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Contents: AG 20-1 Regulars
Features
4 Welcome
26 Turkey in focus
Coronavirus and the Chinese conundrum.
6 Headline News
Openings, closures and industry moves from across Asia.
16 Global View
Our eye on the international arena.
20 People and Places Movers and shakers, ups and downs.
22 Batch
Raw material news and updates.
24 Comment & Analysis
Is glass a soft target for the climate lobby?
Yogender Malik looks at how Asia’s bridge to Europe and the wider Mahgreb region, Turkey, is positioning itself for changing economic conditions moving forward and looking to capitalise on an improving domestic scene…
38 Opening options for the window sector Carlos Machado e Moura and Pedro Borges de Araújo of Jofebar / panoramah!® and Centro de Estudos de Arquitectura e Urbanismo, Faculdade de Arquitectura da Universidade do Porto discuss how evolving window technology has created a range of new architectural options…if only some of the ideas could be combined...
44 Cosmetic packaging trends
Rohan Gunasekera looks at how the cosmetic and personal care markets of the sub-continent are doing their best to absorb some of the excess container glass capacity in the region and provide a new market for innovation going forward……
48 Facades: re-use and recycling
Rebecca Hartwell and Dr. Mauro Overend from the University of Cambridge, UK, discuss overcoming the traditional issues of being a hybrid product when it comes to their eventual re-use and recycle…
26 Your favourite magazine is now available at the App Store… download today to see your first sample issue! Asian Glass: now for mobiles, ipads and androids
48
Anaylsis 54 In Focus
In an interview between regional media Rajesh Khosla, president & CEO, AGI Glaspac, talks about the company’s growth, prospects of glass replacing plastics, technology innovations and so on.
58 Window
Analysis and insight into Indonesia.
62 Refractory Zone
News and developments from the refractory supply industry. 2
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Welcome W
ell, not the greatest start to a new decade of course as we sit again on the brink of an “Asian medical crisis” (the popular media’s way of looking at things) that is becoming a “global medical emergency”. Of course, it is tragic that already several hundred people have died from the dreaded “Corona” virus…but with global influenza deaths usually of the order of up to 500,000 every year, perhaps we shouldn’t quite hit the panic button just yet.
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However, with China’s place so critical in the global supply chain, any change of situation in the People’s Republic sends tremors throughout companies from Hong Kong to San Francisco, and all places in between. With factories returning after the (extended) Lunar New Year break as AG goes to press, it has been noticeable that many firms are expecting just 20% or so of employees to make it back to work, with many factories holding off re-starting production and manufacture until the end of the month instead. For some companies in glass – especially those that depend on China’s increasing dominance of the markets of ultrathin glass – this is problematic. Order books, filled to the brim are suddenly all going to be delayed. Instead, those that were far-sighted enough to support growing production bases in the likes of Vietnam, Indonesia and India are going to be well-placed to slip into some of these overdue product situations and fulfil orders that might otherwise go astray. Where there is an issue for one, there is opportunity for another.
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13/12/2019 13:36
For some companies – and goverments in fact – such a biological intervention, however, relatively minor (and I really stress that people should look at the FACTS not the hyperbole surrounding this virus) is heaven-sent. A chance to kick a combatant whilst its already weakened and struggling under onerous dumping duties and tariffs. The Chinese authorities are supremely aware of the potential here for the country to be rapidly usurped by an eager pack of surrounding nations, many of whom had industries suffer because of China in the past and are now in the position to turn the tables. Will this go on for too long? We hope not. The “I can’t possibly go to China” approach of many European (in particular) companies borders on the ridiculous with the flames fanned by our 24 hour exaggerative media. This could indeed be the best time to strike the deals with the country; with partners eager to maintain trading and indeed not be pillioried for simply being “Chinese”. Remember everyone; the sun will set and rise tonight and tomorrow; the world will keep spinning; the mountains will keep inching higher…and China is still going to be there with its manufacturing might at the end of this. Rather than victimise it, is this not the time to stand up, be counted and lend it some support? Happy reading!
Paul Russell Email: prussell@asianglass.com Direct line: + 44 (0) 208 638 0619 Production and design Tim Mitchell Email: tim@bowheadmedia.com Direct line: + 44 (0) 208 123 0839
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HEADLINE NEWS ASIA Gujarat Borosil sets up a new furnace India Sole producer of flat glass for solar modules in India, Gujarat Borosil has commenced operations from its second float glass line at Bharuch in the state of Gujarat. With this expansion, Gujarat Borosil has an installed capacity of 460 tonnes per day of solar glass for domestic industry and exports. Company’s expansion came after imposition of anti-dumping duties on solar glass imports
from Malaysia. In Feb 2019, Indian government had imposed the long awaited anti-dumping duty on textured tempered coated and uncoated glass, originating in or exported from Malaysia for a period of 5 years. The duty amount is USD 114.58/ MT. The duty will be applied to products from all producers, except M/s Xinyi Solar Sdn. Bhd. Gujarat Borosil had filed a petition requesting imposition
of anti-dumping duty of Malaysian solar glass, stating that the said goods imported by India were below their normal values and consequently, the domestic industry had suffered material injury. Indian imports of toughened (tempered) glass from all nations more than quadrupled since FY14, to reach USD 75mn or 15.9 mn sqm in FY 201819. Out of this, Malaysia’s
share was USD 15.7 mn or 3.8 mn sqm. After the imposition of this duty, Gujarat Borosil does not have to face competition from cheap imports of solar glass from Malaysia. In addition to this, various policy reforms by Indian government to increase usage of solar power will give a boost to Indian glass players, involved in manufacture of solar glass.
Emirates Glass sees profit and output surge UAE Emirates Glass, a subsidiary of Dubai Investments and one of the largest processors of flat architectural glass in the Middle East, announced that it has recorded manufacturing of more than 1.8 million sqm of glass products, valued at over Dh180 million during 2019. Recording a 10 per cent rise in business as compared to the previous year, the company has confirmed more than 40 per cent of business being generated from the UAE. Higher percentage of
customer retention coupled with optimum delivery services have been instrumental in garnering new projects, the company has confirmed. Latest products like Emicool Solite and Emicool Sun T Series have been identified as products that facilitated the maximum volumes of sales. "In line with the current demand for our glass products, it is extremely satisfying to know that our production lines are running in full capacity to meet the high demand. There has been substantial demand
for our premium coated glass product range providing high efficiency and durability to meet the most stringent requirements for high performance window glass products. With Expo on close heels, the UAE's real estate sector has seen rampant projects and we have been active contributors with more than 40 per cent business generated from the UAE market", said Rizwanulla Khan, executive president of Emirates Glass. Emirates Glass currently operates a 60,000 sqm
production facility in Al Quoz and a 32,825 sqm post-temperable glass coating line in Dubai Investments Park since 2010. Emirates Glass currently provides glass and glass solutions to GCC countries such as Saudi Arabia, Egypt, Oman, and Kuwait as well as to Azerbaijan, Australia, Kenya, Lebanon, Turkey, India, Sri Lanka, Pakistan, Bangladesh, East and South Africa, and Canada. The company is focused on enhancing its geographic footprint further.
Kyzylorda factory to begin flat glass production Kazakhstan During this year, Orda Glass Ltd plans to finally begin the output of flat glass in Kyzylorda. As explained in the company, at the moment, construction and installation works are at the testing stage. "At the same time, the installation of the technological equipment of the plant is ongoing. The heating of the melting furnace is scheduled for July 2020," the company said.
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It is noted that 70% of the finished products are planned to be sold in the domestic market, and 30% they want to export to the countries of Central Asia and Russia. At the same time, 226 jobs will be created during the operation of the enterprise. It was expected that the construction of the plant for 42 billion tenge would have been completed in the IV quarter of 2019, but in early April 2019,
it was reported that the plant had not yet been commissioned due to a conflict between the founders. According to the regional department of industrial and innovative development, the American company Stewart Engineers without any arguments decided against further participation in the project, thereby causing the main sponsor of the project, the Chinese company King Charm Development, to re-
think its strategy. However, as differences became resolved, according to reports, Stewart expressed a desire to return as long as Orda fulfilled its obligations under the contract.
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Vedanta targets major investment programme India Vedanta Resources Chairman Anil Agarwal has said the company is planning to invest around Rs 60,000 crore in the next 2-3 years, with the glass sector potentially a major target. The company is also eyeing a top line of USD 30-40 billion and a bottom line of USD 10 million in 4-5 years, Agarwal said at the India Economic Conclave 2019. "I am committed to India. I have already invested USD 35 billion in India in the past 10 years. I have bought 13 companies so
far including Hindustan Zinc, Balco, Sesa Goa and Cairn and all of them are doing well. I hope to invest Rs 60,000 crore in the next 2-3 years," he said. However, he did not give further details on how the company plans to utilise the funds, but hinted at being keen on acquiring a few public sector companies. "We currently have the best in class assets and we are looking at many more nationalised companies. I want
to tell the government that it should not depend on foreigners but depend on us. They (foreign investors) want to make money but we want to make the country. If government depends on us we will also bring in foreign investment," Agarwal added. He also said the company is keenly looking at the glass and optical fibre and cable industries. "Sterlite Tech is doing a good work in optical fibre. I am now keen on developing the glass industry which will be used in
electronics. We are developing the glass used in mobiles, TV sets and computers in countries like Korea, Taiwan and Japan. If the atmosphere in India is conducive we will get to do that here as well. This will give a boost to the electronics industry," he added. When asked about the growth the company foresees by 202425 he said, "we are hoping to have a USD 30-40 billion of revenues and a profit of USD 10 million."
Glasspro to get fourth outing India The 4th edition of glasspro India scheduled from 24 – 26 September at Aerocity ground, New Delhi, showcasing the latest and finest trends and innovation in flat and processed glass products and applications. After successfully organising India’s major glass exhibition in Mumbai in 2019, the 4th edition of glasspro India scheduled from 24 – 26 September at Aerocity ground, New Delhi, showcasing the latest and finest trends and innovation in flat and processed glass products and applications. Also on display will be the latest
glass processing solutions, tools, auxiliary products and services. The growth in the flat glass industry is characterised by the increased use of processed and reflective glass as Indian customers have become more aware of the importance of glass in effectively addressing the concerns of safety and energy efficiency. Considering Government’s vision of smart cities, opportunities in flat glass industry tends to increase. As per the industry need, glasspro India is ready to set up a one
stop destination for the industry professionals to unveil the latest technological advancements, products & application in the world of flat glass industry. The show is supported by AIGMF- The All India Glass Manufacturers Federation Ltd, BAI - Builders Association of India. CCPSConfederation of Construction Products and Services, Ludhiana glass dealers association, Noida glass and dealers association, The Madras glass & plywood merchant association, Rajkot glass merchant association, Glazing
CSG commences float glass operation
society of India. Helping glasspro India to bring together industry veterans under one roof. The 2020 edition of glasspro India focusses on adding new & diverse product categories which also includes doors & windows segment with participation of more than 110 exhibitors, 6+ country participation with more than 6000 trade visitors. Glasspro India 2020 provides opportunity to interact & network with industry experts and will act as an experiencing centre for new technology, solutions & products.
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China/Nigeria One of the, if not the, largest producers of float glass in China, China Southern Glass ( CSG) Holding has commenced operations from its new float glass plant in Nigeria in early January. Located in Ogun Guangdong Free Trade Zone, the newly inaugurated production line has a daily melting capacity of 500 tonnes of float glass per
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day. The float glass line will contribute to the development of the local glass supply chain, sourcing 80% of its raw materials domestically, and further supporting the development of the local network of glass distributors and traders downstream. Some 80% of production is
expected to be sold locally to meet rapidly rising domestic demand, while the balance will be exported to other countries in West Africa. Nigeria’s infrastructure development has led to high demand for float glass, however, currently, most of the supply is met through imports, and is insufficient to meet domestic needs.
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Schott keeps the upward trend World SCHOTT AG has continued on its growth course again in fiscal year 2018/19. The key financial figures developed positively or remained at the solid level of the previous year. “We were able to meet our forecasts from last year and continued the positive business development of previous years despite the difficult global economic situation. For this reason, we are satisfied with the past fiscal year,” said Dr. Frank Heinricht, chairman of the Board of Management, at the Annual Results Press Conference. The international technology group managed to increase its sales by 5.1% to nearly €2.2 billion. The operating result (EBIT), which now stands at €275 million, also improved slightly. Consolidated net profit for the
year amounted to €206 million. All three segments – Precision Materials, Optical Industries and Home Appliances – contributed to the successful fiscal year. On the other hand, the difficult situation in the automotive industry also had an impact on SCHOTT. The Electronic Packaging division that supplies components to the automotive industry, in particular, suffered from this development. At the same time, future topics such as autonomous driving and electromobility offer new opportunities for specialpurpose glasses Sales of more than €506 million were reported out of the North America region. In terms of overall sales, 87% were achieved outside of Germany. In total, 23% of global sales were attributable
to North America. “SCHOTT grew strongly in the North American market led by our Pharmaceutical Packaging business unit,” said Jim Gareau, president SCHOTT North America Inc. “Our investments in the North American region enable innovations to be brought to market particular-ly in the pharma industry where investments allowed for the production of the expanded adaptiQ portfolio.” Investments in property, plant and equipment amounted to €257 million in the fiscal year, an increase of 38% over the previous year. The expansion of the production capacity of an existing plant in India and the construction of a new plant in China were the largest foreign investments. After getting off to a good
start in the first three months of its new fiscal year, SCHOTT expects sales to increase by between 3% and 6% for the year as a whole. The technology group expects impetus to come, among other areas, from a demand for specialty glass for pharmaceutical packaging and ultra-thin glass for the foldable mobile devices of the future. In fiscal year 2019/2020, SCHOTT plans to invest €320 million, the highest amount in the company’s history. One main focus here will be on capacity expansions in the pharmaceutical packaging business in China and India. In Germany, SCHOTT plans to invest in its pharmaceutical packaging business in Müllheim, among other sites, as well as in its manufacturing capacities for specialty glass in Mainz and Jena.
HK recycling services to be resumed China Glass bottle recycling services will resume soon in Hong Kong, two months after collection was stopped because of antigovernment protests in the city. Secretary for the Environment Wong Kam-sing revealed the decision during a Facebook live chat session on Friday, in which the minister took questions from the public about a range of issues including recycling, the city’s climate change strategy, and a long-delayed waste charging scheme. “Now that the situation is relatively calm, we have asked our contractors to resume collection in safe areas such as housing estates and at government community green stations,” Wong said. “Throughout the social unrest, many glass recycling bins were damaged. If the bins filled with glass were poured out into public spaces, it would have posed a danger to both residents and protesters.” Glass bottles, mainly for beer and other alcoholic drinks, were used by protesters to make
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petrol bombs to throw at police. The unrest was triggered by a now-withdrawn extradition bill, but later morphed into a wider anti-government movement. Rubbish and recycling bins have been regularly used to block roads during the more than seven months of protests. Wong added the government was working to ensure there were enough uses for recycled glass, such as in eco-pavements and construction. Over the past two to three years, its efforts had improved the recycling rate for glass bottles from one out of every 10 bottles, to three out of 10, and Wong urged residents to continue to recycle glass. Edwin Lau Che-feng, executive director of The Green Earth, hoped the government could speed up the resumption of glass collection. The group has previously criticised the glass recycling ban, and said it would have caused tonnes of bottles to be dumped in landfills. “Taking away the collection bins was never going to stop people who wanted to use glass
bottles for any illegal activities in the first place. People could just go to any back alley behind a bar and collect the bottles there,” Lau said. The removal of the bins would have just deterred residents’ will to recycle glass, while at the same time businesses that had already trained employees to separate glass from other waste would have to relearn how to handle glass without recycling services, he said. Wong’s live chat session, which he promoted on Facebook as “conversation is better than opposition”, has since been viewed almost 5,000 times. While Wong mostly took questions related to environmental policies, many commenters demanded to know how tear gas, which has been heavily used by police to disperse protesters, had affected the environment. Others simply commented, “five demands, not one less”, the main rallying cry of the protest movement. Only the first demand, the withdrawal of the
extradition bill, has been met. Protesters have also called for universal suffrage in the city, and an inquiry into police use of force. “While Wong is a relatively low profile in terms of politics, it would be difficult to shift people’s focus away from what they consider the most pressing matters, namely police brutality and the government’s inaction throughout the protests,” said Chung Kim-wah, assistant professor at Polytechnic University’s department of applied social sciences.
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Tecglass confirms printer installation UAE Based on a deal signed with Technical Glass and Aluminium Company LLC last year, the innovative Vitro Jet FS24 digital printer with Side Kinetix technology developed in the company’s Lalìn plant, has now been confirmed as an imminent installation in the United Arab Emirates. Measuring 3,300 x 12,000 mm, the Vitro Jet FS24 is designed to optimize printing on super-sized glass. Thanks to the special movement of the print head parallel to the support table, Side Kinetix technology is specifically engineered to always print along the long edge of the glass, making the Tecglass digital printer an effective tool for on-demand client customization of glass 12 meters in length, in
the shortest time possible. This patented technology makes for increasingly efficient printing and production processes. But the many advantages of this model do not end here. It has 1440 dpi print resolution, 12 always- available color channels at maximum speed, 48 individual heads (with 1000 nozzles each) for maximum power and 7 different ink drop sizes to make the best use of Tecglass ceramic inks. This positions the Vitro Jet FS24 among the best tools for maximizing architectural glass use in the most sophisticated decorative design projects. The agreement signed last year formalizes a new partnership between Tecglass and Technical Glass and
Aluminium Company LLC, a steadily growing business known for the extremely high quality of its products and one of the leading glass manufacturers in the United Arab Emirates market area. An especially beneficial choice for a company that
since day-one has carried out some of the most complex and exciting projects in the entire region, consistently focusing on innovative, cutting- edge jobs for the local market, paving the way to the most optimistic expectations for the year ahead.
Dagestan container glass to create new jobs Russia The implementation of the investment project to expand the production of glass containers in the city of Dagestan will create about 200 jobs. The total budget of the investment project will be more than 1.8 billion rubles, Zarema Urazaeva, the head of the press service of the Ministry of Economy and Territorial Development of Dagestan, has released. "In 2020, in Dagestan, on the basis of the plant of DagestanStekloTara OJSC in
the city of Dagestan Lights, it is planned to start an investment project to modernize and expand the existing production of glass containers that meets European standards. The total budget of the project is over 1.8 billion rubles," said Urazaeva. According to her, thanks to the implementation of this project, it is planned to create 192 new jobs. "The project involves the construction of a new furnace with a capacity of 240 tons per day and the installation of production
equipment for the production of glass containers in the amount of 216 million pieces per year in 0.5 liter terms, with a capacity of 0.1 to 5 liters of lightweight glass containers with a neck of any type and diameter," said the agency. She added that the goal of this investment project is to increase the volume of production of the enterprise. "The completion of the project and its commissioning is scheduled for 2021," concluded the Ministry of Economic Development of the region.
Earlier, sources reported that in 2019, the export of glass containers produced in Dagestan almost doubled: from 129 to 245 million rubles. The volume of sales of these products in the domestic market amounted to 700 million rubles. OJSC "DagestanStekloTara" (the city of Dagestan Lights) is the only manufacturer in the republic of glass containers. Export of goods is carried out to Azerbaijan, Georgia and Armenia.
Solar glass float furnace starts operation Vietnam Nippon Sheet Glass (NSG) Group has started commercial production from its Vietnam based solar glass line in the third week of January. This line was previously a float glass line, which was upgraded as part of the plan announced in May 2018 to expand production capacity of solar glass to support the growing solar market in the
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country and region. The restarted float furnace is one of the two lines at NSG Vietnam Glass Industries Ltd. (VGI) located near Ho Chi Minh City. Solar glass production at VGI has been positioned to support a long-term supply agreement with First Solar, the world’s leading provider of comprehensive photovoltaic (PV) solar system.
Manufactured with the online coating technology, in which a conductive oxide on the glass surface is formed during its passage through the float line, NSG’s TCO glass is very durable with a wide range of applications. Online coating also enables cost effective production of coated glass in high volume. With the expanded supply capability
for VA products, such as solar glass and other products, NSG Group intends to drive its growth strategy while supporting the expansion of renewable energy.
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Solar glass plant gets green light Malaysia The $483 million fab will be built by an unnamed ‘multinational glass manufacturer’ at the Kota Kinabalu Industrial Park, in the Sabah region. Rumours had abounded that the project would get the go-ahead, but in a tweet at the turn of the year, the Malaysian Industrial Development Authority seemed to confirm the likelihood: “The National Committee on Investment, co-chaired by YB Datuk @DarellLeiking & YB Tuan @guanenglim approved another 4 projects in the manufacturing sector worth RM5.4 bil on 12/12/2019. The projects will be located in
Sabah, Johor, Selangor and Pulau Pinang” Indeed, it transpired soon after that one of the manufacturing projects announced by Malaysia’s international trade and industry minister Datuk Darell Leiking with that tweet is an MYR2 billion ($483 million) glass factory which will manufacture PV as well as float glass. The identity of the “multinational glass manufacturer” referred to in a press release issued by the minister on his facebook account to publicize the move was not released but it was confirmed the facility will be built at the
Kota Kinabalu Industrial Park, in the Sabah region. In February, Malaysian newspaper the Daily Express had reported a Chinese silica-sandbased glass manufacturer was planning to build a factory at the industrial park, and that the producer already owned and operated a solar glass factory in Malaysia’s Malacca. The company in question could be Chinese manufacturer Xinyi Solar, which has operated a 900-ton annual production capacity factory in Malacca through subsidiary Xinyi Solar (Malaysia) Sdn Bhd since 2016. The company has not responded
Piramal enjoys domestic boost Sri Lanka Piramal Glass Ceylon PLC, Sri Lanka’s only glass bottle manufacturer, saw its December quarter (3Q20) earnings surging amid higher domestic sales, stoked by festive season. According to the interim financial accounts released to the Colombo bourse, the firm reported revenue of Rs.2.3 billion for the quarter under review, up from Rs.1.9 billion reported for the corresponding period, last year. The improved top line boosted the firm’s earnings per share for the quarter to 25 cents or Rs.235.8 million compared to
earnings of 12 cents or Rs.115.4 million reported for the same period, last year. Piramal Glass in an earnings review said domestic sales grew 24 percent year-on-year (YoY) to Rs.1.5 billion while exports grew 10 percent YoY to Rs.804 million. “The investment of over Rs.1 billion made on a sixth production line during the first quarter of this financial year has started paying dividends. This line helped the production to maximise its capacity utilisation and in turn to increase the overall production tonnage. This additional capacity
together with deferring of some export orders helped create space for the increased domestic demand to be catered during the festive season and also to yield maximum results,” the firm said. During the quarter under review, Piramal Glass introduced several new products to its export market, which included a 750ml flint water bottle for the UK market and 1lt juice bottle for Mauritius market. An attractive Cobalt blue of 330ml capacity was launched for Beer, whilst a whiskey bottle range in varied sizes of 180ml, 375ml and 750ml was launched in both flint and emerald green for the
Gas price reduction to aid glass sector Indonesia Indonesia’s largest gas distributor aims to lower industrial gas prices to US$6 per million British thermal unit (mmbtu) by April, from around $8 mmbtu as AG goes to press – a price point that has been considered burdensome for manufacturing industries. PGN president director Gigih Prakoso said on Monday that the company was engaged in talks with gas companies and the government to meet the $6 price mark, as stipulated by Presidential Regulation (Perpres)
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No. 40/2016. The regulation promises cheap gas for the rubber gloves, ceramics, glass, steel, fertilizer, petrochemical and oleochemical industries, which consume 70 percent of Indonesia’s industrial gas. “Hopefully, with all these discussions, there will be a way out such that on April 1 we can implement Perpres No. 40/2016,” he told lawmakers in Jakarta. Four years have passed since the regulation’s issuance yet gas prices still hover around $8 per
mmbtu, hurting manufacturing industry growth, at a time when Indonesia is trying to break free from the middle-income trap. In response, President Joko “Jokowi” Widodo announced last month three possible solutions to reduce prices: domestic market obligation (DMO), fiscal incentive or import relaxation. Jokowi is set to make a decision on the matter by March. PGN has made clear that it favored the DMO option but Gigih, speaking on Monday, said
to pv magazine’s request to confirm if the newly announced factory is part of its expansion plans for Malaysia. Hong Kong-based glass manufacturer Sun Bear Solar Ltd had announced plans for a facility at the Kota Kinabalu park in 2010 but nothing has been heard of that proposed fab since. The Indian government has imposed a trade penalty on textured, toughened (tempered) solar glass from Malaysia since February. The five-year duty of $114.58/metric ton is applicable on solar glass from all Malaysian producers except Xinyi Solar. Indian market. For the nine months ended December 31, 2019, Piramal Glass reported earnings of 35 cents or Rs.330.2 million compared to earnings of Rs.16 cents or Rs.153.8 million reported for the same period, last year. The sales rose to Rs.5.8 billion from Rs.5.4 billion a year ago. For 3Q20 gross profit margin increased to 23 percent from 21 percent YoY while for the nine months gross profit margin rose 20 percent from 16 percent YoY. Piramal Glass Private Ltd holds 56.45 percent stake in Piramal Glass Ceylon as the controlling shareholder. Employee’s Provident Fund has 9.51 percent stake in the company being the second largest shareholder. the company also wanted tax cuts to reduce operational costs. Specifically, PGN wanted the government to eliminate value added taxes (PPN) for when the company purchased gas and do away with a gas distribution tax “that we will use to build infrastructure instead.” PGN expects the slashing of the two taxes to reduce transmission and distribution costs, which respectively comprise 13 percent and 17 percent of its final selling price. The remaining 70 percent comes from purchasing the gas, a price that the government does not want to cut as it would hurt oil and gas producers.
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China Glass 2020 Promotes High-Quality Development of the Glass Industry China
The 31st China International Glass Industrial Technical Exhibition (China Glass 2020) organized by the Chinese Ceramic Society and contracted by Beijing Zhonggui Exhibition Co., Ltd., will make a strong return at Shanghai New International Expo Centre from April 14 to 17, 2020. China Glass 2020 will cover the entire value chain of the glass industry, including flat glass manufacturing, glass production and application, technical glass, processing technology and equipment, raw and auxiliary materials, and refractory materials. China Glass 2020 is committed to providing an excellent market expansion and technology exchange platform for global glass manufacturers and providers of processing equipment.
In-depth processing
The National total output of flat glass from January to November 2019 was 848.43 million weight cases, up 6.9 percent year-on-year. There was a slight increase in the output of processed glass sector, including tempered glass, insulating glass and laminated glass. The overall production and operation of China’s glass industry was stable in 2019. The growth in output was accompanied by a fall in average ex-factory price, showing greater downward pressure on the economic benefit of the industry. As the most notable event in the global glass industry in 2020, China Glass will focus on the industry restructuring and promotion of high-quality development. It will provide more innovative perspectives for the entire value chain from the areas of intelligent manufacturing, low-carbon and low energy consumption, and high efficient production. This event will set up 5 theme exhibition areas, including Hall E1 for international brands, Hall E2 for glass production and application, Hall E3 for tempering furnace & refractory materials, Hall E4 - E7 for deep processing equipment & domestic glass, hall E8 - E9 for refractory, raw and auxiliary materials, glass windows & doors, as well as art glass. As a professional exhibition, China Glass 2020 will provide more products and solutions for the construction, automotive, consumer electronics, household, photovoltaic and other industries.
Big brands arrive…
In terms of size, professionalism and internationalization, China Glass 2020 is a leading exhibition and wind vane of the glass industry. It attracted many mainstream brands from home and abroad. By the end of 2019, 920 manufacturers (including 204 overseas companies) from 28 countries and regions confirmed their participation in this event, including China, Germany, Italy, the United States, the United Kingdom, South Korea, Japan, etc. The total exhibition area exceeds 90,000 m2. Domestic exhibitors include: China Building Materials Academy, Triumph Group, Anhui Huaguang, Xinfuxing Glass, Ruitai Materials Technology, Qinhuangdao Glass Industry Research & Design Institute, China New Building Materials Design & Research Institute, Sinoma Advanced Materials, China Yaohua Glass, Luoyang Float Glass, China Glass Holdings, Taiwan Glass, JING YOW Enterprise, Xinyi Glass, CSG Holding, Jinjing, Shanghai SYP, Kibing, Flat Glass, Shanxi Lihu, Hubei Yijun, Shandong Guangyao, Hebei Yingxin, Shahe Glass, North Glass, Mountain Glass, Land Glass, South Glass Technology, Tenon, Yinrui, Fangding, MGM Glass, EI, GOLIVE, Fushan Glass, BOZA, Weili, Liaoning North Glass, Lewei, Dinganda Glass, Guilin Champion Union, Dardi Water Cutter, Sanjin Glass, Mr. Glass, HIHO Glass, Sanjiang, Zibo GT Industrial Ceramics, ZIBO ASAHI, etc. Foreign exhibitors include: Lisec, Glaston, Vonardenne, Vesuvius, Sefpro, Dip-tech, Benteler, Henry F. Teichmann, Buhler Leybold, Grenzebach, Five Stein, Precision, Hegla, Zippe, Bottero, Fenzi, Intermac, Ocmi, Horn, Koemmerling, Technoform, Teka, Viprotron, Glasstech, Teco, Honeywell, etc. Some of them are Global 500
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companies, such as Schneider, Tüv, Honeywell, AGC, Carl Zeiss, Air Liquide, Sandvik, Heraeus, Air Products, etc.
China Glass 2020 Highlights Energy saving
The strong development of urbanization in China has pushed up people’s demand for energy saving and living comfort, and put forward higher technical requirements for new glass products. With the development of green building, energy-efficient insulating glass, coated glass, electrochromic glass and tempered vacuum glass are penetrating into tier 2 and tier 3 cities, which will greatly expand the deep processing glass market. More domestic and foreign manufacturers at China Glass 2020 will focus on environmental performance, design novelty, processing precision and high quality of glass products, as well as introduce more new products.
Ultra-thin
As one of the raw materials for panels used in photovoltaic power generation and electronic products such as smart phones, televisions and computers, ultra-white and ultra-thin glass have a huge demand in China, and show an increasing trend year by year. Domestic enterprises represented by China Building Materials Academy and Triumph Group will launch innovative products in this field.
Product innovation
Innovation and development of glass industry have been focusing on the direction of thinness, high transparency, large size and multi-function. Some leading glass companies including CSG Holding, Shanghai SYP, Kibing, Mountain Glass, Land Glass, Jinjing, Glaston, and Dip-tech will bring more innovative products and equipment, such as: float glass manufacturing technology, pretreatment and large-scale processing equipment, tempering equipment, insulating glass production line, glass digital printing equipment, etc.
Art glass display
The art glass display area at China Glass 2019 attracted a large number of visitors. Exquisite glass crafts added vivid humanistic and artistic ambience to this technical exhibition. China Glass 2020 will continue to set up an exclusive area for art glass, gathering works of famous domestic glass artists. Chic and unique design of glass crafts will reveal the special charm of glass in the changes of light and shadow.
Industry evolution
In the context of uncertain global economic growth, reduction of excessive capacity, and shift in driving forces for development, the glass industry will benefit from industrial restructuring and policy of stimulating domestic demand. Driven by the requirements of environmental protection and high-quality development, the glass industry shows great demand in the areas of improving processing equipment, investing in environmental facilities, and upgrading in the field of deep processing. China Glass is still the preferred development platform for both domestic and foreign glass enterprises. China Glass 2020 will, as always, maintain close cooperation with domestic and foreign industry institutes and professional media, integrate superior service resources, actively use the Internet and social network to carry out in-depth online and offline promotion, and invite more high-quality professional buyers for exhibitors. Please visit China Glass official website www.chinaglass-expo.com for more exhibition details.
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Pioneer sees flat glass sales slump Philippines Pioneer Float Glass Manufacturing, Inc., formerly Asahi Flat Glass Philippines, is experiencing steep declines in sales of as much as 50 percent on unabated influx of imported cheap, undervalued and substandard glass products. Paul Go, president of the lone integrated glass manufacturing in the Philippines told reporters that its sales continued to drop by 4050 percent year to date. Go noted that illegally shipped glass products have worsened following the issuance of two injunctions from Makati and Pasay regional trial courts on Department Administrative Order 1905 of the Department of Trade and Industry (DTI), which imposes mandatory
inspection and strict monitoring of all glass products. With the indefinite court injunctions, the DTI submitted an opposition to the courts but which was denied. These debacles have tied the hands of the DTI to stop the entry of substandard glass and even monitor the sale of this construction material. The only protection left for the local glass manufacturer is the provisional safeguard measure that DTI imposed in May this year to stem the surge of imported glass as it has caused serious damage to the domestic glass manufacturing industry. The DTI slapped a provisional safeguard duty of ₱2,500 per ton on
imported clear glass and ₱2,800 per ton on tinted imported glass. But Go explained that the provisional safeguard measure is for a limited time only of 200 days only. Even if the Tariff Commission will concur with the DTI decision and decides to implement a permanent safeguard duty, it still has a time limit. But what really hurts the industry more is the absence of regulations on standards as the DAO 1905 had been struck with court injunctions. Without the standards regulation, Go said imported glass have been flowing in and undervalued by as much as 30 percent. The objective of DAO 1905 is to level the playing field by requiring
all glass players to comply with the technical safety and quality standards because glass can be life-threatening if it does not meet the correct standards. In addition, Go stressed the need to level the playing field because Pioneer is also exporting to other countries, which also imposed their own standards. “We comply with their standards and yet imported substandard glass can easily enter the country,” he said noting that the oversupply in glass production China enters the local market without any regard of the domestic standards. Pioneer exports 30 percent out of its 550 metric tons daily production mostly to Asean countries.
Global View Cube unboxes an expanded future UNITED KINGDOM Glass and aluminium specialist Cube Glass is set to near double the size of its footprint with the acquisition of its existing Cumbernauld premises and a planning application for a substantial extension. Cube Glass, which will purchase its 4,200 sq ft factory unit at Tannoch Place from landlord Ashtenne, has submitted plans to build a 3,800 sq ft factory extension. The acquisition also includes enough land to build another 1,700
sq ft unit for further expansion if and when required. Gary Thorn, Cube Glass founder and managing director, said the expansion will enable the firm to cope with bigger jobs. He said: “A positive response from North Lanarkshire Council to our planning application will result in our building a much-needed extension which will permit us to get closer to fulfilling our company’s potential. “The additional space should
deliver a 20% rise in turnover since we will be able to bid for larger aluminium curtain walling jobs with higher contract values. We will also be buying a couple of large CNC machines to carry-out this anticipated additional work. “In addition, with this increased capacity we will be able to meet customer demand for these bigger jobs which, in turn, secures the jobs of our existing workforce. A further spinoff will be the creation of up to four new jobs, including a
couple of apprentices. We hope, again subject to planning consent, to be in a position to move into the new extension by the end of 2020.” Cube Glass has already established a presence in sectors such as education health, industrial, social care, commercial property and residential homes. Recent six-figure contracts have placed the manufacturer and installer on track for another record year of sales and profits.
Brexit: an opportunity for Pfaudler? UNITED KINGDOM Brexit has brought an unexpected bonus to the owners of the Fife arm of Pfaudler. The firm supplies a range of products and services to the chemical and pharmaceutical industries. The Leven facility, which has a staff of 86, provides a range of services including glass lined vessels and the refurbishment of glass lined vessels for the UK market. Turnover at the firm fell by 1% from £16.5 million in 2018, to £16.4m for the year ending August 31 2019.
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However, pre-tax profits fell by 44% from £845,221, to £476,564. The firm employs 133 staff across its UK facilities in Leven and Bolton. In the annual report, financial controller Kathryn McCann attributed the revenues fall in turnover to Brexit uncertainty. She said: “Several customers have been holding off making capital investment decisions. “They have instead been spending on securing their supplies of materials in case of a no deal scenario.” However, Ms McCann added
that because of the extended duration of Brexit, customers are now having to make investment decisions, with several large orders already secured or set be secured in 2020. A Brexit upside for the firm is that customers are insisting on UK manufacture of new vessels because of concern about changes to tariff rules and quality stamps. With a projected increase in volume for the UK market, the firm is looking to increase staff numbers and has already taken on more staff and apprentices. The accounts signal a positive
reversal of fortunes for the firm, which went through a round of redundancies in 2016 amid concerns that large sections of its work could be transferred to Germany. The firm’s focus is on growing higher margin markets including reglassing. The UK proved to be the firm’s biggest market, accounting for £10.1m of turnover, while Asia brought £1m. Europe, the Middle East and Africa attracted £3.4m of turnover and north and south America delivered £1.7m.
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AGC and Citrine to combine on AI glass EUROPE AGC Glass Europe, a European leader in flat glass, and Citrine Informatics are collaborating to use artificial intelligence (AI) to accelerate the development of next-generation glass. Citrine Informatics is a technology platform that harnesses the power of AI to bring new materials to market faster, and capture materials-enabled product value. There is currently high global demand for optimizing optical and mechanical properties for strong scratch and abrasionresistant glass in the automotive and communication industries. The purpose of the collaboration is to look for innovative solutions to meet this ever-higher glass performance demand faster than
ever before. AGC is providing experimental data to build proprietary AI models using the Citrine platform and is iteratively testing the newly suggested materials. The models are improved by Citrine through this sequential learning process, which targets the identification of the best process conditions to reach high-performance glass materials. "The future of materials development depends on speed. Developing these high performance materials faster will require managing and using data more effectively, which includes consolidating data into a single consistent searchable format, as well as structuring, storing, and
using materials data to harness the power of AI," said Marc Van Den Neste, CTO of the Building & Industrial Glass Company from AGC. "Artificial Intelligence is expected to dramatically change how the scientists design experiments or value data, leading to breakthrough results." "AI-driven materials development is the future of the materials industry and we are honored to be working with AGC," said Greg Mulholland, CEO of Citrine Informatics. "The companies who are first to invest in this technology such as AGC, will reap tremendous market rewards." Based in Louvain-la-Neuve (Belgium), AGC Glass Europe
produces, processes and markets flat glass for the construction industry (external glazing and interior decoration), car manufacture and solar power applications. It is the European branch of AGC, the world’s leading producer of flat glass. It has over 100 sites throughout Europe, from Spain to Russia, and employs around 16,500 employees. Citrine Informatics technology accelerates the materials development cycle by combining materials data domain-specific AI. The Citrine Platform is designed to be the operating system of the materials and chemicals industry. Citrine is headquartered in Redwood City, CA.
New owners at Allied to drive a new era UNITED KINGDOM A Yorkshire manufacturing firm which can trace its roots back to the heyday of the industrial revolution has received backing from a global private investment advisory firm. An affiliate of Sun European Partners has completed the acquisition of Allied Glass for an undisclosed sum. Headquartered in Leeds, Allied is one of the largest UKbased manufacturers of glass packaging containers for the premium spirits and food and drinks markets. In a statement Sun European Partners said: “With two manufacturing facilities and a dedicated decoration centre in Yorkshire, Allied is focussed on the short and medium production run segment of the market which values flexibility, a collaborative approach to innovation and extremely high technical standards. “The company continues to benefit from market trends towards premiumisation and sustainability. “Over the last three years, the business has doubled its customer base which includes craft manufacturers and the largest blue-chip organisations
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in the industry and delivered sales growth of 13 per cent pa (per annum).” Chris Carney, Principal at Sun European Partners, said:
Allied to the next level. “Our business is well positioned within a growing market and Sun’s deep manufacturing expertise will be invaluable
“Our business is well positioned within a growing market” “Allied Glass is a market leader in its field with impressive technical capability and a flexible customer-focused approach that sets it apart in serving the highgrowth premium segment of the spirits and drink market. “The impressive management team have been instrumental to the success of the business to date, and we look forward to working together with Alan and his team, whilst further investing in the business to support their continued development.” Alan Henderson, CEO of Allied Glass, added: “We are excited to be working with Sun European Partners as we look to take
as we look to deliver on our potential.” The statement added: “ Sun European Partners has extensive experience in the manufacturing and packaging sector. “In addition to having affiliates that owned Albéa and Coveris, two global leaders in the packaging industry, affiliates of Sun European Partners have completed more than 50 acquisitions in this sector. DLA Piper acted as legal advisers and advice was also supplied by EY, Roland Berge and ERM. Sun European Partners is a private investment advisory firm,
which focuses on identifying companies’ untapped potential. Since 1995, affiliates of Sun European Partners have invested in more than 375 companies worldwide across a range of industries and transaction structures with turnover of around €40 billion. Sun European Partners has offices in London and affiliates with offices in Boca Raton, Los Angeles and New York. Allied Glass can trace its roots back to the latter half of the 1 9th century. Its operations today are an amalgamation of Lax and Shaw, founded by Thomas Lax and John Shaw in Hunslet, Leeds, in 1891, and the Hope Glass Works of Knottingley, originally home to Gregg and Company, which dates back to 1874. Growing numbers of Yorkshire firms are attracting interest from global investors who are looking to strengthen their portfolio.
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People and Places PPG makes board changes United States Glass giant PPG has made the following personnel announcements: • Chancey Hagerty, current vice president, global industrial coatings, will become vice president, global automotive refinish coatings. Reporting to Tim Knavish, PPG executive vice president, he will continue to be a member of the Operating Committee. Hagerty will succeed Gary Danowski, current vice president, global automotive refinish, who has announced his intent to retire, effective March 1. • Kevin Braun, current vice president, industrial coatings, Americas, will become vice president, global industrial coatings. Braun will report to Rebecca Liebert, PPG executive vice president, and join the Operating Committee. • Andrew Carroll, current global technical director, industrial coatings, will become vice president, industrial coatings, Americas. Carroll will report to Braun and will become an officer of PPG. “Gary has been the embodiment of a PPG leader throughout his 38-
year career – a true team player who rose to any challenge,” said Michael H. McGarry, PPG chairman and chief executive officer. “His leadership in five businesses has strengthened the organization and allowed PPG to serve customers in new ways. We thank Gary for his many years of tremendous service, and congratulate Chancey, Kevin and Andrew on their key leadership positions. We are pleased to have a talented group of leaders with broad, proven experience, which provides continuity in driving our global business strategies and delivering shareholder value.” Hagerty began his 24-year PPG career in 1996 at the company’s former chemicals plant in Natrium, West Virginia, and in 1998 assumed a plant-engineering role at the industrial coatings facility in Springdale, Pennsylvania. He moved into sales for industrial coatings in 2001 and since then has held positions of increasing responsibility within both the industrial and automotive original equipment manufacturing (OEM) coatings business units. After a successful assignment in Rolle,
Switzerland, as general manager, industrial coatings, Europe, Middle East and Africa (EMEA), Hagerty returned to the U.S. to his current role in January 2019. Braun began his 29-year PPG career in 1991 at the Springdale, Pennsylvania, facility. He has since held several commercial roles in industrial coatings, fiber glass and architectural coatings in the United States. Braun has also served as general manager, silica products and general manager, architectural coatings, Australia and New Zealand. Carroll began his 29-year PPG career in 1991 at the Allison Park, Pennsylvania, facility in research and development. He also served as director of mergers and acquisitions for the automotive refinish business and director of product management for industrial coatings. Previously, Carroll had several commercial and technical roles within the automotive OEM coatings and refinish business units. Danowski joined PPG in 1982 as a production engineer at PPG’s former Crestline, Ohio, automotive
glass fabrication plant, now part of Vitro Automotive Glass. He relocated to Detroit in 1988 as an automotive glass sales engineer and in 1991 was appointed superintendent of engineering at PPG’s former automotive glass plant in Evansville, Indiana. In 1994, he moved to Paris as director, market development, for PPG’s European glass business. He then returned to the U.S. in 1997 as plant manager of PPG’s former Meadville, Pennsylvania, glass manufacturing facility. He was appointed director, new products and services, flat glass, in 2001; director, production, automotive OEM glass, in 2003; and director, global operations, aerospace, in 2007. He was named vice president, performance glazings, in 2009. In 2011, he relocated to PPG’s European headquarters in Rolle, Switzerland, for his role as vice president, automotive refinish, EMEA. In 2017, Danowski became vice president, global automotive OEM coatings, and in July 2018, he assumed his current role as vice president, global automotive refinish.
FGIA elects new technical manager Canada The Fenestration and Glazing Industry Alliance (FGIA) is pleased to announce the hiring of Nathalie Thibault, who will serve the organization as Technical Manager, Glass Products and Canadian Industry Affairs. Throughout 2020, Thibault will shadow FGIA Glass Products and Canadian Industry Affairs Director Marg Webb to prepare to take on her duties upon Webb's retirement in early 2021.
"Nathalie comes to us with over 15 years' experience in the insulating glass arena," said Janice Yglesias, FGIA Executive Director. "With sales, project management and technical roles throughout her career, she is well-positioned to represent FGIA in various Canadian standards and regulatory arenas, as well as to guide the work of our Glass Products Council members. Her work ethic and experience plus her Canadian residency and
fluency in French all came together to produce the ideal candidate for this role." "The glass initiatives of FGIA are critical to the new organization, so it's exceptionally beneficial to have Nathalie on board so early in 2020, allowing us about a full year of operating together on all glass and Canadian activities," said Webb. "We have the opportunity to travel together throughout this year to all relevant industry events, creating
direct access to first-hand learning experiences. With the volume of knowledge and the vast array of contacts to be retained within this role, a comprehensive and coordinated plan executed over an ample timeframe is sure to create a seamless transition." Thibault lives in Rivière-du-Loup, Québec and will work from her home office. She will be attending the upcoming FGIA Annual Conference, Feb. 10-13.
protect and enhance glass packaging in North America." Mr Paulet said: “It is an honour to be chosen as Chairman of the GPI and I look forward to working with our members to efficiently align our resources and add value
to our mutual businesses. “These efforts will include implementation of GPI’s energetic new programmes to promote the growth of glass packaging in North America, and increase the use of recycled glass."
New Chairman for the GPI United States The Glass Packaging Institute (GPI) has selected Bertrand Paulet, President and CEO of Ardagh Group, Glass – North America, as its Chairman. Scott DeFife, President of the Glass Packaging Institute, said:
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"Mr. Paulet brings to GPI vast experience in the packaging and container industries, and his leadership will be extremely valuable to our members as we create and implement legislation and marketing strategies that
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APB plans construction and awaits permits United States // Borates American Pacific Borates Ltd has enjoyed a productive December quarter and is ready to begin construction at its Fort Cady Borate Project in California once final permits have been approved. The company is targeting increased sulphate of potash (SOP) production, which under the current plan will produce 108,000 tonnes per annum. This increase in SOP production is expected to increase project internal rate of return (IRR) and net present value (NPV) as well as targeting US$345 million annual earnings before interest, tax, depreciation and amortisation (EBITDA) once in full production. An enhanced DFS is expected to be released before April 30, 2020.
During the December quarter the company began initial site works to prepare for the construction of the borate mine, which included improvement to roads, site clearing/clean-up and infrastructure improvements for construction activities. A network gas contract has been signed and initial payment made to ensure network gas is available for first production at the site. The company expects a final, positive permit to be awarded for the project over the coming months. The ABR board believes there is an opportunity to increase production to take advantage of the fact that USA is a net importer of SOP and the only incumbent producer is a high-cost producer. The company will also have
a very low cost of production relative to USA production and imported SOP. Other potential advantages are: • The mine is on the West Coast, which is a major consuming area for SOP; • Growth rates for SOP consumption are stronger than USA GDP given the link to highvalue crops; and • The mine will have the required electricity and gas to power the additional Mannheim furnaces, as the mine has access to grid electricity and network gas The mine will also have access to a convenient logistics solution for increased production, with the process plant within four kilometres of a national rail network and a major interstate highway On December 11, 2019,
the company announced it had completed a placement of 11 million ordinary shares at 25 cents to raise A$2.75 million to three global institutional investors. The placement included a five for six attaching option at 30 cents and funds will be used to progress construction related activities. Discussions are ongoing with major Chinese state-owned enterprises (SOEs) with respect to boric acid and SOP offtake agreements. The company has advised that it is not prepared to sign offtake agreements in the absence of prepayments to support construction or project level investment. Chinese SOEs are expected to visit the site in March 2020.
China market share to continue falling? World // Soda Ash China’s share of the global soda ash market is set to continue declining amid new capacities in Turkey and inflow of US supplies to Asia. In 2019, China exported less than 1.3m tonnes of soda ash, down 6.1% from the previous year. The market outlook for 2020 is downbeat in view of ample supply on both the domestic and global fronts. During the week ended 8 January 2020, dense grade soda ash prices fell $5/tonne to $200-210/tonne FOB (free on board) China; while prices of light grade soda ash fell $3/tonne to $200-207/tonne FOB China, ICIS data showed. China’s import prices of dense grade material in northeast and southeast Asia likewise decreased, slipping $5-10/tonne, to $215-220/tonne CFR (cost and freight) NE (northeast) Asia and to $215-230/tonne CFR SE (southeast) Asia, respectively. Spot prices were at their lowest levels since around October 2016, according to ICIS data. Bulk lots from the US supplied under term contracts for delivery
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in the first two quarters of 2020 were available at lower prices. This includes a 20,000- to 30,000-tonne lot of dense grade natural soda ash which is close to being settled at around $200/ tonne CFR SE Asia, according to market sources. Term 2020 supplies from Turkey were being negotiated at around $200-210/tonne CFR SE Asia to as much as $220/tonne CFR NE Asia. The US and Turkey enjoy lowcost manufacturing processes
due to vast reserves of the trona mineral which is mined and refined into soda ash. In China, two major producers – one from Jiangsu and the other from Shandong - foresee a 5% to 14% reduction in their export volumes for 2020. “Last year, we exported 350,000 tonnes of dense and light grade soda ash and this year we [forecast] 300,000 to 350,000 tonnes,” a source from the Jiangsu-based producer said. In South Korea, the 2020
Potential new soda ash capacity Capacity (tonnes/ Company year) Tata Chemicals
Yildirim Holding
Inner Mongolia Berun Group Sisecam Group & Ciner Group JV
900,000 (+ 250,000)
400,000
5m 2.5m
term import volumes are expected to be cut by 20% for dense grade soda ash due to depressed demand from a major downstream glass manufacturer as the country’s economy struggles with weak exports and construction investments. China may see a consolidation of production bases in the long run given the lack of cost advantage of manufacturing soda ash through chemical processes. New soda ash projects are mostly located outside China.
Location
Status/Start-up schedule
Mithapur, Gujarat, India
Received environmental clearance for capacity addition; targeted to come on stream in late 2021.
Togyzkent village, Sarysu district, Zhambyl, Kazakhstan Inner Mongolia, China Green River, Wyoming, USA
Construction scheduled to start in late 2019; no further update available.
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CIECH aims to get back to production Romania // Soda Ash CIECH Soda Romania, the Romanian subsidiary of Polich chemical group CIECH, has decided to take further measures to keep all its workers and managers at the Govora soda plant in Romania, hoping that the facility will soon resume production if steam supply is provided, the company said in a statement. "It is a serious commitment from us and we hope that all discussions on finding a steam source for our factory will materialize with real support. We call on the authorities and we hope that all political statements on collaboration and solutions will be followed by concrete results," said Witold Urbanowski, the general director of CIECH Soda Romania. The only soda ash factory in Romania is in stand-by mode
since September 18, 2019, after the price of industrial
the form of a partnership from the local administration.
“A cogeneration plant has several advantages, including energy efficiency,”
steam requested by stateowned CET Govora in its last offer was over 75% higher than under the previous contract. The offer is far beyond the possibility of the company to cover these costs, CIECH managers commented. In exchange, CIECH proposed to build a new steam production facility - but asked support in
At the end of October, CIECH prepared an offer for the Ramnicu Valcea City Council, energy producer CET Govora and other local partners, to build together a new thermal power plant in Ramnicu Valcea. “A cogeneration plant has several advantages, including energy efficiency, a reduced footprint on the environment
and not least it can accomplish the needs of several industrial players. First of all, it must secure the delivery of steam at an optimal level, which means that it should meet certain conditions. At this moment we are considering different options. Of course, in the variant of a partnership with the authorities and the other economic agents, the problem of replacing the old, underperforming CET Govora could be solved, but this does not depend on us anymore,” Urbanowski said at that time.
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AG 20-1 asianglass
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News Anaylsis
News
24
Glass: a soft target for the climate lobby?
G
lass is irreplaceable in buildings, making it a key part of the solution to unlock energy savings and help reach Europe’s decarbonisation targets. But it’s also an energy-intensive industry, for which no immediate clean energy alternative is available. As a high-level group of CEOs, academics and politicians gathered in Brussels early this year, to discuss the future of the glass industry, they were well aware that glass was all around them. It was in the windows looking outside, on the table holding their beverages, even on their smartphone screens. “Glass is everywhere,” noted Philippe Bastien, a regional president at AGC Glass Europe. “You cannot do anything without being in contact with glass. You wake up in the morning, you go to the window. You have glass in your shower, you have glass in your oven, and in the car or train you take to work.” The reason glass is everywhere is because as a transparent material, it serves a unique function for which mankind has found no substitute. And this could make the sector a low-hanging fruit in lowering Europe’s emissions. The dinner debate was an opportunity for industry association Glass Europe to present its vision for 2050, a manifesto for how flat glass can contribute to Ursula von der Leyen’s European Green Deal and 2050 decarbonisation target. The industry sees an immediate opportunity, not in the production phase – at least not for now – but rather in the use phase. Glass is an endlessly recyclable material, and right now most of that material lies locked in inefficient uses in buildings. 80% of glass goes to the buildings sector, and 85% of the glass in that sector is still inefficient, using either single glazing or inefficient double glazing. These types of windows allow heating, one of the biggest contributors to emissions in Europe, to pour out of a building. The buildings sector alone is responsible for 36% of total EU emissions. “For the glass industry, the net balance of
asianglass AG 20-1
the emissions remains highly positive,” said Bastien. The CO2 emitted to produce an energy efficient double-glazed window is offset within six to 20 months by its energy savings, according to industry calculations. “I’m not looking for an excuse – it’s very important that we work on the production emissions side, and for sure we have to do that. But we still have room to do more good thanks to the use of our product.” The industry is calling on the EU to enforce energy efficiency legislation that would require these windows to be replaced. Maria Da Graça Carvalho, a centre-right Portuguese MEP who attended the dinner, was receptive to this idea. “There are certain sectors of the economy that are easier to decarbonise than others, so we should start with the sectors that are easier,” she said. “Of course the ones that are more difficult we need to start to find solutions. But for some sectors we can start immediately, like building and construction.” The problem is that the EU has already legislated in this area, extensively. There has been an energy efficiency target in place since 2012, and there has been legislation requiring improved energy performance in buildings since 2010, revised in 2018. The EU will not meet its target of a 20% improvement in energy efficiency by 2020 because national governments have not correctly implemented the legislation. “We have a lot of legislation already to get these goals, but also we have member states that are not doing their duty,” said Nicolás González Casares, a centre-left Spanish MEP who was also at the dinner. “So the Commission has to push them. They have the instruments to tell these countries, you must do it. The Commission can’t only make new rules, they have to force the countries to implement the rules already there.” Of course, it is in the glass industry’s economic interest that these renovations be forced by the EU. It would mean the availability of more glass stock from the recycled windows, and more demand for their products. But the industry says without this
increase in demand, they cannot make the investment needed to reduce emissions from their production processes. Despite building renovation and energy efficiency having been made EU policy priorities, glass demand is still below what it would take to make the needed investments. “The technical challenge [in decarbonising production] for us is huge,” said Christian Quenett, head of architectural glass at NSG Group and chairman of Glass for Europe. “There is no solution on the horizon so far. Every company is doing some research work but we are all too small to find the solution.” The glass production industry in Europe is small, and proportionately so is its emissions. There are 46 glass industrial installations subject to the EU’s emissions trading scheme in 12 countries, producing 10 million tonnes of glass each year. They primarily meet EU market demand. 85% of windows installed in the EU are made with European glass. Those plants are powered chiefly by gas. 75% of the CO2 emissions from flat glass manufacturing derive from the use of natural gas to heat the melting furnace, while the remainder comes from the release of CO2 from raw materials carbonates. The use of recycled glass, called “cullet”, can help tackle the raw material emissions. It also requires less energy to melt. Today it accounts for about a quarter of what goes into European flat glass furnaces. Advances in chemistry could also help reduce these material emissions. But the gas fuel is proving harder to replace. Full-electric melting technology for flat glass not yet available. Hydrogen might be an interesting option, but it currently does not offer the necessary radiation for glass melting and high share of hydrogen causes technical problems to furnaces. It also would require new infrastructure to deliver. “It’s really difficult to find the best compromise between hydrogen or electric energy, or a combination of that,” said Quenett. “That is something where I would hope support from the EU would help us in the next decade to revolutionise the process.”
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Turning a
ANALYSIS: Turkey
Turkish delight at improving markets
Yogender Malik looks at how Asia’s bridge to Europe and the wider Mahgreb region, Turkey, is positioning itself for changing economic conditions moving forward and looking to capitalise on an improving domestic scene…
H
uge investments and steady expansions by existing producers, two new entrants ( one each in float and container glass segments) has made Turkey one of the most dominant glass producers in both- flat and container glass segments in the European and Asian region. All of the glass producers in the three major sub-segments enjoys significant scale of operations, which enable these producers to achieve economies of scale and lower production costs. Most of the producers are also highly backwardly integrated, which further help them in optimising the total cost of production. Economic slowdown has had an adverse impact on glass consumption in Turkey in last one and a half years. After extending the high economic growth of 2017 into the first quarter of 2018, Turkey was confronted with problems such as rising inflation and shrinking domestic demand. This situation was caused by volatility in foreign exchange rates and geopolitical tensions, especially starting from the second half of the year 2018. To address these challenges, the government announced the New Economy Program (NEP). The NEP was designed to promote savings and export-driven growth in order to stimulate the economy. Subsequently, the Turkish Central Bank (CBRT) implemented contractionary monetary measures to support the NEP targets. Economic slowdown in the country has adversely impacted the construction, automotive and consumer demand to a large extent in last two years, which has an adverse impact on flat and container glass demand in the domestic market. But, Turkey’s strategic location provides the country’s glass producer to reach to a number of export markets without incurring too much on the transportation. Sisecam, the glass giant from the country dominates the glass production in all the three major segments of the industry. Sisecam’s domination in Turkish and regional glass market can be understood from the sales and production figures. In 2018, the company registered sales revenues of USD 3.2 billion. The company produced 4.9 million tons of glass, 2.4 million tons of soda ash and 4.1 million tons of industrial raw materials. The company invested a total of USD 650 million in new plants and capacity up gradation of existing plants.
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Glass trade
According to the information from Turkey Statistical Institute (TSI), Turkey exported nearly USD 535 million worth of glass products in the first six months of the year 2019. Exports during the first six months increased by USD 40 million as compared to the export figures for the first six months of 2018. Turkish glass producers exported float glass, container glass and tableware glass to 164 countries across the globe. Italy was the top destination for glass exports from the country. With total exports of USD 45.492 million, Italy accounted for 8 percent of total glass exports from Turkey. Germany with exports worth of USD 43.649 million was second largest export destination. Israel with USD 26.827 million, Spain with USD 26.196 million and USA with USD 25.363 million were the tird, fourth and fifth largest destination of glass exports from the country. During the same period, Turkey’s imported a total of USD 328.407 million worth of glass products. Imports of glass products, which was USD 453. 873 thousand during the first six months of 2018 , decreased by USD 125.465 thousand dollars. China was the largest source of imports of glass products with imports worth USD 65 million. Germany with USD 38 million, Italy and France with USD 25 million and Bulgaria with USD 20 million were the second, third, fourth and fifth largest import destination for glass imports in the country. Another interesting development that is taking place in the wider Central Asian region as investments continue to pour into companies in those countries. As these factories become more and more sophisticated, there is a danger that what were previously extremely lucrative export markets may become less accessible. Take, for example, Azerbaijan where Azerbaijani Ask Glass (a subsidiary of the Azerbaijan Industrial Corporation) has begun exporting glass containers to Georgia, and in 2020 will significantly increase deliveries. Ask Steklo signed a contract with Coca-Cola Bottlers Georgia to supply 2.6 million glass containers to Georgia to dispense Coca-Cola and Fanta drinks in them by the end of 2019. In 2020 export volumes will increase the initial forecast provides for the supply of 10-20 million units of glass containers, according to the Azerbaijan Industrial Corporation.
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a corner?
ANALYSIS: Turkey
EXPORTS REACHED NEARLY US$535M. OF GLASS PRODUCTS IN THE FIRST HALF OF 2019 Ask Glass has been asked to carry out a set of measures to improve the quality of its products. Ask Glass was established in February 2018 and is located in Baku. The company is located on an area of 22 hectares and is equipped with the most modern Italian equipment, along with the use of local raw materials, Ask Glass also purchases glass in Russia, Ukraine and Turkey while the production capacity of the plant is 80-85 million units of glass containers. As this capacity grows, and reliability and quality improve, will there be a decrease in demand from Turkey?
Raw material availability
Availability of most of the raw materials for glass production in Turkey has provided Turkish glass producers with a huge competitive strength in glass production. The fact that Turkey has emerged as one of the largest soda ash producing country has helped Turkish glass producers to source the demand of this critical raw material at very competitive prices. Country’s Ciner Group expanded production at its site in Beypazari, Turkey by 500,000 metric tons in March 2017. This was followed by the start-up of a new soda ash production facility at Kazan, with an annual soda ash capacity of 2.5 million metric tons. Both plants are low-cost Trona based facilities. The favourable production costs at both plants meant they can supply domestic glass producers competitively.
Container glass
Catered by three large and one mid-sized container glass producing companiesSisecam, Park Cam and Gurallar Group and new entrant Basturk Cam, Turkish container glass industry has enjoyed very steady growth rates in recent years. However, significant capacity additions by existing producers and a new entrant in last few years has created a situation of overcapacity in domestic market. Significant demand from Turkish food and beverage sector is the largest contributor for the country’s container glass industry. There were 47,617 food processing and 595 beverage producing enterprises in Turkey as of 2018, according to the latest statistics published by TurkStat. Turkey has a modern and developed
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food processing industry supplying the domestic population and exporting, which represents 16 percent of all manufacturing activities. As of the end of 2018, there were 611 foreign direct investments in food and beverage production: 101 of these were German, 44 Dutch, 33 French, 31 from the United States, 30 from Italy, 26 from Russia, 26 from Iran and 25 Swiss. For container glass segment, 2019 has been a tough year due to softer demand for glass packaging products in the domestic market as a result of contraction in non-alcoholic beverage consumption due to inflationary pressures seen on product prices. Most of the container glass consuming sub-segments kept their inventory levels relatively low considering their lower sales, which had an adverse impact on container glass consumption in the country.
Sisecam- Container division
Sisecam’s glass packaging division is the largest container glass producer with an installed capacity of 1.2 million tons per annum. The company conducts its production activities in Turkey at three facilities located in Mersin, Bursa, and Eskisehir. In 2019, the company has increased the installed capacity at Yenisehir and Mersin plants. In April 2019, the company added 20,000 tons per annum capacity at Yenisehir plant. Later in June 2019, the company increased the installed capacity at Mersin plant by 30,000 tons per annum. Following the commissioning of its fourth furnace at Mersin plant in June 2019, Sisecam’s container glass division increased the installed capacity of container glass production in Turkey to 1.335 million tons per annum with a total of 12 furnaces. The new furnace in Mersin has an installed capacity of 80,000 tons per annum. Sisecam invested USD 18 million to set up this furnace. In 2018, Sisecam’s container glass division had installed a new furnace at Eskisehir plant. The company made an investment of USD 66 million for this furnace, which has added 150,000 tons per annum of container glass capacity. This furnace become operational in July 2018. The company also undertook cold repair of one of its furnaces at Yenisehir plant, which added an additional capacity of 30,000 tons per annum in May 2018.
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Table 1
ANALYSIS: Turkey
In addition to Turkey, Sisecam’s container glass operations are spread to three other countries- Russia, Ukraine, and Georgia. The company has an overall installed capacity of 2.645 million tons of glass containers in these four countries. According to Prof. Ahmet Kırman, Deputy Chairman and CEO of Sisecam Group, “ We are the third largest manufacturer of glassware and the fifth largest manufacturer of glass packaging and flat glass today. In addition to ranking among the top 10 soda producers of the world, we are also the world leader in chromium chemicals. Continuing its production activities in 13 countries, our Group strengthens its capacity and technological power with its innovation, creativity, expertise and qualified human force, and looks toward the future with trust thanks to its product and service quality meeting the changing market needs”.
Plastics Paper Cupboard Glass Carton Wood Metal Paper
40% 25% 15% 8% 6% 5% 1%
Packaging materials in Turkey by market share (%) Paper Cupboard
Glass
Carton
Wood
Metal
Paper
Park Cam Glass
With an installed capacity of 1000 tonnes per day, Park Cam is the second largest container glass producer in Turkey. A subsidiary of Ciner Group, which is one of the largest business conglomerates in the country, Park Cam opened its first production line in Bozuyuk with an installed capacity of 500 tonnes per day in 2013. The company commenced production with the second furnace with an installed capacity of 500 tonnes per day in 2015. Both the plants are biggest rear-fired container glass plants with a daily capacity of 500 tons, and is among the most modern plants in the world in terms of technology. Currently, the company produces 6.5 million glass bottles in flint and green colours. Park Cam has plans to set up two more glass furnaces with a total capacity of 1000 tonnes per day ( 500 TPD each) in coming years. Initially, the company planned to start the construction of third furnace in 2017, but it has been delayed. Upon completion of these two furnaces, the company will become one of the largest container glass producers in the country and region. Park Glass’s parent company, Ciner Group is one of the largest groups of Turkey that carries out activity in mining, energy, glass, chemicals, media, maritime, tourism and other business sectors. Ciner Group is also one of the largest soda ash producer in the country.
Gurallar Cam Ambalaj
More popular because of company’s tableware glass products, Gurallar Group ventured into container glass production in 2014. The new venture, Gurallar Cam Ambalaj commenced commercial production of container glass in February 2015. With an installed capacity of 300 tonnes per day, the company focuses on producing food jars and soft drinks bottles. In November 2019, the company received the Red Dot 2019 Award in Berlin, Germany, one of the most prestigious awards in the design world, for its “Mai Dubai” bottle. Red Dot is a design concept competition that awards outstanding international product designs in a wide range from fashion and jewelry design to electronic devices, kitchenware and furniture. The competition, organized each year to identify and evaluate new designs, have great importance in the manufacturing industry.
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Basturk Cam
Part of the Basturkler Sirketler Group of Companies, Basturk Cam, a relatively newcomer to the container glass industry, is located at the heart of the Malatya agricultural region of Eastern Anatolia. The first phase of the company’s 300 tonnes/day glass melting furnace was commissioned in the mid-2018. According to the company, in its first year of operation, it has produced more than 300 million pieces of glass bottles and nearly 250 million pieces of glass jars. Nearly half of the output went to domestic market, while the other half of the output was exported to1 food and beverage companies in Europe and other neighbouring countries.
Flat Glass
Turkish flat glass industry is dominated by two producers. Sisecam’s flat glass division and Duzce Cam, which entered into flat glass production in the last decade. As mentioned elsewhere in the article, Turkish flat glass industry had to bear the consequences of slowdown of country’s construction and automotive industries. Construction sector in particular has resulted in decline of flat glass demand in the country during last eighteen months. The collapse in Turkey’s currency and surging interest rates have plunged the country’s construction industry into recession during this period. The construction sector was the driving force of the country’s booming economy, which had a track record of more than 5 percent growth. Barometer of country’s construction sector, Istanbul’s Fikirtepe district is the center of a massive urban redevelopment project, but construction activities have almost come to a standstill in last eighteen months.
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ANALYSIS: Turkey
Table 1 2015 2016 2017 2018
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14,044,189
15,525,480
Total float glass exports (sq metres)
Sisecam- Flat glass division
Flat glass division of Sisecam Group is the dominant float glass producer and supplier in domestic market. With seven float glass lines and an automotive glass production line in Turkey, Sisecam has an installed capacity of 1.795 million tons in Turkey. In addition to Turkey, Sisecam also operate float glass operations in nine other countries with an overall installed capacity of 3.2 million tons per annum. The company has participated in a number of prestigious projects in the country. Recently, Sisecam supplied value added glass for Istanbul’s new airport. Sisecam supplied a total of 200,000 square meters of glass (or over 16,000 tons of glass). 44% of the facade of the airport facades is made of glass supplied by Sisecam. High value added glass covers the vertical facades of the central passenger terminal, the terminal blocks, the domes providing light in the building, the sleeves for taking passengers from and to the aircraft, etc. Flat glass accounted for 38 % of the company’s revenue during the first six months of 2019. Container glass business contributed 22 %, chemicals and tableware glass accounted for 21 % and 17 % respectively, while 2 % of the revenues came from other streams. Sales from domestic operations (including domestic market and exports) accounted for 58 % of the company’s revenues, while European operations contributed 24 % of revenues. Russia, Ukraine and Georgia contributed for a further 15 % of the total revenues, while rest 3 % was contributed by operations in other geographies. Many of the company’s investments since 2012 are brown-field projects in markets where Sisecam has prior operational experience, many of the company’s operations are located in emerging markets where geopolitical risks are compounded by low predictability of regulations and policies. For example, the company’s container glass business is particularly exposed to Post-Soviet states with five plants in Russia, one in Ukraine and one in Georgia. Sisecam spent a total of TRY5.1 billion between the years 2013 and 2016 to increase its capacity and diversify its geographical footprint. This included investments in Turkey, Russia, Bulgaria, Romania, Georgia and Italy as well as acquisitions in India, Germany, Slovakia and Hungary. Sisecam made its first expansion into flat glass production outside of Turkey in 2006, opening a flat glass manufacturing facility in Bulgaria, which was followed by the commissioning of a mirror plant and processed glass plant in late 2006 and an automotive glass plant in July 2010. I In 2013, Trakya Cam further expanded in Bulgaria by opening a laminated and coated glass facility. Also in 2013, Trakya Cam continued its expansion in Europe by acquiring Richard Fritz Holding GmbH (“Richard Fritz”), a German company that is one of the leading suppliers of encapsulated automotive glass and currently operates production facilities in Germany, Hungary and Slovakia. In 2015, Trakya Cam invested in new automotive glass factories in Russia and Romania. Trakya Cam acquired all of the assets of Italy-based flat glass producer Sangalli Vetro Porto Nogaro S.p.A. (“Sangalli Vetro Porto”) and Sangalli Vetro Manfredonia S.p.A. (“Sangalli Vetro Manfredonia”) in 2016 and 2018, respectively, and, as a result, became (when including its capacity in Turkey) the largest flat glass producer in Europe in terms of production capacity according to management estimates. The Sangalli Vetro Manfredonia (now known as “Sisecam Flat Glass South Italy”) flat glass production facility, which is located in southern Italy, which recently completed cold repair work, has a production capacity of 190 thousand tonnes per year, a laminating line with four million square metres per year capacity, a coating line with four million square metres per year capacity and a satin coating line with 1.5 million square metres per year capacity. In 2013, Sisecam entered into a 50 : 50 joint venture with leading Indian glass producer Hindusthan National Glass and Industries Limited for a float glass line company in India named HNG Float Glass Limited. In 2018, Trakya Cam purchased HNGIL’s interest in HNG for US$85.7 million and renamed the company Sisecam Flat Glass India Limited. In late 2019, Sisecam also inaugurated its second flat glass investment facility in Sant’Angelo in Puglia, Italy with Italian Prime Minister Giuseppe Conte in attendance.
12,126,789 13,093,531
Table 1 2015 2016 2017 2018
61,014,540 141,132,260 144,690,229 201,325,769
Total container glass exports (Kg)
1
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ANALYSIS: Turkey
UAE Cyprus Italy Israel Portugal Albania Ireland Russian Federation
The opening ceremony of the Manfredonia facilities took place two months earlier than planned on 30th November and was hosted by Şişecam Group Vice Chairman and General Manager Ahmet Kırman. Along with Mr Conte, Turkey’s Ambassador to Rome Murat Salim Esenli, Puglia Regional President Michele Emiliano and Monte Sant’Angelo Mayor Pierpaolo D’Arienzo also attended the ceremony. Speaking at the opening ceremony of the facility, Mr Conte said that he attended the ceremony to show the special importance his government considers the development in the southern part of the country. Extending thanks to Mr Kırman for the investment, Conte stated: “Şişecam has come with a sustainable project both economically and environmentally and taken an important step by putting this facility into operation.” Mr Esenli emphasised that the presence of Turkish company Şişecam in Italy is an indication of the economic power and the visionary perspective of Turkey. He added: “I would like to consider the attendance by Prime Minister Giuseppe Conte in such an important opening as an indication of the importance he and the government he represents to relations and cooperation with Turkey.” He underlined that Şişecam continues to grow in line with its performance-based investment policy with a view to becoming one of the world’s largest three producers in the main areas of activity. He said: “Including our recent soda investment in the U.S., we are operating in 14 countries on four continents, bringing our innovative products to our customers in more than 150 countries and providing jobs to 22,000 people. Mr Kırman added: “Along with additional investments, we have invested more than 55 million euros in the facility, including purchase price and business capital.”
305,474 624,266 430,297 355,006 386,106 407,352 290,228 317,455
Leading float glass export destinations (sq metres)
Table 1 70,676,238 23,710,175 26,322,399 15,452,521 14,223,923 11,219,178 12,438,125 4,294,782
Italy Israel Iraq USA Lebanon France Romania Azerbaijan
Leading container glass export destinations (Kg)
1
Duzce Cam
Established in 2007, Duzce Cam is the only other float glass producer in Turkey. Located in Duzce 2nd Organized Industrial Zone Duzce Cam, commenced commercial production of float glass in 2012 with a capacity of 600 tonnes per day. In 2016, the company added second float glass line with an installed capacity of 800 tonnes per day, taking the overall installed capacity to 1400 tonnes per day
Glass tableware
Two of the most popular global tableware glass producers in the country has made Turkey a regional powerhouse in tableware glass production. Sisecam Group’s company Pasabahce and Gurallar Group have contributed immensely towards the development of country’s tableware glass industry.
Pasabahce
Tracing its history to 1935, Pasabahce is the oldest glass producer in Turkey. The company is among the most reputed global producers of tableware glass. With 12 glass furnaces, over 80 production lines, the company produces value-added, printed and decorated tableware glass products at its highly automated production plants located in Turkey, Bulgaria, Russia and Egypt. Pasabahce Cam has secured competitive advantage in the domestic and export
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1
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CONTINUALLY DESIGNING, BUILDING AND MODERNISING
www.teco.com TOTAL FURNACE CAPABILITY TOLEDO ENGINEERING / TECOGLAS / ZEDTEC / KTG ENGINEERING / KTG SYSTEMS / EAE TECH
ANALYSIS: Turkey
glassware markets and cemented its leading position with its investments at its Turkey based production plants in Eskisehir, Kırklareli and Denizli. The company exports its glassware products to more than 140 countries, boasts a product line of more than 20,000 items and operates 44 stores across the country. During the first nine months of 2019, Pasabahce achieved a total sales of 2,210 million TRY, registering a growth of more than 25 % over the sales figures of 1,763 million TRY. According to management estimates, the tableware glass group had a 67.2% market share in the Turkish market and 8.0% market share globally. It was ranked third globally and (when including its sales throughout Turkey) second in Europe, in terms of revenue.
Gurallar Group
Gurallar is the sixth largest glassware manufacturer in the world and is most famous for the production of its tableware brand, LAV. The company was set up in 1996 by the Gural family, with the aim of creating tableware products under the brand name ‘Gurallar Artcraft’ (later changed to LAV). Company’s tableware production facilities are located in Kutahya, supplying 2 million items every day. Its two production facilities occupy a total area of 300,000 square meters and employ 2,000 people. In total, 3,500 different products are made and exported to 130 countries, including Brazil, China, Philippines, France, Spain and Iran. The company claims to sell its LAV products in 35,000 shops throughout Turkey and a further 100,000 stores around the world.
Egypt looks at auto market
Egypt has long looked at Turkey as a destination for automotive parts, with glass being one of them. However, at present, this remains a distant dream despite the industry’s best efforts. If it did succeed though, then perhaps there would be a surge in imports into the country. Certainly, the Egyptian market itself is proving harder for Turkish companies to enter as a preference for Chinese goods continues to rise. The Egyptian car market witnessed a clear change in the pricing of Turkish cars, after activating the last stage of the Free Trade agreement with Turkey, under which all products exchanged between the two countries shall be free of customs. So, all imported cars from Turkey became completely exempted from customs which revived the sales movement in the local market. But this was not the case for the local feeder industries, as Turkey does not import any of its car components from Egypt. Hence, the Free Trade deal was no use for the feeder industries, the main driver of the localization of automotive industry. Deputy Chairperson of the Chamber of Engineering Industries at the Federation of Egyptian Industries (FEI), Abdel Moneim El-Qady, said there is no positive effect from the agreement on feeder industries, since Turkish cars do not rely on Egyptian raw materials. Moreover, he believes that Egyptian automotive assembly companies prefer Chinese products over Turkish, due to their higher quality and lower prices. Therefore, the agreement will not benefit this sector as well. The deal reduced the price difference between imported cars and locally assembled ones which are subject to 40% customs. It increases the difficulty of market competition, adding to the burden of local assembly companies which will be forced to lower their prices. El-Qady explained that feeder industries supply their production to local assembly companies, while spare parts come second in terms of priority. As for exporting, it is still difficult without incentives that help that local industry to compete globally, similar to the Tunisian experience. In Tunisia, the government obligated car importers to rely on local spare parts, which boosted the feeder industries significantly. In a related context, Ali Tawfik, head of the Federation of Feeder Industries, said China is the main supplier of cars, auto components, and spare parts, however importing from Turkey has several advantages, the most important of which is its geographical proximity. Therefore, shipping
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Company: Sisecam: Flat Glass division
Manufacturing plants: Kırklareli, Mersin, Bursa and Ankara Markets: Domestic and Export Markets Other: Sisecam’s flat glass division is the largest flat glass producer in Turkey. The company operates a total of seven float glass lines and an automotive glass production line in Turkey. Company’s overall installed capacity is 1.795 million tons in Turkey. In addition to Turkey, Sisecam also operate float glass operations in nine other countries with an overall installed capacity of 3.2 million tons per annum.
Company: Duzce Cam
Location: Duzce Industrial City Markets: Domestic and Export markets Other: A relative newcomer in Turkish flat glass industry, Duzce Cam operate two float glass production plant at Duzce Industrial City with an installed capacity of 1400 tons per day.
Company: Sisecam container glass division
Location: Mersin, Bursa, and Eskisehir. Markets: Domestic and export markets. Other: Sisecam’s glass packaging division is the largest container glass producer in Turkey with an installed capacity of 1.2 million tons per annum. The company conducts its production activities in Turkey at three facilities located in Mersin, Bursa, and Eskisehir. In addition to Turkey, Sisecam’s container glass divison also operate container glass plants in Russia, Ukraine, and Georgia. The company has an overall installed capacity of 2.645 million tons of glass containers in these four countries.
Company: Park Cam
Location: Bozuyuk Markets: Domestic and Export Markets Other: A subsidiary of Ciner Group, which is one of the largest business conglomerates in the country, Park Cam operate two container glass furnaces with an overall installed capacity of 1,000 tons of glass containers per day. The company opened its first production line with an installed capacity of 500 tonnes per day in 2013, followed by a furnace with similar capacity in 2015. Both the plants are biggest rear:fired container glass plants with a daily capacity of 500 tons, and is among the most modern plants in the world in terms of technology.
Company: Gurralar Cam Ambaraj
Location: Kutahya Markets: Domestic and Export Markets Other: Gurallar Cam Ambalaj, a group company of leading tableware glass producer, Gurallar Group commenced commercial production of container glass in February 2015 with an installed capacity of 300 tonnes per day.
Company: Basturk Cam
Location: Eastern Anatolia Markets: Domestic and Export Markets Other: Basturk Cam, a relatively newcomer to the container glass industry, is located at the heart of the Malatya agricultural region of Eastern Anatolia. The first phase of the company’s 300 tonnes/ day glass melting furnace was commissioned in the mid:2018.
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Heye Ranger 2 – Camera Check Detection at its best Check detection is one of the most important quality inspections in container glass production. The HiSHIELD Ranger 2 has been developed to fulfill the customer‘s quality expectations and it is fully available in every country.
FULLY MODULAR AND SCALABLE SYSTEM A Ranger 2 system consists of one camera, collecting five images simultaneously via five lenses and fiber optic image guides, the illumination unit and the control unit with the software for image processing, including the decision “container okay or not okay”. Based on the budget and needs of the glass plant, you can start with one system and add any number of parallel systems whenever you want. A typical and recommended configuration would be four parallel systems, each dedicated to and optimized for one of the following types of checks: horizontal shoulder vertical bottom. Each system runs independently and does not need to be synchronised with the others. So there is no influence or need to compromise between the systems. This allows an individual optimisation of all settings (illumination etc.) for the respective type of check. If one system is not available or not adjusted optimally, the others are still fully operational. INTELLIGENT CLOUD MASKING – SELF LEARNING SYSTEMS Every container produced must be regarded as a unique object and any check detection concept has to respect this. For this reason each Ranger 2 system is using Heye’s Intelligent Cloud Masking (ICM). Bearing in mind that each article is distinctive, the Ranger 2 system is designed to investigate each one independently. Accordingly, it is not necessary to teach the detection system, but each container serves as a time saving reference for itself. Moreover, the inspection zones are dynamic in nature. The Ranger 2 system is therefore able to detect different
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variations of checks, as well as to recognize new variations of them during production. Apart from advanced camera and non-contact solutions, smart data is the key. The Heye PlantPilot collects and aggregates production data in the plant. The borders between Hot End and Cold End will disappear, information is shared on the spot. Tracking and tracing as well as the possibility of creating user-specific analysis are additional components, allowing continuous improvement processes to increase productivity. Self-learning systems are one of the cornerstones of Industry 4.0. The Ranger 2 camera check detection proves to be the best solution in the market. Heye’s clear and innovative product strategy, integrating latest camera solutions, remains unchanged. ABOUT HEYE INTERNATIONAL: Based at Obernkirchen, Germany, Heye International GmbH is one of the international glass container industry’s foremost suppliers of production technology, high performance equipment and production knowhow. Its mechanical engineering has set industry standards for more than five decades. Extensive industry expertise, combined with the positive attitude and enthusiasm of Heye International employees is mirrored by the company motto ‘We are Glass People’. Its three sub-brands HiPERFORM, HiSHIELD and HiTRUST form the Heye Smart Plant portfolio, addressing the glass industry’s hot end, cold end and service requirements respectively. FURTHER INFORMATION: Mr. Peter Witthus, Marketing at Heye International GmbH, Lohplatz 1, 31683 Obernkirchen, Germany. Telephone: +49 (0)5724 26-0. Fax: +49 (0)5724 26-539. Email: marketing@heye-international.com Web: www.heye-international.com
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ANALYSIS: Turkey
Turkish products to Egypt takes only four days, unlike Chinese shipments that take more than 30 days to reach the Egyptian ports. Tawfik noted that if Turkish car makers used Egypt-made auto, this would contribute positively to the recovery of local feeder industries, especially following the Free Trade deal. However, it is difficult to export local auto components to Turkey as they have more advanced feeder industries. Turkey exports approximately 1m cars annually, and production costs there are lower than in Egypt because of the huge production volume. Tawfik proposed signing cooperation contracts between Turkish and Egyptian auto companies to benefit from the deal, as some industries to be assigned to Egyptian companies and others to Turkish ones based on product quality and operating cost. Such steps can create an integrated system between the two countries which will reflect on the quality of the final products and their prices. Egypt cannot compete with Turkey in terms of final products, as the Egyptian industry suffer more difficult challenges than Turkey, such as high interest rates and transportation costs. Tawfik pointed out that the feeder industries companies formed a committee to set unified specifications for auto components and spare parts, such as brakes and glass. Those specifications are ready, but they have not been issued yet. He called lawmakers and market leaders to set clear specifications of imported cars, so that importers could refrain from bringing low-quality products that lack international safety standards, which may cause traffic accidents or increase pollution. There should be laboratories to examine imported auto products to ensure their suitability for local use.
Company: Pasabahce
Location: Eskisehir, Kırklareli and Denizli. Market: Domestic and export markets Other: Oldest glass producer in Turkey, Pasabahce is one of the most renowned names in global glass tableware industry. The company ranks the second in Europe, and the third globally in glass tableware production. Also owning the ‘Pasabahce Stores', leader of specialized retailing in Turkey with its unique structure, Pasabahce is one of the oldest enterprises in Turkey with a history of more than 80 years. With a comprehensive product range that includes more than 20,000 handmade and batch:produced products, Pasabahce addresses a large consumer base and exports its products to 140 countries.
Company: Gurallar Group
Location: Kutahya Market: Domestic and export markets. Other: Founded in 1994 as a part of the Gurallar Group, the company has played an important role in the development of the tableware glass industry, breaking the monopolistic nature of the Turkish glassware industry. In 2014, the company underwent a corporate rebranding to transform itself into a global player, deciding to continue its journey with the LAV brand. Developed with the innovative perspective of the Gurallar Group, whose origins dates back to 1948, LAV has brought to the table glassware industry the capability of its parent company together with the experience of the ArtCraft brand.
Investments: will the hand-brake be applied? One of the world’s biggest financial institutions is to squeeze its lending to Turkey this year following tensions between the EU and Ankara over its controversial oil and gas drilling operations in waters off Cyprus. The European Investment Bank (EIB), the lending arm of the EU, has announced it will restrict loans to Turkey which over the last decade have amounted to around €19 billion ($20.94 billion). Brussels is against any exploration for oil and gas in territory that falls under EU member state Cyprus’ exclusive economic zone. However, Ankara claims Turkish drilling ships are operating within Turkey’s continental shelf. The EIB is one of the biggest sources of finance for Turkish infrastructure projects, but it has now said it will stop lending to public agencies in the country, while adopting a selective approach to the private sector in Turkey. However, the bank added that funding taps would remain closed to companies with links to the Turkish government. The EU has felt obliged to take countermeasures against Turkey after it ignored demands not to send a new drilling ship to the Eastern Mediterranean, and its foreign affairs commissioner, Josep Borrell, recently said Brussels was preparing to impose sanctions. Since last year, the EIB has only made one loan to a private company in Turkey, and that was after two years of negotiation for the construction of a greenfield glass-fiber manufacturing plant. Kader Sevinc, a Brussels-based senior EU expert, said that although EU sanctions may have little impact on Turkey’s economic relations with the bloc and its members, they still sent a strong political message.
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“Turkey’s growing financial and energy dependence on certain non-Western actors is worrisome and may lead to grave dangers in the years to come,” she told Arab News. “Progressive local authorities, the winners of 2019 local elections in all major cities, have been subjected to a strong political and administrative pressure from the government, suffering from unfair treatment in terms of allocation of resources,” added Sevinc. In that regard, the EIB’s lending restrictions are likely to affect important infrastructure projects planned in Turkish cities such as Istanbul, Ankara, Izmir and Antalya, which are now governed by opposition mayors. Work in the popular tourist destinations cannot be carried out using municipal resources alone. According to Sevinc, the EU and the West should develop a constructive agenda and create new mechanisms focused on the promotion of democracy and infrastructure development in support of local authorities. “Despite the current government’s policies, Turkey still has a pluralistic society and the EU has a role to play. Let’s not forget, only a constructive Europe can play this historical role,” she said. Turkey has been holding discussions with Brussels about joining the EU since 2005, but prospects faded after talks were de facto suspended following the failed coup attempt in Turkey in 2016. Amanda Paul, senior policy analyst at the European Policy Centre (EPC), said: “Unless there is a change of policy from the EU, the EIB seems set to maintain this approach. A change in stance from the EU would require a change of approach from Turkey vis-a-vis its drilling activities in the Eastern Mediterranean. There is no sign of that happening for the time being.”
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ANALYSIS: Fenestration
Opening options
windows for today…and tomorrow
Carlos Machado e Moura and Pedro Borges de Araújo of Jofebar / panoramah!® and Centro de Estudos de Arquitectura e Urbanismo, Faculdade de Arquitectura da Universidade do Porto discuss how evolving window technology has created a range of new architectural options…if only some of the ideas could be combined…
W
indows have always been at the intersection of various technologies and architectural processes that evolved in parallel and often intertwined. Last century’s breakthroughs in terms of glass and frame allowed the glass to progressively absorb functions traditionally present in other devices ultimately dissolving the window into transparent walls. Nowadays, smart windows intersect previous technologies with electrically activated materials with dynamic properties augmenting their capacity. In this paper, we speculate on an idea of the window of the future according to state of the art in terms of glass and operable frames. We argue that a possible outcome of the combination of different technologies — magnetic and dynamic levitation, transparent photovoltaic glass, vacuum insulated glass, switchable glass, piezoelectric touch-sensitive surfaces or ultra-thin glass — might ultimately change the architectural approach to windows.
More glass, fewer windows?
Imagining the future of the window is not an easy task. It is not even clear whether windows, as single recognizable operable devices, will still exist. Emerging in western architecture as apertures punctured in enclosing walls to introduce light into buildings, admit air and provide framed views to the outside, they are spatial mediators of the relation between interior and exterior like glass doors, which additionally allow movement. Therefore they work as filters, being historically accompanied by a series of devices that regulate light, ventilation, privacy, and atmospherical conditions. Some provide shading — shutters, louvers, jealousies, blinds, screens and curtains —, others security — bars, grills, storm sashes, handles and bolts —, while others — seats, sills, bow-windows, meshes — express different architectural approaches, varying according to climate conditions, cultural roots and social issues Over time, designers envisioned new architectural possibilities for glass doors and windows, which evolved in parallel and often intertwined with various glass
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and frame technologies and frame. The window as a hole progressively faded away as last century’s improvements allowed the size of glass panes to grow, undifferentiating windows and glass doors, and culminating in the glass curtain wall, which simultaneously expanded the window encompassing the entire façade and dissolved it into fully glazed skins. Furthermore, during the 20th century, closed façades become prominent, especially in corporate buildings, with windows that provide uninterrupted views to the exterior but prevent any physical contact with it, as mechanized ventilation systems absorbed the function of air supply. Industrialization, on the other hand, sacrificed the genealogy of window and its local specificities, institutionalizing global practices and standard requirements of thermal efficiency, fire resistance, airtightness and waterproofness. Tempered glass also played an essential role in this evolution, allowing glazing to perform a structural function, which was until then prohibited. With all these changes, windows lost their autonomy as isolated elements and their role as visual framing agents. Glass as a screen wrapping (parts of) the façade replaced the anthropomorphic metaphor of windows as the “eyes” of the building, challenging the traditional concept of window.
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ANALYSIS: Fenestration
Indeed, while historically, one tends to identify windows as the transparent parts of a given façade, the advent of large glass walls challenged the identification of the window and its profile. One could still identify its essence on the operable parts of transparent enclosures, which offer not only views of the outside but practical possibilities of physical contact with the exterior.
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Smart materials, smart glass: intelligent windows?
More recent breakthroughs in terms of glass technology rendered glass truly dynamic, efficiently congregating the different features and possibilities traditionally present in a multi-layered system of filtering devices into a single architectural element with (almost) no thickness. It is a radical mutation in the approach to the scale of walls and openings. Indeed, glass alone can now efficiently control solar gains and radiation with coatings, incorporate blinds or meshes in its cavity, provide unmatched insulation with triple glazing or vacuum glass, dynamically change its opacity and temperature, and ultimately generate energy and convey digitized information converting windows in electronic displays. This shift is achievable mainly through the potential of programmable materials and artificial intelligence methods which promise to enhance the use of our day-to-day objects and devices, bridging and interconnecting them to form “master” devices with uses and applications never thought before. Despite being an old material, glass assumes a predominant role in this revolution, with increasing architectural applications — in windows and façades and also in many different parts of the building structure and devices — as many novel materials and technologies are developed in combination with it. Therefore, glass functions both as a structural material, with customizable mechanical properties thanks to
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ANALYSIS: Fenestration
the improvements in the material itself, and as a base for energy management and interactive systems through coating and printing technologies that implement features that functionalize it actively and passively. Besides lamination for intrusion prevention, high-selectivity coatings for radiation control, layers for heated glass or digital display, the incorporation of interactive functionalities through sensors, displays and actuation capabilities, render glass and windows a vital element of the concept of the “internet of things”. The materials that allow these features are so-called “smart materials”, which are generally grouped into property-changing, energy-exchanging and matter-exchanging [4]. Many are ready for implementation, while others are still under development or commercial applicability. Triggered by light, temperature, pressure, electric and magnetic fields or the chemical environment, they provide functions that are applied to glass leading to “smart glasses” and “smart windows”, intersecting previous technologies with electrically activated materials offering interactivity or switchable properties. Relevant examples of dynamic solutions for glass and windows include: • control of optical transmittance, introducing variations in light transmittance in the visible spectrum to manage solar radiation and privacy as well as decorative issues thanks to materials with colour and optically changing properties under light, thermal or electrical stimuli passively (photochromic or thermochromic) or actively (electrochromic). • control of thermal transmittance, through the management of wavelengths up to the infrared region of the electromagnetic spectrum; the adequate control of radiation transmission and thermal absorption will enable implementation of energy saving strategies for heating and cooling buildings. • memory and shape (or dimension) changing properties under thermal, electrical or magnetic stimuli that can be applied to windows in the development of controllable joints and sealing components with expansive materials; • adhesion changing materials, allowing active or passive control of hydrophobicity of the surface, enabling the implementation of self-cleaning glass or aluminium profiles or antibacterial agents. • photoluminescent smart materials, fluorescent, phosphorescent and electroluminescent materials, enabling specific various lighting possibilities; • piezoelectric and magnetoelectric materials, allowing the implementation of ceramic or polymer sensors and actuators in glass; • photoluminescent smart materials, including self-luminous glass for windows and skylights; • photoelectric and thermoelectric materials, enabling the application of energy generation, storage and management, notably with solar cells for photovoltaic glass or thermoelectric generators. • heat storage materials, contributing to energy efficiency management. • implementation of “transparent electronics”, with sensors, actuators and display capabilities, enabling the highest levels of interactivity and energy management. • Thus, glass “alone” can actively determine the visual, luminous, thermal and acoustic control of environments. Nevertheless, the vast majority of available solutions with dynamic properties is still far from being truly interesting in an architectural point of view. Available switchable glass or photovoltaic glasses, for example, are yet intermediate solutions, imposing to renounce some features: total opacity for electrochromic glass full transparency for (semi-transparent) photovoltaic glazing. [Figure 5] Indubitably, these and the other referred “smart” solutions are promising developments and will have a specific place in the future. However, we believe that the current state of the art is not satisfactory since in most cases their visual noise renders the payoff not evident, unless from an exclusively economic point of view when the client is not the user. It is also worth to note that many of these active properties are electronically stimulated or require the implementation of readout and
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communication system. Therefore the frame becomes particularly relevant — ensuring a complete integration between electronic components and mechanical parts. The role of the frame in art is well known, and George Teyssot interestingly notices, quoting George Simmel’s 1902 essay The Picture Frame: An Aesthetic Study, that “the frame, by the very materiality of its border, […] helps the work of art to exclude anything exterior while offering a concentration on its interior. The frame guarantees the possibility of an autonomous existence for an artwork.” Similarly, with windows and mainly electrically activated “smart windows”, the frame
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ANALYSIS: Fenestration
not only constitutes the definition of the limit but also ensures the real conditions for its dynamic performance. Another idea that is worth bringing to the discussion is the difference between the concepts of “smart” and “intelligent”. While “smartness” is used to refer to state or property changing materials and devices, in a principle of stimulus and reaction, “intelligence” should consist, according to Webster’s definition, in the “power of meeting a novel situation successfully by adjusting one’s behaviour to the total situation”. In today’s standards, this tends to be perceived as the integration of various systems into a fully automated architecture, with electronically enhanced domotic products and IT-based solutions, with systems capable of receiving and processing large amounts of data as an almost human-like ability to respond to different situations. However, we should also see this capacity to self-adjust to time on a broader view, truly adequate to their time, not only able to respond to a momentary time condition. Intelligent buildings should not only have “intelligent” technological components — which likely will become obsolescent in a short time — but also be designed not to degrade the natural environment, cause sickness to the user and, ideally, to respond to cultural shifts, resource issues, and everchanging human needs. In this more holistic perspective, smart windows do present remarkable opportunities to respond to users’ needs and to reduce a building’s energy consumption by dynamically responding to control solar heat gains and environmental conditions and, eventually, produce energy. This ability to help reduce our dependency on foreign resources and inefficiencies in energy utilization is undoubtedly one of the most promising vectors of development. However, available commercial semi-transparent photovoltaic glass is good enough for canopy and skylight applications, guardrails or integrated cladding, but not yet suitable for windows as transparent photovoltaic power-producing surfaces offer only 4-5% efficiency. To achieve 9% efficiency, glass has to lower its transparency to around 30-39% [7], the threshold of “transparent” glass. It is therefore soon to turn windows into vertical power generators. But Michigan State University New near-infrared (NIR) transparent luminescent solar concentrators (TSLC), tested with high transparency (86% visible transmittance) and minimal tinting (94% color rendering index), obtain >20% yields [8], an amount of energy that, in many countries, would be more than sufficient to render the motorization of the window completely autonomous.
The virtual window: from metaphor to reality
A recurrent view for the “window of the future” is the emerging ability of glazing to convey digitized information, sometimes as a window’s virtual analogue. However, OLED capacitive screens features seem more suited to interior elements — TV or computers, interactive tables, glass partitions, displays — or mobile devices rather than the buildings’ exterior envelope. The applications they promise — electronics enabled, touch sensitive, ultrathin, flexible and with advanced functionalities like 3D-projection or augmented reality [9] — can decisively be more useful in automotive design or handheld display devices than façades. Curiously, in 1435, Leon Battista Alberti’s famous treatise De pictura regarded painting as “an open window [finestra aperta] through which the historia is seen” [10], a metaphor commonly referred as the origin of the comparison of the window and picture that has shaped Modern Western thinking about images and the way of seeing the world [11]. Windows are certainly a compelling metaphor for paintings as much as screens, but the real ability of windowpanes to display digitized information seems the step to push Alberti’s metaphor beyond. Many past predictions of the future explored this idea, besides speculating on cities of glass, invisible glass-made characters [12], electronic eyeglasses and goggles, or night-viewing glass implants [13]. A curious example is Slow Glass
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[14], a glass-like substance with such a large refractive index that light takes significant time, even several years, to pass through it. It thereby functions as a screen to the past, or more accurately as a limited time viewer. In the 1966 novel that features it [15], people would use panes of slow glass placed in picturesque sceneries as “scenedows”, scenic windows to allow urban blocks to look out at landscapes stored in the glass. Prices would vary according to its “thickness”, the number of years of scenic view it contains. Despite how interesting these ideas and metaphors might be, their useful application to buildings remains very limited. In 1958, Walt Disney’s cartoon Magic Highway U.S.A. [16], about the future of highways and automobiles, featured windshields with radars. [Figure 6] Sixty years later, cars increasingly use rear-mounted cameras to replace rear mirrors, and the first night-vision systems provide an enhanced view through infrared cameras to spot people and objects, offering an even more objective reality than the one the driver can see in the road ahead through his eyes. [Figure 7] While in 1936, Cameron Menzies’ film Things to Come featured an imaginary 2054 windowless colony with high-resolution floating window-like flat screens [Figure 8], nowadays digital surfaces mimic reality with such quality that displays are being used to replace openings, as in the windowless aeroplane concept [17]. [Figure 9] However, no matter how intelligent these solutions might be for flying faster, consuming less fuel, and providing more solid and aerodynamic structures [18], no other humanbased reason can reasonably justify that choice [19]. The same applies to buildings where, apart from window shops, one can see little advantage in replacing real windows with their virtual analogue. Nevertheless, integrated solutions, like transparent OLED displays with touchscreen abilities, might certainly constitute valuable devices for a window, not as a computer screen replacement but as enablers offering direct intuitive control over all the windows features.
To open or not to open?
A final, yet fundamental, aspect about “the window of the future” remains the question whether it should open or not. Throughout the 20th century, the complete elimination of operable components was pursued in many buildings, especially in large glazed corporate buildings. The most economical solution proved to be fixed curtain walls, inoperable façades offering no individual choice and control, with the function of air supply completely assumed and regulated by decentralized mechanical ventilation system — cooling the building in summer due to solar gains and heating the building in winter to minimize the effect of thermal losses. This environmentally irresponsible and absurd equation created inefficient buildings absorbing huge amounts of heat which require high levels of cooling to remove, representing a significant part of greenhouse gas emissions and is now being tackled by cities like New York and London that envision a ban on inefficient glass skyscrapers [20]. However, besides this economically oriented, dumb down option, other technical and architectural circumstances conducted windows not to open. Therefore, functions that historically were combined in a single element — bringing natural light, providing visual contact, ventilating and spatially connecting with the outside — have been separated [21]. In those cases, despite the visual connection windows can offer, all other senses remain disconnected from the outside as the glass blocks air, sound and space. Among the reasons behind it, high-efficiency and high-performance also pushed for fixed enclosures, even in intelligent façade solutions. Indeed, many restrictive codes impose buildings to operate as perfectly sealed boxes, being completely airtight — with very efficient glasses, insulated frames and airtight constructions — to comply with rigid insulating requirements and face exterior conditions while natural ventilation is often discarded as an unreliable solution, putting buildings at risk of both under- and over-ventilation under different conditions [22].
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ANALYSIS: Fenestration
But despite the widespread belief that airtight construction means closed façades, Passivhaus — the world’s leading standard in energy efficient design — does not require windows not to open, only that the building fabric has good insulation and is entirely airtight to prevent energy waste and discomfort when the building is in use [23]. Therefore, walls, floors, roofs, window and doorframes and junctions must be free from draughts and cold spots (as well as overheating), but windows and doors can be used when necessary or desirable, while a ventilation system operates providing a constant supply of fresh, clean air into the building and taking stale air out. This ventilation system could even be avoided in some cases, using exclusively natural ventilation — especially in mild climates, during the summer months —, but for comfort in cold weathers and energy efficiency reasons, mechanical ventilation with heat recovery is almost always required to meet the Passivhaus standard [24]. Nevertheless, with or without ventilation systems, windows can — and should — open, not leaving behind the feature of physically connecting inside and outside. Alternative air intakes — hatches in mullions, operable cracks in frames, motorized flaps or intelligent trickle vent with pollen filter, noise damper, air flow, and humidity control — have been improved and might ensure some natural ventilation, eventually allowing the breeze and noise, without altering the appearance of buildings from the outside. But the physical/spatial connection is still abandoned in those cases. Ventilation and the operability of windows can indeed create problems with acoustics, and some European codes will not allow windows to open given excessive noise levels. But unless the building stands in particular places like an airport, these are temporary conditions. The combination of a highly performant glass — possibly vacuum-insulated or hybrid — with sensors and motorization to allow windows to automatically and autonomously open and close, would allow buildings to naturally ventilate effectively and reliably, combining cross ventilation and keeping an interior temperature balance, while reducing the needs for heat and mechanical ventilation under certain weather conditions. Sensors to automatically measure interior temperature, oxygen and humidity levels, as well as exterior conditions — temperature, wind, rain, noise, smell and pollution — and fully airtight systems — like magnetic or dynamic levitation [25], possibly combined with memory shape smart materials — are vital to this process. The savings in air conditioning systems, both in terms of cost and architectural impact — serviced false ceilings, for instance —, could channel investments to intelligent façade solutions.
Windows for the future?
Advances in glass technology are finally rendering possible a fully glazed architecture. Paul Scheerbart’s vision of a Glass Architecture (1914) a century ago could become a reality as glass becomes the primary material for architecture, challenging its current use as a mostly functional, invisible element. Being a primary structural material — through its compressive nature — and a performative element — capable of controlling privacy, visibility and light allowed in a transparent environment — glass might play the role of the stone in Middle Age architecture. Though a property changing “stone”, and this is where different possibilities of development may emerge, just like concrete 150 years ago. This brings natural overlapping between the notion of openings and walls, something that derives from the Modern Movement. Under a technological perspective, this path could lead to a merge wall and window solutions in the future. [Figure 10] Envisioning a solution for a window for the future compels us to focus on critical aspects for architecture today, particularly environmental balance, comfort, flexibility and easiness of use. We believe a self-sufficient, dynamic, highly controllable, operable window might be the answer. Not a conventional “smart window” but a congregation of different technologies into an intelligent operable device. Glass is naturally the most crucial part of the process; among the promising glass technologies in the light of current perspectives, we underline the following: • electrochromic glass, possibly allowing control of visibility from each side of the pane and reflection.
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• photovoltaic transparent glass, allowing the glass to absorb part of the solar radiation to generate enough energy so to be independent of other energy sources, therefore rendering this automatic window an energetically autonomous carbon neutral solution. • vacuum insulated glass for a thinner, lighter glass, as well as efficient thermal performance. • piezoelectric, using touch-sensitive materials with electrical induction, to render the window easily activated and regulated through touch from the inside. • Additionally, other technologies can be decisive for the operability of the panes: • magnetic or dynamic levitation for sliding solutions. Providing unmatched window operability, offering zero friction three-axis movements of the windowpane, ensuring absolute water and air tightness, something unachievable with the standard bearing solution. • ultrathin flexible glass for tilt and turn and casement solutions. Flexible glass could be used in an entirely glazed window, waiving the need for hinges. Although still a speculative idea, a flexible and highly cut-resistant structural glass could allow casements to get larger, as their size would no longer be limited by their screwed or glued hardware’s material resistance. Combining these technologies with sensors to monitor the environment and operate accordingly, the architecture of the window could have a considerable step beyond. Somehow paradoxically, the result could almost seem a return to the past, simplifying buildings and reducing our dependence on air conditioning, which is currently responsible for the consumption of scarce urban energy and the production of considerable air pollution. The fact of rendering windows motorized yet energetically autonomous and holding them accountable for the ventilation of a building is a return to their historical role, offering a more natural use with a more significant degree of control and comfort, yet no longer dependent solely on the user’s action to open and close. Architecturally this certainly will constitute an essential change with buildings possibly organized differently. But it is also a lead on how innovation and technological evolution may simplify architecture and bring more sustainable and efficient management of resources.
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ANALYSIS: Container glass
Ready for a close-up cosmetic packaging growth continues Rohan Gunasekera looks at how the cosmetic and personal care markets of the sub-continent are doing their best to absorb some of the excess container glass capacity in the region and provide a new market for innovation going forward…
I
ndia may no longer be the world’s fastest-growing major economy, but the sheer size of the country, young population and rising incomes indicate high growth prospects for cosmetics and perfumery, and with it glass packaging. Given the rate at which the cosmetics and perfumery market has been growing recently, there seems to be plenty of business for container glass manufacturers. Recent investments by container glass majors, both foreign and domestic, indicate the potential. Nevertheless, an immediate increase in cosmetic and perfumery glass packaging capacity is unlikely as excess capacity built up from previous bouts of expansion and market slow downs need to get absorbed. Indian glass major Piramal Glass has announced plans for a big investment to expand production at its plant in Kosamba, western India, and also decoration facilities to supply premium perfume markets, which are growing fast. It is adding three more production lines to meet growing demand. Germany’s Heinz Glas has set up a joint venture with India’s Haldyn Glass called Haldyn-Heinz Fine Glass which is expanding capacity. And Hindusthan National Glass & Industries Limited is relining its furnace for making cosmetic glass. There are many market studies and forecasts that say the cosmetics and personal care industry is one of the fastest growing consumer products sectors in India. The Indian beauty and personal care industry is estimated to be worth USD 8 billion and India’s per capita spend on beauty and personal care is growing in line with India’s GDP growth. Overall, the market is seen moving towards premiumization, with premium segment growing faster than the mass market. Indian brands (both regional and national) have a sizeable presence in the mass category, while premium markets are largely dominated by the international brands. Factors expected to drive the market for beauty products include the trend of growing consciousness about grooming, with half of the rural population aged below 25 years. With increased awareness, the rural lifestyle and habits have started mirroring urban aspirations and lifestyle and this has brought about a shift from homemade solutions to branded products. ASSOCHAM, the Associated Chambers of Commerce of India, noted in a market study that in current times, innovative packaging is playing an
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important role in driving sales of cosmetics, with multinationals preferring to use environment friendly packaging material. In case of men’s fragrances, it notes, innovative bottle designs hugely influence purchase. Further, pressure to manage costs, enclose products in a way that increases shelf-life, reducing tampering, confirmation that the items are not counterfeit, and showcase products in an appealing manner continue to drive demand for innovatively packaged organic cosmetics across the country. With cosmetic glass containers highly challenged by alternatives in plastics and metals, the market is seen moving towards highly innovative products including lightweight, breakage resistant and intricately decorated alternatives. Cosmetic glass container market is dominated by premium perfume segment, which is the main driver of increasing demand. Smaller pack sizes are gaining preference over the conventional large size bottles owing to the increasing trend towards easy to carry pocket-sized bottles, for reasons like affordability and as they can be consumed before the expiration date. Small size bottles relatively have a better shelf appeal compare to large size bottles particularly in personal care and premium cosmetics segments where aesthetics plays a vital role. For glass bottles and jars, one of the major trends has noticeably been within decoration techniques, in particular the use of coloured glass.
Major growth
Indian container glass major Piramal Glass Ltd. is expanding capacity in a big way, aiming to grow very fast in the next 3-5 years and be one of the top three players globally, said Prasanta Mohanty, the company’s Global Chief Marketing Head ( C&P ). “Today, we have glass capacity of 700 tonnes per day dedicated to cosmetics and perfumery. We are investing about 30 million US dollars in expanding our decoration facility and glass production capacity dedicated to cosmetics and perfumery,” he told Asian Glass in an interview. “We doubled our capacity in decoration, with the new capacity already operational while the new glass production capacity will be available by mid-May 2020.” Total capacity of glass dedicated to Cosmetics and perfumery will be increased
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ANALYSIS: Container glass
by 40 tonnes (almost six percent) – from 700 tonnes to 740 tonnes a day. One of the furnaces (with 100 tpd) in Kosamba plant, in the state of Gujarat in India will go for relining in mid-February and will become 140 tpd after relining – this new capacity will be available by mid May this year. Total tonnage at Piramal Glass plants, which also serves the food and beverage and pharmaceutical markets, apart from supplying perfume glass bottle markets across the globe, is now 1,360 tonnes a day. Piramal Glass has two plants in India, one plant in USA and another one in Sri Lanka. Piramal Glass expects its sales of glass containers to cosmetics and perfumery segment to increase by almost 10 percent to close at 145 million US dollars in the financial year ending 31 March 2020, from 132 million US dollars a year ago, Mohanty said. The total value of the global glass packaging market for cosmetics and perfumery, which includes perfume, nail polish, skin care and foundation, is around 2.1 – 2.2 billion US dollars. The cosmetics and perfumery retail or end-product market size, when the containers are filled with perfume and other products, could be 55 to 60 billion US dollars. Growth is coming from the luxury and premium segments of the perfumes glass bottles with the mass market segments either stagnant or shrinking slightly, Mohanty said. Globally, the overall perfume market is growing by 1.3 - 1.7 % with luxury perfume brands growing at about 4 to 5%. In India, there is a marked shift in consumer preferences that augurs well for container glass manufacturers. “The Indian market was not a perfume market earlier. People used body sprays. But gradually we’re observing a shift to perfumes,” Mohanty explained. “We see many people have started wearing perfumes and many
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companies have started filling perfumes in India for the local market. So there is a shift in the Indian market from body spray aerosols to perfume. The perfume business in India has just started growing. Growth is slow now but looking to the population of India, future prospect is very high.” Piramal Glass also engages in a lot of innovation in glass bottle design, given the importance of the look and feel of packaging in perfume buying decisions. “There’s a lot of innovation happening in packaging in the luxury and premium brands and in decoration of glass bottles which plays a very important role in perfume sales,” Mohanty said. A notable example was the launch of Idôle, Lancôme’s newest fragrance, in a bottle made by couple of European glass manufacturers at the Luxury packaging exhibition ( Luxepack) in October 2019 in Monaco, a very thin and very high quality glass container promoted as the world’s thinnest fragrance bottle. “Perfume bottles need good aesthetics, good decoration because the packaging is the first thing that attracts a consumer – the shape of the bottle, its design,” Mohanty said. “Only then the consumer tries the perfume inside, unless it’s a known brand name. So one has to come up with new designs all the time.” Piramal Glass itself offers 50 to 60 new glass bottle and jar designs for perfume and skin care and 40 to 50 new glass bottle designs for nail polish to the market every year, apart from doing customised designs. “We have our own design office where we create our own designs,” Mohanty said. “Also, we installed a new rotary machine recently which can produce glass bottles with 300 grammes plus weight with a very thick heavy bottom, with good aesthetics, uniform glass distribution and where the MOQ (Minimum Order Quantity) can be lower. We do fire polishing and grinding and
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ANALYSIS: Container glass
polishing, on customers’ request, of bottles to enhance the aesthetics and surface finish. We’ve positioned ourselves very well. We produce premium perfume glass containers for customers like Coty, Loreal, LVMH, Puig, Yves Rocher, Sisley, Ajmal, J&J, Revlon, Avon etc to name a few.” A new trend in cosmetics and perfumery packaging is post-consumer recycled glass containers or external cullet in glass bottle manufacturing. “Today, because of environmental concerns, customers are asking for post-consumer recycled glass, whereas previously they insisted on virgin glass,” said Mohanty.
Back from plastic
Globally there is also a reverse shift from plastic packaging to glass, partly owing to environmental concerns stemming from inadequate disposal of plastic waste as well as greater awareness of the benefits of the inert nature of glass to store perfumes and cream versus the risks of some contamination from materials like plastic. Mohanty said competition from plastics is diminishing in cosmetics and perfumery sector. “Today, people are trying to move from plastics to glass. For example, in skin care where there were some plastic jars, now customers are coming back to glass. So we see a reverse trend.” The threat from glass container imports has also lessened in cosmetics & perfumery segment. “Some Chinese manufacturers used to export glass containers to India,” Mohanty said. “Many customers used to buy glass bottles for perfume from China because of cheaper price. Now because of environmental concerns in China, many glass companies have to shut down their production facilities. So there’s not much imports of glass bottles for cosmetics and perfumes in India now.” Piramal Glass intends to continue expanding capacity to meet growing demand in the domestic and export markets with more capacity additions planned in the years ahead. “We plan to expand again next year when a new furnace will be coming up,” said Mohanty. “We have expansion plans for the next 3 -5 years. We’re aiming to become one of the top three glass players globally in cosmetics and perfumery segment.” Hindusthan National Glass & Industries Limited, India’s largest glass manufacturer, has a dedicated furnace for making cosmetic glass which has been just shut down for relining and ‘debottlenecking’ which should yield some incremental capacity improvement. Its capcity is 130 tonnes a day which could increase to around 150 tonnes or so when the relining is over in the next couple of months. Vinay Saran, President, Marketing at Hindusthan National Glass & Industries Limited (HNGIL) said that in India the market for cosmetics and perfumes is growing fast, so packaging is also growing. “We have a cosmetic glass furnace, which is now down for relining and debottlenecking,” he told Asian Glass magazine. “Growth in glass packaging is coming mainly from rising disposable incomes and growing consumer awareness, especially owing to the spread of e-commerce. More people are becoming aware that perfumes are going to be affordable. E-commerce makes it more affordable, compared to earlier when many people could not afford to buy perfumes. That’s what is expanding the market. Also, perfume is one segment where new designs are paramount. Consumers want new products. After some time nobody wants to buy the same thing over and over again.” HNGIL estimates India’s cosmetics and cosmeceutical market will register annual growth of 25 % touching USD 20 billion by 2025 from present USD 6.5 billion from a global market of USD 274 billion. “Principal areas that are expected to grow include colour cosmetics, fragrances, specialised skin care and make-up cosmetics,” the company told shareholders in its annual report. “The Indian industry is growing rapidly at a rate of 13-18 %, more than that of US or European markets. Body care is the largest category and growing at about 4 % CAGR while colour cosmetics was the fastest growing category, at 12 %. The premium segment is expected to grow at 6.3 % per annum.”
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COSMETICS AND TOILETRIES ARE ONE OF THE FASTEST GROWING CONSUMER PRODUCT SECTORS IN INDIA Consumer power
Pragati Glass Pvt. Ltd. President H.R. Bhandari said the market for cosmetic glass, estimated at around 90-100 million US dollars, should grow steadily as the economy grows, enhancing consumer purchasing power. Before India opened up her economy in the late 1990s, cosmetics were considered a luxury product on which there were high government taxes that limited growth. “Since then, the economy has been growing and people have more buying power to buy cosmetic and perfumery,” Bhandari told Asian Glass in an interview. “At the same time, India started making container glass and also exporting.” Pragati Glass, based in Mumbai, focuses on making container glass for cosmetics and perfumery with a dedicated furnace capacity of 130 tonnes per day. Almost 75 percent of total company production is for cosmetics and perfumery. The firm also has a plant in Oman with one furnace with a capacity of 135 tons per day. Bhandari said that while the market is growing he does not see any immediate expansion in capacity for cosmetics and perfumery in the container glass packaging industry. “We had a lot of excess capacity in India a few years back,” he explained. “As demand grows, that surplus capacity is being absorbed. So for now, further investment in glass container capacity will be limited. That will take more time. For now, whenever someone goes for relining of a furnace, they might increase capacity. But green field investments are unlikely in the immediate future.” Pragati Glass not only makes the glass packaging for cosmetics and perfumery but supplies the full service, that includes meeting a customers entire requirement, such as caps, pumps, labels and cartons. “We not only make glass bottles but also offer them (customers) the entire project,” Bhandari explained. “When someone needs glass containers for cosmetic, they also need caps, pump, labels and cartons, which we can supply in-house.” Pragati Glass also has its own in-house design facility with services like frosting, colouring and printing. “Depending on market demands, we keep on making different sizes and shapes of bottles,” Bhandari said. “Cosmetics glass business is not volume-based, especially the perfumery business, unlike other segments like food and beverage where orders are placed for millions of bottles. For cosmetics, orders are for a few hundreds of thousands and we keep on changing shapes and sizes of bottles, especially for mid-level cosmetics makers.” The Haldyn Glass joint venture with Heinz Glas was for manufacture and marketing of clear glass containers for the cosmetics and perfumery industries in India and abroad and part of the firm’s diversification effort. The joint venture
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ANALYSIS: Container glass
company in which Haldyn and Heinz have equal shares will manufacture glass flacons for the perfume and cosmetics industry with technical support from Heinz. The JV company has said it has been able to achieve European standards export quality in the initial period of operation. It also commissioned its decoration plant in March 2018. Carl-August Heinz, owner and CEO of Heinz Glas, has said the Indian market was growing steadily with potential to be the largest market in the world for perfumes. A fourth line could be added to the Indian glass factory with one furnace and three lines. Bhandari of Pragati Glass estimates about 60-70 percent of Indian cosmetics glass production is exported and the rest used in-country. The main export markets are developed countries like Europe and United States. Exports also go to South American countries and also to African and Asian countries. Bhandari expects more growth from developing countries as their econmies grow and peoples’ buying power increases. Unlike in other segments of container glass packaging, the threat from
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cheap imports such as from Chinese suppliers is not there in cosmetics glass. “For cosmetic and perfumery glass, we don’t think we have any threat from the Chinese,” said Bhandari of Pragati Glass. Although there is some import from China, especially by perfume makers bottling in India who ship bottles from China, this is limited. Plastics are also not seen as much of a threat in cosmetics and perfumery packaging, although in the overall market for beauty products, including hair and skin care, plastic does dominate. “In perfumery, I don’t think there is any conversion into plastic,” said Bhandari of Pragati Glass. “The premium products are all in glass. We don’t have any threat of plastic taking market share from glass.” Said Saran of HNGIL: “In perfumes, use of glass is bigger. Although plastics does grow market share in certain segments, there appears to be a shift in consumer preferences as awareness grows of the advantages of glass. It’s not that big for cosmetics and perfumes in India yet, but there’s a perceptible change in consumer mind set. For instance, nobody wants premium perfumes in plastic bottles.”
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Design Implications on Embodied Energy
Unlocking the re-use potential of ANALYSIS: Facades glass façade systems
The distribution of initial embodied energy for building elements differs with each building. Cole and Kernan conducted research on a threestorey office building found that the façade typically contributes around 25% of the total initial embodied energy as highlighted in figure 2. [3] The relative contribution to the initial embodied energy (EE) is likely to continue to rise in significance due to the broad design possibilities that are explored to minimise operational energy (OE).
Rebecca Hartwell1, Dr. Mauro Overend1 1
University of Cambridge, Department of Engineering, UK
Abstract
Play it again… and again… (i)
The ubiquitous insulated glazing unit (IGU) has been referred to as a monstrous hybrid consisting of a mixture of materials or assemblies of components from which it is not economically feasible to salvage the raw materials after their current life. In recent decades there has been an increase i n the use of glass within façade sys tems with little consideration for end-of-life (EoL) recovery. Technical improvements focused on improving operational energy of glazed façades can have unintentional negative consequences on the ability to recover high-value material. This research aims to assess the opportunities of avoidable waste through a comparative life-cycle impact assessment (LCIA) bound to the EoL stage and evaluate the reclamation potential of glass and aluminium from an existing curtain-walli ng glazing unit in different recovery scenarios. A framework for the assessment of recovery potential of glass façade designs is proposed. Further, the technical challenges that prevent glazing systems from exploiting their re-use potential, in terms of the separation of laminated glass and adhesive connections, have been reviewed to direct future experimental research on glass façades designed for disassembly and re-use.
(ii)
Stuff ~ daily to monthly
Space Plan
EMBODIED ENERGY (GJ)
~3 years
Services
~7-15 years
Initial
25 Years
Skin
~20 years
50 Years
100 Years
Structure
~ 30-300 years
Site Work
Structure
Envelope
Finishes
COMPONENT
Services
Construction
Site
~ eternal
Building "Shearing Layers"
Figure 2: i.) EE contributions over a typical building service life [3] ii.) Building split into service lives of elements [4]
The significance of the EE attributed to the façade is scaled up considerably when the whole building lifespan is taken into account. This is commonly referred to as recurring EE and highlighted in figure 4(i) over, 25-, 50-, 100-year building lifespan. The building envelope is significant in terms of recurring EE, in that, in relation to the structure, it typically requires more frequent maintenance and replacement of parts. The failure rate of the IGU has been the subject of recent study. [5], [6] The multi-component nature of the building envelope can create significant challenges in disassembly and the reclamation of glass and other materials from existing systems for re-use or recycling of component parts at EoL. [7], [8]
unlocking re-use potential in facades
Introduction ARebecca Growth in Function Hartwell and Dr. Mauro Overend from the University of Cambridge, Glass façade systems have evolved to serve numerous functions and UK, discuss overcoming theto traditional issues of being a hybrid product meet complex technical requirements. When it comes design for End-of-life can ultimately be defined as the inability for the system to fulfil disassembly, arise asto to whether is a system trade-off when itquestions comes theirthere eventual re-use and recycle… its design function or meet new requirements. Changing user A growth in function
Glass systems have evolved serve numerous comEarly façade aesthetically-driven glasstofaçade design functions consistedandofmeet a small plex technical requirements. When it comes to design for disassembly, questions material mix involving monolithic glass and mostly mechanical arise as to whether there is a system trade-off between meeting improvements connections. During the 1970s-80s, glass envelopes became more in operational energy and the ability to recover glass and other materials for performance-driven and began to incorporate high-performance re-use at their end-of-life (EoL). double-glazing, glass coatings adhesively-sealed to improve Early aesthetically-driven glass and façade design consisted units of a small material 1 1 Rebecca Hartwell , Dr. Mauro Overend air-tightness, acoustic and thermal insulation and sun-protection. The mix involving monolithic glass and mostly mechanical connections. During the volume of glass in buildings has since grown; triple-glazing units (TGUs) 1970s-80s, glass envelopes became more performance-driven and began to 1 University of Cambridge, Department of Engineering, UK and double-glazing units (DGUs) with coatings are nowandconsidered incorporate high-performance double-glazing, glass coatings adhesivelysealed units to improve acoustic and thermal and essential elements of lowair-tightness, and zero energy buildings. TGUsinsulation and coated sun-protection. The up volume of glass in buildings has since grown; triple-glazing DGUs now make 2% and 12%, respectively, of the existing glazing are considered type distribution The units ubiqu(TGUs) itous iand nsuldouble-glazing ate(EGD) d glaziin ng the uunits nit EU. (I(DGUs) GUSuch ) hawith s bsystems ecoatings en referconsist rednow to aof s amore essential elements of low and zero energy buildings. TGUs and coated DGUs now monsmaterials trous hyband rid cmore onsistipermanent ng of a mixtconnections ure of materivia als othe r asuse semof blieadhesive s of make up 2% and 12%, respectively, of the existing glazingearly type distribution sealants. [2] comp onents fr[1], om w hichWhilst it is nosingle-glazing t economicallyunits feas(SGU) ible to sand alvage theuncoated raw (EGD) in the EU. Such systems consist of more materials and more permanent DGUs for 44% and 42% of the EU EGD, respectively, the mateconnections rials afstill ter taccount h e i r c u r r e n t l i f e . I n r e c e n t d e c a d e s t h e r e h a s b e e n an units via the use of adhesive sealants. [1], [2] Whilst single-glazing field meet incre(SGU) ase ofand i n building tearly he uuncoated srefurbishment e of gDGUs lass still wtoithaccount in faenergy çafor de44% sperformance ysand tem42% s wiof th standards l i t t l e the EU EGD, continues tor grow consrespectively, ideration fo d-ofwhich -of lifebuilding (Esuggests oL) rrefurbishment ecovthat ery. the Tecto hlarge nimeet cal amount imenergy proveof m eglass nts in theenfield performance building stock in lower-performance systems will soon be considered focusstandards ed on imcontinues proving otopegrow rationwhich al enesuggests rgy of gthat lazethe d falarge çadeamount s can hof aveglass in
Unlocking the re-use potential of glass façade systems
Abstract
unintunfit entiofor nalfunctional negative cpurpose. onsequences on the ability to recover high-value material. This research aims to assess the opportunities of avoidable waste through a comparative life-cycle impact assessment (LCIA) bound to the EoL stage and evaluate the reclamation potential of glass and aluminium from an existing curtain-walli ng glazing unit in different recovery scenarios. A framework for the assessment of recovery potential of glass façade designs is proposed. Further, the technical challenges that prevent glazing systems from exploiting their re-use potential, in terms of the separation of laminated glass and adhesive connections, have been reviewed to direct future experimental research on gFigure lass fa1: çaCross-section des designedoffoi.)r SGU disasii.) seDGU mblyiii.)anStructural d re-use.Sealant Glazing. Figure 1: Cross-section of i.) SGU ii.) DGU iii.) Structural Sealant Glazing
Introduction 48
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A Growth in Function
Glass façade systems have evolved to serve numerous functions and
requirements and new developments in the area of construction, may
building stock in lower-performance systems will soon be unfit for lead to façade EoL being reached prematurely ie.considered every 20 years or so. functional purpose. [4] For these reasons, façades pose a clear opportunity to concentrate
Design Implications on Embodied Energy Design implications processing techniques that have a high-value and require more energy-
recovery methods, even more so with the advance of new materials and
Thedistribution distribution initial embodied energy for building elements differs The of of initial embodied energy for building elements differs with intensive manufacture. with building. each building. and Kernan research conducted on office a threeeach Cole andCole Kernan conducted on aresearch three-storey storey office found typically that the contributes façade typically building found building that the façade aroundcontributes 25% of the around total Energy Problem Shift initial embodied energy highlighted in figureas 2. highlighted [3] The relative 25%Whole-Life of the total initialas embodied energy in contribution figure 2. [3] policies energy in building construction heavily focus onisimproving to theExisting initial embodied likelyembodied to continue to rise in(EE) significance The relative contribution to(EE) theisinitial energy likely to the due toOE. theSeveral broad possibilities that to minimise operational have studied how decisions made in the design continue to risedesign inresearchers significance due toare theexplored broad design possibilities that energy (OE). stage of the building envelope such as DGUs with low emissivity coatings are explored to minimise operational energy (OE). and TGUs, solar thermal collectors and building integrated solar Stuff ~ daily to monthly (ii) photovoltaic panels affect the OE. [9]–[11] Consequently, other factors Space Plan ~3 years within the life-cycle of the façade such as EE and recovery potential are Services ~7-15 years often overlooked. Chastas, et al. reviewed previous literature on 90 Initial residential buildings to find the ratio of EE to OE energy. It reported an 25 Years Skin EE contribution of 6–20% in conventional buildings, 11–33%~20inyears passive 50 Years 100 Years buildings, 26–57% in low energy buildings, and 74–100% in net zero Structure ~ 30-300 years how energy buildings. [12], [13] This shifting balance has highlighted Site improvements inEnvelope OE, has increased the relative significance of the EE; ~ eternal Site Work Structure Finishes Services Construction Building "Shearing Layers" affected by the selection COMPONENT of locally-available construction materials and methods; manufacturing energy intensity; recyclability potential; Figure 2: i.) contributions over a typical building service life ii.) Building Figurerecycled 2: i.) EE EE contributions over a typical building service life [3] Building split into content; renewability potential; potential toii.)[3] reduce construction split intolives service lives of[4] elements [4] service of elements waste; life span and durability; and maintenance needs. As the energy required for operation decreases, scenarios with a higher potential The ofthe theEE EE attributed the façade up for Thesignificance significance of attributed to thetofaçade is scaled is up scaled considerably recycling and re-use can have a significant impact on the whole-life considerably thelifespan whole building lifespan is taken account. This when the wholewhen building is taken into account. This isinto commonly referred cycle. [14], [15]. However, with nohighlighted internationally accepted, is commonly referred to as recurring EE and in figure 4(i) to as recurring EE and highlighted in figure 4(i) over, 25-, 50-, 100-year building and pragmatic method forThe assessing and over,comprehensive 25-, 50-, 100-year building lifespan. envelope lifespan. The building envelope is significant in terms ofbuilding recurring EE,comparing in that,isin the recycling potential façade materials terms of the structure, material and choice significant in terms of recurring EE,requires in that,more ininrelation to the it relation to the structure, itoftypically frequent maintenance and their embodied impact when looking at future scenarios for building replacement of parts. The frequent failure rate of the IGU has been the subjectofofparts. recent typically requires more maintenance and replacement refurbishment, there littlebeen incentive for re-use. [16] [17] The failure rate of the IGUishas the subject of recent study. [5], [6] (i)
EMBODIED ENERGY (GJ)
between meeting improvements in operational energy and the ability to recover glass and other materials for re-use at their end-of-life (EoL).
The multi-component nature of the building envelope can create significant challenges in disassembly and the reclamation of glass and www.asianglass.com other materials from existing systems for re-use or recycling of component parts at EoL. [7], [8] 1
interlayers and special additives introduces difficulties in recycling. There is some uncertainty in the exact figures for flat glass collection and recycling rates for post-consumer glass. In 2007, it was found that 57% of the 5.1Mt of waste generated from the EU flat glass industry was recycled, including pre- and post-consumer glass. [19] Pre-consumer glass recycling rates tend to be relatively high due to them being driven by internal efficiency improvements within glass manufacturing facilities. More research into glass collection is required to quantify postconsumer recovery rates.
ANALYSIS: Facades
study. [5], [6] The multi-component nature of the building envelope can create significant challenges in disassembly and the reclamation of glass and other materials from existing systems for re-use or recycling of component parts at EoL. [7], [8] End-of-life can ultimately be defined as the inability for the system to fulfil its design function or meet new requirements. Changing user requirements and new developments in the area of construction, may lead to façade EoL being reached prematurely ie. every 20 years or so. [4] For these reasons, façades pose a clear opportunity to concentrate recovery methods, even more so with the advance of new materials and processing techniques that have a high-value and require more energy-intensive manufacture.
Whole-life energy
Existing policies in building construction heavily focus on improving the OE. Several researchers have studied how decisions made in the design stage of the building envelope such as DGUs with low emissivity coatings and TGUs, solar thermal collectors and building integrated solar photovoltaic panels affect the OE. [9]–[11] Consequently, other factors within the life-cycle of the façade such as EE and recovery potential are often overlooked. Chastas, et al. reviewed previous literature on 90 residential buildings to find the ratio of EE to OE energy. It reported an EE contribution of 6–20% in conventional buildings, 11–33% in passive buildings, 26–57% in low energy buildings, and 74–100% in net zero energy buildings. [12], [13] This shifting balance has highlighted how improvements in OE, has increased the relative significance of the EE; affected by the selection of locally-available construction materials and methods; manufacturing energy intensity; recyclability potential; recycled content; renewability potential; potential to reduce construction waste; life span and durability; and maintenance needs. As the energy required for operation decreases, scenarios with a higher potential for recycling and re-use can have a significant impact on the whole-life cycle. [14], [15]. However, with no internationally accepted, comprehensive and pragmatic method for assessing and comparing the recycling potential of façade materials in terms of the material choice and their embodied impact when looking at future scenarios for building refurbishment, there is little incentive for re-use. [16] [17]
Current processes
Façades may be removed from a building as a result of full- or partial-demolition or refurbishment. The EU Landfill Directive introduced in 1999 does not present any specific glass measures. [18] Glass, as an inert material, is easy and relatively cheap to send to landfills, which does not favour the emergence of glass recycling. Based on the author’s discussions with demolition contractors in industry, it has been recognised that the most common deconstruction method involves a demolition excavator with grab/pincer attachment controlled by driver that is used to pry out metal frames. The mixed glass falls to ground and mixed with concrete and/or brick rubble as inert waste. An on-site separation of metals, woods, concrete (including glass) is undertaken with the metals sold on to a re-use or recycling facility (~£200/tonne) where they are usually melted down for recycling. The mixed glass inert waste is sold on for aggregate production at a much lower value (~£1/tonne) or to landfill where a landfill fee is required. The low market value, together with lack of properly organised glass collection mean that despite its re-use and recyclability potential, EoL building glass is almost never recycled into new glass products. Independently, uncoated glass in particular is a very durable material and has high re-use potential. However, the addition of coatings, interlayers and special additives introduces difficulties in recycling. There is some uncertainty in the exact figures for flat glass collection and recycling rates for post-consumer glass. In 2007, it was found that 57% of the 5.1Mt of waste generated from the EU flat glass industry was recycled, including pre- and post-consumer glass. [19] Preconsumer glass recycling rates tend to be relatively high due to them being driven by internal efficiency improvements within glass manufacturing facilities. More research into glass collection is required to quantify post-consumer recovery rates.
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Façade: circular economies Circular Economy for Glass Façades
The EU Environmental Action Programme to 2020 aims to move towards a
The EU Environmental Action Programme to 2020 aims to move towards fully circular economy (CE) in which industry move towards manufacture, use a fully circular economy (CE) in which industry move towards and recovery models that aims to minimise the depletion of the world’s natural manufacture, usewith andproblems recovery models thatinaims resources and deal of waste disposal a wayto thatminimise materials the are depletion of the world’s natural resources and deal with problems re-used or recycled in their best form to reduce their environmental impact byof waste disposal in a way that materials are re-used or recycled in their 2050. [20] best form to reduce their environmental impact by 2050. [20] Transport
Transport
Recycle
Secondary material
Cradle Raw Mineral Extraction
Transport Product Assembly and Transport
Material Production
Product
v Transport of system to site v Construction installation process
Reuse
Materials in Use v Provide functional performance v Maintenance & repair
Construction Process Use
Façade Disposal Transport
End-of-Life
Residual Waste Landfill
Gate
Figure transition through façade lifecycle in terms of energy use Figure3:3:CE CEconcept: concept: transition through façade lifecycle in terms of energy use.
TheThe re-use pathway theauthor authorininfigure figure is the process in re-use pathwaymapped mapped by by the 3 is3 the process in which which discarded components are recirculated and used for the same discarded components are recirculated and used for the same function without function without destruction. Recycling is the process in which destruction. Recycling is the process in which discarded materials arediscarded reprocessed materials are reprocessed into rawThe materials products. The into raw materials for new products. potentialforfornew re-using construction components the construction sectorcomponents has been acknowledged by several potential for inre-using construction in the construction researchers. [21]–[23] Most studiesbyhave focused on the recycling or re-use sector has been acknowledged several researchers. [21]–[23] Mostof narrow groups of materials as aggregate andnarrow steel [24], [25] This studies have focused on such the recycling or material re-use of groups of study aimssuch to identify the opportunities thesteel reclamation of This flat glass from the materials as aggregate material in and [24], [25] study aims building envelope. to identify the opportunities in the reclamation of flat glass from the Findings from an ongoing semi-structured interview conducted by the author building envelope.
with different stakeholders of the façade supply-chain provided a useful insight into the industry’s on façade re-use.interview The initial conducted findings suggest that Findings from an perceptions ongoing semi-structured by the whilst there exists some willingness for re-use, existing demand for re-use of author with different stakeholders of the façade supply-chain provided a façade product is low, largely due to a lack of specification for re-use material; useful insight into the industry’s perceptions on façade re-use. The initial lack of compatibility between re-use material and new projects due to the findings suggest that systems; whilst there some willingness for re-use, bespoke nature of most lack ofexists adequate supply; fear of material failure; existing demand for re-use of façade product is low, largely due a lack transportation and storage difficulties; and limited separability of to composite of specificationQuantified for re-use environmental material; lack of compatibility between re-useof constructions. benefits, improved separability material and and newimproved projectsre-use due to the bespoke of most as systems; components; supply-chain havenature been identified common leverage points that could help address the existing challenges in glass façade re-use.
Environmental Assessment Method System Boundary
The existing research forms a process-based life-cycle impact assessment (LCIA) methodology for comparative environmental impact estimation as prescribed by the International Standard Organisation (ISO) 14040 to demonstrate to what extent the implementation of design for disassembly and re-use at the endof-life (EoL) of glass curtain walling systems has on the environmental impact in terms of embodied energy from non-renewable resources (PENRE EE) and carbon emissions (GWP). [27] [28] LCIA relates the large number of input and output flows in terms of energy used throughout the product life-cycle, known as inventory values, to a smaller number of environmental impact themes. The study is bound to the gate-to-grave and gate-to-cradle stage of the LCIA with a comparison of four different EoL scenarios based on existing design and potential recovery methods. The study considers the energy impacts associated with the primary energy associated with original input materials (including the energy required to extract, refine and transport fuels and the electricity used in the process), system interconnectivities, building deconstruction, material
AG 20-1 asianglass
49
2
(LCIA) methodology for comparative environmental impact estimation as prescribed by the International Standard Organisation (ISO) 14040 to demonstrate to what extent the implementation of design for disassembly and re-use at the end-of-life (EoL) of glass curtain walling systems has on the environmental impact in terms of embodied energy from non-renewable resources (PENRE EE) and carbon emissions (GWP). [27] [28] LCIA relates the large number of input and output flows in terms of energy used throughout the product life-cycle, known as inventory values, to a smaller number of environmental impact themes.
ANALYSIS: Facades
Figure 6: i.) Timber curtain walling system under study [31] ii.) % mass (kg) of constituent material within FU
The material mass figures shown in figure 6(ii) were obtained from the author’s calculations based on construction drawings and material densities.
End-of-Life Scenarios Four hypothetical scenarios, explained in table 1, were constructed to drawofcomparisons on the EoL route that performs best in terms of End life scenarios achieving maximum recovery potential. Four hypothetical scenarios, explained in table 1, were constructed to draw
comparisons on the EoL route that performs best in terms of achieving maxiTable 1: LCIA system boundary applied to four different scenarios for glass façade system mum recovery potential. at EoL to be compared
Figure 4: in in which thisthis study will focus. Adapted from [29], Figure 4: Areas Areasofoflife-cycle life-cycle which study will focus. Adapted from[30] [29], [30]
transportation from deconstruction site to The study is bound to the gate-to-grave and gate-to-cradle stage of the
dismantling, transportation to disposal/recycling/ disposal/recycling/treatment/next use site and site the recycling transportation fromfrom deconstruction deconstruction siteprocesses to LCIA with a comparison of four different EoL scenarios based on existing treatment/next use site and the recycling processes from each EoL scenario based from each EoL scenario based on the original material input. The disposal/recycling/treatment/next use site and the recycling processes design and potential recovery methods. The study focuses considers therecycling energy on the original material input. Thedeconstruction substitution approach substitution approach focuses on the capacities a material. transportation from site onofthe to The from each EoL scenario based on recycling the original material input. impacts associated with the primary energy associated with original capacities of a material.isRecycling is the share of recycled material Recycling share ofthe recycled that could fulfilthat the disposal/recycling/treatment/next usepotential site and thematerial recycling processes substitutionpotential approach the focuses on recycling capacities of a material. input fulfil materials (including the material energy in required tomaterial extract, refine and could the function of primary thematerial next cycle. Thescrap scrap function of primary material in the next cycle. The from each EoL scenario based on the original material input. The Recycling fuels potential is the the share of recycled material that could the including and recycling energy is considered input and fulfil replaces transporttreatment and electricity used in the asprocess), system including treatment and recycling energy ismaterial considered asThe inputscrap and substitution approach focuses on theinrecycling capacities ofcycle. a material. function of primary material the next primary resources (substitution). interconnectivities, building deconstruction, material dismantling,
replaces primary resources Recycling potential is the share of (substitution). recycled material that could fulfil the and including treatment and recycling energy is considered as input function of primary material in the next material cycle. The scrap replaces primary resources (substitution). Input including Billtreatment and recycling energy is considered as input and of Materials 2 Inputcomponent replaces primary resources (substitution). Process analysis Bill of Materials
sequence of relationships site disassembly Processbetween elements comparison operationsof sequence connection diagram Bill of Materials ofsite use relationships forensic breakdown disassembly Datamaterial and component between elements comparison operations (A1-A3) element analysis Process analysis connection diagram of use service life forensic sequence of breakdown material and Inventory relationships site comparison scenario variations for EoL disassembly element analysis Data between elements comparison service life operations (A1-A3) connection diagram use forensic breakdown scenario for of EoL comparison % reclamation in terms of % recovery from variations each material and Output environmental impact pathway: element analysis service life reuse/recycle/incineration/landfill (EE and GWP) % reclamation in terms of % recovery from each Output environmental impact scenariopathway: variations for EoL comparison reuse/recycle/incineration/landfill (EE and GWP) % reclamation in terms of Figure 5: Methodology collection for calculating environmental impact in terms of % recoveryoffrom each Output Figure 5: Methodology ofdata data collection for calculating environmental impact in environmental impact pathway: embodied energy and carbon emissions reuse/recycle/incineration/landfill terms energy and carbonfor emissions. (EE and GWP) Figureof 5: embodied Methodology of data collection calculating environmental impact in terms of Input
Inventory component Data analysis (A1-A3) Inventory
embodied energy and carbon emissions
Functional Unit and System Characteristics Unit and System AFunctional functional unit (FU) provides a functional basisCharacteristics for fair comparison of envi-
Figure 5: Methodology of data collection for calculating environmental impact in terms of Functional Unit and System Characteristics embodied energy andunit carbon emissions A functional (FU) provides a functional basis for fair comparison
of environmental impact across the different EOL scenarios and is the A functional unit across (FU) provides a functional basis fairreference comparison ronmental impact the different EOL scenarios andfor is the basis of Functional and System Characteristics reference basis all gathered data refer to. The façade system selected all gathered Unit data refer to. The façade system selected forscenarios this study isand that environmental impact across the different EOL isused the this study isallthat used in in a refer new educational building A functional uniteducational (FU) a based functional basis forUK. fair comparison of for in infor a new building Cambridge, The functional unit reference basisprovides gathered data to. The façade system based selected this asacross the treatment unitEOL ofeducational Aluminium/Timber Cambridge, UK. The functional fortriple-glazed this study defined as the environmental impact the different scenarios and is the for study this defined study is that used in ofa1new building based in unitised structural glazed curtain walling, 3650 mm x 4550 mm, highlighted in treatment of 1 unit of triple-glazed Aluminium/Timber unitised structural reference basis all gathered data refer to. The façade system selected Cambridge, UK. The functional unit for this study defined as the figure 6(i), at glazed curtain 3650 4550 mm, highlighted in figure for this study isofEoL. that used in a mm newx educational buildingunitised based in6(i), at treatment 1 walling, unit of triple-glazed Aluminium/Timber structural The material mass figures shown in figure 6(ii) were obtained from the EoL. Cambridge, UK. The functional unit for this study defined as the glazed curtain walling, 3650 mm x 4550 mm, highlighted in figure 6(i), at author’s calculations based on construction drawings and material densities. treatment EoL.of 1 unit of triple-glazed Aluminium/Timber unitised structural glazed curtain walling, 3650 mm x 4550 mm, highlighted in figure 6(i), at EoL.
Figure 6: i.) Timber curtain walling system under study [31] ii.) % mass (kg) of constituent material within FU Figure 6: 6: i.) walling system underunder study study [31] ii.)[31] % mass of constituent Figure i.) Timber Timbercurtain curtain walling system ii.) %(kg) mass (kg) of material within FU constituent material within FU.
The material mass figures shown in figure 6(ii) were obtained from the
Figure 6: i.) Timber curtain walling system under study [31] ii.) % mass (kg) of constituent author’s calculations based on construction drawings and from material mass figures shown in figure 6(ii) were obtained the materialThe withinmaterial FU
densities. author’s calculations based on construction drawings and material 50 asianglass 20-1in figure 6(ii) were obtained from the The material mass figuresAG shown densities. author’s calculations based on construction drawings and material End-of-Life Scenarios densities. Four hypothetical scenarios, explained in table 1, were constructed to
SCENARIO
DEMOLITION METHOD
1 2
Hydraulic Crushing Selective Dismantle
PROCESS
EOL ROUTE
Mixed Rubble Parts Recycle
Landfill and/or incineration 90% Glass to road aggregate (10% to landfill) Aluminium to recycling 3 Selective Dismantle Disassemble/ 90% Glass re-used in new separate system (10% to landfill) components Aluminium components reused in new system routes, noSelective energy can beRemove accredited in this case, as this scenario 4 Dismantle system for Direct re-use of façade unit requires energy andcan doesbe not deliver a surplus. re-use in new buildingas this scenario routes, no energy accredited in this case,
At present, theenergy most common EoL scenario within industry is either; Table 1:requires LCIA system boundary applied todeliver four different scenarios for glass and does not a surplus. The existing environmental product forscenario theand Timberfaçade at EoL to be compared. façadesystem system demolition landfill (scenario 1) or routes, no energy can be and accredited in this declaration case, asdismantle this
Aluminium façade system suggests scenario to component recycle (scenario 2). In thea disposal demolition scenario, is The existing environmental declaration formost theitsimilar Timberrequires energy and does not deliver aproduct surplus. At present, the most Glass common EoL of scenario industry isineither; scenario 2.façade [31] is suggests considered towithin beUnlike downcycled aggregate assumed that materials are disposed in alandfill. the other EoL Aluminium system disposal scenario most similar to façade system demolition andisproduct landfill (scenario 1) for or dismantle and whilst production, which requires minimal processing, The existing declaration the Timberscenario environmental 2. [31] Glass considered toadditional be downcycled in aggregate component recycleissystem (scenario 2). Innew the demolition scenario, it issimilar assumed aluminium recycled into aluminium which requires melting down Aluminium façade suggests a disposal scenario most production, which requires minimal additional processing,to whilst that materials are Glass disposed of in landfill.to Unlike the other EoL routes, no the material for reprocessing. scenario 2. [31] is considered be downcycled in aggregate is recycled into new aluminium which requires melting down energy aluminium can be accredited in this case, as this scenario requires energy and production, whichforrequires minimal additional processing, whilst 3 the material reprocessing. does not deliver a 3surplus. Scenarios and 4 to more idealised situations, whereby aluminium is recycled into refer new aluminium which requires melting downre-use Theoptions existing environmental product declaration for the Timber-Aluminium to idealised the development of whereby new separation Scenarios 3made and 4possible refer to due more situations, re-use the material forare reprocessing. façade system suggests a disposal scenario most similar to scenario 2. technologies for component re-use (scenario 3), and performance options are made possible due to the development of new separation [31] Glass is considered to be downcycled in aggregate production, which assurance for system (scenario 4). The selective Scenarios 3 and and 4 refer to more idealisedre-use situations, whereby re-use fortesting component and performance requirestechnologies minimal additional processing,re-use whilst(scenario aluminium3), is recycled into dismantling of façade systems for component re-use (scenario 3) offers options are made possible due to the development of new separation assurance andrequires testing melting for system (scenario 4). The selective new aluminium which downre-use the material for reprocessing. an alternative for the existing process of down-cycling glass material. In technologies for component re-use (scenario 3), and performance dismantling systems for component re-use (scenario 3) offers Scenarios 3 andof4façade refer to more idealised situations, whereby re-use this way, flat glass sheets are recovered, to be directly re-used in the assurance and testing for system re-use (scenario 4). The selective optionsanare made possible due to the development of newglass separation alternative for the existing process of down-cycling material. In building glass industry. Table 2 shows the total % weight to ineach dismantling of systems for component re-use (scenario 3) offers technologies forfaçade component re-use (scenario 3), and performance assurance this way, flat glass sheets are recovered, to be directly re-used the and testing for system re-use (scenario 4). The selective dismantling of each scenario of recovery. an alternative for the existing process of down-cycling glass material. In building glass industry. Table 2 shows the total % weight to façade systems for component (scenario 3) offers alternative for this way, flat glass sheets arere-use recovered, to be directlyanre-used in the scenario of recovery. Table 2: Material outputs by weight %– diversion/collection rates for each scenario the existing process of down-cycling glass material. way, flat glass building glass industry. Table 2 shows the total In%this weight to each sheets areofrecovered, re-used in the building glassscenario industry. Table 2: Material outputs bydirectly weight %– diversion/collection rates for each scenario recovery. to beTOTAL % TOTAL % TOTAL % TOTAL %
Table 2 shows the total % weight scenario ofINCINERATION recovery. RE-USE to each RECYCLE TOTAL % RE-USE
TOTAL % RECYCLE
LANDFILL TOTAL % 100.0% LANDFILL
TOTAL % INCINERATION
Table 2: Material outputs1by weight %–- diversion/collection rates for each scenario SCENARIO 80.5% 11.9% SCENARIO 2 SCENARIO TOTAL 1 - TOTAL % % 89.2% 1.2% TOTAL % 2.6% SCENARIO 3 11.9% SCENARIO 2RE-USE - RECYCLE80.5%INCINERATION 97.0% 2.6% SCENARIO 4 89.2% 1.2% 2.6% SCENARIO 3 SCENARIO 1 97.0% 80.5% SCENARIO 4 11.9% 2.6% SCENARIO 2
Inventory Data 89.2% Inventory Data 97.0% Data Source
SCENARIO 3 SCENARIO 4
7.5%
TOTAL %100.0% 7.0% 7.5% LANDFILL 0.4% 100.0%
7.0%
7.5%
0.4%
1.2%
2.6%
7.0%
-
2.6%
0.4%
Table 2:Data Material outputs bydatabases weight %– diversion/collection rates forLCIA each figures e.g. There are several available for input-data Source Inventory Data scenario EcoInvent, ELCD. [32] For this study, inventory data was taken from the
There are several databases available for input-data LCIA figures e.g.
DataEcoInvent, Source German database, Oekobaudat. Oekobaudat contains generic cycle ELCD. [32] For this study, inventory data was taken life from the
data sets thatdatabases provide suitable averages of thecontains environmental indicators There German are several available for input-data LCIA figures database, Oekobaudat. Oekobaudat generice.g. life cycle Inventory Data
for building materials for life-cycle modules (A1-A3, EcoInvent, ELCD. [32] For this study, inventory data taken B1-B6, from indicators theC1-C4 datathe sets that provide suitable averages of thewas environmental and D). This includes the energy density coefficient, incineration German Oekobaudat. Oekobaudat contains (A1-A3, generic life cycleC1-C4 Data Source fordatabase, the building materials for life-cycle modules B1-B6, There are databases available input-data LCIA coefficient, figures e.g. EcoIncoefficient, factor and demolition/disassembly/recycling data sets that suitable averages of the environmental indicators andseveral D).provide Thistransport includes the for energy density incineration vent, ELCD. [32] For thisThe study, inventory data was taken the (ICE) German coefficient. [33] UKlife-cycle Inventory of Carbon andfrom Energy was used for the building materials for modules (A1-A3, B1-B6, C1-C4 coefficient, transport factor and demolition/disassembly/recycling database, Oekobaudat. Oekobaudat contains generic life[34] cycleBoth data sets that are for aggregate material production data. datasets and D). This includes the energy density coefficient, incineration coefficient. [33] The UK Inventory of Carbon and Energy (ICE) was used provide suitable averages of the environmental indicators for the buildingallows for traceable, freely material accessible and comply with ISO-14040 coefficient, transport factor and demolition/disassembly/recycling for aggregate production data. [34] Bothwhich datasets are materials for life-cycle modules (A1-A3, B1-B6, C1-C4 and D). This includes a comparison of accessible allInventory datasetsand be made. [27] coefficient. [33] The UK oftoCarbon and Energy (ICE) was used traceable, freely comply with ISO-14040 which allows for the energy density coefficient, incineration coefficient, transport factor and for aggregate material production data. [34] Both datasets are a comparison of all datasets to be made. [27] demolition/disassembly/recycling coefficient. [33] The UK Inventory of CarService Life traceable, freely(ICE) accessible withmaterial ISO-14040 which data. allows[34] for bon and Energy was usedand forcomply aggregate production a comparison of all datasets to be made. [27] When considering re-use or recycle options, the reason for Service Life freely accessible and comply with ISO-14040 EoL is Both datasets are traceable, important in order re-use to of coordinate and bestforrecovery which allows a comparison allordatasets to options, beincentivise made. the [27] the When for considering recycle reason EoL is Service Life method. important in order to coordinate and incentivise the best recovery When method. considering re-use or recycle options, the reason for EoL is IGU Butyl Seal IGU Butyl Seal important in IGU order the best recovery Spacer to coordinate and incentivise www.asianglass.com IGU Spacer Middle Pane IGU Butyl Seal IGU Butyl Seal Float Glass method. IGU Spacer Aluminium
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Middle Pane Insulated TR2 Thermally Float Panel Glass Composite
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component/system and can be calculated using equation 1. data sets that provide suitable averages of the environmental indicators for the building materials for life-cycle modules (A1-A3, B1-B6, C1-C4 = đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰ đ?‘‰ đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰ đ?‘‰ đ??¸đ??¸ďż˝ďż˝ďż˝ďż˝ďż˝/������� and D). This includes the energy density coefficient, incineration đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’đ?‘’ đ?‘’ đ?‘’đ?‘’đ?‘’đ?‘’ (1) coefficient, transport factor and demolition/disassembly/recycling coefficient.refers [33] The UK Inventory and Energy (ICE) was Incineration to the process of Carbon heat recovery which can beused converted into usable energy form e.g. electricity, combined heat are for aggregate material production data. heat [34] orBoth datasets andtraceable, power. Efreely is the energy recovered through incineration of for accessible and comply with ISO-14040 which allows Incineration materials calculated using equation 2. made. [27] a comparison of all datasets to be đ??¸đ??¸ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰ đ?‘‰ đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰ đ?‘‰ đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰đ?‘‰ Service= Life
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Service Liferecovered considering re-use orthe recycle the reason forsum EoL is TheWhen total energy from systemoptions, can be equated to the When considering re-use orcoordinate recycle options, the reason for the EoL isbest important in important in order to and incentivise recovery of the re-use/recycle and incineration energy calculated using equation order to coordinate and incentivise the best recovery method. 3. method. IGU Butyl Seal
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The environmental impact profiles for the four different EoL routes in terms of PENRE EE and GWP are shown in figure 8, with the comparison being restricted to the EoL and next use phases. A negative environmental impact indicates that energy saving has incurred by implementing a specific EoL scenario. Without the consideration for any form of performance degradation, scenario 4 provides the most environmental savings of the 4 scenarios and can therefore be considered as exploiting the system re-use potential fully (FRP=100%). Component re-use is able to exploit the FRP to 81.44% in terms of PENRE EE and 83.53% in terms of GWP. Scenario 3 is only made finding a suitable specialist disassembly/reconditioning plant,Byassuming they possible by a process that separates laminated glass. re-usingthat façade are likely to be situated further afield thanisestablished landfill and/or recycling components in new systems, energy saved from material extraction facilities. In the instance where no recycling carried out (scenario 1), a deficitofis and production, which yields higher is benefits than the avoidance environmental benefit is found. landfill by material recycling.
ANALYSIS: Facades
(3)
IGU Spacer
Middle Pane
Aluminium
Without Service Life Consideration
Aluminium
Float Glass
Argon-filled Argon-filled Where a particular material/component, =1, 2, 3 etc. Thermally iInsulated Cavity Cavity TR2
Composite Panel
Transportation
Outer Pane
PVB
Laminated Glass
TR2
Rainscreen Panel Aluminium
Perforated Rainscreen Panel TR1
Inner Pane
Laminated Glass
PVB
ETransport is the environmental impact caused as a result of the transport of materials, components and/or systems and can be Inner calculated using Outer Gaskets Gaskets equation 4. Float Glass
Aluminium
Float Glass
EPDM
Mullion Pressure Profile Aluminium
EPDM
Transom Pressure Profile
Transom Back Plate
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Transom
Mullions
Transoms The total transportation impactCover is Caps a sum of all of the transportation Adhesive Fixing Fixing Dry Connection processes from gate-to-grave (scenario Screw 1) or gate-to-cradle (scenarios 2,3Figure and 4)7:calculated using equation 5. Connection diagram constructed for timber-aluminium glazed curtain Figure 7: Connection diagram constructed for timber-aluminium glazed curtain walling walling system under study đ?’?đ?’? system under study đ?’?đ?’? ∑đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ť = ∑đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ť + ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘ŹCurtain + đ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ť walling framework and panel materials rarely deteriorate when Curtain walling framework and panel materials rarely deteriorate when ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? (5)façade đ?‘Źđ?‘Źđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ť considered independently. However, the multi-component nature of glass considered independently. However, the multi-component nature of systems, highlighted in figure 7, means that the service life and therefore re-use glass façade systems, inbeen figure 7, means thenearest service life Transport distances in thishighlighted study made on potential of one component, is have dependent on the based servicethat lifethe of their nearest and therefore re-use potential of one component, is dependent the permanently connected neighbour component. recycling/remanufacturing/incineration plants. For system and componentonre-use service life of their nearest permanently connected neighbour scenarios, it is necessary to factor service life in the calculation for reclamation component. For system andwere component re-use scenarios, it is with necessary potential. Service life figures established after consultation façade End-of-Life to factor service life in the calculation for reclamation potential. Service manufacturers. The reclamation value for scenarios 3 and 4 at 15and 30-years EEndlife accounts for the environmental impact due to the processes were as a percentage of the serviceafter life remaining. For example, laminated life taken figures were waste established withre-use façade involved in demolition, processing, andconsultation disassembly for Aluminium
3
Aluminium
Timber
Timber
glass with a service life of 25 years is taken to have 40% of its initial value when recovered at 15 years.
using equations 6-8.
đ??¸đ??¸ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ = đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€
Interpretation and Results
đ??¸đ??¸ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ = đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€
Without Service Life Consideration
(6) (7)
The environmental impact profiles for the four different EoL routes in terms = đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€đ?‘€ (8) of đ??¸đ??¸ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝ďż˝
PENRE EE and GWP are shown in figure 8, with the comparison being restricted
the EoL and next use phases. negative environmental impactasindicates that Thetoenvironmental impact of theAEoL processes can be taken the energy has incurred by implementing a specific sum of thesaving preceding equations shown in equation 9.EoL scenario. Without the consideration for any form of performance degradation, scenario 4 provides the
đ?’?đ?’? ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? = ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źsavings đ?‘Źđ?‘Źđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ť + ∑therefore (9) đ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Ź most environmental of + the∑4đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? scenarios and can be considered đ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ťđ?‘Ť đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š
as exploiting the system re-use potential fully (FRP=100%). Component re-use is able toAssessment exploit the FRP to 81.44% in terms of PENRE EE and 83.53% in terms Impact of GWP. Scenario 3 is only made possible by a process that separates laminated The inventory data is associated with a specific environmental impact by glass. By re-using façade components in new systems, energy is saved from aggregating the totaland quantities of all energy from thebenefits EoL and reclaim material extraction production, which yields higher than the avoidprocesses calculated using equation 10. ance of landfill by material recycling. Scenario 2 shows a net avoided impact with the majority of material avoiding ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Ź ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ťđ?‘ť + ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? đ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Źđ?‘Ź − landfill and finding recycling potential in a second use as aggregate material or ∑đ?’?đ?’?đ?’Šđ?’Šďż˝đ?&#x;?đ?&#x;? (10) đ?‘Źđ?‘Źđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘šđ?‘š feedstock for secondary aluminium components. In this instance, exploiting FRP by 29.78% in terms of PENRE EE and 34.42% in terms of GWP, much less than In this the environmental impact in terms of processes Embodiedthemselves Energy are that study, of component re-use. Further, the impacts of EoL (GWP), (kgCO eq.) for each scenario is (EE), (MJ) and Embodied CO 2 2 shown to have the largest impact in scenario 2. Scenarios 3 and 4 are less affected by EoL processes because component or system re-use would not require the melting down of secondary materials to produce new products which is one of the most energy-intensive components of the EoL processing. The environmental4 impact associated with any reconditioning or quality assurance has been taken as negligible. Although, relatively small in relation to material production, material transportation holds a more significant contribution in the component and system re-use scenarios due to the long travel distances associated with
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Figure TotalEnd-of-Life End-of-Life Environmental of i.) Figure8: 8:Comparison Comparison ofofTotal Environmental ImpactImpact in termsinofterms i.) EE (MJ) EE (MJ) and ii.) GWP (kgCO2equiv) and ii.) GWP (kgCO2equiv )
Scenario 2 shows a net avoided impact with the majority With Service Life Interdependency Consideration
of material
landfill recycling potential in over a second useseras It avoiding is likely that there and will befinding some performance degradation the façade aggregate material feedstock forbeen secondary components. vice life. [5], [35] In thisorstudy they have taken asaluminium a percentage of typical In thislifeinstance, exploiting by 29.78% of PENRE EE9.and service figures, proposed by FRP industry, illustratedinbyterms the author in figure 34.42% in terms ofand GWP, much less atthan thatand of 30-year component re-use. Component re-use system re-use a 15lifetime with With Service Life Interdependency Consideration and withoutthe a laminated glass process have been Further, impacts of EoLseparation processes themselves areconsidered. shown to Figure have It is likely that there will be some performance degradation over the 10the highlights to whatinextent the scenarios achieve the4full potentialby of largest impact scenario 2. Scenarios 3 and arere-use less affected façade service life. [5], [35] lifetimes. In this study they have been taken asthe a the system at different service service lifewould is considered EoL processes because component orWhen system re-use not require percentageofofscenarios typical service life figures, proposed by industry, illustrated favourability 3 and 4 over existing scenarios are less significant. the melting down of secondary materials to produce new products which
by the author in figure 9. is one of the most energy-intensive components of the EoL processing. The environmental impact associated with any reconditioning or quality assurance has been taken as negligible. Although, relatively small in relation to material production, material transportation holds a more significant contribution in the component and system re-use scenarios due to the long travel distances associated with finding a suitable specialist disassembly/reconditioning plant, assuming that they are likely to be situated further afield than established landfill and/or recycling facilities. In the instance where no recycling is carried out (scenario 1), a deficit is environmental benefit is found.
Figure service obtained from industry recommendations. Figure 9: 9: Component Component service lifelife obtained from industry recommendations
Component re-use and system re-use at a 15- and 30-year lifetime with and without a laminated glass separation have been AG 20-1process asianglass 51 considered. Figure 10 highlights to what extent the scenarios achieve the full re-use potential of the system at different service lifetimes. When
Figure 9: Component service life obtained from industry recommendations Figure 9: Component service life obtained from industry recommendations
Component re-use and system re-use at a 15- and 30-year lifetime with ANALYSIS: Facades and without a system laminated glass separation process have Component re-use and re-use at a 15and 30-year lifetime with been considered. Figure 10 highlights to what extent the scenarios achieve and without a laminated glass separation process have been the full Figure re-use 10 potential of thetosystem at different service lifetimes. considered. highlights what extent the scenarios achieveWhen is considered the favourability of scenarios 3 When and 4 over the fullservice re-use life potential of the system at different service lifetimes. existing arethe lessfavourability significant. of scenarios 3 and 4 over service life is scenarios considered existing scenarios are less significant.
Laminated Laminated Glass glass panels are comprised of one or more interlayers, sandwiched between or more ofsheets float, interlayers, annealed, heatLaminated glass panels aretwo comprised one orof more strengthened or toughened glass. Laminated glass manufactured sandwiched between two or more sheets of float, annealed, heat-with a poly-vinyl (PVB) interlayer (sandwiched between two flata glass strengthened or butyral toughened glass. Laminated glass manufactured with sheets in (PVB) more interlayer than 70%(sandwiched of laminated glasstwo forflatarchitectural poly-vinyl butyral between glass [37] Lamination is completed in autoclave, whereby the sheetsapplications. in more than 70% of laminated glass for architectural interlayer bonds togetheriswith the glassinpanes at elevated temperature applications. [37] Lamination completed autoclave, whereby the (110bonds – 140°C) and with pressure (~0.8panes MPa). As atemperature result, laminated interlayer together the glass at [38] elevated can and be difficult to separate when[38] it reaches the EoL. The recovery (110 –glass 140°C) pressure (~0.8 MPa). As a result, laminated glass in automotive vehicles hasit been the the subject recent study. [39] glass of can be difficult to separate when reaches EoL.ofThe recovery glass can betwo difficult to separate when it reacheshave the EoL. Theillustrated recovery ofbyglass The existing methods of recovery been of glass in automotive vehicles has been the subject of recent study. the [39]author in automotive vehicles has been the subject of recent study. [39] The two existin figure 11. The two existing methods of recovery have been illustrated by the author ing methods of recovery have been illustrated by the author in figure 11. in figure 11.
Figure 10: Comparison of EoL strategy re-use potential as a percentage (%) of Figure 10: Comparison of EoL strategy re-use potential as a percentage (%) of FRP at 0FRP at 0-years (no performance degradation) with consideration for service life years (no performance degradation) with consideration for service lifeofinFRP each Figurein 10: Comparison of EoL strategy re-use potential as a percentage (%) atscenario 0each scenario. years (no performance degradation) with consideration for service life in each scenario
Disassembly re-use(CR) (CR)opens opens opportunity to extend Disassemblyfor forcomponent component re-use thethe opportunity to extend the the service life of the system. By separating laminated glass panels Disassembly for component re-use (CR) opens the opportunity to extend service life of the system. By separating laminated glass panels for flat glass for reflat they glass re-use, they could forleading use inpanels systems, the service lifecould of the system. By separating laminated glass for use, be re-laminated forbe usere-laminated in new systems, tonew environmental leading environmental savings ofWithout the total system (42.82%). Without savings oftothe totalcould systembe(42.82%). form of systems, glass separation flat glass re-use, they re-laminated forsome use in new however, the of savings CR atof15-years would limited to only aatpercentage some form glassfrom separation however, the be savings from CR 15-years leading to environmental savings the total system (42.82%). Without the of laminated glass SL, and at 30-years, of15-years theSL, laminated be limited to only a percentage ofthe theperformance laminated and at someofwould form glass separation however, the savings from CR atglass can nothe longer be assured so remaining re-use potential islonger attributed 30-years, performance of the the laminated glass can wouldglass be limited to only a percentage of the laminated glass SL,no and at be purely to aso percentage SLofofthe the framework materialsattributed and the glass recycled assured the remaining re-use potential purely 30-years, the performance laminated glassiscan no longer be to a aspercentage aggregate material (33.13%). This is closer to the savings from scenario 2, SL of the re-use framework materials and the glass as assured so the remaining potential is attributed purelyrecycled to a in which the constituent materials are recycled and re-processed into new aggregate material (33.13%).materials This is closer savings from scenario percentage SL of the framework and to thethe glass recycled as components (29.78%) 2, in which the(33.13%). constituent materials are recycled and re-processed into aggregate material This is closer to the savings from scenario The system re-use (SR) scenario is considerably affected by service lifetime, new components (29.78%) 2, in which the constituent materials are recycled and re-processed into as the system lifetime is only as long as that of the least durable part which in new components (29.78%)glass. At a 15-year lifetime, the re-use potential drops this case is laminated The system re-use (SR) scenario is considerably affected by service from 100% at 0-years to 35.22%. At 30-years, the effects of the 25-year SL as the system lifetimeSL only long as that of the least durable The system re-use (SR) isisof considerably affected by service oflifetime, laminated glass andscenario 30-year theas IGU - due to loss in integrity of the part which in this case isis glass. At aof 15-year lifetime, relifetime, asaround the system lifetime only long that thethe least durable seal the perimeter oflaminated the as system -asmean that system nothe longer use potential drops from 100% at 0-years to 35.22%. At 30-years, part which in this value case is laminated glass. At asuggests 15-year lifetime, thethere re- isthe holds re-use as a whole system. This that unless an effects of the 25-year SL ofatlaminated glass and 30-year SL of assurance, the IGU appropriate non-labour-intensive method to for providing performance use potential drops from 100% 0-years 35.22%. At 30-years, component re-use with form of glassand separation yields best potential due to loss in integrity of the seal around the perimeter of system effects of the 25-year SL of some laminated glass 30-year SL ofthe thethe IGU for environmental savings when service life is considered. No current established that the system longer holds valueofas whole system. due tomean loss in integrity of theno seal around there-use perimeter thea system of system flat glass separation currently exists. This that unless is an appropriate meanmethod that suggests the no longer there holds re-use value as a non-labour-intensive whole system. method for providing performance assurance, component re-use with This suggests that unless there is an appropriate non-labour-intensive Technical Challenges in Component Re-use some of glass separation assurance, yields the best potential for environmental method for form providing performance component re-use with Little has been done to address the challenges of composite construction and savings when service life is considered. No current established method some form of glass separation yields the best potential for environmental permanent jointing methods in curtain walling and the IGU that may enable of when flat glass separation currently exists. savings service life is considered. No current established method component re-use. of flat glass separation currently exists.
Adhesive Connections
Due to the desired permanent nature of the joint/seal, removal of such a connection is not considered. Whilst debonding procedures depend on the adhesive5 used (silicone, epoxy or acrylate), adhesives that can be de-bonded or released on command hold strong potential for simplified dismantlement and recycling. Banea et al. formed a review paper that concluded that although there exist numerous proposed methods for adhesive reversibility or de-bonding, currently, there is no generally accepted solution for the disassembly of structurally bonded joints in industry. [36]
Laminated Glass
Laminated glass panels are comprised of one or more interlayers, sandwiched between two or more sheets of float, annealed, heat-strengthened or toughened glass. Laminated glass manufactured with a poly-vinyl butyral (PVB) interlayer (sandwiched between two flat glass sheets in more than 70% of laminated glass for architectural applications. [37] Lamination is completed in autoclave, whereby the interlayer bonds together with the glass panes at elevated temperature (110 – 140°C) and pressure (~0.8 MPa). [38] As a result, laminated
52
asianglass AG 20-1
Figure 11: Automotive windshield EoL disposal route
Figure 11:Automotive Automotivewindshield windshield disposal Figure 11: EoLEoL disposal routeroute.
At time of writing, there are no fully-established delaminating technologies inthere the EU allow large delaminating glass panels to be effectively At Attime of writing, writing, there no for fully-established delaminating time of are that noare fully-established technologies separated from PVB. The existing process involves destructively technologies in the EU that allow for large glass panels to be effectively in the EU that allow for large glass panels to be effectively separated from PVB. crushing theinvolves laminated glass panels as opposed to separating theaslayers separated from PVB. The existing process destructively The existing process destructively crushing the involves laminated glass panels whole so that the havetheto down-cycled into the opposed tothe separating theglass layersmaterials whole so materials have tothe be layers downcrushing laminated panels as that opposed tobe separating cycled into manufacturing process rather than being re-used the the rather than re-usedbecause because wholemanufacturing so the that the process materials have to be being down-cycled into the separated glass fragments dorather not have the to achieve recycling separated glass fragments do notpurity havecontent the purity content tothe achieve manufacturing process than being re-used because into visual glass. Further, cullet still re-melting at still recycling into visual any glass. Further, anyrequires recycling of cullet separated glass[39] fragments do recycling not[39] haveof the purity content to achieve high temperatures. For these reasons, it would be pertinent to devise effective requires at high these reasons, would be recycling into re-melting visual glass. [39]temperatures. Further, any For recycling of culletit still separation methods laminated glassseparation to enable re-use to effectively increase pertinent to for devise methods for laminated glass to requires re-melting at higheffective temperatures. For these reasons, it would be the service life of glass and reduce the energy costs of new glazing applications. enable re-useeffective to effectively increase the service life of glass andtoreduce pertinent to devise separation methods for laminated glass energy costs of new glazingthe applications. enablethe re-use to effectively increase service life of glass and reduce Conclusion the principal energy costs of new glazing applications. The objective of this study was to understand the environmental
Conclusion Conclusion
opportunities for architectural glass façade re-use and propose the technical methods that might exploit such recovery strategies for later experimentation. The principal objective this studybased was to the environmental Four different EoL scenarios wereofdeveloped onunderstand current and potential opportunities forofarchitectural glass façade re-use propose the The principal objective thistostudy to understand the environmental future separation technologies allowwas comparisons in methods forand design for technical that might such recovery for later disassembly to beformethods recognised. opportunities architectural glassexploit façade re-use and strategies propose the Effective consideration of the serviceEoL life scenarios ofrecovery the reclaimed components is on experimentation. different were developed based technical methods thatFour might exploit such strategies for later essential when assessing feasibility re-use. Forwere this study, remaining service experimentation. Four the different EoLofscenarios developed based on life was taken as a percentage of the estimated service life proposed by industry. In reality, the reclamation value would not drop-off to zero at the end of the 5 proposed service life from industry. Implementing system re-use, in the instance of no performance degradation, can potentially increase environmental benefits in terms of EE by a factor of 3.4 times that of the existing recovery scenario commonly used in industry (scenario 2). However, in reality, there is some performance deterioration that takes place and when considering service life interdependencies, the significance in the savings made from system and component re-use are reduced. This is as a result of the multi-component nature of glass façade systems in which their system service life is determined by the service life of their nearest connected neighbour. As a result, with consideration for service life, system re-use shows decreasing is less favourable over longer lifetimes due to the lack of performance assurance of the internal components. This impact is likely to be more severe in more integrated systems such as those that include motorised components with a typical service life of <15 years. Over a longer lifetime, >25 years, and without performance testing, it could be concluded that component re-use with appropriate separation methods could makes a beneficial recovery strategy, with environmental savings in terms of
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ANALYSIS: Facades
EE by a factor of 1.95 times that of the recycling recovery scenario. From an energetic and environmental perspective, component and system re-use hold large potentials in primary energy and embodied carbon savings, with some form of separation process to recover constituent components, performance assurance that could extend the theoretical service life of components together with a functional glass collection and recovery supply-chain. Without such processes in places, the recycling scenario may hold the greatest environmental benefit for the treatment of glass curtain walling units at the EoL. The existing trajectory of façade design evolution creates sufficient challenges in reclaiming glass from existing systems when the façade reaches its EoL. Future regulation may add to manufacturer responsibility that requests details of hosw new façade systems will be recovered. Rising levels of refurbishment are likely to continue to open up opportunities to recover glass from existing stock for re-use. Further, structural adhesives are increasingly replacing bolted connections and there may be new advances in the production of specialised glass in the decades to come. At present there is no established methodology to overcome the technical issues of curtain walling disassembly for maximum material recovery within existing buildings.
Future Research Outcomes
It is necessary to extend the study of the relative environmental impact of different end-of-life routes to different types of façade system to highlight what early-stage design decisions would achieve the most significant savings on the whole-life-cycle and recoverability of constituent materials. There exists a lack of consensus among studies calculating and documenting service life data constituent materials and systems of a glazing unit. Different elements can respond differently to external influences allowing for each to have a different lifespan over which they degrade and/or eventually fail meaning that there are a large number of uncertainties involved in predicting the service life and therefore
salvage value of components. Research into the typical depreciation rates is necessary to help define the actual residual reclamation value at any point in time during the glazed façade life. Further, it would be useful to extend the LCIA to other indicators such as those that consider the scarcity of each resource and the avoidance of landfill. This would be made possible with access to a more complete eco-inventory database. An extended assessment should make considerations for the initial application of recycled content in designs and the use of renewable energy in material processing to ensure the benefits of re-use are not over-estimated. The existing barriers and motivations to glass façade re-use as expressed by industry through a semi-structured interview will be published in a separate review paper. While there is a lack of clarity on the properties of materials and complexity of modules in the types of construction components used in the sector, there will be significant barriers to re-use. [21] Planned research by the authors in this area looks to address the technical challenges in re-using flat glass by experimentally investigating separation methods for separation of laminated glass and joints of aluminium and glass bonded by epoxy and silicone. The development of new debonding technologies and design methods can be fed back into the environmental assessment to promote the uptake of more sustainable designs. By considering a multi-method approach to address the challenges of re-use in the glass façade supply-chain, it will establish the opportunities to recover high-value façade material from existing building stock. Further, it will provide key indicators for future design consideration to allow for initial design and future deconstruction to clearly relate to one another to deliver buildings that truly consider whole-life energy.
References
A full list of reference is available on request.
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In focus
AGI: UPGRADES CONTINUE TO DRIVE BUSINESS In an interview between regional media Rajesh Khosla, president & CEO, AGI glaspac, talks about the companyâ&#x20AC;&#x2122;s growth, prospects of glass replacing plastics, technology innovations and so on. HSIL Ltdâ&#x20AC;&#x2122;s packaging product division, AGI Glaspac, (better known as AGI) was established in 1972. They manufacture high quality glass containers to meet stringent and demanding quality and standards for packaging needs of foods, pharmaceuticals, soft drinks, spirits, beer, wine and other industries. The company has positioned itself as one of the leading container glass manufacturers in the country. Currently, the company melts 1,600 tonne of glass per day. Take us through the history of AGI Glaspac, from its inception to the present day: AGI was established in the year 1972 with a capacity of 80 tonne/day (TPD). In 1981, HSIL Ltd acquired AGI and upgraded the furnace capacity to 180 TPD. In 1996, we achieved its first ISO 9000 certificate. In 2000, the first new furnace (F-2) was added, which increased the capacity to 450 TPD. In 2004, the second new furnace (F-3) was added to raise the capacity to 600 TPD. In 2009, a new greenfield plant was started at Bhongir with the third new furnace (F-4) of capacity 500 TPD, which raised the capacity to 1,100 TPD. In 2011, the company exported its first consignment. In 2012, the fourth new furnace (F-5) was added, which increased the capacity from 1,100 TPD to 1,600 TPD with a colouring forehearth. It is also the largest container glass manufacturing facility at a single location in Asia. In 2016, electrostatic precipitators were installed to reduce SOX, NOX and CO2. In 2017, the company introduced TPM, LEAN and Six
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Sigma. In 2019, we invested in natural gas to curb carbon emissions. We also installed machinery like end-of-the-line packaging for robotic case packer, case palletiser, cullet washing system, automated dry optical sorting system etc. How is the glass packaging industry performing in India? What is the rate at which the company is growing? The glass industry in India is quite old and well established. It remained largely a cottage industry for a long time. In recent years, the industry has transformed from rudimentary mouth-blown and hand-working processes, to adopt modern processes and automation in a big way. However, Indian per capita consumption for glass packaging (1.8kg) is much lower compared to other nations. The following graph shows the comparative consumption in other countries What about Per Capita consumption? The company currently meets approximately 20 per cent of the glass container demand in the country. It plans to increase its capacity by more than 50 per cent in the coming three years. We are present in all the important segments of the glass containers. We are working closely with customers to deliver value in the supply chain and to identify micro opportunities and cater to them. The company has invested in resources like R&D, machinebuilding, machinery and automation so that the best products can be delivered to our customers with the present infrastructure.
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What are the prospects for the growth of the glass packaging sector in India? Despite the low per capita levels, the country’s glass container industry is buoyant, with downstream demand from local beverage, alcohol, food, pharmaceuticals and cosmetics industries. The industry is experiencing a surge in demand, due to the growing purchasing power, urbanisation, modern retail and increasing awareness about health and hygiene among consumers. The industry’s prospects are likely to improve even further in the future due to rising disposable income and India’s GDP rate in the short- and medium-term. The local economy, which remained mostly unaffected by the global financial crisis, has been a major aid for the glass container industry, allowing manufacturers to grow even during these uncertain times. Tell us about your clients in the food and beverage industry. We deliver our products to segments like beer, chemicals, food, coffee, liquor, pharma, soft drinks, beverages, wine and water bottles. We also have our retail B2C segment, with a brand called “Greendrop Glassware,” where we sell our bottles in e-commerce sites like Amazon, Flipkart, Snapdeal etc. Our clients from the food industry are The Global Green Company, Heritage, Reitzal Koeleman, Nestle, HUL and from beverages, Coca Cola, Parle Agro and PepsiCo. Our clients in other segments include ABInBev, Bira91, UB Group, Avantor, Thermofisher, Dr Reddy, GSK, Pfizer and Diageo, amongst others. What are the prospects of glass replacing plastics? We are gearing up to support India’s vision to replace plastic with green and environmentally friendly product glass. We have expanded our capacity to meet the rising demand. Since plastic is lighter in weight and easier to use, glass uses new technology to match the characteristics of plastics. NNPB can produce the best glass bottles, and the current trend is tempering, using appealing colours and other value additions. We are also tailoring our supply chain to cater to the market. One of the initiatives is our retail segments Greendrop Glassware, which deals with B2C and with e-commerce. What are the challenges currently being faced by the glass industry in India? Glass packaging continues to face fierce competition from other forms of packaging in India. Competition from alternative materials is increasing. Some reasons why customers do not use glass are loadability,
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Despite low per capita levels, the country’s glass container industry is buoyant
breakages and unit cost. The industry needs to develop more lightweight bottles and improve the durability of its finished products to compete in the market. In the past, the local container glass industry has concentrated its efforts on such objectives as traceability to restrict counterfeiting. Such an initiative would involve the use of permanent engravings on containers, showing the quarter and year of manufacture. This system could be helpful to protect consumers from any harmful practices employed by spurious product manufacturers. What technology innovations are you adopting? We are trying to set new trends in the industry by leveraging technology to create innovative products that will help meet the already existing demand more efficiently. Some of them include: • Adopting new tempering method for strengthening glass containers • Creating lightweight containers in different geometric shapes • Using newer technologies like single-stage forming to produce thinner but stronger glass containers • Developing a coating on the surface of the glass to avoid strength loss • Creating heat-resistant Pyrex glass • Creating internal embossing glass bottles
Finally, what are the main future plans you have at present? We have already invested in the upgradation of our plant. Our investments are in technology upgradation, inspection, packaging systems, warehousing and logistics. We are also looking at increasing our volumes by at least 50 per cent in the next three years. Our customer base comprises a host of multinational and Indian companies in various business segments. The domestic market is our priority, and we have a clear policy that we would not like to export at the cost of domestic demand. The additional capacity is used for exports to regions like North America, Europe, Africa, Canada, as well as the APAC regions.
AG 20-1 asianglass
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SPECIAL REPORT
MEDIA SUPPORT
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EXPO GUADALAJARA
27-29 JULY 2020
GUADALAJARA, JALISCO Organized By: YT International Enterprise Inc.
Window on
INDONESIA Table 1 2015 2016 2017 2018
Table 1 2015 2016 2017 2018
23,527,720 32,601,840 23,495,884 24,212,061
Total float glass exports (sq metres)
1,999,727 2,910,108 6,887,010 7,953,859
Total float glass imports (sq metres)
Table 1 India Thailand Malaysia Viet Nam Rep. of Korea Australia Japan Philippines
7,192,684 4,304,995 2,602,504 1,652,531 1,257,534 995,626 1,094,588 995,164
Table 1
Leading float glass export destinations (sq metres)
Malaysia China Thailand Japan India
5,443,794 1,815,349 267,477 208,342 153,147
Leading float glass import sources (sq metres)
1
1
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Table 1 2015 2016 2017 2018
Table 1 53,235,309 44,669,689 23,817,173 56,977,567
Total container glass exports (Kg)
2015 2016 2017 2018
73,634,415 117,717,040 142,587,241 124,138,434
Total container glass imports (Kg)
Table 1 Philippines New Zealand Australia Papua New Guinea Viet Nam Malaysia USA
27,942,967 10,361,319 4,143,178 4,051,272 3,739,553 1,408,684
1,248,870 Leading container glass export destinations (Kg)
China Thailand Malaysia India Rep. of Korea France Viet Nam
87,915,894 20,412,567 2,132,192 5,258,207 1,244,210 1,085,610 1,753,010
Leading container glass import sources (Kg)
1
1 Table 1
Table 1 2015 2016 2017 2018
2015 2016 2017 2018
56,523,276 102,042,375 114,294,176 87,915,894
Container glass imports from China (Kg)
Vietnam 71 2,522 7,546,052 1,753,010
Thailand 6,020,294 6,677,508
12,215,689 20,412,567
Container glass imports from Vietnam/Thailand(Kg) Vietnam Thailand
1 1
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Anaylsis
Refractory Zone Noranada solves Union disputes Jamaica Noranda Bauxite has been facing a few obstacles in keeping a leg up in the local bauxite/alumina industry. However the public-private partnership (PPP) entity has now settled all wage disputes with three leading trade unions representing its approximately 800 workers. Although the negotiations with the three unions — Bustamante Industrial Trade Union (BITU), Union of Technical, Administrative and Supervisory Personnel (UTASP and the University and Allied Workers Union (UAWU) — lasted approximately two years, the new agreements are expected to maintain a high level of production at Noranda installations and critically reduce the threat of work stoppages for another two years, at least. The last of the three agreements was signed last week with the UAWU, which represents the production staff, and will continue through to April 30, 2023. The agreement with the BITU, which represents clerical and administrative employees, will be the earliest to end, as it concludes on December 31 this year. The agreement with UTASP, which represents the supervisors, will end on December 31, 2022. Noranda Jamaica Bauxite Partners, formerly St Ann Bauxite Jamaica Limited and prior to that Kaiser Jamaica Bauxite Company, is a partnership between Noranda Bauxite Limited (NBL), a Jamaican limited liability company, and the Government of Jamaica. Noranda Bauxite Limited has a 49 per cent interest in the partnership and holds and operates the physical
mining assets and operations. The Government of Jamaica owns the majority 51 per cent. The negotiations led to an agreement with New Day which, according to Minister of Transport and Mining, Robert Montegue, was necessary to protect the interest of the Government and people of Jamaica, while considering the best options for all parties involved. Noranda mines bauxite ore in St Ann, which is shipped to its plant at Gramercy, Louisiana, and refined into alumina (aluminum oxide). Noranda then converts the alumina into aluminum at its smelter in Missouri. A concession from the Government permits Noranda Bauxite Limited to mine bauxite in Jamaica through 2030. However, there have been a few hiccups recently with anti-mining activists in the Cockpit Country insisting against any mining within that area. However, with the labour issues now a part the long history of the bauxite company, which actually started in Jamaica as the once-giant American firm Kaiser Aluminum in 1967, Noranda can focus more on assuring Jamaicans of its corporate responsiveness, as well as making use of any possible growth fed by the insistent tariffs introduced by the Trump administration which should boost US demand for aluminum. Noranda’s company Chairman and CEO David D’Addario suggested, after the negotiations with the local trade unions concluded last week, that a strong
WRA elects new chairperson World Carol Jackson, Chairman and CEO of HarbisonWalker International (HWI), has been elected as the incoming president of the World Refractory Association (WRA). Jackson began her two-year term in January 2020, succeeding Stefan Borgas, CEO RHI Magnesita, who has led the organisation since January 2018. “I’m honoured to lead WRA through its next chapter and continue building on the tremendous momentum our organisation has achieved under Stefan’s leadership,” said Jackson. “As the global voice of the refractory industry, it is imperative for us to unify and advance the common interests of this trade association, as we promote the value and criticality of refractory in manufacturing to all our stakeholders.” Formed in 2014, WRA has grown from 12 to 22 members in the last two years and has itself
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become a member of the World Steel Association (WSA). Under Borgas’ leadership, the WRA established working groups (Digital Data Standards, HS Codes, International Standards, Environmental Standards, Online Repository of Technological Papers, Communications Committee) to address specific areas of interest to the global refractory industry and its stakeholders. It also hosted the industry’s first Innovation Conference in China in fall 2018. Jackson said that the success in adding and engaging membership under Borgas’ leadership paves the way for WRA to focus on continued growth and further elevate member engagement. She also affirmed that priorities for the organisation would centre around technology and innovation, sustainability, safety, customer collaboration, and communication initiatives to help unlock the full
relationship with them is necessary for the success of its Jamaican bauxite operations. “When we acquired Noranda Bauxite and 50 years of mining rights in Jamaica, we committed to the Government that we would work to reach fair agreements and enhance the stability of our unionised workforce,” D’Addario said. “These three union agreements demonstrate that we have fulfilled that promise, while helping to ensure that our employees remain among the most well-compensated in Jamaica,” he added. The point was seconded by Delroy Dell, Noranda Bauxite’s general manager, who noted that the workforce was the backbone of Noranda’s operations in Jamaica. “The negotiations were tough but fair, and we are proud to work cooperatively with these unions to strengthen our worker protections, and provide fair wages to all our employees,” Dell stated. “I want to thank the union representatives, and our own executive team, for collaborating on these vital agreements,” he added. Noranda Bauxite is the bauxite mining operation of New Day Aluminum Holdings, LLC, which also owns and operates Noranda Alumina, a smelter grade alumina refining operation in Gramercy, Louisiana. New Day also owns and operates Niche Chemical, which markets chemical-grade alumina in North America, along with specialty minerals businesses Niche Fused Alumina in La Bâthie, France and Niche Fused Magnesia in Hull, England. value potential of the refractory industry. “Through my role with WRA, I’m looking forward to applying the passion and intensity that is inherent in our HWI culture to help guide the interests of our global industry. HWI has been a refractory leader and innovator for more than 150 years, and we are intensely at work to evolve our company for the next 150 years. Our company goals and focus on innovation closely parallel the objectives of WRA,” said Jackson. Borgas wishes Jackson every success in the task ahead: “The refractories industry is facing numerous hurdles. The will to innovate within the industry came just in time. But the next challenges are already waiting. The macroeconomic situation is difficult for our business and we also have a major responsibility in the fight against the climate crisis. Carol Jackson will represent the refractories industry with a courageous and strong voice. She will steer us through these stormy times with a safe hand.”
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Façade recycling and re-use Turkey: a country in focus Fenestraton trends: a window for today? Make-up your mind: cosmetic packaging trends Safety glass standards: matching requirements EVENTS: Glassman Asia, PV Japan, Eurasia Glass, Door & Window China, Glass Middle East, Egypt ■ ■ ■ ■ ■
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RHI Magnesita targets sub-continent growth India RHI Magnesita serves industries as diverse as steel, cement, non-ferrous metals and glass. With a turnover of Euro 3.1 billion, 35 production sites and 14,000 employees, the refractory behemoth serves more than 10,000 customers globally. Its shares have a premium listing on the London Stock Exchange and are a constituent of the FTSE 250 index. RHI Magnesita has been operating in India through its three subsidiaries – the BSE/NSE-listed Orient Refractories Ltd, RHI Clasil Pvt Ltd and RHI India Pvt Ltd. Together, they provide refractory products and refractory management services to many large and mini steel plants in India. The company is in the process of integrating its Indian subsidiaries to form one listed entity in India, which would emerge as the largest single refractory solutions platform in India offering the industry’s most comprehensive product portfolio. The merger scheme is currently under NCLT hearings and is expected to be completed before the end of the calendar year. Moreover, as part of its 2022 strategy, the company is looking at inorganic growth in the Indian market with above-average level of investments. The refractory services provider has recently made a small acquisition of a metallurgical equipment manufacturing company in Mumbai. Further, it has inked an asset purchase agreement to acquire a plant and certain other assets of another Indian refractory maker in Cuttack, Odisha. RHI Magnesita India MD and CEO, Parmod Sagar, was in Kolkata recently and in conversation with Steel 360 dwelt at length on the company’s technological offerings, its business developments in India and the challenges it is likely to confront.
Growth forecast
“RHI Magnesita plans to strengthen its footprint in India at a time when steel capacity enhancement and unprecedented rise in steel consumption have turned India into the rising star of the global steel industry. We have already acquired two companies in the country. One is a small Mumbai-based metals
company that manufactures slide gate-handling mechanisms. So, there is a refractory and there is another machine that operates that refractory. This company is currently a 100% subsidiary of Orient Refractories Ltd,” Sagar informed. “This year,” he continued, “we have also concluded an asset purchase agreement with Manishri Refractories & Ceramics Pvt Ltd. This plant is in Cuttack. As part of the agreement we have acquired the land, building and equipment of the said company. As it is an asset deal, we haven’t acquired the company’s business. And we are planning to put up a magnesia carbon production facility at the plant. It will be the company’s first such production facility in India.” Dwelling on the refractory market in India and RHIM’s valued customers, Sagar said: “Almost all the integrated steel manufacturers are our customers like the JSPL Group and the Tata Group. Earlier, Bhushan Steel was a valued customer until it was acquired by the Tata Group.”
Technology leadership
Responding to a query as to how competitive the Indian market is for RHIM, Sagar commented: “There are two distinct segments in the market. First is the high-end product segment that calls for the utilisation of high-end technology. We don’t have many competitors in this segment and we are the market leader in technology. However, in the commodities segment the competition is stiff. There are Chinese traders and a lot many small players competing for space. However, we are hopeful that the merger of our Indian subsidiaries would definitely be a big boost to our business. We will have a bigger product portfolio, be in a position to offer full line solutions to our customers and manage resources far more efficiently.” Speaking about RHIM’s focus on the South East Asian markets, Sagar observed: “We have a strong presence in the emerging South East Asian markets and would like to consolidate our position further. Many RHIM products from India are exported to other parts of the region.” Commenting on the company’s thrust on technology, Sagar
said: “We have a state-of-the-art manufacturing facility in Vishakhapatnam and a state-of-the-art R&D centre is coming up in Bhiwadi, an industrial township. RHIM has two global R&D centres in Leoben, Austria, and Contagem, Brazil. The third is coming up in Bhiwadi. It will take about one-anda-half years to be fully functional. The technology centre will streamline our R&D operations in India.” Highlighting the company’s mining operations that are spread across the globe, Sagar said: “There are not much refractory raw material reserves in India. There are some bauxite reserves and small reserves of magnesia which are basically low-grade, unsuitable for RHIM’s high-end products.” “India and China are our two major markets due mainly to their strong steel fundamentals. Prices are softening in the US and Europe and end-demand remains weak. However, our look-east policy has not been adopted to offset that loss. We are looking at cementing our position in the growth hubs of the global steel industry. We know which are the global growth hubs of the steel industry and are focusing on those regions. In China, for example, the revival of the dolomite plant in Dalian will contribute in a big way to boosting our sales volumes,” he said. RHI Magnesita’s main client base is the global steel industry. Sagar said: “Around 85% of our customers are from the steel industry. The rest are from nonferrous industries like cement, chemicals and glass. Now, we all know the importance of recycling in the steel industry and its impact on sustainability. As a leading global supplier of refractory materials we understand the importance of recycling and reusing materials. As an eco-friendly manufacturer, we focus on increasing the share of secondary raw materials in manufacturing.” Expressing optimism about RHIM’S growth prospects in India, Sagar averred: “Initially, we are looking at growth of around 6% CAGR if steel fundamentals remain strong. With the government’s focus on increasing per capita consumption of steel in the country, we are hopeful of growing at a rate of around 7% per annum.”
RHI moves on MORCO United States RHI Magnesita, the leading global supplier of high-grade refractory products, systems and solutions, acquired Missouri Refractories Co, Inc. (MORCO). “With its more than 45 years of experience in fulfilling the needs of demanding, highly loyal and satisfied customers, MORCO perfectly fits into RHI Magnesita’s strategy to strengthen our position in the North American refractory market. The dedicated team in Pevely, MO, truly is an asset that will contribute to RHI Magnesita’s success in the whole region,” said Stefan Borgas, CEO RHI Magnesita. The site is strategically located in the Midsouth of the United States, a region that is rapidly growing in importance for RHI Magnesita. It
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produces over 400 high-quality monolithic mixes, which serve a multitude of industries, including steel, cement, lime and glass. The employees also have the expertise to provide refractory material for the petrochemical industry. “As a global leader, we look forward to continuing MORCO’s success story and servicing all of the existing customers. In addition, we will open up new opportunities, grow the business and develop new markets for all of these high-quality products and applications,” added Borgas. RHI Magnesita is the leading global supplier of high-grade refractory products, systems and solutions which are indispensable for industrial high-temperature processes exceeding 1,200°C in
a wide range of industries, including steel, cement, non-ferrous metals and glass. With a vertically integrated value chain, from raw materials to refractory products and full performance-based solutions, RHI Magnesita serves customers in nearly all countries around the world. The Company has a high level of geographic diversification with more than 14,000 employees in 35 main production sites and more than 70 sales offices around the world. RHI Magnesita intends to leverage its global leadership in terms of revenue, scale, product portfolio and diversified geographic presence to target strategically those countries and regions benefitting from more dynamic economic growth prospects.
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CREATING LANDMARKS OUR PRODUCTS Clear Float Glass Automotive Quality Architectural Quality Silvering Quality
Cairo Office 52 Cornich El-Nil, Sharifain Tower Maadi - Cairo - Egypt + 202 252 58 005 + 202 252 60 506 11728 info@sphinxglass.com
Tinted Float Glass Sky Blue Euro Grey Euro Bronze Dark Bronze
Cairo Office Sadat City, Seventh Industrial Zone + 204 826 25 220 + 204 826 25 225 32897 www.sphinxglass.com
Pyrolytic Coated Glass Solarlite Coated Glass Vistalite Coated Glass
