Glass International November 2015

November 2015 | Vol. 38 No.10

O-I MANAGING DIRECTOR VERALLIA CEO GIMAV PRESIDENT

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Glass International November 2015

Why speak to 357 sub-contractors when you can speak to one expert?

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Contents

November 2015 Vol.38 No.10

November 2015 | Vol. 38 No.10

O-I MANAGING DIRECTOR VERALLIA CEO GIMAV PRESIDENT

14

www.glass-international.com

2 Editor’s Comment 3 International news 10 O-I interview Black magic

Glass International November 2015

Why speak to 357 sub-contractors when you can speak to one expert?

14 Verallia interview A new era for Verallia

BECAUSE WE DO IT.

For batch plants, cullet systems, preheating, batch chargers, automation and control systems, as well as engineering.

21 ZIPPE INDUSTRIEANLAGEN GMBH · Alfred-ZIPPE-Str. 11 · 97877 Wertheim · +49 9342-8040 · zippe@zippe.de · www.zippe.de nov.indd 1

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Front cover image Zippe www.zippe.de

Country focus 17 Indonesia’s container glass industry enjoys steady growth Italian review 21 Bright future for the Italian industry 24 Vitrum highlights the best of the global flat glass industry 26 Phoenix Award Surasak Decharin: ‘He’s a true glass man’ 30 History 32 Company profile A global company based in the heart of Paris 35 Moulds Reducing energy consumption using sidewall mould ovens

26 Plus find us on Linked-In and Twitter.

@Glass_Int

www.glass-international.com

32

Technical papers 39 Bucher Emhart Glass: Can you afford not to use original parts?

42 Siemens: Pilkington benefits from integrated control system 44 Chpolansky: A laser cladding for moulds 46 Vidromecanica: Cord removal stirrer systems 49 AGC Glass Europe: Preheated oxygen and natural gas in flat glass furnaces 52 IHS Chemical: The new normal 54 Society of Glass Technology and CelSian: CelSian training day comes to the UK 55 Diary

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36 Technical Topics

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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 Assistant Editor: Sally Love Tel: +44 (0)1737 855154 Email: sallylove@quartzltd.com Designer: Annie Baker Tel: +44 (0)1737 855130 Email: anniebaker@quartzltd.com

Technology and takeovers in an ever-evolving industry

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T

his month has been another of those occasions where the glass industry hasn’t stoped moving.

There has been a flurry of new partnerships, equipment launches and the sale of a prestigious glass manufacturer.

As well as this, it has been events season, with a number of glass-related conferences taking place.

These have provided the opportunity for glass professionals to meet, catch up with old friends, share ideas about best practices and learn about new technology on the market.

It was at one such event, Brau Beviale in Nuremberg, Germany where Verallia CEO Jean-Pierre Floris discussed the recent completion of its divesture from the Saint-Gobain group. It means Verallia, with the support if its shareholders Apollo and BPI, is a stand-alone manufacturing company.

Mr Floris said that key to its strategy is to force and bring forward the worth of glass packaging as an innovative material, by reflecting all customer and consumer requirements in terms of quality as well as social and environmental responsibility.

The divesture followed hot on the heels of O-I’s completion of its takeover of Vitro’s container glass business in Mexico last month, one of Verallia’s main competitors on the global stage. It will be interesting to see how Verallia adapts and

expands its global positioning in the future. We speak exclusively with Mr. Floris on page 14 of this issue.

Visitors to Brau were probably packing their bags when, just a few days before the event, there was good news from the UK glass manufacturing industry.

Ardagh confirmed the launch of its new P5 flint furnace at its Irvine plant in Scotland and was joined by the country’s First Minister, Nicola Sturgeon, to celebrate the opening. The £15 million endfired furnace will enable it to reduce emissions while increasing output at the same time. The flint furnace has been designed to increase production flexibility and uses modern, environmentally efficient, end-fired technology, together with the latest inspection equipment.

At about the same time as the Irvine launch, and about 250 miles down the road in Goole, England, flat glass producer Guardian was also celebrating with the opening of a Waste Heat Recovery System. The system enhances Guardian’s environmental credentials by reducing CO2 by 6000 tonnes a year. Both these UK launches prove how important the environment is to the industry and highlight that the industry is constantly evolving.

Greg Morris Editor gregmorris@quartzltd.com

Quartz Glass Portfolio

Monthly journal for the industry worldwide

Directory 2015 Annual international reference source

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Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com Sales Manager: Jeremy Fordrey Tel: +44 (0)1737 855133 Email: jeremyfordrey@quartzltd.com Production Executive: Martin Lawrence Subscriptions Tel: +44 (0)1737 855023 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.

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2 Glass International November 2015

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International News

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Ardagh Group has opened a £15 million furnace at its Irvine plant in Scotland, UK. The new facility was officially opened by Scotland’s First Minister, Rt Hon Nicola Sturgeon MSP. The investment, supported by a grant from Scottish Enterprise’s Aid for Environmental Protection Scheme, secures the future of the 225-strong workforce.

The new furnace will enable the plant to produce bottles primarily for the Scottish drinks industry.

The flint furnace has been designed to increase production flexibility and uses environmentally efficient end-fired technology, together with the latest inspection equipment.

Graeme Shepherd, Director of Operations, Irvine, Ardagh Glass, UK, said: “The Irvine plant is well regarded within the Ardagh Group for the

quality of its output, the calibre of our management and workforce and the professionalism of our customer service, supported by on-going investment in technology and systems.”

First Minister Nicola Sturgeon said: “I am delighted to visit Ardagh Glass to officially open their new furnace. This is evidence of the company’s continued investment in its Irvine site, which is something to be commended.

“I also welcome the news that Ardagh Glass has made a commitment to the Scottish Business Pledge, making them one of first companies in the spirits supply chain to do so.”

The Irvine facility is part of a £500 million investment

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GPS independence GPS, an international supplier of IS machines, spare parts and services, is to become independent from Saint-Gobain, from January 1st, 2016.

Rolf Themann, General Manager of GPS, is taking over responsibility for the medium-sized company via a management-buy-out.

He was able to convince high performance and long-term-oriented private investors with business backgrounds to come on board.

“We would like to take the opportunity as medium-sized German engineering company to respond independently to the challenges of the market“, explained Mr Themann.

The name GPS, the ‘Made

in Germany’ aspect, and the location in Essen will remain unchanged.

The strategic business areas established in 2013 remain stable, focused on IS machines, spare parts and services.

GPS management believes the switch from the SaintGobain group to a medium-sized, owner-managed engineering company will allow it to build its future in a way that is more intensively focused on its core strengths.

It is also looking forward to being able to act with more flexibility, develop innovations and extend its business with the aim of being closer to customers.

Glass International November 2015

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Waltec Maschinen GmbH Kronacher Straße 2a 96352 Wilhelmsthal / Steinberg Germany Phone +49 9260 9901-0 Fax +49 9260 9901-99 E-Mail info@waltec.de

3

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International News

NEWS IN BRIEF

Pharma glass site to be built in Russia

A Megapolis company based in Russia is to build a plant for the production of medical glass in KarachayCherkessia.

It is hoped that the plant will replace 90% of imports of the products in Russia.

An agreement was signed

by Megapolis at the Sochi 2015 International Investment Forum.

The company will produce glass of the first hydrolytic class, used in the production of medical packaging - glass medical tubes, ampoules, vials and cartridges.

The project will be implemented in 2016-2017.

Investments in the project were not disclosed.

Allied Glass opens first Scottish site

Andres Lopez named CEO of O-I Andres Lopez has been named Chief Executive Officer of Owens-Illinois (O-I), effective from the January 1st, 2016.

O-I’s Board of Directors affirmed Mr. Lopez’s appointment at its October board meeting, the final step in the CEO succession process.

Current Chairman and CEO Al Stroucken will retain the role of Executive Chairman of the Board from January 1st, until the annual shareholder meeting in May 2016.

As Chief Operating Officer

held several leadership positions. In 2014, Mr. Lopez was named President of O-I Americas, and was then named Chief Operating Officer in February 2015.

“Over the last year Andres and I have worked closely together to transition all responsibilities for the company,” said Mr. Stroucken.

“The Board is confident that Andres’ passion and his strategic vision for the company will propel O-I successfully into the future.”

Bucher Emhart Glass and PSR renew licence agreement

The spirits packaging specialist has clients that include The Famous Grouse Scotch whisky.

Sales and marketing director Philip Morris said: “This is a strategic decision to be closer to customers, offering a more flexible and personal service as we look to expand our business in the premium whisky and spirit sector.”

The company has taken a five-year lease on a 2,088 square foot space at the Maxim Office Park.

It chose the location on the M8 motorway, close to Glasgow and Edinburgh, for its accessibility to clients around the central belt.

Two promotions at Allied Glass www.glass-international.com

of the company, Mr. Lopez has been responsible for O-I’s business and operations in all of the company’s geographic regions.

He led the negotiations resulting in the recent $2.15 billion acquisition of Vitro’s food and beverage business in Mexico, Bolivia and the USA. Glass International interviewed Mr. Lopez regarding the Vitro takeover in its July/ August issue (p21).

Mr. Lopez joined O-I in 1986 in Colombia, and has since

Allied Glass Containers has promoted Michael Hogley to the position of Head of Design and Decoration.

To coincide with Michael’s appointment, Chris Todd has moved to the position of Innovations Manager.

Day to day operations within the design department will continue to be managed

by Gary Nicholls and Alan Howlgate will remain responsible for Allied’s Decoration facility.

Parkinson-Spencer Refractories has been the UK licensee of Bucher Emhart Glass for the manufacture of Emhart designed feeder expendable refractories since 1970.

This licence gave access to the original Bucher Emhart Glass refractory drawings and manufacturing tolerances and was originally one of four global refractory manufacturing licences operated by Bucher Emhart Glass.

Following a recent review of their refractory licensee operations, Bucher Emhart has decided that such relationships no longer suit the current market situation and, with the exception of PSR’s licence, all other licensee arrangements have been or will be terminated by the end of 2015.

David Parkinson, Managing Director of PSR, said: “I am delighted that Bucher Emhart Glass has decided to continue our licensee arrangement.

“It is a relationship that PSR has enjoyed for the past 45 years and is one that has benefitted both ourselves and the

Bucher Emhart Glass refractory manufacturing plant in Owensville, Missouri, USA by means of mutual cooperation and an exchange of ideas in this specialised area of refractory manufacture.”

Under the new arrangement, PSR will have access

to all the latest Bucher Emhart-designed feeder expendable parts including the type 585 high capacity metering spout refractory parts.

Pictured: Lajos Giczi (right), Bucher Emhart Glass Global Business Manager Refractories, and David Parkinson.

Be first with the news! VISIT: www.glass-international.com for daily news updates

4 Glass International November 2015

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At home in the world of glass

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International News

aging O-I’s premium packaging for blended Scotch The Famous Grouse has launched a premium version in new glass packaging developed by Owens-Illinois (O-I), which features a host of new innovations.

The new pack, for The Famous Grouse Mellow Gold, will also be introduced across all main sizes of the parent brand.

The two initiatives have been designed to capitalise on the growth in premium blended whisky, and challenge perceptions around Blended Scotch.

O-I has been lead developer on most sizes in the portfolio and has produced the first 70cl bottles to come to market.

This container for The Famous Grouse is the first

lightweight design made at the plant using the more traditional blow:blow process.

Scott Gibb, UK Commercial Lead for O-I, said, “This is an exceptionally light container for the blow:blow process.

“Several glassmakers have lighter standards, but we believe no one has ever made such a complex, shaped and engraved spirits bottle at 420g before.

“It required careful parison design to ensure good glass distribution.”

and glass quality enhancements for new or existing air-fuel furnaces. It can help improve your melting operations and reduce emissions. And it can help you overcome heat recovery system problems that can limit production.

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Horn repairs Croatian furnace Germany’s Horn group has repaired a 260tpd endfired furnace at Vetropack’s Straža site in Croatia.

Horn originally built the furnace in 2004, and at the beginning of 2015 it was due for repair. The furnace produces three different glass colours: olive, green and amber.

In Straža the company is a supplier to the Croatian do-

tell me more

burners at the distributor and forehearth were changed to a modern combustion system, using independent left and right control of the temperature in each cooling section of the forehearths.

Horn carried out the complete project with all services for steel, refractory, heating-up and successful commissioning.

Xpar Vision doubles its development team In the last two years Xpar Vision has almost doubled its development team, from from seven to 13 members of staff.

All the team members have a Masters and/or

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mestic market and also an exporter to markets including Slovenia, Italy, Hungary, Bosnia and Serbia.

The complete combustion system was changed to the latest technology, as Horn supplied the individual burner control combustion system with the latest DualFlame AC burners.

All the gas stations and

Phd’s in the fields of A.O. computer science, applied and experimental physics, mathematics, artificial intelligence, chemistry, and mechanical engineering.

This extension is the re-

sult of the company’s commitment to developing its portfolio of hot-end sensor technologies and its application for process automation in the global container glass industry.

Glass International November 2015

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International News

NEWS IN BRIEF

Top 10 stories in the news

HNG to sell subsidiary

India’s Hindusthan National Glass & Industries Ltd has decided to sell its German subsidiary HNG Global, it said in a stock market disclosure.

The company has received board’s approval for the proposal and will seek shareholders’ clearance.

It did not disclose any financial details.

HNG Global was founded in 2008 as Agenda Glas and makes container glass mainly for the domestic market.

It caters to the beverage and food industry and its facility is located in Gardelegen, Saxony-Anhalt.

This month’s most popular news items, as determined by our website traffic r 1 Hindusthan National Glass to sell German company r 2 Vitrum 2015 creates a buzz r 3 Guardian to expand production at DeWitt plant r 4 Andres Lopez named CEO of O-I r 5 Allied Glass opens Scotland site r 6 Construction continues on Kazakhstan float factory r 7 Stoelzle invests €5M in French site r 8 Two promotions at Allied Glass Containers r 9 Friends of Glass to send the recipe of glass to the moon r 10 Verallia becomes independent All full stories can be found on our website, www.glass-international.com/news

Friends of Glass to send glass recipe to the moon

Friends of Glass is working with Lunar Mission One to send the recipe of the material to the moon on the Astrobotic Lander in a bid to preserve it for generations to come.

Lunar Mission One has launched a ‘Footsteps on the Moon’ campaign which aims to put a digital archive containing millions of human footprints on the moon in 2017.

“By sending glass to the moon, we are preserving a fundamental piece of human history that has been in use for millennia,” added FEVE’s Michael Delle Selve, Senior Communications Manager.

Stoelzle invests €5M at French site Stoelzle Group has invested €5 million on a new production line at its plant at Masnières, France.

The production line is for the Perfume & Cosmetics business and was set to begin operation earlier this month.

Stoelzle intends to make Masnières a centre of excellence within the group and

www.glass-international.com

development of key technical competences; and Improved performance and lower costs.

The new step in revitalising the glass production at the Masnières plant is part of an industrial modernisation process and improvement of general working conditions launched in May 2015.

Glassman presentations available Presentations delivered at the Glassman conference in Guadalajara, Mexico, are now available to download for free from the Glassman website: www.glassmanevents.com/ latin-america/conference.

This includes the presentation given by Jose Huerta of

Guardian to expand production at DeWitt plant

Guardian Industries’ has approved a capital project to repair the float glass furnace and expand glass production at its DeWitt, Iowa, USA plant.

The proposed project, expected to begin first quarter of 2017, will increase the plant’s production capacity, add new environmental control technologies and enhance products and services to support its customers.

The DeWitt plant started operations in 1996 and in 2007 added an advanced magnetron sputter coater, which allowed production of Guardian’s ClimaGuard and SunGuard low-E glass products.

has launched an expansion programme based on three pillars: to offer continuous improvement in performance, so as to accelerate the development of new projects and high-end ‘flacons’ for the Perfume & Cosmetics segment; Industrial optimisation of four production lines and the

Grupo Modelo, entitled ‘Voyager Plant Optimisation: A-B InBev’s Roadmap to a Safety Culture’, and Hector Garcia of Gerresheimer’s ‘Evolution of quality requirements in the glass industry’.

The conference was held alongside the Glassman Lat-

in America exhibition, which attracted more than 900 visitors. The next Glassman conference will be held in Abu Dhabi, on the 10th and 11th May 2016.

Those interested in speaking should contact Greg Morris: gregmorris@quartzltd.com.

Schott forms centre of excellence Schott has set up a Ready to Use (RTU) centre of excellence at its Lebanon, PA production facility in the USA. The facility brings together experts and pharma partners at the heart of manufacturing.

The manufacturing plant will become a hub where experts can develop solutions to exploit the full potential of sterile packaging concepts.

The plant’s manufacturing capacity also ensures the se-

curity of supply of RTU vials and other pharma packaging.

Pharmaceutical manufacturers are relying more on RTU packaging as it promotes particle-free drug filling.

Be first with the news! VISIT: www.glass-international.com for daily news updates

8 Glass International November 2015

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Interview: O-I

Black magic

It’s been a busy year for Owens Illinois (O-I), with the acquisition of Mexico’s largest container glass manufacturing enterprise and the popularity of products such as black glass gathering momentum in the beer industry. Sally Love spoke to Vitaliano Torno, Managing Director of O-I Europe, to discuss the company’s latest news and technology.

Why did O-I take over Vitro’s food and beverage business?

O-I has long admired Vitro. It has a well-run business and strong, long-term relationships with its customers.

The acquisition provides O-I access to the strong and growing Mexican and Bolivian markets. O-I’s only presence in Mexico prior to this agreement was with its joint venture with Constellation, IVC. These operations fill a gap in O-I’s global footprint. Vitro F&B’s presence in food and NABs also complements O-I’s portfolio.

“O-I is the world’s largest user of recycled glass. In 2014, O-I used 4.7 million tons of recycled glass

”

www.glass-international.com

globally.

z Mr. Vitaliano Torno, Managing Director of O-I Europe.

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Interview: O-I

What are the conditions of the sale?

O-I paid $2.15 billion for Vitro’s food and beverage glass container business. The sale was effective September 1, 2015.

What types of containers are produced at the plants?

The plants produce much of the same food and beverage containers O-I currently makes, including those for food, beer, soft drinks, readyto-drink and wine.

Will O-I and Vitro share some facilities in Mexico? How will that work?

 z  A selection of O-I wine bottles and the Helix wine closure (below).

Yes, the Monterrey and Toluca facilities will be shared. In the short-term, transition service agreements between both parties will ensure both companies continue to operate without hindrance and serve their respective customers. Longer term, there are plans to permanently split the facilities.

What is O-I’s view of the Mexican glass market? Is there anything unique that differentiates this market from other regions where O-I does business?

Mexico is the world’s largest exporter of beer and the sixth largest market in terms of production.

Like other Latin American countries, Mexico continues to show steady year-on-year growth.

Mexico sits between two regions where O-I has a tremendous presence already, providing an opportunity for growth in a relatively unknown market for O-I.

Continued>>

 Two examples of O-I’s black glass containers for the beer industry.

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Interview: O-I

A new growth model where no more waste is created: this is the objective of the Circular Economy. For more than 35 years the glass packaging industry has adopted this economic model.

Actually, glass is THE example of a product which is a natural fit for a circular economy.

Glass is one of the few packaging materials to be produced in a closed loop. Its intrinsic qualities make it one of the only packaging materials that can be 100% infinitely recycled. Glass packaging can be also reused.

It is important to notice that the circular economy model includes not only environmental elements, but also the social and economic elements, as it looks at how an industry supports and builds on local closed loop systems.

O-I manufactures its products locally and uses local suppliers. More than 70% of the raw materials travel less than 300 km to our plants. O-I also contributes to the local economies – for each direct job, 1.9 indirect jobs are created.

Roughly how much cullet does O-I use in its manufacturing?

O-I is the world’s largest user of recycled glass. In 2014, O-I used 4.7 million tons of recycled glass globally. Some glass furnaces already operate with up to 90% of recycled glass as a raw material.

According to the latest data published by The European Container Glass Federation (FEVE) in September this year, the EU28 average recycling rate for glass packaging is 73%.

Does O-I have any targets in place, in terms of achieving a circular economy?

At O-I, we are focused on continuous sustainable development and improvement. If we want to bring sustainability to a higher level then we have to work in partnership with our customers, suppliers, local communities and employees.

For example, O-I has established a partnership with Carlsberg, one of its major customers, to develop the next generation of packaging: Community Circular Carlsberg (CCC).

This project is a collaborative platform where Carlsberg and O-I, along with other suppliers, combine their strengths to jointly develop packaging for the future.

In addition to working with customers, we also work closely with suppliers.

In France, Poland, Italy and Estonia, cullet suppliers have invested in new facilities located next door to O-I plants providing a strong local solution to

respond to customers’ growing requirements for environmental performance.

As well as sustainability, O-I is well known for its creative design ideas.

Can you explain the process that O-I has for coming up with and introducing new ideas to the market?

Sometimes a customer comes to us with a new design (like Puerto de Indias gin in Spain); in this case our added-value comes from our glass expertise and how we can turn the design into an actual bottle. We also of course develop new designs for customers who brief us, as they would brief a design agency.

Our added-value is that our creative designers know glass, and they are perfectly connected with our technical teams to ensure that their creations can actually be produced.

Depending on the opportunity, we can also proactively propose ideas to customers that are tailor-made to their brand, based on consumer trends, our analysis of their target consumers, or our understanding of their brand positioning and business objectives.

One particular offering that O-I can offer its clients is black glass. How many and which plants produce black glass?

In Europe, we currently have two plants that can make black glass: Alloa in Scotland, serving the spirits industry, and Leerdam in the Netherlands, focused on beer.

Did producing black glass require any upgrades to equipment or machinery, or was it just a case of adjusting the glass recipe on existing equipment?

Both. Hence, O-I has developed a process to produce black glass, which enables each one of our bottles to be fully inspected. Our most recent investment in our Leerdam facility (€21 million in 2014) included an upgrade to produce black glass for our beer customers.

Is it primarily used for beer, and do you think it could be successfully used for other container types?

While our most recent investment and current communication is focused on beer in Europe, O-I pioneered black glass six years ago and it is also available to other categories.

Actually in Europe, we first launched black for spirits. In our Alloa plant, we produce black for various spirits brands, such as Hendricks or Cutty Sark. We also offered black glass to wine customers, such as Belaire. 

O-I Europe, Vufflens-la-Ville, Switzerland www.o-i.com

www.glass-international.com

How important is the circular economy in particular to O-I as a company?

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Personality profile: Jean-Pierre Floris

A new era for Verallia Verallia CEO Jean-Pierre Floris spoke to Sally Love about what its recent acquisition by Apollo Global Management and Bpifrance means for the company.

What parts of Verallia’s global operations has Apollo bought in this deal?

Since October 30th, Verallia fully belongs to the investment firms Apollo and Bpifrance, which now hold 90% and 10% of Verallia’s equity, respectively. With its new shareholders, Verallia is now a stand-alone manufacturing group, fully dedicated to glass packaging.

What advantages will Apollo bring to Verallia?

Apollo is a long-term industrial fund that enjoys an excellent reputation and has expressed its interest in Verallia since 2007, when Saint-Gobain let it be known that it wanted to sell its glass packaging subsidiary.

I would like to add that Apollo wished to invest along with Bpifrance, the French public investment fund, with which Apollo has built a trusting relationship in recent years.

Their partnership has already been fruitful on many operations. Our new shareholders support the management team and myself to implement the operational plan that we presented to them and contribute to the development of Verallia over its markets.

They bring us the investment capacity we need to continue to strengthen our industrial base and our teams’ skills the same way Saint-Gobain did it, and, in addition, to make acquisitions in the future.

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Verallia currently employs nearly 10,000 staff around the world. Will staff see any day-to-day differences under the new owners?

As Verallia’s management has been maintained under my authority, our priority remains the same: to do our job as best as possible, which entails a search for operational excellence, in order to offer our customers an exceptional level of quality and service. With €2.4 billion of gross revenue and 15 billion bottles and jars products in 2014, Verallia is one of three world leaders in the industry.

We are number one in Western Europe and we want to strengthen our leadership. I am pleased to have the backing of our new shareholders for the implementation of these strategic goals and Verallia’s growth.

“We are number one in Western Europe and we want to strengthen our

”

leadership.

Verallia CEO Jean-Pierre Floris. He said the company now had the means to make acquisitions in order to be closer to its customers.

Is Apollo looking forward to entering the glass market? And, what was attractive about Verallia?

Our shareholder has already experienced success in our industry, namely in the United States, and has long believed in the potential of our company.

We have an industrial tool of high quality, competent teams in all areas, a priceless glass expertise and a great capacity of innovation, which enables us to sustainably maintain our customers’ trust.

Moreover, Verallia enjoys a great reputation in our markets and we are fortunate to work with a wonderful material, ecological and rewarding for our customers’ products.

Verallia is also the world leader in several markets: wines and spirits, and soft drinks. We are also well positioned in the beer and food markets.

Our new shareholders, Apollo and BPI, are here to enable us to accelerate the development of Verallia, which goes through two levers: operational improvement and external growth.

Continued>>

14 Glass International November 2015

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Personality profile: Jean-Pierre Floris

What direction will Verallia take going forward, in terms of new strategies to be implemented?

Saint-Gobain has been a good shareholder, which enabled us to be well positioned and involved in our markets. Apollo and Bpifrance deeply believe in Verallia’s development potential.

With them, we have the means to make acquisitions in order to expand our presence close to our customers.

We will study with our new shareholders the opportunities we have to strengthen our positions in some countries, especially in South America, and to establish ourselves where we are not yet present.

I am thinking, for example, of UK, Northern Europe, Eastern Europe and Africa.

 Verallia’s fluorescent glass, one of the company’s latest developments. The glass appears transparent until it is viewed under a blue light.

Will Verallia plants continue to produce the same products as they do now, or will there be a reorganisation in terms of what plants make what products?

What makes Verallia’s strength is our industrial network in the countries where we operate, which allows us to offer a very good service to our customers by optimising costs through the interconnection between our sites.

Verallia’s business is local in nature: our 47 sites around the world are close to our customers, just as in France where many of our plants are located in wine regions.

Our clients appreciate our ability to deliver a large number of different products near their sites.

We want to maintain and strengthen our local advantage.

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Are there any plans to diversify the company’s portfolio by expanding its product range?

In terms of innovation, Verallia is and wants to remain far ahead of competition. We innovate our product, in terms of design, colour and lightness: Verallia releases 1500 new products on the market per year.

We also innovate on the time to market, as well as the communication interfaces with our customers, such as the Virtual Glass application that allows them to visualise bottles 3D. It is this ability to innovate that will enable us to sustainably maintain the trust of our customers.

Will Verallia change any of its branding?

The Verallia brand, which has existed since 2010, is now our banner in every country where we operate.

It is the strength of an independent group to be able to showcase a unique brand that is recognised by our customers.

Are there plans to invest in new equipment or machinery at Verallia plants?

We have a world-class production facility, with 60 furnaces, and we invested over one billion euros in new equipment over the past five years.

For instance, in 2015 we completely remodeled our food jars factory in Neuburg, Germany as well as the factory of Seville, Spain. We will continue to invest to be better positioned in our markets.

In 2016 we plan to include a renewal programme in a factory in Spain and several renovation programmes in France.

What are the main challenges for the glass industry and how will Verallia position itself to face them?

In the glass packaging industry the priority is that we do our job as best as possible. What our customers expect is excellence in terms of quality and service.

We are continuing this quest for excellence.

Thus, we have been implementing for several years a World Class Manufacturing programme in each Verallia factory to keep improving our industrial performance, in order to provide an exceptional level of service and quality to our customers.

Although we are at the highest level in the market, I am convinced that there is room for progress in terms of quality and service. Besides, we are and remain deeply involved in the reduction of our environmental footprint throughout the entire supply chain, from our sites to our packaging, with a product that is 100% recyclable. r

Verallia: www.verallia.com

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Country profile: Indonesia

Indonesia’s container glass industry enjoys growth Indonesia has the world’s fourth largest population with 250 million people living in the South East Asian country. It is also the region’s biggest economy and has enjoyed annual growth of more than 6% in recent years, underpinned by spending among its growing middle class. Seema Gahlaut* presents a review of the Indonesian container glass industry.

R

“From a demand point of view, the trend is moving towards the lighter weight or one-way

”

bottle.

 Mr Ferdyan Khouw, Deputy Director Manufacturing, Mulia Glass.

glass”, said Joseph Haddad, O-I Indonesia’s Director General.

Eric L’Heureux, President Director of Schott Igar Glass, a container producer for the pharma industry, said: “The trend towards higher quality is as strong in Asian-Pacific pharmaceutical markets as it is elsewhere in the world. We expect a growing interest in high-quality pharmaceutical packaging in this region.”

Demand drivers Driven by a healthy growth in the Indonesian food and beverage industry, the Indonesian container glass industry is headed for interesting times.

Investment in Indonesia’s processed food and beverage industry is expected to grow at least 10% to IDR55 trillion (USD$4.6 billion) in 2015 from an estimated investment realisation of IDR 50 trillion in 2014. According to Adhi Lukman, General Chairman of the Indonesian Food and Beverage Association (GAPMMI), investments in this sector have been solid. Foreign investments have been particularly strong in 2014 and are expected to continue.

Continued>>

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obust demand in the country’s food and beverage market has led to healthy growth in its container glass industry in recent years. Indonesia is a country that contains great economic potential, a potential not unnoticed by the international glass industry. The country is being mentioned as an appropriate candidate to be included in the BRIC countries (Brazil, Russia, India and China) as it shows signs of similar advanced economic development. A rapidly growing middle class whose disposable income has grown continuously, and a change in the consumption habits of its vast population has led to increased demand for glass containers.

Currently catered to by four major container glass producers, which have an aggregate installed capacity of more than 425,000 tonnes per year, the Indonesian container glass industry is still dependent on imports for about 20% of its glass needs. While O-I is purely a container glass producer, the other three manufacturers have additional products as well as glass containers.

The years 2014 and 2013 were slow for overall economic growth - the Indonesian economy expanded by 5.02% in 2014 and by 5.58% in 2013 - yet container glass producers have had robust growth in the past two years. Two, O-I and Schott, have expanded their capacity in the past two years.

Ferdyan Khouw, Manufacturing Division Head of Mulia Container Glass, said: “From a demand point of view, the trend is moving towards the lighter weight or one-way bottle. In this case, Mulia Glass, with technical assistance from Nihon Yamamura Glass, has successfully produced and delivered NNPB medium size bottles to our major customers.”

O-I is optimistic about the country’s container glass industry and its prospectus. “To us, Indonesia is one of the markets with great potential in AsiaPacific. We think that if we want to be successful in Asia-Pacific, we have to succeed in Indonesia.

The country is particularly attractive with its large population and high consumption of container

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Country profile: Indonesia

Foreign direct investment (FDI) in the country’s food and beverage industry was $2.5 billion in the first nine months of 2014. Foreign companies are attracted by the country’s population and growing per capita GDP (which expanded from $1,643 in 2006 to $3,468 in 2013 according to data from the World Bank).

As container glass scores over other forms of packaging in high quality products, container glass producers are expecting to increase their share in these segments. Boston Consulting Group expects that by 2020 about 141 million Indonesians will belong to the middle class, almost double from the figure in 2013 (74 million).

The Pharma segment, which accounts for about 16% of container glass demand, is expected to present ample opportunities for container glass producers. According to the Convention on Pharmaceutical Ingredients Southeast Asia, the Indonesian pharmaceutical market is predicted to grow by 6% annually for the next four years.

In 2015, health-related spending in the country is expected to reach $21.7 billion, pushing the pharmaceutical market up to $80 billion in value by 2017.

“The advantage of being part of a multi-national business such as ours is that we can access a range of

”

regional and global resources.  Mr Joseph Haddad, O-I’s Indonesian President.

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O-I Indonesia O-I started operating in Indonesia in 1973, when it was established under the name PT. Kangar Consolidated Industries (KCI). At the time, it consisted of one furnace and four production lines that produced glass bottles and tableware. Later, in 1980, a second furnace was installed, which increased its capacity by three times.

O-I’s Jakarta plant currently consists of two furnaces and six machine lines, which produce around 2.3 million glass bottles per day for some of Indonesia’s leading food, beverage and pharmaceutical brands. Some of its customers include Multi Bintang, PT Asia Health Energy Beverage, PT Djojonegoro, PT Supra Ferbindo Farma and Ultra Prima Adadi. It currently has a one third share of the Indonesian container glass market, and its product portfolio is complemented by another two container glass manufacturing plants in neighbouring Malaysia and Vietnam which it runs with Berli Jucker Public Company Ltd (O-I BJC Glass Malaysia and O-I BJC Vietnam Glass Co).

O-I’s President Director of Indonesia, Joseph Haddad said: “In early 2014, O-I announced a significant investment in the Jakarta plant introducing its innovative neck press and blow (NNPB) technology along with upgrades to existing production lines to increase the speed and capacity of the operations.”

O-I had invested $10 million for the expansion in anticipation of higher container demand in the country. “The advantage of being part of a multinational business such as ours is that we can access a range of regional and global resources. We have a great deal of expertise in lightweighting containers,

 The Muliaglass factory in Indonesia.

and we have colleagues from around the world who are working with our team in Indonesia to equip them with the skills and knowledge they need to successfully manage NNPB production,” stated Mr Haddad.

He added: “In April 2014, we became the first glass packaging manufacturer in Indonesia to receive the FSSC22000, Food Safety System Certification. This certification is a set of global auditing standards which work to ensure the safety of food and its packaging.

“As part of the global O-I network, O-I Jakarta ensures its customers have access to the most advanced glass container manufacturing technologies and services available. In October last year, O-I appointed its first regional container designer based in South East Asia.”

Apart from supplying to its customers, O-I Jakarta also encourages its customers to access additional services to support new product development. For instance, O-I Jakarta works with its regional design team to help customers develop glass packaging designs that differentiate their brands. They also ensure that designs are suited to manufacture and meet customer filling-line and secondary-packaging requirements.

According to the Indonesian financial press, O-I plans to build a new production facility in the next three years. Mr. Haddad said these reports state that the company is looking for a suitable location (other than its existing plant at Cakung).

It plans to invest about US$100 million for the capacity expansion which will double its current production capacity.

Continued>>

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Country profile: Indonesia

PT Mulia Glass is a subsidiary of PT Mulia Industrindo and is the largest of the four container manufacturers due to its portfolio of float, automotive and glass block production.

Established in 1989 in West Java, its container glass unit has about a 40% share of the domestic market.

Mulia Glass also has an installed capacity to produce 612,500 tonnes of float, 45,000 tonnes of glass blocks and 1,20,000 safety glass car sets per year.

With two furnaces and seven production lines, its container division has a 460 tonnes per day capacity. The company mainly produces flint bottles for the food and beverage segments.

Mulia supplies glass containers to domestic food and beverage companies such as Heinz-ABC Food Co; Sinar Sosro (a tea bottle producer); Coca Cola Beverage Indonesia; Indofood and Unilever.

It also exports its container glass to Coca Cola Amatil bottling plants in Australia, RC Cola in the Philippines and to Bangkok Glass Industry, Thailand.

Ferdyan Khouw, Deputy Director Manufacturing at Mulia Container Glass told Glass International: “We are optimistic about the future of container glass industry in Indonesia. Container glass industry in the country is experiencing a steady growth.”

He added that the company plans to add one furnace with a 180 t/d capacity in the east of Indonesia around the end of 2017.

PT Iglas State-owned PT Industri Gelas (Iglas) is the country’s third largest container producer and is the oldest. The Surabayabased Iglas has been producing glass since 1958. The company, once the most dominant in the country’s glass industry, has struggled due to production and process inefficiencies.

Iglas produces container glass for the beverage, food, and pharmaceutical industries and has a capacity of 340 tonnes per day. The company stated it has a 35% market share but, after

viewing its financial reports, these claims look doubtful. The company had INR 70.93 billion in losses in 2013. The firm’s total liabilities stood at Rp 693.7 billion, more than double its total assets of Rp 265.7 billion. It has suffered losses for several years.

The company had planned to install modern technology and replace one of its production lines in 2010 and floated global tenders, but no decision was made.

The Indonesian government had selected it for privatisation in 2012, but bureaucratic delays and a change in government led to the postponement of these plans.

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PT Schott Igar Glass PT Schott Igar Glass is a subsidiary of German multinational glassmaker Schott. It entered Indonesia in 1996 by establishing a joint venture with a subsidiary of pharmaceutical maker PT Kalbe Farma called PT Igar Jaya. In 1997, Schott purchased Kalbe’s 51% stake in the venture and consolidated the Indonesian company under Schott International. Within a few years, Schott moved all its production from Malaysia to Indonesia, to produce for the domestic market and for export.

About 60% of its products are sold domestically, while the rest is exported to about 20 markets in ASEAN, the Middle East, India and Pakistan.

The Indonesian factory is located on a 30,000m2 site in Bekasi and has 70 production lines. It produces 700 million vials, ampoules, pipettes and special articles for the pharmaceutical market every year.

Global companies such as Roche, Aventis and Pharmacia, and domestic companies including Biofarma and Harsen are among the company’s customers. 

*Glass International freelance correspondent www.o-i.com www.muliaindustrindo.com/ mglass.htm http://www.bumn.go.id/iglas www.schott.com/english/company/worldwide.html

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Personality profile: Michele Gusti

Bright future for Italian industry Michele Gusti is President of the Hollow Glass Group at GIMAV and is also Chairman of the Ocmi-OTG company based in Milan, Italy. He spoke to Greg Morris about GIMAV and the Italian hollow glass machinery business.

What does your role as President of GIMAV’s Hollow Glass Group entail?

My role involves coordinating all of GIMAV’s hollow glass members, who are manufacturers of hollow glass machinery and plants. I represent them within GIMAV in an institutional capacity, such as at international meetings, fairs and so on. I have coordinated this joint booth here at Vitrum because I was convinced that Vitrum this year is the most important event, thanks to the Milan Expo being held at the same time. This booth has exhibited the best in terms of Italian hollow glass. All of the participants are involved in one or more activities of production of machines for hollow glass, such as containers, melting, annealing, building machines for tableware and

Michele Gusti is President of Gimav’s Hollow Glass Group and is also President at the Ocmi-OTG glass machinery company based in Milan.

“The Italian industry from a technical and innovation point of view is the number one in

”

the world.

technical glass production and also particularly for the pharmaceutical industry. Pharmaceutical containers made out of glass and glass tubing is the hottest product on the market at the moment.

Is pharmaceutical glass a particularly strong market for Italian companies at the moment?

Yes, both Olivotto Glass Technologies and OcmiOTG are world leaders in the plants for the drawing of glass tubings and for processing glass tubing into pharmaceutical containers such as ampoules, cartridges, vials and so on. Both companies supply the entire world.

Is this the first time there has been a hollow glass stand here at Vitrum?

Until a couple of years ago companies exhibited individually with their own booths. Some still do this, but in general this is the first time they have joined forces to highlight the capacity of the Italian hollow glass machinery industry. This booth covers the full range of hollow glass with the best and most high-tech machinery.

How would you describe the current Italian hollow glass market?

It’s definitely a positive market. From a technical point of view it is the number one in the world. It shares the first seed with the German industry but is slightly ahead, particularly as we are distributed in every country in the world. We are very much concentrated on keeping that first seed for a long time.

Continued>>

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G

IMAV is the association of Italian manufacturers and suppliers of machinery, equipment and special products for glass processing. It was set up in 1980 by a small group of businessmen and now plays a fundamental role in the domestic and international glass industry.

Its hollow glass division comprises 14 companies, 13 of which are manufacturers of machinery and moulds. Its flat glass division comprises 61 members: 46 from the machinery and equipment sector and 15 from the accessories industry.

Its members were well represented at the recent Vitrum exhibition, which included a dedicated Italian hollow glass machinery industry booth, where GIMAV members Antonini, BDF Industries, Glass Service, Ocmi-OTG, Olivotto Glass Technologies and Tecno5 exhibited their products.

GIMAV’s President of its Hollow Glass Division, Michele Gusti spoke about his role and the bright future of the Italian hollow glass sector.

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Personality profile: Michele Gusti

The Italian hollow glass booth at the Vitrum event highlighted the best of the Italian hollow glass industry.

Are there any particular markets or regions that are growing?

We are strong all over the world. The pharma glass market is very strong and is linked to the human population. The converting industry, from tubing to container, is proportional to the number of inhabitants, so obviously developing countries and countries with huge populations such as China and India are the top countries for us.

What are the strengths of the Italian hollow glass industry?

We are just a little branch of the whole Italian industry and the Italian industry from a technical and innovation point of view is the number one in the world. That is why we are so well known and appreciated in so many nations. The Italian machinery industry is generally composed of medium to small companies, particularly family owned who are very much export-orientated.

These are innovative, flexible companies, that are close to the needs of our customers. That’s why we are number one.

Does the Italian industry have many young people joining the industry?

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The machinery industry is very popular. Young engineers are keen to join our company [Ocmi-OTG] because, as a family company we give them good prospects for the future and they understand that we engage our resources for the good of the company, so they are safe. GIMAV is an association of 61 flat glass and 14 hollow glass members, so it is a big network where technicians can share know-how.

As chairman of Ocmi-OTG, what are your plans for the future?

I’m optimistic my company will grow and become stronger thanks to a strong team of marketing and sales people which maintains excellent personal relationships with the top management of every customer, and thanks to the effort of our technical department who keep our products at first place in the industry.

GIMAV, Milan, Italy, www.gimav.it Ocmi-OTG, Milan, Italy, www.ocmigroup.com

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Events world

Vitrum highlights the best of the flat glass industry Nearly 350 companies were represented at the Vitrum trade show recently. This year the event, which focuses on flat glass, included an Italian hollow glass pavilion and incorporated the ATIV conference as part of its programme of special events. Greg Morris attended.

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A

total of 347 companies from the global flat glass industry exhibited, or were represented, at this year’s Vitrum event. The exhibition is dedicated to machinery, equipment and products for glass processing. Companies from 25 countries exhibited and occupied a net surface area of 20,000m2. The majority were from Italy as expected, but also from places as diverse as Australia, China, Egypt, Israel, Germany and Singapore.

Some of the exhibiting companies with large stands included Glaston, Mappi, Dip-Tech, Bottero and Fenzi.

The exhibition floor also included a hollow glass booth where Italian glass machinery association GIMAV had several of its member companies exhibiting.

A total of 18,450 visitors flocked through the gates of the trade show, and over the four days the fair attracted 9,032 Italian and 9,418 international industry specialists and buyers.

Renata Gaffo, Director of Vitrum, said: “The recently-concluded edition of Vitrum upheld the same levels as Vitrum 2013 - in terms of number of exhibitors, net exhibit space and even visitors.

“In recent years the market has produced a kind of ‘natural selection’, favouring those businesses that invested heavily in innovation.

“Vitrum 2015 drew highly-qualified business contacts to exhibitors’ stands and corroborated signs of a slight market upturn.

“Vitrum is known as an extremely technical event focused on the most innovative aspects of the glass processing industry – a specific emphasis that makes it popular with exhibitors and visitors”.

The Vitrum show’s programme of events included the incorporation of the 30th ATIV conference and an exhibition titled ‘The Glass. The Great Unexpected’,

z There were 347 companies represented on the exhibition floor at this year’s Vitrum event.

which focused on the how glass has been used over the centuries. Vitrum also coincided with the Expo 2015 event in Milan, which was also held at the Fiera Milano exhibition centre in Rho, Milan.

Dino Zandonella Necca, President of Vitrum, said: “Visitors to Vitrum 2015 were not only able to preview the very best technology applied to glass and showcased by companies from throughout the world, but were also able to discover interesting cultural aspects inherent in this invaluable material.

“The exhibition illustrates the use of glass in history, design and architecture, an overview of how glass is used in premium production.

“The organisation of this year’s Vitrum required a lot of teamwork that gave rise to joint initiatives, such as the 30th ATIV Conference; the presentation of projects developed by the Milan Polytechnic University students at a workshop promoted by Vitrum; and a group stand dedicated to hollow glass, showcasing Italy’s finest production.”

After the show, Ms Gaffo added:

“The tentative signs of a slight recovery perceived over the last few months were confirmed at the exhibition.

“Vitrum has retained and further strengthened its distinguishing feature, that of being an extremely technical and technological show. We offered a show dedicated to the Italian glass legacy that is known throughout the world.”

Hollow glass Michele Gusti, President of GIMAV’s Hollow Glass Group, said of the hollow glass booth: “I’m happy that hollow glass is back at Vitrum. It’s back with a different spirit as a close knit group of six companies, all GIMAV members who have agreed to display their finest technology in all production sectors: bottles, tableware and pharmaceutical containers.”

His views were echoed by hollow glass exhibitor Emanuele Dalla Fontana, Managing Partner at BDF Industries: “We are here because we are a partner to Continued>>

24 Glass International November 2015

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Events world

PROVEN SCIENCE

GIMAV and thought it was a good idea to promote the best of Italian hollow glass at this event.”

The other companies to exhibit on the stand were Ocmi-OTG, Olivotto Glass Technologies, Glass Service (Italy), Tecno5 and Antonini.

Exhibition floor On the exhibition floor, exhibitors said they were pleased with the show and commented on the high level of visitors.

Elettra Bresciani, Communication Manager at OmniDecor, said Vitrum was an important event at which to meet existing and potential new customers.

She said: “We are here to confirm our Italian origin. It is an Italian show, so we had to be here. It has been a good show so far and we have met some good customers. Today is the second day and it has been busier than the first day, but we expect visitor numbers to peak on the final two days.”

The company produces acid-etch on decorative glass for the architectural industry and was showcasing its latest textures, exclusively created by architect Egidio Panzera.

French company System Res was promoting its vacuum bags used for deairing the assembled interlayer and the two sheets of glass in order to produce a high quality laminated glass.

Technical manager Emmanuel Toulisse said the company was new on the market and was keen to promote itself to the industry.

He said: “Compared to the second day two years ago there are fewer people, but the contacts we have made have been of a very good quality. For flat glass, this is the show we have to be at.”

The company’s main markets are Russia and the Ukraine, but it is focusing on developing markets such as Mexico and Latin America.

ATIV conference About 60 delegates registered for the Association of Italian Glass Technicians (ATIV) conference, which had moved

from its traditional home of Parma, Italy to Milan as a result of the partnership with the Vitrum event.

The day-long conference incorporated 13 technical papers and a welcome ceremony from Alessandro Bandini, President of ATIV and Mr Necca.

Mr Bandini said: “It is the first time we have accepted Vitrum’s invitation to organise our annual conference at Vitrum, with a view to increasing cooperation and synergistic efforts that are indispensible in this area.

“This conference offers Italian glass technicians the opportunity to network and learn from international experts, technicians and scientists.”

Mr Necca said: “In my capacity as Vitrum’s President I’m honoured to host the 30th ATIV Conference in Milan. It is the start of a new form of cooperation that involves several players in the industry.

“The financial crisis has taught us that synergies among the different activities are a must. I am very pleased that ATIV’s President, Mr. Alessandro Bandini, accepted our invitation.”

Papers covered topics in the hollow and flat glass industries and were presented by representatives from companies, research centres and universities.

Companies that presented papers included Glass Service of the Czech Republic and Iris Inspection Machines of Lyon, France.

Some of the papers presented included ‘Installation of a new batch preheater in South Africa’ by Zippe’s Hansjuergen Barklage (published in the October 2015 issue of Glass International), ‘Hollow Glass Moulding Precision’ by Pneumofore’s Francesco Amati, and ‘Glass Strengthening with a Femtosecond Fiber Laser’ by Sisecam’s Dadal Ariburnu.

The next Vitrum trade show is due to be held in Milan in 2017. 

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z The opening ceremony at Vitrum.

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Vitrum 2015, Milan, Italy, www.vitrum-milano.com GIMAV, Milan, Italy, www.gimav.it ATIV, Parma, Italy www.ativ-online.it

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25 Glass International November 2015

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‘He’s a glass man’ This year, Mr Surasak Decharin of Bangkok Glass was named the 45th recipient of the Phoenix Award ‘Glass Person of the Year’. After more than 30 years with Bangkok Glass, he has been instrumental in growing the company from a one furnace operation to a 13 furnace affair, and transforming it into the largest glass manufacturer in Thailand. Sally Love attended the awards dinner, held in his honour in San Francisco.

W www.glass-international.com

hen you meet Surasak Decharin, he is polite, humble, and friendly. The winner of the 45th Phoenix Award for ‘Glass person of the year’, Mr. Decharin has been key to the growth and success of Bangkok Glass, although his common refrain is that the company’s success is down to “good fortune”, and “teamwork”.

Joined at the event by his wife of 21 years and their son, the evening was a celebration of both his professional career and his personal achievements.

Recovering from adversity The symbolism behind the phoenix myth is in itself a fitting description for the challenges endured by Bangkok Glass in recent years, with the global economic recession further affected by political unrest in Thailand. This was followed by the devastating floods that affected Thailand in 2011, which completely submerged the group’s Ayutthaya plant, resulting in a 40% loss in capacity for the business. Under Mr. Decharin’s guidance, however, Bangkok Glass has been able to come out

the other side stronger than ever, maintaining its position as Thailand’s largest glass manufacturing company.

Mr. Decharin touched upon these troubles during his acceptance speech, and what it means for both the company and the region: “Having been involved in the glass industry for more than 34 years, I can say that this really has been a wonderful journey of excitement, enjoyment, as well as friendship, and of course a lot of tension. This is especially in Thailand, where we have had to deal with a natural disaster.

“Although some may argue about how ‘natural’ this was, it really was a disaster: Floods, drought, political unrest – somehow it becomes part of normal routine… But having said that, I think you would all agree that Asia as an emerging market, which is almost half of the global population and is therefore half of the world’s future of consumer spending, will continue to be an important arena for the glass industry.”

Continued>>

26 Glass International November 2015

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Phoenix Award

z Mr. Decharin (front centre), with current committee Chairman Tim Park (front, second from right), joined by the eight former committee Chairmen that were able to attend the event, including last year’s Chairman Wally Evans (front, far right).

‘Good fortune’

Bangkok Glass’ survival, throughout the good and the tough times.”

Personal and professional

“The nomination provides me with great personal pride.

I am really grateful for this

”

recognition

Having retired from his day-to-day duties at the company earlier this year, Mr. Decharin has remained as Director and advisor to Bangkok Glass, and he spoke about the fortuitous timing of the award at this stage in his career: “The nomination provides me with enormous personal pride. I am really grateful for this recognition, especially at this time in my life, when I had not expected it.

“I started my career after my first degree, 44 years ago, the year when the Phoenix committee was born. And now I am here as the 45th recipient, in my retirement year… I began my career in an investment bank by accident, but I stayed here by choice.”

Tim Park,recounted the highlights of both Mr. Decharin’s career and his personal achievements.

After graduating with a degree in accounting in 1971, Mr. Decharin began his career in an industrial finance corporation in Thailand, before moving to the UK to sit a further degree in 1976. In 1978 he and his wife had their son, before returning to Thailand in 1981 where he joined Bangkok Glass as its Finance Manager.

Remaining at Bangkok Glass ever since, Mr. Decharin was named President in 2000, and this year has been recognised for his contribution to the glass industry for his role in management.

Continued>>

www.glass-international.com

Introducing Mr. Decharin on to the stage, Chairman of the committee Tim Park highlighted his humble nature: “When I had a chance to meet with him, he told me, he didn’t understand why the committee had chosen him, and that he had just been doing his job at Bangkok Glass.

“The success of Bangkok Glass, he said, is due to good fortune… Surasak’s hard work for Bangkok Glass has led it from a one furnace operation to today, where it has 13 furnaces and is the largest producer in the country, and one of the largest in the region.

“He’s a great leader, and under his guidance his company has grown and grown. And to this day he says ‘ah, good fortune’. That’s why we have the Phoenix Award, to recognise people like Surasak.”

Accepting the award, Mr. Decharin thanked the audience for being there, and was adamant that the company’s success was a shared achievement, across the company: “I am here today feeling extremely honoured by your nomination for the Phoenix Award… I’m certainly not eligible to claim all the achievement as my own, because success is never a creation of any one person, but is in fact the sum of a team effort.

“People at Bangkok Glass have worked tremendously hard over the years to get the company to where it is today, and we have been extremely well supported by our business partners and suppliers from the glass industry… I continue to be grateful for the team effort that has ensured

27 Glass International November 2015

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Phoenix Award

z Mr Decharin (front, seated third from right) is joined by the Phoenix Award Committee members at this year’s event.

The Phoenix Award Dr. Bernd-Holger Zippe, who has been named as next year’s Chairman of the Phoenix committee, opened the awards this year by explaining the purpose of the Phoenix Award and its symbolic significance: “It is the purpose of the Phoenix Award committee to select each year a person, now living, who has been active in and has made significant and major

contributions to the glass industry.

This may be in the field of science, production, or education relating to glass. As a symbol of this award, the recipient shall be presented with a glass sculpture representing the mythological phoenix bird.

“According to Greek mythology, only one phoenix bird existed at a time.

The phoenix bird lived for 500 years

www.glass-international.com

Speaking of Mr. Decharin’s achievements, Mr. Park said: “He’s proud to be a member of Bangkok Glass and of the glass industry; he’s a glass man.

But, I think he’s actually [more] proud of his marriage to his wife, and of course their son.”

This pride was evident in the closing remarks of Mr. Decharin’s speech, when he spoke of his wife in particular: “To my Bangkok Glass colleagues at home, I would like to extend my thanks, as well as to all the past and present business partners, colleagues, and friends, I can’t thank you enough for your support throughout the years.

“I would also like to thank my family for the lifetime of support, and my wife, who I am indebted to for keeping me together.

and then settled in a nest, and set it on fire. From the ashes of its body, a new phoenix bird arose to carry on the tradition. This combination of long life, dramatic rebirth, and continuity, makes the phoenix bird the symbol for the progressive, dynamic glass industry, which works with the material that first came from ancient Egypt and can be forever recycled.”

“I asked her to retire 10 years ago. The plan back then was she would retire, and wait for three years until I retired – that was the plan. However, a three year wait has become ten years, and I am really grateful for her patience.

“Last but not least, I would like to extend my sincere gratitude to all the Phoenix committee and the team who have been involved in this organisation and this great event. None of this would have been possible without your contribution.” 

www.phoenixawardcommittee.org

“He’s a great leader, and under his guidance his company has grown and grown.

And to this day he says ‘ah, good fortune’.”

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Saving Energy and Fuel Lubisol Ltd is offering significant savings of energy and fuel by efficient thermal insulation of glass furnace crowns.

The Lubisol crown insulation design is based on the principle that the usual light silica bricks insulation is partly replaced by the Lubisol insulation, applied over the light silica bricks. It is followed by a layer of Lubisol Cover Coat on the top. The thickness and the total cost of the insulation remain almost the same, but the heat losses from the crown are reduced by about 800-1000 W/m². The amount of the saved fuel is around 1300-1500 m³/m²/year natural gas or 12001400 kg/m²/year heavy oil. The cost of the saved fuel is significant.

The insulating material Lubisol 2-SL has a very low specific density of 0.3 kg/dm³, a high working temperature of 1500 °C and a very low thermal conductivity of 0.11 W/m.K at 500 °C. The cost for one cubic meter of this insulating material is lower in comparison with the cost of the light silica bricks, and in the same time it is about 3 times more efficient.

The Lubisol crown insulation package is suitable for application on all types of glass furnaces producing any type of glasses, including float glass, container glass, tableware or technical glass. It is very suitable for insulation of silica crowns as well for AZS and alumina fused cast crowns. It has been applied recently on 80 glass furnaces all over the world.

The efficient Lubisol insulation package brings significant energy and fuel savings without any additional material and labor costs. It is just a very good technical solution and a better option for the glass industry. _____________________________________________ website: www.lubisol.com e-mail: office@lubisol.com

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History

Prof. John Parker Turner Museum of Glass and ICG

Tin can!

Prof. John Parker* discusses the use of tin in glassmaking processes.

www.glass-international.com

T

in mining was once a dominant industry in south west England.

This activity was in full swing even in Roman times and continued until the ores were exhausted last century.

The latin name for tin, stannum, led to this area being named ‘the Stannaries’ and Sn for its chemical symbol.

A major early use was the tin/copper alloy whose name heralded the Bronze Age; later, pewter with 90% tin was important and now its low melting point accounts for its use in solders.

Over the years, however, it has also played an important and varied role in glass production. It melts at 232°C, ideal for the float glass process, where molten glass floats on a shallow liquid tin bath to give sheets with two fire polished, and hence ultra-flat surfaces without expensive grinding and polishing.

This application depends also on its physical properties (density, surface tension); these give an equilibrium and commercially saleable thickness for the glass close to 6mm. The tin leaves its mark, exchanging with sodium ions in the glass surface to a depth of several microns.

This can affect subsequent processing, e.g. it aids silver nanoparticle formation when staining glass yellow.

As a metal it resists oxidation and is silvery in appearance, giving an application based on its reflectivity.

Mirror makers in Venice perfected the use of a mercury-tin amalgam as the reflecting medium. Much earlier, the Romans and Egyptians investigated ways of depositing tin coatings on glass.

Even the discovering by Liebig of silvering techniques did not completely displace tin. It’s still used as an activator on the glass surface to improve the bonding between metallic silver and the inorganic glass.

Tin compounds also often fuse easily,

giving some of the lowest melting point in organic glasses e.g. tin lead fluorophosphates.

When dissolved in the glass, tin exists in two oxidation states, a 2+ ion called stannous and a 4+ ion called stannic.

Consistent with its 4+ state it sits in the 4th column of the periodic table, sandwiched between germanium and lead.

As with lead it has two oxidation states because its 5s outer levels are more stable than the 5p levels; the two 5s levels are occupied in Sn2+. Ancient chemists could not easily distinguish tin from lead or chemically separate them and the Romans named tin ‘white lead’.

In the oxidised 4+ state the tin-oxygen bond is strong, so SnO2 has a high melting point and a low solubility in the glass melt.

It replaced antimony compounds after the 2nd to the 5th century AD as an opacifier, giving creamy white glass containing fine SnO2 crystals. Its effectiveness in this application is increased by its high refractive index, related to its electronic structure.

High refractive index is also why many glass artists use stannous chloride. Sprayed onto hot glass it deposits as an oxide. If sufficiently thick (>100nm) the strongly reflected beams from the coating and the coating-glass interface can interfere constructively and increase reflectivity.

This varies with wavelength and viewing angle, giving a colourful iridescence.

A similar process has been used since the 1970s to deposit thinner layers on hot bottles entering the annealing lehr.

These add 50% to glass strength allowing light-weighting. Just as tin has a positive role in improving glass-to-metal seals so tin oxide layers assist by forming a strong bond to both the glass substrate and an organic coating sprayed on at the lehr cold end. This coating reduces friction and the amount of damage

caused by glass-to-glass contact.

Its refractoriness in a glass melt underpins another application – as an electrode in electric melting. At room temperature SnO2 is an insulator but its resistance falls at higher temperatures – it becomes semiconducting, enhanced by low concentrations of Cu, Sb etc.

In use it must be hot to conduct but, particularly for lead glass or highly oxidised melts, molybdenum of MoSi2electrodes are attacked and SnO2electrodes have a place.

Because tin has two oxidation states in glass it is invaluable for in situ redox reactions. Alchemists used stannous compounds (Sn2+) to reduce watersoluble gold salts to a red colloid of nanocrystalline gold.

Its role in glasses is similar. On melting, both gold and tin dissolve as ions, a fraction of the tin being stannous. On cooling, Sn2+ ions grab any opportunity to transform to Sn4+.

Any gold ions present gain the released electrons, becoming gold metal. The resulting red, so-called cranberry glass colours still attracts collectors.

The two weakly bonded 5s electrons in Sn2+ increase refractive index because they interact strongly with light – their energy level corresponds to near UV photons. These same energy levels give SnO2 a smallish band gap.

Antimony, indium and fluorine doping introduce electronic defects and enhance semiconductivity.

Such materials give transparent conducting layers, which have been used for heated car windscreens, electroluminescent devices and as conductors in PV solar cells. r

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

30 Glass International November 2015

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Company profile: Fives

Fives was chosen by Turkish group Düzce Cam for the design and supply of two of its float lines.

A global business from the heart of Paris Situated in the heart of Paris, Fives is a global organisation active across many industries. Its glass division was formed in 1947, and in the near 70 years since it has achieved hundreds of references in the flat and hollow glass industries.

Greg Morris met Executive Vice President for Glass, Thierry Valot.

www.glass-international.com

F

ives’ glass division is renowned for its R&D capabilities and groundbreaking ideas. It has recently developed two new pieces of equipment for the flat glass industry that it says improves the performance of glass production for automotive and ultra-thin applications.

Both developments are currently under test at glassmakers’ facilities.

The company is active in both the flat and hollow areas of glassmaking. Within float its core competence is in the melting furnace, tin bath and annealing lehr. It has 90 tin bath references, 135 annealing lehr references and has built 20 complete lines.

In the hollow market its speciality is electric melting, electric boosting, oxy electric furnaces and conditioning equipment such as forehearths.

Mr. Thierry Valot, Executive Vice President for Glass, heads the division. He has been with the company for 18 years and worked in its various other divisions before the move to glass four years ago. He had previously worked in automotive and was head of innovation at the company’s other subsidiaries, but says he was keen to move to glass because it is the division with the most

“By using this equipment... the glassmaker can do almost anything he

”

wants.

innovation: “The nice thing about glass is, it is a very historical type of industrial activity but there are still so many innovations.”

These innovations include recent developments related to the Prium brand. The first is Prium Bath Edge Control, which is a new configuration for forming the glass ribbon in the flat glass process.

The company is testing it at a European glassmaker and has so far had positive feedback.

Results will be announced by the end of 2015 and Fives expects to promote the feedback early in the New Year.

Mr. Valot noted that because the geometry is different, the benefits are that the glassmaker has the ability to pilot the forming process exactly as he wants, without all the geometrical limitations of the combustional design. “By doing this we can dramatically improve the optical quality of the glass,” he added.

“A developing application for glass today is the automotive market – for applications in this market optical quality is most important. By using this equipment you release many limitations of Continued>>

32 Glass International November 2015

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Company profile: Fives

z Mr. Thierry Valot, Executive Vice President for Glass at Fives.

The company has a testing facility in Bar-LeDuc, in the east of France, where it can conduct small tests such as combustions and thermal effects at the early stage of prototypes, but does not have a full-scale industrial facility itself – instead, it conducts tests at glassmakers’ facilities.

Its second recent development was tested at a glassmaker last year and is being tested again this year. Its Prium Bath Hot Air Cooler is a tin bath cooling system that offers advantages including a reduction of condensation defects, possibilities for waste heat recovery, lighter maintenance works and improved working conditions for workers around the tin bath.

Fives said another of its strengths was its flexible approach. Some customers may want the best available technology, while others may want an affordable solution with guaranteed good glass.

Fives can offer both solutions.

Mr. Valot said: “We have a range of technologies.

We have sophisticated, fully automated lines or can propose conventional, more affordable designs with different types of refractories. We always optimise the design so that the cost is always affordable. We always adapt our offer to perfectly match what the customer is expecting.”

the commercial design, so the glassmaker can do almost anything he wants. He can improve his forming process and, therefore, the optical quality of the glass.”

R&D The company has a close relationship with glassmakers, where Fives engineers listen to the glassmaker’s concerns and questions.

“The partnerships are key, especially in glass because we know that innovation in glass is difficult, because we know that once a float plant is ‘live’ it’s for 15 years at least. So, if the innovation doesn’t work the glassmaker has to live with it for the duration of the furnace.

“We have this close relationship with the production people where we understand their concerns, where we can improve their life and solve the problems they have.”

The R&D team is shared across all the entities at Fives and is therefore present in France, the UK and China. Its R&D team spends time commissioning and involves itself in sales, as experts who can talk with customers. “It means our R&D people are close to the operations of our customers.”

“For each offer we can build something which is totally flexible...

I think this is unique in the glass

”

industry.

He said that the company has even been able to match the Chinese on price while offering European know-how and quality. Fives is a worldwide group so has a number of domestic suppliers throughout the globe. Fives can use these contractors and can use them quickly: “If we make an offer in any country in the world, even where we haven’t been in any glass plants, we can optimise the local contacts. This is great for the end customer, who likes to work with people from his own country. We optimise the design to a European standard of engineering.

“So we have the ability to source in a totally optimised way depending on the customers requirements.

“For each offer we can build something which is totally flexible, we tune the offer according to the customers requirements. I think this is unique in the glass industry.” r

Fives, Paris, France www.fivesgroup.com Continued>>

www.glass-international.com

 The Düzce Cam facility in Turkey.

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Company profile: Fives

Recent applications Vivix

Düzce Cam

Vivix, Recife, Brazil, selected Fives as the Engineering, Procurement and Construction Management (EPCM) contractor for its 800 to 880mt/day float glass line. Fives was selected as the contractor for the complete process line, composed of the batch plant, the melting furnace, the tin bath, the annealing lehr and the cutting line.

It incorporates Fives’ Low Energy Melter (LEM) technology and an automatic glass thickness transition control system. The Prium Melt Float LEM is a new generation melting furnace designed to meet the challenge of ever increasing energy prices. It incorporates several features whose combination enables up to 20% less energy and greenhouse gas emissions than other melting furnaces.

Düzce Cam, Turkey, chose Fives for the design and supply of its first float glass line in 2007, with a 600mt/day melting capacity for clear and light tinted glass for residential and the automotive markets.

Then, three years later it selected Fives for its second, 800mt/day float line. The float line incorporated the Prium Melt Furnace LEM.

z The Prium tin bath at Vivix.

z The Prium Melt Float LEM installed at the Vivix plant in Recife, Brazil.

 The Prium tin bath at Düzce Cam.

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34 Glass International November 2015

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Moulds

Reducing energy consumption using sidewall mould ovens Samuel Leaper* discusses how mould pre-heating ovens can reduce a factory’s energy consumption if installed in the sidewall of the lehr rather than as a standalone unit.

U

Conserving energy With energy conservation in mind, the company designed a mould pre-heating oven that is installed in the sidewall of the lehr rather than as a traditional standalone unit (Figs 2 & 3). This reduces the energy used in pre-heating moulds to zero, and provides a return on investment.

Through the use of radiant heat, it’s possible to pre-heat the moulds to a temperature ready for installation in the container-forming machine.

The sidewall mould oven can be incorporated into a new annealing lehr or as a pre-fabricated package that can be retrofitted to existing annealing lehrs.

Installation takes less than 12 hours and can be performed by either the glass factory or by E.W. Bowman. The lehr sidewall mould ovens are typically installed in either zone 2 or 3 of a lehr section, as this provides suitably high temperatures to pre-heat the moulds while not placing too much strain on the

z Fig 1. A mould pre-heating oven, prior to installation on the sidewall of a lehr. Right: Figs. 2 & 3. The mould pre-heating oven installed on the lehr, along with a view of the inside of the oven.

thermal performance of the lehr.

To ensure that the lehr remains efficient even with the removal of the lehr sidewall insulating material, the mould oven features heavy, insulated doors and high grade insulating materials in its outer casing, resulting in no identifiable heat loss in the zone as a result of the installation of the mould oven.

Reported benefits This technology has been employed by some of Europe’s leading glass manufacturers for several years. Last year, a prominent glass manufacturer in South East Asia installed its first E.W. Bowman sidewall mould oven. This was the first unit to have been supplied to the region and initial feedback has been positive, so much so that it is anticipated that the glass manufacturer will standardise on this mould oven system.

The typical payback period is around

12 months, although in some cases it can be as low as seven months. However, this is dependent upon the condition and efficiency of existing mould ovens, the condition and brand of the lehr, the lehr set up, and lehr maintenance.

Feedback has also indicated that there has been no identifiable increase in lehr energy consumption as a result of the installation of the mould oven, resulting in mould pre-heating costs becoming zero, a reduction in energy consumption and carbon footprint.

Additional reported benefits are that manufacturers are no longer required to carry mould oven spares and there are zero maintenance requirements for the mould oven due to the lack of moving parts. r

*International Sales Manager, E.W. Bowman Inc., USA www.ewbowman.com

www.glass-international.com

S-based E.W. Bowman has supplied annealing and decorating lehrs to the container glass industry since 1959. Over the years, the company has added several lehr and oven related products to its portfolio. One such product is the mould pre-heating oven, used to pre-heat glass forming moulds prior to their installation in the forming machine ready for production (Fig. 1).

Originally, these mould preheating ovens were always supplied as ‘standalone’ units. This meant they relied on an external source of electricity and an independent source of heating energy, typically either gas fired burners or electric heating elements.

With the increased focus on energy efficiency and energy conservation in recent years, E.W. Bowman has reviewed this technology and identified possible areas for improvement.

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Technical Topics

John Henderson Henderson Technology

Compressed air John Henderson* discusses recent developments in the field of compressed air installations, and the effects it can have on a factory’s equipment and running costs.

www.glass-international.com

B

asic maintenance engineering can be a somewhat ‘Cinderella’ area in even a modern glass factory. Often near the bottom of the pile is compressed air, and although I have written about this before I thought it worthwhile to return to the subject as newer developments have come along.

In my previous column, I related the story of some old reciprocating pump compressors situated in a basement where temperatures and humidity were distinctly tropical in nature: how the system was inefficient; the product wet and dirty; and the running costs hidden in the general factory electricity costs. The system worked and delivered compressed air to the very forgiving machines we were using at that point.

When we invested in a new, faster, more efficient tubing line, the existing compressed air provision was nowhere good enough. A part of the project’s capital spend was on a helical screw compressor with all the filters necessary to give us clean, dry air. Dry, in this instance, means very dry: the air had to pass down a hot glass tube, the inner surface of which was coated with a glass that was resistant to alkali metal vapours but susceptible to the attentions of any water molecules there. Too much absorbed moisture meant reduced lamp life, or possibly no lamp at all.

Not all compressed air installations may have such critical parameters as this, but even so the air needs to be clean and dry for it to be used to its best advantage whether it is supporting power generation through to precision paint spraying.

When it comes to replacing compressed air systems there are potentially conflicting priorities, such as improving

“All of us like to get value for money, but it is critical when looking at compressed air replacement to challenge some of our long held assumptions relating to production downtime costs, running costs, and regular

”

maintenance spends.

energy efficiency (carbon footprint!), a production supporting specification, and spending limits. However, more recent developments in the field of compressed air will allow engineers more flexibility when designing systems. One of the design considerations that needs to be reviewed for a more modern system is standards compliance.

Compressed air is within the remit of the ISO 8573 group of standards. A good guide to permissible level of oil, dirt and moisture contaminants is given in ISO 873-1 and it is incumbent on engineering staff to ensure all certifications and warranties are in place.

In most glass factories the compressed air pipework was made from black iron and/or galvanised steel which in general is susceptible to corrosion both from the inside and outside, particularly at joints.

Newer options such as aluminium are now available with inherently better corrosion resistance and they do away

with the cyclical painting cost necessary for iron and steel pipes. Indeed some manufacturers offer colour coded pipes which are colourfast for several years.

All of us like to get value for money, but it is critical when looking at compressed air replacement to challenge some of our long held assumptions relating to production downtime costs, running costs, and regular maintenance spends.

Also important is the use of flow calculation models, which can check current pipework efficiency and more importantly advise on improvements. As a supplement to this modelling, it can be useful to use system energy calculator tools where these are available to get at least an estimate of the payback on system changes.

It might seem strange to talk about the aesthetics of a compressed air installation in a glass factory, indeed my experience would suggest that this is not even in the vocabulary of some of the engineers working on compressed air installations.

However, if you are renewing systems at the cold end of the lehr where you are trying to maintain hygienic conditions to meet customer demands on product cleanliness, or there are hygiene requirements in a filling line hall, you just might want any exposed pipework to look as if it is part of the overall design concept.

So, although some might see compressed air as a ‘Cinderella’ area they might end up as a ‘Baron Hardup’ if they neglect it. (with apologies to puns anonymous). r

*Henderson Technology, Sheffield, UK info@hendersontechnology.com www.hendersontechnology.com

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Container glass

Can you afford not to use original parts?

T

he job of the Purchasing Manager in the container glass industry has never been easy.

In these days of fierce competition from other materials, globalisation of markets and increased quality demands from customers, the purchasing function faces new challenges. This is particularly true in the area of accessories and replacement parts to keep the production and inspection lines operating.

The manager is expected to demonstrate negotiating expertise by continually reducing the cost of purchased materials and services. He or she has to cope with wider product ranges, more flexible production methods and financial penalties for downtime and defects. Add to this the trend away from traditional mechanical methods towards electronic solutions, and it is unsurprising that the purchaser feels under pressure.

One way to react is to use today’s improved communication channels to seek out alternative suppliers and to consistently take the business to whoever offers the lowest price. There may be some short-term benefits in this approach, but is this valid in the long term? Before dismissing the original equipment manufacturer as a parts supplier, the manager would be well advised to consider the following questions:

 The 535 mechanism with original parts.

Am I really saving money by purchasing cheaper?

There is no such thing as a free lunch. In almost all cases, lower parts purchasing costs will be accompanied by a higher risk of (at best) early failure and, at worst, expensive damage and long downtime.

This is a gamble which some may be prepared to take, but is it a good bet?

Studies carried out by Bucher Emhart Glass show that a modern, well designed and operated IS machine can be expected to produce a contribution of about €1200 per hour, (€20 per minute) depending on size, location and ware produced. By achieving a saving of 15% on one average section part that, for example, has a price of €400, a Purchasing Manager could congratulate himself on a saving of €60.

However, if a lost production time of only three minutes should result for any reason connected to these substitute parts, then the savings would be wiped out, and longer production losses could produce an expensive ‘cost saving’ exercise.

The same logic applies to larger items: if a purchaser manages to locate an alternative source offering a 20% saving on a particular mechanism which the original manufacturer priced at €1000, then the good news is that on a 10-section machine, this would result in a saving of

€20,000 – at first sight a great deal. The bad news is that if over their lifetime these bargains achieved only two hours less of production (or the equivalent in fewer good containers packed), then the exercise would be a loss-maker. These do not seem like good odds on which to wager the profitability of the business!

Do all suppliers offer the same product quality?

How secure would we feel flying in an aircraft whose maintenance parts had been selected on the basis of cost rather than proven functionality? The fact that a supplier can produce a part to a drawing is no guarantee that it will function as the original machine designer intended.

High-performance mechanisms demand tight tolerances, which some suppliers may not be able to hold, or even be aware of. A cheaper material can be substituted for that specified so that the part looks the same as the original, but how does this affect its functionality?

Surface hardness plays a vital role in the life of many parts, but unfortunately the most effective hardening processes tend to require specialised equipment, which is capital-intensive and difficult to control. A low-price supplier will be sorely Continued>>

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Garij Göhrich* outlines how the role of the Purchasing Manager has never been easy, and considers a number of questions the manager should regard before making a purchasing decision.

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Container glass

tempted to cut corners here. Bucher Emhart Glass has designed the tolerances and material specifications of each part to fit the requirements of the entire machine, and already has available the processes necessary to produce them. All of its manufacturing plants are certified to ISO 9001 or 9002.

What is the value of ‘one-stop shopping’?

The practice of ‘cherry-picking’ – placing a multitude of small orders with the cheapest supplier for each item – is tempting, but of questionable value.

It assumes that the purchasing personnel have time on their hands and it fails to take into account the minimum cost of producing and processing an order, which may be in the region of €100 per order if fully costed.

A parts-only supplier would normally offer only those parts which he deems to be profitable or feels capable of producing (typically a few hundred items), and will often be unable to supply many vital items which are slower-moving or difficult to manufacture.

Bucher Emhart Glass maintains more than 50,000 hot end items, together with 40,000 inspection spares.

The story does not end with the breadth of the parts range. Placing a large number of small orders leads to chasing up a large number of uncoordinated shipments through a variety of channels, resulting in high overhead costs at the receiving end.

On a personal level, few of us would choose to spend our free time travelling around between supermarkets, comparing prices and selectively purchasing in each shop only a small number of items from the household shopping list. Any benefits do not justify the effort. We get everything we need at the one location where we feel most comfortable doing business.

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Is this really the part I need?

In a perfect world, a Maintenance Manager would know exactly what parts he requires at all times. Reality is different.

Mechanisms are updated, designs rationalised and new functionality introduced. An adaptation is required for a special container or to fit existing equipment.

In such cases, competent technical advice is essential and this is most likely to be found at the original machine manufacturer, particularly if the company is large enough to maintain a team of experts for this purpose.

How long do I need to wait?

There is little point in saving a few percent on the cost of a part, only to suffer expensive downtime or damage while waiting for it to arrive.

Only the largest suppliers can sustain the infrastructure to establish and maintain reliable supply and logistics chains to support their global customers.

For example, the main Bucher Emhart parts distribution centre has served its European customers with an overnight delivery service for 4,900 of the most commonly required parts (S-Class Parts).

This makes the actual location of the supplier facility irrelevant – the order is placed one day and the goods arrive the next. Destinations in other continents with time-consuming customs formalities can be supplied within days.

What is the lifetime of this part?

If a copied item costs substantially less than the original, then corners must have been cut somewhere. This weakness may not always be immediately apparent, but will often show up in a reduced product lifetime. A 15% cheaper part that lasts only 50% of the life of the genuine article is no bargain.

Is the machine warranty invalidated?

No one would expect a car manufacturer to honour a guarantee if parts from another supplier had been fitted and the same applies to IS machines. Damage resulting from the installation of substandard parts may not be limited to the parts themselves.

The performance of whole mechanisms can be severely degraded by the use of lower quality copies of seemingly unimportant items such as bushings or pins. If the mechanism is located outside the section, (for example in the feeder, shear or gob distributor), then the entire machine may be shut down.

What effect could this have on plant liability?

Any powerful equipment can be dangerous if operated or maintained incorrectly, and glassmaking machinery is no exception.

Given the exposed mechanisms in an IS machine, mechanical and electronic reliability of operation are vital to the maintenance of safety standards.

Through its network of customer relationships, Bucher Emhart Glass monitors under-glass performance of

their machine components. This enables design and operating parameters to be adjusted if necessary to preserve safety levels.

Can you be sure that the parts you install will be compatible with the operating environment your workforce is expecting? Using non-original copies in place of original parts could raise unpleasant legal liability issues.

Can I afford to get it wrong?

Buying a part that does not fit the household appliance for which it was intended is frustrating.

The stakes are much higher in roundthe-clock glass plant operations. A replacement part that fails to fit or perform as expected, produces not only great frustration, but also expensive downtime (€20 per minute) and even this is only the start of the story.

The cost of fitting a new part will often be similar to the cost of the part itself.

Imagine the financial effect of having to remove an entire mechanism from a machine because a small ‘alternative source’ replacement part was not up to the standard of the rest of the assembly?

Add to this the effort to find a properly functioning item quickly and then go through the installation procedure a second time. Any initial savings would have evaporated long before the machine restarted. Emhart Glass knows of cases where a ‘cheap’ split ring caused damage to all plunger mechanisms in a machine, which resulted in expensive stripping, rebuilding and downtime.

Conclusion The capital-intensive nature of the container glass industry, coupled with its 24-hour/seven-day working cycle, puts a high premium on maximising production hours. Sourcing parts from suppliers who did not design the originals carries with it an inherent risk of reduced performance and damage.

Therefore, attractive savings at the time of purchase can quickly turn into the nightmare of expensive downtime.

Purchase cost is only one element (and not even the most important one) of ‘total cost of ownership’. The experienced Purchasing Manager knows this, and selects his suppliers accordingly. r

*Product Manager, Bucher Emhart Glass, Cham, Switzerland www.bucheremhartglass.com

40 Glass International November 2015

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Automation  Energy efficiency improvements at Pilkington

Pilkington benefits from integrated control system Siemens and IconSys have delivered an integrated control-system technology solution that enables Pilkington UK to tackle productivity and operational efficiency challenges.

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F

acing pressure to ensure that productivity and reliability were enhanced on a key toughened glass production line, Pilkington UK has seen improvements in product quality, waste volume and operational efficiency, thanks to the recent upgrade of its automation control system technology.

A previously fragmented portfolio of legacy technology has now been brought together to provide a holistic control system overview that is driving performance improvements at a critical production site for the UK’s largest glass manufacturer.

Efficiency levels The combination of Siemens’s automation technology along with IconSys’ control system and glass sector expertise has delivered an effective control system, which provides production control so the manufacturer can meet market demands for higher quality glass, as well as improve

overall operational efficiency levels.

Upgrading the control solution for the busy glass production line was a challenge, as it had to take into account the varying control needs of each stage of the finished product line, including the furnace, wash station and measuring stations, as well as the requirement to transport the glass sheets between the various production stages. The integration of the system also had to be undertaken during a suitable slot within a demanding glass production schedule without affecting day-to-day operations.

Steve Martin, Head of the Glass Sector team at Siemens UK & Ireland, said: “The existing control system did not provide the precise control required to meet the fine tolerances Pilkington UK was aiming for. The accuracy of the process was also undermined by the legacy hardware, which was proving to be increasingly problematic.

“They had a fragmented portfolio

of technology solutions that was, on occasion, compromising efforts to optimise performance. Siemens’ Totally Integrated Automation (TIA) approach was the technology framework on which the finalised solution was based.

“We worked with IconSys, who designed and built the new control system required to operate the entire glass line, and with it meet the product quality, waste reduction, reliability and efficiency targets we set for the project.”

Nick Darrall, Operations Director for IconSys, explained: “Not only is the control of the glass production stages now improved, but speedy access to essential data to inform production-related decisions and ongoing monitoring of the line is now in place.

“An office PC allows operators to easily identify any of the hundreds of glass sheets emerging through the production Continued>>

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

TABLEWARE Toughening Lines

 Pilkington’s sites are benefiting from energy savings.

process and fulfill orders to multiple worldwide customers. The integrated combination of PLC, controllers, drives, I/O, SCADA, motors and cameras provides an overall control system for the glass line driving efficiency at all stages.

on spindles

Accurate analysis The project was completed without any disruption to existing work scheduling, and Pilkington has reported benefits to its daily operations.

The availability of key data to provide analysis around any reported problems or changes in quality performance has allowed the management team to more effectively interrogate potential reasons for any issues as they arise.

This information also informs and supports predictive maintenance strategies and ensures production reliability is not compromised.

Product quality demands in line with market requests are now being met and exceeded, while from a cost perspective the measurable reduction in waste from the production line has contributed to a more efficient process and saving money.

Derren Gittins, Downstream Operations Director for Pilkington UK is delighted with the outcome of the control system upgrade.

He stated: “We truly value the partnership approach we have with Siemens and IconSys. “Their combined glass sector expertise and quality-driven support has ensured that the project implementation progressed smoothly without any disruption to our production commitments, and the subsequent integration of control technologies across the plant is providing benefit in terms of access to essential real time data so we can make informed decisions.”

As a result of the control system integration, Pilkington UK, which operates within a competitive sector, is now better placed to meet its optimised performance and efficiency targets, as well as satisfy the demands of its customer base across the globe. 

Siemens UK, Frimley, UK www.siemens.co.uk/entry/en/ Glass International November 2015

RIM TEMPERING

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

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Moulds

A laser cladding for moulds Michel Rege* discusses the coating of moulds by ‘procede CHPO’, a laser cladding technique developed by Chpolansky and hailed by the company as its new weapon in improving production performance and lightweighting.

C

hpolansky is a medium size company with 130 people, located a few kilometres from Paris Sud University. The company has collaborated with the university to develop its laser cladding technique for materials used for mould production in the glass industry.

The production process for a glass bottle consists of an injection of viscous glass (700-1200°C) inside bronze, cast iron or steel moulds, which work as a heat exchanger during the production cycle.

Glass problems can appear during moulding, as abrasion and oxidation occur on certain sensitive parts of the moulds, causing thermal fatigue due to moulding cycle constraints.

The surface deterioration of the glass is, of course, linked to the effect of abrasive glass and to damage on oxide layers activated by a medium temperature of around 500°C and thermal cycle due to repeated contact with the glass. For this

reason, moulds have to receive a specific coating treatment using materials with adapted high properties at the level of sensitive parts, such as edges or grooves.

The two main coating techniques are coating by welding and spraying. Coating by welding relies on classic techniques such as TIG or MIG. Thermal coating by spraying allows for a hardfacing surface.

It consists of spraying fine particles (typically 5 to 100 µm) in the form of a vector gas, which is used to spread them up and to carry them until substrate.

The accumulation of heat particles and melted on substrate allows for the heat realisation of the coating.

The laser cladding technique Laser cladding is a technique that consists of coating a part with a filler material that has specific properties. This coating technique is the subject of the present study, which looks at increasing the

Parting line seam

Bushing

Neck

(b) (a)

z Fig. 1: Illustration of the preparation (a) before coating and (b) after.

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PTA Significant bath merger

Laser Weak bath merger

Significant and irregular penetration Weak penetration Substrate temperature in limit of metallurgical tranformation

Substratet temperature <100: no metallurgical transformation

Significant and irregular HAZ

Very weak HAZ, may be considered as not existing

Preheating 400°C

No preheating

 Fig. 2: Demonstrating the reduction of HAZ and MZ

lifetime of moulds for the glass industry.

The edges of moulds are coated to guarantee hardly-visible seams and to slow down damage linked to thermal fatigue. The target coating zones are the surfaces that come in contact with hot glass, in particular the seam at the parting line, ring and neck (Fig.1).

The mould’s role is to give the glass bottle an accurate shape with a determinate surface appearance. The mould should also permit an optimum glazing, which occurs via an efficient cooling of the bottle. For that, the glass industry uses the mould’s blowing system.

However, the thermal properties of the material constituting the mould also play an essential part at this level. The mould material should have a good thermal conductivity in order that the metallic surface in contact with the glass does not suffer a too prominent overheating, which could result in sticking. The surface should also, however, not be too cold at the contact point, as this can result in defaults corresponding to cracking initiated from the surface.

The coating of a metallic part for glass industry moulds can be achieved by three distinct and well-known techniques: r Power Gun (PG): The oldest technique, which involves poor working conditions and health problems and gives random results; r TIG (Tungsten Inert Gas) process, which uses plain rods, is expensive and unsuited for coatings in the glass industry; r Plasma Transferred Arc (PTA) technique: This is the preferred industry method, in spite of its difficulty of implementation and its lack of reproducibility.

to weak thicknesses.

Metal d’apport

With current coating methods (PG, TIG and PTA), coated seams create important Heat Affected Zones (HAZ) and a Mix

Zone mixte ZAT Substrate Chalumeau or PTA

Substrate Laser

Continued>>

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Moulds

Zone (MZ) (alloy constituted by chemical elements from substrates and filler metal).

The coated cord is consequently larger and the thermal homogeneity qualities of the mould are affected.

If the glass is cooled heterogeneously, then follows an important variation at the level of the coating zones follows.

This leads, of course, to a fragile bottle.

The quantities of glass and filler metal have to be increased to overcome this problem, which results in associated economical issues (filler metal and energy consumption, transports, consumption cost...)

In order to homogenise the thermal properties of moulds and enable the lightweighting of bottles, in 2010 Chpolansky became interested in a laser cladding technique used in other industries, but not implemented for glass moulds.

The results obtained from previous studies have shown both the feasibility of and interest in laser cladding, and have encouraged Chpolansky to depose a patent called ‘Procede CHPO’.

The company has created a laser cladding cell dedicated to the glass industry inside its premises (an investment of €1M), and has hired engineers who are in charge ofam Bowman_Ad_185mm_128mm 7/1/03 11:24 the laser cladding project.

Deposit

Substrate Cast iron

Fig. 3 shows a metallurgical study carried out at Paris, Sud University, which demonstrates the microstructure of an interface of a coated mould material. The deposit microstructure shows a very fine aspect, with a weak porosity rate.

Conclusion 80µm

Ni

z Fig. 3: Results from a metallurgical study carried out at Paris, Sud University.

The laser cladding process ensures accurate control and a rapid deposit of raw materials, with a realisation time three times faster than the traditional PTA method. The use of the laser technique enables us to coat moulds whatever the production step and to depose only the necessary quantity of powder (150 gr. per mould with laser cladding process instead of 400 gr. per mould with the PTA process).

The laser technicality also allows for the reduction of HAZ and MZ to a weak thicknesses (Fig.2), which favours the maintenance of the thermal properties of Page 1 the mould.

Since May 2014, different sets of moulds and neck rings have been tested on IS machines.

Results confirm the improvement of the thermal homogeneity of moulds and a better wear resistance.

Coating via the ‘Chpo Process’ helps to: r Optimise the production of heavy or ultra light-weight bottles; r Permit the use of neck rings with solely metal edges, in order to increase efficiency on bronze material; r Is an economical asset for the production of moulds (preheating, powder, machining...); r Allows for the possibility to work on existing moulds, to increase their lifetime. r

*Director, Chpolansky, Marcoussis, France www.chpolansky.fr www.youtube.com/user/ChpolanskySAS

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45 Glass International November 2015

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Forehearths

z Fig 1. Double Helical stirrers.

Cord removal stirrer systems Ricardo Barreto* outlines a system that helps remove defects in glass articles caused by the cat scratch cord method.

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C

at scratch cord is a defect that might appear on glass articles. It is a problem that can appear and disappear and evolve only on some production lines.

There are several conditions that cause high-density viscous glass to appear when the glass flows onto the spout.

Deeper zones where the glass is colder are the most critical zones.

The cords visible on the glass surface are the result of different glass properties and composition. Dissolution of refractory materials is the reason for the difference in composition in the glass.

The source and cause of cat scratch cord is not possible to eliminate but the defect in the glass can be removed with the installation of Vidromecanica’s cord stirrer systems in the forehearth.

Vidromecanica, in collaboration with glass plant manufacturers, developed a cord dispersal stirrer system with the purpose of mixing the dense viscous glass with a cord that is present on the bottom of the forehearth. One or various twin counter-rotating stirrers are installed to lift the dense cord glass that follows on

the bottom. The cord material is dispersed in the molten glass before arriving to the spout, eliminating the visual defect.

The stirrer speed required to lift and mix the cords is about three rotations per minute. A remote control panel is provided with an inverter that controls and indicates the stirrer speed.

The stirrer type and design are chosen depending on forehearth widths. Helical stirrers are usually used in thinner sections and paddle type stirrers are installed in wider sections (Fig. 1).

To correctly eliminate the cat scratch effect, the equipment must be designed with the appropriate configuration and characteristics and installed in the right position.

These systems can be installed on forehearths that produce green, amber or flint glass. The equipment should be installed in the colourant forehearths, since they also have cord defects.

In addition to elimination or reduction to approved levels of cord defects, there are other advantages to using the company’s system, including: no drain is required to avoid cords; no waste of

drained glass; energy saved in remelting the contaminated glass; no glass output reduction; improved homogenisation of temperature; reduction in rejects; and higher quality glass.

Vidromecanica’s engineering team is responsible for the commissioning, start-up and training, and in this way guarantees that the equipment is correctly installed. Maintenance procedures are taught to the customer’s team.

In the late 1990’s Vidromecanica established a quality management system to control its order fulfilment process.

Suppliers were included in the quality management through detailed technical specifications, goods inspections, and supplier assessments. An independent audit certifies the Quality Management System twice a year. In 2009, the company was certified according to EN ISO 9001:2008. r

* Vidromecanica, Marinha Grande, Portugal www.vidromecanica.com

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Furnaces

Preheated oxygen and natural gas in flat glass furnaces Antonella Contino* and Fabrice Fasilow discuss a breakthrough furnace technology that, from initial results, has substantially reduced melting energy as well as CO2, NOX and SOX emissions. to be able to characterise the process and further improve it. A third layer of actions is linked to the improved use of data collected from sensors by defining and applying a control loop to stabilise and adapt the process online.

An investment from AGEU in those three categories of actions lead to a continuous energy efficiency and GHG emission improvement (Fig. 2).

Nevertheless, the trend of energy consumption over recent years has shown that without a major technological breakthrough improvements within classical furnaces (regenerative air combustion furnace) will remain limited.

Action is required to improve and risks have to be taken by the industry to pursue the effort.

AGC Glass Europe has developed flat glass furnace technology (Fig. 3) that uses pure oxygen instead of air as an oxidiser, combined with the recovered energy from waste gases to preheat oxygen and natural gas. As 79% of nitrogen contained in air is useless for the combustion process and produces nitrogen oxides (NOx) at

Continued>>

Dis r act uptive ion s

Second order “Let’s do things right” First order level= core technology “Let’s get the best” z Fig 1. Incremental development of energy saving actions.

90 80 70 60

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Third order “Let’s do better”

high temperature, it is known that the use of pure oxygen instead of air helps reduce the energy required for combustion and prevents the formation of NOx. Nevertheless, the application of oxy combustion is rare in the flat glass industry as its economical profitability is low and technical challenges are associated with it such as foam and furnace corrosion).

AGC Glass Europe overcame the profitability issue by developing a system that re-uses heat from the flue gases to preheat oxygen and natural gas before it is injected into the furnace. This yields extra energy savings. The energy recovery system is a two-step methodology. First, hot waste gases (~1350°C) from the furnace combustion preheat air to around 700°C in a metallic recuperator. Later this preheated air will be, burner by burner, divided into two flows to preheat oxygen at 550°C and natural gas at 450°C in crosscurrent heat exchangers.

100

Relative specific energy (1880=100)

New technologies “Let’s change it”

Incremental

A

GC Glass Europe has been focusing its manufacturing and R&D activities on lowering its energy consumption and greenhouse gas (GHG) emissions from flat glass furnaces.

These activities are divided into four levels: from state of the art, to disruptive technologies (Fig. 1).

The first step in reaching the best energy performance of flat glass furnaces can be defined as getting the best available know-how on state of the art technology.

To achieve this, efforts have been made to fundamentally understand all the physical phenomena linked to the melting of raw materials. This has been carried out by using CFD numerical simulation, analyses of energy audits performed on site, standardising best furnace design, and testing and spreading best equipment and practices among the float furnaces of the group.

Once the foundation for the ‘best’ furnace has been set, the second action is related to the correct monitoring of furnace parameters. The selection of the most adequate sensors is a key issue,

50 40 30 20 10 0 1890

1910

1930

1950

1970

1990

2010

Years

z Fig 2. Specific energy required to melt 1 ton of glass (1880=100).

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Furnaces

Gas

 Fig 4. A prototype of

Oxygen

Air 250°C

an air/fumes recupera-

Air 700° C

tor in France.

Recuperator Gas 450°C

Oxy 550°C

 Fig 3. Oxy combustion furnace and heat recovery scheme.

Flue channel Oxy-gas furnace

 Fig 5. The Czech Air

Regarding the technical challenges and risks, numerous studies have been carried out at both an R&D level (such as 3D numerical simulation; lab furnace tests) and on an industrial scale (conversion to new technology of one burner in a classical furnace), to try to decrease industrial uncertainties.

Industrial application

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Republic oxy-furnace.

The final technical validation of this breakthrough technology could only be performed by taking a risk for a real industrial prototype start-up.

The first industrial application was located in Boussois, France, and started in 2008 (Fig. 4) with the aim of validating the feasibility of producing good quality architectural clear glass with a hybrid combustion, using partially heavy oil and partially natural gas.

During this first experience, AGC Glass Europe evaluated and validated technical items. These included technology design (furnace, burners, refractory); safety issues linked to hot oxygen use; glass melting settings (fire curve, atmosphere and foam management); and environmental and energy interests.

Valuable know how and experience were acquired on site to complete the preliminary studies carried out in a lab before a prototype start up. Unfortunately, the economic market situation led to production being halted at this furnace in 2013.

This first project was funded in part by the European Commission EnvironmentLIFE Programme-HotoxyGlass- LIFE07 ENV/F/179.

The second industrial application was located in the Czech Republic (Fig. 5). It

was aimed at demonstrating the maturity and potential of the new technology by producing high quality automotive colour glass (which has higher quality requirements than architectural glass), using only natural gas as a combustible (more corrosive atmosphere; more foaming on the glass surface).

This second application started in mid2014 and is still under evaluation, but has promising initial results. The first glass from an oxy combustion furnace has been supplied to an automotive customer.

This project was also funded in part by the European Commission Environment-LIFE Programme-HOxyGas- LIFE11 ENV/CZ/488, for the implementation of preheated oxygen and gas combustion technology to produce high quality colour glass for the automotive industry, and by the European Commission SILC Programme (FHRS) for fumes heat recovery system implementation.

Benefits Compared to 100% gas air combustion technology, which is a state of the art reference, this project should allow the furnace to decrease melting energy by 19.7%, reduce CO2 emissions by 5.5% (taken into account CO2 emitted by O2 production).

NOX emissions will be decreased by 79.2%, SOX emissions by 35.5% and dust emissions by 67.7%.

These prototypes serve as an example to the AGC Group as the most ecological flat glass furnaces in the world. The breakthrough technology that was developed is now being validated for the combustible and glass products market, thanks to the two industrial prototype

furnace experiences.

It should be noted that the economical evaluation of the technology is closely linked to energy prices (both fossil fuels and electricity), which can be a barrier to its deployment in some countries.

Environment The technology described in this article is part of AGC Glass Europe’s environmental policy. Environment is one of the four shared values of the AGC group and is an essential part of the company’s Social Responsibility. AGC Glass Europe is taking its environmental responsibility seriously and turned this responsibility into a challenge: a challenge to achieve the best balance between sustainable development and economy, and to make improvements in terms of profitability, comfort and safety, aesthetics and environmental impact.

AGC Glass Europe’s environmental policy has a double focus: - To be at the forefront in developing new products with improved environmental performance during their lifetime.

- To manufacture these products using the best available technologies from an environmental point of view, to minimise the environmental impact. r

*Domain Project Leader, AGC Glass Europe, Gosselies, Belgium. http://www.agc-glass.eu/ References: http://www.oxyfuel-heatrecovery.com/ http://www.agc-hoxygas.eu/ http://www.agc-fhrs.eu/

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Raw materials

z The IHS Soda Ash conference took place in Barcelona, Spain.

The ‘new normal’ The ‘new normal’ and what this means in relation to the global soda ash industry was the key topic at the 2015 IHS Soda Ash Business Outlook in Barcelona, Spain recently. Greg Morris reports.

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I

n the opening speech of the event, Marguerite Morrin, Senior Director at IHS, explained the status quo of current market conditions were likely to be rocked over the coming years, with some industry players in a more favourable position than others.

In recent years, the ‘normal’ for the soda ash industry has been a strong growth of 4% per year, amid rising production costs and an average oil price of around $100/ bbl. Rapid development in China has helped to fuel demand for container and flat glass, combined with strong demand from South America.

However, this period of normality was brought to an end in mid-2014 by the drop in global crude oil prices to around $50/bbl. This coincided with a slowdown in growth in China and a drop in demand from developing countries, particularly those who rely on oil and commodity exports to fund rapid growth. These factors, combined with the threat of new low-cost capacity coming on stream in Turkey in 2018, are expected to create a ‘new normal’ for the soda ash industry,

which is likely to be more volatile than has been seen up until now.

Turkey A key feature of the day’s agenda was an update on the current status of the expansion projects in Turkey, by Tanzer Ergul, the General Manger of Eti Soda.

Mr Ergul explained that various key stages of the construction process had been initiated, the sites for both of the expansions in Kazan and Beypazari have been cleared, and pictures alongside computer representations confirmed that large concrete slabs have been laid.

The questions from the audience are no longer whether the project will go ahead, but instead what will be the global impact of 3 million tons of new low-cost capacity on the edge of Europe.

China The final speech from the first session of the day was presented by Vincent Ledoux-Pedailles, in collaboration with Ethan Jiang, both senior analysts at IHS. Mr Ledoux-Pedailles sought to explain

how the Chinese president Xi Jinping’s description of the ‘new normal’ for China’s economy relates to soda ash production and demand in China.

The outlook for Chinese economic growth is expected to be more modest than in previous years. As rates of construction in China adjust down to more maintainable levels, demand for flat glass is expected to decrease. Decreased domestic demand is expected to create an environment that will see larger Chinese producers turn their attention to exports and could bring them into direct competition with exporters already established in the region.

Energy Chris Holmes, Managing Director, Global Gas and LNG Consulting, IHS, explained the current situation and outlook for energy globally. Global energy prices have fallen, which has created a situation of winners and losers. Lower oil prices have yet to push Saudi Arabia and its Continued>>

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Raw materials

Downstream users After lunch, several downstream users presented their respective outlooks on the soda ash industry.

The first of these was a briefing on the state of the container glass industry in Russia, presented by Pavel Bobosik, CEO, Ekran Container Glass. Mr Bobosik explained the difficulties faced by glass producers in Russia, highlighting falling demand and difficulty securing a steady supply of soda ash. He explained that government legislation on alcohol is causing many to turn away from premium spirits, commonly packaged in glass bottles. He also explained that the remote location of his plants leads to some difficulty in purchasing soda ash.

The use of recycled broken glass, or cullet, in the production of glass enables the cost of production to be reduced.

The dynamics of the cullet market can vary greatly from country to country, explained Matthew Demmon, Managing Director, mkd32 Ltd. While the use of cullet is a major feature in the production of glass, security of supply can be difficult to maintain. Container glass producers are the major users of cullet, as flat glass producers can use only the highest quality cullet. Mr Demmon explained that demand is driven by availability, and that prices in the UK have recently

increased.

Continuing the discussion around industries related to soda ash, Joost Ubbens, Director Procurement, PQ EMEA, spoke about the continued development of the sodium silicates industry. Global demand for sodium silicates is expected to increase by 2.4% between 2013 and 2018, with China accounting for a large amount of this growth. The development of silicates for advanced applications is leading to the production of higher value products; a cost build up described by Mr Ubbens shows how silicon dioxide with a value of $0.05 per kg can be refined and used to produce specialised silicates which have a value of $50 per kg.

Sodium bicarbonate is often produced in tandem with soda ash. Much like soda ash, sodium bicarbonate has a broad spectrum of end-use sectors. Giordano Zappelli, Senior Vice President, GBU Development & EMEA Commercial Head, Solvay, explained the regulations that cover each of these end-use sectors, ranging from food to pharmaceuticals.

Global demand for sodium bicarbonate is estimated to be over 4 million metric tons in 2015, with the major end use being animal feeds. As end uses become more intricate and the regulation more strict, the responsibility of producers to produce top quality product will increase. However, these factors do have the potential to create a positive pricing outlook for the producers in the near future. The final presentation of the day focused on the future of soda ash production and in particular how it might interact with a topical business issue: environmental sustainability.

Christian Theiste, Managing Director, EnPro, explained how EnPro has developed technology that utilises waste CO2 emission for the production of soda ash. Much of the equipment for the plant is in place; however, troubles with securing investment have led to a delay in construction. Mr Theiste was questioned on the commercial viability of the process, which he confirmed was more expensive on a cost per ton basis than natural soda ash production.

Nonetheless, producers in Europe will no doubt follow the development of this technology closely. 

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OPEC allies in the Gulf to change their market share production policy. However, with other OPEC member finances under pressure, speculation surrounding a reversal in strategy prior to a December meeting of members could support prices, albeit temporarily. If WTI prices stay below $45/bbl (as forecast) then US production is poised to slow sharply in the next few months. Holmes finished with a final message that energy prices are low, but are not expected to remain this way in the long term.

One of the real impacts of the drop in crude oil prices is on global logistics costs.

Raj Patel, Managing Director of Newport Industries, explained how these costs have fallen recently, in part owing to low fuel bills but also due to an oversupply of available vessels. This issue is particularly prevalent in Asia, a region that is expected to see increased movement of soda ash, as producers turn their attention to exports. Patel presented on both bulk and pneumatic discharge methods, explaining that while pneumatic is favoured in many respects it is the more expensive technology.

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Events world

CelSian training day comes to the UK In celebration of The Society of Glass Technology (SGT) centenary, and with support from British Glass, CelSian Glass & Solar will hold its five-day Glass Technology Course for the first time in the UK at Chapeltown, Sheffield on 29th February 2016.

C

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elSian’s Roeland Brugman said: “CelSian has presented at and supported the SGT Furnace Solutions Conference for many years.

When we asked Neil Simpson to support CelSian as our UK support, we were looking to run our first UK dedicated glass course. Neil immediately saw there was an opportunity to support the SGT to celebrate its centenary.

“As the SGT offices are in the British Glass and Glass Technology Services (GTS) building with laboratory facilities, it is the perfect venue!”

Dave Dalton, CEO of British Glass, said: “When CelSian approached British Glass we saw this as a great opportunity to collaborate and support the SGT. While we have our own specific dedicated training courses, this CelSian - NCNG Glass Technology Course will be to the UK glass industry’s benefit.”

Prof Russell Hand, President of the SGT, added: “We want as many people and organisations to be part of the SGT Centenary celebrations.

“We have many events planned, from Furnace Solutions to our Centenary Conference in Sheffield, and social events including the Yorkshire Section Dinner Dances in 2015/ 2016, as well as a golf tournament. Clearly, any training which supports our members and the glass industry is important to the long term needs of the industry. It is great that CelSian and British Glass are supporting our centenary”.

The training course CelSian organises a five-day, glass technology training course for the international glass industry several times each year.

The course was developed in cooperation with the NCNG (National Committee Netherlands Glass industry).

The UK course is scheduled from Monday, 29th February until Friday 4th March, 2016 at the SGT, British Glass and GTS offices in Chapeltown, Sheffield.

 A previous training day held by CelSian.

The course is open to the employees of international glass producing industries and related suppliers. The in-depth course covers aspects of glass and industrial glass production from raw materials to formed product, from relationships between glass composition and properties relevant to glass melting, to furnace technology.

The important subjects related to energy consumption and environmental issues are covered in detail.

The teachers have long-standing knowledge and experience with glass science & technology and worked in the field of container glass, float glass, tableware, fibre glass, glass wool & special glass. Since 1990, the course has been given to more than 1000 employees from glass industries globally. All presentations will be presented in English.

All participants receive a text book (2 volumes, 800 pages). The five-day training course is being offered to employees of Glass Trend member companies for £2300 and £2850 for non GlassTrend members – per participant, including an introductory e-learning course by internet and excluding taxes/duties, hotel accommodation and travel costs.

The new interactive e-learning course involves watching 11 short films and answering multiple choice questions via a website on the internet.

All participants will receive a personal user name and password two weeks before the classical course, so that they can take this course at any time during this twoweek period.

The required time to take the introductory course is around two to three. This training course will take a maximum of 25 registrations.

The provisional programme and the trailer of the e-learning course can be found on the GlassTrend website (www. glasstrend.nl website, tab ‘’events & agenda’’).

Target group The course is aimed at experienced engineers in the glass industry to receive a more detailed understanding of the glass production process, entrants in the glass producing industry and related suppliers and young glass technologists and scientists. Level: high technical and academic.

The participants receive: r A five-day classical course dedicated to glass technology for glass industries; r An introductory e-learning course by internet, in the two weeks preceding the classical course; r A comprehensive textbook on industrial glass production, glass properties and glass technology of about 800 pages; r The Power Point presentations (pdf formatted presentations); r Lunches & classroom access; and Dinner/evening event r 2x invitations r

To note interest and for more details contact neilsimpsonfsgt@btinternet.com or elize.harmelink@celsian.nl

54 Glass International November 2015

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The glassmaker’s diary

Events world

r International Congress on Glass 2016 A platform for the dissemination of glass science and technology information.

April 7th - 11th 2016 Shanghai International Convention Center (SHICC), Shanghai, China.

CONTACT: icg2016@vip.sina.com www.icg2016shanghai.com

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r China Glass 2016 Annual Chinese exhibition returns to Shanghai.

April 11th-14th 2016 Shanghai New International Exhibition Centre, China.

CONTACT: ceramsoc@163.com www.chinaglass-expo.com r Glassman Middle East 2016 The Glassman exhibition and conference returns to the Middle East for the first time since 2009.

May 10th - 11th 2016 Abu Dhabi National Exhibition Centre, UAE. CONTACT: jeremyfordrey@quartzltd.com kenclark@quartzltd.com www.glassmanevents.com r Mir Stekla 2016 Annual Russian exhibition.

June 6th-9th 2016 Moscow Expo Centre, Pavilion Number 2,Russia.

CONTACT:re@expocentr.ru www.mirstekla-expo.ru/ r ESG 2016/SGT 100 conference 2016 marks the Society’s centenary year and it will celebrate with events including a return to the University for its Annual Conference.

September 4th - 8th 2016 University of Sheffield, UK. CONTACT: www.esg2016.eu r Turner Memorial Lecture The Turner Memorial Lecture will take place during the Centenary Conference and will be given by Professor Edgar Zanotto: his subject will be Glass Myths.

September 2016 Sheffield, UK CONTACT: www.centenary.sgt.org/Events r glasstec 2016 The bi-annual returns to Düsseldorf.

September 20th - 23rd Messe Düsseldorf, Germany CONTACT: www.glasstec-online.com

We deliver the essential building blocks of glass: chemically pure silicon dioxide for uniformity, highly reactive sodas and alkalis to speed the melt, aluminas for strength and durability, and calcium and magnesium rich oxides for stability.

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For product information and local availability contact us: U.S. and Canada: 800-243-9004 Fax: 800-243-9005 Worldwide: 203-422-2500 Fax: 203-972-1378 E-mail: ContactUs@glassmaker.com

r Reception The SGT will host a reception to honour Professor Wes Turner on the day of its 100th anniversary.

19th November 2016 Sheffield, UK CONTACT: www.centenary.sgt.org/Events ® TM GLASSIL, SILEX, MATRIX and PURESIL are registered trademarks and trademark.

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