June 2018—Vol.41 No.6
INTERVIEW: PHOENIX AWARD WINNER COMPANY PROFILE: SGD’S FURNACE NUMBER 2 BATCH PLANT I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
Glass International June 2018
When reliability is not negotiable.
ZIPPE – BECAUSE WE DO IT.
Batch Plants • Cullet Plants • Factory Cullet Recycling • Automation Modernization • Engineering • Glass Recycling • Batch Charging Glass Level Controlling • Preheating • Maintenance & Service
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To make glass better, put us in the mix. Improving combustion can enable you to increase glass production, reduce fuel consumption, enhance glass quality, and reduce emissions, such as NOx, SOx, CO₂, and
particulates. Let Air Products’ in-house modeling and melting experts help you get there. For more than 70 years, we’ve delivered safe oxygen solutions, from our very first oxygen enrichment applications to our continuously evolving portfolio of low-emissions Cleanfire® oxy-fuel burners. You can count on Air Products for reliable gas supply and to help optimize your production—just like we have done for hundreds of furnaces all over the world. Contact us to put the skills and experience of our global team to work for you. Optimal melting takes one key ingredient: Us.
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June 2018 Vol.41 No.6
June 2018—Vol.41 No.6
INTERVIEW: PHOENIX AWARD WINNER COMPANY PROFILE: SGD’S FURNACE NUMBER 2
BATCH PLANT I N T E R N A T I O N A L
A GLOBAL REVIEW OF GLASSMAKING
Glass International June 2018
When reliability is not negotiable.
ZIPPE – BECAUSE WE DO IT.
Batch Plants • Cullet Plants • Factory Cullet Recycling • Automation Modernization • Engineering • Glass Recycling • Batch Charging Glass Level Controlling • Preheating • Maintenance & Service
Front cover image www.zippe.de
Company profile SGD Pharma: SGD Pharma celebrates Furnace 2
21 Packaging Marpak: Protection in packaging
24 Environment Sisecam: Sisecam’s sustainability approach
28 Batch plant EME: Premix technology for improved distribution of minor materials
GI Cover june.indd 1
Personality profile Oliver Wiegand: Phoenix Award winner combines technology with tradition
32 Zippe: Zippe builds Turkmeni batch plant 33
Company profile: Pace Glass: Pace Glass breaks ground on recycling facility in New Jersey
35 History: The evolution of refractories
Events review: GlassTrend seminar: GlassTrend discusses how to make the industry greener
Plus find us on Linked-In and Twitter.
38 Events review - Glass appreciation: Glass Appreciation course provides great introduction to glassmaking Training: O-I Poland: Global programme trains manufacturing leaders
41 Analysis: Russia Russia’s container market in 2017 @Glass_Int
42 Events: China Glass review Visitor numbers rise by 49% at China Glass 2018
Glass International June 2018
www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: firstname.lastname@example.org Editorial Assistant: Sheena Adesilu Tel: +44 (0)1737 855154 Email: email@example.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: firstname.lastname@example.org
Youth is the key to the future of glassmaking
famous football commentator in England once reported that teams ‘never win anything with youth’. He made the comments on national television in the UK shortly after Manchester United had been comprehensively beaten on the opening day of the seasons against a mid-table team. The comment was heavily publicised over the subsequent weeks and seemed to galvanise Manchester United. The team went on to not only win the league that season but to embark on arguably their most successful period in their history, culminating in a European Cup win a few years later. The youngsters in question included now household names such as David Beckham, Ryan Giggs and the Neville brothers. I was reminded of those comments when leaﬁng through this issue of Glass International. Two young faces have contributed immensely to the glass industry this month in varying roles. Giorgio Minestrini was named winner of the best paper at the Furnace Solutions event. The engineer from Italy provided a paper about the Prime Glass project, which, alongside colleagues from Stara Glass and Stazione Sperimentale del Vetro (SSV) aimed to contain NOx in regenerative end port furnaces used in glassmaking. The project helped reduce NOx by between 30/40% - a tremendous achieve-
ment for which credit should go to all involved in the project. The second young face is that of Marie Lurquin, an engineer from SGD Pharma who helped lead the recent Furnace number 2 project at its Saint Quentin La Motte site in northern France. She was named Godmother of the new furnace thanks to her work in leading the successful project. Mme Lurquin has only been working in the industry for a few years but hopefully she has a bright future ahead of her. It is young people such as Giorgio and Marie who are the future of the industry and who can point the way forward. It is well known there are not enough young people in the industry and entering the industry. There have been concerns expressed at recent glassmaking conferences that only older, experienced engineers have attended. Conference organisers have questioned why young engineers have not been given permission to attend. What does the future hold for an industry that does not invest in its youth? Hopefully both Giorgio and Marie, in their own small way, can provide an inspiration for other youngsters to follow their example. Greg Morris, Editor email@example.com
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United National Council of the glass industry (Steklosouz) Glass International annual subscription rates including Glass International Directory: For one year: UK £173, all other countries £242. For two years: UK £308, all other countries £432. Airmail prices on request. Single copies £47.
Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2017 edition: UK £206, all other countries £217. Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.
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Glass International June 2018
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NEWS IN BRIEF
Unimin becomes Covia
Batch plant specialist Zippe Industrieanlagen has acquired the glass unit from the Finnish company Lahti Precision. The glass unit will continue its operation under the new company name Lahti Glass Technology. The previous owner has exited the glass business. Existing orders will however be completed with the support of the new entity. Mr. Jarmo Näppi will be the new Managing Director of Lahti Glass Technology and remains the contact person for customers, along with his team of professionals.
Zippe CEO, Dr. Philipp Zippe, said: “We are extremely happy about this acquisition, as it will create new opportunities in the development of new technologies, combined with the ability to serve our customers even better through increased service capabilities and an expanded geography for our national and international clients. “Lahti will bring in further competencies e.g. in the field of raw material weighing, while we will also collaborate in the field of Research & Development in order to create outstanding technological
solutions for which the potential has now become mutually bigger,” he said. “The technologies and individual market strengths of both companies complement perfectly,” said Mr Näppi. Service-orientation will be strengthened further due to an increased international footprint and a bundling of competencies. Lahti Glass Technology will continue to serve its existing customers in the same way while now having the additional back-up of Zippe’s specialists from its headquarters in Wertheim, Germany.
Verallia celebrates Vauxrot furnace Verallia has invested €28 million in its Vauxrot, France glass container plant. The plant’s furnace has been totally rebuilt and extended to supply a 4th production line. The investment has modernised production equipment and increased the capacity of the site, which Verallia said was a champion of fast colour and model job-changes. The site can now make up to 700,000 bottles a day for the wines and spirits market, and the beer segment, supporting the boom in micro-breweries
in particular. Vauxrot is one of two group plants in France to produce
yellow and dark amber bottles, alongside its Saint-Romain-lePuy, Loire site.
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Glass for Europe unveils relaunched website
Flat glass trade association Glass for Europe has launched its new-look website. The new website was launched yesterday during the annual meeting with national glass and glazing associations. The new website is the last step in the change of visual identity of Glass for Europe, following the launch of the new logo in October last year.
Anchor Glass fire
Anchor Glass’s Henryetta, Oklaholma, USA plant suffered from a large fire. According to local media reports, the fire damaged four of the plant’s six shops inside. Authorities suspect a ruptured oil line in the basement of the plant in Henryetta was the cause of a blaze.
O-I to close Atlanta site
O-I is to cease production at its Atlanta, GA, USA plant. The closure is expected to occur on or after July 18, 2018 and the company said the continued decline of the US beer market was the reason for the closure. The world’s largest container glassmaker said it would facilitate the closure in a respectful manner for the 250 people staff impacted at the plant. The site’s customers will be served by other domestic plants in its network. “The required capital outlay for the Atlanta operations and continued decline of beer in the domestic market influenced the decision to close the plant,” it said.
Zippe acquires Lahti Precision’s glass business
Glassmaking raw materials company Unimin is now known as Covia, following a merger. The combination of Unimin and sand miner Fairmount Santrol was completed recently. Covia will be an industrial mineral company with about $2 billion in annual revenue.
5 Glass International June 2018
news JUNE.indd 3
Stara Glass engineer wins Furnace Solutions award
Introducing the Cleanfire® ThruPorte™ burner A prescription for aging regenerators Undergoing regenerator repairs or having difficulty maintaining full production in an aging furnace? Turn to Air Products’ new Cleanfire® ThruPorte Oxy-fuel burner for an onthe-fly heating solution to avoid downtime or extend your furnace campaign. This patented and commercially-proven technology, installed from the underside of your port, allows you to add heat where and when its needed. Key features: • Tandem water-cooled oxy-fuel burner and oxygen staging lance • Proven durable design that can be easily installed in an existing port, while the furnace is running • Adjustable flame length and angle for optimal heat distribution and surface coverage • Remote, wireless and continuous online monitoring of burner performance • Available for rapid deployment To make glass better, put Air Products in the mix.
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Stara Glass’s Giorgio Minestrini won the award for best presentation at the Furnace Solutions event. Mr Minestrini won the Michael Garvey Award for his paper Primary Techniques for NOx containment for a More Sustainable Glass Industry. On receiving the award Mr Minestrini, pictured on the left of the photo, said: “I would like to dedicate this award to all of us in the glass scientific community because I think that no one can work alone and thanks to the work of all of us the glass industry can reach
higher and higher.” The Furnace Solutions event is organised by the UK Society of Glass Tech-
nology’s Melting Technical Committee (MTC) and took place in Lucideon, Stoke on Trent, UK.
US bank backs Nigerian float manufacturing plant The US bank Multilateral Investment Guarantee Agency (MIGA) has backed the $71.9m build of Nigeria’s first float glass-manufacturing plant. The aim of the plant is to meet the rising infrastruc-
ture-driven domestic demand in order to diversify the Nigerian economy. Nigeria’s infrastructure development has led to demand for float glass, however most of the supply is through imports and does
not meet domestic needs. The plant will have a capacity of 500 tonnes per day and will produce tinted and solar control coated glass. 80% of production will be sold locally and the balance exported.
Iris recruits sales manager Iris Inspection machines has recruited a sales manager for the South American and Iberian regions. Gaétane Le Dru joined Lyon-based Iris Inspection machines as Area Sales Manager for Spain and Portugal, as well as for Central and South America. Ms Le Dru has 25 years experience in sales and customer support roles. She developed direct technical experience of the international hollow glass
manufacturing business while working at Sonicam for four years, selling the company’s mould polishing equipment.
Iris Inspection machines is dedicated to the delivery of non-contact inspection solutions for container and tableware producers.
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3/10/17 11:12 AM
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NEWS IN BRIEF
US glass producer Owens Corning has completed the acquisition of China’s Guangde SKD Rock Wool Manufacture. Mineral wool is the primary insulation material in China due to its lifesaving and fire protection properties. The US glass producer now has seven insulation manufacturing facilities in China that provide a full temperature range of products including fibre glass, extruded polystyrene foam, cellular glass and mineral wool insulation.
Austria’s Interpane has celebrated the tenth anniversary of LiSEC’s KSR plant. Interpane based in Parndorf, Austria invested in a new KSR plant from technology provider LiSEC 10 years ago. It has since been a core part of its glass production in order to grind glass sheets. Markus Halbauer, Processing Team Leader at Interpane, said: “The KSR station runs like clockwork. The KSR station runs in a three-shift operation and produces an average daily rate of nearly 2,000 linear metres.
IVC installs Vertech’s SIL equipment
Mexican container glassmaker IVC has installed Vertech’s SIL equipment on its fourth furnace. Industria Vidriera de Coahuila (IVC) is a jointventure between OwensIllinois (O-I) and Constellation Brands based in Nava, Mexico. French technology supplier Vertech has installed SILC on 13 production lines. In addition 14 decoration lines have been equipped with SILDeco, a SIL product dedicated to decoration. It has equipped more than 50 production lines in Latin America.
Fives Mexican success Engineering furnace group Fives has secured an order for electrical boosters in Mexico. The boosting will help the customer – which produces soda lime glass - to increase the pull of the furnace as well as their glass quality. It will give them better control and boost
the thermal currents of the molten glass within the melter, raise up the bottom glass to the surface at the barrier and allow it to circulate back to the back of the furnace. The boosters will also help improve batch retention, residence time, refining, quality
and increase output. Fives is a boosting specialist with more than 140,000kW installed around the globe. It is a new customer for Fives, which has re-entered the Mexican glass market with its electric furnace-related equipment.
Heye International provides support for Thai glassmakers Heye International offers a training centre to provide support for Thai glassmakers. Two engineers are employed to provide detailed hot and cold end training and support for Heye customers. Support is available 24 hours/day, seven days/week in Thai and English. It also includes spare parts support and all remote services in particular, diagnostics and remote adjustments. Thailand is home to some
of the region’s leading players and features advanced manufacturing technologies. In recent years, Heye has realised sales growth in the region, with customers in the Philippines, Vietnam, China, Korea, Taiwan and Thailand. The majority of these installations feature Narrow Neck Press and Blow (NNPB) forming process technology as an alternative to conventional blow-blow production methods.
Pennine celebrates 50 years Pennine Industrial celebrated its 50th anniversary with a birthday party for its customers, suppliers and friends. About 70 people attended a cocktail reception and meal close to its headquarters in Skelmanthorpe, near Huddersfield, UK. The company supplies conveyor chains, sprockets, and drives to the glass and food sectors for conveying cans and bottles, as well as engineered plastics. Its Owner, Graham Hobbs, spoke of his pride at how far the company had come since it was founded as Pennine Technical and Design Services by his father, Leonard, in 1968. He told the audience:
“When I think back 50 years ago my dad had two employees and we’re now at 68 employees and I’m proud of that. “I’m proud of the many people who have worked in one sense for me and in one sense with me. Some of the people have been with me for more than 30 years.” When Graham started working for the business 45 years ago, his father had an idea to do with chains and suggested Graham focus on it.
“He offered me a desk with a phone and that’s how I started,” said Graham Hobbs. He added: “Years later people would ask him if it is nice to work with your son and he would joke, I don’t know, I work for him!” “I think my father would be very proud to where we are. I’m obviously proud it’s a family business, I’m proud of my kids and I’m proud of the fact that for 50 years we have taken on apprentices every year.”
8 Glass International June 2018
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WHEN QUALITY MATTERS www.parkinson-spencer.co.uk
NEWS IN BRIEF
Cognac celebrates 55th
Verallia’s Cognac facility celebrated its 55th anniversary with an open day for the families of the site’s 500 employees and subcontractors. The day was organised with the participation of all the site’s teams and gathered more than 300 visitors. The day’s agenda included a guided tour of the plant, photo exhibition highlighting the team’s glassmaking know-how and solidarity, various activities run by the employees and glassmakers’ sports associations, planting of a tree and a country evening. Plant manager, Christian Garnaud said: “Our ambition is to be a benchmark glass plant and we have all the trump cards in our hands to get there.”
AGC Glass Europe celebrated the 120th anniversary of its Boussois float glass plant in northern France. Delegates included the District Sub-Prefect, politicians, press and glass specialists. A 180 x 40 cm float line cake was baked to mark the occasion. The plant is the largest producer of flat glass in France, with two float lines and a total capacity of more than 1,300 tonnes per day. It consists of 230 employees and specialises in clear glass production (Planibel Clearlite) and glass with a high light transmission (Planibel Clearvision) for the construction and indoor furnishings industries.
Saint-Gobain in France
Saint-Gobain, will invest in a €45m blowing glass mineral wool production line at its Isover plant in Chemillé near Angers, France. The line is being built to meet a rising demand in the French market for roof space thermal insulation solutions. The company also plans to open production lines at its plants in Azuqueca, Spain and Vidalengo near Milan, Italy.
Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1. Guardian Glass makes €50 million investment � 2. Ardagh plant plans downtime � 3. Verallia invests €28m to modernise � 4. Iris Inspection recruits sales manager � 5. Unimin becomes Covia following merger � 6. The second Convention of Glass discusses the future � 7. Pennine Industrial celebrates 50 years � 9. Saint-Gobain to invest €45m � 10. IVC installs Vertech’s SIL equipment
Stölzle appoints CEO Stölzle Glass Group has appointed Georg Feith as CEO. Mr Feith took over the position at the European glassmaker at the beginning of May and is familiar with the company, having started his career at the group’s Köflach plant in the 1990s.
He had previously been a CEO in several companies such as the Glanzstoff Group and, recently, alongside Stölzle group owner Dr Cornelius Grupp, Managing Director of CAG Holding. “It is a great pleasure for me to take responsibility as CEO
of the glass group to ensure the further success of our six European production plants and three decoration sites.”
Ramsey Expands All-Steel Conveying Chain Offering Ramsey recently expanded the All-Steel line of conveying chains to include Side Guide style chains. Ramsey All-Steel chains are 100% steel and were originally introduced in Centre Guide style chains. Unlike other chains, which use head protector links made from pressed metal and are susceptible to cracking, All-
Steel chains use guard links made from 100% hardened, alloy steel. Ramsey states that the AllSteel links will never crack under pressure. It said: “If you have tried other chains and had problems with pressed metal links cracking, those days are over. This product breakthrough is available only from Ramsey.”
NSG invests in coated glass Nippon Sheet Glass (NSG) is to invest 38 billion yen ($346.9 million) in the expansion of the production capacity of coated glass. The investment in online transparent conductive oxide (TCO) coated glass aims to
support the solar market. This investment will fund the restart and upgrade of a currently dormant float line in Vietnam, and kick-start the construction of a new glass production facility in the USA over the next three years.
The expansion of TCO coated glass is the next step in NSG’s shift towards value-added (VA) products as it supports a long-term supply agreement with the photovoltaic (PV) solar systems provider, First Solar.
10 Glass International June 2018
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Personality profile: Oliver Wiegand
Phoenix Award winner combines technology with tradition Wiegand-Glas owner Oliver Wiegand is the 2018 Phoenix Award Glass Person of the Year. The Phoenix Committee recognised his drive to embrace new technology in modern container glassmaking. Greg Morris visited Steinbach am Wald to meet him.
liver Wiegand grew up to the sound of glass. As a boy, he could hear the noise of glass bottles being rejected on the cold end, which was located metres away from the familyowned glass plant. His house was only a few steps away from the Wiegand-Glas works in Steinbach am Wald. At weekends his father, Konrad, would take him on a tour of the plant. “Glass was discussed all the time: over breakfast, at lunch, dinner, it was part of my life. I think I was aware of glass as soon as I was born,” Mr Wiegand (pictured right) recalls with a smile. “During the tours of the glass plant my father would show me what was new, what was the latest technology, what was done in certain sectors, so I really grew up in the glass plant. If people had asked me questions about glassmaking I’m sure I could have answered them.”
Humble Mr Wiegand was recently named as the Phoenix Award’s Glass Person of the Year for 2018. The award recognises those who have made an outstanding contribution to the glass industry. He said: “I’m really very honoured to receive this award, it is a great honour to be a Phoenix Award winner. For me the Phoenix award is the Oscar of the glass industry and if you look at the other people who have received the award in the past, it is humbling that I am in the same company as them.” The Phoenix Committee said it recognised Mr Wiegand’s forward-thinking and drive to embrace new technology. This has allowed the company’s now four glass container plants to increase production, while at the same time manufacturing cleaner, more environmentally friendly glass. It said: “His openness to work with suppliers in developing and, all importantly, testing new technology in real time glass production is one of the reasons why he is so well respected within the glass industry.”
� Mr Wiegand grew up metres from the Steinbach am Wald site.
Mr Wiegand took over as managing director of Wiegand-Glas in 1996 alongside his cousin Nikolaus. After studying mechanical engineering at the Technische Universität München (Munich), he completed an advanced studies course which combined business and engineering in 1993. He worked for an automotive supplier after graduation. When his father retired due to ill health, Mr Wiegand decided it was time to follow in his father’s footsteps. “In my heart I always thought I would work for Wiegand-Glas. My sister had always said she would not be involved in the family business so, as the only son, it was on me to work there. “Glass is interesting because it is never the same and never gets boring. Every day there is a new challenge and I enjoy that, being able to solve the different problems.” The history of Wiegand-Glas and the Wiegand family can be traced back to the 16th century. Oliver is the fourth generation of the family and runs the company with his cousin Nikolaus Wiegand.
12 Glass International June 2018
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Personality profile: Oliver Wiegand
some of these technological innovations. Nearly every week we have visitors from all around the world looking at the technology we use. “We are based in the countryside and the advantage of that means we don’t have a ﬂuctuation of staff. People work here for a number of years - from the beginning of their career to retirement - so there are a number of experienced employees here. We have very good people in our plants and they make it all possible. “It needs a driver, someone to drive innovation and implement it and drive the people to make it work.”
Technology Wiegand-Glas has worked with global suppliers to introduce new technology at the plant, which has improved efﬁciency and is environmentally friendly. One example is a batch and cullet preheater which it developed with fellow German company Sorg and was the ﬁrst glass manufacturer to install the equipment. “We have a furnace here where the batch and
Groundbreaking technology The Phoenix Committee highlighted that Wiegand-Glas embraced new technology. Some of this has included :
While the company uses new technology it also keeps the family values and traditions formed over the many years of glassmaking. The Phoenix Committee highlighted the role the company has made in using new technology in its plants and Mr Wiegand said: “It makes me proud for the company to have led the way with
� Batch and cullet preheater Working with German engineering company Sorg, Wiegand ﬁrst installed the batch and cullet pre-heater on its furnace number one at its Steinbach plant. With this system the hot waste gases arising from the glass melting process are led through the raw material and cullet mix. The raw material and cullet are heated up and the waste gases are cooled. The preheated cullet is directly taken into the glass melting furnace by the batch and cullet preheater. The energy content can be saved during the melting process. Using a batch and cullet preheater a considerable amount of energy as well as CO2 can be saved. A second batch and cullet preheater was installed which quickly led to 14% energy savings.
� NIS machine Together with Bucher Emhart Glass it developed a fully automatic IS machine. Nearly all mechanisms are driven by servo-electric motors which offer a higher stability of the glass forming process. Shorter job change periods and more ﬂexibility in the production programme are further advantages of this machine. Abstaining from pneumatic drives, compressed air is being saved; at the same time the noise pollution for machine operators is being considerably reduced. � LoNOx melting furnace This melting furnace, developed together with a furnace designer, was optimised to 0.50 g/m³ in order to comply with the German regulations for NOx-emissions. Continued>>
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Personality profile: Oliver Wiegand
cullet preheater is installed which has energy consumption below 3 gigajoule per tonne. “I don’t know of any other furnace in the container glass industry which has such a low energy consumption.” It was also the ﬁrst manufacturer to use an NIS forming machine from Bucher Emhart Glass and was also the ﬁrst glassmaker to produce an ultra-lightweight one-way polymer coated glass container. It is also the only company to install two in-line coating machines on two production lines for ultra light beer and soft drink bottles. While much of this work is done in conjunction with glass suppliers, Mr Wiegand is quick to praise the work of the International Partners in Glass Research (IPGR), based in Aachen, Germany. Wiegand-Glas became a member shortly after the foundation of the IPGR in the 1980s and Mr Wiegand was its chairman between 1998 and 2009. He has been deputy chairman since April 2016. The eight container glass manufacturers and one glass technology supplier that comprise the IPGR embark on research and development projects together and combine their knowledge in an effort to develop technology that will improve the efﬁciency of the glass manufacturing process. This is followed with a practical application in a glassworks. “Wiegand-Glas has developed many things with the IPGR which are in use in our plants now. We have a very good exchange of information on the technical side, which has given us an advantage,” states Mr Wiegand. There have been disappointments too for Wiegand-Glass, naturally. For such a company that is prepared to try new innovations there have been times when technology has not worked. But Mr Wiegand is philosophical about this. “You have to take the risk. It costs to invest in new technology but if it works you can earn money with the products. We have had times when the risks did not work. For example, the NIS took years before it was in a commercial status. It took a lot of patience and a lot of dedication from staff, but in the end it worked.”
Environment The Phoenix Committee highlighted the environmental work the Wiegand Group has achieved. The company operates two recycling facilities in Germany, with the ﬁrst installed in the 1970s. Every Wiegand-Glas container now contains between 80% and 95% of cullet generated in its own facilities. Mr Wiegand said: “I’m proud of what has been achieved here in recent years. We want to be technically the leader in the industry. “We are passionate to work with new technology, the new technology must give us an advantage in terms of cost savings, or efﬁciency or quality or air quality improvement.
“We do a lot of testing of new equipment, we have partnerships with suppliers where they can test their new equipment in our plant and we will support them to make it a successful product on the market. “I think we have a good reputation and we have requests from glass plants around the globe to do training here, which shows how highly regarded we are.”
Father Mr Wiegand is also quick to acknowledge the inﬂuence his father has had on him and his career. “Everything I began to know about glass came from my father, he introduced me to glass at a young age and was always prepared to give advice and knowledge about glassmaking.”
About the Phoenix Committee Each year the Phoenix Committee awards an individual who it feels has made an exceptional contribution to the glass industry. Previous winners have come from all ﬁelds of the glass industry such as science, production, glass education, glass containers, ﬁbre glass, scientiﬁc glass, ﬂat glass, tableware, art glass and electronic glass. The committee comprises a number of major glass suppliers who meet every Spring to choose the recipient. The individual is then awarded a sculptured Phoenix bird at a banquet held every October. Recent previous winners have been: � 2017 James O’Callaghan, co-founder of Eckersley O’Callaghan, UK. � 2016 Cho Tak Wong, Chairman of Fuyao Glass Industry Group, China. � 2015 Surasak Decharin, Bangkok Glass, Thailand. � 2014 G. Clinton Shay, Corning Inc, USA. � 2013 Chandra Kumar Somany, HNG, India. � 2012 Lino Tagliapietra, a Glass Artist, Italy � 2011 Juan Rafael Silva Garcia, General Director, Fevisa, Mexico
Konrad Wiegand started working for the company in 1963, was MD until 1996 and remained on the board until 2007. While his father is no longer involved in the business today, he is always keen to chat to Oliver about the latest news at each of the plants. Konrad is unfortunately unlikely to attend the Phoenix banquet in Konstanz, Germany in October due to old age, but Oliver will be joined by his wife and several other family members. While Oliver has no children himself, his cousin, Nikolaus has four so it is likely the glassmaking company will remain in the Wiegand family for many years to come. �
Wiegand-Glas, Steinbach am Wald, Germany www.wiegand-glas.de Phoenix Award, www.phoenixawardcommittee.org
14 Glass International June 2018
personality profile phoenix.indd 3
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EME GmbH Âˇ E-Mail: email@example.com Âˇ www.eme.de
Company profile: SGD Pharma
� Mr Rogier addresses guests at the ceremony.
“I’m very proud because the restart was very good and we reached high production standards in very few days. We were inside the budget and we completed the project four or ﬁve days ahead of schedule. So it was a great success for us
” says Christophe Rogier.
SGD Pharma celebrates Furnace 2 The plant director of SGD Pharma’s Saint Quentin la Motte site, Christophe Rogier, spoke to Greg Morris about his pride in his team after the successful inauguration of a new furnace 2 at the site.
r Christophe Rogier is a very happy man. The plant director of SGD Pharma’s Saint Quentin La Motte site has just seen the successful inauguration of the rebuild of furnace number 2. The project for the electric furnace rebuild was completed four days ahead of schedule and finished under its €5 million budget. “I’m very proud because the restart was very good and we reached high production standards in very few days. We were inside the budget and we completed the project four or five days ahead of schedule. So it was a great success for us,” he states. Its previous furnace number two was installed in 2015 when the new, flagship, Saint Quentin (SQLM) plant in Picardy opened. But the conditions inside an electric furnace that produces borosilicate Type 1 glass are particularly aggressive. It means that rebuilds every two to three years are common.
The furnace was rebuilt by the plant’s staff – with help from external contractors - and the furnace’s capacity was increased by 10% from the previous furnace’s 300 million vials a year. Two staff were deployed to focus entirely on the project, helped by a steering committee comprising of seven of the plant’s staff, including Mr Rogier. Then, while the 40-day project took place, many of the plant’s employees helped. Work included demolition of the old furnace, the rebuild, warm up and start of the machines. Their hard work was rewarded when, in an inauguration ceremony, about 70 local dignitaries and invited guests attended. They watched on as the project leader, Mme Marie Lurquin, lit the oven. In a glassmaking tradition, Mme Lurquin was named the Marraine – the Godmother – of the furnace. Continued>>
16 Glass International June 2018
Company profile SGD.indd 1
Company profile: SGD Pharma
� Marie Lurquin was named � The new furnace is hexagonal shaped.
the Godmother of the new furnace number 2.
� More than 70 people attended the inauguration ceremony.
� The furnace was designed by SGD’s own staff.
The SQLM plant was opened in 2015 after the demerger of SGD’s pharmaceutical and perfumery glassmaking departments. While SGD built a new plant in Saint Quentin, the company’s perfumery division became a new company, Verescence, with its plant at Mers les Bains located just 6km from the SQLM facility. The SQLM site is dedicated to parenteral and nasal products and makes Type 1 clear and amber glass from its two furnaces, each with two production lines. It employs 300 people on a 13-hectare site, with a factory footprint of 11,000m2. The pharmaceutical vials made at the site range in size from 1.5 ml to 3 litres. The original Furnace number 2 was installed in a turnkey design by Fives Stein in 2015. Mr Rogier states that SGD had a successful experience with electric furnaces at the Mers-les-Bains site. While the furnace in Mers was square-shaped and used dipped electrodes from the top of the oven, the new SQLM furnace uses immersed electrodes and is hexagonal shaped. The immersed electrodes means the fining of the glass is improved, states Mr Rogier. “Electric furnaces are environmentally friendly without gas emissions and have a better energy efficiency,” states Mr Rogier. While the SQLM team used the original Fives 3D drawings to rebuild the furnace, the project itself was overseen by its own plant staff. “We have some very experienced and experimental people within both the group and the plant so we were able to manage this project,” states Mr Rogier. “Fives supplied the first electric furnace but we did the rebuild by ourselves, with the support of external companies. “For a furnace you can always find something to improve upon. We designed all the improvements by ourselves with the support of the original drawings.”
17 Glass International June 2018
Company profile SGD.indd 2
Company profile: SGD Pharma
fresh aspect then the plant loses its beauty. “I think this is still the most beautiful glass plant in the world because the team have done such a great job. I receive very good feedback from customers when they visit and a lot have said this is the best plant they have visited!”
The company also wanted to keep an electrical furnace for market purposes. “The pharma sector is a very stable sector and after we moved from Mers we wanted to be consistent and keep the same technology because it is proven for our market.” SGD Pharma has recorded a 10% growth in the past two years. According to senior management, this is due to the quality of the glass at the Saint Quentin plant, which is regarded as the flagship of its five global sites.
Quality The site’s Furnace number 1 is an oxy gas furnace. While it has a higher consumption of energy it offers the company more flexibility. The company can produce the flint and amber glass on both furnaces, but it tends to focus its colour glass changes on furnace 1 because it is more convenient to make changes. The rebuilt furnace has been increased in size by 10% due to meet the demands of an increasing market. “We saw a benefit to increase the capacity, but not by much, because when you totally change the size of a furnace you have to repair everything and the costs rise. We have increased it by 10% which is a reasonable rise.” The company took the time to maintain and make improvements to the plant, such as painting and cleaning, at the same time. The new furnace feeds two Emhart IS machines, which can produce single, double, triple and quadruple gob. The plant uses Iris Inspection equipment and during the rebuild period it also installed a swabbing robot from Socabelec. “Swabbing is a means for more robust production and a way of improving quality. Human operators don’t swab in the same way and with the same oil quantity. But a robot is automatic and consistent every time.” He adds: “The plant feels a lot fresher – it was a new plant anyway but if you don’t maintain this
� The Saint Quentin la Motte site only opened in 2015.
Mr Rogier has had a 20 year career in the industry, first with Saint-Gobain before joining SGD in May 2014. His career has included roles in R&D, production management, as industry director for solar glass, investment director at Sekurit, as well as experience in project and plant construction in countries as varied as India, USA, China and Germany. He believes the future of glassmaking lies with industry 4.0 and thinks it can bring benefits to manufacturers. The new plant is designed with the latest technologies available and the company uses an IT system called Hypervision, which connects all aspects of the glass plant. “We don’t talk about supervision here but Hypervision in our case. This means we have already started the infrastructure of Industry 4.0 and we will continue to develop it in in the spirit of statistical process control and six sigmas. “Our customers are the pharmaceutical industry and they work to save patients lives. We work to the same objective so we need to control 100% our vial to be sure the vial that we produce will contribute to the patient’s safety. So we need to reduce the risk of defects and to increase the control of production. “The best way to do this is statistical process control and to do this you need Industry 4.0 because you need data and to input this into a computer. The technology is available for big data and we can increase the use of statistical process control and see the results.” More use of Industry 4.0-related technology will also help attract more young talent to the glassmaking industry. SGD has already made successful inroads to attracting young people to glassmaking, with Mme Lurquin a prime example. Mme Lurquin is a young batch and furnace engineer who joined the company in 2015. France has a college dedicated to glass and ceramics in Limoges, but Mr Rogier concedes that young French people are being attracted by jobs away from industrial manufacturing. For now Mr Rogier is happy to focus on the next challenge in his career. “Glass has provided me a very interesting and varied career. When you work for 20 years in the sector you see the glass industry as a family. “It is an ancient material but there are always things to develop and learn, and this makes it such an interesting sector.” �
SGD Pharma, Saint Quentin La Motte, France www.sgd-pharma.com
18 Glass International June 2018
Company profile SGD.indd 3
FIVES TECH + FIVES TEAM
PRIUM® LEHR, COMBINED WITH SERVICE EXPERTS, FOR AN OPTIMIZED INVESTMENT AND A TROUBLE FREE OPERATION FIVES DESIGNS AND PROCURES ANNEALING LEHRS, PRIUM® LEHR, according to the line process specification, product application, site situation, selecting the most appropriate solution to optimize Capex and Return On Investment time: — Precise theoretical thermal balance calculation — Fuzzy logic temperature control — Proportional control — Patterned hot air process — Experienced and specialized service team — Continuous annealing process
Prium Lehr v02.indd 1
All industrial processes involve, at one stage or another, the usage of contained heat, whether to produce the paper we use on a day-to-day basis, the steel for railway lines, the glass windows for the trains, or the cement that supports the foundations of our houses. Being present in so many different industries makes us proud of the service we offer and gives us a sense of belonging, with active and responsible participation in the world around us.
With a network of more than 30 subsidiaries and partners, from America to Japan, the Lizmontagens Thermal Technologies Group expanded its industrial services worldwide for the past decades, becoming the global leader in glass furnace construction and one of the leading references in heat containment for industry.
Copyright, ÂŠ Lizmontagens Thermal Technologies - May, 2018
40 yearsâ€™ service to the industry
anniversary edition Av. Almirante Gago Coutinho, n. 56 - 10th, 1749-041 Lisbon / Portugal Tel. + 351 218 429 270 / Fax. +351 218 409 412 / firstname.lastname@example.org / www.lizmongroup.com
Protection in packaging � Marpak unveiled its new storeroom and showroom in May.
ackaging company Marpak Extrusions is celebrating the opening of a new showroom and warehouse. The UK company has grown its business over the past five years thanks to increased links to a number of container glass manufacturers. The new 11,000ft2 space was unveiled earlier in May and will include warehouse space for its reels of polythene packaging, sales and training offices as well as a showroom for its sister company, Talos. The site is just round the corner from its Westland Square, Leeds production facility. Jamie Gibson, Director of Talos, which is part of the Marpak Group, said he was pleased with the new site. “Over the past five or six years we have had massive expansion in the business. The increased production means we keep outgrowing everywhere that we have, so this new site allows us to keep stock for customers as well as provide office space and a showroom.”
Packaging protection Marpak Extrusions provides a flexible polyethylene-based packaging to the container glass industry which is used to protect pallets and bottles in the cold end. The pallets containing stacks of bottles are transported from the glassmaker to be filled, so it is imperative that the bottles are packed tight and securely within the packaging to protect the bottles. Thanks to major R&D and increased collaboration with Ardagh, Marpak’s thin-film packaging has become the industry leader. “Our customers have had their customers say that if they want to supply them, they have to use the Marpak film,” states Mr Gibson. “It makes me feel very proud to know that our film is now the goto standard.”
Environmentally friendly The company has focused on downgauging in recent years, which is
the process of making the film thinner while retaining the same strength characteristics. Marpak has worked closely with Ardagh and can now supply an 80 micron film. The industry standard in Europe is typically 120 to 130 microns, so Marpak is now making inroads into the European market. Mr Gibson said: “Ardagh were keen for cost savings and wanted to get those cost savings for the right reasons. “They didn’t just want a thinner material they wanted the thinner material to have the right mechanical properties, so we worked with them and our technical supplier to get the best film on the market with the lowest micron. So it was cost savings for the right reasons. “If you go from say 100 micron to 80 micron then it is a 20% cost saving. On 3000 tonnes of material at £1500 a tonne it is a considerable saving over the year.” Continued>>
Packaging group Marpak Extrusions has enjoyed rapid growth over the past few years and capped its expansion with the opening of a new warehouse and showroom near its headquarters in Leeds. Greg Morris visited and spoke to Jamie Gibson*.
21 Glass International June 2018
packaging Marpak.indd 1
� Marpak’s manufacturing process takes place on nine lines at two manufacturing sites.
The disadvantage of a higher micron is the fact a glassmaker will use more film, which means higher costs. A lower micron means less heat is used in the packaging process as well as less material in the packaging. Marpak worked with its technical supplier, Total Petrochemicals in France, to develop the film. Total supplies the primary ingredient, Metallocene Polyethylene, under the brand name Super Tough. The Metallocene is then blended with several other ingredients at Marpak’s sites to make the final film. “We’ve introduced something new to the market which is this new blend, the Super Tough, which we’ve done to stay ahead of the competition and to help customers. “We have good relationships with a number of glassmakers and it’s because we work closely with them. If there is an opportunity for them to save money and reduce their carbon footprint, we will tell them what we can offer them.” The film can be completely recycled provided it is free of labels and fragments of dust. Marpak is spreading the message that it should be kept inside to reduce the risk of fragments and is thus able to be recycled.
History The company was formed in 1979 by Jamie’s father Richard. He was working for a Swedish company but, with a young family, did not want to travel as much. In the early days Richard was the sole employee, working from an office based in his home. It began supplying the glass industry in the 1980s and has now grown to
incorporate 45 staff on three sites. Its two manufacturing sites have nine extrusion lines – with six based in Westland Square and a further three at nearby Brown Avenue in Leeds. While 40% of its business is glass it also supplies other sectors such as construction. Its most famous customer is UK retailer, John Lewis, for which Marpak supplies coverings for its mattresses. It supplies the majority of UK container glass manufacturers as well as sites in Ireland, Sweden, Denmark, Germany, Portugal, Spain, France and The Netherlands. It supplies these companies with its reels of film, which weigh 600kg and consist of 2000 metres of material. Each reel will typically run at 320kg an hour in a glass factory, which means the reel will last for one day on a line and produce approximately 100 packs, depending on the pack height and speed of the line. Jamie himself has been with the company for 14 years and been involved in all aspects of the company. “I started off at the bottom and learnt everything, from the technical aspects of the film through to buying the product myself. I’ve got good relationships with our polymer suppliers, so if anything new comes up or I need advice then I’ve got people to turn to. “I’ve developed really good contacts in the industry in terms of people working in the glass plants so, if I’ve ever got questions, I’ve got people to turn to. It gives me a massive advantage over somebody who wants to sell in these plants.” The film is available in a variety of colours but the glass industry tends to
choose a transparent type. The company is already investigating downgauging to 75 microns, but the process to launch a new product can take years. As well as developing and trialling the product, a number of people have to agree to the new product, including the buyer, cold end manager and finished products manager. “Everybody has to get on board and it’s about convincing them that the product will save money and be efficient as well so that they won’t get complaints from their customers. “So it is a process and that’s why it takes time because you have to make sure it’s right.”
Philosophy While the company’s growth has been linked to growth in the glass industry it is also about its philosophy. “It’s about working with customers. It’s important we don’t just install a product and walk away, we give our customers more than that.” The company has expanded rapidly in recent years and while Mr Gibson doesn’t discount the idea of further expansion in the future, it is likely to consolidate for the time being. “We’re always looking to expand but we have to do it for the right reasons. We have to be conscious of the team we have and the gaps we might create by expanding too rapidly.” �
*Director of Talos, part of the Marpak Group, Leeds, UK www.marpak.co.uk
22 0 Glass International June 2018
packaging Marpak.indd 2
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Şişecam’s sustainability approach Prof. Ahmet Kirman, Şişecam Group’s Vice Chairman and CEO, discusses the Turkish glass manufacturer’s environmental plan. The company has built a solar glass plant to produce renewable energy, reduced the weight of its glass packaging and dramatically increased its recycling rate, among many actions.
hile striving to be among the top global companies in all of Sisecam’s core fields of operations, we take into account the social, environmental and economic pillars of sustainability to bring an equitable, viable and bearable future for the next generations. Sisecam has mainstreamed its sustainability principles in its corporate strategy and realigned its operations to add value to generations to come while striving to become a fair and transparent global player.
through climate neutral – 360 degree circular model; and preserves natural resources that Sisecam relies on and Sisecam’s institutional heritage for resilient and sustainable generations to come. Sisecam PRESERVE natural resources that we rely on and our institutional heritage for resilient and sustainable generations to come by engaging in and implementing conservational and restoration practices. By doing so, Sisecam also contributes to SDG 6 (clean water), SDG 14 (life under
� Prof. Ahmet Kirman,
� Its flat glass products provide savings
Sisecam’s Vice Chairman and CEO.
from heating expenses in the winter.
� Glassware production.
Sisecam’s sustainable strategy and action plan also contributes to the universal call to action captured by the 17 Global Goals of the 2030 United Nations (UN) Sustainable Development Agenda. Sisecam’s way forward on the sustainability pathway is built on the PRESERVE, EMPOWER and PROGRESS sustainability pillars. Its Sisecam’s global sustainability approach that empowers its employees and stakeholders by advocating and engaging in practices that encourage diversity and inclusion; progresses
� Sisecam achieved 8% lightening in its glass packaging products.
24 0 Glass International June 2018
water) and SDG 15 (life on land). Sisecam EMPOWER’s its employees, local communities, vulnerable groups and supply chain to become an active player for sustainable solutions and international enabler by advocating and engaging in practices that encourage diversity and inclusion. Through this approach, Sisecam contributes to SDG 5 (gender equality), SDG 8 (decent work and economic growth), SDG 10 (Reduced Inequalities) and SDG 17 (global partnership). Sisecam contributes to PROGRESS through climate neutral 360 degree circularity model, which includes but is not limited to the sustainable use of energy, natural resources, digitalisation and innovation while encouraging and enabling the equal participation of women and vulnerable communities. By doing so, Sisecam also contributes to SDG 7 (clean and affordable energy), SDG 9 (industry, innovation), SDG 12 (responsible consumption and production) and SDG 13 (climate action). Sisecam’s medium and long-term vision
is to establish an enabling environment for institutional heritage stewardship, to become an international enabler and advocate of sustainability, and to operate climate – neutral 360 degree circular plants. Our solution approaches for sustainable work is four fold, that is: commitment to global agenda, governance, reporting and advocacy, and environmental management & solutions. � Commitment to Global Agenda: Operating in line with the principle that energy and environmental performance is one of the core components of its sustainable success, Sisecam pursues the UN Sustainable Development Targets (UN SDT). The planned projects are integrated into all the operations globally, taking into consideration the SDT performance indicators. Interventions are conducted with a focus on ‘energy efficiency, renewable energy use, carbon emissions and waste recovery’ and are prioritised within the framework of our sustainability strategy. These targets are accomplished
within an effective governance structure. Sisecam ratified the UN Global Compact in 2017. It commits to implement universal sustainability principles and take steps to support UN goals within the Global Compact framework and be a part of the movement, to operate responsibly and find solutions to global challenges. Sisecam’s commitment to the Global Compact’s principles is in line with its aim to become an international enabler while sharing our knowhow with global communities and drive the economic, social and environmental sustainability. � Governance: To ensure an effective governance structure, Sisecam’s Sustainability Committee was established in 2015 to manage the group’s objectives under the sustainability principles with a holistic approach. To ensure effective implementation on the ground, working groups function under the Sustainability Committee. The key areas for the working groups are related but not limited to: Environment, Production Technology & Energy, Inclusion & Diversity; Occupational Health & Safety, Innovation Management, and Corporate Social Responsibility. Sisecam is an active player to contribute to the global sustainability agenda. Beside seeking innovative solutions at its operations levels, Sisecam is listed on the BIST Sustainability Index, prepares an annual sustainability report, advocates sustainability through international events, and enhances glass recycling through community-based campaigns. � Reporting & Advocacy: The sustainability reports prepared for each production group within Sisecam and also uploaded as an audio book to facilitate easy access for visually impaired internal and external stakeholders. To further advocate and raise awareness among the global community of the company, the 1st International Sustainability Workshop was organised with the theme of ‘Towards an Interdisciplinary, Interactive and Creative Sisecam’ in 2017 with the participation of 153 employees (Female: 40%, Male: 60%) from our national and international plants. The key outcomes of the event were the Waste Management, Sustainable Energy and Water, Diversity and Inclusion, Digitalisation and Data Management roadmaps.
25 Glass International June 2018
� Environmental Management & Solutions: As part of the company’s sustainable environmental and energy response, Sisecam aims to leave a habitable world for future generations, while striving to minimise the environmental impacts generated by its operations. By doing so, Sisecam focuses on the efficient use of natural resources in its production processes, by reducing wastes at the source, carrying out effective water and energy management practices and design products with a reduced environmental impact. To respond to the international requirements, all group companies work with the ISO 14001 Environmental Management System globally, which is also enhanced with a cross checks mechanism and shared Best Available Technologies. Sisecam also recognises that being a global player and working in an energy intensive sector, action to combat climate change is of great importance. It has been part of the Carbon Disclosure Project (CDP) since 2011. The company ranked among the 58 participant companies from Turkey reporting to the platform in 2017. Carbon emissions performance regarding the group’s operations in Turkey and Bulgaria, as well as detailed information on the strategy followed and risk and benefit analyses carried out are disclosed to the public in accordance with the principle of transparency. According to our sustainable strategy and action plan, we target to reduce GHG emission intensity of the group’s total glass production by 5% and produce at least 10 products labelled with carbon and/or water footprint in the next five years. We manage our operations on the basis of international energy management standards, and implement energy efficiency projects to ensure a continuous energy consumption reduction. We have invested in renewable energy. We recently installed a 6.2MW solar power plant, which is the second largest roof type solar power generator in Europe, at the ﬂat glass plant in Mersin. Sisecam has a target of providing 12MW energy through renewable energy sources in the next five years. The corporate waste management programme includes comprehensive practices that support waste reduction at its source, recycling and reuse. Efforts are also being pursued with stakeholders to expand a recycling culture. In 2017,
26 0 Glass International June 2018
Sisecam collected and recycled 54% of the materials that were used for products’ packaging, and nearly 16,000 tonnes of paper, cardboard, plastic, and wood were recycled. Sisecam Group works to improve Turkey’s glass recycling infrastructure. It supports the transition to a ‘recycling society’ domestically while also monitoring activities abroad. Glass and Glass Again, Turkey’s most comprehensive sustainability and social responsibility project, was launched in 2011. With the aim of raising the glass recycling ratio to European levels, it continues to work in cooperation with local administrations and licensed companies. The key elements of this project are to raise public awareness for separate collection of glass packaging waste at its source; improve the infrastructure for collecting glass packaging waste; modernise recycling facilities; and increase capacities. Since the start of the project, training regarding recycling was provided to more than 250,000 primary school pupils, and awareness raising activities carried out by local authorities that reached 3 million people. By the end of 2017, by investing in a sustainable future with glass recycling, Sisecam Group had: � Managed cooperation with 163 district municipalities in 24 cities; � Offered 19,800 bottle banks for the use of municipalities. With the recycled glass, the group has: � Saved 912,000 tons of glass that was set to be landfilled as waste ; � Achieved energy savings at a level that would meet the heating and hot water needs of 38,300 homes; � Prevented carbon dioxide emission equivalent to the withdrawal of 328,400 automobiles from the roads; � Prevented carbon dioxide emission equivalent to air clarified by 28.1 million trees.
besides long-running financing opportunities on easy terms. We also design products that help to reduce the environmental impact. For example, our ﬂat glass products provide savings from heating expenses in the winter by reducing heat losses by 50% as against standard double-glass, and from cooling expenses in the summer by reducing solar heat intake by 40-65% compared to standard double-glass. We also produce solar energy glass, which is an input for the renewable energy sector. Sisecam achieved 8% lightening in its glass packaging products. Thus, 6,727 tonnes of glass savings were ensured with an increase of more than one and a half times as against the previous period and 4,978 tonnes of CO2 emission was prevented in 2016. Furthermore, Sisecam’s soda products are the input that reduce the energy consumption of furnaces in glass production. The use of soda reduces the melting temperature, theoretically ensuring energy savings of 8-10%. Sisecam recognises that to ensure the future generation’s sustainability, actions at local, corporate and global level are a must while empowering, progressing and preserving future generations’ welfare. Sisecam Group progresses through a climate neutral and 360 degree circular model and preserve the environment and institutional heritage to ensure a sustainable future for next generation without frontiers. �
Sisecam Group, Istanbul, Turkey www.sisecam.com.tr/en/
Sisecam established Sisecam Environmental Systems Inc. in cooperation with the European Bank for Reconstruction and Development (EBRD) in mid-2016. This cooperation, which is a first in the world, aims to accelerate the modernisation of glass recycling companies in Turkey. It seeks to provide know-how transfer support for the companies � Its soda products are the input that reduce the energy consumption of furnaces in glass production.
We Don’t Make the Glass, We Make it Possible • Glass Melting Furnaces • Batch Plants • Engineering • Turnkey Projects • Annealing Lehrs • Project Management
For more than 70 years HFT has provided world class engineering, procurement and construction services to the global glass industry. Our leadership, experience, quality focus and attention to details have given HFT a highly respected reputation worldwide.
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Environment Batch plant
Premix technology for improved distribution of minor materials Dr. Sebastian Woltz* of EME discusses premix technology and highlights its advantages and benefits. The companyâ€™s experience in recent years has been that dosing and mixing accuracies of minor materials and their homogeneous distribution in the batch is particularly important to meet increased quality demands.
is a member of the Sorg Group and is active in the field of raw material, batch and cullet handling for all sectors of the glass industry. It provides turnkey plants and single components, process technology, projecting and planning, construction and engineering, project managing, installation and commissioning. Aside from the major raw materials such as sand, soda ash, dolomite and feldspar, minor ingredients, such as fluxing agents (e.g sodium sulphate, fluorspar), fining agents (e. g. sulphates, arsenic, antimony, fluorides), colourants (e.g selenium, cobalt oxide, iron oxides or salts) or decolourisers (e.g selenium, cobalt) are also part of a batch formulation in the glass industry. The challenge is to achieve a perfectly blended batch regardless even if there are
ďż˝ Fig 1. EME automatic premix technology.
raw materials with extremely different ratios included in the batch formula. It must be guaranteed that the minor additives are also well distributed in the batch. The risk of raw materials crosscontaminating different furnaces when producing glass of different colours in a single batch plant must also be considered in the concept. Physical and chemical
homogeneity of the batch is of upmost importance to achieve stable conditions in the melting furnace and yield glass products with maximum strength and aesthetic appearance. Therefore the batch mixing technology must be designed to meet high demands. Continued>>
28 0 Glass International June 2018
GH_1-2pp_Ad_A4+Bleed_Layout 1 15/08/2016 10:53 Page 1
> DEPENDABILITY > FLEXIBILITY > DURABILITY
BATCH CHARGING EQUIPMENT
BATCH WETTING EQUIPMENT
GLASSWORKS HOUNSELL We make new, we make spares, we refurbish and we advise. We have a tradition that dates back to our foundation in 1877 and we adhere to core values that have stood the test of time. How well our products work and how long they last drive our commitment to quality, allowing us to remain a leading manufacturer.
Please visit us at Glastec, Hall 13 A85 to discover what we can do for you.
Tel: +44 (0)1384 560666
Masters in manufacturing
Park Lane, Halesowen, West Midlands, B63 2QS, UK PRECISION BRITISH ENGINEERING
Environment Batch plant
EMV 5/2 1xLS
EMV 5/2 1xLS
EMV 5/2 1xLS
EMV 5/2 1xLS
Scale 01 25kg ± 5g
AC EMV 5/2 2xLS
Scale 02 Mixer premix 250 l
� Fig 3. Barrel tilting station for minor materials.
Premix Hopper 01
Bilder in diesem Fliesschema sind Beispiele bereits gelieferter Anlagen und dienen nur der Veranschaulichung.
The pictures in this flow-sheet are examples of already delivered plants and are to be understood as illustration only
Liste der allgemeinen Abkürzungen ABBREVIATIONS USED IN THIS FLOWSHEET Abréviations utilisées dans ce schema functionnel
� Table 1. Typical batch composition of container glass. EMV 5/2 1xLS
Scale 03 40kg ±xxg
EMV 5/2 EMV 5/2 2xLS EMV 5/2 2xLS
limestone 16.6% selenium 0.0009% salt cake
� Fig 2. Principle flow sheet automated
Typical batch compositions for the production of different colours in the container glass industry are listed in Table 1 to show the differences in batch formulas. There are huge differences in the ratios of the batch components (e.g sand 64.3 % in comparison to selenium 0.0009 %). For minor materials, much stricter requirements are demanded of the equipment with regard to dosage and weighing ranges as well as accuracies (e.g weighing capacity may vary from 3.500kg for sand down to 200g for colouring agents). When dosing and weighing them directly in the mixer, sensitive dosing and scaling laboratory-type equipment must be installed. The implementation under normal batch house conditions, with limited
AC = Automatische Waagenkontrolle CC = Stromkontrolle EMV = Elektromagnetventil EBRA = Elektronische Bremse ELS = Notendschalter FIC = Filterreinigung FMIN = Füllstandmessung leer FMAX = Füllstandmessung voll FMEAS = Füllstandmessung Höhenerfassung MD = Belegtmeldung MM = Feuchtemessung IRD = Infrarotdetektor LS = Endschalter PTC = Thermistor Motorschutz PS = Druckschalter PIS = Steckverbindung RC = Drehzahlkontrolle RC_BI = Drehzahl- und Richtungskontrolle RPS = Reparaturschalter RSW = Seilnotschalter SAL = Elektronischer Sanftanlauf SSW = Sicherheitsschalter SK = Schichthöhenkontrolle TC = Temperatur Regelung TRC = Schieflaufkontrolle
AUTO CHECK FOR SCALE
contrôle automatique des balances
deadCURRENT leaf CHECK VALVE ELECTROMAGNETIC
BRAKE THYRISTOR CONTROLLED EMERGENCY LIMIT SWITCH FILTERCLEANING FILLING LEVEL INDICATOR MIN FILLING LEVEL INDICATOR MAX FILLING LEVEL MEASURING SYSTEM MATERIAL DETECTION MOISTURE MEASURING INFRARED DETECTOR LIMIT SWITCH TEMPERATURE PROTECTION PRESSURE SWITCH PLUG IN SOCKET ROTARY CHECK ROTARY/DIRECTION CHECK REPAIR SWITCH ROPE SWITCH ELECTRONIC SOFT STARTER SAFETY SWITCH CHECK OF LAYER THICKNESS TEMPERATURE CONTROL TRACK CHECK
contrôle du courant green électro magnetic vanne
frein électronique interrupteur de fin de course d' urgence nettoyage du filtre indicateur de niveau min. indicateur de niveau max. systéme de mesure de niveau détection de matériel mesure d'humidité détecteur à infrarouge commutateur de fin de course protection du moteur à thermistance interrupteur à poussoire connecteur male-femelle relais tachymétrique relais tachymétrique avec interupteur de secour interrupteur de réparation corde de délenchement avec interrupteur de secour démarreur lent électronique interupteur de sécurité Contrrole de l'épaissuer de la couche contrôle de température contrôle de biaisement
16.8% 16.2% -
Die in den Waagen angegebenen ± xx Werte geben die statische Wägegenauigkeit an. Es sind keine Angaben über die erreichbare Dosiergenauigkeit. The ± xx values mentioned in the scales represent the statical weighing accuracy. They do not stand for the obtainable dosing accuracy. Les valeurs ± xx indiquées dans les bascules réprésentent la précision de pesage statique. Il ne s'agit pas de données de précision de dosage qu'on peut atte Anlagenteile innerhalb der gelben Flächen sind als Option im angebot enthalten. The plant partswithin the yellow fields are included in our quotation as an option.
space, is difficult and challenging. Name: Modified: Date: Name: Date: Another important issue to consider is File: that the entire minor material must be distributed in the batch without any losses during transfer and mixing. In addition the wetting of the batch in the mixer, through the surface wetting of all particles, creates a tacky state of the batch and makes it more difficult to distribute the minor materials evenly. Considering these aspects, it is common to premix the minor raw materials rather than to dose them directly to the mixer.
The premix technology In general, premix means a mixture of minor materials with a major component of the batch as carrier material (Fig 1). To achieve a uniform and homogenous premix, the carrier material should have similar nominal grain size, similar grain
size distribution and similar specific gravity, should not be hygroscopic and Draw. by: contain no water. In the glass industry, soda ash and limestone are most commonly used as carrier materials; sometimes sand is also used. The batch is normally wet with water in the mixer to reduce dusting in the melting furnace, save energy and to avoid decomposition and segregation during the batch transport and storage. However, exothermic reactions of the water with some of the raw materials (e.g formation of soda hydrates) create a hot and humid atmosphere in the batch mixer. This results in condensation within the mixer and the transfer devices (e.g chutes or down pipes). Here the minor additives Wockerather Weg 45
Tel:+49 2431-96180 Fax:+49 2431-74687
© by EME GmbH [Form A2 42
30 0 Glass International June 2018
*Area Sales Manager, EME, Erkelenz, Germany. www.eme.de
LAB-PRECISION VOLUME MEASUREMENT
SPT2 ON THE PLANT FLOOR
Precision volume measurement is no longer conﬁned to the lab. SPT2 delivers consistent, high-accuracy volume measurements and pressure testing on the plant ﬂoor, with rapid throughput.
would tend to stick, if they were not embedded in a carrier material. Also the risk of sticking to a mixer paddle or on the inside surface of the mixer will be reduced significantly, when the minor raw materials are not introduced directly to the mixer but rather distributed via a premix. Another advantage is that the premix storage, dosage and mixing equipment can be located away from the main mixer and therefore the transfer devices of the minor material to the pre-mixer can be designed to be as short as possible to minimise transfer routes and transport losses. The more sensitive dosing and weighing equipment can also be better protected against environmental conditions such as vibrations, dust or infiltration. The filtration system of the pre-mixer can be optimised according to the special conditions, for example avoiding sucking of the minor particles into the filter. Due to the possibility to produce larger premix batches, the dosage and scaling equipment can be engineered with greater weighing ranges and more industrial equipment can be installed (Fig 2). Despite the fact that the risk of losses of the minor raw materials is lower with the premix technology, the possibility to have a more homogenous distribution of the minor materials in the batch exists. The risk of cross-contamination of different furnaces when producing glass of different colours in a single batch plant will also be reduced. Cross-contamination remains a major concern since only traces of amounts can have an impact on the furnace performance and the final product quality (Fig 3). Provisions to avoid the transporting of flint and coloured batches on the same conveyor belts highlight this issue. The premix can be executed manually (manual - by hand weighing and feeding of the premix raw materials to the premix mixer and manual feeding to an intermediate storage bin), semiautomatic (manual weighing but automatic transport to an intermediate storage bin) or full automatic (automatic feeding, dosing, weighing and mixing). In smaller production plants, it makes sense to execute the premix manually or semi-automatically since the volume of additives is small and the applied scaling and weighing technique is sensitive and costly (in proportion to the related investment required for the complete batch plant). Special attention must still be paid to de-dusting requirements associated with toxic materials, such as selenium and cobalt, to meet the local safety regulated limits which are often critical with manual handling. The main disadvantage of the premix technology is the additional investment that has to be made. Nevertheless, if a premixing unit is not foreseen during the first stage, it is important that the layout and the concept of a new batch house are always designed in such a way that a future upgrade can be executed without any major structural changes. �
See us at glasstec Dusseldorf, Germany 23–26 October, 2018 Booth 14/C28 AGRINTL.COM
31 Glass International June 2018
Batch plant Environment
Zippe Turkmeni success � Zippe CEO, Dr Philipp Zippe (left), Chairman Dr Bernd-Holger Zippe (right) and the delegation from Turkmenistan.
ippe has built a batch plant for a Turkmenistan ﬂoat and container glass site. Its customer, Horn Glass, concluded a contract with the Turkish company TEPE Türkmen Insaat ve Ticaret for the delivery of a complete turnkey production plant for ﬂoat and container glass. Zippe designed and built a new batch plant to supply the 250t/d ﬂoat furnace and a 50t/d container furnace. Installation works took place between December 2016 and October 2017. The commissioning of the container line took place in November 2017 and the ﬂoat line in December 2017. A delegation of Turkmenistan operator personnel visited Zippe in Wertheim, Germany for training of dosing and mixing plants equipment (pictured). The Batch Plant is designed as a tower plant including 14 silos with a storage capacity of four days. The feeding of the raw material silos takes place mechanically by means of bucket elevators and big bags. The weighing process is carried out by nine scales: fully electronic container scales for the main raw materials, and fully automatic rotary container scales for the small components and for cullet with dosing belt conveyors. The mixing system consisted of three mixers in total. Each mixer was strictly assigned to the corresponding furnace. The third mixer functions as a standby mixer for both furnaces. ‘Critical’ raw materials are weighed directly into the corresponding mixer as a premix in order to prevent contamination. Cullet storage is also located within the batch plant. The cullet feeding, crushing, storage and weighing for ﬂoat and container glass takes place separately. Cullet weighing and feeding is executed by means of dosing weighers in a sandwich technique. The delivery also included the hot and cold cullet recycling of the container glass furnace, consisting of down pipes, scraping conveyors, pre-crusher and belt conveyors. The cullet recycling delivery for the ﬂoat furnace contained a blade crusher, edge crusher and belt conveyors. �
Zippe Industrialagen, Wertheim, Germany www.zippe.de
Company profile: Pace Glass
Pace Glass breaks ground on recycling facility in New Jersey Pace Glass has broken ground with its new glass recycling facility in Andover Township, New Jersey. The new site will focus on residue glass from singlestream operations. Sheena Adesilu spoke to George Valiotis* about the company’s expansion. � George Valiotis, Pace Glass’ CEO (left) and Steve Valiotis, father and Pace Glass investor (right).
� Michael Mahoney, COO, Steve Valiotis and George Valiotis (from left).
“My partners and I like recycling very much and it just so happens it’s
� Artist’s impression of Pace Glass facility final design with logo.
good for the
he New York-based recyclable glass processor has announced plans to build a new $70-90 million glass recycling facility in New Jersey. The new facility will enable Pace Glass to triple its production capacity to more than 15,000 tonnes per week and 90 tonnes per hour of commercialgrade recyclable glass. The site will be situated on 87 acres and produce 800,000 tonnes of glass per year. The expansion will focus on scraps from all the recycling yards in the entire New Jersey region. Pace Glass states it will be the “world’s largest glass recycling facility.” George Valiotis, CEO of Pace Glass, said: “It was just a natural expansion because of the increased
environment demand of cullet in the US. “New Jersey is centrally located, it is a good location in the Northeast and the government and building rules are very friendly there. “They’re more open-minded with recycling standards. We can pull in recyclables from New York, Connecticut, Ohio, Massachusetts or New Jersey.” At the recent ground breaking ceremony, Mr Valiotis was given the Congressional Certificate of Recognition for service to the community by US Rep Josh Gottheimer (D-NJ), who’s 5th District includes the plant site. Continued>>
� Pace Glass facility construction design.
33 Glass International June 2018
Pace Glass.indd 1
Company profile: Pace Glass
“The town of Andover has been instrumental in giving us our approvals, and we feel fortunate that they have been so
Pace Glass.indd 2
Pace Glass will create approximately 80 local jobs in two daily shifts and 60 truck driving jobs, in order to deliver the recycled glass cullet to manufacturers in the Tri-State area - upstate New York, Massachusetts and Pennsylvania. Mr Valiotis said: “It was an honour [to receive the award]. We didn’t expect that. My partners and I like recycling very much and it just so happens that it’s good for the environment. “It’s an honour that we can put those two things together and actually be a leader in the industry. “Especially in densely populated cities throughout the Northeast, the process of how glass is recycled has literally become broken. “Through our innovative technology that is able to capture and repurpose 90% of what is currently landfilled, Pace Glass has found a way to remedy that. “The town of Andover has been instrumental in giving us our approvals, and we feel fortunate that they have been so supportive.” Pace Glass’ new site will focus on 30 Materials Recovery Facility (MRF) glass single stream operations, which is the residue from other recycling operations. The glass processor anticipates 80-90% of its feedstock to be MRF glass. Mr Valiotis explained: “[We are focusing on MRF glass] Instead of focusing on clean glass, which is limited and is usually produced for beverages,
beers and bottle retention centres. “It’s harder [to focus on MRF glass] because the feedstock is relatively contaminated and it has a lot of other items in there. “Our production utilises optical sorters and a very good combination of equipment to sort and recover the cullet by colour, as well as produce very clean cullet for our customers. “Our new facility will also produce finegrind materials destined for Owens Corning, JM and Knauf Insulation.” Plans for the New York recycling firm’s new plant include increasing its intermodal delivery reach to other areas of the United States via flatbed railcars and barges. It will effectively become the nation’s largest facility by output. Pace Glass also aims to make the new site energy conscious. This will involve using solar panels, renewable energy and other waste energy technology to burn waste and create electricity. The construction of the new plant is to be completed over the next 14 months and operations are expected to begin in early 2019. �
*CEO, Pace Glass Pace Glass, New York, USA www.paceglassinc.com
Prof. John Parker
The evolution of refractories
ncient glassmakers needed not only fuels and raw materials but also a furnace to melt their product. They had to build a mechanically stable structure to contain the heat but also needed crucibles to hold their glass melts. The operating temperatures they were able to generate by burning their available fuel and wood, did not exceed 1100°C but the crucibles were exposed to the same fluxes used to melt the principal glass ingredient, sand. These fluxes could attack the furnace structures as volatile species or as dust; ash from the fuel was another source of reactants. These early glassmakers in Syria and Egypt worked alongside metallurgists melting copper, tin, brass and bronze and they also required crucibles and furnaces. There was a co-existing pottery industry that made various vessels and more complex shapes. Now clays have a relatively high proportion of water and so, after first forming, must be carefully dried; much of the water though is chemically bonded and is not lost until the clay is fired above 800°C, when it decomposes with a substantial volume reduction. This shrinkage easily leads to cracking during manufacture, so firing crucibles has always been a slow process requiring extended times at high temperature for equilibration. Additionally, from early times, carefully selected pre-fired material – grog – was added to the clay to stabilise it. Even clean pieces of broken pots were used, while in more recent centuries silica sand has served a similar role. So early glassmakers had the skills to make small pots a few centimetres high in which they could melt their batches. By the 7th century the technology had developed to the point where these clay
pots could be large enough to hold half a tonne of glass. Larger pots were made by coiling a preprepared strip of clay around a circular base and slowly building up the side of the crucible. After reaching the required height, the walls were carefully kneaded into their final shape. More recently covered pots holding a tonne of glass have been made, which involves the glassblower’s iron being introduced through a small opening. Several pots were placed inside a furnace at once; if these crucibles remained hot they could be re-used but the initial manufacturing process was a skilled and slow job – for larger pots it involved puddling the clay for days under foot to remove any trapped bubbles, which could cause the pot to explode during its first firing with dangerous consequences if it already held molten glass. It has been suggested that pot-makers would occasionally make a defective pot deliberately to remind the owners of glasshouses of their importance. Fireclay slabs could also be used for furnace walls but naturally occurring sandstone outcrops were an alternative. In the UK they are found in the English Pennines and were a popular building material used for housing but they were also used by early glassmakers for furnace buildings. The refractories industry began to develop its processing technologies and improve its raw material sources to create better quality materials in the 18th and 19th centuries. Higher firing temperatures allowed the manufacture of bricks with lower porosities and hence greater corrosion resistance. Siemens’ development in 1870 of regenerative glass tanks, combining both roles of containing heat and the glass melt, also drove change.
It followed a trend that had started 100 years earlier, with some 20 patents for tank furnaces having been taken out in the UK during that period. The refractory materials of choice continued to be fireclay or sandstone until the 1930s and, consequently, the furnaces had relatively short lives of a few months. After all, the furnaces were being operated to dissolve silica. Early fireclay refractories belonged to the SiO2-Al2O3 system chemically. At one extreme, silica has a melting point of 1723°C and, at the other, alumina has a higher melting point of 2040°C. Importantly between these extremes a compound called mullite exists with an approximate composition of 2SiO2.3Al2O3 and a melting point of 1810°C, higher than for silica but less than for alumina. Compositions between silica and mullite start to melt at 1595°C (or lower in the presence of impurities) with high silica compositions giving a much greater proportion of liquid at this temperature. The compositions that are most refractory are therefore close to pure silica or have a much higher alumina content. By 1950 most fireclays that were in use in the UK fell in the range 27-41% Al2O3. The naturally occurring sandstone blocks that were also used typically had around 10% Al2O3. Interestingly there is archaeological evidence for the construction of large tanks to melt glass even in ancient times with the material produced being shipped around the civilised world for re-working. Such tanks used a one-month campaign to produce a melt and then were simply demolished to recover the glass. �
*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk firstname.lastname@example.org
Prof John Parker* investigates the materials used by glassmakers in the past construct their furnaces.
35 Glass International June 2018
Environment Events review: GlassTrend seminar
GlassTrend discusses how to make the industry greener Glassmaking professionals discussed how forthcoming climate legislation will effect the industry at the GlassTrend seminar. Delegates from companies such as O-I, Vidrala and Verallia attended the event. Greg Morris was among them.
� GlassTrend took place at Schneider Electric’s office in Marktheidenfeld, Germany.
he Paris climate change agreement and its impact on glassmaking was the main theme at the GlassTrend seminar. A total of 17 speakers provided papers under the theme ‘How to face the technological challenges of the Paris climate agreement’ at the two-day event. The seminar, organised by Dutch company Celsian, was well-attended with 88 delegates from 14 countries – a record number for the conference. Attendees ranged from brand owners, glass manufacturers, associations, institutes and glass machinery suppliers. Some of the companies to attend included suppliers such as BDF Industries, Henry F. Teichmann, Sorg, FIC, Glass Service and Fives Stein. Glassmakers to visit were AGC of Japan, Ardagh, Saverglass, Libbey, Corning and Schott, among others. There were also a number of guests from research institutes and associations such as FEVE, Italy’s Stazione Sperimentale del Vetro (SSV), Rutgers University in the USA and the Gas- und Wärme-Institut Essen. The first speech was provided by Heineken’s Global Category leader for
Glass Packaging, Charles Richardson, who gave an update of his paper On Our Way to the Greenest Bottle, given at last year’s event. The global brewer has embarked on a campaign to drop the C out of CO2 and aims to reduce its carbon footprint and increase its use of renewable energy to 70% by 2030. It wants its glass suppliers to adopt a similar strategy (see Glass International, July/August 2017, page 14). The next, keynote presentation, was given by Royal Dutch Shell’s Ewald Breunesse, who discussed Trends and Technology in Energy and Industry. He said most of the company’s business is not from providing fuel at petrol stations – as most people know the company - but by providing energy to industry. He discussed some of the options available for companies involved in energy intensive sectors to meet CO2 reduction targets and become climate neutral. This includes options such as carbon capture and utilisation of storage and intensive use of renewable energy from offshore wind and solar power.
� Heineken’s Charles Richardson. Fabrice Rivet, FEVE’s Director for Environment, Health and Safety, presented a paper titled ‘The new ETS after 2020: is winter coming?’. His paper detailed the timeline that glassmakers face in their efforts to decarbonise by 2050. The fourth phase of the EU Emission Trading Scheme (ETS) will start in 2021 and last 10 years until 2030. He explained that the ETS is the spearhead of the EU climate change policy and covers about 12,000 installations and 2 billion tonnes of CO2 a year. The ETS creates a carbon market by putting an absolute (and decreasing every year) cap on the CO2 emissions from stationary installations. The aim is for the sectors covered to reduce their greenhouse gas emissions by 43% between 2005 and 2030. About €2 to 3 billion is at stake for the container glass sector alone for the period 2021 and 2030, he stated. The key features for the ETS after 2020 is a new carbon leakage metric. To be on the carbon leakage list and receive free Continued>>
36 0 Glass International June 2018
allowances up to the benchmark level, this metric should be greater than 0.2. In his conclusion, Mr Rivet said there is an increased pressure to decarbonise and glassmakers should get on the carbon leakage list as soon as possible. The rules will be completely changed by 2050, which for some glassmakers is just two furnace lifetimes away. The final paper devoted to legislation and future trends was delivered by O-I’s Jim Nordmeyer who discussed Towards the Path of Decarbonisation – understanding legislative challenges. He believed that carbon pricing was not necessarily the answer and said ‘bold
merits. As renewable electric generation grows arguments will become stronger for CO2 neutral all-electric melting. Fives has investigated ways that smaller all-electric furnaces can be increased in size to serve large glass container production. One suggestion is a modular approach, to put three 100 tonne electric furnaces together. This has the added benefit, being able to close one furnace for a part repair while the other two still function. Erik Muijsenberg, Vice President of Glass Service, delivered a paper on behalf of Stuart Hakes, of FIC UK who was unable to attend.
people but I’m also pleased with the content and how much energy everyone put into it. “GlassTrend put a programme together that we thought would move the entire industry a bit further forward. I felt everybody was interested from the first minute right up to the end.” Referring to FEVE’s paper that detailed the timeline that glassmakers face in their efforts to decarbonise by 2050, he said: “It’s a challenge which we need to address and solve collectively. This includes the brand owners, the furnace designers and builders, and guys like us. Then hopefully we can move the
� FEVE’s Fabric Rivet.
� Jim Nordmeyer from O-I.
� Andy Reynolds of Fives Stein.
action is required’. The glass sector as a whole had to solve the challenge of decarbonisation – ‘it takes a village to raise a child,’ he added. Critical to a successful decarbonisation plan is to critically analyse the entire life cycle of a container. This starts with raw material extraction, manufacturing, transport, use and then recycling, reuse or disposal at its end of life. Once a clear understanding is established, an impactful strategy needs to be put in place in collaboration with customers, local government and suppliers. Finally, he added that most US companies remain committed to addressing climate change, despite President Donald Trump’s withdrawal from the Paris agreement. The next session was dedicated to full electrical and hybrid furnace designs. Andy Reynolds, of Fives in the UK, described the Up-scaling of All Electric Melting Technology. The lack of a substantial presence of allelectric melting in container glassmaking is the result of economics of fuel usage and operational costs rather than technical
His paper examined how electric melting can go a long way to achieve the EU’s CO2 reduction targets. He believes electric furnaces can eventually be increased in capacity to 600 tonnes a day. The company is designing a furnace for a customer that requested 350 t/d, while most electric furnaces today range between 1 to 200t/d. Only 5% of glass is electric melted today and with more experience this can be increased up to 12% in years to come, he said. “Electric is here and is something for the future, for sure,” he said. Rene Meuleman of Schneider Electric and Plansee’s Rudolf Holzknecht gave further papers about electric melting. Day two included sessions devoted to low carbon raw materials, low combustion technologies and carbon capture and valorisation. Papers are available from the GlassTrend website to members only. Harmen Kielstra, Managing Director of conference facilitator, Celsian, said he was pleased with the event. He said: “It’s one thing to have 88
needle, because we have to.” The conference took place at Glass Trend member company Eurotherm by Schneider Electric’s office based in Marktheidenfeld, near Würzburg, Germany. The event included a breakout session where seven groups of between 10 and 12 people were invited to discuss what the future of the industry might be. “We think everyone appreciated it,” said Mr Kielstra. “Someone in the float industry might have a solution that had never been thought of in the container sector, or vice versa, so it is something where we can build on each other’s knowledge.” This was the 36th Glass Trend conference. The first one took place in 2001 and has been held twice a year since. The next seminar takes place within the ICG Annual Meeting 2018 held in Yokohama, Japan, between September 23 and 26. �
GlassTrend, Eindhoven, The Netherlands, www.glasstrend.nl
Events review:GlassTrend seminar
37 Glass International June 2018
Environment Events review-Glass Appreciation
Glass Appreciation course provides great introduction to glassmaking British Glass hosted a ‘Glass Appreciation – an introduction to glass’ course, delivered by technology speakers from Glass Technology Services (GTS). Guests included Guardian Industries, Saint-Gobain, Hanson and Nestlé. Glass International’s Sheena Adesilu attended and reviewed the day.
� Martyn Marshall, Principal Glass Technologist at GTS, and guests in laboratory.
he trade association for the UK glass industry British Glass hosted a one-day ‘Glass Appreciation – an introduction to glass’ course. Experts at GTS, an independent consultancy, test and research laboratory for the glass industry, delivered the course. The Glass Appreciation course was a great introduction for both new starters in the glass industry and people just coming into contact with the material. These include technologists or manufacturers in food and drinks companies. Philip Marsh, Business Development Manager at GTS said: “It’s a very mixed audience who attend. “We seem to be moving in recent years more towards brands, retailers and the food and drinks or spirits manufacturers, so it’s typically someone with a QA type of role.” When I arrived at the headquarters of British Glass in Sheffield, UK the Events and Training Coordinator, Meg Grattidge, led me into the classroom. There were 14 delegates from companies
such as Guardian Industries, SaintGobain, Hanson, Nestlé, Glassworks International and The Department for Business, Energy and Industrial Strategy. The majority of visitors were newcomers to the industry. The two speakers throughout the day were Martyn Marshall, Principal Glass Technologist and Oliver Wallwork, Product Performance Technologist, both from GTS. They carried out two separate presentations on the discovery of glass, families of glass and forming, as well as glass strength, annealing and stress. After each speaker finished, our group went into two different laboratories to see how glass was made and tested. As a newcomer to the glass industry, I was fascinated to see burning hot molten glass emerge from the furnace. It was the first time I had seen glass in its molten state like this and I was curious and surprised when I saw how the glass changed shape and form. Mr Marsh explained: “GTS has been running the Glass Appreciation course for more than 15 years.
� Guest in laboratory. “We refreshed it in the past year to a one-day course. “The demand for today’s course was over-sold and we are already booking onto the next course.” For a newcomer such as myself, it provided plenty of opportunity to discover more about the material. I learnt that glass has an infinite recyclability, from a raw material perspective, as it can be used over and over again. I also learnt that there is a process for testing glass safety and durably, which is to break the glass inside machines with various forces in a laboratory. Gareth Jones, Operations Director at British Glass said: “GTS and British Glass are a fantastic first point of contact for any questions that people may have and to give advice and guidance in regards to the glass industry.” British Glass partnered with GTS due to the laboratory’s expertise, knowledge and previous experience delivering the same type of courses to customers. Continued>>
38 0 Glass International June 2018
British Glass - Copy.indd 1
Committed to your success � Sheena Adesilu sees molten glass for the ﬁrst time in the laboratory.
Welcome to Covia – formed in 2018 through the merger of two leading organizations: Fairmount Santrol and Unimin Corporation. We are a leading provider of minerals and � Oliver Wallwork, Product Performance Technologist at GTS, was a speaker
material solutions for the Industrial and
in the classroom.
Energy markets, with a broad array of
The course is run every two or three months. If there is a demand British Glass is happy to put on further courses, including in-house and bespoke. Mr Jones explained: “Hopefully, the course will delegates further knowledge, understanding of what is possible and what kind of things they need to consider when they’re looking at new products or developing new packaging. “Hopefully it will help make their process more efficient and prevent some of the manufacturing issues later down the line.” The course was informative and practical, with friendly speakers and assistants. It was interesting to get to know the different guests, which companies they were representing and what they hoped to gain from the course. To improve the course, I think that British Glass and GTS could give each guest a plan of the presentations and activities for the day, including who is speaking. This could be in the form of a leaﬂet, ﬂyer or hand out. I learnt a lot about how glass has been developed, the different types, how it is made and tested, as well as the different ways in which it can be broken. I would recommend the course to newcomers within the industry who want to get a taste of the processes, technology, supplying and testing in glassmaking. �
high-quality products and the industry’s
British Glass and GTS, Shefﬁeld, UK www.glass-ts.com/training www.britglass.org.uk/knowledge-base/events-and-training
most comprehensive and accessible distribution network. We have an extensive portfolio of glass products* and apply our solutions mindset to help you enhance your products and improve your glass melting processes.
For product information and local availability contact: PHONE EMAIL
* ®TM GLASSIL, SILEX, MATRIX and PURESIL are registered trademarks. Copyright © 2018 Covia Holdings Corporation. All Rights Reserved. COVIA is a trademark of Covia Holdings Corporation. British Glass - Copy.indd 2
Environment Training: O-I Poland
� The participants who took part in O-I’s PMDP programme.
Global programme trains manufacturing leaders O wens-Illinois (O-I’s) successful Plant Manager Development Programme (PMDP) in its Jaroslaw plant in Poland is about to reach its 100th graduate. The programme identifies and inspires workers to train as manufacturers who have excellent operational experience, a passion for glassmaking and a desire to address complex technical challenges. In the final session of PMDP, 21 managers from five continents and 13 countries took part in a week of workshops at the Jaroslaw plant in Poland, a bottle producer for the baby-food industry. The group had already spent a week in two other O-I locations: Perrysburg, USA and Lima in Peru. John Webb, O-I’s Senior Vice President and Chief Human Resources (HR) Officer, said: “This programme introduces participants to global subject matter experts from whom they can learn firsthand. “Our goal is to make O-I the most attractive glass company in the world to work for. “PMDP plays a part by providing plant
leaders with a global network of their own and training them not just in operations and technology but also in leadership and business management. “Over half of the programme consists of leadership topics because these are the men and women who will take our company forward.”
Teamwork PMDP brings together plant managers from O-I’s operations around the world and talent from the next level of supervisors. Over the course of three months, they work together to enhance collaboration and teamwork throughout the company, as well as share ideas to create a high performing organisation. Johan Victor, Job Change Coordinator in the UK is one of the managers who took part. He said: “What I like most about O-I is that you can make an impact and improve the lives of your colleagues and customers every day. “As leaders in the plant, we solve the challenges of making innovative glass containers while maintaining filling line
speed, protecting the environment and providing great value for money. “This Plant Manager Development Programme convinces me that the company offers a clear opportunity for me to develop my career to the highest level.” This year’s group brings the total number of programme graduates to almost 100. The PMDP also provides leadership and skills training for workers at all levels of the company. Pablo Vercelli, Vice President and HR for O-I Europe, said: ““We’re transforming our business as we innovate to meet our clients ever-evolving needs to help build their bands, produce sustainable packaging and become valued partners. “And, as we transform, our people can also seize the opportunity to change.” This is the fifth edition of the programme and previous graduates have reported that they are using the leadership tools and methodologies they had learnt to improve the performance of their plants. �
O-I, Perryburg, USA www.o-i.com
40 0 Glass International June 2018
OI Poland.indd 1
Russia’s container market in 2017 I n accordance with Rosstat data from 2017, a total of 12.17 billion units of glass food containers were produced, which is 1.96% less than a year ago. In absolute terms, the decline was 0.24 billion units. At the same time in January-May 2017, the monthly production of glass containers was higher than last year’s level, but from June 2017, the monthly production of glass containers was lower than last year’s figure (Fig 1). The decline was caused by a drop in production of narrow-necked containers by 0.8% compared to 2016. At the same time, the share of the glass jar, respectively, increased from 16.32%, to 17.12%. The Russian Federation produced 12.17 billion glass container units in 2017. A total of 116.8 million units were imported and 580.4 million units exported. Thus, the capacity of the market of glass containers by the results of 2017 amounted to 11707.1 million units.
1,05 1,02 0,87
At the same time, the capacity of the glass-bottle market amounted to 9619.4 million units by the end of 2017 and glass jars - 2087.7 million units (Fig 2). According to the results of 2017, the beer industry accounts for 61.2% of the total demand for glass containers. The alcoholic beverage and cognac industry is 19.8%. The share of the wine industry, including the production of wine drinks and champagne is about 10.1%. About 8.7% are soft drinks, less than 0.2% for juices and nectars and about 0.1% for low-alcohol cocktails (table 1). Thus, consumption of glass containers for 2017 amounted to 9746.2 million bottles and 1747.3 million cans. Despite the fact that the production of beer and vodka has increased, due to the decline in the production of champagne, wine and soft drinks, the total demand for glass bottles has decreased, which has affected its production volumes.
1,15 1,14 1,08 1,06 1,09 1,08 1,07 1,071,06 1,07 1,04 1,04 1,02 1,00 0,97 1,00 0,97 0,96 0,95 0,93 0,92
VVS Info, Moscow, Russia http://vvs-info.com
In the short term, in connection with the continued growth in beer production, LVI and wine in 2018, the output of narrow-necked containers is expected to grow. The volume of production of glass jars will also grow. Thus, for the year 2017 the production of cans increased by 2.8% against the level of 2016. The reason is the growth in the production of canned food and coffee. Thus, the total output of glass containers in 2018 will grow by 0.5-1.0% as compared to the results of 2017. If the current trend persists in 2019, we can expect further growth in glass container production by another 0.71.0% (Fig 3). �
May June July 2016
� Fig 1. Dynamics of glass container production in 2016 and 2017, billion pieces.
May June July Aug
� Fig 2. Monthly capacity of the glass container market in 2017,million pieces.
Beer 5960,6 Champagne 169,0
Grape and fruit wines
Vodka, LVI and Cognac
Juices 16,8 Low alcohol drinks
Total 9746,2 2011
2018 2019 Estimate
� Fig 3. Forecast of glass container production, mln. Pcs.
� Table 1. Consumption of glass bottles in 2017, million pieces.
41 Glass International June 2018
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Environment Events: China Glass
This year’s China Glass exhibition was a truly international show with exhibitiors and vistors from all around the world. Glass International’s Sheena Adesilu was among those to attend.
Visitor numbers rise by at China Glass 2018
isitor numbers increased by 49% at this year’s China Glass event. The event, organised by the Chinese Ceramic Society, consisted of 33515 visitors, which is a rise of 49% compared to when it was last held in Shanghai two years ago, when 22,560 visitors from 65 countries attended. The visitors this year were made up of 28971 Chinese delegates and 4544 overseas guests. The total number of exhibitors was 865, which is a decrease from 886 two years ago. The exhibitors were made up of 612 Chinese companies and 253 overseas businesses. In total, there were 24 overseas companies that exhibited for the first time. Overseas associations, including BMWI, VDMA, ICE Italy and GIMAVVITRUM organised more than 80 companies to exhibit in the German, Italian and United States pavilions. Among the hundreds of exhibitors at the Shanghai New International Expo Centre were All Glass, Glass Service, Bottero, Pneumofore and Antonini from Italy, Electroglass from the UK and Interglass from Mexico. Soon Lee, Sales and Technical Director of the Malaysian hot repair specialist Nosco Asia, said: “In the last 20 years, not many companies have been able to
� � Top: The China Glass event attracted global vistors as well as exhibtors, such as BDF.
do fibreglass repair, especially for E and C glass, because they are very corrosive raw materials. At Nosco Asia, we have repaired fibreglass successfully. “The Chinese market has changed a lot in the past two years because the government has implemented strict environmental regulations in many small companies. “China is a major player [on the world stage], because the volume of glass they produce is huge and they have a big consumer market. “Many Chinese glassmaking companies
are looking for oxy-fuel firing and to improve pressure. The cost of glassmaking is higher because of the raw materials and labour costs.” Daniel Hilfiker, President of the Italian air and vacuum manufacturer, Pneumofore, said: “We have some of the largest glass factories in China using our equipment successfully, including for both vacuum and compressor. “We are highlighting the fact that the machines must be efficient, which means they should consume less electrical power in order to become more environmentally
42 0 Glass International June 2018
China Glass Review.indd 1
� The Glass International team welcomed many guests to its stand.
friendly. The Chinese market is not as big as it used to be but it has represented in some years almost 50% of our turnover. “We have noticed that the influences from foreign industries are increasing. “China is an emerging player because the big, powerful, so-called ‘Bric’ nations; Brazil, Russia and India are sharing the world economy of the emerging markets but we also see how China is trying to protect its internal product and doing quite well.” Emmeti, an Italian packaging line company, has been looking to break into the Chinese glass industry for a long time but was held back by the cheap price of the technology levels and local competition. Fabrizio Boschi, Sales Director of the Glass Containers Division, believes now is the perfect opportunity to get into the market. “We believe that China is a fast growing market as far as hollow glass goes and it has big potential for the future. “We are promoting our standard level of automation for glass factories because I believe it is good enough to improve the efficiency and quality of the hollow glass here in China. “There have been big changes in the market in terms of environmental politics, such as the closure and relocation of many of the old glass factories in the main cities to create new technology for the production of lightweight models with a high quality and high-speed production. The Chinese market makes up 5-10% of our sales. “Our equipment today includes new speed production which cannot be handled manually because of the cost and speed of the new lines.” Paul Hutchinson, Sales Director of UK bonded refractory supplier, DSF, echoed his views. “Typically, we exhibit at China Glass to meet the international visitors and keep in touch with the Chinese market.
“There are a lot of refractory manufacturers in China servicing domestic customers, so it’s a difficult market to get into – not impossible but difficult - and covers such a big area. “There’s been a big push to improve the environment and reduce pollution the market has shrunk, and better, newer producers are thriving. “The quality is slowly improving in China in terms of refractory production. “They are probably getting on an even playing field with the European companies and more level in terms of cost as well.” Jens Rosenthal, Managing Director of German batch and cullet specialist EME (a member of Sorg), said: “We have a partner here in China called Shanghai Precision, who we are supporting during this exhibition and we are telling customers that they can have international standard technology in an international market. “We are highlighting our experience, equipment and technology for the technical glass industry, like TFT glass and cover glass products. “A lot of Chinese companies are now investing abroad and building new factories all over the world. “The Chinese market makes up 90% of Shanghai Precision’s sales and 5% of EME’s sales. The Chinese market is a major player [on the world stage] for certain products for us like fibreglass.” Graham Womersley, Sales Director at the UK conveyor chain specialist, Pennine Industrial, believes that now China is investing in high-speed bottle machines, the company can sell their equipment in the market. “We have a new two-pin chain that’s been undergoing development and tests for over two years. “We’re now very happy with it, it’s proven itself in the glass industry and this is now the first show we are exhibiting Pennine’s new two-pin high-speed conveyor chain. “It’s not an easy market because it very much depends on personal relationships and you have to actually come out, travel and meet people. There are more European machines coming into the Chinese market and there is a growing market for wine and beer bottles. “China is becoming a major player [on the world stage], not only for their own market, but obviously for the international export market as well.”�
Events: China Glass
43 Glass International June 2018
China Glass Review.indd 2
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