Glass International October 2019

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October 2019—Vol.42 No.9

COMPANY PROFILE: GALLO GLASS FRENCH COUNTRY OVERVIEW FOCUS ON PHILIPPINES I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

From raw material intake ntake to batch charging Glass International October 2019

Batch plants

After sales service

Batch charging technology

ging technology Consulting

Upgrades and modernization

ation Cullet treatment & recycling systems

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Contents

www.glass-international.com Editor: Greg Morris Tel: +44 (0)1737 855132 Email: gregmorris@quartzltd.com Assistant Editor: George Lewis Tel: +44 (0)1737 855154 Email: georgelewis@quartzltd.com

October 2019 Vol.42 No.9

Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com Managing Director: Steve Diprose Chief Executive Officer: Paul Michael Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com

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

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Editor’s Comment + International news

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Company profile: Gallo Glass Gallo Glass embraces the latest digital technology

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Brand equity Brand equity can be enriched in glass

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Company profile: Phoenicia Glass The container glass manufacturer out on its own in Israel

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French overview Glassplants in France and statistics

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Events review: Glassman Europe An update on O-I’s Gironcourt plant

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Events preview: Glass Focus All set for Glass Focus awards

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SGT annual conference Newcomer wins award and Bill Brookes’ farewell address

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Control systems: BDF Electronic updating

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Events review: World Soda Ash Conference Glass demand benefits soda ash production

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Country overview: Philippines Philippines’ container sector grows

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Case studies: Smart Windows A high-tech solution to the paradox of glass

50

History Frederick Carder

Plus find us on LinkedIn and Twitter.

@Glass_Int © Quartz Business Media Ltd, 2019 ISSN 0143-7838

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Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com

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International News

2019 DIARY

GREG MORRIS, EDITOR

October

FRONT COVER IMAGE: www.eme.de

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Increased perspectives

Just like the glass bottles on a production line that go endlessly round and round, my life has reached that stage of constant repetition.

I’m not complaining, but as a result of mortgage, kids and - gulp! -middle age I am at the period in my life where the winsome days of youth are a long time ago.

Structure and routine have replaced the fragmentation and freedom of my early days.

Like the vast majority of people I am undergoing that transformational phase into a ‘real’ adult.

And with it I bring a variety of experiences and views into my role.

The subject of perspectives struck me as I read through this issue.

We interview those at the beginning of their career, some in the middle and someone who has been in the industry for a long time.

Each are from a different generation but each in their own small way has helped move the sector forward.

In a similar vein, and entirely accidentally, the first four speakers at the recent Glassman Europe conference were women.

Each of these brought a different set of experiences to an industry regarded as male dominated.

One concept of what makes a good community is one where all ages and genders participate. The glass industry is making inroads into this.

We know the glass industry needs to recruit younger people and increase its diversity. But the evidence is there that strides have been taken.

Be first with the news!

VISIT: www.glass-international.com for daily news updates

Nampak Glass sold for RS 1.5 billion Nampak is to sell its glass business for RS 1.5 billion (US$99.1 million) to Isanti Glass 1.

Isanti Glass 1 is 60% owned

by Kwande Capital and 40% owned by an AB InBev subsidiary, South African Breweries (SABSA).

Kwande Capital is an investment company established in 2010, with a focus on investing in companies with high growth potential in the manufacturing, oil and gas sectors.

Nampak’s glass business is one of only two container glass manufacturers in South Africa and has an estimated market share of 25%.

It operates three furnaces

which supply nine forming lines at its site in Gauteng, Roodekop, southeast of Johannesburg, South Africa.

It also operates its own cullet sorting and processing plant on site.

Nampak has been in the glass manufacturing business since 1984.

Nampack CEO, Andre de Ruyter, said the sale of the proceeds would be used to reduce its debt.

The sale is subject to the fulfilment of various conditions and is subject to approval of the South African competition authorities.

20-25 5th ICG Winter School 2019 Wuhan, China www.icglass.org 28-31 80th Conference on Glass Problems (GPC) A conference for glass manufacturers and suppliers.

Columbus, Ohio, USA www. glassproblemsconference. org 31 International Glass Forum A one-day event dealing with the future of the glass industry in Russia.

Moscow, Russia http://steklonew.incontrast. ru

November

13 Fundamentals of Glass Training sessions aimed at glass technologists.

Sheffield, UK www.britglass.org 20 Heat Transfer in Glass melting Furnaces One-day training course exploring the fundamentals of heat transfer processes.

Istanbul, Turkey www.celsian.nl 21 Glass Focus A daytime conference followed by an awards evening over dinner.

Sheffield, UK www.britglass.org.uk/glassfocus-2019 21 - 22 Sisecam International Glass Conference Glass in the Sustainable Future Istanbul, Turkey www.glassconferencesisecam.com 27 - 28 Glassprint 20019 Conference and exhibition dedicated to glass decoration.

Düsseldorf, Germany https://glassprint.org

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International News

NEWS IN BRIEF

Gerresheimer opens US technology centre

Global container glass manufacturer Verallia has hailed the success of its Initial Public Offering (IPO).

The company launched itself on Euronext Paris and said the IPO was a great success with French and international institutional investors.

The IPO raised €888 million including €838 million sold

by Horizon Parent Holdings, which is 90%-owned by AIF VII Euro Leverage, an invest-

ment fund managed by an affiliate of Verallia’s owner, Apollo Global Management.

It was the largest IPO in France since 2017, which raised €1.2bn.

Verallia is the third-largest glass manufacturer in the world, producing 16bn bottles and jars while generating €2.4bn in revenues last year.

It operates from 32 factories across 11 countries and will use the funds to expand into

what it says is an undersupplied market.

“In Europe the market is quite tight and there is a shortage of capacity. We will use this IPO to make acquisitions and expand,” said Verallia Chief Executive Officer Michel Giannuzzi.

Based on an offering price set at €27 per share, Verallia’s market capitalisation is €3.2 billion.

Ground broken on Arglass plant Arglass Yamamura has officially broken ground at its Georgia, USA site.

Plant officials and local dignitaries took part in the event at the site in Valdosta-Lowndes County.

The container glassmaking site will create 150 jobs in the local area.

“Georgia, specifically the Valdosta region, will allow us

to run a very flexible, efficient, and cost-effective manufacturing operation, while remaining close to our customer base in the South and eastern parts of the United States,” said Arglass Yamamura CEO José de Diego-Arozamena.

Arglass Yamamura is a joint venture partnership between Japan-based Nihon Yamamura Glass Co., and Cambium

Arglass.

The company will operate a facility that incorporates the latest glass forming technology and controls for a reduced environmental footprint.

Furnace start-up begins Q4 2020 and will be fully operational Q1 2021. Production capacity is 100,000 metric tons per year/265,000,000 units per year.

Guardian’s Ohio plant to close Guardian Glass intends to close its Milbury plant in the state of Ohio, USA. The float glass manufacturer filed a WARN notice to the state of Ohio stating that it intends to close its Millbury fabrication plant on State Rt. 795 and will start eliminating the jobs of its 100 employees on or about November 20.

The move will result in job losses for 77 hourly and 23 salaried employees who work at the plant, located at 24145 W. Moline Martin Rd. near Woodville Road in Millbury.

In its filing with the Ohio Department of Job and Family Services, Guardian Glass, based in Auburn Hills, Mich., gave no explanation for the

closing but called it a business decision. The plant makes consolidated, mirrored and vacuum insulated glass.

Guardian said it expects to begin eliminating jobs starting on November 20 and will continue to lay off workers in phases through the closure.

Employees are not represented by a union.

Zippe receives Osotspa Thai batch plant order

Zippe Industrieanlagen has received an order for a new batch plant in Ayutthaya from Osotspa (Siam Glass) in 2017.

The two older batch plants, which had supplied furnace AY#1 and furnace AY#2, were replaced by a new Zippe batch plant.

The plant is designed for a total melting capacity of 470 tonnes per day.

Commissioning of the new furnace AY#2 is planned for February 2021.

CelSian agrees SGS partnership

Dutch process optimisation consultancy group CelSian Glass & Solar has entered into a global process measurement partnership with SGS. CelSian can now rely on SGS’ operational capacity around the world for process measurements, while SGS has taken over the emission measurement activities from CelSian in The Netherlands.

“This is a win-win for both parties involved”, said Business Manager Marc van Ryckeghem of SGS. Harmen Kielstra, CelSian’s Managing Director, said: “It is an important step in the development of CelSian.”

www.glass-international.com

Verallia hails IPO offering

Pharmaceutical and packaging glass manufacturer Gerresheimer has opened an innovation and technology centre in the USA. Company CEO Dietmar Siemssen opened the centre located in Vineland, New Jersey, USA at a customer event with more than 100 participants.

The company said it will intensify glass innovations as well as optimise all its processes to enable its global network of plants to make pharmaceutical glass of the highest quality.

The team will work on new products, further digitisation, process capabilities and camera inspection systems.

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International News

BA Glass plots $227 million Bulgarian furnace

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Portuguese bottle maker BA Glass plans to invest in the expansion of its Bulgarian capacity.

BA Glass will build two new furnaces to double the production capacity of its facilities in Bulgaria.

The company currently operates two furnaces in the country - in Sofia and Plovdiv.BA Glass acquired Bulgaria’s Drujba Glassworks from Greek glassmaker Yioula in 2017.

It has since invested in its Plovdiv site with a new end-fired regenerative furnace which increased capacity by 70%. It also included four automated lines where beer bottles will be produced.

The new furnace, which became operational this year, is expected to help the company increase its output in the country from 330,000 tonnes in 2018 to 340,000 tonnes this year and 380,000 tonnes in 2020.

The company has also built a new electrostaticfilter for nitrogen and sul-

phur oxides that purifies gases from all the plant’s furnaces. A second furnace will be constructed again in Plovdiv next year, replacing the existing one, with its capacity doubled.

A second kiln will be built at the plant in Sofia, where a furnace is currently in operation, which will double production.

Beta Glass investment Beta Glass’s furnace capacity upgrade at its Agbara, Ogun, Nigeria plant is on schedule to be completed in June 2020.

The $30 million investment will include a new furnace from German engineering group Horn and an extra line from Italy’s Bottero group.

It will increase the plant’s capacity by an

extra 35,000 tonnes and pioneer the use of the Narrow Neck Press and Blow (NNPB) technology in West Africa.

This will enable Beta Glass to bring lightweight, non-returnable glass bottles to the Nigerian market for the first time.

Beta Glass operates two plants in Nigeria ­- the other is its Delta plant in Del-

ta state ­- and has an output of 1.5 million bottles a day.

Its products include beer, spirits, soft drinks, pharmaceutical and cosmetics glass jars and bottles, which range in size.

The new furnace will bring total capacity to 750 tonnes per day and have four production lines, bringing the total number of lines to eight.

Piramal Glass to invest €30 million on expanding capacity India’s Piramal Glass has invested €15 million to add three new Premium Perfume Bottle manufacturing lines.

All the three manufacturing lines are expected to be ready by May 2020.

It has also invested €15 million to modernise and expand its decoration fa-

cility in Kosamba, India with the addition of new automated printing and colour coating lines.

Piramal Glass has two glass-manufacturing facilities in India, one in USA and one in Sri Lanka, as well as offices and facilities in India, USA, France, Germany, Brazil, UAE, UK,

China, and Sri Lanka, with an overall capacity of 1375 tonnes per day.

During the 2019 fiscal year the company sold around 2 billion pieces of nail polish bottles, around 550 million pieces of perfume bottles, and around 60 million pieces of skin care jars.

Glass International October 2019

10/10/2019 09:38:52

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International News

NEWS IN BRIEF

Apple awards $250 million to Corning

Apple has awarded $250 million from its Advanced Manufacturing Fund to Corning Incorporated, supplier of precision glass for iPhone, Apple Watch and iPad. It is on top of the $200 million the company received from Apple’s Advanced Manufacturing Fund in May 2017.

The combined investment supports Corning’s research and development into glass processes, equipment and materials integral to the delivery of next-generation consumer devices.

Glass for every generation of iPhone, including iPhone 11 and iPhone 11 Pro has been made at Corning’s Harrodsburg, Kentucky plant.

PaneraTech hires two for SmartMelter project

PaneraTech has hired two new members of staff to work on its SmartMelter furnace health solution.

Jon Wechsel has joined the company as the new SmartMelter Services Manager.

Ece Isel has joined the IT team in Ankara, Turkey as Senior Product Manager.

www.glass-international.com

Sainsburys to increase use of glass bottles?

The Guardian has reported that Sainsbury’s could soon sell milk and fizzy drinks in returnable glass bottles.

The supermarket said the move as part of a drive to halve the amount of plastic packaging it uses over the next six years.

It currently uses nearly 120,000 tonnes of plastic packaging a year and is pledging to reduce that figure by 50% by 2025, with its own label and branded grocery products coming under scrutiny.

Sainsbury’s said the push on plastic would mean using alternative materials such as glass, lighter-weight plastics, and the introduction of ‘refillable packaging at scale’.

Top 10 stories in the news Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1. Nampak Glass to be sold for RS 1.5 billion � 2. Piramal Glass to invest €30 million � 3. Beta Glass’s $30 million Nigerian investment � 4. Guardian Glass to close Milbury, Ohio plant � 5. Stölzle hires Forglass to supply new furnace � 6. Glass consumes more than half of soda ash production � 7. Verallia hails successful IPO offering � 8. Zippe receives Osotspa batch plant order � 9. Solvay increases glassmaking raw material capacity � 10. O-I set to install Magma technology at Holzminden plant

Bormioli Pharma to acquire R&G Beteiligungs Italian pharmaceutical glassmaker Bormioli Pharma is to acquire primary glass packaging group R&G Beteiligungs.

R&G is active in the business of plastic and glass primary packaging mainly used

in the pharmaceutical industry. It employs approximately 270 people and operates two plants in Schleusingen and Altenfeld, both in Germany.

R&G registered a turnover of €25.6m and an EBITDA equal

to €4.1m (representing 16.0% margin) in the fiscal year 2018.

The transaction is due to close during the fourth quarter of 2019.

Bormioli is owned by the Triton Fund IV.

Gerresheimer increases use of PCR glass at Momignies site Gerresheimer has been successfully producing glass with a high proportion of post-consumer recycled (PCR) material for over 10 years in Momignies, Belgium.

“We have been using recycled glass for cosmetic packaging for over 10 years now, making us market pioneers,” says

Nicola Balena, General Manager at Gerresheimer Momignies.

“Our recycled glass packaging has won over many of our customers seeking to improve their packaging sustainability without trade-offs.

“We are committed to the circular economy and only pro-

duce cosmetics packaging with a high post-consumer recycled glass content. We are ahead of the market in this respect.”

Gerresheimer has developed glass for cosmetics packaging that has the highest percentage of post-consumer recycled (PCR) material available today.

Forglass opens expanded plant Forglass has celebrated the opening of an expanded and modernised production plant.

The plant near Czestochowa, Poland, will be used to manufacture batch plant machinery and steel structures for batch plants and furnaces.

The expansion of the pro-

duction plant was aimed at increasing production capacity and expanding the scope of production with large-scale constructions and devices.

The new assembly department allows clients to participate in testing the equipment prior to shipment and deliv-

ery.

The modern anti-corrosion and automated welding facilities assure work conditions in line with demanding global environmental standards.

In addition, an Enterprise Resource Planning (ERP) system has been implemented.

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International News

NEWS IN BRIEF

Pennine appoints trainee sales engineer

Pennine Industrial Equipment has appointed Will Law as a trainee international sales engineer.

Will recently graduated from Sheffield Hallam University, UK with a firstclass honours degree in Material Engineering.

He is looking forward to eventually doing business in Asia as well as the rest of the world.

Although Will is new to sales, he aims to bring new insight to Pennine and hopes to build relationships with new and existing customers.

Bovone to open United States branch in 2020

Italian flat glass manufacturer Bovone will open a new branch in North Carolina in the United States in 2020 intended to serve the North American markets.

The new headquarters is a strategic decision aimed to answer market demand, in synergy with Bovone’s technology distributor in the area, Salem Distributing Company.

The headquarters will consolidate the presence of the brand in a market that, year after year, continues to value made in Italy technologies.

www.glass-international.com

Conference presentations to download

Conference presentations from Glassman Europe are now available to download for free.

A total of 17 presentations were given at the event in Lyon, France and they are now available to download.

The conference themes were Trends in Glassmaking on day one and the Future Glass Forum on day two.

Papers were given by the likes of FEVE, Rabobank, ABI InBev, SGD Pharma, BV Glas, Xpar Vision, Novaxion, FAMA, Glass Service and Siemens.

Visit https://www. glassmanevents.com/europe/ conference to download the presentations.

Hite Jinro Ind selects Socabelec for its Jinju plant South Korean container glassmaker Hite Jinro has chosen a Socabelec swabbing robot for its Jinju plant.

Hite Jinro is a beer and soju producer and is to rebuild its Jinju plant in February 2020.

The reconstruction of the furnace is also an opportunity to use the latest technology to produce glass containers.

Hite Jinro wanted to invest in automatic swabbing to guarantee the highest level of productivity. After a long investigation process, including

visits abroad to meet other users to get their feedback, it selected the Socabelec swabbing-robot. It cited customer user satisfaction, reliability of the robot, on-the-fly swabbing without stopping production, without rejecting containers, as well as a high level of safety for operators working together with the robot, as the main criteria for the decision.

Pictured left Mr. Lim C.E.O. Hite Jinro, right Mr Marco Veri C.E.O. Socabelec.

GlassTrend deemed a success A meeting dedicated to process automation and big data in the glass industry was deemed a success.

The GlassTrend seminar was hosted by Linde at the Agora building in Munich, Germany recently and was devoted to subjects such as machine learning, industry 4.0 and big data.

As well as speakers from the suppliers and manufacturers, it included presenters from outside the glass industry.

Anne-Jans Faber, Chairman of GlassTrend, said that GlassTrend was aiming to introduce speakers from other

sectors in order to increase industry perspectives.

He said: “GlassTrend seminars are known for their high level and interesting speakers.

This meeting was about data analytics and sensors and there were several examples from other industries where we can learn from.”

One of the speakers was from compatriot company Machines2Learn, which builds algorithms based on huge amounts of data.

Another guest speaker was Braincube which has worked with Verallia and Ardagh, as

well as travel companies.

The event also included speeches from traditional glass-related companies such as Ardagh, Owens Corning, Sisecam and Siemens.

Mr Faber said: “The day to day issue for the glass manufacturers has been getting the data from the furnaces, and they have organised that.

“The next chapter is to make sense of this immense pile of data they have obtained.”

The next GlassTrend meeting will be hosted by Sibelco in Belgium on March 31-April 2 and will focus on raw materials.

Verallia Spain awards electrode holder contract to Fives Verallia in Spain has awarded Fives the supply of 21 Prium VariCool electrode-holders for its plant of Azuqueca de Henares, Spain plant.

A furnace reconstruction will take place at then beginning of next year and Fives will supply and install the

electrode-holders.

Fives installed 30 holders at Verallia’s Burgos plant in Spain last year and which have been in successful operation since.

Fives said the Prium VariCool equipment is the latest generation of holders availa-

ble on the market and allow a variable and high cooling capacity.

It has installed electrode-holders for more than 20 years and said its equipment was known to be robust and reliable.

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Company profile: Gallo Glass

Gallo Glass embraces the latest digital technology � Main picture: The plant in California. � Overleaf: Some Gallo Glass bottles and company founders Ernest and Jullio Gallo.

California-based winemaker and glassmaker Gallo Glass has recently completed a capacity expansion and modernisation. Its revamped furnace three has � the latest environmentally friendly technology while its forming and inspection equipment rely on digital technology. Technology innovations have run through the history of the company, Vice President John Gallo tells Greg Morris. www.glass-international.com

John Gallo.

I

nnovation runs through the veins of Gallo Glass. Gallo Glass has invested in the future of glassmaking, just as it did when it was formed more than 60 years ago The Modesto, California-based winemaker and glassmaker has recently completed an expansion and modernisation of its Furnace Three operation.

The investment included a new energy efficient furnace, triple gob wine bottle forming machines and the latest inspection machinery. The technology will allow the glass plant to increase production by 20% to its current 500,000 tonnes per year capacity. The plant will maintain the same overall footprint and help towards meeting the

State’s climate change goals.

Similar to how the glassmaking arm of the company originated in 1958, the investment was based on moving the company forward and ahead of its rivals in what is a competitive businessas China imports into California.

Back in 1958, company founders Ernest and Julio Gallo invented a glass colour called Flavor Guard.

Today it is an industry-wide colour commonly known as reduced champagne green.

The Gallo innovation was the first type of reduced champagne green in the industry and was used to help stop UV light spoiling sweet wines.

Today, company Vice President John Gallo is the

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Company profile: Gallo Glass

� Triple Gob IS machine.

Continued>>

www.glass-international.com

third generation of the family to run the business and that thread of innovation still remains integral to the company.

“This expansion today is very similar to how we got into the business in 1958. We were looking for a cost competitive advantage, as well as an innovation which is important to us.

“We started on a a continual innovation and that has run through the company to the present day.”

Over the years Gallo Glass has been at the forefront in new technology, both in regards to efficiency and to sustainability. One of its most notable moves in recent years was the introduction of oxy-fuel technology back in the 1990s. This reduced NOx by 80%, the equivalent of taking 97,000 cars off the road.

“My father was big on sustainability and he was the one who got our glass plant into oxy-fired furnaces, which were the first in the world.

“That environmental trait started with him. It was one of my father’s many contributions and it was a big innovative step for us.

“Before then we had all conventional-fired furnaces and to take this jump into oxy-fired furnaces with Praxair and Corning was a big step.

But he had a long term environmental view.” That was particualrly relevant California which has particularly stringent environmental standards.

The recent expansion is similarly pioneering.

It involved the introduction of high-tech, digital glassmaking technology. The triple gob forming machines used for wine bottles are the only ones in the United States as far as Mr Gallo is aware.

The six month project began in September 2018 and involved more than 250 trade workers at its peak. The expansion will create 30 jobs within the glass plant. German engineering company Sorg supplied an oxygen-fired furnace while technology partner Bucher Emhart Glass supplied servo NIS forming machines and inspection machinery.

This forming and inspection equipment brings the hot and cold end under one roof using Emhart’s closed loop technology and, using its Scout equipment, means the hot and cold end can communicate with each other.

The relationship with Emhart began when Gallo Glass was formed. The Swiss technology group supplied a six-section IS machine and was instrumental in developing the plant. Today a Technical Assistance Agreement is in place between the two organisations. Gallo Glass staff regulary attend Emhart’s R&D centre in Connecticut, USA for training, while Emhart provides operational and best practice support.

Mr Gallo said: “We’ve tied our future strategy in terms of technology to Emhart, we think they have the right vision going forward, they’re investing in the right way and we want to support that by buying their equipment, by building technical assistance agreements with them, and to do training, operating support and development with them.”

In Mr Gallo’s words the development expansion has the ‘full suite’ of technology and sensors from Emhart. Each of the lines has its robots, each has the Symplex gob image which takes pics of the gob, the blank radar, which takes pics of the loading into the blank and the FlexRadar which takes infra red imagery.

Gallo Glass is also a committed member of the International Partners in Research organisation, based in Aachen, Germany. Alongside fellow glassmakers, Fevisa, Nihon Yamamura Glass, Orora, Sisecam, Vetropack, Vidrala and Wiegand-

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Company profile: Gallo Glass

Glas, as well as Emhart, the organisation strives to increase the competitiveness of the glass industry by sharing research in a non-competitive environment.

“We have always been very open over the years and have built relationships with organisations such as the IPGR, FEVE and the Glass Packaging Institute (GPI). They are very reciprocal and working with these organisations has been very beneficial.”

It was this openness and willingness to share information, as well as its advances in oxy-fuel technology that persuaded the Phoenix Award committee of glass technology suppliers to recognise Mr Gallo as its Glass Person of the Year in 2008. The committee said the company had a focus on continual improvement in the technology of glass making and sustainability.

FAST FACTS �

4 natural gas oxygen fired furnaces.

�

14 individual section forming lines.

�

5 colours available - Eco Flint, Antique, Dead Leaf Champagne Green and California Flint.

�

Each Gallo Glass bottle contains up to 50% recycled glass.

�

California’s largest single site user of recycled glass.

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Gallo Glass recycles and reuses 93% of its process water daily.

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Environment The environment was a focus when the new equipment was installed. California plans to reduce CO2 emissions by 40% by 2030, which is only one furnace lifetime away.

The new furnace commissioned at the plant has been pre-engineered to install Praxair’s waste heat recovery system to help achieve higher targets. The new technology can further reduce furnace energy demand and CO2 emissions.

All of Gallo Glass’ wine bottles produced are sold within California. About 80% will be used by Gallo’s own winery and the remainder sold to the more than 4200 wine makers in the state.

The new capacity will give California’s wineries the option to buy locally produced bottles direct.

Gallo can typically supply glass within two weeks of order placement and deliver just in time for filling at the customer.

Gallo Glass has noticed the trend in the growth of boutique wineries. The premium wine segment is growing by 4-8% a year and Gallo’s premium customers are increasingly asking for faster service and more flexibility.

The Emhart NIS servo machines can run multiple bottles on the same line. This provides customers with increased marketing options to customise bottles at a lower upfront mould cost and enable shorter production orders.

Mr Gallo himself has spent a lifetime surrounded by glass. As a child he remembers joining his father on Sunday visits to the glass plant and to its nearby company-owned limestone mine. It was during these visits that he gained an interest in glass, an interest which has lasted all his life.

“Growing up with glass was a major part of my life. It was during these trips that I started to develop an interest in it and became fascinated by how glass was made.”

He admits though that when he was young, conversation around the family dinner table would invariably turn to wine and the winemaking business rather than glass!

After leaving college he worked in the winery and gained an understanding of a customer’s perspective and the importance of glass from a customer side. Then, after 20 years, he moved to glassmaking in the mid 1990s. He had spotted opportunities in sustainability and in bulk glass and wanted to pursue them.

The company then pursued a policy of lightweighting its wine bottles. The bottles had traditionally been very heavy but the group managed to reduce its standard bottles by 20% and its premium wines by 10%. At the time they were the lightest in the Californian wine industry.

Mr Gallo estimates that approximately 35 million cases of wine have been lightweighted which when transportation is also taken into account, has made a significant contribution in its sustainability efforts. He has also overseen the conversion to bulk glass. Over the course of 10 years the group converted the majority of its 18 lines to bulk glass.

One of the most satisfying aspects of his career has been witnessing the switch of glassmaking from a largely manual process to a technological one.

“We have seen people adapt and use the new technology. Through innovation we have seen the glass process evolve and change and bring in a new generation of glassmakers. It has gone from more physical work such as swabbing to a more servo driven, precision process, which uses data to work smarter and to prevent defects.

“We’ve seen seen our team members go from the more traditional method of making bottles to a new generation who utilise the technology.”

“Our technology platform is set up for future closed-loop functionality and automation to attract the next generation of glass employees.” �

Gallo Glass, Modesto, California, USA www.galloglass.com

12 Glass International October 2019

Company profile Gallo glass.indd 3

09/10/2019 14:52:44

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Brand equity

Brand equity can be enriched in glass Emma Bowers and Richard van Breda suggest that the glass industry should take a lead in enhancing brand equity.

Arguably one of the most globally recognisable brands can be immediately recognised simply by the shape of the bottle (Fig 1). In fact, the shape we recognise today was the result of a competition in 1915 to develop a new bottle that could stop from being copied so easily. The now famous bottle was patented in 1915 by the Root Glass Company of Terre Haute, Indiana, USA. The creative brief given to Root called for a bottle that could be recognised when broken on the ground or by touched in the dark. Apparently, the designers researched Coca in their local library and it led them onto Cocoa and to the Cocoa pod concept design that we recognise today. The shape has stood the test of time and has become the icon of the brand all around the world. It is instantly recognisable and everybody is familiar with it – there is no need to even mention the brand!

Contrasting this, some of the bestknown beer brands in the world use a bottle that has instant recognition as a beer bottle, but it could be one of many brands (Fig 2). The shape of the glass bottle does not carry any specific brand identity in these cases.

These two simple examples demonstrate the importance of how packaging shape, not just the material and its overall functionality are critical and integral components building brand iconography. Logic thus suggests that this presents a genuine opportunity for glass to enhance brand equity and positively support appropriate brand values. In many instances brand owners will utilise multiple packaging offerings to ensure they are able to reach as many consumers in as many occasions needs as possible.

However the brand will often use the

glass package as its premium and most marketed offering.

Other packaging What can be learnt from some of the other packaging substrates? Many of the other packaging materials have standard format shapes across their ranges (Fig 3). The package shape is dictated by function, rather than brand. The majority of beverage packaging substrate options have generic forms. Metal cans which have a uniform external shape no matter if it contains a sparkling soft drink, beer, fruit juice or alcoholic mixer. The same is considered for fibre based (carton) packaging, in neither case does the form give insight to the brand or product.

PET (Plastic) packaging offers a wider range of format sizes and convenience packaging at a low cost (Fig 4). Fulfilling the needs of a large number of customer and consumer channels, and is a material that can offer brand owners more tailored shapes than a can or carton.

However frequently seen in supermarket and discounter channels in a very generic shape which is offered for mainstream convenience and offers almost no brand identity and is designed purely for functionality.

These other types of beverage packaging, generic in form, understand this disadvantage and often rely heavily on the label and printing on the large surfaces to carry brand images. In many cases the increased printed surface areas of the packaging allows for iconography to be displayed. Ironically, differentiation can also be a powerful tool for standout.

A great example is by using a ubiquitous fibre carton and place it on a shelf full of plastic bottles in the water aisle and you instantly have high impact standout!

� Fig 2. A long neck

� Fig 1. Arguably the

beer bottle – the

most iconic packaging

shape identifies it

shape – with instant brand

immediately as a

recognition from the

beer – but it could be

shape of the bottle.

any one of many beer brands.

Label industry The label industry is moving forward at a rapid rate with many innovations which are creating sensational new graphics and options for labels. Labels have moved on from the traditional paper format moving to options that include metalised, PSL (no look label) and now high-speed digital printing is starting to open the door for truly personalised high impact labelling.

Ironically, digital printing appears to be gaining more traction in plastics rather than glass, mainly due to the relative ease of application on plastic versus glass.

Yet, in most of these developments it appears that the label industry is leading the charge on development.

Given that generally the most significant component of the packaging value chain is the package (glass, plastic, metal, carton) itself, does it not make sense for the primary package to take a greater role in enhancing the brand? As such the question must be asked, if there is an Continued>>

14 0 Glass International October 2019

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09/10/2019 15:19:47

Brand equity

opportunity for the glass containers makers to get more involved in the development of further innovations to make glass more indispensable in the pursuit of creating iconic brand images for their customers? Do you believe that the glass industry can take a stronger leadership role in this area?

Building brand equity In closing, brand owners look to build equity in their brands in multiple ways but shape and personalisation are certainly two key considerations. The glass industry can learn more about where it can play effectively and provide greater equity to the brands they support.

There is a genuine role for every type of packaging in the market. Brand owners and marketers build out their portfolio propositions based on robust and intelligent OBPPC (Occasion Brand Price Pack and Channel) architecture in which several packaging formats and materials will likely feature. But one thing is certain, brands with optimal equity are those that are able to maximise re-use of its lead package or hero image also known as hero pack. Make glass the hero! � About the Authors Emma Bowers and Richard van Breda both have extensive experience in packaging and glass particularly. Their specific experience in large global FMCG businesses allows them to provide a fresh perspective to glass manufacturing from both sides of the supply relationship.

In a series of articles, a number of industry relevant topics will be discussed and unpacked. The topics will provide another perspective the industry often reflecting the opinion of the glass customer or consumer. In doing so, we will discuss some opportunities we see for the industry and hope to spark some debate in the process.

We’d love to hear from you with any comments, questions or other topics you would like us to cover in upcoming publications.

Richard van Breda Richard van Breda Consulting richard@richardvanbreda.com

3

www.glass-international.com

Emma Bowers Managing Partner, Green Puffin Consulting Limited emma@greenpuffinconsulting.com www.greenpuffinconsulting.com

4

�Fig 3. Metal and carton packaging – shapes are brand agnostic. � Fig 4. A large format PET bottle with a generic shape – designed with function in mind and ambivalent to the brand.

15 Glass International October 2019

Emma.indd 2

09/10/2019 15:19:48

� Mr Ben Simon has worked with the company for 14 years.

Israel’s only container glass manufacturer From a government owned company in the 1960s to being privatised in the 2000s, Phoenicia Glass container manufacturer has gone from strength to strength. George Lewis spoke to Michel Ben Simon*.

Government beginnings The decision to put the company in the south of Israel in the 1960s was a well thought out process.

It was built there due to the location of the sand for which Phoenicia use.

As a then government-owned company, getting people into employment was also high on the list of priorities. So basing the company in Yeruham helped provide jobs to many people in the town.

The significance of basing the company there still remains today, with employees still coming from Yeruham and neighbouring town Dimona with now approximately 240 employees.

Phoenicia was government owned all the way until 2004, when it was bought out and privatised

by Israel Equity Group.

A strong foundation Phoenicia has a furnace capable of 300 tonnes per day, and four production lines manufacturing bottles and jars of many colours for companies including Coca-Cola, Sprite, Pepsi and Heineken.

Phoenicia is also able to produce wine bottles, which are used in the local Israeli market.

Mr Ben Simon says that between 80-100 different products are produced at the Yeruham plant.

Until 2006, those products were created predominantly for the domestic market, but with regulation changes in the country, Phoenicia was able to export further afield to different countries including Jordan and Italy.

In 2018, Phoenicia looked at opportunities in the international market and talks started to export to countries such as Belgium, Greece and Cyprus.

The Minister of Economics for Israel acted as a consultant for Phoenicia, to aid talks and build relationships with other European countries.

Mr Ben Simon says that his hope for the company is to ‘export 40% to 50% of the total capacity of Phoenicia to these new countries in the future.’

But despite developments within the country, exporting can be difficult. This is due to high transport costs out of Israel.

Mr Ben Simon believes that because some countries have no strong business relations with Israel, thus not being interested in importing the Continued>>

www.glass-international.com

S

ince its humble beginnings in 1968 as a government owned company formed in the south of Israel, Phoenicia Glass is now a strong exporter of container glass to European countries and beyond, despite being the only container glass manufacturer in the country.

Michel Ben Simon started out at the company 14 years ago as a Plant Manager. After eight years in the role, Mr Ben Simon was asked to head up a team to rebuild the plant’s furnace and to switch the company to natural gas.

Once this was completed, Mr Ben Simon was promoted to the role of Vice President of Projects and Regulations.

17 Glass International October 2019

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Company profile: Phoenicia Glass

on the roof of its plant. This is also to give Phoenicia the ability to produce its own electricity, which would be provided to the country’s main grid.

This project would help improve electrical efficiency in the manufacturing process going forward.

Mr Ben Simon believes that these projects are beneficial to both Phoenicia and to the country and environment as a whole. He says the projects would be “saving (Phoenicia) money whilst also helping to protect the Despite being the environment.”

Having the ability to get back 80% of glass only container bottles back exported around the globe means that the circular economy stays intact. manufacturer in Phoenicia invested in a small processing line in order to reproduce glass. This glass given Israel, Phoenicia gives back to Phoenicia is cleaned and reformed, ready to be used again.

“

strong

bottles. But despite this making it harder to find new markets, this hasn’t stopped Phoenicia.

He said: “Despite being the only manufacturer in Israel, Phoenicia gives strong competition to rivals in Turkey, Italy and east Europe”.

Mr Ben Simon also explained that due to the location, it can be difficult to attract talent.

But they had recently hired eight IS and maintenance workers from Zimbabwe, who are helping to train employees.

www.glass-international.com

Keeping it green Phoenicia prides itself on a strong customer service and a ‘green oriented production plant’ and shows its commitment to sustainability by using 90% recycled cullet.

The company also uses 60% recycled flint, lower than Phoenicia would like due to lack of material available in the country.

Phoenicia has invested in anti-pollution pieces of equipment for the furnace.

This was partly due to regulations in Israel being strict in a bid to combat air pollution in the country but it is something Phoenicia want to press forward with in the future.

Phoenicia has also invested in a recycling permit for the reduction and improvement of the company’s sewage water.

Mr Ben Simon said that the company moved to natural gas seven years ago to reduce carbon coming from the heat of the furnace to melt raw materials to form the glass. This was changed because natural gas is said to be a greener source of energy.

Projects Mr Ben Simon explained that there were two big projects on the horizon for Phoenicia.

The first is a 5MW power plant to supply and produce its electricity in-house. He expected completion of the plant to be in 2021.

The second project is to build a solar panel system

competition to rivals

Strong distance relationships

Despite being the only container glass manufacturer in Israel, building relationships in Turkey, Italy and with equipment suppliers across the globe has been imperative for Phoenicia. east Europe The company uses an IQ scanner from Tiama to monitor and create more accurate data in real time. The French company also provided inspection machines to Phoenicia. � Leading technology Emhart supplied one IS machine to Phoenicia. suppliers have provided The now defunct GPS provided the other equipment to the plant. machines at the plant. Despite the company not trading anymore, this hasn’t stopped Phoenicia using these machines, as Germany’s Rath Group now has the licence to produce mechanical parts.

Sorg supplied the furnace, while MSK supplied a new shuttle car and shrink machine.

He explained that he was confident in asking for help or training from these companies whenever Phoenicia needed.

The company has even used its relationships with European countries to hire supervisors to create on the job training from beginning to end.

”

Future furnace When asked what Phoenicia has planned for the future, Mr Ben Simon said that approximately €25 million will be spent on a furnace rebuild. This is likely to be completed in 2022.

Apart from that it is to empower current and future employees at the plant. Mr Ben Simon said that Phoenicia want to provide ‘unlimited investment in people’ and this comes straight from the top with owner Mr Morton Mandel whose main aim is to make sure employees have all the training and requirements necessary.

To sum up Phoenicia and its time as a manufacturer, Mr Ben Simon said: “It’s a big challenge that never stops.” �

*Vice President of Projects and Regulations Phoenicia Glass, Yeruham, Israel www.pgw.co.il

18 Glass International October 2019

company profile phoenicia.indd 2

10/10/2019 08:39:21

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Map of French hollow glassplants

20 0 Glass International October 2019

France.indd 1

09/10/2019 14:56:37

Map of French hollow glassplants

ARC GROUP HEADQUARTERS, ARQUES

GERRESHEIMER CHALON S.A./ FLACOR

O-I FRANCE / BEZIERS O-I FRANCE / GIRONCOURT O-I FRANCE / LABEGUDE O-I FRANCE / PUY-GUILLAUME O-I France / REIMS O-I FRANCE / VAYRES O-I FRANCE / VEAUCHE O-I FRANCE / VERGEZE O-I FRANCE / VILLEURBANNE - HEAD OFFICE O-I FRANCE / WINGLES

NIPRO PHARMAPACKAGING / AUTHON-DU-PERCHE

NIPRO PHARMAPACKAGING /

LUCENAY LES AIX PLANT

POCHET DU COURVAL/ BEAUGENCY

POCHET DU COURVAL / GAMACHES

POCHET DU COURVAL /

GUIMERVILLE PLANT

POCHET DU COURVAL HQ PARIS

SAVERGLASS GROUP /

HEADQUARTERS FEUQUIERES

SAVERPLUS / SAVERGLASS GROUP COULOMMIER

ALPHAGLASS / SAVERGLASS GROUP ARQUES

TOURRES & CIE /SAVERGLASS

GROUP, LE HAVRE

SCHOTT FRANCE PHARMA SYSTEMS SAS Pont-sur-Yonne SCHOTT SFAM FRANCE CASTELJALOUX

SGD PHARMA PARIS

SGD PHARMA SAINT-QUENTIN LA-MOTTE

SGD PHARMA SUCY-EN-BRIE

STOELZLE MASNIÈRES PARFUMERIE SAS

VERALLIA FRANCE/ALBI

VERALLIA FRANCE/ CHALON SUR SAONE

VERALLIA FRANCE / COGNAC

VERALLIA FRANCE / LAGNIEU

VERALLIA FRANCE / OIRY

VERALLIA FRANCE / SAINT-ROMAIN

VERALLIA FRANCE / VAUXROT

VERALLIA HEADQUARTERS

PARIS LA DEFENSE

VERESCENCE / MERS-LES-BAINS

VERESCENCE / VERRERIES DE L’ORNE

VERESCENCE / VERRERIES DE LA SOMME

VERESCENCE / HEADQUARTERS

PATIO DEFENSÉ

VERRERIES BROSSE/ZIGNAGO VETRO

ROUEN SUR BRESLE

WALTERSPERGER/ BLANGY SUR BRESLE

Continued>>

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21 Glass International October 2019

France.indd 2

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Map of French hollow glassplants

Employment Total employees. - Manufacture of hollow glass Year

No of employees

yoy % change

2008

23544 0.00%

2009

21929 -6.86%

2010

21558 -1.69%

2011

21251 -1.42%

2012

20580 -3.16%

2013

19964 -2.99%

2014

19560 -2.02%

2015

19167 -2.01%

Source: Institut national de la statistique et des études économiques (2019)

Summary

�

No of companies: 10

�

No. of locations:26

�

No. of furnaces: 48

manufacturers: � Current O-I, Verallia, Verrerie du Courval, Saverglass, SGD Pharma, Verescence, Verrerie Brosse, A l p h a G l a s s , Gerresheimer, Stoelzle. �

Capacity: ≈4,131, 800 TPA

Source: Glass Global (2019)

� In 2015, 19,167 people were employed in the core container glass sector. � Employment in this industry has been decreasing in recent years.

Capacity Capacity of EU container glass Country TPD TPA Germany

13,785 5,031,525

France

11,320 4,131,800

Italy

11,502 4,198,230

United Kingdom

8,015

Poland

7,606 2,776,190

Spain

6,932 2,530,180

2,925,475

Portugal

4,589 1,674,985

Rest of the EU

13,980

Total

77,729 23,339,560

5,1027,00

Source: Glass Global (2019)

Value of the French container glass industry Value of French container glass traded (2013-18) Year

2013

2014 2015 2016 2017 2018

€ 21,602,000

€ 5,290,000

€ 5,180,700

€ 7,143,000

€ 6,786,000

€ 13,479,000

€ 11,830,980

€ 11,888,910

€ 13,087,600

€ 12,257,360

€ 13,034,690

€ 362,868,510

€ 425,909,027

€ 393,921,892

€ 410,249,730

€ 406,969,260

€ 447,160,040

€ 751,655,956

€ 698,875,010

€ 684,645,126

€ 694,765,876

€ 726,518,161

€ 727,199,718

€ 132,564,213

€ 128,865,338

€ 117,031,320

€ 135,204,740

€ 137,384,420

Total sales revenue

€ 25,742,200

€ 371,795,838

€ 385,012,532

€ 345,843,900

€ 383,600,796

€ 250,320,629

€ 1,505,089,304

€ 1,659,372,462

€ 1,219,321,266

€ 1,580,978,426

€ 1,693,295,317

€ 1,607,627,697

Source: Euro Stat (2019)

�

The French container glass industry achieved sales revenue of €1.6 billion in 2018 a -5.1% decrease on 2017.

France’s non-EU trade of container glass Source: Euro Stat Trade Market Access Database (2019)

France in 2018 was the largest � trader with non-EU countries.

French container glass � exports to non-EU countries totalled around €236 million (24% of total EU exports).

22 0 Glass International October 2019

France.indd 3

09/10/2019 14:56:38

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23.03.17 15:54

Events review: Glassman Europe

1

2

The recent Glassman Europe event included a two-day conference devoted to trends in glassmaking. Speakers included analysts, associations and a case study on the capacity expansion at O-I’s plant in France.

3

3a

4

5

1. Greg Morris, conference chairman; 2 Susan Hansen, Rabobank; 3 Emma Bowers, Puffin Consulting; 3a Richard van Breda consulting, 4 Sheryl Webersberger, BV Glas; 5 Aline Casagrande, AB InBev.

10

11

12

13

10. Paul Schreuders, Xpar Vision; 11 Matthieu Dumesny, Novaxion; 12 Pascal Huguet, Siemens; 13 Jasa Polutnik, Steklarna Hrastnik.

An update on O-I’s Gironcourt plant T he engineering group responsible for the construction of the O-I Gironcourt plant in France gave an update on its progress at the recent Glassman Europe event.

Nicolas Lelorrain, Project Manager at Chovet-Db2i, gave a presentation titled O-I and Chovet-Db2i set for success on Gironcourt partnership, at the event in Lyon, France in September.

Chovet is responsible for the engineering, procurement and construction management (EPCM) of a new furnace at the Gironcourt site. Once completed the €60 million investment will increase the number of furnaces at the plant to three, with nine production lines. It means O-I can produce 1.9 billion beer bottles a year compared to the current 1.3 billion.

Mr Lelorrain said the project was still on schedule to be completed by March 2020.

He said: “All signs currently point to success in early Spring 2020. We are confident, given our experience with the Guadalajara, Mexico plant. Everything is still on schedule.”

O-I selected Chovet because of its impressive display in the construction of the Saverglass container glass plant

in Guadalajara, Mexico, which recently celebrated its first anniversary.

“As project manager over there the construction was managed perfectly from start to finish. Construction began in

2017 and took only 327 days to finish.”

He added: “For Chovet the partnership means taking ownership of our customers multi challenges and overcoming them.

“For O-I, by calling in a third-party engineering group, means they have peace of mind on a challenging project.”

The project had the backing of a

number of parties, including the local authority and the French train operator SNCF, which had renovated a nearby railway line to ensure supplies could easily be transported to the site.

“We think the new furnace and commissioning of a production line is an exciting venture which brings together people who share the same values, culture and love of glassmaking to achieve something truly great,” Mr Lelorrain concluded.

The Glassman conference included 17 presentations over two days. The conference explored two themes: Day one was devoted to Trends in Glassmaking while day two was titled the Future Glass Forum and investigated themes such as Industry 4.0, digital glassmaking and Big Data in glassmaking.

Keynote speaker Susan Hansen, Global Strategist for F&A Supply Chains, of Rabobank, provided a presentation titled The future of plastic packaging in a (more) circular economy.

She discussed global consumer trends and the impact on plastic packaging demand before moving on to sustainability and circularity challenges and opportunities. She finally asked what

24 0 Glass International October 2019

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6

7

8

9

6 Erik Muijsenberg, Glass Service; 7 Fabrice Rivet, FEVE; 8 Daniel Backhouse, Sheffield Hallam University, 9 Nicolas Lelorrain, Chovet.

14

15

16

17

14. Kevin Fiedler, SGD Pharma; 15 Thierry Barriant, Glass Service; Eleonora Bordini, Marposs; Juan S. Farias, FAMA.

the future holds for plastic packaging, particularly since the rise of the Blue Planet effect.

The second keynote speech was provided by former Coca-Cola executive Emma Bowers and former SAB Miller executive Richard van Breda. They discussed the container glass industry from a customer perspective and asked Is the container glass industry aligned to customers' expectations? This paper was published in the July/August issue of Glass International.

Sheryl Webersberger, Product Policy Advisor of German association BV Glas then provided an environmental overview with a paper titled The container

glass industry and its role in the circular economy.

Sustainability and the environment were the themes of the next few papers.

Aline Casagrande, Circular Packaging Global Manager, at AB InBev discussed the company’s sustainability strategy.

Erik Muijsenberg, Vice President at Glass Service in the Czech Republic, then highlighted how a reduction in CO2 emissions is both necessary and possible.

Then FEVE’s Director of Health, Environment and Safety, Fabrice Rivet, discussed Decarbonisation and the Circular Economy. His paper outlined what glassmakers need to do in order to meet strict forthcoming European legislation.

The final paper before lunch came from a more scientific rather than industrial angle but presented environmental possibilities for glassmakers. Dr Daniel Backhouse, a Post Doctoral Research Fellow at Sheffield Hallam University, discussed how Biomass Ash is both a past and a present raw material in glassmaking.

An abridged version of his paper was also published in an article in the July/August 2019 issue of Glass International.

The remaining three papers on day one were focused on new technologies in the industry. After Nicolas Lelorrain’s talk, Paul Schreuders, CEO of Xpar Vision, highlighted a new world of glassmaking before Mathieu Dumesny of Novaxion concluded the day with a talk about the swabbing robot.

The second day’s talks focused on the future of glassmakng and included presentations from Siemens, SGD Pharma, Steklarna Hrastnik, Glass Service, Ametek Land, Marposs and FAMA. Glassman Europe was a combined trade show and conference that took place in Lyon, France. The trade show’s focus was on the glass packaging industry such as container glass, tableware and pharmaceutical glass.

The 735 visitors included guests from France, UK, Germany, Italy, Russia, Turkey and Mexico, among others. Companies represented included Vetrobalsamo, O-I, Heineken, Verallia, Ardagh, WiegandGlas, Caltex, Ekran, Stoelzle Flaconnage and SGD Pharma. �

*All conference presentations are available to download from the Glassman Europe website https://www.glassmanevents.com/europe/conference *The next Glassman takes place in Seoul, South Korea on February 25 and 26. www.glassmanevents.com/asia

www.glass-international.com

Events review: Glassman Europe

25

French and glassman review.indd 2

09/10/2019 15:47:16

Events preview: Glass Focus

T

he Glass Focus combined conference ands awards evening, organised

by British Glass, will take place on Thursday 21 November 2019 in Sheffield, UK The event includes a full daytime programme of speakers, networking and discussions, followed by the evening gala awards dinner – all hosted at the Mercure St Paul’s Hotel, in the heart of the city.

The awards are the showcase for the £1.6bn UK glass industry and everyone with a stake in glass is invited. It is an opportunity to celebrate and network with decision makers including glass manufacturers, machinery and material suppliers, recyclers, brands and buyers, policy makers and researchers.

The deadline for this year’s entries has now passed. This year’s categories are: � Design of the year – container � Design of the year - flat � Innovative solution � Health and safety action � Sustainable practice � Apprentice of the year � Strengthening business through people

� Last year’s winners.

All set for Glass Focus awards The winners will be named during the evening awards dinner. Last year’s winners included O-I, Ardagh Glass, Saint-Gobain and Pilkington. The prestigious Company of the Year award went to Nippon Electric Glass Fiber based in Wigan, UK.

Conference The awards evening will be preceded by a day time conference. Confirmed speakers include ICG President and current Phoenix Glass Person of the Year, Alicia Duran. She will discuss the subject of Women in Glassmaking.

Andy Williams, Manufacturing Lead at the CBI, will cover issues and changes in UK manufacturing.

Other speakers are Sanjay Patel – founding Partner at The Packaging Collective who will discuss The purpose & 5Ps of packaging, Brian McMillan, Chair of Glass Futures, The latest developments from Glass Futures and Martyn Marshall, Principal Technologist at Glass Technology Services Ltd. �

British Glass, Chapeltown, Sheffield, UK www.britglass.org.uk/glass-focus-2019

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Glass focus preview.indd 1

09/10/2019 15:17:34

Fo Founded in the late 90s and set up in the province of Parma, ALL GLASS s.r.l. has been the protagonist of a deep and constant evolution GL over the years, consolidating its presence in the National and ov Int International market as a leading supplier of “Cold End" equipment and the most advanced technological packaging equipment for the an Glass Industry.

Gla ALL GLASS has several production units, which cover an area of AL approximately 15,000 square meters. app Our staff consists of approximately one hundred employees equally divided managers, technical employees and specialized production among executives, execut engineers. extensive experience gained over the years being the most preferred Thanks to our ext supplier for small smal and big manufacturing companies, All Glass is today a reliable partner for the de development of "Turnkey" solutions.

We are leading tthe market, thanks to a wide range of technical and performing industry in the "Cold End" area starting from different types of solutions for the glass g LEHR unloading con conveyors up to the complete package of the finished products in the warehouse, incorporating special machines and equipment for the treatment of the most different containers - standard standard, shaped,, p perfumery, pharmaceutical and tableware p products - both y, p "Cases" in "Bulk" and in "Cases".

The commitment and the ability to realize important nt projects has led ALL GLASS to play a pre-eminent role all over the world ass a most preferred and reliable turnkey project supplier.

A customer-oriented Company, a wide and versatile tile production range, a flexible and dynamic internal structure combined with continuous investment in the research and development ment area (R & D) ers. make ALL GLASS a unique interlocutor for his customers.

ALL GLASS’s goal is the customer’s satisfaction, achieved hieved through hard and thorough work starting from the pre-sale, sale ale and after sales phases.

Every step of the project is carefully studied and d d pursued thanks to the expertise of our team and mostly to the constant cooperation with ourr customers. Nothing is left unexplored, since we know w that the detail can make the difference to the successs of a project.

The constant and continuous improvement, which is a "must"; the care in the choice of raw materials and d components, the customer oriented philosophy make ke ALL GLASS stand out as a leader, a highly efficient and fully reliable company in the development of industrialized alized and integrated systems for the Glass Industry.

All Glass S.r.l. Via Cesare Sarti, 20 - 43029 Traversetolo (PR) - ITALY Tel. +39 0521 340810 - Fax +39 0521 340805 - Web: www.allglass.it - E-mail: info@allglass.it REA: 207043 - P.Iva e C.F. IT 2051840342 - Capitale Sociale: € 1.000.000,00 i.v.

Le o Co lu G ur C you arn m LA le r f h bu SS an ul ow s, P fir l p to Oh RO e ot u io BL bur ent nm • O EM ne ia a ct S r so l wi sk 28 CO lu th -2 N t 9 FE ion •B R s el E N … lo CE w sF Su ite

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Events review: SGT annual conference

Glass sector newcomer wins Lucy Oldfield award for nuclear research A

� SGT President, Stuart Hakes, presented Jessica Rigby with the award at the evening banquet during the annual conference.

She met Prof Paul Bingham, Professor of Glasses and Ceramics of the Materials and Engineering Research Institute (MERI) at Sheffield Hallam University, who described some of the nuclear-based projects the unit was involved with.

These are fundamentally chemistry and maths-based, which sparked Ms Rigby’s interest.

“So it all fell into place,” she added.

This September she started the second year of the three-year PhD after completing a placement at the Hanford, Washington State nuclear site in the USA during the summer.

“I’m really enjoying it. I’m surprised by the amount of research currently going into glass.

“A year ago I would have said glass is glass and it has been around for so many years that there cannot be much more to research.

“But actually having listened to talks at the SGT and the events I’ve attended, I’ve realised how much research is still going on and that there is a huge future in it.

“I’ve got loads of ideas of what I want to do in the future, nuclear waste glass is really interesting and there is still so much work going on in the UK. “It’s also an industry all around the world so I think I might go down the route of nuclear glass in future.

“But there are still two years of my PhD to go so I will keep my options open.” �

Society of Glass Technology, Chapeltown, Sheffield, UK, www.sgt.org Sheffield Hallam University, UK https://www.shu.ac.uk/research/ specialisms/materials-andengineering-research-institute Continued>>

www.glass-international.com

PhD student who only entered the glass sector a year ago has won an award for her research.

Jessica Rigby was joint winner of the Society of Glass Technology’s (SGT) Lucy Oldfield award for her work on glass formulations for treatment of nuclear waste at the Sellafield site in the UK. The Sheffield Hallam University student spent three months researching the project before submitting a 20,000word report titled Development of Novel Glass Formulations for Treatment of Post-Operative Clean-Out (POCO) Wastes for Decommissioning of the Sellafield Site.

The report, written shortly after she began her PhD, was the first time she had worked with glass.

She said: “In three months I went from not knowing how glass was made to writing a report and all of the analysis, so it was a steep learning curve.

“But I was in the right surroundings for it, there are many PhD researchers and Post Docs all working on glass here at Sheffield so there were plenty of people to ask.”

She received the award from SGT President Stuart Hakes, at an evening banquet in Trinity Hall, Cambridge, during the SGT’s annual conference.

Ms Rigby admitted she was surprised and flattered to have won, particularly as she did not have a background in glass.

“When I read the report back, knowing how much more I know about glass now, I can see how it can be improved.”

Ms Rigby studied theoretical physics at the University of Sheffield as an undergraduate before completing a Masters in Engineering and Management at Sheffield Hallam.

After finishing the Masters she was keen to become involved in a project which involved nuclear engineering and mathematics.

29 Glass International October 2019

SGT.indd 1

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Events review: SGT Annual Conference

Bill Brookes gives his farewell address at SGT in Cambridge Outgoing SGT President Bill Brookes gave his valedictory speech at the SGT Annual Conference in Cambridge, UK. He describes how electric melting, hydrogen and Glass Futures all have a role to play in the future of glass.

P

aradoxically I find myself addressing eminent glass academics and glass experts who have researched or melted many thousands of tonnes of glass in their careers, although I have only ever melted one kilo of glass from the raw materials.

However, I have been working with glass all my life. At one point I was Chief Engineer of a major TV tube manufacturer where we were responsible for producing one million TV tubes per year between 1964 and 1974. The TV tube industry was a heavy user of both gas and electricity and as a result of this I became a member of the Energy Institute and a Chartered Engineer in Energy.

Therefore, this is a topic which I feel I have reasonable experience of and which at the present moment is a hot topic.

Emission reduction Governments love to issue edicts and regulations and our current one is no exception. Firstly, they have required the glass industry to reduce its carbon dioxide emissions by 30% by the year 2030 – about 10 years from now.

Secondly, by 2050, only 30 years away, the glass industry is to cease emitting carbon dioxide!

Now, despite its penchant to direct us, the government has recognised the challenge it has set for one of the major, UK, users of carbon based fuels.

Accordingly, it has set aside a potential ÂŁ33 million fund for research and development of the technologies and techniques which will be needed to achieve this reduction.

In response, the glass industry, glassmakers, universities and suppliers have joined together and created an organisation called Glass Futures, a not-for-profit company, to manage the research and development on behalf of

A review of the SGT conference will appear in the next printed issue.

A online review of the SGT conference and our video blog with conference organiser, Alan Reynolds, is available via the Glass International website.

Visit www.glass-international.com and search for Alan Reynolds. the glass industry.

So where are we?

Glass Futures is spearheading the UK glass industry drive towards zero carbon. A road map has been developed and published which is being updated, outlining the route and initiatives required.

A site has been selected and allocated by St Helens Council to erect a purpose built research and development centre in the home of the British flat glass industry. A second site is expected to be developed on a University of Leeds campus to assist with the research and development. Basically, St. Helens is the hot end and Leeds the cold end.

The Society of Glass Technology, as an advisory board member of Glass Futures is playing its part in these activities.

In our Sand to Splendour industry conference discussions you have heard of developments in batch formulations and materials and higher cullet ratios.

We can increase the electric boosts on our conventional furnaces.

The facilities are available to capture and store carbon dioxide.

There is a developing hydrogen industry in the UK. All-electric melting is a well-established technology although not widely used.

And finally we have grid-scale electrical storage which is being installed in some UK glassworks.

So, what is the nature of the beast that we have to contend with?

Continued>>

30 0 Glass International October 2019

SGT.indd 2

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

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Events review: SGT Annual Conference

By its very nature the glass industry is a high capital investment undertaking of tens of millions of pounds. Its furnaces, the heart of the glass process, have long lives – ten to 15 years, usually with a midlife upgrade. It may be that furnace life can be extended to 20 years.

We are fortunate that the UK’s glass furnaces did not arrive out of the blue all at once. Different furnaces, even in the same company, are at different stages of their life cycles.

This will be a help to us in implementing the upgrades and changes necessary.

Electrical boost is an well-established and understood technology with a welldeveloped support infrastructure.

Glass companies as a rule tend to be cautious and prudent, which is perhaps as well, otherwise they would not stay in business.

Revolution So what do we need? As one not involved in the actual melting and development in the industry, it would seem to me, that the last three decades have been ones of steady evolution. But time is running short – what we need is a revolution.

The glass industry has had a couple of revolutions in the last hundred years.

The first was the Owens machine, which came upon the scene in America and the UK in the early 1900. It decimated the hand blown bottle industry, one machine being capable of at least 72,000 bottles a day. That is the equivalent of 150 glass blowers together with their assistants and all the people needed to support a medium to large sized glassworks.

The second revolution was the Pilkington float process. As an aside both of these processes were developed by private companies, not huge multinationals. The float process rendered the continuous twin grinding and polishing system, which I saw in 1957, completely redundant.

A modern float plant produces between 3000 and 5000 metres an hour – a huge quantity of glass by historic standards.

Both of these processes made big profits for those who adopted them rapidly.

However, both suffered, in their initial stages, from some lack of flexibility and what in the gas burner field would be called a poor turn-down ratio. Big is not always beautiful.

The way forward While preparing this paper I reflected on some of the things I saw when, as a

student, I visited Switzerland in 1957.

In Lausanne we visited the Cornharz Glass Works where, among their other furnaces they were using a 30-40 tonne a day unit melter to provide flexibility and rapid response to the requirements of the wine and spirits industry. It was servicing eight IS machines.

On the same visit we went to the Electroverre factory at Romont where they had a Cornelius type 100-tonne a day allelectric furnace. This had solid carbon electrodes and fed a Foulcart updraw sheet process. The electricity came from a small hydroelectric plant adjacent to the factory.

Is the unit melter and the 100-tonne a day furnace part of the way forward?

We need to shorten the renewal cycle of our furnaces and to increase the flexibility of the melting system. We need to incorporate new developments on a smaller scale, more quickly.

A 100-tonne a day all electric melter would supply about 20 IS machines. A slightly larger 150-tonne a day would probably be the minimum for a mini float line.

The shorter working life of each unit should enable us to increase flexibility and speed up development.

However all-electric melting may not be the ultimate way forward for some organisations who may wish to incorporate hydrogen heating, either as the sole source of energy or in hybrid combinations. Carbon capture will be part of all future glass works.

What next?

We need to develop a Model T unit melter of 100 to 200 tonnes – cheap and easy to repair. We need to rapidly develop hydrogen burners. Some of us have had experience of hydrogen on a small scale.

However its deployment on the scale required for glass melting is a different matter. Teesside has a hydrogen gas grid but it does not have a glassworks.

We need to rapidly develop a nationwide hydrogen distribution system. This will be a very interesting exercise.

We need to rapidly develop standardised, packaged carbon capture units. We are fortunate that most of our glassworks happen to be in areas of previous coal mines. It should be possible to store the CO2 in the deepest of the old seams, many of which are between 2000 and 4000 feet down.

So what do we do in the meantime? We should continue the development of all of the existing systems, batch materials,

cullet recycling, electric boosting etc. The magic bullet will not arrive overnight.

We need to adopt grid scale electrical storage now. Those of us who were unfortunate enough to be in the north of England in August this year will be only too aware of the fragility of our electricity distribution system after a power cut resulted in stoppages of trains and planes for periods of three to five hours.

The technology exists, the Hornsdale Tesla grid scale electric storage facility in Western Australia gave a seamless switchover when two major generating units failed simultaneously.

It does work, if we can persuade the National Grid to adopt it.

Glass Futures Glass Futures, with its potential funding is a one-off opportunity. If we fail to grasp it we will have only ourselves to blame. There is a road map which is being updated constantly. The technologies already exist. However 10 years is not long – they need rapid development.

We have the skills but not necessarily all of the people. Industry is willing to change and academia is taking up the challenge to supply the shortfall.

So how does the SGT sit in all of this?

As an advisory board member it is our role to provide unbiased input and outsider comment. On the practical side our library provides a hundred years of experience and our staff are willing to provide research assistance.

As the technologies develop they will have to be implemented. Specialist training courses will need to be developed to do this. The SGT with its combination of academia and manufacturing should be in a position to provide independent accreditation.

All this sounds so easy. To plagiarise Morecambe and Wise in the Andre Previn sketch, ‘we have all of the notes but not necessarily in the right order’. It will be a bumpy ride.

Electric melting we think we know. Its universal application may give us some unexpected problems.

Hydrogen is a fuel of the future. From experience it is a dragon to be tamed - it has sharp claws, sharp teeth and a twin sting in its tail. At the moment, big is appropriate – in the future it may not always be so. �

Society of Glass Technology, Chapeltown Sheffield, UK www.sgt.org

32 0 Glass International October 2019

SGT.indd 3

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53035 MONTERIGGIONI (SI) ITALY - Strada di Gabbricce, 6 Tel +39 0577 304730 ifv@fonderievaldelsane.com

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Control system

Electronic updating E

www.glass-international.com

lectronic updating or replacing represents an element of extreme attention in any technological context in order not to compromise the production continuity.

BDF has designed solutions that allow its customers to have a smooth and safe transition in any context.

The result of the ADV8000 and ADV1000 control systems, confirm the success of BDF Industries as a global market leaders for performance and reliability. It has driven its engineers to develop a new electronic for the control of the machine on its latest evolution ADV8050 and ADV1050.

The experiences acquired over the years within thousands of installations together with all the requests for improvements received by our customers, with a deep upgrade of the control structure are the base for the new generation of electronic ADV herewith described.

Customer and market needs have led BDF to develop a new CPU, called

IB50, which replaces the historic IB40 maintaining main functionalities but, clearly, implements all the advantages of using a current construction technology with the following advantages owned

by BDF Industries. It uses a removable compact flash for storing all work data, houses a front USB port that is used in case of software upgrades. It increases memory capacity and 4x calculation speed and includes a complete file system with native tools that allows debugging and problem-finding much more flexible, immediate and effective than previous hardware.

There is also the possibility of developing new software tools and gadgets useful for the operator and installer; and has an operating system that is a minimal Debian Linux distribution with realtime patches (RTAI) for managing the ISAGRAF PLC that remains perfectly compatible with IB40.

The timer has been implemented with controls for stirrer motors programmable

directly from SCADA machine, multidrive type gob distributor control (also in the special SG-DG version for large volume containers) and IWS weight control system with full stroke transducer on plungers.

Statistical count implemented with subdivision of the causes by type and predisposition of connection with plant statistics systems.

Monitor machine provides pressures with trace saving the control of manifolds drain valves, anyway the options availability depending by control model.ďż˝

BDF Industries, Vicenza, Italy

ďż˝ The ADV-8050 and (above) the ADV 1050.

34 0 Glass International October 2019

BDF.indd 1

09/10/2019 15:30:53

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ADV_bdf_2018_ARMADIO.indd 1

09/10/18 14:02

Events Review: World Soda Ash Conference

Glass demand benefits soda ash production The increase in glass demand has benefited not just glass manufacturers but those who supply raw materials to the industry as well. Greg Morris attended the IHS Markit World Soda Ash Conference in Cannes to find out more.

T

he global soda ash market is thriving thanks to increased demand from the industries it serves, such as glassmaking.

There has been a wave of capacity announcements by manufacturers of the vital glassmaking raw material, with two capacity increases confirmed days before the IHS Markit World Soda Ash Conference. So there was a general air of confidence and expectation in Cannes, France where a record-breaking 325 delegates attended the event. The fourday meeting comprised of a two-day conference, a day training workshop and welcome reception and a final day walking tour of the town. The conference comprised of 16 presentations, the majority of which were from soda ash producers and analysts, as well as a paper from glass manufacturer O-I. Soda ash is a key raw material and is used as an additive in the glassmaking process. It is used in the glass industry for the production of flat, container, fibre, and other speciality glass.

Reviews of the papers from some of the soda ash papers follow, but first we focus on keynote speaker Marguerite Morrin, Executive Director, Chemicals at IHS Markit, who was introduced as the encyclopaedia of the soda ash industry by conference chairman Hazel Kreuz.

“If there is a synonym for soda ash, it is Marguerite Morrin,” she said.

Global overview In a 30-minute opening presentation Ms Morrin gave a global soda ash overview and its environmental impact. She said the glass industry consumed more than half of the 60 million tonnes of soda ash produced in the past year. The flat glass sector is still the largest single user with 29% of demand. The container industry used 19% and other glass segments 5%.

Construction is the largest driver for flat glass demand so any investment growth in construction has an impact on flat glass.

In 2019 this positively impacted on China but was slower elsewhere, she said.

Construction growth in the US has declined by 7.5% this year due to a combination of factors. Between 2007 and 2014 there were 11 float plant closures in the USA. But there are signs of positive growth - NSG’s Pilkington brand plans to open a

� Marguerite Morrin.

float plant in Ohio in 2020, while a float plant is planned in Mexico in 2021.

“Long term there is some positive growth for construction in in the region,” she said. The soda ash world is a mixture of conflicting dynamics right now, with each region very different. Europe, for example mainly uses synthetic soda ash, has a strong environmental focus, has invested in green energy and has the world’s highest recycling rates.

China is at the forefront of new environmental technologies and is tackling air pollution while in the Indian sub continent both local supply of soda ash and of imports are growing.

In South East Asia there is a huge amount of solar glass being developed but little local demand.

Despite tepid demand growth across the African and Middle East region, the largest expansion in capacity outside China has been in Turkey.

South America has had large demand losses as a result of the turbulent political situation in Venezuela and Argentinian economic downturn. The USA is the largest natural soda ash producer but its energy source is primarily coal.

It also has low levels of glass recycling.

Despite the introduction of the forthcoming Arglass site in Georgia next year, container glass production in the USA is in decline, but is rapidly growing in neighbouring Mexico.

36 0 Glass International October 2019

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Events Review: World Soda Ash Conference

Expansions There have been a number of recent soda ash production capacity expansion announcements around the world, with two announced just before the start of the conference. These are reported in the Solvay and Genesis Alkali articles below.

The largest capacity expansion announcement was that of the Inner Mongolia group which plans to add 10 million tonnes in Henan and Inner Mongolia, China. Ms Morrin pointed out this was still speculative and she was waiting to hear more information. China also plans to add 2 million tonnes of synthetic soda ash capacity. China has dominated soda ash capacity expansions since the year 2000 and has added 24 million tonnes of mostly synthetic soda ash mostly to meet domestic demand.

The largest capacity expansions in recent years - outside China - have been in Turkey. It has added 3 million tonnes capacity - all has already been absorbed by the market. India plans to add an additional 1 million tonnes by 2024, with more sites under study, including greenfield expansions.

In the USA, Turkey’s Ciner group is adding 3.3 million tonnes of capacity mostly at the Green River natural soda ash site in Wyoming. One of these projects will be in partnership with Turkish glassmaker Sisecam.

In South East Asia, the Chu Lai Soda

A Turkish soda ash group will soon nearly double its production capacity thanks to new investment.

The Ciner group’s We Soda company plans to increase its soda ash capacity from a � Ayse Olgar current 7.1 million tonnes to 14.1 million tonnes of the crucial glassmaking raw material.

The group has Trona mines in Turkey but has also expanded its network into the USA. Delegates at the IHS Markit World Soda Ash Conference in Cannes, France were told the group comprises of Eti Soda, Kazan Soda and Ciner Wyoming companies.

Sales and Marketing Director, Ayse Olgar, gave a presentation titled Ciner’s Soda Ash Plans.

She told delegates current production is currently at 7.1 million tonnes but with capacity expansions and investments it will reach 14.1 million tonnes by 2025. operation in Vietnam is due to restart, The Ciner group’s soda ash which will bring 330kt on stream. investments only began in 2009 when In terms of demand, the container glass its Eti Soda Group began production sector is a positive and a negative. While with an output of 1.1 million tonnes. demand has increased for container glass In the past 10 years it has formed due to environmental concerns about the Kazan Soda group, acquired plastic, the more glass recycled means OCI Resource Corp – renamed less soda ash is used. The EU is the largest Ciner Wyoming – and ramped up container glass producer and also has the production at its Kazan Soda plant to largest recycling rates. The US has lower 7.7 kt each day. The Eti Soda facility recycling rates and often has a single is based in the Beypazari district of stream collection compared to Europe’s Ankara while Kazan Soda is based to multi stream collections. the northwest of Ankara. Kazan Soda Single stream glass can get started construction in 2017 after a contaminated when in contact with $1.5 billion investment. The company other materials and has to be treated produces 2.5 million tonnes of dense before it goes back to a glass plant. The soda ash from a 20km2 site. closure of the Ardagh glass plant in Ciner Wyoming is based at the Milford, Massachusetts was followed Green River facility in Wyoming. The by the shutdown of two local recycling Ciner group has recently formed an plants. The infrastructure needs to be in additional investment project named place for glass recycling to work, stated Imperial, which comprises of Pacific Ms Morrin. In a light-hearted conclusion, Soda and Atlantic Soda, to establish she nominated Palm D’or awards new soda ash projects in the USA. (Vert) to China for best innovation and The group will increase production best improvement, to India for best capacity at Kazan Soda by 600,000 demand opportunity, Turkey for best tonnes by 2021 and at Ciner newcomer, best on environment went to Wyoming by 1 million tonnes by Europe, while the USA was best supply 2022. Pacific Soda – a joint venture opportunity. with Turkey’s Sisecam glassmaker IHS Markit World Soda Ash Conference, - and Atlantic Soda are expected to Cannes, France increase production capacity by 2.7 https://ihsmarkit.com/events/World-Somillion tonnes each.

da-Ash-Conference-2019/overview.html

www.glass-international.com

Turkish soda ash supplier plans production increase

37 Glass International October 2019

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Events Review: World Soda Ash Conference

Glass consumption set to grow in India Glass is the fastest growing segment for the Indian soda ash industry, a conference heard.

Sunil Bhatnagar, President of soda ash producer GHCL told the IHS Markit World Soda Ash Conference that demand for glass will rise in India.

Glass growth will be led by infrastructure investments and replacement of PET bottles with glass.

Unlike the rest of the world, current Indian demand for soda ash is not led by the glass industry. The detergent sector is instead the highest consumer with 40% of demand compared to 32% consumed by the glass industry. But Mr Bhatnagar said the glass industry will increase its use thanks to favourable government policies. The Autmotiove Mission plan 2016-2026 aims to increase GDP contribution from the automotive sector from 7% to 12%. Meanwhile a scheme to create 100 smart cities will boost construction.

“When cities are developed we all know what this means for glass,” he said.

He said the container glass sector grew by 8% CAGR between 2016 and 2018 and that average per capita consumption of container glass in India is still low at 1.8kg compared to 27.5kg in the USA and 9kg in China.

Food and beverage consumption is set to triple in India by 2025 he said and recent environmental legislation has promoted the use of container glass instead of PET. “All in all there is a very healthy trend for the flat and container sectors for the next decade,” he said.

India is expected to develop 4 million tonnes of soda ash capacity in the next year thanks to capacity expansions.

Two 500kt greenfield plants have been confirmed: one from GHCL will come on stream by 2023, the other from Tata in 2025. A a third greenfield plant, from Nirma, is expected to be confirmed

� Sunil Bhatnagar.

shortly. In his conclusion he stated that a high consumption base, coupled with growing purchasing power and continuing urbanisation will fuel growth in soda ash and its allied industries in India at a steady pace. The Indian government is in its 2nd term and committed to provide a favourable policy framework for the domestic manufacturing industry. Domestic soda ash manufacturers are investing in augmenting their capacities as well as improving their cost efficiency. It means there will be a decline in the dependence on soda ash imports.

Solvay increases glassmaking raw material capacity Soda ash producer Solvay will increase its soda ash production capacity by 600 kilotonnes at its trona-based Green River site in Wyoming, USA. It said the capacity expansion will meet long-term global demand growth in various applications.

In a presentation to the IHS Markit World Soda Ash Conference in Cannes, France Christophe Clemente, President of Solvay’s Global Business Unit Soda Ash & Derivatives, said global soda ash demand will increase by 16 million tonnes by 2030.

Timely investments are required to ensure security of supply, he said.

Solvay will also expand its sodium bicarbonate capacity by 200 kilotonnes in its Devnya plant in Bulgaria, to address global demand growth for flue gas treatments which improve air quality.

The combined investments total €185 million, spread over the next three years.

Mr Clemente said. “The Green River capacity increase reinforces our position as a long-term, sustainable supplier for our customers.

“Our plant is among the best-in class competitive soda ash assets in the world

� Solvay’s site in Green River, Wyoming.

and is ideally positioned to address global market demand.”

Global soda ash demand is forecast to grow by 10 million tonnes, excluding China, between 2018 and 2030 – with 4 million tonnes between now and 2023.

Demand is driven by export markets such as South East Asia, Brazil, the Middle East and Africa for the manufacturing of flat and container glass, and Latin America for the extraction of lithium.

Solvay’s Green River facility produces soda ash from trona, a naturally

occurring mineral.

The 600 kilotonnes investment will leverage on the existing infrastructure and is spread over the next three years, with production starting to ramp up by the end of 2021.

Solvay’s sodium bicarbonate capacity expansion by 200 kilotonnes in Devnya, Bulgaria is part of the existing 75/25 joint operation with Sisecam. The new production line is expected to be operational by the end of 2020.

38 0 Glass International October 2019

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Events Review: World Soda Ash Conference

Genesis to increase soda ash capacity at Green River operation Genesis Energy will invest $300 million to increase its soda ash glassmaking raw material facility.

The US company said it will expand its Granger production facility, at Green River, Wyoming, USA to increase soda ash production by 750 kilotonnes a year.

The construction of the expansion is scheduled to begin in Q4 this year (2019). The increased production is anticipated to be available for sale in Q2 2022.

It will bring the company’s production at Granger to a level in excess of 4.2 million tonnes.

During the construction of the expansion, the Granger facility will continue to produce soda ash at current rates.

During the IHS Markit World Soda Ash Conference in Cannes, France, its Vice President for Technology and Business Development, Aaron Reichl, gave a presentation titled US Natural Soda Ash and Solution Mining.

He described the Green River site as an ‘unbelievable deposit’ and at the current production rate of 20 million tonnes of trona mined a year there is still 2000 years of trona reserve remaining in the deposit.

“It is an endless supply which is unparralled in the mineral and mining universe,” he said.

The site is formed of 25 layers or ‘beds’, of commercial importance. A bed has to be more than 2 metres thick to be of commercial importance.

The shallower beds are in the northern part of the Green River site while the southern ones are deeper and thicker by up to 10 metres.

Five companies currently have leases to mine at the Green River site.

Genesis Alkali has two beds – Granger and Westvaco, while Ciner Wyoming, Tata Chemicals, Solvay and the Ciner/ Sisecam partnership, Imperial, are the others The lease blocks are largely clustered in the north of the site where

the beds are shallower and have been developed using dry mining.

Mr Reichl then described the development of the Green River site, the various methods used to mine the trona from the site and a discussion about solution mining.

Genesis invented the Sesqui and Monohydrate soda ash processes and has pioneered the solution mining process in the Green River basin. In the future 45% of production will be based on solution mining while any future investments will likely be solution mining based.

� Aaron Reichl.

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Country profile: Philippines container

PHLIPPINES CONTAINER GLASS PLANTS

MANILA

www.glass-international.com

ANGLO WATSONS GLASS: Calamba, Manila ARCYA GLASS CORPORATION: Makati City, Manila ASIA BREWERY INC. / CABUYAO GLASS PLANT: Cabuyao, Laguna SAN MIGUEL YAMAMURA CO. / MANDAUE PLANT: Metro Cebu SAN MIGUEL YAMAMURA CO/CAVITE plant: Manila SAN MIGUEL YAMAMURA PACKAGING CO, corporate office: Mandaluyong City, Manila

43 Glass International October 2019

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Country overview: Philippines

Philippines’ container sector grows The Philippines has an economy transitioning from one based on agriculture to one based more on manufacturing and services, writes Seema Gahault*.

C

atered by four container glass producers, which operate five production plants, the Philippines container glass industry has registered steady growth in recent years.

Growth in the domestic beverage market - both alcoholic and non-alcoholic - has driven demand.

With a population of more than 108 million at the end of 2018, the Philippines is one of the fastest growing economies of the South East Asia region.

Container glass producers have reaped rich dividends of steady economic growth.

Its Gross Domestic Product (GDP) grew 6.2% in 2018, the slowest in three years, as high prices of basic commodities coupled with slower agriculture expansion tempered growth.

However, the World Bank has projected the GDP to grow 6.5% this year and by a slightly higher 6.6% in 2020 and 2021.

With a median age of 23 years and a high degree of urbanisation, the country is expected to remain an attractive market for container glass producers operating in the country for years to come.

It comprises of 7,200 islands and can be geographically divided in three major divisions according to the concentration of container glass producers. Luzon is the largest and northernmost grouping.

It is home to the capital city Manila and most of the container glass production facilities. Container production is concentrated around Manila as the Philippine’s capital accounts for about 10% of the country’s total population of 108 million, and for about 39% of the country’s GDP. Visyas in the central region has the booming city of Cebu, which is the next target area of the country’s container glass producers. The province has one of the two container glass plants of country’s largest producer SMYPC. Cebu is the host location for the next Asian Federation of Glass Manufacturers (AFGM) meeting, which takes place between October 14 and 17 Minadanao, located in the Southwest is the Philippines agricultural hub.

The Philippines container glass industry

does have challenges. The country has a prohibitive cost structure related to logistics, energy and raw materials, which are not available domestically.

Its container producers have low capacity utilisation rates compared to counterparts elsewhere in the region.

The year 2018 presented a few challenges for the sector due to a demand slowdown in the beverage industry due to the imposition of excise tax on sweetened beverages. The law imposed a Php6 per litre specific tax on beverages containing caloric and non-caloric sweeteners and a Php12 per litre specific tax on those containing high-fructose corn syrup, this resulted in a 14% industry-wide volume decline in the non-alcoholic beverage market in the country, as manufacturers passed on the tax to consumers.

Demand drivers Alcoholic and non-alcoholic beverages are the major demand drivers.

With a production of 1,780,000 Kl of beer in the year 2017 ( Source- Kirin Beer University Report- 2018), beer production grew by 7.9% in the year compared to 1,649,700 Kl produced in 2016.

The Philippines is the 25th largest beer producing nation globally.

The country has registered steady growth in beer production in recent years, despite an overall slowdown in beer consumption in the region.

Recent investments in beer production facilities in the country are expected to remain key demand drivers in future.

Non-alcoholic beverages, especially energy drinks and iced tea, have gained momentum recently.

San Miguel Yamamura Glass San Miguel Yamamura Glass is the largest container glass producer in the country.

The company accounts for more than 60% of the domestic market share.

SMYPC, the parent company, was established in 1991 as a joint venture between domestic business conglomerate San Miguel Corporation and Japanese container glass producer Nihon Yamamura Glass. It produces and sells a

variety of glass bottles such as beer, liquor, condiments and beverage bottles. The company is steadily expanding globally, with with exports to Europe, USA, Australia, Southeast Asia, the Middle East, and Africa.

Its parent company, San Miguel Corporation (SMC) is one of the Philippines’ largest and most diversified conglomerates, with revenues that accounted for about 5.9% of the country’s GDP in 2018, through its highly integrated operations in food and beverages, packaging, fuel and oil, power, and infrastructure.

SMYPC operates two container glass plants at Cavite (near Manila) and Mandaue (Cebu) with an overall installed capacity of 1400 tons per day of container glass for beverage, food and pharmaceutical industries. In early 2019, the company commenced operations from a new furnace at its Cavite-based plant. With an installed capacity of 300 TPD, the new furnace feeds four production lines.

Initially, SMYPC had planned for an 800 TPD furnace in late 2016 at the company’s industrial estate in Davao Occidental, but had to shelve its plans in favour of the 300 tonnes per day furnace at Cavite.

The Mandaue, Cebu complex was inaugurated in 1967 – the container glass plant commenced operations a year later with an initial capacity of 70 TPD, which was later increased in several expansions.

The plant today has an installed capacity to produce 130 million bottles for beverage and food segments.

An estimated 60% of the total output of SMYPC’s glass division goes out to meet the glass bottle demand of its sister companies, which operate under the San Miguel Group.

These companies are producers of alcoholic and non-alcoholic beverages and packaged food in the country.

In addition to the container glass production units, San Miguel Yamamura Packaging also owns SMC Yamamura Fuso Mold Corporation.

Continued>>

44 0 Glass International October 2019

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Country profile: Philippines container

Company San Miguel Yamamura

Location

Installed capacity

Cavite (Manila)

1400 TPD

Mandaue ( Cebu)

Technology suppliers Emhart, Zippe, Bowman, Land Instruments, Siemens

Packaging Corporation Asia Brewery Inc.

Cabuyao, Metro Manila

400 TPD

Emhart

Anglo Watsons Glass

Calamba, Metro Manila

220 TPD

ShamvikGlasstech

Arcya Glass Corporation Calamba, Metro Manila

160 TPD

Emhart, ShamvikGlasstech,

Incorporated

Lubisol Engineering

Table 1.Container glass producers in the Philippines.

It is a joint venture between San Miguel Corporation, Nihon Yamamura Glass Company and Fuso Machine & Mold Manufacturing Company.

The company was established in 1994 to supply the mould needs of container glass manufacturing operations.

Asia Brewery Incorporated

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A subsidiary of LT Group Inc., Asia Brewery Incorporated (ABI) operates a 400 tonnes per day container glass plant at Cabuyao.

The 400 hectare production complex is located 45km from Manila in the town of Cabuyao, Laguna.

The plant meets the demand of the company’s beer, spirits and non-alcoholic beverages. It also sells container glass to external customers in the country.

Founded in 1982, ABI is a major player in the domestic glass industry.

ABI offers a variety of popular alcoholic as well as non-alcoholic beverages. Its revenue in 2018 reached Php15.1 billion, 9% higher than Php13.9 billion in 2017.

In 2018, the company’s volume of container glass sold to third party customers increased by 22% as more capacity was shifted back to production of orders from external customers.

ABI has recently pursued large commercial glass customers through the emphasis on excellence in quality and customer service. As a result, it has been able to become a container glass supplier to leading non-alcoholic and food producers in the country for their glass container requirements.

Anglo Watsons Glass

WORLDWIDE AVAILABILITY 46 0

Philippines.indd 3

www.hotwork.ag contact@hotwork.ag Tel.: +41 71 649 20 90

A subsidiary of Alliance Global Group, Inc. (AGI), Anglo Watsons Glass began operations in 1994 as a glass manufacturer after it acquired a manufacturing plant in Canlubang, Laguna.

The company has an installed capacity to produce 220 TPD of container glass, primarily for the liquor industry.

The company initially catered to the glass bottle demand of its sister group,

Emperador Brandy. However, in later years, Anglo Watsons Glass directed started to supply glass bottles to other domestic liquor companies.

In 1999, parent company AGI obtained approval from the Securities and Exchange Commission to broaden its primary business. It diversified into the food and beverage and real estate development and services business, and, a few years later, into the quick service restaurant (QSR) business.

AGI is a holding company presently engaged in the food and beverage business (manufacturing and trading of consumer products), real estate (investment in and development of real estate, lease of properties, hotel operations and tourism-oriented businesses), and QSR (McDonald’s).

Currently, AGI’s subsidiaries include, among others, Emperador Distillers, Anglo Watsons Glass, Alliance Global Brands, Megaworld Corporation, Travellers International Hotel Group, Golden Arches Development Corporation and Golden Arches Realty Corporation.

Anglo Watsons’s sister company, Emperador Brandy is one of the largest spirits producers in the country.

With sales revenue of Php 47.1 billion in the year 2018, the company is a leader in domestic brandy and spirits market.

Arcya Glass Located at Calamba, Laguna, about 50km south of Manila, Arcya Glass Corp is a mid-sized producer of glass containers for the food and beverage industry.

The company has an installed capacity to produce 160 tonnes of glass container per day. The bulk of the company’s output goes to some of the most established food and beverage producers in the country. �

• Freelance corespondent, Glass International www.smypc.com www.asiabrewery.com www.arcyaglass.com

Glass International October 2019

10/10/2019 09:44:30

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Case study: Smart Windows

A high-tech solution to the paradox of glass

James Steinbauer* describes how smart windows with built-in intelligence can change their tint based on cloud cover and the angle of the sun.

www.glass-international.com

T

oday, building developers talk about the ‘paradox of glass’ – a choice between wellness or sustainability.

As governments throughout the world implement stringent energy standards, architects will need technologies that can both reduce a building’s carbon footprint and give them the freedom to design the healthy buildings people want to live and work in.

View believes the choice between wellness and sustainability is a false one.

View has developed smart windows with built-in intelligence, allowing them to predictably change their tint based on cloud cover and the angle of the sun.

This high-performance technology – a combination of durable nano coatings, intelligent controls and machine learning software – controls glare and heat to optimise comfort levels for occupants while also increasing energy efficiency.

On the inside of the glass, an electrochromic coating, made up of thin layers of ceramic metal oxide, deflects visible light and solar heat gain. When a certain level of light hits the glass, a tiny electrical shock jolts ions from one layer to another, making the glass tint. The darker the tint, the more solar radiation and glare the windows control.

Occupant wellness The greatest benefits of smart windows comes from improving occupant wellness.

A recent study by Dr. Alan Hedge, a professor in the Department of Design and Environmental Analysis at Cornell University, showed that natural light can reduce eye strain by 51%, headaches by 63% and drowsiness by 56% – dramatically improving health and productivity.

But traditional windows amplify the sun’s energy like a greenhouse. Building occupants can only spend so much time near them before they start to get uncomfortable.

During a collaborative study with Canada Lands, a property management company that has installed View Smart Windows in its Toronto office building, researchers moved employees from an office with regular windows to one in the same building with smart windows.

Those employees reported a significant reduction in vision-related health problems, including a 78% reduction in eye strain, 80% reduction in headaches and an elimination of drowsiness.

For most companies, smart windows aren’t the only solution, but just one component of a larger shift to health and wellness in building design. Others

can include furniture and carpeting free of harsh chemicals; LED light bulbs with a high CRI (colour rendering index) rating, which closely mimic natural sunlight; even incorporating biophilic design elements, such as greenery, indoor waterfalls, and paint colours, that mimic the outdoors.

“We didn’t just put in View Smart Windows and say, ‘That’s it,’” said Wayne Sumner, Founder and Chairman of Jackson Sumner & Associates, which incorporated View into its new office building in Boone, North Carolina, USA. “We went through quite a bit of effort to make sure smart windows were part of a bigger plan to create a healthy indoor environment.”

In an increasingly competitive job market, property owners and investors are making the smart decision to incorporate technologies and services that enhance a building space for the people inside. And there’s evidence this pays off. At the end of the Canada Lands study, employees who worked in the office with smart windows reported being three times more excited to come to work, five times prouder of their office and five times more likely to rate their office as healthy and productive.

48 0 Glass International October 2019

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Case study: Smart Windows

“There’s this coolness factor,” said Meghan Tuohig, the Chief People Officer at Overstock.com, which installed 30,000ft2 of View smart windows into its Salt Lake City headquarters. “Not just temperature wise, but a cool factor about the glass that employees really appreciate. The glass demonstrates that we are invested in their wellbeing, in their comfort, and also in innovative technologies.”

Energy efficiency With the promise of creating breathtaking views and flooding offices with natural light, glass has never been more important than it is today. But glass can

also be wasteful. It transmits and holds the sun’s heat like a greenhouse, leading building occupants to switch their HVAC systems into overdrive.

Thankfully, traditional glass windows are no longer the only option.

Smart windows not only make windows healthier for their occupants, but also the environment. They improve a building’s energy efficiency by helping to cut down on electricity consumption from lighting, heating, ventilation and air conditioning. Smart windows even help reduce electricity use during the hottest months of the year (the peak load), meaning building owners can downsize their HVAC equipment.

The Canada Lands study, which was conducted over seven months in Toronto, found that smart windows reduced interior temperatures by up to 12 degrees Fahrenheit, leading to a significant drop in HVAC demand and electricity cost savings of 21%. After the San Francisco International Airport installed View smart windows in its Terminal 1, it saved $900,000 in ventilation and tens of thousands of pounds of CO2 emissions per year.

Ms Tuohig, of Overstock.com, noted that its decision to install smart glass at its new headquarters ‘contributed significantly’ to the property’s LEED Gold certification.

“We knew that this was the environmentally responsible choice for us to make,” she said. � About the Author James Steinbauer is a writer and journalist who reports on science and the environment. He has a particular interest in stories that deal with how we can build cities to be more sustainable.

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49 Glass International October 2019

View glass.indd 2

09/10/2019 15:43:01

History

Prof. John Parker

Frederick Carder Prof John Parker* and co author, S Ellis, discuss the founder and designer at Steuben Glassworks.

www.glass-international.com

F

rederick Carder was born in Staffordshire, UK in 1863. Ignoring his father’s disapproval, he left school at 14 to work in the family pottery at Brierley Hill, initially shovelling coal.

Eventually though his natural curiosity and unsatisfied artistic temperament led him to negotiate a deal with his father - more responsibility in the pottery in exchange for evening classes. After a day’s work, Carder had a three-mile hike to the Dudley Mechanics Institute to study chemistry, metallurgy and electricity; he also joined Stourbridge School of Art. Saturday afternoons at John Northwood’s glass studio developed his skills in cameo engraving and wax modelling; seeing Northwood’s copy of the Portland Vase he was ‘Struck with the possibilities of glass’.

Northwood recommended a change in direction and in 1880, aged 17, Carder moved to Stevens and Williams (later Royal Brierley Crystal), where he stayed 23 years. His glass engravings, often flowers and birds, used skills honed at Art School.

He helped establish Wordsley School of Art and taught there himself, explaining glass melting chemistry and the practical applications of glass. Carder’s extensive knowledge of art and glassmaking encouraged the Director of Education for England to send him to glass firms around Europe and America. The prize?

To improve the troublesome Staffordshire glass industry.

He probably met Thomas Hawkes during one such trip, leading to an invitation to make glass blanks in the USA that Hawkes’ factory could decorate.

Around this time both his first son (7) and John Northwood sadly died, no doubt factors influencing his decision to emigrate. At 40, he established with Hawkes the Steuben Glass Works in Corning. Over the next 30 years, they created 7,000 designs in the Art Nouveau style, in vogue from the 1890s and based on sinuous patterns of leaves and flowers,

befitting Carder’s background. Their catalogue used a palette of 140 colours, many applications requiring matched expansion behaviour of different glasses in combination. Steuben was highly successful, built on the skills and techniques Carder brought from Stevens and Williams and his understanding of glass chemistry and properties.

During WW1 Steuben as a 'nonessential industry' was closed; afterwards raw materials shortages meant they struggled to regain profitability. It was taken over to become the Steuben Division of Corning Glass Works. Carder was retained as manager, continuing to design into the 1930s when changes in fashion and the Great Depression caused sales to decline; the shift in tastes during the 1920s and 1930s to Art Deco based more on geometric patterns than nature did not suit Carder. A new chief designer and manager were appointed, with Carder as art director. Coloured glass was dropped and the focus became clear glass.

Carder constructed his own studio and began perfecting techniques such as ‘cerre perdue’, lost-wax casting. He formally retired in 1934, although continuing to experiment until he was 96. He died in 1963, just after his 100th birthday.

Given Carder’s connection with John Northwood, his frequent use of the cameo style is unsurprising but the ornate Venetian style was another influence and the glass factories and museums he visited throughout Europe also inspired him. He would sketch shapes and designs, noting colours and these influenced his own work. He was particularly impressed

by French glassmakers: François-Eugène Rousseau, Ernest-Baptiste Léveillè and Emile Gallé. Carder’s work is often compared to that of Louis Comfort Tiffany and René Lalique, especially his iridescent glassware, the well-known and popular ‘Aurene’, produced mainly in gold and blue shades (less frequently:

green, red and amber).

His work was esteemed for its grace, quality and beauty. Notable achievements were his casting of a memorial window to honour soldiers from Corning who died in WW1 (including his second son), and developing architectural applications, such as the cast panel in the RCA building in the Rockefeller Centre. The panel used the newly developed Pyrex glass and processing had to be adjusted to its temperature-viscosity behaviour.

Carder received many prizes and commendations. He was elected an honorary member of the American Ceramic Society (1938), a fellow of the Society of Glass Technology (1939) and was awarded an honorary doctorate by Alfred University (1960).

Steuben was sold by Corning in 2008 as they moved towards high technology production.

Schottenstein bought Steuben, but financial difficulties caused the factory’s closure in 2011. Steuben glass is no longer made on a large scale.

The Corning Museum of Glass, which houses a wonderful gallery devoted to Carder, reintroduced a limited range of Steubenware in 2014.

The Carder Steuben Club promotes interest in Carder’s glass. Members are collectors, scholars, dealers, and friends who encourage the enjoyment of and research into the history and artistry of his work. Carder had a close relationship with Professor Turner, whose museum I curate. Several pieces in this collection were gifts from Carder and a subsequent article will explore their relationship. �

Bibliography The Glass of Frederick Carder - Paul V. Gardner (1971)

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

50 Glass International October 2019

History oct.indd 1

09/10/2019 15:43:37

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Tiama: your co-pilot on the way to the Smart Factory Introducing YOUniverse, unique to Tiama and further proof why we are the leaders in business intelligence within the glass manufacturing industry. YOUniverse has been specifically developed with YOU and your needs at its core. Utilizing flexible and automated “plug and play” systems YOUniverse makes the inspection process smarter and capable to adapt to any changes.

From batch plant to the warehouse, YOUniverse creates a maximum flow of information to enable as many machines as possible to “talk” to each other to improve efficiency, productivity and profitability. With its open information interchange, this revolutionary system allows machines from any manufacturer to be linked to the YOUniverse.

Welcome to the future – yours and your factory‘s.

Take your first step towards Smart Factory technology by visiting youniverse.tiama.com

Intelligence

Monitoring

Traceability

Inspection

Service

Real-time Process & Quality Controls