Glass International November 2020

WWW.GLASS-INTERNATIONAL.COM November 2020—Vol.43 No.
10
O-I GIRONCOURT INTERVIEW

ARDAGH SUSTAINABILITY CASE STUDY
RECYCLING
I N T E R N A T I O N A L A GLOBAL REVIEW OF GLASSMAKING
www.refel.com
Glass International November 2020
Excellence Made in Italy
FUSED CAST REFRACTORIES
GI Cover November.indd 1 17/11/2020 11:19:57

To make glass better, put us in the mix.
Improving combustion can enable you to increase glass production, reduce fuel
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Contents
www.glass-international.com
Editor: Greg Morris
Tel: +44 (0)1737 855132
Email: gregmorris@quartzltd.com
Assistant Editor: George Lewis

Tel: +44 (0)1737 855154
Email: georgelewis@quartzltd.com
Designer: Annie Baker
Sales Director: Ken Clark

Tel: +44 (0)1737 855117
November 2020
Email: kenclark@quartzltd.com Vol.43 No 10
Sales Executive: Manuel Martin Quereda
2 Editor’s Comment +
Tel: +44 (0)1737 855023
International news
Email: manuelm@quartzltd.com
Managing Director 10 Company profile: O-I’s Gironcourt

Tony Crinion A project inspired by teamwork
tonycrinion@quartzltd.com
14 Recycling: Ardagh Group
Ardagh Group celebrates sustainability
10
Chief Executive Officer: Steve Diprose
award for its remeltable briquettes
Chairman: Paul Michael process
Subscriptions: Elizabeth Barford
Tel: +44 (0)1737 855028 Fax: +44 (0)1737 855034 17 Recycling: Krysteline
Email: subscriptions@quartzltd.com The realities of Glass Recycling
Published by Quartz Business Media Ltd,
Quartz House, 20 Clarendon Road, Redhill, 23 Recycling: EME
Surrey RH1 1QX, UK.
Tel: +44 (0)1737 855000. Fax: +44 (0)1737 855034.
Two companies combine their expertise
Email: glass@quartzltd.com for glass recycling
Website: www.glass-international.com
27 Recycling: Zippe
Zippe delivers in the field of glass
recycling
Official publication of Abividro -
the Brazilian Technical Association of Automatic
Glass Industries
14 30 Recycling: Recresco
The PRN system is ripe for reform
not replacement
33 Event review: Soda Ash conference

Glass under the spotlight at IHS Markit
soda ash conference
Member of British Glass Manufacturers’
Confederation
38 Event review:
Glass Focus 2020 awards winners
British Glass Focus goes virtual
45 45 Personality profile: Guenter Lubitz

A career dedicated to the container
glass industry
China National Association for Glass Industry
49 Sustainability: Fraunhofer
Glass engineered to defy flames
52
United National Council of the
glass industry (Steklosouz)
50 Company profile: Glassbusters
Glassbusters answers the call of
Glass International annual subscription rates including hospitality sector’s recycling needs
Glass International Directory:
For one year: UK £185, all other countries £255.
For two years: UK £335, all other countries £460. 52 Company profile: Orora Glass
Airmail prices on request. Single copies £50.
Printed in UK by:
Orora Glass completes furnace
Pensord, Tram Road, Pontlanfraith, Blackwood,

rebuild
Gwent NP12 2YA, UK.
54 Smart glass: Nodis Glass
Glass International Directory 2020 edition: How smart is your glass?
UK £206, all other countries £217.
Printed in UK by: Marstan Press Ltd, Kent DA7 4BJ Plus find us on LinkedIn and Twitter.
Glass International (ISSN 0143-7838) (USPS No: 020-753) 55 History: Refiner’s fire
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1
Contents.indd 1 18/11/2020 13:36:39

International News
GREG MORRIS, EDITOR

WWW.GLASS-INTERNATIONAL.COM November 2020—Vol.43 No.10
O-I GIRONCOURT INTERVIEW

ARDAGH SUSTAINABILITY CASE STUDY
RECYCLING
I N T E R N A T I O N A L A GLOBAL REVIEW OF GLASSMAKING
www.refel.com Be first with the news!
VISIT:

FRONT COVER IMAGE:
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www.refel.com
for daily news updates
Good riddance to 2020 FUSED CAST REFRACTORIES
Well, that was a year like

no other! As we approach
the end of 2020 the general
Glass Futures secures £15m

feeling towards the past
12 months has been one of
good riddance - let’s move
on to 2021.
Hopefully we will never
UK Government investment
have to go through the
same feelings of anxiety
and helplessness that many
went through in March and
April as the lockdowns took
hold around the world.
While some sectors of
the industry were hit hard by
the impact of the pandemic,
on the whole – and I say
this cautiously – the glass
industry is gradually
overcoming the worst of the
virus because it was deemed
essential in most regions of
the world.
The container segment
has reason to feel optimistic
as it enters a new year.
Momentum feels like it is Glass Futures has secured a St Helens, reviving the closed pool City Region Combined
building on a number of £15 million investment from United Glass facility. Authority, which is aiming
fronts, particularly when it the UK Government as part of The plant will be capable of to provide a further £10m for
comes to the environment.
UK Research and Innovation producing 30 tonnes of sus- works to make the building
FEVE and its members
have formed the Furnace (UKRI)’s Transforming Foun- tainable glass a day – equiva- suitable, St Helens Borough
for the Future project which dation Industries Challenge to lent to 60,000 wine bottles - Council who is allocating £9
aims to build the world’s first build its Centre of Excellence which will be used in products million towards the cost of the
large hybrid electric furnace in St Helens, UK. such as jars, bottles, windows, project to be recouped in rent
to run on 80% electricity. The funding will be used doors, and fibre glass. paid by Glass Futures and glass
German glass association to establish a state-of-the-art The remaining funding is sector companies will contrib-
BV Glas has secured funding
glass furnace R&D facility in being provided by the Liver- ute a further £20m.
to investigate the suitability
of hydrogen instead of fossil
fuels in the glass production
NSG Pilkington North America

process. In Italy, Stara Glass
is working with partners
in the Life Sugar project
ignites Luckey, USA furnace

to reduce emissions in
glassmaking. In the UK, the
Glass Futures project has
received Government sign
off to construct a £54 million NSG Pilkington North Amer- The facility has a melting man, Regional Director for Ar-
glass hub for sustainable ica has ignited the furnace at capacity of 600 tonnes per day chitectural Glass and Solar at
manufacture of glass. its greenfield Luckey, Ohio, conductive oxide (TCO) coat- NSG Pilkington.
We may be in a pandemic USA plant. ed glass to supply the solar The facility has created 150
now, but there are reasons
The official lighting ceremo- market. new jobs as well as several jobs
to feel optimistic about glass
manufacturing in the future. ny took place on 11 November The lighting was officially in the construction sector dur-
at the 500,000ft2 facility. conducted by Richard Alt- ing the building of the plant.
2
news new template GL.indd 1 18/11/2020 14:13:04

International News
NEWS IN BRIEF
Horn completes furnace

rebuild for Sivesa
Horn has completed the repair
of Crown Sivesa’s Furnace A
at its Orizaba facility, Mexico.
Container glass
manufacturer Crown Sivesa
is based in Orizaba, Veracruz,
Mexico.
The latest project included
the repair of a 260 t/d
recuperative furnace with two
production lines for container
VERCANE project aims to

glass with a melting area of
109 m².
The furnace is designed
in appliance with advanced
decarbonise glass production

technology and a maximum
melting output of 290 t/d to
produce either 290 t/d flint or
amber glass or 280 t/d green
glass.
A French consortium has bon neutral glass melting). solutions based on decarbon-
launched an R&D programme The purpose of the pro- ised energy sources. Sibelco and CelSian to
which aims to decarbonise the gramme is to support the VERCANE will study differ- share expertises
glass manufacturing process. industrial glass sector in its ent carbon neutral energy sys- Sibelco and CelSian have
The consortium, formed by efforts to decarbonise glass tems that could be compatible entered into a collaborative
energy group ENGIE, glass fur- production by evaluating en- with the glass melting process: agreement to leverage
nace supplier Fives, and glass ergy sources for a sustainable hydrogen, bioresources and their respective experience
manufacturers Saverglass and industrial process. process electrification. It will and knowhow around raw
Verescence, has launched the VERCANE aims to develop also explore options to adapt materials and glass melting
processes.
VERCANE programme: fusion sustainable scenarios of en- existing melting furnaces to
The agreement will involve
de VERre CArboNEutre (car- ergy transition by designing new energy sources. the sharing of laboratory
functions and joint research.
Sibelco’s Ilse Kenis, EVP,
Glass and Performance
Ardagh Group plots multi-million Materials, said: “Through
this partnership we aim
investment in its glass division

to offer enhanced support
to customers in the glass
industry seeking innovative
solutions to the challenges
Ardagh Group is planning jority of this will be focused New capacity brought on they face, such as reducing
investments in its glass man- on its cans business with ap- stream will be supported by energy consumption and CO2
ufacturing facilities, its Chair- proximately 15% of this to be new long-term customer con- emissions and improving
man and Chief Executive Paul invested in its glass division. tracts, said Mr Coulson. production efficiency.”
Coulson said. The investment will be in The investment programme
The glass and metals pack- growth projects in Europe as will be funded from existing Visy sells Auckland
ager plans to invest $1.8 bil- well as cost reduction and ef- cash resources, free cash flow facility for NZ$178 million
lion across its business over ficiency enhancing projects in and, where necessary, incre- Visy Glass has sold its
Auckland manufacturing
the next four years. The ma- North America. mental debt.
facility to Centuria Capital
Group for NZ$178.3 million
(US$118.5 million) on a 20-
India’s HSIL plots Bhongir glass year sale-and-leaseback,

triple net lease deal.
It means the capital group
manufacturing furnace investment will lease the facility back to
the glass manufacturer for
the next 20 years.
Indian glassmaker HSIL is to nace with five manufacturing the Indian market as well as
The Visy Glass facility is
invest in its Bhongir plant lines which will manufacture some exports to US, Australia, New Zealand’s only glass
with a INR220 crore invest- pharmaceutical vials as well and parts of Europe countries. bottle and jar manufacturing
ment (US$35 million). as perfumes, cosmetics and The unit will be operational site and was established in
The revamped site will in- spirits. by September 2022. 1922.
clude a 150 tonnes per day fur- The unit will also focus on
3

International News
Pilkington UK investigates
Cleanfire® carbon capture capabilities
ThruPorte™ Burner Pilkington UK is assessing The award will support technology which uses up
the feasibility of deploying experiments to quanti- to 40% less energy than
carbon capture technology fy the compatibility of current commercially
A prescription for aging regenerators at its glass manufacturing C-Capture’s carbon cap- available technologies.
facility. ture technology with the It uses a new class of sol-
Undergoing regenerator repairs or having
It supported C-Capture requirements of the glass vents that are amine and
difficulty maintaining full production in an Ltd in its successful appli- manufacturing industry. nitrogen free, are not classi-
aging furnace? Turn to Air Products’ Cleanfire cation for funding through C-Capture, based in fied as hazardous, are inex-
ThruPorte oxy-fuel burner for a quick, cost- Innovate UK’s Sustainable Leeds, UK, has patented a pensive, and could be man-
effective heating solution to avoid downtime Innovation Fund. low-cost carbon capture ufactured on a large scale.
or extend your furnace life. This patented and
commercially-proven technology, installed
from the underside of your port, allows you to
add heat where and when it’s needed.
Forglass begins construction of
Key features:
furnace for Stoelzle Masnieres
• Tandem water-cooled oxy-fuel burner and
oxygen staging lance assembly Polish glass engineering perfumery and cosmetic forehearths, all manufac-
company Forglass is to market. tured in three Forglass fa-
• Proven durable design; easily installed in
supply the new furnace for Forglass will supply its cilities in Poland and ready
an existing port while furnace is running
Stoelzle’s Masnieres Par- technology in the design for installation in France.
• Adjustable flame length and angle for fumerie plant in northern construction and commis- Having completed the
optimal heat distribution and surface France. sioning of the furnace. design phase of the project,
coverage Stoelzle’s Masnieres Par- It will include the com- Forglass is set to begin the
fumerie is a specialist in bustion system, electric construction phase before
• Remote, wireless and continuous online
extra white flint glass pack- boost, cooling system, steel the end of the year.
monitoring of burner performance
aging for clients from the structure and five complete
• Available for rapid deployment
To make glass better, put Air Products in the mix.
O-I Glass and Krones sign

tell me more collaboration agreement
airproducts.com/thruport
O-I Glass and Germany’s and packaging line speed direct-to-glass digital print-
800-654-4567, code 9091 Krones have signed a col- and efficiency; enhanced ing technology.
laboration agreement to agility and flexibility of re- With this agreement, the
innovate together and to sponding to market trends; two companies are com-
jointly create solutions for development of innovative bining O-I’s knowledge of
the glass market. and sustainable glass sys- glass with Krones’ compe-
Focus areas include im- tems; and advancements tence in manufacturing
provements in glass filling in digital solutions such as machines and filling lines.
© Air Products and Chemicals, Inc., 2019 (42615)


Our sights are set.
Neutron® targets thin and thick areas by mapping glass distribution inside your
entire container – no matter the shape – with no contact at full production speed.
AppliedGlass.com
AppliedVision_GlassInternational-Feb-2020-Full Page.indd 1 1/30/20 1:52 PM

International News
Top 10 stories in the news

NEWS IN BRIEF
Campaign launched by
British Glass
A campaign has been
Our most popular news over the past month, as determined by our website traffic.
launched by British Glass to
#SpeakUp4Glass and remind All full stories can be found on our website.
consumers about the special
qualities of glass bottles. � 1. Ardagh plots multi million investment in its glass division
Leading experts from the � 2. French VERCANE project aims to decarbonise glass production
world of wine and packaging � 3. Pilkington UK investigates carbon capture capabilities
came together to debate � 4. Vidrala invests €21 million in Spanish furnace upgrade
what makes glass still their � 5. Encirc unveils 900t/day furnace
number one favourite way to � 6. Visy Glass sells Auckland facility for NZ$178 million
package wine.
� 7. O-I Glass and Krones sign collaboration agreement
The experts brought
their own personal and � 8. Ardagh’s upgraded German glass plant features Heye technologies
professional perspectives to � 9. NSG Pilkington North America ignites Luckey, USA furnace
the debate, which touched on � 10. FEVE’s ‘Furnace for the Future’ project gathers momentum
topics such as the meaning of
true recyclability, the unique
chemistry of wine and why it
needs special packaging, and
the joy of drinking wine that
has been laid down for several For the latest Industry News scan the QR CODE
years. using your iOS or Android device
Air Products donates
$15,000 to glass sector
Vidrala invests €21 million in

Air Products has donated
$15,000 to The Ceramic and
Glass Industry Foundation
(CGIF) and The Glass
Spanish furnace upgrade

Manufacturing Industry
Council (GMIC) to foster
innovation by the next
generation of ceramic and
glass professionals. Vidrala has invested €21 mil-
The CGIF will use its lion in its Furnace 2 at the Llo-
portion of the grant to expand dio plant in northern Spain.
the Foundation’s student The upgraded furnace has
outreach programmes to new automation and refrac-
attract, inspire, and train the
tory solutions, enabling an
next generation of ceramic
and glass professionals. energy-efficient process and
a more sustainable operation.
Installation of Vietnamese State-of-the-art forming
float glass plant machines in the hot-end and
The Phu My, Vietnam 600t/d inspection and palletising
ultra-clear float glass line equipment in the cold-end
was successfully fired-up on now allow a better process This will open the door for It says this is a significant
October 25, 2020. control with maximum flexi- Vidrala to have its first collab- milestone and an example of
This project was designed bility. orative robots in the plant. investing in Industry 4.0.
and constructed by China
Triumph International
FEVE’s ‘Furnace for the Future’

Engineering Co. Ltd (CTIEC).
As the first ultra-clear

float glass production line in
project gathers momentum

Vietnam, this project adopts
CTIEC’s ultra-clear float glass
production technology and
core equipment with CTIEC’s FEVE’s (European Container project brings together a total run on 80% green electricity.
independent intellectual
Glass Federation) ‘Furnace for of 19 industry companies Eu- The pilot project will allow
property rights.
The project will quickly fill the Future’ project has taken a ropean container glass man- us to switch to green energy
the gap in the domestic ultra step forward after a dossier was ufacturers including Ardagh like electricity. It will be the
clear glass market in Vietnam sent to the European Commis- Group, Vidrala and O-I to world’s first large-scale hybrid
and will export to ASEAN sion to help fund the project. build the world’s first large- oxy-fuel furnace to run on
region. The ‘Furnace for the Future’ scale hybrid electric furnace to 80% renewable electricity.
6

E pect more
EME Glass
Recycling Plants
The magic of glass recycling

EME GmbH · E-Mail: contact@eme.de · www.eme.de Glass is our Passion
International News
NEWS IN BRIEF
Glass scientists win Otto

Schott Research Award
The 16th Otto Schott Research
Award has been awarded to
Professors Sabyasachi Sen
and Josef Zwanziger for their
achievements in fundamental
and experimental glass
research.
Professor Sen, of the
Tariq Glass’s second float

University of California, Davis,
is being recognised for his
sustained contributions to
fundamental and applied
glass set to start production

research on oxide and non-
oxide glasses, including
structural modelling
and characterisation
measurements.
Professor Zwanziger,
Pakistan’s float glass and table- After the commencement of pura, Pakistan.
of Dalhousie University in
ware producer, Tariq Glass will commercial production, Tariq The new factory will almost
Canada, was one of the first
scientists to develop NMR soon commence commercial Glass will become the largest double the company’s produc-
(nuclear magnetic resonance) production from its second float glass producer in Paki- tion capacity.
techniques to study the float glass line. stan with an installed capacity The company’s existing
atomic structure of glass. The new float glass line with of 1050 TPD of float glass from float glass (Unit–1) furnace
an installed capacity of 500 two production units. will complete its campaign
Glass Service seminar TPD has been supplied by Chi- Spread over a built-up area life by June 2021 and will be
set for September 2021 nese company Qinhuangdao of 22,000m2, for Tariq Glass’s closed for a rebuild.
The 16th International Yaohua Glass. Unit-2 is located in Sheikhu-
Seminar on Furnace Design
– Operation and Process
Simulation, hosted by Glass
Bucher Emhart Glass sees gradual

Service (GS), will be held on
22-23 September 2021 in the
Czech Republic.
It will be open to all wanting
to learn more about Industry
4.0, artificial intelligence,
recovery in equipment demand
hybrid melters including Swiss glass engineering com- the extraordinarily high pri- der of the year. Sales should
hydrogen optimised by CFD
pany Bucher Emhart Glass saw or-year figure, but the decline continue to recover but will
simulation.
The 2021 Seminar will a gradual recovery in demand was less pronounced than in be significantly lower year on
focus providing solutions to in the third quarter of this the first half of 2020. year.
reduce CO2 emissions by 40% year. Sales also recovered, as in- Net sales for the Janu-
or more by the year 2030. In its third quarter finan- stallations and onsite service ary-September period this year
cial report, the Cham, Swit- became at least partially possi- were CHF 285 million ($310
GTS secures robotics zerland-based company said ble again. million) compared to CHF 372
funding order intake during the peri- It expects demand to im- million ($405 million) in the
Glass Technology Services, od fell by almost half versus prove further over the remain- same period last year.
(GTS) working alongside
partners I3D Robotics and
Lucideon, have been awarded
funding to develop intelligent
Alphaglass plots €37 million
robotic systems to improve

production processes
within the energy-intensive
foundation industries.
The GTS R&D team will
Arques furnace rebuild
provide support and research Saverglass factory Alphaglass 20%. glass manufacturing site as
into a range of glass solutions is planning a €37 million fur- Alphaglass is a luxury wine well as Alphadec, a glass deco-
and sectors. nace rebuild at its Arques facil- and spirits bottle manufactur- ration workshop.
Projects span from
ity, northern France. er and said it had a difficult The investment is antici-
fundamental scientific
research, to the development The investment will also in- Spring but that orders had in- pated to create at least 50 new
of novel glass compositions, clude an eigth production line creased in the summer. jobs.
through to commercialisation. and will increase capacity by The facility includes the
8

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Data is power. However, only our industry leading machines can communicate
with each other, automatically collecting and sharing data throughout the hot
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first fully automated lines, Emhart Glass is the only supplier worth talking to.
Start the conversation at emhartglass.com
Company profile: O-I’s Gironcourt facility
A project inspired by teamwork

O-I’s recent furnace 3 project
at its Gironcourt, France
facility was its largest in nearly
two decades. Greg Morris
spoke to Jean-Pierre François,
the man tasked with leading
the project, to discuss how
communication and teamwork
were key to its success – and
how O-I overcame the final
hurdle of Covid.
� Jean-Pierre François,
speaking at the ignition ceremony.
T
here was a small tear in Jean-Pierre François’ at its culmination, he admits he felt emotional.
eye when furnace 3 at O-I’s Gironcourt plant He said: “When we heated the furnace and gob
was ignited in August this year. loaded the machine after two years on site I had
The furnace lighting ceremony at the north- a high level of emotion, and if I remember well a
east France facility was the culmination of nearly small tear in my eye. It was like a baby was finally
two years of project planning and hard work by here.
the entire team. The €60 million investment in “To shepherd the project from A to Z was a great
the facility was one of O-I’s largest in nearly two feeling and I will never forget it.”
decades and at its peak, nearly 350 people were
working on site. Expansion
Mr François, O-I’s South West Europe The Gironcourt expansion was first outlined
Engineering Lead, was in charge of the project and, towards the end of 2018 as a result of increased
10
Company profile O-I Gironcourt.indd 1 18/11/2020 13:43:51

� Furnace 3 was part of a � The O-I Gironcourt facility.
€60 million investment from
O-I at Gironcourt.
demand for more bottles from O-I’s customers.

They had reported an increase in enquires and
therefore wanted to grow their businesses, as well
as increase the appreciation of glass.
The Gironcourt facility, which specialises in
beer bottle production and is strategically located
close to the German border, was the ideal location
to invest in.
Mr François, who has worked for the company
for 22 years, was chosen to lead the project.
He said: “I was surprised at first and quickly
recognised what a privilege it was to be chosen.
The organisation had placed their confidence in
me so I had to demonstrate that they had made a
good decision.
“With our team, we wanted to do something
that would be dedicated to what was needed and,
above all, that would produce the right bottles to
satisfy customer and consumer requirements.”
Communication
While Mr François had worked on manufacturing
projects before, nothing was on the same scale as
the Gironcourt investment. His first task was to
draw up a communication structure which would
ensure all stakeholders were kept informed of
developments at each stage of the programme. Its
purpose was to ensure that everyone was aligned
in order to drive the build of the furnace.
All dimensions were covered in the
communication plan and included health
and safety, quality, customers, engineering,
manufacturing, legal, technical, HR,
communications and supply chain. The
communication structure was created in January
2019 and was only dropped in autumn this year.

“It was an important project, quite long, that
required good lines of communication so everyone
was clear on their responsibilities.
“This structure of roles and responsibilities was
crucial to the success of the project. If we did not
have a structure where everyone understood what
had to be done and what their counterparts were
doing, it could have been a failure.”
Continued>>
11

Company profile: O-I’s Gironcourt facility
Meanwhile the internal communication � Gironcourt specialises construction in a manner that it would be able to
continued throughout the duration of the in the production of beer restart easily and without jeopardising anything.
assignment. An internal newsletter was launched bottles. Mr François admits it was heartbreaking to be so
which informed existing staff at the plant of all close to their end goal when the lockdown rules
progress on the new furnace. The facility’s two came into play.
other furnaces continued to produce glass while He said: “The project was a rollercoaster of
construction work took place and it was important emotion and this moment was a big one. But it was
for staff to know of milestones and updates from the same all over the globe, we didn’t complain
the building site. and we discussed what we had to do.”
Lastly from a communication perspective, every After a long discussion, the group implemented
two weeks Mr François would meet O-I’s then specific procedures to stop and restart the furnace
European President Vitaliano Torno to update him without jeopardising construction, and which
on progress. would also be carried out in a safe way.
Despite the hurdle caused by Covid, the furnace
Training was successfully ignited on August 27 this year
Gironcourt-sur-Vraine is located in a rural area during a lighting ceremony attended by local
of France and the next challenge was to hire dignitaries and senior O-I executives.
“People are key in

60 new employees and to train them in glass Mr François said he felt tremendous gratitude
manufacturing. when the furnace was ignited. One was as a result
It was then that O-I’s Human Resources of the feedback from the people who were working
department became key. In conjunction with our business. Alone on the new furnace.
the regional authorities, it held a series of job He said: “The main satisfaction has been the
fairs to source new members of staff. The local we can fail but we positive feedback from our key customers. We
authorities and mayors remained key to the engaged them throughout the project and finally
project throughout, with a steering committee cannot succeed. had the chance to deliver the first bottle to them.
meeting every two months to provide regional “It was exactly the bottle we expected to have so
governments with progress updates. As a team we there was great satisfaction in that, not just for me
The world’s largest container glassmaker received but for the company, because we built the furnace
more than 800 resumes for the 60 positions at always find exactly for them.”
the new furnace. It had a dedicated organisation Despite his experience in manufacturing,
to filter the applicants. Once the new workers solutions, Mr François still learnt a lot from the two-year
were hired they received more than 50,000 man operation. He will deploy those skills gained on
hours of training about the glass manufacturing always innovative this project on any future assignment, even if it is
process and the different specialities they would of smaller scale to this one.
work in. They received training in a classroom as and are always able “If we want to be successful in such a project there
well as on the shop floor, shadowing staff on the is a simple recipe: people, teamwork and passion. I
site’s furnaces 4 and 5 to ensure they reached the to move met extraordinary women and men within O-I and
”
requiste level of know-how required. externally and I think we learned from each other
A typical furnace rebuild would have forward. and we are much stronger for the next project.
approximately 200 people on site but such was the “People are key in our business. Alone you can
scale of this investment that, at its peak, there were fail but you cannot succeed. As a team we always
340 people on site. These were divided throughout find solutions, always innovate and are always able
the facility, from the batch plant to the palletiser. to move forward.
“I can also say that nothing is possible without
Covid passion. I can tell you the glass industry has a
The project was running on schedule when, in singular thing and that is passion. For me, if you
March this year, the Covid pandemic struck and have passion, teamwork, and good people, you can
France went into lockdown. The installation had succeed in every project.” �
reached a critical stage of construction, with the
erection of the furnace and the chambers within
the oven. Team members discussed how to stop the www.o-i.com
12

Recycling: Ardagh Group
Ardagh Group recently

won a Sustainability
Award for its method of
producing remeltable
Ardagh Group
briquettes. Brendan
O’Meara* describes the
process.
celebrates
sustainability award
for its remeltable
O
nce collected for recycling, glass
briquettes process
contains certain contaminants
which must be removed by
processing at a glass recycling plant to
ensure the maximum amount of glass
collected is suitable for remelt. These
contaminants include:
� Organics (paper, plastics, caps,
rings, and labels)
� Inorganics (ceramics, Stones,
Porcelains or CSP)
� Metals (ferrous and non-ferrous)
� Heat-resistant and lead glass.
During this processing, and as a result of

breakages incurred in collection, around briquettes from the fines, which can be focus on:
10% of the recovered glass (cullet) will safely used in the furnace to make new � Improvement of the quality of the
be broken into small particles, typically glass bottles and jars. delivered cullet
<4mm, also referred to as ‘fines’. The Ardagh’s research and development has � Defining specifications for allowed
fraction size of this material is too small culminated in the design of a processing contaminant values to increase cullet use
to be sorted by current sorting equipment plant to close the recycling loop and � Engagement with cullet suppliers
technology. use 100% of recycled glass containers and equipment manufacturers in a
The fines cannot be remelted in the recovered through the various collection partnership approach to improve the
furnace as they contain high levels of systems across the UK. The plant will be cullet quality.
loose organics and fine particle CSP which the first commercial type in the world. The Cullet Team is given executive
can cause defects in the containers, such support by Ardagh’s Chief Sustainability
as blistering and particle inclusions. They Background Officer, emphasising the importance
also cause foaming in the furnaces which For more than 12 years Ardagh has been placed on sustainability and the Circular
forms an insulation on the surface of at the forefront of initiatives to increase Economy. Their endeavours have greatly
the molten glass and requires additional the percentage of cullet used in glass improved the quality of the processed
energy to penetrate and continue the batch recipes for container glass. Ardagh cullet procured through positive
melting process. considers cullet to be the most important engagement with suppliers and cullet
For these reasons, in the UK market, but also most volatile raw material. Cullet processing equipment manufacturers.
around 10% of recovered cullet is diverted has long been a component of the batch Recovery of the lost 10% represented
into aggregate or ends up in landfill: a recipe for producing container glass, the next challenge.
cradle to grave scenario, as it can never be but the quality of the cullet is critical for
recovered. container production. Fines Recovery Research and
Ardagh Group has embarked on a To address all aspects of cullet, Ardagh Development
project to achieve full recyclability of took a decision to initiate a Cullet The project to transform the fines into a
collected glass containers, by developing Team, responsible for all aspects of the briquette is driven by the known benefits
a method to produce remeltable procurement process for cullet with a of using cullet:
14
0
Recycling Ardagh.indd 1 17/11/2020 11:58:48

Recycling: Ardagh Group
rudimentary production line for a scaled

trial of briquettes into an Ardagh furnace.
The line was able to produce 150 tonnes
of briquettes which were successfully
melted in a controlled trial in Ardagh’s
Knottingley glass facility.
The success of the trial encouraged
the project team to move to the final
stage. The goal was to achieve a more
robust briquette with the physical
properties to be transported, handled
and stored without deterioration. The
resulting briquettes were then subjected
to various tests: immersion in water,
compression testing, drop testing and
High Temperature Melting Observation
Studies (HTMOS) and performed
excellently.
Following on from the success of the
initial trial, Professor Paul A. Bingham of
Sheffield Hallam University has published
an article2 on the positive effects of using
briquettes in the batch recipe.
Ardagh Group’s briquettes

created from glass fines
Commercialisation of the briquetting
process is the final step, and after
extensive assessment of equipment,
Wrights has designed a detailed plant to
produce commercially viable briquettes.
Ardagh’s Cullet Process Engineer,
� Ardagh Group’s briquettes created from glass fines Brendan O’Meara, said: “The ability
to use 100% of recycled glass to make
new glass containers is a significant
achievement which will reduce the
� Reduced energy consumption. For � The additional cullet volumes need for raw materials, reduce energy
every 10% of cullet used, energy costs are available as briquettes will help to achieve consumption and CO2 emissions, and
reduced by 2-3%. the objective of 95% cullet and 5% raw improve the environmental impact of
� For every 6 tonnes of cullet used, materials within the glass batch. glass packaging.
carbon dioxide is reduced by 1 tonne. A “We are incredibly proud that this
10% increase in cullet reduces particulates Partners initiative has been recognised with a
by 8%, nitrogen oxide by 4%, and sulphur During the initial concept and Research Sustainability Award and is a finalist in
oxides by 10%. & Development phase, Ardagh engaged several other glass and recycling industry
� Reduced environmental impact of with CelSian Glass & Solar, located in awards.” �
raw material quarrying. The Netherlands, which carried out 18
� Over a tonne of natural resources laboratory experiments to determine the References
are conserved for every tonne of glass ideal Briquette recipe. 1 https://www.gpi.org/why-recycle-
recycled, including 1,300 pounds of sand, Wrights Engineering joined the project glass
410 pounds of soda ash, 380 pounds of during the Plant Design and Product 2 Article in International Journal of
limestone, and 160 pounds of feldsparl. Improvement phase, working with Applied Glass Science 10(1) August 2018
In addition to these incremental Sheffield Hallam University to optimise h t t p s : / / w w w. r e s e a r c h ga t e . n e t /
increases, there are additional benefits: the recipe, with the goal of reducing the p u b l i c a t i o n /3 2 6 8 8 4 8 5 2 _ M e l t i n g _
� For a plant processing 100,000 percentage of binding agent required, as Behaviour_of_Waste_Glass_Cullet_
tonnes per annum of collected glass this constituted the most expensive part Briquettes_in_Soda-Lime-Silica_
10,000 tonnes will be diverted away from of the recipe and was essential to make Container_Glass_Batch This article
landfill. Glass recycler, URM, forecast the project viable. is protected by copyright. All rights
their plants diverting 50,000 tonnes per Ardagh supported a successful reserved.
annum away from aggregate and landfill application by Wrights and Sheffield
into briquetting. Hallam University for grant support for * Cullet Process Engineer Glass-Europe,
� Reduced CO2 emissions and fuel their research and development. This Ardagh Group
consumption from transporting waste. grant allowed Wrights to produce a www.ardaghgroup.com
15
Recycling Ardagh.indd 2 17/11/2020 11:58:48

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United Kingdom
Recycling
The Realities of Glass Recycling
Steve Whettingsteel*
discusses how the
challenge for all glass
recycling businesses is
the same, balancing out
the environmental issues
with the normalisation
of a profitable waste and
recycling strategy.
T
here is an ideology that glass is suitable for Remelt. cleaning, processing and recovery.
infinitely recyclable and can be made All Remelt furnaces require high Clearly source segregated glass
into new glass repeatedly without quality feedstock to minimise rejects and collections is the best way of maintaining
degrading its quality. maintain quality. Almost all used glass glass quality, but the costs are often too
Even though this may be possible in containers have some form of label, cap, high to be economically viable, while all
an ideal world, the realities are far more seal or sleeve. For an optical sorter to the time glass has a low or negative value.
challenging. The public, industry and operate the glass bottle must be broken, It is this vicious cycle which is a factor in
even Government have consistently been labels removed or abraded, and necks holding back the development of glass
mis-informed and ill-advised as to what is crushed to remove sealing rings and caps. recycling.
realistic and practical. This action of breaking and crushing To increase the uptake of glass collection
The industry faces many challenges, creates a quantity of glass too small for and remove the glass from MRF, 100%
but none greater than misinformation. cost effective optical colour sorting. of incoming glass must be adequately
It is a technical impossibility for all used At the most basic level of processing monetised to warrant the investment.
glass to be considered as furnace ready and recovery the message of the ‘the only Spain, Portugal, China and Thailand
feedstock, this is grossly misleading in so true glass recycling is bottle to bottle’ is are a few countries which have a Remelt
many ways resulting in a large percentage already challenged. capacity equal to its consumption.
of waste glass ending up in landfill as daily There are many other factors which Often a country will produce a bottle
cover or used as a low value aggregate challenge the cost effectiveness of colour which is different to that of the
substitute. producing furnace ready cullet such as containers being imported, whether that
People need to understand the furnace capacity, distance, collection be green for wine or amber for beer, a
whole recycling process, its challenges, strategies, MRF design, quality and value. perfect example of a mismatch between
regionality and which technologies In almost all cases it is the low value of Remelt capacity and glass consumption is
are available and capable of processing glass which determines its status within that of the USA.
100% of all incoming glass, significantly the waste hierarchy. Currently most With a conservative Remelt capacity
enhancing the quality of all waste collection systems and MRF lines consider of circa 5 million tonnes across all states
glass, not just that considered as Remelt glass as a low value material and treat it and consumers generating 12.5 million
feedstock. accordingly, often removing it early in the tonnes of waste container glass annually
Promoting the use of cullet as being low process along with heavily contaminated there will always be challenges for any
CO2 is misleading, the reality is the CO2 rejected materials. recycler.
is calculated as arriving at the furnace Often this material is sieved at 12mm
with no CO2 footprint from its recovery, (1/2”) to remove the fines for landfill daily
reprocessing or disposal of glass not cover and the remainder sent for further Continued>>
17
recycling Krysteline_converted.indd 1 17/11/2020 11:59:55

Recycling
It is unfortunate the public, industry Glass that cannot be used for Remelt is there is a need to work with stakeholders
and legislators believe ‘bottle to bottle’ is often sized <12mm (1/2”) and comingled to re-focus glass recycling towards the
the only true recycling. with Ceramic, Stone and Porcelain (CSP). process of ‘economic recovery and re-use
Inevitably with such disparity between This glass is the most challenging aspect of ALL waste glass.’
demand and supply in the glass recycling of glass recycling due to its high levels
system, like most other countries around of multi product contaminates and Solution?
the world the USA finds itself in crisis difficulty to be optically colour sorted. Achieving a higher recycling rate and
with the vast majority of the 7.5m tonnes It is key for glass to be in a quality one which commands lower CO2 across
surplus going to low value aggregates or appropriate for its intended marketplace all uses requires several changes. The
landfill as landfill daily cover. for an effective recycling programme marketing message needs updating to be
Things are no different in the UK, to exist. Many recycling programmes more realistic and inclusive.
despite current statistics showing the UK are mandated for a percentage of glass Any new strategy must consider landfill
has an excellent recycling rate of 68.8%. recovered to go to Remelt. Where there daily cover as just landfill. As with any
In fact of the 2.3m tonnes of waste glass is no Remelt site within economic well-conceived strategy the economic
produced, 750k tonnes is used to create distance, such an ill-conceived contract viability must be at its forefront. When
new containers in the UK, 600k landfill daily cover is considered
is exported ‘to be recycled’ recycling there needs to be
the remainder as landfill daily some serious change! The
cover or aggregates. The figure UK has a well-conceived PRN
of 68.8% is based on glass system where a revenue can
being considered to have been be generated to help cover
recycled if it has gone through the processing costs. In recent
a recycling plant and has been times the PRN has been broken
weighed on the weighbridge, down in to Remelt and Non-
not that it has been used in the Remelt, following the narrative
creation of another product. that in some way Non-Remelt
Additionally, in the UK was holding back the value of
landfill gate fees are averaging PRNs, time has proven this not
£125 ($160) per tonne. However, to be correct. In the past PRNs
like in so many other countries have been issued against the
because glass is technically simple crushing of glass as a
inert it is allowed for use as material suitable for subbase,
landfill daily cover and this with little care for quality or
reduces disposal at landfill to cleanliness. It would make
little over £15 ($20) per tonne! sense for this material to have a
Such a low gate fee is seen as an lower PRN value. However, for
economically viable option by markets which require sizeable
many for the cullet that cannot investments, often greater than
be used by the Remelt industry. that required for cullet, the
It is plain to see from these PRN value should be higher.
two examples that supply � Recycled glass aggre- Surely it should be the true
and demand are not and gate being used to infill CO2 value which determines
cannot be matched to Remelt. trench on the Islands of the PRN value. Having a clear
In the UK this could be St Pierre & Miquelon. indication of the CO2 footprint
further exacerbated in 2021 of recycled glass at its various
when tariffs may apply on stages will undoubtably help
exported material destined for industrial partners to increase
consumption in the EU. its use of recycled products and
challenges the economics of any recycling decrease their own CO2 footprint.
The Challenge programme and often creates a negative If CO2 is a major factor in any business
The price per tonne paid by the Remelt CO2 footprint. In no way is it suggested strategy, does it not make more sense for
industry is proportionally low compared that glass should not be going to Remelt, the CO2 footprint of any recycled product
to say, plastic, but the processing costs just the right glass at the right price in the to determine its value? If the PRN value
may often be higher. right location. increases as the CO2 footprint decreases
In most cases any glass recycler is An efficient glass recycling plan or it will surely increase the potential for
operating on slim margins which limits strategy requires the buy-in of multiple strategic investment into technology
investment in new technologies that end users, producers, cullet users, which can process and recycle all glass,
could reach new, non Remelt markets. collectors, recyclers and Government. not just a proportion.
This results in landfill daily cover Often this is the case, but the message
being the lowest cost route of disposal, is ‘glass to glass’ which suits the Remelt
something rarely admitted by the industry but handicaps all other industries
industry or legislators. as well as the recycler. To convert all glass Continued>>
18
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Recycling
� Krysteline K500-C-SC glass recycling plant installed in Malta.
For example, if there isn’t a Remelt system where industry cooperates with in any country or region should be the
furnace in reasonable proximity to the legislators to develop products and create capability to recycle effectively while
MRF then surely other marketplaces demand. Creating an independent glass establishing a variety of markets across
for the waste glass (where it can be used authority could provide the conduit several industries to create a stable
locally) should be seen as being low CO2. between industry, the recyclers and platform and revenue stream.
But, how do we stimulate interest in investors. Our technology is developed from a
alternative products to fuel such a system? different perspective than others. We
Currently there is no independent End Markets sought solutions for the enhancement
body/organisation which is focused Establishing and developing economic of the most challenging glass in the
on the development of the whole markets for the <12mm (1/2”) glass with a waste stream, recovering and refining
glass industry. As always R&D, and the low CO2 footprint is driving innovation. glass which cannot be used in the Remelt
associated universities and industrial A few examples of products are: industry. A range of technologies provide
partners, is imperative in any successful 1. Cementitious materials, as processing plants and solutions for a
market development. Considerable work supplements to Ordinary Portland diverse global market.
in the commercialisation of glass sand Cement (OPC) Krysteline’s technology and strategy
for cement is an example of how industry 2. Silicon Fertilisers is not designed to use Remelt cullet as
has cooperated with universities and 3. Foam glass feedstock for other marketplaces, our
government to create a low CO2 product 4. Fibreglass & Glass wool partnership with Picvisa is proof we
which has pent up demand. 5. Asphalt sand consider all glass equally in each project
The gap between where we are today 6. Water filtration and committed to long term sustainability
and what industrial partners want in 7. Expendable abrasive of a process which creates an ultra-high
the future is one which investors find 8. Fillers for plastic, paint, adhesives, quality cullet for Remelt through our glass
challenging. It takes vision and tenacity mastic and caulking clean-up systems which enhance cullet
to seize an opportunity, change how quality prior to optical sorting.
society thinks and create a strategy more No Remelt industry exists in many Krysteline understands for some
fitting for a modern world. locations around the world and exporting people, producing non Remelt could be
Technology is evolving fast, optical is prohibitive. Creating sustainability and considered detrimental. But it is clear
sorters are improving their efficiency, employment by creating an aggregate a greater understanding of the current
but still struggle with the economical substitute for French drains, trench fill system and the issues it faces is vital for
separation of the smaller sizes. and pre-cast concrete blocks is a low CO2 its survival. It’s time to develop a more
The <12mm material has always use of waste glass in these areas. A well- inclusive strategy one of ‘Glass recycling,
been the challenge, its diversity of conceived cost effective plant will produce the process of economic recovery and use
contaminate, variable moisture content quality aggregates to replace marine sand of ALL waste glass’. �
as well as putrescible content challenge often the cause of ASR in concrete due to
most systems. its high salinity. *CEO & Managing Director, Krysteline
A higher quality standard than PAS Technologies Ltd,
102 could lead to a terracing of product Krysteline Strategy Southampton, UK
quality, PRN & CO2 values and support a The start point of any recycling initiative www.krysteline.com
20
0

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

Join the worldwide network of interests
centred on making glass great
The Society of Glass Technology exists to serve people who are
interested in the production, properties or uses of glasses, whether
from a commercial, aesthetic, academic or technical viewpoint.
It is a non-profit making organisation serving a worldwide membership
publishing journals and text books, organising meetings and
conferences on glass related topics.
You can now join the SGT by going to www.sgt.org and selecting your
journal choice and appropriate package. You will also be able to see the
comprehensive history and activities of the society.
Serving the Glass Community for more than a century

www.sgt.org +44 (0) 114 263 4455
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Recycling
Two companies combine

their expertise for glass recycling
Dr. Sebastian Woltz* and Helmut Killinger** discuss a new glass partnership
which gives customers expert knowledge and experience from a batch house
and cullet specialist and a cullet sorting specialists.
T
he glass industry works continuously view of a cullet sorting specialist. separation. Although, KRS already
on its commitment to circular delivered many sorting systems and
economy by increasing the Introduction of the companies recycling lines for the container and
proportion of recycled glass used in EME, a member of the SORG Group, is flat glass industry, its primary focus was
production. This results in saving natural active in the field of raw material, batch customers from the waste glass recycling
resources and energy as well as reducing and cullet handling for all sectors of the industry (Pic 1, above).
the carbon dioxide emissions. As a glass industry. Turn-key plants and single
result of evolving technical and quality components, process technology, project Glass Recycling
requirements from the glass producers on definition and planning, construction The proportion of post-consumer
their suppliers, EME and KRS Recycling and engineering, project managing, recycled (PCR) material has continuously
Systems are pleased to announce our installation and commissioning are increased in the recent years for all
undertaking of a strategic partnership provided by EME. As a result of increasing types of glass, including container glass,
agreement. demands and requests from our key flat glass or fibre glass. This increased
This partnership formalises our existing customers to be involved as a strategic cullet demand has resulted in a higher
strong partnership and provides a strategic partner in glass recycling and sorting expectation for the specification and
focus on the individual requirements of projects, EME is currently very active in quality of the recycled glass, especially in
glass producers onsite requirements. this market. regard of contaminants that are difficult
Combined, both companies have over a KRS Recycling Systems, a partner to be sorted because of their special shape
century of experience in the glass industry company of Sesotec, engineers and or colour. Impurities delivered with the
and have large market share in their delivers separators, as well as turnkey recycled glass, such as CSP, ferrous metals,
respective areas. With the combination plants for the glass recycling industry. non-ferrous metals or organics have a
of these two major players, customers KRS provides customised concepts and significant impact on the final product
get expert knowledge and experience has various optical sorters, in-house quality and thus on the productivity of
from the view of a batch house and cullet technology and know-how for crushing
treatment specialist, as well as from the and drying, as well as for organic Continued>>
23
Recycling EME.indd 1 18/11/2020 13:52:16

� Pic 2: Pilot Recycling Plant.
a glass furnace. Due to the increasing

importance of post-consumer recycled � Pic 3: Glass Recycling Technology.
material, glass producers can no longer
only rely on external waste glass recycling
companies to deliver the required quality
but must have their own capabilities to
reliably control on the incoming quality
of the glass cullet.
The decision for the partnership
between EME and KRS was based
on the ever-increasing interest and
demand of customers to implement
sorting machines, as well as advanced
glass recycling systems apart from the
traditional waste glass recyclers.
Therefore, constant development and
optimisation on the single machines, as
well as the complete process are necessary
and the input of different viewpoints of Sensor systems* Detection of
various specialists in their fields is an

C COLORS and CSP
essential advantage. C-C Improved CSP-detection, e.g. for differentiation of dark-glass from CSP
These onsite solutions have various X HR (heat resistant glass)
advantages, primarily a higher quality Fo Pb (leaded glass)
can be achieved due to the elimination of M Metals (ferrous and non-ferrous)

N** Plastics
additional contamination from external
sources during storage and transport *All sensor systems for the FLASH separators can be combined and are upgradable in one sorter, e.g. K9 Flash MXC-C-Fo+N
of the cullet to the glass plant as well as ** Only available for K9 separator project
additional quality control before entering

the batch house.
Glass recycling test facility material approved. This is especially available for dried cullet. The cullet
Together, EME and KRS offer equipment important when difficult impurities must is transported horizontally via a belt
for all steps of the cullet treatment be sorted out (pic 2). conveyor to the optical sorting machine.
process, including cullet preparation Due to the efficient dimensions, compact
(handpicking, crushing, screening, Optical Sorting Technology design, the breakage of glass cullet is
drying), contamination removal (organic The key equipment of a glass recycling minimised. In addition, the machine is
separators, ferrous separators, non- plant is the sensor based optical sorting more precise and efficient and less steel
ferrous separators, CSP-sorters, heat- system. KRS, one of the world-wide construction is needed (pic 3).
resistant and lead glass sorters) colour technology leaders, developed in Both systems are built up modular and
sorting (e.g. flint-amber-green-other). collaboration with Sesotec, two different have optional different sensor systems
All projects are designed and engineered systems: ‘Spektrum’ (free fall system) and available (Table 1-above).
in accordance with individual customer ‘K9’ (horizontal belt conveyor sorting
Outlook
needs. It is worth mentioning that KRS system).

has installed a pilot recycling plant on With the ‘Spektrum’ system, the cullet As the two companies are committed
its premises in Neuschönau , Germany. is transported via a vertical chute to the to innovation and creating customer
At this pilot plant it is possible to test sorter. The sensor is positioned behind focused solutions, we are excited about
sample input cullet from individual the gliding plate and the contamination the many advantages such a partnership
customers with the original machines (e.g. CSP, metal, off-colour) is detected can offer to the market. �
and equipment that will be later installed and ejected in gravity fall. The ‘Spektrum’
at the customer’s site. Thus, the quality consists of two high resolution line *Sales Director, EME, Erkelenz, Germany
of the input materials can be precisely cameras and can detect contamination **CEO, KRS Recycling Systems,
defined and/or verified. Additionally, the even under wet conditions. Neuschönau, Germany
type and number of required machines The horizontal system ‘K9’ is the newest www.eme.de,
can be tested and the quality of the output generation of separation technology hwww.krsrecyclingsystems.us/
24
0
Recycling EME.indd 2 18/11/2020 13:52:28

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Don’t just look at it,

look into it.
Tiama Xlab – the revolutionary sampling system
Turn virtual reality into reality with the

new Tiama Xlab.
This highly flexible laboratory module can be installed at

the hot end, the cold end or in the laboratory. It loads
the container automatically and makes a 3D scan,
generating an image composed of millions of facets.
The 3D image can be rotated and “dissected” on all

sides. Virtual volume, capacity, and vacuity can be
measured as well as glass distribution fully mapped.
You can also analyse engraving, embossing and much
more. Practically all container types and shapes can be
inspected and it’s non-destructive because the image
(and not the container itself) is “cut” virtually.
For an online presentation of the Xlab please contact

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Recycling: Zippe
Zippe delivers in the field

of glass recycling
Zippe Industrieanlagen is a German batch and cullet systems specialist and
recently celebrated its 100th anniversary. It also specialises in the field of glass
recycling for glass factories, states Markus Werner*.
Z
ippe Industrieanlagen installed the recommended to apply a label removing has several sorting stages, sorting will be
first recycling plants with CSP devices system. As a last step, the cullet will be executed additionally according to colours
35 years ago, and has continued to sorted according to the required colours. – apart from the disturbing substances.
innovate since then. Depending on customer requirements
Recycling has become more important. Synergies of Competences (information as to incoming material and
What used to be the norm in industrial To handle projects in the field of recycling required sorting quality) several sorting
countries in earlier times, is now on the optimally, Zippe works together with systems can be connected in series.
agenda in almost all countries of the specialists in the area of sorting systems.
world. Here, the company Binder + Co is an All-inclusive
However, there are still big differences important partner to Zippe. According to customers’ information,
in the quality of the collection systems. Zippe and its partners will design,
Thus, in some countries, for example, construct, and offer optimum plants –
the raw material glass is being collected internationally! The customer decides, if
and then sorted according to its colour. he likes to receive an offer “only” about
Whereas in other countries glass is being basic engineering, equipment, installation
collected completely mixed. Also, the supervision, and commissioning by
proportion of foreign substances (metals, Zippe, or e.g., also services like steel work,
ceramics, waste in general …) differs from on site construction, and trainings.
country to country. Each customer will be advised
All this information as well as the individually by Zippe with its extensive
required capacity of the plant are discussed experiences.
between Zippe and the customer at the The higher-level control, which is also
beginning to work out a recycling plant being developed and designed by Zippe,
according to customer needs. controls all processes of the applied
machines.
Sequence of a Recycling Process Of course, the quotation by Zippe also
In many cases, manual sorting stations comprises a layout. This already indicates
are included in the post-consumer glass important information as for example
recycling plants after the cullet addition building dimensions and the positioning
in order to allow a first sorting out of large of the machines.
foreign substances. In this way the customer can estimate
After that whole bottles and big cullet � Zippe’s CEO, Dr Philipp Zippe at a commission- far in advance which buildings and what
will be crushed to achieve a subsequent ing of a recycling plant. amount of space will be required.
efficient sorting process. Modifications to adapt the new
Suction equipment is also often Its systems do not only separate various recycling plant to any existing structures
integrated at the beginning of a recycling impurities such as ceramics, stones, or will be realised by Zippe in direct
plant to extract light materials such as porcelain (CSP) from the cullet, but also communication with the customer.
paper or light plastic parts. Here, a special detect and eliminate metals by means
organic separator will be applied by of a metal detector. Furthermore, it is Current projects
means of which the light materials will be also possible to detect heat-resistant or Zippe has already designed and
separated from the heavy glass with the leaded glass by means of special sensors commissioned several batch plants for
help of a ventilator. which will be integrated if required by the Thai customer Siam Glass.
To minimise the ejection of wrong customer.
cullet (because of existing labels), it is Since each of these sorting machines Continued>>
27
recycling Zippe.indd 1 18/11/2020 13:48:47

Recycling: Zippe
� An overview of a simple recycling plant.
The scope of its last order comprised In this plant, coarse impurities are Conclusion
a recycling plant including metal and eliminated at manual sorting stations at In summary, Zippe is not only able to
non-ferrous metal separation, organic first. design and plan individual glass recycling
separation, ceramics, stone and porcelain Subsequently, the cullet will be factories but also supplies all necessary
separation (CSP) as well as colour conveyed to a two-roller-crusher. equipment and control systems.
separation. The capacity of the first When the cullet has been crushed to an Furthermore, its scope of services
expansion stage was 30 t/h. With an optimum size, it will be transported via an also comprises the installation and the
adjustment ordered at a later stage, the Eddy current separator. commissioning of these plants.
capacity was enlarged to 45 t/h. Here, magnetic metals will be removed Further services like error elimination
Furthermore, a label remover was added again before non-magnetic metals (e.g. and so on are certainly quality standards
during a later modification in order to aluminium) will be eliminated. for all plants.
minimise the ejection of labelled cullet. After removal of all metals, the cullet To be available 24 hours a day for our
Zippe has designed and delivered the will be transported to a screen where customers via our hotline is equally self-
complete plant control system as well all fragments < 8 mm will be sieved. In evident for us. Thus, Zippe in cooperation
as all core components like sieving and the following sorting system, foreign with its technology partners, can supply
magnetic technology and optical sorting materials like ceramics, stones, and high-end plants in the field of glass
machines from company Binder + Co. porcelain (CSP) will be removed. recycling technology. �
Another recycling plant will soon be Now the cullet is completely processed
built in Tunisia. This recycling plant for the customer and can be added to *Project Planning,
has been developed for Zippe customer the melting process. The capacity of this Zippe Industrieanlagen, Wertheim,
Sotuver. plant is 15 t/h. Germany www.zippe.de
� An overlook of a Thai customer commissioned

recycling plant.
28
0
recycling Zippe.indd 2 18/11/2020 13:50:01

T
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Wi
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Recycling
The PRN system is ripe for reform

not replacement
Replacing the PRN system with an ‘all-in’ deposit return scheme is not the
answer for glass says Recresco director Tim Gent.
O
ver the last 40 years, the UK threat in the long term. packaging into the household recycling
has worked hard to increase Under DRS, consumers are incentivised bin is removed.
packaging recycling rates through with a deposit refund to return rather The most effective way to drive glass
a combination of heightened consumer than discard used packaging and bottles. recycling rates is to make the current
awareness, kerbside waste collections and DRS is already widely used across Europe, system work harder. One of the main
enhanced regulation around packaging however evidence of a move towards issues which must be addressed is the
producers. single use plastics as a direct result of current remelt/aggregate differential
The Packaging Recovery Note (PRN) glass being included which was designed
system which provides evidence that in DRS is a worrying to encourage glass
obligated businesses have met producer development. Indeed into remelt but simply
responsibility requirements of the Germany reported doesn’t go far enough.
Packaging Waste Regulations, has a 60% increase in There is room for a
undoubtedly helped to drive this change. single use plastic significant increase in
The system, while not perfect, does consumption after the differential which
what it was designed to do; it increases including glass in its would encourage
recycling rates. DRS[2]. recyclers to properly
For glass, the PRN system has helped The 2018 Raise invest in effective
the glass industry achieve one of the UK’s the Glass Study sorting technology to
highest recycling rates of any packaging commissioned by deliver remelt grade
material at 68.8%.[1] FEVE to assess the end product.
Glass also has well established impact of mandatory With the current
household collection schemes for DRS measures � Tim Gent PRN value almost
recycling that have proven extremely clearly showed that equal for crushed or
effective in changing consumer behaviour including glass in a remelted glass, there
and supporting the circular economy. deposit return scheme did not increase is little incentive for recyclers to make the
There is no doubt the PRN system works, glass recycling rates and none of the financial commitment required to remelt.
however there is room for improvement. top six countries leading the way in By increasing the differential more
glass recycling (Belgium, Slovenia, would make its way back to a sustainable
The move towards DRS Luxembourg, Sweden, Ireland and quality product that can be reused and
There has been a lot of focus lately on a Austria) include glass in the DRS.[3] recycled again and again.
proposed deposit return scheme (DRS) as Germany provides another useful The current system is a good one
an alternative way to drive recycling rates example boasting the most successful that works, but it is also notoriously
in the UK. glass recycling rate for a glass inclusive complicated, unregulated and open to
Earlier this year, the Scottish parliament DRS country however, more than 80% of misuse and even fraud.
voted in favour of an ‘all-in’ DRS for the total recycled is collected through the The circular economy relies upon
Scotland which will take effect from July established bottle bank system; not the a joined-up approach that ensures
1st, 2022. More recently a group of MPs DRS[4]. resources are used repeatedly for as long
lobbied the Prime Minister to extend as possible and waste is minimised.
the all-in DRS to the rest of the UK with Reform the current system Revenue generated from PRN sales
the intention of driving recycling rates Both Sweden and Austria consistently funds better recycling practices and more
to meet increased targets. However those excel in glass recycling through an sustainable packaging production.
in the glass industry including waste efficient bottle bank system and Extended It is time to challenge the industry by
management experts, British Glass Producer Responsibility (EPR). reforming the PRN system to unlock the
and FEVE have raised serious concerns DRS puts kerbside glass recycling at full potential of an already successful glass
warning that imposing DRS on glass will risk by diverting glass packaging away recycling model with proven results. �
be counterproductive with the potential from kerbside and bottle bank collections
to reduce rather than increase glass potentially leading more glass into landfill Recresco, UK
recycling; posing a greater environmental as the convenience of putting heavy glass https://recresco.com
30
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Recresco.indd 1 17/11/2020 12:09:20

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Event review: Soda Ash conference
Glass under the spotlight at soda

ash conference
Soda ash is a pivotal raw material in glassmaking and glass provides the larg-
est market for soda ash. The recent IHS Markit World Soda Ash online con-
ference included a session devoted to Prospects for Glass, where four glass
experts provided updates.
Indian overview fast pace because of the increase in India’s The companies with the largest
The Indian glass industry expects a V population - a total of 19 million new capacities are HNG, AGI, CP Glass and
shaped recovery in 2021, a soda ash consumers enter the legal drinking age Piramal Glass.
conference was told. every year, for example. Lockdowns and business outages as a
Bharat Somany, President of the All Food spending in India is expected to result of the pandemic caused a reduction
India Glass Manufacturers Federation grow at 10% CAGR. Glass is currently the in container glass demand ranging from
(AIGMF), provided an Indian Glass preferred choice for premium milk shakes, 24% to 33% depending on the region in
Industry Outlook during the IHS Markit yogurts and flavoured milk. India.
World Soda Ash Conference recently. The carbonated soft drink market is But while the pandemic has reduced
A combination of government experiencing a slowdown driven by the beer and liquor demand for the time
stimulus, consumer choices and planned availability of healthier alternatives and being, the pharma and food sectors are
expansions will ensure the container glass high taxes. Global brands have shifted expected to have huge growth post Covid.
segment grows in future years, he said. their containers from glass to PET. “Covid has changed the market
While the beer and liquor glass sectors India’s pharma sector is expected to be a dynamics”, Mr Somany said. People are
have suffered a knockback as a result manufacturing hub compared to the rest more cautious and are choosing better,
of lockdowns, the pharma and food of the world in future. healthier packaging.
segments are anticipated to record huge Its pharmaceutical packaging market is The industry expects a second round
growth post Covid. expected to be $3.57 billion by the end of of Indian government stimulus to boost
Mr Somany began by outlining the 2023 at a CAGR of 9.2%. manufacturing and demand in the new
history of the glass industry in India. The share of glass packaging in liquid year.
Firzobad is the Glass City of India where formulations is high due to safety and The IHS Markit World Soda Ash
production of glass began in the 17th longevity factors. Conference took place online between
century. India’s installed container glass October 19 and 22. �
Mass glass manufacturing began capacity is approximately 11,600 tonnes
in 1946 with the formation of HNG, a day, which is set to grow as a result of
followed by global companies such as AGI, announced expansion projects. Continued>>
Piramal Glass, Asahi and Saint-Gobain in
subsequent years.
Today, modern technologies common
to the world are used in the production of
container and float glass in India, he said.
The Indian glass container market is
estimated to be worth around $1.1billion.
Current consumption of container

glass in India is 1.8kg per person, which
compares to 89kg per person in South
Korea, 50.5kg per person in Germany and
27.5kg per person in the USA.
“There is huge potential for the glass
industry to grow in India,” Mr Somany
said.
The Alco-Bev, pharma and food
segments are expected to see the most
growth in future.
The Alco-Bev segment will grow at a
33
Soda Ash.indd 1 18/11/2020 13:53:54

Event review: Soda Ash conference
INCREASING GLASS COLLECTION FOR RECYCLING

The European Glass Container customers, municipalities around was a key priority for the sector and that
Federation (FEVE) discussed its platform Europe and 80% of national countries. customers were increasingly asking for
to increase cullet collection, during a The remaining 20% of countries are environmentally friendly products.
recent soda ash conference. anticipated to be involved soon. The more cullet that is used in the glass
Stefano Cassano, Chairman of the The 90% target is a big challenge manufacturing process means fewer CO2
Circular Economy Group spoke about he said, which is currently at 70%. emissions, less energy used and fewer
FEVE’s Close the Glass Loop cullet The platform was launched in June natural resources used.
collection scheme which aims to recoup with the full support of the European Just 10% of cullet used leads to a 5%
90% of recycled glass. Environmental commissioner. reduction in CO2 emissions and 2.5%
He told the IHS Markit World Soda “We are just at the starting point but reduction in energy use. At the same
Ash Conference online that the scheme we expect to get big results in the next time, 1 tonne of cullet used means a
involved all stakeholders from the years,” he said. reduction of 1.2 tonnes of raw material
European glass industry, brands and He added that CO2 emission reduction used so cullet is very important.
GLASS CRUCIAL AGAINST CLIMATE CHANGE
Flat glass products and recycling is up to 30% of energy consumption in “From our perspective there is low
making a contribution in the fight buildings could be saved by replacing hanging fruit such as in the buildings
against climate change, a conference windows from single to double or triple sector where the materials exist to have
was told. glazing. passive or energy positive buildings.”
Cedric Janssens, Public Affairs He added: “The starting point of this Europe has already announced it
Manager at flat glass association Glass presentation is that we acknowledge wishes to double the renovation rate of
for Europe, told the World Soda Ash there is global warming and there existing buildings. Future ideas to help
Conference that glass is part of the is a need to act. There is a collective ensure Europe is carbon neutral by 2050
solution in the fight against climate responsibility to act as individuals and include the use of decarbonised fuels
change. companies. What can you do to act such as hydrogen and electric in the glass
“Glass is a fantastic material from quickly and smartly?” manufacturing process, the ambition to
an environmental perspective, it is While the existing potential of recycle more end of life building glass,
infinitely recyclable and in flat glass we products to reduce emisions needs to be and to invest into R&D to abate process
make products that make possible the tapped into, ways to reduce emissions emissions.
reduction of emissions in other sectors even further in the future also needs to “We are at a crucial time in Europe
of the economy.” be investigated. now, we know where we want to land
An example of this was a recent study “What do we do and when do we but we have to define what will be our
between Glass for Europe and Dutch do it in terms of action, what is the pathway.”
research group TNO, which found that sequencing?” he said.
PACKAGING AND ENVIRONMENTAL COSTS
Container glass manufacturers will Conference was told that schemes environmental transition.
have to focus on the environment if the such as FEVE’s Close the Glass Loop Matthew Hancock, Principal Analyst
industry is to continue to thrive, a soda cullet collection project and the focus at IHS Markit, said historically, glass
ash conference was told. on finding alternative furnace fuels was the go-to container for most drinks,
The IHS Markit World Soda Ash show the sector is making a successful but this changed when plastics and
Continued>>37
34
0
Soda Ash.indd 2 18/11/2020 13:54:38

TOP ROLLER
TOP STANDS FOR QUALIT Y – OF COURSE
Top rollers are among the most important parts of a tin bath.
These machines are used in pairs in the forming section.
Each pair, consisting of master and slave, works synchronously
and has to create optimal conditions for a smooth production process.
That requires nothing but the highest quality standards!
Since 1884 we are passionate about building

glass melting technology and driven by
innovative thinking. That’s why we constantly
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Events review: Soda Ash conference
Continued <<34
aluminium became more prevalent. In some sectors the

materials even superseded glass.
But in recent years glass has benefitted from the
shift in public perception of plastic. Glass is seen
as the ‘greener’ alternative to plastics because of its
recyclability.
But the carbon cost of producing glass needs to be
taken into consideration when the two materials are
contrasted.
Mr Hancock demonstrated the variability of SUPPLY CHAIN
container glass recycling from region to region.
Glass recycling in the EU is at about 76% but in the CONFIDENCE
US and China it is much lower. Europe has a history
of being the world’s largest container glass producing
region. Historically it’s also been a large wine and beer 5 LOCATIONS ACCROSS
producer and consumer.
Container glass has a niche in this sector and is
UK AND IRELAND
regarded as the packaging material of choice so it
is no surprise that Western Europe is the largest
• Soda Ash • Sodium Sulphate •
producer of container glass. As there are so many glass • Feldspars • Chrome •
manufacturing facilities, producers are often close to
sources of recycling for glass. Europe has a number of
Barium Sulphate • Sodium Nitrate
glass recycling facilities and that makes it worthwhile
and cost effective for glass producers to recycle glass.
But cullet is heavy and expensive to transport, so for SPECIALISTS IN THE
US and Chinese container glass producers it can often
be less worthwhile to process and supply it as they are GLASS INDUSTRY
not located close enough to supply demand.
Container glass remains key to soda ash and accounts
for about 18% of total soda ash demand. Europe is the
largest demand sector for soda ash where it accounts for
about 38% of that total. So it is important for soda ash
that container glass remains a key packaging material.
“In a post Covid world where we’re all more aware
of environmental issues producers will have to take
into consideration the environmental impact of glass,
particularly compared to other packaging materials
such as plastics and aluminium especially as plastic has
become more recyclable,” said Mr Hancock.
“What does this mean in reality? It means increasing
recycling infrastructure, increasing incentives to
recycle, it also means improvements in furnace
technology, which is happening, and how these
furnaces are powered.
“It is clear that this transition is happening, there are
great examples such as FEVE and how the container
glass industry is decarbonising.
“Moving forward that is the way that the container
glass sector will continue to thrive post Covid.”
Contact details
IHS Markit World Soda Ash Conference online:
https://ihsmarkit.com/events/World-Soda-Ash-Conference-2020/overview.html
The All India Glass Manufacturers Federation: www.aigmf.com Contact us:

European Container Glass Federation: www.feve.org +44 (0)20 8332 2519 +44 (0)20 8940 6691
sales@newport-industries.com
Glass for Europe: https://glassforeurope.com/
37
Soda Ash.indd 3 18/11/2020 13:54:41

Event review: Glass Focus 2020 award winners
British Glass Focus goes virtual

After a record number of entries, British Glass has announced the winners
of this year’s Glass Focus awards, held virtually for the first time due to the
Covid-19 pandemic.
T
he British Glass Focus awards has Glass, said: “This year the quality and “For the 2020 awards we have received
gone virtual for the first time this number of entries has been extraordinary our highest number of entries to date as
year due to the ongoing Covid-19 and a real challenge to judge. Given well as a number from overseas, which is
pandemic. Despite this, there was a record the current situation, it has been very a testament and a real good news story for
number of entries. encouraging to read and see some great our industry.”
Commenting on behalf of the judges, examples of products, techniques, and We find out a bit more about the
Nick Kirk, Technical Director at British practices from across the industry. winners and their entries below.
British Glass, Chapeltown, Sheffield UK

https://www.britglass.org.uk/glass-focus-2020
DESIGN OF THE YEAR – FLAT
WINNER: NSG PILKINGTON FOR SANITISE GLASS
In October 2020 Pilkington UK, part of SanITise can be used on the Insulated chambers, while it can also be installed
the NSG Group, launched SaniTise, a Glazing Unit’s (IGU) interior surface of within buildings when used alongside
transparent antimicrobial glass. building facades, or any exterior shared an artificial UV-LED system.
SaniTise has a photocatalytic coating spaces such as bus stop shelters and zoo This is because the product rapidly
which becomes activated when enclosures where many different people achieves its full antimicrobial activity
exposed to UV light. touch the glass throughout a day. upon exposure to the artificial UV light.
The coating’s photocatalytic It could also be used on external Pilkington SaniTise can then be used
properties generate reactive oxygen facing windows in hospitals, as the in applications such as wall cladding,
species which provides activity against coating on the interior surface of the partitions, mirrors, or tabletops.
enveloped viruses and other microbes. IGU is naturally activated through UV NSG Pilkington confirmed the
The photocatalytic process generates exposure from daylight. product is ready for launch after
reactive oxygen species which provide There are also opportunities to use its antimicrobial properties were
activity against enveloped viruses and the product in medical devices such independently verified.
other microbes. as glove boxes and UV sterilisation
38
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Glass focus.indd 1 18/11/2020 13:57:05

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DESIGN OF THE YEAR – CONTAINER

Stoelzle took two elements of Japanese
culture, the rice wine drink, Sake, and a
traditional method of carbonising wood, WINNER: STOELZLE’S CARBON SAKE BOTTLE
Yakisugi.
The bottle was produced in black glass,
and Stoelzle was able to replicate an
authentically tailored wood-like texture
on to a carafe style bottle. The bottle
is acid-etched, with large embossed
logography and a splash of red also
helping to create an eye-catching design.
Stoelzle saw an opportunity to design
a concept Sake deserves. Its aim was to
create a brand that provides a prestigious
quality of bottle, both in aesthetics and
manufacturing but also that is authentic
enough to encompass Japanese culture in
more than just name.
Stoelzle developed a variety of 3D wood
textures which was then materialised
with acid-etched glass.
Carbon Sake is intended to leave a
lasting impression on those who see it,
touch it or drink from it. The likeness
to wood gives the design an edge; it is
realistic and instantly recognisable as
different. Coupled with the black acid-
etch finish, it truly embodies Yakisugi.
Stoelzle hope that the unique
and confident qualities of the bottle
encourage the consumer to use and re-use design work in glass, Stoelzle was pleased Carbon Sake is the building block of life
the bottle as a decanter or as a re-purposed to introduce the design as a concept for and is meant to be shared.
receptacle. Having successfully made the the Sake market. True to Japanese culture,
INNOVATIVE SOLUTION
WINNER: STEALTHCASE
Indoor spaces are often enveloped by into a ’glass antenna’ that improves indoor of the glass (to date, no effect has been
thermally insulating building materials wireless connectivity, which could mean detected by its manufacturing partners).
(such as concrete, metal and metal coated a reduction of between 15db-20db in the In its default form, the StealthCase
low-E windows) that weaken wireless building envelope. technology improves signals of up to 6 GHz
signals. StealthCase licensed its technology to frequency band (i.e. the key frequencies
This means wireless signals can cause glass manufacturers incorporating the used by many public safety/ first responder
problems by pushing wireless devices technology. The technology does not networks, 3G, 4G, 5G mobile and Wi-Fi
to operate close to their limit, which require any power or periodic maintenance networks) but it can also be optimised to
ultimately result in slow and unreliable to function and it is also unaffected by any enhance only certain part(s) of it as well
data connections and dropped calls inside power outages. – for example the first responder network
buildings. The antennas are invisible to the but not the Wi-Fi frequencies due to IT
StealthCase’s patented passive antenna human eye and hence do not affect the security considerations.
technology mitigates the issue, improving transparency of the glass. They do not The antenna can be ablated on glass using
indoor connectivity. cover the entire surface area – instead, a the manufacturer’s existing equipment,
It can be incorporated into glazing by narrow ‘ablation strip’ close to the edge with some modifications. This minimises
creating a microscopically thin lasered suffices for a typical residential window. any disruption to the manufacturing
two-dimensional antenna pattern on the Furthermore, the antennas do not process and the technology adoption
glass metal coating. This turns the glass compromise the insulation properties costs.
40
0
Glass focus.indd 2 18/11/2020 13:57:41

SUSTAINABLE PRACTICE WINNER: ARDAGH GROUP
In order to achieve 100% recyclability and is referred to as ‘fines’. These fines closing the recycling loop and using 100%
of post-consumer glass containers, contain high levels of loose organics and of recycled glass containers recovered
Ardagh Group has developed a method fine particle CSP which cause defects through the various collection systems
of producing briquettes from the fine when made into glass containers. across the UK. The plant will be the first
particle glass rejected during the glass The ‘fines’ also cause foaming in the commercial type in the world and due to
recycling process. furnace which forms an insulating layer be built in 2021.
Cullet has long been a component of on the surface of the molten glass and By re-purposing materials that are
the batch recipe for producing container requires additional energy to penetrate currently diverted to aggregate or
glass, but the quality of the cullet is and continue the melting process. landfill to become new glass packaging,
critical. For these reasons, the 10% has been an reducing energy and emissions in the
Collected glass contains various accepted loss for many years. furnace, the briquettes will improve the
contaminants which make it unsuitable Ardagh has worked with CelSian environmental impact of glass packaging
for remelting. It must undergo glass technologists, Wright Engineering manufacture.
processing at a recycling plant to remove (Wrights) and Sheffield Hallam University See article earlier this issue for more
contaminants such as plastics, caps and to design a processing plant which will information on the briquettes project.
labels; ceramics, stones and porcelains turn the glass fines into briquettes,
(CSP); metals; heat resistant and lead
glass.
Currently, of the collected glass
processed into cullet, up to 90% is
remelted and the other 10% is diverted to
aggregate for road surfacing, to produce
sandblasting media or to landfill.
The reason for this 10% loss is the
fraction size, which is typically <4mm,
RISING STAR
WINNER: ERIN MILLER OF ENCIRC
Erin Miller is a graduate at Encirc, knowledge and research towards

working in the batch and furnace this project through producing a
department. Ms Miller joined report on bio-diesel by comparing
Encirc via the Cheshire Energy the behaviours of the fuel to
Hub (CEH) graduate programme diesel. Her work and involvement
and has been an outstanding significantly supported the
colleague and advocate for Encirc initiation and progress of the bio-
and the glass industry since day diesel project.
one. Ms Miller has played a
The CEH scheme is designed significant role in Encirc’s
to offer six-month placements ‘Women in Manufacturing’
across three different campaign, which aims to

organisations to allow a wealth encourage women to pursue a
of engineering knowledge to be career in manufacturing.
gained from a diverse range of Ms Miller has also been active
sectors across industry. in supporting British Glass
At present Ms Miller is with its Glass Futures Forum,
undertaking a secondment from participating in discussions
Encirc to Glass Futures, working (hosted by British Glass) on how
as a Project Manager to support its to encourage and make young
industrial fuel switching project. people aware of the glass industry
Erin contributed invaluable and the careers available.
41
Glass focus.indd 3 18/11/2020 13:57:55

HEALTH AND SAFETY ACTION WINNER: NSG PILKINGTON UK

As part of NSG Pilkington UK’s Health providing a health screening, when it was that can encourage the user to seek
and Safety day, the company introduced not possible to see a health professional, medical help if necessary.
a Wellpoint Health Kiosk. was beneficial as statistically middle-aged Users can see their results on screen,
The machine was supplied free of men are far less likely to visit their doctor. printed out of the machine or emailed to
charge by St Helens council and provided It is also believed that monitoring the an email address of their choice.
the users with health-related information health and lifestyle of individuals leads NSG Pilkington was provided with the
on cardiovascular fitness, blood pressure to clear actions by employees to improve information with which to analyse the
and weight. health. This improved health can lead to collated data anonymously.
Employees were able to access the increased productivity and reduced losses Most participants identified that they
machines at any time of day and were through sick days. would likely or very likely to use a kiosk
encouraged to do so. The kiosk also provided insight into the again. NSGs intend to hire the kiosk every
As an older, male dominated workforce, user’s mental health by asking questions year due to its popularity.
STRENGTHENING BUSINESS THROUGH PEOPLE WINNER: ENCIRC

During lockdown, the Encirc workforce created for the whole workforce to convey worker submissions.
was effectively split in two – with office- the importance of Encirc’s factory workers Immediate steps were taken to promote
based employees working from home, during the pandemic. onsite safety for factory workers going
and factory staff working safely onsite to Two engaging videos and social tiles into the plants with #InitTogether
continue production of much-needed were also created to reinforce messaging branded safety messaging displayed on
glass packaging. around the vital nature of Encirc’s screens around the sites and on posters.
Reminding staff of the crucial role of role and why sustainability during the The ‘In It Together’ campaign
the glass sector was key to maintaining a pandemic was so important. An internal united the workforce during one of the
focused and engaged workforce, and ‘In sub-campaign encouraging people to company’s most challenging periods,
It Together’ was chosen as the unifying ‘raise a glass’ to their co-workers via a selfie helping Encirc support the retail sector
message. with their favourite glass product was also with the sustainably packaged goods it
A ‘Thank you’ video message was rolled out on Workplace and received 40 desperately needed.
Continued>>
42
0
Glass focus.indd 4 18/11/2020 13:58:15

MARKETING IMPACT
WINNER: ALLISTER MALCOLM GLASS FOR ITS

‘BEAUTY, ARTISTRY, CHERISH FOREVER’ CAMPAIGN
Allister Malcolm Glass’ ’Beauty, Artistry, tailor-made piece of art for their home.
Cherish Forever’ is its key message. The After the show aired, the company
goal was to attract new trade customers noticed a rise in followers across social
while also engaging directly with art media.
lovers to entice them to commission Product placement of larger scale one
Allister Malcolm directly. The challenge off pieces and the completed final piece
for the studio glass artist is to achieve this for the show lead to many one-off bespoke season awards was shared on social media
on a limited budget. commissions. and reached over 35,000 potential new
Part of its campaign was to gain more Allister Malcolm also appeared on clients (Pictured above).
exposure and reach potential clients another TV programme in ‘Salvage Recent media coverage has led to
wishing to commission bespoke one offs. Hunters - The Restorers’ and also applied fulfilling many bespoke commissions for
Allister applied and was selected out of to the Crafts Council to become part of individual clients.
hundreds of applicants for BBCs ‘Home is the directory. In a challenging year Allister Malcolm
where the Art is’ which aired in July. Lastly, the company has been creating is delighted that its strategy has helped
The programme showed how Allister corporate gifts for Wolverhampton not only survive but increase its brand
responded to a client’s brief to create a Wanderers Football Club and its end of awareness.
COMPANY OF THE YEAR – ENCIRC
In announcing the Company of the Year award, British Glass President Dave Dalton said Encirc had participated in a number of
projects this year – such as the fuel switching project in its Derrylin, Northern Ireland facility - and was also an active member of
British Glass.
Mr Dalton said: “It is a well-deserved win, the company has been involved in a whole range of activities this year, which is
spectacular. The management and staff at Encirc have been great advocates of the glass industry.”
43
Glass focus.indd 5 18/11/2020 13:58:22

We print
your world
Uniting inks and substrates
to create a uniqueness,
which is incomparable.
Koenig & Bauer Kammann GmbH

Weidehorst 80
32584 Löhne
kammann.de
Personality profile: Guenter Lubitz
A career dedicated to the

container glass industry
Guenter Lubitz has worked in the glass the possibility to melt container glass, employing
a more advanced method and to further develop
industry for 43 years, rising from an apprentice the strength properties of container glass and its
as a laboratory glass instrument maker to production technologies.
become a member of the board at Vetropack 2. When and how did you enter the
industry?
Holding. He recently retired from the company I had my first contact with glass as an industrial
to set up his own consultancy. Here he reflects material in 1968 because I started and completed
a three-year apprenticeship as a laboratory glass
on the highlights of his career. instrument maker. This was more of a coincidence.
Originally, I wanted to do an apprenticeship as a
chemical laboratory assistant. After my military
1. What did you most enjoy about service in the German Navy, I studied glass and
working in the container glass sector? ceramics in Germany.
The daily interaction with people and technology
and to face a new challenge in production every 3 .What have been your career high-
day. In later years I enjoyed working with people lights?
from different cultures, such as in Thailand and My career highlights:
working for Vetropack with people in seven � Working three years in Thailand as part of a
different countries. Another great opportunity was consulting project at Bangkok Glass Industry;
� Planning, constructing and starting-up a
new production facility with a 350 tonnes/day
� Guenter Lubitz. furnace and three production lines at Oberland
Glas in Wirges after the German reunification
together with a competent project team;
Continued>>
CV OF GUENTER LUBITZ
� Apprenticeship as laboratory glass instrument maker
� Study of glass and ceramic at university of Duisburg,
Duisburg, Germany
� 1977 – 1985 Production Engineer and Head of
Production at VEBA Glas and Oberland Glas Neuburg,
Germany
� 1985 – 1988 Production Manager and Technical
Director at Bangkok Glass Industry, Bangkok, Thailand
� 1989 – 1993 Plant Manager at Oberland Glas in Wirges,
Germany
� 1993 – 1999 Plant Manager and Technical Managing
Director at Gerresheimer Glas, Germany
� 2000 – 2003 Performance Director and Plant Manager
at BSNglasspack, Germany
� 2003 – 2020 Managing Director of Vetroconsult
and Member of the Executive Board at Vetropack Holding,
Switzerland
OTHER ACTIVITIES
� Board member of German Glass Society, DGG
� General managing board member of GlassTrend
� Chairman of International Partners in Glass 45
Research IPGR
Lubitz.indd 1 17/11/2020 12:12:46

� Taking over the plant management of and is a clear trend towards weight reduction of
Gerresheimer Glas in Düsseldorf, which was glass packaging. Due to cost pressure the industry
at that time the largest container glass plant in had to improve productivity through installation
Germany - Planning, constructing and collecting of 12-section triple- and quad-gob production
experiences with an oxy-fired melter with batch forming machines and to reduce headcount.
and cullet preheater together with a strong project Worth mentioning are also the significant
team at Gerresheimer Glas in Düsseldorf ; increase of quality and achieving environmental
� Working on the development of the cased requirements. Clearly there is a transition towards
gob process with a team of OI and Gerresheimer automation and digitalisation.
specialists;
� Integrating the Nemsova plant in Slovakia, 5. In your opinion, what are the largest
the Gostomel plant in Ukraine and the Trezzano challenges facing the container sector?
plant in Italy into the Vetropack group regarding In my opinion, the greatest challenge is to achieve
production and techniques; the greenhouse gas reduction targets by 2050.
� Working on the development and Other challenges are to further develop forming
commercialisation of thermally-hardened and inspection technology to meet future quality
container glass, called VIP glass (Vetropack requirements and to remain competitive – and
Improved Performance Glass). to attract young, well educated people to our
The piece of work I am most proud of is the industry.
development and commercialisation of thermally- How to tackle them? Despite all efforts to evolve
hardened container glass, VIP Glass. melting technology towards hybrid and hydrogen-
It took eight years of development in cooperation oxygen-fired furnaces, I expect that there are still
with Bucher Emhart Glass and a highly motivated a considerable number of conventional furnaces
Vetropack project team. in operation. Due to the lifetime and necessary
investment and infrastructure, it will not be
4. What have been the biggest changes possible to replace many of them.
you have seen in the industry? But there will be a trend towards larger furnaces,
The shift of glass packaging for the soft drink melting up to 1,000 tonnes per day. By 2050, the
and juice segments towards PET in Germany in Below, Mr Lubitz with forming of container glass will still be performed
the 90s. Traditional German companies such as members of the International with today’s processes, but mainly in triple- and
Oberland Glas and Gerresheimer were taken over Partners in Glass Research quad-forming.
by European or international groups. There was (IPGR). The standard glass forming machine will be fully
What will you miss the most about the container glass sector?
“The contact with interesting colleagues, business partners,

industry experts, academics, and so many other individuals
in our industry. ”
46
Lubitz.indd 2 17/11/2020 12:13:03

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systems.
Also, the machines will be much easier to job change. Machine segments
will be prepared in the workshop and replaced by quick-change systems
during job change. With the aid of artificial intelligence, pack to melt has
reached a level above 90% with superior quality.
One machine operator supervises two or three glass forming machines.
Swabbing of moulds and mould exchange will be done by robots.
Thanks to automation, only 50% of today’s workforce will be needed, but
they will be highly-educated specialists.
By 2050 the cold end lines will be equipped with fewer, but self-learning,
inspection machines. So, the main focus of inspection will in future be at the
hot end, with immediate feedback to the forming machine and self-correction
systems. There will be full traceability of moulds, machine parts and final
products. Production will be done on demand, stock levels will be less than 30
days, and inventory will be stored in automated warehouses.
Our success will also certainly depend on finding and keeping the very best
personnel and engineers.
6. Is there a single piece of advice you would give to any pro-

spective newcomer about to start work in the glass sector?
The container glass industry is a conservative and cautious industry. To develop
Furnace Draining our technology further and to achieve changes takes time, perseverance and a
willingness to take risks. The glass industry is not a fast-moving industry like
IT, for example.
Usually the industry operates its production facilities for 12 years and only
then comes the opportunity to introduce technological changes. Although
the container glass industry has indeed evolved technologically, individual
engagement remains the real foundation for success. 
Recycling Drain 7. Are you optimistic about the future of the sector?
I am extremely optimistic. Glass was first mentioned around 3,000 B.C., and
my clear expectation is that container glass will still exist in future and remain
the superior packaging material. People have recognised that careful handling
of our resources and avoiding waste might help rescue our environment.
By 2050, returnable packaging in Western Europe will be the dominant
material. It will not be made from annealed glass, but mainly from thermally-
hardened container glass, which is produced in both in-line and off-line
Furnace Heat-Up processes. Thus, with the same strength properties, the weight of returnable
packaging glass can be reduced by up to 50%.
Vetropack has already launched the first 3.5 million “VIP” beer bottles in
Austria in 2019.
8. What will you miss the most about the container glass
sector?
The contact with interesting colleagues, business partners, industry experts,
academics, and so many other individuals in our industry.  
Experienced Teams
9. What are your future plans personally?
First of all, I will spend more time with my family and I will enjoy my hobbies,
like gardening, jogging and fishing.

But I will not retire completely because I still feel fit and active. I would
like to make my over 40 years of experience available to the container glass
industry. This could be done as part of a consulting project, as I am presently
doing for Vetropack.
WORLDWIDE
The optimisation of production, education and support of young managers
in production and the execution of special projects are key areas of my possible
AVAILABILITY consulting activities. Based on my extensive network, I can also involve other
experienced and retired production specialists if necessary. �
Further information:
www.hotwork.ag email: guenter.lubitz@containerglassconsult.com
48 contact@hotwork.ag
Tel.: +41 71 649 20 90
Lubitz.indd 3 17/11/2020 12:13:06

Glass engineered to defy flames
� Dr. Holger Wack (left), Damian Hintemann (middle) from Fraunhofer UMSICHT and Thomas Baus (right) from Hörmann KG Glastechnik received the
Joseph von Fraunhofer Prize for the hydrogel-based fire-resistant glass they developed.
A new type of fire-resistant glass that holds up under even extreme heat
created in collaboration between a research institute and a door manufacturer
has helped Dr. Holger Wack*, Damian Hintemann* and Thomas Baus*** win
the Joseph von Fraunhofer Prize.
G
lazing developed by Fraunhofer for long and shatters. The researchers then scaled it up from
UMSICHT and Hörmann KG is This actuates two mechanisms: For one, the beaker to a demonstration cell at
designed to have fire-resistant the water in the gel evaporates and cools Fraunhofer UMSICHT.
panes that do not contain carcinogenic the intact second pane. For the other, a “We were able to take the idea out of the
acrylamide, so they can be processed with heat-insulating salt layer forms. lab and into a practical application within
no toxicological risks. The Fraunhofer researchers first just four years – a very short time for the
The production line that makes the combed their database to screen for gels development effort that goes into end-to-
novel fire-protection doors generates that could be suitable for this sort of fire- end process engineering. Implementation
just 20 kilograms of process waste a day resistant glazing. Some 60 attempts failed. time is usually ten to twelve years,” said
– far less than the 150 to 160 kilograms Compelled by thoroughness, they Hintemann.
produced in the past. tested a basic component that, as the The Hörmann family decided to spin
Production is more automated, the theory goes, would never work. “But it off Hörmann KG Glastechnik in 2016 on
process is leaner, and traceability and does,” said Wack with a smile. the merits of this successful development,
reproducibility are ensured across the The researchers were reluctant to building a new plant in Saarland,
board. show their hand. The project had a few Germany where the fire-resistant glass is
In the event of a fire, the glass instances like this when something now produced.
withstands flames and heat over 1,000°C worked that clearly shouldn’t have. The family was particularly impressed
for up to 120 minutes, as required by the with this implementation of research
given fire regulations. Four years from beaker to results into practice and, with the
Dr. Holger Wack and Damian business outstanding collaboration between
Hintemann of the Fraunhofer Institute The project was auspicious from the start. Fraunhofer UMSICHT and Hörmann.
for Environmental, Safety and Energy The first fire test the researchers carried “We did more than merely develop fire-
Technology UMSICHT, and Thomas Baus out after a short time in development resistant glass, said Baus, emphatically.
of Hörmann KG Glastechnik are to be already showed promise. The glass held “We reinvented the production of fire-
awarded the Joseph von Fraunhofer Prize up in a 30-minute fire performance trial. resistant glass.” �
for this ground-breaking development.
� The new fire-resistant glass produces * Dr. Holger Wack and Damian
Cooling water vapour and a around 85% less process waste and has a Hintemann** of the Fraunhofer Institute
heat-insulating salt layer shorter production process. for Environmental, Safety and Energy
Fire protection glazing contains a Technology UMSICHT
transparent gel rich in water and **Thomas Baus of Hörmann KG
electrolytes between two glass panes. If a Glastechnik
fire breaks out, the pane facing the flames https://www.fraunhofer.de/en.htm
does not withstand the high temperature https://www.hoermann.com/en/
49
Franhofer - Copy.indd 1 17/11/2020 12:19:00

Company profile: Glassbusters
Glassbusters answers the call of

hospitality sector’s recycling needs
An osteopath-turned-entrepreneur is helping the hospitality sector create
a streamlined plan for recycling waste using an engineered glass crushing
machine. George Lewis spoke to Pete Ancketill* about Glassbusters’ company
beginnings, how it’s adapted during the Covid-19 crisis and its future plans.
L
ondon-based Glassbusters was set up in He said: “The rest of industry only tip bottles (to
the early 2000’s to improve glass recycling the glass recyclers), we only tip ‘sand’, which are
in the hospitality sector by using an shards of glass normally between 15ml-20ml in
engineered machine completely made in the size. Anything smaller, which is approximately 4%,
UK to instantaneously crush glass into industry- is deemed too small and is turned into aggregate.”
approved sized pieces which are taken away with As with many businesses, Covid-19 has affected
minimal hassle and noise. Glassbusters as well. With some of the 10-strong
“We are working against traditional waste team having to be put on furlough, and even some
management techniques,” says Pete Ancketill, who of his lorries put on furlough as well, Mr Ancketill
graduated from the British School of Osteopathy has had to adapt the business.
and had a 20-year career which included working He said: “As an entrepreneur you have to have
for professional rugby league teams before working guts, stamina, and the ability to see opportunities.”
his way to the waste management industry. Around 98% of Glassbusters’ business stopped,
After an appearance on BBC’s television show due to the majority of its partners being pubs,
Dragon’s Den in 2016, in which he accepted a clubs, restaurants and hotels, but Mr Ancketill
£200,000 offer from then “Dragon” Nick Jenkins, pivoted the business and used the same lorries
he then decided to turn it down after the show. that was taking glass to be recycled to helping
Mr Ancketill now provides the waste businesses to move buildings or downsize.
management to some high-end venues across
the country including in London, Manchester, The beginnings of Glassbusters
Birmingham and Edinburgh, in which some After two decades as an osteopath, Mr Ancketill
venues are creating up to ten tonnes of glass wanted to try something new and start up his own
waste per month, all of which is crushed using Mr business. While sitting in a pub he had something
Ancketill’s machines. consistently bothering him - the sound of glass
Dragon’s Den is a TV series in which budding bottles being thrown in bins.
entrepreneurs get three minutes to pitch their “Pubs have little respect for silence”, he said. This
business ideas to five multimillionaires willing to lack of quiet was where the idea of Glassbusters
invest their own cash. Mr Ancketill said the reason � Glassbusters recycle was born. He researched into what the hospitality
for turning down such a substantial offer on the around 100 tonnes of glass sector was doing to recycle glass at the time and
TV show was because he was ‘looking for the right from various venues per decided that the glass crushers at the time were ‘too
partner’, not just financially but someone who can week. commercial, industrial, noisy and cumbersome’
bring the company new ideas and avenues. and went about creating something with less noise
Alongside hospitality venues in London, and less expense to the sector.
Glassbusters also works with Network Rail and With the help of his father, a trained engineer, Mr
J.D Wetherspoons pub at London’s Victoria train Ancketill had a glass recycling machine completely
station, collecting all the glass and other waste designed in the UK, with the outside box created
material and recycling it, which amounts to by another family member working for a sheet
around 100 tonnes of rubbish per week, driving it metal company and the computer programmed
to recyclers URM in Tilbury, Essex. by a UK engineering company. He also had a
The understanding of what the glass recycling willing pub landlord in a north London pub who
industry wanted took time, but Mr Ancketill spoke had a basement big enough for the machine to be
to prominent glass recyclers such as Recresco and installed in.
URM to ask what glass is required and the size it Mr Ancketill then won funding worth £100,000
needs to be. from Innovate UK which was used to create another
Approximately 96% of the glass recycled by more compact ‘hand fed’ machine approximately
Glassbusters is turned back into new bottles. the same size as a fruit machine (pictured below)
50
Company profile glassbusters version 2 USE THIS.indd 1 17/11/2020 12:23:18

Company profile: Glassbusters
and didn’t need to be located in a basement. It has created floor tiles using 75% recycled glass
This could be could be plugged in within the crushed in one of its venues mixed with concrete.
main bar area. But there has been some more positive news in
The machine created is a 240 volts item of the world of recycling in the UK. Dr Nick Kirk of
s
technology, the same as the average kettle and British Glass said there was an increase in glass
is able to crush up to 750 bottles before needing recycling during the first lockdown with Leeds,
emptying. Mr Ancketill says that ‘despite being Yorkshire seeing a 20% increase in recycling in
a complex machine, inside it’s very simple to April 2020, while this shot up to a 60% increase in
use’. The machines comes flat packed ready for May compared to 2019 figures.
installation by Glassbusters’ own engineers. Despite the hospitality sector being closed the
Yet instead of just installing and leaving increase in household recycling made up for this
the customer to familiarise and operate it, the shortfall, Dr Kirk said.
company maintains its relationship with its Mr Ancketill is slowly getting his team back
customers, training all staff how to use the together following the first lockdown, and is
machine, and calling the publicans daily for the hoping his waste management company can
first month to ensure the machine is working well help play a part in the use of more cullet in glass
and is understood. � The ‘bar to basement’ recycling in the future.
The original machine was called ‘bar to machine helps venues Glassbusters is to rebrand and become ‘Waste
basement’ and later patented, and allows bottles crush bottles into industry Stream’, to create a complete waste management
to be put through a hole in the bar, crushed safely approved sizes ready to be company. It is open to offers from investors who
while dropping down and held, and then collected taken away by Glassbusters can propel the company to new markets. �
by Glassbusters at a later date. recycling team.
Mr Ancketill said that the idea was to ‘efficiently
and effectively crush glass that’s safe and to be able *Managing Director, Glassbusters, London UK
to compact glass conveniently close to the pubs’. www.glassbusters.co.uk
He decided he wanted to bring his idea to the
market and exhibit at a trade show. Despite no � The smaller machine
example to physically show during the exhibition, is able to fit into most
he said the response was ‘phenomenal’ and pubs and works off a
seemed to take to the idea. normal 240v plug socket
From the show, a representative from the Tate without the need for a
Gallery in London asked Mr Ancketill to work with basement.
the company to look at the logistics of the recycling
of its glass bottles, and how it could prevent noise
at the venue.
He said: “Our technology is adaptable to small
medium and large businesses. We can tailor to a
venue’s specific response. We are a bespoke service
provider.”
Over the past ten years of installations,
Glassbusters has never lost a customer and no
machine has ever had to be taken away or replaced.
The future
Mr Ancketill spent £200,000 to acquire a patent to
own the future developments in the US, Europe,
UK, China, Japan and Canada, and hopes to
provide the technology to partners in these parts
of the world.
He is investigating whether the machines could
have telemetry-based intelligence, meaning

Glassbusters could tap into theWi-Fi of a pub from
anywhere and tell the landlord how many bottles
had been crushed and invoice the exact amount
instead of just when the machine is full.
The company is also working with a supermarket
on a machine for public use that he hopes is in
shops next year. He believes this type of machine
will create a desire for the general public to use a
deposit return scheme and recycle glass effortlessly.
Glassbusters has examined alternative ways to
reuse its own glass during the Covid-19 pandemic.
51
Company profile glassbusters version 2 USE THIS.indd 2 17/11/2020 12:24:55

Company profile: Orora Glass
Orora Glass
completes furnace rebuild
Congratulations on the recent furnace rebuild. What to undertake important repair and maintenance in
does a rebuilt furnace mean for both Orora and for your our batch plant and packaging areas.
customers?
The recent rebuild provides Orora with an ‘as Generally, furnace rebuilds are a challenging time for a
new’ furnace, forming machines and inspection glassworks and require careful planning? How did this
equipment. All upgraded to the latest technology rebuild compare to previous rebuilds, particularly in
including furnace refractories, insulation, forming light of the Covid pandemic?
machine servo technology and optical inspection Covid-19 has been a significant feature for all
equipment. operating activity, including the recent G2 furnace
As a result, customers have the comfort of rebuild. A comprehensive Covid management
reliable and consistent supply of the exceptional plan was implemented to look after the health and
quality product that Orora is known for. safety of all personnel working across Orora’s sites
and on the rebuild project.
Did any other work take place at the same time in the Travel restrictions were a complicating factor
glassworks? with overseas specialists prevented from entering
The furnace rebuild is a critical opportunity for Australia. These teams would normally oversee
major upgrade, overhaul and refurbishment the detailed construction and commissioning.
works. We replaced one of our forming machines Pleasingly, Orora’s site operations, engineering and
upgrading from 16 to 20 section operation with local contractors successfully stepped in and filled
new servo invert, takeout and three axis sweepout this void to ensure that the project was completed
technology. We installed a new cullet handling successfully. This was a great demonstration
system including wet scraper and process of the teamwork at Orora Glass, with everyone
water pumps. The cold end inspection area was supporting each other throughout.
completely replaced with new bottle and cullet
conveyors, inspection loops and new inspection Have you increased capacity as a result of the rebuild?
machines to ensure our high pack quality meets The recent capacity expansion and furnace rebuild
our customer expectations. We also used the time projects have increased the G2 furnace output by
52
Company profile Orora.indd 1 17/11/2020 12:26:48

Company profile: Orora Glass
Andrew Barreau* discusses Orora Glass’

recent furnace rebuild at its Gawler, South
Australia facility. The rebuild also included
upgrades in its forming machines from 16
to section as well as investments at the
cold end.
furnace at Orora Glass, where it is melted down so

that it can be made into new products.
We are also creating closed loop systems with
customers to improve glass collection rates and
reduce waste going to landfill. By working closely
with one customer, 350 tonnes of waste glass has
been diverted from landfill since the programme
began in 2019.
Orora has currently invested $200 million in the past

five years in the plant. What differences have you seen
in the plant at that time?
Orora has a very high focus on employee safety,
quality and customer service. Most of the
investment has been focussed in these areas. There
have been major improvements in IS machine
safety, reducing manual handling risks and bottle
inspection by utilising the latest servo and robot
technology. From a supply perspective, we have
12%, which equates to an additional 20 million invested in additional warehousing and stock
bottles per annum. management system including automated storage
and retrieval improving our flexibility and delivery
Did any environmental considerations come into place to customers.
when considering the new furnace? Orora recently completed construction of a new
At Orora, sustainability is fundamental to $35.0 million warehouse on site. The 35,000m2
everything we do. We aim to minimise our warehouse is equipped with autonomous Laser
“At Orora,
impact on the environment and are continuously Guided Vehicles (LGVs), which deliver optimal
improving the sustainability of our products efficiency, accuracy and enhanced safety. The
and services. Consistent with this aim, we LGVs operate by following over nine kilometres of
incorporated several upgrades into the rebuild to sustainability QR codes which guide their path throughout the
make the furnace more energy efficient and reduce warehouse.
the environmental impact. It included an epsilon is fundamental The new warehouse enables us to hold
crown, upgraded insulation, closed in batch significantly greater inventory on-site, reducing
charging, variable speed drive fans and a t-piece on to everything off site storage and transportation costs as well as
”
the waste gas stream for future waste heat recovery. enhancing responsiveness to customers.
we do.
Do you plan to increase the amount of cullet used in the Generally, how would you describe the glass market at
glassmaking process at the plant? the moment, particularly in the light of the pandemic?
Yes, we are actively seeking opportunities to The glass market in Australia saw some dramatic
collect and use more recycled glass or cullet. Orora changes earlier in the year as stay at home orders
currently recycles over 80% of all glass collected and travel restrictions came into effect.
through South Australia’s container deposit Fortunately, Orora’s Beverage businesses were
scheme. From 1 Oct 2020, Orora commenced classified as essential services and have continued
collecting waste glass from Western Australia’s to operate seamlessly throughout the pandemic. �
container deposit scheme boosting our available
cullet. 100% of the cullet we receive goes into the Orora Glass, Gawler, Australia https://www.ororagroup.com/
53
Company profile Orora.indd 2 17/11/2020 12:26:52

Smart glass: Nodis Glass
How smart is your glass?

New nanotechnology maximises energy savings and minimises carbon foot-
print. Mike Holt* discusses how Nodis’ TruTint smart glass can help reduce
emissions by 50%.
P
ublic and private standards and
market demands are driving the real
estate and transportation industries INSIDE TRUTINT GLASS
to reduce their impact on energy use and
the overall ecosystem.
Buildings consume 40% of a city’s We start with colour coated nanoparticles.
energy and generate 45% of its CO2 These are suspended in microscopic wells in
emissions. our nanoimprinted film.
Vehicle manufacturers also intend
to reduce their carbon footprint and
improve consumer comfort.
One game-changing solution for both
industries? Smart glass, a technology to
better control light and infrared entering
a building or vehicle. The film is then sandwiched between two sheets
However, the full potential of smart glass of glass (laminated windows). Electric power is
has not yet been realised. Existing smart connected to each side of the conductive film
glass technologies do not fully address coating.
energy efficiency, comfort, aesthetics and
architectural requirements. They lack
the capacity to control infrared, the real
cause of heat within a building, and they
take as long as 20 minutes to shift.
In addition, existing approaches
can’t offer colour options or electrically
change colour. Finally, the cost of
implementation is high, making the Applying electric power orients the nanoparticles
limited benefits even more unattractive which act as small light shutters. This allows
or too expensive for the market. setting of any level of tint from clear to completely
Smart glass technology company opaque. By placing three layers of plastic film
Nodis has pioneered a smart glass film between the two sheets of glass, we can select any
called TruTint to respond to all of these colour for the glass (opaque, transparent or any
issues. Nodis was created in 2014 to tint colour in between).
commercialise a nanoparticle-based
smart glass and display technology
developed by Dr. Sergey Shokhor and his
team. Thus, the amount of light allowed into manufacturing approach.
The company has since attracted the build can be regulated by the degree Buildings are the largest users of energy
investment from the Singapore National of voltage applied. and greenhouse gas producers. Vehicles
Research. Nodis TruTint reduces energy must better adjust to glare, heat and
Nodis technology suspends colour consumption and CO2 emissions by reduce their environmental impacts.
rod-like nanoscale particles in an organic 50%. The system automatically controls Smart glass technology now exists that
liquid and then sandwiches them illumination, and infrared for heating can contribute significantly to these
between two pieces of glass. and cooling, reducing building energy goals. �
In a natural state, the suspended cost and CO2 emissions. It switches in
particles randomly organise and then under one second and it can display an
block light. When voltage is applied to infinite number of tints. *Advisor and Board Director
the suspended particles, they align and Finally, TruTint sells at much lower Nodis Glass, Columbus, Ohio, USA
light passes through. cost as a result of its high-volume www.nodiscorp.com
54
0
Nodis Glass.indd 1 18/11/2020 06:30:06

History
Prof. John Parker

Refiner's fire
Prof John Parker discusses how to ensure bubble-free products.
M
y dictionary defines the word 100 hours from 1m down. In the working Borosilicate glasses have even used sodium
‘refine’ as ‘acquire polish or end the melt viscosity is high enough chloride (boiling point, 1413˚C); it doesn’t
elegance’. I like that when applied for forming and this time increases a release oxygen but has a sufficiently high
to glass but it’s not the whole story. For hundredfold. Refinement does not come vapour pressure at melting temperatures
glassmakers the term usually refers to the easy. to cause bubble growth.
whole range of processes that eliminate The secret to success is refining agents, Furnaces 2000 years ago were much
bubbles from the product, although some chemicals added to the batch which aid cooler than now but the melt was richer
use ‘fining’ for this and reserve ‘refining’ bubble removal. These are compounds in fluxes to lower viscosity and facilitate
specifically for chemical processes using that decompose at high temperature, refining. The few large tanks existing then
‘refining’ agents. releasing oxygen. Now how can creating also used time to complete the process –
20% of the batch used for glass melting more gas remove bubbles? It works because 30 days for refining and homogenising.
is unavoidably air. Much larger volumes of the gas is released later in the process Crucibles being much shallower also
carbon dioxide, several hundred times the when the larger bubbles have already required less time for bubbles to disappear
batch volume, are created during melting gone and only a few smaller bubbles and Fe-rich impurities in the batch with
as soda ash and limestone decompose remain. The oxygen release occurs in Mn added as a decoloriser probably
(sodium and calcium carbonates). Most small amounts over a temperature range; aided refining. More recently arsenic and
of these gases escape but as sand dissolves it does not create new bubbles but diffuses antimony oxides compounds proved
the melt viscosity rises, trapping bubbles into existing bubbles causing them to effective refining agents, releasing
which can only rise slowly to the surface. expand. And larger bubbles rise faster. oxygen at relatively low temperatures
I say bubbles – glass makers are particular These redox reactions go into reverse without colouring the glass. The trend to
about their use of words; generally, as the melt is cooled in the working end increasing temperatures for melting was
bubbles <0.2mm are called seed. Bubbles and that also plays a role. Any remaining made possible when sodium sulphate
spoil the appearance of glass and in bubbles are likely to be small with a very became available as a batch component
products such as a car windshield they slow rise time. But any oxygen they in the 19th century. It releases oxygen
become a critical defect because they can contain can diffuse out to re-oxidise the at higher temperatures better suited to
seriously impair the driver’s vision. Glass redox ions to their fully oxidised state. modern operating conditions as well as
manufacturers therefore have Quality The consequence of oxygen loss is that having other useful effects.
Control procedures on the production an already small bubble shrinks further. There is a limit to the effectiveness of
line to check for and eliminate products Because of surface tension the internal refining agents. Higher concentrations
with bubbles. pressure in the bubble rises and the release more gas and can create new
So how does refining work? We all have solubility of all the gases increases. The bubbles - too much of a good thing.
watched the clearing of fine bubbles in a final shrinkage of the bubble is more than Apart from chemical refining,
pint mug of beer. The viscosity of beer is that due to oxygen loss alone and indeed bubbling, i.e. direct blowing of gas
around 0.01 poise and bubbles near the the bubble may even fully dissolve and (helium) into the melt, can flush bubbles
bottom rise around 150mm. A formula disappear. out. Other methods include ultrasonics
derived by Stokes predicts a rise time of 6 What are the magic chemicals that or low-pressure. If bubbles still remain
seconds for bubbles of 0.1mm radius. The release oxygen? Well they are all things mass spectrometry can analyse both their
time depends inversely on size squared that can exist in more than one oxidation composition and their pressure, helping
and therefore small bubbles are at a major state in glass, elements such as arsenic to pinpoint their source. �
disadvantage in the race to the top. In a (As3+, As5+) and antimony (Sb3+, Sb5+)
glass melt the viscosities are much higher, but also colouring agents such as iron
perhaps 10 000 times greater at the (Fe2+, Fe3+) and manganese (Mn2+, *Curator of the Turner Museum of Glass,
hot spot. A rise time of six seconds for a Mn3+). Alkali-free glasses with high The University of Sheffield, UK
similarly sized bubble becomes 17 hours melting temperature, such as LC display www.turnermuseum.group.shef.ac.uk
from 15cm below the glass surface and glasses, use tin oxide, SnO2 (Sn2+, Sn4+). j.m.parker@sheffield.ac.uk.
55
History.indd 1 17/11/2020 12:30:53

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ifv@fonderievaldelsane.com www.fonderievaldelsane.com
Laser welded 2 pin Conveyor Chain

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WWW.GLASS-INTERNATIONAL.COM November 2020—Vol.43 No.

O-I GIRONCOURT INTERVIEW

I N T E R N A T I O N A L A GLOBAL REVIEW OF GLASSMAKING

Excellence Made in Italy

FUSED CAST REFRACTORIES

GI Cover November.indd 1 17/11/2020 11:19:57

Assistant Editor: George Lewis

Sales Director: Ken Clark

Managing Director 10 Company proﬁle: O-I’s Gironcourt

33 Event review: Soda Ash conference

45 45 Personality proﬁle: Guenter Lubitz

Pensord, Tram Road, Pontlanfraith, Blackwood,

© Quartz Business Media Ltd, 2020

Contents.indd 1 18/11/2020 13:36:39

GREG MORRIS, EDITOR

O-I GIRONCOURT INTERVIEW

I N T E R N A T I O N A L A GLOBAL REVIEW OF GLASSMAKING

www.refel.com Be first with the news!

Glass International November 2020

for daily news updates

Good riddance to 2020 FUSED CAST REFRACTORIES

Well, that was a year like

Glass Futures secures £15m

NSG Pilkington North America

in the Life Sugar project

ignites Luckey, USA furnace

news new template GL.indd 1 18/11/2020 14:13:04

Horn completes furnace

VERCANE project aims to

decarbonise glass production

investment in its glass division

(US$118.5 million) on a 20-

India’s HSIL plots Bhongir glass year sale-and-leaseback,

news new template GL.indd 2 18/11/2020 14:13:13

To make glass better, put Air Products in the mix.

O-I Glass and Krones sign

© Air Products and Chemicals, Inc., 2019 (42615)

news new template GL.indd 3 18/11/2020 14:13:15

AppliedVision_GlassInternational-Feb-2020-Full Page.indd 1 1/30/20 1:52 PM

Top 10 stories in the news

Vidrala invests €21 million in

Spanish furnace upgrade

FEVE’s ‘Furnace for the Future’

As the first ultra-clear

project gathers momentum

Glass International November 2020

news new template GL.indd 4 18/11/2020 14:13:35

The magic of glass recycling

Glass scientists win Otto

Tariq Glass’s second float

glass set to start production

Bucher Emhart Glass sees gradual

robotic systems to improve

news new template GL.indd 6 18/11/2020 14:13:42

A project inspired by teamwork

Company profile O-I Gironcourt.indd 1 18/11/2020 13:43:51

demand for more bottles from O-I’s customers.

2019 and was only dropped in autumn this year.

Company profile O-I Gironcourt.indd 2 18/11/2020 13:44:37

“People are key in

Company profile O-I Gironcourt.indd 3 18/11/2020 13:44:54

Ardagh Group recently

During this processing, and as a result of

Recycling Ardagh.indd 1 17/11/2020 11:58:48