Glass International September 2021

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September 2021—Vol.44 No.8

ŞIŞECAM CEO INTERVIEW DIAGEO SUSTAINABILITY OVERVIEW LUBRICATION IN GLASSMAKING I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International September 2021

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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 Designer: Annie Baker Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com

September 2021 Vol.44 No 8

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Managing Director Tony Crinion tonycrinion@quartzltd.com Chief Executive Officer: Steve Diprose Chairman: 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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Member of British Glass Manufacturers’ Confederation

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China National Association for Glass Industry

United National Council of the glass industry (Steklosouz)

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Editor’s Comment + International news

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Company profile: Sisecam CEO Sisecam for the future

17

Renewables: Wiegand-Glas The benefits of biomethane to glassmaking

21

Environment: Zippe Eco friendly batch and cullet production

24

Environment: Diageo A sustainable plan from glass to grain

28

Future of Forming: FAMA What will forming be like in the future?

30

Women in Glass: Consol Celebrating Women in Glass month

33

Environment: Ametek Land Decarbonisation in the glass industry

37

Lubrication: Graphoidal A complete lubrication package for glass

41

Lubrication: Xpar Vision An integrated process approach

44

Lubrication: Kluber Challenges for the container sector

47

Lubrication: Condat Making the right lubrication decisions

49

Digital technology: VDMA Why use blockchain and track and trace in the glassmaking sector?

52

Environment: UKRI The challenge of foundation industries

Glass International Directory 2020 edition: UK £206, all other countries £217.

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International News

GREG MORRIS, EDITOR

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Save our summer

September, and the time to return to work, a new school year and the opportunity to reflect on a relaxing summer.

However this summer was one of the strangest in living memory: devastating wildfires and heatwaves in southern Europe and in the Northwest of America, while northern Europe endured monsoon rain and in Germany, tragic floods.

July and August is traditionally the time in the northern hempishere to wind down and relax. But with climate change they have become the ‘wild west’ months in recent years, a period where it is impossible to predict what the weather will be like each day.

It was a timely reminder ahead of the COP26 talks later this autumn of how fragile our climate is.

In a feature interview this issue, Diageo’s Procurement leader suggests consumers are more savvy than ever about packaging and its environmental impact on the world. Gen-Z and the future consumer base will be very different to all that has been known before. They are digital natives and have grown up with social media.

They can rapidly spread the word of what packaging is healthy for the environment - and what is harmful.

The glass industry is in a strong position to appeal to this new generation of consumer. It is further ahead in its discussions on how to reduce carbon emissions from the manufacturing process than some other sectors, for example.

But more needs to be done if we are to save our summers.

Ciner Group to invest 1.9 billion TL in Ankara facilities

Turkish glassmaker Ciner Group will invest 1.9 billion liras (US $228.9 million) in its Ankara manufacturing facilities.

The company will produce 237,250 tonnes of glass bottles annually as part of its new in-

vestment in Ankara Sincan.

Part of the 1.9 billion liras will also be invested in Ciner Group’s Bilecik glass plant.

Park Cam, one of the Ciner Group companies, has also committed to investing 1.2 Billion TL in its Bozüyük glass

factory.

The construction phase has already started and will have a production capacity of 2.8 billion glass bottles per year and employ an additional 100 people.

Vidrio Formas starts second glass manufacturing facility Mexican manufacturer Vidrio Formas has started a second production facility to increase its capacity to deliver glass containers to its customer base.

The new facility is located in Lerma, about one hour away from Mexico City and 10 minutes away from the original

Vidrio Formas glassworks.

The plant includes a batch plant with the capacity to support the installed furnace and the future installation of a second furnace, a new regenerative end-fired furnace with a capacity of 320 t/d and two glass container production lines.

Preparations are already underway to install two more lines to begin production by the end of 2022.

The new plant increases the throughput capacity of the company by 30%. With the two additional production lines in 2022 the increase will be 60%.

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International News

NEWS IN BRIEF

Revimac installs IS machines at Frigoglass

Revimac has installed two 10-section IS machines at the Frigoglass (Beta Glass) site in Agbara, Nigeria.

The order included feeders and the machines have started production.

Despite all the problems and delays due to the Covid situation, technicians and specialists of the customer together with Revimac supervisors, did a great job during the installation and start-up of the machines, respecting the project schedule of the customer.

Pilkington UK has manufactured architectural glass at its St Helens, UK facility using hydrogen power in a world-first trial.

The trial is a key step in the manufacturer’s plans to decarbonise and could see a transition to using hydrogen to power all production at the site, which currently uses nat-

ural gas.

The switch means that the float glass furnace – which accounts for the majority of the company’s overall carbon emissions – would be able to run with hugely lower emissions.

The aim of the trial was to demonstrate that the furnace, in which the raw ingredi-

ents of the glass are heated to around 1,600 degrees centigrade, could run safely at full production without impacting product quality.

The initiative is part of the ‘HyNet Industrial Fuel Switching’ project to decarbonise industrial processes across the North West of England.

Heinz-Glas back at pre-Covid levels of glassmaking German glassmaker HeinzGlas is now producing at pre-Covid levels with the international market recovering faster than expected.

The construction of the furnace at the newly built production site in Jiangsu province began at the end of July 2021, with production expect-

ed at the beginning of 2022.

Expansion into South America is also continuing for Heinz-Glas, with an office building, storage space and a hall for finishing all being built in Brazil.

There is also a joint venture in India is currently running at full capacity and is consid-

ered by Heinz-Glas to be an important success factor for supplying the domestic and Indonesian markets.

And lastly, its furnace in Dzialdowo, Poland which was affected by major damage, has also been rebuilt so that regular production can be resumed before the end of the year.

Borosil Renewables adding two more solar glass lines India’s only solar glass producer Borosil Renewables is considering adding two more lines to its plant in Bharuch in the state of Gujarat.

Lines four and five will each

consist of 550 tonnes per day and are scheduled for construction in 2023 and 2024.

With the addition of these new lines, it will take Borosil Renewables’ overall capacity

to 2,000 TPD of solar glass by the end of 2024.

The company’s third furnace is currently under construction and will commence operation in May 2022.

Rath builds new Budapest pre-assembly area

Rath Group has built a new pre-assembly area at its production site in Budapest, Hungary.

The newly refurbished and modernised pre-assembly area has been completely rebuilt on 400 m2, levelled (+/1 mm flatness, accuracy to DIN 18202) and equipped with reference markings for angle marking.

Robert Nusszer, Managing Director of the global Sales Unit Glass, Rath Group, said: “The refurbishment of this area allows professional preassembly to be carried out to international standards, so that requirements of glass industry customers can be met even more perfectly in the future.”

Guardian Glass plots Russian expansion

Guardian Glass is to add a jumbo laminated glass production line at its Ryazan, Russia plant.

It said the investment supports the region’s strong growth in the commercial, residential and interior sectors and the call for glass products that address safety, security and acoustic performance.

As a result, Guardian Glass Russia will offer the region an improved product mix including SunGuard and ClimaGuard coatings on laminated substrates for various applications.

www.glass-international.com

Pilkington UK glassmaking powered by hydrogen

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International News

NEWS IN BRIEF

Heye International appoints MD

Glass manufacturing technology supplier Heye International has appointed a Managing Director, who will join on October 18.

Hans-Peter Muller will be responsible for the development and implementation of the future strategic approach of the company, delivering new business projects through sales negotiations in different countries internationally.

Together with the team, he will continue to develop the customer base, maintain customer relations and support the development of a prospect pipeline.

GreenGlass recycles 75 million bottles in 2021

GreenGlass said that by recycling this amount of glass waste, more than 6,500 tonnes of CO2 have been saved, the equivalent of the emissions produced by an airplane that flies around the world about 350 times.

Established in 2013, GreenGlass paved the way of the glass recycling market in Romania, under a €5 million investment with a recycling capacity of 110,000 tonnes/ year.

The company turns 100% glass waste into a valuable resource for the glass packaging industry.

www.glass-international.com

Zippe constructs Guardian batch house

Zippe has developed a new batch house with batch transport and cullet return system for Guardian Glass’ Czestochowa plant in Poland.

In addition, nine high performing float glass batch chargers, one batch charger as a substitute in case of need – were also supplied via a separate order.

This is the second float furnace on site and the new installation has more than doubled the plant’s capacity..

Zippe’s work included the design, manufacturing and installation of the steel structure, the process equipment and the control

Vetropack sees increased European glass demand Vetropack Group increased net sales from goods and services by 23.3% to CHF 399.2 million ($437.1 million) compared to CHF 323.8 million ($354.7 million) last year.

A total of 7.1% of the increase in sales was generated by the new Vetropack glass-

works in Moldova.

In Europe, the demand for glass packaging rose.

In the first half of the year, it sold 2.89 billion units of glass packaging, 23.0% more than in the previous year (2.35 billion units).

It forecasts that consumer

behaviour will not fundamentally change in the second half of the year and is therefore planning to fully utilise its expanded capacities. Under ideal conditions, revenue can reach the value of the first half-year and stocks can also be slightly built up.

Encirc set to expand filling capacity by 40% Encirc is set to increase its wine filling capacity by a further 75 million litres over the next year to meet growing demand, which will see its Beverages facilities capability increase by up to 40%.

The investment plans will mean the introduction of a

new filling line at iys Elton, UK site among other new projects.

The company’s 360 model allows global brands to bulk ship their wine to its Elton site that is filled into bottles made at the same facility and then delivered directly to retailers.

Encirc experienced its most

successful year to date in 2020, with its filling lines being at almost full capacity.

During the year, more than 400 million bottles of wine and carbonates were filled and sent to UK and European retailers.

Sisecam secures $75 million IFC Covid-recovery loan Sisecam has received a $75 million loan to boost its post-Covid recovery.

The investment by the International Finance Corporation (IFC) will help fill a COVID-impacted funding need for

the Turkish company.

The IFC funding will help Sisecam sustain its operations, contributing to its post-COVID recovery through increased competitiveness, exports, and economic activity.

IFC said the financing would help Sisecam implement its capital expenditure programme delayed by COVID-19 and finance its working capital needs, alleviating the impact of the pandemic.

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International News

Top 10 stories in the news

NEWS IN BRIEF

Saint-Gobain European site sales

Saint-Gobain has sold two of its glass operations in France and Germany, while SaintGobain Sekurit has closed a site in Portugal, putting 130 jobs at risk.

The company sold its French glass processing and shaping company Aurys to a former manager of SaintGobain.

The group has also sold the German tempered glassmaker GVG Deggendorf to the Swiss Arbonia group.

A separate part of SaintGobain’s operations, SaintGobain Sekurit, also closed its production site in Portugal and laid off 130 workers due to accumulated losses in recent years.

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Vidrio Formas starts second glass manufacturing facility Pilkington UK architectural glass production powered by hydrogen Ciner Group to invest 1.9 Billion TL in Ankara manufacturing facilities India’s Kapoor Glass and Borosil Renewables secure glass manufacturing awards Saint-Gobain sells two parts of organisation and closes another site O-I Glass issues 2021 Sustainability Report O-I integrates energy-saving air compressors in French facilities Heye International appoints Managing Director Piramal Glass renamed to PGP Glass Feature: Consol Glass celebrates its Women in Glass

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

HFT promotes Sam Leaper to Sales Director

HFT has promoted Sam Leaper to its Director of Glass Business Development.

Mr Leaper has been with HFT for four and a half years and has contributed to the growth of the business.

He will lead HFT’s Sales and Marketing Department as it continues to grow and offer global glass makers with turnkey project support and EPC solutions from initial conception, through development, design and execution.

www.glass-international.com

Schott forms new Indian partnership

Germany’s speciality glass company Schott has a new partner: the Serum Institute of India (SII), the world‘s largest vaccine producer and manufacturer of biologics.

SII has bought a 50% stake in the Indian joint venture Schott Kaisha from former co-owners Kairus Dadachanji and Shapoor Mistry.

The joint venture is an Indian manufacturer of pharma packaging products such as vials, syringes, ampoules and cartridges used to package life-saving medications.

It said it was securing its supply of pharma packaging amid rising global demand.

Stoelzle aims for CO2 savings with digital technology Premium spirit glass bottle manufacturer Stoelzle aims for energy and CO2 savings after it integrated a digital performance monitoring solution into its production lines.

It has integrated technology from Hark, a Leeds, UK-based start up, at its Knottingley, UK production site.

Hark’s technology is being integrated into two production lines and will deliver asset performance monitoring.

The Hark Platform will support integrations with motors and inverters on the production lines, enabling remote asset performance monitoring.

Through partnerships, Hark is

able to provide the hardware to connect these assets effectively.

A continuous stream of data will be fed into the cloudbased platform for analysis, so that Stoelzle can understand its operations more accurately and highlight any asset opportunities immediately.

Ferro shareholders approve Prince acquisition Shareholders of glass coatings and colour solutions provider Ferro have approved its acquisition by an affiliate of Prince International Corporation.

Under the terms of the proposed merger, Ferro shareholders will have the right to receive $22.00 in cash, without interest and less any ap-

plicable withholding taxes, for each share of Ferro common stock that they own immediately prior to the effective time.

Upon the terms and subject to the satisfaction or waiver of the conditions set forth in the merger agreement PMHC Fortune Merger Sub, an affiliate

of Prince, will merge with and into Ferro, with Ferro continuing as the surviving corporation in the merger and as a direct or indirect wholly owned subsidiary of Prince.

Ferro anticipates the merger to close in first quarter of 2022 pending antitrust and regulatory approvals.

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International News

NEWS IN BRIEF

Youth help kickstart IYOG 2022

A photography competition for youngsters titled Glass in our Lives helped kickstart India’s celebrations of the International Year of Glass 2022.

Chief Guest Dr. Reinhard Conradt, Vice President and President Elect of the International Commission on Glass (ICG) unveiled a touring exhibition on ‘Glass in our Lives’ at the virtual Annual General Meeting of the All India Glass Manufacturers’ Federation (AIGMF).

Online entries were invited from the age group between 7-24 years to participate in the 1st Photography Contest, a kickstart event to mark International Year of Glass 2022 activities in India.

A Jury of Members representing a cross section of glass sectors and regions decided the top three photographs out of approx., 7,000 entries received from educational institutes and Youth across India.

Rescheduled GPD Finland dates announced

Glass Performance Days (GPD) Finland, originally scheduled for October 2021 will now take place on 16-18 February 2022.

The hybrid event will also include workshops will be on the 15th and 16th of February, followed by the conference sessions and networking activities on the 17th and 18th of February.

www.glass-international.com

AGC’s Fleurus site to restructure after losses

AGC Automotive Belgium will carry out a restructuring plan for its Fleurus site in Belgium, with 40 people out of the 188 workers set to lose their jobs.

A repositioning of the activity is said to be essential to ensure the long-term survival of the site.

The savings are said to be essential both to reduce the expected financial losses for 2021-2022 and to try to ensure the site’s long-term survival by attracting new models and/ or new investments.

Ametek Land improves SGD Pharma furnace production Ametek Land has provided in-furnace thermal imaging to optimise the borosilicate glass production at a SGD Pharma’s manufacturing facility in France.

SGD Pharma chose Ametek Land’s Near Infrared Borescope (NIR-B-656- Glass) in-furnace thermal imaging system to optimise the production and quality of borosil-

icate glass from its new 50tpd oxy-gas furnace at its St Quentin Lamotte, France, facility.

The new system replaces the company’s existing CCTV system.

The NIR-B-656- Glass solution provides SGD Pharma with a true-temperature radiometric image, so live continuous temperature values can be obtained.

The high quality of the purge applied on the lens delivers a clear image, providing the same views as the previous CCTV system managed.

The most important benefit is the capability to obtain a furnace thermal profile continuously in the oxy-gas furnace, confirming the hot spot locations are aligned with the furnace design and batch line.

O-I integrates energy-saving air compressors in French facilities O-I’s facilities across France have invested in centralised computer control systems for air compressors, which provide lower energy needs, fewer emissions and cost savings.

A plant’s compressed air system serves functions, driving machine movements and other uses throughout the glass manufacturing process.

It’s among a plant’s more energy-intensive systems, but the new computer software helps the system work more efficiently and decreases electricity demand. Decreasing demand also saves on a plant’s energy costs.

Previously, a plant’s six to 10 compressors would operate independently.

But the new software creates efficiencies by linking a plant’s air compressors as a network.

This gives full visibility to the teams on one screen, allowing each plant to get an automatic selection of the best available combination to optimise energy efficiency while meeting the plant’s compressed air needs.

Ambev completes Brazilian furnace rebuild Container glass manufacturer Ambev has completed the rebuild of its furnace number 1 at its Rio de Janeiro site, Brazil.

The 360t/day end-fired fur-

nace has three production lines and has been in operation for 14 years.

A heat up ceremony recently took place with members

of the Ambev team as well as members of Horn, the German furnace engineering company.

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Company profile: Sisecam

CEO aims to build the ‘Şişecam of

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Görkem Elverici* was recently appointed CEO of Sisecam. We hear from him about his appointment and the global plans for the Turkish glassmaker.

You have been the CEO of Şişecam at a unique moment in its history, namely that all the joint operations are now combined into a single entity. How significant is this consolidation to the future of the company?

GE: Despite the challenging environment brought by the global pandemic, we recorded a key milestone in our corporate history by consolidating all our operations into a single entity.

We have completed the largest merger of the Turkish capital markets with exemplary success.

With this strategic move, Sisecam has taken a major step forward to shape its future.

With the completion of this effort, ‘One Sisecam’ entered a new era, jumping into a rising stage with global excellence. Simplifying its legal entity and shareholding structure; consolidating all its

activities under one entity will further enhance Sisecam global competitive position.

We are now focusing on a multidimensional transformation process, which is going to build the backbone of “Sisecam of the future”.

With the transformation that is aimed to provide more agility and simplicity, we will have the necessary infrastructure to adapt to the changing conditions of the world that will emerge after the global pandemic and will have even stronger foundations and capabilities to benefit the changing trends that will carry Sisecam into the new era.

What do you see as the main goals of the company over the next years?

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Company profile: Sisecam

the Future’

sustainable growth and profitability.

We are evaluating the potentials for different business areas in line with our existing business objectives.

Our five-year target is: � We aim to increase the share of our nonTurkey sales above 70% level, which is currently at c. 64%.

� Şişecam manufactured 4.9 million tonnes of glass at its production facilities during 2020.

GE: Sisecam will continue value creating portfolio management, expanding its global presence in existing businesses and entering into new business areas.

In this aspect we have initiated a new investment in Hungary in glass packaging and in the US in soda ash segments.

We will also continue our investments in Turkey that will reinforce our leadership in Turkey.

Sisecam continues to look into potential opportunities to broaden its horizon in global scale with new investments through M&As and greenfield activities.

The fields we are interested in and considering are not only limited to glass industry, but we are also looking into many potential sectors with

We are also proud to be taking a part in responding to Covid-19 while keeping our core values and targets of our Sustainability Strategy “CareforNext” during such challenging time.

We remained in trusting that the common goal that brings the whole of humanity together is very simple and basic: ‘Healthy planet, healthy people in the pursuit of sustaining our only and One Planet and Common Future’.

Do you anticipate the use of more digital technology within Sisecam’s facilities?

GE: Sisecam views digitalisation as a new culture and way of doing business that encompasses the entire value chain.

Continued>>

www.glass-international.com

� Gorkem Elverici was appointed as the new CEO of Sisecam in July 2021.

� We are planning to increase our production outside Turkey above 50% level, which is currently at c. 42%. � As we continue to grow in our fields of activity, we will also evaluate organic and inorganic growth opportunities. � Wherever there are opportunities for sustainable growth, we will be there too. � Our goal is to increase the EBITDA margin by an additional 200-300 basis points per year after two to three ars following the merger.

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Company profile: Sisecam

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Numerous huge digitalisation programmes are underway across our global operations.

Sisecam has been adopting digital transformation not only as digitalisation of the production line and facilities, but also increasing the digital capabilities of the business units such as supply chain, finance and human resources.

Under the new post-merger organisational structure, Sisecam is speeding up its digital transformation journey to achieve greater operational excellence globally.

We have an infrastructure digitalisation initiative underway that is one of the world’s top three largest SAP programmes that are carried out at the moment.

We will unite our 43 facilities located in 14 countries and all our sales systems to a single digital infrastructure to make them part of a unified functional business model.

How did Sisecam react and adjust its production as a result of the Covid pandemic?

GE: In 2020, despite the pandemic, Şişecam manufactured 4.9 million tonnes of glass at its production facilities. In addition, the company produced 2.2 million tonnes of soda and 4.1 million tonnes of industrial raw materials in this same period.

Although the Covid-19 pandemic has resulted in unprecedented changes in our lives and the economies, navigating through uncertainties with a dynamic approach to crisis management and the ability to quickly adapt to changing conditions, Sisecam has continued to create value in the extraordinary atmosphere of the pandemic.

Sisecam adopts the philosophy of “people first” in all its operations. We quickly implemented and followed all applicable rules, restrictions and guidelines set by public health and governmental authorities in every country we operate.

Ensuring the health and safety of our 22,000 employees located in 14 countries has always been a top priority of our business strategy.

Since our current business lines require uninterrupted production, Sisecam has quickly adapted its production plans and business processes by considering emerging developments in its target markets and geographies.

� It has recently announced its first glass packaging facility in Hungary.

“Sisecam views digitalisation as a new culture and way of doing business that encompasses the entire value chain.

”

Judging from Sisecam’s production output, do you think the trend for glass is increasing post-Covid?

GE: In the circumstances of the pandemic in 2020, despite the differentiating performances of Sisecam’s business partners and customers, we managed to achieve a lucrative year. Increased awareness of health and hygiene during the pandemic accelerated the demand for glass globally.

Opportunities continue in the glass packaging business, where the epidemic-related downside risks on the demand side are relatively limited as it is a food, beverage, and pharmaceutical industry supplier for 2021.

The flat glass industry was affected adversely by the Covid-19 pandemic in 2020. However, in the upcoming months, there has been a rapid growth in the housing renovation market and with the pent-up demand; the flat glass demand started to increase. We also see recovery of flat glass consumption in Turkey, Europe and other regions we operate.

Despite the pandemic, we continued our investments with an amount of approximately 1.9 Billion TL (US$224.9 million) in 2020. Our main investments during the effects of the pandemic are mentioned below.

We turned our Polatlı facility into Europe’s largest flat glass base with the eighth furnace we ignited in Turkey in October with an investment of approximately US $140 million.

Following the Polatlı facility, in March 2021, we ignited our TR6 furnace upon the completion of its cold repair process, in our Yenisehir flat glass production facility.

With the completion of the Mega Jumbo production investment in Yenisehir, Sisecam became one of the few producers in the world that produces flat glass up to 16 metres .

Sisecam will continue to create value by actively using its two million tonnes of flat glass production capacity in Turkey, upon the completion of our fifth flat glass furnace’s cold repair process in the last quarter of 2021 in our Yenisehir facility.

Last year, we also completed the renovation and modernisation investment of our Sisecam South Italy facility, which is our second flat glass Continued>>

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Company profile: Sisecam

investment in Italy.

As the largest flat glass producer (in terms of installed capacity incuding Turkey) in Europe, we aim to make Sisecam South Italy, our second flat glass production facility in Italy and our third flat glass production facility in the EU, strategically beneficial in terms of our flat glass activities in Europe.

Sisecam will establish its first glass packaging facility in Europe with two furnaces in Kaposvár, Hungary.

As mentioned before, we are also planning to make two float line investments in Turkey, which will increase our production capacity in the country by 30%, to 2.6 million tons by the end of 2023.

Can you describe some of Sisecam’s sustainability initiatives within its manufacturing facilities?

GE: We continue our operations with the aim of reaching Green House Gas reduction target as part of our sustainability strategy.

As a global party and a supporter of the United Nations Sustainable Development Goals, Sisecam initiated its five-year corporate sustainability strategy under the title “Care for Next” in 2017.

We are now in the process of building our 2022-2030-sustainability strategy.

As a result of the efforts made in 2020, we took important steps forward in terms of sustainability, including:

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� We saved 263.028 GJ of energy and prevented 103,471 tonnes greenhouse gas emissions in 2020. � We ensured that 55% of the product packaging materials that we released were collected from the market and recovered. We have increased our local supply ratio by reaching to 83% in raw material supplying from the local markets. � As part of our Sustainability Strategy, we have transitioned to lower-NOx combustion systems at nine glass furnaces as of 2020. � Within the scope of our goal to reduce NOx emission values from glass furnaces we have implemented such systems in 47 of 49 furnaces.

� Sisecam prevented 103,471 tonnes greenhouse gas emissions in 2020 through its sustainability goals.

� As part of our commitment to design glass packaging products, lightweight glass packaging solutions that can be produced with less raw materials and less energy are produced. By implementing a design change, 14% reduction in greenhouse gas emissions has been achieved only via single bottle type.

Can you briefly explain what initiatives Sisecam’s R&D facilities are focusing on and how important they are to the company?

“We continue our operations with the aim of reaching Green House Gas reduction target as part of our sustainability

”

strategy

GE: Sisecam has dedicated its Research and Development efforts and operations to developing highly innovative, environmentfriendly, competitive products and production technologies.

Our research and development centre, where 164 scientists work together in 29 well-equipped expert laboratories, focus to develop new glass compositions, new glass coatings, new processes, formulations, designs and melting technologies to add value to the comforts and aesthetics of life through innovation by pushing the boundaries of glass science and technology.

In recent years, a decent amount of investment have been made in the field of magnetron sputtering coating technologies and the theoretical production capacity has been increased five times in the last eight years. Thus, we increased the variety of our heat and solar control products.

In addition, we have solid targets for thin and lightweight glass solutions in the near future for automotive applications and with this focus, we started to develop glass prototypes by using thin glasses which are strengthened by chemical tempering technology.

Additionally, projects undertaken to develop glass systems offering resistance to different types of attacks, such as ballistic attacks or explosions, for use in security and safety applications continue at full pace.

In the field of glassware sector, beyond the standard decoration, functional coatings are also developed and widely used. Developed by Sisecam’s R&D centre, thermochromic coatings that change colour with temperature and photochromic

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SUPPLY CHAIN CONFIDENCE

5 LOCATIONS ACROSS UK AND IRELAND • Soda Ash • Sodium Sulphate • • Feldspars • Chrome • Barium Sulphate • Sodium Nitrate � The company is the largest flat glass producer in Europe.

coatings that change colour in daylight are innovative coatings developed for this sector.

As mentioned before, in 2020 we implemented V-Block Technology that prevents the growth of microorganisms on glass surfaces being pioneer with our 45 years of investments.

SPECIALISTS IN THE GLASS INDUSTRY

Any finishing comments about your new role as the CEO of Sisecam?

GE: I have been a member of the Sisecam Family since 2013 and had been serving as the CFO for the last seven years.

I have always been honoured to be a part of such a strong and influential industrial organisation, which has transformed first into a regional and then a global power over its 85-year history Sisecam will move forward into the future to achieve its ambitious goals with the bold decisions and devotion of each and every Sisecam employee and I am honoured to be leading this growth journey. �

CEO* Sisecam, Istanbul, Turkey https://www.sisecam.com.tr/tr/

www.glass-international.com

How important will the investment in a glass packaging facility in Hungary be to Sisecam?

GE: Sisecam will establish its first glass packaging facility in Europe with two furnaces in Kaposvár, Hungary.

The greenfield glass packaging facility with an investment of €220 million, will have an annual net production capacity of 330,000 tonnes, and is expected to start its operations in 2023 and reach full capacity by 2025.

We have operated in Hungary for eight years with our encapsulated glass facility.

Sisecam is a strong player and has had a positive track record in the Hungarian market. Our new investment offers attractive opportunities and advantages to support our growth in the European glass packaging market.

Contact us: +44 (0)20 8332 2519

+44 (0)20 8940 6691

sales@newport-industries.com

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Alternative fuels: Biomethane

Wiegand-Glas adds biomethane to the Eco2Bottle toolbox German glassmaker Wiegand-Glas recently partnered with biomethane producer bmp greengas for its customer soulproducts. Lukas Neubauer* discusses why the use of biomethane can play a part in the manufacture of a ‘greener’ glass bottle.

� The partnership with bmp greengas is part of Wiegand-Glas’ ‘Eco2Bottle toolbox’ which aims to make the company a more

R

eusable glass packaging can be used around 50 times before it is melted down again and put to a new use.

So glass fulfils the requirements of a circular economy in terms of reuse and recycling to the highest degree.

Nevertheless, in many cases more can be done to improve the energy balance of glass containers. This is because glass production, from melting to forming and beyond, is an energy-intensive process that often makes use of natural gas.

Wiegand-Glas has reacted and in doing so has also fulfilled the wish of soulproducts GmbH: the production of a product line with biomethane.

Wiegand-Glas launched the Eco2Bottle concept in 2020, sending a clear signal for environmental protection and resource conservation to the market and its customers. The concept envisages avoiding, reducing or compensating CO2 emissions in all production steps - together with food and beverage producers all the way to the consumer. “It all comes down to individual solutions,” says Lukas Neubauer, Head of Controlling & Corporate Development at WiegandGlas. “We look at each customer, each market and each product very closely, provide recommendations for the entire supply chain and then develop the

right packaging solution with the help of an optimally coordinated toolbox.”

Consideration is given to power supply, recycling, the weight of the glass, further packaging, logistics and, of course, the energy needed for the production itself.

Eco2Bottle toolbox Already from the first Eco2Bottle, the 0.75 l. Bordeaux bottle, the possible measures for avoiding and reducing emissions are well known, which is why they are only briefly explained below. The electricity used, which comes from the normal Continued>>

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sustainable manufacturer.

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Alternative fuels: Biomethane

� Biomethane is a natural energy source so no emissions are emitted during the

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production process.

German electricity mix, can be replaced by green electricity.

Wiegand-Glas currently uses green electricity generated from hydropower.

Furthermore, for each packaging it is checked whether the weight can be reduced or the amount of cullet. Less energy is needed to melt the old cullet than would be required for primary raw materials.

In addition, the packaging design is optimised, if possible. Attention is paid to using reusable intermediate layers instead of corrugated cardboard layers, and at the same time trying to get as many bottles as possible on to one pallet.

With the production of the soulbottle, the possibility of replacing the natural gas used in production with biomethane was added for the first time. Soulproducts gave Wiegand-Glas the impetus to switch a complete production to biomethane and that’s how the contact with bmpgreengas came about.

“By using biomethane, we are resorting to a natural energy source generated from biogenic gases,” Lukas Neubauer reports.

“This avoids emissions that would otherwise occur when burning natural gas in the production process.” Especially in energy-intensive industries like the glass industry, there is a huge potential of CO2 savings with biomethane.

Roughly, it can be said that the use of biomethane can save about 30 to 40% of the total emissions per packed tonnage, based on the ‘cradle to customer plus waste’ approach.

The percentage given depends on

several factors, including cullet use, glass colour and, most importantly, the furnace at which the item is produced.

Feeding biomethane Due to its calorific value properties, biomethane can be transported via the existing gas network without technical conversions, long-term preparations or additional investments. By purchasing biomethane, Wiegand-Glas gives the order for a certain quantity to be fed into the balancing circuit of its energy supplier, which it can then use for production

Additional costs Even though the price of gas has risen sharply in recent weeks and months, companies still have to dig deeper into their pockets for biomethane.

So it definitely involves a certain willingness to invest to reduce CO2 emissions. However, feeding biomethane into the grid also brings advantages for companies subject to emissions trading. This is because under the Federal Emissions Trading Act (BEHG) and the European Emissions Trading Scheme (EUETS), biomethane is currently exempt from the CO2 price up to and including 2022, and even for an unlimited period depending on the substrate and verification.

Biomethane quality It is important to know that there are very different biomethane qualities. The term ‘quality’ is a little misleading here, because all biomethane is first of all good,

green gas, whether produced from liquid manure, energy crops or biogenic residues and waste. However, it does make a difference where and how the biomethane is produced or obtained. Whether in Germany or in other European countries, from maize or municipal waste. WiegandGlas currently uses biomethane obtained from German municipal waste, as this is particularly regional and sustainable.

Perspective and news Within the framework of an Eco2Bottle project, Wiegand-Glas customers now have yet another opportunity to genuinely reduce emissions by using biomethane in the production of their glass packaging.

Furthermore, it also applies that with each customer it is checked individually which measures make sense and how these can be implemented step by step. Thus, after the soulbottle, other Eco2Bottle projects followed in which biomethane was used, for example the first beer bottle as an Eco2Bottle, a 0.75 l. individual bottle for the Haberstumpf brewery in Trebgast, Northern Bavaria �

*Head of Controlling & Corporate Development, Wiegand-Glas, Steinbach am Wald, Germany https://www.wiegand-glas.de/en Mr Neubauer will speak at the Renewable Glass Manufacturing conference, held digitally on November 9 and 10.More information via www.glass-international.com

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www.growth-group.com

Don’t just look at it, look into it.

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

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

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

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

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

Data – the deciding factor

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

Environment

Heading for eco-friendly batch and cullet production Environmental protection is becoming increasingly important and has always been a top priority at Zippe. Philipp Zippe* provides a few examples of how the company contributes to environmental protection in several areas.

Energy saving by waste-heat recovery

Further advances in preheating technology As many of our customers aim at reducing CO2 emissions, batch preheating is increasingly in demand, especially during the last 18 months. In 2021, an advanced mechanism was developed by Zippe’s engineers, theoretical models have been applied, and the technology is currently being tested. The objective is to develop a system that maintains the same high preheating efficiency but ensures a highly reduced dust carry-over. We aim

� Pic 1. Furnace silo with a Zippe preheater on the right.

� Pic 2. Zippe batch preheater.

to achieve this by complex modelling, testing, and improving the air and pressure flow within the system. During the pandemic two orders were placed for large scale preheaters for European container glass producers which are currently in the realisation phase (Pics 2 and 3).

Glass recycling - saving precious raw materials and reducing CO2 emission Aside from decreasing costs, saving raw materials is an important aspect of environmental protection. Therefore, Zippe specialises not only in internal, but also in external cullet (post-consumer glass) recycling. 35 years ago it installed recycling plants with Concentrated Continued>>

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Batch and cullet preheating systems have been known to the industry for more than 40 years. In 1984 Zippe Industrieanlagen filed its first patents regarding this technology, and the first preheater was installed in the same year. Initially the original preheaters were mainly so-called plate-heat exchangers and were designed for preheating cullet. Later these systems were designed to handle higher volumes of raw materials (sand, soda, etc.), and their technology became more advanced.

Over decades a lot of effort has been put into coping with this challenge. Today, second generation preheating systems can run safely without material flow problems and with lower cullet ratios than in the past.

Zippe has built a significant percentage of the batch preheaters in operation today.

It is known throughout the industry that applying this technology can save up to 15% of the total melting energy. These systems can be implemented at greenfield sites, but also be retrofitted. Due to the increased focus on green technologies, Zippe is continuously improving this technology (Pic 1).

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Environment

� Pic 4. Layout of a Zippe recycling plant.

� Pic 3. Layout of a Zippe batch preheater, bucket elevator, furnace silo and

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batch charger.

Solar Power (CSP) devices. Numerous developments and innovations followed.

As part of our efforts to reduce energy consumption and emissions, the focus was on developing high-performing glass recycling plants for our customers, together with specialised partners for CSP sorting technology.

As a result, several plants have been successfully realised in the past and give confidence for a future with a higher utilisation of recycled cullet.

While recycling is a standard practice in many regions of the world, there are still countries with a high potential of using more cullet by applying recycling technologies.

In the long run it pays off, not only for the environment, but also for glass producers. Therefore, several glass producers contracted Zippe to realise post-consumer glass recycling plants (pic 4).

In its aim to decrease its carbon footprint, Orora, an Australian sustainable packaging solutions provider, awarded Zippe the contract to design and deliver a new glass beneficiation facility.

The new plant will enable Orora to increase the amount of recycled content in its glass packaging, which will deliver sustainability benefits, including a reduction in energy consumption, CO2 emissions, and in virgin raw materials used to manufacture glass, as well as diverting waste away from landfills.

Higher recycling rate at Siam Glass in Thailand Recycle for the World is the slogan of Siam Glass. By installing a high-standard recycling facility with a current capacity of 45t per hour, Zippe is now a part of this cycle and helps to avoid wasting precious raw materials (Pic 5).

Another recycling plant has been developed by Zippe for Sotuver in Tunisia, which is now in the realisation phase.

Zippe is not only able to design and plan individual glass recycling factories, but also supplies all the necessary equipment and control systems. Furthermore, its scope of services also comprises the installation as well as the commissioning of these plants.

Further green contributions at the Wertheim headquarters As early as the late 1980s and early

1990s, we greened the roofs of some of our buildings, thereby making a valuable contribution to environmental protection and CO2 reduction. These green oases offer ideal conditions for birds and insects, just as the large green areas around our premises offer a retreat for all company members.

Early in 1999 we installed solar collectors to enable the in-house utilisation of valuable solar energy.

Furthermore, our latest building, the new Engineering Centre at the headquarters in Wertheim, Germany, was equipped with geothermal heating for environmental reasons.

In addition, we are in the process of partly converting our company car fleet to e-cars. Last but not least, we are digitising our business activities whereby the use of printers and paper is continuously reduced.

It feels good to make a contribution to environmental protection and to further explore this path together with our associates and customers around the world.

For more than 100 years Zippe Industrieanlagen has supplied highperformance machinery and batch and cullet systems to the international glass industry. With a team of committed engineers and experts, Zippe can offer its customers the best economic and ecologic solutions to suit their needs. �

Zippe Industrieanlagen, Wertheim, Germany www.zippe.de

� Pic 5. 3D model of a recycling factory in Thailand.

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T hi si snotas ol arecl i ps e

Wi r eEdgedet ect i on

wi t hz er ocompr omi seby

Environment

Diageo’s grain to glass sustainable plan

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Global glass customer Diageo officially launched its 2030: Spirit of Progress action plan last year, with the aim of being more sustainable, championing inclusion and diversity, and promoting positive drinking. George Lewis spoke to Lucy Fishwick* about how the company plans to reach these goals.

D

iageo owns some of the most well-known beverage brands in the world, including Guinness, Smirnoff and Johnnie Walker. It has a total of more than 200 brands spanning 180 countries globally.

In November 2020 it launched its 10year action plan called the Society 2030: Spirit of Progress as a way to ‘expand its lens’ to hit targets across the company, including becoming a more sustainable

and inclusive organisation .

The plan is split into three main ‘pillars’: Promoting Positive Drinking, Championing Inclusion and Diversity and Grain to Glass Sustainability. Diageo says it wants its consumers to ‘drink better not drink more’.

Lucy Fishwick, Diageo’s Head of Procurement for the company’s Glass to Grain Sustainability, has only taken up this role recently, having previously

been the Global Procurement Category Director for Glass and PET. Ms Fishwick has been at the company for nearly eight years, so has seen first-hand the role Diageo is playing to create a more inclusive and sustainable industry.

Ms Fishwick’s role includes making strategic decisions on Diageo’s suppliers around the world. But this role was adapted slightly due to Covid-19 which prevented her from visiting many of

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Environment

them since starting in the role.

Despite difficult conditions, she has been able to rely on Category Managers from every region who have helped her settle into the role and give her the knowledge she needs to make strategic sourcing decisions.

She said: “It’s been a bit of a challenge.

I have only been able to see one supplier due to Covid and only seen one furnace in my life so far (in person) apart from in YouTube videos!

“I’m absolutely desperate to get out

complete supply chain and be able to take a broader view of what its impact is globally, not just internally.

Ms Fishwick said: “Our 10-year plan is to build a more sustainable world, building on a legacy of our founders to create positive impact in our company, our communities and societies overall.”

Ms Fishwick explained that the company’s ‘grain to glass sustainability’ goal, for which she now works closely on, is ‘all about making sure we are ready for the future’.

“The consumer attitude will shift and we want to win when it does”, she said.

Diageo is committed to working towards a low-carbon future by eventually using 100% renewable energy to achieve

company’s value chain.

Ms Fishwick hopes that halving Scope 3 emissions can be ‘a good stepping stone to a complete net zero supply chain before 2050’.

She added: “It’s fair to say sustainability is growing and growing but at different rates in different markets, but we will not get to our 2030 targets without collaborating with our suppliers and our peers.”

The second ‘pillar’, ‘championing inclusion and diversity’, involves making Diageo a more inclusive and diverse culture.

It aims to have 45% representation of leaders from ethnically diverse backgrounds by 2030 as well as 50% of

� Diageo owns some of the world’s most famous brands, including

� � Lucy Fishwick has been at Diageo for eight years, and now works on one of the company’s ‘three pillars’ – it’s Glass to Grain Sustainability.

there and see people and the furnaces.”

She understands the importance of Diageo’s 10-year plan for the future of the glass industry.

She explained: “We can’t sit back and wait for consumer’s mind to shift otherwise we will be on the back foot.”

The three pillars Diageo’s latest plan has meant the company can continue to look at the

net zero carbon emissions across its direct operations, while also working with its suppliers to reduce indirect carbon emissions by 50% by 2030.

It also wants to use 60% recycled content while also using 30% less water.

It is also bidding to have net zero Scope 1 and 2 carbon emissions along with halving its scope three emissions by 2030.

Scope 1 emissions covers direct emissions from a company’s owned or controlled sources, while Scope 2 emissions covers indirect emissions from the generation of purchased electricity, steam, heating and cooling consumed by the company.

The Scope 3 emissions include all other indirect discharges that occur in a

all leaders being women, along with 60% females on the board at Diageo. It will also provide skills and training to over 1.7m people to help create an inclusive hospitality sector.

Ms Fishwick explained that ‘as our consumers are the most inclusive and diverse, how can we expect to be able to interact with them unless we are living and breathing the same values’?

She said that while the aim is to get to 50% of women in leadership by 2030, it hopes to get there much sooner with women currently in those roles at around 39-40% already.

She also explained that the company Continued>>

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Guinness, Smirnoff and Bailey’s

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Environment

� Earlier this year Diageo became the latest company to collaborate with glass manufacturer Encirc and Glass Futures to use biofuel-powered furnaces. is trying to ‘level the playing field’ rather than promote one sex over the other, and this shown by the equal parental leave given to Diageo employees.

The last ‘pillar’ is to promote positive drinking and this includes looking at helping bring the company reach a new audience, while also trying to change the attitudes of up to five million drivers towards drink driving and educating a further 10 million people on the dangers of underage drinking through its awardwinning alcohol education awareness programme, Smashed .

www.glass-international.com

Biofuel trial In April 2021, Diageo became the latest company, after Heineken and Carlsberg, to collaborate with glass manufacturer Encirc and Glass Futures to use biofuelpowered furnaces, collaborating to reduce the carbon footprint of the bottle-making process by up to 90%.

The trial produced 173,000 of Diageo’s Black & White bottles, which also used 100% recycled glass. This made the batch the most environmentally friendly ever produced for a Scotch whisky brand.

Ms Fishwick said: “To be part of the trial to get to 90% carbon reduction was hugely exciting because it is absolutely aligned with our ambition and long term view.”

John Aird, Senior Packaging Technologist at Diageo said at the time of the trial: “This trial is just a first step in the journey to decarbonise this aspect of our supply chain and we still have a long way to go, but we are delighted with the results of the collaboration and the platform it creates for future innovation.

“We see Glass Futures as a great opportunity to develop new technology and to help deliver net zero glass

manufacturing and we are delighted to support them in that mission.”

The future for Diageo Despite having the majority of its products in glass for more than 250 years, Diageo remains committed to keeping it as its ‘primary format’.

Ms Fishwick lauded its glass bottles as a ‘thing of beauty’ and would like to see the brands remain in glass for the foreseeable future. But she said the whole industry must work hard to be environmentally better and be able to entice future generations to the industry.

She said: “We’ve got to embrace Industry 4.0. Glass is going to have work hard to make sure we bring new talent in and grow for the future.”

She added that it is imperative the industry looks to the future to see the impact of the work being done now.

She explained: “As the next generation

comes to the market were going to have a consumer base that has grown up very different to those before, grown up with social media etc., with more knowledge.”

She believes the Western world understands more the need to be more sustainable and that knowledge is increasing every day.

She feels the next generation of consumers are more savvy about the environmental impact on the world.

She hopes that Diageo can play its part in reinforcing the message to be more sustainable and with the Spirit of Progress 2030 action plan available for all to see and be judged on, she believes it can push the message out across its brands globally. �

*Head of Procurement - Glass to Grain Sustainability London, UK https://www.diageo.com/

� Diageo’s Spirit of Progress action plan aims to make the company ‘a more sustainable and inclusive company’ by 2030.

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

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

It is a non-profit making organisation serving a worldwide membership publishing journals and text books, organising meetings and conferences on glass related topics.

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

Serving the Glass Community for more than a century

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Forming

The future of forming Daniel Arredondo* and Mario Gonzalez** highlight what they anticipate the future of forming will be.

A

manufacturing processes.

Remote support was a key point for continuity; a worthy investment in connectivity and information analysis, without forgetting that machine safety is very important, in the coming years, we will seek to integrate robots into the IS machines in the mould lubrication process, which will help protect the operator and prevent direct contact with the machine when it is in motion.

At FAMA we know that health and safety is very important to our customers, so in the near future we will have more robust systems in the industry.

The glass container industry has grown in knowledge in recent years, taking it to high levels of productivity, in FAMA we see an area of opportunity in the inclusion of Industry 4.0 concepts to mark the new direction towards prediction and use of artificial intelligence systems, which will turn our customers into a greater benefit by reducing their downtime or increase their daily quantity of containers with

high quality rates.

Currently we already have access to information in the cloud, and we expect it to grow exponentially in order to make the tools provided by data analysis more and more robust and, as mentioned above, the customer perceives it as a tool for better preventive maintenance and faster action in the event of deviations in the different glass container manufacturing processes.

We have a long-term vision to incorporate technologies that bring measurable benefits to our customers.

Finally, the use of Digital Twin has become an important tool to increase the reliability of the mechanisms being designed, or to locate any weaknesses.

Today, FAMA uses this tool as part of its daily work. �

*4.0 technology leader, **Electronic Technology Manager, FAMA, Monterrey, Mexico https://fama.com.mx/en/

www.glass-international.com

t FAMA we combine modern technology and a highly committed workforce that allows us to generate strategic alliances to transform our customers’ productivity to outstanding levels.

Our experience in the glass packaging industry allows us to offer transformed solutions in machinery and services, automation and metal mechanics in the glass industry.

We have been integrating systems to our IS machines for more than five years with a focus on Industry 4.0, which has helped us to improve processes in container manufacturing.

The Covid-19 pandemic took us all by surprise and under the new health protocols and even when restrictions began, our electronics and systems continued to operate, with connectivity between the process and the Cloud.

These systems provided us with process connectivity, alarms and event tracking that allowed us to track our customers’

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Women in Glass

T

hroughout August in South Africa, Consol Glass honoured the women who work in the glass industry through a far-reaching internal and external campaign.

The company had several initiatives that encouraged and empowered women to take control of their careers.

One of these was the company’s ‘Women in Glass’ programme designed specifically to facilitate this empowerment process.

The year-long programme targets young women at supervisory and junior management levels to enhance retention and drive skills development of women in the business.

“As we aim to nurture our next generation of leaders, the first group of 20 young women will be building competencies in various areas, such as the ecosystem of influence, cultivating allies through communication, emotional intelligence, seeking opportunities, resilience and creating personal leadership characteristics,” explained Thami Mkhuzangwe, Senior Group Executive: Human Resources & Corporate Affairs.

In addition, several of the company’s other programmes, such as apprenticeships and ‘learnerships’, have a strong bias towards growing the number of young women who are recruited for

Consol celebrates its Women in Glass

� Consol Glass celebrated its Women in Glass throughout August.

training.

This focus on inclusivity extends to two other external programmes supported

by Consol Glass on local communities.

A New Venture Creation (NVC) ‘learnership’ project for unemployed youth with disabilities and farming ‘learnerships’ for emerging farmers from disadvantaged backgrounds have both included a notable number of women among the beneficiaries.

“Through initiatives such as these, we

hope to inspire, motivate and encourage women to be the best that they can be, so that every woman’s success is an inspiration to another,” added Mr Mkhuzangwe.

Below we hear from some of the many women at Consol Glass, discussing their experiences and why they chose the glass industry.

Johannesburg, South Africa https://www.consol.co.za/

JUANITA FARMER, SUPERVISOR:

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INSPECTION & PACKAGING - CONSOL GLASS, BELLVILLE

� Juanita Farmer is an Inspection and Packaging Supervisor at Consol’s Bellville plant.

Juanita Farmer found herself in the glass industry by pure chance and the moment she stepped into her role, she found the glassmaking process fascinating.

“Once you start working here, glass runs through your veins and Consol is an outstanding company to work for. I enjoy every minute of it and look forward to the challenges every new day holds,” says Ms Farmer.

Ms Farmer started at Consol Glass on a contract basis as a line attendant almost 20 years ago. After a year, she was promoted to line controller, specialising in baby food jars.

Having built extensive experience in this role over 15 years, Ms Farmer was promoted to shift supervisor in 2018, a position she still holds.

She believes that women bring a unique, dynamic aspect to the business.

They are not only able to analyse and problem solve in difficult situations but are emotionally adept to empathise and

bring “heart” to different scenarios.

She thinks that this helps to enhance understanding and cultivate open, nurturing relationships with peers across all levels at Consol.

Women are also experts at being proactive and multi-tasking, as they do this all the time within their day-to-day lives. This is a crucial skill within Consol and any other organisation.

She said: “As women in glass, there are so many more opportunities for us to prosper, empowering ourselves with more skills and knowledge.

“We have attributes such as curiosity and being courageous, that is why God handed women the task of bringing another life into this world. So don’t let anybody tell you differently. You can achieve anything you set your mind to.”

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Women in Glass

PRISCILLA SIFUMA, CONTINUOUS IMPROVEMENT MANAGER - CONSOL GLASS, KENYA Priscilla Sifuma believes women are organised and multifaceted, which enables them to manage multiple roles in the workplace.

“Women by their virtue are very warm natured. They are good trainers and excellent mentors, skills which help to build a highly motivated workforce that translates into overall improved productivity,” she said.

As the continuous improvement manager at Consol Glass Kenya, Ms Sifuma knows too well how challenging it can be to work with cross functional teams across the business to drive improvement opportunities.

In high school, Ms Sifuma excelled in her science-related subjects but, being from a humble background, she could not immediately afford to study further after school.

She started at the Kenya plant as

a lab assistant in 1987 and used her salary to pay for her studies. She enrolled in a technical college where she studied Analytical Chemistry.

She later completed a Business Administration degree to develop her leadership abilities, setting her on a path to be part of the management team at the company’s East African plant.

Ms Sifuma said her love for chemistry drew her to the glass industry.

“The whole process of glass formation was just so fascinating for this young girl from the village who was passionate to succeed in life,” she explained.

She added: “I was happy to be part of the team that was researching raw material sources and suppliers long before our first production began.

I enjoyed it so much that I decided this is what I want to do for a career.”

Ms Sifuma said that because the best things come in glass, the � Priscilla Sifuma demand for glass packaging will works at Consol continue, as will opportunities for Glass’ plant in advancement and new technology.

Kenya as its She said that women need to Continuous grow their leadership capability Improvement and develop self-confidence to Manager. thrive in a male dominated work environment.

QUALITY ASSURANCE CONSOL GLASS, CLAYVILLE Ormie Motsapi has been with Consol Glass for a total of 11 years and is currently a quality specialist, with a certification in Total Quality Management.

Before joining Consol Glass, Ms Motsapi had no experience or exposure to the glass industry. It was only when she applied for a position to assist with the C4 furnace that she became fascinated by the glass production process and has been hooked ever since.

She said: “I enjoy everything, starting from the cullet plant to the finished glass product that leaves our site. If you don’t know anything about the glassmaking process, you will think it is easy. But if you know how much it takes, you will appreciate what it takes to produce the perfect glass container.

“I enjoy every part of my job and the challenges that come with it,” shares Ms Motsapi.

She said she has benefited from various training opportunities, such as the Consol supervisory programme and fracture analysis training, to be equipped for the role that she currently holds.

She believes women should start empowering themselves by grasping opportunities to study further, rather than waiting to be pushed in that direction.

“We need to start challenging for managerial roles when they are advertised, even those that are typically believed to be for our male colleagues,” she added.

She encourages Consol to break the glass ceiling in the industry by introducing more women in senior management positions.

“We have women who are capable, all they need is to be mentored and trained, and then given the opportunity,” concluded Ms Motsapi.

� Ormie Motsapi is a Quality Assurance Specialist at the Clayville plant.

www.glass-international.com

South African container glassmaker Consol Glass celebrated the women who work in many different areas throughout its plants. We find out more about the campaign and hear directly from some of Consol’s female employees.

ORMIE MOTSAPI, SPECIALIST:

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Women in Glass

NOREL LANDMAN, RETAIL MANAGER - CONSOL GLASS, HEAD OFFICE “It’s kind of fun to do the impossible.”

This is a quote from Walt Disney that Norel Landman lives by, as she is passionate about everything she does, and absolutely loves a challenge.

Ms Landman has been part of Consol for almost seven years. With both a B Prim Ed teaching and B Com Marketing degree, she has been working in the FMCG industry for about 16 years before joining Consol.

Ms Landman found herself in the glass industry by chance and she explains that it is funny how little you know about an industry until you start living and breathing it.

“Who knew that glass could be so exciting with so many natural and environmentally friendly qualities and benefits,” she said.

As the Retail Manager for the company, Ms Landman successfully managed the two existing retail shops,

launched a third shop in 2017 and recently introduced The Consol Online shop.

“The Retail division has grown from a marketing initiative to a fully-fledged profitable business within the broader

Consol, while staying true to our original marketing objective of growing the glass brand,” shares Ms Landman.

She believes that women inherently have amazing qualities that add value to the business. Women are determined in getting the job done, are problem solvers daily, they are naturally curious - wanting to learn and know more - and they are passionate about what they do.

Most importantly they build authentic connections with those around them. She believes it is very important for women to find a way to make these qualities shine in their daily work life.

“Consol has allowed me to explore and grow as a woman in the glass industry but most importantly the company has given me the space to challenge myself every day to try and do the impossible,” adds Ms Landman.

� Norel Landman is the Retail Manager at the Consol Glass Head Office in Johannesburg.

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Decarbonisation

Industrial Glass Combustion Decarbonisation - Where to start?

Neil Simpson* and Philippe Kerbois** discuss how we can learn from history to help tackle the emissions challenge facing glass manufacturers.

O

� 100% Oxy Furnace from last peep hole. 62 colour palette highlights refractory cold spots, air ingress, hot spots, rundown and more.

yield, energy, and emissions. Performing an in-furnace thermal survey on an existing asset has the highest potential to demonstrate the value of a survey.

Hopefully, the subtle nuances of the furnace operation will be known by the batch and furnace team, but perhaps not fully understood. An in-furnace thermal survey can take one to three days, depending on the furnace type and size and the support provided by the site.

On oxy, recuperative, or small end-fired furnaces, a survey should be achievable in one day with the appropriate preparation by the site, and three days for a float furnace if all regenerators are included.

The typical justification for a survey is for NOx; however, that is not where to start. Start with the basics. Depending on

the furnace design, weir wall, bubblers, electrodes, deep refiner, where is the design hot spot location? Where is it in reality? At flame-out reversal, where is the batch line, where is there overheating/ over-cooling, and are there any holes?

What are the regenerator target wall temperatures? If you stop the overheating, you reduce the wear and risk of holes. If you fix the holes and/or clean/ repair regenerators, you save energy, NOx and now CO2! By optimising the thermal profile, you improve yield, make more money, and reduce CO2. Potentially pull more tonnes or reduce throat temperature to save energy NOx and CO2. By improving heat transfer, you lower NOx, Continued>>

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n 6th August 2021, the Intergovernmental Panel on Climate Change (IPCC) finalised the first part of the Sixth Assessment Report, Climate Change 2021: The Physical Science Basis. We suspect and hope that most people now recognise that the recent extremes in weather are an indicator that something needs to be done. The challenge is, where do we start?

While many countries have set goals for 2050, the biggest challenge is often knowing where you are and how you got there. By realising the journey that our predecessors took, we can learn from history about what has worked and what has not, to avoid re-inventing the wheel and repeating past mistakes.

While it may be obvious, it is worth reminding ourselves that process optimisation, including energy efficiency, is the easiest place to start; however, the reality is that benchmarking is probably the best place to start.

A thermal survey using the Ametek Land Near Infrared Borescope (NIR-B) is frequently the start point on a furnace in the second half of its life. Any quality and yield improvements will always, traditionally, have the highest value by financially impacting the bottom line.

The CO2 reduction and savings should, in reality, now be included in the financial evaluation.

During the last four Glass Problems Conferences, we have documented the potential to recover lost production through thermal profile optimisation, identify regenerator blockages, increase heat transfer, lower NOx, and support refractory repairs. This year, we will cover the survey of a float furnace.

Realistically, most new furnaces should achieve their rated compliance for pull,

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Decarbonisation

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� Cross-Fired Regenerative Furnace camera location showing thermal profile change over time each End of Firing L-R.

energy, and CO2. When troubleshooting a quality issue, the payback of the survey can be in hours, and that is ignoring CO2.

From a practical perspective, the best time to have a survey is when you are starting to become borderline on NOx. The longer you delay a thermal survey, the more savings (including CO2 reduction) you will potentially realise that you have already missed. The dilemma that all glass manufacturers now have is: what design will their next furnace be? Assuming +10 years, then what do you build and what design contingency is included?

Having a survey performed 2-3 years before the scheduled re-build offers the opportunity to understand better why your furnace operates the way it does. If you don’t learn from your existing furnace and validate CFD models, your next furnace design could be +20 years old. If you have to convert to a hybrid furnace, where would you put the electrodes, and where would you put oxy burners and/or hydrogen? We don’t believe you will find the answer in a magazine but look at your existing furnace first.

In the United Kingdom, the Energy Savings Opportunity Scheme (ESOS) Phase 3 deadline is 5th December, 2023, and there is a current consultation from the Department for Business Energy & Industrial Strategy (BEIS). This may ask for new steps to improve the uptake of energy savings.

Thus far, every in-furnace survey that Ametek Land has performed has had a payback. The majority have installed a permanent NIR-B at the next

� End Fired Regenerative Furnace View from Peep Hole #1 End Firing L-R Negative Image with Isotherms to show cold spots and areas with risk of NaOH condensation

furnace repair. An increasing number, when refractory conditions permit, are installing before the end of the furnace campaign. Operator education and training are key elements following commissioning, so the image generated is ‘not just a pretty thermal picture’ but a meaningful tool to optimise the furnace for yield, pull, energy, NOx, and CO2.

The cost is covered by OPEX and reduces the furnace CAPEX. The instrument can support ceramic welding and regenerator repair using oxy firing. If you can safely get one more day of production out of the furnace as a result of the information from the NIR-B, it will cover the cost of the instrument. This all reduces CO2!

Using the NIR-B as part of the cooldown and heat-up can potentially reduce the delays glass-to-glass. Since the

operators now know the operation and trust the NIR-B, the furnace is optimised faster, and compliance tests are achieved.

Ignoring payback from pull, yield, and energy, but looking to the UK EU ETS allowances average, a 4% reduction in CO2 would provide a one-year payback on CO2 credits alone.

A satnav may know your destination, but the directions will be incorrect if it does not know your precise location. The NIR-B helps you find where you really are on the decarbonisation journey. �

*Simpson Combustion and Energy, neilsimpsonfsgt@btinternet.com **Ametek Land, Dronfield, UK, www. https://www.ametek-land.com/

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21.05.21 12:26

Over 1000 production lines are equipped with Graphoidal Shear Spray Systems.

Contact us today to find out how our latest technology can help you.

Graphoidal Developments Ltd, Broombank Road, Chesterfield S41 9QJ, England Tel: +44 (0) 1246 266000 Email: sales@graphoidal.com Fax: +44 (0) 1246 269269 Website: www.graphoidal.com

Lubrication

A complete lubrication package for glass manufacturing Andrew Clarkson* explains how Graphoidal can provide a total package for an integral part of the bottle forming process.

G

� Fig 1. 4+4+4 Shear Funnel and Scoop MSSU.

tailor the lubrication for the gob delivery equipment.

The industry requires consistency for all aspects of the production process, this is achieved by the equipment monitoring and control programmed into the shear spray system.

To have accurate repeatability offers better and sustained gob delivery, reducing oil and water consumption.

Bacterial growth is a risk that can affect shear spray systems causing unexpected downtime and a loss in production. Using an Oil in Air system, the Oil is mixed with the water at the Spray Bar eliminating the potential for bacterial growth within the pipework, potentially reducing production downtime and unexpected maintenance.

The ability to dose of up to 1/2000

ratio Oil to Water consistently, precisely with automatic back and detailed human interface unit offers confidence and great return on investment.

Graphoidal Multi Shear Spray Systems have been designed to keep up with a fastmoving consumer goods environment, and to instil assurance and reliability that is a necessity for the container glass industry.

The system is equipped with automatic redundancy programmed to activate under alarm conditions. This ensures consistent and stable lubrication delivery while reducing the impact to production.

Easily defined alarms allow for quick and easy fault finding, combined with on-site training given by our specialist Continued>>

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raphoidal Developments, the Chesterfield, UK-based lubrication and engineering systems specialist now offers a complete solution for shear and gob delivery lubrication and cooling.

Its expertise is in precise pumping, control of mixing, dosing and spraying of the lubricants and coatings which form a vital part of the glass production process, both in hot end and cold end areas.

As a Rondot Group company, its success has been achieved by providing our customers with the support they require, with the ability in some instances to remotely support with our advances with Industry 4.0.

With thousands of products installed globally, Graphoidal Developments has a proven track record in the supply of quality equipment to the glass packaging industry.

Development of the Graphoidal Multi Shear Spray Unit brings further benefits with the addition of upper funnel lubrication, as shear and gob delivery is a critical component to the bottle forming process. (Fig.1) The addition of lubricating the upper funnels improves the delivery process, whereas previously the funnels may have relied on excess lubrication from the shears with no control.

With Graphoidal’s direct lubrication process, it gives the customer full control of their lubrication, with the ability to manage consumption.

The reduction in oil and water usage on the delivery system can potentially reduce container defects, which could also reduce consumable costs.

Graphoidal’s centralised shear, funnel and scoop system provides the operator with a central control station.

The user-friendly easy-to-use software empowers the operator to independently monitor oil consumption on a line-byline basis, while also allowing the user to accurately alter the dosing ratio to

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Lubrication

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� Fig 2. Graphoidal precision dosing pumps with individual monitoring blocks.

engineers, provides the user with the knowledge and capability of, on site fixes, reducing associated production down time (Fig 2).

Having efficient cooled and lubricated Shear Blades is imperative for the bottle forming process; too much water can have an adverse effect on the cooling process and is found to be inefficient and non-economical.

Graphoidal spray bars are designed to create a fine, atomised mist that cools the blades through evaporation.

Evaporation cooling the blades provides the most efficient cooling and lubrication with minimum consumption.

The ability to supply different oils to the Shears, Funnels and Scoops independently, offers a great range of diversity to tailor the lubrication process.

With ever increasing costs for materials, demand for more efficient and economical equipment is high.

Container glass groups require a premium quality system that delivers on application, efficiency, and a great return on investment.

Graphoidal is committed to developing innovative products that can be tailored to each project to provide highly efficient lubrication solutions to make its customers manufacturing process more efficient, productive, and profitable (Fig 3).

Floor space is at a premium within any manufacturing environment, so the ability to integrate systems together to reduce the number of cabinets is an advantage.

By integrating the lubrication of Funnels with the Shear and Scoop system, it has created a one-point reference for all

� Fig 3. Individual line backup pumps.

the production lines.

Graphoidal’s automatic ratio control powered by Siemens technology provides an intelligent system, which encompasses the ability to manage dosing, relevant to water flow.

Sensors built into the cabinet allow the system to identify pulses from oil flowing through Graphoidal pump monitor blocks.

The easily identifiable LED indicates via a flash using neodymium magnets to show oil is dosing but can also indicate fault conditions by a constant flashing light aiding in fault finding.

The primary dosing pumps which are pneumatically driven, dose a set constant amount of oil, this aids in the ability to keep consistently dosing oil but is regulated on time.

Time is defined from the ultra-sonic flowmeter in place on the water inlet.

Each production line will have a water supply incorporating its own flowmeter.

Monitoring water flow allows for dosing to automatically dose faster or slower relevant to the rate of flow.

This feature takes the responsibility

away from the operator to change the dosing value if changes are made on the shear platform regulator unit.

Graphoidal Multi Shear Spray Units can be tailored for a single production line up to currently six production lines.

Graphoidal systems can be integrated with a Graphoidal Autofill system with ease.

The automatic fill unit works off level sensors in the tanks within the cabinets to provide a clean refill system preventing contamination into the hydraulic system.

Graphoidal understands its systems are critical in a 24hour production line process; therefore, automation integration is vital to reduce operator interaction.

Graphoidal - Your partner for providing innovative, economical, efficient, and forward-thinking solutions that give you the crucial competitive advantages you need. �

*Technical Sales Engineer Graphoidal Development Limited, Chesterfield, UK

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Lubrication

Integrated process approach is key to lubrication Paul Schreuders* discusses further trends towards digitisation of the glass forming process, with further integration of technologies and intelligent use of data. Xpar Vision’s BlankRobot forms an important element in that trend.

Analysing the effectiveness of traditional swabbing gives the answer to the reason for this high frequency.

Firstly the application of lubricant is inconsistent; not one mould receives the same quantity every time. Operators change every shift and do not have the same skills or follow the exact routine.

Typically they take the brush soaked in lubricant and swab multiple sections.

Logically the first section receives more lubricant than the next ones.

Together it results in uneven distribution of graphite to the moulds.

At the same time the procedure of lubrication is considered as a standard for years, where no attention to possible improvements is given to: ‘We have always done it like this’.

Fig 1 illustrates the control chart of a single cavity from the Xpar Vision IR-D system each time the operator swabs.

The forming process has to deal with the impact and needs time to recover. As mentioned earlier this process behaviour is different from cavity to cavity resulting in a variety of unwanted effects from the common swabbing procedures.

Overlooking the above, the question to

� Fig 1. The heavy

answer is when is lubrication effective?

Two elements play a role here.

Firstly the lubricant used gives a durable layer of graphite to the blank and neck ring surface. Additional ingredients in the lubricant determine how long this layer of graphite performs during production.

Here we observe clear differences between the available lubricants. Often glassmakers are committed to a brand and type of lubricant already for years, simple because it is worked initially.

At the same time the lubricant can only perform durably when it is applied perfectly to the mould surface. Next to the requirement that lubricant actually has to connect to the surface, in this context it also means that the layer of graphite should be evenly distributed horizontally and in a vertical direction you would like to apply a thinner or thicker layer thickness depending on the friction caused by gob loading. And this has to be done consistently in time, from shift to shift.

Bottom line, it is all about a lubricant with the right composition of ingredients that is applied precisely and consistently for a durable result.

� Fig 2. BlankRobot by Xpar Vision.

impact of swabbing is clear.

Continued>>

www.glass-international.com

U

ntil coatings on surfaces of moulds and neck rings are not durable enough to provide long term protection against the harsh impact of gob loading, proper lubrication is inevitable. Besides lubricating moving parts, lubrication or swabbing aims to minimise the friction of hot glass at loading (blank side) and final forming (blow side) by applying a layer of graphite to the surface of the moulds and neck rings. It is necessary to keep the ISMachine running!

Glassmakers wish for consistent operation and do not want to exchange moulds and neck rings frequently.

Generally, swabbing is seen as a remedy for many inconsistencies in the forming process, such as changing gob shapes, instable loading conditions, deteriorating coatings of moulds, and changing cooling conditions. These result in different state per cavity in terms of performance throughout the production run; cavities with worst performance are the trigger for swabbing the full machine (all sections) again. As a result the machine operator is instructed to swab moulds on average every 20 minutes.

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Lubrication

For many years the only method of lubrication was carried out by the operator. Manual swabbing can never give a consistent performance as it is dependent on skills and accuracy of the machine operator who is exchanged shift by shift. Due to this inconsistency each time the operator swabs, a (heavy) disturbance in the forming process occurs resulting in low quality product. As a reaction to the losses caused by swabbing the operators were expected to swab ‘onthe-fly’ with higher health and safety risk as a consequence. At the same time, in terms of consistency of application, this aspect was compromised even more.

In summary, manual lubrication has many negative side effects when trying to achieve the need to swab: apply grease in an optimised way for best mould performance.

robots need to swab so often? The answer lies in the fact that the knowledge of application is failing with the swabbing robot suppliers, thus with the users as well.

Connection between type of lubricant and how to apply this lubricant by the specific swabbing robot is often failing, resulting in poor application which is compensated by swabbing more often.

Automated precision swabbing Application of the lubricant is the key factor for good lubrication.

Prior to the market introduction of the BlankRobot, (Fig 2) knowledge of application has been the basis of design (Fig 3). From the drawing board Xpar Vision’s BlankRobot is developed for high precision application. The result, as

Automated swabbing

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It was inevitable that the consistency was searched for in automatic lubrication systems.

Several automatic systems have been introduced over the years: � Spraying assemblies fixed per section � ABL or Carboflam technology based on cracking (burning) acetylene � Robotised swabbing systems moving from section to section In recent years the majority of automatic lubrication systems installed have been based on a robot moving along the IS machine swabbing section by section.

This method has been considered to be safer and healthier for workers on the shopfloor, has a lower total cost of ownership (less maintenance and exchange of parts) and importantly brings higher consistency as there is less or no variation in application between sections.

The operating methods differ if you review the different swabbing robots offered today. Generally their starting point is to copy the traditional manual swabbing procedures into automated ones. Still the same swab intervals are used or even in a higher frequency: every five to seven minutes is not uncommon.

We should again realise that every swab action results in an impact to the forming process stability.

It raises the question why these swabbing

� � Fig 3. result of applying lubricant

by BlankRobot compared to an alternative.

seen in Fig 3, is obvious when comparing application of lubricant.

Clearly seen is the difference between the two examples. The uneven and uncontrolled application by the alternative swabbing robot illustrates the answer to the earlier stated question: why do these robots need to swab so often?

With BlankRobot the application is nearly perfect. The BlankRobot performs with high precision to maintain a durable layer of graphite to the mould surface for a long time. It could be considered as coating rather than swabbing. The ‘coating’ is a result of good evenly distribution of the graphite inside the lubricant while having good adhesion to the mould surface. It allows the user to apply lubricant where he wants and how thick he wants.

The high precision of application comes with several important advantages.

As mentioned, the user has full control where and how thick he wants to swab, resulting in good quality bottles without swab impact (defects or pollution).

Next, it ensures durable operation which results in extended lubrication intervals of up to two hours while maintaining good quality. The impact of swabbing to the forming process performance is minimised dramatically.

Side effects are that mould sets remain longer in operation (less repairs), and maybe even more important, the health and safety of the machine operator is positively impacted.

Vision about automated swabbing While automated precision swabbing today already provides a higher level of forming process performance we strongly believe there is room for further improvement! In our vision the next developments will integrate automated precision swabbing with the requirements of the individual performance of the cavity as well as using the BlankRobot for additional automated tasks at the blank side.

Automated precision swabbing integrated in process control Robot swabbing needs new thinking and working methods.

We recognise that more automated swabbing procedures are needed. Differentiation is required at start up of the production run, in stable operation, immediately after exchange of blanks and towards the end of the production run. In every situation the BlankRobot should provide accurate precision swabbing.

At the same time forming process parameters that influence the automated precision swabbing should be controlled.

You can consider the temperature working range of the blanks in relation to the adhesion of the graphite layer to the mould surface. You can also think of reducing the friction (impact) at the loading of the gob by allowing less variation in gob loading parameters as length, speed and position where the gob enters the blank.

Users would also reconsider their procedures in regards to mould repair and preparation. Is common use of blank coating in mould preparation

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VRGS

Lubrication

needed or would uncoated blanks give better performance in combination with automated precision swabbing?

Intelligent automated precision swabbing Our aim is to minimise the impact of swabbing as much as possible. When looking at line/machine performance it is built up by adding the individual cavity performances. Every cavity essentially has its own forming behaviour depending on gob delivery, gob loading, mould condition, timing set-up and so on. To improve the forming process behaviour or performance at line level it is necessary to optimise the individual cavity performance. In this context automated swabbing should be adapted to the individual cavity behaviour. Here the intelligent use of process monitoring data comes in.

With sensors different process steps of the forming process (gob cut; gob weight; gob loading; blank temperatures; cavity performance; bottle quality) are monitored on cavity level giving the status of individual cavity performance. Based on sensor data analysed intelligently in real-time, the automated swabbing procedure will be adapted per single cavity.

Cavity differences which originate

by IS-Machine design (outer vs. inner sections/cavities) are eliminated and it

will be possible to anticipate on process deviations (coming from e.g. loading, temperatures, mould condition).

Only when the swabbing cavity is based in an adaptive automated way, full alignment with the forming process is in place which results in maximum forming process control, with a boost of line performance as logical consequence.

Additional automated tasks at the blank side While reading this article carefully you have noticed that swabbing intervals are increased up to two hours or even more where alternative swabbing robots continue swabbing in 20 minutes intervals. Within the design concept of the BlankRobot it has been anticipated that the idle time in between swab actions gives opportunities to assign other tasks to the BlankRobot as well.

The development of additional tools to connect to the BlankRobot arm will allow for new tasks to execute automatically to relieve the workload of the Machine Operator further and to reduce his/her exposure to health and safety risks.

With adapted tooling the BlankRobot will be able to maintain deflector coating, control gob loading by alignment of deflector and long trough. It will (visually) inspect the blank side for misalignments of malfunctions of equipment and measures temperatures and wear of

coating and parts. The BlankRobot will not only generate additional sensor data for intelligent use (AI) but is also steered

by AI to perform corrective actions of alignment to prevent deviations of process parameters and thus control the forming process for better performance.

Summary In this article the need and necessity of lubrication is outlined and placed in the context of traditional swabbing by hand for which a transformation to automated lubrication is started in recent years. Simply installing a swabbing robot to the IS-Machine is not enough.

In depth knowledge of the parameters that influence proper application of the lubricant exposed the opportunities for increase of forming process performance when automated lubrication methods are optimised further. Xpar Vision explained the relation between automatic lubrication and individual cavity performance and how these are optimised by using sensor data intelligently. The vision goes even further with more automated tasks will be assigned to the BlankRobot. �

*CEO, Xpar Vision, Groningen, The Netherlands www.xparvision.com

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21/09/2021 06:12:51 03.02.21 15:04

Lubrication

Three challenges for the container glass industry Jonathan Cruz* explains common problems for IS machine lubrication and how these can be overcome.

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lass containers are one of the most common types of packaging in the beverage industry, where we can have beverages such as beer, carbonated beverages, liquors and household.

For the manufacture of bottles, the blow-blowing technique is mainly used, where the operation of the independent section machines constitutes the pillar and the key to achieving the company’s production levels.

Melting furnaces, which handle more than 100 tonnes of glass per day and produce up to 300 containers per minute, feed them.

Resistance to high temperatures

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The process demands high temperature ranges around 220°C where the mineral base oils cannot reach a lifetime that favours the lubrication of the most remote points.

Synthetic ester-based oils are hightemperature oils with superior thermal resistance than conventional ones.

To analyse thermal stability, the following tests were performed: � Dish test (open and capped); � TGA (Thermogravimetry analysis with dynamic temperature sequence).

� Thermal stability tests can help manufacturers reduce costs.

With these tests, evaporation and ageing behaviour as well as oxidation resistance can be analysed.

TGA results show that the evaporation loss of these Kluber oils at operating temperatures is very low, up to 25% lower, which means that the oil will retain its lubricity longer in the mechanisms.

Minimal carbon residues formation The amount of carbon residues due to temperature effects on the oils increases the preventive stoppages for maintenance and cleaning of the machine.

In addition, the machine is exposed to sudden production stoppages associated

� Percentage of carbon residue with various base oils.

with the clogging of the lubrication veins.

The amount of carbon residues left by a mineral oil is 20 times greater compared to a synthetic oil.

To evaluate the high temperature oils,

the Eisenmann test (complete evaporation according to Eisenmann) and the Panel Cooking test were performed.

In addition to the Eisenmann test, also the Panel Cooking test shows the residue

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Lubrication

formation behaviour of oils (in terms of quantity and appearance) under thermal conditions.

The test is usually performed by us or by competitors for evaluating other high-temperature oil applications than those described in this paper. However, the Panel Cooking test shows the residue behaviour of the oils subject to thermal stress on the steel sheets used for this test.

Long relubrication periods The low evaporation loss and low residue level ensure longer relubrication periods than conventional oils.

Additives with properties reactive to black light, working as indicators or lubricant film developer, favour visual inspections confirming lubricity and avoiding mechanisms over lubrication.

Our glass specialists can help you to learn about IS Machine Inspections and how our oils overcome these challenges favour lower maintenance to achieve glassmakers’ goals.

Our resume includes:

in thermal stability tests can reduce consumption quantities and energy costs. � Besides thermal stability and wear protection, residue formation is a crucial criterion for many users. The residue amount should be as low as possible and easy to dissolve. � In general, products showing a minor tendency to residue formation

reduce cleaning and maintenance work.

If residues are even easy to remove, energy savings and longer service life are possible as well. �

*Glass Market Manager Klüber Lubrication, Querétaro, Mexico https://www.klueber.com/mx/

www.glass-international.com

� Products showing good results

� Evaporation loss compared to competitor oils

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22/09/2021 13:59

Lubrication

� Condat’s Condaglass 400 lubricant.

� Condat’s Lubriscore self-scoring system helps customers understand the differences in products.

Making the right decisions with Condat F

rench lubrication company Condat shares the conviction that the company can be a wonderful lever of innovation to respond to contemporary challenges: climate change, diminishing resources, pollution etc.

Supporting customers and partners towards responsible performance, that combines social and environmental issues, is a main objective for the company.

Initiated several decades ago, this responsible commitment is based on one of the Condat Group’s fundamental values: BUILD TO LAST. Guided by this historical value, since 1854 the company has been pursuing a long-term strategy that contributes greatly to its longevity.

It has been therefore one of the forerunner to develop industrial lubricants and other speciality products with a reduced environmental impact, without compromising either their performance or the safety of users.

As an example, the company launched its first biodegradables lubricants 20 years ago.

CSR commitments & assessments Since publication in 2010, the guidelines of the ISO 26000:2010 standard have been a guide for Condat’s decision-making and actions.

Although this standard does not lend itself to certification, it provides the

right guideline to all companies being aware that social responsibility and environmentally friendly behaviour are key factors for success.

In 2018, Condat went a step further in its CSR policy by joining the international ECOVADIS platform.

An independent body, assessed in 21 criteria divided into four themes, assesses its CSR performance annually in: � � � �

Environment HR Human rights Business ethics Responsible purchasing policy

Continued>>

www.glass-international.com

Condat has launched a self-scoring rating system for lubricants alongside a new swabbing grease. We hear about more about the company’s new developments.

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For 2020, Condat has been awarded Silver level by ECOVADIS, recognising its far-reaching sustainability and CSR policy.

This achievement placed Condat among the 25% of the best rated global companies by ECOVADIS and among the top 6% of companies in this economic sector / lubricants.

Lubriscore, a self-scoring system for ecodesigned products In order to provide customers better readability and total transparency on its products, Condat established Lubriscore in 2020.

The Lubriscore is Condat’s self-scoring system that weights the product properties based on life cycle criteria:

www.glass-international.com

� Raw materials and design � Production � Transport � Use � End of life This rating includes impacts on people and the environment and takes into consideration the state of the knowledge at the time of the assessment and changes to regulations.

A bonus is applied in case of compliance with a label or certification; as for example for an ECOLABEL certified product.

Based on a point system and on the answers given to about twenty questions, the Lubriscore grants, or not, the product with an associated number of stars.

The more eco-designed a lubricant is, the higher the number of stars it gets, the ratings range being from one to three stars.

The Lubriscore rating is available for a wide range of Condat lubricants, including metalworking fluids, wire drawing soaps, cold heading oils, hydraulic oils, die lubricants, cooling lubricants, hardening/quenching fluids and maintenance lubricants.

A brand-new swabbing grease solution without graphite Part of Condat’s eco-designed product offer, Condaglass 400 is a dedicated swabbing grease without graphite.

Without graphite means a lot in your glass bottle manufacturing process.

Indeed, removing graphite and the black aspect of the grease can lead to less transfers on glass ware (bottles, glass

blackened products when swabbing the blank, blow and neck ring moulds. And the same improvement occurs at the mould workshop.

Condat’s R&D department worked on this new formula for approximate two years and the challenge was to reach the same performances as the graphited products commonly used on blank mould applications that are of references on the market.

Condaglass 400 is made of a mix of renewable vegetable based oils and recycled refined oils.

Particular attention was also paid on endusers when developing the product, that’s why Condaglass 400 Safety Data Sheet does not display any hazardous pictogram.

Finally, thanks to its high flash point, Condaglass 400 limits fire risk and ensures equipment and co-workers protection, especially as swabbing compounds are generally applied on 450°C moulds.

Thanks to its responsible formulation, this lubricant obtained a 1-star score Lubriscore rating.

Success story highlight One European leader in glass manufacturing has already chosen Condaglass 400 for producing its cosmetics and perfumes articles made of OPAL glass.

When swabbing their cast iron moulds, the results have been impressive as � Condaglass 400 is made of a mix of renewable they were able to reduce vegetable based oils and recycled refined oils. their automatic rejects after greasing drastically.

Using its previous graphited lubricant, the rejects were in-between containers for food or cosmetics), thus three to four, whereas with Condaglass reducing your automatic rejects after 400 they only set for two automatic rejects greasing. after greasing.

As a result, glass manufacturers generate The company has since experienced less waste and observe immediate significant productivity increase and productivity gains. generated less waste. � Without graphite also means a cleaner working environment for the operators in Chasse-sur-Rhône, France the gob forming area.

They do not handle graphited and https://www.condat-lubricants.com/

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Digital technology

Why use blockchain and track & trace in the glass industry?

Automation and digitalisation are making their mark on glass as a product and on how it is made. They therefore require digital forms of tracking and methods to manage and exploit the glut of data being produced, reports Gesine Bergmann.*

T

� QR codes as a tool to engage with consumers and to provide useful product information.

individual pane, cutting down on error rates caused by incorrect programming.

It is possible to record every single piece of information about a pane, including the location where it is installed – a real asset later on if the pane has been damaged and needs to be replaced, or if it is going to be reused or recycled.

Creating links to customers Laetus, a provider of hardware and software for quality control and track & trace systems, and Kezzler, which makes software for cloud-based applications, have chosen to follow a different path.

The two companies have combined their track & trace technologies over as many as five different levels, with the aim of making end product information more transparent on the market through the use of QR codes (which act as digital fingerprints).

This approach creates an added value for consumers, which in turn boosts sales: a study by MIT revealed that improving supply chain transparency results in a

2–10% increase in willingness to pay.

The end customer is given a better insight into the manufacturing process, and / or can use digital platforms such as apps and websites to gain added benefits along with the product itself. This approach aims to foster more trust.

For companies it also provides an opportunity to establish customer loyalty, enhance the reliability of the brand and quality standards, and prepare for developing products in the future.

Production aspects such as recycling, the environmental footprint, supply chain monitoring and increased automation also play an important role.

The system can be fully integrated into an existing production environment, even extending beyond the factory itself.

It can end either in an interface with the customer’s production management system or in a cloud application that end consumers can use.

Continued>>

www.glass-international.com

his has repercussions for everything from project management, production and internal logistics right through to the customer.

The glass industry is also faced with the challenge of doing its part to meet objectives set in climate policy, i.e. how to approach recycling and a circular economy concept once a glass product reaches the end of its lifecycle.

Disposal and demolition firms alike need information on how to handle, separate and reuse materials.

Navigating this new world means collecting and evaluating as much data as possible, ideally using digital technologies – and this is where track & trace comes in.

This process begins from the moment a company receives an order and can be based on methods including laser marking – something that is offered by Hegla boraident for example.

These methods make it possible to organise and optimise the internal steps involved in production and track both products and processes throughout the entire lifecycle.

A virtual ID is created in the production planning stage and then laser-printed onto the glass pane before cutting it. This ID takes the form of a data matrix code that is 99.9% machine-readable.

As processing continues, the glass is identified multiple times, the code is read and each reading process is shown in the higher-level production system, along with the location and time at which it occurred. This provides a seamless overview that makes it possible to intervene quickly if anything goes wrong.

Not only that, but it prevents glass from going missing and allows damaged panes to be remade quickly.

The data programmed into CNC milling and drilling centres can be linked to each

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Digital technology

www.glass-international.com

Blockchain technology – for more than just cryptocurrencies As digitalisation becomes more widespread, data security is steadily gaining importance for companies.

Originally used for cryptocurrencies, blockchain technology is now increasingly being considered for applications in product lifecycle management (PLM) and becoming more attractive for industrial applications.

Instead of storing transaction data on just one server, this technology duplicates it for multiple parties worldwide known as miners. This concept is why blockchain is also referred to as distributed ledger technology in many cases.

A chain of consecutive data blocks is created whose stored information cannot be altered as soon as it is digitally sealed. As the block size is limited, the technology cannot be used to transport large quantities of data. In cases where an extensive data file needs to be secured, the hash value associated with the file is used: this is stored in the blockchain and creates a unique relation to the original file. The blocks are linked to one another using a cryptographic method. Each miner stores a copy of the entire blockchain, which prevents attackers from changing or erasing the blockchain unless they were able to gain control over more than 50% of the miners.

Smart contracts have made it possible to automate business processes in the blockchain by storing executable programme codes.

The principle is based on the ‘if-then’ rule: when a customer makes his or her most recent leasing payment for a machine, for example, the machine is automatically released for the period that follows this.

A benefit of this method is that business partners can interact directly with one another, without the involvement of intermediaries. Oracles come into play in cases where data from external sources containing third-party information needs to be incorporated into the blockchain so that a smart contract can be reviewed or executed.

In this context, an oracle is a kind of translator or interface that verifies information using real-world facts and events, then transfers the data to the blockchain and makes it available for smart contracts to use.

This means that oracles can act as a trigger for smart contracts, setting in motion certain processes.

Companies always have to start with deciding whether the blockchain method is appropriate for their needs. The example of Prostep, an expert in PLM processes and solutions, shows the application of blockchain for managing the right to manufacture certain components using 3D printing.

The project known as SAMPL – Secure Additive Manufacturing Platform (https:// sampl.fk s.tuhh.de/en/home.html), which is being funded by the German Federal Ministry for Economic Affairs and Energy, considers copyright and product liability law as a means of distinguishing original copies from counterfeit ones, issuing licences, safeguarding printing rights and paving the way for new valuecreation models and business models.

A consortium led by Prostep and consisting of ten companies and institutions has produced the following results: � The development of a trustworthy supply chain from the rights holder to the printing service provider and right through to the end customer (chain of trust) � The development of a reference platform with blockchain and printer integration � Blockchain technology for licensing, documenting printing process data and tracking components � Component tracking by means of RFID chips, QR codes or other methods This platform is based on a data exchange solution called OpenDXM GlobalX, which makes it possible to execute 3D printing orders globally on demand (for spare parts, as an example), license printing processes and process documentation, and use blockchain technology to ensure traceability and provide evidence of authenticity.

It provides users with access to processes that use much less energy than bitcoin blockchains.

“In addition to this application, there are numerous other ways in which blockchain technology could be exploited. To assess whether it would be suitable for an application, it is useful to apply the golden rule of four out of seven: in other words, blockchain is worth considering in the context of an application if it would bring four out of seven potential benefits”, recommends Dr Martin Holland, Director of Strategy & Business Development at Prostep.

Blockchain in the glass industry Turning to an example of a project involving glass production, a master’s thesis being written by Thomas Lenze at A+W Software analyses options for capturing and managing data in insulating glass production that uses manual and automated processes.

One potential application would involve an insurance company using a smart contract application to gain access to stress testing information after a hardening process, so that it can then ascertain the product liability risks.

Requirements for digital documentation in the context of Building Information Modelling (BIM) also need to be considered.

The process chain is made up of the cutting and prestressing stages, along with the heat soak test, insulated glass production stage including the auxiliary materials and all the serial numbers, with everything working on the basis of the barcode on a single pane.

The process as a whole involves recording data, assigning the barcode ID and linking this to the overarching system. This covers everything from the glassworks material batch, the individual pane assignments, the curing oven temperature/time profiles and the heat soak oven to the batch numbers for the sealants.

If this data is provided in a blockchain, it then becomes possible to create any number of channels that each deliver certain items of information to certain users, such as the insurance company in this case. �

**Glass Technology Forum, VDMA, Germany Email gesine.bergmann@vdma.org, www.glass.vdma.org Other links: www.pilkington.com www.boraident.de www.tu-ilmenau.de/anw/ www.sura-instruments.de https://ispa.institute/ *The contents of this article were the subject of an event held in June 2021 by the VDMA Research and Technology Industry Working Group, part of the Glass Technology Forum.

The working group meets several times a year and discusses technical developments in mechanical engineering that are of relevance to the glass industry

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REGISTER NOW

82

nd

November 1 — 4, 2021 Greater Columbus Convention Center Columbus, Ohio USA

GPC is the largest glass manufacturing event in North America, attracting global manufacturers and suppliers to exchange innovations and solutions

where the glass manufacturing industry meets

Organized by:

Endorsed by:

Environment

The Transforming Foundation Industries Challenge Dr Hugh Falkner* highlights some of the funding opportunities available to UK glass companies in their quest to be more sustainable.

www.glass-international.com

R

ecognising the common challenges shared by the UK’s foundation industries (metals, glass, paper, cement, ceramic and chemical sectors), the UK Government is investing £66 million of public funding to support the innovation needed to reduce their energy and resource use.

UKRI’s Transforming Foundation Industry Challenge, managed by Innovate UK, is already on target to attract an additional £83 million of private sector investment.

While the glass and other products made by the foundation industry sector are often taken for granted, they provide essential products and materials to the sectors that support our way of life – such as construction, aerospace, automotive and packaging.

These materials cannot realistically be replaced as part of the economy before 2050, and indeed are unlikely to be even within our children’s lifetimes. So, as we move towards a sustainable future, it is imperative that these materials are produced in a more environmentally sound, but commercially viable, manner.

The Transforming Foundation Industries (TFI) challenge programme, which will run until 2024, is designed to both stimulate and pull through the multi-sector that are required to make this happen.

An aspect of the programme is a recognition that many of the challenges are too big for any of the sectors to tackle alone, and so cross-sector working to share both knowledge and the costs of innovation is central to the work.

In heat recovery, advanced sensors, condition monitoring, automation and digitisation, companies have seen the benefits from collaborative cross-sector working.

By creating a larger cross-sector market opportunity, existing suppliers

are adapting proven solutions from other sectors to meet the needs of the Foundation Industries.

The TFI challenge is best known within the glass sector for its £15m contribution to the £54m Glass Futures global centre of excellence.

Opening Autumn 2023, this flexible 30t/day batch plant at St Helens will dramatically speed up the development of new products and processes. But in addition, the Challenge is on track to invest in over a hundred innovation projects on the way to meeting its wider objectives, many of which will benefit the glass sector. The following examples illustrate the breadth and ambition of the opportunities that are being explored with Challenge funding.

Glass Cullet conversion to Waterglass (GUITAR) Sodium silicate (waterglass) is used as a feedstock in the Glass, Cement, Steel and Chemicals processing sectors, where applications include detergents and ‘cementless’ binder systems for building products.

A project led by Re-gen Waste is developing a process that mixes waste glass cullet with sodium hydroxide at a temperature of just 150C, producing sodium silicate at a much lower energy cost than with traditional methods.

Re-gen Waste Ltd draws on several years of alkali activated binder expertise at Queen’s University Belfast (QUB), and leads a multi-partner team of collaborators: Ecocem GB leading the research on a one-part binder system, Quinn Building Products producing prototype Autoclaved Aerated Concrete (AAC) blocks, and T&J Recycling providing expertise in the pre-processing of glass cullet.

Hybrid sintering for decarbonisation

and productivity in manufacturing Sintering of raw ceramic or glass powder is an energy intensive process, requiring peak temperatures of 1200-1800°C, over several hours.

This collaboration between Lucideon and the University of Sheffield will explore how combining flash and cold sintering technologies could provide densification within seconds, offering a dramatic reduction in the energy and time requirements for this process.

Raman high temperature monitoring Technology originally designed for nuclear waste decommissioning is being developed by SME IS-Instruments for use in high temperature furnace or stack/ flue monitoring. The Raman-based instrument exploits the properties of hollow core micro-structured optical fibres (HC-MOFs) to provide unparalleled levels of specificity and accuracy in a single instrument.

The cross-sector project partnership includes Glass Technology Services (GTS), Breedon Group (Cement) and Wienerberger, with academic support from Southampton’s Optoelectronics Research Centre and Sheffield Hallam’s Materials Engineering Research Institute.

Upcoming funding opportunities Glass companies with a registered UK presence could be eligible to receive research funding from one of several Transforming Foundation Industries Challenge grant funded competitions.

These competitions can offer support of up to 70% of eligible project costs.

The Small scale R&D programme opened in August and offers support for smaller R&D projects costing £25k-£250k.

Continued>>

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� An artists impression of the Glass Futures site, UK, which is due to open in Autumn 2023.

TFI Small CR&D Competition Briefing - KTN (ktn-uk.org) The Investor Partner programme introduces qualifying high growth potential companies to our appointed equity investor partners. Companies that are successful in gaining equity investment from one of these partners would then be eligible to apply for an Innovate Grant of up to the value of the equity investment. The maximum size of grant available through this competition is £1.4m.

Our investors were selected through a competitive process, and bring a variety of sector and business growth expertise to help companies grow at pace: � Heritage Group Ventures � Clean Growth Fund � Midven � Speedinvest � Turquoise International This is an ongoing competition, closing

10th November 2021.

Transforming Foundation Industries Investor Partnership Launch Event - KTN (ktn-uk. org).

The Large Scale Demonstration programme will support projects of over £5m that demonstrate future technologies at active foundation industry sites. This is opening on October 11th 2021, register at Foundation Industries - KTN (ktn-uk.org) to receive the latest information on this and other TFI activities.

Why innovation is essential The support of Glass Futures has helped Encirc to create a bottle using 100% recycled glass and ultra-low-carbon biofuels shows that dramatic a reduction in the environmental impact of container glass is now possible.

But the glass sector isn’t alone in developing new types of packaging, with the plastics and paper sectors also vying to meet the evolving requirements of

both retailers and their suppliers who have their own zero net carbon ambitions.

And changes in recycling schemes could also tip the balance either way.

So this makes it all the more important that the glass sector works together to maintain its competitive advantage, and to find new markets that exploit glass’s unique properties.

Through offering grant funded support for innovation projects, the TFI Challenge is a great opportunity to help the sector to find new ways to reduce its energy and resource consumption. If you would like to found out more about how you could be part of the Challenge, visit Foundation Industries - KTN (ktn-uk.org). �

*Innovation Lead on the Transforming Foundation Industries Challenge, London, UK https://ktn-uk.org/materials/ foundation-industries/

Tempering Lines on spindles

TEMPERING Lines on belt

vidromecanica@vidromecanica.com

www.vidromecanica.com

www.glass-international.com

RIM tempering

53 Glass International September 2021

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PUT THE DATES IN YOUR DIARY

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This two day virtual event will highlight some of the potential solutions the glass industry has in order for it to be net zero/low carbon in its manufacturing processes, particularly ahead of the 2050 deadline agreed at the Paris Summit.

Topics covered will be sustainable glass manufacturing such as the use of electric glass manufacturing, hybrid furnaces, biofuels, hydrogen etc.

The Renewable Glass Manufacturing conference will include presentations from Coca-Cola, Diageo, Wiegand-Glas, Encirc and Steklarna Hrastnik.

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