itself. In consequence, the detection of small defects (down to 50μm and beyond, depending on the number of cameras) becomes possible at a high glass band speed with high resolution in both lateral directions.

Optical metrology Glass thickness and stress are commonly measured inline at the cold end by sensors traversing perpendicular to the travel direction of the endless glass band. The process of producing thin glass intrinsically imposes a high glass band speed at the cold end.

To achieve a dense mesh of high resolution data when sampling the glass band a sensor travel speed in the range of a few metres per second is desirable, so as to achieve a spatial lateral resolution in the mm range. dr.schwab GmbH developed a combined stress and glass thickness sensor which can be accommodated in one sensor head and needs just one traversing unit, thus saving space and cost. The glass stress measurement is accomplished by laser polarometry (relative birefringence) and is over a wide range tolerant to variations of glass height and tilt.

The measurement of the glass thickness is done by laser interferometry for thin glass or laser triangulation for larger glass thicknesses.

For thickness measurements however, height variations and tilt of the glass influence the measurement result.

To achieve a robust, stable and correct measurement of the glass thickness, these variations can be eliminated inline by a redundant symmetrical optical setup that takes ‘glass thickness’, ‘glass band tilt’ and ‘height drift’ simultaneously into consideration for automated correction.

This feature is particularly useful for thin glass, where height drifts and tilted glass on the conveyor is more common than for several mm to cm thick glass.

Benefits of process statistics By combining the information from both metrology (e.g. glass thickness and stress measurement) and camera-based vision techniques (for glass defect detection), and subsequently feeding them – thanks to the abundance of data acquired inline - into process statistics tools, one can reveal useful information on systematic product parameter variations, thus allowing the improvement of process capability.

Glass makers benefit directly from higher yields and get a better handle on running their process systematically, with tighter specification limits or higher process capability indices.

*COO, dr. schwab GmbH Grenzebach Maschinenbau www.grenzebach.com

Ramsey Chain.

You’d go to great lengths to protect your investment. www.ramseychain.com sales@ramseychain.com +1-704-394-0322 Pictured is Ramsey’s patented Lifeguard® chain

Glass International July/August 2014

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W: W: www.sheppee.com www.sheppee.com

High Temperature Insulation LUBISOL #2-SL 1600 Lubisol Engineering Co. is offering a new type of refractory foamed material for high temperature insulation. Lubisol #2-SL 1600 (Supper Light) has a low specific density of 0.3 kg/dm³, a very high working temperature of 1600 °C and very low thermal conductivity: 0.05 W/m.K at 20 °C. Heated at higher temperatures it does not melt, but only starts shrinking.

It is supplied as a wet mix of granules, packed in plastic bags, ready for use. The application is done by light ramming.

The new material is very suitable for thermal insulation of all kind of industrial furnaces, kilns and heating appliances. ___________________________________________ Contact: Prof. S. Lyutskanov, G. Manager www.lubisol.com e-mail: office@lubisol.com

Handling

Quad gob ware handling

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Wilfried Seidensticker* discusses how Heye supports quad gob operation through retrofit of modern 3-axis servo pusher equipment on existing machines to meet the challenges of modern container glass production.

W

are handling itself begins with the pusher system, which transports containers from the dead plate to conveyor belt.

Recently, Heye has launched the new high-speed pusher type 2158. The optimised motion profile results in a highly accurate container positioning on the conveyor belt. Hence, a maximised production efficiency and ambitious quality results can be achieved.

The new pusher type, replacing the former version 2155, combines high speed with long-lifetime and less parts.

This new 3 axis-pusher has for the past two months run successfully on a 10-section Quad Gob IS-machine in a European glass plant.

The replacement of the old solution was done in less than two 24 hours, and due to the superior new ware handling solution it is possible for the output of the machine to be raised.

Additional advantages of the new pusher solution are: Increased life-time through reduced wear; Longer service intervals; Less storage costs for spare parts, as common parts are used with the 2-axis series (2157); Shorter job change times through improved profilesetting; and Improved usability through quick exchange of pusher fingers.

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*Hot End Product Manager, Heye International, Obernkirchen, Germany email: marketing@heye-international.com web: www.heye-international.com

Handling

Robotic glass handling

R

oboload-Pro is robotic glass handling designed for high performance loading or unloading of glass processing lines.

Apart from the obvious advantages of speed and accuracy, removing manual handling automatically introduces a raft of additional benefits including consistency of product and output, elimination of damage to glass coatings due to finger marks, elimination of risk to operator health and safety due to fatigue and reduced labour costs.

In three-shift operation Roboload-Pro can cover the duties of two people per shift: Six wages saved means the capital cost can be recouped in little more than a year.

Programmable

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Roboload-Pro is programmable to lift glass from rack in multiple positions, each rack protected by a gate system which prevents personnel exposure to the robot’s working area. Rack 1 can be changed while work continues from Rack 2, and vice versa, in total safety and without any interruption to production.

The specially designed vacuum

46 Glass International July/August 2014

Roboload-Pro is programmable to lift glass from rack in multiple positions

suction frame and pass-through conveyor allows automatic handling of coated glass without any contact to coated surfaces.

Loading of single, double or triple lites in a single 15-second cycle means tremendous performance of up to 12 lites a minute.

This equates to five seconds per piece, depending on glass size.

Roboload-Pro can be viewed in action on the Ashton Industrial Youtube channel by going to www.ashtonindustrial.com, scrolling down to the article headed ‘Watch the Action’, and following the links.

Ashton Industrial, Harlow, UK www.ashton-industrial.com

Events world

Mir Stekla at its best This year the 16th International Mir Stekla ‘World of Glass’ exhibition was held within the Expocentre Fairgrounds in Moscow, Russia. Glass International was there to cover the event and get a feel for the state of the Russian glass industry.

D

edicated to glass, technologies and equipment for the manufacture and processing of glass, Mir Stekla is the largest annual international exhibition for the glass industry in Russia, the CIS and Eastern Europe.

This year the event attracted more than 240 exhibitors from 24 countries, including 80 Russian companies, and sold a total of 5,700m2 to companies such as Bucher Emhart Glass, Sorg, Heye International, Iris and Sisecam.

Companies from all around the world were there, including representatives from Germany, China, the UK, Israel and Italy, which had a pavilion area consisting of more than 30 companies.

With a reported 9,000 visitors, the event was a success for the companies who came to do business in this part of the world. There was a wide range of glass sectors on display, with manufacturers and suppliers represented across the container, flat, decorative and glass printing divisions.

The exhibition floor was bustling, with machinery demonstrated by the likes of Bottero and Glaston, printed glass pieces on display from DipTech amongst others, and drinks provided by Sisecam at its busy and social booth.

This year was the first time the event was jointly organised by the Expocentre and StekloSouz, (the United National Council of Glass Industry Enterprises for

Russia), with the aim of supporting the development of the glass industry in Russia.

A conference was also held alongside the exhibition. Running over two days, the sessions were entitled ‘Main Trends in Fighting against Production and Use of Counterfeit Glass Products’, and ‘Issues Concerning Quality of Raw Materials for Glass Industry Enterprises’.

This overall focus on maintaining high standards was reflected in the mood of the exhibition, which many exhibitors agreed was the busiest it had been since 2008, when the Russian

continued » Glass International July/August 2014

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At the Mir Stekla official opening, Mr Michail Tolkachev (front) and Mr Victor Osipov (behind) congratulated Glass International for its Russian language issue.

47

Events world

www.glass-international.com

market started to decline.

In terms of the Russian market itself, the general consensus was that while the market level currently remains fairly stagnant, it is expected that over the next two or three years demand will increase. This was a view echoed by Victor Osipov, President of StekloSouz.

At the event’s opening ceremony, Mr. Osipov noted that within Russia the national production of pharmaceutical glass is one area in particular that is developing and growing.

Currently, approximately one third of pharmaceutical glass in Russia is produced by domestic factories, but the government has set the goal of raising this figure to 80% by 2019.

48 Glass International July/August 2014

To reach this, the volume of domestic production must increase more than three-fold over the next few years.

With regards to flat glass, Russian imports have decreased dramatically due to increased domestic production since the 1990s, and today imports of the product make up only 6% of the country’s total demand.

Production of flat glass in Russia is further expected to rise due to government targets for the construction of new houses by 2020.

It is a similar picture in terms of the production of glass containers, as well as new plants for the production of foam glass. Mr. Osipov concluded that this year’s slogan for Mir Stekla, “All from

glass and all for glass”, conveys the organisers’ intention that the exhibition will cover all aspects of the glass industry, under one roof.

At the end of the official opening Mr. Tolkachev, Deputy General Director of the Expocentre, also noted that: “We are very happy this year with the strong international media support of our Mir Stekla exhibition by world leading international magazine Glass International from the UK, which has published exclusively for our exhibition a special issue in the Russian language.”

Mir Stekla 2015 will be held 8-11 June, 2015 at the Moscow Expocentre. www.mirstekla-expo.ru/en/

Fibres

An overview of basalt fibres Davide Pico, Teresa Benczek and Thomas Gries* outline the history of basalt fibres and how European companies have recently seen their potential.

Definition of basalt Basalts are volcanic rocks produced by the solidifying magma escaped from Earth's interior to the surface or seabed in the context of effusion activities.

They are the largest distributed type of volcanic rocks on the oceanic ridge and on the mainland.

Due to the quick cooling rate, the crystallisation’s growth in solidifying basalt is low compared to that of plutonic rocks.

The mineral content and the chemical composition in basalts vary depending on which geographical site they have originated from. Basalt is usually composed of SiO2 in a range between 45% and 52% followed by Al2O3 (~1216%), iron oxide (~6-18%), alkaline earth (~10-20%) and alkalis (~2-8%)[1].

The crystalline fraction is composed mainly of plagioclase (such as albite and anorthite) and pyroxene (mostly augite).[2]

Since 1991 basalt fibre companies have been privatised and the basalt fibre technology become unrestricted. But until recently production was located principally in Russia and Ukraine.

The fibreisation process for basalt and glass is similar. Raw materials are melted and supplied via feeder channels to the spinnerets, the so-called bushings. The bushing is made of platinum and rhodium alloy and its bottom is composed of a set of nozzles through which the melt flows forced by its hydrostatic pressure. The melt is consequently quenched at solidification temperature by drawing. The filaments pass over a sizing applicator before being

wound by the winder. The process is described in Fig 1.

In contrast to common glass fibres, basalt is a natural rock composed of a bright variety of oxides. The chemical composition is the main process parameter and has a direct influence on melt viscosity and process temperature.

Moreover the mechanical properties as well as the chemical stability of the fibres depend on their chemical composition.

In general, the viscosity is related to xi the mole fractions of the main oxides in

continued »

Basalt

E-glass

S-glasss

E-CR glass

AR-glass

Characteristic

Natural rock

High dielectric

High strength

Corrosion resistance

Alkali resistance

Carbon

Strength [GPa]

3,00-4,84

3,40-3,50

4,02-4,65

3,5

3,5

3,5-6,0

E-Modul [GPa]

93-110

72-74

83-86

80

72

230-600

Dichte [g/cm3]

2,6-2,8

2,54

2,49

2,68

2,68

1,80

Liquidus T,[°C]

1220

1064

1500

1160

1200

-

Fibreforming T,[°C]

1300

1200

1565

1230

1300

-

80

136

65

70

100

-

SiO2 [%]

49,6

52-56

65

58,2

60,7

-

Al2O3 [%]

15,7

12-16

25

11,6

-

-

-

1,0

16,5

-

16-32

10

23,7

-

-

6 T (F-L),[°C]

K2O + Na2O [%]

4,6

CaO + MgO [%]

15,1

Fe2O3+ FeO [%]

11,7

-

-

-

-

-

-

-

-

-

21,5

-

Basalt fibre spinning process

ZrO2 [%]

The first basalt fibre spinning process was patented in 1923 by Paul Dhe but it was from the early 1960s that research in this area really grew. It was financed mainly in the former Soviet Union where the know-how of basalt fibre production was kept undisclosed for military use.

B2O3 [%]

-

5-10

-

-

-

-

ZnO2 [%]

-

-

-

2,9

-

-

TiO2 [%]

1,3

-

-

2,5

-

-

2-3

1-2

8-10

-

2-5

15-30

C [%] Price [€/kg]

> 90

Table 1. Properties of basalt, glass and carbon fibres [5,7,8].

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A

new type of man-made fibre has entered the market in recent years. Fiberised basalt is a product situated in the commercial sector of technical fibres between special glasses and carbon fibres (Table 1).

Their commercial production started in Russia and Ukraine but the competitive price combined with their properties has attracted new European companies and research institutes.

49 Glass International July/August 2014

Visit us at Glasstech Dusseldorf Hall 13

Fibres

the melt and can be expressed by the viscosity modulus MV[4]: ‘and research institutes is the determination of raw material potentials in terms of spinning behaviour as well as the final product. Actually in Austria, Belgium, Czech Republic, Hungary, Germany, Italy, Spain, Ukraine and Russia, several research institutes as well as R&D departments in the industry are engaged in basalt/natural rock fibre projects. Basalt fibre is longer a geographically controlled Russian and Ukrainian research field.’

Fig 1.

1. crushed stone silo; 2. loading station; 3. transport system; 4. batch charging station; 5. initial melt zone; 6. secondary heat zone with precise temperature control; 7. filament forming bushings; 8. sizing applicator; 9. strand formation station; 10. fibre tensioning station; 11. automated winding station.[3] 4 5

1

6

7

2

8 9 3

10

Literature [1] fibre

11

A. Bartl, D. Pico: “Revolutionary high-performance based

on

basaltic

rock”;

Chemical

Fibers

International, 58 (2008), S. 240 - 241.

Brown, G.M.: Mineralogy of basaltic rocks. In Hess,

based in basalts from the European north of Russia. Glass

HD: Advanced inorganic fibers: Processes, structures,

H.; Poldervaart, A.: Basalts - The Poldervaart treatise on

and Ceramics 58 (2001), H. 3-4, S. 100-104

properties, applications. Kluver Academic Publishers,

rocks of basaltic composition. Band 1. 1.Aufl..- New York;

[5]

1999.

London; Sydney: John Wiley & Sons, 1967, S. 103-162

materials based on fibers from basalt-type rock materials.

[8]

[3]

Refractories and Industrial Ceramics 45 (2004), H. 2, S.

on continuous basalt fibre and basalt fibers reinforced

Mechanical Properties of Basalt and Glass Fibers: A

144-146

polymers. International Conference on Experimental

Comparison. Textile Research Journal 79 (2009), H. 7, S.

[6]

Mechanics 2008. Nanjing. 8.-11. November 2008.

645-651

continuous and staple fibers from rocks in Krasnodar

[4]

Krai. Glass and Ceramics 67 (2010), H. 5-6, S. 165-168

Deák, T.; Czigány, T.: Chemical Composition and

Morozov,N.; Bakunov, V.; Morozov, E.; Aslanova,L.;

The glassmaker’s diary

Granovskii, P.; Prokshin, V.; Zemlyanitsyn, A.: Materials

Novitskii, A. G.: High-temperature heat-insulating

Tatarintseva, O.; Khodakova, N.: Obtaining basaltic

[7] Wallenberger FT, Mac Chesney JB, Naslain R, Ackler

19th ISNOG ISNOG deals with the synthesis, processing, modeling and physical properties of glass ceramics and new functional glasses.

August 24th -28th 2014 Jeju Island, South Korea CONTACT: www.isnog.org/index.php 38th AFGM Conference Asean Federation of Glass Manufacturers: The theme for 38th Asean Glass Conference is 'Go Green with Glass'.

September 8th -11th 2014 Penang Island, Malaysia CONTACT: http://38afgm.com/main/ CelSian - NCNG International Glass Technology Course A five-day, glass technology training course for the international glass industry, developed in cooperation with the National Committee Netherlands Glass industry (NCNG).

September 8th -12th 2014 Eindhoven, The Netherlands CONTACT: http://www.glasstrend.nl/news.php?uid=21 GlassBuild America Annual event that brings the glass and fenestration industries together.

September 9th -11th 2014 Las Vegas, USA CONTACT: www.glassbuildamerica.com

Zhang, X.; Zou, G.; Shen, Z.: Experimental research

* Researchers, Institut für Textiltechnik (ITA) der RWTH Aachen University.

September 10th -12th 2014 Durham, UK CONTACT: www.durham2014.sgt.org 12th ESG Conference The conference will focus on ways to improve the quality and performance of glass products in their various applications.

September 21st -24th 2014 Parma, Italy CONTACT: http://www.ativ-online.it/Indexus.htm Sri Lanka Glass Expo 2014 Provides a platform for industry leaders to expand their business and stay up to date with the industry.

October 3th -5th 2014 Colombo, Sri Lanka CONTACT: www.lankaglass.net glasstec International fair for the glass industry, machinery/equipment, skilled trade, architecture.

October 21st -24th 2014 Düsseldorf, Germany CONTACT: www.glasstec.de Glasstech Asia 2014 Southeast Asia’s trade event for the glass industry.

November 25th -27th 2014 Manila, The Philippines CONTACT: www.glasstechasia.com.sg/

Living Glass and GLASSAC As with each of its predecessors, this conference will draw together those who are at the forefront of glass science.

www.glass-international.com

[2]

51 Glass International July/August 2014

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GLASSMAN EVENTS VISIT: www.glassmanevents.com

COMBUSTION EQUIPMENT

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

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

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Manufacturers and suppliers of selas square port gas & air valves

GAS

Special cast irons and alloys for glass moulds

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