Glass International July August 2017

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July/August 2017—Vol.40 No.7

HEINEKEN INTERVIEW FRENCH OVERVIEW FURNACES FEATURE I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International July 2017 GI Cover July aug.indd 1

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Contents

Vol.40 No.7

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July/August 2017—Vol.40 No.7

20

HEINEKEN INTERVIEW FRENCH OVERVIEW FURNACES FEATURE I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

2 Editor’s Comment

5 International news

14 Company interview: Heineken

Heineken urges glassmakers to follow its example and be greener 20 Energy efficiency: Schneider Electric The efficient future of the glass

industry is ‘all electric’ 22

Glass International July 2017

28

Front cover image www.pennine.org

24 Company Profile: Arc International €60 million strategy takes shape

28 Company Profile: Stölzle Masnières Investing in know-how

Inspection 34 Iris Inspection machines: Next generation software for advanced

inspection technology 37 Tiama:

Statistical process control to measure

glass thickness 41 Ametek Land:

Thermal imager for furnace

temperature reading 45 AGR International:

A testing station for glass container

pressure strength 48 Marposs:

Marposs installs flexible gauging

equipment at Verallia’s Albi site 53

34

Events World: Heye symposium Heye event discusses digital age

91 Coatings: Stewart Engineers

IGU coatings on the 4th surface

Plus find us on Linked-In and Twitter.

www.glass-international.com

Glassman Europe catalogue

Furnaces 70 Events World: Furnace Solutions

Global delegates in attendance 75 Praxair:

Optimelt at Libbey reduces emissions 81 Fives Group:

Larger capacity all-electric furnaces 86 Fosbel:

Regenerating the regenerators 88

@Glass_Int

French overview French container glass plants

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July/August 2017

88

92

Events World: Convention of Associations Vitrum organises first associations’ meeting, in Venice.

97

Recycling Glass recovery in waste treatment

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Editor’s comment

Greg Morris

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

Summer slowdown?

Not in the glass industry

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I

thought it was supposed to be quiet in the summertime?

This time of the year is traditionally when things slow down. Newspapers call this the silly season when, due to a lack of newsworthy events, frivolous stories make the headlines.

It’s the time of year when the weather turns warmer, people go abroad for a holiday and the pace of life becomes more relaxed. But, true to form, the glass industry has not conformed to expectations this year!

It has been a busy few weeks. There have been a number of large, breaking news stories which will affect a number of people in the glass industry.

Some of the large names of the sector, such as Vidrala, Bormioli Luigi and Bangkok Glass have all announced investments in recent weeks, which is obviously good news for the industry.

A few of the big stories have occurred in the time between it takes to publish our news pages and this comment page.

Those news stories will now be published in the September printed issue but, if you want to be first with the news, I recommend a visit to our website or to subscribe to our free weekly newsletter distributed every Tuesday.

Its number of subscribers has steadily increased since it was introduced a few

years ago and it is noticeable that the number of stories we publish in the newsletter has increased as well.

This is a reflection of a healthy, dynamic and vibrant glass industry.

Some of those companies mentioned in recent newsletters feature in this month’s printed issue.

The first article this month is from Heineken in The Netherlands, which warns the glass industry must react rapidly to changing environmental legislation and trends, or it risks losing business from the globally known brewer.

It has offered to collaborate with glass manufacturers and share know-how in an effort to drive the industry forward.

The industry already has excellent environmental credentials but the fact remains that it requires a lot of energy to melt glass. Collaboration has been a theme at several of the meetings I have attended recently. It was certainly the case at Furnace Solutions, the Heye International Symposium and the First Convention of Associations in Murano.

Only by swapping information and putting the brightest minds together will the industry move forward. � Greg Morris, Editor gregmorris@quartzltd.com

Production Executive: Martin Lawrence Managing Director: Steve Diprose Chief Executive Officer: Paul Michael Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com

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.

Email: glass@quartzltd.com Website: www.glass-international.com

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

Member of British Glass Manufacturers’ Confederation

China National Association for Glass Industry

United National Council of the glass industry (Steklosouz)

Glass International annual subscription rates including Glass International Directory: For one year: UK £169, all other countries £238.

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Airmail prices on request. Single copies £46.

Printed in UK by: Pensord, Tram Road, Pontlanfraith, Blackwood, Gwent NP12 2YA, UK. Glass International Directory 2017 edition: UK £206, all other countries £217.

Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Glass International (ISSN 0143-7838) (USPS No: 020-753) is published 10 times per year by Quartz Business Media Ltd, and distributed in the US by DSW, 75 Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage paid at Emigsville, PA. POSTMASTER: send address changes to Glass International c/o PO Box 437, Emigsville, PA 17318-0437.

Quartz Glass Portfolio

Monthly journal for the industry worldwide

Sales Executive: Manuel Martin Quereda Tel: +44 (0)1737 855023 Email: manuelm@quartzltd.com

Directory 2017 Annual international reference source

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Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2017 ISSN 0143-7838

Glass International July/August 2017

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07/08/2017 10:10:53

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International News

Pochet Group invests €200 million in its French plants The site will receive several million euros for its modernisation which will be invested in both its hot end and in its finishing section.

The company has a glass manufacturing site in Guimerville, as well as a finishing section at the site.

Its Gamaches and Beaugency sites are decoration and finishing sites, respectively.

Its Beaugency plant will re-

Vidrala secures €45 million loan for Italy

portedly receive €2.5 million with the aim of increasing production to 4 million perfume bottles a month from the current 2.5 million bottles.

The plant will close in August to undergo a nearly complete facelift, improving ergonomics and working conditions. Only the space dedicated to the lacquering will not move, as well as the storage platform of 4000m².

Bormioli Rocco sold to two buyers Italian glass manufacturer Bormioli Rocco has been sold to two different buyers.

Its tableware business will be sold to Bormioli Luigi glass container manufacturer while its pharma unit to Triton private equity firm.

Bormioli Rocco’s majority stakeholder, Vision Capital, acquired the business in 2011

from Banco Popolare.

Vision already sold Bormioli’s cosmetics division in December 2013 to Austrian Stölzle Glass Group and Bormioli’s food and beverage division to Swiss Vetropack Holding in June 2015.

Julian Mash, CEO of Vision Capital, said: “Through Vision Capital’s ownership, along

with Bormioli management, we have executed a strategic plan and delivered strong financial growth, resulting in both the Pharma and Tableware businesses achieving record profitability in 2016.

“We are confident the two units will continue to flourish under the ownership of Triton and Luigi Bormioli.”

Vidrala wants to buy Portugal’s Santos Barosa for €250 million Spanish glassmaker Vidrala has executed a letter of intent for the acquisition of a controlling stake in Portuguese container manufacturer Santos Barosa Vidros.

Santos Barosa manufactures and sells glass containers and

owns a production facility in Marinha Grande, Portugal.

It produces around 400,000 tonnes of glass a year, with an estimated turnover for 2017 of €135 million, and an estimated operating result, EBITDA, of €34 million.

business is today in pole position.

“Inside the group, Verallia Portugal perfectly embodies the values of Verallia, especially professional commitment and customer service,” stated Jean-Pierre Floris, Ve-

CTIEC signs 600t/d float contract in Kazakhstan

China Triumph International Engineering Company (CTIEC) has signed an EPC contract for the first 600t/d float glass production line in Kazakhstan with Orda Glass.

Entrusted by Mr. Peng Shou, board chairman and president of CTIEC, Mr. Ma Mingliang, vice president of CTIEC, signed the contract with Mr. Yerzhan Sagimbayev, board chairman of Orda Glass.

It was witnessed by Mr. Bakytzhan Sagintayev, Prime Minister of Kazakhstan, and Mr. Krymbek Kusherbayev, Governor of the Kyzylorda region.

Encirc success at Glass Focus awards

The agreed transaction price amounts to a value equivalent to €250 million.

The figure could vary depending on the indebtedness assumed at the transaction closing. The deal is expected to close in Q3 2017.

Verallia Portugal’s 30th anniversary Verallia Portugal has celebrated its 30th anniversary by gathering together customers, partners and local authorities in its Figueira da Foz plant.

The occasion also celebrated Verallia’s success on the Portuguese market where the

Vidrala has secured a €45 million loan to help transform its Italian production site.

The loan from the European Investment Bank (EIB) will be used to completely rebuild its Corsico site near Milan in Italy, in order to transform it into a ‘smart glass factory’ by the end of 2018.

It said the production site will incorporate the most advanced innovations in the manufacturing process of glass.

rallia’s Honorary Chairman during the event.

From its two furnaces, the business produces more than 2 million bottles and jars a day for still wines, ports, sparkling wines, beers, spirits and soft drinks.

UK glass manufacturer and bottler, Encirc, enjoyed success in four industry award categories at this year’s Glass Focus 2017 event at the Royal Armouries in Leeds.

The Glass Focus Conference and Awards dinner is hosted by industry trade body, British Glass, and showcases the year’s achievements from within the UK’s glass sector.

Encirc impressed the judges with its commitment to corporate responsibility and staff wellbeing, winning the Sustainable Practice and Strengthening the Business through People categories.

Encirc’s entry was boosted by its recent £6 million investment in a new onsite railhead at its Elton plant.

www.glass-international.com

The Pochet group plans to invest €200 million in its French glass manufacturing sites.

The investment forms part of its Ambition 2023 project for the 2015 to 2018 period, which will see the Pochet Group transform its equipment to increase competitiveness and ensure growth.

Central to the investment will be its Guimerville manufacturing site in Normandy.

NEWS IN BRIEF

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International News

NEWS IN BRIEF

futronic website

Germany’s futronic has given its website a complete facelift.

The relaunched site puts the emphasis firmly on content – case studies and other stories are used to communicate a comprehensive picture of the control system specialist’s competencies and activities.

The concept and design are based on a new corporate identity, developed in close consultation with Jetter AG. The aim is to make the partnership and the common bond between the two companies more visible. www.futronic.de

Ardagh’s Polish bottle

Łomza Brewery, has launched the Łomza Jasne beer in a premium new bottle design, introducing modern features to the sleek bottle.

Working with Ardagh Group in Poland, in-house designers used their creativity and technical expertise to develop different bottle designs to meet the brief, from which the final shape was selected.

“The bottle’s fresh look is achieved using two design techniques: traditional embossing and debossing.

It has a 500ml capacity and is tall and imposing, giving it real shelf stand-out,” explains Roman Sobecki from the design department of Ardagh OEG Design, Gostyn glassworks.

www.glass-international.com

Siemens discusses digitalisation benefits

Siemens discussed the benefits of digitalisation at the recent GPD conference.

Bernhard Saftig, head of Siemens vertical glass business, told the Tampere, Finland conference digitalised solutions along the value chain allow glass plant operators and equipment suppliers to be faster, and more efficient and flexible.

“Digitalisation will change the face of the glass industry as much as electrification and automation did in earlier times. The result will be huge leaps forward in productivity.”

Zippe successfully installs batch plant at Mexico’s IVC Zippe Industrieanlagen has successfully installed a batch plant for a 560tpd furnace at Mexico’s Industria Vidreria de Coahuila (IVC).

Wertheim, Germany-based company Zippe implemented the project on a turnkey-basis

and its scope of supply included two cullet return systems for the new melting furnaces, F3 and F4.

IVC is a joint venture between US-based glass manufacturer Owens-Illinois (O-I) and the brewer, Constellation

Brands.

The new building site is in the city of Nava, north Mexico, 30km from the Texan border in the USA. The plant will manufacture bottles exclusively for a directly adjacent brewery.

Thailand’s BG Container Glass to build 400 t/d furnace BG Container Glass (BGC), a subsidiary of Bangkok Glass, is to build a 400 tonnes a day furnace in Ratchaburi, Thailand at a cost of Bt2 billion ($58.8 million).

Supasin Leelarit, Bangkok Glass executive vice president for the group, told The Nation newspaper the factory would support greater domestic demand for glass containers.

It will also help overcome an energy shortage in the company’s factory in Rayong, which is facing an inadequate supply

of natural gas.

The Ratchaburi plant will be completed and ready to start operations in the third quarter of next year.

“As we want to supply our glass container products and services to our customers, we have to locate our factories in various areas where our customers’ plants are located.

“For example in Khon Kaen and Prachin Buri, our factories are located next to our customers’, such as Boon Rawd and Kratingdaeng,” Supasin

said.

BGC currently operates five glass-container factories in Pathum Thani, Ayutthaya, Khon Kaen, Rayong and Prachin Buri, with a combined production capacity of 3,335 tonnes per day or 1.2 million tonnes a year (around 4.5 billion bottles a year).

Supasin said Bangkok Glass was ready to move forward with its strategies to enter different business segments across the Asean region.

Ardagh selects Xpar technology Ardagh’s Nienburg plant in Germany recently installed an Xpar Vision InfraRed Dual (IRD) camera system, including an InfraRed Gobweight Control (IGC).

The IR-D systems are positioned on both sides of the

conveyor belt, between the IS Machine and the Hot End Coating tunnel, providing real time information about deviations in the Hot End of the glass production process.

Herbert Wilcken, Plant Manager at Nienburg, said:

“The benefit of the IR-D system is that it provides us with real time information about deviations in our production process.

“Therefore we are able to adjust as quickly as possible.”

6 Glass International July/August 2017

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International News

IRIS to unveil 2018 Evolution Software at Glassman Europe

spection solutions, offering a range of equipment to satisfy the precise requirements of the world’s leading glass packaging manufacturers.

More than 15% of turnover is invested in R&D every year, illustrating the company’s focus on increasing the precision of hollow glass inspection and the detection of defects in order to maximise productivity in the glass container manufacturing process.

The latest example of this commitment is the release of its 2018 Evolution Software.

Innovative features of this specially developed software include new defect algorithms

British Glass calls for seminar papers

for better and more precise identification and extended inspection, with a generalisation of all detection tools, body finish and base, to nonround articles, specific shapes and engraved articles.

Improved repeatability of article orientation is assured, with new base inspection tools included as the recognition of engraved zones etc.

Glassman Europe 2017 takes place at the Cité de Congrès, Lyon on 6-7 September.

Attendees are invited to visit Iris Inspection machines on Stand No E01. www.glassmanevents.com/ europe/

San Miguel Australian acquisition Philippine group San Miguel Corp (SMC) has bought a South Australian wine bottler and packaging company to boost earnings and take advantage of more opportunities in the region.

In a disclosure to the Philippine Stock Exchange (PSE), SMC said its subsidiary, San Miguel Yamamura Australasia, had acquired Barossa Bottling Services.

“With the acquisition, the company expects the Australian and New Zealand packaging business to contribute up to AUS$300 million, as advised by Mr. Ramon S. Ang, President and Chief Operating Officer of the Company,” it said.

Barossa Bottling Services’ is an independent bottling and packaging entity servicing artisan wineries in Barossa, Eden

and Clare Valleys, Adelaide Hills and Riverland in South Australia Mr Ang said SMC was “bullish on the Australasian market and will continue to look for bigger and better opportunities in that region.”

“In the meantime, our Philippine operations will continue to expand to meet growing domestic and export demands,” he added.

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British Glass is calling for seminar presentations, based on practical examples of large manufacturing businesses securing funding for improvement in energy efficiency and carbon reduction, for a one-day glass industry event.

The UK glass industry is pursuing a programme on energy efficiency and decarbonisation. But building the business case to secure funds remains a barrier.

Capital costs can be high and paybacks periods are often of more than two years; traditional loans are usually unattractive for this work.

British Glass is organising a one-day seminar on funding for decarbonisation and energy efficiency work on Thursday, November 2 in the north of England, venue TBC, – which will be attended by British Glass members’ and non-members.

Poco Graphite increases manufacturing capacity

Entegris subsidiary, Poco Graphite, is to expand its capacity to produce graphite material and speciality coatings for semiconductor and high-performance industrial applications by securing the use of the former small diameter graphite electrode factory of Superior Graphite in Russellville, Arkansas, USA. As part of the agreement, Poco Graphite will have access to the assets of the facility, as well as the current workforce.

“Hi-tech industries are increasingly reliant upon continued innovation in advanced materials to enable their growth.

“As a result, organisations are looking to highpurity/high-performance materials that are specifically engineered for their applications to gain a competitive advantage,” stated Stuart Tison, boss of chemicals and engineered materials at Entegris.

www.glass-international.com

IRIS Inspection machines will unveil its latest software release at this September’s Glassman Europe exhibition in Lyon, France.

Visitors to the event will be able to assess the extended features of the 2018 Evolution Software as part of this world premiere.

With headquarters on the outskirts of Lyon, Iris Inspection machines is among the international glass container industry’s most innovative suppliers of cold end inspection technology.

The company specialises in the development of camera-based, non-contact in-

NEWS IN BRIEF

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International News

Tiama focuses on online service at its third seminar

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Key features:

Tiama focused on online service packages during its 3rd service seminar.

Support is central to its range of solutions so Tiama hosted its third twoday seminar which had the aim to improve services offered to its customers.

The seminar gathered most of Tiama’s global service department which represents nearly 60 experts from 21 countries,

such as Egypt, Thailand, Iran, Turkey, Russia, China, USA, UAE, Costa Rica, UK, Italy, Spain and Germany.

The two-day programme was filled with workshops and presentations of the growing service portfolio that highlighted the latest novelties such as Small Private Online Courses (SPOCs), on-line simulators, new tailored training

programmes, services contracts and hotline packages.

“We are aware that Customer Service, based on a truly local presence, is one of our strongest added-value and we will definitely continue to support all of our products’ performances and maintenance with local specialists,” said Paulo Pereira, the global Tiama After-Sales manager.

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James O’Callaghan, co-founder of British structural engineering consultancy Eckersley O’Callaghan, has been selected as the 47th recipient of the Phoenix Award and ‘Glass Person of the Year 2017’.

This distinguished global award recognises outstanding contributions to the international glass industry.

James is the first structural engineer to receive this award, and the first British recipient since Sir Alistair Pilkington, the inventor of the float glass process, was awarded the

prize in 1981.

The Award celebrates James’ contribution to advancing the application of structural glass in the built environment.

His work has seen glass

panels grow in size with connection details rationalised on a journey of projects that has incrementally increased transparency, ambition and redefined industry benchmarks.

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International News

Heat Up Latin America supply Mexican cullet system

However, as this might have addressed the dusting problem, it is non-economical as it takes longer to fill the furnace compared to cullet blowing.

Heat Up Latin America applied a different method for

Anchor Glass CEO

cullet fill diminished dusting of about 90% and finished the entire process at a rate similar to a standard cullet blowing.

It precluded unnecessary expenses entailed by delayed production start.

Pennine launches HYPERDRIVE 2 Pin Conveyor Chain Pennine has worked for three years with the National Physics Laboratory, local universities, specialist steel suppliers and metal treatment companies to reach the launch of its New 2 Pin Laser Headed Inverted Tooth Conveyor Chain.

After three years of development and extensive testing both at Pennine Industrial’s UK manufacturing facility and under glass with glass container manufacturers, it has launched its 2 Pin Laser Headed Inverted Tooth Conveyor Chain.

The Hyperdrive Chain has been specifically designed for

the future of glass container handling. The Hyperdrive Chain will excel in the most demanding environments of high-speed glass production.

Only the highest quality European manufactured steels are used in Pennine’s UK factories to produce this new range of chains. CNC controlled heat treatment of individual parts results in high quality components and a chain with minimum elongation.

Unlike the original single pin Pennine Premium Conveyor chain assembled by Pennine for 40 years, the new range of Hyperdrive Chains

has a newly designed two pin rolling bearing joint that reduces vibration and gives a smoother cleaner engagement around the drive sprockets.

The reduced vibration at higher conveying speed, mean less elongation and longer chain life.

When used in conjunction with the company’s involute tooth sprockets, customers will get increased life with reduced maintenance resulting in less loss of production.

Hyperdrive is available directly or through Pennine’s 22 agents and partners .

Anchor Glass Container Corporation has named Nipesh Shah as its Chief Executive Officer.

Mr. Shah will succeed Jim Fredlake, who informed the board of his intention to retire from Anchor Glass.

Mr. Shah joins Anchor Glass from Consolidated Container Company, where he served as Senior Vice President and General Manager for the Consumer and Industrial Group.

He holds a Master of Science degree from the University of Akron and a Bachelor of Engineering Degree from Maharashtra Institute of Technology.

Saint-Gobain Spain installs hydrogen systems

Dutch company Hygear, a specialist in on-site gas generation technologies, has fulfilled the delivery and installation of its Hy.Gen systems at Saint-Gobain flat glass manufacturer.

Two Hy.GEN 50 systems were installed at SaintGobain’s L’Arboc, Spain facility. The contract for the hydrogen supply was signed in August last year.

Guardian rewards hard-working students

Guardian Industries Corp and its US subsidiaries have awarded 20 students throughout the US with scholarship dollars from the Guardian Industries Educational Foundation (GIEF).

Winners represent all of Guardian’s businesses, including Guardian Glass, SRG Global and Guardian Building Products, as well as the corporate office.

“We believe a good education helps set a solid foundation for opportunity and future success,” says Ron Vaupel, president and CEO, Guardian Industries Corp.

“Our scholarship winners have worked very hard to have the opportunity to continue their education and we are pleased that we can play a role in helping them.”

www.glass-international.com

Heat Up Latin America had a successful heat up on a new 600TPD container glass furnace in Mexico, where an improved cullet filling method was introduced.

Customary methods of filling glass furnaces have not been efficient, either cause glazing of the superstructure or lead to production delay.

One common procedure is the standard cullet blowing – rapid but antecedent to complications due to dusting.

Another method is the water-cooled vibrating system, wherein dusting is minimised because the cullet is slowly vibrated into the furnace.

NEWS IN BRIEF

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International News

Top 10 stories in the news

NEWS IN BRIEF

Henry F. Teichmann acquires E.W Bowman

Glass industry engineer and contractor Henry F. Teichmann, has acquired glass annealing lehr manufacturer E.W. Bowman.

Teichmann and Bowman have both served the global glass industry for decades.

Teichmann and Bowman will jointly provide more engineering, project and annealing solutions to the glass industry around the world. Both companies are located in the Pittsburgh area of Pennsylvania, USA.

Ardagh energy success

Ardagh Group, Glass – North America, has been awarded three Energy Star plant certifications for superior energy performance from the Environmental Protection Agency (EPA) – the only US glass container manufacturer to earn this recognition.

The three Ardagh Group manufacturing facilities, located in Bridgeton, N.J.; Dunkirk, Ind.; and Madera, Calif.; have demonstrated best-in-class energy performance and perform within the top 25% nationwide for energy efficiency when compared to similar plants across the country.

www.glass-international.com

Website for UK’s Glass Futures project

The Glass Futures research and development project in the UK has a new website.

The website was revealed at this year’s Furnace Solutions conference in Stoke-on-Trent, UK. The website, www.glassfutures.org, provides more details about the £20 million project which will be based in the Magna building in Rotherham, UK when it opens in 2018.

Glass Futures is a not for profit company which will provide a centre of excellence in glass comprising of R&D, innovation and training and up-skilling. It will contain a demonstration-scale glassmaking furnace of 30 tonnes per day capacity.

Our most popular news over the past month, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1 Vidrala to buy Portugal’s Santos Barosa for €250 million � 2 Verallia Group celebrates 30 years in Portugal � 3 GPS, Ametek Land and Entegris sign up for Glassman Europe � 4 Heat Up Latin America provides cullet system for 600 tpd Mexican furnace � 5 Bormioli Rocco sold to two buyers � 6 Digital glassmaking under the spotlight at Heye symposium � 7 Ardagh launches website for online purchase of glass food jars � 8 O-I partners with St Mungo’s to mark 200 years in glass � 9 Global associations vow to work together to move industry forward � 10 IRIS unveils 2018 Evolution Software release at Glassman Europe show

Heinz-Glas Piesau plant selects GPS IS 8 machine Cosmetic glass manufacturer Heinz-Glas has chosen a Glas Produktions-Service (GPS) IS 8 section machine for its Piesau, Germany plant.

The German-based GPS said the machine will produce articles at high speed in single, double and triple gob mode for its compatriot company.

GPS recently patented six technological developments, which are new to the entire industry.

FEVE appoints new President The European Container Glass Federation, (FEVE), has elected Ardagh Glass Europe CEO, Johan Gorter, as President.

It also elected Verallia’s Honorary Chairman, JeanPierre Floris, as Vice-President for the 2017-2019 term. The appointments mark a milestone as FEVE celebrates its 40th anniversary this year.

Mr Gorter said: “It is an honour to take on this role and I believe that collectively, we can continue to drive innovation and sustainable growth in

the glass packaging sector.”

“In the past 15 years, the consumption of products packed in glass has increased across Europe despite a challenging economy. To ensure that position I will support our industry in its efforts to drive technology advancement, energy efficiency and circular economy policies which are critical for Europe’s future.”

Pictured: L-R, Jean-Pierre Floris, Johan Gorter and Adeline Farrelly.

Be first with news! Visit www.glass-international.com for daily updates.

You can also find us on Twitter and Linked In.

12 Glass International July/August 2017

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13.06.17 13:27

Company interview: Heineken

Heineken urges glassmakers to

www.glass-international.com

T

he first thing you notice about Heineken Netherlands huge site in Zoeterwoude, are the wind turbines.

The tall, elegant structures were recently installed at the combined brewery and offices as part of the company’s drive towards a climate neutral brewery (pictured above).

The Zoeterwoude site employs 1700 people and is one of the largest breweries in Europe. The beer brewed at the plant is exported to 179 countries.

Two thirds of the 10 million bottles and cans filled that are filled each day at the plant are exported, with one third of that figure to the USA alone.

The site has made huge steps in becoming a climate neutral facility. As well as installing the four wind turbines, which produce nearly half of the site’s electricity, it also uses bio-gas generated from its own waste water and reduced its water consumption.

Jan Kempers, Heineken Netherland Supply’s (HNS) Programme Manager Sustainable Development, helped spearhead this drive to sustainability at the company.

He has now called on the company’s supply chain, including glassmakers, to embark on a similar environmental drive.

Mr Kempers said: “We’ve been on a journey for a few years where we aim to have a climate neutral

� An overview of the Zoeterwoude brewery and offices.

brewery here. We’ve expanded that to the supply chain because 11% of the emissions of our total supply chain come from the brewery itself, while 89% comes from supply chain partners.

“The aim of the project is to try to make the glass sector move. We want to help and inspire them to move in the direction of climate controlled glass production.”

Dominant role Glass, of course, plays a dominant role in the supply chain of this Heineken brewery with bottles making up approximately 64% of its packaging mix. All the glass produced at Ardagh’s Moerdijk plant in The Netherlands, for example, is used by Heineken.

Despite its environmental qualities, such as its endless recyclability, the fact remains that a mass of energy is required to make glass.

According to HNS, approximately 524,000 tonnes of CO2 are produced a year from the glass bottles it uses, primarily as a result of the glassmaking process. Approximately 34% of its supply chain impact comes from one-way glass.

“The heritage of our product is in glass. Most of our consumers prefer glass and would definitely Continued>>

14 Glass International July/August 2017

Company Interview HEINEKEN.indd 1

27/07/2017 11:17:34

f

The Heineken brewery in Zoeterwoude, Holland is Europe’s largest brewery. It has been on a journey to become a climate neutral brewery for several years. It wants its suppliers to do the same and has called on the glass industry to reduce its environmental footprint. Heineken Netherlands Supply’s Programme Manager for Sustainable Development, Jan Kempers, discussed the project with Greg Morris.

� Mr Kempers.

follow its example and be greener like to keep glass in the packaging landscape of the future,” said Mr Kempers.

“We would ideally like glass, aluminium and a bio-based packaging material as the future.

“But while glass is inert and endlessly recyclable it has to be remelted again, so there is an advantage and a disadvantage, as there is with all packaging materials.”

While the company is keen for its suppliers to begin making changes as soon as possible it does understand it will be a slow process. However, HNS fears a tipping point is approaching where consumers will make decisions based on the environmental impact of a packaging product.

“We feel consumer pressure, it is our business,” said Mr Kempers. “We have people that investigate consumer preferences and we are aware that the change will come, the environment will be an important driver for consumer preferences particularly if impact of climate change becomes more visible “With the Paris agreement on climate change, we envisage more consumer pressure. It is not as pronounced at this stage but the tipping point will come.

“Business discussions five or 10 years ago were always about price, quality and taste. Now environment sustainability has become higher.

BOTTLES ARE DOMINANT FOR THE PACKAGING MATERIAL IMPACT PACKAGING MIX (HNS)

TOTAL ABSOLUTE EMISSIONS (HNS)

Other

per pack type

Pack types 13%

ktonnes CO2e/year, 2015 524

Aluminium Cans 23%

140

Bottles

24

64% Bottles

� Glass plays a dominant role in Heineken’s packaging mix.

Aluminium Other pack cans types

We feel the pressure from consumers and if we lose our business our suppliers will lose their business.

It is a knock on effect.”

Mr Kempers has worked for the company for 32 years with a career that has taken in bio-technology, R&D, microbiology, process technology and quality assurance. He switched to sustainability development seven years ago and hopes that Continued>>

www.glass-international.com

o

Company interview: Heineken

15 Glass International July/August 2017

Company Interview HEINEKEN.indd 2

27/07/2017 11:17:45

Company interview: Heineken

with his experience and knowledge of the supply chains it will help bring about the transition the company and its suppliers are facing.

While he acknowledges glassmakers have made sustainability improvements, such as lightweighting of bottles and more energy efficient furnaces, he feels glassmakers need to make a fundamental change in their environmental strategy rather than continuously making small steps.

“Continuous improvement won’t bring you a climate neutral beer bottle, you have to leap forward. That is the message to our glass suppliers.

We want them to think differently, it is now not only the cost that is the focus, it is the reduction of the carbon footprint too.

“We have installed four wind turbines on our site, why couldn’t a glass factory be able to do so? Natural gas is running out in this country, so alternatives have to be found.

“The alternative we believe for a glass factory is electricity but if they can find another solution from renewable energy then all the better.”

HNS has not expressed a date for when it would like its suppliers to meet its targets, but wants to have its own production climate neutral in a couple of years.

Four-step strategy It has a four-step strategy to reach its target, three of which are already familiar to glassmakers.

The first is the re-use of bottles and promote the application of returnable bottles, the second is to reduce the weight of bottles as well as improve the pack type efficiency of new bottles. The third strategy is to decrease landfill and increase the recycled content of glass. The fourth strategy is to use renewable energy for glass bottle production.

www.glass-international.com

Electrical furnaces HNS wants its glass suppliers to stop relying on fossil fuelled furnaces and adopt alternative energy sources for its furnaces, with electrical-fired furnaces its prime choice.

It wants more cullet to be used in glass and for glassmakers to investigate their raw material sources.

“We have spoken to major suppliers, there was a positive attitude towards it and to make a move towards it. We understand it is far from simple but we need to do it if we want a future packaging portfolio with glass in it. Ithis transition takes time. We feel the pressure from the market coming, so we need to see action.

“Most of the plants that we use are large plants and the cost of failure is enormous. If the furnace goes down you’re out of business. If you produce lower levels of quality you run into problems in our market because a glass defect is a reason for a recall and the cost of a recall is enormous. So, on the quality side the requirements are substantial and that makes them careful. They only move when they know it is safe to make a step.

“We can help them with our knowledge, we have ideas about how to do this, it is not something they have to do by themselves. There is no one company that can solve it by themselves, you have to collaborate. We have developed a model for collaboration in which we go for individual ambitions and shared ambitions for everybody to reach this climate model.

“This project is an open invitation to not only the bottle suppliers but the furnace builders as well to make a collaboration all over the chain and realise this.”

� Four wind turbines hve been constructed at

A perfect scenario, Mr Kempers said, would be a climate neutral glassmaking site within five years time.

“The worst case scenario would be if the glass suppliers cannot meet our targets so we would of course then have to look to other materials.

It has engaged with its other packaging materials, such as the manufacturers of aluminium cans to review their environmental habits, but glass has the most importance to the company.

“Greening our suppliers is part of the total journey to make this brewery carbon neutral. This is one piece of the puzzle but we have pieces of the puzzle ahead of us. This is not an initiative that stands on itself but is part of a bigger programme.

“We have significant challenges in other parts of the supply chain so it is not only limited to glass.

We realise it is a journey of years and we need to start it before we run out of time. When the market starts asking for it then it is too late.” �

Zoeterwoude.

Heineken Netherlands Supply, Zoeterwoude, The Netherlands www.heinekennederland.nl/

16 Glass International July/August 2017

Company Interview HEINEKEN.indd 3

27/07/2017 11:17:50

FIC - White Maze Double ad_Layout 1 26/07/2017 10:12 Page 1

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Energy efficiency

The efficient future for the glass industry is ‘all-electric’ The aim of this paper is to stimulate glass manufacturers into rethinking their existing melting technology and considering all-electric melting in the near future, writes Rene Meuleman*

www.glass-international.com

G

lass melting has been carried out for nearly 6000 years and for most of that time wood was used as the energy source.

It was only comparatively recently in around 1880 that the industry began to use fossil fuels like oil and natural gas.

At this time, the regenerator had already been invented to improve the efficiency of steel blast furnaces and this was soon adapted by the glass industry on the early side port furnaces, very similar to how we know them today.

During those thousands of years of glassmaking, less than 150 years’ worth of fossil fuels were used and it is possible that they will not be around for another 150 years.

Although new fossil fuel resources have recently become available, the world has at last begun to understand that burning them results in unavoidable carbon emissions, and therefore this method must come to an end.

Glass melting still needs to continue at this point in time because we have not yet discovered a viable replacement material.

It is therefore likely that glass will be around for many centuries to come and that the inevitable future for a carbon efficient glass industry will be ‘all-electric’.

History With no disrespect to past furnace design developments and the achievements that have been made, they are mostly still based on original technology.

Traditional side and end port furnaces are proven technology that has been developed and tweaked to a level of efficiency, low emissions and life time that simply cannot be improved any further. Since the efficiency level came down to 2.4 MWh/ton in around 1990, no big improvements have been achieved.

Consequently further CO2 and NOx emission reductions slowed to halt as well. Oxy-fuel firing, batch pre-heating, waste heat recovery, submerged burners, etc. are great advances but the bottom line remains the same: they all increase the complexity of the melting system and CAPEX, do not avoid CO2 emissions, and in most cases cannot reduce NOx emissions any further.

The use of fossil fuels has become the fundamental problem and technology cannot overcome these issues sufficiently.

The fuzziness of politics Just like many other raw materials, as soon as we start believing that resources are coming to an end we find new ones.

That is also applicable for fossil fuels.

So why should we even start considering diverting from fossil fuels?

Science has proven that CO2 emissions are related to global warming which will likely lead to serious environmental issues for humanity.

Legislation, customers and common sense will force the industry to step away from fossil fuel firing sooner or later. By 2050, the EU aims to cut greenhouse gas emissions to 80% below 1990 levels.

Milestones to achieve this are 40% emissions cuts by 2030 and 60% by 2040.

All sectors need to contribute.

One famous Dutch beer brewer1 is putting a lot effort into reducing its carbon footprint and estimates that 53% of this is related to its packaging material.

The pressure to reduce emissions comes from many sides. No matter which side we agree or disagree with, it will impact how glass is melted in the future.

Technological evidence Most glass melting furnace technology goes back 100 years or more.

Over the years different developments have led to huge energy efficiency and Continued>>

18 Glass International July/August 2017

Schneider E Efficiency.indd 1

28/07/2017 10:30:34

FIC - White Maze Double ad_Layout 1 26/07/2017 10:12 Page 2

, Tomorrow s Technology Today

FIC... the only electric glass melting company which thinks outside the box

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

A Division of Glass Service

Energy efficiency

emission improvements, and many furnace suppliers are still working on enhancements, forced by the fact that fossil fuel energy remains cheap.

However, that will change, and assumingly much faster than many of us expect.

As previously mentioned, most of those improvements implicate a more complex technology that results in additional maintenance and CAPEX, the use of nonenvironmentally friendly chemicals, and limitations to equipment lifespan.

Most glass smelters perceive their melting process as complex enough and are not keen on modifying it further. They want to focus on their core business, without the issues of managing and maintaining complex industrial installations requiring high numbers of technical personnel.

Keeping the system simple has been a key argument for many decades. Now that the world around us seems to be changing rapidly our efforts to elongate the lifetime of furnaces up to +15 years is working against us.

In fact most glass manufactures only have one opportunity every 10 to 15 years to introduce a new innovative melting process, so it is not surprising that having to live with that decision for the next 15 years makes them extremely risk averse.

Who can blame them? It reminds me of a comment made by one of our customers: “In God we trust, but here you have to come with facts”.

Technological research and development needs to provide evidence of improvements, otherwise politics forces us to rely on expectations.

www.glass-international.com

Electrical heating Electrically heated furnace technology is almost as old as regenerative furnace technology. In fact the first furnace patent on electrical melting was issued to Sauvageon in France, in 1907.

A first successful cold top furnace ran in Norway from 1920 to 1925 using carbon electrodes and Cornelius in Sweden had operating furnaces as early as 1925, producing amber and green glass.

In 1952 the industry started to use molybdenum electrodes2, and in around 1975 high current SCR’s (thyristors) became available leading to the principal of solid state furnace boosting systems we know today.

Most modern traditional container, fiber and float furnaces are now equipped with electrical furnace boosting,

contributing 10% to 50% of the melting power.

All-electric melting efficiency Even in the early days, all-electric melting efficiency at 4.4GJ/ton4 (1.3MWh/ton) was already close to today’s most efficient fossil fuel fired furnaces at 4GJ/ton (1.1MWh/ton).

Since the introduction of all-electric furnaces, huge efficiency improvements have been achieved, reducing energy usage levels to 2.8GJ/ton (0.78MWh/ ton) (20% cullet) or less3. The power consumption is not likely to go below 2.6GJ/ton (0.72MWh/ton).

Most of the electrical power ends up in the melting process anyway and only relatively low energy losses come from transformers, busbar and control efficiency. Compared to traditional fossil fuel heating at 4GJ/ton (1.1MWh/ton), energy use is around 35% less.

An electrical furnace is naturally easy to control and maintain but it is important to consider the engineering of the electrical system alongside the furnace design. Like a burner system for a traditional furnace, the electrical system is not a sub system but should be part of the total design and needs to be fully integrated.

Bringing steelwork, refractory, cables, busbars, electrodes, transformers and control together in one design is essential for the efficiency success of the whole system.

Advantages of all-electric melting Compared to high efficiency fossil fuel fired smelter systems, all-electric furnaces are sophisticated but very straightforward in terms of design.

Regenerators or burner skids are not required, and expensive high temperature crowns are not necessary. Higher pull rates can be achieved without any problems.

No combustion related CO2, thermal NOx or SOx emissions are released.

Potentially less evaporation of volatile and expensive raw materials, like boron and lithium, etc. will occur, which makes exhaust filtering much easier.

Also the carry-over problem will almost vanish. Smaller furnaces could be considered, for example, one furnace that feeds one forehearth which feeds one ISmachine, might become a new concept for bottle manufacturing.

Disadvantages of electric Although all-electric furnace concepts are very simple in principle, there are some

implications to consider when changing over to this technology.

At room temperature glass or glass compositions are electrical insulators.

In order to start the electrical heating process it needs to run through a preheating sequence similar to the method used in container and float furnaces.

An all-electric furnace also needs a stable, reliable power grid, and due to different melting and fining behaviors the glass composition needs to be changed.

Electrical tariffs need to come down in price, and in order to lower the carbon footprint electricity would need to come from renewables instead of coal fired power plants. Electrodes need to be maintained by advancing them in case wear leads to higher resistance.

There are new methods to counter electrode wear, which would need to be investigated further. Another issue, especially for the container industry might be how this kind of furnace would handle extremely high amounts of cullet, which may result in different ways cullet and batch are managed.

Flexibility Electrical power tariffs are strongly related to availability, and the electrical energy market is changing rapidly.

Suppliers and utilities subsidized by government grants are investing in wind, bio-mass and solar power generation.

Citizens also invest in solar panels instead of keeping their money at zero interest in banks.

Buzz words such as ‘smart grid’, ‘tariff tweaking’, ‘peak shaving’ and ‘frequency control’ have become familiar terms, and it is recognised that money can be saved if our electrical energy consuming system becomes more flexible. To lower the risk of total grid failure some utilities offer money to be in control of huge industrial loads, to be able to temporarily switch them off when needed.

More refined is the method of controlling the network’s frequency (Dynamic Fractional Frequency Reuse) by tweaking the power consumption of some massive power consumers.

Basically electrical power consumers are financially rewarded if they make part of their electrical power consuming system available for remote power control.

Lower peak power demand can lead to lower tariffs. In that case, a dynamic load management system capable of Continued>>

20 Glass International July/August 2017

Schneider E Efficiency.indd 2

28/07/2017 10:30:34

Energy efficiency

controlling parts of the electrical system to ensure that agreed peak power levels are not exceeded, will lower the overall cost of electrical energy.

A glass furnace, containing a huge amount of molten glass can or should be able to accommodate the flexibility needed to profit from these rewards, grants and lower electrical tariffs.

Glass manufacturing, being part of the high energy consumer community and rapidly changing energy market, needs to look for furnace designs that better fit both todays’ and tomorrows’ requirements.

Sophisticated data analysis and (model based) control strategies should help operators to calculate the available freedom of control, allowable melting energy fluctuations, allowable fossil to electric ratio fluctuations and predict the impact on glass quality.

The bottom line is that there is no escape from thinking ‘out of the box’ and stepping away from tradition.

Conclusion

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YOUR PARTNER OF THE GLASS INDUSTRY – WORLDWIDE!

As a supplier of process and electrical power supply control systems in this business for over 50 years, we consider ourselves to have a strong understanding of the glass industry’s requirements and concerns.

For several years now we have been promoting the efficiency, financial and environmental benefits of moving to electric heating and have recently witnessed high levels of interest and growth in our SCR controlled power supply systems.

The move to all-electric will not occur overnight, however the industry is beginning to listen and accept the implications of not starting.

We stick to our intuition that the efficient future for the glass industry will be all-electric, and we are thinking ahead about what needs to be done to eventually achieve that conceptual change.

Let us have your feedback and perhaps involve us in your internal discussions on electrical heating power supplies and control systems with other enablers and innovators to make this happen: there is no escape and remember, all-electric has been around for +100 years already. �

References: 1.

Jan Kempers: Heineken: On our way to the greenest bottle

2.

Handbook of Glass Manufacture 1960

3.

Hubert de La Forest Divonne and Andy Reynolds Fives UK

4.

NCNG: Textbook 2012 Glass Technology Course

*Business Leader Global Glass, Eurotherm by Schneider Electric, Worthing, UK. www.eurotherm.com/glass This is an abridged version of a paper presented at the 14th International Seminar on Furnace Design, held in Vsetin, Czech Republic in June.

Waltec Maschinen GmbH

Mr Rene Meuleman will be speaking at the Glassman Europe event in Lyon, France on September 6 and 7. He will discuss ‘Industry 4.0 needs a pragmatic

Kronacher Straße 2a 96352 Wilhelmsthal / Steinberg Germany

approach’ on September 7.

More information about the event from www.glassmanevents.com/europe/ future-glass-forum

Phone +49 9260 9901-0 Fax +49 9260 9901-99 E-Mail info@waltec.de

Andy Reynolds, Managing Director of Fives Group discusses ‘Larger capacity all-electric furnaces’ on page 81 this issue.

www.waltec.de Schneider E Efficiency.indd 3

28/07/2017 10:30:35

French container glass plants

French Glass Container Plants Continuing our focus on France ahead of the Glassman Europe event in Lyon in September, below is a map of all the country’s container plants.

www.glass-international.com

F

rance has one of the most varied and largest glassmaking industries in the world.

Its range of glassmakers serve the nation’s world famous wine and beer industries, its globally renowned cosmetics and perfumery sectors as well as the pharmaceutical business.

The world’s largest container glass company, Owens-Illinois (O-I) has the most container plants in France with nine manufacturing facilities as well as its French headquarters in Lyon.

It has a wide a spread of plants, ranging from the vineyards of Bordeaux in the west all the way to the German and Swiss borders in the east.

Fellow glass container manufacturer Verallia, with its corporate headquarters in Paris, has seven glassmaking plants and a similar spread across the country. It has recently invested in new equipment at its Oiry and Albi plants, as reported recently in Glass International.

It also plans to invest €12 million on the renovation of a furnace at its Cognac facility this year and €20 million on its Vauxrot glass plant near Crouy.

The group also has two integrated decoration facilities and two household glass treatment centres in France, where collected waste glass is processed into factory-ready cullet.

There is a cluster of glassmaking plants in the north of the country, particualrly in the well-known Bresle Valley area of Normandy. Pochet du Courval has two sites in the Hodeng au Bosc area, as well as a decoration facility in Beaugency, south of Paris.

It has recently undertaken its Ambition 2023 plan which will see it invest €200 million for the 2015-2018 period.

Fellow glassmaker Stölzle has a site dedicated to cosmetics based in Masnières in the Nord department of northern France. The site has been transformed since the company acquired the site in May 2015.

Stölzle has invested €14 million in the site, which is now the group’s Centre of Excellence for the perfume and cosmetics industry. �

29 Lille 28 21 23 Amiens 9 Dieppe

Le Havre

30

19 20 27 2532 34

24

Paris

26

33 12 Reims

6 13

11 22 31

Strasbourg

3

Cognac Chalon-sur-Saône

14

Lyon

Clermont-Ferrand

7

1 16 17 8

5

Bordeaux

Toulouse

4

18 Montpellier

2

15

Montelimar

10

Marseille

Container Glass Plants located in France 1. O-I Head Office, Villeurbanne

20. Tourres & Cie, (owned by Saverglass),

2. O-I plant, Beziers

Le Havre

3. O-I plant, Gironcourt sur Vraine

21. Alphaglass (owned by Saverglass), Arques

4. O-I plant, Labegude

22. SGD Head office, Paris

5. O-I plant, Puy Guillaume

23. SGD plant, Mers-les-Bains

6. O-I plant, Reims

24. SGC plant, Sucy-en-Brie

7. O-I plant, Vayres

25. Pochet du Courval, Guimeville plant,

8. O-I plant, Veauche

Hodeng au Bosc

9. O-I plant, Wingles

26. Pochet du Courval, Beaugency Plant

10. O-I plant, Vergèze

27. Pochet du Courval, Gamaches Plant

11. Verallia, Head Office, Paris

28. Verescence plant, Mers-les-Bains

12. Verallia Vauxrot, Crouy

29. Verescence Somme

13. Verallia Oiry, Oiry

30. Verescence Orne

14. Verallia Cognac, Châteaubernard

31. Verescence Head Office, Paris

15. Verallia Chalon-sur-Saône, Chalon-sur-Saône

32. Verreries Brosse (Zignago Group),

16. Verallia Lagnieu, Lagnieu

Vieux Rouen sur Bresle

17. Verallia Saint-Romain, St Romain Le Puy

33. Stölzle Glass Plant, Masnières

18. Verallia Albi, Albi

34. Waltersperger, Blangy sur Bresle

19. Saverglass, Head office, Feuquières

22 Glass International July/August 2017

French focus.indd 1

08/08/2017 12:11:41

Company profile: Arc International

Arc’s €60 million strategy takes It’s been two years since French tableware manufacturer Arc International agreed a €60 million investment plan from financial group Peaked Hill Partners (PHP). Greg Morris spoke to the company’s CEO, Tim Gollin, at its headquarters in Arques, France to find out how things have progressed since the takeover.

www.glass-international.com

T

here is a renewed sense of confidence about Arc International now. The renowned French glass tableware manufacturer was in financial woe when Glass International last visited in mid2014. Shortly afterwards, in February 2015, US financial group Peaked Hill Partners (PHP) stepped in and agreed a deal to buy the 200-year-old company for €60 million.

It hasn’t looked back since. In the intervening two years it has invested €200 million across the business, with half of the investment in its French headquarters.

The group has 21 furnaces globally with a total of 700,000 tonnes of melting capacity. Much of the investment went into rebuilding its capacity and extending the lives of its furnaces.

Arc International’s CEO, Tim Gollin, founded the PHP investment firm and was previously a partner in JPMorgan Chase’s private equity unit, One Equity Partners.

He said: “We’re in a much more stable position and in a better shape to look at what our options are going forward. Business has been pretty good.

“Last year with some of the furnace rebuilds we didn’t get the volumes and revenues we wanted, but this year has turned out well, with volumes and revenue significantly above last year, so it feels right.”

The company has its headquarters in Arques in the Pas-de-Calais region of France with half of its furnace capacity located there.

It has five sites globally: its Milleville, NJ, USA site has 110,000 tonnes of capacity, its Ras-al Khaimah, UAE facility has 100,000 tonnes (although not all of it is currently active), Nanjing in China has 90,000 tonnes while its Gus Khrustalny plant in Russia has 70,000 tonnes of capacity. It manufactures about 2 billion of tableware items a year.

So what was the appeal of investing in Arc International?

“It’s unusual you get the chance to buy a business with a 200-year legacy, leading position in its markets, good operations but suffering from

� The company produces 2 billion tableware items a year.

� Arc’s largest customer is Ikea.

essentially a bad capital structure,” Mr Gollin said.

“Our opportunity here was to help fix the capital structure and then work on creating better value with the brands.

“So the last two years has been investing behind the brands, product lines and customers to create more stock to sell to the market. The tag line for us internally is ‘great design at affordable prices’.

That’s our focus. How are we going to deliver value to customers so that the customer says ‘I don’t want to go anywhere but Arc’.”

The company is flexible. It cannot just cater to, say, the high end market because the market is not big enough. It has to be present in all the different tiers of distribution. So it has offerings for the entry price point customer, something suitable for the mid-market range and something for the high-end group. Its brands for the general public include Arcopal, Cristal d’Arques Paris, and Luminarc, while its brands for professionals are the Arcoroc and Chef&Sommelier ranges.

� Arc has recently invested €200 million in the business.

Continued>>

24 Glass International July/August 2017

Company profile arc international.indd 1

28/07/2017 09:48:04

s

shape

Customers One of the problems the company reportedly suffered from before the investment from PHP was cheap competition from overseas. But that looks to be a problem of the past.

“If you look back 40 years you had regional differences in technological capability and regional differences in labour cost. That arbitrage has fallen away. Our labour cost in China today is not that much different to our labour cost in Western Europe and USA. That’s partly a function of global labour. There is no real advantage in China in regards to labour cost. By the time I’m done bringing it across from China there’s no advantage. We ship goods today from France to China. We ship some products from China to France but it’s more about balancing product capacities and less about structural alteration.

“I grew up in the import business back in the days when you imported stuff from China into the US because it was cheap but that has sort of gone.

“We think if we focus on how we go to market and on productivity in our factories, we can compete for less because the customer will never pay a higher premium for long delivery. So if we can give a fast delivery at the same price we win.

“The market became global for some years and now because technology is generally available to everybody, nobody has a huge technology advantage. It is an established, mature technology.

We have a few tricks but everybody has tricks. We think we’re pretty good, but the other guys are good too.

“Where we can really add value is by bringing in new designs and bringing goods to market faster, basically speeding up the pace of innovation in our category.”

The company’s largest customer is Ikea and Arc has learnt from the business practices of the Swedish household store, which ultimately means lower prices for Arc’s customers.

“They’re a great customer. They are the largest in our category, are really capable as purchasers and understand the cost structure of the industry. They understand the rhythm of our business, they’re deeply knowledgeable about the supply chain, and our production footprint and their retail footprint overlaps really well. Of course they’re tough, they buy effectively, but they’ve also got a business model that is effective because they are focused on squeezing cost out of the supply chain and delivering value to their customers. We look at that and say we’d like to be more like you. We’ve learned tonnes from them because their ways of doing business are very efficient.”

Trends Tastes and trends change, as has the market. In the past it was common for a newlywed couple to receive a huge, expensive crystal glass collection Continued>>

www.glass-international.com

s

Company profile: Arc International

25 Glass International July/August 2017

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Company profile: Arc International

www.glass-international.com

for their marriage and would keep it for a number of years. But today fewer people get married in North America and Western Europe and those first big purchases no longer happen.

“The market has changed. When we go to market now, we say how do we make products that are relevant to people’s lifestyle today. They are not going to be permanent. People are constantly swapping what they want. It’s a fashion purchase and it has got cheaper,” stated Mr Gollin.

“So we have to be sensitive to the changing patterns of buying. We need to have things that solve people’s problems rather than things that are trying to make a statement about your life. People feed their children at different hours of the day.

The idea of having a huge casserole and everybody sitting at the table at the same time where they eat and pray together does not work because that’s not how families are today.

“We have to adapt our products to the way society is changing and that is a really interesting set of challenges for us from a product development point of view.”

� Arc International’s headquarters in Arques employs 5000 people.

The company spends a lot of time in the field, going to events and viewing how people use its products. The food service sector in particular is an area where people move to different ways of eating or consuming and tends to lead what will happen in home use.

Apprenticeship scheme

� Arc has five production sites around the globe.

Mr Gollin describes the company as being only 10% of the way into its long-term plan. Its average age of employment is 52 so has a generation of people who will retire in the not-so-distant future. It has started an extensive apprenticeship programme and has successfully employed 200 youngsters in various roles throughout the business in Arques.

At the same time the company has modernised the plant. It wants to make the work more engaging and attractive to the workforce as well as more challenging.

“Lots of people want to design glass, lots of people want to figure out cool ways to run the production lines to get better yields, so we have to find stuff that’s more intellectually challenging and rewarding.

“It means moving away from a traditional top down structure to one of empowering people on the shop floor to run and manage the business or production line, or managing the customer warehouse, or managing the customer team.

“We shift the focus from saying your job is to put this in a box for 30 years to your job is to figure out how to better serve the customer.”

It has tentatively embraced the concept of Industry 4.0 and the idea of big data, but has reservations about the amount of data that is out there. While 20 years ago the challenge was the acquisition of data, the problem now is having enough bandwidth to absorb all the data available.

“Are we going to use it? Yes, we want to benchmark units against each other, we want to find out what our best practices are.

“We have social internal networks for general best practices but the question is how much data can our guys absorb while hopefully making good quality glassware and focusing on their day job.” �

Arc International, Arques, France. www.arc-intl.com/

26 Glass International July/August 2017

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Conveying glass around the world for over 30 years

Premium Conveyor Chain and Sprockets +44 (0) 1484 864733 sales@pennine.org www.pennine.org

Full page advert.indd 1

28/06/2017 11:54:51

Company profile: Stölzle Masnières

Investing in know-how Greg Morris met with Etienne Gruyez, Managing Director of Perfumery and Cosmetics for the Stölzle Group’s Masnières site in France. It acquired the facility two years ago and transformed it into a Centre of Excellence for the perfume and cosmetics industry.

www.glass-international.com

The Masnières site has been transformed in recent years, since the takeover. What has taken place?

Yes, since May 2015, when we restarted Masnières.

This site is dedicated solely to perfume and cosmetics – that is one of the reasons why the group acquired this entity, to buy the know-how in perfume and cosmetics.

The site is going to be 200 years old next year, and clearly we didn’t buy it for the buildings, because they were old, we didn’t buy it for the machinery, because it was old – the reason to buy Masnières was really for the know-how of the people.

Within the group the idea is that Masnières is what we call ‘the Centre of Excellence’ for perfume and cosmetics. Every customer request, every new project comes through Masnières, where we study it. Even though in some cases it will be manufactured at our site in Poland, everything for the client starts in Masnières.

We have our design team here, which was part of the investment so that we can do everything for the customer: They can come here with the full design specifications or just the idea, and we make the design.

For example, one customer gave us a napkin with a drawing on it and said “this is our project, we want a football for our perfume”, and so the team designed it. We took their idea, and designed a range that was launched this year in three sizes.

We do the design, we do the 3D mock up, and then because we have invested heavily in the mould department, we can do a trial mould inhouse. We can do a sample on the production

� � The Masnières site and its Managing Director, Etienne Gruyez.

line in the morning, make a modification on the mould in the afternoon, and go back again in the evening.

In 2015 we invested €5 million, in 2016 we invested €5 million, and this year we will invest around €4 million – so, €14 million in total, across the factory.

This was on new quality check machines, and we have redone the lines and invested in new equipment. We are also trying and developing some new equipment with manufacturers such as Tiama, for example.

The goal was to bring the know-how to the next level, and with higher quality.

What strategy do you focus on in Stölzle Masnières?

The main strategy of Masnières is time to market.

We need to be the fastest. We are in a region where we know we are not the cheapest, Western Europe, but what makes a difference to the client is time to market.

We are geographically close to the clients here. We are 1.5 hours from Paris, so it is easy for the clients to come here and work with our development team.

We are not the only ones in the market with a high quality product, but where we try to be different is on the speed. The market changes quickly. The average time for us to develop a new design is four weeks, that is standard but it’s still very fast.

Continued>>

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Company profile: Stölzle Masnières

If we include our decoration facility which is across the road, we have 335 employees.

Do you place much emphasis on training at Stölzle Masnières?

Before, people would have one skill. Now, usually we try to train them to do two jobs and have two sets of know-how, so that on one day they can work on the hot end, the next day on the cold end.

It gives us more flexibility on the production line, but also it gives them more interest in their job – instead of always doing the same thing, they can learn new skills.

As with Arc International, we have had a grant from the regional government to help with the training programme. The northern region created a special fund for Arc and for us so that we can train our people, because there’s a real know-how in the glass industry here.

Last year we recruited 24 new people that studied what I would call ‘the base’, which is usually the cold end. This year we have recruited another 12.

Another thing is that Stölzle Masnières used to be a closed factory; nobody visited it.

Last year, for the first time in the history of the company, we had a family day, so people could bring their families and show them the glass factory because it had always been a mystery. It’s important for the staff, so they can be proud of what they are doing.

We have started programmes and visits with local schools so they can come and see who we are and what we do. I wouldn’t say the glass industry

“Yes, for us Industry 4.0 is linked to the time to market. The goal is to be fast in development and flexible, so we aim for four weeks development time.

”

is not well known, but it is seen as an ‘old’ industry.

I think we need to show students that we also use the latest technology, we use big data, Industry 4.0, we have to be fast – to give them some appeal.

You mentioned Industry 4.0, is that something you’re interested in?

Yes, for us Industry 4.0 is linked to the time to market. The goal is to be fast in development and flexible, so we aim for four weeks development time. We are also concentrating on having a lean supply chain, and seeing how we can shorten the lead-time between the processes.

It’s also starting to work with the customer on how to share information in terms of sales volume and so forth, so we can better manage our inventory.

The environment is also important. We have worked on reducing our footprint as much as we can, in terms of energy consumption, treatment of the water, we bring our products in using boats so that we don’t use as many trucks, we recycle water, we have the flue treatment system at the back of the factory so that we don’t pollute the air.

Our clients, especially in perfume and cosmetics, are strong on their environmental footprint and so today it is a minimum.

If you can’t prove your credentials then you are out of the game. It has become a standard.

Continued>>

www.glass-international.com

How many staff do you have here?

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Company profile: Stölzle Masnières

Are your customers predominantly global or from France?

Our customers are global, although it’s true that with perfume and cosmetics the market is mainly driven by French brands: L’Oréal, Chanel, LVMH Group, Groupe Rocher, so we do have a big footprint from France. We also have customers in Sweden, the Middle East, the US. Our customers are about 60% French, 40% the rest of the world.

If one of your American clients has an idea for a design, would that still come to Masnières first?

Yes. We have a US office in New York with a developer there, so we have the technical knowhow available in the US office to immediately be able to say ‘yes we can do this’ or ‘no we cannot do this, this is how it could be modified’. Then the request comes here.

For the time to market and because of time difference it is important to have that person available there to immediately answer.

Our customers appreciate the fact we are global, that we have a global footprint in terms of factories as part of the Stölzle Group.

We have our sister factory in Poland we can use, as what we do here we share with them. We use the same tools and the same suppliers, so it’s easy to transfer from one plant to the other if necessary.

www.glass-international.com

Have your customers seen the benefits since Stölzle took over the site?

Yes. The first thing was, we asked them to come here. Before they would come to do an audit, but it makes a difference if you are the one asking them to come and be part of the development process.

We are trying to design to cost. What can we design that is easier to produce and therefore more economical for them?

The other thing that they’ve seen, although bear in mind I’ve only been in the group for three years, is that Masnières used to have a bad reputation because it was closed off, and it was not clean.

Now, clients congratulate us on the cleanliness, on the presentation, on the motivation of the staff, so yes they do see the investment.

There was a limited investment over the past 15 years, and now in two years we have managed a complete transformation.

How proud are you of what you’ve achieved so far?

I’m personally proud of my team, because yes I’m the Managing Director but I’m not alone, I have all my team.

I use the image of the triathlon. At first you swim, because at the time the company needed to swim, to survive to get back and do the transformation.

We have done that step but now we have to do

the bicycle and it’s a long race because in the meantime the competition has not stopped. So now we have to be on the bike and go faster and take the lead. The last race will be in the next two years: the running.

So yes I’m very proud, but the race isn’t over!

Now we have to pedal twice as fast to catch them.

Have you expanded your product range?

We are in the process of doing so. We have two things: 90% of our business is customer-specific design, they come with their design and that is linked to one client; that’s their shape. 10% of the business is on standard shapes. We have a standard collection that we provide to smaller clients that cannot afford to buy their own moulds.

We are expanding on the customer-designed shapes, and with the standard shapes we have developed a new, high end line that we call the Private Collection, five shapes that were introduced in 2015 at LuxePack.

Last year we continued expanding, and this year we introduced new cosmetic lines. Right now we are working on a separate business that we have started, the perfume diffuser.

How important is decoration to perfume and cosmetics?

It’s crucial. If you look when you go to a store, there is hardly any glass that is ‘just glass’, it will have a special cap or something. When you buy a perfume, the first thing you actually ‘buy’ is the design, because before you smell anything it is the design that attracts your eye and makes you try it.

Then you get into the smell, but the first thing that attracts you is the design.

We cover every type of decoration that you can possibly imagine, and we are also developing some new ones. We have developed two patents last year and are presenting them to selected customers.

Are there any trends in decoration?

Personalisation, so that people feel they are buying their own perfume.

We have also started to play with the sense of touch, so you have the visual when you look, then the smell. We are working with some clients so that when you hold the bottle it gives you another impact. It will help you memorise the bottle and make people feel really involved in buying the perfume.

We are also doing new treatments where it feels like you’re touching something very rough, or as if you’re touching stone.

The goal is that the brand can differentiate itself from the competition.

Continued>>

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ENDTOEND Full-Process Excellence

Company profile: Stölzle Masnières

Do you notice trends dependent on geographical regions?

Yes. Overall, the big brands try to be global, but they launch limited editions depending on the market. For example the Middle East loves gold, so they will design something with a lot of gold because for that market it needs to shine.

Asia is not a big market for perfume, it is more for cosmetics and creams – although that trend is coming, as the Chinese are more into perfume.

Europe and the US are pretty much the same.

Brands try to be global, because of the cost of launching. For example, when they use an actress as the face of the perfume, the advert will be global.

What decoration techniques do you offer at Masnières?

With the Polish and French plants together we offer everything, so spraying, pad printing, frosting, and hot stamping, which is growing.

Inkjet printing is new, and we have developed a lot of techniques with this, for example creating the wood effect that we spoke about earlier.

You feel like you’re touching wood but it’s inkjet printing, and that’s something we developed here. We do gluing, sleevings, we do all of that, which is a big strength of Stölzle.

As a group we offer everything inhouse. It’s good for the client, as they come with the idea and leave with a finished product.

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Has there been an emphasis on the automisation of machinery?

Yes, especially in the control area. To have good glass it starts in the hot end. Before, you would produce the glass and then check it to see whether it was good or bad, and if so throw it away.

There was a lot of waste, but we have invested in technology where, for example, we take a picture of each gob, and measure the temperature, the weight and the angle, because the way the gob will fall into the machine will give you the quality even from the beginning.

We have invested a lot in improving the quality from the hot end. You still have some defects that you can only find in the cold end, for example the bottle neck and so forth. Every line is equipped with visual quality machines, so that also reassures our customers.

We are also working with big data. We always say ‘glass is magic’, and it’s true. We have people here that know how to look at the gob, and they tweak maybe two things on the machine and then it just works. But in the end, what that person has been able to do is gather in their mind some data about what this machine can do, and what they need to do to modify it and get a result.

So we are trying to take measurements on pressure, temperature, angle and so forth, so that

on future production we can replicate all the best parameters.

This is something new, gathering that big data, and there’s still a lot to do because we have so many factors and indicators in a glass factory, but in the end it’s only the human that knows how it all fits together. We want to take the data, gather it, and see how it’s linked.

Our role is to do that, to work on the big data and see what makes an impact on glass production, the goal being that we can be faster when we launch the production because we have the right parameters.

How big is the Masnières site?

We have one furnace with four lines and we do around 70 tonnes a day. The site is huge – they used to have five furnaces here. Today we only have one running. There is a second furnace; we are waiting for the market to grow and then we can hopefully start it up .

What do you look for in a supplier?

First of all we use the Group know-how, which was a benefit to Masnières because Stölzle already use some machines and suppliers so we benefitted from that knowledge. After that, for suppliers, it’s just being able to work with the specifics of perfume and cosmetics.

We have seen many suppliers that are used to working with bottles, they come and say ‘we have this wonderful machine for visual inspection’, but when you go to use it on small items the machine can’t process it. Plus, we have complicated shapes, with bumps and spikes and so forth. So we need a supplier that is capable of knowing the perfume and cosmetics sector, or has the will to improve in that industry.

We are working with some of our suppliers on improving some of their machines.

How would you like to see this site evolve over the next few years?

We want to continue the growth, and continue the training of our employees, to continue the know-how. I see two aspects: From the customer side, Stölzle Masnières could become a ‘design playground’. The designer can come here and say ‘I’ve got this idea, is it possible to do it in glass?’

Then, from the Stölzle Group’s point of view, every company is looking for growth and so it would be to start the second furnace.

We want to improve the results we have with this one furnace, and then grow with the second one. But again, it will all depend on satisfying our clients: they are the drivers. �

Stölzle Masnières, France www.stoelzle.com

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www.growth-group.com

...so that nothing bad gets in or out!

Closing up your doghouse is a really good way of ensuring that you stay open for business because the less energy that escapes and the less cold air that comes in, the better – and this is where the new improved HORN batch charger comes into play.

HORN's innovative design results in a tight doghouse, greatly reducing energy and emission values. Just some of the advantages: • preglazing of the batch inside the doghouse – for furnaces with or without batch preheating • reduced carry-over of raw materials • reduced energy consumption • reduced NOx emissions • reduced wear and tear

the HORN optimisation program: for more information, visit www.hornglass.com

Inspection

Next generation software for advanced inspection technology Sonia Debets* highlights the extended features included within Iris Inspection machines’ 2018 Evolution Software release and the benefits provided to glass container customers throughout the world.

E

very year, Iris Inspection machines reinvests more than 15% of the company’s turnover in research and development. The team is constantly working on future versions of software for tomorrow’s Evolution machines, with a challenge to increase the precision of hollow glass inspection and the detection of defects, in order to maximise the productivity of the glass container manufacturing process.

Iris specialises in the development of camera-based, non-contact inspection solutions, offering a range of equipment to satisfy the precise requirements of the world’s glass packaging manufacturers.

Its strategy is based on partnerships developed with key customers throughout the world. The technology used in its glass inspection solutions complies with CE and UL standards, with the Iris organisation conforming to ISO 9001 norms.

existing Iris inspection modules in the coming months. A series of extended features have been incorporated within the 2018 Evolution Software release for use with the following equipment: � Evolution12 sidewall and sidewall stress inspection machine. � Evolution5 base, finish and base stress inspection machine with mould number reader. � Evolution1 standalone finish inspection machine. � Evolution ultimate transparent defects camera inspection machine,

dedicated to perfume and cosmetic containers. � Evolution dim online measuring inspection machine.

Among its many extended features, the 2018 Evolution Software incorporates new defect algorithms, with selfadjusted parameters and limited user parameters. The development team has also introduced new defect classification methods, showing the difference between blisters, stones, grease marks, black spots and glass repartition.

Continued>>

Extended features

www.glass-international.com

The company’s latest innovation typifies its long-term commitment, involving the release of its next generation software, which will be adopted on all new and

� Evolution machines equipped with 2018 software version.

� 3D inspection tool inspects in the engraving zone.

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Inspection

ELECTROGLASS THE KEY TO IMPROVED

ENERGY EFFICIENCY

� Line over Finish detected with the new widemouth finish station.

There is no limitation on inspection, with the generalisation of all detection tools, body finish and base, for non-round ware, specific shapes and engraved articles. New 3D geometrical inspection tools have also been added, so that the Evolution12 machine always gives the same result, irrespective of article orientation.

Finish inspection station A new widemouth finish station uses a latest generation light source. There are two main benefits of this new inspection station. Being universal, it does not need to be adjusted independently for every different article, because the same setting works for all articles. In addition, it is extremely stable, so that variations of article position on the belts of the Evolution5 machine do not affect the image to inspect.

Long-term partnerships Iris Inspection machines has created meaningful, long-term partnerships with industrial customers in the space of less than three decades in the areas of electronics and software for machine automation. In addition, exceptional knowhow has been realised in the most innovative vision technologies.

The company’s ambition is to be recognised as the most trusted supplier of inspection systems for the international glass packaging industry. As a leader in technology, the company anticipates customer needs and provides long-term and cost-efficient support for its solutions in the field of glass quality control. This partnership with customers is the key to sustainable development.

The 2018 Evolution Software release will be unveiled at the Glassman Europe 2017 exhibition in Lyon, France on 6-7 September. Attendees are invited to visit Iris Inspection machines on Stand No E01 to discover its exciting extended features.�

*Sonia Debets is Area Sales Manager at Iris Inspection machines, Bron, France. www.iris-im.fr

HIGH EFFICIENCY ALL-ELECTRIC FURNACES, FOREHEARTHS & BOOSTING FOR ALL GLASS TYPES

The Specialists in Electric Glass Melting and Conditioning

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IRIS inspection.indd 2

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www.xparvision.com

Bright ideas. Better glass.

XPR1009_Adv_corp_A4_fc.indd 1

09-02-12 11:37

Inspection

Statistical process control to measure glass thickness Tiama’s Pascal Leroux* highlights how a processing device offers glassmakers the opportunity to access all thickness measurement data for each container.

Overleaf, Consol Glass’s Christian Jakob reports how the device has helped with soft internal blisters detection.

Measurement capability During its 55 years of development, Tiama has assisted glassmakers in their search for productivity gains and efficient glass thickness measuring systems, in order to reduce the weight of the container while guaranteeing the mechanical strength.

This contribution has led to a number of inventions which have in turn, broadened the limitations of these existing systems and allowed for fresh prospects in the search for optimisation to be developed.

Tiama’s Universal Thickness Measurement (UTM) device offers a wide range of glass thickness measurements available to the industry. A processing

unit hosts up to four levels of controls which can be applied to the following choice of probes: � LBT – 20mm wide-band measurement. The thin wall measurement area can be increased to a 60mm wide inspection when using three probes. � LED – Compact triangulation measurement working with new white LED suitable for most colours of glass. � CHROMA – Chromatic probes with the widest possible appliance (shapes including non-round, colours).

UTM performs six simultaneous measurements: thickness (mini, maxi. & average); ovality; glass distribution ratio and large blisters detection.

UTM is designed to be installed on all Tiama rotating machines MX4, M, CHECK+, and C0 as well as on most of the carousel machines available on the market. However, when associated with a Tiama MX4, all the measurement results for each container can be accessed to conduct a complete process follow-up through SPC.

Higher productivity SPC can help monitor process behaviour.

It uses sampling and statistical methods to monitor the quality of an ongoing process. A graphical display provides a basis for deciding whether the variation in the output of a process is due to common causes or due to out-of-the-ordinary assignable reasons.

Whenever assignable causes are identified, a decision can be made to adjust the process to bring the output back to acceptable quality levels.

This continuous anticipation and early detection are powerful tools for

� Universal Thickness Measurement with three LBT probes in Wadeville, South Africa.

productivity improvement.

Today, thanks to its sensors, the Tiama MX4 is capable of collecting all the available measures, namely ovality, gauging, airtightness, leaner, dimensional and thickness and of associating them directly with the mould number of each single container. All these precious data are then forwarded to the supervising systems such as the Tiama IQ scan for immediate process drift prevention.

The SPC method is the first step to improve overall quality, efficiency and profitability. Quality control and plant managers can evaluate current production samples, to find how to transform them into improved production line efficiency.

Continued>>

www.glass-international.com

T

he glass packaging market demands a constant increase in article complexity, driven by multinationals promoting their distinctive-styled branded food, beverages and cosmetic containers. Packaging matters almost as much as the content so companies invest in both the aesthetic and functional aspects of their bottles or jars, as a way to convey a premium experience to the final consumer.

Glass manufactures are challenging each other with creative ideas to offer customised article portfolios.

But environmental concerns have grown, as have productivity concerns, therefore glassmakers struggle to manufacture lighter-weight articles.

When producing non-round and lightweight containers a key criterion to master is the glass thickness, but it does not end there. Tiama can now provide access to all thickness measurement data for each single container, allowing for better Statistical Process Control (SPC) and for gains in productivity.

37 Glass International July/August 2017

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Inspection

Customer case study: Consol Glass Christian Jakob works in the Engineering Department at Consol Glass in South Africa.

He reports how the UTM device associated to the Tiama product range has helped with soft internal blisters detection.

Can you tell us about yourself and your role at Consol?

I commenced my career in Consol Glass in 2001 at our Clayville plant as a shift mechanic working on inspection equipment. From there I progressed to dayshift, then to the electrical department and gained experience throughout the whole plant.

Afterwards I became a shift manager and from there to line management. For the last six years I have worked in the group quality department at H/O. My work in the quality department was to give assistance to our customer on the technical side such as customer interfacing, line audits, technical advice on equipment and ware handling, audit our factories with regards to inspection equipment (establish a standard across the Consol group) and to evaluate new inspection equipment. I am currently in the engineering department working on projects but still have a line to the quality department regarding customer interaction and line audits.

What does Consol Glass do?

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Consol Glass specialises in making glass containers for the food and beverage industries inclusive of the beer, alcoholic fruit beverage, wine, fruit juice, soft drinks, mineral water and spirits markets.

Consol owns operations in Nigeria and Kenya with a new greenfield operation under construction in Ethiopia due for launch in 2018.

Consol is the largest glass producer in Africa. Our vision is to be the first choice for container glass supply to all customers across the African continent by offering glass solutions to our customers on a reliable basis at competitive prices and to be the supplier and pack of choice across Africa.

Consol recently bought some UTM systems equipped with LBT (Large Band Thickness), can you explain what the issue was?

We had a problem detecting a soft internal blister, which was located in the heel base area on one of our beer bottles which we manufacture. Blisters came in various positions and sizes on the bottle – they don’t only come in one position and in one size.

Some blisters created thin glass where others created more of a shadow with the glass still being well within spec.

This was not the only problem, the blister created a thin membrane on the inside of the bottle which makes it even more difficult to detect.

These bottles were manufactured on production lines where the current inspection was the MCAL & MULTI 3 combined with the Check + version 5.

Why did you choose Tiama?

As these bottles were running in our plant where the majority of inspection equipment was manufactured by Tiama, we contacted Tiama for assistance.

We sent a range of soft internal blisters together with some good bottles to Tiama in France.

Together with the Tiama team on its testing line we challenged/trailed the MCAL 4 HD (+ the dynamic zones and masking) and the UTM – LBT system to see whether it would be possible to detect and reject the soft internal blisters while not losing any good bottles in the process.

Together with the MCAL 4 HD, and the LBT we further trailed the HCI (Heel Camera Inspection) which we set-up to inspect for Vertical and Horizontal defects in two different zones.

We had some good results in France hence we decided to upgrade our current inspection in South Africa.

Can you describe more precisely what this MCAL4, LBT & HCI association has brought?

The MCAL as a HD system sees the softer defects much more intensive/clear which enables us to identify the defect easier.

The bottle which had this specific defect also had a huge amount of embossing, which creates a bigger problem having maximum inspection detection.

The MCAL 4 comes with a dynamic zone function which in this case enabled us to be able to inspect the bottle in between the embossing, and with the masking function enabled us to increase the sensitivity in the embossing and the surrounding areas.

The LBT laser system enabled us to inspect a broad band of 20mm instead of a single dot 1/10thmm.

This not only made it easier for us to

� Christian Jakob, Engineer, Consol Glass.

set-up (very user friendly) it also allows us to inspect a much wider band (more coverage) of the glass bottle.

This led us to set-up three LBT heads on the beer bottle enabling us to cover/ inspect +- 45% of the bottles body.

The HCI system unfolds the image of the bottle, which in this case covered an area of +- 35mm from the heel up. This inspection defects through transmission so it was easy to set-up and detect the blister in the heel.

We have two zones with two different algorithms activated in each zone.

The one zone looks for vertical defects and the other for horizontal defects. In this way we can detect the shadow that the blister creates and reject it.

What are the next steps?

Consol has ordered and installed new equipment/conversion kits as well as the LBT and HCI systems for most of our production lines as we think it will enhance our inspection capability and protects our customer requirements better than before.

We have and more so now are working closer together with Tiama when we find or see a defect which we or our customers deem as not acceptable to find a solution in detecting the defect and reject it. �

*Carousel & Laboratory Product Manager, Tiama, Vourles, France www.tiama.com Consol Glass, Gauteng, Johannesburg, South Africa www.consol.co.za

38 Glass International July/August 2017

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Inspection

Thermal imager for accurate furnace temperature reading

� NIR-B Glass inserted through Holophane’s glass melt tank wall at Les Andelys plant in France.

E

nsuring consistent temperatures in glass melt tanks is an essential part of maintaining high-quality glass production and extending the campaign life of the furnace.

Within the furnace, a variety of temperature measurements can be taken at different locations. It is important to be able to trend temperature measurements throughout the furnace, such as in the crown and port arch areas.

The melt line temperature and batch transit time need to be recorded and used

for comparison, along with temperature ‘visualisation’ of cold spots in the refractory wall that can indicate air leaks typically caused by structural issues.

There are other considerations as well, such as the impact of fluctuating temperatures on the process and on the furnace, itself.

Emission control In addition, there is a global focus on emission control, and, to date, Europe, specifically the UK, has taken the lead on

curtailing glass-furnace emissions. Recent legislation has resulted in two major changes to glass-melt furnaces.

First, emission controls have been tightened, meaning that large holes can no longer be cut into the refractory to enable viewing of critical areas.

Not only did this practice cause wasted energy from heat loss and a lack of emission control, it also was difficult to keep the opening free of debris.

Continued>>

www.glass-international.com

Mark Bennett, Glass Industry Lead at Ametek Land, looks at how infrared temperature measurement helps improve efficiency and optimise quality within glass production, while reducing emissions and providing better protection.

41 Glass International July/August 2017

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Inspection

A

B

C

A. Thermal image of a glass melt tank by a Near Infrared Borescope. B. NIR-B Glass thermal image of inside Holophane’s glass melt tank at Les Andelys plant in France. C. Thermal image of inside glass melt tank, using Ametek Land’s NIR-B Glass.

The second change in response to emission legislation was a transition to the use of oxy fuels. Oxyfuelled furnaces use pure oxygen. That means there is no nitrogen, and, hence, NOx emissions are substantially reduced.

However, use of these fuels has its challenges. While they are not among the majority, oxy-fuel-based furnaces are a rapidly growing trend.

Given that the fuels burn hotter, the need for thermal imagers that can keep pace and provide accurate temperature reading, has gained in importance.

Running even slightly hotter affects the refractory insulation within the furnace.

www.glass-international.com

Thermal imaging With innovations in remote, infrared imaging technology, hundreds of thousands of temperature measurement points now can be taken every second, providing operators with greater temperature accuracy and enhanced temperature control in the melt tank.

Technologies such as Ametek Land’s Near Infrared Borescope (NIR-B) thermal imager, provide continuous monitoring and allow for the display of high-quality visual images that can, for example, be used to optimise flame propagation. Short wavelength imaging cameras produce high-definition (656 x 494 pixel) thermal images and enable accurate temperature measurement from any point.

There are many advantages to thermal versus visual imaging and point temperature measurements.

Using a permanently installed thermalimaging camera that actively records all necessary and useful data means that the video can be stopped at any frame and measurements taken of all of the ports at the exact same point in the process, so that reversals can be tuned more

� Ametek Land’s Near Infrared Borescope -NIR-B Glass.

accurately.

Additionally, any structural damage caused by out of normal operating range high temperatures can be caught quickly.

For example, if a crack is developing, it may show up as a cold area where air is being pulled in.

Using thermal imaging, the identification of a problem as soon as the process begins allows corrective action to be taken before it develops into something far more serious, avoiding potentially dangerous situations, high repair costs and lost production time.

Thermal imaging technology makes it possible to accurately image the temperature of a large area of the furnace through only a small opening in the wall, giving the operator access to data that would have previously been either time consuming or impossible to collect.

That capability allows the operator to focus on specific areas of interest, to measure live data points and to store the data for future analysis. By monitoring live video, operators can begin improving melt-tank efficiency and enhance product quality, resulting in reduced process costs.

The auto-retract version of the NIR-B provides an additional level of protection from damage from overheating, should water or air services fail, therefore reducing any associated maintenance or replacement costs.

Real-time data The latest infrared temperature measurement systems allow real-time data to be streamed in time-lapse modes.

That allows process engineers to

visualise the flow of the glass melt batch over the process time. As a result, alarms can be set in the control equipment to alert operators and ensure optimum quality glass production.

Highly accurate thermal imaging also can extend the lifespan of the melt tank and provide greater asset protection through more accurate temperature measurement. Thermal imaging devices measure, monitor and log refractory temperatures allowing information to be transmitted instantly, which can trigger alarms if temperature differences occur. Thermal imaging cameras can be positioned underneath the melt tank to detect hot spots early, potentially preventing a break-out below the tank.

Infrared borescope equipment also has been found to extend the lifespan of the melt tank and provide greater asset protection through more accurate temperature measurement.

These recent advances in measurement technology are helping plants to improve the melt tank process, both in terms of output quality and cost reduction.

Adding thermal-imaging capabilities that enable operators to maintain accurate visuals of the entire glass-melt tank, as well as take temperature measurements at any point in the process and in any location within the tank, has proven to be an invaluable asset for a modern glass plant. �

Ametek Land, Dronfield, UK. Email land.enquiry@ametek.com Website www.landinst.com

42 Glass International July/August 2017

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Inspection

A testing station for glass container pressure strength Agr International’s SPT2 automated pressure and volume measurement system offers technology and efficiency for glass bottle testing at the production line, reports David Dineff*.

� � Patented ‘floating head’ firmly holds bottles during testing to eliminate the possibility of finish breaks.

of sample sets on a regularly scheduled basis with testing data fully documented, regardless of the time of day or availability of manpower.

The combination of volume measurement along with pressure testing also offers advantages. Of significance is the savings resulting from the automation of the labour intensive and timeconsuming task of volume measurement.

No less important, however, is the ability of the SPT2 to perform routine volume measurement outside of the laboratory, on the plant floor in a regular plant environment.

Close proximity to production improves testing efficiency and makes it practical to perform volume and fill-level measurement, more often, on a regular and timely basis.

As a result, plant operators have the means to measure volume and fill level

with precision, on a regularly scheduled basis throughout the production run, making it possible to better manage and meet customer quality requirements.

Measuring volume The SPT2 provides volume measurement results in three forms: brimful volume, fill point at a defined volume and volume at a defined fill point.

All three measurement forms are captured with every test, in a single, automated test cycle. The automation of volume measurement in this manner with the SPT2 delivers productivity gains when compared to current manual methods performed in the laboratory.

For example, the SPT2 performs a volume measurement (all three measurements) of a typical beer bottle in 30 seconds from Continued>>

www.glass-international.com

T

he SPT2 automated testing station is designed to provide critical pressure strength and volume performance data for glass containers, on a sampling basis, on the production floor.

Integrated into the production line, the SPT2 can automatically test and collect pressure and volume data on bottles selected for sampling, without operator intervention, on a 24/7 basis at a rate of up to 270 bottles per hour.

The high throughput rate and continuous, hands-free operation offer an advantage when it comes to testing efficiency and frequency of sampling.

More frequent sampling translates into faster detection of pressure related issues.

With early detection, corrections can be made faster and, as a result, the amount of held or discarded ware can be reduced.

Automated or hands-free operation (in sampling configuration) permits testing

45 Glass International July/August 2017

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Inspection

start to finish. This includes handling the bottle, measurement, data capture and documentation. Compared to an average of 2+ minutes for volume measurement in the laboratory using the gravimetric method, the SPT2 provides a 4x increase in productivity and throughput, all without the constraints associated with traditional laboratory testing. In addition, with a few extra seconds, further savings can be gained when bottles are pressure tested immediately following volume measurement. If the system is integrated with an automated sampling system, additional efficiencies can be realised.

With automatic sampling, volume measurement can also be staged throughout the day to occur between pressure testing jobs to maximise testing and take advantage of the efficiency of the system.

the container. Furthermore, the volume measurement system on the SPT2 is selfcontained, requires no delicate scales and is not affected by water density, flow rate, vibrations or issues that commonly plague other methods.

Pressure testing At the heart of the SPT2 pressure testing module is an advanced, controlledvelocity pressure generation system that can pressurise containers up to 69 bar (1 minute equivalent) while providing accurate and controlled pressurisation throughout the testing process. The pressure system is designed specifically to meet the rigid testing requirements defined in ASTM C-147, Standard Test Method for Internal Pressure Strength of Glass Containers, and ISO 7458, where a constant-rate of increasing pressure must

www.glass-international.com

How it works The volume measurement system incorporated in the SPT2 utilises positive-displacement technology. In simple terms, the positive-displacement approach employed by the SPT2 works as follows: a known volume of fluid is transferred from a temperature compensated calibrated piston and cylinder into the test container. At the same time, the fill level is monitored as the container is filled to overflow.

More specifically, the SPT2 incorporates a calibrated cylinder at the centre of the volume station.

During the volume measurement process, a piston pushes water from the calibrated cylinder into the bottle. A defined volume of water, relative to the container size and specifications, is dispensed into the container. The SPT2 measures the dispensed volume by tracking piston motion with a high-resolution encoder. As the container fills, the level of the water meniscus is measured by a highresolution displacement sensor.

The positive-displacement method offers a number of advantages. Most significant is the accuracy. This filling technique, in tandem with a fill-height sensor makes it possible to deliver defined fill and volume measurements at any point within the process, to an accuracy of + 0.5ml. Other advantages include little or no effect on measurement precision due to water quality, container shape or rate of fill, regardless of the size and volume of

� Agr SPT2 is designed for efficiency, offering precision volume measurement and pressure testing for glass containers in a single, compact system.

pressure point (proof testing), or to destruction. If used for proof testing there is an option to rapidly break the bottles to avoid introducing whole, waterfilled bottles into the cullet stream. An important feature of the SPT2 is its ability to tightly control bottle pressurisation on both ends of the spectrum.

The 69 (1000 psi) bar upper limit provides the capability for the performance testing of heavy-wall champagne bottles or other high-strength bottles.

For low pressure testing, this system overcomes the problem of false breaks by continuously monitoring and evaluating pressure readings to differentiate between leaks and actual low pressure breaks. SPT2 has the sensitivity to accurately report bottle failures as low as 1.4 bar (20 psi).

Simplicity A Linux-based architecture and operating system is used to manage the continuous, multi-function operations of this system. Linux’s ability to run on embedded computing platforms is an advantage for the elevated temperatures of the factoryfloor environment and 24/7 operation of the SPT2. Linux was chosen over PC-based operating systems because it offers better efficiency, stability, security and long-term availability.

The system is compatible with process management systems used within the glass bottle industry.

To maximise throughput, the SPT2 employs a two-station design with concurrent volume measurement and pressure testing operations.

A servo-controlled positioning system provides for optimal bottle travel and placement through the system. Continuous bottle management and closed-loop monitoring of all processes facilitate bottle processing and throughput.

Versatility be applied to the bottle in a precise and defined manner.

The SPT2 exceeds these requirements by offering an un-matched level of precision in the control and application of pressure, resulting in high accuracy and repeatability of test data.

Pressure testing can be performed in two ways. The SPT2 offers the choice of pressurising bottles to a pre-defined

The gripping system on the SPT2 can accommodate bottle finishes up to 38mm and adjust for bottles of varying diameter and height without job change.

To firmly hold bottles during testing and eliminate the possibility of finish breaks, a patented ‘floating head’ gripper insert is used. This design overcomes the Continued>>

46 Glass International July/August 2017

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Inspection

Pressure Testing and Volume Measurement in One System

� Agr SPT2 incorporates an integrated volume measurement system that performs volume measurements simultaneously with pressure testing, on the plant floor, with laboratory accuracy.

Industry-leading pressure testing and volume measurement, with laboratory precision, on the plant floor!

24/7 automated testing Simple operation Versatile bottle management supports a wide range of ware No job change 25% faster throughput than other industry offerings

issues and problems related to rigid inserts, making it possible to firmly grip bottles regardless of variations in finish diameter or ovality, without creating stress points that promote finish breaks.

Another added feature of the system is the ability to adjust ‘dynamically’ to accommodate bottles of different sizes or from multiple production lines. This includes bottles with different diameter finishes as well as different heights.

Details of the bottle height, finish and volume are stored with each job, making it possible to perform in-process job changes to test bottles from different manufacturing lines, or handfeed a set of bottles as required, without the need to stop and reconfigure the system, maximising testing efficiency.

Configurations

*Product Marketing Director, Agr International, Inc., Butler, PA, USA. email ddineff@agrintl.com. www.agrintl.com

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Versions of the SPT2 are available for pressure testing only or combined pressure and volume testing.

The SPT2 can be used as a stand-alone testing station for near-the-line or lab use, integrated into a sampling line in conjunction with a plant-wide process management system, or configured as part of Agr’s OmniLab automated measurement system.

When configured with the OmniLab system, pressure and volume as well as external dimension, ID, push-up, weight and thickness can be measured in a single hands-free operation with data correlated into one comprehensive report.

The SPT2 and OmniLab are part of Agr’s on-line, laboratory testing and quality control devices for the glass container and filling industries. �

CALL US TODAY! Learn how SPT2 can improve your quality management program and profitability.

AGRINTL.COM • +1.724.482.2163

47 Glass International July/August 2017

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Inspection

Marposs installs flexible gauging equipment at Verallia’s VOA site Eleonora Bordini* provides a case study of how Marposs equipment was installed in the Verallia VOA site in Albi and how it integrated with products from two other glass inspection companies.

V

erallia’s VOA plant in Albi, France is a historic French glass container manufacturer.

It was founded in 1896, employs 300 people and has two furnaces and six manufacturing lines that produce approximately 800,000 bottles a day.

It specialises in the development and production of high-end bottles mainly for wine, spirits and soft drinks, even in small batches, thanks to the flexibility of its manufacturing process.

It recently invested €24M to modernise half of its production equipment (Glass International, May 2017, page 10).

Furnace number 1 is dedicated to high quality extra-flint and flint glass production and was completely rebuilt, together with its three production lines to gain flexibility and to strengthen its positioning on the small and mediumrun high-end markets.

This investment also involved an innovative inspection line, including Marposs VisiQuick flexible gauging machine for measuring the dimensional and geometric characteristics of glass containers, on a sample basis.

www.glass-international.com

Inspection line The inspection line, installed in the cold end, near the glass container production line, included products from three companies: Marposs, Somex and Vertech.

The inspection line is composed of: � Marposs VisiQuick, flexible gauging machine with a special conveying system; � Vertech SIL, production monitoring software; and � Somex Roburst, automatic glass bottle pressure tester.

� Cameras and range of measurable containers.

The inspection line includes four input conveyors (a, b, c, d Fig 1), to house four sets of different articles.

Glass containers to be measured are manually loaded on the conveyors.

Containers present on the conveyors are delivered, one set at a time, in a sequence programmed on Vertech SIL, to a single input conveyor (IN) entering the VisiQuick machine.

A pick & place device brings the containers from the input conveyor inside the VisiQuick machine where they are measured with cameras (1), as far as external parameter are concerned (height, verticality, parallelism, diameters

on body neck and finish, long/short side and diagonals on non-round containers, angles, radiuses and many others), and subsequently with a bore gauge (2), measuring mouth internal diameter, at different depths, and internal profile.

The internal profile measurement is accurate thanks to the integration of a linear encoder, fully synchronised with the bore gauge readings. This feature is based on Marposs proprietary technology (the DigiCrown network system).

After being measured on the VisiQuick machine, containers are delivered to a Continued>>

48 Glass International July/August 2017

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Tooth Chain

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Excellent guiding characteristics, a long service life, reliable delivery: our laser-welded inverted tooth conveyor chains are convincing in any production setting. They offer a wide variety of application options: from hot bottles to entire vehicles, they carry the product precisely to the right location.

Reliable, safe, efficient and always tailored to the specific application.

Renold GmbH Zur Dessel 14 31028 Gronau (Leine), Germany Phone +49 5182 58724 toothchain@renold.com www.renoldtoothchain.com

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Inspection

doesn’t need to programme the recipes, relevant to the articles to be measured, twice, either on the SIL and/or the VisiQuick.

The inspection line was manufactured and installed in record time, just after three and a half months from the order, thanks to the close cooperation among all the parties involved in the project.

The VisiQuick machine has a modular structure and can include additional measuring stations.

For example stations to measure weight, push-up or glass thickness.

� Fig 1 Gauging Line Layout

Marposs

single output conveyor (OUT) that can convey them alternatively to the Somex Roburst machine (A) for pressure test, to an accumulation table (C), or to a scrap chute (B).

The path the container will follow after the inspection on the VisiQuick machine is programmed on the Vertech SIL. The advantage of this solution is that the inspection line doesn’t need to be supervised all the time.

After placing four sets of containers on the four conveyors, the operator can dedicate himself to other activities, while containers are being measured.

The capability to measure four different articles, in sequence, without any human intervention, is possible because of the VisiQuick machine’s full flexibility.

In fact, no retooling is required when the container to be measured changes, even though dimensions and shapes are

different. This feature is not present in any other glass container gauging machines available on the market.

Thanks to the communication protocol developed between Marposs and Vertech, recipes programmed on the SIL are sent to the VisiQuick machine. So the operator

� The software on display.

Marposs is a specialist in precision equipment for measurement and quality control in the production environment.

The company was founded in 1952 and has experienced continuous growth since then. It is present in 34 countries, almost everywhere with its own organisation, and currently employs 3100 people.

Production is based at its headquarters in Bentivoglio, Italy and in other countries such as China, Germany, Japan, Korea, USA. VisiQuick machines are installed in the plants of the main glass containers manufacturers such as Bormioli Luigi, Saverglass, Shandong Huapeng, Verallia and Zignago Vetro.

Most of these customers purchased more than one machine.

More information about the VisiQuick machine is available from http://www. marposs.com/product.php/eng/glass_ containers_flexible �

*Product Manager, Marposs, Bentivoglio, Italy www.marposs.com

www.glass-international.com

� Gauging Line Rendering.

50 Glass International July/August 2017

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Glassman Europe-Lyon Catalogue

Welcome to Glassman Europe!

It also includes a floor plan, exhibitor list and a products and services guide.

For the first time the Glassman event will include two free conferences rather than the usual one.

Industry 4.0 has become a common talking point in the sector in recent years and the Future Glass Forum, held on the show floor, will attempt to decipher what is Industry 4.0 and how the glassmaking sector can benefit from it.

A number of companies have started to use the new digital technology and have already reaped the rewards. The conference will hear from organisations at the forefront of this technology.

Elsewhere, in a change from our usual technically-led conference, our second symposium will focus on the current trends in the industry.

A number of speakers ranging from glass manufacturers, associations and industry analysts will provide papers about the current talking points in the sector. I bid you all a successful and rewarding show.

Greg Morris, Editor, Glass International

www.glass-international.com

France has a diverse and innovative hollow glassmaking industry that has a rich heritage.

It is home to globally known glassmakers such as Verallia, O-I and Stölzle as well as a number of more ‘local’, smaller-sized organisations such as Pochet du Courval, Saverglass and Verreries Brosse.

Alongside this, of course, are a number of equipment suppliers to the industry who lead the sector in terms of creating new technology for the industry.

Lyon is home to a number of these suppliers some of whom are exhibiting at this event. I would particularly like to thank Iris Inspection machines, based in the nearby town of Bron.

The company has provided invaluable support in the organisation of this show and it is unveiling its latest software at the Glassman Europe exhibition.

Visitors to the event will be able to assess the extended features of the 2018 Evolution Software as part of its world premiere.

This catalogue features the details of a number of exhibitors.

It outlines the role of the company in the glass sector, what it does, its contact details, and the stand number of where to find them on the show floor.

Venue: Cité de Congrès, Lyon Wednesday 6th September - Opening times: 09.30-17.30 Thursday 7th September - Opening times: 09.30-16.00 ORGANISER: Quartz Business Media Ltd

53

Picture courtesy of Pixabay

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Glassman Europe-Lyon Catalogue

EXHIBITOR LIST

COMPANY NAME

& F

STAND

www.glass-international.com

Conference

AGR International Inc E07 All Glass B05 Ametek Land (Land Instruments International) B01 Antonini S.r.l A04 BDF Industrie Spa D08 Bernard Bonnefond D11 Car-Met srl B11 Celsian Glass & Solar Bv E09 Changshu Jianhua Mould Technology Co. Ltd D10 Electroglass Ltd G01 EME GmbH D03 Emmeti Spa B12 Ernst Pennekamp Gmbh & co. ohg E04 Eurotherm by Schneider Electric E11 Excelsius Global Services GmbH sponsor FAMA F01 FIC UK Ltd D01 Flammatec D01 Fusiontec srl B09 Giancarlo Perego Spa C09 Glass Global A02 Glass International Magazine C11 Glass Machinery Plants & Accessories K14 Glass Service D01

Exhibitor information correct at time of going to press.

54 Glass International July/August 2017

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Glassman Europe-Lyon Catalogue

& FLOOR PLAN Organisers’ office

STAND

GPS Glasproduktions-Service GmbH A06 Henry F. Teichmann Inc. C12 Heye International GmbH C01 Horn Glass Industries Ag C10 Iris Inspection Machines E01 Lahti Precision Oy H07 Marposs Sas G03 Messersì Packaging E03 Motim Fused Cast Refractories Ltd C07 Nikolaus Sorg GmbH & Co. Kg D03 Parkinson-Spencer Refractories Ltd C02 Picvisa A05 Pneumofore E06 Poco Graphite A08 Proteis G06 Reckmann gmbh C05 Renold GmbH - Tooth Chain B08 Revimac Srl B09 Siemens Ag F02 Sinex Industrie Sas G13 Sipac Spa B12 Somex B07 Stara Glass Spa G04 Tempsens Germany - Proteis G06 Van Putten Instruments Bv B02 Vidromecanica C04 VMA GmbH F03 Zecchetti Srl E02 Zippe Industrieanlagen Gmbh H01

www.glass-international.com

COMPANY NAME

55 Glass International July/August 2017

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ARE YOU

CERTIN

®

TO BE THE BEST

IN GLASS? The most advanced glass container protection in a 3-step program to improve your coating quality and production efficiency.

MORE HOMOGENEOUS HEC FRICTION FREE BOTTLE TRANSFER HIGHER PRECISION OF FINAL COATING

glasscoating-arkema.com

Glassman Europe-Lyon Catalogue

Stand E07 Marco Palma, 615 Whitestown Road Butler, PA 16001, United States Phone: +39-335-6050541 Email: mpalma@agrintl.com Website: http://www.agrintl.com Agr International Inc. offers a variety of equipment and services specifically designed to meet the quality assurance needs of the global glass container manufacturing, filling and packaging industries. Agr’s products include on-line wall thickness measurement, automated sampling equipment and a variety of testers and gauges for use in the laboratory or on the production floor. Measurement and testing of glass container thickness, pressure, strength and coating are all part of Agr’s line of quality assurance equipment. In addition to its headquarters in Butler, PA, USA, Agr offers world-wide sales and service with offices in Italy, Poland, Germany, Thailand, Spain, China, Austria, Luxembourg and Mexico.

Agr products play a significant role in the quality and safety of containers and packaging used around the world. Agr products can be found in over 120 countries.

ALL GLASS SRL Stand B05 Mr. Marco Ballerini Via Cesare Sarti, 20 43029 - Traversetolo (PR) Italy Phone: +390521340810 Email: sales@allglass.it Website: http://www.allglass.it Nowadays All Glass is recognised as a worldwide leading supplier of conveying lines and palletisers in the cold-end area of the glassworks industry. The numerous references in such installations for the most important international glassworks allowed All Glass to make a name for himself as reference partner in this sector. In last years all the most important glassworks chose All Glass gaining full satisfaction in terms of excellent performance, efficiency and service. Considering that the production of glass furnace never stops, in its machinery All Glass uses first-class components and long-term tested elements only. All Glass technical structure is organised to guarantee a constant assistance during all the steps of design, assembling and start-up and to assure a prompt after-sales support during the maintenance periods. Making use of consolidate synergies, All Glass is

the ideal partner to entrust the service of complete engineering for turn-key new solutions and for retrofits or relocations of existing installations. The keys of All Glass team’s success are the constant research in direct symbiosis with Clients to develop taylor-made customized solutions, and the natural bent to after-sales assistance and support, which makes All Glass be the ideal partner in terms of performance

AMETEK Land (Land Instruments International)

Stand B01 Mark Bennett Stubley Lane, Dronfield, Derbyshire S18 1DJ United Kingdom Phone: +44 (0) 1246 417691 Email: land.enquiry@ametek.com Website: https://www.landinst.com/ AMETEK Land is a specialist in the design and manufacture of monitors and analysers for industrial infrared non-contact temperature measurement, combustion efficiency and environmental pollutant emissions. AMETEK Land has supported the global industrial community for over 70 years with innovative and reliable products and solutions. AMETEK Land will showcase the benefits of its NIR-B Glass, a new thermal imaging Near Infrared Borescope, designed specifically for use in glass-melt tanks with an optional auto-retract version for additional instrument protection. It will show how the NIR-B Glass provides continuous real-time temperature data, combined with a crystal clear thermal video image, allowing a single solution to replace the traditional approaches of visual cameras and periodic hand-held pyrometry. AMETEK Land will also showcase: - Cyclops, highquality portable non-contact thermometer, providing precision spot temperature measurement with unmatched accuracy and reliability. - LSP-HD, infrared linescanner, for detection of small temperature differences across the width of the glass product providing optimum product quality through improved process control. - Lancom 4, portable combustion and stack emissions gas analyser, offering the best accuracy available from a portable gas analyser, achieved by using an advanced sample conditioning system.

ANTONINI S.R.L Stand A04 Via Medaglied’oro Della Resistenza Empoli (FI) 50053 Italy Phone: +39 0571 93221 Email: com@antoninisrl.com Website: www.antoninisrl.com Antonini srl is an Italian company working since 1946 in hollow glass. Antonini supplies annealing and decorating lehrs, tempering lines, mould prehating kilns, thermal shock lehrs, cold end coating spray and dosing unit. The company is very active also in upgrading and reparation of second hand lehrs of all brands. Low consumption and zero maintenance are the strong qualities of Antonini’s equipment, together with the post sales service, made by high specialised technicians. All equipment is made in Italy and all materials are high quality, to keep the standard in a top level.

Up to today more than 1600 new lehrs have been installed.

BDF INDUSTRIE SPA Stand D08 Via Dell’Industria 40 Italy Phone: +39 0444 286 100 Email: BDF@BDF.IT Website: http://WWW.BDF.IT BDF Industries is an Italian company with headquarters based in Vicenza, Italy and has 111 years of history and tradition of mechanical and automation competence.

Serving glass manufacturers all over the world for more than 60 years lead us to a deep knowledge of glass processing equipment (both forming and melting ).

Our experience in design, manufacture, installation and start-up of turn-key projects, together with our dedication to fulfil customer requirements, represent our core skills.

BERNARD BONNEFOND Stand D11 Philippe Bernard 7 Allée Mathieu Murgue - Terrenoire 42100 Saint Etienne France Phone: +33477953000 Email: bernardbonnefond@wanadoo.fr Website: http://www.bernardbonnefond.com BERNARD BONNEFOND est. in 1925. The main product is the Varivolt: An On Load Stepless Voltage Variation Transformer, Continued>>

www.glass-international.com

GUIDE TO EXHIBITORS

AGR INTERNATIONAL INC.

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from 30 to 30.000 kVA, specially used in the glass industry, for Electric Furnace and Boosting. Turnover 13.5 M€ - Export sales more than 80%. Other products : I.V.R. (induction voltage regulators) – from 30 to 1.000 kVA Subsidiaries: Bernard Engineering: Industrial installation and commissioning services of Bernard Bonnefond equipment, expertise in electric boosting for glass furnaces Amppelec: Special Bus-Bars for high current (1.000 to 50.000 A) Contact : Philippe Bernard: 00.33.4 77 95 30 00 Fax : 00 33 4 77 95 78 06 philippe.bernard@bernardbonnefond.com www.bernardbonnefond.com

CAR-MET SRL

www.glass-international.com

Stand B11 Mr Mario Zanin Via Cavour, 9 31013 Cimetta Di Codogne’ - Treviso Italy Phone: +39 0438 794784 Email: info@carmetspa.it Website: http://www.carmetspa.it Since 50 years Car-Met dedicates its activity to the hollow glass, decorating and tempering industry, has been chosen to develop the own technology with the aim to improve the performances of the machines assuring always a lower consumption and offering to customers the highest technology available in the market.

Car-Met has the complete construction of its machines under its own control: design, structure, mechanical components, combustion installation, burners and the electrical installation are carried out inside the Italian plant. This system enables to control and assure the qualitative standard, makes possible the respect of the delivery terms, allows to have spare parts always available and to be always in the condition to satisfy customers’ requests.

CELSIAN GLASS & SOLAR BV Stand E09 Zwaanstraat 1 / building TZ 5651 CA Eindhoven Netherlands Phone: +31 40 249 0100 Email: infodesk@celsian.nl Website: http://www.celsian.nl/ Born out of TNO Glass Group and built on multiple years of high precision glass molding at Royal Dutch Philips. Since

2012 we are an independent company focusing on improving process efficiency at glass manufacturers worldwide. Our proprietary software models are used by our customers to optimise glass melting processes. Minimising costs for end users and environment. CelSian is 100% owned by First Dutch Innovations BV, a joint venture between First Dutch Capital (60%) and Dutch research organisation TNO (40%).

Our well trained, multi-disciplinary team is based in Eindhoven, The Netherlands and works worldwide on customer projects. We have worked on more than 30% of active furnaces worldwide. Implementation of our models have proven to optimise glass properties, deliver savings in energy and/ or increasing furnace lifetime. More than 1500 participants have joined our well known glass training course in Eindhoven, UK or USA. We also run GlassTrend, a platform for operating companies and institutions active in the field of glass and glass manufacturing. This consortium aims to continuously improve the competitive strength of the glass industry by organising knowledge sharing, network events and also managing pre-competitive projects.

date technology for Electric Furnaces, Forehearths and Boost Systems for all glass types, as well as Precision Control Bubblers and ancillary equipment, such as Glass Level Sensors, Throat Heating and Drain Systems. Our scope of supply includes design and specification, equipment supply and installation, plus commissioning of individual specialised equipment or complete system packages. All Electric Furnaces ranging from 200kg to over 250 Tonnes/day provide operating economy and glass quality assurance. High efficiency Convection Current Control Boost systems improve furnace pull and glass quality and enable significant tonnage increases with simultaneous reductions in electrical consumption. All Electric Forehearths for both volatile and non-volatile glasses offer substantial energy cost savings compared with other all-electric and gasfired designs. Electroglass high quality, insulated, water-cooled electrode holders are available for horizontal and vertical applications. Based in south east England we offer a global service to our customers in all five continents with local representation in many regions.

CHANGSHU JIANHUA MOULD TECHNOLOGY CO.LTD

EME GmbH

Stand D10 No.3 Zhong Tian (E)Rd Shajiabang Town, Changshu City Jiangsu Province 215559 China Phone: +86 512 52509323 Email: charles@jhmould.com Website: www.jhmould.com JH Mould is the leading mould maker (No.1) in China, Asia, since it acquired the OITianjin mould shop in 2014. The company has an automatic foundry, container, tableware and accessory mould shop.

Main mould supplier for world renowned companies like O-I, Verallia, Arc and Libbey.

ELECTROGLASS LTD Stand G01 Mr Richard A Stormont 4 Brunel Road, Manor Trading Estate, Benfleet, ESSEX, SS7 4PS United Kingdom Phone: +44 (0) 1268 565577 Email: info@electroglass.co.uk Website: http://www.electroglass.co.uk Electroglass is an independent specialist in all-electric glass melting, conditioning, electric boosting and related systems.

Based on decades of experience and ongoing technical development, Electroglass provides the most up to

Stand D03 Jens Rosenthal Wockerather Weg 45, 41812 Erkelenz Germany Phone: +49 2431 9618-0 Email: contact@eme.de Website: http://eme.de EME is a leading global supplier of batch preparation plants, cullet handling equipment and batch charging technology to the glass industry. Customised solutions ranging from single component supply to complex turnkey batch plants.

EMMETI S.p.A. Stand B12 Fabrizio Boschi Via G. Galilei, 29, 42027 Montecchio Emilia (RE) Italy Phone: +39 0522 861911 Email: emmeti@emmeti-spa.it Website: http://www.emmeti-spa.it Established in 1982, Emmeti is one of the leading suppliers of palletizers and

depalletizers to the global glass market.

The synergy between Emmeti and its associated company Sipac allows to offer a complete range of palletising, depalletising and conveying lines – either semi or fully automatic, sweeping or gripping, high or low level solutions. Emmeti can also design, in conjunction with Sipac, complete cold end and packaging lines manufactured, assembled and tested entirely at its own plant. Customers deal with one supplier only for the integration of all the equipments.

ERNST PENNEKAMP GMBH & CO. OHG Stand E04 Thorsten Seidel Königsfelder Str. 38-42 58256 Ennepetal Germany Phone: +49 2333 605 0 Email: info@pennekamp.de Website: http://www.pennekamp.de Pennekamp is the leading manufacturer of Lehrs, Handling Systems and Glass Coating. This refers to Container Glass, Float and Display Glass, Solar Glass and Automotive Glass Processing. The scope of supply includes: Container Glass Annealing Lehrs (Float, Solar & Display), Decorating Lehrs, Toughening Lehrs, Automotive Glass Processing, Servo Lehr Stackers (one to four axis), Ware Transfers, Water cooled segmented Cross Conveyors, Dosing Units, Cold End Sprays, Under Belt Sprays, Belt Cleaning Brushes, Burner Low Emission Unit (BLEU), Mould Oven.

EUROTHERM By Schneider Electric Stand E11 Christian Megret 6 chemin des Joncs - CS 20214 69574 Dardilly cedex France Phone: +33 (0)4 78 66 45 00 Email: christian.megret@schneider-electric.com Website: http://www.eurotherm.tm.fr For over 50 years Eurotherm by Schneider Electric have been at the forefront of power and process control in the glass industry, providing scalable, next-gen engineered solutions with fast return on investment​.

Based on our products, systems and services, our solutions are specifically designed to optimise energy and operational efficiency from end to end, with the flexibility to buy what you need now and expand later. Eurotherm have developed a Continued>>

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YES, THERE REAL REALLYY IS A

A400.4

UV50

2560 m3/h 4 bar(g) 250 kW

3240 m3/h 450÷0.5 mbar(a) 90 kW

AIR COMPRESSOR

VACUUM PUMP

UV SERIES VACUUM PUMPS

BETTER SOLUTION FOR COMPRESSED AIR AND VACUUM SUPPLY IN HOLLOW GLASS PLANTS

low cost of operation

A SERIES AIR COMPRESSORS

Capacity up to 5120 m3/h at 2.5 to 10 bar(g).

Low maintenance, negligible repairs, high energy savings, and high reliability make this the least costly long-term solution available today. Typical ROI when replacing other systems is 12-18 months.

simple, reliable, durable

first class support

easy to install and run

tested & proven worldwide

Capacity up to 6480 m3/h at 450 to 0.5 mbar(a).

Direct coupling means few moving parts, low rotation speed, low temperature. This virtually eliminates repairs and ensures superior reliability and longevity.

Ready-to-use turnkey system with optional Variable Speed drive and heat recovery. No foundation or water needed. Compact footprint.

Each unit comes with system engineering and a 5-year performance guarantee.

Service by Pneumofore-certified technicians is available anytime.

Dozens of leading glass plants have chosen Pneumofore rotary vane units over liquid ring or screw pumps. The results are crystal clear: high energy savings, steady, trouble-free performance, and of course, slashed costs of operation - over decades.

In operation at Allied, Ardagh, Canpack, Consol, Gallo, Gerresheimer, HNGI, O-I, Sisecam, Verallia, Vidrala, Wiegand and more.

SINCE

Pneumofore SpA • Via N. Bruno 34, Rivoli, 10098, Italy • +39 011.950.40.30 • www.pneumofore.com

1923

SWISS ENGINEERING ITALIAN DESIGN GLOBAL PRESENCE

ISO 9001 ISO 14001 CERTIFIED

Glassman Europe-Lyon Catalogue

range of scalable power control solutions ideal for the efficient operation of high energy glass processes. From advanced power control, best of breed transformers and expertly designed system layout, to intelligent burner control, the methods and technologies used help prevent unnecessarily high energy costs, fines and taxes, and offer a cost effective way to increase furnace productivity in a stepwise manner.

FAMA Stand F01 Keramos 225 pte, Colonia del Prado, Monterrey Mexico Phone: +52 (81) 8863 2822 Email: ventasfama@vitro.com Website: www.fama.com.mx FAMA has more than 70 years of experience serving the glass industry. Now we expand our products and services worldwide offering integral solutions for glass manufacturers. We have a specialised workforce and high quality standards and services that will bring solutions to enhance our customers’ success into their operations. Our wide range of products and services can be classified into five categories: Moulds, Machinery, Special Equipment, Automation and Engineering Services.

www.glass-international.com

FIC UK Limited

Stand D01 Mr S C Hakes Longrock Industrial Estate Penzance, Cornwall TR20 8HX United Kingdom Phone: +441736366962 Email: general@fic-uk.com Website: http://www.fic-uk.com F.I.C. (UK) Limited design and supply allelectric furnaces as well as electrical boosting systems for a wide range of glass types and manufacturing processes including TFT, float, fibre, container and borosilicate. We have a wide range of electrode holders including our High ‘Q’ holder in which the cooling circuit is replaceable in under 10 minutes, and our Maxi ‘Q’ holder in which there is no weld inside the furnace refractory blocks making it ideal for more aggressive glasses. We can supply all-electric forehearths offering major energy savings as well as other glass

conditioning options such as our Isothermal unit for glass conditioning in the forehearth or distributor to eliminate top-to-bottom and side-to-middle temperature differences.

This system will significantly improve thermal homogeneity in coloured glasses and high productivity forehearths in flint glass. We also offer heat extraction systems to extract heat from the glass to aid glass conditioning and reduce gas consumption by the use of removable water-cooled tubes. In addition, these water-cooled tubes can be used to prevent premature shutdown of a furnace by rendering safe worn refractories.

These systems are particularly effective in extending throat life.

FLAMMATEC Stand D01 Petr Vojtech Rokytnice 60, 755 01 Vsetin Czech Republic Phone: +420 571 498 566 Email: info@glammatec.com Website: http://www.flammatec.com FlammaTec, spol. s r.o. (Czech Republic) and its daughter company FlammaTec GmbH of Germany have become leading suppliers of advanced burner technology for glass furnaces. FlammaTec was founded by two partner companies (STG Combustion Control GmbH & Co KG, and Glass Service, a.s.) as a joint venture. The long term know how of how to supply optimal and flexible heat into the glass can be found back in the advanced burner concepts. After eight years since its start in 2008, FlammaTec has already supplied well over 2500 burners to over 120 projects on float, container, tableware and special glass furnaces. Such a strong reference clearly shows the benefit of this innovative combustion technology that offers high performance solutions to the FlammaTec customers. FlammaTec burners improve heat transfer from combustion to the glass melt and thus also improve furnace efficiency and lower emission when replacing conventional burners. FlammaTec offers the following advanced LoNOx burner types: • Underport Gas Injector, Flex or Freejet • Underport Gas/Oil Dual Injector, Flex of Freejet • Underport Heavy Oil Injector (also can be used for backup solutions) • Sideport Gas Injector, Flex • New Oxy/Gas Burner

FUSIONTEC SRL

GLASS GLOBAL

Stand B09 Mr. Gilberto Volpato - President Via Mario Carraro, 9/11 36075 Alte di Montecchio Maggiore (VI) Italy Phone: +39 344 0468762 Email: fusiontec@fusiontec.eu Website: http://www.fusiontec.eu Fusiontec is a Revimac company founded with the purpose to integrate under one roof all activities related to the industrial manufacturing of refractory materials for furnace/working end, forehearths and feeder expendables. Revimac and Fusiontec may offer a complete package including high quality material refractories and equipment for the full control of the glass melting & conditioning process.

Stand AO2 Grafenberger Allee 277-287 40237 Düsseldorf Germany Phone: +49 211 2807330

GIANCARLO PEREGO SPA Stand C09 Michele Giordano Via Marchesina, 58 Trezzano S/N - Milano Italy Phone: +39 02 48400060 Email: gperego@gperego.it Website: http://www.gperego.it Giancarlo Perego Spa, founded in 1964 by Mr. Giancarlo Perego, is now a day one of the major molds makers for glass industry.

With a covered area of more than 12000m2 , divided in two production plants, one in Trezzano S/N(MI), Italy, and a second one in Hum Na Sutli, Croatia, the company is selling its products all around the world with a huge presence in all continents.

The significant investments made by G.Perego Spa during the last year allowed to the company to be independent from subcontractors. G.Perego Spa today produces all moulds and accessories internally, being able to constantly check its own quality step by step. With the support of the completely renewed Croatian plant, G.Perego Spa has a capacity of 4500 cavities per month, almost 50000 per year. Our technical department is constantly close to our customers driving them to innovative solution in terms of drawings and materials. Our focus is to continuously help our clients to speed up the production processes and increase the ‘pack to melt’ that we consider as a fundamental indicator of glass production efficiency, and consequently one of our target. G.Perego Spa acts as a mould maker, but thinks as a glass manufacturer.

GLASS INTERNATIONAL MAGAZINE

Stand C11 Quartz House 20 Clarendon Road, Redhill Surrey RH1 1QX United Kingdom Phone: +44 (0)1737 855000 Email: glass@quartzltd.com Website: http://www.glass-international.com ​Glass International offers readers the latest news from across the hollow, container, flat, and speciality glassmaking industry and is the official media partner for the global Glassman events.​The magazine focuses on industrial, economic and environmental issues affecting the industry and includes articles discussing the latest developments and challenges in glass manufacturing.

Regular features comprise of global news and events, company and country profiles, and previews and reviews of important industry conferences and exhibitions.​

Glass Machinery Plants & Accessories Stand K14 Luciano Molina Via Antonio Gramsci 57 20032 Cormano Italy Phone: +39-02-66306866 Email: luciano.molina@glassonline.com Website: http://www.glassonline.com Glass Machinery Plants & Accessories, is an international magazine dedicated to the hollow and special glass industry.

GLASS SERVICE Stand DO1 Erik Muijsenberg Rokytnice 60 755 01 Vsetin Czech Republic Phone: +420 571 498 511 Email: INFO@GSL.CZ Continued>>

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GPS GLASPRODUKTIONSSERVICE GmbH Stand A06 Klaus Pöting Ruhrglasstrasse 50, 45329 Essen Germany Phone: +491608408514 Email: poeting@poeting.de Website: http://www.gps-essen.com Machines IS, du feeder, machines, servo pousseur, machine conveyeurs, stacker, arche, jusqu’au bout froid.

H​ enry F. Teichmann, Inc. is celebrating its 70th year of services to the glass industry.

Since 1947, our engineering, technical service, purchasing, construction and project management teams have been committed to providing turnkey services for batch plants, complete glass plants, electric furnaces, container glass furnaces, float glass furnaces, fiber glass furnaces, foam glass furnaces, sodium silicate furnaces, pressed glass melting services, TV glass furnaces, hand glass processes, tableware and lighting products. E.W. Bowman, a world famous annealing lehr manufacturer also based in the Pittsburgh area of USA, is now part of HFT. Together, HFT and E.W. Bowman will provide more turnkey solutions to the glass industry worldwide.

HEYE INTERNATIONAL GMBH IRIS INSPECTION MACHINES Stand C01 Jens Langer Lohplatz 1 31683 Obernkirchen Germany Phone: +49 5724 26 452 Email: sales@heye-international.com Website: http://www.heye-international.com We are Glass People. Heye International, based in Obernkirchen, Germany is one of the foremost suppliers of production technology, high performance equipment and know-how for the container glass industry worldwide. Our mechanical engineering has set the standard in the industry for more than 50 years. The industry expertise, attitude and enthusiasm of the employees of Heye International form the motto “We are Glass people”.

The three sub-brands HiPERFORM, HiSHIELD and HiTRUST form Heye International’s portfolio.

HORN GLASS INDUSTRIES AG

HENRY F. TEICHMANN INC.,

Stand C12 Daniel Chen 3009 Washington Road McMurray, PA 15317 United States Phone: +1-274-941-9550 Email: dchen@hft.com Website: http://www.hft.com

solution partner for the worldwide glass industry. With its abroad subsidiary companies in Czech Republic, India, Malaysia and China, Horn match the glass industry requirement for local and fast activities. With its more than 130 years of experience in glass melting, Horn has a wide range of experience in the design, manufacture and supply of different furnace types for production of lighting ware, tableware, containers, cast glass, float glass, solar glass and technical glassware.

The range of products and service not only includes utility equipment such as combustion systems, electric control equipment as well as modern process controlling with SCADA systems of the highest standard, to name but a few, but also the design engineering and site service.

Stand C10 Yvonne Walker Bergstrasse 2 Germany Phone: +49963692040 Email: y.walker@hornglas.de Website: http://www.hornglass.com Horn Glass Industries AG, a German specialist in the design and supply of complete glass melting technology is a

Stand E01 Jean-Luc Logel Z.I. du Chêne 14 rue du 35ème Régiment d’Aviation 69500 Bron France Phone: +33 (0)4 72 78 35 27 Email: contact@iris-im.com Website: http://www.iris-im.com Iris Inspection Machines is a leading provider of turnkey sorting solutions for glass containers of any shape or colour, including wine, beer, jars, liquor and Champagne bottles, pharmaceuticals, perfumes and food containers. A team of dedicated Research and Development engineers has evolved a performing range of equipment to match the industry’s demanding requirements and satisfy the quality needs of key international brands.

Iris Inspection Machines is known for its Evolution 12 sidewall and sidewall stress inspection equipment, for its Evolution 5 base, base stress, finish and mould reader machine. But Iris has recently introduced two new items dedicated to the perfume, high value liquors and flaconnage industries. Evolution Ultimate for transparent defects and Evolution Dim for precise dimensional on line. The company has based its development on a long-term partnership with glassmakers in the field of glass defects detection, as well as on an exceptional know-how in the most innovative vision technologies. Iris was the first to develop and propose a 12 camera inspection machine. The success of Iris is due not only to the exceptional efficiency

of its Evolution machines range but also to the excellent support provided by engineers worldwide.

Lahti Precision Oy

Stand H07 Jarmo Näppi Ahjokatu 4 A, P.O.B 22 Finland Phone: +358 3 829 21 Email: sales@lahtiprecision.com Website: http://www.lahtiprecision.com Companies of all sizes all over the world have selected Lahti Precision as their supplier of batch plants, cullet recycling systems, waste fibre glass recycling systems, engineering studies, and plant modernisations. With over 200 references, everyday more than 50,000 tons of raw materials are processed with the aid of Lahti Precision’s technology to be melted to the highest quality standards required for float glass, bottles, strong reinforcement fibers, warm insulation wool, flat TVs, LCD panels, bright tableware, and various other glass products

MARPOSS SAS Stand G03 Eleonora Bordin ZAC de la Madeleine 3,5,7 Rue de la Tuilerie, 77500 Chelles, France E-mail: bologna@it.marposs.com www.marposs.com Marposs is a world leader in the supply of gauging systems for dimensional and geometric inspection for industrial environment.

Thanks to its 65 years of experience, metrology know-how and its wide range of products, Marposs is able to give an answer to any gauging necessity by providing measurement components, benches or measuring machines up to fully automated lines.

Marposs is headquartered in Bentivoglio (BO), Italy and is present in 34 countries, in 25 countries with its own sales and service network and in nine countries with agents/ distributors.

The group has 3,100 employees.

300 service engineers, located in the various branch offices worldwide, provide immediate and qualified assistance to Continued>>

www.glass-international.com

Website: http://WWW.GSL.CZ Glass Service (GS), headquartered in the Czech Republic with offices in the Netherlands, USA, China and Slovakia, is a leading consultant in the field of glass melting, furnace control, operation, troubleshooting, and optimising furnace designs. GS programmers have developed in-house mathematical modeling software enabling the optimisation of glass melting and combustion processes in glass furnaces and forehearths. More than 700 different projects have been completed using GS software. Presently a new version of furnace modeling software (GFM 5.0) is being developed. GFM 5.0 uses a new generation of non-orthogonal mesh which enables proper representation of all geometric features and local refinement. GS has its own laboratory for glass defect analysis and analyzes more than 2,000 defects yearly.

Additional testing capabilities utilise basic and applied research in the field of glass melting, GS has invested considerable effort into developing a new technology called a “Supervisory Advanced Control System” using our proprietary software known as the Expert System - ESIIITM. More than 155 installations have been successfully deployed worldwide. GS supplies high quality selected raw materials to the glass industry.

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customers, including: • Machine tool makers; • Gauge and fixture makers; • Automotive industry and their suppliers; • Glass industry; • Aerospace industry; • Electronic industry.

Marposs has been operating in the glass industry for over 20 years providing products and applications for dimensional and geometrical inspection of: • Automotive glass; •Glass containers (for food, pharmaceutical, cosmetic and perfumery); • Glass for applications in the solar energy sector.

Regarding glass containers inspection, Marposs can provide both reconfigurable measuring systems, using contact sensors (Quick Set), and flexible measuring systems (VisiQuick), mainly based on non-contact technology, to be used in the laboratory or near production line Quick Set is a reconfigurable bench for measuring: • External diameters; • Straightness of the labelling area.

VisiQuick is a flexible and modular machine that can include several measuring stations to carry out the following controls on the containers: • External dimensions non body neck and finish, height, verticality, bent neck; • Inner mouth diameter and profile; • Weight; • Push-up; • Glass thickness.

www.glass-international.com

MESSERSÌ PACKAGING Stand E03 Denis Pizzera Via I Maggio,8 Italy Phone: +39071963861 Email: denispizzera@messersi.com Website: http://www.messersi.com Messersì Packaging, a leading company in the packaging market, established its position into the market with the production of PP and PET strapping band and with a complete range of packaging machines: automatic and semi-automatic strapping machines, wrapping machines, hooding machines, thermo-shrinking system and complete packaging lines. Over 35 years of product and service quality Messersì is the partner that comes up with new construction concepts for just the right, most effective, high-performance and sustainable solutions. Messersì is a byword for the conceptual and cultural innovation of industrial packaging, customized for

any production line, any manufacturing and logistic sector, in all time zones, in all continents. Messersì presents itself to its customers as a single point of contact for the supply of machines and/or automatic packing, handling, storage and logistics systems for the ceramic industry. The whole process is managed in-house, from the offer to the design stage, from production to installation. Our values: - Customisation - Sustainability - Quality - Technology Flexibility - Customer care systems for all types of manufacturing, logistics and supply chains, machines and lines that complete the end-of-line functions – packaging and storage.

MOTIM FUSED CAST REFRACTORIES LTD Stand C07 Timföldgyári utca 9-13 9200 Mosonmagyaróvár Hungary Phone: +36 96 574 284 Email: corundum@motim.hu Website: http://www.motim.hu/ Motim Electrocorundum Ltd. manufactures electrofused mineral products. The total production capacity is approximately 50.000 tons. The White Fused Alumina gives more than the 50% of the product structure. One of the main fields of application is the abrasive industry, which uses grits classified according to the FEPA international standards for the production of abrasive paper and cutting and grinding wheels as well as other abrasive tools. This product is also used on the field of sand blasting where it is used as the blasting media. The other user’s circle is made up of the costumers who are manufacturers of shaped and unshaped refractory solutions designed mainly for the steel and foundry industries. The additional products – Fused Mullit, Zircon Mullit and Spinell grits – are typical raw materials in the fields of refractory industry and ceramic industry.

The mentioned application areas represent our traditional target market, however in our product structure the tailor made products, manufactured according to the unique demands of the special applications, are more and more significant, such as investment casting, laminate boards, kiln furniture for the IT industries, dental applications, cosmetic industry etc., and this tendency makes the continuous technological development even more reasonable.

NIKOLAUS SORG GmbH & Co. KG

Stand D03 Dr. Hartmut Hegeler Stoltestrasse 23 97816 Lohr am Main Germany Phone:+49 093525070 Email: hegeler@sorg.de Website: http://www.sorg.de Sorg has been serving the glass industry continuously since 1872. Together with our group of companies, we offer total solutions from raw material delivery through glass conditioning with the services to keep our equipment running long and reliably. Sorg solutions provide our customers the lowest total cost of ownership over the life of their investment. Sorg is the leading worldwide supplier of glass melting and conditioning technology, engineering, equipment and services for float, containers, flat glass, fibers, tableware, solar glass, etc. We serve customers in over than 70 countries.

Innovations include a new burner mount to make burner adjustments simple. This eases optimal combustion setup with the minimum amount of NOx emissions. The integrated angle adjustment setting allows easy adjustment of the burner angle via hand spindles or optionally with a motor from the furnace control room. Come to our booth D03 to learn more.

PARKINSON-SPENCER REFRACTORIES LTD Stand C02 Simon Parkinson Holmfield Halifax, HX1 2QD United Kingdom Phone: +441422254472 Email: admin@parkinson-spencer.co.uk Website: http://www.parkinson-spencer.co.uk Parkinson-Spencer Refractories Ltd is a leading supplier of refractories and engineered solutions to the glass industry.

We can serve almost all sectors of the glass industry but our primary business is in the container, tableware and flacconage sectors. Our heritage is in refractory manufacture and we specialise in the production of bonded refractories for the feeder, forehearth and distributor. As the only licensee of Bucher Emhart Glass

we are one of the leading suppliers of feeder expendable refractories for the glass industry. Our forehearth channel blocks, distributor glass contact blocks, superstructure refractories and insulating materials comprise the complete refractory assembly for the forehearth and distributor.

Our engineered products and services, combined with our refractory manufacturing capabilities, provide the complete package for the glass conditioning process, an offering which makes us unique in our sector of the glass industry. Our System 500 forehearth, designed and developed to achieve optimum results in glass thermal homogeneity and fuel consumption, is at the forefront of glass conditioning technology.

Our control and combustion systems provide the perfect accompaniment to this equipment. Our PSR Cord Dispersal System is the only guaranteed solution to the ‘cat scratch’ cord defect with over 170 successful installations to date.

PICVISA Stand A05 c/Isaac Newton, 2 08280 Calaf (Barcelona) Spain Phone: +34 93 801 7610 Email: info@picvisa.com Website: http://www.picvisa.com Picvisa Machine Vision Systems, S.L. is an innovative SME with a technological base, specialized in machine vision technology and manufacturing optical sorting equipment.

The company offers solutions for glass recycling and reprocessing using optical sorting technologies. More than 15 years experience in the European markets, in the US and in Brazil. The technology developed

by Picvisa can also be used for plastic, paper and metal separation. The company has been awarded a major European grant under the R & D program H2020 for the development of artificial vision solutions for the extraction of glass contained in municipal solid waste. Therefore, the installation of its continuous material recycling test line has been recently completed, which allows to improve and confirm recovery rates in individual material streams or mixed streams, such as MSW.

Continued>>

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Glassman Europe-Lyon Catalogue

PNEUMOFORE

Stand E06 Mr. Rolf Hilfiker Via N. Bruno 34, Rivoli Italy Phone: +39 011.950.40.30 Email: info@pneumofore.com Website: http://www.pneumofore.com Founded in 1923, Pneumofore manufactures vacuum pumps and air compressors for industrial applications worldwide and supplies the hollow glass industry with centralized vacuum and compressed air systems, designed for the pneumatic requirements of the IS machines. With references such as O-I, Verallia, SGD, Ardagh, Gallo and many more, Pneumofore compressors and vacuum pumps are found worldwide, whenever customers require extraordinary reliability and constant performance. Leader in rotary vane technology, Pneumofore solutions focus on efficiency, durability, minimal Life Cycle Cost, and high environmental respect.

Products At Glassman Europe 2017, the company presents the UV Series vacuum pumps, ranging in capacity from 250 to 6480 m3/h with 0.5 mbar(a) residual pressure, and its latest market entry: the A400, the world’s largest, single-stage, air-cooled, rotary vane air compressor. This unit has 250 kW of nominal power for a capacity of 2560 m3/h and pressures from 2.5 to 10 bar(g). As for all the compressors of the A Series, which ranges from 67 to 2560 m3/h, several options are available, like the VS drive, remote control or connection to any PLC system. Each option facilitates heat recovery and air cooling even in harsh environment up to 50°C.

POCO GRAPHITE

www.glass-international.com

Stand A08

At Glassman, Poco Graphite will display precision ware handling solutions and unique Glassmate graphite materials that improve performance in container glass production, reduce machine downtime and increase yields. Poco is known for its designs, particularly precision holders and inserts that allow fast accurate machine setup and insert replacement. Standard steel holders are available in several types and sizes. Inserts are available as semi-finished blanks, or can be precision machined to a specific finish. Application specialists can assist in the selection of the optimum graphite grade based on pickup, application, and length of the production run. Featured products will be Poco’s new Interior Locking Spring System (ILS) 18 and 22mm holders, which significantly reduces foreign object debris and targets smaller bottle manufacturing.

Stand G06 54 Route de Brignais, 69630 Chaponost France Phone: +33 0437253464 Email: jf.vasta@proteis.eu Website: www.proteis.eu Proteis is specialised in the field of instrumentation, industrial and laboratory equipment. With the help of our partners we have selected and developed product ranges, solutions and services that can bring real benefits: - Improve process quality and traceability, productivity, plant reliability, reduce costs as well as minimise maintenance costs.

- Improve energy performance, reduce environmental impact and reduce emissions - Compatibility of our solutions with FDA standards 21CFRpart11, NADCAP, AMS2750 - Environmentally friendly maintenance and surface treatment products compatible with ISO14000 - Recovery and recovery of waste heat

Stand C05 Werkzeugstrasse 19-23, Hagen North Rhine-Westphalia, 58093 Germany Phone: +49 2331-3501-0 Email: info@reckmann.de Website: www.reckmanngmbh.com

containers manufacturers in the world by supplying a wide range of machinery and equipment in the hot-end area. Revimac is the founder of Fusiontec, born with the purpose to integrate under one roof all activities related to the industrial manufacturing of refractory materials for furnace/working end, forehearths and feeder expendables. Revimac and Fusiontec offer a complete package including high quality material refractories and equipment for the full control of the glass melting & conditioning process.

SIEMENS AG

RENOLD GMBH - TOOTH CHAIN

PROTEIS

RECKMANN GMBH 300 Old Greenwood Road Decatur, Texas 76234 United States Europe: Poco Graphite, SARL 1 rue des Vergers 69760 Limonest France Phone: USA +1 940 627 2121 Europe: +33 (0)4.72.52.00.40 Email: pocoeu_sales@entegris.com Website: www.poco.com

Platinum Thermocouples Quality “Made in Germany”. With more than 45 years of experience and with 185 employees we are one of the leading manufacturers of temperature sensors. We are specialised in the production of high quality thermocouples for the glass industry: + Thermocouples PtRh-Pt type S/R and B + Various designs (customized) for all applications (Forehearths/Feeder/Stack/ Crown) + From single up to triple elements also with platinum thimble made of alloy (PT10%Rh) or specifically stabilized platinum DPH + Recycling of waste (old platinum) + Buying of old platinum + Best prices. Test us!

Stand B08 Uwe Gillert Zur Dessel 14 D-31028 Gronau (Leine ) Germany Phone: +49 5182 587-24 Email: Uwe.Gillert@renold.com Website: http://www.renoldtoothchain.com Renold GmbH is a subsidiary of Renold plc, a leading international manufacturer and supplier of industrial chains and related power transmission products with more than 140 years of experience, 23 locations and more than 2000 employees. The brand Renold Tooth Chain stands for well over 100 years of experience in the field of tooth chains, worldwide distribution and innovations, expertise for drive and transport technology in field of glass production and processing the 2-pin rolling pivot joint and the laser welded axle pivot in plates as an unique selling point with a high customer benefit and technological leadership in the field of drive and conveyor tooth chains.

REVIMAC S.R.L. Stand B09 Mr.Pietro Agnetti - Export Manager Via Mario Carraro, 19 36075 Alte di Montecchio Maggiore (VI) Italy Phone: +39 0444 493494 Email: pietro.agnetti@revimac.com Website: http://www.revimac.com Revimac belongs to the Bottero group of companies. The company boasts an experience of 28 years with the major glass

Stand F02 Pascal Huguet 360 rue Louis de Broglie 13593 Aix-en-Provence France Email: Pascal.Huguet@siemens.com Website: http://www.siemens.com/glass Siemens AG (Berlin and Munich) is a global technology powerhouse that has stood for engineering excellence, innovation, quality, reliability and internationality for more than 165 years. The company is active in more than 200 countries, focusing on the areas of electrification, automation and digitalization. One of the world’s largest producers of energy-efficient, resourcesaving technologies, Siemens is a leading supplier of efficient power generation and power transmission solutions and a pioneer in infrastructure solutions as well as automation, drive and software solutions for industry. The company is also a leading provider of medical imaging equipment – such as computed tomography and magnetic resonance imaging systems – and a leader in laboratory diagnostics as well as clinical IT.

SINEX INDUSTRIE SAS Stand G13

Stéphane Parant 6 route de Claix 16400 La Couronne France Phone: +33 613553851 Email: stephane.parant@sinex-industrie.com Continued>>

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Glassman Europe-Lyon Catalogue

SIPAC S.p.A. Stand B12 Fabrizio Boschi Via Berettinazza, 25 43010 Fontevivo (PR) Italy Phone: +39 0521 611811 Email: sipac@sipac.pr.it Website: http://www.sipac.pr.it/ Sipac designs and produces bottle and package conveying systems, accumulating solutions, elevators, lowerators, lane dividers, optical detection system for noround or special container orientation and other package transportation systems.

Sipac and Emmeti, together, can provide full service engineering, manufacturing and commissioning of production lines, as well as any type of revamping lines, in order to best suit the customers’ demands. Along with the systems designed and produced by Emmeti, Sipac can incorporate equipment from sub-suppliers for turnkey projects.

SOMEX Stand B07 Brian O Keeffe Udaras Industrial Estate Ballyvourney, Macroom, Co. Cork, Ireland Phone: +353876682919 Email: bokeeffe@somex.ie Website: http://www.somex.ie Manufacturer of automated instruments for Glass container manufacturers, ‘On Line’ or Laboratory, Internal Pressure Test, Pendulum Impact, Vertical Top Load, Internal Volume/Capacity. Our instruments have been validated and are used by most of the large glass container manufacturers.

We recognize our customers operate in a cost sensitive industry, Somex is trusted by our customers for providing value for money instruments and reliable after sales support. If you are upgrading existing inspection equipment or considering future automation projects for inspection equipment I would look forward to

discussing, we are exhibiting at Stand B07, I look forward to meeting you there - Brian O Keeffe, CEO.

STARA GLASS S.P.A Stand G04 Piazza Rossetti, 3A/1 Genova, 16129 Italy Phone: +39 010 576391 Email: staraglass@hydragroup.it Website: www.staraglass.it Turn-key installations - Manufacturing plants engineering: - Design for glass furnaces - Hybrid systems for heat recovery Supply: - Supply of refractory - Supply of facilities and equipment - Automation and process control Research and development: - NOx Reduction - Combustion optimisation - Flue gas recirculation services: - Construction and demolition of furnaces - Heating up and hot maintenance - Combustion optimisation and endoscopies - Commissioning and start-up - After sales: - Spare parts - Customer care - Custom training.

TEMPSENS GERMANY PROTEIS Stand G06 (See Proteis)

VAN PUTTEN INSTRUMENTS BV Stand B02 Pascal van Putten Buitenwatersloot 335 2614 GS Delft Netherlands Phone: +3115 2131580 Email: pascal.van.putten@vpinstruments.com Website: https://www.vpinstruments.com VPInstruments offers customers easy to use compressed air flow meters, gas flow meters and industrial energy monitoring solutions. Our proprietary three-in-one bidirectional flow meters offer you the most complete solution for compressed air and gas flow measurements. Our products can be found in many industrial production plants, for example glass production, food and beverage, automotive, pharmaceutical.

Get real time insight in your energy consumption with our energy monitoring software. Use our compressed air flow meters to check consumption of machines, allocate costs and monitor leakage level.

Discover where you can save 10 to 50% on your energy bill.

VIDROMECANICA Stand C04 Ricardo Barreto Rua Central Nº22 Garcia 2430-017 Marinha Grande Portugal Phone: +351 244 555 060 Email: vidromecanica@vidromecanica.com Website: http://www.vidromecanica.com Vidromecanica manufactures equipments for the glass industry since 1984. Development, design & manufacture of machinery and development of the control system for the glass production lines is handled by our specialists. In close cooperation with our customers and glass industry businesses, we are engaged in the development of individually tailor-made high performance machines. We have shpplied over 1000 machines in 60+ countries. Vidromecanica’s main equipments are: Annealing and decorating lehrs, Belt tempering lines for tableware, Spindles toughening lines for stemware, Chemical tempering machines, Special glass thermal treatment ovens, Moulds pre-heating kilns, Servo-stackers, Hot-end coating hoods, Cold-end coating spraying systems, Thermal Shock Machine, Scraper conveyors, Cullet crushers, Cullet processing plants.

VMA GMBH Stand F03 Fred Vogler OT Wuembach, Graefinauer Strasse 2 98704 Wolfsberg Germany Phone: +49367855870 Email: fred.vogler@vma-online.de Website: http://www.vma-online.de/ VMA - Your specialist for optical and noncontact measuring techniques in the glass industry. At Visuelle Messtechnik und Automatisierung (VMA) based in Wümbach, Germany, we have more than 50 years of experience in the glass industry and develop innovative solutions and state-of-the-art technology. Our highly qualified engineers develop optoelectronic measuring and test systems used in the production of container glass and flat glass all over the world. We also offer special customised solutions for all your glass requirements e.g the production of tube glass and rolled glass. Our systems incorporate optical, non-contact measuring technology that reliably detects thin areas in the glass without leaving any traces. VMA products also reduce your workload because our systems do not require time-consuming recalibration, even after continuous use. We adapt our systems to your plant equipment

according to your wishes and can even train your personnel. We offer an on-site service for system installation and provide rapid assistance should you have any problems or questions.

ZECCHETTI SRL

Stand E02 Miriam Garimberti Via Galileo Galilei, 1-1/A 42027 Montecchio Emilia (RE) Italy Phone: +39 0522 867411 Email: m.garimberti@zecchetti.it Website: http://www.zecchetti.it Zecchetti proposes Conveying/Palletising turnkey lines for empty glass containers, from Lehr discharge up to finised pallet warehousing. The lines can cope with almost all kinds of articles and with a very wide range of speeds. The long experience and the cooperation with the biggest glass factories has located Zecchetti among the worldwide leader manufacturers. The ability to propose, manufacture and supply the AS/RS Warehouse system as well, allows Zecchetti to act as unique supplier for the complete empty container cold end section.

Peculiar feature of Zecchetti is to aim at making Customer’s life easier, namely by studying with them and then realising solutions “Made-to-Order”.

ZIPPE INDUSTRIEANLAGEN GMBH Stand H01 Alfred-Zippe-Str. 11, 97877 Wertheim Germany Phone: +49 9342 8040 Email: zippe@zippe.de Website: http://www.zippe.de Zippe has dedicated all activities to the international glass industry. Acting as a partner in the area of melting material preparation, the design, manufacturing, installation and commissioning of plants, on turnkey basis if required, Zippe offers: Batch Plants - Automation - Modernization - Engineering - Factory Cullet Recycling - Glass Recycling - Batch Charging Glass Level Controlling - Preheating Maintenance & Service

www.glass-international.com

Website: http://www.sinex-industrie.com Sinex Industrie is specialised in the design and manufacture of vibrating equipment dedicated to glass industry. We design tailored solutions for composition (vibrating extractors and vibrating dosing units) and cold-end lines (vibrating plates). The vibrating extractors and dosing units are used for mastering a volumetric flow under silos/hoppers. The vibrating plates are used for mastering a smooth transfer for your unstable glass containers between the lehr belt and the cross conveyor. ​

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

Our employees are practical, conscientious, and experienced in every phase of the glass industry. As a result of our clients’ successes, we have become recognized worldwide as one of the largest independent – Engineers and Contractors to the Glass Industry.

The key to the success in turnkey projects is to seamlessly integrate ...

• Engineering • Procurement Services • Construction Services • Project Management • Annealing Lehrs

Annealing Lehr Manufacturer E.W. Bowman, Inc. is now part of Henry F. Teichmann, Inc.

Engineers and Contractors to the Glass Industry 3009 Washington Road

•

McMurray, PA 15317-3202

+1 724 941 9550

Fax: +1 724 941 3479

info@hft.com

•

USA

www.hft.com

Air compressors

Control systems, forming

Feeder mechanisms

Pneumofore VP Instruments

BDF Industrie Spa GPS Glasproduktions-Service GmbH Remivac Srl

BDF Industrie Spa GPS Glasproduktions-Service GmbH Nikolaus Sorg GmbH & Co. Kg Remivac Srl Sinex Industrie Sas

Ampoule/vial forming machinery Renold GmbH - Tooth Chain

Annealing lehrs/kilns Car-Met Srl Ernst Pennekamp GmbH & Co OHG Henry F Teichmann Inc Vidromecanica

Batch chargers BDF Industrie Spa Electroglass Ltd EME GmbH Horn Glass Industries Ag Lahti Precision Oy Zippe Industrianlagen GmbH

Batch plant EME Gmbh Henry F Teichmann Inc Lahti Precision OY Picvisa Zippe Industrianlagen GmbH

Control systems, hot end Glass Service GPS Glasproduktions-Service GmbH Parkinson-Spencer Refractories Ltd Reckmann GmbH VMA GmbH

Control systems, cold end VMA GmbH

Control systems, melting BDF Industrie Spa Bernard Bonnefond Electroglass Ltd FIC UK Ltd Glass Service Nikolaus Sorg GmbH & Co. Kg Reckmann GmbH

Cullet handling systems

Coatings, hot/cold end

EME Gmbh Lahti Precision Oy Picvisa Vidromecanica Zippe Industrianlagen GmbH

Antonini Srl Vidromecanica

Decorating equipment, hollow glass

Combustion equipment

Car-Met Srl Ernst Pennekamp Gmbh & Co Ohg Renold GmbH - Tooth Chain Vidromecanica

Car-Met Srl Flammatec Fusiontec Srl Nikolaus Sorg GmbH & Co. Kg Parkinson-Spencer Refractories Ltd Remivac Srl

Container forming machinery/components BDF Industrie SPA FAMA GPS Glasproduktions-Service GmbH Heye International GmbH Poco Graphite Renold GmbH - Tooth Chain Remivac Srl

Engineering/plant design services EME Gmbh FAMA FIC UK Ltd Henry F Teichmann Inc Lahti Precision Oy Nikolaus Sorg GmbH & Co. Kg Picvisa Zippe Industrianlagen GmbH

Flat glass production machinery Renold GmbH - Tooth Chain

Forehearth assemblies Electroglass Ltd FIC UK Ltd Fusiontec Srl Horn Glass Industries Ag Nikolaus Sorg GmbH & Co. Kg Parkinson-Spencer Refractories Ltd

Gases, industrial VP Instruments

Handling & packaging equipment, cold end All Glass Srl Emmeti Spa Ernst Pennekamp Gmbh & Co Ohg GPS Glasproduktions-Service GmbH Sinex Industrie Sas Sipac Spa Zechetti Srl

Handling equipment, hot end Heye International GmbH Poco Graphite Renold GmbH - Tooth Chain Remivac Srl Sinex Industrie Sas

Inspection equipment, flat glass VMA GmbH

Inspection equipment, hollow glass AGR International Inc FAMA Heye International GmbH Iris Inspection Machines Somex

Continued>>

www.glass-international.com

GUIDE TO PRODUCTS & SERVICES

Glassman Europe-Lyon Catalogue

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Glassman Europe-Lyon Catalogue

Lehrs, annealing/ decorating

Project management services

Antonini Srl Car-Met Srl Ernst Pennekamp Gmbh & Co Ohg Henry F Teichmann Inc

Henry F Teichmann Inc Horn Glass Industries Ag Lahti Precision Oy

Car-Met Srl Ernst Pennekamp Gmbh & Co Ohg Poco Graphite Sinex Industrie Sas Vidromecanica

Melting furnaces Bernard Bonnefond Electroglass Ltd FIC UK Ltd Horn Glass Industries Ag Nikolaus Sorg GmbH & Co. Kg

Mould maintenance equipment Changshu Jianhua Mould Technology Co. Ltd FAMA Gianfranco Perego Spa

Oxy-fuel technology Flammatec Henry F Teichmann Inc Nikolaus Sorg GmbH & Co. KGg

Palletisers All Glass Srl Emmeti Spa

Plant utilities

www.glass-international.com

Horn Glass Industries Ag Pneumofore VP Instruments

Raw materials Fusiontec Srl Picvisa

Refractories Fusiontec Srl Motim Fused Cast Refractories Ltd Parkinson-Spencer Refractories Ltd

Technical assistance/ training EME Gmbh Flammatec Gianfranco Perego Spa Henry F Teichmann Inc Heye International GmbH Parkinson-Spencer Refractories Ltd Poco Graphite

Temperature measurement equipment Ametek Land (Land Instruments International) Glass Service Nikolaus Sorg GmbH & Co. Kg Reckmann GmbH

Trade publications Glass International Glass Machinery Plants & Accessories

Picture courtesy Pixabay

Lehr loaders/unloaders

Turnkey glass plant construction

Pollution control systems

Henry F Teichmann Inc Horn Glass Industries Ag Picvisa

Flammatec

Vacuum Pumps

Process control equipment

Pneumofore VP Instruments

AGR International Inc FIC UK Ltd Glass Service Heye International GmbH Lahti Precision Oy Nikolaus Sorg GmbH & Co. Kg Reckmann GmbH Zippe Industrianlagen GmbH

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Events world: Furnace Solutions

Global delegates attend Furnace Solutions conference and training More than 100 delegates from around the globe attended this year’s annual Furnace Solutions event, including Glass International’s Greg Morris.

www.glass-international.com

T

he combined conference and training day in the UK saw delegates attend from Japan, Turkey, USA, Germany and the UK where they heard a variety of papers about the use of furnaces in glassmaking.

Delegates were from furnace suppliers and glass manufacturers and included technology suppliers such as Parkinson Spencer Refractories, Teco, Zippe, Fives Stein, CelSian, and FIC UK as well as glassworks such as Verallia, Stolzle Flaconnage, Drujba Glassworks, Beatson Glass, Allied Glass, Bormioli Luigi, Guardian Glass, Nippon Electric Glass and Ardagh Glass.

More than 100 people attended the event, which was once again held at Lucideon, Stoke-on-Trent, UK. Sisecam’s Corporate Energy and Environmental Manager, Tunc Goruney, won the Michael Garvey award for the best paper at the conference.

His paper, titled Pushing the Envelope of Waste Heat Recovery in Oxy-fuel Tableware Furnaces, outlined a project at Sisecam’s 200 tonne per day furnace in Targovishte, Bulgaria.

The project was co-funded by a €1.7 million grant from the European Commission LIFE programme and also included a technology partner, Air Liquide.

His paper discussed waste heat recovery from an oxy-fuel furnace via the implementation of reactant preheating technology.

The technology has already been validated by several applications to extend the benefits of oxy-fuel combustion in tableware and float furnaces.

Mr Goruney reported up to 8% natural gas savings and in excess of a 90% NOx reduction compared to an end-fired regenerative air-fuel furnace.

Michael Garvey was a former Guardian Glass engineer who tragically died in a climbing accident just days after the 2008

� Michael Garvey award winner Mr Tunc Goruney (left), with Melting Technical Committee Chairman, Nigel Longshaw.

Furnace Solutions event.

There were 11 papers throughout the day-long conference, each of 30 minutes duration.

Glass Futures The conference had started with a joint-

presentation from Dr Richard Hulme of Guardian Glass and Dr Nick Kirk of Glass Technology Services (GTS). They spoke about the Glass Futures project in the UK, which is a not for profit Continued>>

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Events world: Furnace Solutions

organisation created and owned by the glass community.

The £20 million project will be based at the Magna site in Rotherham, UK. Dr Kirk told the audience that the project is the brain-child of the British Glass association and its aim is to provide a facility that will be a centre of glass excellence and deliver R&D, innovation training and up-skilling.

“It is a global platform for growth, innovation and training for the whole glass community,” said Dr Kirk. “It is an ambitious project that is making progress,” he added.

of glass per day for windows, bottles and fibre glass.

The furnace will have two feeds for both flat and container glass investigation.

Dr Hulme said the project was for the industry by the industry. It would provide the industry with an opportunity to try out new ideas without risk to production.

Dr Hulme said: “In many ways Glass Futures is an extension of the Society of Glass Technology itself. We want people to talk together and discuss common problems and find common solutions.

They can compete in the marketplace on

� More than 100 delegates attended Furnace Solutions this year. Photo credit: SGT

we would like to, furnaces are very complex and some of the things we’d like to isolate, we cannot do very easily. Glass Futures can help us reduce the risk of development.”

Dr Kirk said Glass Futures is an innovation, technology, and training and research centre all in one. It is a space where academia and industry can bridge the gap and work together. It is somewhere where new products and processes can be developed on an industrial scale and where the British Glass decarbonisation roadmap of 2050 can be delivered.

“We also hope to help develop the next generation of glassmakers here. How do we make the industry more exciting? We are competing against the aerospace and automotive industries for example in high-tech engineering so we have to make our industry exciting.”

It will offer apprentieships in batch and furnace, forming and in surface coating.

It will also provide Virtual Reality to help provide training with IS machines, for example.

Although based in the UK the two speakers emphasised that the centre will be available for use by the entire global glass industry.

About £5 million in funding has been secured from the UK government. The site is planned to open late next year.

� Mr Richard Stormont, Electroglass Managing

� Martina Jezikova, of Glass Service.

Director.

It is backed by a consortium of glassmakers and suppliers including Owens-Illinois (O-I), Encirc, Guardian Glass, Teco, Siemens, Leeds University Hallam University and Swarovski.

At the heart of the project will be an oxy-fired furnace producing 30 tonnes

service and price, but can sort out the technology and the science together.”

Guardian operates 26 float lines around the world and the cost of lost production is high. This cost limits what it can do when it wants to try new technology.

“We can’t always do the experiments

Yakup Bayram of US company PaneraTech discussed how radar-based sensors could optimise furnace life. An abridged version of his paper appeared in Glass International’s June issue, page 40.

He discussed how radars had evolved from applications in military defence, to detecting cancers, to use in the glass industry.

PaneraTech, alongside industry partners, has pioneered the use of radarbased sensors to measure refractory thickness and detect early stage glass leaks into sidewall and furnace bottom insulation.

Radar technology is a non-invasive technology, he said, that operates from outside the furnace to determine wall thickness and assist manufacturers in maintaining their furnaces in order to increase life span.

The company’s technology had been validated with blind trials at container, float and tableware furnaces.

Horn COO of R&D Technology Continued>>

www.glass-international.com

Radar technology

71 Glass International July/August 2017

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Events world: Furnace Solutions

Christoph Jatzwauk discussed Furnace Design and Equipment for Extended Furnace Life. The performance of modern furnaces in Western Europe is optimised to almost its maximum.

The potential for further improvement to increase the efficiency of furnaces is low. Various solutions have been discussed to increase furnace efficiency, one of those is the construction of a mega end-fired furnace. He used the example of a 175m2 melting area furnace of up to 700 tonnes per day. The furnace is fuelled

by LNG, HO and Petcoke and has four boosters of 1500kVA. It has several special features. For example the flue gas channels in the basement of the regenerator are not situated in the end face but on the sides, similar to a cross-fired furnace.

Previous Michael Garvey award winner Joaquin de Diego, of Praxair, gave an update on the company’s Optimelt technology.

Mr de Diego won the award at Furnace Solutions 2015 for his paper about the Optimelt technology in use at Pavisa’s plant 50 tonnes a day furnace in Mexico.

The technology uses conventional regenerators and endothermic reforming reactions between fuel and recycled flue gas to recover flue gas exhaust heat Now the Optimelt thermochemical regenerator process is being implemented in Libbey tableware manufacturer’s plant in Leerdam, The Netherlands, supported by a LIFE grant from the EU. An abridged version of his paper appears as an article in this issue, page 75.

www.glass-international.com

Regenerators Fosbel’s Business Unit Director for Europe, Joe Mackintosh, discussed Regenerator Maintenance. The regenerators are the heart of a furnace and as such are a vital part of the overall glass melting process.

He described how there has been a move in recent years to maximise furnace life and extract as many benefits from the furnace as possible. This has placed a stress on regenerators, as well as other parts of the furnace. Fosbel has put together a series of solutions to the common problems seen on regenerators as they age.

These include wall replacement, crown over-coating, chequer top cleaning, blockage removal, by-pass installation and re-packing. Mr Mackintosh described how some of the problems can be addressed. A technical article from Mr Mackintosh, which addresses these issues, can be found in this issue, page 86.

� Praxair’s Mr Joaquin de Diego.

Electrical melting Electroglass Managing Director Richard Stormont discussed Electrical Energy in Glass Melting and Conditioning. His paper explained some of the reasons why electric melting and conditioning systems are widely used despite the apparent cost differential. Electricity is expensive and in most regions of the world electricity might be between two and four times the cost of gas or oil, per unit of energy. So what are the benefits of using electricity as a source of energy in glass melting and conditioning processes? The key factor is process energy efficiency. In almost every fuel-fired furnace, more energy is lost to the environment in direct losses from the furnace structure and heat lost in the combustion gases, than actually goes into melting the glass. In a coldtop all-electric melter, there are no combustion gases and associated losses, and heat losses through the batch blanket and furnace superstructure are low, with typical superstructure temperatures of little more than 100oc. This in particular is where production unit size and furnace

� Fosbel’s Mr Joe Mackintosh.

capacity are extremely important. A typical 250 tonnes per day fuel-fired furnace might have a thermal efficiency of at best say 45%. That is, 45% of the total energy input goes into melting the glass and 55% is lost. However, in a small fuel-fired furnace of say 30 tonnes per day capacity, that thermal efficiency may drop to 20 or 25%. In other words, 75-80% of total fuel energy input is lost, making melting energy cost per tonne of glass very high. A well-designed 250 tonnes per day all-electric melter will have a thermal efficiency of about 85%, with only 15% of heat energy input being lost. As furnace size decreases the energy efficiency of electric melters remains high, and a welldesigned 30 tonnes per day all-electric melter will still have a thermal efficiency of over 70%.

Looked at another way, for a furnace of 250 tonnes per day capacity a fuel-fired furnace may use twice as much energy as the same size of electric melter. In simple terms of energy cost alone, if electricity is more than about twice the cost of fuel per unit of energy, a fuel- fired furnace of this size is likely to be the economic choice.

For smaller furnaces, often appropriate for tableware, cosmetics containers and other more specialist products, the picture is different. For a furnace of say 20 tonnes per day capacity, a fuel-fired furnace may use approaching four times the amount of energy than the same size of electric melter. As a rough guide, where the cost of electricity per unit of energy is about three times the cost of the same amount of gas energy or less, then purely on the basis of melting energy costs, electric melting is likely to be the economic choice for furnaces up to around 40 tonnes per day.

Other papers were given from the Czech republic’s Glass Service, Holland’s CelSian, France’s Sefpro and by Mark Bennett of Ametek Land, who discussed Infrared Temperature Measurement in the Glass Melt Tank. He described a new Near Infrared Boroscope which provides a truetemperature radiometric image, so live temperature values can be obtained from >324,000 pixels. An abridged version of this paper is in this issue, page 41.

The Furnace Solutions papers are now available from the Society of Glass Technology’s (SGT) website, www.sgt.org (log-in required). �

The next Furnace Solutions training day and conference is due to take place on June 6 and 7, 2018 at the same venue. www.furnacesolutions.co.uk for details.

72 Glass International July/August 2017

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28/07/2017 10:33:54

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Furnaces

Optimelt set to reduce emissions at Libbey’s oxy-fuel fired furnace J. de Diego*, H. Kobayashi**, S. Laux , and M. van Valburg and G. Wijbenga*** discuss the implementation of Praxair’s Optimelt system at Libbey’s Leerdam plant in The Netherlands. The system was originally installed at Pavisa’s container glass site in Mexico with successful results, as published in a paper in Glass International May 2015 by U. Iyoha.

Hot syngas to furnace Endothermic reaction to syngas (CO and H2) Preheating of mixture Injection of natural gas into flue gas recirculation

� Fig 1. Optimelt reforming process.

� Fig 2. Optimelt oxy-syngas flame at Pavisa, Mexico.

First glass production startup Boost the regional economy with 5.0 millions

Improvement of the knowledge and skills of Libbey’s team

Oxy-fuel furnace rebuild

2017

Most energy efficient large scale glass furnace of its kind worldwide

45-60% less CO2/year 25-35% less Nox/year

First reductions in energy consumption and air emissions Optimelt implementation

2018

45-60% energy less used for the process

2019

� Fig 3.Optimelt project timeline at Libbey Leerdam.

Its Optimelt TCR system is similar in the cyclic operation to conventional air-heating regenerators, but unique in its design to combine the conventional preheating step with a thermochemical reforming process without using a catalyst.

An industrial scale Optimelt system has been installed at the Libbey Royal Leerdam plant in The Netherlands to

reduce energy costs in the glass melting process and to address future stricter environmental reduction requirements.

The project is partly funded by the European Union under a Life grant.

Continued>>

www.glass-international.com

L

ibbey Holland (Royal Leerdam) has been at the forefront of new technology implementation to ensure competitive and sustainable production, based on the Vereniging van Nederlandse Glasfabrikanten (Dutch Glass Maker Association) roadmap ‘Routekaart 2030’.

By cooperating with technology providers, Libbey has pursued its goal of increased glass furnace efficiency and reduced emissions.

Because of the strict emissions legislations on NOx, SOx, and particulates3-4, there is a need for CO2 emissions reduction to meet the Paris Climate Accord goal for a carbon neutral environment by 2050.

Due to the unpredictable outcome of the ETS system development period after 2020, a pro-active approach is required.

The conversion of air-fuel furnaces to oxy-fuel combustion is generally known to improve furnace energy efficiency and reduce natural gas consumption.

Recovering waste energy from oxyfuel flue gas has the potential to further improve energy efficiency and to reduce the operating costs of oxy-fuel glass furnaces.

Praxair’s Optimelt thermochemical regenerator (TCR) heat recovery system provides a compelling solution to maximise the heat recovery from oxyfuel fired glass furnaces, to improve energy efficiency of the furnaces, and to minimise furnace emissions.

75 Glass International July/August 2017

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Furnaces

.6

0.8

JL Burner TCR

0.9 kg/t

0.8 Nox range OPTIMELT TCR and Praxair JL Burner

0.6 0.4 0.2 Projected range for L1 (air leak max 268Nm3/h)

0.0 0

5

10

15

20

0.6

All sulfates (Oxy)

25

30

� Fig 4. Projected NOx emissions at the Leerdam site.

Optimelt recovery process1-2 The heart of the technology is to recover waste heat by the well known endothermic reforming reactions of methane with steam and carbon dioxide in regenerators, Fig 1.

Hot flue gas from the oxy-fuel furnace is directed to a regenerator chamber to heat and store heat in the checker pack and is cooled to about 650°C before exiting the regenerator.

A portion of the cooled flue gas is then recycled, mixed with natural gas and introduced at the bottom of a second regenerator. This mixture absorbs energy stored in the refractory checkers.

When the gas mixture is heated above a certain temperature, various endothermic chemical reactions occur at atmospheric pressure to form ‘syngas’ containing hydrogen, carbon monoxide, soot and other hydrocarbons without the need of a catalyst. The reformed gas or syngas leaves the regenerator at the top and is combusted with oxygen in the furnace.

The ability to upgrade the energy content of the natural gas fuel into higher energy-content hot syngas results in fuel savings of about 20% to 30% compared to conventional oxy-fuel and regenerative air-fuel furnaces, respectively.

TCR-Syngas burner design The oxy-syngas burner produces a bright and luminous flame due to a high concentration of soot in the syngas.

The burner is designed to provide an adjustable temperature profile in the combustion space by using separate injection of oxygen jets. By using the deeply staged combustion concept, NOx emissions are reduced and a long flame can be obtained to avoid hot spots over

35

40

fu r

Particulate (Oxy) (EPA) Na2SO4 (Oxy)

0.5

ce

na

ur

f xy

1.2

O

Particulate (Oxy) (Europe) (EPA Method 5)

0.4

0.8

0.3 0.2 0.1

0.0

0.5

1.0

1.5

2.0

2.5

nge

ected ra

gas proj

TCR-syn

0.0

N2 in the furnace (% wet or 1 kPa partial pressure)

www.glass-international.com

0.7

lg/short ton-glass

NOx emission (kg/t or 1/2lb/ston)

1.0

Particulate emissions, g/kg-glass

A Burner

Ai r

1.2

na ce

Particulate (Air) (EPA)

0.0 3.0

3.5

4.0

Specific pull, ton /(day m )* (* corrected for tpd by electric boost) 2

� Fig 5. Projected particulates emissions at Leerdam. the glass/batch surface near the burner.

The direction and the velocity of each oxygen jet are carefully designed to avoid flame impingement in the batch area and to keep a low gas velocity over glass melt to minimise batch carry over and alkali vapour volatilisation. Fig 2 shows a picture of the syngas flame in the 50tpd furnace at Pavisa, Mexico.

Reduced energy and emissions at Leerdam The project timeline for the industrial scale Optimelt system being installed at Libbey Royal Leerdam is in Fig 3.

The new oxy-fuel furnace is designed to operate either as the standard oxy-fuel fired furnace or as the oxy-syngas fired furnace with the Optimelt TCR. The furnace will start as the oxy-fuel fired furnace in mid-2017 and this furnace operating condition will be optimised first. The TCR operation will start about three months later and the performance evaluated over one year.

Natural gas savings and CO2 reduction

The Optimelt system fuel savings are, in general, about 20% relative to the oxyfuel baseline without heat recovery, but vary +/- 3% depending on the glass type, cullet ratio, furnace type, furnace age and furnace size.

At Leerdam, the projected energy reduction and associated CO2 emissions reductions are about 45-60% compared to the existing recuperative air combustion furnaces. Compared with air fired regenerative furnaces about 28% fuel savings are expected for furnaces less than 150 tpd and about 30% for furnaces greater than 300 tpd at the mid furnace campaign.

NOx Emissions NOx emissions depend on burner type selection (staged versus unstaged), air leakage control (sidewall cooling, batch charger openings, peepholes openings and furnace maintenance), fuel and/or oxidant nitrogen content and niter used in the batch.

Projected NOx reductions will be in the range of 25 - 35% lower than currently and well below the target value of 0.9kg/ ton.

The Optimelt TCR burner system uses the deeply staged combustion process and has demonstrated low NOx emissions at Pavisa’s1 50 TPD furnace in Mexico, even with high N2 concentration in the furnace atmosphere.

Fig 4 shows NOx emissions from oxyfuel fired container glass furnaces. Green data points show measured NOx emissions at different N2 partial pressures(*) in the furnace and the light green band shows the projected NOx emissions as a function of % N2 concentration in the furnace at sea level. (*Note: Due to the high elevation of Mexico City the atmospheric pressure is only about 0.76 atmosphere. The N2 concentration of 30% wet corresponds to 23kPa at Pavisa.)

Dutch natural gas contains a high nitrogen concentration of about 13% and the projected furnace N2 concentration ranges from 10 to 16% wet depending on the amount of air leakage into the furnace at Leerdam.

In spite of the relatively high N2 concentration in the furnace NOx emissions below 0.6 kg/t are projected.

Continued>>

76 Glass International July/August 2017

Praxair.indd 2

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Furnaces

Furnace

Oxy-fuel

Pull (stpd) 210

Cullet

Colour

(%) 40

flint

SO2 SO2 Notes (lb/ston) (kg/t) 0.41

0.21

after filter

1.60

0.80

filter bypassed

Oxy-fuel 366

60 green 1.63 0.82

Oxy-fuel

158

50

flint

0.76

0.38

flue port sampling

Oxy-fuel

279

50

flint

0.65

0.33

flue port sampling*

Oxy-fuel

342

25

flint

0.97

0.49

Air-regen

342

25

flint

0.92

0.46

Air-regen

419

20

flint

3.54

1.77

*0.65, 0.88lb/t in separate stack measurements

� Table 1. SO2 emissions from container furnaces.

www.glass-international.com

Particulates emissions Alkali vapour volatilisation is the main cause for particulates emissions and silica crown corrosion.

Typically 80 to 90% of particulates emissions are sub-micron particles of Na2SO4. Furnace and burner designs are known to make large differences on the alkali volatilisation rate and particulates emissions.

Preventing high local glass surface temperature and high gas velocity over the glassmelt by proper furnace and burner designs are key factors controlling alkali vapour volatilisation and particulate emissions.

In early furnace conversion projects from air fired regenerative furnaces (red data points) to oxy-fuel furnaces (yellow data points) about a 30% reduction in particulates emissions was measured.

Oxy-fuel furnace and burner designs have been improved since then with taller crown height and low gas velocity burners.

A 50% reduction on particulates emissions (data points in other colours) has been achieved in comparison with the emissions from earlier oxy-fuel fired furnaces.

The light green highlighted area in Fig 5 shows projected particulate emissions at the furnace exit under Optimelt operation based on CFD simulations.

The particulate emissions at the stack are controlled with a bag house at Leerdam.

SOx emissions Most sulphur emissions from the glass furnace are gaseous SOx emissions and approximately equal to the difference between the sulphate input into the furnace as the fining agent and the sulphur retention in the glass melt.

In a typical air-fired flint container glass furnace about one third of the sulphur input to the furnace comes out

as SOx emissions. Sulphur retention in the glassmelt depends on glass redox (i.e glass colour) and the amount of sulphate required for good fining reactions depends on the operation of the glass furnace.

Thus, many factors influence the ultimate emission of gaseous SOx5.

In oxy-fuel fired furnaces the higher water vapour pressure in the furnace atmosphere increases the water dissolution in the glassmelt, which in turn lowers the sulphate dissociation temperature and leads to a start of the fining reactions at a lower glassmelt temperature6.

Since dissolved water acts as a fining gas and enhances the fining reactions of sulphate in the glassmelt, it allows a reduction of the amount of other fining gases (mostly SO3 and O2) required for fining. Thus, the fining agent (Na2SO4) input amount is typically reduced by 20 to 30% under oxy-fuel firing to achieve the same level of fining.

By reducing the sulphate input under oxy-fuel firing sulphur emissions can be reduced.

Combustion conditions in the furnace also affect SOx emissions. Reducing atmosphere over glassmelt and flame impingement on the batch are known to cause dissociation of batch sulphate and to increase SOx emissions.

Table 1 shows measured SOx emissions from several glass furnaces. SOx emissions of 0.4 to 0.8 kg/ton are typically achieved without using sulphur scrubber/filter for flint glass under oxy-fuel firing.

Conclusion Praxair’s Optimelt thermochemical regenerator heat recovery system provides a compelling solution to minimise furnace emissions and maximise heat recovery from glass furnaces, and to improve furnace energy efficiency.

The system combines preheating and endothermic chemical reactions to

recover waste energy from the flue gas and to produce a hot syngas stream which has about 1.2 to 1.3 times the heating value of the natural gas fed into the bottom of the regenerator.

This technology has been in operation on a commercial 50 tpd container glass furnace in Mexico since late 2014 and is now being implemented on a larger tableware furnace at Libbey Leerdam in The Netherlands.

A 45 to 60% reduction of CO2 emissions compared to the existing recuperative furnaces is projected. NOx, CO, SOx and particulates emissions are also expect to be reduced.

References 1. A Gonzalez, E Solorzano et al , ‘Optimelt Regenerative Thermo-Chemical Heat Recovery for Oxy-Fuel Glass Furnaces’, 75th Conference on Glass Problems, November 2014.

2. U. Iyoha et al, ‘Thermochemical Regenerator System Proves Itself at Pavisa’, Glass International May 2015, pp 29-30.

3. SJVUAPCD (2011), ‘Glass Melting Furnaces’, Rule 4354, Amended, May 19, pp 4354-5 to 4354-6.

4. ISSN 1977-0677 (2012), ‘Official Journal of the European Union’, L 70, English Edition, Volume 55, 8 March, p 19.

5. H. Mulller-Simon, K. Gitzhifer, “Sulphur massflow balances in industrial glass melting furnaces”, Glass Technol.: Eur.J.Glass Sci. Technol. A, April 2008, 49 (2), 83-90.

6. H.Kobayashi, R.G.C. Berkens, Fifth conference on advances in the fusion and processing of gas, 1997, Toronto, Canada.

*Corporate Fellow at Praxair Euroholding, Madrid, Spain. **European Manager Combustion Market Applications, Praxair, Danbury, CT, USA. ***S. Laux, M. van Valburg and G. Wijbenga of Praxair and of Libbey Holland, Leerdam, The Netherlands also contributed to this article. sho_kobayashi@praxair.com joaquin_de_diego@praxair.com Praxair Inc. Danbury, CT, USA, Web: www.praxair.com/ Royal Leerdam,Libbey Holland, Leerdam, The Netherlands, www.libbey.com

78 Glass International July/August 2017

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Furnaces

Larger capacity all-electric furnaces Andy Reynolds* discusses the opportunities for electric glass furnaces in container glass melting, stating that electric furnaces of up to 300 tonnes a day are likely.

� Fig 1. All-electric furnace system (cold-top vertical melting).

example, with glasses exhibiting volatile constituents (borosilicate), when no fossil fuel is available; or when local emission regulations add unacceptable cost to pollution control.

The view that electric melting is ‘environmentally cleaner’ is true only if the carbon cost of electricity generation is low, and in many parts of the world generating electricity still produces sufficient carbon to determine that it is environmentally cleaner on a ‘global basis’ to melt glass by burning fossil fuel in the furnace. But things are changing – and quickly. In parts of the world, wind and solar power generation is tipping the balance in favour of electricity.

This is true in parts of Europe and the US, and in other countries impacted positively by the percentage of electrical power generated by nuclear means.

And what about on a ‘local basis’? Here things become interesting: Regional or on-site power generation by renewable means may result in a local producer seeking to use electricity. Several large glass plants in Europe are installing their

own wind turbines (often supported by local environmental initiatives). In such cases using excess power internally may be more interesting than selling it back to the national grid.

Fossil fuel reserves are not unlimited.

Even with the temporary reprieve provide by shale gas, over the coming decades the cost of gas and oil must rise. With the growth of renewable power, electricity cost will (in relative terms) fall. At some point, in the not-too distant future, electricity will become the favoured and dominant primary energy source for glass melting – it is inevitable.

Capacity limitations All-electric furnaces tend to currently be applied to ‘special’ glasses’ i.e. higher value with lower capacity requirements including borosilicate, high-quality cosmetic, tableware, opal and technical glasses such as high-alumina coverglass. In these markets, furnace sizes are restricted by production requirements Continued>>

www.glass-international.com

T

he future is bright, the future is clean, will the future be electric for container glass melting?

As suppliers of electric melting technology and all-electric furnaces we are often asked what maximum capacity is technically possible for an all-electric furnace. The standard answer is ‘there is no technical limit’. Perhaps this answer is too simplistic because there are challenges to constructing and operating large all-electric furnaces.

The breakthrough for electric melting technology will come when it can be considered economically viable for larger scale container production (where, of course, air-gas and oxy-gas technologies dominate today) and this requires that all-electric melting technology proves its technical credentials for furnaces in the range of 100 to 300 tonnes per day (tpd) and perhaps above.

In most parts of the world, electricity prices versus those of gas or oil still governs that all-electric melting is only considered viable when technical considerations take precedence. For

81 Glass International July/August 2017

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Furnaces

Temperature oC 1260 1280 1300 1320 1340 1360 1380 1400 1420 1440

Check-current-density 0.25 0.50 0.75

1450

1250

1

0

� Fig 2. Current density is concentrated at elec-

� Fig 3. CFD modelling of convection currents

trode tips.

inside an all-electric furnace.

3.OE-01 2.SE-01

Melt (%)

2.OE-01 1.SE-01

1.OE-01

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5.OE-02

of course, in all cases, as the melt area increases, opposing electrode separation increases.

If the separation between ‘firing’ electrodes increases, then the electrical resistance is higher and applied voltages must increase. High voltages are not desirable but can be managed with appropriate safety precautions so in pure technical terms this cannot be considered as a restriction to size.

Positioning electrodes in the furnace bottom is also possible and allows electrodes to be brought closer together even in large furnaces. However, such configuration is only suitable for lower quality glasses requiring less refining because convection currents driven by localised heating near electrodes will extend to the furnace floor, thus diminishing residence times.

0.OE+00

0

2.1856

� Fig 4. CDF modelling of a concept rectangular

0

50

100 150 200 250 Residence time (h)

300

350

� Fig 5. Residence times for CFD concept model.

electric furnace.

rather than technical limitations, common furnace capacities range from 10TPD up to 100TPD with melt areas up to 50m2. Fibre and cellular insulation applications may warrant larger melt areas (the largest supplied by Fives Stein to date is 75m2 (160TPD). Large container all-electric furnaces of >200TPD have been built but with mixed results.

Assuming the economics of energy costs can be resolved, what is the largest all-electric furnace possible and what would it look like? In preparation for the time when the opportunity presents itself, Fives Glass has potential solutions.

Melt area

www.glass-international.com

A common design philosophy on power systems for electric melting is to position opposing pairs of electrodes (or groups of electrodes) connected on each end of the secondary transformers coils.

The electrodes are placed on opposite

sides of the melting chamber ‘fire’ across the tank. Heating is the result of the Joule effect applied against the resistive load of the glass melt.

All-electric furnaces are often hexagonal (or round) to allow balanced 3-phase power systems with phases connected 120 degrees to each other.

Rectangular and square furnaces are also used with a variety of connection configurations – all have the same philosophy of opposing electrode groups ‘firing’ across the glass melt.

Electrodes can be installed horizontally (through the sidewalls), over-thetop of the sidewalls, or vertically/ inclined through an intermediate shelf structure (Fig 1). This means

Electrode heating effect It is significant that the electrical heating effect is concentrated around electrode tips (Fig 2) not distributed evenly across the conducting melt, a consequence of high electrical current density at the electrode/glass interface.

The resulting hot-spots drive strong convection currents. It is these that are the primary mode of heat transfer through the body of the melt (rather than by the Joule effect itself).

Intuition would suggest that in large furnaces, central regions may suffer from a lack of heat. This is not the case – at lease up to quite large areas. CFD modelling indicates that in a hexagonal shelf-type configuration, convective forces remain strong to the central region of the chamber even when electrodes are placed significant distances apart (Fig 3).

The central region of the furnace attains the required

� Fig 6. One solution to large scale production requirements (a modular approach).

Continued>>

82

Fives to use.indd 2

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Furnaces

temperature distribution and melt-rate remains within acceptable narrow ranges. This configuration has been applied successfully

by Fives to 40m2 (melting high-quality glass) and we are confident that a furnace of 60m2 and higher will achieve the same result.

As an aside, it should be noted that there are electrode power connection options, which do not ‘fire’ across the tank but instead around it between adjacent electrodes. It is counterintuitive not to ‘pass current’ through central regions of the furnace.

Since the main mode of heat transfer is via convention the heating effect is similar. This mode of connection can also lower the applied voltages required.

Residence times In fuel-fired furnaces, the glass melting processes occur in the horizontal sense, the division between melt and refining parts is established with thermal barriers, bubblers and even physical obstructions (weir walls for example). The aspect ratio of the furnace can be extended to lengthen the separation between charging point and throat. Short cuts to the throat can thus be prevented.

In cold-top vertical melting it becomes more difficult. Whatever the melt area, at some point on the glass surface batch sits directly above the throat and introduces the potential for short-cuts from the underside of the batch layer directly to the throat.

Electrode orientation and the use of wall structures such as shelves can play a part in creating barriers in the vertical glass flow (a break in the flow currents is clearly visible in Fig 2).

Increasing glass depth will help – although it should be appreciated that short cuts are possible even in deep furnaces if poorly designed. Fig 4 shows a CFD model of a concept rectangular furnace designed to study the problem under different modes of operation; an unwelcome short cut shown in the particle trace exhibits itself as an undesirable ‘peak’ early on the residence time curve (Fig 5).

In the 40m2 application mentioned above the furnace glass depth extended to almost 4m. Such a depth brings design challenges such as control of glass ingress into critical joints particularly around the throat, although these are surmountable.

Larger furnaces, whether hexagonal or other shape, may need to be even deeper depending on quality requirements.

Fives is considering the implications of depths in excess of 5.0m, perhaps utilising double-shelf arrangements.

The future What if large hexagonal or rectangular furnaces prove too difficult?

There is another obvious solution – the modular approach. There is already a proven melting ‘module’ with a capacity of 100TPD. It is known that with modern control and monitoring systems two such modules could be operated side by side to produce identical output melt characteristics, so why not link them together to produce one large system.

Multiple melting production lines are not new (particularly in fibre production) – applying it to large scale production requirements for higher quality glass type is more innovative (Fig 6).

Such an arrangement offers possibilities for maintenance and rebuild programmes allowing parts of the system to be repaired on the run. So, 100 to 300TPD all-electric furnaces are not just possible, they are probable and soon. �

*Managing Director, Glass, Fives Group, Didcot, UK www.fivesgroup.com

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Furnaces

Regenerating the Regenerators Joe MacKintosh* describes how regenerators are the lungs of a furnace and a vital part of the glass melting process. He describes the many innovations to maximise heat recovery and make furnaces more efficient.

S

ometimes regenerators are overlooked when furnaces are considered but they provide an amazing service, allowing higher melting temperatures to be achieved leading to greater output.

Coincidentally, as more stress is applied to the regenerators, life expectancy can diminish. If the regenerators fail the furnace cannot continue to operate without remedial action.

The trend over the last 10-15 years has been to push furnaces to the limit of their economic life. This means to the point where either the cost of maintenance is prohibitive or thermal efficiency or glass quality become compromised.

Couple this with the need for more tonnes from the same melting area and it presents a challenge to those companies offering any type of repair service. The result is that more innovative solutions have been developed to answer the call.

Traditional repair techniques are considered here as well as recent innovations as they apply to the regenerators. Put simply a regenerator is a large box filled with heat transfer medium. There are two possible failures areas – the containment can be breached or the heat transfer medium can collapse.

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Structure repair The structure can be treated both internally and externally. The major weak areas are the crown and the upper walls all of which are exposed to the highest temperatures in the regenerator (about 1350°C).

The flow of gases in the regenerator never ceases (except for a few seconds at reversal) and gas velocity across a surface is a factor that leads to corrosion. In addition to this there are ‘dead’ areas in the corners of the chamber where the gas flow is almost zero, which can lead to an accumulation of alkalis in these areas subsequently promoting corrosion.

Material choice for the upper walls and crown also plays a part in the process.

Hanging bricks installed and area being consolidated using ceramic welding

Completed repair

� Regeneration crown hole repair.

Most chambers are either magnesite or mullite and several are built from silica.

Much depends on the type of furnace and the glass being made – container or float. Each design has a balance of positive and negative properties all of which are considered when the original furnace is built. The various materials also bring different problems to bear. Recent times have seen a number of furnaces suffering from ‘saddle-back’ regenerator crowns and this has been attributed mainly to inferior creep resistance of the refractories used in the construction.

In an end port regenerator, the dividing wall between two regenerators is the only wall in the entire furnace which does not have a cold face.

This makes it susceptible to creep (permanent deformation) and one of the main symptoms of this is a sinking of the wall followed by a sinking of the crown skews. This leads to the all-too-familiar saddle shape of the crown. Once this occurs it is impossible to reverse and the only recourse is to rebuild the crown.

Typical damage to the upper areas of the chamber includes holes in the structure, general wear of the walls and crown and destabilisation of the target walls.

Holes in the structure can be repaired using a variety of conventional techniques including hanging bricks for larger holes, patch material for sealing and Ceramic Welding for a more permanent repair.

As with any repair the first step is to define the extent of the damage. Then

the various options for repair can be listed and an economic evaluation given to each possibility. Factors such as the life time required, cost, the impact on production etc are all considered to reach a final decision. Based on the desired result, the required repair can be undertaken.

Examples come from both ends of the repair spectrum.

One repair was for a hole in the regenerator crown of a furnace due for rebuild four months later. An extensive and costly repair did not make sense so a quick application of gunning material enabled the hole to be sealed and the furnace continued in production without problems up to the scheduled rebuild.

A second example was of a regenerator, silica crown which had thinned considerably (it was about 50mm thick over more than 50% of the surface area).

In this case the customer wanted a more lasting repair so we elected to overcoat the entire crown using a zircon patch material. Additional skew channels were installed above the existing skews and the crown was overcoated from side to side to a thickness of 150mm. This created a self-supporting structure once the zircon material had bonded at temperature. The furnace went on producing good glass for a further five years.

Occasionally the target walls can become unstable. Large furnaces are particularly susceptible to this because Continued>>

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Furnaces

Repairing the checkers A major challenge is to repair the checker work or packing area of the regenerator.

Although structurally simple (it is essentially dry bricks piled on top of each other) it plays a vital role in the furnace operation, providing extra energy to ensure melting temperatures can be achieved. This structural stability is an advantage and disadvantage.

On the plus side removing checkers from the top of the pack is straightforward and with the correct tools the bricks can be replaced. But trying to remove bricks from the lower levels of the regenerator can lead to a complete collapse of the checkers above.

Cleaning rather than repairing is a common strategy to prolong the life of the checkers. This is usually achieved by thermal means.

Either the furnace is fired from one direction for extended periods to effectively overheat one side of checkers, or burners are set at the bottom of the checkers to heat them from below. The main concern with this type of procedure is the risk of overheating and damaging the rider arches, which are critical components supporting the entire pack.

A less intrusive procedure has been developed by our Italian partner that involves sand-blasting, from below, the debris from individual chimneys.

Once enough chimneys have been cleared then the natural heating from the furnace will help to clear adjacent chimneys. The whole process is controlled using water-cooled cameras extended into the chimney. This prevents damage being incurred in sensitive areas.

The technique has been used widely throughout Europe and continues to be refined and improved.

Sometimes the checker pack is beyond cleaning and a more radical approach is required. If the damage is in the top few

layers it is possible to create access holes using a chainsaw. Then, with watercooled plates and hooks, the offending areas can be cleared, ensuring that the debris does not block the chimneys below. This method has been used when inferior bricks have been laid in the top settings and deteriorated. As mentioned previously, using the correct tools it is possible to reset the top layers providing the brick quality allows this.

As we move down the chamber the challenges increase in complexity and require careful planning before an attempt at intervention.

One ingenious technique actually allows the middle section of the checkers to be repacked while leaving the top section untouched.

Furnace operators are aware of the condensation zone in the checkers, where the alkalis and sulphates carried in the waste gas, come out of their gaseous form and create viscous and corrosive glasses which deposit on the checker bricks. This build-up reaches a point where the entire checker work is blocked.

The technique only works for chimney blocks which have the ‘mouse-hole’ in them, since it relies on these holes to create a channel across the entire chamber. Water-cooled rods can be fed

through the ‘mouse-holes’ and anchored on the far wall to create a support structure for the checker blocks above the area. Once the upper section is secured the area in the middle where the blockage has been identified can be demolished and re-packed with new checker blocks.

These are built up to the underside of the supported blocks before the supports are carefully removed. All this can be performed while the furnace continues to operate albeit at a reduced capacity. Once the re-pack is completed the furnace can resume normal activity.

Summary Various problems in the regenerators have been described along with a number of options to manage repairs and allow furnace operations to continue.

This can be either due to catastrophic failure at an early stage of the furnace life or a planned strategy to extend the normal furnace life. It has been shown that there are repair techniques available which can help in even the most critical circumstances – you have only to ask the right people - Fosbel. �

*Business Unit Director Glass Europe, Fosbel, Brook Park, Ohio, USA www.fosbel.com

�New

checkers installed

�Checkers supported with cooled bars so blockage can be removed

� Partial checker replacement.

View from outside showing lance and camera in position

View of inside showing lance and camera in position

TV monitor to see what is happening

� Regenerator cleaning.

www.glass-international.com

there are long runs of straight walls.

The wall material also has an influence on performance because gradual deterioration of the brick over time can lead to dimensional changes which promote bowing of the wall in or out of the regenerator chamber.

This problem is difficult to repair and in extreme cases where the furnace was not as old, we have replaced the entire wall section by section without interrupting production. This type of repair has to be well-planned and executed using correctly trained people.

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Heye event discusses the digital era Digital glassmaking, Industry 4.0 and operational excellence were among the subjects of Heye International’s recent symposium. Greg Morris was there.

M

ore than 70 glassmakers from around the world attended the symposium where they were able to discover some of the latest concepts in the production of glass.

Key among these is the rise of the use digitalisation in the manufacture of container glass and this was addressed early on during day one of the two-day conference.

The event included 13 presentations which, as well as focusing on digitalisation, examined motivational concepts to achieve glass operation excellence.

Glassmakers from Australia, Brazil, Thailand, Mexico, the Middle East, India, South Korea, China, Egypt, the USA and several European countries were among those who attended the event in Hamburg, Germany alongside representatives from glass associations and Heye International staff.

www.glass-international.com

Opening speech Opening the symposium, Heye International’s managing director, Dirk Pörtner, said: “We will talk about digital change, which will see a huge change in our professional lives. This is something which we are facing and is happening if we want or not. Change is something that has happened many times before.”

The company has been working on the challenges of digitalisation for many years.

“We in Heye are prepared to offer new solutions for the future to your companies.

The industry will move forward and has to move forward,” added Mr Pörtner.

Digital transformation Ernst Raue, former head of CeBit and an Internet of Things expert, provided the first presentation and stated that management must lead digitalisation – it is a top-down process.

“Do the board and top management have a vision for this strategy? What is the strategy? Is there a vision, strategy and a willingness for co-operation?

Is there guidance from the board and management?” he stated. “It is not always possible to do everything on your own,

you may have to collaborate,” he added.

Companies use digitalisation to make their factories more agile, so they can achieve greater levels of flexibility and are better able to adapt to customer demand, he said.

Digitalisation can support customer centricity, he added. Are current offers meeting future demands of customers for products and services? Is your organisation in a position to recognise customer needs and react as required.

The role of people in a digital workplace was also discussed. Factories will require Continued>>

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Events world: Heye Symposium

a new way of working so a company will need to build a digital workforce.

The make-up of the workforce will need to change and companies will need to recruit and retain employees accordingly.

“It is critical not to underestimate the importance of people in the digital factory,” he stated.

He believes a business should act now as many companies have already begun their digital transformation. China will lead the way in digital age, with the USA not far behind, he concluded Dr Michael Kranz, the Chief Information Officer at Thyssenkrupp Steel gave a viewpoint of digitalisation from a traditional manufacturing company.

He described digitalisation as the 4th industrial revolution and said data was the oil of the 21st century.

“We at Thyssenkrupp have become a software company as well as a steel producer,” he said.

He discussed how the company has

initiative two years ago where it was felt a culture change was required to learn about the new way of working. It met start ups and venture capitalists to gain ideas and then brought together a variety of staff of all ages and from different areas of the business to focus on its digital transformation. The result was the � Heye International’s managing director, Dirk Pörtner, opened the event.

� More than 70 global glassmakers attended the Heye International symposium.

formation of its the Digital Acceleration Office (DAO) organisational tool, which focuses on four areas: digital technical abilities, digital dialogue, digital value projects and digital cultural skills.

Economic growth Erik Nielsen, Head of Economics at Unicredit, said that while we live in uncertain times today, when was it ever certain?

“The most dangerous times are when we thought things were certain,” he said.

In terms of economics the world is looking good, with growth picking up nicely. The biggest political risk is from Donald Trump, he said.

Global growth is expected to grow by 3 to 3.7% between 2015 and 2020.

Since a trough in 2013, the Eurozone has created 6 million jobs, 1.7 million of those in Germany. Wages in the EU have steadily increased, which will lead to more consumption, which has already started to rise.

“As an economist I have to say I love this recovery very much. There has been nice steady growth across Europe and it has not exploded too much.”

He described Donald Trump as the most ineffective president in US history with his fiscal expansion plan looking like a non-event. Inflation is creeping up and there is large unemployment in the US, with a slowdown in growth.

Since he came to power there has been a drop in support for populist right-wing parties in Europe, he added.

He also feared China’s credit bubble would burst.

“The red warning lights are flashing,” he said. He also warned that the UK economy had slowed dramatically since the Brexit vote last year.

Karine Dussimon, Senior Analyst, Packaging at Euromonitor, described the glass packaging prospects in the global food and drinks industry. Of the 3.4 trillion units of retail packaging sold globally in 2016, 305 billion units were glass bottles and jars.

She forecast 1% average annual growth for global glass packaging to the year 2020 but said the landscape was dominated by first PET and then glass. PET had benefitted from a major shift from tap water to plastic bottled water. � Henrik Bonne of Ardagh.

Continued>>

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Glass prospects digitalised the entire value chain from raw materials to the end product. This has produced better and new services for its customers, he said.

One of the challenges of the new world was the ability to bridge the gap between older and younger workers.

“We don’t say the old world is a bad world, it has advantages.

“Experienced workers have more expertise, knowledge and stronger customer relations. But if you look at digital natives, they are more agile, take risks and have a new way of thinking. The aim is to bring these two together.”

The company formed its One Steel

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Events world: Heye Symposium

� Axel Schroeter, Heye

www.glass-international.com

� Barbara Macialczyk.

The top category for glass packaging between 2016 and 2020 remains beer bottles with 140 billion units sold in 2016. This was followed by sauce jars, carbonates, spirits, wine, bottled water and dairy. Alcoholic drinks make up 61% of the total glass volumes with foods the second largest application and soft drinks the third.

While she forecast a decline in growth for glass in alcoholic drinks in North America, she stated that mature markets were still key with Western and Eastern Europe coming back to growth, as well as Latin America and the Middle East.

In China, beer packaging was losing out to metal beverage cans. But while there was a contraction in beer packaging, the market had moved to more premium products, such as crafted beer.

India had a more promising outlook for glass and beer. Per capita consumption of beer had increased and was bought predominantly in glass bottles rather than a can. It also has an established returnable bottle system which helps keep prices down.

While it was a positive story, she warned that prices could increase rapidly due to a complex and expensive tax regime, although this varies from state to state.

The returnable bottle is also popular in Brazil which keeps prices under control.

The country is going through a difficult economic period and brewers have become more interested in smaller sizes such as the 269ml, 300ml and 350ml sized bottles. They hope this will lead to impulse purchases and smaller formats is another way of keeping costs under control for the consumer.

The US has high market saturation levels and slow growth for beer packaging.

The prevalent concern is health rather than calorie intake. People want less but more quality beer. The mainstream

� FEVE’s Michael Delle

International Product

Selve.

Manager for cold end.

domestic beer sector is struggling against craft and imported lager. Import lager is set to overtake domestic lager by 2020, with most imports from Mexico.

Key markets in Europe such as Germany and the UK had shown growth for glass beer packaging, although discount stores tend to go for cans. Glass opportunities abound and there has been a lot of marketing to make beer more interesting.

In France, for example, beer went from being drunk by men at football to a more trendy drink with lot of variety that catered to different people.

Beer now has an identity and a heritage with a story to tell.

Friends of Glass FEVE’s Michael Delle Selve described the Friends of Glass campaign and how it has got 90 million people engaged with glass through press and social media.

The campaign started when it was felt it was time to take action after aggressive campaigns from other materials. “We wanted to take ownership of certain messages, such as the recycling message,” said Mr Delle Selve.

The group built the strategy with glass people, pushed the message, and spoke to consumers, particularly women.

Women tend to be more sensitive to health messages and want the best quality for their new born baby and family. They also tend to be the main purchaser at the supermarket.

The campaign focused on health in its first year, taste in its second, the environment in its third and this year on sustainability and recyclability.

It is targeting young consumers who are less aware of the recycling and health benefits of glass.

Ardagh excellence Day two saw two particularly interesting

presentations from Ardagh.

Barbara Macialczyk, Ardagh Marketing Manager, described how the company innovates. Its innovation process is driven by a cross functional team of different people created from its staff. This team was picked from different departments in different countries from Europe who could share their culture and experiences.

“The aim is to be perceived by customers as a market leader in innovation,” she said.

Henrik Bonne, Director of Operational Excellence at Ardagh, stated that the company wants sustainable operational excellence to be a habit.

“We strive for it continuously, but it can never be reached. We can always get better.”

He highlighted a big data project recently implemented at its plants, the Ardagh Production System (APS), which is a web-based platform of knowledge that all staff can use and which it believes will bring extra percentages in productivity.

The APS provides photos and information on all known glass bottle defects, and provides a list of possible causes and related actions.

All 216 of its glass lines from its 36 plants use it and each time a defect is found, operators feed new information into the system.

The system took a year to implement and required two staff to input all known data about defects into a computer system for a year. It was only rolled out into action in April this year.

“It’s a huge information pack growing every minute. We believe this will bring extra percentages in productivity.” �

Heye International, Obernkirchen, Germany www.heye-international.com

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Surface coatings

IGU Coatings on the 4th surface Ron Hunt* disucsses how dual pane IGUs with 4th surface CVD can offer similar performance to triple pane IGUs but at a fraction of the cost.

W

Profit Using CVD coatings on the 4th surface means more profit for IGU manufacturers.

Dual pane IGUs with 4th surface CVD offer similar performance to triple pane IGUs at a fraction of the cost. End users buy windows based on price, aesthetics, and performance. Offering a slightly cheaper dual pane IGU with similar performance to triple pane IGUs attracts many buyers.

Aesthetically dual pane IGUs tend to look better than triple pane IGUs because they have higher light transmission. Dual pane IGUs are also lighter so they can use less framing material and lighter weight hardware. All the 4th surface advantages work to increase profits for manufactures.

One of the drawbacks for sputtered (soft coated) glass is that it is easily damaged. Sputter coated glass cannot be placed on the 4th surface because it oxidizes and falls off the glass. Some sputter manufacturers have advocated specialised sputter-coatings that get baked on in an additional tempering process.

The problem with this approach is that it is cost prohibitive. The bake on approach takes an expensive process (sputtering) and adds another expensive process

Using CVD on the 4th surface enables manufacturers to meet and exceed end user expectations while increasing their profit margins.

(tempering) that results in a glass that is not competitive. Glass manufacturers using pyrolytic coatings start with the most economical energy efficient glass (pyrolytic CVD) and are then able to fabricate the IGU handling the CVD glass just as if it were base glass. The toughness of CVD glass means that fabricators don’t need to carry out special operations like edge deletion and don’t have to use glass quickly to avoid spoilage.

Manufacturers using CVD glass have less scrap and better inventory because pyrolytic CVD glass can be handled and stored just as base glass.

Energy efficient Energy efficiency is much better when CVD is used on the 4th surface. Window insulating efficiency is measured using U-value, the lower the value the better.

Total window energy efficiency also takes Solar Heat Gain Coefficient (SHGC) into account, and pyrolytic coatings tend to have better SHGC than sputter coating.

1.9 W/m2K is a typical centre of glass U-value for a pyrolytic Low-E coating on the 2nd surface. Adding a coating to the third surface would only improve the

U-value by about 7%. By using tough CVD coated glass it is possible to install an additional coating on the 4th surface resulting in a 22% reduction in U-value.

U-values are the inverse of R-value being the typical insulation effectiveness rating: dual pane IGUs using CVD on the 4th surface can achieve R-values of 1 m2K/W or more (higher is better).

These highly insulating windows can help manufacturers meet a new wave of strict energy efficiency standards being mandated by governments and embraced by end users.

End users generally look for low cost dual pane IGUs that have good energy performance. Using CVD on the 4th surface enables manufacturers to meet and exceed end user expectations while increasing their profit margins.

Manufacturers that embrace CVD will be able to satisfy energy conscious end users, increase manufacturability and increase profits. �

*Process Engineer, Stewart Engineers, Wake Forest, North Carolina, USA info@stewartengineers.com www.stewartengineers.com

www.glass-international.com

hen you produce the toughest coating, it goes places your competitors can’t; that’s what pyrolytic CVD is able to do. Most people in the glass industry know that a dual pane insulated glass unit (IGU) has four surfaces - the 1st faces outside and the 4th faces inside. Coatings are traditionally placed on the 2nd surface (where coatings have the largest impact). CVD coatings can be placed on the 2nd surface and on the very harsh 4th surface.

Using CVD coatings on the 4th surface helps manufacturers increase profits by making windows that are low cost and high performance.

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Events world: Convention of Associations

� Gimav President, Aldo Faccenda provided the first association

� � Organisers Vitrum President,

paper

Dino Zandonella Necca (right), alongside Vitrum Director, Laura Biason.

T

www.glass-international.com

he first International Convention of Glass Industry Associations brought together delegations from Italy, Germany, France, the UK, Spain, Poland, Russia, Australia, Brazil, Slovakia and the United States of America.

The two-day event was organised by the Italian exhibition Vitrum and was the first time where glass industry associations had convened under one roof to discuss and tackle the most relevant topics of interest to the industry.

The convention took place on the historic glassmaking island of Murano, in Venice, Italy, within the Stazione Sperimentale del Vetro (SSV), research centre. The 18 participating associations each gave 10-minute presentations highlighting their primary activities and services on day one. On day two they reported back with suggested areas the glass industry should focus on, such as education, training, the environment and energy efficiency.

Their feedback and suggestions will be evaluated by Vitrum, which will decide on a number of sub categories that are of interest to all the associations.

The idea is to then organise a formal meeting of each sub-category at the Vitrum exhibition in Milan, Italy, in October.

Afterwards, organiser and Vitrum President, Dino Zandonella Necca, said he was thrilled by the number of associations that had participated.

Vitrum organises first

The first International Convention of Glass Associations focused on the issues, challenges and opportunities facing the glass industry. Associations from around the world gave presentations outlining their suggestions. Greg Morris attended.

� Alicia Duran

� Cedric

� Lorenzo

Carrera of the

Janssens, Public

Mencancini,

International

Affairs Manager,

of Italy’s

Commission of

representing

ATIV group.

Glass (ICG).

Glass Alliance Europe.

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a

� Delegates attended from all � Dr Bernd-Holger

around the globe.

Zippe, of Germany’s VDMA

associations’ meeting

� Lucien Belmonte, of Brazil’s ABIVIDRO

� Patrick Gavaghan, of the Australian Glass and Glazing Association (AGGA)

“For us at Vitrum, having successfully assembled the leading glass industry associations in our country, in Muranocradle of the history and tradition of global glassmaking - is a huge satisfaction.

“The enthusiasm that was already palpable on the first day of work sessions spread contagiously to the second day of

meetings, confirming that our initiative was right on target,” he said.

“As business entrepreneurs and institutional representatives, we are all united by a genuine passion for glass, a precious and irreplaceable material.

And that was clear in these two days of meetings. Being able to express our

respective needs, country by country, with the aim of bringing common aims into focus and concentrate our energies on a shared goal for the entire industry was the winning component of this important meeting”.

Continued>>

� Stefano Manoli, of

� Lina Incocciati,

� Victor Osipov

Stazione Sperimen-

of Italy’s

of Russia’s

tale del Vetro (SSV),

Assovetro.

StekloSouz.

research centre.

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Laura Biason, director of Vitrum, said: “This is only the beginning of a journey that will focus on the world of glass and its related processing.Future meetings have already been set. The first operational working groups will meet on October 4th during Vitrum 2017 and, in the Spring of 2018, the second annual meeting will be held in Murano.”

Gimav The convention started with a presentation from Italian association GIMAV. President, Aldo Faccenda, stated Italian glass industry sales amounted to €1.3 billion in 2016, up 5.09% from the preceding year.

Flat glass sales were up 7.25% while hollow glass sales increased 1.05%.

Exports for the entire sector were up 5.39% from the previous year, with Eastern Europe, Asia and North America its main markets. Gimav itself has 71 members and represents companies from the flat and hollow glass industries as well as from the accessories sector.

likes of O-I, Vidroporto, Nadir Figueiredo and Vidraria Anchieta in hollow glass and Guardian, Schott and Vivix in flat glass.

The country’s glass industry employs 13,000 people and had sales of US$4 million in 2016.

Australian Glass and Glazing Association Patrick Gavaghan, of the Australian Glass and Glazing Association (AGGA), outlined the role of the group and its work between 2012 and 2017.

There was a major skills shortage in glazing and glass processing – Australia is surrounded by cheaper glass-producing countries from the ASEAN region.

As a result it launched a successful training programme aimed at encouraging more people to join the industry.

The association’s achievements include the implementation of an accredited company programme encompassing safety, skills, compliance and technical matters as well as the introduction of an industry-wide mentor programme at all

� � Delegates were treated to a demonstration of the skills of the Murano glassmakers at the Abate Zanetti Istituto Scolastico Superiore ‘Glass High School’.

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Abividro Lucien Belmonte, President of Brazilian association ABIVIDRO, admitted the domestic glass industry was currently experiencing a tough period. It produced a total of 3.5 million tonnes of glass last year – 2 million tonnes for flat and 1.5 million tonnes of hollow glass. In the past three years float production has decreased by 35% and hollow by 3%. The problem is high gas prices in Brazil while the transmission of electricity in such a vast country is expensive. Conversely, per capita glass consumption has grown significantly in Brazil between 2000 and 2015, with an increase between 11.9 to 24.4 kilos per Brazilian in 2015.

The Abividro association represents the

employee levels (see Glass International, September 2016, page 68). It has also developed a Master Glazer programme and restructured a glass and glazing trade qualification. Glazing apprentice completion rates had risen by more than 27% and the association has also launched 45 online units to support the training of glaziers and glass processors.

Assovetro Lina Incocciati, of Italian glass packaging association Assovetro, explained the group represents 75 companies working in the field of glass production and transformation. In 2016 the Italian glass industry produced 5,346,817 tonnes of glass and employed 22,800 people.

Approximately 57% of its member companies are from the container glass industry and include Ardagh, Bormioli Luigi, Bormioli Rocco, O-I Italy and Zignago Vetro. Its technical activity includes collaboration with the SSV research group and it also collaborates with the Co.Reve.Ve glass packaging recycling organisation.

ATIV Compatriot Lorenzo Mencancini, of the ATIV group, said its purpose was to promote the technical and scientific knowledge of glass technicians and those related to the industry. It operates in the sectors of food and beverage, tableware, pharmaceutical and special glass in the hollow sector and in float and processing in flat glass. Every year about 100 members attend its annual conference and every four years it helps organise a European or international glass meeting.

Glass Alliance Europe Cedric Janssens, Public Affairs Manager outlined the role of the five industrial sectors that comprise the Glass Alliance Europe group based in Brussels, Belgium.

The associations are FEVE (container), Glass for Europe (flat), European Domestic Glass (tableware), Glass Fibre Europe and the European Special Glass Association (speciality).

Among the Glass Alliance Europe missions are to enhance the exchange of information, regroup all European glass industries to work on common issues and to strengthen the voice of glass industries in Europe. The glass industry has a strong and diverse industrial base with 500 plants in 24 European countries employing 500,000 people.

Total production had increased 3.5% between 2015 and 2016 from 33.6 million tonnes to 34.9 million tonnes.

The vast majority of this (61%) was container glass, with flat glass comprising 29%. There are 46 float glass installations in Europe and six producers that produce 650 tonnes a day on average at each site.

The European packaging glass (container glass) industry employs 125,000 people (40,000 people direct) in Europe with 160 plants in 20 countries. It produces 80 billion products a year with 74% of production collected for recycling.

Production is steadily increasing with health and the environment driving consumers’ preference for glass.

Continued>>

94 Glass International July/August 2017

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Events world: Convention of Associations

The next challenge is to continue to sustainabily and competitively grow the industry in Europe.

Tableware comprises 3% of total European glass production and the European Domestic Glass Association comprises 16 companies. These include the likes of Arc International, Baccarat, Bormioli Luigi and Sisecam Pasabahce. Total EU production in 2016 was 1.181 million tonnes.

Stazione Sperimentale Vetro (SSV) SSV Director General, Stefano Manoli, outlined the role of the research centre. It has 53 employees and served 700 customers last year from 35 countries. It is devoted to the promotion of the technical development of the glass industry.

The majority of its activity is in analysis and technical assistance. The majority of the glass it works with is hollow and flat, but also tableware and speciality. A large group of staff work on energy and environmental areas and it also works on a variety of topics such as glass defects, chemical analysis, measurements and mechanical properties of containers. It has worked with companies under non-disclosure agreements (NDA), with associations and on pre-competitive research studies. Some of the projects it undertook in 2016 under NDA include batch and energy costs, colour development, nuclear waste in glass, and improving mechanical resistance in container treatment – so a variety of topics.

VDMA The final presentation of the day was from Germany’s VDMA, where its Glass Director, Dr Bernd-Holger Zippe, provided an overview of its role. The forum is an industry representative, service provider, advisor and communicator for its members. It meets once a year at its annual assembly and general topics tend to be the economic situation and outlook, trade shows, public relations and technical issues.

Its research and technology working group meets twice a year and participants include equipment suppliers, glass manufacturers and research bodies. Current topics of interest are Industry 4.0 for the glass industry, lamination, safety glass and chemical strengthening.

The event also included a tour of the Stazione Sperimentale del Vetro glass research centre and a visit to the Abate Zanetti ‘Glass High School’ on Murano. � Vitrum takes place October 3-6, 2017 in Milan, Italy www.vitrum-milano.com

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Recycling

Glass recovery in waste treatment Spain’s Picvisa has developed a recycling solution that recovers glass from municipal waste and sold as a marketable product. Its new testing centre process line has been designed to treat 10 t/h of residual waste and to produce clean and marketable glass from heterogeneous wastes that contain different levels of contamination.

S

PICVISA Test Centre The Picvisa Test Centre consists of a full-scale demonstration facility of waste treatment and recycling which was built in 2017 with the support of the European Commission’s H2020 Grant issued by the Executive Agency for Small and Medium-sized Enterprises (EASME).

The process line has been designed to treat 10 t/h of residual waste and to produce clean and marketable products, such as glass, plastics and metals, from heterogeneous wastes that contain different levels of contamination. Several companies have already sent materials to be sorted and characterised and marketable cullet has been obtained.

PICVISA optical sorter The Seeglass optical sorter uses the transmitted light that passes through the transparent and translucent elements, as well as the reflected light from dark elements, to analyse materials that have been singulated in front of the viewing area of the optical sorter. This singulation of particles is achieved using a lowfriction inclined ramp. The camera catches the passing and/or reflected light into specific wavelengths which accentuate the difference between acceptable and rejected products. Once the software of the image processing determines that an object corresponds to the acceptable parameters, a high-speed compressed-air ejector is activated at the precise time the object passes the blowing-out nozzles. The target product is then removed from the main stream and the rest of materials continue in a straight line to an output outlet.

Picvisa has also launched this year optical sorting software incorporating datamining

processes and industry 4.0 applications for material sorting and recycling.

Large amounts of data are processed for performance analysis of the optical sorting process, including plant management applications and internalised problemprevention controlling.

Real-time visualisations and operator interfaces are developed for local and remote operation, such as touch-screens, mobile phones and tablets, allowing intuitive equipment configuration and monitoring. Numerous new features also incorporate throughput analysis, continuous auto-diagnosis and alarm handling including, in many cases, the prevention of possible events.

Continued>>

www.glass-international.com

panish sorting materials group Picvisa has developed a machinevision solution of glass recovery from municipal solid waste using an R&D project that was granted with H2020 funding issued by the European Commission (EASME).

The solution refers to the recovery of glass and other recyclables from rejects and residue streams issued from mechanical and biological treatment (MBT) plants of municipal solid waste (MSW).

Although glass is the main reclaimed material, as cullet, small elements of plastics and metals are also recovered.

The technical implementation consists of a sequence of mechanical and optical sorting equipment to be installed in new or existing facilities of waste treatment and recycling facilities. Cullet-as-output is obtained as a marketable product.

The company built a full-scale demonstration and test centre facility at its premises in Calaf, in Barcelona, Spain where a wide range of feedstock was tested. This included the residues stream of the mechanical phase of the MBT processes, such as the rejects from compost refining, incineration slag, household waste and co-mingled waste.

The strain on non-renewable natural resources has increased, and this has magnified the importance of sensible waste treatment solutions.

In Europe, new legislative and fiscal drivers have contributed to an increase in the desirability of recycling glass.

But large amounts of glass are not collected by separate streams for household waste glass collection because municipalities do not provide a differentiated way of collection, or because people do not respect waste collection instructions.

Large amounts of glass waste are then

97 Glass International July/August 2017

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Recycling

ENGINEERED SOLUTIONS FOR GLASS CONDITIONING PROBLEMS

Samples of reclaimed glass issued from household waste after the optical sorting process The Picvisa solution may also include the withdrawal of impurities and colour sorting of the reclaimed cullet (flint, green, amber/brown, blue, etc.).

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PARKINSON-SPENCER REFRACTORIES LTD Holmfield, Halifax, West Yorkshire, UK. HX3 6SX Tel: (44) (0) 1422 254472 • Fax: (44) (0) 1422 254473 Email: admin@parkinson-spencer.co.uk • www.parkinson-spencer.co.uk

mixed with residual waste such as biodegradable wastes and recyclables.

In Europe, it has been observed that glass waste which is mixed with co-mingled and residual streams (wet or dry streams including MSW organic matters) remains steady around 5% to 7% of them (in weight). This glass currently contaminates the recyclables and, in the case of a composting facility, also contaminates the compost as output. In the cases of MBT processes, where the compost is screened, most of the glass waste finishes at landfill.

The Picvisa solution is in line with the European Community environment action plans, and provides a demonstrated technology of high recovery rates and residues reduction at the waste treatment plants (MBT) and material recovery facilities (MRF).

It maximises the glass recycling and reduces the amount of waste to be sent to landfills, while phasing-out landfilling and incineration to non-recyclable and non-recoverable waste.

The Picvisa process line is easy to build (modular units, fast installation and small footprint) and is also easy to operate (high precision computer control, conventional maintenance procedures). The sorting technology is environmentally friendly without X-rays and without liquid residues. In some cases, the process line may also provide derived-refuse fuel (RDF) as output.

Waste management and recycling companies may sell the reclaimed glass and recyclables, and consequently reduce landfill costs, increasing their facilities’ throughputs.

The Picvisa solution provides high recycling rates and contributes to the development of circular-economy strategies of communities concerned about their waste management.

Payback periods of the Picvisa solution are considered short enough by customers who are currently showing their interest in investing in this technology.

The environmental and economic benefits encompass the progression of the application of this solution. �

*Picvisa, Barcelona, Spain www.picvisa.com info@picvisa.com

98 Glass International July/August 2017

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