Glass International November 2017

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November 2017—Vol.40 No.10

ALLIED GLASS - INNOVATION ORORA GLASS COMPANY PROFILE THAI TABLEWARE OVERVIEW I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International November 2017 GI Cover nov 17.indd 1

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Contents

November 2017 Vol.40 No.10

Editor’s Comment

4

International news

12

Company profile: Innovation manager Allied Glass: Staying ahead in innovation.

16

Company profile: Orora glass: Forming a presence in Australia.

20

Country overview: Thailand: The Tableware glass sector in Thailand.

November 2017—Vol.40 No.11

ALLIED GLASS - INNOVATION ORORA GLASS COMPANY PROFILE THAI TABLEWARE OVERVIEW I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International November 2017

12

Front cover image www.hornglass.com

16 24

Plus find us on Linked-In and Twitter.

@Glass_Int

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24

Company profile: IPGR: IPGR benefits from move to Aachen.

29

Digital technology: Siemens: Siemens and EME install technology at Gallo Glass.

32

Market overview: IFC: Urbanisation drives glass demand.

36

Forming: Heye International: Full cycle cooling for high speed production from Heye.

38

Phoenix awards: Phoenix award honours James O’Callaghan.

41

Diary

43

Plant utilities: Unimin: DustShield to suppress dust

44

Events world: FEVE conference Digital glassmaking at Luxepack.

46

History: Polarised views.

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Glass International November 2017

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Editor’s comment

Greg Morris

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

Digital slowly takes over in the glass industry

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A

quick glance through this issue’s news pages reveals it has been a busy month in the glass industry, particularly in the flat sector.

The segment’s largest manufacturers, including AGC, Guardian, Saint-Gobain and Pilkington have all been busy, making investments, securing contracts and modernising themselves for the future. Clearly this is a positive sign for the industry, particularly in Italy, where AGC and Pilkington have both been involved in the news.

The news featured in the printed issue is only a tiny minority of the events that have taken place in the past month. For news junkies, I suggest taking a look at the Glass International website, or join our Linked In group or, better still, to sign up for our free weekly newsletter.

While print is still the favoured material for most of us (including me!) the rise of online and the digital age has been the movement of our time. For those of us in the publishing industry online offers vast opportunities, alongside the traditional printed medium.

There are no space restrictions online, so it means news articles can be given the breadth they deserve. It is also immediate.

Readers located thousands of miles away from Glass International in the UK can stay up to date each day rather than wait

for weeks for the latest printed issue to arrive in the post.

Regular readers should already receive our digital issue direct to their inbox. In this digital world, when people are used to receiving information immediately and in small chunks, we hope to bring the glass media up to date.

The glass industry itself is facing up to the digital era. Industry 4.0, digital glassmaking, A.I, Big Data and the Internet of Things are increasingly common terms heard throughout the sector. Anecdotally, I’ve heard the flat glass industry is at the level of Industry 3.6 while hollow glass is lagging at Industry 2.8. The hollow and container sector has some catching up to do!

We launched the successful Future Glass Forum in Lyon in September, which is a free-to-attend conference with the aim of discovering more about how digital can improve the glassmaking process. The next event is in Bangkok in January alongside the Glassman Asia exhibition. It is possible to pre-register for the event – digitally of course – at the Glassman Asia website. �

Greg Morris, Editor gregmorris@quartzltd.com

Directory 2017 Annual international reference source

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Glass International November 2017

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It’s always the smaller pieces... , Tomorrow s Technology Today

GLASS SERVICE

A Division of Glass Service

International News

NEWS IN BRIEF

Schott opens Chinese pharma plant

Schott has opened a packaging production plant in China.

The plant will produce 2 billion pieces a year is managed by the joint venture Schott Xinkang.

The site will enable the company to provide Chinese pharmaceutical manufacturers with packaging products even more effectively in the future.

It is located at the Schott Xinkang headquarters in Jinyun, Zhejiang, and will manufacture ampoules, vials and cartridges made of glass tubing for the domestic pharma industry.

Sisecam brings global glass industry together

Sisecam Group brought together the leading names of the global glass industry to discuss the future of the sector and new technologies in Istanbul.

The 32nd Sisecam Glass Symposium hosted the annual meeting of the International Commission on Glass (ICG) which included 400 participants from 25 countries.

The event brought together glass industry representatives, universities and scientific institutions from around the world.

AGC opens Cuneo site

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AGC Flat Glass Italia has officially inaugurated its new float line in Cuneo, Italy.

After a cold repair process of three months and a €25 million investment, the float will present technologies to enhance the plant’s productivity and its environmental impact.

It will also improve the performance of the existing product range produced in Cuneo.

The opening ceremony was attended by the AGC Group President and CEO, Takuya Shimamura, the Regional President Building & Industrial Glass Europe, Philippe Bastien, representatives of the local authorities and the press.

Guardian Glass launches emissions control system Guardian Glass has inaugurated an emissions control system at its Dudelange, Luxembourg float plant.

Mrs. Carole Dieschbourg, Luxembourg’s Minister of the Environment, and Mr. Dan Biancalana, Mayor of Dudelange, joined Guardian Glass in Europe leadership for the official inauguration of the con-

trol system.

Guus Boekhoudt, Vice President of Guardian Glass in Europe; Jose Miguel Villacorta, Dudelange Plant Manager, and Jean Ries, Director Government and Public Affairs Guardian Europe all also witnessed the massive installation that reduces NOx, SOx and dust from the float glass process.

The control system has been fully operational for four months and ensures the Dudelange plant complies with limits set by the Luxembourgish Environment Agency and with the EU Industrial Emission directive. A similar system was installed at the Guardian Glass Bascharage, Luxembourg plant in 2013.

AGC Glass orders Zippe technology AGC Glass has ordered a batch plant and cullet return system from Zippe for its second glass float line in Guaratingueta, Brazil.

Zippe will supply the entire plant with the exception of the concrete works turn-key.

AGC and Zippe will both rely on on a Siemens SPS System S7 400H control system.

AGC aims for the best quality in weighing and chose a solution from Zippe.

Zippe’s standard remote access was implemented in order

to realise future plant extensions and modifications as efficiently as possible.

The cullet return is controlled by a Siemens S7 300 SPS and connected with the batch plant control system by a fibre optic cable.

Asahi India Glass starts Taloja plant Asahi India Glass (AIS) is to commence production at its Taloja float glass plant.

The Taloja plant will add to AIS’s scale and flexibility in providing supplies to customers in the architectural and auto segments, which includes all leading automotive OEMS. The company also has a fifth auto glass plant in Gujarat, India. The Taloja plant will have the capability to produce high-quality value-added glass for the architectural and auto-

motive glass segments, with an installed capacity to manufacture 550 tonnes of glass per day.

Mr. Sanjay Labroo, MD & CEO, Asahi India Glass (AIS) said: “The Taloja plant will not only increase our capacity by 60% but it will have the ability to make the highest grades of glass for the architectural market directly, and for value-added purposes such as mirroring, hard-coating, soft-coating and processing. It will also have the capability to make the highest

standards of automotive raw glass giving AIS 100% capability to make our own automotive glass.”

The formal inauguration was attended by Mr. Masahiro Takeda, Regional President – Asia Pacific, Building & Industrial Glass, Asahi Glass Co. (AGC), along with Mr. Sanjay Labroo, MD & CEO, Asahi India Glass Ltd (AIS), Mr. Sanjay Ganjoo COO, Architectural Glass, AIS, along with other senior management members.

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4 Glass International November 2017

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International News

Turkish tableware group LAV opts for Iris technology has turned to Iris Inspection machines for camera-based inspection equipment for its two manufacturing sites in Kütahya, Turkey.

LAV ordered its first Evolution Ultimate machine for test purposes in 2016.

The camera-based machine is dedicated to the identification of cosmetic defects in the sidewalls of luxurious glassware, including tableware, perfumery and premium spir-

Emhart stability

its bottles.

Evolution Ultimate is equipped with 16 HD cameras for the complete coverage of sidewalls and rims in tumblers and stemware.

Following the successful completion of trials, LAV ordered another seven Evolution Ultimate inspection machines at the beginning of 2017.

It placed a third order, this time for two more machines, in recent weeks.

Vidrala in Santos Baros acquisition Spanish glassmaker Vidrala has completed the acquisition of the Portuguese company Santos Barosa Vidros.

Santos Barosa manufactures and sells glass containers through a production facility in Marinha Grande, Portugal.

The company produces

more than 400,000 tons of glass per year and obtained an operating result, EBITDA last 12 months at September 2017, of €32.8 million, equivalent to a margin of 25.1% over sales.

The deal, completed in an all-cash transaction, implies an enterprise value of €252.7

million.

A statement said: “Vidrala has have long admired Santos Barosa’s business, founded on outstanding manufacturing facilities and strong commercial relationships in the attractive Iberian glass packaging market.”

Condat acquires Renite lubrication French company Condat has acquired Renite’s lubricant activity.

The acquisition is a good opportunity for Condat to strengthen its diversification strategy in North America,

thanks to Renite reputation and technology there.

Renite’s range of lubricants and custom solutions for the glass industry is also a main asset in the deal.

Glass customers will benefit

from lubricants dedicated to their specific needs, plus extra products for the maintenance of their machines and various lubricating equipment (from distribution, spraying, dosing and dilution.)

SGT visits Saint-Gobain’s UK site Members of the SGT’s Melting Technology Committee visited the Saint-Gobain Glass, Eggborough, UK site.

The visit included a tour of the modern float glass facility and the MTC’s October meet-

ing. The committee also welcomed Bill Brookes to his first MTC meeting as the Society’s President. The committee is welcoming speakers for next year’s Furnace Solutions.

The theme for Training Day

6 is ‘Furnace Operation and Instrumentation’ including all processes – Forehearth distributors and burners.

The theme for Furnace Solutions 13 is Furnace Optimisation.

The European market for Bucher Emhart Glass remained stable at a high level, it reported in its Q3 financial report.

The North and South American markets were up on the same period last year, while other sales regions also demonstrated solid demand overall.

Order intake for the first nine months this year was CHF324 million compared to CHF272 million in the same period last year – a 19.1% increase.

Iranian glass lubrication presentation

Belgium companies Socabelec and VDV Lubricants presented their swabbing portfolio to a group of Iranian container glassmakers.

The two companies gave three speeches during the event held in Iran where they discussed manual lubrication and introduced Socabelec’s swabbing robot.

Vertech R&D Director

French company Vertech’ has appointed Michaël Gauthier as its R&D Director.

He will manage its R&D developer’s team as well as new developments. Michaël and his team will be working on the entire module range for SIL system, a monitoring solution for the glass industry.

Michaël joined Vertech’ in 2012 as a member of the development team, and became a Product Manager for the SILX solution, a fullweb platform providing production KPI to managers.

Pilkington restart

Pilkington Italia has commenced warm-up of the furnace for glass production at its Porto Marghera plant, in Venice, Italy.

The new line has been upgraded with the latest technologies and will produce 600 tons/day of float glass.

The investment will also include the installation of emission control systems in the atmosphere, in line with environmental rules.

www.glass-international.com

One of the world’s most dynamic manufacturers of glass tableware is investing strongly in the latest camera-based inspection technology.

Turkish specialist LAV manufactures 700 million table glass items annually, including tea sets, beverage glasses and soup bowls, which are exported to 130 countries.

Within the past 12 months, the relative newcomer to the global table glass business

NEWS IN BRIEF

7 Glass International November 2017

news nov.indd 3

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Bottero securers Guardian and Saint-Gobain orders

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Italian company Bottero celebrated its 60th anniversary by securing new orders from Guardian and SaintGobain.

The Cuneo-based company exports 95% of its product overseas, owns four manufacturing plants around the world and, thanks to its ability to land ongoing work orders in the industries in which it op-

erates, has set its sights, by 2020, on breaking the €200 million ceiling in annual sales.

The company was formed in 1957 when Pasquale Bottero left his job at a glass manufacturer’s shop in Vernante, Piedmont to launch Bottero Costruzioni Meccaniche jointly with Antonino Faccenda, and to introduce the earliest inno-

vations in flat glass processing machines.

The company recently acquired three new orders for laminated glass systems: two lines for the US Guardian Group for its plants in Hungary and Thailand, and one for Saint-Gobain, for a German facility.

The overall value of the three orders is more than €10 million.

Strategic Materials opens Wisconsin recycling facility North America’s largest glass recycler, Strategic Materials, has opened a glass processing plant in Delavan, Wisconsin.

The facility was built

in response to the state’s need to increase glass recycling. The 125,000ft2 facility sits on 15 acres, and was expected to begin production in early No-

vember.

The Delavan location will replace the company’s East Troy, Wisconsin, facility and will retain nearly all of its employees.

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O-I to build Mexican furnace O-I is set to build a fifth furnace at its glass container production plant in Nava, Mexico.

The world’s largest glass container manufacturer has also expanded its 5050 joint venture with Con-

stellation Brands.

The jv operates the container production plant in Nava, Mexico that provides bottles exclusively for Constellation’s adjacent brewery.

The brewery brews Mex-

ican beer brands for export to the United States.

The relationship now provides for the fifth furnace at the plant and has extended the term of the joint venture agreement by ten years, to 2034.

Excelsius sold to Robur Germany’s Excelsius Global Services has been sold to the Robur Group.

Excelsius, based in Lohr, provides a variety of services to the glass industry, including heat up and expansion control, controlled cool down, and cullet fill using blowing or vibrating feeding methods.

Robur Group is a company focused on high-end technical services that are

crucial to the performance of an industry. Its goal is to buy excellent Industry service businesses to build a leading Mittelstand (SME)-company.

Some of the industries it is already focused on include wind turbines, water technology and pump maintenance. The acquisition was confirmed at the beginning of October.

Frank Schwarzenau, Ex-

celsius Managing Director, said the acquisition would benefit both companies.

He said: “I am very excited about the future because this acquisition brings shared synergies to both parties.

“The Robur group recognised the exceptional services that Excelsius provides and it will benefit from our operational management services.”

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International News

Top 10 stories in the news

NEWS IN BRIEF

Vetropack appointments

Vetropack Holding has appointed two new business division managers.

Boris Sluka (1965) will take over as General Manager of the Business Division Czech Republic/Slovakia, which comprises the Vetropack Moravia Glass and Vetropack Nemšovà companies.

With effect from 1 March 2018, Johann Eggerth (1967) will take over as General Manager of the Business Division Switzerland/Austria, which comprises the Swiss company Vetropack and Vetropack Austria.

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. O-I to set build Mexican glass container furnace by 2019 � 2. Vidrala completes Santos Barosa acquisition � 3. Turkish tableware specialist opts for Iris inspection technology � 4. Stölzle Masnieres provides finished samples in four weeks � 5. Schott opens Chinese pharmaceutical glass plant � 6. Bangkok Glass selects GPS for its Ratchaburi plant � 7. Glass For Europe increases in size � 8. Excelsius sold to Robur Group � 9. Vetropack appoints two business division managers � 10. Bottero secures Guardian and Saint-Gobain contracts

South Korea’s Samkwang Nonsan chooses Xpar Vision

the South Korean market.

Knowing that the market is transparent, this is a good starting point for new investments to come.”

In the meantime, Samkwang Nonsan staff have been trained at Xpar Vision’s base

Celsian Glass & Solar in Eindhoven, The Netherlands has appointed Joost Laven as its segment leader for furnace support.

Mr Laven (1984) has a master in mechanical engineering from Delft University of Technology and specialises in energy management.

He joined O-I Manufacturing in 2011 and since then has held several jobs in operations and energy optimisation.

in Groningen, the Netherlands. Furthermore, the systems have been installed on the production line and an Xpar Vision consultant/trainer has given several on-the-job training sessions at the plant. egate, if it avoids landfill.

Stölzle can provide finished samples in four weeks Digital glassmaking has enabled Stölzle’s Masnieres site in France to offer its customers finished samples in less than four weeks.

The site is the company’s centre of excellence for perfumery and cosmetics and it

now offers its customers more flexibility in development and in production runs.

The site’s Managing Director, Etienne Gruyez, said: “The industry is adapting to keep relevant with the digital big bang. For example we can

provide new finished samples to our customers in less than four weeks thanks to a complete digitalisation of the design phase.

“Digital printing allows us to also minimise errors and reduce costs.”

futronic appoints head of sales

Stephan Pies is set to become futronic’s Head of Sales.

He will take over the job from Michael Preuss, who plans to concentrate more on his duties as Managing Director, on 1 January 2018.

Pies has been with the company since 2011. He previously trained as a mechatronics fitter prior to taking a degree in Business Engineering, specialising in electrical engineering, at Konstanz University of Applied Sciences. He will have overall responsibility for all futronic divisions. His main task on the operative side will be to look after key accounts.

Pies said: “We want to continue growing in all segments.”

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

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South Korea’s Samkwang Nonsan has chosen Xpar Vision’s InfraRed Camera and Gob Weight Control System.

Mr. Kon-hee Han, Managing Director of Samkwang Nonsan, said: “We continuously want to improve our efficiency and quality level and we see this investment as a necessity to maintain our position as leading supplier to the South Korean market.”

Xpar Vision CEO Paul Schreuders, added: “We are very proud to welcome Samkwang Nonsan as a new customer in the Korean market.

In addition, we have two of our technologies exposed to

Celsian appoints Joost Laven from O-I

11 Glass International November 2017

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Company profile: Allied Glass

Staying ahead in innovation “Innovation is extremely important to Allied, it’s one of our key pillars and all our customers

”

demand it

www.glass-international.com

� Top: Mr Chris Todd. � Above: The Torq closure.

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Company profile: Allied Glass

Continued>>

www.glass-international.com

Innovation is a key word in the glass industry and for a glassmaker it means designing bottles that are relevant to today’s consumers. Greg Morris spoke to Chris Todd, Allied Glass’s Innovation Manager.

A

llied Glass has a culture where innovation is encouraged, the company priding itself on being at the forefront of creative thinking, its ability to come up with new ideas keeping its product offering fresh and original.

The UK glassmaker, which makes premium bottles for the luxury spirits sector, encourages every department within the business to innovate including its design centre which devotes a lot of time to creating new ideas which will appeal both to its customers and ultimately end consumers.

But what drives this thinking? Where does the creative inspiration come from? What gives a bottle that special something which will appeal to the end consumer and help ensure loyalty to a particular brand?

Allied’s Innovation Manager is Chris Todd, who is based in its Knottingley, UK plant. Mr Todd has worked for the company for more than 10 years and has worked in the glass industry for 30 years.

He previously worked at the Knottingley plant when it was called Gregg and Company and has also worked for Rockware, now Ardagh, in its’ Yorkshire, UK glassmaking plants.

While most of his career has been spent in the design and innovation area of glass, Chris was educated as an engineer and his first job was as a mould engineer, working with the hot and cold ends he has a broad understanding of the entire glassmaking process.

“Innovation is extremely important to Allied, it’s one of our key pillars and all our customers demand it. We realise we have got to be innovative because of the company’s size. One of our key strengths is our flexibility. We can be very reactive.

I think it’s of benefit to our customers just how flexible Allied can be and because of that we are a lot more open to innovative products, we are a lot more willing to try things.”

Larger glassmakers who have invested in large machines want them running all the time and anything that stops them running is seen as an issue. But today, variation has become key, which in turn requires smaller runs on the production line.

“Smaller runs mean a lot of job changes, which can reduce efficiency. But because of the nature of what we make, we do a lot of job changes so we are used to it. It’s one of our strong points,” says Chris.

Ideas for new bottle designs at Allied come from two sources: either from within its’ own design team, or externally after discussions with customers.

One of its recent innovations that initially came from a customer was the Torq natural cork stopper, unveiled in the summer.

Chris says: “Within the design centre we do pro-active projects where we do our own research, create our own ideas and present them to customers, but this one in particular came from a customer request. There is a lot of variation, sometimes we get told exactly what people want,

13 Glass International November 2017

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www.glass-international.com

sometimes we’re given a challenge where we have to come up with a solution and this was one of those.”

There were several partners in the project – Edrington, Guala Closures, JC Robeiro and Allied Glass – to create the natural cork stopper. The reason for the innovation was the rise in exports of spirits to areas such as the Asia-Pacific region. The hot and humid conditions can expand the liquid inside the bottle and push the cork out. Sometimes this damage can be invisible until the point of sale or consumption, which causes damage to brand reputation.

The Torq Closure was designed to address the issues of failures in hot countries. The glass finish and the closure are threaded, so a small twist upon the closure application secures the cork, with the threads preventing any upwards creep or movement.

A typical innovation from initial approach to or from a customer to the final product can take between 20 to 30 weeks. The portion of creating an idea and making sure it is what everybody wants can take time, but once it is approved it can take about 18 weeks until the final product.

So how does Allied create the ideas for the bottles that we will see on a supermarket shelf?

The ideas they present have to resonate with the customer. During a typical 45-minute customer presentation, Chris will present several samples and try to bring as many ideas to life as possible.

The company’s samples contain little identifiers, innovations and small attention to details which help differentiate the bottle. The attention to detail is known as extrinsic values and are the signposts that say ‘this bottle is worth it, you need

to buy this’.

Chris states: “We understand the marketplace, understand what we can do, understand what is achievable, and because innovation is so key to us we are always trying to push that bit harder and that bit more. They’re not great leaps of faith but when you look back over 10 years you’ve come a long way. They’re smaller steps and easier to achieve. Over time you’re producing things that you wouldn’t have 10 years ago.”

Key to Chris’s role is to keep an eye on trends. He does this by attending trade shows and chatting to industry people. Allied has invested in its sales team recently so it not only serves the larger international spirit manufacturers but also the smaller craft producers.

“We have lot of meetings internally where we share the intelligence we get from attending design exercises or presentations at larger customers and by listening to what smaller producers are saying.”

Allied Glass has also commissioned its own research with the Retail Institute on premiumisation and what it is about packaging that is perceived as being premium. The research from the Institute is woven into Allied’s customers presentations.

Insights from the research state that among key drivers of the spirits market at the moment are millennials, provenance and premium.

Millennials There is a focus on smaller serving sizes at the moment, which is linked to accessibility of premium products. Millennials – those who were in their late teens or early 20s at the turn of the century – have grown up with so much choice and fast-paced innovation that brands are having to deliver more variety and choice. For the spirits market, a 70cl bottle is inaccessible to a millennial because of the price. Millennials want to try lots of things and a smaller serve gives them the opportunity and affordability to try lots of variations.

Provenance Trust has become a massive trend in recent years.

Trust in large institutions such as governments, religion and the wealthy has eroded in the last 10 to 15 years. Consumers are looking to trust in something and that is why there has been an increase in things that have provenance because to have provenance creates a trusted product.

The rise of the recent craft drinks culture is linked to provenance. People want to know where things have come from, consumers are more willing to trust something that is made on their doorstep rather than something presented to them by a large conglomerate organisation. People are willing to pay more for the fact they get a good story or know the person who has made it.

Continued>>

14 Glass International November 2017

Company profile allied glass.indd 3

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Company profile: Allied Glass

One aim of a bottle is to tell the story of the product within, people don’t buy into a brand anymore they buy into a lifestyle, they want that brand to say something about themselves. They want the brand to have the same sort of values that they have.

This is presented to them through the packaging, marketing, social media and how the brand acts. Allied’s role is to ensure the packaging plays a part in presenting those sorts of values.

One recent example from Allied is Masons Gin, which is made locally in Yorkshire. The bottle has a Yorkshire Rose on the bottom, which is subtle enough that you have to look for it. The rose gives the packaging an extrinsic value, it helps reinforce the gin as a locally-made Yorkshire gin and adds to the story.

Premium Almost universally around the globe trading up by consumers has driven growth in premium spirits. Middle classes in developing nations along with discerning consumers with large disposable incomes in mature markets have been driving this trend. Distilled spirits, particularly gin, dark spirits and all whiskies have been growing in the premium sector. People are actually drinking less but better. Younger people drink less alcohol than the older generation, so while the sale of alcohol is down among millennials so they drink less. But when they do drink they trade up in their purchasing choice.

Differentiation is key to premium packaging and works to create unique packaging that invokes curiosity and has rarity connotations. Rare is premium and quality. But only slight differentiation is needed, moderate typicality is preferred by consumers. Something too typical or atypical can have a negative effect.

All trends essentially emerge from the consumer, so for company’s such as Allied, it is essential to keep an eye on fads, habits, cultures, movements and big decisions. Trends take a long time to develop, some things that are popular today may only be a fad and quickly fall out of fashion.

“You have to remain relevant to the consumer, as soon as you’re not relevant you’re not selling anything,” says Chris.

On average Allied brings 78 new products a year to market, although not all will be innovations. An Innovation team will comprise of between five to eight people drawn together from different departments within the company. Cross functional teams always work well together, says Chris.

“There is a lot of competition out there and we need to have a full pipeline of ideas and the flexibility to react when an idea does resonate with somebody. There also has to be a high-level commitment from everybody because ideas and innovations are delicate and can be easily quashed.”

Chris cites the Masons gin bottle as his favourite innovation from an aesthetic basis and the Torq closure because it solved a problem. His love of the job remains undimmed.

“I enjoy it because the whole trends side fascinates me. I’ve worked for a long time in the glass industry and it grounds you, so you can’t get too flighty with the innovation side of things.

Things have to be fit for purpose in the industry but equally I like to push the boundaries. I like to think that anything is possible.

“There are always things to learn and that’s another reason why I like it. It’s a constantly challenging and moving environment. What you’re working on today, within 20 weeks you’ll see it in the supermarket and there’s something nice about helping achieve something you see every day.” �

SCRAPER CONVEYOR

Automatic Chutes

CULLET CRUSHER

Allied Glass, Knottingley, UK www.allied-glass.com • Belt and spindles tempering lines • Decorating lehrs • Chemical tempering ovens • Roller annealing lehrs • Mold pre-heating kilns • Stackers + cross conveyors • Scraper conveyors • Cullet crushers • Thermal shock test systems Contact us: vidromecanica@vidromecanica.com Company profile allied glass.indd 4

www.vidromecanica.com 14/11/2017 15:24:31

2016 anuncio HALF PAGE CASCO.indd 1

25/05/2016 09:08:01

Company profile: Orora Glass

Forming a presence in Australia Australia’s Orora Glass recently completed a $42 million investment project to increase glass bottle production at its manufacturing facility in Gawler, South Australia. Its General Manager, Greg Savage, describes the company and the long-term partnership with its major technology supplier, Heye International.

O

rora has completed a $42 million investment project to increase glass bottle production at its manufacturing facility in Gawler, South Australia. The investment has expanded the glass bottle forming lines at the, increasing capacity by 60 million bottles per year. The expansion uses Heye technology. The 62-hectare site employs 350 people.

www.glass-international.com

Why did you to decide to upgrade the plant?

The South Australian wine industry in particular is experiencing a sustained period of growth fuelled by exports to key global markets, particularly in Asia. The Gawler facility is already one of the largest glass manufacturing facilities in the Southern Hemisphere and the investment enables us to meet the increased demand for high quality glass bottles. The benefits include an increased speed to market. Less reliance on imports removes risk of supply and fluctuating costs in international markets and delays in the extended supply chain.

Who are your main customers and what products do you make?

The Gawler plant produces different bottles for the wine and beer segments. Glass product is produced

� The Gawler plant recently completed a $42 million investment.

“The most important factors are cost, reliability and

”

innovation

for the big Australian brands as well as the contract wine bottling and craft beer industries. The majority of manufactured glass bottles at Gawler are for wine, with the remainder for beer. Its main geographical market is Australia and its export destinations are predominantly in Asia, the USA and UK.

How would you describe the Australian glass market at the moment?

We are seeing strong growth in wine exports, whilst the domestic wine sector is growing but at a slower rate while beer consumption is fragmenting with strong growth in craft beer.

We are seeing continued lightweighting of wine bottles for commercial brands down to 330 grams, shorter runs and more individual proprietary bottles for the premium segments. At Gawler we are responding by building more expertise in job changes and the ability to support shorter production runs.

Is digital glassmaking important to Orora Glass?

Digital analysis in production is still evolving. We Continued>>

16 Glass International November 2017

Company profile Orora.indd 1

14/11/2017 12:39:40

WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS

REACHING THE ASIAN MARKET Glassman Asia will be the ideal opportunity to network with industry professionals from around the world whilst learning about the latest products and services on the market.

Container glassmakers in Thailand are enjoying an unprecedented

We are looking for producers, manufacturers and service providers within the following fields to exhibit their products and services: • Raw materials

• Processing machinery

• Batch Plants

• Laboratory services & analytical equipment

boom in demand. Higher consumption of energy drinks, beer and

• Melting furnaces

food sauces in Thailand and the region means glass packaging is

• Combustion equipment

more required than ever before. Experts predict that by 2020 the

• Refractories

Asia Pacific glass packaging market will be valued at $25 billion.

• Feeders & forehearths

The country has an established glassmaking sector with container

• Hot end handling materials & systems

producers Bangkok Glass, Berli Jucker Public Company (BJC) and Siam Glass all well-known in the industry.

• Annealing & decorating lehrs • Cold end handling materials & systems

TO FIND OUT MORE CONTACT:

• Decoration materials & equipment • Instrumentation/process control systems • Turnkey plant construction services & technical assistance & training • Software providers

• Tempering/laminating plants

Ken Clark, Sales Director t: +44 (0)1747 855117 e: kenclark@quartzltd.com Manuel Martin Quereda, International Sales Executive t: +44 (0)1737 855 023 e: manuelmartinquereda@quartzltd.com

CONTACT US TO BOOK YOUR STAND

WWW.GLASSMANEVENTS.COM/ASIA Organised by:

Join the Glassman Events Group

Glassman_Asia_1p_Ad.indd 1

Official media partner:

@glassmanevents

13/09/2017 11:55

Company profile: Orora Glass

are monitoring developments in industry closely and are excited about the possibilities it may bring.

What are the most important factors you consider when deciding upon your new machinery equipment suppliers?

� Heye International was its technology partner for this investment.

The most important factors are cost, reliability and innovation. We are also interested in developing long-terms partnerships with our suppliers who invest the time and resources to understand our business and bring improvement opportunities forward. A good example is our long-term relationship with Heye, which has been very successful. We worked with Heye on the recent expansion of the Gawler plant. It provided 20-section compact machines, which replaced the existing 16-section machines. Importantly, they built the machines to fit in the existing footprint, otherwise we would have faced extensive civil works to accommodate larger machines.

How many furnaces and how many lines does the plant have?

How do you hope the plant will evolve over the next five years?

Three glass furnaces with the majority of volume dedicated to wine glass production. Six machine lines with narrow neck press and blow (NNPB) capability on five of those lines.

Seven colours We have warehouses dedicated to holding wine bottles in the Barossa Valley to supply all customers located within this region.

www.glass-international.com

Technology overview Major technology partner is Heye. World class inspection equipment – Xpar hot end inspection, Emhart Veritas on each production line Packaging equipment is MSK and Zippe batch house

a value-added service. The application attractively packages and labels wine products, which increases on-shelf visibility and supports brand promotion.

The sleeving also helps conceal off-coloured glass, which is a by-product of colour changes when new bottle colour campaigns commence. This in turn saves energy which was formerly used to re-melt the glass.

It meets growing customer demand for high impact packaging to support promotions. The new sleeve application is designed to enhance and build on our existing glass bottle range by easily transforming any bottle into a powerful marketing tool. This technology complements the capacity expansion project at the Gawler glass facility.

As part of a complete and flexible production solution, recyclable glass sleeving can streamline, process and create efficiencies for a customer’s bottle supply. Customers can now overcome the challenges of directly printing onto glass and eliminate the restrictions of applying labels over contours. By utilising off-colour glass for sleeving (depending on the sleeve type) production costs are reduced and the cost of marketing can be offset.

Orora’s bottles and sleeves are manufactured and conveniently applied, at the one facility. Once bottles are dressed for success, they are delivered to the required facility. Now it is possible to expand the on-shelf presence, reach and appeal of a customer’s brand, without making any change to the product itself. A finished product is now transformed from simply functional to highly saleable, by fully utilising the bottle surface area as a marketing landscape. Glass sleeving technology encompasses design, packaging production and point-of-sale marketing.

� Orora’s sleeve technology enables bottles to be sleeved and delivered just in time.

We are a customer-led business and will make additional investments that meet the growing demands of the market. At this stage we are focusing on optimising the expanded forming lines. Looking ahead, we will continue to assess opportunities to further develop the Gawler facility in line with our customers’ requirements. �

Orora Glass, Gawler, South Australia https://www.ororagroup.com/what-we-do/products/ glass-bottles

Could you tell me a little bit more about your shrink sleeve technology, introduced in July last year?

The equipment installed is Fuji seal with sleeves provided from a number of manufacturers, including Le Mac, CCL and label makers. It means bottles are sleeved and delivered just in time, in MOQs as small as one pallet.

The shrink sleeve decoration process is offered as

18 Glass International November 2017

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Country overview: Thailand

www.glass-international.com

B

uoyed by huge domestic and regional demand, low manufacturing costs and lifestyle changes, Thailand has taken the lead to become one of the largest producers of tableware glass in the ASEAN region in recent years. Investments in capacity expansions and wider products offerings have produced world class tableware producers in the country. These expansions have also enabled domestic producers to increase exports of tableware glass in the last decade.

Thailand has one of the most dynamic tableware glass producers in the South East Asian region.

The country defies the global average of the glass tableware industry (Its tableware globally accounts for 24-26% of the tableware industry). The subsegment accounts for more than 30% of the total tableware produced and consumed in the country.

A changing lifestyle and an expanding middleincome population have led to a growing number of consumers interested in tableware glass products, many of whom wishing to use them as a means to express their sense of identity. Thailand’s household disposable income is growing significantly. Between 2010 and 2016 the income expanded at a CAGR of 6.5%. With changing lifestyle and growing middle-income population, an increased number of people are developing a taste for products with a unique design to differentiate from others.

There are no official records for tableware glass production and consumption but most of the producers agree that tableware glass consumption has grown by more than 6% per year in each of the last five years.

With an installed production capacity of 180,000 tons per annum and an output of about 140,000 tons, the country ranks among the top tableware glass producers globally. Four large producers (including one opal glassware producer) account for more than 40% of the total tableware glass produced in the country. Smaller producers, which until now were confined to niche segments are increasingly spending on technology and process upgrades to challenge the domain of recognised and bigger players in the domestic and export markets.

Improved technology has been a priority of Thai tableware glass producers in recent years. It has enabled them to increase their quality. Some of these producers are also OEM suppliers for established tableware glass brands in Europe and Japan.

In addition to meeting domestic demand, Thai tableware glass producers export about 45% of their domestic production to other ASEAN countries, the rest to Asia, Europe and Americas.

Most raw materials used in the production of tableware glass are available in Thailand. Some key raw materials are imported from other Asian countries and Europe. Raw material prices have remained steady for tableware glass producers

The tableware glass sector in Thailand

in the past two years. However an increase in energy cost, in particular natural gas and liquefied petroleum gas costs has directly affected production costs.

Ocean Glass Ocean Glass is by far the largest tableware glass producer in Thailand. Located at Bangpoo Industrial Estate in Samut Prakarn province, the company has a total production capacity of 150 million pieces of tableware products per year. It is one of only a few suppliers in South-East Asia whose glassware is also in vogue in the demanding

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Country overview: Thailand

European and Japanese markets.

The company operates subsidiaries in two of the most populated markets of China and India in order to facilitate exports to these countries in a smooth manner. Technical assistance from the Japanese company, Toyo Sasaki Glass has enabled Ocean Glass to make quality products from its manufacturing facility. Ocean Glass has three brands - Oasis, Oasis Professional and Lucaris. The former two are soda-lime glassware, while Lucaris is a trademark for premium level of lead-free crystal glass. (see Table) Located in the Bangpoo Industrial Estate on the

Company

Location/ Province

Technology Supplier/s

Ocean Glass

Samut Prakarn

Forma Glass, Toyo Sasaki,

Lucky Glass

Ratchburi

Horn Glass, EME

Nakornpathom

PD Refractories

futronic, Siemens United Glass Company Eastern Glass Manufacturing Company Ltd Kong Thavron Glassware Company

Bang Khae, Bangkok Sam Phran, Nakornpathom

Bangkok Modern Glassware Company (BMG) Union Victors Company Limited

Bangkae, Bangkok Bangkok

Thai Soojung Glass Company (Opal Glassware)

Sampran, Nakornpatom

Inter Product Glassware Company Ltd

Bangkok

United Glassware

Sampran

brand. Lucaris is a collaboration between Ocean Glass, Toyo-Sasaki Glass of Japan, and awardwinning designer Martin Ballendat of Germany.

Set up at the start of this decade with an investment of 1 billion baht with advanced furnaces and technology from Japan and Germany, Lucaris is a lead-free and barium-free crystal glass, with high clarity and brilliance.

The closure of the crystal glass furnace for more than six months affected the sales volume adversely in 2016. The company achieved net sales of 2040.6 million Baht in the year 2016, an increase of 2.64% compared to 2015, when it had a net sales of 1987.91 million Baht. 70% of the total sales came through export markets. The company has been generated more than 65% of its export revenues for the last five years. Domestic sales increased by 10.04% in 2016 due to growth of B2B and food service channel to support hotel and restaurants.

However, the biggest chunk of company’s salesexport sales was stagnant due to world economic Continued>>

www.glass-international.com

Ahead of the Glassman Asia hollow glass event in Bangkok in January, Glass International examines the Thai tableware industry, which is one of the world’s most dynamic with its offerings as likely to be found overseas as it is domestically.

Next month we examine the Thai Container glass industry.

outskirts of the capital, Ocean Glass commenced glassware production in 1982, three years after the company, Ocean Glass, was set up as an industrial diversification of Ocean Insurance Group.

In 2009 it entered into license and technical assistance agreements with Toyo-Sasaki Glass Company Limited for a period of five years.

Under the terms of the agreements, ToyoSasaki Glass provided the company license and technical information in the manufacturing and distribution of glassware and crystal products.

Ocean Glass was awarded a Good Design Award in 2005 and 2011. It has collaborated with 5-star hotel chains, prestige restaurants and bars, as well as brands such as Swarovski to promote its tableware glass products in domestic and export markets.

Its design activities take place at the Bangpoo facility. Glassware shapes and structures along with enhancements such as decals, frosting, gold rims are designed with the aid of CAD software.

In 2016, production was effected due to closure of its one of the furnaces between March 14 – October 31, 2016 for cold repair and maintenance. This furnace produces crystalware under the Lucaris

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Country overview: Thailand

slowdown and high competition in two of the most important markets - China and India.

Rebounding strongly in the first quarter of 2017, Ocean Glass achieved net sales of 515.3 million Baht, a growth of 29.5% compared to the corresponding period in 2016. Management attributed strong performance in China, India and Indonesia behind the surge in sales in the first three months of the year.

Lucky Glass Starting from a small workshop in the 1960s, Lucky Glass has transformed itself among one of the most recognised tableware glass brands in the South East Asian region. Earlier known by Kaew Thai Charoen Part Limited and Thai Neutral Glass Company Ltd, the company adopted its current name in 1988, when it shifted its operations to Kratumban, Samutsakorn on an extensive area.

Since this expansion Lucky Glass has never looked back and has gained domestic and market share.

Popularity of its products and rising demand from domestic and exports market forced the company to undertake another major expansion in 2010.

The management also shifted its manufacturing at a new production plant in Ratchaburi Industrial Estate, in Ratchaburi province. This new plant covers an extensive area of 16 acres. Equipped with best in class technology from Horn Glass (furnace) and EW Bowman (lehrs), Lucky Glass has an installed capacity of 180 tons per day of tableware glass.

www.glass-international.com

Soojung Glass Company

22

Soojung Glass Company is a producer of opal tableware glass, a category which has gained huge in-roads in the domestic Thai market. Located at Nakhon Pathom, the company commenced commercial production of tableware glass in 1984.

The company has an installed capacity to produce 24,000 tons of tableware glass products per annum.

Sudajit Mahakayanun, Exports Manager at Thai Soojung Glass says: “The wide range of product categories, impeccable quality and competitive prices have made us one of the fastest growing companies in tableware industry. We continually apply cutting edge technology in glassware to manufacture products of the highest quality that satisfy the needs of our customers. Through the years our business, we have developed sustaining relationships with all the business partners and have established great reputation with customers around the globe.”

United Glass Company United Glass Company, also known as Etna in the domestic market, is a producer of handmade coloured tableware glass products in Thailand. It

produces handcrafted tableware glass products in vibrant colours which are food and dishwasher safe.

According to Pisit Sirathanantchai, Managing Director of United Glass: “Every piece of glass crystal is produced by experienced glass masters using exclusive and personal techniques inherited for centuries. Our core strength lies in the technical capability that allows us to offer our customers with products of superior quality, value and variety. Our products cover an extensive range of glassware, both clear and colour, emphasising on stylish and unique designs.”

The company has received several domestic and international design awards such as Good Design Award in Japan. It was also the first tableware glass producer to receive the Thailand Trusted Mark (TTM) by Department of International Trade Promotion (DITP) in 2012.

Lotus Crystal Established in 1993, Lotus Crystal is a mid-sized tableware glass producer with an installed capacity to produce 60,000 pieces of tableware glass per month. The product range consists of a full range of handmade crystal, bowl and vases etc. The company produces crystal wares for mid and high ranges. It also works as an OEM supplier for many global and local customers.

Union Victor Established in 1947 in China Town, the oldest business centre in Bangkok, Union Victors was founded by Mr. Chavan Chaithiraphan, the former president. Originally, the company started its business as an importer of machine-made glassware and subsequently acted as an agent for machine-blown glass in the domestic market. With a long experience and expertise, the management finally decided to take a step forward by starting its own factory to produce soda-lime in hand-made and mouth-blown glass, which began operations in 1980.

Kong Thavron Glassware Company Kong Thavron Glassware Company produces handmade and mouth blown tableware glass products from its Sampran, Nakornprathom based manufacturing facility. Operating in tableware glass segment since 1975, the company produces antique and basic tablewares in 15 different colours.

Bangkok Modern Glassware Company Bangkok Modern Glassware Company is a subsidiary of Kong Thavron Glassware Company.

The company produces fused glass tableware products in attractive designs and colours. �

Glassman Asia takes place at the BITEC in Bangkok, Thailand on January 24 and 25. It includes two free to attend conferences – one devoted to Industry 4.0 in glassmaking, the other which focuses on Trends in Glassmaking. In addition, a parallel exhibition will include a number of the world’s largest hollow glass equipment suppliers.

Glass International November 2017

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Company profile: IPGR

www.glass-international.com

T

he International Partners in Glass Research (IPGR) organisation has been at the forefront of glass technology investigation for more than 30 years. The research association’s members are nine of the world’s leading glass container manufacturers as well as a major technology supplier to the sector, Bucher Emhart Glass.

Its aim is to increase the competitiveness of glass as a packaging material against other materials.

While the association has been active at doing this, it has also in recent months completed a move to Aachen, Germany from its former home in Bulach, Switzerland.

On top of that it has also relaunched its website with a more modern, contemporary feel.

The move came about after the IPGR’s General Manager, Christian Roos, received an offer of a professorship at the RWTH university in Aachen.

He discussed the proposal with IPGR members who felt there was an advantage of being associated with such a strong university. Mr Roos would take over the professorship at the university while remaining General Manager at IPGR. Mr Roos said: “It’s worked very well so far.

We’ve established ourselves in Aachen close to the university and are now just organising the legal and technical details about how the IPGR can be attached to the university.”

Collaboration remains at the heart of the IPGR’s ethos. Its members, all seemingly competitors in the glass market, come together to discuss how to move the glass packaging industry forward.

Mr Roos said: “What makes us different to other associations is that we don’t do lobbying, we do pre-competitive to competitive R&D, which is very unique. There are some other associations that do pre-competitive work, but IPGR focuses on R&D and not on lobbying. We decide each year on a certain budget and a project and then some fundamental R&D for these projects.

“There is a very active atmosphere at IPGR, very progressive and pro-active and it’s very enjoyable.

“Many of the IPGR companies are family owned and have a completely different approach to research and development and risk taking compared to large companies that are owned by shareholders.”

The initial reason for the foundation of the IPGR 33 years ago in 1984 was the was the wish to increase the strength of glass containers. The founding members wanted to make glass more competitive through research. At the time the initial research was increasing the strength of container glass packaging. While research remains at its core, the organisation has evolved to also commercialise its results and make them available to the rest of the glass industry.

The organisation has two working groups. One deals with furnaces, batch composition and glass composition while the other technical committee focuses on forming. Both groups officially meet twice a year and tend to meet more frequently

IPGR benefits from move to Aachen The IPGR recently moved its headquarters to the German city of Aachen and has forged stringer links with the city’s RWTH university. Here IPGR General Secretary Christian Roos discusses the recent move and updates on some of the research group’s recent work.

IPGR member

� Bucher Emhart Glass (Switzerland)

companies:

� Fevisa (Mexico)

� Orora Glass (Australia) � Sisecam (Turkey) � Vetropack (Switzerland)

� Gallo Glass (USA)

24 Glass International November 2017

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Company profile: IPGR

� Vidrala (Spain) � Wiegand-Glas (Germany) � Nihon Yamamura Glass (Japan)

IPGR executive committee:

� Chairman: Gunter Lubitz

� R&D Manager: Mr Orzol

� Deputy chair: Oliver Wiegand

� Furnace Committee

� General Manager: Christian Roos

� Technical Committee

one member company and the results so far have been extremely good. So we will see how we can utilise and commercialise it.

“It helps fund IPGR and we hope it will have benefits for the industry too.”

The IPGR is formed of nine member companies who each have two staff in both committees, so consists of 18 people.

One advantage the IPGR has is its ability to do testing at member companies, on a production line. “Again, it’s a big benefit to have these family owned, mid-sized companies because it is much easier to get into the production areas, they are open to give you a section of an IS machine for testing, which is incredibly generous.”

It is also made clear to all member companies about competition.

“If you ask a container glass manufacturer if he wants either a 5% of market share of a competitor or a 1.5% market share of alternative packaging materials industry, such as PET, cardboard or cans Continued>>

www.glass-international.com

when working on various projects.

The IPGR’s executive committee will usually meet once a year, or twice a year if there are particularly important subjects to discuss.

Today’s big talking points among members revolve around the environment and specifically energy and emission reduction. It started a large project three years ago focused on decreasing energy consumption in glass melting. That focus has since been expanded to decrease emissions as well. “If you decrease energy consumption then you obviously decrease emissions as well but there are also other special ways to work on the reduction of emissions, and that is what member companies are also focusing on,” said Mr Roos.

It also has one project in the proof of production stage where it is investigating alternative raw materials that reduce energy consumption.

Its glass forming committee has developed a coating which decreases the amount of swabbing required in the container glassmaking and extended the non-swabbing period to about five days. The project began seven years ago and the IPGR now hopes to commercialise the results.

“It’s a huge reduction.

We’ve implemented it at

25 Glass International November 2017

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Company profile: IPGR

Since 1947, Henry F. Teichmann, Inc. has grown and progressed on the theme: “Satisfied clients are our most important asset.”

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the answer is clear. The real competitors are outside the glass industry,” states Mr Roos.

Mr Roos himself joined the IPGR in 2009 after working for Schott for 10 years. After a year’s sabbatical traveling the world, he was offered the role at the IPGR. “The attraction of the role was the high degree to form and shape an international association and to have the possibility to do strategic development in that field.

“I enjoy working here. We have a lot of opportunity to bring in our own ideas. There is also a real motivation among members to step into a project and bring about benefits to the glass industry. We have a short decision-making time: members meet, they see a proposal, discuss it and then say yes or no. There a no big hierarchies which slow you down, we have a rapid decision making process. Everyone is highly motivated, members really want to see the success of a project.”

Mr Roos has worked in the industry for 18 years and his fascination with glass remains.

“There are still so many things to learn about glass. It is not an obvious material compared to metals or ceramics, it still has some niche areas to explore.

“Compared to other materials glass has a much broader application range and possibility of variations than is usually thought of. Because of that variation you can still learn a lot. “I particularly enjoy working with container glass and the IPGR members because the companies are willing to take risks. When a company is willing to take risks and step into R&D you can really move things forward. If you’re always cautious you will never take big steps.”

The IPGR is keen to remain small and agile. Its new look website is not necessarily to attract new members.

“If we grew to say 20 members, we lose the benefits of the rapid decision making process. The more members the slower it becomes to make an agreement among members. “The website is there to post some basic information about IPGR and give details about what we do.”

Now it has moved to Aachen it will forge stronger links with the RWTH, benefit from its knowledge in other areas and hopes to set up a testing facility in the future. A proposal is a prototype container glass production facility with a small, 2 tonnes furnace also capable of trials of coatings and mould materials for example. �

IPGR, Aachen, Germany www.ipgr.com

26 Glass International November 2017

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14/11/2017 12:41:54

End of the road for ‘cat-scratch’ cord drains Almost 200 PSR Cord Dispersal Systems installed Money-back guarantee Pay-back time measured in weeks

WE HAVE THE BETTER SOLUTION www.parkinson-spencer.co.uk

WE ARE GLASS PEOPLE

ROTOR MECHANISM

THE ROTOR SEGMENTS PROVIDE AN EXCEPTIONAL THERMAL HOMOGENEITY High gob weight constancy Precondition for precise gob loading High lifetime of the mechanisms Proven for many years

www.heye-international.com

RZ_HEY_AZ_Rotor_Mechanism_GlassInternational.indd 1

02.06.16 14:44

Digital technology

� Gallo Glass commissioned EME Maschinenfabrik Clasen to plan and upgrade the batch plant and parts of the cullet return system at its glass bottle production facilities.

Rumans Photography

Siemens and EME install technology at Gallo Glass Gallo Glass was the first place that the Sorg group implemented a solution for plant-wide automation based on Simatic PCS 7, and their initial experiences with Simit were excellent. Bernhard Saftig* reports.

Plant-wide automation With the now completed upgrade of the batch plant at the glass production facilities located in Modesto, California, EME was able to go one step further on behalf of its customer and implement an end-to-end, cross-supplier automation system based on the Simatic PCS 7 process control system. “The switch to Siemens was new territory for Gallo Glass,” says Knüttel, stressing the importance of the project. It was a complex task, especially since there are several hundred different combinations and transportation routes that the batch can follow within the batch plant and on its way to the melting tanks. With the Siemens Siwarex U and Siwarex FTC weighing modules, it was also possible to integrate weighing

applications directly into the automation system.

Flexibility and reliability Originally, the four melting tanks in operation were supplied by two batch plants, with the tanks assigned to a specific plant. This meant a relatively high deployment of staff to operate the two plants. With the new solution, the demand on the operators is reduced because the new system, including the control system, is fully redundant: weighing, mixing, and transport to the tanks. The result is a tremendous increase in flexibility and operating reliability at Gallo Glass.

Continued>>

www.glass-international.com

T

o modernise its plant during operation, the US glass manufacturer, Gallo Glass commissioned EME Maschinenfabrik Clasen to plan and upgrade the batch plant and parts of the cullet return system at its glass bottle production facilities. Because these projects are always accompanied by an automation system, Siemens also participated as a longtime supplier to the Sorg Group. “What was probably decisive was that, with the batch plant from EME and the melting tanks from its sister company Nikolaus Sorg, we were able to supply core technology from a single source,” explains Roger Knüttel, Manager of the Control Engineering Department at EME. “This meant one interface less and a seamless automation concept.”

29 Glass International November 2017

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Technology Metals | Advanced Ceramics

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Your glass quality is too important to trust to just any Molybdenum Glass Melting Electrode. > Sustainability H.C. Starck, a global leader in the manufacture of high quality Molybdenum Glass Melting Electrodes for over 50 years > Performance With outstanding proprietary coatings to minimize oxidation and bubble formation during furnace commissioning > Quality and Control A vertically integrated supply chain producing molybdenum powder through the fabrication of glass melting electrodes

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Digital technology

� Gallo was impressed by EME’s consulting, project planning, and implementation services. Rumans Photography

Virtual commissioning with Simit In addition to its first-time use of Simatic PCS 7, EME also successfully premiered Simit. “The Gallo Glass plant is so complex that Simit was essential for us for conducting tests and evaluations. It optimised our engineering and substantially shortened the commissioning time,” says Knüttel.

“We’re positively astounded by the simulation platform.”

Praise from all sides Gallo Glass’s converted plant has now been in operation since August 2015,

and the company has been impressed

by EME’s consulting, project planning, and implementation services. The excellent support throughout all project phases was especially important to the plant operators, a compliment that EME gladly passes on to Siemens: “Siemens’ products and particularly its support are exemplary; there isn’t a competitor that comes anywhere close,” says Knüttel. �

*Head of Glass Division, Siemens, Karlsruhe, Germany Gallo Glass, Modesto, USA www.galloglass.com

� For the first time, Gallo Glass chose the plantwide automation concept from Siemens for the conversion of its plants. Rumans Photography

EME, Erkelenz, Germany www.eme.de www.siemens.com/glass Tel. +49 (0)911/895-0 contact@siemens.com

Efficient burner control made simple When it comes to glass production, everything is under control: Our versatile mass flow controllers allow gas flows to be set precisely and with maximum repeatability – irrespective of pressure and temperature fluctuations. The Type 8741 MFC is also a genuine communications expert: Flexible interfaces ensure seamless data exchange between control and field levels, with minimum installation effort. That means crystal clear benefits for your production.

Mass Flow Controller Type 8741: This communications expert will keep everything under control.

We make ideas flow. www.burkert.com

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Market overview

� High rises and hotel buildings in Punta Pacifica, Panama City, Panama.

Photo: Gerardo Pesantez / World Bank

Urbanisation drives revival in glass demand Fast-growing emerging markets are at the forefront of a global revival in glass investment as burgeoning urban middle classes drive sales of glass used in everything from building homes and offices to bottling soft drinks. Rozita Kozar, Chief Investment Officer at International Finance Corporation (IFC) reports.

www.glass-international.com

A

fter a painful period of restructuring following the 2008 global financial crisis, a leaner and more efficient glass industry is well placed to take advantage of improved market conditions in emerging Asia, Eastern Europe and Africa.

Not only are these markets expanding rapidly, but most of them are underserved.

Take India, a country of 1.29 billion people, has just eight float-glass lines, with another four under construction.

China, by contrast, has 225, representing roughly half the world’s float-glass capacity.

“For several years now, global demand for float glass has exceeded the global GDP growth rate by 3% on average, with strong growth coming from emerging economies,” said Sabine Schlorke, IFC’s Global Head of Manufacturing and Global Portfolio Manager of Manufacturing, Agribusiness and Services.

While emerging markets offer considerable promise, they can also pose tough challenges. Investors may confront an opaque regulatory landscape, an unpredictable political scene, inadequate infrastructure and unfamiliar, sometimes volatile foreign-exchange regimes. For all these reasons, long-term financing can be difficult to obtain.

A Reliable Source of Funding for a Sector in Recovery IFC, a member of the World Bank Group, is stepping up investments in glass, an industry critical for economic development and smart urbanisation.

IFC provides debt and equity financing to private-sector companies making investments in regions that are underserved by commercial banks. With a presence in more than 100 countries, IFC provides more than financing. It also offers industry expertise, technical

assistance on social and environmental best practices, and advice on how to operate in difficult environments – all backed by six decades of experience in emerging markets.

Since 1978, IFC has provided $1.38 billion in financing for glass projects in countries such as Brazil, Bulgaria, Thailand and Uganda.

Partners have included established global players such as Pilkington and Owens Corning, as well as emerging companies, such as Turkey’s Sisecam Group and India’s Hindustan National Glass & Industries Ltd. With a global recovery in full swing, IFC is now ramping up its investments in the sector. In July 2017, for example, IFC announced its largest loan for a glass company in the past decade, a $100 million loan to NSG UK Enterprises to Continued>>

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Market overview

� Bottles.

(Image: Shutterstock)

Promising markets

finance sustainable architectural and automotive glass production in Brazil and Poland.

The new investment will help NSG expand in emerging markets and support research and development aimed at lowering the company’s carbon footprint through the introduction of energyefficient technology.

Formerly named Pilkington, Britishbased NSG UK Enterprises, a subsidiary of Japan’s NSG Group, has operations in more than 20 countries throughout USA, Europe and Asia.

A strong competitor in today’s global glass market, NSG UK has shifted its strategy from volume production to value-added products and solutions like vacuum glazing, toughening, integrated photovoltaic technologies, and various coatings, which provide for solar control, thermal and sound insulation and fire protection. Pilkington’s focus on clean

Investment needs in emerging markets will likely remain high for a long while.

Economic growth - a driver of demand for glass - is poised to accelerate in emerging markets to 4.6% in 2017, according to the latest International Monetary Fund forecasts, compared with expansion of just 1.8% in advanced economies.

Among the fastest growing markets are emerging and developing Asia (excluding China), which is forecast to expand 6.3% in 2017, and India, with a gain of 7.6%.

In sub-Saharan Africa, growth is likely to more than double this year, to 2.9%. As a rule of thumb, glass sales in developing countries can be expected to increase at roughly 1.5 to 2 times the pace of GDP growth.

Emerging markets are not just expanding – they are growing more diverse, sophisticated, and urbanised, driving demand for float glass used in the construction of hotels, office buildings and airports and in automobile assembly, as well as container glass for beverages.

By mid-century, the urban population of the developing world is expected to more than double, to almost 5.2 billion people.

And as these markets mature, demand will grow for value-added float-glass products, such as energy-efficient solar control and insulation.

Africa Ethiopia offers a good example of the potential in sub-Saharan Africa. Of its 100 million people, just 17% live in cities, compared with a global average of more than 50%. Ethiopians consume an estimated 800 grams of container glass per year, compared with 70-80 kilograms in a developed country such as France.

Sub-Saharan Africa is also among the world’s most underserved markets. Global players have yet to establish a presence in the region outside of South Africa, the continent’s richest nation, which has just two float-glass lines.

As a result, a country such as Nigeria, Africa’s most populous with 200 million people, imports between 1,500 and 1,600 tons of float glass per day, equivalent to the output of two to three float glass lines.

Float glass consumption in Nigeria is forecast to grow at an annual pace of 6-7%.

At least one company, Saudi Arabia’s Construction Products Company, or CPC, already has plans for further expansion into construction materials, with Sphinx Glass, its Egyptian float glass manufacturing facility, as a first step. IFC committed an equity investment of up to $33.3 million in Sphinx with the goal of potentially doubling float-glass capacity to up to 1,200 tons per day, or 600,000 tons per year. IFC is actively helping the company develop a new corporate governance policy and implement several energy efficiency improvements moving forward.

Continued>>

www.glass-international.com

technologies and ‘green’ glass, like triple glazing glass products, is contributing to energy conservation and social and environmental sustainability – a key focus of IFC investments.

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Market overview

� A section of the F&F Tower, banking district, Panama City, Panama. Photo: Gerardo Pesantez / World Bank

Turkish success story Sisecam Group offers a model for CPC’s ambitions. In the course of more than three decades, IFC has helped Sisecam consolidate its position in Turkey and then expand beyond the country’s borders to become one of the world’s top 10 glass makers, and the only one among them to offer a full range of products encompassing float glass, container glass and tableware.

IFC has supported Sisecam projects in Russia, BosniaHerzegovina, Bulga-ria and Georgia, countries where longterm financing was otherwise difficult if not impossible to obtain. In 1996, for example, IFC financed Sisecam’s $26 million purchase and modernization of Ksani, a government-owned container glassmaker. At the time, it was the largest foreign investment in Georgia since its independence from the Soviet Union in 1990. In Bulgaria, IFC financed greenfield float glass and

tableware projects worth $160 million.

Sustainability In 2015, IFC helped Turkish glass maker Trakya Cam, a subsidiary of the Sisecam Group, save energy in Turkey and Bulgaria by providing a $75 million long-term financing package to the company to boost its energy efficiency investments.

It has helped Trakya Cam, Turkey’s leading glass manufacturer, revamp furnaces and waste heat recovery in its plants in Turkey and in Bulgaria, which are predicted to save up to $11.2 million per year in direct energy and cut greenhouse gas emissions by over 60,000 tons.

It is just one example of how IFC aims to promote sustainable glass production in emerging markets that both boosts productivity and helps combat climate change. �

International Finance Corporation (IFC), Washington DC, USA www.ifc.org

Introducing…

www.glass-international.com

The driving force of the refractory industry RHI and Magnesita.

A new global leader in refractories.

Find out more at rhimagnesita.com

34 Glass International November 2017

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LATIN AMERICA 2018 21-22 March 2018, Guadalajara, Mexico

ARE YOU READY FOR GLASSMAN LATIN AMERICA?

WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS

WHO WILL VISIT? As an exhibitor at Glassman, you can

Glassman Latin America 2015, also held in Guadalajara was a

expect to meet and do business with:

sell-out event with 95 international companies represented within

• Presidents / owners

the exhibition. 965 glass professionals from 21 countries attended,

• Technical / production directors

including delegations from a number of large manufacturers such as

• Factory managers

O-I and Grupo Modelo. In 2018, the event will remain at the same

• Plant engineers

venue, but we have moved to a larger hall to accommodate the

• Technicians / engineers

demand from organisations wanting to exhibit. To ensure that you

• Production / R&D / test & inspection

secure a stand in a prime position, please reserve your space as

personnel • Education & training personnel

soon as possible.

• Consultants / researchers

TO FIND OUT MORE CONTACT:

• Sales & marketing managers

Ken Clark, Sales Director t: +44 (0)1747 855117 e: kenclark@quartzltd.com Manuel Martin Quereda, International Sales Executive t: +44 (0)1737 855 023 e: manuelmartinquereda@quartzltd.com

CONTACT US TO BOOK YOUR STAND

WWW.GLASSMANEVENTS.COM/LATIN-AMERICA Organised by:

Join the Glassman Events Group

Untitled-1 1

Official media partner:

@glassmanevents

17/10/2017 10:24

Forming

Full cycle cooling for high speed production from Heye Conventional cooling of the blow mould unit operates only in certain mould positions. Consequently, consistent cooling of the mould cannot be ensured for the entire forming cycle at blow side, resulting in less container stability and less production speed.

T

he latest blow mould axial cooling is capable of permanently cooling the moulds during the entire process cycle. Thus, compared to other cooling systems, a much better cooling performance can be achieved. Regardless of mould open or closed position the full cooling power is ensured during the entire process cycle.

Double telescopic tubes with big crosssections provide for maximum volume flow. Thanks to an improved cooling piece design, optimised flow paths are ensured.

This provides for increased stability, better quality and higher production speeds. The axial cooling can be refitted in existing IS-machines.

� Full cooling power is ensured during the entire process cycle.

Optimial flow paths Big tube cross-sections and double telescopic tubes provide for maximum volume flow. In the area of the telescopic tubes the flow path is nearly straight, in the area of the ball joints it is redirected very slightly. The cooling piece distributes the cooling air in fan-shaped pattern equally on the mould halves.

www.glass-international.com

Easy job change A specially developed cooling piece holder allows performing the blow mould holder exchange quickly and easily. By loosening a few screws the holder can be separated in a simple way from the cooling piece.

Flexibility by telescopic tubes The axial cooling can be applied for different glass container heights. The telescopic tubes flexibly adapt to the different distances between cooling foot and mould holder. For particularly short moulds the distance can be compensated by an additional cooling piece adapter.

Advantages: � High cooling efficiency by double telescopic tubes; � Uniform cooling air distribution on the moulds; � Optimised flow design; � Compatibility for all holder applications; and � Easy and quick job change.

Carefully selected variables and spare parts guarantee a high process quality.

Heye International stands for innovative design, combined with precise manufacturing and long lifetime. Lately, the new 360° blow mould axial cooling has proven its benefits under glass in a Mexican container glass operation. �

Heye International, Obernkirchen, Germany

� Optimised flow paths.

Email: marketing@heye-international.com www.heye-international.com

36 Glass International November 2017

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Recruitment

Project Manager Research and Development

The IPGR-group, International Partners in Glass Research, is offering the post for a project manager in research and development.

The International Partners in Glass Research (IPGR) is a research association founded 1984, based in Aachen, Germany. IPGR is in close cooperation with the RWTH Aachen University. The members of IPGR are nine renowned companies within the container glass industry from all over the world.

The aim of IPGR is to create a vital, international research network and to conduct R&D projects for its members.

We are looking for a project manager for research and development in an international environment with high motivation for team-orientated hands-on working. The focus of the position is on melting and conditioning of glass as well as energy and raw-materials.

You lead and manage R&D projects from kick-off to implementation in a container glass plant. After profound strategic and technical consulting you establish timelines, manage internal and external resources and conduct the R&D work together with the IPGR members. You implement derived results at our member companies.

We are seeking an outstanding candidate with sound scientific education, relevant working experience and a strong track record in the glass-industry, preferably furnace operation and melting of glass. You are ideally an engineer or material-scientist with focus on glass and you have a sound background in glasses or ceramics, thermodynamics and kinetics of glass melting, and energy intensive processes. Project management and team coordination experience is required. Fluent English and willingness to travel internationally is mandatory.

The candidate is a pro-active, strategic-thinking personality with a hands-on approach and very good communication skills. The candidate reports to the IPGR management board.

We offer a highly motivated team, flat hierarchies, self-dependent working and project responsibility.

If you would like to apply your expertise please send your application to: IPGR - International Partners in Glass Research Prof. Dr. Christian Roos, P/O-Box 10 07 54, 52007 Aachen, Germany christian.roos@ipgr.com www.ipgr.com

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Phoenix Award honours James O’Callaghan The 47th recipient of the Phoenix Award, James O’Callaghan was presented with the phoenix sculpture at an event in London.

He was nominated thanks to his work with software giant Apple which has transformed the use of glass.

www.glass-international.com

T

he Phoenix Award committee presented its ‘Glassperson of the year’ award to structural engineer James O’Callaghan at a glittering event in London, UK. Mr O’Callaghan is the 47th recipient of the award and was nominated for his use of glass in new and innovative ways as a load-bearing material.

His work with Apple has led to the construction of some of Apple’s most eye-catching retail stores and constructions, all mainly made of glass.

More than 100 glass suppliers and manufacturers gathered to honour him in London’s County Hall Westminster.

Visitors travelled from as far afield as USA, Thailand, and countries across Europe to honour Mr O’Callaghan. They were joined by last year’s recipient, Chairman Cho Tak Wong, founder of Fuyao Glass, who had travelled from China, and 2015 winner, Surasak Decharin, of Bangkok Glass, Thailand.

Introducing Mr O’Callaghan to the stage, this year’s Phoenix chairman, Paul Hutchinson, of DSF Refractories in the UK, said: “I’ve had the privilege to meet James a couple of times leading up to this event and he’s got a clear passion and an understanding of glass not only as a structural material but also an understanding of its production and the current limitations of its manufacture. The first time I met James what I particularly liked is that we talked about the float glass process for probably an hour and we even talked about tin bath block.

“I part own a refractory company and I rarely talk about refractories for more than an hour so I was impressed. I thought here is a guy that has got a real interest and attention to detail!”

“Obviously if you know the glassmaking process you can push the boundaries of what can be achieved and this is what James has done to phenomenal effect.”

� Below: The Phoenix committee, with Mr O’Callaghan, centre.

38 Glass International November 2017

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Phoenix Awards

� Phoenix Chairman, Paul Hutchinson (left), presents the award to Mr O’Callaghan.

Mr Hutchinson said that James’ love of glass was sparked during an introduction with Apple while he was working in New York in 2001.

“In Steve Jobs he discovered a partner who was as fascinated with the potential of glass as he was and who had the funds to develop the use of the material. The collaboration with Apple accelerated innovation and led to the design and creation of some of the iconic Apple retail stores that are synonymous with James today.”

“James’ work and ideas have probably affected everyone’s business in this room – we have many glass industry suppliers here. So persuading glassmakers to produce larger laminated glass panels has in turn set challenges to suppliers to the glass industry.

“He has helped create new applications for the use of glass and the knock on effect with technology associated with glassmaking will no doubt help the more innovative in the industry to thrive.”

Mr O’Callaghan attended the event with his wife, parents and a number of present and former colleagues from the UK and the USA, including from companies such as Google and Apple, as well as Eckersley O’Callaghan, the agency he co-founded.

During his acceptance speech he said he was humbled to have been awarded the honour, particularly as he was the first British recipient since Sir Alistair Pilkington, creator of the float glass process.

“I have had the great fortune to work with many creative, pragmatic and inspiring people, many of whom are here tonight and for which I’m deeply thankful.

“The innovation journey I’ve been part of has been about pulling together people, organisations, institutions and encouraging them, inspiring them to make great things. It’s about creating the belief around the concepts and the ideas you develop, among the team to make more ambitious things and designs.”

He showed photos of his work throughout his speech. This included the cube concept for Apple’s store in 5th Avenue, New York, the Apple IFC in Shanghai, and the Apple Zorla in Istanbul, which is a giant cube with four monolithic glass walls and no visible fixings.

Beginnings He told the audience that he knew he wanted to be an engineer from the age of 10 when, during a visit to an uncle, he saw the Humber Bridge in the UK for the first time.

“I marvelled at the bridge whenever I visited him. I then tailored my education, my choices and my degree to a career as an engineer. I was Continued>>

www.glass-international.com

Acceptance speech

39 Glass International November 2017

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One of James’ innovations has been to persuade glassmakers to make larger laminated glass panels.

Working with companies such as Beijing North Glass and Germany’s Seelee has helped increase the size from 6 metres to 12 metres. An example of this occurred in 2011 when James was asked to revamp the 5th Avenue cube store in New York. The original cube built in the early 2000s contained 90 pieces of glass, while the modernised store contained just 15 panels.

James concluded: “The only way we can innovate is to do so as a team. It requires all those that design and make it to support and make it happen. Apple has been a supportive client in this regard and has had a direct influence in the way glass is manufactured and produced. It has worked hard to make glass the core of our development.” *An interview with Mr O’Callaghan appeared in the September 2017 issue. �

www.phoenixawardcommittee.org

www.glass-international.com

fortunate I didn’t need to think twice about it and it’s certainly something I’ve been happy with. It’s led me to a most enriching and satisfying life as an engineer. Engineering surrounds us in everything we touch, engineers are the silent army that makes everything happen for us all and they are rarely recognised for the importance of their craft.”

His career has taken him to London, Seoul in South Korea and then the USA and the defining meeting with Apple. In his initial meeting with Mr Jobs, James had to describe a highly technical concept about curved glass stairs.

But after just a couple of sentences he was stopped abruptly by Mr Jobs. While James wondered is he was being too technical and should simplify what he was saying, Mr Jobs said: “It’s not the content, it’s your accent!”

James said: “The opportunity to work with Steve was incredibly inspiring. He loved materials and he became a big lover of glass. This love affair afforded us the opportunity to express our dreams of how to use glass in architecture and how it could evolve.”

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The glassmaker’s diary

Diary

Glassman Asia 2018 Two-day free exhibition and conference focused on the hollow and container glass manufacturing process. Includes conference: the Future Glass Forum which explores aspects of Industry 4.0 in glassmaking.

January 24-25, 2018 Bangkok International Trade and Exhibition Centre (BITEC), Bangkok, Thailand.

CONTACT: gregmorris@quartzltd.com www.glassmanevents.com/asia CelSian - NCNG Glass Technology Course The CelSian Glass Technology course provides an overview of glass manufcaturing technology as well as an understanding of the chemical processes involved..

March 12 - 16th, 2018 British Glass headquarters, Chapeltown, Sheffield, UK. CONTACT: www.celsian.nl/subscribe Glassman Latin America 2018 Mexico has become a hub of hollow glassmaking in recent years with a number of investments. This two-day free exhibition and conference is focused on the hollow and container glass manufacturing process. It includes the conference, the Future Glass Forum which explores aspects of Industry 4.0 in glassmaking March 21-22, 2018 Jalisco A, Expo Guadalajara, Guadalajara, Mexico CONTACT: gregmorris@quartzltd.com www.glassmanevents.com/latin-america/

GLASS HAS A GREAT PAST.

GlassTrend Seminar on CO2 neutral glass production The objective of this meeting is to bring together experts from the glass industry to exchange information in the field of CO2 neutral glass production.

April 18th - 19th 2018 Marktheidenfeld, Germany.

CONTACT: www.celsian.nl/subscribe/ China Glass 2018 Annual exhibition that alternates between Beijing and Shanghai.

April 19th - 22th 2018 Shanghai New International Expo Centre, China.

CONTACT: www.chinaglass-expo.com/showgsy/WebReg/ default1.htm Mir Stekla 2018 Mir Stekla is Russia’s largest international trade show of glass products, manufacturing, processing and finishing technology.

May 28 -31st 2018 Expocentre, Moscow, Russia.

CONTACT: www.mirstekla-expo.ru/en/ glasstec 2018 International trade fair for glass production, products and processing.

October 23-26, 2018 Düsseldorf, Germany.

CONTACT: https://www.glasstec-online.com

YOUR PRODUCTION HAS A GREAT FUTURE. An IS machine keeps going almost indefinitely – provided the control system doesn’t let you down first. In practice, however, discontinued products or obsolete interfaces can seriously impact your competitiveness ahead of time. This is where we step in.

With more than 40 years’ experience in automation, FMT24S distributed control systems and FDU24S

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drive solutions, we have the know-how to refurbish any IS machine in the market. Now and in the future.

automation in a new dimension

futronic GmbH · Tolnauer Strasse 3-4 · 88069 Tettnang (Germany) Tel. +49 7542 5307-0 · Fax +49 7542 5307-70 · info@futronic.de

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Plant utilities

DustShield to help suppress dust The DustShield treated sand application for dust reduction has been proven to help reduce dust in glass manufacturing applications. It also complies with new a new health and safety standard in the United States. the treated sand can enable glass manufacturers to remain below the new OSHA PEL, and may enable levels below the action level. Following successful in-laboratory development of the dust suppression technology, Unimin invested in the installation of equipment to supply material for industrial trials to achieve proof-of-concept on a commercial scale.

Specific glass applications In-house testing was conducted specifically for glass applications. Glassil DustShield treated sand testing was conducted to simulate and evaluate the effect on both the process and the finished glass itself as compared to

Untreated Silica Sand

Oliver monitors were used to collect glass batch RCS data in the dustiest area of the processing facility. The monitors were not fixed to an employee, but instead placed at a fixed point and allowed to remain there for eight hours. The trial was successfully completed and showed the following: � Dust suppression effectiveness of the treated sand correlated with laboratory dust suppression testing. � Glassil DustShield treated sand performed as expected based on the inhouse laboratory testing procedures for glass applications, without detriment to the finished product. � The fixed-location results indicated that if the monitors had been attached to

GLASSIL® DUSTSHIELD™ Treated Silica Sand

� Untreated Silica Sand (left) compared to Glassil Dustshield treated silica sand (right). results using untreated glass sand. These evaluations included optical properties such as dominant wavelength of the processed glass and batch-free melting time for the glass melting process. For these tests, the treatment additive dosage was increased above the required level and the treated sand was used as a direct replacement for the untreated glass sand.

The results showed that the chemical additive is compatible at, and above, required treatment levels.

Upon completion of the in-house evaluations for glass applications, a trial with the treated sand was conducted at a glass manufacturing facility. Dorr

an employee, the OSHA PEL and AL level requirements would have been achieved.

As of this writing, additional trials are on-going with glass manufacturers to prove the dust suppression effectiveness of the treated sand, to provide additional verification of effective use in glass applications, and to achieve qualification at specific glass manufacturing facilities.�

Unimin Corp, New Canaan, CT, USA E-Mail: GlassilDustshield@Unimin.com Website: www.unimin.com

www.glass-international.com

U

nimin has introduced Glassil DustShield treated sand.

The launch is in response to the United States Occupational Safety and Health Administration’s (OSHA) new respirable crystalline silica (RCS) standard.

Unimin has achieved the necessary engineering controls at the sand source to produce the chemically-treated sand product to help industries comply with the new OSHA standard under normal operating conditions.

Testing shows the treatment does not negatively affect the flowability of the sand, will not deteriorate after application and will remain effective from the time of application at the sand plant until it enters glass manufacturers’ furnaces.

The new OSHA standard for the glass industry takes effect in 2018 and reduces the RCS permissible exposure limit (PEL) from 100µg/m3 to 50µg/m3 over an eighthour time-weighted average (TWA), and sets an action level (AL) of 25 µg/m3 (eight hour TWA).(1) Among other requirements, the new standard requires engineering controls to limit worker exposure.

Because of the high interest driven by engineering and work practice controls being required to reduce and maintain exposures below the new PEL, Unimin developed a solution, directly with silica sand, that can be used without requiring extensive capitalisation, special equipment or additional maintenance.

Critical to the process was ensuring that the solution did not create any detrimental side effects in the manufacturing process or finished product.

Glassil DustShield treated sand provides protection throughout the supply chain without interfering with normal operations or the finished product. Glassil Dustshield treated sand implements engineering controls at the source.

Under normal operating conditions,

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Events world: FEVE conference

Digital glassmaking on the agenda at Luxepack The European Container Glass Federation (FEVE) organised a conference devoted to glass packaging trends at this year’s Luxepack event. The conference featured a panel of six glassmakers discussing subjects such as digital glassmaking and sustainability. Greg Morris attended.

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E

uropean glassmakers discussed digital glassmaking and consumer trends during a show devoted to luxury packaging.

The annual Luxepack exhibition held in Monaco featured an array of glassmakers demonstrating new features to benefit luxury brand and packaging.

The show is dedicated to high-end packaging and featured glassmakers who serve the luxury goods markets such as perfumes and cosmetics and spirits, alongside companies who serve other packaging markets such as plastics and paper.

The European glass flacons industry is globally renowned in the perfumery and cosmetics sector for its packaging design, production and decoration know-how. As a key component of the glass container industry, it is imbedded in Europe where it employs some 9,500 people. The sector includes packaging for pharma and it is also the reference in other luxury and high-end segments such as prestige wines.

The final day of the three-day show included a 90-minute conference organised by the European Container Glass Federation (FEVE).

The conference theme was How Glass Packaging meets Emerging Consumer Trends and included a panel of six FEVE member companies. These were Stolzle, Verescence, Bormioli Luigi, Pochet du Courval, Heinz-Glass and Verrireres Brosse of the Zignago Vetro group. The panel was moderated by Michel Fontaine, President of the Conseil National de L’Emballage.

for development. We need quick answers, we need to know is it viable or not, we need to react to the market. So what we have developed at Stölzle is the capability to integrate the digital world to create an item in four weeks.

“This is just an example of what we can do and it is not over, it is just the beginning. What the client needs is flexibility and that’s what digital brings.

Agility is what we try to offer at Stölzle.”

Times Square

Agility Etienne Gruyez, Managaing Director of Stölzle’s Masnières plant in France described how digital glassmaking has improved the speed of the glassmaking process at the facility. The plant can now provide new finished samples to its customers in less than four weeks thanks to a complete digitalisation of the design phase.

“When we say four weeks we mean pretty much from the drawing all the way to the technical drawing, the 3D print, the glass production and decoration in four weeks. This is what we offer on a regular and a standard basis for our clients.”

He added: “Time is the essence in glassmaking. We have heard over and over at Luxepack about agility agility agility.

We hear our clients us asking how can you be faster, what can you do better, we need to be faster. We can no longer wait, six months, nine months or even 12 months

His presentation was followed by Virginia Elliott, Global Head of Sales at HeinzGlas. She unveiled the company’s latest flacon, the Times Square perfume bottle, which features a digital screen on its front to where consumers can upload a message, video or music. Whenever the consumer lifts the bottle, the flacon plays the selected media, such as a song or film footage.

Continued>>

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� The panel of glass industry manufacturers who

� Etienne Gruyez,

� François-Xavier Cheru,

Stölzle.

Commercial Manager at Verrières Brosse.

The company has been working in partnership with the multimedia business DS.Xpress for two years to design and make the bottle.

She said: “This new next generation flacon is the integration of the digital era with classic glassmaking. This is the beginning of being able to so something we never thought possible.”

The refillable Flacon means customers can personalise their own bottle. In order to do so have to register on the Heinz-Glas website. The flacon can be customised with a personal message and optimised in an intuitive way. The customer can upload their own images, videos and music, they can select their favourites and send them to the flacon.

Ms Elliott said: “You can give this as a present to a loved one and they will not just have a nice experience with the perfume but with the flacon as well.”

Tests had been carried out to ensure the screen does not react if the alcoholic content of the bottle splashes onto it.

Second and third generation bottles are planned in six months and in a year’s time, she said.

Sustainability François-Xavier Cheru, Commercial Manager at Verrières Brosse, discussed the group’s sustainability initiatives.

This included a warehouse roof at its Zignago Italia site, which had helped save 3000 tonnes of CO2 and a new glass bottle.

The company has started producing energy using the biomass process. It not only delivers energy to its own facility but to neighbouring homes as well. Verreries Brosse is based in northern France and is part of the Zignago Vetro group of Italy.

The company is a hollow glass manufacturer and manufacturers glass for the food and beverage as well as the beauty sectors.

It has invested in a new company that specialises in collecting Post Consumer Recycled (PCR) glass. The company uses about 90% of recycled glass, and within this 90% a total of 75% of it is PCR. “It means that within this 90%, 75% is glass that comes from outside the factory,” said Mr Cheru. The company saves 35% on its CO2 production using this type of glass compared to classical glass production.

Samuel Joachim, Group Innovation and Development Director at Verescence, stated brands want to have ease of access to high quality packaging that meets increasingly demanding design and techno logical requirements.

“This can only be achieved with the most advanced know how in glass production. Brands also want to have more environmentally friendly solutions.

We are able to provide measurement tools and products that help customers reduce their environmental impact.

The life cycle analysis software can provide nine measurements on a particular bottle or jar and compare its environmental impact.

The company has also successfully lightweighted its jars and bottles, with one from 98 grams to 60 grams of glass.

“We have produced that but want to go further,” he said.

Simone Baratta, Prestige Perfume Business Unit Director at Italy’s Bormioli Luigi, discussed the company’s CSR strategy and said the group was one of the first to use electric melting in the 1970s.

“We implement new initiatives that are effective and sustainable when they are completed. We cannot just talk about doing things better – we implement them and this is a very important point.

“We have introduced environmental and social KPIs to monitor the results and

the results have been very satisfactory.”

The company also has an aim to reduce a plant’s CO2 levels by 40% by the year 2020.

“At the moment we are perfectly aligned with this target,” he said.

Isabelle Lallemant, Groupe Pochet Marketing and Innovation Director, said Pochet du Courval, based in the Bresle ‘Glass Valley’ in Normandy, France, had three pillars on which it bases its brand on. The first of which is know how, the second is to think local and the third to think global in developing a product.

“There is no luxury without the know how. We have 400 years of know how and we need to preserve it and to transfer this know how into the heart of luxury. We do 300,000 hours of training in our factory to make sure we don’t lose this knowledge.

“The second pillar is to act local, with the Glass Valley as a partner all around us to realise the finishing. We are the only factory doing both hot and cold end functions in the same place.

“The third thing which is key in our group is to think global when developing a product. Clients do not only buy products but confidence too, so when we develop we need to think globally and offer responsible luxury packaging.”

Conference chairman, Michel Fontaine, concluded: “It was amazing to see how European glassmakers are eager to adapt to changing consumer needs, while not compromising on quality, elegance and prestige which is a ‘must’ for brands.

“They continue to both produce gorgeous luxury products and give priority to sustainability, transparency and authenticity. They must do it to continue to be leaders. �

Luxepack 2018 takes place in Monaco on October 1, 2 and 3. http://www.luxepack.com Conference organiser FEVE is celebrating its 40th anniversary this year. More information from www.feve.org

www.glass-international.com

spoke at the FEVE conference in Luxepack, Monaco.

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History

Prof. John Parker

Polarised views Prof. John Parker observes disannealing stresses in glass.

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I

remember my school physics teacher explaining why a stick partially immersed in water appeared to be bent and a swimming pool was actually deeper than it looked.

This was my introduction to refractive index, but back in 1669 Erasmus Bartholin had observed something even stranger.

Objects viewed through large Iceland Spar crystals (calcite, CaCO3) gave a double image, and one image circled around the other when the crystal was rotated.

A century later, French physicist Etienne Malus observed that one of these images sometimes disappeared if the light had already passed through another calcite crystal. Eventually this led to the concept of polarisation, where light is understood as an electric field vibrating perpendicular to its path. The plane containing this vibration and the travel direction defines its polarisation.

The organisation of atoms in crystals, particularly any asymmetry, can affect light polarised in dissimilar directions differently. For example in calcite all the planar triangular carbonate groups lie parallel and result in a large difference in refractive index for light with parallel and perpendicular polarisations, an effect called birefringence. Glass though should be isotropic i.e. affect light equally whatever its polarisation but this is not so if stresses are present. Tension separates the atoms, decreasing proportionately refractive index for light polarised in the same direction; compressive stresses increase it. Now stresses can be complex but at points along the light path can always be resolved into two perpendicular components, which may be tensile or compressive and have different magnitudes. Propagating light splits into rays polarised along these two principal directions, one travelling faster (lower r.i.), the other slower. They become out of step by an amount termed retardation, which depends on the refractive index changes, and gives a way to assess stress.

Measurement of retardation uses an optical set-up which recombines the two rays on exit from the glass so that they interfere. Zero retardation results in destructive interference and gives ‘black’. Path differences of one, two wavelengths do the same but retardations of half, one and a half wavelengths allow strong transmission. Usually white light containing all the spectral colours is used. Each colour gives the same dark/ bright/dark sequence but the dark bands correspond to different retardations so when all wavelengths are combined coloured fringes result. However for weakly stressed glass viewed in white light, black (zero stress) or a difficult-toquantify shade of grey is seen. Tension and compression give the same colour and so are indistinguishable. So a crystal plate of defined thickness is inserted into the optics to add a whole wavelength of retardation (for yellow light) and shift to a more sensitive part of the colour sequence. Tension and compression also give different colours because the retardations either add or subtract from that of the standard plate.

While the instrument produces a defined colour sequence according to the stress level quantitative measurement is less easy. Standards have been created though using thin glass discs, pre-stressed in a furnace in a standard way by cooling under pre-defined conditions. Actual samples are compared with the colours seen at the edge of 1, 2, 3 … superimposed strain discs.

More sophisticated instruments such as the Berek and Senarmont compensators, often used by mineralogists, introduce a variable and measurable ‘compensating’ retardation which cancels the material retardation to give black.

At the turn of the 20th century polarised light was not widely used in the UK glass industry although it was more widespread in Germany and among the geological community for identifying

minerals. Early instruments were termed polariscopes although Americans used the expression strain viewer.

Historically polarised light was generated using strongly birefringent minerals such as calcite (Nicol prism).

Later the creation of polarising sheets based on oriented long chain polymeric molecules produced the same polarising effect. Large sheets are expensive but a similar effect could be produced using a glass sheet. If set at the ‘correct’ Brewster angle reflected light is weak in intensity but 100% polarised. Combining this with a concentrated light source and a smaller polarising sheet gave a strain viewer a wide field of view for examining a bottle not only through its base but also when held horizontally.

Early issues of the Journal of the Society of Glass Technology include detailed drawings of such equipment for measuring stresses and over time they became vital for controlling annealing.

Experiments on the relaxation of stressed glass at different temperatures were undertaken using long transparent rods where the increased path lengths gave measurable retardations even if stresses were low. The glassmaker could improve his productivity where previously poorly annealed articles broke during cutting.

It even became possible for workers to observe stress development during manufacturing by wearing glasses with polarising lenses. The science of glassto-metal seal manufacture developed by combining mathematical modelling with practical measurements using polarised light will be taken up later. �

Bibliography https://www.microscopyu.com/techniques/ polarized-light/introduction-to-polarized-light

*Curator of the Turner Museum of Glass, The University of Sheffield, UK www.turnermuseum.group.shef.ac.uk j.m.parker@sheffield.ac.uk

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47 Glass International November 2017

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