Glass International October 2017

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October 2017—Vol.40 No.9

PROFILE: ZHAOQING TONGCHAN CONTAINER GLASSMAKER INDUSTRY 4.0 CONFERENCE REVIEW DECORATION I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International October 2017

Our fresh breeze for all types of glass production Float Glass

Fibre Glass Tableware Container Glass

Thin Glass

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“see us at Glassman Bangkok and Glassman Mexico”

TWO PIN LASER HEADED CONVEYOR CHAIN

Contents

October 2017 Vol.40 No.9

2 Editor’s Comment

WWW.GLASS-INTERNATIONAL.COM

5 International news

October 2017—Vol.40 No.9

12

PROFILE ZHAOQING TONGCHAN INDUSTRY 4.0 REVIEW BATCH PLANT I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International October 2017

Our fresh breeze for all types of glass production

17

Float Glass

Lubrication 17 Socabelec: SGD Kipfenberg and Ardagh benefit

from swabbing robot.

Events review 21 Glassman Europe: All set for the digital area.

26 Company profile

Ramsey Products: Silent chain speaks volume.

Fibre Glass Tableware Container Glass

Thin Glass

EME GmbH · E-Mail: contact@eme.de · www.eme.de

Front cover image www.eme.de

Company profile Zhaoqing Tongchan: Investments boosts Zhaoqing Tongchan’s market profile.

21

Spirits Packaging Summit: 29 O-I to speak at summit

History 30 The importance of the ICG

32

Furnaces BV Glas: A vision for 2050: an 81% reduction in glass furnace energy.

Furnaces 35 Simullex: Making better use of electric boosting in

glass furnaces.

40

Decoration 44 Fermac:

Fermac celebrates successful Satimat

installation in France

Events review 46 World Soda Ash conference: What effect will new Turkish soda ash

capacity have on global glass industry?

Plus find us on Linked-In and Twitter.

@Glass_Int

www.glass-international.com

Decoration 42 KBA-Kammann:

KBA-Kammann delivers 200th machine

to Pepper Décor

42

Batch house 49 Forglass:

Batch house technological assistant

www.glass-international.com

26

Coatings Stewart Engineers: Value-added coatings can save struggling glass manufacturers.

1

Glass International October 2017

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Editor’s comment

Greg Morris

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

Buildings and structures to inspire a new generation

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I

t was an absolute pleasure to see so many members of the glass industry in my home country of England recently.

Industry leaders travelled from all around the globe to attend the Phoenix Award banquet in celebration of this year’s recipient of its ‘Glass Person of the Year’ award, James O’Callaghan.

People travelled from afar – from the USA, China, Thailand and from mainland Europe – to be at the black-tie event in London, UK. The organisation of the event was impeccable and is a worthy meeting of the glass industry calendar. It was great to chat to people from around the globe in the shadow of the Houses of Parliament and Big Ben. Everyone of the people involved in the organisation deserves a pat on the back.

They did the industry proud!

The award’s recipient was a worthy winner. Successive governments and the private sector have concentrated on the service industry to boost the UK’s economy in recent years, which has meant a decline in manufacturing and less focus on heavy industry.

It has subsequently meant a reduction of young talent that wants to work in materials and manufacturing.

But Mr O’Callaghan has helped put glass back on the map, thanks to a

successful design partnership with one of the world’s largest companies, Apple.

The engineering agency that he coformed, Eckersley O’Callaghan, has been responsible for designing Apple’s buildings and stores, some of which are the most iconic of this century.

From New York, Turkey, Japan and elsewhere, Apple’s glass buildings always catch the eye. Mr O’Callaghan deserves praise for helping make glass more attractive to a new generation. Hopefully it will stimulate renewed interest in the material’s uses and applications.

Mr O’Callaghan’s interest in glass was sparked 20 years ago by studying the then little known application of glass as a load-bearing structure. Maybe people admiring these buildings will discover a similarly unknown use of glass?

Here’s hoping that the next generation of engineers will be inspired by the structures and decide to forge a career in the industry.

Previous recipients of the Phoenix Award have been righly recognised for their work in springing the sector forward and Mr O’Callaghan is no exception. The recipient of the Phoenix Award 2018 will have some big shoes to fill. � Greg Morris, Editor gregmorris@quartzltd.com

Directory 2017 Annual international reference source

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Glass International October 2017

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International News

NEWS IN BRIEF

A batch plant for float glass was successfully put into operation at KBI Thailand by Germany’s Zippe .

The float plant at Kabinburi, Thailand was successfully commissioned at the beginning of September.

KBI Thailand is a subsidiary of Thai container glass manufacturer Bangkok Glass, which has extended its product scope into float glass.

Zippe has previously supplied container and cullet

glass plants for Bangkok Glass.

“For this reason we are especially pleased that the float glass subsidiary KBI counts on Zippe technology for batch recycling as well as cullet return,” said Zippe Industrieanlagen Project Manager, Heiko Brand.

At the beginning of September, the plant was commissioned according to schedule without complications. The plant is designed for a daily capacity of 600 tons per day.

The weighing of raw materials is effected by seven container scales. Two high performance pan mixers with 3000 litres are implemented as mixers, which guarantee ideal batch homogeneity.

Cullet addition is effected continuously after the mixing process by three belt scales to enable an ideal batch/cullet sandwich. Zippe said it wished KBI a successful production with the modern float plant.

Mexico’s IVC orders Vertech SIL system on seven production lines Mexico’s Industria Vidriera de Coahuila (IVC) has placed an order for a Vertech’ SIL system on seven production lines.

The system will be installed on four production lines on its furnace number 3 and three lines from furnace 4. Both furnaces’ decoration lines and mould shops will also be installed with the SIL system.

The IVC plant in Nava, Coahuila, Mexico is a joint venture between O-I and Constellation Brands.

The order was placed in the middle of December 2016 after the successful installation of SIL on the six lines of furnaces 1 and 2.

With several improvements specifically developed for the

plant throughout the year, the SIL version is set to improve plant operations for the demanding expectations of the market.

Vertech’s presence in Latin America has been growing recently as the region, prolific in the production of glass containers, continues to supply the market with products.

Saverglass sets Mexican date Construction of Saverglass’s container glass facility in Mexico is making rapid progress.

The French company has invested €100 million in the new container glass facility, about 40km from Guadalajara.

The commissioning date

has been fixed for June 2, 2018 and aims to produce 80 million bottles a year.

The unit will produce bottles for tequila, wine and rum and produce bottles in a variety of colours.

The group will focus on

three markets: American wines, tequila and the rum market in the Caribbean and Central America.

600 pillars have been sunk into the ground for production, composition and storage buildings at the 25-hectare site.

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Ardagh Chief Executive Ian Curley, has resigned and will leave at the end of the year.

Current Executive Chairman, Paul Coulson, will become Chairman and Chief Executive. Ardagh has appointed Johan Gorter as Chief Executive of its global glass business.

Mr Gorter currently heads up the European glass business and is an Ardagh director. He has been with Ardagh for 10 ten years.

“Johan has played a key role in the successful development of our glass business in Europe,” the company said.

Owens Corning to expand capacity

Owens Corning plans to invest $50 million to rebuild a glass melter and expand production capacity by 25% at its Chambéry, France, composites manufacturing facility.

The investment will support the growing demand for thermoplastics in Europe.

The melter is expected to be operational by mid-2018.

After the rebuild, all thermoplastic chopped strand products from the Chambéry facility will be based on boronfree Advantex glass.

BDF Industries exports machinery to Guatemala

Italy’s BDF Industries has recently exported its glass forming equipment to Grupo Vical’s plant in Guatemala.

Thanks to the insurance support of SACE, the Vicenzabased company has sold its machinery in Central America with protection against default risk The operation with SACE, has enabled the company to offer its Guatemalan customer payment conditions while insuring €2.4 million against default due to commercial and political reasons.

“Being able to offer our customers convenient payment conditions makes our commercial offering more competitive,” said BDFs Andrea De Corinti.

www.glass-international.com

Zippe installs batch plant at Bangkok Glass float line

Ardagh CEO quits

5 Glass International October 2017

news oct.indd 3

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Augmented Reality brings Encirc Designs to Life Introducing the Cleanfire® ThruPorte™ burner A prescription for aging regenerators Undergoing regenerator repairs or having difficulty maintaining full production in an aging furnace? Turn to Air Products’ new Cleanfire® ThruPorte Oxy-fuel burner for an onthe-fly heating solution to avoid downtime or extend your furnace campaign. This patented

UK container glass manufacturer Encirc has launched an augmented reality (AR) offering for customers which uses technology to bring glass container designs to life.

The service means Encirc customers can view their glass packaging design concepts in real-world settings as well as move and amend them quickly.

The AR technology service superimposes a com-

puter-generated design onto a customer’s point of view via an iOS app on a tablet or smartphone.

When compared to the typical method of 3D printing prototypes, this digitisation of the design process increases the efficiency and speed at which Encirc’s customers’ products come to market.

The new AR offering will build on Encirc’s current design options which al-

ready allow customers to create innovative and effective containers through the use of Computer Aided Design (CAD) technology.

Combined, Encirc’s CAD and AR services will ensure the technical quality of the product is optimised, while the aesthetics still meet the desired requirements.

Pictured: Rob Coates, Product and Graphic Designer, Encirc.

and commercially-proven technology, installed from the underside of your port, allows you to add heat where and when its needed.

Key features: • Tandem water-cooled oxy-fuel burner and oxygen staging lance • Proven durable design that can be easily installed in an existing port, while the furnace is running • Adjustable flame length and angle for optimal heat distribution and surface coverage • Remote, wireless and continuous online monitoring of burner performance • Available for rapid deployment To make glass better, put Air Products in the mix.

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Horn and Zippe commit to Glassman in Thailand event German glass engineering companies Horn and Zippe have signed up to exhibit at the Glassman Asia event.

Both companies have secured booths at the combined exhibition and conference, which takes place in Bangkok, Thailand on January 24 and 25th.

Zippe specialises in the construction or modernisation of batch and cullet plants for the international glass industry. It recently installed a batch plant for the KBI Thailand float glass project in Kabinburi.

Horn Glass is a specialist in the design and supply

of complete glass melting technology.

It has more than 130 years experience in the design, manufacture and supply of different furnace types for production of lighting ware, tableware, containers, cast glass, float glass, solar glass and technical glassware.

Other companies who have also confirmed their participation include Italy’s All Glass and Emmeti from Italy, FIC UK, and Reckmann of Germany.

The Glasman Asia exhibition and conference takes place at the Bitec exhibition centre, Bangkok,

Thailand between January 24 and 25, 2018.

It will also include a free to attend conference titled the Future Glass Forum, which will investigate digital glassmaking and the rise of Industry 4.0 in container glassmaking.

Several speakers have confirmed their participation at the event, including Xpar Vision, Iris Inspection machines, cm.project.ing, Glass Service of the Czech Republic and Eurotherm by Schneider Electric.

The event website is w w w. g l a s s m a n e ve n t s . com/asia/

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Glass is our Passion

International News

Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1 O-I to close Envigado plant and build new furnace in Colombia � 2 Saverglass’s Mexican facility sets commissioning date � 3 Industry leaders attend Glassman Europe � 4 Verallia’s celebrates €12 million Cognac investment � 5 Delegates hail successful Glass Service furnace seminar � 6 Gerresheimer appoints new CEO � 7 Glass packaging production grows 2.9% � 8 Glassman Europe conference papers now online � 9 Heye innovations benefit Taiwan Glass � 10 Horn and Zippe commit to Glassman Asia

Encirc to invest £50 million in furnaces at Derrylin plant Encirc plans to invest £50 million to upgrade its Derrylin, UK plant and rebuild its furnaces.

The furnaces will be rebuilt n 2019 and 2021 to accept natural gas which will be piped to Derrylin in a scheme called the Gas to the West initiative, reports the Impartial Reporter.

The £250 million gas project will see the construction of approximately 200km of

pipeline linking Coalisland, Cookstown, Derrylin, Dungannon, Enniskillen, Magherafelt, Omagh and Strabane to the existing gas network.

“Bringing gas in will help environmentally, it will help with our emissions and it also takes three large road tankers [of oil] off the road per day.

But it means we will produce less glass because oil is more efficient at melting glass,” En-

circ Managing Director, Adrian Curry, said.

“The complication is that we have to design our furnaces differently. We’ve worked very closely with Arlene Foster and her team a number of years ago and more recently with the gas providers to get to a point where everyone is certain this is going to happen because it does influence heavily on the decisions we make,” he added.

GMIC and CGIF receive grants from O-I and Roman Manufacturing The Ceramic and Glass Industry Foundation (CGIF) and The Glass Manufacturing Industry Council (GMIC) in the USA have received a $20,000 grant from the Owens-Illinois (O-I) Charities Foundation.

The grant will be used to support CGIF outreach programmes and provide travel grants to college-age students.

GMIC also received a $1,000 grant from Roman Manufacturing to support the 78th Conference on Glass

Problems student travel grant programme. The CGIF will use $10,000 of the grant to support the Foundation’s programmes which introduce students to ceramic and glass science.

The remaining $11,000 will fund travel grants that will allow 32 college-age students to attend the 78th Conference on Glass Problems to be held November 6 - 9, 2017, at the Greater Columbus (Ohio) Convention Center.

“We are extremely grateful to the O-I Charities Foundation for this generous grant which will enable us to expand our outreach programmes,” said Marcus Fish, CGIF Director of Development.

“This grant demonstrates how everyone benefits when progressive organisations like the O-I Charities Foundation commit to investing in the future of their community,” said Robert Lipetz, GMIC’s Executive Director.

Stölzle website launch

Stölzle has launched a new website. Its site, www. stoelzle.com includes changes to the style layout for navigation, and has been technically adapted for mobile and desktop versions.

A video in the header of its home page – The Art of Making Glass – shows its passion to manufacture highend packaging glass.

It has also improved the structure of its content, so readers can enjoy a quicker read. Navigation includes sections for products, decoration, career and jobs, quality management, purchasing and logistics.

NGA and GANA combine?

The US glass associations look set to combine.

Both association boards have approved a proposal to merge and is likely to take place by the start of 2018.

Between now and then, the leadership will establish a joint integration working group to create a roadmap for the integration.

Glaston’s €3 million deal

Glaston has sold a GlastonAir glass tempering machine to China Triumph International Engineering Co. (CTIEC).

Delivery is planned to take place in mid-year 2018 and the deal is valued at €3 million. CTIEC has entered into projects in new glass, new materials and renewable energy.

“GlastonAir meets all our demands for high-quality thin tempered glass,” said Peng Shou, Chairman and Managing Director at CTIEC.

Vitro fire

A leaking furnace at Vitro’s flat glass site in South Middletown Township, Pennsylvania, USA caused a fire.

More than 40 firefighters and emergency services attended the blaze.

Despite the intensity of the fire, all staff were evacuated and accounted for with only one injury reported.

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

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Top 10 stories in the news

NEWS IN BRIEF

9 Glass International October 2017

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International News

NEWS IN BRIEF

Praxair votes to merge with Linde

Praxair’s shareholders have voted to approve the merger with Linde AG at Praxair’s special meeting of shareholders.

The approval is a milestone in the combination of the two companies in the global industrial gas industry under a new holding company named Linde plc.

The business combination is expected to be completed in the second half of 2018.

Nippon completes PPG deal

Japan’s Nippon Electric Glass has acquired PPG’s fibreglass facilities in the US. The sites are in Chester, South Carolina, and Lexington and Shelby, North Carolina; and research-and-development and administrative operations in Shelby and Harmar, Pennsylvania.

The business employs more than 1,000 people and had sales of about $350 million in 2016.

Ardagh’s Belgium bottle

Ardagh’s North America group has launched its 750ml Belgian Crown beer bottle.

It is available to buy on its BOB site (BuyOurBottles. com). The 750ml Belgian bottle with a crown finish is manufactured in amber glass that is endlessly recyclable.

“Ardagh Group continues to focus on expanding its portfolio for the craft beer market,” said John Orr, Vice President of Craft Beer Sales for Ardagh Group’s North American Glass division.

Peter Cas has become General Director of Slovenian hollow glass manufactuer Steklarna Hrastnik following a three month stint as Deputy General Director.

He decided to join Steklarna

Hrastnik due to its vision and strategic focus, which places employees in the centre.

With the aim of consolidating the company in the top-quality niche segment he will manage the company by

pursuing operational excellence, flexibility and customer-orientation.

He will continue to foster good relationships with employees and a responsible attitude to the environment.

Friends of Glass inspires millennials about recycling Friends of Glass teamed up with celebrity rapper and comedian Ben Bailey Smith (Doc Brown) and ex-Britain’s Got Talent contestants The Bottle Boys to create the campaign Endless Chorus.

The campaign was inspired by the findings of a new pan-European study by Friends of Glass in 11 EU countries revealing that young consumers have many positive perceptions of glass packaging, but many don’t fully un-

derstand all the environmental benefits that glass offers.

A video was made, in which patrons of a student bar are surprised by a talking wine bottle. Using hidden speakers, Doc Brown first introduces himself to patrons, and then sings a medley combining memorable tunes from many eras and improvised lyrics.

While the tunes are played through beer bottles by The Bottle Boys, Doc Brown croons about the bottle’s various life

cycles as a juice container, a jam jar and other roles.

To watch the video, go to https://youtu.be/gMREM7YwaUE Brook Hayes, communications manager at British Glass said: “As our research revealed, younger consumers are not fully aware that all glass packaging is a permanent natural resource that can be infinitely recycled without losing its quality.”

BDF completes Majan furnace rebuild

Curvink success

The BDF team has successfully carried out the rebuilding of Furnace 1 at Majan Glass.

With this operation, the Omani plant has concluded the first step regarding the improvement of its entire glass plant and process control.

The 45-day glass-to-glass

Schott expands US plant

Momignies furnace rebuild

Curvink of The Netherlands has sold two Till full colour UV inkjet printing lines, which can print 70 bottles per minute.

The lines will go into production in 2018.

www.glass-international.com

Slovenia’s Steklarna Hrastnik names General Director

Schott is to expand its delamination controlled vials manufacturing facility in Lebanon, PA, USA. The expansion will take place in early 2018.

Gerresheimer has completed the rebuild of one of its furnaces at its Momignies, Belgium plant The plant makes a diverse

period was met, with glass in line on 29 September, after a challenging job of deep cold repair, which was extended on full checker blocks replacement and complete forehearths change, control systems upgraded on the furnace and on the Batch Plant, where

range of glass for the perfumes, cosmetics and beauty sector and operates two furnaces. One of them is the only furnace in the group that

BDF was involved along with its Automation Division.

A C Class repair on one on the existing BDF lines completed the work scope after a successful C Class repair and NNPB process start up on another existing line.

produces opal glass and offers a full portfolio to Gerresheimer’s customers. Opal glass can be used for segments such as spirits, food and household.

10 Glass International October 2017

news oct.indd 6

17/10/2017 12:28:02

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GLASS SERVICE

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Company profile: Zhaoqing Tongchan

Investment boosts Zhaoqing Tongchan’s market profile Chinese container glassmaker Zhaoqing Tongchan supplies to global beverage brands such as Heineken and Carlsberg from its plant in Guangdong province.

It recently undertook a major investment at its site involving several European technology suppliers, such as Vertech, Horn, Heye, Iris, MSK, AGR and Antonini. Its Vice Plant Manager, Mr. Weng Jianzhong, discusses the company.

� The Vertech SIL system was installed by the Chinese con-

www.glass-international.com

tainer glassmaker during a recent major investment.

� The SIL system has a wide coverage of the production process and it fits the glassmaker’s actual needs.

What do you make and what is your most popular product?

As far as the equipment and production capacity of single plant is concerned, Zhaoqing Tongchan Glass Technology can rank in the top 10 of Chinese companies. We mainly produce middle end and high-end beer bottles with our main customers being Heineken, Carlsberg, Budweiser, Zhujiang and Qingdao.

Can you give a brief history of the company?

We are located in Jintao Industrial Zone of Jinli Town, Gaoyao District, Zhaoqing City, Guangdong Province. Zhaoqing Tongchan Glass Technology is a modern glass bottle producer, which is invested

by Shenzhen Tongchan Group with a total investment of RMB690 million ($103.5 million) and nearly 500 workers, belonging to the Shenzhen state-owned Assets Supervision & Administration Commission as a wholly state-owned company.

Continued>>

12 Glass International October 2017

Company profile Zhaoqing Tongchan.indd 1

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...but the world’s leading glass companies come to FIC to solve theirs

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e-glass ■ container glass ■ float glass ■ display glass ■ electric furnaces

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, The World s Number One in Furnace Technology FIC (UK) Limited, Long Rock Industrial Estate, Penzance, Cornwall TR20 8HX, United Kingdom GLASS SERVICE

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Company profile: Zhaoqing Tongchan

� The recent investment also included IS machines from Heye International.

� Opposite page: Zhaoqing Tongchan Glass Technology’s headquarters.

“Our strength is also in our glass manufacturing equipment, with whole lines of advanced equipment imported from

www.glass-international.com

our overseas

”

suppliers

How many furnaces do you have and what is your daily production capacity?

How would you describe the Chinese container glass market currently?

Right now we have one plant with two furnaces.

Our daily output is between 1.25-1.64 million bottles

The current Chinese container glass market is a buyer’s market experiencing disordered competition. The consumption of beer bottles is decreasing year by year and more recycled bottles and cans are being used. At the same time, there is an increasing need for glass packaging for the food industry, which compensates for the decreased requirement for glass products in the beer industry.

The strengthening of state environmental protection regulation is good news for competitive enterprises. With the combination of different factors, large production groups similar to the European market could appear in China.

What are the company’s strengths?

Technology strength with several independent intellectual property rights: a.

Furnace designing and modification; b.

Modification of equipment specific to the glass industry; c.

Batch composition; d.

Cullet processing; and e.

Circular economy technology Our strength is also in our glass manufacturing equipment, with whole lines of advanced equipment imported from our overseas suppliers.

We hired Horn Glass to design the furnace, forehearth and working end and to supervise the installation. We have 10-section triple gob IS machines and 10-section double gob IS machines from Heye International and an annealing lehr from Antonini. The inspection machines have been supplied by Iris Inspection Machines, multi-purpose inspection machines from Heye International on the line and inspection equipment from Agr International off the line.

A palletiser and a hot shrinking machine was supplied from Germany’s MSK. Our management system was certified to ISO9001 in June 2011, certified to ISO2200 in February 2013, certified to ISO1400 in January 2016 and we adhere to the implementation of lean management.

Who are your main customers geographically?

The main customers are located in Guangdong, Hainan, Yunnan, Jiangsu and Zhejiang provinces and also several Asian countries. About a quarter of our products are exported to overseas market including Indonesia, Thailand, Malaysia, Vietnam, Laos and Burma.

You recently installed Vertech’s SIL system on five of your lines. Why did you choose the SIL system?

With such a large investment in our company, we are not able to achieve profitability if we don’t produce medium-end and high-end products.

Therefore, we could only focus on production management to achieve effectiveness. Quality Control feedback through paperwork obviously cannot keep pace with the development of the company. It becomes the common idea that making use of the real production information plays an important role in influencing the output.

Naturally, the installation of an information system on the line became the common needs of the company, which is also one of the essential aspects for customer audit.

As a professional producer of information systems for the glass industry, Vertech’s development team are always seeking for perfection of the system to satisfy the customer’s needs. Vertech was the first choice for our company as the SIL system has a wide coverage of the production process and it fits our actual needs.

Continued>>

14 Glass International October 2017

Company profile Zhaoqing Tongchan.indd 2

12/10/2017 12:42:14

Company profile: Zhaoqing Tongchan

TEMPERING LINES on belt Opal - Borosilicate - Soda-lime glass

What benefits will the SIL system bring to your company?

With the increase of our staff’s profi ciency in the SIL system, we can reduce the losses caused by the fact that the cold end used to not be able to feedback the problems found in cold end to the hot end for a solution. Thus the time of corrective actions to be taken can be reduced, and we can achieve the target of improving the output percentage.

TABLEWARE Toughening Lines on spindles

Did any other investments take place at the plant at the same time?

We also took the opportunity of a cold repair of our furnace so hired Horn to redesign the furnace, forehearth and working end for us. And we also discussed the upgrade of our inspection machines with Iris Inspection.

How will the investment benefit your customers?

Seen from the management referred to in ISO9001, the investment in SIL could further perfect the traceability of our products, which is a very reliable tool for the customer to guarantee the quality of products.

RIM TEMPERING

What key qualities should your machinery and production equipment suppliers have in order for you to consider using them?

Facing the current market with cruel and disordered market competition, I personally think the machine and equipment should have the below key factors: 1. Closely fi t production needs; that are easy to learn and operate; 2. A high price-performance ratio: they should be able to bring visible economical benefi t to us and also help us reduce manpower; and a 3. High operation effi ciency: low failure rate and low maintenance cost.

How would you like to see the company evolve in the next five years?

As long as we can get rid of the predicament of this year and take full advantage of being a state-owned company we will grow bigger and stronger by combining the efforts of all the Tongchan people to take the opportunity to invest in the furnace #3. �

*Zhaoqing Tongchan Glass Technology, Guangdong, China Glass International October 2017

CHEMICAL TEMPERING • Annealing lehrs • Decorating Lehrs • Hot&Cold-end coating • Mold pre-heating kilns • Stackers • Scraper conveyors • Cullet crushers • Thermal shock test systems vidromecanica@vidromecanica.com www.vidromecanica.com

Company profile Zhaoqing Tongchan.indd 3

12/10/2017 12:42:21 2016 anuncio HALF PAGE TEMPERAS.indd 1

23/05/2016 17:33:15

Lubrication

SGD Kipfenberg and Ardagh benefit from swabbing robot Since installation of a Socabelec swabbing robot at SGD Kipfenberg and at Ardagh’s Moerdijk plant the two companies have reported improved productivity. Marco Veri* provides a case study of the installations and explains how the glassmakers achieved this.

� The SGD-K and Socabelec team involved in the project. From left to right: Raphaël Valli, Socabelec Engineering Manager; Marco Veri, Socabelec CEO; Luc Deffontaines – Technical Director (SGD Group); Reiner Becker – Technical Director (SGD Kipfenberg); Cyril Escure - Expert Hot End systems (SGD Group); Kevin Fiedler – Project Manager (SGD Kipfenberg); and Axel Neubauer – Deputy Production

P

harmaceutical glass manufacturer SGD Kipfenberg bought a Socabelec swabbing robot in April 2017. It was installed on July 3rd on an Bucher Emhart IS machine consisting of 10 sections triple gobs with 16 cycles/minutes driven by a FlexIS controller.

SGD Kipfenberg said it selected Socabelec’s swabbing-robot because: the robot is surrounded by a cage, which is safer for the operator, the construction is robust and it is of an industrial design, the positioning of the robot in front of a section is precise (less than 0.1mm)

and repetitive, so it can support external new devices for vision gob loading and temperature measurement.

Socabelec was born in 1965 and was well known for many years in the automotive flat glass industry. As an integrator of automation and robotics, it invented the swabbing robot on the fly. Its first patented swabbing robot on the fly was installed in December 2013 in Ardagh Glass’s Moerdijk plant in The Netherlands.

In combination with a swabbing oil dedicated to be sprayed by a swabbing

robot (formula patented), the glassmaker is able to run without any rejection of the product after swabbing.

The advantages of Socabelec’s swabbing robot are: 1) We are swabbing on the fly, which means we don’t stop production to swab, there are no gobs going to the cullet during spraying. We use less oil so that there is no reject of bottles after swabbing (depending of product and production).

Continued>>

www.glass-international.com

Manager (SGD Kipfenberg).

17 Glass International October 2017

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Lubrication

www.glass-international.com

� Machine before swabbing robot installation.

2) The production team can decide to swab more often, for example, every six minutes with less oil instead of every 30 minutes with a lot of oil. In this way if the temperature’s blanks are more stable then production is more stable.

3) Because we are swabbing blanks opened while the glass is transferring to the blow side, then there is no contamination of plunger.

4) We have a special programme when the operator wants to swab the finishing mould in the same time, if needed we are spraying the neck ring. In this case one gob is going to cullet.

5) We installed a new beam replacing the existing one with the push buttons panels. This beam will support the robot to leave full space free to access to the machine for operator.

6) Our robot is inside a safety cage totally protected against human contact so people can stay close even when the robot is swabbing.

7) The cage supporting the robot is robust and stable by construction.

� Machine after swabbing-robot installed 8) The travelling robot is controlled by a 7th robot axis, so the positioning, in front of sections, is accurate and repetitive.

9) There are several devices and sensors for safety purposes to prevent accidents with humans.

10) We can upgrade the equipment later, installing devices as temperature measurement, gob vision using camera sensors, to help people to improve production.

11) We use a waiting position for the robot outside the machine in a ‘cold’ area, where people can carry out maintenance, test spay, create a new model.

12) We use our own patent for swabbing, so no risk of conflict and complaints later.

13) Our robots have been installed in Ardagh’s Moerdijk’s plant in The Netherlands, which is one of the most demanding and efficient Ardagh plants, so the robot is proven. It is HMI developed and user oriented.

14) The Moerdijk plant increased productivity by 2% after installation.

15) Robot and specific oil increased the

live time of blanks compared to manual swabbing. In SGD Kipfenberg the live time has increased from 74 hours to 242 hours before changing moulds.

16) The swabbing robot can run in double, triple or quadruple gob , in NNPB or Blow-Blow processes for IS machines 4”1/4, 5” or 6”1/4, with angular or parallel blank opening.

The Socabelec robot installed in SGDKipfenberg on line 31 on the Emhart IS machine is swabbing 100% of the section.

It blanks every six minutes and the neck ring once per hour.

After six weeks of 24/7 production the oil consumption is less than 600 grams/24hours for a machine at 480 bottles per minute. Since the robot was started, SGD-Kipfenberg has been running without rejection after swabbing. �

*CEO, Socabelec, Ham-sur Sambre, Belgium. www.socabelec.com

18 Glass International October 2017

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Events review: Glassman Europe

All set for the digital era The global hollow and container glass industry met to discuss future trends at Glassman Europe in Lyon, France.

The Future Glass Forum conference devoted to Industry 4.0 in container glassmaking proved a popular seminar.

EME’s manager Control Engineering Department, Roger Knuttel, stated how the digital factory and plant-wide automation would be a base for Industry 4.0. He discussed the Virtual Factory and stated that Industry 4.0 comprises digital patterns and methods for displaying processes virtually.

These processes can be projected and simulated on a PC before they are implemented in the real world.

Xpar Vision CEO, Paul Schreuders, spoke about Container Glass Forming in 2020/2025 and the Dark Factory. He described the Dark Factory as a fully automated shop floor. This will bring lighter and stronger containers, produced with (almost) zero defects at higher speed and with minimal human dependency.

Day two opened with Calogero Agostino, Sales Account Melting & Automation, BDF Industries talking about Industry 4.0, the end of walled gardens as the basis for machines & equipment interactions.

This was followed by cm.project. ing’s Daniel Schippan discussing how the digital age can influence digital and simulated glass plant design.

Using virtual reality, it is possible to simulate building concepts, check easiness of equipment maintenance and check the correct position of valves and instruments.

Heye International’s Mark Ziegler talked about the Heye Smart Plant Solution, which is the company’s vision of a Smart Factory that integrates the latest Industry 4.0 technologies. Christian Megret, Business Leader Global Glass, Eurotherm - Schneider Electric, discussed how Industry 4.0 needs a pragmatic approach. He said the digital approach can lead to a better understanding of processes, improves quality and throughput, increases flexibility and increases attractiveness to potential new employees. It is also more energy effective and reduces carbon footprint. Marco Veri, CEO of Belgium’s Socabelec, discussed how the Swabbing Robot holds the keys to Industry 4.0. Glass will need to move from classic industry to Industry 4.0.

One area, swabbing and the lubrication of the blank moulds, had always been performed manually by operators.

Continued>>

www.glass-international.com

I

ndustry 4.0 and the digital era was the big talking point at a leading glass event recently.

Speakers from established technology suppliers such as Siemens, Xpar Vision, Glass Service and cm.project.ing discussed how digital manufacturing will effect the container glass industry.

They spoke at the inaugural Future Glass Forum, a free to attend conference held alongside the Glassman Europe exhibition in Lyon, France.

The 11 speakers over the two-day conference discussed how container glass manufacturers can embrace the digital era. Pascal Huguet, the keynote speaker from Siemens, gave a 30- minute discussion titled The advantages of digitalisation in the glass industry.

He described digitalisation as the next level of productivity for the glass industry, using computing power, new sensors, communication, cloud computing and simulation.

Erik Muijsenberg, Vice President at the Czech Republic’s Glass Service, described How the Industrial Revolution 4.0 will impact the glass industry. He described Industry 4.0 as a collective term for technologies and concepts of value chain organisation. Based on the technological concepts of cyber-physical systems, the Internet of Things, it facilitates the vision of the Smart Factory.

Cyber-physical systems monitor physical processes, create a virtual copy of the physical world and make decentralised decisions. Over the Internet of Things, cyber-physical systems communicate and cooperate with each other and humans in real time.

21 Glass International October 2017

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Events review: Glassman Europe � Paul Schreuders, CEO, Xpar Vision.

Socabelec’s swabbing robot had been installed at Ardagh’s Moerdijk plant in The Netherlands to remove manual swabbing, increase productivity and provide a short pay-back.

Since the installation, 95% of manual swabbing had been removed, productivity had increased 2% and pay back had been in less than one year. The company has now sold 12 robots around the world in 18 months.

� O-I Procurement and Logistics Leader for France and Spain, Sylvie Lemond.

www.glass-international.com

Trends Another free to attend conference also took place alongside the Future Glass Forum. This conference, titled Trends in Glassmaking, looked at today’s industry talking points.

The keynote speaker was O-I’s Sylvie Lemond, Procurement and Logistics Leader for France and Spain, who said the company was constantly innovating.

“Being a global company we have the advantage of being able to leverage ideas from all around the world. However, we cannot innovate in isolation. What we need is to work collaboratively.

Collaboration is key to obtain step changes. That’s why the discussions and presentations at this event are key to nourishing the thoughts and driving the intention to become smarter and to obtain step changes together.”

She added that by working collaboratively to demonstrate to young engineers, designers and marketers what a great industry the glass sector is.

“We need to get the message out that glass is the place to be, a great place to develop your career. There are many exciting challenges that require the best brains in engineering, technology, designs and marketing.”

Charles Richardson, Heineken’s Global Category Leader Glass-Packaging, described Heineken’s route to its greenest bottle and urged glassmakers to follow its example. A feature article on this appeared in the July/August 2017 issue of Glass International, page 14.

Etienne Gruyez, Managing Director of Stölzle Masnieres Parfumerie plant in northern France discussed the 200year-old-plant’s transformation in recent years. Again, an interview with Mr Gruyez appeared in the July/August 2017 issue of Glass International, page 28.

Barbara Macialczyk, Marketing Manager, Ardagh Glass spoke about how Ardagh innovates. Its innovation process

� Heineken’s Global Category Leader Glass-Pack-

� Etienne Gruyez, Managing Director, Stölzle

aging, Charles Richardson.

Masnières Parfumerie.

� Pascal Huguet, Siemens.

� Barbara Macialczyk, Marketing Manager, Ardagh Glass.

� Melanie Basset, Sales Manager, Vertech.

� Adeline Farrelly, Secretary General, FEVE.

Continued>>

22 Glass International October 2017

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Screen printing and full colour inkjet printing on glass bottles (from 5 until 500 bpm)

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Events review: Glassman Europe

is driven via a cross-functional team and its aim is to be perceived by customers as the market leader on innovation and an ideal partner for innovation projects.

Some of its recent innovations include a variety of Absolut Vodka bottles, such as Absolut Unique.

Pavel Bobosik, CEO of Russian container glassmaker Ekran based in Siberia, discussed the challenges and opportunities in the country’s container glass industry. While demand for glass containers has dropped since a peak in 2012, things are slowly beginning to improve.

The black market for vodka has been tackled, which should mean more legal production of vodka and glass bottles and in the beer market, there is less reliance on PET packaging.

Susan Hansen, analyst at Rabobank, discussed what packaging was ticking all the right boxes and the opportunities for container glass. She felt there was more innovation in other packaging industries and that plastic has met the demands of the convenience food culture.

Glass needs to innovate with items such as the selfie camera on plastic coke bottles, and possibly combine the innovation with new logistics solutions.

An extended article about this was published in the Dec/Jan 2017 Glass International, page 12.

FEVE Secretary General Adeline Farrelly discussed glass industry trends and stated there is plenty of innovation in the industry, citing the Friends of Glass campaign to encourage more interaction with glass. In the past three years more than 90 million young Europeans have read, shared and engaged about the benefits of glass packaging as part of the campaign.

Dr Nick Kirk, of the UK’s Glass Futures project discussed the proposed £20 million research centre in the UK, which will benefit the domestic and international glass industry. The centre will include a new 30 tonne furnace for flat and container-focused companies to conduct research on, rather than stopping their own production lines.

The final speaker was Richard van Breda, former Director, SABMiller, who asked Can Cullet ensure that Glass remains a key and relevant packaging medium? To ensure survival, glass needs to make itself more relevant and competitive in the mass market and cullet may well provide the solution. But the entire value chain needs to promote glass recycling.

� Marco Veri, CEO, Socabelec.

� Erik Muijsenberg of Glass Service discussed Industry 4.0 in container glassmaking.

� Roger Knüttel, Manager Control Engineering

� Richard van Breda, former Director, SABMiller

Department, EME.

and independent consultant.

24 Glass International October 2017

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Events review: Glassman Europe

The industry understands the benefits of using increased amounts of cullet but its use is globally relatively low. This paradox needs to be rectified if glass is going to remain an attractive packaging material, relevant to the demands of modern times and consumers.

Conference papers from both events are available to download for free from the Glassman Europe website (www. glassmanevents.com/europe). Click the Future Glass Forum and/or Conference buttons to download the presentation you require.

� Pavel Bobosik, Director, Ekran.

vice-president of Region Auvergne-Rhône-Alpes, to EME Managing Director, Jens Rosenthal.

� Mark Ziegler, Marketing Manager, Heye International.

� Calogero Agostino, Sales Account, Melting & Automation, BDF Industries.

� Dr Nick Kirk, Glass Futures.

� Susan Hansen, Rabobank’s Global Strategist Food&Agri Supply Chain .

Europe’s largest container glass manufacturers attended the Glassman Europe exhibition. Renowned container glass manufacturers such as O-I, Verallia, and Ardagh visited..

The European manufacturers were joined by visitors from glassmaking facilities from around the world such as Thailand’s Siam Glass, Nihon Yamamura Glass from Japan, Turkey’s Sisecam and Vical from Costa Rica.

Some of the job titles of the glassmakers in attendance included President’s, Purchasers, Technical Director, R&D Director, Managing Director and Technical Buyer.

Companies among the 831 visitors to the event included BA Glass from Portugal, Vidrala from Spain, Stölzle from sites across Europe, Wiegand-Glas from Germany, Steklarna Hrastnik of Slovenia, Anheuser-Busch InBEV from Belgium, Kuwait’s Gulf Glass Manufacturing, Bormioli Rocco of Italy and Gurallar Glass Packaging from Turkey. France was also represented by companies including Saverglass, Pochet du Courval, SGD, Danone Waters and Arc International.

Ken Clark, Glassman Sales Director said: “We have had good feedback from our exhibitors who have said it was a successful event. “We believe that this has been one of the best Glassman Europe’s in recent years thanks to the quality of visitors and the geographical reach of the visitors who attended.

“I’d like to thank all of the exhibitors, visitors, conference speakers and the Lyon regional government who have helped make this such a memorable event.”

The next Glassmans take place in Bangkok, Thailand on January 24 and 25 and in Guadalajara, Mexico on March 21 and 22, 2018. �

www.glassmanevents.com

www.glass-international.com

Exhibition

� Left: Iris Inspection Machines CEO, Jean Luc Logel (left) introduces Philippe Meuiner (centre),

25 Glass International October 2017

events review glassman.indd 4

17/10/2017 11:27:52

Company profile: Ramsey Products

Silent chain speaks volumes

Ramsey Products was recently granted a European patent on its Lifeguard conveying chain, which will lead to increased business. Glass International spoke to David Holcomb* to discuss the business.

www.glass-international.com

Can you tell me about the history of Ramsey Products?

Ramsey Products was founded in 1923 by Joseph H. Ramsey. At the time, Joseph was a recent graduate of Cornell. He got into a debate with some engineers who thought that the silent chain of the day was the best it could be. Joseph thought otherwise and set out to prove them wrong.

He designed and built a machine that would allow him to test the performance and capabilities of chain. He then spent the next year and a half testing all the chain he could find. With all those test results and a real idea of what made a chain good, Joseph proceeded to create a chain that could stand up to his ‘wear-out’ machine. When he achieved that, he got a patent on the chain and

started a company.

Today, Ramsey Products designs and manufactures silent chain for conveying and power transmission applications.

How many locations does Ramsey have around the world?

Ramsey has representatives and warehouses in North America, Asia, Europe and Africa. We have customers in more than 70 countries. Our customers often expect fast delivery of standard chains, so we stock thousands of feet of chain in warehouses all around the world to meet these expectations.

Continued>>

26 Glass International October 2017

Company interview Ramsey.indd 1

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No GL GOI St vem A N op be CO SS P G T la by r 6 N R O T un o F O ch ur -7 in ERE BLE HE of sui Co NC M ou te lu E S r n to mb ew cel us off ebr , Oh er ate io in th ? gs e !

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Company profile: Ramsey Products

Geographically, what markets are most important to Ramsey?

months. If you are not getting multiple years out of your chains, contact us and let one of our engineers come take a look at your machines and provide solutions to improve the life of your chains. There is no service charge, it’s what we do!

Unlike other suppliers, Ramsey’s only focus is silent chain and sprockets. Since we only produce silent chains, every market is important to us. But, I do see increased opportunities for the Middle East and possibly Africa in the future.

Where are you seeing the most growth at the moment?

Geographically, we are seeing growth in Europe and in the Middle East. In those areas, we see a lot of new opportunities with the 2-Pin Sentry Conveyor chains. We have taken technology from our Automotive Power Transmission Division and incorporated it into the new Sentry Chains. These chains are truly state of the art and unlike any other 2-pin conveyor chains on the market. We are seeing many leading manufacturers switch to this new design.

Are you noticing any trends in the glass industry at the moment?

“

We have

invested millions of dollars on new technology over the last five years.

Do you invest a lot in R&D at Ramsey?

We are seeing machine builders pushing the limits to increase the speeds of glass production. What was fast 10 years ago, is not so fast now. With these changes, chains are required to be more durable, improve the bottle spacing consistency and run for longer periods of time.

Another shift is in the research and testing of new materials such as coated chains and stainless steel chains. Ramsey has been manufacturing stainless steel chains for more than 40 years, however it has been used primarily in other industries. Now we are producing multiple stainless steel grades for customers requiring higher temperatures and for

R&D has always been a big part of our company, it’s part of our history, but over the past couple of years we’ve focused on R&D more than ever. We think it is important to continue to develop new products to help glass manufacturers.

We were recently granted a European patent on Lifeguard and just after that we received a patent for the RKO Knock Out Tool and R-Select - no one else makes a chain like this one, and it too is covered by a patent. And I’ve already mentioned our newest chain, Sentry. Now we are working on some new materials that will be big when it comes to the life expectancy of certain chains. It all starts with R&D and an investment by Ramsey to be a leader in quality products and technology.

www.glass-international.com

Your Lifeguard conveying chain was recently granted a European patent.

Has this increased business in the region for you?

Lifeguard has been a huge success. We have seen a significant increase in the demand for Lifeguard in Europe and expect this to continue to grow.

However, Europe is not the only place, Lifeguard has been successful in most of the world. Glass manufacturers are realising the significance of the new technology and using it to their advantage.

This was a real breakthrough in the glass industry, especially for companies manufacturing small bottles.

What is the average lifetime of the conveying chains? Does it depend on product type or bottle type?

The average lifetime of a chain will vary from customer to customer and from supplier to supplier. There is no straight answer to that question. However, a high quality chain, with proper maintenance, will provide a long life of service. These chains are built to run years, not

I expect this trend to continue as we look to improve the chains and keep up with the new technology emerging from glass machine

”

builders

customers who are spraying special coatings on the glass and damaging the steel chains. Although these chains are slightly more expensive, we are seeing a return on the investment by the customers in down time and better quality glass.

And over the next five to 10 years, what changes (if any) do you see happening at Ramsey?

I expect Ramsey to continue to focus on Research and Design. We have invested millions of dollars on new technology over the last five years. I expect this trend to continue as we look to improve the chains and keep up with the new technology emerging from glass machine builders.

The chains we are building today exceed the requirements of the machine builders, but we want to continue to be a step ahead of the curve. I expect a few more products to be introduced later in 2017 that will lay the groundwork for many years to come in the glass industry. �

*VP of Sales, Ramsey Chain North Carolina, USA www.ramseychain.com

28 Glass International October 2017

Company interview Ramsey.indd 2

16/10/2017 15:44:35

Campagna pubblicitaria Digital Fermac 210x142 003.indd 1

22/01/16 12:52

will discuss Packaging Trends and Observations in premium Spirits at a forthcoming event devoted to spirits packaging.

The Spirits Packaging Summit 2017 takes place in Edinburgh, Scotland on November 16th and includes a number of papers and panel discussions about luxury spirits.

O-I UK’s Marleting and New Business Lead, Paul McLavin, will consider the packaging implications of the latest developments in the craft spirits sector.

His paper will assess how the regular emergence of new craft products is served by innovations in standard glass packaging such as new shapes, colours and decoration to maintain differentiation.

Where the premium spirits sector has traditionally been known for heavy glass

designs, it will show how environmental specifications have been improved and costs offset by more modern, lighter weight container design.

It will also demonstrate how scalability is built into packaging strategies as brands move from standards to low volume bespoke, illustrated by brand stories from around the world.

Panel discussion Another speaker at the event is British Glass CEO, David Dalton.

He will participate in a panel discussion about sustainability issues for development.

The session will explore the challenges and opportunities in maintaining consideration of sustainability while developing, designing and marketing attractive spirits packaging.

� What techniques/products are brands using to try and combine luxury packaging with sustainability? � Why does glass remain the material of reference, conveying quality, preservation and purity? � Is the glass industry ready to embrace the need for changes? � Will we see new rules and regulations before too long? � Will the industry embrace alternatives for glass?

Other speakers during the day-long event include global brewer Diageo, Edrington and Strathearn Distillery as well as independent consultants and brand experts.

An exhibition will run alongside the conference and features companies such as O-I, Beatson Clark, Croxons and Crown Packaging. �

The Spirits Packaging Summmit 2017 takes place at the Assembly Rooms, Edinburgh on November 16th. http://www.packagingnewslive.com/spirits

www.glass-international.com

O-I to speak at Spirits Summit O-I

29 Glass International October 2017

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History

Prof. John Parker

The importance of the ICG Prof. John Parker discusses why the International Commission on Glass remains as relevant as when it was first formed by Prof W.E.S. Turner in 1933.

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A

Google search for ‘ICG’ uncovers many meanings - International Cucumber Growers, the International Crisis Group, the Institute of Cosmology and Gravitation… and one where G is for Glass.

In 1915 Prof W.E.S. Turner realised that the UK glass industry was burdened with problems, mostly generic to several companies. Each falsely imagined their situation was unique and that sharing information might undermine their financial integrity.

He first created a University Department of Glass Manufacturing and the Society of Glass Technology as antidotes, determined that the principles of physical chemistry should improve glassmaking. Soon his views struck a chord with contemporaries further afield.

During the 1920s he expounded his ideas with almost missionary zeal, and discovered like-minded people in Germany, France, Italy, Spain, USA and elsewhere. Joint activities followed: to produce clear scientific definitions, set agreed standards, and stimulate joint research projects.

In 1933 they led to the creation of an overarching body, the International Commission on Glass (ICG) linked to a triennial Congress series, which, apart from a break during WW2, has continued to grow. Following the 24th event in Shanghai, the 25th Congress in 2019 will be in Boston, USA. ICG membership is based on national glass societies, each paying a fee set by that country’s glass production. All are represented on a Council which sets ICG policy. Where no Glass Society exists, a Ceramic Society often encompasses glass interests and can adopt this role.

Occasionally other organisations such as University departments or large companies with glass interests have taken on the mantle of representation.

Other bodies with shared interests have become affiliated members. Over its 84

years, membership has evolved eastwards, mirroring changes in international trade, and industrial affiliations have increased to reflect globalisation.

While the ICG’s Council has overall responsibility, day-to-day decision making is delegated to a Management Board (MB): the ICG president (Dr M Choudhary, Owens Corning), an executive secretary, treasurer, vice-president and the chair of the Coordinating Technical Committee (CTC). A new vice-chair is elected triennially to replace an outgoing president and normally becomes the president-elect in the penultimate year of the president’s term.

The CTC, currently chaired by Prof H Inoue, of Japan, has eight members. Its TC Chairs also attend meetings, usually twice a year. While international standards, e.g. for viscosity, chemical durability and thermal expansion, formed the early cornerstones of ICG’s scientific activities, an organisational structure of 25 TCs has since evolved, with different areas expanding and declining in response to industrial and academic needs.

Now 500+ scientists and technologists from academia and industry in 30 countries are involved.

The committees interact within clusters whose themes are: glass properties, glass structure, glass applications, glass production, and communications/ education and archaeology. Aims range from international standards for chemical analysis and durability, to validating software for modelling studies.

The ICG web site (www.icglass.org) tells more of this story.

ICG runs annual conferences with typically 300-400 delegates while every third year a major international Congress may attract a thousand. The aim is to bring together people with shared interests in industrial and scientific issues in glass technology. The intention is that networking and an attitude of give-andtake goes far in problem-solving.

Such meetings allow TCs to meet and share both methodologies and results in pre-competitive areas. Noteworthy outputs can be marked by a prize during the Opening Ceremony; some reward upand-coming scientists while others are for lifetime achievements.

While prizes help to stimulate activity among young research workers, transferring information to and generating enthusiasm in the next generation of glass technologists is another role of ICG, achieved through seminars/schools, textbooks, even film clips on You Tube.

ICG organises annually Winter and Summer Schools for new researchers in China and France. The Montpellier School will run for the 10th time in 2018.

Creating reference works such as dictionaries was an early role of ICG, recently replaced by generating roadmaps to guide the developments needed to underpin glass applications for the next 25 years. ICG adapted to a changing political and social landscape since its inception when six countries combined to work collaboratively for a brighter future for glass. Viscosity measurements are no longer a priority.

Improving furnace efficiency while minimising environmental impact is.

Chemical durability has become a focus of the nuclear industry and also for those making glass for contact with foodstuffs and drugs. Computer modelling has allowed Prof Turner’s early dreams of applying reliable physical and chemical principles to come close to fruition. ICG has proved resilient to changing demands and continues to offer an environment which can be a catalyst for change and also provide an environment for educating the next generation of glass technologists. �

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

30 Glass International October 2017

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07/09/2017 12:47

Furnaces

A vision for 2050: an 81% Germany has ambitious plans to reduce its glass furnace energy consumption by 81% in 20250 compared to 2010. Christiane Nelles* of BV Glas association explains how the industry plans to achieve this.

W

� BV Glas is part of the ‘Initiative Energieeffizienz-Netzwerke’ campaign to achieve energy efficiency.

hile the political aim of a reduction of the greenhouse gas (GHG) emissions in Germany in the range from -80% to -95% in 2050 has been set, authorities, industry and non-governmental organisations try to map out pathways on how to transform society and industry in becoming almost GHG-neutral.

In 2013, the German federal environmental agency (UBA) published the ‘Germany in 2050 – a greenhouse gasneutral country’ study, which analyses all the relevant sources of emissions of greenhouse gases, described in the German National Inventory Report (NIR).

The study describes the technical measures required to achieve a greenhouse gas reduction of 95% in the middle of this century compared to 1990.

It does not include an evaluation of the costs or describe the policy instruments needed. In this vision of Germany in 2050 energy produced is totally GHGneutral. Only 14 million tonnes of CO2 equivalents are left to industrial processes and the biggest share of the 5% emissions left goes to the agricultural sector with 35 million tonnes of CO2-equivalents.

The glass industry is one of ten industry sectors focused on in the projections, due to its high-energy intensity. In 2015, the glass production sector in Germany employed around 54,000 people at 405 sites with a production of 7.5 million tonnes and a turnover of €9.2 billion.

Today, 73% of the glass sector’s energy use in Germany is covered with natural gas (about 13.5 TWh) and around 22% Continued>>

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reduction in glass furnace energy with electricity (about 4TWh). Heavy fuel oil has virtually ceasesed to play a role in the glass sector’s energy supply with only 4%. Other energy sources add up to 1%. In addition to CO2-emissions from gas and fuel, around 20% of process emissions derive from the decomposition of the carbonates in the batch.

A target scenario, with a German glass industry producing glass at today’s productions levels with 81% less final energy has been developed, using technical improvements and resource efficiency gains.

The study explains that a combination of a higher cullet use, recovery of waste heat and full electrical melting could lead to a minimum of CO2-emissions emitted during glass melting.

Flat glass products and special glass products are used over long periods of time in buildings, automotive and other applications and cannot be recycled like bottle and jars.

BV Glas action: cullet Bundesverband Glasindustrie (BV Glas), the Federal Association of the German Glass Industry, started a nationwide campaign in 2011 to increase the quality and the amount of container glass cullet.

The aim is to consistently inform the consumer which types of glass should be put in the bottle bank and which types

fired with electrical boosting, the study claims that with a full electric furnace of 120 tonnes melting capacity per day the specific heat demand is less than 1MWh per tonne of glass, compared to 2MWh per tonne of glass with conventional furnaces. In electric furnaces, less diffuse waste heat is produced since the furnace crown is cold. However, no CO2 -emissions are only accountable if the electricity is produced a 100% with renewable energy sources.

BV Glas action: energy efficiency BV

Glas

is

part

of

the

‘Initiative

More requirement Every 10% of cullet added to the raw material reduces the energy demand for melting by 2-3% and CO2-emissions by 2.4-3.6% (the reduction of process emissions taken into account). Cullet is a highly valuable basic material for glass melting. In the container glass industry around 60% of batch raw materials is replaced by cullet. Under the assumption of the necessary high quality, an even higher share of cullet would be possible for the production of bottles and jars, but the market for cullet has become tense over the last years. In the flat glass industry, the cullet usage rate is around 30%. Due to quality requirements of the flat glass in the building and automotive sector, mostly internal cullet, leftovers from the own production process or from refining processes, is used. The cullet share in mineral wool production amounts to 40%. In the processing of special glass there are limited opportunities to use cullet due to high quality requirements and a variety of different glass textures that make a recycling infrastructure barely possible.

The study of the federal environmental agency aims at an average cullet rate of 60% in all glass sectors and therefore a reduction of the energy demand of the German glass industry by 15%. However, BV Glas performed a study that found the amount of cullet available for recycling in other glass sectors than container glass, too low to achieve this target.

� The general reach of the recycling campaign was 1.5 billion people.

of glass products are not suitable for container glass recycling. The campaign flyer has been distributed more than 270,000 times during the last six years.

More than 100,000 people visited its campaign website and the general reach of its recycling message in 2016 was 1.5 billion (Pic 1, above).

Enhancing energy efficiency The ‘Germany in 2050 – a greenhouse gas-neutral country’ study proposes to recover the heat released during the cooling process of the glass which leaves the forming process at temperatures of around 600 degrees Celsius. On the annealing lehrs the heat demand ranges between 180kWh per tonne for flat glass and 108kWh for container glass.

Full electric melting is identified as the major greenhouse gas saving technique in 2050. Most glass furnaces today are gas

Energieeffizienz-Netzwerke’ an initiative of the federal ministry of economy to find 500 energy efficiency networks by 2020.

Greenhouse gas emissions in Germany should be reduced by 5 million tons with the help of all networks. The networks meet regularly and discuss energy efficiency measures. At the end of the 2- or 3-year duration of the network, the CO2-reductions are monitored to make sure the efficiency aim could be achieved.

BV Glas has already established three networks: ‘Rennsteigenergie’, a regional network with members of glass producing companies and companies from other industrial sectors; ‘GlasNET’, a network with glass producing and further processing glass companies and ‘Effinet@ Schott’, an internal network from the special glass company Schott.

Continued>>

www.glass-international.com

%

Furnaces

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Furnaces

Companies exchange information on energy efficiency technics and projects at the network meetings, as well as the information presented by external advisors from scientific institutions or companies. The focus of the topics ranges from glass furnace design to compressed air and heat and cooling demand of factory buildings or offices.

Special problems of the glass industry can be discussed and developed further, even with energy saving devices, such as LED lighting. This for example can cause a problem in glass factories where LED ceases to function when exposed to high temperatures above the glass furnace (Pic 2, first page).

Combination The UBA ‘Germany in 2050 – a greenhouse gas-neutral country’ study concludes, if switching to full electric furnaces in 2050 can be realised, the specific heat demand will add up to 0.8MWh per tonne of glass produced. This again will derive to only 0.68MWh per tonne of glass, with the help of the increased use of cullet. The authors claim that the heat demand for cooling the glass can be fully recovered.

The final energy would be reduced by

81% per year compared to 2010, where 25.47TWh primary energy was required for the glass industry as a whole.

The total energy consumption of the glass industry in Germany would shrink to 4.8TWh electricity per year coming from renewable energy. Only a minor share of process emissions would remain.

A competitive glass industry on our path to a GHG-reduced glass production is required. If the CO2-saving potential of glass products is taken into account, such as energy saving glazing, it demonstrates how much the industry already contributes to energy saving in Germany today, far ahead of the year 2050. �

Conclusion

References

BV Glas regards the outcome of the study as a vision for glass production in 2050 that might be at some point of time technically achievable, let alone the crucial economic competition issues.

Various taxes and levies on energy, especially on electricity, make for costly and energy intensive glass production.

There are reductions on some cost burdens, such as the special equalisation scheme for the EEG apportionment, but they are only granted to a minor share of the glass producing medium-sized companies.

Furthermore, the constantly changing laws and regulations, concerning energy and climate policy, cause insecurity in long-term capital-intensive investments such as building a glass furnace that costs several million Euros.

1 ‘Germany in 2050 – a greenhouse gas-neutral country’:

https://www.umweltbundesamt.

d e / p u b l i k a t i o n e n / g e r m a ny - i n - 2 0 5 0 - a greenhouse-gas-neutral-country 2 ‘Germany in 2050 – a greenhouse gas-neutral country’:

https://www.umweltbundesamt.

d e / p u b l i k a t i o n e n / g e r m a ny - i n - 2 0 5 0 - a greenhouse-gas-neutral-country p. 38 3 ‘Energy consumption of the German Glass industry in 2015’: Statistisches Bundesamt Tab_02_205_WZ_231 4, 5,6,7,8 ‘Germany in 2050 – a greenhouse gas-neutral

country’:

https://www.

umweltbundesamt.de/publikationen/ germany-in-2050-a-greenhouse-gas-neutralcountry p. 189

*Advisor Energy and Climate Policy, BV Glas, Düsseldorf, Germany www.bvglas.de

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34 Glass International October 2017

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Furnaces

Making better use of electric boosting in glass furnaces Electric boosting plays an important role in increasing output capacity in glassmaking. Mahdie Moaveni* discusses how the benefits of boosting can only be realised with well-designed and correctly positioned boosters.

Efficient boosting configuration The mentioned benefits of electric boosting can come true just in the case of a well-designed boosting.

The wrong positioning of the electrodes can adversely cause the conflict in terms of the convection flow and short cut current of the glass melt. Conversely the right electrodes arrangement regarding

Side wall electrodes

Melting bottom electrodes

Side wall & barrier electrodes

ďż˝ Fig 1. Glass streamlines in the melting tank; centre line, side view.

size, immersion depth in glass, spacing, number of electrodes and transformers, and of course the connection configuration of electrodes can not only reinforce the convection currents, prevent the short current of glass and increase the residence time, but also make the furnace operation controllable.

There are many aspects that should be taken into account for an efficient boosting system design of the furnace.

Some of the common issues will be pointed out here.

At the preliminary stages of conception, the type of product, glass composition, furnace geometry, splitting concept of fossil and electric energy and the desired product quality are crucial parameters to decide about the necessary number of transformers and the electrodes arrangement. Of great value is also the presence of other elements, for instance batch preheating, bubbling nozzles,

etc. in combination with the electric boosting, focusing on their influence on the glass current’s convection and the short cut path in the melting.

The capital costs as same as the operation costs regarding the number of transformers and electrodes, electrode cooling systems, etc influence the decision-making for each project individually.

The practicability of electric boosting implementation in terms of maintenance such as exchanging and pushing the electrodes related to the position of electrodes should be considered too. It is an important subject for the installation of bottom electrodes depending on the glass colour and predicted bottom temperature as well as the necessary size and weight of electrodes.

Continued>>

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E

lectric boosting as a means of increasing output capacity, as well as of improving glass quality is an important part of energy sources in many fossil-fired glass melting furnaces.

It is not only an efficient way to increase furnace output capacity, but also an essential tool for rapid control and stabilisation of the bottom temperature and energy saving in case of a pull variation.

In case of a pull rate variation, electrical boosting provides flexibility to achieve the desired melting bottom and riser temperature.

The furnace operation stability after a colour change in the furnace can also be accelerated through electrical boosting.

The other function of electrical power besides providing a part of the necessary melting energy is fine-tuning of the glass quality. A reasonable convection flow in the furnace besides a proper bottom temperature and sufficient residence time of the molten glass in the melting area ensures the necessary melting and refinery condition of glass. However, the glass refinery depends strongly on the glass composition too.

The reduction of emissions (NOx, SOx) - those related to fossil combustion makes electric power an environmentally friendly energy source in glass production.

35 Glass International October 2017

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Refmon Verallia

Stoelze

Owens-Illinois

We thank you all

BA Vidro

Belref

Duralex

SGD Ardagh

For attendance at 1st

Glass Defect, Refractory and Technology Training in Lyon, September 2017

For the first time, Glass Service and CQ Masso held a seminar in Lyon to share our Quality commitments with Glass people. Generality on Glass, bubble & solid defects analysis and possible source, corrosion and exudation of AZS, control on refractory, innovation on expendables, boosting optimization, furnace control and design optimization and numerical modeling on IS forming platform were parts of the seminar. Attendees appreciated the quality of presentations, the experience of trainers and the particular atmosphere we created to promote exchange and connection. We wish to see you again for next edition in 2019. MG

Furnaces

Case I

Pull Rate

tpd

370

Product

Container Glass

Colour Green Cullet

% 60

Length

mm 14000

Width

mm 8500

Melting Surface

sqm

119

Melting Depth

mm

1200

Ref. Depth

mm

2200

Specific Melting surface

t/sqm

3.11

Doghouse

2 Side wall

Burners

3 (each Port)

Natural Gas

Nm³/h

1150

Electric Boosting

kW

1600

Energy Consumption

KJ/Kg

3153

� Table 1. General furnace geometry and energy consumption description.

CFD simulation In usage of modeling study, knowledge can be gained regarding the temperature profile, the currents in the glass bath and the combustion space of the glass melting furnace. Advanced computer modeling and an analysis of glass melting furnaces are reliable tools, which allow the forecast and visualization of the effect of the electric field in the different electrodes’ arrangement in the furnace prior to implementation. An aggressive process on account of high temperatures allows less experimental investigations about the effect of the electric boosting arrangement on the glass current flow in the furnace. The process parameters are virtually impossible to measure.

Even the particle trace test can give some information about the residence time but not about the path of particles and other quality factors.

CFD simulation can investigate those process parameters. It gives information about quality aspects such as residence time and path of critical particles with shortest residence time of each case study.

We have the possibility to consider as many different scenarios in the melting tank as necessary. This includes aspects according to the requirements of furnace design: different operation parameters, different pull rate, integration of batch preheating system as well as installation of air bubbling row and its position. The concept of fossil firing regarding different impact of end fired firing, cross air fuel firing heating and oxy fuel firing as heating media on the glass current flow in melting tank and finally the overall impact of furnace elements peculiarity and furnace geometry specification are aspects that can be considered.

The optimum furnace design leads to a reduction of investment costs, highest pull rate concurrently gaining desired product quality, reduction of product loss and increased furnace life.

Design failures such as constructive or minor mistakes concerning the positioning of electrodes, bubbling, etc. cause insufficient refinery and difficulties in achieving the desired riser temperature, hence an increase of seed counts and inhomogeneity in the product. The result is a reduction of pull rate or sometimes an early repair of the furnace to fix the problem with the installation of more electrodes or bubbling nozzles, which is a laborious, precarious and costly job.

Many such problems could be prevented in advance through the prediction of CFD Simulation.

The modelling study is useful in the elementary stage of new furnace concept developments as well as for the performance optimisation of existing furnaces.

This contribution is related to the results of a case study about the effects of the boosting system arrangement.

The goal of this study is an evaluation of the impact of the electric boosting arrangement on furnace performance.

Therefore, energy consumption and the necessary electric power as same as all other boundary conditions have been held constant for all cases, but in different number and position of electrodes in each case.

An end-fired furnace has been considered for the modeling study. As an electrode arrangement, the application of side wall boosting, melting bottom and barrier boosting as well as the combination of them on the glass melt has been assumed.

Table 1 contains the geometry description and energy consumption of the furnace.

Three modeling cases are executed: Case I_V 01: 12 side wall electrodes Case I_V 02: 12 bottom electrodes under blanket Case I_V 03: Six side wall electrodes and ten barrier electrodes

After performing the modeling studies on the mentioned cases, the outcome data was evaluated. The most important aspects are impact on the current flow, the batch shape, the hot spot, the bottom and riser temperature, the residence time, the path of the critical particles with low residence time and finally on glass quality. Some of these points are contributed in this article.

Riser temperature Table 2 depicts the temperature of the melting tank and superstructure in mentioned points. The furnace with 12 side wall electrodes results in the highest riser temperature as well as the highest crown temperature above the dam wall (Hot spot) but the lowest bottom temperature within three electric boosting arrangements. That means the glass surface temperature has been increased and that there is a weak convection flow in front of the wall.

The second case, 12 bottom electrodes under blanket, shows an increased bottom temperature, which is the result of electrical heat energy released around the bottom electrodes. The riser temperature has the lowest value in comparison with the two other cases.

Finally, the furnace with six side wall and ten barrier electrodes results in moderate values of riser temperature as well as bottom temperature. The crown temperature above the wall (Hot spot) is in this case lower than in the other two cases.

According to these results a stronger convection flow in case of barrier boosting in combination with side wall boosting can be expected in the melting area. Due to the benefits of improved convection flow, the heat transfer of combustion energy into the glass is more efficient as well.

Convection flow Looking at the glass current flow in the melting area in front of the wall, it is observed that the case with side wall & Continued>>

Case I_V 01

Case I_V 02

Case I_V 03

Side Boost

Bottom Boost

Side & Barrier Boost

Riser Temperature (°C)

1263

1259

1260

Crown Temperature (Hot Spot) (°C)

1592

1592

1586

Bottom Temperature (under batch) (°C)

1162

1183

1179

Bottom Temperature (in front of wall) (°C)

1177

1208

1204

� Table 2. Temperature in the melting tank and superstructure.

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Furnace description

37 Glass International October 2017

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Furnaces

barrier boosting has a strong convection flow, whereby the two other cases have a weak circulation and the glass stream pushes towards the glass surface.

By implementing the barrier electric boosting in Case I_V 03 more convection flow in the melting area was achieved.

Fig. 1 shows the glass streamlines in the melting tank.

Bottom temperature

Case l-V03

Case l-V02

Case l-V01

A

� A. Graph 2. Residence time

Case l-V03

One of the methods to judge about glass quality is the massless particle trace.

A number of massless particles will be released through dog houses in the melting tank. Concerning the path of particles, viscosity, velocity, the residence time and the temperature of the region which particles pass on their path, some indexes have been derived which give information about the quality of melting, refining, mixing, sand dissolution and bubble growth in the glass melt.

Particularly the values and the path of particles with shortest residence time, which are called critical particles, should be observed and evaluated.

Residence time is simply the time in which the particle spent on its way between the starting point (batch chargers) and the target (Riser). In Graph 2 the difference of residence time value of critical particles in the furnace which have the shortest residence time is demonstrated. The furnace with side wall boosting has the lowest value opposite to the furnace including barrier boosting with the longest residence time of critical particles.

The melting index is a function of local temperature on the trajectory, of dynamic viscosity of glass and of time. The higher the value of melting index of each trajectory, the longer time has the particle spent in regions of high temperature and of low viscosity. Thus, the melting index

informs us about the quality of melting along the trajectory (Graph 3).

Mixing index is an indicator of inhomogeneity dilution capabilities. It is a function of local velocity gradient tensor and diffusivity of typical cord compound (Al2O3, SiO2, and ZrO2). The results tell us how many times a 1cm thick cord has been diluted while it follows the massless particle trajectory.

Sand dissolution index is a computation for each massless particle’s trajectory which corresponds to sand grain tracing. Statistics are performed on the resulting values. For each trajectory, the theoretical largeness of sand grains that would be able to be dissolved is calculated. Consequently, as the sand grain travels through the glass melt, it gradually dissolves at the rate given by the grain growth function that depends on temperature.

Case l-V02

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Glass quality

� Graph 1. Average glass temperature 50 mm above the refractory along the furnace length.

Case l-V01

The proper bottom melting temperature is a crucial parameter so the sand cord can be diluted prior moving to refining zone.

The average across glass temperature, 50mm above the refractory, along the furnace length is demonstrated in Graph 1.

The bottom temperature of the case with the melting bottom electrodes is distinctly higher than the two other cases, subsequently the case of side and barrier boosting. The lowest bottom temperature belongs to the furnace with the 12 installed electrodes on the side wall.

B

� B. Graph 3. Melting index of critical particles

Bubble growth index is a refining indicator which depicts the speed of growth and dissolution of the bubbles in the glass melt.

The comparison of the all quality indexes demonstrates the advantage of electric boosting with a combination of side wall and barrier boosting in this case study.

The case study shows that the 119m2 furnace with side wall & barrier boosting results in higher furnace efficiency in comparison to the case with side wall boosting and the case with melting bottom boosting regarding: temperature profile in the melting depth, convection flow in the melting area, glass quality and bottom temperature The results of the modeling study illustrate boosting configuration has an important influence on furnace performance regarding glass quality, temperature distribution and glass current in the furnace. With the right positioning of the electrode in fossil and electric furnaces, even while keeping the same amount of energy, the factors referred above can be improved.

This study has been performed for the mentioned design parameters.

Any changes in the furnace concept regarding furnace geometry, type of glass or the usage of other elements such as bubbling and preheating system can lead to different outcomes. It is essential to find the individual solution for each furnace concept in terms of furnace geometry and process parameters. Thus, an optimum furnace performance can be accomplished through an effective electric boosting configuration. �

*CEO, Simullex, Altenstadt, Germany Tel +49 9602 6175448 Web www.simullex.com

38 Glass International October 2017

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WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS

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

Container glassmakers in Thailand are enjoying an unprecedented

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

• Processing machinery

• Batch Plants

• Laboratory services & analytical equipment

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

• Melting furnaces

food sauces in Thailand and the region means glass packaging is

• Combustion equipment

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• Refractories

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

• Feeders & forehearths

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

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13/09/2017 11:55

Coatings

Value-added coatings can save struggling glass manufacturers Ron Hunt* discusses the benefits of value-added coatings and how they can transform the fortunes of a glass manufacturer.

T

he glass industry is more competitive today than at any time in history.

Manufacturers must offer valueadded products to remain competitive.

In developed countries, most windows have a Low-E coating. Low-E is expected to remain the highest volume value-added product sold by most facilities.

With Low-E being the mainstay value-added product, manufacturers must focus on providing the best Low-E product when looking to add or expand their range of value-added products.

Analysis of trends in energy costs, regulations, and markets all point to an increased demand for Low-E in the future. Facilities with existing value-added product lines should consider expanding their installed capacity now to stay ahead of market expansion.

Major capacity upgrades and new value-added installations often take a year or longer to complete. Long lead times on upgrades mean that, in a strong market, manufacturers without adequate capacity will lose market share.

Even as efforts to increase energy efficiency become increasingly popular, energy demand continues to rise.

According to the EU Energy Trends to 2030 report (prepared by the European Commission) global fossil fuel prices (oil, gas, and coal – all of which the glass

tel

www.glass-international.com

ho D. Trump’s

added processes such as CVD coating use relatively little energy; therefore the incremental cost to produce value-added products will remain relatively constant compared to growing base glass costs. As the price gap between base glass and value-added glass shrinks, demand for base glass will fall.

Emission reductions

industry relies on heavily) will increase by 39% over the next 10 years. As energy prices rise, market forces will drive the cost per ton of base glass up. Value-

Regulations aimed at reducing emissions and lowering energy use have had a major negative impact on glassmakers’ profit margins in developed areas such as Europe, the US, and even China. Glass production, while an environmentally clean industry, creates a large amount of CO2.

Many new regulations are aimed at reducing CO2 emissions, and even developing countries are under increasing pressure to meet more stringent regulations.

As with energy costs, meeting these new requirements will drive up base glass prices.

Value-added products tend to fall under easier to meet pollution regulations, and the price of complying with these regulations is already built into the cost of Continued>>

40 Glass International October 2017

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Coatings

the system.

Sudden changes in regulations can and do occur quickly, leaving manufacturers at risk of being unprofitable. There are often exemptions and credits for manufacturers that produce green or energy saving products, which facilitates compliance with stricter regulations from a budgetary standpoint.

CVD and sputtering systems can both produce energy saving coated products such as Low-E, but the AcuraCoat CVD system in particular can produce Transparent Conductive Oxide (TCO) coatings that are in demand by large solar manufacturers.

Producing components for solar panels may qualify manufacturers for exemptions and/or credits. TCO products have a substantially higher profit margin than base glass or even Low-E; higher margins will put producers with these systems in a better position to comply with regulations and remain profitable.

Sputter coatings Sputter coatings have traditionally been able to comply with energy standards that CVD coatings have struggled to meet, but modern CVD coatings such as those produced by the AcuraCoat

systems can now exceed even the most stringent requirements. Insulated Glass Units (IGUs) with AcuraCoat glass can have U values (U value is a standard measure of thermal conductivity) down to 0.2 and a R5 (R value is a standard measure of thermal resistivity) insulation rating. High haze has traditionally been a problem with CVD coatings at lower U values, but new advances have allowed Stewart Engineers’ AcuraCoat Low-E to have haze so low it cannot be perceived.

Market demand for value-added glass is increasing faster than demand for base glass. Growth in demand for energy efficient glass alone is growing by 15% per year (base glass demand is growing by 5%). Consumers are concerned about energy efficiency, which is driving them to Low-E products with lower U values that older coating facilities cannot produce.

Window units are being produced with double or even triple glazing, and lower cost and higher performance windows are also decreasing the payback time for investment in energy saving windows.

The above factors are dramatically increasing demand for coated glass.

Overall glass demand will grow in the future, meaning manufacturers with a

high value-added capacity will fare the best. Sputter coating installations have a much lower capacity than similarly priced CVD systems. Manufacturers seeking to install or expand their value-added capabilities should strongly consider the AcuraCoat systems offered by Stewart Engineers. AcuraCoat systems are capable of converting up to 75% of base glass production into a broad range of valueadded products.

Installation and production costs are also lower than sputtering systems; the AcuraCoat system is the best choice for most facilities.

Manufacturers who do not invest in value-added products early enough and gain the skills necessary to produce them efficiently and profitably will be caught on the wrong side of the trends in the glass industry.

Stewart Engineers provides the equipment and knowledge that can keep a facility at the forefront of technological changes in the glass industry. �

*Process engineer, Stewart Engineers, Wake Forest, NC, USA info@stewartengineers.com www.stewartengineers.com

GLASSMATE® The Industry Standard for Advanced Hot End Processing

Adding value through material science.

Batch to batch uniformity and consistency enables increased pack rate across long runs or multiple jobs Long wear properties reduce common process variation Thermal conductivity of POCO high performance graphites eliminate checking Chemical structure of graphite enables use at high temperatures Uniform isotropic microstructure provides high strength and allows for increased life regardless of finish

www.glass-international.com

• • • • •

Contact us and learn how POCO can help reduce defects and increase pack rates in your hot end processes. www.poco.com ISO 9001:2008 & AS9100:2009 POCO® and GLASSMATE® are registered trademarks of Poco Graphite, Inc. ©2017 Poco Graphite, Inc., All rights reserved.

41 Glass International October 2017

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Decoration

KBA-Kammann delivers 200th machine to Pepper Décor KBA-Kammann recently delivered its 200th Machine Type K15CNC. The Czech Repubilc based decoration company, Pepper Décor, was the recipient. � The new Pepper Decor building is under construction, finished by the end of the year.

KBA

-Kammann is celebrating the manufacture and delivery of its 200th K15CNC Machine.

The equipment was delivered to its customer, Pepper Décor which is based in the Czech Republic.

Pepper Décor’s owner, Sergiy Perets discusses the company and the project with KBA-Kammann (KBAK).

�L, Mr Sergiy Perets, R, Mr Axel Bohlmeier of KBA-Kammann.

www.glass-international.com

When and why did you establish your company?

Originally, I come from another part of the screen printing industry, my company in Ukraine produces ceramic decals for tableware.

The business has been running very well now for many years, but the growth rates are low. I decided to look for new business opportunities outside of my existing line, both product wise and geographically. I thought about printing on glass packaging, such as bottles and cosmetic flacons.

It is related to my decal business, because it is also screen printing, yet also completely different.

I knew KBA-Kammann, it is well known around the globe and and I knew its range of products, but I actually never saw a machine.

In May 2012, I was invited to see some machines and meet with the sales team in Bad Oeynhausen, Germany. During this meeting, we developed the idea, to

start some market research to find out if and where there are good places for a new player.

Together with the Kammann sales team, we conducted thorough market analysis and I decided for Prague in the Czech Republic.

Subsequently, Pepper Decor was registered in 2013 and the first machine delivered in 2014.

Why did you name your company Pepper Décor?

My last name is Perets and that translates as ‘Pepper’. From this, I believe, we have created a very recognisable corporate identity.

How did your new business get started? Which difficulties did you experience?

We did not have any customers when we bought the machine. We spread the word that the latest Kammann K15CNC machine was being installed in Prague and that brought us a lot of attention.

This was from existing decorators, who wanted to subcontract to us their overflow business during peak season and new customers, who were looking for highest quality and shorter delivery times.

After a few months of single shift, we had to establish a 2nd and 3rd shift to cope with the growing demand. So, the biggest difficulty we experienced was to establish a comprehensive educational

42 Glass International October 2017

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Decoration

and training programme for new operators.

But with the help of Kammann, these difficulties were rapidly overcome and we are now ready for further growth.

You just took delivery on your second machine after exactly three years. What are your long term goals?

I am planning our growth in various respects: first of all, the existing market for glass bottles, cosmetic flacons and drinkware still offers potential: from

Prague, we can offer competitive services to all of Europe. Secondly, we decided to extend our range of services by offering decoration also to the plastic industry: our new machine has a unique feature, which allows us to print plastic packaging and glass packaging on one and the same machine!

The idea came up when I realised some of my existing customers also have plastic as well as glass packaging among their products. And as it turns out, they strongly supported me to also offer this service.

� The KBA-Kammann K15CNC machine was delivered to Pepper Decor.

And thirdly, we are preparing and supporting our growth by building a new factory near Prague airport, which will reflect our customers and our own high expectations in quality, design and productivity: � 3000 - 4000m² of storage, 2000 2500m² of production space and 300m² of offices, all customised to our exact needs, will offer enough space and a perfect layout for production.

We are planning to move into our new factory in September.

My long term goal is to stay creative and to develop new ideas in partnership with Kammann and its team. That is the most important.

We have come so far! I am sure, there will be more machines from Kammann and maybe even a further production site….let’s see! �

www.glass-international.com

Pepper Décor, Prague, Czech Republic www.pepper-decor.cz/en/ KBA-Kammann, Bad Oeynhausen, Germany www.kba-kammann.com

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Decoration

www.glass-international.com

Fermac celebrates successful Satimat installation in France I talian decoration company Fermac has installed the first Ink Jet Printing machine developed on a rotary CNC version with 12 stations. The F12 Jet Art installation was at decoration company Satimat, located in Longroy, France.

Satimat is a specialist in acid etching and cleaning of glass bottles for the cosmetic-perfume and spirit sectors.

The company already has decorating department with printing equipment such as screen printing, semi automatic and fully automatic CNC, pad printing and hot foil stamping.

This machine (pictured) is able to print on to any developable shaped item, cylindrical and conical. Thanks to its full digital process, the machine can realise decoration not achievable with conventional processes such as excavated or curved surface, embossing, variable data and numbering.

This is an industrial alternative process for the sublimation and it is much better quality than the pad printing for the 4-colour process image reproduction on a cylindrical or shaped item. The maximum printing height is 210mm.

On small cosmetic jars, depending on the artwork, the ouput can achieve between 40 to 60p/min Adrian Briffard, Commercial Manager at Satimat said: “In a time when the digital makes it own laws and where costs are traced, we have decided to associate the digital to the packaging.

“The pride of a product is in the personalisation of the packaging.

“Often opposed to the budget, this custom can now become flexible and intelligent. A single file sent to our machine will make a multiple of possibilities.

Multicolour, pictures, texture, choose the limits yourself.

Embossed or concave bottles, we can project the decor in a variety of angles.

“The spirits, candles, cosmetics and perfume sectors are possible markets for us withn this machine. We were Fermac’s first customer on the rotary machine in digital printing so both companies had to understand the limits of the technology.

“At the moment we want to increase the

44

The F12 Jet Art machine installed at Satimat has the following configuration:

possibilities of the machine, but we have to be patient. It’s a sensible technology so everything has to be perfect before any validation.” �

Fermac, Parma, Italy www.fermac.it Satimat, Longroy, northern France, www.satimat.fr

� Loading conveyor with Pennine metallic belt and special pre treatment device UVTREAT (double half ring burners with pyrosil). � Loading with linear camera for angular positioning; � Geometrical control station for tolerance check of each item; � Primer ink jet station with UV Led pinning; � First white ink jet station with UV Led pinning; � Second white ink jet station with UV Led pinning; � Cyan ink jet station with UV Led pinning; � Magenta ink jet station with UV Led pinning; � Yellow ink jet station with UV Led pinning; � Black ink jet station with UV Led pinning; � Top coat ink jet station with UV Led pinning; � Unloading station.

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

ARE YOU READY FOR GLASSMAN LATIN AMERICA?

WHERE THE HOLLOW GLASS INDUSTRY MEETS TO DO BUSINESS

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

Glassman Latin America 2015, also held in Guadalajara was a

expect to meet and do business with:

sell-out event with 95 international companies represented within

• Presidents / owners

the exhibition. 965 glass professionals from 21 countries attended,

• Technical / production directors

including delegations from a number of large manufacturers such as

• Factory managers

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

• Plant engineers

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

• Technicians / engineers

demand from organisations wanting to exhibit. To ensure that you

• Production / R&D / test & inspection

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

personnel • Education & training personnel

soon as possible.

• Consultants / researchers

TO FIND OUT MORE CONTACT:

• Sales & marketing managers

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

CONTACT US TO BOOK YOUR STAND

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

Join the Glassman Events Group

Untitled-1 1

Official media partner:

@glassmanevents

17/10/2017 10:24

Events review: World Soda Ash conference

What effect will new Turkish soda ash capacity have on global glass The opening of 2.5 million tonnes of new Turkish soda ash capacity by the end of the year is likely to have a fundamental impact on the global glass industry. What will it mean for glass manufacturers around the globe? This was one of the discussions at the recent IHS Markit World Soda Ash conference in Dubrovnik, Croatia. Greg Morris was there. � Marguerite Morrin.

www.glass-international.com

S

oda ash plays an important role in the manufacture of glass. It is an essential raw material, which is placed in the batch. The amount of soda ash available on the market and its cost can effect a glassmaker’s budget.

Several leading glassmakers from the flat and hollow sectors were among the record high of 282 delegates in attendance at the three-day event, which included a two-day conference and a training day devoted to soda ash.

Delegates came from 120 companies and 40 countries to the annual event, which was this year held in Dubrovnik, Croatia (main pic). Visitors came from

countries including China, USA, Australia, Brazil France, UK and Turkey.

Game of Thrones The conference featured 15 presentations and opened with a paper from Marguerite Morrin, Senior Director, Soda Ash, IHS Markit, who gave a global overview of the soda ash market.

Television series Game of Thrones is filmed in Dubrovnik and her paper was titled Global Soda Ash, Game of Thrones.

She said: “The whole idea of the Game of Thrones is about power, competition and ambition and the ultimate aim is to gain influence and exceed to the throne.

As Turkey adds this 2.5 million tonnes of low cost capacity, we witness our very own Game of Thrones unfold.”

Turkish group Ciner is in the process of opening its Kazan Soda site, located about 40km from the Turkish capital, Ankara and which is due to be fully commissioned by the end of the year. It is the biggest challenger to the world’s two largest soda ash exporters, the USA and China.

Ms Morrin said: “Who thrives and who suffers depends on the games that each player is at liberty to play and we must also remember that the games change Continued>>

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i

� A total of 282 people attended – a record high.

industry? � The Kazan Soda site in Turkey will be fully commissioned by the end of the year.

� Sinan Solaklar.

� Chaoran Ding.

� Christophe Clemente.

over time. Then the games each player plays will influence what market share Turkey can take in different parts of the world.”

In her global overview she focused on a number of regions in the world.

Western Europe had seen a net decrease in capacity of 1.5 million tonnes since 2009 as well as a drop in demand. Until 2009 the US and China imported to the region but since the opening of Ciner’s Eti Soda production site in Turkey in 2009, most imports come from Turkey.

It is a different picture in Central Europe which has a net surplus of capacity and is a large exporting region. There are still

opportunities for growth in the region thanks to the opening of two new float glass plants in Poland. Turkey may look for a bigger market share in Central Europe but perhaps the biggest threat for Central European soda ash producers is the competition they face in export markets. It exports much of its capacity to Western Europe. In 2010 Turkey exported 800,000 tonnes to Western Europe, up from 100,000 tonnes in 2008, which was a sharp increase in a short period of time. “A similar effect could hurt Central European potential to export to Western Europe from the end of this year,” said Ms Morrin.

US outlook The US dominates the North American market, which includes Canada and Mexico. Capacity is concentrated at the Green River, Wyoming, USA mine. While domestic demand has declined since 2009 exports have grown 6% a year since 1980. This year it is forecast that 7 million tonnes of US soda ash will be exported.

It exports 20% of its output to Canada and Mexico, while South America and South East Asia are important markets, but the US faces challenges in these markets. There is only one soda ash Continued>>

www.glass-international.com

a s

Events review: World Soda Ash conference

47 Glass International October 2017

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Events review: World Soda Ash conference

producer in South America – a small plant located in Argentina – that means it is a huge importing region. Brazil is the largest market in the region, consuming 1 million tonnes while Argentina and Chile are also big markets.

“South America is a very important and developing region of the world,” said Ms Morrin. Demand for soda ash has grown 4% since 2000 from 1.5 million tonnes to 2.6 million tonnes today.

“The big question is not about demand but where will the supply come from.

South American imports have grown in tandem to demand over the past 20 years.

The US dominates as a supplier but Turkey is targeting this market and has ambitious plans for this part of the world.”

There is no soda ash capacity at all in South East Asia so the region is also a huge importer. It has seen positive demand potential with the opening of a number of glass plants in recent years. Demand has risen 3% a year since 2000 from 2 million to 2.8 million tonnes a year. Demand is expected to rise with float glass plants in Malaysia and Vietnam, and container plants in Thailand expected to open up opportunities. The US dominates imports while China, Kenya, Turkey and Europe also import to the region.

www.glass-international.com

India Demand for soda ash has grown by 5.5% a year since 2000 in the Indian subcontinent and there are opportunities there, said Ms Morrin.

The glass sector is not as developed as other parts of the world, particularly in flat glass. The container glass sector has opportunities but in some instances has been capped by alcohol laws. Domestic soda ash producers dominate in India but production is concentrated in Gujarat in the west of the country.

“The big question for the Indian market is about supply. There is demand potential because there is very low per capita demand today. It may not have the same growth trajectory as China but none-theless potential is extremely positive.”

Demand in the CIS region of Europe is, not surprisingly, dominated by Russia. It is a region difficult for external suppliers to supply to due to its huge geographical expanse. There have been regional issues with container glass and a preference for PET in the beer sector, although this is changing now, with more preference for glass. The final region focused on was China, which is the largest and fastest growing market in the world.

Demand has grown 8% a year since 2000, compared to the Rest of the World demand which had an average growth of 3.2%. China’s soda ash capacity is spread across the country, as is demand.

Since 2000 demand has increased by 18 million tonnes while capacity has increased by 22 million tonnes. This excess capacity means China is the second largest exporter in the world.

In her conclusion, Ms Morrin said that Turkish capacity will cause a new Game of Thrones with new competition in the market. Expansions will trigger capacities to close and supply to relocate.

“But demand won’t disappear. Costs are not static and will change over time depending on crude oil and raw material prices. What could be a competitive supplier today may well not be so competitive in a number of years time.

“China has been the big growth story of the last 15 years but built capacity to meet its own domestic demand. The question is will other developing parts of the world such as India, South America, South East Asia and Africa be able to do the same?”

Turkish overview Ciner’s Vice President of Glass and Chemicals, Sinan Solaklar, provided an overview of the group’s activities.

The company has three soda ash capacities as well as Turkish glassmaker, Park Cam, which makes about 1000 tonnes a day of container glass.

Ciner’s three soda ash plants are Eti Soda, located 120km from Turkish capital Ankara, Kazan Soda, about 40km from Ankara and Ciner Resources, which has a stake in the Green River mine in the US. The company is also one of Turkey’s largest ship owners and in 2018 plans to allocate five new vessels for the Mediterranean Sea and Far East. The ships will only be used for the group’s soda ash distribution.

The Ciner group started soda ash production in 2009 with Eti Soda and in 2011 brought the Kazan site’s Trona deposits from global miner Rio Tinto.

In March this year it completed an expansion at Eti Soda with a new line and an extended capacity to 1.5 million tonnes. During 2017 it also started commissioning of its first line at Kazan Soda. A second line will be commissioned in late September and further commissioning’s of a third, fourth and fifth line due in October. By January 2018 it expects Kazan’s capacity to reach 2.5 million tonnes a year.

The expansion will increase the company’s overall soda ash capacity to 6.5 million tonnes – Eti Soda with 1.5 million tonnes, and Ciner Resources and Kazan both at 2.5 million tonnes a year.

The Kazan site is 320km from Derince port, which is the company’s main port for bulk exports from both its Turkish soda ash plants. Kazan is 14km from a railway hub which has a direct line to the port. Ciner is in the process of completing a tender to build a 14km railway line to the hub, which will enable it to rail freight its product direct to Derince.

The railway line is expected to be completed by the end of 2018. The port is served by 149 silo trailers from Eti Soda, which is located 280km from Derince.

All the silos are dedicated to soda ash transportation only.

“They go to the port full of soda ash and come back empty in order to discard any risk of contamination,” said Mr Solaklar.

The port itself has also been improved since the Kazan extension and includes a 330-metre pier exclusively for the company. It has also invested in a new ship loader, which has a loading capacity of 1500 tonnes an hour.

China update The Chairman of the China Soda Industry Association, Chaoran Ding, gave an overview of the country’s industry.

He said in 2016 the country’s soda ash capacity was about 29.37 million tonnes, which is expected to increase by about 1 million tonnes in 2018.

About 36.5% of the product is used by the domestic flat glass industry and 22.3% used by the domestic hollow glass industry. Approximately 7.6% of its soda ash output is exported, he said. The export level will remain above 2 million tonnes a year for some time, he said.

Further presentations were given by the likes of Christophe Clemente, president of Solvay’s Soda Ash business, Kiran Global Chem Limited, which spoke about the Indian soda ash industry, and Botswana Ash Managing Director, Montwedi Mphati, who discussed the African Soda Ash outlook. � *The next World Soda Ash conference takes place in Xi’an, China in September 2018.

Details to follow.

IHS Markit World Soda Ash 2017 conference, https://www.ihs.com/events/world-soda-ash-conference-2017/overview.html

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Batch house

Batch house technological assistant Piotr Knast* discusses how a batch plant technological assistant provides improved support for glass property control.

Such a system, which is referred to by Forglass as the Batch House Technological Assistant, could provide support for better glass properties’ control.

Firstly, it would signal the need to undertake the search for the origin of glass chemical composition or density fluctuations greater than the defined limit values.

Among those reasons, one could list: Na volatility fluctuations from a surface of glass melt resulting from unstable melting conditions, increased carryover of raw materials, uncompensated humidity of raw materials, mechanical losses of materials between the batch house and the furnace and so on.

Another important possibility is the ∆p

∆sand

∆soda

(g/cm3)

∆dolomite ∆limestone

(% of weight)

+0.78

simulations of probable fluctuations of glass chemical composition (and its properties) in case of raw material replacement or, for example, increased rate of foreign cullet in the batch.

Another function, which is certainly not the last one, is the possibility of optimising the glass colour change in the furnace, by simulating various scenarios for that operation in order to select the most optimal one.

For instance, it is possible to estimate the time required to feed the batch without the sulphate if it is changed from flint to amber.

Continued>>

∆CT [s]

∆RMS

∆WRI

[%]

∆WR

∆TLIQ

[OC]

+0,01 +0,1 +0,41 +1,55 -0,1

-0.001 -1,64 -0.42 +0,58 +0,94 +2,14 +5,16

-2,11

+0.19 -0,12 +0,08 +1,03 -2,25

-1,98 +0,20 -0,14 +0,18 +1,18 -2,36

-0.78

-0,01

-0,1 -0,41 -1,55 +0,1

+1,64 0,42 -0,58 -0,94 -2,14 -5,16 +0.001

+2,11

-0,19

+0,12 -0,08 -1,03 +2,25

+1,98 -0,20 +0,14 -0,18 -1,18 +2,36

� Table 1. Raw material weights fluctuations (expressed in % of nominal weights) resulting in the glass changed density on the level of ± 0,001 g/cm3 and corresponding fluctuations of formation parameters.

Cooling time (∆CT), relative machine speed (∆RMS), working range index (∆WRI), working range (∆WR) and liquidus temperature (∆Tliq).

� Fig 1. Fluctuations of cooling time (∆CT) caused by counter-directed fluctua-

� Fig 2. Fluctuations of liquidus temperature (∆Tliq) caused by counter-directed

tions of soda and limestone weights for which the glass density fluctuations are

fluctuations of soda and limestone weights for which the glass density fluctua-

within ±0.001 g/cm3.

tions are within ±0.001 g/cm3, the batch fluctuation level allowed.

www.glass-international.com

I

t has been 37 year since Pool’s influential article on a practical glass composition control and today it is unlikely for any glassworks to apply the system in a form formulated by him (1).

The reasons are obvious: 1) greatly enhanced accuracy of XRF spectrometers and 2) their decreased prices.

Despite the system itself being archaic, Pool’s list of 38 elements and parameters of the process line which requires regular monitoring and maintenance if the glass composition fluctuations are to be held within narrow limits, is still valid.

The contemporary tools of collecting and analysing data cannot be compared with those which were at Pool’s disposal.

One of the intriguing possibilities provided by the control systems currently installed in batch houses is a possibility to estimate, in real time, the chemical composition and properties’ fluctuations of the glass delivered to the production machines.

This is on the basis of: 1) the weight of all raw materials in the subsequent portions of the batch which have entered the furnace within any specified period of time, 2) the chemical composition and its fluctuations of the raw materials in deliveries and batch portions, and 3) the residence time distribution obtained from furnace mathematical modelling.

49 Glass International October 2017

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Batch house

of time which enables precise assignation of the chemical composition to the raw materials used in each portion of the batch.

7,0 6,0

% glass

5,0

� Fig 3. The residence

4,0

Residence time

time distribution of flint

3,0

container glass in the

2,0

deep refiner type end

1,0

fired furnace, 360 tpd.

0,0 1

11 16 21 26 31 36 41

6

46 51 56 61 66 71 76 81 86 91 96

Residence time [hr]

The traps of glass stable density The glass density measurement accuracy by a sink-float method is ±0.0002g/cm3 and the allowed fluctuations for the container production are ±0.001g/cm3.

Table 1 presents the estimated fluctuations of material dosages (expressed in % of nominal weights) changing the density of typical sodalime container glass on the level of ± 0.001g/cm3 and the corresponding fluctuations of selected glass forming parameters: cooling time (∆CT), relative machine speed (∆RMS), working range index (∆WRI), working range (∆WR) and liquidus temperature (∆Tliq).

Figs 1 and 2 present the effects of simultaneous counter-directed fluctuations of soda and limestone weights on the changes of cooling time and liquidus temperature. It can be noted that density fluctuation of 0.0002g/cm3, which equals the accuracy of the flotation method might be the consequence of

simultaneous lowering of the soda ash content by 1.7% and increasing the content of limestone by 2%.

Such systematic fluctuations may result the CT’s fluctuation by -0.5 s which is negligible but Tliq’s by as much as +5.8oC which is significant. Density fluctuations are even less sensitive to the counterdirected fluctuation of the amounts of soda and dolomite.

Fluctuations database Raw materials suppliers constantly monitor their chemical composition.

Monitoring of the composition of materials from current deliveries is also a practice of many glass plants.

Using XRF spectrometers enables making the analyses of the produced glass and the raw materials with relatively little work-load. On the basis of such databases, average fluctuations of the raw materials’ chemical contents can be estimated for an individual batch or for any specific period

Fluctuation of SiO2

72,27%

SiO2 [wt%]

72,26% 72,25%

� Fig 4. Simulated

72,24%

SiO2 fluctuation in

72,23%

final glass caused by batch variation.

72,22% 20

40

60 Time [hrs]

80

100

120

Continued>>

Fluctuation of density

99,52 Cooling time [s]

2,4836 2,4835 2,4834 2,4833 2,4832 2,4831

Fluctuation of cooling time

99,54

2,4837

Density [g/cm3]

www.glass-international.com

72,21% 0

Many furnaces operating in glassworks have been pre-modelled with the use of mathematical simulations.

One type of information which may be obtained from such a model is the residence time (RT) distribution, for instance between the dog house and the throat.

The RT distribution obtained from the model may be verified using chemical analyses of the glass obtained from the furnace during the change of the chemical composition at a defined time.

The tracer method may also be applied.

In case of soda-lime container glasses, ZnO may be used as such a marker.

In container glass, the RT of the glass flowing between the dog house and the throat are in the range from approx. 4-5 up to 100 hours.

In case of float glass, the RT range is longer, between approx. 10 to approx.

250 hours (2).

The total RT of batch/glass product transition is the sum of: 1) the batch buffering time in the batch plant and furnace silos, 2) the glass flow time between the dog house and the throat and 3) the glass flow time along the distributor and the selected forehearth.

Fig 3 depicts the residence time distribution (on the dog houses – throat distance of flint container glass in an end fired deep refiner type furnace.

The melting area is 126,4 m2. The total volume of glass mass in the furnace is 166.08 m3 (≈ 415.2 t). Glass output is 360t/d (specific output – 2.85 t/(m2·d)).

The furnace delivers the glass to three K48/43-30’ feeders with efficiency of 100 – 140 tonnes per day. The glass residence

99,50 99,48 99,46 99,44 99,42

0

20

40

60

80

100

120

Time [hrs]

� Fig 5. Simulated density fluctuation of final glass caused by batch variation.

99,40 0

20

40

60

80

100

120

Time [hrs]

� Fig 6. Simulated cooling time fluctuation in final caused by batch variation.

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Batch house

times in the distributor and forehearths are: L1 – 2.7 hours, L2 – 2.2 hours, L3 – 3.2 hours respectively.

The batch buffer in the furnace silo equals 2 x 6 hours = 2 x 27.41 portions.

Batch/glass transition assumptions The system of online simulation of batch glass composition fluctuations for the example of the furnace described in point 2.2 is based on the following assumptions: Glass from every batch portion is delivered to L1 line within 20 to 108 hours (six hrs is the batch buffering time in the furnace silo, five hrs is delay RT time in furnace, six and 94 hours are the minimum and maximum RT of the glass in the furnace respectively and three hrs is the glass RT in the distributor and the L1 forehearth).

The glass from every batch portion is divided into 94 hour’s portions in accordance with the RT distribution illustrated in Fig 3. The total share of all 94 portions is 1.

At a selected hour, the forming machine receives the glass from the 94 x 4.759 = 430.46 subsequent batch portions, with

the shares proportional to every portion at a given time, in accordance with the RT schedule (where: 360 tons per day is glass pull out from the furnace, 3.755 is a portion of 1 batch, 0.8723 – batch/glass conversion coefficient). The total share of all portions is 4.759.

All the materials (sand, soda, limestone, dolomite, feldspar, calumite and sulphate) are delivered by vehicles with a carrying capacity of 27t.

A reusing of cullet collected in the five following days is assumed.

The fluctuations of chemical compositions and uncompensated material humidity used in the simulations for the given raw material delivery and batch portion were calculated using the random number generator on the basis of real values of chemical compositions variations and humidity of the materials used by the glassworks.

The weight fluctuations of individual materials was assumed at the accuracy level of the standard scales used by Forglass (sand ± 0.2 kg, soda, limestone, dolomite, calumite, feldspar ± 0.1kg, sulphate ± 0.02kg, own and foreign cullet ± 2kg).

Glass fluctuations caused by batch Fig 4 to Fig 6 displays the fluctuations of SiO2 concentrations as well as density and cooling time calculated on the basis of 431 batch portion are presented.

29 deliveries of sand, nine of soda, two of feldspar, four of dolomite, six of limestone, two of calumite and one of sulphate are used for batch preparation is this period.

The results indicate that the Forglass Glass Batch Technological Assistant is a useful tool for glass properties prediction at the moment of batch preparation. �

References 1. Poole J.P. Practical glass composition control. Glass technology. 1984, Tom 25, 2.

2. Beerkens R. Simulation of essential process steps in industrial glass melting.

Prague : 23rd Interanational Congress on Glass, 2013.

*CEO, Forglass, Krakow, Poland www.forglass.eu

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51 Glass International October 2017

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