Glass International November 2021

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November 2021—Vol.44 No.10

KAPOOR GLASS INTERVIEW INTERNATIONAL COOKWARE PROFILE BRITISH GLASS FOCUS AWARDS I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

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Contents

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Deputy Editor: Jess Mills Tel: +44 (0)1737 855154 Email: jessmills@quartzltd.com Designer: Annie Baker Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com

November 2021 Vol.44 No 10

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Editor’s Comment + International news Company profile: International Cookware International Cookware plots latest furnace rebuild

Chairman: Paul Michael

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Subscriptions: Jack Homewood Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com

Company profile:Kapoor Glass India Family business with improvement in its DNA

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Recycling: Krysteline The process of economic recovery and use of all waste glass

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Recycling: EME Preheating solutions to improve energy efficiency in glass plants

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People profile: Günther Mlynar/Zippe Zippe says goodbye to Gunther

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Forming technology: Siemens Siemens servo drive improves indexing times

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Hot End technology: Waltec Waltec moves towards better ‘economics’ for press lines

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Moulds: Gerresheimer Digital simulation of the glass moulding process

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Raw materials: Ecoterm Recycled material to aid sustainable glass production

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Regional overview: Asia Asia opts for lighter glass

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International Year of Glass All systems go

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Inspection: Isra Vision Solutions for glass display inspection

48

History Year of Glass update

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British Glass Focus awards All the winners from this year’s event

Chief Executive Officer: Steve Diprose

Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.

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Official publication of Abividro the Brazilian Technical Association of Automatic Glass Industries

Member of British Glass Manufacturers’ Confederation

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China National Association for Glass Industry

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Managing Director Tony Crinion tonycrinion@quartzltd.com

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International News

GREG MORRIS, EDITOR

Be first with the news! For breaking, up to date news

FRONT COVER IMAGE: www.falorniglass.com

VISIT: www.glass-international.com

for daily news updates.

Is the 1.5 C goal still alive?

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o

This is the last issue of 2021 and is the time of year to reflect on the past 12 months.

Much of 2021 was focused on the recently concluded COP26 meeting in Glasgow.

It is tempting to ask what was the point of the two-week summit after the major fossil-fuel producing governments failed on any definitive agreement to end production of coal.

But while politicians bickered, it was heartening to see the amount of people in attendance so infused about the topic and the scale of their ambition for change.

If governments are unable to reach agreement then perhaps the wave of change will come from consumers and business.

Edelman’s Trust Barometer reveals 64% of consumers are belief driven buyers and would switch or boycott brands based on their beliefs on societal issues.

Generation Z in particular is especially influential, making use of hyper connected technology to raise awareness of issues.

Their influence will only grow as they rise higher up the workplace ladder.

The glass industry is ahead of the curve in this regard and has made huge strides in its decarbonisation efforts to further improve glass’ environmental credentials.

Recent news from Encirc, Ardagh and Pilkington about the use of renewable energy in their manufacturing processes was more encouraging than any news coming out of COP26.

Sisecam plans €84 million Turkish glass investment

Sisecam plans to invest in a furnace with a 155,000-ton annual capacity at its Eskisehir, Turkey glass packaging production facility.

The investment is in response to the growing potential of glass packaging from the rapidly expanding demand for hygienic solutions around the world.

The €84 million glass manufacturing furnace is planned to be commissioned at the beginning of 2023 and is in response to increased demand for glass packaging.

Aimed at boosting Sisecam’s global glass packaging production capacity to 3.2 million tons per year, this major investment will provide

input to numerous sectors.

Sisecam Chairman of the Board of Directors Prof. Dr. Ahmet Kırman said: “Sisecam has decided to invest in a new furnace in Eskisehir, where it currently has four glass packaging furnaces in operation.

“This new investment will allow us to meet growing glass packaging demand in Turkey resulting from heightened health awareness while also implementing our export strategies.

“Sisecam, currently running glass packaging production operations in Turkey, Russia, Ukraine, and Georgia, also announced in June that it would invest in a greenfield facility with a 330,000-ton

annual capacity in Hungary.”

Prof. Kırman stated that the size of the Turkish glass packaging market largely remained intact in 2020 despite the adverse effects of the pandemic.

The domestic glass packaging market went on to trend positively in the second half of 2021 with the easing of Covid-19 restrictions, the opening of the HORECA channel to a great extent, and the positive effect of rebounding tourism.

Prof. Kırman added: “Eskisehir stood out as the right location for our new investment due to its market access potential.”

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International News

AGI glaspac on track to open clear glass plant in January

furnace from Horn Glass Industries, which will serve six IS Machines.

The facility will supply approximately 2.5 million pieces of clear glass per day within

Vitro to invest $70 million in container furnace

Mexican manufacturer Vitro is to invest $70 million for the construction of a glass container furnace at its plant in Toluca.

Construction of the furnace will begin this year and start its operation in the first half of 2023.

The investment was approved by the Board of Directors to meet the increase in demand for glass containers.

“The furnace will have modern technology to manufacture high-valueadded glass containers with sustainable processes,” said Shlomo Frymerman, Director of Glass Containers.

the ranges of 2ml to 1000ml.

Types of glass produced will be for the cosmetics and perfumes sectors as well as the pharma, carbonated water and spirits sectors.

Pilkington hires Managing Director Pilkington UK has appointed Neil Syder as managing director to lead the glass manufacturer as it adapts to an age of decarbonisation and targets new opportunities.

Neil has 30 years’ experience within the company to the post.

Most recently as head of operations, Neil has brought a new standard of efficiency and customer focus to the St Helens manufacturing op-

erations. He was the second Syder to hold the position of head of operations at the glass giant, moving temporarily to Sweden as a child as his father established the company’s Halmstad plant.

Neil began at the company working in R&D in the 1980s, building experience over four decades in specialist glass coatings, running production lines, and operational planning.

Neil takes over from Matt Buckley, who retires after serving as managing director for more than a decade and having spent 30 years with the business.

The change takes effect from the end of December 2021.

Mr Syder said: “It’s an exciting time to take this new post, with the glass industry set to play a transformative role in an age of decarbonisation.”

Prince selling glass business Prince International is exploring the sale of its glass coatings and porcelain enamel business in the US and Europe.

Prince is exploring a sale of its business to obtain the regulatory clearance required to

complete the Ferro Corporation transaction. Prince said in May it had agreed to buy Ferro for $2.1 billion.

The transaction is anticipated to be completed in the first quarter of 2022.

“We are focused on a seam-

less execution of this sale process as part of the broader Ferro acquisition and will pursue the best path forward to benefit Prince, its stakeholders and the business,” said D. Michael Wilson, CEO of Prince.

Bucher Emhart Glass reports ‘high demand’

Glass container technology supplier Bucher Emhart Glass reported ‘very high demand’ in its latest financial note.

The Swiss-based group said demand for glass containers rose strongly again thanks to the easing of restrictions in the gastronomic sector and at major events.

Order intake increased by 76.2% to CHF392 million ($426.4 million) for the first nine months of this year, compared to CHF223 million ($242.5 million) in the corresponding period in 2020.

PGP Glass ignites 250t/ day Horn furnace

Indian container glass manufacturer PGP Glass has ignited a 250t/day furnace supplied by Horn Glass Industries.

The end-fired furnace, named furnace J, was integrated into the glass manufacturer’s Jambusar, India facility.

Horn supervisors for utility and electrical equipment were on site to support the processes.

The container glass furnace, with seven forehearths, produces cosmetic/premium flint glass.

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Indian glass manufacturer AGI glaspac is on schedule to open a clear glass plant in Bhongir, India in January 2022.

The container glass plant will be supplied by a 154t/day

NEWS IN BRIEF

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International News

Vitro inaugurates Brazilian glass decoration centre

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Mexican glass manufacturer Vitro has opened a decoration facility in Camaçari, Bahia, Brazil.

The flat and container glass producer has been in the Brazilian market for more than 10 years and said the new site would enable it to react more rapidly to customer needs.

Initially the centre will

serve the Brazilian cosmetics glass sector with the option to expand at a later date.

The site contains technology for painting, silk screening and hot stamping, which is the type of decoration required by its markets.

Around 29 people will work at the site but the fa-

cility can accommodate up to 90 staff depending on customer demand.

Roberto Díaz Kirk, Vitro’s South American Sales and Marketing Director, said: “Brazil is a big market with a great potential to keep growing and we see Vitro being part of that growth.”

Ardagh produces 80% recycled glass Absolut bottle Ardagh Glass Packaging’s limited edition vodka bottle ‘Absolut Voices’ has an 80% recycled glass content.

The sapphire-blue, premium bottle has the highest percentage of recycled glass of any Absolut products to date. The high recycling rate in Sweden allowed more recycled glass cullet to be available to Ardagh for use in its furnace.

Ardagh worked with Absolut and design agency Brand Union to create the bottle, which celebrates the trailblazers and ‘wavemakers’ of the world as reflected in the bottle’s soundwaves design.

Maria Persson, NPD Project Manager at Ardagh, said: “The effect of the 360 degree design feature was achieved by creating irregular circles with shallow embossing to give life to the waves.

“Our product design

team created the desired effect using their in-house sculptured embossing technology and expertise to give it a lifelike quality and standout impact.”

Elin Furelid, Global Head of Absolut Portfolio & Design said: “Celebrating diverse and different viewpoints has always been in our spirit.

“We’re continuously inspired by the idea that the world becomes a better place when we come together beyond differences, share good times and empower one another. That spirit is what Absolut Voices is all about”.

Glass International November 2021

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REVOLUTIONISING GLASS MAKING The NIS from Bucher Emhart Glass The servo electric driven NIS machine outperforms traditional IS machines through enhanced, precise motion, perfect repeatability and a faster setup time. It is significantly reducing noise and energy consumption. The NIS is the most flexible (95 mm QG – 5” TG – 6 1 ⁄4” DG), high-performance future‑proof forming machine, ready for the revolutionary change that automated End to End technology will bring.

emhartglass.com

International News

Top 10 stories in the news

NEWS IN BRIEF

Virtual trials to begin on lightweighting bottles

Three companies will collaborate on a coating technology which could increase the strength and reduce the weight of glass bottles.

Dassault Systèmes, Ardagh Group and Exxergy will begin ‘virtual twin’ trials on Diageo’s Johnnie Walker bottle in January 2022 to research and develop a coating that will enable the glass bottle to be lightweighted without compromising its strength and shape – an industry first.

The virtual trial will use science-based methods to reduce the time and cost needed to test glass products, while reducing the raw materials and energy used in the process.

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Cristalerías de Chile plots construction of third glass production facility Encirc set to use hydrogen in container glass manufacturing process Ardagh produces 80% recycled Absolut glass bottle Sorg to rebuild furnace at Weck Glass Glass Futures takes the stage at COP26 BV Glas: Rising energy costs could hamper energy transition Beatson Clark invests £1 million into on-site recycling facility Hindusthan National Glass appeals against insolvency proceedings Berlin Packaging to acquire Le Parfait from O-I Glass Schott to invest €70 million in Chinese pharmaceutical glass manufacturing facility

For the latest Industry News scan the QR CODE using your iOS or Android device

Cameroon manufacturer plots investment

Cameroon container glass manufacturer SABC plans to invest FCFA 5 billion ($8.8 million) to boost the production of its glassware.

The limited company breweries in Cameroon (SABC) said it was considering the renovation of furnace No. 1 (line 11) and the acquisition of a third forming line within the subsidiary company Cameroonian glassworks (Socaver).

It said the renovated furnace no.1 would start at the end of 2023, while the new forming line would be ready by the end of April next year.

O-I ignites €30 million Seville glass manufacturing furnace

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Cristalerías de Chile plots third facility

CristalChile plans to build a third glass manufacturing facility.

The Chilean container glass manufacturer said the expansion, combined with modernisations at its two other facilities, would allow it to increase capacity by 50% compared to 2019.

The company faces greater demand in future. The first stage of the future plant is estimated to be in operation within four years.

O-I Glass has inaugurated a €30 million furnace at its Seville, Spain container glass manufacturing site.

The updating and overhauling of the Seville plant will ensure the maintenance of almost 200 direct jobs and another 100 indirect ones, according to the company.

The investment focused on the construction of a new furnace, the optimisation of its energy efficiency and reduc-

ing its environmental footprint.

The company has also completely renovated two production lines, which translates into a 10% increase in plant capacity and greater flexibility to adapt to market demand.

The renovation of the plant was carried out between May and July. During the work, almost 500 professionals worked on-site, 350 of them external technical specialists, many of

whom travelled to the plant from other countries.

Pablo Arenas, plant director, said: “It is a commitment to a quality professional occupation, which generates employment with high added value for the local socio-economic fabric and also for the stability of the industrial sector that needs to gain weight in the productive structure of the country and specifically in regions such as Andalusia.”

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International News

Bangkok Glass signs English football sponsor agreement

NEWS IN BRIEF

O-I creates community recycling programme

O-I has created ‘Glass4Good’, a community-based programme to incentivise glass recycling at its facilities.

The programme will provide glass recycling facilities in previously unavailable areas and give back to communities where O-I employees live and work.

The O-I Charities Foundation will make a series of financial contributions based on the amount of recycled glass collected.

Glass4Good will also explore public-private partnerships to overcome barriers to glass recycling and get glass packaging back into the circular economy.

Encirc partners with Nugan Estates

UK glass container manufacturer and bottler Encirc has partnered with Australian wine producer, Nugan Estates, to bottle and distribute its wine products to the Irish market.

Through its 360 model, Encirc will create glass bottles and fill them with more than 600,000 litres of wine for Nugan every year, all from its purpose-built site in Elton, Cheshire.

The beverages will be imported to Elton via bulk shipping methods before being shipped directly to the Irish retail market.

This process ensures Nugan’s products are delivered in the most sustainable way possible.

Bangkok Glass has become an official sponsor of Oxford United professional football team.

The Thai-based container and flat glass manufacturer has become the sponsor of Oxford United’s training ground.

Bangkok Glass boast a full range of glass packaging materials across all international markets and is recognised as Thailand’s largest provider of glass and packaging as well as

derstand the values we have: a growing football club with great links to local businesses, a club that is determined to continue to be at the heart of our community.”

Pavin Bhirombhakdi, CEO Bangkok Glass Group of Companies said: “We will work together to expand and make it an even greater resource for everyone associated with the club, the city and the county.”

Ardagh Glass shipments slip 3% Ardagh Glass’s shipments in the third quarter were 3% lower than the third quarter of 2020, with similar reductions in Europe and North America.

The world’s second largest container glass manufacturer reported revenues were unchanged on a reported basis and fell 1% at constant currency compared to the same period last year.

In its latest financial note adjusted EBITDA of $162 million was 11% lower than the

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being one of the largest businesses in Asia.

Oxford United Managing Director Niall McWilliams welcomed Bangkok Glass, and said: “It’s genuinely exciting for us to be working alongside a global business which has great connections with a number of sports and businesses in the UK and around the world.

“I think Bangkok Glass un-

Neil Simpson will host a fiveday online training course on combustion methods and furnace optimisation.

The courses will run from 8:30-12:30 (GMT) each day beginning Monday Dec 6 and will be repeated the following week at the later time of 13:00-17:00 (GMT).

Contact: secombustioncourse@gmail. com to book your place.

prior year constant exchange rates, reflecting lower shipments and increased costs in both regions.

Q3 2020 coincided with the re-opening of the hospitality sector after lockdowns and shipments therefore increased by 6%. Shipments for the third quarter of 2021 were 3% above 2019 levels.

Revenue for the quarter in Glass Europe fell 6% compared to the same period last year, of which almost half was

attributable to its engineering equipment business.

Adjusted EBITDA for the quarter of $104 million was 10% lower than the same period last year due to the impact of higher energy and other costs, partly offset by a strong operating performance and a contribution from its growth investment programme.

In Glass North America, revenue of $444 million increased by 3% compared with the same period last year.

O-I reports shipments down 1% Shipments of O-I’s glass containers were down 1% in Q3 2021 due to choppy demand patterns stemming from low inventory levels and ongoing global supply chain issues.

In its latest financial report, the world’s largest container glass manufacturer reported that production levels had rebounded from the prior year, which had been impacted by lockdowns.

Andreas Lopez, CEO, said the combination of market conditions for glass containers, O-I’s ongoing transfor-

mation and the introduction of MAGMA was building a favourable pathway for the company.

“Yes, to an agile and resilient company. Yes, to a new paradigm for glass and yes to profitable growth. We are confident these plans will enhance value for all our stakeholders and ensure sustainable prosperity for O-I.” He added that the Magma Generation 1 line has been commercialised in Germany, while its Generation 2 line in Streator, Illinois was piloted in

the second half of this year.

The company is investing up to $680 million over the next three years which will include up to 11 Magma lines. Expansion plans are focused on its markets across Latin America, premium spirits in the US and the UK and premium beer in Canada.

Glass is poised to benefit from mega trends such as wellness, sustainability and premiumisation. Global market growth is anticipated to rise 1.6% a year and higher in the principal regions.

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WHEN QUALITY MATTERS www.parkinson-spencer.co.uk

Company profile: International Cookware

International Cookware plots latest furnace rebuild

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hile construction of a furnace rebuild at International Cookware’s glass manufacturing facility may not be for another seven months, it doesn’t mean that Johann Brunie and his team are not already busy.

Preparation work on the new oven has already begun, with discussions about the schedule, modelling of how the furnace will look and, importantly, the environmental aspects of the investment.

His team has already had discussions with modelling experts from Glass Service in the Czech Republic about the rebuilt furnace. The talks focused on the geometry of the new oven and ways to improve the modifications.

The glassmaker has already placed refractory orders with its long tem partner, French compatriot Sefpro, ahead of the construction next year.

The project has received funding from the France Relance project, a French government scheme to help boost domestic industry as it recovers from the lockdowns caused by the pandemic. Grants are

given to companies which have decarbonisation strategies and that have aims to reduce their emissions.

The operation in summer 2022 will enable the glassmaker to further increase its energy efficiency and pursue its electrification aims. The integration of the rebuilt gas-oxygen/electricity combination oven will increase the electrification rate from 49% to 54%. It will save 3800MWh of power a year, or 1100 tonnes of CO2e per year.

Mr Brunie, who is International Cookware’s Technical Director, said: “We were talking about the decarbonisation of furnaces nearly 25 years ago when our engineers decided to test the electrification of the furnace in 1998. So you could say we were decarbonisation pioneers.

“At the time we were thought of as quite strange by focusing on environmental issues but today decarbonisation is a huge issue.”

Even 16 years ago, the reduction of emissions was a theme at the site. In 2005 its engineers cut NOx emissions by switching from air gas burners

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French tableware glass specialist International Cookware is plotting a furnace rebuild set for next summer. As Johann Brunie tells Greg Morris, the company has been at the forefront of decarbonisation for 25 years.

to oxy gas burner, which have been in place ever since.

International Cookware is known for producing the Pyrex brand of kitchen cooking glass, under licence from brand owner, Corning. From its site in Chateauroux, France the cookware is distributed to Europe, the Middle East and Africa.

The facility produces a variety of shapes, weights and dimensions of cookware glass for the international brand. While the majority of production is for Pyrex it does take the occasional order for cookware glass from other companies as well, usually retail stores.

Unlike container or float glass manufacturers, International Cookware only produces borosilicate glass. This type of glass is manufactured at a temperature approximately 200 Celsius higher than soda lime glass. This has consequences for the furnace, which ages more rapidly than those used in other glass manufacturing sectors. Borosilicate glass contains boron, and when this evaporates it attacks the furnace crown. Subsequently, it means furnaces have to be rebuilt every five years compared to approximately 10-12 years in container and 15 years for float glass.

Mr Brunie said: “While it is expensive to have to rebuild a furnace every five years, from a technical perspective it is very interesting. It means we have to evolve every five years and means we can add the latest furnace technology.

“It also means we stay up to date on the latest furnace designs in the glass industry.

“A furnace rebuild is always a challenge but it is easier for us because we do it so often.”

Such is the company’s own in-house expertise that it does not have to rely on traditional furnace suppliers such as Sorg and Horn to provide furnace equipment.

“We don’t buy furnaces from the traditional furnace suppliers, we own our own drawings, we have our own technology and we have people in the team able to modify drawings. We know our furnace and forehearth internally and we are able to carry out a rebuild by ourselves.”

But every five years they will talk to technology experts and preferred suppliers to discuss subjects such as geometrics of the furnace and for their views on technologies for the new oven.

The rebuild itself will take place for two months beginning at the end of June. The Chateauroux site has one furnace , while the company also owns another furnace at the recently acquired Duralex site in Loiret, France.

While larger glass manufacturers have the luxury of many furnaces, where they can trial new innovations on, International Cookware does not have this.

“We have to study a lot about what we can put inside our furnace and that is the point of working with Glass Service and FIC UK, for example.”

A huge maintenance project will also take place at the same time with the modernisation of some

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Company profile: International Cookware

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Company profile: International Cookware

“

We were

talking about the decarbonisation of furnaces nearly 25 years ago when our engineers decided to test the electrification of the furnace in 1998. So you could say we were decarbonisation

www.glass-international.com

pioneers.

of its presses. The site has four presses and one is set to be retrofitted during the rebuild.

Alongside this in the cold end, the group has invested in robotic stacking to stack its dishes automatically. Such is the variety of shapes and dishes produced by the factory that it had taken time to find the right provider. It has adapted its lines and a provider, Prototig based in Limoges, France, will provide customised machines for two of its four lines.

The average production time of a Pyrex product is 28 to 30 hours. Due to the huge variety of weight, shapes and dimensions it manufactures, staff on three of its four production lines will switch from one product to another each day.

The complexity of the glass shapes means it has not yet found the right automatic inspection solution.

It has tried with several suppliers and a variety of cameras. The first technical challenge is to get the right view because, unlike a bottle, when you inspect the side of a Pyrex dish it is hard to see anything while a camera from the top is problematic because of the conveyor.

“A big challenge is the view itself as well as the variety of dishes, so it is a huge challenge to get good automatic inspection.”

”

International Cookware acquired the struggling French tableware manufacturer Duralex only in January this year. At the time International Cookware said it would allocate a budget of €17 million to invest in the site by 2024.

Mr Brunie’s role as Technical Director will be to oversee any technical investments at the Loiret site. So far the group has provided maintenance of the site’s equipment but the aim is to transfer the technologies used at Chateauroux to the Duralex site.

Any future investments will focus on reduced emissions.

Hydrogen A major talking point in the industry has been the transition to the use of renewable energy in the manufacturing process. A number of potential energies have been discussed industry-wide such as biofuels, increased use of electricity and lastly hydrogen. International Cookware is investigating the latter in a project alongside Air Liquide and Sefpro. In a project called Hyrex, it will focus on the use of hydrogen in its glass furnaces during next year’s rebuild and will trial the use of hydrogen injection inside its burners.

The trial aims to observe the impact the flame on the glass quality. All being well the company hopes to assess the impact and then prepare the use of hydrogen in a rebuild in 2027 or 2032.

While modelling carried out by Glass Service was positive, Mr Brunie acknowledges the company needs to take it step by step and assess how the furnace behaves with more electricity.

The grant from the France Relance project has helped the company to take on such a rebuild after the Covid pandemic. The plant had to reduce capacity at the start of the pandemic but, from the second half of the year, saw a huge upturn thanks to the increase in people cooking at home. The plant employs 390 people working in rotating five shifts. Johann has worked at the company for 13 years in what will be his third furnace rebuild.

“I was young in 2012, I was in charge in 2017 and will be in charge again in 2022.

“For me a furnace rebuild is what makes the enjoyment of my job. It is a huge challenge making again a furnace for a factory where there is only one furnace and it is what provides the spice of my job.

However, I will lose 5kg during the rebuild because it will be very stressful, but it is part of the job!

“The manufacture of glass is a fantastic process.

Glass by itself is a fantastic material and when you work for Pyrex it is a high quality product.

There is investment and the resources to make this improvement on energy and our environmental footprint.” �

International Cookware, Chateauroux, France, https://www.pyrex.fr/

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GLASS SERVICE

A Division of Glass Service

Company profile: Kapoor Glass India

Family business with improvement in its DNA Vial manufacturer, ampoule producer…and glass equipment builder. Faced wth the prospect of purchasing expensive European glass production technology, Kapoor Glass decided on a unique approach: it would customise the machinery itself. Greg Morris spoke to Udit and Dhruv Kapoor about the company’s success. cold-end inspection system for glass vials as well as a cosmetic inspection system for vials.

The award was the culmination of a strategy adopted by the company in 2010 to focus on the European pharmaceutical market. It meant producing high quality glass to meet the demanding standards of European customers but often at lower - or ‘Chinese’ - prices

Honoured Mr Kapoor said it was a privilege to be recognised by the AIGMF. He said: “It was a real honour to get that kind of recognition, we had been chipping away working in our back yard and then to get that recognition at a global scale was testament to our team, staff, management, supplier partners and vendors.

Everyone came together and it means a big deal to Continued>>

www.glass-international.com

P

harmaceutical glass manufacturer Kapoor Glass was recently awarded the CK Somany award for Innovation and Technology by the All India Glass Manufacturers Association (AIGMF) for its work in progressing the industry forward.

AIGMF judges commended the company in developing a variety of customised glass manufacturing equipment which has enabled it to compete with large European corporations in the pharmaceutical glass sector, where quality standards are incredibly stringent.

Judges congratulated Kapoor Glass Director, Udit Kapoor, for the company’s development of an ‘indigenous hot-end camera system, along with operating software, to achieve online automation control over key production parameters to end up with quality production of glass vials of international standards.’

Among the systems that Kapoor developed were a hot-end camera inspection unit for ampoules, a

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Company profile: Kapoor Glass India

us to get that recognition.

“We had sent in the AIGMF submission without really expectng to win. When we got the call telling us we had won we were completely surprised.

Judges said we were the most interesting company.

When they saw our submission a lot of the big players in the Indian industry realised they were importing this equipment without realising it was being made in their own back yard.”

The hot end camera system, called Dimension+, was developed as a result of the increase in the speeds of ampoule filling lines and the resulting requirements of dimensional accuracy, inspection quality standards and thus reliability of its products.

The system was completely developed in house including the software development and all mechanical components.

The system has proven results at operating speeds of up to 100 ampoules/minute with rejections lower than 1% and a standard deviation of lower than 0.05mm on the stem/sealing diameter of the ampoule and closer dimensional tolerances for constriction and bulb diameters.

This results in an improved opening of ampoules by medical organisations with consistent pressures and a lower generation of glass particles.

Strategy

business that we

Mr Kapoor said the company had changed strategy approximately a decade ago when it decided to focus on the European pharmaceutical market.

Kapoor worked with established European glass technology manufacturers, such as Italy’s OCMI, France’s Modern Mecanique and Germany’s Ambeg, to purchase forming equipment.

It would then purchase hardware such as cameras and robots from leading suppliers around the globe. Finally, its team of in-house engineers would customise the equipment to meet the company’s specific requirements.

It was at first a steep learning curve for the company.

Udit, pictured below left, said: “We started slowly but we learnt a lot very quickly! We went to Japan, we went to the main companies in these sectors and learnt all the intricate details about the processes.

“Our policy was to buy only the best hardware becaue it solves 90% of the problems. We have a good electronics team and we believe some of the best software engineers in the world are in India now. We would buy the equipment, the software engineers would then write a programme to make it all work and then we would integrate it.

are in so our main

Continued>>

“We are humbled by where our product goes, it is pharmaceutical, it is the lifesaving

aim is not to let our customers down no matter

”

what

16

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T hi si snotas ol arecl i ps e

Wi r eEdgedet ect i on

wi t hz er ocompr omi seby

Company profile: Kapoor Glass India

“You have to give customers what they want and our customers want the best. The software has to be fleixble because no two customers want the same thing. All the equipment which we build and design and implement has to be adaptable, especially when we have global customers with different standards.”

Dhruv added: “The quality required by customers are changing every day as the world moves towards zero defect.

“It means we have to continuously innovate, we are always trying to get better. We continuously ask ourselves how are we better today compared to where we were yesterday? It is our mantra. There is a continuous improvement mindset which is basically how do we get to zero defect?”

Innovation A case of innovation was the recent implementation of the cosmetic inspection systems for glass vials, highlighted by AIGMF judges.

A customised system from European supplers would not have justified the cost. Instead the group designed a conveyor which included a sixaxis robot which could identify and track each vial on the conveyor, special non-polymer grippers, a telecentric lens to avoid parallax errors, four high speed cameras which could take at least 25 images per vial, and special lighting to see the highest contrast between the mark to be detected reliably.

The system that it is now to be the blueprint for a succession of conveyors, which will be adopted throughout its facilities in the future.

www.glass-international.com

History Udit is the third generation of the Kapoor familty to work at the company. A graduate of Southampton University, UK where he completed a degree in Electrical Engineering, he joined the company 17 years ago. The company was formed in 1962 by Dharmender Kapoor and has been 100% family owned since. Father Sanjeev Kapoor. was the second generation of the family to serve the business and is its Managing Directeor today.

After originally focusing on the domestic Indian market it now serves 32 countries with Western Europe its largest region. It had previously been a domestic supplier but after the expansion of overseas corporate giants into the Indian market,

coupled with the importation of Chinese vials and ampoules, it changed tact.

Udit’s brother Dhruv joined the company in 2016 after completing a degree in Electrical Engineering from Cranfield University, UK. He is currently its Commercial Director.

Expansion The group will expand into a new facility located across the road from its Mumbai manufacturing hub at the end of this year. The move to Unit 3 will increase the company’s manufacturing capacity to 2 million pieces a day. The hub will focus on the production of cartridges for the insulin and dental sectors in particular and create up to 75 new jobs.

An important aspect of the glass manufacturing facility will be its focus on Industry 4.0-related production equipment and automation. The facility will have to room for expansion into the Ready to Use (RTU) vial sector and the company already has plans for a pilot line in this regard.

Dhru said: “The new faciity is where we are really trying to build something unique, where everything is online and focused on Industry 4.0.”

The company plans to expand its footprint back into India. While 90% of its production is currently exported, it plans to sell more to the domestic market. It is exploring new manufacturing facilities in north and south India in order to cut lead times to customers.

The Indian healthcare market had started to transition towards higher standards even before the pandemic, but has accelerated since lockdowns.

“About 15 years ago the company changed lanes and focused on the west. There has been a shift in the domestic market and we want to be involved again. Indian customers want better quality products in healthcare and lifestyle. Now, without distrubing our export business we aim to grow our footprint in India,” said Dhruv.

“We are very humbled by where our product goes, it is pharmaceutical, it is the lifesaving business that we are in so our main aim is not to let our customers down no matter what.” �

Kapoor Glass India, Navi Mumbai, India https://www.kapoorglass.com

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Air Products is blazing a new trail for oxy-fuel burner technology . . .

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The patent pending Cleanfire HRx burner offers you expanded functionality and flexibility with unmatched performance. It can deliver: • Increased flame radiation for high fuel efficiency • Ultra-low NOx emissions • Foam reduction capability for higher-quality glass • Enhanced productivity • Optional remote performance monitoring feature • Integrated high efficiency oxygen supply system This burner is the latest innovation in the long line of industry-leading Cleanfire® burners for the glass industry, which are now able to utilize hydrogen as a fuel, for a lower carbon footprint. To learn more or to schedule a demonstration in our state-of-the-art lab, call 800-654-4567 (code 10868) or visit airproducts.com/HRx.

© Air Products and Chemicals, Inc., 2021

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www.vidromecanica.com 13/04/2020 09:29:59

FIC SGT advert 2020 AW_FIC-Society advert 2019 27/01/2020 16:29 Page 1

Society of Glass Technology Join the worldwide network of interests centred on making glass great The Society of Glass Technology exists to serve people who are interested in the production, properties or uses of glasses, whether from a commercial, aesthetic, academic or technical viewpoint.

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You can now join the SGT by going to www.sgt.org and selecting your journal choice and appropriate package. You will also be able to see the comprehensive history and activities of the society.

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Recycling

Recycling: The process of economic recovery and use of ALL waste glass Steve Whettingsteel* discusses some of the challenges in creating truly sustainable glass and outlines a series of refinement solutions.

The Myth of Bottle to Bottle A further challenge is the long chain CO2 cost of delivering glass to a furnace, the claimed CO2 benefit of using cullet does not account for its recovery, recycling, transport, nor the disposal to landfill of the glass which is not suitable for remelt (pic 1).

Having a clear demonstrable CO2 value for cullet or other glass products along any part of its recovery, processing and re-use should be part of any responsible strategy, and to use the glass in a way where the true CO2 cost of each product or market determines its use.

Contrary to popular belief efficient and effective alternative markets for glass unsuitable for remelt can play a

� Pic 1. Green colour sorted remelt quality cullet. substantial in the overall reduction in CO2 of the glass recycling industry.

Many governments and authorities blindly sign up to the policy of ‘the only true glass recycling is the production of new glass’, not considering the total capacity of furnaces within an economic distance, or the matter of what coloured cullet requirements these furnaces have.

This often leads to a glass recycling programme to collapse or indicate disproportionally high cost, eventually having to concede landfill daily cover as material having been recovered and repurposed to meet recycling rates and targets.

� Pic 2. Broken car windscreens (laminated glass)

It is often touted that optical sorters can recover cullet at 3mm, which of course they can, but how efficiently and at what cost per tonne?

There is a natural balance of economics in glass recycling which is lacking in clarity.

This lack of clarity is detrimental in creating long term stability of the whole glass recycling process.

Supporting the development of low CO2 sustainable alternative uses for the glass unsuitable or uneconomic for use as cullet should be championed, not derided.

Their use provides economic stability for the recycler, as well as improving overall cullet quality and availability.

Keeping Waste Glass out of Landfill Glass that cannot be used for remelt is often sized <10mm (1/2”) and contaminated with Ceramic, Stone and Porcelain (CSP) among other materials. This glass is certainly the most challenging aspect of glass recycling due to its high levels of multi product contaminates, putrescibles and organics, as well as being uneconomic for optically sorting (Pic 2).

There are also a number of ‘harder to recycle’ glass products that while they cannot be recycled in a local MRF, can be recycled by dedicated glass processing plants. These include but are not limited to: heat treated glass (such as Pyrex or drinkware), laminated glass (such as window glass or car windshields), pharmaceutical glass, solar panels and CRT. The challenge within the glass recycling industry is to create a sustainable low CO2 product from 100% of the glass entering the recycling facility.

Continued>>

www.glass-international.com

C

ontrary to popular belief it is a technical impossibility for all used or recycled glass to be considered as furnace ready feedstock.

However unfortunately the public, industry and legislators have been misled to believe that ‘bottle to bottle’ is the only true form of glass recycling.

While this is the ideal in a utopian circular economy, in reality globally in excess of 50 million tonnes of glass is produced annually, with less than 40% being used for new glass production.

Therefore, not considering any other end markets for the processed waste glass results in a large percentage ending up in landfill as daily cover or used as a low value aggregate substitute Where possible remelt cullet should always be the primary marketplace for recycled glass, however limitations of furnace capacity in many countries, low cost of imported glass, colour disparity, quality, contamination, location, and economics have proven over decades to be the principle challenge in creating sustainability.

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Recycling

The majority of recycling plants around the world are either mandated or prefer to target the recovery of remelt cullet as a known market and to dispose the <10mm glass to landfill or low value aggregates, losing any of its CO2 benefit. A practice that has gone unchanged for decades.

However, there is hope, industry and academia are cooperating around the world to create high value low CO2 products and marketplaces for this challenging material: 1.

Cementitious materials, as supplements to Ordinary Portland Cement (OPC) � A green ultra-high-performance glass concrete (UHPGC) with a compressive strength (fc) of up to 220 MPa � UHPGC provides technological, economical, and environmental advantages compared to traditional ultrahigh-performance concrete (UHPC).

2. Silicon Fertilisers � Increased yield by up to 300% • Improved cell structural strength of the plant 3. Foam glass � This material is incredibly lightweight and can be used to build walls, regulate heat in refrigerating equipment, as an hydroponic substrate, or used as floating and filtering material.

It is an advanced heat insulating material, easily cut and cemented. � Classification A1 when tested to BS EN 13501-1, contributing to the fire safety of a building.

www.glass-international.com

4. Fibreglass and glass wool � Thermal Insulation, making it warmer in winter and cooler in summer. � Improves the acoustic insulation of walls, floors and roofs. � Classification A1 when tested to BS EN 13501-1, contributing to the fire safety of a building.

5. Water filtration � Using crushed glass as a water filtration medium for swimming pools, car washes and wastewater treatment plants has become more commonplace over the years. � Due to the characteristics of Imploded glass, the use as a filtration medium is well suited and has a higher filtration power compared to sand. It also lasts longer, in many cases glass has been known to remain effective up to 10 years,

compared to two to three years with sand.

Additionally, in many remote locations and Islands around the world no remelt industry exists and exporting specialist sands and powders is prohibitive.

Specialised small-scale glass refinement plants are available at very economic rates; these being designed with adequate

� Pic 3. An example of an alternative recycled glass marketplace - Water filtration

flexibility to create products to suit local demand. In some cases, the creation of aggregate substitute for French drains, trench fill and pre-cast concrete blocks; may be the only low CO2 possibility, so efficient low cost processing should be deployed.

The Benefits of Alternative Marketplaces Not only do alternative end markets solve the problem of waste glass going into landfill: In some cases, it replaces the need for mining of virgin materials and prevents the shipping and haulage of sands and powders from many locations around the world (pic 3).

All markets must offer environmental and economic benefits, focusing on the needs of each individual client and establishing an inclusive strategy ensures the commercial viability of glass recycling no matter its location or traditional constraints.

Such solutions create sustainability and employment locally, open up new revenue streams and offer the recycler the opportunity to choose which marketplace it will produce for based on the costeffective conditions and requirements of the region, always working alongside remelt where possible, but always making use of 100% of all glass and avoiding landfill at all cost.

Companies and organisations are actively looking to reduce their carbon footprint and environmental impact by sourcing local suppliers, using recycled materials or saving energy for example.

All three of these examples could be met by a recycling facility that is open to supplying a number of end markets, including remelt, ensuring that 100% of glass which enters the gate has an end market and a sustainable value.

This would keep transportation costs down, creating use locally for a product that would otherwise go to landfill.

Increasing demand for recycled materials will only strengthen and stabilise the marketplace as well improving the economics of a MRF driving investment.

Innovation is required and a desire to understand and mandate greater diversity and sustainability for all glass.

In fact, research has shown many recycled glass products offer technical benefit over those being displaced, as well benefiting from the characteristics and properties of glass which underline its credentials through sustainability. This is only possible through well-designed cost-effective technology focused on enhancing quality and consistency.

Inclusive approach Krysteline is well placed to provide sustainable glass recycling and refinement solutions across a spectrum of markets and locations, all considerate of their CO2 footprint.

Our strategic and inclusive approach offers solutions for the processing and recovery of 100% of all waste glass.

By considering the feedstock and delivering technology that provides clients with the means to produce high quality end products that service the demand of traditional marketplaces and also to assist in the development and growth of sustainable alternative marketplaces.

Specialising in processing and refinement of the glass generally perceived as being too poor or too difficult to process.

We have worked with most types of glass, from multi-layer bullet proof glass, through to car windshields, industrial flat glass, and the challenging MRF glass and 10mm fines. Our machinery is used globally to produce recycled glass products ranging from expendable abrasives and foam glass to water filtration and cement, and of course cullet for the production of containers. We aim to keep 100% of waste glass out of landfill! �

*CEO, Krysteline Technologies, Southampton, UK https://www.krysteline.com

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Recycling

� Pic 1. Glass bottles ready to be put back into the recycling process.

Preheating solutions to improve energy efficiency in glass plants T

he latest data shows that the majority of glass produced in Europe is recycled.

This result has been obtained through awareness campaigns and strict laws that require manufacturers, and customers, to take responsibility for recycling product packages.

The recycling rate in Germany is high The cullet addition into a melting furnace can be up to 60% for flint glass and 90% for green glass. The country has policies in place regarding waste management, such as the Packaging Ordinance that obliges manufacturers to collect all their product packages after consumers have used them.

Another legislation, the Closed Substance Cycle and Waste Management Act, demands that manufacturers avoid producing any waste. If waste is inevitable it must be recycled and, when recycling

is not an option, it must be disposed of responsibly. Similar regulations are in place in many countries around Europe and the world.

Glass: the material of choice Glass has retained its position as the most recycled closed-loop packaging material in the world. For new generations, glass will be the material of choice to achieve a more sustainable world (Pic 1).

Advantages of recycled glass � One kilogram of cullet saves around 1.2 kg of raw materials such as sand, sodium carbonate and limestone.

Therefore, recycled glass helps the world to conserve rare, finite and renewable resources - diminishing glassmakers’ need for raw material. � As recycled glass has a lower melting temperature, it reduces the production

energy consumption; glassmaking feed mixtures with 10% of cullet use 3% less energy. � Glass made from recycled glass reduces air pollution by 20% (it also decreases the exhaust gas concentration) and water pollution by 50% compared to glass made from raw materials. � The reduction in CO2 emissions means that glassmakers need fewer CO2 certificates. � Used glass can be reprocessed into new glass products without any quality loss. � Glass has an unlimited lifetime, meaning that it can be melted and recycled infinitely. � It is a sustainable, environmentally friendly material.

Continued>>

www.glass-international.com

With customer interest in energy-saving equipment increasing, the pressure is on suppliers to provide sustainable solutions. EME plans to reduce CO2 emissions and increase energy efficiency with its investments into batch and cullet preheating systems.

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Recycling

� Limitless availability: glass is abundant. � Glass manufacturers can get it from production scrap; it can be obtained from collection and recycling systems, the construction industry (windows, insulation material, greenhouses), the automotive industry and many more places (screen, cooking hobs, lamps, etc.). � Recycled glass is cheaper than raw materials such as sand, soda, lime, etc and provides a higher melting capacity. � The use of recycled glass as a raw material allows heat recovery in a cullet preheater.

Energy efficiency EME, a member of the Sorg Group, is improving its systems with energy-saving waste-heat recovery. The heat transfer at combined batch and cullet preheaters can be done by direct or indirect contact between the raw material and the hot flue gases. Flue gases are composed of vapour, small particles, heavy metals, acidic gases and carbon dioxide, amongst other combustion products.

EME created technology that pushes energy efficiency even further, such as the BATCH3 system. The company has also invested in developing technologies that help glassmakers reduce CO2 emissions

and increase glass pull.

CO2 reduction

Another trend in the industry is the imperative reduction of CO2 emissions.

Although the use of recycled glass reduces greenhouse gas emissions during the manufacturing of a container, the glassmaking process naturally produces carbon dioxide, emitted throughout the melting process (that uses fuel) and during the decomposition of carbonates.

As 75% of the CO2 released is due to the use of fossil fuel to heat furnaces, the decrease in the emission rates is highly dependent on energy efficiency increase.

EME’s 100 years of expertise allows the company to create innovative solutions that will contribute to a more competitive industry. The company is continuously investing in the research and development of highly efficient equipment that can reduce energy consumption, as well as particles and CO2 emissions.

Tackling energy waste In the fight against energy waste and CO2 emissions, the industry can integrate EME’s solutions that include batch and cullet delivery and storage, transport, management, preheating and charging technologies, as well as cullet treatment.

A specialist in batch preparation

plants, cullet handling equipment and batch charging technology for the glass industry, EME is always attentive to industry trends. The company’s goals are to provide a seamless service, problemfree equipment and comprehensive solutions for the glass sector.

Don’t get left behind EME has been delivering full planning, execution, and commissioning of internal cold and hot cullet return installation and cullet treatment for over a century. EME’s solutions include dosing, weighing, transport, sorting (magnets, CSP and colour sorting), crushing, dedusting and screening.

The company also supplies preheaters for cullet and raw materials, helping to reduce energy use, and special cullet and batch chargers with doghouse seal.

With the demand for more sustainable solutions, glass recycling is more important than ever.

Cullet treatment equipment is an investment in your company’s image and the planet’s future (pic 2). �

*EME GmbH Erkelenz, Germany www.eme.de

� Pic 2. Flow Diagram -

www.glass-international.com

Recycling Process.

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WWW.HORNGL ASS.COM

ADVANCED LEVEL OF ELECTRIC BOOSTING As an innovative technological leader in the global glass industry, we have a crucial responsibility towards the future of our planet. Therefore an environmentally friendly platform for electric boosting is available: E-Fusion – HORN Power Boosting.

HORN’s answer to the future way of glass melting focuses on our environment by creating a new boosting world which takes electric boosting to a whole new level.

HORN has bundled its forces to use sustainable energy in order to reach less CO2 emissions. Our specialists and comprehensive service package ensure a highly efficient performance of the plant over the entire life cycle.

People profile: Zippe

Zippe says goodbye to Günther Mlynar

Zippe’s Chief Technology Officer Günther Mlynar is saying goodbye after a 31-year association with the batch plant specialist. Glass International spoke to him ahead of his retirement.

www.glass-international.com

1.

How are you feeling about your forthcoming retirement? What do you plan to do in retirement?

Well, after so many years working for company ZIPPE and – certainly – after more than 40 years in employment, naturally it is not so easy to see oneself retiring.

On the other side I am certainly looking forward to spending more time with my wife, my family and to have time for oneself. I have several hobbies and I am mainly looking forward to travelling more.

2.

What is your overall feeling of leaving Zippe?

It was nice to having contributed a bit to the success of the company and in the end to the glass industry overall.

In this connection I would like to give special thanks to the Zippe-family, who I got to know and worked with for over three generations and who have supported me all the time. Our cooperation has always been fair and loyal.

However, I must not forget the many employees and colleagues of mine – without them and their engagement and cooperation this success would

“It was nice to having contributed a bit to the success of the company and in the end to the glass industry overall

”

not have been possible.

I do not worry about the future of company Zippe.

There is a young, engaged and competent team that has grown up in the meantime.

3. How long have you worked at the company for? What are some of the highlights of your time at the company?

I started in 1990 as a young engineer in the sale department. There we designed and calculated the plants and discussed solutions with the customers.

It was a nice time. I learnt a lot from and with the customers about the glass industry.

In the year 2000 the head of the projecting department retired and I became his successor.

I had to lead a young, experienced team of engineers. I travelled a lot visiting customers.

Later in 2005 I became General Manager responsible for Technology & Sales.

And in 2016 I was appointed to be the CTO! There have been many highlights. I enjoyed always visiting customers and travelling in many countries. There were always exciting projects for me – modernisations and modifications during

28 Glass International November 2021

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production were always a challenge. One of the most interesting projects was in 1996 when we received three big orders for Float Glass Plants at the same time from a large Float Glass Producer.

*

4.

Is there something you are most proud of achieving during your time at Zippe?

We found special customers with whom we still have a very close and successful relationship. These are for example Guardian Glass, Bangkok Glass, Siam Glass, O-I, Saint-Gobain and Verallia and Wiegand-Glas here in Germany.

New equipment which we developed is for example the Vibrotube Charger, Heat Recovery Systems and Preheaters.

Moreover we did a lot of advancements and ongoing developments in Batch and Cullet Plant Technology – more reliability, dust-reduction and health care and safety. In these field we have been active during the last decades.

6.

Do you have any suggestions for how the glass industry should go forward in forthcoming years?

There are new upcoming challenges in the next decades, especially in the glass production.

CO2-neutral production, flexible production on demand, high recycling rates and raw material consumption.

7.

How do you plan to celebrate your last days at Zippe?

Quiet and thankful. It was always exciting and a pleasure to work for the glass industry with the Zippe-team and with the customers.

Thanks again to the Zippe-family and their confidence. �

www.zippe.de Glass International November 2021

People profile Zippe Gunther.indd 2

* latest swabbing-robot installed in July 2017 in Germany

5.

What are your thoughts about the overall glass industry itself and the people you have met over the years?

The glass industry is a relatively small branch of business with high potential, clever minds and many good ideas. Glass is a fantastic material the potential of which is still very big.

Who would have thought of LED-lamps, display glass, optical glass fibres, TFT-glass many years ago?

Glass is a material which we meet in our lives every day in different facets. All people who I meet in the glass industry have always been enthusiastic about this material and the possibilities it offers.

24/11/2021 09:48:38

Forming technology

Siemens servo drive improves indexing times Siemens has produced a servo drive system that can increase the number of cycles per minute for machinery. Matthias Porzig1, Tobias Feige2 and Dominic Ackerschewski3 discuss how this shorter index time has influenced Ambeg’s output. � Pic 1. Chuck lifting device: transfer station from the A part to the B part. The transfer must be fast to remain high quality.

� Pic 2. Up to 60 cycles per minute: automated rotary indexing machines for pharmaceutical and cosmetic glass products from Ambeg are reliable and productive, thanks to consistent, end-to-end high-performance components from Siemens.

www.glass-international.com

A

t up to 60 cycles per minute, Ambeg Dr. J. Dichter is taking the output of its glass forming machines to a new level. A high level of automation, high-performance servo drives at cycle time-related (connection) points and the know-how of perfect interaction, has led to the shorter index time. Other benefits include a consistently high product quality and a reduced rejection rate.

As a manufacturer of machines for tubular glass packaging, Ambeg has constructed machines for products such as bottles, syringe barrels and cartridges.

Rotary indexing machines produced by this family-owned company are still operating today according to a proven principle: a rotary conveyor feeds glass tubes to a central rotary indexing table, known as the ‘A’ part.

30 0 Glass International November 2021

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Forming technology

� Pic 3. Connected to a Simatic S7-1500TF via Profinet, new Sinamics S210

� Pic 4. Compact powerhouses: Simotics S-1FK2 servomotors provide three

single-cable servo converters synchronise the traversing movement of the roll

times the torque of the previous solution; with only one cable, they’re also easier

tongs precisely and highly dynamically.

to seal against oil.

These tubes are partially heated several times over burners and gradually formed using roll tongs at multiple stations.

After being transferred to a second rotary indexing table – the ‘B’ part – the base or (in the case of syringe barrels, for example) the open, opposite end of the glass container is formed (Pic 1). The speed of the A part determines output, which is why it is the focus of further development.

60 cycles per minute

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Whereas the limit of ‘traditional’ servo machines is approx. 40 cycles per minute, the latest developments by Ambeg are already reaching 60 cycles - the output of one product per second (Pic 2).

“The indexing time from station to station is also critical for quality,” says Matthias Langer, Head of Engineering at Ambeg, “because the faster the indexing, the more time that remains for forming and the more gently and precisely the glass can be formed. We literally fight for every millisecond.”

Manufacturers of high-end products, such as syringe barrels for the pharmaceutical industry, whose subsequent processes are highly automated, have to deliver glass that is absolutely precise and of a consistently high quality. � Pic 5. Simotics S-1 FK7 servomotors also synchronise interaction between the material feeder and rotary indexing table in the A part.

Continued>>

31 Glass International November 2021

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Forming technology

End-to-end automation Servo drives have long been the norm for the rotary indexing machines at the glass tube feeder, the two rotary indexing tables, the forming tongs and other auxiliary equipment. The demand for a much higher performance has resulted in a new, comprehensive automation and drive concept, as well as in Ambeg’s choice of Siemens for its drives. Consequently, in addition to controllers and HMI devices from the Simatic product range, the company has since been using Sinamics converters and Simotics S servomotors provided by the automation specialists.

“We want to automate as consistently as possible,” is our motto. For this reason, the machine builder ultimately converted the drive system for the forming tongs to a latest-generation Siemens solution: a Sinamics S210 single-cable servo system (Pic 3) and matching Simotics S-1FK2 servomotors (Pic 4).

This has yielded a number of benefits.

Due to the holistic automation concept in the TIA environment, diagnostics are already a standard functionality and require no additional configuration.

Converters from the modular Sinamics S120 series and Simotics S servomotors were already being deployed wherever higher performance was required.

Like the new Sinamics S210, they also communicate with the Simatic PLC via Profinet IRT and, when necessary, via the fail-safe Profisafe protocol.

Controllers for every task The functionality required of a machine or line determines the performance of the controller selected. The Simatic S71500 portfolio supports finely scalable solutions – from standard CPUs in various performance classes and fail-safe F CPUs for safety-related tasks to technology CPUs for more sophisticated motion control functions.

The latter are the first choice when cam and positioning functions are required.

The highly dynamic, synchronous processes of the glass tube feeder and rotary table in the A part or the coordinated lifting and in-feed motion at the shaping tongs are notable examples (Pic 5). As a result, Ambeg is able to implement highly dynamic and precisely reproducible motional sequences that combine high quality with maximum productivity.

would introduce further improvements.

What pushed Ambeg’s proven technology to its limits was the demand, on the part of prominent pharmaceutical customers, for 60 cycles per minute.

It’s also what inspired the design engineers to operate the rotary indexing table in the A part using an extremely rigid and precise direct drive from Siemens. Thanks to the Sinamics S120’s optimised control, machine vibrations can be reduced to a minimum despite an extremely high dynamic, which in turn protects the mechanical construction.

This enables stable and low-maintenance high-end applications operating at 60 cycles per minute. �

1. Head of Technical Consulting and Promotion Drive Technology 2. Project Specialist Motion Control and Drive Technology in Technical Sales Support

High-end application processes

3. Sales Manager for Digital Industries Siemens Digital Industries, Nuremberg, Germany

The Berlin-based company wasn’t a leading innovator, nor was it constantly on the lookout for new technologies that

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www.growth-group.com

Don’t just look at it, look into it.

Tiama Xlab – the revolutionary 3D sampling solution Turn virtual reality into reality with the new Tiama Xlab.

This highly flexible laboratory module can be installed at the hot end, the cold end or in the laboratory. It loads the container automatically and makes a 3D scan, generating an image composed of millions of facets.

The 3D image can be rotated and “dissected” on all sides. Virtual volume, capacity, and vacuity can be measured as well as glass distribution fully mapped.

You can also analyse engraving, embossing and much more. Practically all container types and shapes can be inspected and it’s non-destructive because the image (and not the container itself) is “cut” virtually.

For an online presentation of the Tiama Xlab please contact us at marketing@tiama.com.

Data – the deciding factor

Hot end technology

Waltec moves towards better ‘economics’ for press lines � Fig 1. The servo technology will allow glassware factories to increase their sustainability

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and efficiency.

Herman Green* reports that Waltec’s next-generation ESERVO press technology and powered performance components are driving the sustainable optimisation of hot end processes.

M

any in-market pressing machines and processes for tableware, cookware, glass bricks, insulators, washing-machine windows and other pressed products are still powered by obsolete technologies. Although most of the time these are still functional, they no longer comply with today’s economical and environmental requirements.

This has become a huge challenge for older glassware factories. Survival and profitability are connected to investments

in smart and clean technology now more than ever. Shareholders, owners, banks and other investors are pushing this agenda more and more. Validating investments in new machines is no longer based solely on speed and output. It has become essential to reach compulsory targets related to resource efficiency, cost reduction, lowering environmental impact and boosting supply chain values.

As such, new technology transitions are quickly transforming costs into revenue.

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Hot end technology

Investments in contemporary ESERVO technology can increase profits and upgrade existing press lines (or add new ones). Servo-driven key components reduce energy consumption whilst improving efficiencies and output - in other words ‘eco-nomics’ (Fig 1).

Waltec’s starting point is an average glassware factory specialised in the production of pressed items and running with 20 to 40-year-old presses. Some of these presses are still powered by obsolete, energy-intensive pneumatics whilst others are running on more recent proportional hydraulics - but are still outdated and very inefficient. Switching to servo-driven press technology will generate the following sustainable benefits and savings.

Servo powered pressing cylinder The ESERVO pressing cylinder (Fig 2) generates a heavy-duty pressing force of up to 20 tons and saves up to 85% on energy costs compared to conventional hydraulics (Table 1).

Hydraulic oil changes are no longer required and, as such, reduce maintenance costs while contributing to a cleaner environment. Lower emissions (operator health) and less danger (oil fire) leads to better safety on the shop floor.

Savings compared to

SINGLE GOB 6T

DOUBLE GOB 6T

SINGLE GOB 16T

proportional hydraulic cylinder

118.000 kW/year

236.000 kW/year

294.000 kW/year

1.700.000 m³/year

3.400.000 m³/year

2.900.000 m³/year

pneumatic cylinder (compressed air)

�

Table 1. Savings of proportional hydraulic cylinder compared to pneumatic cylinder.

Savings compared to pneumatic main closer (compressed air)

SINGLE GOB

DOUBLE GOB

118.000 kW/year

236.000 kW/year

� Table 2. Savings of a pneumatic main closer (for hinged/split mould items only).

Savings compared to

ESERVO PUSHER

pneumatic pusher (compressed air)

59.000 /year

� Table 3. Savings of a pneumatic pusher.

Savings shown in the tables are based on 24/7 operations, 350 days per year, on the basis of best practice management estimates requiring local on site validation and cross-checking with our technical service unit.

Reference is an upgraded cookware/tableware press.

Available for hinged/split mould items, such as beer mugs, only.

Conventional mould closing and locking is empowered by a pneumatic driven cylinder in which both movement and force are not controllable. High compressed air consumption, extensive wear and tear of mould-edges, oil vapour pollution and limited cycle speed are the limitations of this older technology.

The new generation of main closers improves both the closing process repeatability and accuracy (Fig 3). Using a strong and energy-efficient servo motor saves up to 80 m³/h of compressed air at a standardised 5 bar operating pressure (Table 2). High precision movement and soft-touch closing and locking extend the life cycle of the mould. High-speed mould locking up to 0.1 seconds saves valuable time when pressing.

Servo powered pusher for pushing article into the annealing lehr Pneumatic cylinders drive conventional pushers with horizontal and vertical strokes, but this consumes a large amount

� Fig 2. The pressing cylinders could save factories

� Fig 3. The highly precise main closer will save

up to 85% in energy costs.

valuable time when pressing.

of compressed air and the movements are difficult to control. Installing a servo pusher (Fig 4) in this part of the process saves up to 10 m³/h of compressed air (Table 3).

The servo pusher operates by using two servomotors, each one being independently responsible for either horizontal or vertical movement. Speed and movement consequently becomes 100% precise, repeatable and controllable when pushing the product into the annealing lehr. Smooth and soft touch

movement guarantees lower rejection levels for scratched and damaged glass.

The absence of pneumatic valves also lowers maintenance costs.

By switching to ESERVO press technology, the ‘eco-nomics’ for this glass factory may total up to 130 m3/h compressed air saving, 80% less energy consumption and 20% higher output.

Servo technology is also more precise and highly repeatable.

Continued>>

www.glass-international.com

Servo powered main closer

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Hot end technology

� Fig 4. By using two servomotors, the servo pusher becomes 100% precise.

As a result, this factory has two options moving forward: upgrade its existing press lines or opt-in for new press lines.

Based on the previous data, it can balance the available capex against the potential investments, benefits and savings more easily.

Last but not least, servo technology facilitates the Industry 4.0 Compliance.

Digitalisation and collection of process data, in combination with operational analytics, can be used to stay ahead of the competition.

ESERVO technology, combined with

Waltec’s WTRACK productivity software, can improve data-driven processes and take Waltec’s ‘eco-nomics’ to the next level.

A Waltec customer, who recently upgraded its existing press configuration with ESERVO press cylinders as well as other components, had this to say about its experience: “We must admit, that up to today, we are by far exceeding our targets related to cost and energy savings, speed and efficiency.

“Commissioning this new technology with Waltec’s team went very fast, was hassle-free and reliable.

“Our ramp-up times have improved and our forming process became more safe and sustainable.

“Consequently, the team is running a more stable and predictable process simultaneously collecting data for further process improvements”. �

*Global Sales Director, Waltec Maschinen, Wilhelmsthal, (Steinberg), Germany https://www.waltec.de/

Your SPC under supervision

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Moulds

Digital simulation of the glass moulding process Philipp Amrhein* discusses how the digital design of the glass mould is contributing towards Gerresheimer’s sustainability aims. speak, using computer-based simulation software. Subsequently, the results are transferred via interfaces directly to the three-dimensional CAD software of the mould design department, and the mould processing -machines use them

directly to create the mould tools. It is also gratifying that the simulation software reduces development time by up to 70%.

Continued>>

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G

erresheimer has set itself the goal of applying sustainability criteria to 100% of new product developments by 2023.

For example, glass simulation helps to achieve perfect, uniform glass distribution. It can improve strength and contribute to weight reduction and the avoidance of rejects. Simulation software used by Gerresheimer for this purpose tunes the production parameters based on CFD (Computational Fluid Dynamics or numerical flow mechanics). In this way, potential for improvement can be identified at an early stage and the development time can be shortened.

“The production of the glass container starts with the design of the mould. The more precisely the mould is designed and manufactured, the better its quality in terms of glass distribution, visual appearance, strength and weight,” says Philipp Amrhein, Manager New Product Development & Mould Design at Gerresheimer in Lohr, Germany.

The weight of bottles, flacons, and jars in particular plays an important role in energy consumption and therefore in both production and transport logistics. Considering all chemical and physical glass parameters, the moulding production process and the design of the moulds are optimised with the aid of digital simulation on the computer.

The mould cooling is also optimally designed for the respective process by means of CFD simulation. This leads to stress reductions in the glass container and thus to an effectively improved quality of the entire production process, for example by avoiding high scrap rates.

Reduction of development time What used to take lengthy empirical trials to achieve a stable production process is now done in a matter of minutes, at the push of a button so to

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Moulds � Thermal load stress.

process.

Environmental aspects

� Result of the process simulation analysis of the glass wall thickness distribution.

Rapid detection of vulnerabilities Based on the well-known finite element analysis (FEA), the stresses resulting from the product requirements are calculated on the glass containers. Based on these results, weak points can be avoided even

before the finished article drawings of the product. In the meantime, computeraided simulation of the moulding process and product requirements has become an indispensable part of daily mould design and our continuous improvement

The global volume of packaging is constantly increasing and with it the negative impact on the environment.

The transition to a circular economy is an important concern for us. We want to improve the environmental impact of our products throughout their entire life cycle - including production, transport, use and disposal. In many cases, the packaging solution is an integral part of the system, without which some medications would not be as user-friendly and safe. In this way, we lay the foundation for a sustainable product right from the development process and aim to ensure that the environmental impact is considered from the outset. �

Gerresheimer, Lohr, Germany www.gerresheimer.com

Autoclave-free Lamination System for Flat Glass Production Energy- and cost-efficient inline production of laminated glass

• Fast lamination due to contact heat transfer under vacuum

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• No Pre-Nip, No Vacuum bagging or rack preparation necessary • Low energy and manufacturing costs compared to autoclaves • Short cycle times of 5 to 20 minutes depending on the glass build-up

Engineering is our DNA burkle.tech

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Raw materials

Recycled material to aid sustainable glass production

B

lack copper oxide (CuO) is a fine black powder, of high purity and versatility, which can be manufactured from completely recycled raw materials.

It is used in the chemical sector as a catalyst, in the feed industry as a supplement and in the production of fireworks as a pigment. It is also used in the industrial glass sector, mainly for the production of container glass and to get specific types of colouring, as well as in the ceramic industry.

In recent years, Ecoterm has witnessed a progressive change of direction by its customers, who are increasingly aware of all the aspects related to environmental sustainability.

The request for recycled materials to be

used in production processes increases day by day, with the aim to use 100% of recycled material within the next 10 years.

Thermal process For the production of black copper oxide, Ecoterm is the only European company that has always used a thermal production process as opposed to chemical.

It uses raw materials discarded from other industries, such as copper scraps from foundries, and obtains a cupric copper oxide with a high purity (CuO 99% min).

Ecoterm holds the necessary authorisation to collect and transform several waste codes (CER) into secondary raw material (SRM), completely recovering

the waste introduced into the production cycle.

Once the raw material has been collected, the production process removes all of the impurities inside using only heat and mechanical systems, without adding any kind of chemicals.

This makes the whole cycle extremely ‘green’, especially if compared to the classical chemical production process.

Here the final product is obtained from the ignition reaction generated by cupric nitrate trihydrate, cupric hydroxide or copper carbonate.

Finally, the raw material is micronised to get the grain size requested by the customer, through mechanical processing, for the different fields of application.

This new type of recycled material can be used in the glass industry.

Perhaps it should be considered as a secondary type, when reflecting the quantities of copper oxide compared to (for example) cullets, but it is still essential for achieving sustainable development goals by 2030. �

Ecoterm, San Felice sul Panaro, Italy https://www.ecoterm.info/en

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Black copper oxide (CuO) is a fine black powder for use in the container glass sector to get specific types of colouring. An Italian company, Ecoterm, produces the material sustainably by using a thermal production process as opposed to a chemical one.

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Regional overview: Asia

Over the past decade, a number of Asian container glass producers have opted for lightweight glass bottles. Glass International presents an overview of lightweight glass production in three major Asian glass markets.

www.glass-international.com

Asia opts for lighter glass L ightweight glass bottles have become extremely popular in the global container glass industry over the last two decades; a number of glass producers have added lightweight bottles to their portfolio in recent years.

Rapid advances in manufacturing technology has made it possible to create particularly thin-walled lightweight glass containers. Instead of the traditional blow-and-blow process, glass producers have chosen the narrow-neck-press and blow process.

Lightweight glass technology enables glass manufacturers to produce bottles to weigh much less while remaining as strong and stable as their heavier predecessors.

In 2019, the average weight of bottles had fallen by 30% over the previous decade, according to figures from Statista.

For example, Accolade, the biggest wine bottler in the UK, has decreased its proportion of bottles over 500g from 17% in 2017 to 3% in 2020. Over the same period, the amount of bottles that weigh less than 390g has risen from 24% to 42%.

Recently, global brewer AB InBev developed the world’s lightest longneck beer bottle for commercial production.

Frederik De Graaf, Global Director of Packaging Technology Development at AB InBev said: “If used on a year’s worth of glass production for AB InBev

brands in Europe alone, this would be the equivalent to taking 62,000 cars off the roads annually, in terms of CO2 emissions.”

The brewer has reduced the weight of its standard longneck beer bottle from 180 to 150 grams, reportedly cutting its CO2 emissions by 17% per bottle.

“This success is the fruit of intensive collaboration with our external glass partners, having shared knowledge and worked together on new glass coatings, new mould coatings and modern converting technology to strengthen the glass.”

Mr De Graaf went on to highlight the difficulties within the project.

“When reducing the weight of the bottle, we were faced with strength challenges – beer is, of course, a carbonated drink and inside pressure can build up due to the gas expanding under certain heat conditions.”

AB InBev is now exploring how to release the new bottle, initially in Europe, as a one-way deposit. The next challenge for the company and its glass suppliers will be to further develop technologies to lightweight returnable bottles, which need to survive many cycles.

Asian production Much like their European counterparts, Asian producers have embraced

lightweight container glass production technology .

Although the volume of lightweight glass containers produced in Asia is far less (as a % of total production) than Europe, it is growing each year.

Along with the savings in raw material, energy and total cost of production, lightweight containers are also gaining in popularity due to rising transportation costs. The growth in e-commerce, and demand for cost-efficiency in relation to fuel, will create more opportunities in the near future in Asian countries.

Japan Japanese container glass producers have been the pioneers of lightweight glass production in Asia.

Major manufacturers Toyo Glass and Nihon Yamamura Glass Company have provided technical assistance to a number of glass producers, as well as producing their own lightweight bottles.

They have assisted the Philippines’s San Miguel Yamamura Glass (SMYPC), South Korean Kumbi Glass Corporation and Technopak Solutions, Indonesian PT Muliaglass, Vietnam’s San Miguel Yamamura Haiphong Glass and Thailand’s Siam Glass.

The Japan Glass Bottle Association determines the lightweight level of all glass containers using a specific

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Class

Degree of Light weighting ( L Value)

Level I

1.4 < L

Level II

1.0 < L< 1.4

Level III

0.7 < L < 1.0

Level IV

L < 0.7

L value is calculated by the following formula, L Value = 0.44 × Mass (g) ÷ Brimful Capacity (ml) 0.77. project

� Table1 mathematical formula. The containers are then divided into four classes from Level I to Level IV, with IV being the ‘ultra lighweight bottle’ category. (Table 1) According to the Nihon Yamamura Glass website: “Lighter weight bottles help conserve resources during production, conserve energy during production and transport, and reduce CO2 emissions.

“In addition to bottles for general use, we also develop ultra-lightweight bottles for specific customer products.”

Japan’s Kirin Brewery reduced the weight of its reusable beer glass bottles in recent years with the assistance from the country’s container glass producers and Japan’s Institute of Packaging Innovation.

Kirin Brewery opted for innovations such as ceramic coating, that forms a thin film on the outside surface of glass bottles, an impact resistant shape design and a bottle mouth design. The bottle mouth is easy to open, can be tightly sealed and is chip resistant, achieving Japan’s lightest returnable glass beer bottles in all three sizes: large, medium and small.

India With an installed capacity of more than

12,000 tonnes per day, India is the second largest container glass producing country in Asia. Container glass producers in the country, Hindusthan National Glass and Industries (HNGL), AGI glaspac and PGP Glass (formerly Piramal Glass) have invested in the technology for the production of lightweight glass containers.

AGI glaspac’s President & CEO, Rajesh Khosla told Glass International: “AGI glaspac produces beer containers in amber, green and flint colours throughout the year in NNPB (Narrow Neck Press and Blow) & BB (Blow and Blow) technologies for almost all the major customers in India and some European customers.

“Glass is the preferred packaging material for beer due to its superior UV absorption properties. We can nurture a basic idea or concept through a stepby-step product development process to realise the final packaging product using our professional design capabilities.

“Our focus is not only on quality but also on introducing new products to the market quickly. We now have a comprehensive bottle design service, a glass analytical laboratory and a training

school.

“The technology for production of glass containers by NNPB method i.e. press-and-blow developing of lightweight narrow-necked glass container products, has been implemented in our both plants, which have a capacity of 1600 tonnes/day.

“For each sector like pharma, liquor, beer and food, we have light-weighted bottles constituting 10 to 14% of our production.”

The market size of the Asia-Pacific container glass market is forecast to reach US$ 61.0 billion by 2026, at a CAGR of 4.3% between 2021-2026.

He added that lightweight glass has been a gamechanger, which offers the same resistance as older glass materials and higher stability, reducing the volume of raw materials used and CO2 emitted.

It has led to increased demand for glass containers due to its various benefits, such as being infinitely reusable, recyclable and refillable. It has led to the increased adoption of lightweight glass, which is a vital factor contributing to its market growth.

Countries such as India, South Korea, China and Thailand have observed a substantial increase in beer consumption.

Mr Khosla added: “In striving to make lighter weight glass containers available, technologies dictate the final limit of what can be achieved.

“By implementing developing technologies in forming and related areas, significant advancement in weight reduction may be realised.

“On the other hand, the increase in beer consumption has also positively impacted the Asia-Pacific container glass market as most beer is packaged in glass bottles.

“The wide availability of other alternative packaging materials is estimated to create challenges for the growth of the Asia-Pacific container glass market.”

India’s largest producer of wine, Sula Vineyards, has opted for lightweight glass bottles for packaging of its wine products.

Company Executive Rajeev Samant, said: “In FY’21 we have completely moved away from importing glass bottles for packaging, by developing a domestic vendor for manufacturing bottles. Our bottles were previously imported from France and Dubai, whereas now they are supplied from AGI glaspac in Hyderabad, Continued>>

www.glass-international.com

Regional overview: Asia

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Regional overview: Asia

India. This has led to massive savings in freight carbon emissions in our supply chain. We sourced about 3,000 MT of glass for packaging domestically in FY’21.

“We have worked with our vendors to develop lightweight bottles.

Manufacturing of lightweight glass bottles requires less amount of heat during the melting process, the bottles are more convenient to transport and can be cooled using less energy.”

ASEAN The region has seen a number of container glass producers emerging from small-scale to mid and large-scale manufacturers in the past two decades.

Thailand’s Bangkok Glass Industry, Thai Glass Industry, Siam Glass, Indonesian PT Mulia Glass and the Philippines’s SMYPC have emerged as some of the most important players in the region. All of these producers have adopted to the production of lightweight glass bottles in varying degrees in the past decade.

An executive from Siam Glass told Glass International in a communication on the condition of anonymity: “There is no doubt that lightweight

glass bottles enables container glass producers to save raw material and energy costs by a considerable degree.

But, there has been some hesitancy among the end-user segments. In particular, some producers in the alcoholic beverage sub-segment are still reluctant in using lightweight glass bottles for their products.

Their most cited concern is about how their products may be perceived if they opt for lightweight glass. As consumers often associate the weight of the bottle with the quality and luxury of the product and, by extension, the brand. An example

of this is how more expensive, luxury wine brands often have heavier bottles in comparison to cheaper wine products.”

Siam Glass Industry operates a total of six glass melting furnaces at three production facilities in Thailand at Rojana, Samut Prakarn and Ayutthaya.

These production facilities are equipped with NNPB production to produce lightweight glass containers for energy drinks and beverage industries. �

https://www.yamamura.co.jp/english/ https://www.agi-glaspac.com https://www.osotspa.com/new/en/osotspagroup/index.php

www.glass-international.com

Glass experts Furnace support Process optimization Training and R&D Celsian’s aim is to minimize the cost of making glass for end users and the environment. We have an agile team of glass experts using proven methods like furnace modelling, laboratory measurements and practical furnace health checks to optimize glass melting processes. We also train operators and glass technologists through our standard course, dedicated programs and various e-learning modules. We strive to be the best partner for optimization of glass production worldwide.

www.celsian.nl

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Overview: International year of Glass 2022

All systems go for Year of Glass The International Year of Glass 2022 (IYOG) has launched a fundraising campaign for its flagship event.

About the International Year of Glass 2022 Over the past 60 years, the General Assembly of the United Nations has acknowledged important fields of

international endeavours and their contributions to society by declaring United Nations International Years. The International Commission on Glass (ICG), along with the Community of Glass Associations (CoGA) and the ICOM Glass, the International Committee for Museums and Collection of Glass of the International Council of Museums, promoted a United Nations International Year of Glass for 2022.

It will underline the technological, scientific and economic importance of glass — a transparent and enabling material underpinning so many of our technologies which can facilitate the development of more just and sustainable societies that meet the challenges of globalisation. It is a valuable medium for art and its history is shared with that of humankind.

Glassy materials have in recent decades fostered numerous cultural and scientific advancements: � Glass is the main conduit of our knowledge-based society. Glass optical fibres have stimulated a change of paradigm that has led to a global communications revolution; they are the backbone of the internet and the associated globalisation of information.

Glassmakers have given us touch-sensitive glass covers for our mobile phones that revolutionised the way we communicate with each other. � Glass is the chemically resistant container material for many of our lifesaving medicines of today. This was particularly important in the world’s quest for the delivery of a vaccine to fight the COVID-19 pandemic. A strengthened glass container has dramatically improved

the reliability of the EpiPen treatment of life-threatening anaphylactic shock from severe allergic reactions. � Glass sheets support solar cells and give clean energy; glass fibres reduce our carbon footprint by strengthening wind turbine blades, by insulating our homes and through carbon capture and sequestration (CCS); the vitrification of hazardous waste is increasing nuclear energy safety, � Bioglass compositions have advanced health care with their ability to: integrate with human bone; stimulate the human body’s natural defence to heal flesh wounds; aid tissue design and regeneration; resolve hearing and dental issues. � Glass optics and optoelectronics have evolved so that the James Webb space telescope can now study the very first moments after the big bang and expand understanding of the Universe. � Glass melting is being de-carbonised and glassy products are being safely recycled. � Archaeologists are learning more about ancient trade routes and the politics of raw materials. � Glass artists across the globe have given humankind an awareness of this wonderful material including its remarkable methods of fabrication, inherent beauty, and ability to capture and display nature’s full spectrum of colour. �

For more information, the donations tool and news items see the web site www.IYOG2022.org

www.glass-international.com

T

he Opening Ceremony will take place in Geneva Switzerland on February 9 to 11 and will showcase an array of internationally recognised speakers primed to place Glass at the heart of the UN 2030 Humanitarian Goals.

The audience will include important political figures and noteworthy members of the glass community, although in numbers possibly restricted by COVID. The proceedings will be live-streamed for those unable to attend and available later as a recording.

A book highlighting the same aspirations will be released simultaneously.

IYOG is committed to financing the Opening Ceremony without recourse to fees. So, the support of its endorsers: institutions, companies, artists and educators is vital.

A fundraising campaign has been launched through its website, https:// donate.iyog2022.org/; individual donors can participate using PayPal or Stripe (credit or debit card).

IYOG said: “We are now focusing our campaign on companies, associations and institutions able to support IYOG with larger gifts. Such donations will be invaluable and will decide whether we can proceed.”

Many other events are also planned: trade fairs, conferences, magazine articles, exhibitions in art galleries and museums, talks, factory open days and newspaper articles.

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Inspection

� Pic 1. Defect detection from the raw material to the finished display .

Solutions for glass display inspection

www.glass-international.com

Traditionally, quality control has relied on manual inspections, leaving room for human error. Isra Vision* discusses how using its technology from the raw material to the final product can produce faultless glass and increase profits.

T

ouch screens and displays are all around us, whether on smartphones, coffee machines, ATMs, in our cars or at our workplaces. Technologies for ever thinner displays and vibrant quality, outlandish shapes and new applications open up additional market potential in consumer electronics and industrial markets.

At the same time, however, they place increasingly higher requirements on functionality and optical quality. To meet these tough standards, Isra Vision develops and produces mature inspection methods that ensure end-to-end process

and quality control – from raw glass production, films and foils, all the way to complete displays and finished products.

These methods increase efficiency and profitability in the production of displays and, ultimately, boost customer satisfaction (Pic 1).

Touch displays enable the convenient and intuitive operation of devices and machines; they are also robust and easy to clean. As a result, they are becoming increasingly widespread in production plants, medical technology and other areas of industrial applications.

The automotive industry is currently

setting trends in this area with the introduction of pillar-to-pillar displays spanning the entire vehicle width in new vehicle generations. These present important cockpit functions and allow all the car’s communication and infotainment systems to be operated.

In addition, they are perfectly fitted and often feature curved shapes and integrated sensors.

It is expected that this trend will also continue in other applications.

This will require new procedures for glass processing and finishing, as well as corresponding inspection processes

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Inspection

during manufacturing. Such quality inspection is essential to meet the stringent requirements in terms of robustness to mechanical loads, troublefree functioning and operability, fit and optical quality.

Quality assurance from the beginning

Fully automatic inspection Thin display glasses are also subjected to a fully automatic inspection just like optical films. Isra Vision FPM-Inspect (flat panel master) combines tried-andtested technologies for optical quality control with precise materials handling technology for use in clean rooms. This allows the system to identify even the tiniest surface, glass, or edge defects (Pic 3).

In addition, FPM-Inspect monitors particle contamination on the substrate, thus enabling conclusions to be drawn

� Pic 2. Isra Vision SMASH surface inspection system for plastic film material.

regarding the air quality in the cleanroom.

Here, too, the inspection system works with mature software algorithms to improve the production process and to detect and eliminate the causes of defects.

When it comes to the 100% monitoring of evenness, rippling and reflection optics, even in large glass surfaces, Isra Vision P2 (PowerPlate) delivers precise data in a matter of seconds. Alongside defects in and on the material, this also allows the immediate detection of 3D shape defects, preventing the materials in question from being processed further.

Quality control Perfect optical films, thin films and display glasses form the basis of high-quality displays. However, they only become a fixed unit with optical characteristics and functionality once they have been joined together during production.

In this production step, quality control is just as important as inspecting the raw materials. Dimples on the cover glass and other defects can occur when adhering the layers, which cannot be

recognised with the naked eye, but compromise the optical properties and function of the product. SpecGAGE3D was specially developed to reliably detect local unevenness, supporting structures or read-throughs before and after joining the display layers using deflectometry. To do so, a stripe pattern is projected onto the display and the reflection is captured by multiple cameras and subsequently evaluated. Any detected defects are then classified immediately.

Curved glasses and displays Deflectometry is perfectly suited for the inspection of curved glasses and displays, like the cover glasses of smartphones.

Curved edges and concave shapes are becoming increasingly popular in this field and in the automotive industry; displays of the same size require a smaller installation width and the shape allows information to be seen more easily on the edges. At the same time, they set even more stringent requirements in terms of Continued>>

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Whether they employ TFT (thin film transistor) or OLED (organic light emitting dioxide) technology, modern displays consist of many layers made of different materials that are usually extremely thin. Optical films, thin-film and thin-glass in the actual TFT or OLED display and cover glass are joined together during the production process, achieving a perfect union of form and function.

However, even the smallest defects in one of the layers can compromise the properties and function of the display.

Isra Vision is a specialist in optical inspection and defect detection for every single layer; its solutions identify and reject defective materials before installation, minimising the number of imperfect end products produced and increasing the profitability of production. Isra Vision’s ‘Smash’ is a system for inspecting the surfaces of optical films. It detects defects, including minute scratches, marks and production residue on film materials and coatings on web materials (Pic 2).

Line cameras guarantee a high inspection speed of up to 1,000 metres per second while also enabling the highest image resolution. At the same time, customised lighting supports the reliable detection and intelligent classification of defects that would be invisible to the naked eye. In turn, this allows conclusions to be drawn regarding causes or defective process parameters, which can be continuously monitored and optimised.

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Inspection

Crystal-clear quality

� Pic 3. Isra Vision Flatpanel Master performing thin glass surface inspection for displays.

quality inspection, as the fit and shape must be exactly right in addition to the perfect surface and optical quality.

The SpecGAGE3D inspection system from Isra Vision enables shape inspection of curved and flat displays and plastic optics – such as light guides – by generating measurement data, which is superimposed with the target data of a digital twin in a CAD comparison.

It thus creates a difference-map of the inspected material that is precise to the nearest micrometer. The system uses point comparison, profile sections or fullsurface evaluation to check deviations from the target geometry reliably and efficiently and then visualises them.

Bending moulds are a possible source of defects in curved and flat displays. With NetGAGE3D, Isra Vision offers precision measurement technology for this, too, by identifying defects in the graphite mould. In doing so, it ensures quality and thus reduces the likelihood of defects that could otherwise be reproduced in thousands of displays during production.

profit, while an excessively relaxed quality inspection leads to complaints and dissatisfied customers. A fast, fully automatic and 100% optical inspection solution solves this problem. It is easy to integrate, detects typical cosmetic defects such as scratches, bubbles, indentations and polishing marks and delivers objective and reliable results.

The SpecGAGE3D inspection system can be used during the final control and is ideally suited for the measurement and inspection of all transparent and reflective surfaces. Inspecting flat or curved displays, as well as 2D / 3D cover glass, glass back panels of smartphones and other glossy housing parts is also possible with the inspection system. This system immediately decides how to sort goods based on defined tolerance ranges and automated defect classification (Pic 4).

Increasingly larger and thinner glasses, flexible materials and complex shapes are posing ever more strict requirements for the manufacturing of displays. To meet these stringent standards, and ensure the best possible quality while also achieving high productivity and process reliability, companies need end-to-end processes and quality control.

It begins with the inspection of the raw materials and accompanies the entire production process right through to the end product. When defects are detected during this process, connected inspection solutions ideally allow them to be precisely linked to their cause in the upstream production steps. This also enables the effects of process parameter changes on all further processes to be tracked and monitored.

Isra Vision offers a portfolio of optical inspection solutions for every step of display manufacturing. Thanks to the inspection data gathered, plant operators can continuously optimise their processes and can thus achieve optimum product quality, production stability and, ultimately, profitability.

As a result, they deliver flawless materials and products – and guarantee high customer satisfaction. Moreover, the deployment of fully automatic inspection systems in production plants ensures compliance with current and future quality standards, as required, for example, in the automotive industry. �

*Isra Vision, Darmstadt, Germany www.irsavision.com

� Pic 4. Deflectometric surface inspection of the end product .

www.glass-international.com

End product The final check is to ensure that the finished product looks perfect and is free of errors. This is still often performed as a manual cosmetic inspection – with all its disadvantages. Subjective judgment, the dependency of the inspection result on the person carrying out the test and the general limitation of the human ability to recognise minimal quality deviations are all flaws of this method.

This final inspection has a great influence on the profitability of production. When minimal defects are screened too strictly this reduces

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History

Prof. John Parker

Year of Glass update Alicia Durán* and John Parker** discuss the latest news of the International Year of Glass, 2022.

www.glass-international.com

I

n May 2021, the news was broadcast to the world through glass fibre links that the United Nations had endorsed 2022 as the International Year of Glass.

The application took 18+ months to prepare and included a 30 minute video clip, an electronic brochure and documents explaining how glassy materials played a vital role in supporting the humanitarian goals encompassed within the UN 2030 declarations, available at: www.iyog2022.org.

The preparation of the application and its subsequent administration have rested largely on the International Commission of Glass, especially the shoulders of Prof Alicia Duran (Spain).

The Spanish Ambassador, a colleague of Prof Duran helped to steer the UN application through its various stages. Crucially we were joined by the Community of Glass Associations and the International Committee for Museums and Collections of Glass (ICOM).

Our web site generated almost 2000 letters of endorsement from 81 countries, many in time for submission with the documentation.

Numerous hurdles were overcome en route, not least the Covid Pandemic.

Although preparation time is short, social isolation has left a thirst for the events being planned. Foremost is the Opening Ceremony in Geneva, 9-11th February.

30 internationally recognised speakers are primed to explain the role glass has in supporting UN 2030 goals.

Audience numbers are limited by Covid restrictions so talks will be live-streamed to make them widely available.

A book released during the event will complement the talks. Invitations are out to sponsor aspects of the Opening Ceremony and offers are already arriving (see iyog2022.org).

The ICG Triennial Congress in Berlin in July while celebrating DGG’s centenary will also be part of the IYOG programme; the closing ceremony will be in Japan.

Several trade fairs will showcase glass and its vital role in society including VITRUM, Milan, October, 2021, Glasspex/ Glasspro in Mumbai, March, 2022; the China International Glass Industrial Technical Exhibition, Shanghai, 13th16th April; Glassman, in Monterrey, 11th12th May; Mir Stekla in Moscow, 6th-9th June; & glasstec, Düsseldorf, 20th-23rd September, 2022.

Also agreed are: a) an event in April/ May celebrating the discovery of ancient Egyptian glass in King Tutankhamun’s Tomb, ’From Pharaohs to High Tech Glass in Egypt’, April-May 2022, b) a US Glass Day in Washington DC, June 2022; c) an ‘Iberoamerican International Congress on Women in Glass: ‘Artists and Scientists’ in Madrid, d) an International Festival of Art, Stourbridge, August, e) an event in Venice, September, f) dedicated issues of several glass Journals and other activities.

To coordinate and publicise events, various committees have been created although the final effort will rest on the shoulders of local organisers.

These committees include a) an overarching Steering Committee, and b) a council of representatives from the various regional committees representing countries that have endorsed the proposal (now 81). Local regional committees united by geography and language will be responsible for organising and publicising their programmes and are expected to offer activities promoting glass.

For example, the Indian community has already launched a photographic competition for younger people with the remit to capture aspects of glass in everyday society.

Others are planning legacy projects that leave a permanent mark, museum displays, You Tube clips, Art Gallery exhibitions, special issues of stamps, factory open days, floodlit archaeological sites, books, conferences.

The core committees will promote educational programmes and create a

worldwide network to share best practice and imaginative teaching materials at all levels. ICG schools in France and China will be themed around the UN 2030 goals. Museums and Art institutions are coordinating numerous events displaying and extolling the virtues of glass, its uses and value from Art through Architecture to Science and Technologies over millennia. Another aspiration is gender balance throughout.

There is no intention to organise events centrally – after all, there will be perhaps 10,000 activities. The central organisation offers access to the IYOG logo and a network of contacts to help share ideas and distribute prepared materials: posters, display boards, articles, comics, You Tube clips and so on.

So, we hope that you, our readers will be inspired to grasp the opportunity and promote all aspects of glass production, the sweep of its history, its contributions to the arts, its imaginative use in architecture, its recyclability, and its many roles in ensuring our well-being, both in poor and rich communities.

Your input in organising events and supporting activities both in person and perhaps financially too, will help to ensure a memorable event for the whole of society.

Follow us on our web site. It includes a donations tool, contact points, sponsorship information and ultimately a database where activities can be uploaded for all to discover.

Do take every opportunity to let your colleagues and friends know what is happening, open your doors, give talks, speak to your local press, radio and TV services and use social media to broadcast the news. �

*President, International year of Glass www.iyog2022.org **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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British Glass Awards

Winners revealed for annual Glass Focus awards The British Glass Focus awards celebrated the achievements of the UK glass manufacturing sector over the past 12 months. Jess Mills attended.

B

usinesses from across the glass supply chain came together to celebrate the many achievements of the industry over the last 12 months.

For the second year in a row Encirc were crowned Company of the Year and also took home the Innovative Solution and Strengthening Business Through People awards while Saint-Gobain Glass won three awards including Rising Star, Health and Safety Action and Sustainable Practice alongside Morley Glass & Glazing.

British Glass CEO Dave Dalton said: “It’s no secret that our industry has faced, and is still going through, some difficult times over the last year which makes it all the more special to be able to welcome everybody back to the Glass Focus Awards to celebrate what we have all achieved together in person.

“We have seen some truly remarkable entries this year, from the incredible innovations that allow our industry to continually evolve and the sustainable

actions that drive us forward to our goal of reaching net zero carbon emissions, to the beautiful designs that adorn our buildings and bottles, the unrivalled talent of our workforce and everything in between.

“It’s been a pleasure to welcome everybody back to the awards; we are all extremely proud of the achievements of our industry over the last year and we look forward to building on these in the coming year and beyond.”

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British Glass Awards

COMPANY OF THE YEAR: ENCIRC

British Glass CEO Dave Dalton said the award was of particular status for companies that have given, not just a tremendous contribution to the UK glass industry, but played their part in helping British Glass too, such as attending events and applying support to industry and the various committees as well as being a part of its lobby process.

In presenting the award he commented on Encirc’s dedication to industry, particularly its actions for change, the environment and energy switching.

Mr Dalton further said Encirc had championed diversity, health & safety and mental wellbeing for its employees, and played its part for British Glass this past year.

Ardagh Glass was also commended for attending the vast majority of predictors and groups that British Glass had organised over the year, as well as its support of the industry.

Pilkington was similarly praised for supporting British Glass in its negotiations with the government on energy policy.

Pilkington’s demonstration of hydrogen in one of its furnaces was considered to be pivotal to the company’s nomination, due to the positive environmental impact it could have in the glass industry.

Mr Dalton also highlighted Aradgh’s ‘furnace of the future’ as the project for which the company had received its nomination, describing it as a ‘great contribution to glass manufacturing’.

Continued>>

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Encirc was the overall winner for its environmental work and wellbeing agenda, whilst Ardagh Glass and Pilkington NSG were highly commended for their commitments to sustainability.

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DESIGN OF THE YEAR CONTAINER: ALLIED GLASS The Portman Group's recent survey evidenced that two-thirds of Brits who were drinking alcohol before, are drinking the same, less or stopped drinking altogether.

This behaviour does not look set to slow down and offers a sustained opportunity for manufacturers within the category to launch new and innovative products.

CleanCo, has capitalised on this trend, creating a range of non-alcoholic premium beverages, using traditional distillation processes, to produce sophisticated grownup drinks. To compliment these beverages, they have launched an elegant bespoke glass bottle, adding to the drinking experience while giving the brand an on-shelf presence when gracing any bar or supermarket shelf.

Previously packaged in a standard bottle, this proprietary bottle’s design brings out the brand's premium credentials, so therefore better complimenting the liquid inside.

The Art Deco design directly references the 1930's cocktail era but also American prohibition. The perfect combination of glamour and abstinence and a nod to CleanTs mocktail potential. Famous Art Deco buildings like the Chrysler building inspired the shape of the bottle, the style evoking delicate design, expensive materials and elaborate details, the perfect match for CleanT. As ever, the devil is in the detail which is created by manufacturing excellence, the clean lines, and sleek geometric stylised forms

being complemented by the raised punt.

The bottle is highly tactile thanks to the perfect emboss yet designed for easy handling by bartenders and consumers alike. A sustainability benchmark, the bottle is made with a staggering 81% recycled content, before being decorated using sustainable inks and sprays. An exciting piece of sustainable glass packaging, which sets a benchmark in an exciting and innovative category.

DESIGN OF THE YEAR - FLAT:

Applied directly on glass using standard glass coating equipment, Ubiquitous Energy’s coating is highly transparent and colour neutral.

The transparent solar coating selectively absorbs and converts non-visible light (ultraviolet and infrared) to electricity while maintaining visible transparency. It also functions as a low-E and solar control coating in addition to its electricity generation by blocking infrared light that is commonly known as solar heat. The transparent solar coating can be applied to vertical surfaces of buildings turning traditional windows into aesthetically pleasing, highly energy efficient, and electricity generating windows that are desired by architects, designers, and occupants.

THE GLASS

www.glass-international.com

COMPANY

Continued>>

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SIGN UP TODAY TO RECEIVE YOUR FREE COPY Furnaces International brings readers a selection of technical features focusing on all aspects of the international furnaces market, as well as industry news, investments, and the latest products and projects Published quarterly in a digital format, Furnaces International and the new monthly newsletter, are sent to the inbox of over 25,000 industry professionals.

As publishers of Aluminium International Today, Steel Times International and Glass International, we are able to compile this knowledge and bring you the latest developments on: • Energy Efficiency • Hot Repairs

• Maintenance • Heat Treatment

• Thermal Processes • Testing and Measurement

Look out for the December issue which contains The Furnaces International Buyers’ Guide. It is the essential guide to furnace manufacturers and suppliers of furnace equipment and services to the industrial heating/process industry.

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Event review: Glass Focus Awards 2021

HEALTH AND SAFETY IN ACTION: SAINT-GOBAIN GLASS

Saint-Gobain Glass identified the potential need for on-site Automated External Defibrillator’s (AEDs) several years ago particularly noting the aging population of its workforce.

It recognised that due to the size of its facility, one unit would be inadequate, therefore it purchased six units which were distributed across the factory. Several training events

were organised where everyone on site was encouraged to attend with the objective of showing people that anybody can use the units. You do not have to be medically trained.

On the morning of the 18th August 2021, unfortunately one of the team collapsed on the shopfloor.

The nearest person to him was Jonathan Longley, a Float Line operator who started CPR. He called to one of his colleagues to get an AED, which was brought to him immediately. By this time, Pete Taylor another Float Line operator, had joined Jonathan and between them they administrated CPR and deployed the AED unit which gave the needed shock to the stricken person.

Seeing a fellow colleague in such a condition was horrendous. However, both Pete and Jonathan stayed completely calm and focussed, providing fantastic first aid support which brought the individual back to life.

Two Emergency Road Ambulances and the Yorkshire Air Ambulance attended the site, where the lead person in the team said if the colleagues had not correctly administrated CPR and used the AED, the person would had suffered severe cardiac arrest and would not have survived.

The person is now recovering well and successfully made it to his daughter’s recent wedding.

www.glass-international.com

MARKETING IMPACT: ARMSTRONG GROUP To celebrate five key milestones over the course of 2020, Encirc enlisted Armstrong help to create a bold and inspiring campaign to support virtual customer events. Powerful messages and stylish imagery gave Game Changers the gravitas to cut through the noise with ground-breaking claims and Encirc’s ambitious plans for the future. Reported to be the best campaign Encirc had ever run, Game Changers attracted serious interest from some of the world’s highest profile brand owners.

The first presentation secured contracts with leading beverage brands, followed by adaptations of the campaign for future presentations.

With many positive comments and potential partnerships, Encirc’s sales are expected to grow by 7% as new contracts are put in place.

As a result, Encirc has requested Armstrong’s help again to create a variety of campaigns and presentations, including updating the history of the Vidrala Group, a video on

Encirc’s commitment to decarbonising the industry and a 3D animation focusing on an innovative digital deposit return scheme that Encirc will be putting forward to the UK government.

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British Glass Awards

INNOVATIVE SOLUTION: ENCIRC

of these products. The project formed part of the Department for Business, Energy and Industrial Strategy (BEIS) Energy Innovation Programme, within which Glass Futures is leading a £7.1m project to help determine the most effective route to switch the glass sector to low carbon fuels. As expected, glass customers – some of the biggest names in the industry – were quick to take advantage of the trial, ordering millions of the new ultralow-carbon containers. For Diageo, the trial produced 173,000 Black & White bottles, making the batch the most environmentallyfriendly bottles ever produced for a Scotch whisky brand. John Aird, Senior Packaging Technologist at Diageo, said: “This trial is just a first step in the journey to decarbonise this aspect of our supply chain and we still have a long way to go, but we are delighted with the results of the collaboration and the platform it creates for future innovation.”

Aston Fuller, General Manager of Glass Futures, added: “The trial is delivering fantastic results for the manufacturer, end user and consumer. Through this trial with Encirc, we are seeing the dawn of Net-Zero technologies with this full-scale trial of a new alternative low-carbon fuel.” Carlsberg ordered one million of the new bottles for

its Danish pilsner. The trial had “huge potential” said senior procurement manager, Sam Brakes. “We’re proud to be working with pioneers in the industry, contributing to the development of a low-carbon future.” 1.4 million bottles of Heineken are also destined for UK supermarket shelves. Matt Callan, brewing and operations director, Heineken UK, said: “The trial is a huge step forward in finding a scalable solution to reducing carbon from glass manufacturing.”

This year, Encirc conducted a groundbreaking trial to create the world’s most sustainable glass bottle, sending shockwaves across the packaging and beverages worlds.

The company worked with industry research and technology organisation, Glass Futures, to not only prove that glass containers could be created using only the power of biofuel, but also by using up to 100% recycled cullet. It is thought that this world-first initiative will pave the way for an industry-wide reduction in carbon emissions, as the glass sector moves away from fossil fuels, and towards lowcarbon alternatives like biofuel and green hydrogen.

Continued>>

www.glass-international.com

During the height of the COVID-19 pandemic, Encirc had an aspirational mission to create the world’s most sustainable glass bottle using biofuel. This project was undertaken alongside industry research and technology organisation, Glass Futures, and technology partner Siemens. The trial would be the first example of a glass container being created purely through the power generated by ultra-low-carbon biofuel, while using up to 100% recycled glass. By employing the use of computer modelling, continual laboratory analysis, and ongoing consultation with Glass Futures prior to the trial, the researchers ensured that the execution would go without a hitch. The existing fueldelivery and combustion technology at Encirc required minimal modification to allow for a successful trial; just a few off-the-shelf upgrades and careful tuning of operating parameters. Made out of waste organic materials, biofuels are a renewable and much more sustainable fuel source than those traditionally used by the glass sector, and can reduce the carbon footprint of each bottle by up to 90%. By using up to 100% recycled glass to create the new bottles, the trial, which announced success in Q1 2021, was able to even further minimise the lifetime impact

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RISING STAR: WILL RUANE, SAINT-GOBAIN GLASS Will Ruane, 26, joined Saint-Gobain Glass with a First Class Honours degree in Accounting and Business Economics from the University of Hull. Having undertaken an internship in Finance, Will decided that he would like to apply his mathematical and analytical skills to the production environment, and with the support of the senior leadership team, we put together a comprehensive training programme to support his development towards his target of Float Line senior management. Will’s training programme has focused on hands-on learning of core foundation skills, to help him become the complete glass manufacturing manager of the future. The highlights of his training programme include: Health and Safety – a six-month experience as a Health and Safety assistant, learning key principles and systems and supporting the sharing of safety best practice on site. Following this intensive introduction to Health and Safety, Will played a lead role in producing the SaintGobain Glass Covid-19 protocols during the

pandemic. Production Planning – six months learning production scheduling, developing his appreciation of customers, their needs, and the importance of delivering to plan.

During this time Will also became a member of the Customer Focus and Service Pillar, learning about Continuous Improvement and delivering improvement projects in warehouse and dispatch areas. By the end of the period, Will was able to fully undertake the role of site Production Planner. Production Assistant – Laminating Line – 12 months’ hands-on experience learning the day-today running of the smallest production line and gaining first-hand experience of people management. During this time, Will also undertook a Level 3 First Line Management apprenticeship, gaining a Distinction grade, and underpinning his practical experience with formal people management tools and techniques.

By the end of this period Will was able to run the line independently in the absence of the department manager. Production Assistant – Float Line – Will’s current role.

Will moved to the Float Line as Production Assistant in September 2019 and has spent the last two years learning the technical aspects of the Float production process, starting with the Batch area, moving on to the Furnace and then to the Float bath and Lehr. His training has been both practical, learning from experienced colleagues, and theoretical ones using Saint-Gobain’s library of technical knowledge and online learning modules. Learning has been underpinned with time working on shifts, to develop his understanding of shift-based operating teams, and their tasks and routines.

Due to his excellent performance to date, Will achieved his career highlight by being selected by the global technical team for the critical role of ‘Reporter’ for the recent Furnace repair, a role usually given to someone with much more experience. This role involved the taking and analysis of critical process parameter measurements on a daily basis, daily technical reporting to the senior international team, acting as the key liaison between local and international resources and responsibility for writing the final highly detailed technical report on the whole project, putting into practice both his technical learning and his academic background. Appointing Will to this vital role demonstrates not only his own excellent development and fantastic work ethic, but also confidence in his abilities and his capacity to learn and develop.

Paul Wilson, Saint-Gobain’s Industrial Director and Louise Maloigne, HR Director, accepted the award on Will’s behalf (above).

www.glass-international.com

STRENGTHENING BUSINESS THROUGH PEOPLE: ENCIRC

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SUSTAINABLE PRACTICE:

AND MORLEY GLAZING

Buildings contribute considerably to global waste production and they consume significant natural resources for their construction. For these reasons, SaintGobain Glass is committed to play a leading role in creating sustainable buildings and introducing circular economy principles into its product streams and activities. One way that it strives to minimise the environmental impacts of its activities is to include more recycled content in its glass.

One issue has been how to return more postconsumer glass (glass from old windows) to its factory. It currently operates the UK's largest cullet return scheme and since the introduction of cullet use in the manufacture of float glass, has been able to increase the amount of recycled glass utilised to over 40%. The aim is to increase this to 50% by 2025. The cullet scheme recycles in excess of 60,000 tonnes of glass annually, which has

Ignite was developed in response to the growing need of talent in glass manufacturing and how new technology and sustainability will continue to create additional opportunities and challenges for glass producers’ and the foundation industries.

Ignite is Encirc’s early careers initiative, the name echoes the heat, fire and temperature of its furnaces.

led to a reduction of NOX emissions and raw material usage.. Float, coated and mirrored glass can all be recycled, representing a major benefit for customers and the environment.

far recycled 646 tonnes of glass cullet, and each tonne saves enough energy to power the average home for six months (284 energy years saved per household).

It has developed end-of-life glass processing machines to automate the process of recovery.

One of these machines has been installed at Morley’s factory in Leeds, which enables them to crush and recycle glass from old windows and doors from their customer network and from window installers in the area.

It also prevents 300kg of CO2 going into the atmosphere per tonne. On top of that, the recycling of the glass has saved 532,729kg of virgin sand from being used in the manufacturing process of new glass (as of 01/09/2021).

The cullet is returned in bulk to Saint-Gobain to manufacture new glass energy efficiently in its glass furnace. All the money the company receives for the cullet is put into a newly formed GreenVision Fund, which is available in grants of up to £500 to local schools and charities to help fund environmental projects such as sensory gardens, wildlife habitats and allotments. So far the fund has reached £30,000 and it will continue to grow as more waste glass is recycled. It is therefore an ongoing sustainable fund for the local community wishing to create sustainable projects and environments in the long term.

Most importantly perhaps, this initiative saves post-consumer glass going to landfill, which would otherwise be there indefinitely.

The fund will continue to be available as long as glass is recycled. As a result of the success, Saint-Gobaint is about to install a larger, more automated machine to replace the original CRUSH machine and the GreenVision Fund will continue to grow and be made available to good causes.

The CRUSH scheme, as it is called, has so

This initiative supports the company’s commitment to the closed-loop processing of end-of-life materials and objective to use 50% cullet in the manufacture of its glass by 2025 (currently 40%), and support the group’s objective of achieving net zero by 2050.

The Ignite programme specifically looks at the recruitment and development of apprentices, promoting diversity, and offering placements, and graduate opportunities within the business.

The Ignite programme has demonstrated success since its launch with three apprentices either going into full time roles including Fitters and IS Operators or moving into further or higher-level education programmes funded

by the Ignite programme. Over the last three years more than £100,000 has been invested in the recruitment and training of graduates and apprentices in areas such as mechanical and electrical engineering, HSE, Glass Design Engineering, Process Data Engineering, Quality and HR. By the end of 2021 around 20 employees are expected to take part in the Ignite programme across the business.

www.glass-international.com

SAINT-GOBAIN GLASS

57 Glass International November 2021

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LIGHTENING THE IMPACT OF HEAVY INDUSTRY

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11-12 MAY

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Explore our strong connection: sustainablemelting.sorg.de