Glass International November 2016

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November 2016—Vol.39 No.10

STÖLZLE FLACONNAGE VERALLIA UKRAINE FURNACE OPENING BATCH PLANT I N T E R N A T I O N A L

A GLOBAL REVIEW OF GLASSMAKING

Glass International November 2016

SOUTH AMERICA 2017 29-30 March 2017, Buenos Aires, Argentina

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Contents

November 2016 Vol.39 No.10

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2 Editor’s Comment

4 International news

November 2016—Vol.39 No.10

STÖLZLE FLACONNAGE VERALLIA UKRAINE FURNACE OPENING BATCH PLANT I N T E R N A T I O N A L

11 Stölzle Flaconnage: Furnace inauguration at Knottingley, UK

A GLOBAL REVIEW OF GLASSMAKING

Glass International November 2016

11

14 Forglass: Batch house supplier that focuses on top quality workmanship 17 Techglass: Furnace supplier with an emphasis on quality 21 Company profile: Verallia Ukraine unveils furnace

SOUTH AMERICA 2017 29-30 March 2017, Buenos Aires, Argentina

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Front cover image www.teco.com

21

25 History 26 Phoenix Award: Phoenix Award honours Fuyao Chairman Cho Tak Wong

Batch plant 31 EME: The digital batch house

26

Process control 39 Eurotherm Schneider:

Understanding the value of precision process control 41 Glapor: Cellular glass enjoys a comeback

Plus find us on Linked-In and Twitter.

44 glasstec: Industry looks outward at glasstec opening event @Glass_Int

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44

47 Diary

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36 Zippe: Construction starts on Zippe’s batch plant at Mexico’s IVC

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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

www.glass-international.com

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

BA Vidro makes all the headlines this month

Sales Director: Ken Clark Tel: +44 (0)1737 855117 Email: kenclark@quartzltd.com

Y

Chief Executive Officer: Paul Michael

ou wait ages for a bus and then two come along at once, as the saying goes, and it felt that way in one particular week this month.

The glass industry had been relatively quiet in terms of recent acquisitions but then, all of a sudden, there was a flurry of them.

Usually, we’d report on several companies that were involved in the transactions but this time there was only one group which seemed to have gone into overdrive in its acquisition activity: Portugal’s BA Vidro.

Over the course of a few weeks this autumn the container manufacturer has acquired HNG Global in Germany, Greece’s Yioula Glass and its Bulgarian and Romanian units: Stirom and Drujba Glassworks. These acquisitions alone made people sit up but then, in its most eye-popping deal, it agreed a partnership with CVC financial group to jointly buy the USA’s Anchor Glass for a whopping $1 billion.

This news seemed to catch the glass industry by surprise. The story broke just as our weekly newsletter was published, sending our webstats into overdrive as a huge number of people clicked on the news story.

People were left scratching their heads as to where the money for all the deals had came from and why BA was suddenly snapping up so many companies.

Production Executive: Martin Lawrence Managing Director: Steve Diprose

The Anchor acquisition is unprecedented in BA Vidro’s history – it has never manufactured glass on another continent before.

For more than 100 years the group had, relatively quietly, gone about its business of manufacturing container glass in the Iberian countries of Spain and Portugal.

While it had made a few acquisitions in its home country and neighbouring Spain, it wasn’t until its 100th anniversary in 2012 that it made its first acquisition outside of Iberia, that of Poland’s Warta Glass.

It was the first steps towards its internationalisation. Make no mistake, this is a well-run company, headed by group CEO Sandra Santos and its chairman Carlos Moreira da Silva. Its financial report of 2015 reveals a solidly managed company, with sound financial guidance from management and investment when required.

During an interview with Glass International in last month’s issue, Mrs Santos said the group’s focus was on its customers. It developed 415 new projects in 2015, which represents eight new products a week. Expect this innovation to continue as it seeks a more international audience stateside.�

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For two years: UK £295, all other countries £416.

Airmail prices on request. Single copies £45.

Greg Morris, Editor gregmorris@quartzltd.com

Glass International Directory 2015 edition: UK £206, all other countries £217.

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Quartz Glass Portfolio SOUTH AMERICA 2017

Subscriptions: Elizabeth Barford Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 Email: subscriptions@quartzltd.com Published by Quartz Business Media Ltd, Quartz House, 20 Clarendon Road, Redhill, Surrey RH1 1QX, UK. Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.

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

Member of British Glass Manufacturers’ Confederation

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

29-30 March 2017, Buenos Aires, Argentina

Monthly journal for the industry worldwide

Directory 2015 Annual international reference source

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Glassman specialist exhibitions rotate between America, Asia and Europe © Quartz Business Media Ltd, 2016 ISSN 0143-7838

2 Glass International November 2016

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It’s always the smaller pieces... , Tomorrow s Technology Today

International News

NEWS IN BRIEF

Berlin Packaging to acquire Bruni Glass

Italy’s Bruni Glass is to be acquired by Chicago-based Berlin Packaging.

Berlin Packaging is looking to extend its footprint in the European market, and its current portfolio of products includes plastic packaging and closures.

Bruni Glass is a container glass manufacturer that caters to the food, wine, and spirits markets. It has been operating for over 40 years, with its headquarters near Milan, Italy.

BA Vidro to acquire Anchor Glass and Yioula Glass Portuguese container glass manufacturer BA Vidro, in partnership with CVC Capital Partners financial group, is to buy USA’s Anchor Glass for US$1 billion.

BA Vidro has also completed contracts to acquire the glass packaging businesses of Yioula Glass in Greece, Romania and Bulgaria. This deal is not part of a joint venture.

The agreement excludes Yioula’s Ukranian plants and

GIMAV appoints Vice Presidents

The team of people that will oversee the activities of Gimav for the 2016-2018 term was appointed at the Board of Directors’ meeting in October.

Vice Presidents Michele Gusti of OCMI-OTG and Nancy Mammaro of Mappi International were elected and will work alongside President Aldo Faccenda of Bottero.

glassware operation. The businesses included in the deal correspond to an annual capacity close to 550,000 tonnes BA Glass manufactures glass bottles from facilities across Portugal, Spain, Poland and Germany.

The joint-venture deal with CVC is expected to help Anchor Glass capitalise on market opportunities as it enters its next phase of development Anchor Glass has six man-

ufacturing facilities across the US, with 11 furnaces and 31 machines that produce 5 billion glass containers a year..

CVC Capital is a London, UK private equity and investment advisory firm and has raised more than $65 billion in commitments since the firm’s inception in 1981.

The seller is KPS Capital Partners which bought Anchor in 2014.

45 exhibitors confirm presence at Glassman South America

JIC secures SGD Pharma shareholding

SGD Pharma has confirmed China Jianyin Investment (JIC) is now the group’s new shareholder.

JIC is a long-term investor with $57 billion under management. It will allow France’s SGD Pharma to focus on its development and investment plans as part of its global growth strategy.

Vetri Speciali orders Zippe batch plant

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Italian container glassmaker Vetri Speciali, based in Trento, has ordered a new batch plant from Zippe Industrieanlagen.

The batch plant will serve a furnace that produces more than 150 tonnes a day.

One feature of the plant is the automatic premix plant for colouration/decolouration.

A Siemens S7 type electronic control system will also be installed.

The Trento-based glassmaker makes containers for the special glass sector.

45 of the industry’s leading suppliers to the glass manufacturing industry have signed up to take part in Glassman South America, the leading trade fair dedicated to the hollow and container glass industry.

Held in Buenos Aires on the 29th and 30th March 2017, Glassman South America will offer exhibitors and visitors the chance to take advantage of Argentina’s expanding glass industry, as well as the improved international trade relations that the new government has actively encouraged.

Companies that have confirmed their presence at the

show come from Argentina itself, as well as countries further afield such as Mexico, the USA, and across the whole of Europe.

These include Bottero, Heye International, Sorg, Iris Inspection Machines, Stara Glass, Tiama, Teco, Pneumofore, Interglass, Vidromecanica, Pennine Industrial, FIC UK, Quantum and Antonini, amongst others.

Exhibitors at the event cover the entire hollow glass-making spectrum, from mixing and weighing to hot end equipment, to inspection equipment, through to cold end

packaging, and everything in-between.

The wine-rich area of Argentina is home to a number of container glass manufacturers, including global glassmakers O-I and Verallia and domestic manufacturers such as Cattorini and Rigolleau.

South and Central America has been one of the most dynamic regions in the hollow glassmaking sector in recent years.

To find out more information on the exhibition and its accompanying conference, visit: www.glassmanevents. com/south-america/

4 Glass International November 2016

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International News

O-I invests €25m in Italy Owens-Illinois (O-I), the world’s largest container glass manufacturer has invested €25 million to upgrade the capabilities and sustainability of its Origgio plant in Italy.

The modernisation of the plant primarily involved the complete refurbishment of the glass furnace. O-I has also installed advanced control software to enhance the compre-

hensive management of the production process with great advantages in terms of safety.

Further investment in forming machines improve the sustainability and energy efficiency of the entire plant, which will produce containers with lower average weights than before.

During the furnace rebuild, 180 employees received 3,500 hours of cor-

porate training on safety, quality, technical innovations made to the plant and operations of newly installed control machines.

“Thanks to the support and teamwork of our employees, we were able to bring the plant back to full operating speed in just 20 days from the furnace re-opening,” said Benedetto Troia, Director of O-I Origgio’s plant.

Japanese Glass Association visits Ardagh Irvine Ardagh’s glass bottle manufacturing plant in Irvine, Ayrshire, UK played host recently to representatives from the Japanese Glass Bottlers Association.

The group toured the plant, and were impressed by its general cleanliness and efficiency. They took particular interest in how the plant was increasing its use of recycled glass.

“This gives us an opportunity to showcase the

contribution we make to the spirits industry in Scotland and the local economy,” remarked Graeme

Shepherd, Director of Operations, Irvine, Ardagh Glass UK.

EU glass recycling reaches 74% The average glass recycling rate in the EU28 zone has reached the 74% threshold for the first time.

According to figures from the European Container Glass Federation (FEVE), this means more than 11.6 million tons were collected throughout the European Union in 2014 or 3.5% more than in the previous year.

The majority of that goes back into making new packaging: glass stands alone as the most closed loop recycled food and drink packaging in the

EU and in the world, said FEVE. Countries such as Sweden, Belgium, Germany or Slovenia continue to outperform. Other well performing countries like Austria or Denmark have recorded a slight decrease in recycling despite a positive consumption trend.

In the Czech Republic, Finland or the Netherlands the downward trend was on par with shrinking consumption.

In Spain or Bulgaria, glass recycling is steadily increasing but there is a

quite important gap to fill.

The gap is even more important in Romania, Cyprus, Slovak Republic or Greece.

Adeline Farrelly, FEVE Secretary General said: “The industry is calling for a supporting legislative environment that acknowledges the superior status of materials that can be infinitely recycled without loss of properties and can remain safe for human health and the environment. Such materials permanently keep their qualities.”

Glass International November 2016

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International News

NEWS IN BRIEF

Libbey reports sales decrease in third quarter

Tableware manufacturer Libbey reported lower sales in its third quarter results.

Net sales were down 2.4% compared to the same period last year, at $196.9 million compared to $201.8 million.

Libbey chairman and CEO, William A. Foley, said: “Third quarter results were seasonably lower, consistent with the expectations we provided last quarter, as challenging market conditions persisted across our various sales channels and end-markets.”

New format for Vitrum

Vitrum 2017 will have an entirely revamped format that aims to noticeably increase the number of machines and innovative solutions being debuted at the show.

This is as well as seminars and conferences for trade professionals, B2B meetings, easier access to the two new exhibit halls, and robust involvement from the international trade associations.

Schott celebrates 25 years in Mexico

Schott Glass will increase the investment in its pharmaceutical packaging production in Cordoba, Mexico, to further support the pharmaceutical industry in North and Central America.

The plant in Cordoba began operating a quarter of a century ago, with 25 employees working in a oneshift-operation.

Zippe at Vetropack Austria

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Zippe Industrieanlagen is to modernise Vetropack Austria’s second weighing line.

The order was placed with Zippe by Horn Glass company of Plößberg, Germany, who will act as the general contractor.

The modernisation will take place during operation of the plant. The rebuilding includes the complete exchange of weighing scales and of the second mixer, including all necessary adjustment works.

Beatson Clark bottle for BrewDog Craft beer company BrewDog has commissioned a bespoke bottle from glass manufacturer Beatson Clark for its new range of limited-edition beers.

The 375ml embossed Champagne-style amber beer bottle

has been produced for BrewDog’s Abstrakt range.

The brewery releases only a very small number of limited edition batches of Abstrakt per year, and each batch is known only by its release code.

The new bottle has the BrewDog logo embossed on the shoulder and complements the 660ml Vichy beer bottle that Beatson Clark already supplies to the brewery.

HNG a‘potential sick company’ One of India’s largest container glass manufacturers, Hindusthan National Glass & Industries, will report to the Board of Industrial and Financial Reconstruction (BIFR) as a ‘potential sick company’.

The company said its accumulated losses over the last four years amounted to

more than 50% of its peak net worth.

“The company would be defined as a potential sick company under the Act,” it said in a notification.

It blamed over supply in the container glass market and consequent decrease in capacity utilisation, along with

sluggish growth in demand.

According to HNG’s annual report, the combined effect of higher capacity and the slowdown in demand led to a lower capacity utilisation affecting margins.

In June 2016, the company sold its HNG Global German subsidiary to BA Vidro.

Electroglass appoints Technical Manager UK electric melting and boosting specialist Electroglass has appointed Jean-Christophe Arraez as its Technical Manager.

“Jean-Christophe has more than 25 years’ international experience in glass chemistry, furnace and forehearth engineering, operation and management, involving fuel-fired, electrically boosted and all-electric glass melting and conditioning,” stated Electroglass Managing Director, Richard Stormont.

“His industry experience embraces soda lime, borosil-

icate, fluoride opal and lead crystal glasses for cosmetics and general containers, the pharmaceutical industry, kitchen and tableware, decorative and other products.

“He is also multi-lingual, and joins our Projects Engineering Manager, Steven Tawn, and Electrical Engineering Manager, Andrew Barlow, as a key member of our management team.”

Pictured: Richard Stormont (right) welcomes Mr Arraez to Electroglass.

8 Glass International November 2016

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International News

NEWS IN BRIEF

Top 10 stories in the news

Libbey Toledo strikers return to work

Libbey workers have voted to accept an agreement between unions and the company following a recent union strike at its Toledo, USA plant.

According to union representatives, sticking points in the dispute were working conditions, wage increases, mandatory overtime and a draconian attendance policy.

Our most popular news items, as determined by our website traffic All full stories can be found on our website, www.glass-international.com/news � 1 BA Vidro to acquire Anchor Glass and Yioula Glass � 2 O-I invests €25 million in Italian plant upgrade � 3 Hindusthan National Glass: ‘potential sick company’ � 4 Beatson Clark bottle for BrewDog � 5 Electroglass appoints Technical Manager � 6 Bucher Emhart Glass opens new Elmira facility � 7 Prestigious Phoenix Award presented to Chinese glass industry veteran � 8 Schott celebrates 25 years in Mexico with investment � 9 New format for Vitrum 2017 � 10 Japanese Glass Association visits Ardagh Irvine

UGSC awards glass strength research grant

The Usable Glass Strength Coalition (UGSC) has awarded an $80,000 grant to the Colorado School of Mines (CSM), to carry out research that aims to improve the understanding of manufactured glass products’ strength properties.

Principle investigator Ivar Reimanis will lead the research, Fundamental Understanding of Strength Limiting Flaws in MultiComponent Glass.

“The opportunity to apply the most modern, atomisticlevel tools to examine strength-limiting flaws in glass is truly inspiring, and we at Mines are looking forward to making an impact,” said Dr. Reimanis.

New book from American Glass Research

www.glass-international.com

American Glass Research has published a book entitled Color Atlas of Stones in Glass.

The book provides a comprehensive description of 39 stones, accompanied by more than 300 original colour photographs, images and spectra.

Detailed identification tips, compositions, causes and sources are given for each stone, as well as its physical and crystalline characteristics.

The atlas is intended to help identification of the most common glass stones across the container, tableware, flat and fibre glass sectors.

The book is available from AGR via its website: www. americanglassresearch.com

Bucher Emhart opens Elmira plant Bucher Emhart Glass has opened its Elmira facility.

The new facility provides space for manufacturing, administration, and engineering for Bucher Emhart Glass’s inspection business.

The importance of the inspection business within Emhart Glass became clear with the recent launch of the End to End strategy and is now reflected in the facility.

The facility features a high bay manufacturing operation divided into two sections by large overhead doors. One section is used for the machine shop and shear blade production, while the other is used for assembly, machine testing and warehousing.

The property also contains a free-standing building with a hangar door that serves as storage for crated machines awaiting shipment.

Photo (l-r): Mike Curry, Vice President Inspection Business;

Susan Mathers, US Controller and US General Manager; Pat Ervin, Director, L&M Inspection/ Site Manager; Martin Jetter, President Bucher Emhart Glass; Tom Santulli, Chemung County Executive; Tom O’Mara, New York State Senator.

Croxsons’packaging for artisan gin Glass packaging company Croxsons has produced a bottle design for House of Elrick gin.

Producing just 600 bottles per batch, the House of Elrick is the only artisan small batch gin producer that uses fresh,

filtered water straight from Loch Ness.

In creating the packaging, Croxsons used its 700ml Little Pasha bottle design with a stopper cork, sprayed in a matt blue finish and screen printed

with silver ink to communicate a distinctive appeal.

In addition to the 700ml version, Croxsons is also working on a miniature 50ml and a 350ml version of the same artwork.

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Furnace inauguration: Stölzle Flaconnage

Furnace unveiled at Flaconnage

Stölzle Glass Group invited its customers and partners to celebrate the recent rebuild of its white flint furnace and extensive revamp of the plant in Knottingley, UK. Guests were given a tour of the plant after a welcome speech from Plant Manager, Thomas Riss. Greg Morris was among those to attend the celebratory event.

S

� Above, the new furnace at Stölzle Flaconnage’s UK site. � Below, the old furnace.

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tölzle Flaconnage has officially inaugurated its new furnace and modernised site at its plant in Knottingley, UK. The £17 million investment included a 180t a day white flint furnace, which will allow the company to increase its feeder colour capacity and capability in the high-end luxury drinks sector. The investment will also allow the company to increase its flexibility, meeting the trend for small volume production runs and quick turnarounds.

The new furnace will pull glass on an area of 65m2 and feed five flint production lines. The focus will be on tallware, gift products and feeder colouration, all made of flint glass with a fire polishing option on all production lines.

The new IS machines allow several different bottle shapes to be manufactured simultaneously and allow bottles of up to 4.5 litres to be produced.

Further investments were made in cold end inspection facilities and decoration technology, implementing a high speed spraying line and a new automated printing machine and accessory application.

As plant manager Thomas Riss said, the company also did not forget the Continued>>

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Furnace inauguration: Stölzle Flaconnage

� Bottero’s IS machines were installed as part of the factory revamp.

� Lee Rumford, Engineering Manager, highlights the control panel during a plant tour.

� MSK’s shrink wrap machine.

� Emmeti’s palletiser was also installed.

� Thomas Riss, Plant Manager, welcomes attend-

www.glass-international.com

ees to the event.

environment. As well as providing better quality glass, the furnace will also save energy and reduce emissions.

Thanks to the optimised engineering of its combustion chamber, gas feed, burner and regenerator set up, the new furnace will reduce the plant’s carbon footprint by 13% per tonne of glass produced.

Substantial improvements in the plant’s water consumption and compressed air were also realised. The company has decreased its water consumption by 50%, saving the equivalent of 450,000 bathtubs of water a year, with almost all process water being recycled.

Investment The inauguration took place almost a year to the day when Stölzle’s owner, Dr. Cornelius Grupp, decided to invest in the factory after completing an evaluation of the business. The original furnace was built 21 years ago in 1995. In 2006 it had a repair, and was then partially rebuilt in 2009. It was pulling 150 tonnes at the end of its life. The new furnace was installed

over the course of this summer, with work starting to disassemble the furnace on July 4, with glass to glass taking 56 days.

The work required a batch house modification from Forglass and a new furnace from Techglass – both companies are based in Krakow, Poland.

Stölzle also introduced two new IS machines from Bottero, one being a tallware machine for bottles up to a size of 500mm capability, which it did not have before. On top of that, two of the machines are equipped with colouring equipment. The installation of the tallware machine required Stölzle to install a new lehr, supplied by Antonini.

At the cold end it introduced new inspection equipment and, for the first time, installed a completely automatised palletising line, from Emmeti.

Parallel to the investments on the production line, it invested in a KBA Kamman K15 printing device, which will allow Stölzle to print four colours in one pass.

Group CEO Johannes Schick also

attended the inauguration event and said Stölzle Flaconnage will be a centre of excellence with regards to the development, production and decoration of premium prestige bottles.

“Our task is to ensure our customers can be proud and to help create a best selling bottle. We want to say we have helped build a brand which is fast growing.”

He added: “We wanted to create a place where our workers can feel proud of what they do and where wonderful bottles are the outcome. It’s important they don’t feel hidden in the darkness, we want to give them the space where they can set the standards for tomorrow.” �

*A three-page interview with Stölzle CEO, Johannes Schick, was published in the July/August 2016 issue of Glass International. To obtain a free copy of this please contact the Editor.

Stölzle Flaconnage, Knottingley, UK www.stoelzle.com

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Company profile: Forglass

Batch house supplier that focuses Polish company Forglass recently completed the batch house modification at the Stölzle Flaconnage plant in Knottingley, UK. Forglass CEO Piotr Knast discusses the installation and provides an insight into the company.

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Congratulations on your recent batch house modification at Stölzle Knottingley site. Can you tell us a little bit more about the equipment and why, in your opinion, Stölzle chose you to do the job?

Thank you. At the bidding stage, we made a simple yet exceptionally functional 3D model of the plant, and such a model enabled ourselves and Stölzle engineers to find the optimal solution to satisfy their requirements.

Each plant has its own characteristics, and you cannot just apply a common solution. You have to make an effort to listen carefully to what the customer is saying. I believe we made it. Using limited financial resources, we delivered a worldclass batch house.

As for tools, I would narrow them down – excluding standard ones – to communication workshops, which means listening to a customer, and the aforementioned 3D model.

Have you worked with Stölzle before?

I’ve known Stölzle for more than 15 years. This company is an important customer, developing as fast as our cooperation.

We intend to keep that cooperation for as long as it is possible – I do hope they are reading.

� Forglass recently completed a batch house installation at Stölzle Flaconnage in Knottingley, UK.

Did the Knottingley installation require any particular challenges or was it a straightforward job?

The scope of delivery included two return parallel transport lines for five cullet lines, including two colouring ones, together with a batch house. We have designed, manufactured, and installed the equipment with controls and visualisation.

It was a challenge because solutions would have to be adjusted to existing buildings, and the deadline was short.

However, there were a few things that made our job easier, such as very good cooperation with the client – I do hope they are still reading.

Why should glass manufacturers consider Forglass when it comes to sourcing new equipment for their factories?

We formulate our role in a simple way: we need to assist our customers to earn money, so they are able to share some of their profits with us. First, we need to find a solution matching the actual needs of a customer, and ask ourselves: what would we invest our money in if we were glass manufacturer?

We focus on simple solutions and top quality workmanship, which is easier to sustain as we Continued>>

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o

on top quality workmanship perform all production at our own facilities.

As well as maintaining 24-hour operation in the glassworks, we also ensure the equipment to be supplied is to specifications.

This is achieved by designing and manufacturing scraper conveyors, bucket conveyors and so on at in-house facilities.

Can you tell me a little about the company’s history?

Four years ago we merged three companies which had worked independently for glass works for 20 years, which has enabled them to complement each other, to offer comprehensive solutions at a different level, and to change reality.

This plan succeeded. Each of the companies is now a single department: Automation, Mechanical and Ceramics Construction.

In the meantime, we’ve been graced by a group of experienced engineers and smaller companies that liked our concept, and subsequently affected the way we built our company.

Being fully aware of facts, I am bound to say that today we are a large, experienced and hardworking team, and we are open to changes and challenges as all our history comprises of changes.

We have implemented a training programme for young graduate engineers of the future, which includes both in-house training and in the glass plants. This means there will be well-trained and experienced engineers to continue offering the industry the service it requires.

These young engineers also bring new ideas, from which we can learn and improve.

� Forglass ensures all equipment supplied is to specifications.

In view of these programmes I believe we are putting in place structures that will allow us to look to the future with a firm feeling of security.

When talking to glass manufacturers, have you noticed any particular recent trends such as environmentally friendly equipment or emissions reductions?

Of course theses two points are important to the industry and we will work closely with them and listen to their ideas, but European laws will probably dictate any progress.

Where is Forglass’ strongest geographical region?

As of today, the whole of Europe is our sales market, however, we do not set any geographical limits, we are prepared to consider and take all opportunities to offer our high class and cost effective services.

Of course we have to take into account possible financial limitations that can apply to ourselves and potential customers.

How strong is the Polish glass industry and does it have a rich glass heritage?

Of course the Polish glass unfortunately does not have its own Murano or even Bohemian glass tradition, but the glass industry in Poland is quite strong. Due to an acquisition process in the 1990s we now have most of the international glass producers in Poland.

Continued>>

www.glass-international.com

s

Company profile: Forglass

15 Glass International November 2016

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Company profile: Forglass

These include O-I, Ardagh, Saint-Gobain, Stölzle, Pilkington (now NSG) and Guardian.

Thanks to that, Polish glass factories have the latest in production line configuration.

The best production figures among other factories in the group are a result of Polish worker and engineers’ skills. Poland is in 6th or 7th position in glass production in EU. The Polish glass industry means not only massive scale production of container, float or glass wool but also beautiful and unique tableware and houseware glass, especially hand made.

You can find such products on the shelves of many respectable stores. Unfortunately it is still quite often the case that items designed by Polish artists, made by Polish craftsman in Polish glass factories, such as at Krosno, is offered under.

Now it is only made outside of production sites but the situation is changing for the better. The Made in Poland label means excellent quality at a reasonable price.

� A batch house control panel.

always be ready to solve any issues on good terms and in good time.

A company that will know a lot about its customers, a trusted company that will promptly deliver the best solution in respect of both technical and economic terms. Obviously, our core business will be glass furnaces and batch houses. It will all be possible due to exceptional staff.

I believe that the Forglass company will have a broad impact on the quality of services provided by other companies.

How would you like to see your company evolve over the next five to 10 years?

How many staff do you have and how many offices/plants?

Thank you for that question – it will be a pleasure to answer.

I project Forglass as a first class partner for a number of regular customers, and receptive to any potential customers, yet without any strong urge to conquer a whole world. I think we will be a normal company with normal people, which will

We currently have 200 staff in our glass furnaces and batch house divisions.

We have representatives in the UK, France and Tunisia as well as our Polish plant and offices. �

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

Pictured Left to right: Steve Harris Global Sales Manager - Glass Tracy Merrill UK Customer Services Iwona Szkoda-Giannaki Head Chemist - Glass Mo Farah Production Manager - Glass

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Michal Bochen Sales Manager - Glass

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16 Glass International November 2016

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Company profile: Techglass

Furnace supplier with an emphasis on quality Polish company Techglass recently installed a new furnace at Stölzle Flaconnage’s site in Knottingley, UK. Its president and founder, Andrzej Skowiniak, provides a company overview to Greg Morris.

Congratulations on your recent furnace installation at the Stölzle Knottingley site. Can you tell us a little bit more about the furnace and why, in your opinion, Stölzle chose you to do the job? � Mr Andrzej Skowiniak, Techglass founder and President.

� The main requirements from Stölzle for the furnace, such as the one below, were

– in Czestochowa (STC) and in Wymiarki (STW).

Techglass has constructed two fully equipped furnaces with forehearths of its own design for STC. The last of these big turnkey projects was completed successfully in 2012. Since then we have been providing different kinds of services connected with the maintenance of the furnaces

high quality glass and low energy consumption.

Continued>>

www.glass-international.com

Thank you, Greg. It is a medium size U-flame regenerative furnace producing high quality container glass for alcoholic beverages. It is fuelled by natural gas and electric boosting is installed for bigger pull.

High quality of glass and reduced environmental impact were the main requirements of this project.

It was then our great advantage from the beginning that other furnaces that we supplied to Stölzle in the past are known for excellent glass quality and reduced environmental impact.

The new furnace is built where the old one was, with no changes to the spouts’ positions. It was a challenge to design a furnace with pull higher than the old furnace had and which would fit in the same space. For a green field project you can get a standard design from your archive and modify it slightly to fulfil all requirements. That’s relatively easy. You can’t use the same easy strategy for a project like the one executed in Knottingley and it is exactly where a skilled and experienced design team, like our team, makes a difference.

Our offer for Stölzle covered every system, every piece of equipment from batch charger to the spouts. We did it all by ourselves, without any subcontractors. That is why we were able to guarantee a short glass-to-glass period, which of course was also significant for the customer.

What other projects have you worked on with Stölzle?

Although it was our first project for Stölzle UK, we’ve cooperated with Stölzle for many years in numerous projects of various scale: from small repairs to new turn-key projects. We have good experiences in cooperation with Stölzle in the Polish market. Stölzle has two glass plants there

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Company profile: Techglass

and forehearths in STC. When Stölzle bought the Wymiarki plant it quickly decided to rebuild it and they chose us to do it. Techglass performed the rebuild from glass to glass there in 2015.

So, based on our positive experiences in cooperation the next project was just a matter of time. The same year we were queried about the furnace cold rebuild in Knottingley, UK.

Did the Knottingley installation require any particular challenges or was it a straightforward job?

A project like this is never straightforward. The sheer amount of old materials to be dismantled and transported out of the production shop and then the new ones to be transported in and installed in a very specific order, would give every project manager a headache.

Sometimes only refractory materials with some steel structure are replaced. In Knottingley every system was replaced as well, from combustion system, cooling systems to control system. It was a challenge to execute a project this big in the small space of the production hall in a short time. Quite often the ideas that look good on paper during the preparation phase, turn out to be non-workable on site and you need to come up with new solutions.

In Knottingley, we had assumed for example that we’d be able to use a crane for heavy lifting, but it was not possible due to insufficient space.

We proposed a solution that was accepted by Stölzle and the works were not delayed.

Every plant is different, so every project brings its own problems to be solved. We are very good at that, it is one of our main strengths that we never give up on finding the best solutions, and since we have a lot of experience, we do it fast. The Stölzle team was very helpful in making their decisions concerning our proposed solutions, so we were able to finish the project before the deadline.

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Why should glass manufacturers consider Techglass when they source new equipment for their factories?

First of all, our team is the company’s greatest advantage. We employ 140 people – from designers, technology engineers, control systems engineers to steel workers. We are therefore capable of executing turn-key large scale projects based on our own human resources covering the whole production process, from modelling through designing to construction and heat-up.

I think that the second key factor is the high quality of the products we provide. Due to the fact that most of the systems and equipment Techglass supplies comes from our in-house production, we are able to control its quality thoroughly. We can cover the entire scope from the batch silo to the spouts, so choosing us the customer limits the number of contractors on site and it is much easier to plan all activities. Needless to say, that greatly lowers the risk of collision problems, which take

� Techglass’s headquarters and production plant is in Krakow, Poland.

a lot of time to solve if more than one contractor is involved. What is more we always treat every customer individually, providing them tailored solutions. Techglass does not sell the furnaces offthe-shelf. Also, we do care about the after sales services, trainings and consulting to make our customers familiarised with our installed furnaces.

Furthermore, we provide hot works and audits between the cold rebuilds to help our customers keep their furnaces in a good state of repair.

Combining these factors all together leads to the successful outcome of the projects and customers’ satisfaction.

Can you tell me a little about the company’s history?

Techglass was formed in 1990 by a group of people formerly employed by the state-owned ‘Institute of Glass and Ceramics’. In Poland it was a time of great opportunities after the breakthrough of 1989 when it was finally possible to start your own company. At the beginning our operations were limited to minor repairs, but step by step we gained momentum and extended the range of our services and products to the current level. Now, after 25 years, we are a trusted supplier of companies such as Owens-Illinois (O-I), Saint-Gobain, Zoujaj and Stölzle for turn-key multimillion projects, which shows the distance we covered from the humble beginnings in the 1990s.

Have you noticed any recent trends from glassmakers?

A glass manufacturer, as any other manufacturer, has always been interested in lowering expenses while improving or at least maintaining the quality of the product. Expected lifetime and energy consumption of a furnace are therefore among the hotly discussed topics during every tender process. The glass industry is quite conservative, the changes are relatively slow.

One trend that clearly stands out concerning glass melting is the reduction of the environmental footprint of the furnace. It follows the rise of awareness of the environmental protection in the population, but also the penalties for exceeding limits of emissions reinforce this trend.

Continued>>

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Company profile: Techglass

Where is Techglass’s strongest geographical region?

Europe is our strongest region, but we are present in many others. For example, now we are in the last phase of a turn-key project in Saudi Arabia, our second turn-key project there in two years, and in the furnace construction phase of a turnkey project in Poland for Zignago Vetro. This year we completed two complex furnace rebuilds in Ukraine for Verallia and for Vetropack. Last year we executed rebuild projects in Germany for O-I and Saint-Gobain. Of course, the Polish market is important for us and we are very active there. In the last two years we have completed two complex furnace rebuilds for O-I and for Zignago Vetro. In the mentioned period, we also executed a turnkey project for Can-Pack. In addition to these big projects, we have been also involved in many smaller ones in different countries such as India, The Netherlands, France and Egypt.

Is there an emphasis on innovation and Research and Development?

We focus on two main research areas: energy consumption and process automatisation.

There are a couple of ways to optimise energy consumption, like heating the batch or waste gas energy recuperation. The aim of automatisation of the glass melting process is to have a system with only a couple of parameters to be set, like the type of the bottle or the pull. Everything else, the temperature curve, the electric boosting power and others, should be controlled automatically.

Currently we are quite far away from that vision, but we’re getting there.

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How strong is the Polish glass industry and does it have a rich glass heritage?

The Polish glass industry is not among the strongest in the European Union, but its growth is the fastest. The total output of all companies is about 3500 thousand tons per year. Glass containers – mostly bottles – constitute about 1400 thousand tons out of the total output.

This volume is achieved by a couple of international companies which are present in the market such as O-I, Ardagh, Can-Pack, BA Glass, Stölzle and Zignago Vetro.

Most of the Polish glass plants have been overhauled recently. Concerning the float glass

� Techglass’s furnaces have been installed throughout Europe and beyond.

sector, there are also several worldwide players active in Poland: Saint-Gobain, Euroglas and Pilkington. They produce approximately 1200 tons per year and their facilities are among the most modern in Europe.

There are also glass wool producers, like Isover and Ursa, present in Poland. In our opinion the glass container branch has the greatest potential of growth in the Polish glass market.

How would you like to see your company evolve over the next 5 to 10 years?

We are now in a long transition process in the company. The employees that joined us in the first years and became key to our operations are gradually retiring. A new generation is replacing them and this process takes time.

This is the biggest challenge we are now facing, but I’m positive that everything will be fine. We are lucky that we specialise in glass furnaces as in the years to come there will be most probably no material that could replace glass and no new glass manufacturing technology.

The demand for our products and services will be therefore at least maintained at the current level.

How many staff do you have and how many offices/plants?

We employ 140 employees. They belong to one of our departments: Furnace Design, Combustion Systems, Control Systems, Masonry, Steelworks, Production, Logistics, Project Management and Office Administration. The headquarters and production hall are located in Krakow. The Furnace Design Department is based in Warsaw. �

*President, Techglass, Krakow, Poland www.techglass.pl

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Company profile: Verallia Ukraine

� Verallia in Ukraine: Zorya’s furnace #2 is dedicated to high quality extra-flint.

Verallia Ukraine reaps the benefits of modernised furnace Verallia Ukraine’s new furnace number 2 at its Zorya plant means the company can offer more complex-shaped bottles as well as more flexibility to its customers. Managing Director Daniel Saksik discusses the recent investment.

The modernisation of furnace #2 has given us more opportunities to produce complex-shaped bottles.

Verallia can now offer another service – short-run production for market players in the segment of low-volume premium editions.

This installation is also a strategic move that will have a significant impact on Western European countries, with Verallia plants becoming more flexible to serve customer orders and support one another.

Why did you decide to modernise?

Having observed an increased demand in recent years for limited editions made of high quality flint glass, Verallia in Ukraine decided in 2013 to respond to this market’s requirements by launching the production of extra flint glass.

To achieve this, we use special high quality raw materials. This was one of the first steps in presenting Verallia in Ukraine as a high-end market producer of premium bottles.

Between 2013 and 2016 demand for short runs grew significantly, and Verallia in Ukraine implemented in its Zorya plant the single gob process and, for the first time in Ukraine, the Flex Line, supplied by Glass Production Service.

Considering demand in both domestic and export markets for premium products, Verallia in Ukraine consequently modernised its furnace in 2016. Its furnace #2 now feeds three production lines equipped with Flex Line technology, enabling several articles to be produced simultaneously: small runs that offer customers greater flexibility.

Is it a larger furnace than before?

As Verallia decided to fully modernise the furnace, yes, capacities were also slightly increased. But even more than capacity, our main target was flexibility. And in this respect we are successful.

Will the furnace allow Verallia to extend its offering to customers?

The new furnace is taking our premiumisation strategy one step further.

Thanks to this new installation and the equipment already installed, we are able to increase our production flexibility, providing Verallia in Ukraine with a range of technical capabilities to produce a variety of products with complex shapes, thicker bases, and different types of body and finish.

Historically, Ukrainian customers prefer strong drinks. The market has become more marketingdriven and glass needs to adapt to create different designs, shapes and colours with perfect quality. All these factors are important to appeal to customers

Can you tell me more about the 200 models the plant makes?

The number is rather impressive, considering we mostly manufacture different types of bottles.

But thanks to the flexible line on which we were able to produce 1-3 different items, we had 200 models per year. The latest modernisation improvements and additional Flex Lines will help us meet tomorrow’s challenges.

Continued>>

www.glass-international.com

What benefits will the new furnace bring to Verallia and its customers?

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What other complementary modernisation actions occurred?

Furnace #2 was fully modernised in 2016. The hot and cold ends were completely revamped and new inspection machines were installed. In addition to significant changes on the technical side, Verallia also improved working conditions for its 566 Ukranian employees.

We have also taken advantage of Verallia’s operational excellence programme, which lets us apply best practices, train our teams to the highest standards in the glass industry and offer top products to our customers.

� Customers, staff and partners view the revamped site.

Who are the plant’s main customers?

Our customers are the biggest Ukrainian spirits and food producers, such as Bayadera Group, Nemiroff, and Eastern Beverage Trading in spirits, and Mondelez, Chumak, and Fozzi Group in food.

Verallia in Ukraine has a high proportion of export sales.

Zorya’s furnace #2 is dedicated to high quality

How long did the refurbishment take?

A three-year programme in terms of preparation, this quite complex project was completed in 65 days from glass to glass on the Zorya plant. But what is even more important – all rebuilding and restarting deadlines were met. The first glass products were produced just as planned. This was quite an achievement.

The new equipment installed in 2016 is only one step in the global investment programme to fully refurbish the Zorya plant, which began in 2014.

This will be a step-change in Verallia’s expansion through an increase in our flint and extra flint production capacity, further product quality improvements for the benefit or our Ukrainian and non-Ukrainian customers as well as an optimisation of our energy efficiency.

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Did you have any specific environmental specifications when you chose the furnace supplier?

During the rebuilding of the furnaces, which takes place every 10 to 14 years, Verallia always uses the most energy efficient technologies for glass melting. For instance, our proficiency in melting has enabled us to lower the energy consumption of furnace #2 in Zorya by more than 20%.

Our Zorya plant has put a huge effort to decrease the non-melting energy consumption, thanks to three main actions : � Optimisation of energy consumption on lehrs and feeders: Optimising burning and additional isolation on feeders. � Energy saving on compressors : Optimisation of compressor station usage, elimination of air leaks. � Installation on furnace #2 energy saving

lighting. Diode lamps installed are more efficient and consume less energy in less time.

Regarding waste, the priority is to set up solutions to reduce the quantities generated and for recycling and recovery.

The improvement in the integration of cullet, both in quality and in quantity, is one of Verallia’s main objectives. Verallia uses internal and external cullet at its Zorya plant.

� The new installations will enable Verallia in Ukraine to extend its partnerships with customers who have expressed a preference for extra-flint glass.

extra-flint and flint glass production has been completely rebuilt, together with its three production lines. Verallia has accordingly given itself the means to boost its position on the small and medium-run high-end markets. These new installations will also enable Verallia in Ukraine to extend its partnerships with many customers who have, over the years, expressed a real preference for extra-flint glass.

Where does the plant export?

We export glass products to 16 countries. Many Western and Eastern European customers have already partnered with us to launch products in different market segments. Our main export markets are Poland, Germany, Romania, Hungary and the Baltic countries. �

*Managing Director, Verallia Ukraine, Zorya plant. www.ua.verallia.com

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History

Prof. John Parker

Joint account

Prof John Parker investigates the bonding of glass, an intricate process that dates back to Roman times. as glass companies and academe learned to collaborate. The dimensional changes are not precisely linear with temperature and are particularly rapid near the glass transition. So tabulated TEC values had to indicate the temperature range of measurement to enable the design of glass compositions matching the substrate to which they were to be bonded.

Now present-day artists can access a wide palette of coloured glasses all with similar TECs. Following its application by geologists, polarised light was introduced in 1915 to monitor annealing. Stresses influence light propagation, depending on their orientation relative to the plane of polarisation, and this facilitates stress measurement.

Thermal mismatch stresses can also be computed for complex situations. Interestingly telecoms optical fibres require the joining of different glasses for light guiding and their designers must consider the effect of stress on signal dispersion.

Practical glassmakers, however, adopted simple ‘tricks’ to match expansion behaviour, such as joining blobs of the two glasses to be compared and pulling a composite fibre. Any difference in expansion leads to a bent fibre whose radius of curvature measures the expansion mismatch. An extreme form of this led to a method of making glass wool from kinked fibres consisting of two unmatched glasses.

A similar approach used by potters was to glaze just one side of a ceramic rod to see which way it bent after firing.

An application of particular technical importance throughout the last century was the creation of reliable glass-tometal seals. Platinum metal seals were easily made because its TEC matches that of common glasses but were not commercially viable. Copper has almost twice the expansion of glass but its ductility allows some stress relaxation during cooling. Making a seal using thin

metal wires or sheets concentrates the stresses in the (stronger) metal. Even the Romans discovered they could gild glass and modern artists often coat hot glass using thin gold or silver sheets. Now, the control of relative dimensions, the use of graded seals and composite wires have facilitated the joining of much wider range of metals to a variety of glasses and allowed our lighting, electronic and chemical industries to blossom.

Of course zero stress is not necessarily the goal, but rather a stress distribution that maintains/improves the product strength e.g ceramic glazes are typically under compression.

Unmatched joins are still problematic.

Small fragments of ceramic in the cullet stream or refractory defects in raw materials generally have much lower expansion coefficients than glass.

Consequently as the manufactured article cools, the glass around the defect cannot contract as it should. This ‘stretched’ layer is under tension and cracks easily run outwards from the defect. When the article is subject to external stresses or even during annealing, such cracks can extend and cause failure. Silicon produced by powerful reducing contaminants such as aluminium is similar. Initially molten it forms spheres, but when solid its low expansion (contraction) coefficient causes exceptionally high tensile stresses.

Conversely metallic defects often give low stresses because they shrink faster than the glass without bonding to it. �

Bibliography Glass to metal Seals, I Donald, Society of Glass Technology, 2007 Basic optical stress measurement in glass, H. W. McKenzie & R. J. Hand, Society of Glass Technology, 1999

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

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T

hat the Romans were able to produce objects of the quality of the renowned Portland Vase is staggering. This dark blue cameo vase was decorated by cutting through an outer casing of white glass to give intricate mythological scenes that many believe hide a deeper historical narrative. Not only was the quality and artistry of the engraved images remarkable but, for the technologist, so too was the joining of two glasses of different compositions and properties without fracture. Wedgewood created ceramic copies in 1790 but only in 1876 did John Northwood successfully reproduce it in glass after the original was deliberately broken by a visitor to the British Museum (1846).

Why is joining different glasses so difficult? Glasses are characteristically stiff - high stresses are needed to create even small dimensional changes and vice versa. Consider the bonding of glass to a different material. The bond forms near the glass transition temperature when viscous liquid morphs to solid (typically 550°C); cooling to room temperature causes differential contraction, magnified by the large temperature drop. Such differences in shrinkage, although small, can introduce unacceptably high stresses in the glass. So a poorly chosen glaze on pottery may craze; the refractories in a glass furnace cannot be recycled between melting and room temperatures without cracking; and a metal wire passing through the envelope of glass vacuum equipment may induce fracture.

How were solutions found? Early technologists relied on trial-anderror and rules-of-thumb to identify suitable compositions. Measurement of the thermal expansion coefficient of glass (TEC) came much later. Because the dimensional changes are small, precision dilatometers were needed.

By the early 20th century, the need for standardisation was appreciated and best practice methodologies were developed

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Phoenix Award honours Fuyao Glass Chairman Cho Tak Wong

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The Phoenix Award Committee presented its ‘Glassperson of the year’ award to Chairman Cho Tak Wong, founder of Fuyao Glass, at a prestigious event in Ohio, USA. Sally Love was there.

Local benefits This year, Chairman Cho Tak Wong, founder of Fuyao Glass, was honoured at a banquet event in Dayton, Ohio, USA. Members of the Committee, the press, and guests of Mr. Wong himself, who joined him from China to celebrate the achievement, attended the event.

The dinner was planned to coincide with the opening of a new Fuyao plant in Ohio, which will bring 2,000 jobs to the local area and increase Fuyao’s worldwide presence. As such, the Governor of Ohio, John Kasich, was on hand to open the proceedings.

Speaking of the benefits the new Fuyao plant will bring to the community, Mr Kasich underlined how “This is a relationship and a friendship that can never be taken for granted.”

He added: “The future is really ‘sky’s the limit’, but that means that in this community we have to make sure we have a deep friendship and deep partnership with this company. I can’t thank all of you enough for what you’ve done.”

Global impact Holger Zippe, above and Paul Hutchinson, below, gave speeches before presenting the award to Chairman Cho.

The impact that this one Fuyao plant is having on a town’s community can put into perspective the effect that each Fuyao plant must have on communities around the world. The company being the creation of one man is, therefore, even more significant.

Cho Tak Wong was born in 1946 in rural China, near Shanghai. His family had once been prosperous, but after events during the Chinese Civil War in the 1940s their fortune changed. As a teenager he had to drop out of school, and to make a living he sold fruit and tobacco on the streets of his hometown, repaired bicycles, and worked on farms.

Holger Zippe, Chairperson of the Phoenix Committee, told of how the idea to manufacture flat glass for automotive first occurred to Chairman Cho: “One day in 1984 he bought a walking stick for his mother as he finished a shift. When he brought the stick into the car, the driver warned him not to break the car’s glass, as it was too expensive.

“He later learned that this kind of glass was all imported, as no one in China could make it. ‘Why can’t I do it?’ was the question that drove him from now on.

“After making his first contact with glass in a small water-meter glass factory in 1983, Mr Cho personally founded Fuyao Glass Industry in 1987 in Fuqing.”

The success of the company took off from that moment. Today, the company has a web of production plants as well as sales and marketing offices around the world, including China, Hong Kong, America, Europe, Australia and Russia, and is the largest automotive glass supplier in China.

Its customers include Audi, Bentley, BMW, Chrysler, Citroen, Ford, Honda, Hyundai, Mercedes Benz, Toyota and Volkswagon amongst others, and the company directly employs over 8,000 people around the world.

The Award Welcoming Chairman Cho to the stage, Mr. Zippe said: “We have come here today from very large distances from all over the globe, to honour and celebrate the 46th winner of the prestigious Phoenix Award, Chairman Cho Tak Wong, a legend in the glass industry.

“It must be added that Chairman Cho is a very humble, noble, and generous person. He has founded the Heren foundation in memory of his father, where he has contributed more than $1 billion to the development of society.

“We are happy now to honour a great and true entrepreneur. A widely remarkable person, a great glassman, and the first glass person of the year ever from the People’s Republic of China: Chairman Cho.” The 70-year-old Chairman Cho was full of humility and humour, speaking via a translator to accept the award on behalf of himself, his friends, and his employees: “I am very excited, also moved, by this award. I am grateful for two things. First, thank you to the committee for giving me this precious award. I am also grateful for all the friends who have come from far away to attend this event.

“When I received the notice that I would be given this award, I find it hard to find the right words to describe my feelings.

“I am very excited after all the applause I have received tonight. I have my own reading of all this applause, but what does it mean? One of my interpretations is that it is to congratulate me; that I have been successful.

Continued>>

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T

he Phoenix Award is presented each year to an individual who has made a significant impact on the glass industry. The Phoenix Award Committee, which decides the winner, is made up of suppliers to the industry, and the rules are clear: It can be awarded for work in any field of the glass industry, such as academia, production or art, but the person must still be living.

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The members of the Phoenix Committee 2016, with recipient Chairman Cho centre right and Holger Zippe, Chairman of the Committee, centre left.

“The other interpretation is of encouragement, meaning, ‘you’ve been doing ok, but keep on going’.

“So, if it was meant to congratulate me, I think the honour has not much to do with me.

“As all of you know, during my lifetime when I was in my youth and middle age, China did not allow private economy. In the 80s, China started to have a new policy of economic reform, and that’s when private enterprises were allowed, and that’s when I started my company.

“And so, if it were not the right timing, I wouldn’t have had this honour. And so I think the honour should go with this age.

“In my years of growing the business, I received great support and encouragement from all over.

So this award goes to all the friends, whether they are here or not, for their support. In my 30 years of career I have had an outstanding team of employees. They are comprised of engineers, marketing people, management people, and they have afforded me great support in this business, so this award should go to them as well.

“My interpretation of the award is that it’s meant for encouragement. I am fairly young, so for the remaining part of my life I should just keep on going.” �

www.phoenixawardcommittee.org

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Lizmontagens_ad_2016.pdf

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> DEPENDABILITY > FLEXIBILITY > DURABILITY

>

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>

BATCH WETTING EQUIPMENT

>

GLASS PRODUCTS

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Please visit us at Glastec, Hall 13 A85 to discover what we can do for you.

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Masters in manufacturing

Park Lane, Halesowen, West Midlands, B63 2QS, UK PRECISION BRITISH ENGINEERING

glassworkshounsell.co.uk

Batch plant

The digital batch house Roger Knüttel* describes how the modern batch house is now far more than an area just for the preparation of batch, but is integrated into a plant wide automation concept.

Core Components Hardware concept of a digital factory The heart of the EME Batching System is a modern and powerful programmable logic controller (PLC) of the type Siemens Simatic S7-400, combined with weighing

� Fig. 1: Batch plant and furnace as part of a plant wide automation.

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modern batch house is far more than a plant for the preparation of batch for glass production.

A modern batch house is integrated into a Plant Wide Automation concept (Fig. 1) and equipped with standard interfaces for connecting the automation world with global corporation, e.g. for data exchange with ERP Systems, data provision for integrated reporting, and so on.

The Totally Integrated Automation (TIA) concept not only provides a uniform operating philosophy and a quick overview of operation specific data, but also ensures complete management over the entire life cycle of a plant.

As a pioneer for Plant Wide Automation (PWA) in the glass industry, EME has already equipped numerous systems with control system solutions for the entire batch and melting area. We continue with this philosophy today.

I would like to discuss the core components of a modern batch house, describe modern concepts for raw material management, a concept for the optimisation of the production process, briefly present our universal batch solution and sketch our idea of a virtual factory.

� Fig. 2: Access to the offloading bins with barcode and/or RFID.

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Batch plant

� Fig. 3: Simulation of a raw material conveyor.

units of the same manufacturer, namely Siwarex U, FTC or FTA. This is in keeping with the idea of Totally Integrated Automation (TIA).

Alternatives, such as ControlLogix from Rockwell and its weighing processors are also offered as solutions for customers with specific product needs.

Due to the modular design in hardware and software, such a system can be adapted to all conceivable tasks in the area of the automation of industrial plants.

The modularity in the hardware results from the use of freely available standard modules of the respective manufacturer, which in the event of a fault are easily replaced by a cost-effective replacement device. This hardware modularity makes any conceivable expansion of automation possible. This means that existing plants can also be upgraded step by step to the new technology.

production. The customer therefore relies on a mature and proven plant concept.

In this context it should be mentioned that over many years we have upgraded numerous old control systems to the EME concept, largely carried out during normal production.

This stringent modularisation and standardisation and the maintenance of the functional compatibility of the EME batch system over numerous innovation cycles guarantees the customer a smooth transition for future upgrades of his system.

Through our basic philosophy we also have the possibility to test the entire functionality of the software in a simulation environment, even without the control cabinets. Even with system upgrades of plants, we can test the additional new software before implementing it into the running system.

Software concept of a digital factory

Raw material management

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Base components As standard systems, we use either PCS7, with the APL library from Siemens combined with the EME APL Batch Library, or our proven batch library for Simatic S7 and WinCC. Alternatively the EME Batch Library for Rockwell is used in specific applications.

During the delivery, unloading and storage process of the raw materials in the batch plant there are three points that are the main focus. Firstly, the reliable

selection of the correct raw material silos to prevent contamination that will lead to production problems. Secondly, the exact determination of the delivered material type and thirdly, balancing of raw materials.

As a concept, the following best practice can be roughly sketched. Details are always customised (Figs 2 & 3). � The raw material supplier registers his delivery at the raw material receiving area. � The barcode data on the delivery note is copied to an RFID card, with additional Data (customised to customer needs). These RFID cards are marked with defined colours. � The gross weight of the truck registered at the goods receipt scale and is temporarily stored in the system. � The colour of the RFID cards is assigned to base on corresponding unloading stations that are marked with the same colour. � At the unloading stations, further safety measures can be implemented against unauthorised access, such as, boom control and barriers. � By reading the RFID card at the correct unloading point, the corresponding raw material silo is selected and access is granted to the unloading station. � The supplier can now empty his raw material and finally finishes his delivery process by using the truck scale for the second time. From the stored gross weight and the difference, the net raw material weight is calculated and transferred as delivered quantity to the loaded silo. Thus, the filling level of the silo is accurately recorded.

When dosing, the quantities extracted from the silo are subtracted from the silo level.

Philosophy The modularity described above under the heading Hardware concept is extended by the use of standard software modules, which are always developed on the basis of many years of experience and knowledge from running plants.

We have developed several standard libraries for various automation systems.

These libraries include a knowledge of process engineering processes in glass

� Fig. 4: EME Preventive Maintenance System.

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Batch control at its best

The core of the EME batch house control concept is a powerful PLC controller with integrated weighing units for container and belt scales. The standard system is based 100 % on Siemens PCS7, however, also other brands like Rockwell, Schneider or other PLS´s will be supplied.

The EME system employs modular hardware and software, so that it is easy to scale systems up or down in order to adapt them exactly to the requirements of each individual installation.

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

Glass is our Passion

Batch plant

The raw material quantities managed by the mass balance feature of the EME batch system are not only required for checking the fill level, but also for the inventory control and for the accurate and timely procurement of raw materials.

All data is stored on a MS SQL Server database and synchronised with a redundant partner server.

The connection to the customer’s ERP system via standardised interfaces or via its own access to the data in the SQL Server is always a standard part of our system software.

Optimisation of the production process

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The production of batches of the highest quality in the shortest possible time, while taking into account plant safety (even in the event of a fault), is an intrinsic property of any EME batch house application.

For this purpose, each batching plant is divided into functional units. These are coordinated via defined interfaces throughout the EME batch system.

Examples of functional units are the large raw material scales, the minor-ingredient scales, the mixer(s) and the batch transport to the furnace bins.

The division of the batch plant into functional units produces distinct advantages: � A clear and transparent process. � High Performance Batching. Once a functional unit has passed its product to the following unit, it is available once again for a new request. Long and unnecessary run-down times are a thing of the past. � Technologies such as sequential batching can be easily integrated into a system at any time. � Simplification of redundant transport routes and the smooth changeovers in the event of failures. � Step-by-step upgrades or conversions of old plants; even during normal production.

Tools The AddOn, EME BatchTools, is a universal, independent batch system fully integrated in PCS7, S7 and Rockwell. It is operable via Windows and any standard internet browser, such as Google Chrome, Firefox and IE. It is also available via all popular display devices such as PCs, tablets and Linux devices.

This Visual Studio Net-based batch application includes:

� Coordination of the production process via the recipe settings � High performance batching � Route control � Production data management � Recipe management (MS SQL Server or MS Access) � Batch archiving and consumption analysis (MS SQL Server) � ERP Interface (SAP, etc.) � Universal data interfaces -> XML, XLS, CSV, PDF, EXCEL, RTF � Interface to text. Software, such as batch calculation programmes. � Data management � Synchronisation of all data � Automatic backup of all system parameters, setpoints and settings. � Detailed evaluation and diagnosis of batch production � Diagnosis and analysis of dosing accuracies by means of curve, standard deviation, etc. � Integrated webserver

Preventive maintenance To ensure a high technical availability of a batch house, a well thought-out maintenance concept should always be the basis of operation (Fig. 4).

The EME Module for preventive maintenance supports the customer for proactive preventative maintenance of the plant.

The run times of all selected items of equipment are recorded by the module and the defined maintenance intervals are compared by the system to generate a maintenance list.

EME maintenance has the following functions, including: Using default maintenance parameters based on the EME maintenance manuals; fully-flexible adaption of these settings; export/ import of all data as XML, print out of all data as PDF, Excel, Word, including a maintenance document/description as PDF for any standard device; synchronisation of all data between the SCADA servers; generate maintenance units as a block, and at the backend is the MS SQL Server as a fast and reliable database.

After changing parameters, settings, etc. the module can automatically carry out the synchronisation the data points with the other SCADA server.

When creating a new maintenance schedule for a device, the system knows its maintenance type and suggests the EME standard parameters for use.

These EME standard base settings are

always part of any EME installation and are stored in the SQL database. The user can completely change all these settings to his or her specific needs. Therefore customer specific maintenance schedules can be implemented in every plant.

The virtual factory The design of the system as a virtual twin in a simulation environment is a key component for optimal system testing of batch plant software and the training of the customer’s personnel.

Although in its infancy the current systems already reveal the great potential of the virtualisation of a system.

Today, virtual commissioning allows testing in a simulation environment without the physical system itself being required. The interconnections of all signals, whether they are analogue or digital sensors, or switches and pushbuttons, are tested in the simulation.

Further to the complete production process of the plant in all operating modes, specifically in automatic mode, the data exchange with MES / ERP systems are also verified.

This means that virtually all functional and operational faults can be corrected before commissioning.

Partial and modular tests are already possible during the engineering phase to check the functionality of even new software modules as well as new process engineering procedures.

The risks of software commissioning on site are practically eliminated. Possible software errors and malfunctions do not lead to serious consequences, thus avoiding costly damage to equipment and injury to persons.

The commissioning engineer can then concentrate on specialised tasks on site such as the calibration of the scales and setup of field devises.

The virtual system enables the training of the customer personnel long before commissioning. Emergency scenarios, without jeopardising the live system, can also be simulated.

A subsequent installation of the virtual plant environment at the customer’s site further extends the possibility to instruct new employees without risk and to further train existing employees. �

*Manager Control Engineering Department, EME Maschinenfabrik Clasen, Erkelenz, Germany www.eme.de

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Batch plant

� Concrete works in progress with mixers in the front.

Construction starts on Zippe’s batch plant at Mexico’s IVC Heiko Brand* reports on progress of the construction of the Zippe batch plant at IVC, in Piedras Negras, Mexico.

I

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n August of this year, Zippe started the construction of a new batch house at Mexican company Industria Vidreria de Coahuila (IVC). IVC is a joint venture between the US-based container glass manufacturer Owens-Illinois (O-I) and the large brewery, Constellation Brands.

The new building site is located directly on the Texan state border and will manufacture bottles exclusively for the brewery, which is directly adjacent.

Zippe Industrieanlagen will implement

the project on a turnkey-basis. Zippe’s scope of supply also includes the two cullet return systems for the new melting furnaces, F3 and F4.

The raw materials will by primarily supplied via railroad. As an alternative, trucks can be unloaded as well. The raw material transport into the silos will be carried out by means of a mechanical transport system.

The actual batch house is a concrete plant with round silos. The main raw

materials are weighed by means of six container scales, while the small components are added via two small component scales.

The raw material mixing will be effected by two high duty pan mixers of 5250 litre-volume in order to ensure the corresponding redundancy.

Continued>>

� 3D view of the unloading hall, batch house, batch transport and cullet return system.

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Don‘t you want to get the most out of your batch and cullet plant?

Rising costs mean glass production must be as efficient as possible.

If a batch plant has been in operation for many years it is obviously no longer at the technological cutting edge. In this case refurbishing and modernizing, indeed optimizing by Zippe, makes perfect sense. Our specialists inspect each plant and then tailor concepts to promote operational reliability and increase efficiency on every level.

Contact us for all your requirements in terms of batch plants, cullet systems, pre-heating, chargers, automation and control systems, as well as engineering.

ZIPPE – BECAUSE WE DO IT.

ZIPPE INDUSTRIEANLAGEN GMBH · Alfred-ZIPPE-Straße · 97877 Wertheim · +49 9342 - 8040 · zippe@zippe.de · www.zippe.de

Batch plant

� 3D view of the Batch Plant.

The cullet addition takes place after the mixing process.

Therefore, in connection with the weighed mixer post hopper, an optimum batch-cullet sandwich can be created. The two melting furnaces with two weighed furnace silos each will be fed by means of a mechanical batch transport. The batch plant is designed for a total capacity of 960 tons per 16 hours.

Cullet return system

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Another feature is the fully-automatic cullet return system for the F3 and F4 melting furnaces. The internal plant cullet is transported directly into the cullet silos, which are attached to the batch house. It means the cullet can be immediately reintroduced into the melting process.

The entire ‘batch house’ project as well as the two internal cullet plants will be implemented on a turnkey-basis. The scope of supply includes the complete engineering services, the supply of mechanical equipment and the control system. The automation system of the project consists of several PLCs and a SCADA system.

The raw material intake, weighing and transport as well as the cullet return system are controlled via Siemens’ S7-400 and S7-300 PLCs. The core component of the weighing system are Zippedeveloped weighing indicators Z-WI-102 and Z-BWS-102, designed particularly for the glass industry. The system is operated via two WinCC-SCADA stations. Two redundant servers ensure high availability and reliability of the system.

The local operation of different plant parts such as unloading, raw material intake and cullet return can take place via several 12” Touch Panels.

There is also a mobile panel available to control the devices in the weighing area. The local subsections such as concrete construction, steel structures, assembly, piping, cabling, as well as commissioning and personnel training will be managed by Zippe.

The start-up of this new, modern and powerful installation is planned for early summer 2017. �

*Project Manager, Zippe Industrieanlagen, Wertheim, Germany www.zippe.de

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Process control

Understanding the value of precision process control René Meuleman* and Amber Watkin** discuss the benefits of high end precision process control products compared to more basic control. This is an abridged version of a paper presented by Michael Brownhill at the Society of Glass Technology Centenary Conference in Sheffield, UK recently.

Temperature control When designing or retrofitting systems,

it might be tempting to choose a basic Proportional, Integral, Derivative (PID) temperature control solution to save money, but the level of control and accuracy provided by this kind of equipment will likely cause problems because it is unable to control the temperature in different areas of the furnace precisely, or react quickly to unforeseen temperature events (Fig. 1).

Maintaining the desired viscosity of the glass melt at all times involves tight temperature control, so what is needed is a modern precision PID temperature controller or precision Programmable Automation Controller (PAC).

These will have accurate inputs and outputs, along with special algorithms embedded in the control strategy to deal with common heating and cooling issues in industrial processes.

Optimised energy use During the furnace startup sequence, users probably want to heat the glass up as quickly as possible. Multiple temperature

Overshoot

Temperature

Temperature Time

Continued>>

Set point (SP)

Set point (SP) Precision PID control

measurements need to be made across the furnace and fed into the controller, to calculate and output the resulting values that will achieve a uniform temperature across the glass melt.

The problem with basic PID control in this instance, is that it will not be intelligent enough to prevent overshoot of the desired temperature setpoint and will take a long time to stabilise the different areas of the furnace (Fig. 2).

High end precision PID control, on the other hand, has embedded algorithms to tightly control temperature, so setpoints are reached with minimal overshoot during ramps and the process variable stabilises faster. For example, in Eurotherm products the ‘cutback’ algorithm helps prevent overshoot.

The cost of investing in a precision control system is easily justified against the energy savings and increased productivity brought by faster temperature stabilisation over the

Overshoot inhibition

Time

� Fig 1. Precision PID control contains special algorithms that help to keep

� Fig 2. When operating temperatures are outside the desired setpoint, the

the process variable as close to the setpoint as possible, even during ramps and

result is wasted time and energy, defects from under or over heated material

other unexpected temperature variations.

and possible scrap product.

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ometimes, it can be a struggle to explain to customers why they should consider specific products and systems to achieve the best process control for their application.

The benefits are often based on technical specifications and terminology that may not be in their specific area of expertise. Choosing equipment based on lowest price can be costly in the long run, but equally, choosing the most expensive may provide features that will never be used. It is therefore important for both supplier and customer to find the best price versus performance.

For Eurotherm by Schneider Electric, it is useful for customers to understand what to look for before making a decision to sell or purchase a specific system. With that in mind, the authors will explain some of the hidden benefits of high end precision process control products and solutions compared to cheaper, more basic control.

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Process control

Precision input Unstable noisy input Less accurate input

� Fig 3. Accurate inputs with high rejection to noise help achieve precision PID control by supplying exact

Temperature

measurements to the PID algorithms for more precise calculation.

Time

lifetime of the furnace. Eurotherm has spent more than 50 years perfecting these kinds of algorithms with glass processes in mind, along with advanced Autotune features that automatically set ideal parameters in the PID control loops to suit the application. Taking care of this often manual task achieves automatic efficiency and repeatability in the process, even compared to the most sophisticated model-based control strategies, which are not able to compensate for a badly tuned process.

www.glass-international.com

Accuracy Glass manufacturing plants create a lot of electrical noise when power is switched to electrical heating elements, furnace boosting systems, bushing control or variable motor drive systems.

The noise can be picked up by sensors like thermoelements and their cables situated nearby, resulting in interference on signal input and output (I/O) cables connected to the control system.

Compensation cables that are run near to power cables are a common culprit. In the case of basic controllers, the distortion on an I/O channel can lead to incorrect measurements and control outputs that adversely affect the temperature of the glass melt. Precision controllers with accurate I/O have specially designed circuits that are able to reject the levels and frequency of electrical noise that typically occur in industrial environments.

It is important to look at the specifications and choose control system products with inputs and outputs that are firstly, isolated from other channels and secondly, isolated from the main processor side of the circuit. This reduces interference from adjacent channels and protects adjacent circuits from damage if the channel rating is accidently exceeded.

Also worth checking is the quoted noise rejection. A higher value means less interference and Eurotherm has put a lot of work into the design of its circuits

over the years to offer isolated I/O up to 300Vac and high noise rejection thanks to specially selected high grade components and tried-and-tested circuit design.

While on that subject, it is also worth mentioning that the accuracy of a basic control product I/O channel will start to drift over time due to low grade components and poor design.

Eurotherm’s design and component choice greatly reduces this issue, typically quoting a low ppm (parts per million) value of drift/year, enabling a more stable glass manufacturing process, with longer calibration intervals.

It does not make sense to discuss accuracy of 1/100°C or even 1/1000°C if all the components in the loop fail to meet similar high accuracy specifications. Users also need to consider the errors brought about by the difference in temperature between the precious metal part of the thermocouple and the connection to the analogue input module.

Compensation cable is used between these points because it is not commercially viable to run the precious metal the full length of the system, nor possible because of the physical properties of some of the metals. Known as Cold Junction Compensation (CJC), a second temperature measurement needs to be introduced to calculate the compensation value between the two points.

In most Eurotherm products, the temperature at the input channel end is measured using platinum high stability temperature sensors, while basic PID controllers use cheaper and less accurate components (Fig. 3).

Thermocouple drift What about the accuracy of the thermocouples themselves?

In glass processes, these are typically made from combinations of platinum and rhodium to give stable readings at high temperatures. The problem with rhodium, however, is that when subjected

to high temperatures, it migrates over time into the platinum wire. The result is a long-term downward drift, eventually affecting the temperature and consistency of the glass.

The benefit of using precision or advanced controllers is that they usually come with maths functions and programming features that can apply more automation to the process.

In this case, a strategy can be implemented to automatically offset the thermocouple temperature in a positive direction by a small amount each month, counteracting the downward drift and maintaining the calibration accuracy of the thermocouples for a longer period of time.

System supplier selection When researching the best control products and solutions, it is worthwhile considering the expertise and support provided by the supplier and manufacturer. It is likely that a glass furnace will need to run for at least 15 years, so it would be wise to find a company that offers engineering services and a choice of support levels to help keep the plant running 24/7.

Companies such as Eurotherm, with extensive knowledge in the glass industry, will be able to advise on best practice for making energy savings, efficiency improvements and quality enhancements.

Eurotherm has more than 50 years’ experience in precision control and automation technologies and it is in the company’s DNA to keep on innovating and developing different ways of improving processes.

Whether that is through the use of new components and technology or better design of circuitry and algorithms, it has always been Eurotherm’s aim to give customers a competitive edge.

That is why the company made its precision control strategies and accurate I/O available across the whole product range, from discrete controllers to system platform products and precision redundant PAC range. �

*Global Glass Business Development Manager **Glass Marketing Application Engineer Eurotherm by Schneider Electric, Limburg an der Lahn, Germany, rene.meuleman@schneider-electric.com, www.eurotherm.com/glass

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Cellular glass

Cellular glass enjoys a comeback Cellular glass has been produced since 1932, but today it is attracting renewed attention. Dr. Hans Strauven* discusses the old ways of thinking about cellular glass for thermal insulation and demonstrates that, thanks to recent innovations, cellular glass deserves a larger part of the market.

The above statements are out of date.

While many believe them to be true, their actual scientific base is doubtful.

They neglect new production methods and formulations, because the majority of the production capacity is still based on scientific work from 80 years ago.

In the flat glass world, glass ranges from small single pane windows with large optical distortion, to large onlinecoated triple glazing without any optical distortion. Float glass is the standard, produced in large plants, while a few small companies still produce the old optical distorted glass for the renovation

� Installation of cellular glass boards

of historical buildings. Roughly the same evolution is happening with cellular glass, which evolved from small boards to large boards on one side, and foamed glass gravel at the other.

Producing cellular glass The majority of cellular glass on the market is closed cell cellular glass. This material has a combination of properties, which cannot be obtained with other base materials such as polymers, metals or ceramics. Closed cell cellular glass has the following combination of properties:

� Stable, low thermal conductivity (down to 0.036W/mK); � High compressive strength; � Vapour and (generally) gas tight; � No water absorption; and � Geometrical stability.

The general production method of cellular glass is the powder method, where the glass is ground to a certain particle size distribution. Afterwards or during grinding, a foaming agent is mixed with the glass powder. In the case of a solid foaming agent, the addition is preferably done during grinding, while a liquid foaming agent is added in a separate mixing procedure.

In a further step, the glass powder is sintered at around 600°C to enclose the foaming agent and further heated up to 800°C or more until the foaming agent starts to gasify and induces foaming. If large blocks or boards are requested, the foam is slowly annealed, while if gravel is requested, cooling happens naturally or is even accelerated with a water mist.

Depending on the foaming agent (and to a lesser extent the glass composition), a closed or open celled foam is obtained.

Open celled foams are generally a consequence of crystallisation, induced by the foaming agent.

Typical foaming agents that induce open celled foams are gasified by Fe2O3 reduction, such as MnO2 and or by decomposition, such as CaCO3, BaCO3 and others. After reduction/ decomposition, the remaining oxide induces crystallisation and in that way creates the open cell content.

Closed cell cellular glass is foamed with a carbonaceous foaming agent, which is oxidised by SO3 in the glass and then by Continued>>

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t seems that, just as the polymer industry never succeeded in pushing glass out of the bottle industry, all kinds of organic foams used for thermal insulation, such as expanded polystyrene (EPS), extruded polystyrene (XPS), Polyurethane foam (PU), and Polyisocyanurate (PIR) were not able to overtake cellular glass in the thermal insulation market. Cellular glass is mostly used in the building industry, where a long lifetime is required.

In many continents, the need for durable building is important and is the reason for renewed attention to cellular glass. However, as with all products with a long history in the rather conservative building industry, the old thinking remains active and innovations in cellular glass are unknown.

The so-called dogmas in the old way of thinking are that: � Cellular glass is only available in small dimensions; � Cellular glass is the best thermal insulation, but is expensive; � Cellular glass is the most ecological thermal insulation, but is expensive; � Cellular glass plants can only be profitable with a large production capacity and so is a risky investment; � Cellular glass plants need long production lines and are difficult to implement. They already have a large ecological footprint due to their minimum production capacity; � Cellular glass only has a function as thermal insulation, with a future market share of only 1% of the insulation market; � The new technology for producing cellular glass is not available on the market, causing high priced cellular glass.

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Cellular glass

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ďż˝ Complete application with cellular glass boards and cellular glass gravel

more substances containing SO3 that are added to the mixture.

The carbonaceous material is converted to gas and does not induce any crystallisation. Some manufacturers use carbon black or another carbon, while others use an organic foaming agent such as glycerin. Also, SiC can also be used to foam a closed cell foamii.

When carbonaceous materials are used, it can be necessary to use a reducing atmosphere during sintering, which avoids oxidation of the carbonaceous foaming agent by air instead of SO3 in the glass. An alternative of the reducing atmosphere is to add some waterglass to the mixtureiii.

Waterglass covers/solutes the foaming agent and improves the sintering of the glass, but may reduce the chemical resistance of the cellular glass. SiC foaming agent decomposes above the sintering temperature and does not need a reducing atmosphere or waterglass for the foaming of glassiv.

After foaming, there are two options: ďż˝ The foam can be cooled naturally to produce gravel. In this case, organic foaming agents combined with water glass or SiC are the advised foaming agents, because the foam has to remain more or less black. ďż˝ The ribbon can be annealed to obtain cellular glass boards of up to 3x1.5 m in case of continuous foaming, and even larger dimensions should be possible.

Dogma 1: small dimensions The foaming can be done in a mould or on a belt. In the latter case, an endless ribbon can be foamed and the dimensions are, in principle, only limited at one side by the width of the belt.

When mould foaming is used, we are limited on both sides. With mould foaming up to 0.475m x 0.400m can be produced, while Glapor with continuous foaming has 3m x 1.5m and larger in its range. The use of recent continuous foaming technology increased the possible dimensions by a factor of about six, and has eliminated dogma 1.

Dogma 2: high cost A glass composition can be used for foaming as well as waste glass. With the special glass composition, a thermal conductivity down to 0.038 W/mK can be reached at the expense of at least doubling the energy consumption (OPEX) and the large investment in a glass melting furnace (CAPEX).

However, it has been demonstrated that a thermal conductivity of 0.045 W/mK is possible when only waste glass is used without remelting.

In this case, lower energy consumption during production is combined with a smaller investment due to the elimination of a glass melting furnace. The new trend to foam directly from waste glass has eliminated dogma 2.

Dogma 3: Expensive ecological thermal insulation Cellular glass is the best thermal insulation due to its combination of properties and slightly higher thermal conductivity. It is now available at prices comparable with mineral wool at equivalent density.

At the same time, this material can show a better ecological balance than special glass composition cellular glass because no glass melting furnace is used and the glass powder is foamed in a neutral atmosphere with optimum natural gas combustion. In this way dogma 3, having

the best ecological balance but only at a high cost, is eliminated.

Dogma 4: large investment required for a production plant Investors are scared by the large capacity of profitable cellular glass plants today.

The development of continuous foaming and new recipes, starting from waste glass without remelting, has eliminated dogma 4. A cellular glass plant for boards can be a natural extension of a glass recycling plant, eliminating a lot of transport and handling cost.

The absence of a glass melting furnace improves the business plan.

Dogma 5: only long production lines are possible The new Glapor technology for the annealing of a cellular glass ribbon (not available in the public domain) has reduced the length of a production line and also improved the ecologic footprint of a cellular glass plant.

It only makes sense to invest in a glass melting furnace when recycled glass is not present and we have to start from raw materials like sand, soda ash and limestone. Dogma 5 is no longer present.

Dogma 6: thermal insulation Cellular glass only has 1% of the market today. This is a consequence of the expensive prices of the past.

The new technology for continuous foaming and the new recipes with organic foaming agents on waste glass without remelting have induced a severe price drop towards high density mineral wool.

As a consequence, the cellular glass market can grow by partially taking the existing market of other load bearing thermal insulations with comparable cost.

42 Glass International November 2016

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Cellular glass

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

� Cellullar glass used in a flat roof - in this case the cellular glass is directly foamed from recycled glass.

On top of that, other applications are possible if open cell cellular glass is used.

With this material, acoustical absorption would be possible with noncombustible, fibre-free material.

Kinetic energy absorption without any rebound is possible with closed or open celled material.

It is clear that dogma 6 is certainly not correct if the price of cellular glass drops thanks to recent innovations and applications.

TABLEWARE Toughening Lines on spindles

Dogma 7: new technology is not available on the market The new continuous process and recipes to foam waste glass without remelting are available at Glapor.

Glapor produces cellular glass boards and gravel, but also builds cellular glass plants for other investors, thus eliminating dogma 7.

The price drop will create space for initiatives to increase the impact of this man-made, durable thermal insulation.

Building constructors and investors are kindly invited to investigate the opportunities of this new cellular glass technology.

Conclusion

RIM TEMPERING

The above seven dogmas, which are more than 80 years old, are incorrect due to recent developments in continuous foaming and waste glass foaming.

A new age has begun, with investments in cellular glass plants and an increased usage of this glass material as thermal insulation and also in other applications.

*R&D, Glapor Werk GmbH, Mitterteich, Germany

www.glapor.com References

i http://www.lamberts.de/en/about-us.html ii S. Köse, Untersuchungen zur Blaehdynamik des Schaumglases, 1981. iii L. Lakov et al., Journal of Chemical Technology and Metallurgy, 48, 2, 2013, 125-129 iv S. Köse, Untersuchungen zur Blaehdynamik des Schaumglases, 1981. v Edwin 0. Cartwright, US Patent 2981317 (1961), Shock absorbing safety seat, line63 Glass International November 2016

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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Events world: glasstec opening

Industry looks outward at glasstec opening event glasstec opened once more with a dinner event for selected guests from across the industry, featuring a panel discussion with industry leaders from OwensIllinois (O-I), AGC, Saint-Gobain, Schott and Apple. This year, the focus was on how the glass industry can better interact with the rest of the world to further its own development and interests. Sally Love reports. glasstec 2016 welcomed 40,000 visitors and more than 1,200 exhibitors over the four day event. Before the show started, however, an evening event was held for press and industry leaders at the Classic Remise in Dusseldorf, where Frank Heinricht of Schott, Patrick Dupin of Saint-Gobain, Jean-Francois Heris of AGC, Vitaliano Torno of O-I, and Adrian Betanzos of Apple were invited to discuss their views on the strengths and opportunities in the glass industry. A common topic was the need for the industry to communicate with consumers, customers and academic institutions, to further both the popularity and strength of glass as a material.

www.glass-international.com

Sustainability O-I Europe President Vitaliano Torno summarised his thoughts on the strengths of the glass industry in three points, which encompassed the main themes of the evening’s discussion.

His first point was sustainability, which he highlighted as being the key issue that the industry needs to communicate to consumers, to maintain glass packaging’s market share.

He said: “Everybody in this room knows it’s a sustainable material, it means we can recycle and reuse it. By definition we are a sustainable material, but our problem is the way we communicate. We need to get better at explaining what a great material glass is. The mission for us is not to become more sustainable, but to communicate what we do.”

Schott Chairman, Dr. Frank Heinricht, also underlined its intrinsic importance to glass, and packaging glass in particular, as a material: “Glass forms an intimate part of a sustainable lifestyle. Sustainability is

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Events world: glasstec opening

customers and consumers alike. “Glass is the only thing where you get exactly what the producer put in – and nothing else.

“Health is another key driver for our industry, and we need to pay attention, and again we need to keep communicating.” He highlighted the extensive amount of unknown chemicals that leach into food, drink and cosmetic products that are packaged in plastic products as opposed to glass, and the need to publicise the inert values of glass to a health-conscious society.

Patrick Dupin, President of Flat Glass at Saint-Gobain, also stressed the

� Clockwise: Bucher Emhart Glass, Bottero, Iris Inspection Machines, GPS.

importance of sustainability in the flat glass industry, citing the need for more sustainable plants as one of the top challenges facing the sector today, with a focus on “more sustainability in our plants, proven recyclability and ecological equipment.”

Innovation Mr Dupin also underlined the need to keep up to speed with digitalisation within the glass manufacturing and processing industries, saying: “Those that integrate and invest with this approach will be best suited to meet the new challenges in the market and the industry.”

This sentiment was echoed by JeanFrancois Heris, President of AGC Group, who warned that an inability to change and progress with the digitalisation movement will lead to companies being “at the back of the train.”

The need to innovate was a recurring theme throughout the discussion, with one of Dr. Heinricht’s opening statements highlighting the innovations that were to be on display at glasstec.

“Today’s world is hard to imagine without glass, let alone the world of tomorrow. This is highlighted particularly well in the special show, glass technology live.

“GTL will present the latest product developments and spectacular exhibits, such as switchable glass, for example, which controls indoor temperature by electrical voltage, or – even more amazing – through biological organisms. Or, allow you to marvel at the optical glass fibres that allow you to create a special atmosphere. Or discover ultra thin glass, thinner than human hair.

“Today more than ever, glass forms the link between high-tech and humans; it’s a material of unlimited possibilities…

The innovative capability of this material is far from exhausted, despite being the oldest man-made material.”

Adrian Betanzos, Head of Architectural Materials at Apple Retail Development, brought the conversation back round to the need for the glass industry to communicate, in order to create the right environment for future innovations.

Mr Betanzos oversees the supply chain for all cladding elements in Apple stores around the world, including materials such as stone, metal and concrete, but with a stronger focus on glass in its structural application.

Continued>>

www.glass-international.com

also the thing that keeps the consumer focused on hollow glass, or rather, keeps the container glass industry busy.

“More than any other sector in the glass industry, this one is exposed to key competition from alternative materials. It is obvious that glass continues to be very popular with consumers.

“Many companies have understood that glass perfectly aligns with top trends like sustainability, safety, and health.”

Echoing Dr. Heinricht’s sentiments on health, Mr Torno underlined this issue as his second key point that the glass industry needs to better communicate to

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Events world: glasstec opening

Above: Vitaliano Torno addresses the crowd.

Below: Adrian Betanzos (right) oversees the supply chain for all cladding elements in Apple stores around the world.

He underlined his belief that the industry can, again, help itself by better communicating outside of itself, in order to further its interests.

He pointed out, “A lot of universities don’t teach anything about glass. You get one or two semesters on wood, on concrete – what about glass? There are a few universities in Europe, but there are engineers and architects all over the world.

“You need people to innovate, to take things to the limit, and to do that they need to know the basics. You cannot prosper learning by the book, so we need to educate more. What are we doing as an industry to inspire future brains? Why aren’t books about glass in every single architecture school?

“As industry leaders, I need you to invest in the future, invest in the brains, and invest in the designers.”

Innovation was also Vitaliano Torno’s third key point in terms of challenges for the container glass industry: “Especially important for us in Europe, is the capability to innovate.

“Innovation means people. Europe, as a market, is flat at best.

And so we have to upgrade what we do, which means more innovation and flexibility, which is as important as efficiency.”

Summarising his three points, and again highlighting how the industry needs to advertise itself across all three he noted: “We have to communicate about how sustainable we are: Sustainability, food safety and health, and innovation. But we need help. We need the engagement of everybody. If we were to do that, I think we can reshape our industry.” �

glasstec, Düsseldorf, Germany. http://www.glasstec-online.com/ Glass International November 2016

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Diary

The glassmaker’s diary

� The Key Success Factors for Recycling Glass from the Construction Industry A seminar in Brussels on the recycling of glass from the construction industry , organised by Ferver and Go4Circle.

November 25th, 2016 Thon Hotel City Centre, Brussels, Belgium.

CONTACT: www.ferver.be/en

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December 6th & 7th, 2016 Havana, Cuba.

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January 9th & 10th, 2017 Bangkok, Thailand.

CONTACT: www.agrintl.com � AGR – Fracture 1 AGR Bangkok’s seminar on testing and fracture diagnosis of glass bottles..

January 11th & 13th, 2017 The Landmark Hotel, Bangkok, Thailand.

CONTACT: www.agrintl.com � Glasspex India 2017 International exhibition for glass production, processing and products.

February 23rd - 25th Greater Noida, New Delhi, India.

CONTACT: http://www.glasspex.com � Glassman South America

International exhibition and conference for the hollow glass manufacturing industry.

March 29th & 30th, 2017 Centro Costa Salguero, Buenos Aires, Argentina CONTACT:www.glassmanevents.com/south -america � China Glass 2017 International trade fair for the regional glass processing and hollow industry.

May 24th to 27th, 2017 International Exhibition Center, Beijing, China CONTACT: www.chinaglass-expo.com

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� Mir Stekla 2017 International trade fair for the regional glass processing and hollow industry.

June 5th to 8th, 2017 Expocentre, Moscow, Russia CONTACT: www.mirstekla-expo.ru/en/

Glass International November 2016

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Defects no longer know where to hide

Intelligent engraving inspection The Evolution 12 engraving identification and inspection module is a software innovation that allows the machine to identify engravings in a container’s body or base.

Because it is very difficult to predict how an engraving will look, this module dramatically improves inspection in these areas. By calculating the position of the engraving, the machine identifies the pixels related to the engraving, as well as those that relate to a defect.

This algorithm has been improved and tested over recent months on several production lines, including those devoted to beers, carbonated beverages, wine and high value spirits.

VISIT US AT GLASSTEC 2016 DĂźsseldorf, Germany

20 - 23 Sept. 2016 - Hall 14 Booth C22